UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BASIC DESIGN AND PERFORMANCE ANALYSIS OF MICRO-

HYBRID GENERATOR

This report is submitted in accordance with the requirement of the Universiti

Teknikal Malaysia Melaka (UTeM) for the Bachelor of Electrical Engineering

Technology

(Industrial Power) with Honours.

by

ABDUL HAFEEZ BIN ABDUL MALIK

B071210132

930328-10-5211

FACULTY OF ENGINEERING TECHNOLOGY 2015

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Basic Design And Performance Analysis Of Micro-Hybrid Generator

SESI PENGAJIAN: 2015/16 Semester 2

Saya ABDUL HAFEEZ BIN ABDUL MALIK

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti

Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan ( )

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan

atau kepentingan Malaysia sebagaimana yang termaktub

dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS)

Alamat Tetap:

NO. 17, JLN 1/4J, BANDAR DAMAI

PERDANA, 56000, CHERAS, KL

Tarikh: ________________________

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi:

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi

berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai

SULIT atau TERHAD.

iii

DECLARATION

I hereby, declared this report entitled “Basic Design And Performance Analysis Of

Micro-Hybrid Generator” is the results of my own research except as cited in

references.

Signature :………………………

Name : Abdul Hafeez Bin Abdul Malik

Date : ………………………

iv

APPROVAL

This report is submitted to the Faculty of Engineering Technology of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Engineering

Technology (Industrial Power) (BETI) (Honours). The member of the

supervisory is as follow:

……………………………….

(Mdm. Halyani Binti Mohd Yassim)

v

ABSTRACT

Micro-hybrid generator is a stand-alone power system (SPS). It is a green

technology that produces electricity from the combination of solar and hydro system.

This paper focuses on the basic design and concept of micro-hydro generator as it is

a backup supply for the solar system. The principle of solar system will not be

discussed in detail in this research. The purpose of this paper is to design a micro-

hydro generator with power output from 5 kW to 100 kW. Analysis is carried out

using the fundamental theory for micro-hydro system. This research is divided into

several parts. The first part is searching the potential site for micro-hybrid generator

installation in Malaysia. Second part is applying the fundamental theory for micro-

hydro generator system. In this part, the suitable design for micro-hydro system was

analysed. The overhead tank, turbine to be used and pump power was calculated

during the analysis. This type of green technology is still classified as a new

technology in Malaysia. So, it is recommended to see the status of implementation in

Malaysia. This research will help to reduce our dependence on using the non-

renewable sources for generation of electricity. It also raises standard living of

residents in remote areas because this system is suitable to be develop at the off grid

area.

vi

ABSTRAK

Penjana mikro hibrid merupakan sistem tenaga yang berdiri dengan sendiri

(SPS). Sistem ini merupakan teknologi hijau yang menghasilkan tenaga elektrik

daripada gabungan sistem solar dan hidro. Kajian ini menumpukan kepada reka

bentuk asas dan konsep penjana mikro hidro sebagai bekalan sandaran untuk sistem

solar. Di dalam kajian ini, prinsip sistem solar tidak dibincangkan secara terperinci.

Tujuan kajian ini adalah untuk mereka bentuk penjana mikro hidro dengan keluaran

kuasa dari 5 kW hingga 100 kW. Analisis dijalankan menggunakan teori asas bagi

sistem mikro hidro. Kajian ini telah dibahagikan kepada beberapa bahagian.

Bahagian pertama adalah mencari tapak yang berpotensi untuk pemasangan penjana

mikro hibrid di Malaysia. Bahagian kedua adalah mengaplikasikan teori asas bagi

mikro hidro sistem. Dalam bahagian ini, reka bentuk yang sesuai untuk sistem mikro

hidro telah dianalisis serta dibincangkan. Saiz tangki, jenis turbin dan kuasa pam

telah dikira pada bahagian ini. Teknologi hijau seperti penjana mikro hibrid masih

diklasifikasikan sebagai teknologi baru di Malaysia. Jadi, ia adalah disyorkan untuk

melihat status pelaksanaannya di Malaysia. Kajian ini akan membantu untuk

mengurangkan kebergantunganterhadap penggunaan sumber-sumber yang tidak

boleh diperbaharui untuk penjanaan tenaga elektrik. Ia juga dapat meningkatkan taraf

hidup penduduk di kawasan pedalaman kerana sistem ini sesuai untuk dibangunkan

di kawasan luar bandar.

vii

DEDICATIONS

This research is dedicated to Almighty God for providing me peace, strength and

makes it easier for me to complete it.

viii

ACKNOWLEDGMENTS

All praise for Allah, with blessings and His grace that has made it easier

journey along this learning.

