Category: Local Fabrication

PELTON TURBINE TRAINING AT CREATECH, Philippines

12/11/2019

Last month, practitioners from Philippines and Malaysia gathered for a training session on Pelton micro hydro turbine fabrication. The session was the second part of a two-part training organized by HPNET and Sibol Ng Agham At Teknolohiya (SIBAT), to strengthen local capacities in fabrication and manufacturing.

The training responded addressed the knowledge exchange needs of HPNET Members in the Philippines and Malaysia who require skills to design and build Pelton micro hydro turbines.

Following an online training in November, the in-person training ran from December 2 - 7 and was held at SIBAT's Center for Renewable Energy and Appropriate Technology (CREATech) in Capas, Tarlac, Philippines. The overall aim was for participants to acquire knowledge of the design, manufacturing and testing of Pelton turbines, including fabrication of the Pelton runner assembly.
Participants benefited from an opportunity for hands-on learning, in addition to technical and theoretical presentations.

Within Pelton Turbine Design, sub-topics covered included:

Single and multi jet turbines;
Vertical and horizontal axis turbines;
Direct and belt drive systems;
Net head calculations and shaft calculations;
Pelton runner sizing;
Bearing and belt selection;
Other components.

The resource person for this training was HPNET Member Mr. Ajith Kumara from Simple Engineering, a senior micro and mini hydropower specialist based in Sri Lanka. Mr. Kumara has extensive experience training practitioners in design and fabrication aspects of various electro-mechanical components of small-scale hydropower.

This training was made possible by SIBAT, WISIONS and Simple Engineering.

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ONE STUDENT'S JOURNEY IN COMMUNITY MICRO HYDRO WITH HPNET

6/22/2015

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ACREST technician, Momanyi Oreri, fabricates a crossflow turbine runner on the lathe in his workshop in Bangang, Cameroon.

There are few singular moments in life that redefine who we are; always in retrospect, those moments are abundantly clear. In October 2010, as a wide-eyed and barely-sophomore civil engineering student, I sheepishly attended a callout event for Purdue University’s relatively new “Global Design Teams” initiative. The lights dimmed on one presentation entitled “Development of Community Power from Sustainable Small Hydro Power Systems -- A Capacity Building Project in Bangang, Cameroon”. The title alone appealed to my self-ascribed environmentalism, my burgeoning lust for nomadism, my engineering intrigue, and my misguided “do-gooder” morality. I approached the presenter, Dr. Laurent Ahiablame, after his slideshow and, informing him that I had no prior knowledge of small-scale energy projects, inquired what level of experience is required to become a member of the team. He said, “All are welcome in this field -- the technology is built for everyone. There are many people who will guide you along the way, if only you show the dedication.”

Now five years on, as I prepare to take on a new role as Projects Officer for Green Empowerment in Myanmar, I reflect on the decisions, experiences, and people that brought me from that presentation at Purdue University to this point.

Between 2011 and 2014, I took lead of the micro hydro project in Bangang village, Cameroon, tasked with developing a 40kW scheme featuring a collaboratively designed and locally fabricated crossflow turbine. Under the auspices of Purdue’s Global Engineering Program (GEP) and the African Center for Renewable Energy and Sustainable Technology (ACREST), my team ran the gamut of development successes and foibles.

Our first turbine prototype was funded by a competitive student grant from the U.S. Environmental Protection Agency, but barely a year after its inception, and merely three weeks into testing, that prototype was permanently decommissioned due to a catastrophic, indeterminable failure in August 2012. The specific mechanical failure was quickly pinpointed and reported in great detail in the team’s 2013 publication on the incident, but the devastating incident had a great bearing on my worldview as an engineer, as evidenced in the conclusion:

“Engineers’ constant pursuit of higher efficiencies in lieu of a true understanding of appropriate technologies, often a function of culture, and the resultant failures of those biases are well documented. The subsequent necessity for cross-disciplinarity is also well understood. The most compelling prospect for future research in the micro-hydropower field relies critically on the intersection of culture and engineering. All facets of true cross-disciplinarity and multiculturalism should be explored for successful project design and implementation."

Indigenous technicians at Tonibung CREATE fabricate crossflow turbine components at their workshop in Penampang, Sabah.

