McKinney J.D., Warnick C.C. Microhydropower Handbook Volume 1
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Microhydropower Handbook,
Volume 1
by EG&G Idaho for the U.S. Dept. of Energy
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National Technical Information Service (NTIS)
5285 Port
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. MICROHYDROPOWER HANDBOOK - VOLUME I
EG&G Idaho, Incorporated
Idaho Falls, ID
Jan 83
DE83-006697
IDO-10107-Vol.1
(DE83006697)
Distribution Category UC-97e
.
l
MICROHYDROPOWER HANDBOOK
Volume 1
J.
0. McKinney, EGhG Idaho
Prof. C. C. Warnick, University of Idaho
B. Bradley, Bradley Engineering
J.
Dodds, EG&G Idaho
T. B. McLaughlin, EG&G Idaho
C. L. Miller, EG&G Idaho
G. L. Sommers, EG&G Idaho
B. N. Rinehart, EG&G Idaho
Published January 1983
EG&G Idaho, Inc.
Idaho Falls,
Idaho 83415
.
Prepared for the
U.S. Department of Energy
Idaho
Operations Office
under DOE Contract No. DE-AC07-76ID01570
Published by the -
Technical Information Center
U.S. Department of Energy
i .
I
.
DISCLAIMER
“This book was prepared as an account of work sponsored by an agency of the United
States Government. Neither the United States Government nor any agency thereof, nor any
of their employees, makes any warranty, express or implied, or assumes any legal liability or
responsibility for the accuracy, completeness, or usefulness of any information, apparatus,
product, or process disclosed, or represents that its use would not infringe privately owned
rights. Reference herein to any specific commercial product, process, or service by trade
name,
trademark, manufacturer, or otherwise, does not necessarily constitute or imply its
endorsement, recommendation, or favoring by the United States Government or any agency
thereof. The views and opinions of authors expressed herein do not
necessarily
state or
reflect those of the United States Government or any agency thereof.”
This report has been printed directly from copy supplied by the originating organization.
Although the copy supplied may not in part or whole meet the standards for acceptable
reproducible copy, it has been used for reproduction to expedite distribution and
availability of the informat’ion being reported.
.
Available from the National Technical Information Service, U. S. Department of
Commerce, Springfield, Virginia 22 161.
Codes are used for pricing all publications.
The code is determined by the number of pages in the
publication. Information pertaining to the pricing codes can be found in the current issues of the following
publications, which are generally available in most libraries: Energy
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and Index
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and publication, NTIS-PR3GO available
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NOTICE
THIS DOCUMENT HAS BEEN REPRODUCED
FROM THE BEST COPY FURXISHED US BY
THE SPONSORING AGENCY. ALTHOUGH IT
IS RECOGNIZED THAT CERTAIN PORTIONS -
ARE ILLEGIBLE,
IT IS BEING RELEASED.
IN THE Ii’?TEREST .OF MAKING A,VAILABLE
AS MUCH INFORMATION AS POSSIBLE.
.
I’
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ACKNOWLEDGMENTS
The authors would like to thank the following people a!:';~ ::,-.,.'~.5::.,:,:
for their contribution to this handbook:
A. Batra, C. Grub@, and E. Jewel1 of Centrac Associates, Inc.;
G. L. Smith of Appropriate Technology; and
J. Volkman of Intermountain Energy Systems
for supplying draft material for the handbook.
3. T. Parker, EG&G Idaho, technical writer; and
S. C. Hall, EG&G Idaho, illustrator.
Meinikheim Machines, Banks, Idaho; and
GSA International Corporation, Katonah, New York
for reviewing the handbook in draft form.
K. Grover of GSA International Corporation
who supplied much practical design information, and whose
.
experience in the hydropower field is reflected throughout the
handbook.
.
P
CONTENTS
3.
INTRODUCTION
.....................................................
l-l
1.1
Purpose
....................................................
l-3
1.2 Cost of Development
........................................
1-5
1.3
Category of Developer
......................................
l-5
1.4
Organization of the Handbook
...............................
l-6
1.5
Event Sequence
.............................................
l-7
1.5.1
List of Events
.....................................
l-7
1.6
Event Schedule
..............................................
l-15
2.
WHAT IS HYDROPOWER?
...............................................
2-l
2.1
History and Typical Microhydropower Systems
................
2-2
2.2
Head
.......................................................
2-4
2.3
Flow . . . . . .
................................................
2-6
2.4 Kilowatt . .
................................................
