UNIVERSITI TUN HUSSEIN ONN MALAYSIA

STATUS CONFIRMATION FOR UNDERGRADUATE PROJECT REPORT

DEVELOPMENT OF PORTABLE LOW HEAD SMALL HYDRO GENERATOR

FOR RURAL ELECTRIFICATION
ACADEMIC SESSION : 2021/2022

I, MUHAMMAD HAIQAL BIN HALIM, agree to allow this Undergraduate Project Report to be
kept at the Library under the following terms:

1. This Undergraduate Project Report is the property of the Universiti Tun Hussein Onn Malaysia.
2. The library has the right to make copies for educational purposes only.
3. The library is allowed to make copies of this report for educational exchange between higher
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Approved by,

(MUHAMMAD HAIQAL BIN HALIM) (PN. RASIDA BINTI NORJALI)

Permanent Address:
NO 1056,
TMN DESA PERMAI REPAH,
73000 TAMPIN,
NEGERI SEMBILAN.

20 JUNE 2021 20 JUNE 2021

Date: Date:

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 ii

DEVELOPMENT OF PORTABLE LOW HEAD SMALL HYDRO GENERATOR

FOR RURAL ELECTRIFICATION

MUHAMMAD HAIQAL BIN HALIM

A thesis submitted in fulfillment of the requirement for award of the Bachelor of

Electrical Engineering Technology (Electrical Power) with Honors

Faculty of Engineering Technology

Universiti Tun Hussein Onn Malaysia

JUNE 2022
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I hereby declare that the work in this thesis in my own except for quotations and
summaries which have been duly acknowledged

Student : …………………………………….............

MUHAMMAD HAIQAL BIN HALIM

Date : 16 JUNE 2022

: …………………………………….............
Supervisor
PUAN RASIDA BINTI NORJALI

Co-Supervisor : …………………………………….............
DR NORAIN BINTI SAHARI
 iv

Thanks, in a special way for my mother and dad.

KAMISAH BINTI AHMAD

HALIM BIN HASAN

Who always gave me endless encouragement from the beginning of my study

For the inspiring supervisor,

PN. RASIDA BINTI NORJALI

DR. NORAIN BINTI SAHARI

Thank you for your guiding since the beginning of the PSM 1, and thank you for your
endless support and giving me new knowledge

For all my friends,

My BNE course mates

Thank you for giving me ideas and support in whatever I do

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ACKNOWLEDGEMENT

Praise to the Lord, the Almighty God for his wills and blessings, I have completed my
Projek Sarjana Muda (PSM) for my first degree of Bachelor of Engineering Technology
(Hons.) Electrical Power.

I would like to thank all those people who involved in this project from the start
until the end of my last year's project sincerely and express my appreciation. First and
foremost, I would like to express my sincere appreciation and deepest gratitude to my
supervisor, Pn. Rasida Binti Norjali, for her guidance, constant attention, generous idea
and enthusiastic support to me during the research project beginning with the final year
project 1 through the final year project 2. The idea that she gave me helped me a lot in
achieving my project.

I do also like to thank my family members for their continued encouragement,

commitment, and motivation to make sure I have completed this project. Last but not
least, I would also like to thank my dearest friends for supporting me broadly during the
final year project. They have helped and dedicated their time to complete this project
from day 1 to complete the final year project. I could not finish this project within the
specified time without them all. Finally, a thousand thanks also to all who contributed to
the success of this project directly or indirectly. Thank you.
 vi

