Locally-developed micro hydropower

AIDER has built eight MHPs, ranging from 7.5 kW to 100 kW, electrifying a total of about 450 households in rural municipalities of the Analamanga and Atsimo Andrefana regions.  Five of the projects are owned and operated by AIDER.  All of the systems use turbines that have been locally manufactured by AIDER, thereby having generated local employment.  In addition to providing reliable electricity to households, the MHPs power town halls, police stations, clinics, churches, schools, and street lighting. ​

Last quarter HPNET board member Biraj Gautam described our project, focused on the development of a Turgo turbine design, appropriate for local manufacture in Nepal. Whilst common in larger scale hydropower and with some off-the-shelf products available, the Turgo turbine is not currently manufactured by micro-hydropower companies in Nepal. As a medium head turbine, the Turgo offers a viable option for sites where the characteristics make the choice between Pelton and Cross-flow turbines difficult. This article provides an update on our progress in the project so far.                                                   

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Site Visit

Unfortunately, the ongoing coronavirus pandemic has prevented PEEDA staff from visiting the field site. A feasibility study is required to find out the technical and socio-economic features of the site and the community. Technically, we need to evaluate the current status of the civil structures and installed equipment. In addition, we require measurements of the powerhouse layout so that the new turbine can interface with existing components. From a socio-economic perspective, we want to understand how the plant is managed, whether the plant generates sufficient income, and assess the opportunity to maximise the plant’s capacity factor. It is important that we ensure that the plant is sustainable in delivering electricity to the community. We continue to monitor the coronavirus situation and hope to be able to visit the site when it is safe to do so. 

3D CAD Design
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Using the head and flow rate from the site and our scaling model, it has been possible to begin the detailed design of the Turgo turbine. The long-term intention is to develop a range of Turgo turbine designs appropriate for sites across the micro-hydropower range. We have been developing calculation sheets for all of the key components which allow dimensions to be determined. We have developed a parametric 3D CAD model that is linked to the calculation sheets. This allows us to quickly adapt the design depending on inputs into the calculation sheet. The 3D design is taking place collaboratively between the Electrical Energy Management Group at the  University of Bristol and Nepal Yantra Shala Energy. The design objective is to produce a design that can be readily manufactured in Nepal with existing machinery and readily available materials. It is expected that detailed design will be completed soon allowing the production of engineering drawings to begin. Initially, the focus is on developing a complete design package for the site in Taplejung. This will include 2D engineering drawings, bill of materials, and supporting 3D CAD files allowing the design to be manufactured in Nepal. Subsequently, we will use the parametric 3D model to generate multiple design packages for the complete operational range.​​
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​This article was written by Joe Butchers, PhD candidate at the University of Bristol. The project is titled Upscaling locally manufactured Turgo Turbine: Dissemination and Demonstration includes the Electrical Energy Management Group at the University of Bristol, PEEDA, Nepal Yantra Shala Energy, Turbine Testing Laboratory at Kathmandu University and HPNET as project partners, and is funded by Energize Nepal.  The work undertaken by the University of Bristol is also funded through an EPSRC Impact Acceleration Account titled Development of an open-source Turgo turbine design tool.

​The unit has been installed in Naubise, Dhading which is about 22 km from Kathmandu Valley. This unit is available for anyone interested to see it in operation.

To introduce a new micro hydropower technology to Nepal, it was important to understand the capability of micro hydro companies and the manufacturing processes that are available. This information can be used to ensure that the design of all components for a new type of turbine is appropriate for manufacture in the context of Nepal. A thorough study was conducted of the Nepali manufacturing companies which are based in Kathmandu and Butwal, central Nepal. Our study showed that manufacturers in Nepal tend to have access to the same equipment and materials, meaning that the processes for fabricating Turgo turbines tends to be very similar. However, as casting is an external process, the interface between the micro hydro companies and casting companies is a potential risk to the quality and accuracy of the Turgo cups. ​

Next Steps

The next steps for the project are to increase the technology readiness level of the Turgo turbine in Nepal. This will enable manufacturers to be equipped with all of the necessary information to design, manufacture and install Turgo turbines. A joint effort of all the partners,  including HPNET, will be facilitated to improve technology readiness. There are two parts to this future research:

• Workshop on Turgo Design and Manufacture

This workshop will provide the information needed for key stakeholders to be able to identify potential sites for the Turgo turbine, size and design the turbine system, manufacture the Turgo runner, and install and test the system. Both theoretical and practical support will be delivered in the workshop to ensure that a good understanding of the turbine is developed in the Nepalese micro hydropower manufacturing community.
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• Open-Source Repository of Turgo Turbine System Design and Webinar

The scalable tools and drawings for the Turgo turbine will be placed in an open and free web-based repository, enabling access for any stakeholder that is interested in the Turgo turbine. This will allow micro-hydropower manufacturers, in Nepal and worldwide, access to the necessary details to construct a complete Turgo turbine system. Alongside the drawings, guides will be developed to enable the knowledge generated from both projects to be shared with the audience, for example key constraints in casting Turgo cups, jigs required to assemble the runner, and how to select an appropriate site for the turbine.
The project team will also install a micro hydropower scale Turgo turbine at a site to demonstrate its potential for the future. With these plans in place, we hope the future for the Turgo turbine in Nepal is bright!

This article was written by guest blogger and HPNET Board of Representatives Member, Biraj Gautam, who is the Research Team Leader of the project and Chief Executive Officer at People, Energy and Environment Development Association (PEEDA) in Kathmandu, Nepal.

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 to 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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Last week, HPNET members in Indonesia and Malaysia came together to share their micro hydropower expertise and support each other's important work in energy access. HPNET Board members Gerhard Fischer and Ardi Nugraha of PT Entec Indonesia visited the TONIBUNG team at CREATE in Sabah, Malaysia to provide input on turbine design and fabrication techniques.

TONIBUNG has pioneered community-based micro hydro in Malaysia, working in partnership with  remote, indigenous communities for over 25 years. Despite their ample experience and expertise, the team is always looking for opportunities to improve their techniques and expand their impact.

HPNET facilitated the start of the partnership between TONIBUNG and PT Entec, way back when, and the network has benefited immensely from the ongoing contributions of both organizations. It is great to see continuous knowledge exchange (often self-initiated, as in this case) between these long-standing HPNET Members.

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