UNIVERSITY TEKNIKAL MALAYSIA MELAKA

MODELING OF HYDRO WIND TURBINE

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Process)

by

NG KEN HOU

B050710031

FACULTY OF MANUFACTURING ENGINEERING 2011

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Modeling of Hydro Wind Turbine

SESI PENGAJIAN: 2010/11 Semester 2

Saya NG KEN HOU 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 yang termaktub di dalam

AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

Alamat Tetap:

16, Jalan Tawas Baru 3,

Taman Tasek Damai,

30010 Ipoh, Perak.

Tarikh: 17 May 2011

Disahkan oleh:

PENYELIA PSM

Tarikh: _______________________

** 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.

DECLARATION

I hereby, declared this report entitled “Modeling of Hydro Wind Turbine” is the results

of my own research except as cited in references

Signature :

Author’s Name : NG KEN HOU

Date : 17 May 2011

APPROVAL

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

partial fulfillment of the requirements for the Degree in Bachelor of Manufacturing

Engineering (Manufacturing Process). The member of the supervisory committee is as

follow:

………………………………

Supervisor

i

ABSTRAK

Sumber tenaga boleh diperbaharui adalah sumber tenaga alam yang tidak habis-

habisan Kini, manusia menggunakan tenaga angin dan tenaga hydro untuk

menghasilkan elektrik. Batteri hanya mempunyai jangka penggunan yang singkat

dan tidak dapat membekalkan penjanan kuasa bagi jangka masa panjang di tempat

yang terpencil. Penyelesaian yang dicadangkan untuk menyelesaikan masalah ini

adalah dengan mengembangkan turbin yang dikendalikan oleh tenaga angin dan

hydro. Objektif bagi projek ini adalah untuk mereka satu turbin hydro angin dan

menyiasat pendahuluan operasi bagi turbin hydro angin yang telah direka. Tinjauan

pustaka dibuat terhadap turbin angin dan hydro untuk mendapatkan pemahaman

yang lebih baik terhadap konsep dan prinsip asas bagi turbin angin and hydro yang

telah ada. Tiga konsep rekaan bagi model turbin hydro angin telah dilakarkan dan

konsep yang terbaik telah dipilih melalui cara pemilihan konsep Pugh. Konsep yang

telah dipilih dikembangkan menjadi rekaan teliti dengan mengunakan perisian

CATIA dan bahan yang sesuai untuk memfabrikasikan model turbin hydro angin

telah dipilih. Proses pembuatan yang telah digunakan untuk memfabrikasikan model

turbin hydro angin adalah kimpalan MIG, “bending” and “riveting”. Turbin hydro

angin ini telah dikaji dan data yang terkumpul dianalisakan. Keseluruhan penemuan

dalam projek ini disimpulkan dan cadangan pembaikan bagi turbin hydro angin

model disarankan pada akhir projek.

ii

ABSTRACT

Renewable energy sources are the natural resources that are inexhaustible. Today,

people use wind energy and hydro power to make electricity. Battery has the

limitation of short usage lifetime and cannot provide long term power generation in

isolated places. In this project, the proposed solution to solve the problem is by

developing a turbine operated by wind and hydro power. The objectives of this

project are to design and investigate preliminary operation of hydro wind turbine

designed. Literature review is done on the wind and hydro turbine to gain a better

understanding of the concept and fundamental of existing wind and hydro turbine.

Three concepts of design for the hydro wind turbine model are sketched and the best

concept is selected through the Pugh concept selection method. The detail design of

the selected concept is generated using CATIA software and the suitable materials

are chose based on light weight property. The main manufacturing processes used to

fabricate the hydro wind turbine model are MIG welding, bending and riveting. The

hydro wind turbine is tested and the data gained is analyzed. The overall findings are

concluded and recommendation of improvement for the hydro wind turbine designed

is suggested at the end of project.

iii

ACKNOWLEDGEMENT

First and foremost, I would like to express my deepest sense of gratitude and

appreciation to my respected project supervisor, Associate Professor Ir. Sivarao A/L

Subramonian, for his support, useful guidance, encouragement, valuable advice and

constructive comments during the time this final year project was being developed.