ABSTRACT

Hydroelectricity is electrical energy generated when falling water from reservoirs or

flowing water from rivers, streams or waterfalls run of river is channeled through water
turbines. Off-grid hydro generator is an economical and practical approach to generate
electric power in rural areas. Large number of successful high head hydro generator
have been reported however the application of low head hydro generator is uncommon.
Low head hydro system generally recognized using complex blades, larger structure and
electromechanical to convert energy. This leads to higher cost and more complex
system. On the other hand, the potential to explore low head hydro system is huge
because there is where population is concentrated. Therefore, the aim of this project is to
develop a portable low head small hydro generator for rural electrification. This system
will use spiral turbine which is less complex compared to commonly used turbine such
as Pelton and Crossflow turbine. In addition, the PVC pipe will be used as turbine blade
which is more economical compared to conventional turbine blade such as aluminum
and steel. This PVC pipe is lightweight, strong and easy to install because it can be cut
and shaped in a variety way. Furthermore, it also has solid resistance to water due to
composition and immune to any outdoor use like resistance to water, wind and sunlight.
The study was conducted on 23rd May 2022 until 29th May 2022 at river Kampung
Chegor, Kuala Pilah, Negeri Sembilan. The higher gradient angle which is at 35 0 of
hydro generator could reach up the voltage, current and power to 3.7V, 2.53A and
9.46W respectively. The DC output produced by the hydro generator can be seen as the
experimental setup. This system also consists of battery that can store energy and can be
used as a stabilized the output of voltage when connected to the load. The objective of
this project has been achieved. In summary, this project could exploit the opportunity of
generating electric power from low head sites with reasonable cost.
 vii

ABSTRAK

Hidroelektrik ialah tenaga elektrik yang dijana apabila air yang jatuh dari takungan atau
air yang mengalir dari sungai, anak sungai atau air terjun yang mengalir sungai
disalurkan melalui turbin air. Penjana hidro luar grid adalah pendekatan yang
menjimatkan dan praktikal untuk menjana kuasa elektrik di kawasan luar bandar.
Sebilangan besar penjana hidro kepala tinggi seringkali berjaya digunakan namun
penggunaan penjana hidro kepala rendah adalah jarang dilaporkan. Sistem hidro kepala
rendah umumnya diiktiraf menggunakan bilah kompleks, struktur yang lebih besar dan
elektromekanikal untuk menukar tenaga. Ini membawa kepada kos yang lebih tinggi dan
sistem yang lebih kompleks. Sebaliknya, potensi untuk meneroka sistem hidro kepala
rendah adalah besar kerana terdapat tumpuan penduduk. Oleh itu, matlamat projek ini
adalah untuk membangunkan penjana hidro kecil berkepala rendah mudah alih untuk
elektrifikasi luar bandar. Sistem ini akan menggunakan turbin spiral yang kurang
kompleks berbanding turbin yang biasa digunakan seperti turbin Pelton dan Crossflow.
Selain itu, PVC paip akan digunakan sebagai bilah turbin yang lebih menjimatkan
berbanding bilah turbin konvensional seperti aluminium dan keluli. Paip PVC ini ringan,
kuat dan mudah dipasang kerana ia boleh dipotong dan dibentuk dengan pelbagai cara.
Tambahan pula, ia juga mempunyai ketahanan pepejal terhadap air kerana komposisi
dan tahan terhadap sebarang kegunaan luaran seperti rintangan air, angin dan cahaya
matahari. Kajian telah dijalankan pada 23 Mei 2022 sehingga 29 Mei 2022 di sungai
Kampung Chegor, Kuala Pilah, Negeri Sembilan. Sudut kecerunan tinggi penjana hidro
boleh mencapai voltan, arus dan kuasa sehingga 3.7V, 2.53A dan 9.46W. keluaran DC
yang dihasilkan oleh penjana hidro boleh dilihat sebagai persediaan eksperimen. Sistem
ini juga terdiri daripada bateri yang boleh menyimpan tenaga dan boleh digunakan
sebagai output voltan yang stabil apabila disambungkan kepada beban. Objektif projek
ini telah tercapai. Ringkasnya, projek ini boleh mengeksploitasi peluang menjana kuasa
elektrik dari tapak berkepala rendah dengan kos yang berpatutan.
 viii

CONTENTS

TITLE ii
DECLARATION iii
DEDICATION iv
ACKNOWLEDGEMENT v
ABSTRACT vi-viii
CONTENTS ix-xii
LIST OF TABLES xiii
LIST OF FIGURES xiii-xvi
LIST OF SYMBOLS AND ABBREVIATIONS xvii
LIST OF APPENDICES xviii