Upon that revelation, my attention was drawn away from the engineering jigsaw puzzle that is micro hydro systems design and reinvested more purposefully in understanding the intricate and complex cultural fray that ultimately determines the success or failure of any micro hydro project. I found kindred spirits amongst faculty and graduate students in Purdue’s Department of Anthropology. My reflection of this revelatory time was chronicled writ large in my 2014 TEDxTalk, Community Power -- Realizing Sustainability in Development. This opportunity to speak, along with one last successful bid for funding to support hybridization of the Bangang system, effectively punctuated my tenure as team leader with the takeaway lesson that nothing trumps the culture element in community micro hydro. It is the single most accurate predictor of project success and failure.

Upon graduation, I was warmly welcomed into the familial micro hydro scene of South and Southeast Asia by Dipti Vaghela, a micro hydro practitioner and network coordinator for HPNET, and Dr. Chris Greacen, a small power producer policy expert and World Bank consultant. My conversations with them paved the way for the next stage in my journey: Borneo.

Through HPNET’s extensive network of practitioners in the region, I was quickly introduced to Gabe Wynn and Adrian Banie Lasimbang. Banie, an engineer, serves as the founding director of Tonibung, a non-profit organization located outside of Kota Kinabalu in Sabah which strives to provide rural, indigenous villages with access to clean water and electricity through renewable energy and sustainable solutions. Founded in 1991 to equip relocated indigenous peoples with the skills needed to adapt to unfamiliar agricultural circumstances, the organization now prioritizes integrated projects that serve the greatest human need, prove sustainable over time, and have the possibility of broader impact beyond any single community. Gabe, an anthropologist and environmental scientist by trade, wears two hats as a co-director of Penampang Renewable Energy Sdn Bhd (PRE) -- a social enterprise company set up to cater to Tonibung’s technical renewable energy demands, such as turbine fabrication and consultancy; and as the Borneo Program Manager for Green Empowerment -- a Portland-based community development non-profit which he has been representing in Southeast Asia since 2011.

Between December 2014 and May 2015, I had the great privilege of interning under Banie’s and Gabe’s instruction at Tonibung’s Center for Renewable Energy and Appropriate Technology (CREATE). CREATE, founded in 2013 as direct outcome of HPNET’s 1st Annual Gathering of Practitioners, is a local fabrication facility which has recently begun manufacturing high-head, low flow pelton turbines for the Malaysian context. By the time I set foot in their workshop, CREATE was already well-primed for a push into locally sourced, locally fabricated crossflow turbines -- an entirely new animal for the highly skilled indigenous workshop technicians to sink their machines into. With my background in crossflow design stemming from my years in university, it was easy for me to feel at home in the CREATE space as we co-learned the nuances of civil works design and site selection.

Rendering showing what the finished TMT-100 turbine is expected to look like. The design from Remote HydroLight is currently being fabricated at Tonibung CREATE in Sabah, North Borneo.

Things progress quickly at Tonibung, and by March 2015, we had a site selected for crossflow implementation in a remote Murut village of the Bornean interior called Saliku. Pulling once again from HPNET’s wealth of knowledge and resources, we contacted a legendary (and prominently open source) turbine designer, Owen Schumacher, whose 20+ years working in Afghanistan yielded the implementation of hundreds of community micro hydro sites. Owen graciously afforded us personal, in-depth design guidance, recommending a crossflow design branded the “Traditional Mill Turbine”, or TMT, by his organization, Remote HydroLight.

Fabrication of Tonibung’s first crossflow turbine for real-world application began with the TMT-100 (so named for its 100mm effective width) in late April 2015 and continues to this time of writing, with fabrication expected to be completed by July 2015. You can stay informed about CREATE’s crossflow fabrication, and all other Tonibung activites, on their Facebook page. The open source nature of Owen’s simple TMT design allows for, and necessarily encourages, modification by workshop technicians around the world according to their local context and conditions. A complete list of Remote HydroLight’s open source turbine offerings can be found here, and their contribution to the field of open source Electronic Load Controllers (ELCs) can be found here.

Certainly, there is not enough space in a single blog post to identify all, or even most, of the influencers who have blazed the trail for me to pursue community micro hydro, but suffice it to say that my experience and good fortune has depended principally on the kindness of mentors, peers, and role models to help me find each new rung of the ladder. If one thing is certain, Laurent’s assurance to me lo those 5 years ago still holds as true today as it ever did. “All are welcome in this field -- the technology is built for everyone. There are many people who will guide you along the way, if only you show the dedication.”

By Patrick Pawletko, HPNET member

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the flow

PELTON TURBINE TRAINING AT CREATECH, Philippines

PT ENTEC TEAM VISITS TONIBUNG IN MALAYSIA

ONE STUDENT'S JOURNEY IN COMMUNITY MICRO HYDRO WITH HPNET

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