I want to express my gratefulness to every one of the individuals who gave

me the possibility to finish this report. An extraordinary appreciation for my

supervisor, Mdm. Halyani Binti Mohd Yassim, who’s committed in stimulating

suggestions and support, helped me to facilitate my research especially in composing

this report.

To those I love, my mother, Sarinah Binti Yusof, my father, Abdul Malik Bin

Abdul Rahim, Nurulhuda Binti Hashim, Wan Muhammad Aqib, Samir Malik, Ali

Mohd Hidayat, Rifaat Abdel Rahman, Muhammad Hilmi, Shukri Bin Yahaya, and

all friends who always guide me in completing this research. Without them, I was not

able to complete this task.

Only God is able to reward you. Thank you.

ix

Table of Contents DECLARATION ................................................................................................................. iii

APPROVAL ......................................................................................................................... iv

ABSTRACT ........................................................................................................................... v

ABSTRAK ........................................................................................................................... vi

DEDICATIONS .................................................................................................................. vii

ACKNOWLEDGMENTS ................................................................................................. viii

LIST OF FIGURES ............................................................................................................ xii

LIST OF TABLE ............................................................................................................... xiv

LIST OF SYMBOLS AND ABBREVIATIONS ................................................................ xv

CHAPTER 1 .......................................................................................................................... 1

INTRODUCTION ................................................................................................................. 1

1.0 Introduction ............................................................................................................. 1

1.1 Background ............................................................................................................. 1

1.2 Problem Statement .................................................................................................. 4

1.3 Objectives ................................................................................................................ 5

1.4 Scope ...................................................................................................................... 5

CHAPTER 2 .......................................................................................................................... 6

2.0 Introduction ............................................................................................................. 6

2.1 Hydro Power Plant .................................................................................................. 7

2.1.1 History Development of Hydro Power Plant ........................................................ 7

x

2.1.2 Categories of Hydro Power ................................................................................... 7

2.2 Micro Hydro Power Generation ............................................................................. 9

2.2.1 Micro-Hydro Operation ...................................................................................... 11

2.3 Head and Flow ....................................................................................................... 13

2.3.1 Newton’s law Equation ....................................................................................... 14

2.4 Water Turbine ........................................................................................................ 15

2.4.1 Categories of Water Turbine ............................................................................... 16

2.5 Water Pump ........................................................................................................... 20

2.6 MATLAB Simulink .............................................................................................. 21

2.7 Programmable Logic Controller (PLC)/CX-Programmer ..................................... 22

CHAPTER 3 ........................................................................................................................ 23

SYSTEM DESIGN AND DEVELOPMENT ...................................................................... 23

3.0 Introduction ........................................................................................................... 23

3.1 Review of The Potential Site ................................................................................. 25

3.1.1 Resources Available In Sabah ........................................................................ 25

3.1.2 Solar Potential In Sabah ................................................................................. 26

3.1.3 Rain Fall Capacity In Sabah ........................................................................... 28

3.2 Application of Fundamental Theory .......................................................................... 29

3.2.1 Calculation of Head Tank ................................................................................... 29

3.2.2 Turbine Calculation ............................................................................................. 31

3.2.3 Pump Calculation ................................................................................................ 33

3.3 Simulation ............................................................................................................. 35

3.4 Data Analysis and System Efficiency .................................................................. 44

xi

CHAPTER 4 ........................................................................................................................ 45

RESULT AND ANALYSIS ................................................................................................ 45

4.0 Introduction ........................................................................................................... 45

4.1. Design of Micro-Hydro System ............................................................................ 45

4.1.1 Phase 1 (Overhead Tank) ............................................................................... 47

4.1.2 Phase 2 (Turbine) ........................................................................................... 49

4.1.3 Phase 3 (Pump Power) ................................................................................... 56

4.2 ANALYSIS FOR SYSTEM EFFICIENCY .......................................................... 61

CHAPTER 5 ........................................................................................................................ 67