CHAPTER 1 INTRODUCTION
1.1 Background of Studies 1-2
1.2 Problem Statement 2
1.3 Objectives 3-4
1.4 Scopes of Project 3
1.5 Structure of Thesis 3-4

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 5-6
2.2 Summarize of Previous Related Works 6
2.3 Mini-Hydro Turbine: Solution To Power 6
Challenges
2.3.1 Design Analysis of Mini-Hydro Turbine 6-7
2.3.2 Implementation of Project 7-8
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2.4 Ultra Low Head Hydroelectric 9

2.4.1 List Performance of Types Turbine 9
2.4.2 Graph Chart Performance of Each 10
Turbine
2.5 Local Installation Method For Low Head Pico- 10
Hydropower In The Lao PDR
2.5.1 Low Head Pico-Hydropower Prototype 11
2.5.2 Type of Installation Method 11-12
2.5.3 The Data Record For Types of 12
Installation Methods
2.6 Preliminary Design of A Mini Hydroelectric 13
System
2.6.1 Methodology of Mini Hydroelectric 13-14
System
2.6.2 Conceptual Design Stage 15
2.6.3 Preliminary Design Stage 16
2.7 Design and Analysis of Small Hydro Power 17
2.7.1 Types Head Level of Hydro Power 17-18
2.7.2 Components of Hydro System 18-19
2.7.3 Small Hydro Turbine System Design 20
2.8 Effect of Turbine Material On Power Generation 21
Efficiency From The Water Vortex Hydro
Power
Plant
2.8.1 Instrument For Experimentation and 21
Experimental Methodology
2.8.2 The Comparative Property of Steel and 22
Aluminum Material
2.8.3 Result of Experimentation Between 23
Steel and Aluminum Turbine
2.9 Developing A Portable Hydroelectric Generator 24
Using Axiomatic Design Method
 x

2.9.1 Design of Portable Hydroelectric 24-25

Generator
2.10 A Feasibility Study of Small Hydro Power For 25-26
Selected Location in Egypt
2.10. 1 The Block Diagram 26
2.10.2 Prototype of Superficial Hydro Power 27
Plant
2.10.3 Result of Project 28
2.11 Previous Project Comparison 29-31
2.12 Main Part In Portable Hydro Generator System 32
2.12.1 DC Motor 32
2.12.2 Smart Charger Controller 33-34
2.12.3 12V Battery 34-35
2.12.6 Inverter 35
2.13 Summary 36

CHAPTER 3 METHODOLOGY
3.1 Introduction 37
3.2 Block Diagram 37-39
3.3 Flow Chart 40
3.3.1 Low Head Portable Hydro Generator 40
3.2.1.2 Explaination of Operation Low 41
Head Portable Hydro
Generator
3.3.2 Process of Analysis The DC Output 42
3.3.2.1 Explaination Process of 42-43
Analysis The DC Output
3.3.3 Process of Time Taken For Charging 43
and Discharging Battery
3.3.3.1 Explaination Process of Time 44
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Taken For Charging and

Discharging Battery
3.4 Project Development Process 45
3.4.1 Hardware Development 45
3.4.2 Design of Project 46-47
3.4.3 Design of Circuit Diagram 58
3.5 Costing of Project 49-53
3.6 Summary 54

CHAPTER 4 RESULT AND DISCUSSION

4.1 Introduction 55
4.2 Hardware Prototype 56-51
4.3 DC Output of Speed, Voltage, Current and Power 62
of Small Hydro Generator With Different Angle
4.3.1 The Result of Output Voltage Low Head 63-64
Small Hydro Generator
4.4 The Time Taken of Low Head Small Hydro 65-66
Generator For Charging and Discharging Battery
With Different Gradient Angle
4.4.1 The Result of The Battery For Charging 67-68
and Discharging
4.5 Summary 69

