1. Anand Krishnan Plappally
Micro Hydel Turbine
Prof. P. M. V. Subbarao
Prof.Sanjeev Jain
Prof.Santosh Satya
Anand Krishnan Plappally
IIT, DELHI

2. Mangal Turbine on River Sajnam, Bhailoni Lod Village Lalitpur Dist.
Dr S K Saha ,IAS Reviewing the Mangal water Wheel

3. Objective: VVisits to the different Sites in Gharwal area and
eEstimation of hydro potential of these sites.
MMeasurement of geometry and performance of the existing water wheels.
DDevelopment of improved design of water wheel to
increase the efficiency of the wheel.
decrease the cost of the wheel, and
increase the reliability of the system.
DDevelopment of various utility devices using Hydel Power other than the Electric power.
IImprovisation of Mangal Turbine

4. HHISTORY
The first reference to its use dates back to about 4000 B.C., where, in a poem by an early Greek writer, Antipater, it tells about the freedom from the toil of young women who operated small handmills to grind corn.
AAs early as the first century, waterwheels of the vertical design were replacing the horizontal waterwheel.
An early horizontal-wheeled watermill used for grinding grain in Greece was the called Norse Mill. In Syria, the watermills were called "noriahs". They were used for running mills to process cotton into cloth.
OThe three distinct types of water mills,
The simplest and probably the earliest was a vertical wheel with paddles on which the force of the stream acted.
Next was the horizontal wheel used for driving a millstone through a vertical shaft attached directly to the wheel .
Third was the geared mill driven by a vertical waterwheel with a horizontal shaft.

6. Applications: Grinding Grains Rural Electrification Irrigation
De Husking
Cotton combing
Rice Huller
Other Agriculture related machines

7. Contact Agencies in India
HESCO is a NGO working on these perennial hydraulic resources in the TEHRI GARHWAL (UTTARANCHAL) for providing electrical and mechanical power to rural public.
SIDH is a NGO in Mussorie.
CIMMYT (INDIA) , DELHI
There are other organizations.

8. Past Experience and Current Work
Design, Fabrication and Erection of 5 kW Horizontal Axis Hydro-Turbo Pump on a small river near Jhansi.
Designing , Fabricating and Testing of 3.5 kW Horizontal Axis Hydro-Turbo Pump cum Generator on a Drainage Canal at Sonipat.
Design, Fabrication of 3.5 kW Vertical Axis Hydro-Turbo Atta Chakki cum Alternator at Lacchiwala, near Dehradun.
Generation of Data Base of various Micro Hydel Resources in Uttaranchal sites.
Design of Micro Hydel stations. - Three sites.

9. Specify flow rate and head
Start
Specify flow rate and head
Calculate flow power
Power requirement?
Flow or head enough for required power production
Yes No
Require water storage and P E utilization?
Power can be produced
Start Turbine Design `
Select turbine speed as per power consuming device
No. of vanes to be kept odd
Material for manufacture according to availability: (best M, S material)
Design for assembly of the system; turbine, power transmission devices, pump or alternator as required
Install & stop

10. Comparative chart of Old and Improved Mangal Turbine
Comparative chart of Old and Improved Mangal Turbine
Specifications
Farmers Version Mangal turbine
New Design I Mangal Turbine
Weight of turbine
1500 kg
350 kg
Outer diameter of wheel
4.0 m
1.26m
Wheel speed
13 RPM
70 RPM
No. Of blades 24 14
Head
1.5m
Water consumption
1800 lit/sec
500 lit/sec
Flow turning angle
70o for Big blade
49o for Small blade
110o
(One type blade only)
Blade width
Big blade = 670 mm
Small blade = 435 mm
380mm
Blade depth
Big blade = 235mm
Small blade = 100 mm
100mm
Gear box
3 stages
Gear Ratio 1:125
2 stages
Gear Ratio 1: 21.54
Material
M.S.
Specific Speed
75 RPM
3771RPM
Pump discharge
22 lit/sec
19.5 lit/sec
Output power
6 KW
Efficiency
22.7%
72%
Cost of wheel
Cost of gear box
80,000
120,000
7,000
14,000

11. Schematic View of Micro Hydel Turbine having horizontal runner

12. Mangal Turbine (Old design)
Improved Design(version-1) of Mangal Turbine by IIT Delhi on River Sajnam,Lalitpur Dist.Bhailoni Lod Village
Mangal Turbine (Old design)
New Turbine Design

13. Improved Mangal turbine Improved Mangal Turbine
Specifications
Improved Mangal turbine
Version 2
Improved Mangal Turbine
Version 1
Weight of turbine
450 kg
350 kg
Outer diameter of wheel
1.5 m
1.26m
Wheel speed
50 RPM
70 RPM
No. Of blades 15 14
Head 1m
1.5m
Water consumption
500 lit/sec
Flow turning angle
1290
110o
(One type blade only)
Blade width
520mm
380mm
Blade depth
145 mm
100mm
Gear box
2 stages
Gear Ratio 1:30
Gear Ratio 1: 21.54
Material
M.S.
Design Principle
Poncelot inlet / Girard outlet
Pelton/impulse wheel
Poncelet inlet/Girard outlet
Efficiency
82%
68%
Cost of wheel
Cost of gear box
Rs10,000
Rs25,000
Rs7,000
Rs14,000

16. Figure Showing Gharat having vertical runner

17. EXISTING DESIGN Grinder adjusting lever Bush Bearing Alternator
Grinding Wheel
6” Pulley
12” Pulley
Top Bearing
Lower Bearing
EXISTING DESIGN
Penstock
Water Wheel
Main Shaft
Wooden Base
40” Pulley
18” Pulley
Canal

18. New Design Grinder adjusting lever Generator Gear Box Main Shaft Canal
Penstock
Water Wheel
Main Shaft
Bush Bearing
Wooden Base
Grinder adjusting lever
Grinding Wheel
10” Pulley
12” Pulley
Gear Box
Generator
Canal
Forbay
New Design

19. Dhan Cutter, Alternator
Site visited
Head available
(in M)
Flow Rate
(l/sec)
Wheel Speed
In RPM
Output Speed
Diameter of wheel
In CM
No. of Blades
Power Output
In KW
Applications
Sangtiyawala
1.40
480 90
1500
106 16 1
Chakki,
Alternator
Bhogpur Gharat (1)
2.30
889 95 2
Dhan Cutter, Alternator
Bhogpur Gharat (2)
645
104 84 29 -
Chakki
Donkwala (1)
1.50 70
100 30
Donkwala (2) 97
Donkwala (3)
1.25
Naya Gharat
,Lacchiwala
1.85
634 50
107 11 5
Chakki, Dhan cutter,
Unnat Gharat
0.6
352
New Design
342 73 3
Chakki, Alternator

20. Specification of upgraded wheel for Garwhal area

21. Gear box arrangement for Micro Hydel Turbine
To Turbine wheel
Input Shaft 100 RPM
First pair
G.R = 3.88
Second pair
Output Shaft
1500 rpm
Bevel Gear & Pinion
G.R = 1
To Alternator
Gear box arrangement for Micro Hydel Turbine

22. Computational Flow Anlysis