And not forget to my examiner and panel, Mr Mohd Fairuz Bin Dimin@Mohd Amin

and Mr. Ammar Bin Abd Rahman respectively. Thank you for the guidance.

Next, I would like to thank all my course mates and friends, for their moral support

and valuable help that they had offered to me throughout my course of studies.

Last but not the least, a special note of thanks is also dedicated to my classmate, Ow

Yong Chia Hau in helping me to fabricate the hydro wind turbine model. Without his

helping, the model will not fabricate successfully.

iv

DEDICATION

Dedicated to my supportive father and mother, who sacrificed so much for his

children. I would like to extend my heartiest thanks to my beloved family. They are

understanding, supportive, loving and caring especially for the period during

development of this project. Special appreciation to all of you.

v

TABLE OF CONTENT

Abstrak i

Abstract ii

Acknowledgement iii

Dedication iv

Table of Content v

List of Tables ix

List of Figures x

List of Abbreviations xiii

1. INTRODUCTION 1

1.1 Introduction 1

1.2 Problem Statement 2

1.3 Objective 2

1.4 Scope 2

1.5 Proposed Solution 3

2. LITERATURE REVIEW 4

2.1 Wind Turbine 4

2.1.1 Types of Wind Turbine 5

2.1.2 Components of Wind Energy Systems 6

2.1.3 Current Wind Turbines 7

2.1.4 Major Components 8

2.1.4.1 Nacelle 10

2.1.4.2 Rotor 12

2.1.4.3 Tower 13

2.1.4.4 Balance of System 13

2.1.5 Wind Speed Measurement 14

2.1.6 Simulation 15

2.2 Water Turbine 15

2.2.1 Types of Water Turbine 16

vi

2.2.1.1 Pelton Turbine 16

2.2.1.2 Francis Turbine 17

2.2.1.3 Kaplan Turbine 18

2.2.2 Implementation 19

2.2.3 Hydropower Plants 20

2.2.4 Working Mechanism 21

2.2.5 Head and Flow 22

2.2.6 Rotor Angle 23

2.3 Wind Hydro Turbine 23

2.3.1 Power Generation 23

2.3.2 Power Storage 25

2.3.3 Simulation 25

2.3.4 Application 26

3. METHODOLOGY 27

3.1 Flow Chart of Work 28

3.2 Study of Existing Turbine 29

3.3 Conceptual Design 29

3.3.1 Concept One 29

3.3.2 Concept Two 30

3.3.3 Concept Three 31

3.4 Design Selection 32

3.4.1 Pugh Concept Selection 32

3.5 Detail Design 34

3.5.1 Materials 36

3.5.2 Wind Turbine Design 38

3.5.2.1 Wind Blade 39

3.5.2.2 Frame 40

3.5.2.3 Hose Cylinder 41

3.5.3 Water Turbine Design 42

3.5.3.1 Turbine Blade 42

3.5.2.2 Frame 44

3.5.4 Generator Design 44

3.5.4.1 MXN13FB11H Motor 45

vii

3.5.5 Base Design 46

3.6 Model 48

3.6.1 Metal Inert Gas Welding (MIG) 48

3.6.2 Bending 48

3.6.3 Riveting 49

3.6.4 Wind Turbine Fabrication 49

3.6.4.1 Frame 49

3.6.4.2 Hose Cylinder 51

3.6.4.3 Wind Blade 52

3.6.4.5 Wind Turbine Assembly 53

3.6.5 Water Turbine Fabrication 54

3.6.5.1 Turbine Blade 54

3.6.5.2 Frame 55

3.6.5.3 Water Turbine Assembly 55

3.6.6 Base Forming 56

3.6.7 Generator Fabrication 58

3.6.8 Hydro Wind Turbine Assembly 59

3.7 Test and Analysis 61

3.7.1 Water Flow Distance Testing 61

3.8 Recommendation 63

4. RESULT & DISCUSSION 64

4.1 Results 64

4.1.1 Model 64

4.1.2 Wind Turbine Testing 66

4.1.2.1 Water Flow Distance 66

4.1.2.2 Analysis of Data 67

4.2 Discussion 68

4.2.1 Assembly of CAD Components 68

4.2.2 Failure of Designed Hydro Wind Turbine 69

4.2.2.1 Incline Revolved Water Hose Overly Large 69

4.2.2.2 Water Hose and PVC Tube Diameter Excessively Big 69

4.2.2.2 Improper Tighten of Water Hose 70

viii

5. CONCLUSION & RECOMMENDATION 71

5.1 Conclusion 71

5.2 Recommendation 72

5.2.1 Wind Blade Design 72

5.2.2 Hose Cylinder Size 72

5.2.3 Slope of Revolved Hose 73

REFERENCES 74

APPENDICES 77

A 77

B 78

C 79

D 80

E 81

ix

LIST OF TABLES

2.1 Description of Nacelle Components 11