CONCLUSION & FUTURE WORK .................................................................................. 67

5.0 Introduction ........................................................................................................... 67

5.1 Conclusion ............................................................................................................. 67

5.2 Limitation .............................................................................................................. 68

5.3 Recommendation ................................................................................................... 68

APPENDICES ..................................................................................................................... 69

APPENDIX A ...................................................................................................................... 70

APPENDIX B ...................................................................................................................... 71

APPENDIX C ...................................................................................................................... 72

APPENDIX D ...................................................................................................................... 73

REFERENCES ..................................................................................................................... 74

xii

LIST OF FIGURES

Figure 1.1: Available Renewable Energy Source in Malaysia ……………………..2

Figure 2.1: Example of Large Hydro Power Plant ………………………….……….9

Figure 2.2: Nepal Micro-Hydro Power House ……………………………….…….10

Figure 2.3: Micro-Hydro System .............................................................11

Figure 2.4: Head of Micro-Hydro ............................................................13

Figure 2.5: Francis Turbine ..................................................................16

Figure 2.6: Kaplan Turbine ...................................................................17

Figure 2.7: An Old Pelton Wheel............................................................18

Figure 2.8: Cross Flow ........................................................................19

Figure 2.9: Solar Pump Water ...............................................................20

Figure 2.10: MATLAB/Simulink.............................................................21

Figure 2.11: CX-Programmer.................................................................22

Figure 3.1: Flow Chart for Research ……………………………………………….24

Figure 3.2: Average annual trend value for every state in Malaysia ……………27

Figure 3.3: Yearly rainfall trend for Sabah ...............................................28

Figure 3.4: System Block Diagram of Micro-Hybrid Generator …………...….…36

Figure 3.5: System Block Diagram of Micro-Hybrid Generator ……………….…37

Figure 3.6: Solar System (On) …………………………………………..………….39

Figure 3.7: Micro-Hydro System (Off) ……………………………………….…….40

xiii

Figure 3.8: Solar System (Off) …………………………………………………41

Figure 3.9: Micro-Hydro System (On) …………………………………………42

Figure 4.1: Micro-hydro system circuit design …………………………..……46

Figure 4.2: Effect of radius of tank and pipe diameter

towards power input to turbine ……………………………………48

Figure 4.3: Graph of output power generated against torque …………………53

Figure 4.4: Graph of relationship of power output with

the radius of water tank ………………………………………/….54

Figure 4.5: Calculation for friction factor …………………………….………58

Figure 4.6 Effect of radius of tank and diameter of pipe

towards pump power ………………………………………………60

Figure 4.7: Effect on every changes of the radius of tank

and diameter pipe to the efficiency of the system ……….…….62

Figure 4.8: Effect of output generated and pump power

towards system efficiency ………………………………….…….63

Figure 4.9: Design to be applied for micro-hydro system…………………….66

xiv

LIST OF TABLE

Table 2.1: Hydro categories ……………………………………………………….7

Table 2.2: Classification of Head for Micro-Hydro System ................................13

Table 2.3: Categories Of Turbines .......................................................................15

Table 3.1: Energy per hour produces in every cities in Malysia ..........................24

Table 4.1: Calculation for phase 1 ……………………………………...………..47

Table 4.2: Speed of turbines …………………………………………..…………49

Table 4.3: Generator synchronous speed ……………………………..…………50

Table 4.4: Calculation for phase 2 ……………………………………..………...51

Table 4.5: Absolute roughness for different type of material ………..………….57

Table 4.6: Calculation for phase 3 ……………………………………..………...59

Table 4.7: Calculation for efficiency ………………………………….…………61

Table 4.8: Result for constant radius of tank ……………………………………64

Table 4.9: Design to be applied for micro-hydro system ……………………….65

xv

LIST OF SYMBOLS AND ABBREVIATIONS

AC: Alternating Current

DC: Direct Current

PLC Programmable Logic Controller

SPS Stand-alone Power System

PSP Private Sector Participation

RES Renewable Energy System

HE Hydro Energy

Q Flow rate l/s

ρ Density of water [1000 kg ]

g Gravitational force [9.81 m ]