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion 70-71

5.2 Recommendation For Future Improvement 71
REFERENCES 72-73
APPENDIX A 74
APPENDIX B 75
VITA 76
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LIST OF TABLES

2.1 The Data Output Voltage, Current and Speed From Three 8
Different Flow rate
2.2 Turbine Selection Table For Ultra Low Head 9
2.3 Typical Characteristic Of Pico-Hydro Installation Methods 12
2.4 The Various Head and Specific Speed of Turbines 19
2.5 Different Using Generator and Direct Drive Pump 20
2.6 A Comparative Between Steel (Fc) and Aluminum (Al) 22
Material
2.7 The Result of Experimentation Output Torque Power and 23
Efficiency
2.8 Marginal Homogeneity and Wilcoxon Signed Rank Test 25
2.9 Result of Working To Charging The Battery 38
2.10 Comparison Between Related Work Previous Project 29-31
3.1 List of Component 45
3.2 List of Material 49-54
4.1 Small Hydro generator Data Table 62
4.2 The Data of Hydro Generator For Charge and Discharge 66
Battery
 xiii

LIST OF FIGURE

2.1 Block Diagram of Turbine Flow Process 7

2.2 System Hydro Setup 7
2.3 Plot Graph Between The Output Current and Voltage At 8
Three Different Flow Rates
2.4 Typical Turbine Application Range Chart 10
2.5 The Prototype of Low Head Pico-Hydropower 11
2.6 Laying Installation Method 12
2.7 Standing Installation Method 12
2.8 Angle Installation Method 12
2.9 Flowchart of The Experimental 14
2.10 The Piping Layout In A Household 15
2.11 The Size and Water Temperature Piping Layout 15
2.12 Rapid Prototyping Technology 16
2.13 Hydraulic Bench 16
2.14 The Types of Hydro power Plant Based On The Head Level 18
2.15 Impulse Turbine Side View of Wheel And Jet 19
2.16 Hydroelectric Power generation 19
2.17 Schematic of System 20
2.18 The Block Diagram Process of Free Vortex Hydro Power 21
Plants
2.19 The Prototype of Free Vortex Hydro Power Plants In 21
Laboratory
2.20 Figure of Water Turbine 22
 xiv

2.21 The Turbines Were Set In The Small Generator From The 22
Free Water Vortex Hydro Power Plants
2.22 The Total Efficiency of Both Turbine 23
2.23 Virtual Design For Portable Hydroelectric Generator 24
2.24 Block Diagram of project 26
2.25 The Francis Turbine Used In The project 27
2.26 The Design Turbine 27
2.27 MPPT and PWM Graph 33
2.28 MPPT Performance Match Between The Charger and The 34
Battery
3.1 The Block Diagram of The Project 38
3.2 Flowchart of Whole Process Low Head Portable Small 40
Hydro Generator
3.3 Flowchart of Measured The DC Output Low Head Portable 42
Small Hydro Generator
3.4 Flowchart of The Time Taken For Charging and Discharging 43
Battery Process
3.5 Side View of Project 46
3.6 Top View of Project 46
3.7 Front and Behind View of Project 47
3.8 Low Head Portable Small Hydro Generator Connection 48
Circuit
3.9 Panel Box For Circuit Connection 49
4.1 Hardware Prototype 56-57
4.2 Measured Testing By Digital Multimeter 58
4.3 The Measured of Speed of Turbine Hydro Generator By 59
Using Tachometer
4.4 The Hydro Generator Component 60
4.5 Wiring Components In Panel Box 61
4.6 The Voltage, Current and Power Performance of Low head 63
Small Hydro Generator With Different Gradient Angle
 xv

4.7 The Generator Speed Performance of Low Head Small 64

Hydro Generator With Different Gradient Angle
4.8 The Time taken For Small Hydro Generator To Charging and 68
Discharging Battery
 xvi

