1. Small-Scale Hydropower Optimization ME/EE Senior Design Project 2004/2005 Customer: John Law Mentors: Ralph Budwig (ME), Brian Johnson (EE) Phillip Arpke Kelly Jobes Jamin Juhasz Karl Krohmer Jill Nieborsky

2. Problem Definition Optimize Small-scale Hydropower System For Residential Heating Optimize Small-scale Hydropower System For Residential Heating The Generator Is Capable Of Providing 3.7 kW Power The Generator Is Capable Of Providing 3.7 kW Power Last Spring During Maximum Flow, The Generator Provided Only 1 kW Of Power Last Spring During Maximum Flow, The Generator Provided Only 1 kW Of Power

3. ConstraintsConstraints Site Vs. Lab Conditions Site Vs. Lab Conditions Site: 9 cfs and 40 ft/s Site: 9 cfs and 40 ft/s Lab: 1 cfs and 16 ft/s Lab: 1 cfs and 16 ft/s Inherited Features Inherited Features Three-phase Generator Sunk Cost Three-phase Generator Sunk Cost 12-inch Penstock Pipe To 6-inch Round 12-inch Penstock Pipe To 6-inch Round On/Off Operation With Maximum Flow On/Off Operation With Maximum Flow

4. Project Milestones Lab Tests Of Initial System Lab Tests Of Initial System RPM RPM Static Torque Static Torque Power Output Power Output System Design System Design Hydro Lab Hydro Lab Randall Creek Randall Creek Performance Verification Performance Verification Lab Lab Field Field

5. Cross-flow Turbine Background Banki Turbine Banki Turbine Top Water Entry Falling Action  =80%

6. Design Improvements Increased Power Output Increased Power Output Nozzle Redesign Nozzle Redesign Reduced Water Drag In “Hot Spot” Reduced Water Drag In “Hot Spot” Viewing Window Viewing Window Old Configuration New Configuration

7. Nozzle Design (Lab) Design Based On Fluid Velocity (16 ft/s) Design Based On Fluid Velocity (16 ft/s) 15.75 in 2 Cross-sectional Area 15.75 in 2 Cross-sectional Area Hydraulic Area Constant From Round To Square Hydraulic Area Constant From Round To Square

8. Nozzle Design (Field) Design Based On Flow Rate (9.63 ft 3 /s) Design Based On Flow Rate (9.63 ft 3 /s) 31.875 in 2 Cross-sectional Area 31.875 in 2 Cross-sectional Area Hydraulic Area Constant From Round To Square Hydraulic Area Constant From Round To Square

9. Housing Design Eliminated Water Drag In “Hot Spot” Eliminated Water Drag In “Hot Spot” Plexiglas Top For Viewing Flow Pattern Plexiglas Top For Viewing Flow Pattern

10. Electrical Schematic Three Components Three Components Resistive Heating Load (12 Ω) Resistive Heating Load (12 Ω) Capacitor Bank (135 µF) Capacitor Bank (135 µF) Induction Generator Induction Generator

11. ManufacturingManufacturing Welding Test NozzleInstalling the Runner Fitting Circular Flange to Lab NozzleBridgeport CNC Machine

12. TestingTesting Measured Generator and Turbine RPM With No-load, Shunt Capacitors Only, and 12 Ω Load With Shunt Capacitance Measured Generator and Turbine RPM With No-load, Shunt Capacitors Only, and 12 Ω Load With Shunt Capacitance Measured Power Output For Three Cases Measured Power Output For Three Cases Measured Static Torque Measured Static Torque TurbineGenerator Electrical Box Water Supply

13. Laboratory Results RPM Tests TurbineGenerator % Improvement Free-Spin RPM Test409 RPM81 No Load RPM Test297.5 RPM1785 RPM20 Capacitors w/o Load201 RPM1171 RPM13 w/Capacitors w/Load218 RPM1271 RPM12 Static Torque Test Force (lb) % Improvement 2-ft Arm15.534 3-ft Arm10.2532 Electrical Power (Watts) % Improvement 141.4 53

14. Field Performance Diversion SetupDiversion Canal Installed Turbine