H Net head (m)

Dpipe Pipe diameter (m)

Dtank Tank diameter (m)

Vol.tank Volume tank (l)

r radius tank (m)

v Velocity (m )

A Area ( )

KE Kinetic Energy (Joule

PE Potential Energy (Joule)

M Mass (kg)

xvi

N Rotational speed of turbine (rpm)

T Torque of shaft (kNm)

D Runner throat turbine diameter (m)

Angular velocity of turbine (rad/sec)

P Power input to the turbine (kW)

µ Efficiency

f Fraction factor

1

CHAPTER 1

INTRODUCTION

1.0 Introduction

This chapter introduce about renewable energy and its benefits.

1.1 Background

The first power network was created by Thomas Edison in 1882 in the United

States. DC generator was used to generate energy and this energy is distributed using

underground cables. However, this system has a disadvantage which power can only

be spread in small distance from power station. The first AC power network was

formed in the United States in 1885. During this year, William Stanley has created a

transformer which is intended to rise or decline the amount of voltage. In 1888,

Nicola Tesla has become the first person who invented the induction motor. The

purpose of the creation of an induction motor is to generate AC power to substitute

the existing DC power. Among the advantages of AC generator is that it can produce

better power than DC generator. Moreover, the power can be spread in a wide range.

Grid system was designed to connect the utility network with the main

electrical grid. The term off-grid means that the system is not being connected with

the main electrical grid. Stand-alone power is one of the off-grid systems. It is

developed to provide electricity to rural areas.

2

Distributed energy is stored or produced by several of grid connected devices

which is also referred to as distributed energy resources (DER). There are some

differences between conventional power station and DER. First, DER system uses

renewable sources such as wind, solar, biomass and hydro. The use of resources for

the system can reduce the effects of pollution on the environment. Moreover, it is

also not bounded by the fluctuation in price of non-renewable energy. On the other

side, the conventional power station use natural resources such as gas, coal, and

nuclear to generate electricity. The use of non-renewable sources will indirectly

contribute to environmental pollution due to emission of carbon dioxide produced

from combustion of the sources.

For conventional power station, it is centralized and often requires electricity

to be transmitted over long distances. Unlike conventional power system, DER is a

system that is flexible and decentralized. It can be managed and coordinated within a

smart grid. Renewable energy is energy that always available and never run out of

resources. It can be divided into two types which are potential energy and non-

potential energy. Figure below shows various type of renewable energy available in

Malaysia

Figure 1.1: Available Renewable Energy Source in Malaysia

Renewable Energy

Potential Energy

Solar

Hydro

Biomass

Non-Potential Energy

Wave

Wind

Geothermal

3

In Malaysia, solar and hydro systems have shown a good growth. Both

systems use clean and environmental friendly energy resources. Malaysia has an

equatorial climate with high temperatures and wet months all over the year. This is

an advantage for Malaysia to lead the research of solar system used in industries.

Application of this system can be seen in low energy consuming equipment. For

example, the system is used to heat water in a hotel and power up street light.

In this era of globalization, the demand for fossil fuels is increasing. Same

goes with the price of fuels (Muda and Tey 2012). Because of Malaysia is too

dependent on this resource, we should be aware that sooner or later, this resource

will be exhausted (Malaysia Country Report, Energy Situation in Malaysia: Present

and Its Future).

The Malaysian government is aware of this problem. Therefore, the

government has introduced a plan to use renewable energy resources instead of fuel

source in generation of electricity. The government`s efforts can be seen when the

plan is included in 8th Malaysia Plan (2001-2005). According to Amer Aqel (2013),

the government is committed to continue this program and it has been included once

again in the 9th Malaysia Plan (2006-2010).

4

1.2 Problem Statement

In some rural areas, they have difficulties to access to electricity. This happens

because of the difficulties in installing the distribution system in the area. There are

several factors that prevent the installation of the system. Among them are the hilly

shape of the earth surfaces, region with water flow like rivers and thick forest. In

order to get electricity, diesel generator is used. It has been applied for a long time.