LIST OF SYMBOLS AND ABBREVIATIONS

V - voltage
A - Ampere
AC - Alternative Current
DC - Direct Current
W - Watt
Kw - kilowatt
MW - Megawatt
rpm - revolutions per minutes
ℓ - Litter
sec - Second
Hz - Hertz
TNB - Tenaga Nasional Berhad
UTHM - Universiti Tun Hussien Onn Malaysia
UMP - Universiti Malaysia Pahang
m - meter
cm - centimeter
PMSM - Permanent Magnet Synchronous Motor
BLDC - Brushless Direct Current Motor
PWM - Pulse Width Modulation
MPPT - Maximum Power Point Tracker
PVC - Polyvinyl Chloride
% - Percentage
 xvii

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Gantt Chart for PSM 1 78

B Gantt Chart for PSM 2 79

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CHAPTER 1

INTRODUCTION

1.1 Background of Studies

In our country, hydroelectric energy plants are the most common being an impoundment
facility. Hydroelectric power is a form of energy that harnesses the power of water in
motion such as water flowing over a waterfall to generate electricity. In an impoundment
facility, a dam is used to control the flow of water stored in a reservoir. When more
energy is needed, water is released from the dam. Once water is released, gravity takes
over and the water flows downward through a turbine. As the blades of the turbine spin,
the generator will produce a power. But all the hydroelectric dams in our country will
not help to provide power to a home or village outside the reach of the electric power
grid.
This project is another option for gathering electric power from moving water
sources. A “Portable Hydro generator” is a rotary machine that takes energy from
moving water. By using portable water power generator fed from a river or stream,
individuals can gather consistent power from the water, no matter how far from the
utility power grid they may be. This project will focus on the usage of water turbine
power generator that suitable for low pressure head river and inverted the power supply
source of direct current (DC) into alternating current (AC) source that could be used for
domestic purpose. These system water turbines generate very reliable power with a very
 2

simple design. Some kind of runner or propeller is attached to a shaft that operates an
alternator to generate power when water turns the runner. No matter what source of
running water that had on property, if it supplies a year-round flow of water, there is
most likely a water turbine power generator well-suited to provide electricity[1].

1.2 Problem Statement

Hydro generator for off-grid system is a practical approach to generate electric power in
rural areas. There are huge number of successful high head hydro generator have been
reported. However, the application of low head hydro generator is exceptional. Low
head hydro system generally recognized using complex blades, larger structure and
electromechanical to convert energy. This leads to higher cost and more complex
system. On the other hand, the potential to explore low head hydro system is enormous
because there is where population is concentrated. Therefore, the aim of this project is to
develop a portable small hydro generator for rural electrification. This system will use
spiral turbine which is less complex compared to commonly used turbine such as Pelton
and Crossflow turbine. In addition, the PVC flexible board will be used as turbine blade
which is more economical compared to conventional turbine blade such as aluminum
and steel. This PVC flexible board is lightweight, strong and easy to install because it
can be cut and shaped in a variety way. Furthermore, it also has solid resistance to water
due to composition and immune to any outdoor use like resistance to water, wind and
sunlight.

1.3 Objective

There are three main objectives for this project which are:

1. To develop a portable low head hydro generator for rural electrification.

2. To analyze the DC output that generated by the portable low head hydro generator
from different gradient angle.
 3

3. To study the time taken by the portable low head hydro generator for charging and
discharging the battery.

1.4 Scope of Project

This project is focused on the portable water generator for generate current power
supply.

Therefore, this system will cover the scope as followed:

1. Using 12V DC motor, the rotation will directly rotating a shaft that joint
alongside with spiral turbine blade that take energy from moving water to
generate maximization of the current power supply.
2. Using 12V smart charger power control board storage battery charging
controller to determine the optimum charge current or terminate charging.
3. Inverter to convert direct current (DC) that produced from the battery into
alternating current (AC).
4. 12V battery to store chemical energy and converts it to electrical energy.
5. Using different gradient angle for collect data for DC output.
6. Using material PVC to design spiral blade of turbine.