2.2 Description of Rotor Components 12

2.3 Description of Tower Components 13

2.4 Description of Balance of System Components 14

3.1 Concept Scoring Matrix 33

3.2 Materials Used for Water Turbine Fabrication 36

3.3 Materials Used for Wind Turbine Fabrication 37

3.4 Materials Used for Base Forming 38

3.2 Materials Used for Generator Fabrication 38

4.1 Water Flow Distance for 89mm Diameter PVC Tube 66

4.1 Water Flow Distance for 114mm Diameter PVC Tube 67

x

LIST OF FIGURES

2.1 Two Basic Wind Turbines, Horizontal Axis and Vertical Axis 5

2.2 Components of a Wind Energy System 6

2.3 Wind Turbine Diagram 7

2.4 Schematic View of Wind Turbine 9

2.5 Schematic View of Wind Turbine Major components 9

2.6 Schematic View of Wind Turbine Major Subcomponents 10

2.7 Pelton Turbine with One Jet 16

2.8 Pelton Turbine with Four Jets 17

2.9 Francis Turbine 18

2.10 Kaplan Turbine 19

2.11 Working Mechanism of Hydro Plant 22

3.1 Flow Chart of Work 28

3.2 Schematic Diagram of Concept One 30

3.3 Schematic Diagram of Concept Two 31

3.4 Schematic Diagram of Concept Three 32

3.5 Main Parts of Hydro Wind Turbine 34

3.6a Third Angle Projection View of Hydro Wind Turbine 35

3.6b Detail Drawing of Hydro Wind Turbine 35

3.7 Wind Turbine 39

3.8 Angle between Two Wind Blades 39

3.9 Wind Blade 40

3.10 Frame of Wind Turbine 40

3.11 Hose Cylinder 41

3.12 Water Turbine 42

3.13 Angle between Two Turbine Blades 43

3.14 Angle of Turbine Blade 43

3.15 Turbine Blade 43

3.16 Frame for Water Turbine 44

3.17 Generator 45

xi

3.18 MXN13FB11H Motor 45

3.19 Bending Angle for Four Sides of Base 46

3.20 Holes of Hose Cylinder and Turbine Blade 47

3.21 Base 47

3.22 Frame for Wind Turbine 49

3.23 Lathed Shaft 50

3.24 Screwing of Lathed Shaft to the Frame 50

3.25 Complete Frame 50

3.26 Holes for Cable Tight 51

3.27 Tighten the Water Hose with Cable Tight 51

3.28 Complete Hose Cylinder 51

3.29 Riveting of Wind Blade 52

3.30 Completed Wind Blade 52

3.31a Wind Blade Screwing 53

3.31b Hose Cylinder Screwing 53

3.32 Assembled Wind Turbine 53

3.33 Sticking of Zinc Plate on Nut 54

3.34 Completed Turbine Blade 54

3.35 Water Turbine Frame 55

3.36 Assembled Water Turbine 55

3.37 Dimension for Wire Mesh Base 56

3.38 Wire Mesh Base 56

3.39a Sweeping of Fiber Glue 57

3.39b Sticking of Fiber 57

3.40 Stiffen Fiber Base 57

3.41 Side View of Generator Frame 58

3.42 Frame of Generator 58

3.43 Screwing of Motor on Frame 58

3.44 Completed Generator 59

3.45 Position of Hydro Wind Turbine Components on the Fiber Base 59

3.46 Connection of Water Turbine and Generator 60

3.47 Assembled Hydro Wind Turbine Model 60

3.48 Head Specially Fabricated for Water Flow Testing 62

3.49 Replacement of Testing Head 62

xii

3.50 Clamping Head Using Handrill 62

3.51 Water Flow Distance 63

4.1 Hydro Wind Turbine Model 65

A1 Gantt Chart for PSM I 77

A2 Gantt Chart for PSM II 77

B1 Detail Drawing for Wind Turbine 78

C1 Detail Drawing for Hydro Turbine 79

D1 Detail Drawing for Base 80

E1 Detail Drawing for Generator 81

xiii

LIST OF ABBREVIATIONS

AC - Alternating Current

AWS - Average Wind Speed

CAD - Computer Aided Design

DC - Direct Current

DG - Distributed Generators

HTGS - Hydro Turbine Generating Sets

IG - Induction Generator

MHPP - Micro Hydro Power Plant

MIG - Metal Inert Gas

MPT - Maximum Power Tracking

MWPT - Micro Wind Power Turbine

NDE-HS - Nonlinear Differential Equations for Hydraulic System

PMSG - Permanent Magnet Synchronous Generator

PVC - Polyvinyl Chloride

RPM - Revolution Per Minute

SCIG - Squirrel Cage Induction Generator