Unfortunately, the fluctuation of diesel price which keep increasing has become a

burden. Main energy resources for electricity in Malaysia are from natural gases

(53.2%) and coal (30.4%), which in emission of carbon dioxide (CO2) and the

thinning of ozone layer that lead to increase in temperature. Solar system is an

alternative to conventional power system. Solar system has grown in Malaysia

rapidly. Unfortunately, solar system has several disadvantages. Solar system only

operates during daylight and depends on the climate. It can be said that solar system

cannot provide a constant access to electricity.

These problems can be overcome by combining the solar with a micro-hydro

system. Combination of both systems has improves system reliability. Moreover, the

combination of these two systems will not cause pollution to the environment. This

research discusses about the new micro hybrid-generator through the combination of

solar and micro-hydro system that can produce electricity from both system. This

research focuses on the basic design and concept of micro-hydro generator as it is a

backup supply for the solar system

5

1.3 Objectives

There are three objectives of this research:

1. To review and choose the most potential site for micro-hybrid

generator system installation in Malaysia.

2. To design micro-hydro system as a backup power for stand-alone

solar system.

3. To analyse system efficiency by using Matlab / simulink.

1.4 Scope

Firstly, this research focuses on the basic design and concept of micro-hydro

generator as it is a backup supply for the solar system. The principle of solar system

was not discussed in detail in this research. The fundamental theory for micro-hybrid

generator system is applied. Among the calculations taken referred are calculations

of the head tank, turbine and water pump. The output power generated from micro-

hybrid generator system is between 5 kW to 100 kW.

6

CHAPTER 2 THEORETICAL BACKGROUND

2.0 Introduction

In the era of globalization, the demand for fossil fuels is increasing. Same

goes for the price. Because of Malaysia too dependent on these resources, Malaysian

should be aware that sooner or later, these resources will be finish.

Malaysian government is aware of this problem. The government has

introduced a plan to use renewable energy resources as an alternative energy sources

in electricity generation. The government`s efforts can be seen when the plan is

included in 8th Malaysia Plan (2001-2005). The government is committed to

continue this program and it has been included once again in the 9th Malaysia Plan

(2006-2010).

Today, hydropower has been a catalyst for economic and social development.

The participation of Private sector (PSP) in Rwanda that implement a small hydro

projects for rural electrification has been a great impact on society. Among the

projects run by PSP is micro-hydro generator. PSP also committed to the

implementation of the project for the development of rural areas (Pigaht and van der

Plas 2009).

7

2.1 Hydro Power Plant

2.1.1 History Development of Hydro Power Plant

The first hydroelectric power plant was installed in Cragside, Rothbury,

England in 1870. Hydro power has been used in industry since 1880 in Grand

Rapids, Michigan, when a dynamo driven by a water turbine was used to provide

theatre and storefront lighting. Today, hydropower plants are much more reliable and

efficient than the fossil fuel-fired plants (Baird, 2006). This resulted in a proliferation

of small- to medium-sized hydropower stations distributed wherever there is an

adequate supply of moving water and a need for electricity. As electricity demand

grows, the number and size of fossil fuel, nuclear and hydropower plants increases.

In parallel, concerns arise around environmental and social impacts (Edenhofer et al.,

2011).

2.1.2 Categories of Hydro Power

Water is a clean and environmental friendly source of energy. It is the ideal source for electricity generation. Hydro power plants convert the potential energy of water into electricity Mohibullah et al (2004). The determination of the size of the hydro power plant depends on the desired output power. The figure below shows the hydro category, power range that can be created and the number of homes powered.

Table 2.1: Hydro categories

8

1. Pico Hydro Power Plant

Hydro power generation under 5 kW is known as pico-hydro. It is

very suitable to be applied in area that required small amount of

electricity. M.F. Basar (2011) said that pico hydro power plant only

need a small stream to generate electricity.

2. Micro Hydro Power Plant

It produces the output power less than 100 kW. Micro-hydro can

generate electrical power to small remote communities. Sometimes,

the output is connected to the electric power network.

3. Small Hydro Power Plant

Mini and small-hydro are in the same class. It can provide power not

more than 10 MW. It can be connected to conventional electrical

distribution network as low-cost renewable energy.

4. Large Hydro Power Plant

Large hydro power generation is often referring to facilities that can

produce from over a few hundred Megawatts to more than 10 GW

power.