1.5 Structure of Thesis

Chapter 1 initiated with the background of the study, which briefly introduced the topic
under study. The problem statement described in this chapter is to illustrate the gap in
the current work related to portable hydro generator system. The objectives and scopes
of the study also discussed in this chapter.
Chapter 2 explained the introduction to the main part of this project. Their
properties explained in detail. The type of hydro generator also discussed. The hardware
 4

that is used was describe in the next subsection. Lastly, previous related works were also
presented in this chapter.
In chapter 3, the methodology is presented. The detail on hardware development
were discussed. The chapter begins with the block diagram of the project. Then, the flow
chart of each system was describe. The process and costs for the development of the
project are also included in this chapter.
Chapter 4 presented the hardware results and discussion. In this chapter, voltage
performance and results for portable hydro generator was discussed. Then, the parameter
of the portable hydro generator were compared with the flow rate from the velocity of
sectional area of river to validate their performance.
Finally, chapter 5 gives the conclusion of the findings in chapter 4. It also
highlighted the contribution based on the analysis achieved, as well as t
recommendation on this topic for future research.
 5

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

This chapter presents an overview of portable hydro generator system for generated
electricity. The previous related works that has been done by past researchers are also
reported in the following section. Literature review plays an important role for starting a
new research because it ensures the conducting project is in a new concept or idea which
had not been done by others. Besides, literature review is a simple way for researcher to
gain the knowledge about the topic by reading the details of research that relevant to the
project. Researcher evaluates the content of journal or article to understand the
technology used or important steps that must be alert during conducting the research.
Moreover, the researcher can save much of time on collecting and analysis data by using
the data or result from the reference that conducted by previous researcher. Therefore,
literature review is one of the processes that must be executed before starting a new
research. Then, the theoretical of hydro generator system as well as the equipment used
in this project also will be discussed.
In this report, literature review as the method to collect data about hydro
generator system for generated electricity will be used. User can use the electricity that
produce from hydro generator to supply the home appliances through energy store in
 6

battery. The journals or articles should explain about the theory and function of the
hardware and technology used in portable low head small hydro generator.

2.2 Summarize of previous related works

The previous works that related to this scope of project are summarized in the following
section.

2.3 Mini-Hydro Turbine: Solution to power challenges in an emerging society

with abundance of water

The article research was done by Okhueleigbe et. al [2]. This article discusses the
designing and constructing the mini hydro turbine that can generate electricity from
hydro energy that can be used at the domestic to electrical appliances. It also explains
the sections for hydro turbine step by step from alternator construction and rectifier
circuit, construction of pelton turbine wheel and construction of turbine casing. It also
addressed the performance of the voltage, current and speed that determined using three
different flow rates.

2.3.1 Design Analysis of Mini-Hydro Turbine

Figure 2.1 illustrates the block diagram of turbine flow process to generate energy from
moving stream of water into mechanical energy. The Pelton turbine will moving due to
force from the falling water reservoir. The torque and power that producing from the
water falling will rotate the alternator at consistent speed to generating electric voltage at
the output to supply the load.
 7

Figure 2.1: Block diagram of Turbine flow process [2]

2.3.2 Implementation of Project

Figure 2.2 shows the implementation for hydro turbine setup with detail process. The
process is to implement with 3 difference water flow; half flow, ¾ flow and full flow to
collect data which flow is generate more efficient energy. The water is filled into the
water tank storage and each of valve will determine the difference flow rate of water.
When the valve is open, the water will fall to the Pelton turbine wheel and rotating the
alternator to generate the electric voltage. Moreover, when the alternator is rotating, the
water flow will come out to the water outlet.

Figure 2.2: System hydro setup [2]

 8

Table 2.1 and Figure 2.3 show the full water flow rate that is generate high output
voltage and current between the other two flow rates. The full flow rate produced high
speed, torque and power that producing from the water falling that can rotate the
alternator at consistent speed to generating electric voltage at the output.