2-8
2.5 Power Equat
i
on .............................................
2-11
2.6 Microhydropower Sources
..*,.,.,.,.........................*
2-14
2.6.1
Natural Sources (Run-of-the-Stream)
................
2-14
2.6.2 Manmade Source
.....................................
2-20
2.7 Typical Example Sites
..,* . . . . . . .,* ,.....I . . . . . . . . . . . . . . . . . .
2-24
2.7.1
Manmade Source
.....................................
2-24
2.7.2 Run-of-the-Stream Source
...........................
2-26
3.
POWER POTENTIAL . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..".........
3-l
3.1 Power Required
. . . . . . . . . . . . . . . . . . . . . . . .
....................
3-l
3.1.1 Typical Household Loads
..a....
....................
3-l
3.1.2 Metering
I..,,,.,,.............
.....................
3-5
3.2 Inspection of
Potential Hydropower Devel
opment .............
3-8
3.2.1
Manmade Sites
......................................
3-8
3.2.2
Run-of-the-Stream Sites
............................
3-10
Iii
.
.
3.3 Determining Available Flow . .
.
.
3.3.1
Flow Duration Curve
3.3.2
Existing Stream Flow
3.3.3
Stream Flow Correlati
..........................
:,-;:
............................
7- ;i
Records
.......................
3-15
on . . . . . . . . . .._............__.. Z-21
3.3.3.1
Flow measurement . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.3.3.1.1
Container method
.............
?--Z;
3.3.3.1.2
Weir method
..................
3-26
3.3.3.1.3
Float method
.................
3-34
3.3.3.2
Flow computations . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.3.3.3
Exceedance value flow duration curve . . . . . 3-42
3.4 Head and Distance Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.4.1
Head Measurements . . . . . . . . . . . . . . . . . . . . . . . .."........ 3-48
3.4.1.1
Pressure method for measuring
pool-to-pool head at run-of-the-stream
site . . . . . . ..*............................ 3-48
3.4.1.2
Level survey to measure head at
run-of-the-stream sites, canal drops,
and industrial discharge sites . . . . . . . . . . . 3-53.
3.4.1.3
Survey methods for manmade dams with
low head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.4.2
Distance Measurement for Run-of-the-Stream Site . . . . 3-56
3.5
Determining Design Capacity, Head, and Flow for
Category
1
Developers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3.
J
3.
3.
5.1 Power Requirements and Minimum Flow Known;
Calculate Head . . . . . . . . . . . . ..e.......p........a..... 3-,%
r, 9
d.L
i-lead Fixed and Flow Known; Calculate
Design
Capacity . . . . . . . . . . . . . . . . . . . . . . ..l...I........
. ::-:;:I
i '5
J . d
Head and Poti?r i:eqGirement; 'Crirj\~:~; Calcitlate
Mipiqum Flow ant: Percentage Exceedance . . . . . . ,., :
C:J
5.4 Head an,d Flow Vary; Calculate Cesign Capacity. . .
';, .
'1
i! .,
3.5.4.1
Seasonal head fluctuation . . . . . . . . . . . . ,
?--i?
3.5.4.2
Eri-atjc head fluctuat,icn
- ,.
. . . . . . . . . . .
. .
.iL
3.6 Determining Design Capacity, Head, and Flow for
Category 2 Developers I.....J....r..........,......
1.6.1 Head Fixed and Flow Known; Calcclate Design
Capacity . . . . . . . . . . . . . . . . ..e...............
3.6.2 Variable Head and Known Fiow; Cafculate Des;
Capacity . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
3.r Dei-rrmjning J\c~!,al FI;eyLIV. ,,... ,.. . . , ..,..
.
.
.
i v
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4.
DESIGN, EQUIPMENT, AND SAFETY REQUIREMENTS .......................
4-l
4.1
Turbines ................................................... 4.1-1
4.1.1 Impulse Turbines .................................... 4.1-1
4.1.1.1 Pelton wheel turbine ..................... 4.1-3
4.1.1.2 Crossflow turbine ........................ 4.1-4
4.1.1.3 Turgo impulse turbine .................... 4.1-5
4.1.2
Reaction Turbines .................................. 4.1-7
4.1.2.1 Francis turbines ......................... 4.1-8
4.1.2.2 Propeller turbines ....................... 4.1-9
4.1.3
Pumps Used as Turbines ....................... ..1... 4.1-10
4.1.4 Turbine Application ................................
4.1-14
4.1.5 Regulating Turbine Speed ........................... 4.1-17
4.1.6 Turbine Setting .................................... 4.1-18
4.1.7 Draft Tube ......................................... 4.1-19
4.2
Contact Turbine-Generator Manufacturers and Suppliers ...... 4.2-l
Microhydropower Turbine-Generator Information Request ....