SPS - Sim Power System

THD - Total Harmonic Distortion

TSP - Transient Stability Program

VFC - Voltage and Frequency Controller

1

CHAPTER 1

INTRODUCTION

This chapter describes about the background of the project and briefly explains about

the problem statement for this project. Then, the goals and scope of the project are

identified. Finally, the proposed solution is briefly discussed.

1.1 Background

Renewable energy sources are the natural resources that are inexhaustible.

Renewable energy sources have attracted attention world-wide due to soaring prices

of fossil fuels. Renewable energy sources are considered to be important in

improving the security of energy supplies by decreasing the dependency on fossil

fuels and in reducing the emissions of greenhouse gases. Importantly, renewable

energy produces virtually no greenhouse gas emissions. This can protect earth from

pollution. Examples of renewable energy are wind, hydropower, solar, geothermal

and biomass.

Wind is simply air in motion caused by the uneven heating of the earth‟s surface by

radiant energy from the sun. Today, people use wind energy to make electricity.

Wind power has been used for pumping water, milling grain and driving other

mechanical devices start from thousand years ago. Nowadays wind farm commonly

employs groups of wind turbine, located either on land, near-shore and off-shore, to

harness wind energy for mass production of electricity. A wind turbine is a device

fitted with blades which converts kinetic energy of the wind into rotational motion to

turn an electrical generator and produce electricity. Wind power is commonly used in

many countries including Germany, Denmark, Spain and United.

2

Hydropower is energy that comes from the force of moving water. The force of

moving water can be extremely powerful. Hydropower is called a renewable energy

source because the water on the earth is continuously replenished by precipitation.

Hydro energy uses water to create power. Hydropower converts the energy in

flowing water into electricity. Most hydroelectric power comes from the potential

energy of dammed water driving a water turbine and generator. The quantity of

electricity generated is determined by the volume of water flow and the amount of

"head". “Head” is the height from turbines in the power plant to the water surface

created by the dam. The greater the flow and head, the more electricity produced.

1.2 Problem Statement

The light of alert sign board that located at the dangerous and isolated area like sea is

operated by using battery at night. But battery has the limitation of short usage

lifetime and cannot provide a long term power generation. Furthermore, the

replacement of new battery in this isolated place is trouble and inconvenience.

1.3 Objective

The objectives of this project are to:

i. Design a hydro wind turbine.

ii. Develop a hydro wind turbine model.

iii. Investigate the preliminary operation.

1.4 Scope

This project focus on prototype a turbine that operated by wind and hydro power.

The maximum dimension of the hydro wind turbine is 50mm length, 30mm width

and 40mm height.

3

1.5 Proposed Solution

The problem can be solved by develop a turbine that operated by wind and hydro

power. This hydro wind turbine can provide a long term power generation and is no

need of doing any battery replacement when usage life time is over.

4

CHAPTER 2

LITERATURE REVIEW

This chapter contains of literature review on the types, development and application

of wind turbine, hydro turbine and wind hydro turbine.