Table 2.1 The data output voltage, current and speed from three different flow rate [2]

Figure 2.3: Plot graph between the output current and voltage at three different flow
rates [2]
 9

2.4. Ultra low head hydroelectric

Zhou et al. has reviewed the current achievements on Ultra Low Head hydroelectric
technology to stimulate discussions and participation of stakeholder to develop related
technologies for further expanding its utilization as an important form of renewable
energy [3]. This article also discusses the characteristics of Ultra Low Head hydropower
generation that similar to those of wind power generation, such as low output power and
slow fluctuating rotation speeds. For example, common types of generators are list in
this report is squirrel cage induction generator and permanent magnet synchronous
generator. This type has cost effective choices for Ultra Low Head hydropower
generation.

2.4.1 List Performance of Types Turbine

Table 2.2 shows the performance of each turbine with their rated head and rated output.

Table 2.2: Turbine selection table for Ultra Low Head [3]
 10

2.4.2 Graph Chart Performance of Each Turbine.

Figure 2.4 shows the performance range chart of turbines between flow rate and head.

Figure 2.4: Typical turbine application range chart [3]

2.5 Local Installation Methods for Low Head Pico-Hydropower in The Lao PDR

The research was done by Julius Susanto et. al [4]. The study is to determine the low
head pico-hydropower use in the remote mountainous provinces of the Lao PDR due to
the widespread lack of access to grid electricity and favorable hydropower condition.
This process of article has discussed the main types of installation methods for low head
pico-hydro turbines and the diverse variety sites where the recommended installation in
the rural parts of the Lao PDR. The paper also discuss the different installation method
are used and provides a derivation for theoretical power output for each method.
 11

2.5.1 Low Head Pico-Hydropower Prototype

Figure 2.5 shows the prototype of low head pico-hydropower that produced by J.
Susanto et. al [4]. This prototype consists of generator, output wires, shaft and turbine.

Figure 2.5: The prototype of low head Pico-hydropower [4]

2.5.2 Type of Installation Methods

Figure 2.6, Figure 2.7 and Figure 2.8 show the three main types of installation methods
used for low head pico-hydro in the PDR. First installation method is laying installation
method, the pico-hydro turbine will install in stream of the river and positioned it is lies
at a slight angle to the horizontal with the propeller facing the water flow of the river.
Then, the standing installation method for pico-hydro, the turbine is installed in an
upright position with generator directly above the propeller and at a gross head of 1.5 to
3m. Therefore, the angle installation method is used when a river water flow encounters
a drop in elevation and the pico-hydro turbine will installed at an angle over the drop.
 12

Figure 2.6: Laying installation method [4] Figure 2.7: Standing installation method [4]

Figure 2.8: Angle installation method [4]

2.5.3 The Data Record for Types of Installation Methods

Table 2.3: Typical characteristic of pico-hydro installation methods [4]

 13

2.6 Preliminary Design of A Mini Hydroelectric System

Jusoh et al have reviewed a common topic for renewable energy that has been discussed
continuously since the past few decades [5]. This article has discussed the generating
and restoring energy needs to be developed, without neglecting the effect toward the
environment itself. The water flow shall initiate the system by moving the inner mini
blades and convert rotational motion to the shaft, which links to the DC generator. The
changes from kinetic energy shall then be converted to electrical energy, which shall be
preserved for later use. As a result, this system is able to provide an economical way to
produce electrical energy without affecting the environment. This research objective to
validate the concept of this product in a normal household environment [9].

2.6.1 Methodology of Mini Hydroelectric System

Figure 2.9 shows the system process for mini hydroelectric system. The process is
divided into two stage; first stage is discussing on the conceptual stage for the system
and the second stage is about the preliminary stage for mini hydro system. The basic
idea behind this invention is to use the pipeline's water pressure to propel the water
turbine. The shaft connected to the DC generator rotates as the water turbine turns. The
kinetic energy will then be converted to electrical energy by the DC generator. The
Experiment Flow Chart will be used to track the overall process.
 14

Figure 2.9: Flowchart of the experimental [5]

 15

2.6.2 Conceptual Design Stage

The conceptual stage is an examination of an idea's viability, as the name implies. The
goal of all related activities is to collect data and information from sources such as
books, conference papers, journals, patents, and other sources. Figures 2.10 and 2.11
show the related references for the piping system in a typical household [5]. Finally, all
of the data and concepts gathered will be summarized into their respective categories.