4.2-4
m
4.3 Go/No-Go Decision and Design Criteria Selection ............ 4.3-l
4.3.1 Go/No-Go Decision ................................... 4.3-l
4.3.2 Design Criteria ..................................... 4.3-7
Design Specification .............................
4.3-8
4.4
Intake System .............................................. 4.4-l
4.4.1 Water Quality ......................................
4.4-2
4.4.2
Run-of-the-Stream Sources and Canal Drops .......... 4.4-4
4.4.2.1
4.4.2.2
4.4.2.3
4.4.2.4
4.4.2.5
Stream diversion works ................... 4.4-5
Intake and power canal ................... 4.4-8
Settling basin ........................... 4.4-14
Forebay
..................................
4.4-18
Trashrack
................................ 4.4-22
4.4.2.5.1
4.4.2.5.2
4.4.2.5.3
4.4.2.5.4
4.4.2.5.5
4.4.2.5.6
4.4.2.5.7
4.4.2.5.8
Trashrack design area ........
4.4-28
Length of trashrack wetted
area ......................... 4.4-29
Nominal width ................ 4.4-30
Width of the trashrack ....... 4.4-31
Bundle size .................. 4.4-33
Trashrack supports ........... 4.4-35
Width of trashrack support
structure .................... 4.4-35
Length of trashrack support
structure .................... 4.4-36
i..
V
4.4.3
4.4.4
4.4.2.6 Penstock intake . . . . . . . . . . . . . . . . . . .
. . .
4.4.2.7
,. i-r:-;;i
Additional hardware . . . . . . . . . .
.,....A.....
4.4-41
4.4.2.7.1
Skimmers
.................
4 <,-Cl
4.4.2.7.2
Stop log weir check
........
$ 4-43
4.4.2.8
Alternative layouts
......................
4.4-42
Existing Dam Intakes
........
...........
............
4.4-42
4.4.3.1
Open flumes
..............................
4.4-47
4.4.3.2 Siphon penstock
..........................
4.4-47
Design Layout
..........................
............
4.4-4s
4.5.7.1
4.5.7.2
4.5.7.3
4.5.7.4
4.5.7.5
4.5.7.6
Hydrostatic thrust
.......................
f+.5-jil
Thermal expansion apd ccntracticn
Pipe spans and support
........... . :I::
4 I:,-.+!
.I;.
4.1-:!I
U!traviolet degradation
.............
4.5-X
Pensbck anchoring
.......................
'i c, ... r
Freezing .................................
ii.5-37
4.5.8
Design layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
:a :-
4.6 Powerhouse . ..l.......,_l.l.~,l.................... _.
. :A !..
.
4.5 Penstock and Valves
................
........................
4.5-l
4.5.1
Locating the Penstock
4.5.2
..............................
Design Layout
4.5-l
.....................
........
4.5.3
.........
Material Selection
4.5-3
....
.............................
4.5.4
Penstock Sizing
4.5-3
................
....................
4.5-6
4.5.4.1
Selecting pipe diameter
..................
4.5-f-i
4.5.4.2
Selecting pipe material
..................
4.5.4.3
4.5-11
Calculating penstock system head loss
....
4.5-16
4.5.5
Valves
.......................
.........
............
4.5-20
4.5.5.1
Penstock intake
..........................
4.5.5.2
4.5-20
Penstock upward slope
....................
4.5.5.3
4.5-20
Turbine isolation valve
4.5.5.4 Turbine bypass "Y"
..................
4.5-21
..........
.............
4.5-26
4.5.5.6
Turbine flow control valve
...............
4.5-27
4.5.6
Siphon Penstock
.................
..-
.................
4.5-28
4.5.7
Additional Design Considerations
...................
4.5-X
4.6.1
Physical Features of the Powerhouse .,........ .
4.6.2
Powerhouse Size and Dimensions
4.5.3
Minimum Powerhouse Standards ..:.:::::::::::::::. ,
ipment . . . . . . . .
. .
. . . . . . . . . . . . .
4.6.4
4 6.5
Location and Mounting of the Equ
Powerhouse Costs . . . . . . . .
. . . . .
a
': .
5.1;
Desigri Layout _- . . . . . . . . . __
vi
., . .
.