2.1 Wind Turbine

Wind turbines used to generate electricity come in a wide variety of sizes. Large

wind turbines, which are usually installed in clusters called windfarms, can generate

large amounts of electricity. Large wind turbines may even produce hundreds of

megawatts of electricity, enough to power hundreds of homes. Small wind turbines

which are generally defined as producing no more than 100 kW of electricity, are

designed to be installed at homes, farms and small businesses either as a source of

backup electricity, or to offset use of utility power and reduce electricity bills.

Wind turbines produce electricity by using the natural power of the wind to drive a

generator. The wind is a clean and sustainable fuel source, it does not create

emissions and it will never run out as it is constantly replenished by energy from the

sun. In many ways, wind turbines are the natural evolution of traditional windmills,

but now typically have three blades, which rotate around a horizontal hub at the top

of a steel tower. Most wind turbines start generating electricity at wind speeds of

around 3-4 metres per second (m/s), (8 miles per hour); generate maximum „rated‟

power at around 15 m/s (30mph); and shut down to prevent storm damage at 25 m/s

or above (50mph).

5

Patel, D. et al. (2010) have analyzed the impact of wind turbine generators on

network resonance and harmonic distortion. First, a representative study system is

devised where the impact of different elements of power system on system resonance

frequencies is analyzed. Then the influence of system background harmonics on

harmonic distortion is shown for the study system as well as for one of the actual

Hydro One distribution feeder systems. It is shown that several scenarios are possible

when these resonant frequencies align with harmonic frequencies that are likely to be

injected by other power electronic based system equipment including distributed

generators (DGs), thus causing unacceptable total harmonic distortion. Results for

the study system further shows that the addition of a specific number of SCIG‟s may

cause an unacceptable value of THD due to network resonance.

2.1.1 Types of Wind Turbine

There are two basic types of wind turbine which are horizontal axis wind turbines

and vertical axis wind turbines. Figure 2.1 shows the two basic types of wind

turbines. Horizontal axis turbines need to be aimed directly at the wind. Because of

this, they come with a tailvane that will continuously point them in the direction of

the wind. Vertical axis turbines work whatever direction the wind is blowing, but

require a lot more ground space to support their guy wires than horizontal axis wind

turbines. (Clarke, 2003).

Figure 2.1: Two basic wind turbines, horizontal axis and vertical axis (Clarke, 2003).

6

2.1.2 Components of Wind Energy Systems

There are four basic components of typical wind energy system which are including

rotor, gearbox, enclosure and tail vane. Figure 2.2 shows the basic components of a

typical wind energy system. A rotor is consisted of blades with aerodynamic surfaces.

When the wind blows over the blades, the rotor turns, causing the generator or

alternator in the turbine to rotate and produce electricity. Gearbox is matched to the

rotor speed to that of the generator or alternator. The smallest turbines which are

under 10 kW usually do not require a gearbox. The function of enclosure or nacelle

is to protect the gearbox, generator and other components of the turbine from the

elements. A tailvane or yaw system is used to align the turbine with the wind.

Horizontal axis wind turbine is mounted on a tower and vertical axis turbines are

usually built on the ground. (Clarke, 2003).

Figure 2.2: Components of a wind energy system (Clarke, 2003).

7

2.1.3 Current Wind Turbines

Today‟s wind turbines use blades to capture the wind‟s kinetic energy. Wind turbines

work because they slow down the speed of the wind. When the wind blows, it pushes

against the blades of the wind turbine, making them spin. They power a generator to

produce electricity. Most wind turbines have the same basic parts which are blades,

shafts, gears, a generator, and a cable. Some turbines do not have gearboxes. These

parts work together to convert the wind‟s energy into electricity. (National Energy

Education Development Project, 2010).

Figure 2.3: Wind turbine diagram (National Energy Education Development Project, 2010).

The wind blows and pushes against the blades on top of the tower, making them spin.

The turbine blades are connected to a low-speed drive shaft. When the blades spin,

the shaft turns. The shaft is connected to a gearbox. The gears in the gearbox increase

the speed of the spinning motion on a high-speed drive shaft. The high-speed drive

shaft is connected to a generator. As the shaft turns inside the generator, it produces

electricity. The electricity is sent through a cable down the turbine tower to a

transmission line.