Figure 2.10: The piping layout in a household [5]

Figure 2.11: The size and water temperature piping layout [5]
 16

2.6.3 Preliminary Design Stage

Figure 2.12 and Figure 2.13 show a prototype must be built and tested in accordance
with the design specifications. Pipes, shafts, and DC generators will be procured for
the design based on standard and compatibility factors. The blade, on the other hand,
will be made to order using rapid prototyping technology. The product's material
selection process is critical in ensuring that it is suitable for the system and can
withstand the maximum load applied. PVC and PC have been chosen as the primary
materials for the main component, which is the pipe and blades.
Then, during the experiment, the Hydraulics bench will be used to assess the
Mini Hydroelectric performance. The flow rate should be suitable for general use in a
typical household (from 0.2 liter/s and up). To monitor the product's power output, the
DC motor must be connected to the LED. The result of using a digital multimeter must
be recorded in relation to each specified flow rate.

Figure 2.12: Rapid prototyping technology [5]

Figure 2.13: Hydraulic bench [5]

 17

2.7 Design and Analysis of Small Hydro Power for Rural Electrification

The journal was done by A. L. Dametew [6]. This paper addresses power generation for
rural application. The small hydropower generator highlighted about the design
Operation procedure, recommendation and possible economic impact for electrical
power production. The design of project is to assess the potentials and impacts of small
hydro power for development select proper material for small hydro power. This project
is the most cost effective and to be considered for rural electrification. A complete
design of turbine has been done in this paper. By using this cross flow turbine system, it
is suitable for installing small hydroelectricity power plant by low head and flow rate.
This paper also explains more detail of turbine material such as runner diameter, runner
length, water jet thickness, blade spacing speed, number of blade curvature, turbine
efficiency.

2.7.1 Types Head Level of Hydro Power

Figure 2.14 shows the three common types of hydro power based on the head level. The
height of head will affect the choice of the turbine that has selected in the hydro power.
The low head is not to use dam to generating electrical energy. It is use barrage from
water river flow. When the water river flow is high, the alternator will produce high
electricity. Meanwhile, the medium and high head hydro power using dam to generated
the electricity. The linear variation of pressure by water height will impact to the
generator for produce high output electricity.
 18

Figure 2.14: Three types of hydro power plants based on the head level [6]

2.7.2 Component of Hydro System

A complete hydropower system considers the major components such water storage and
water filtering mechanism, penstock with valves, turbine and generator. The water
filtering is the important aspect to the system design. The filtering is installed to avoid
the turbine damage from sticks, stone and leaves that can reduced the performance of the
blades. The turbine will probably require cleaning at some stage for this design in order
to stop these solid bodies from damaging the turbine. Then, penstock must have strong
material to withstand the water pressure. The length of pipeline is needed to direct the
water to the turbine. Meanwhile, the design turbine must compact to the head level. It is
the important role stationary guide varies. At even low head, the propeller turbine is
more compact to better efficiency. For example, it must obtained over an operating
range by using ble vanes in the Kaplan turbine. For medium and high head, a reaction
turbine requires high speed and pressure in the runner to require a massive casing
thickness. The pressure is confined to the small nozzle which convert the head to an
atmospheric pressure jet of high velocity. The jet strikes the buckets and impart a
momentum change. The buckets have an elliptic split cup shape and are called Peton
wheels.
 19

Table 2.4: The various head and specific speed of turbines [6]

Figure 2.15: Impulse turbine side view of wheel and jet [6]

Figure 2.16: Hydroelectric power generation [6]

 20

2.7.3 Small Hydro Turbine System Design

Figure 2.17 and Table 2.5 show schematic of the system and the advantages of using
generator and direct drive pump respectively. The author claimed that the direct drive
pump is more advantageous than conventional generator.

Figure 2.17: Schematic of System [6]

Table 2.5: Different using generator and direct drive pump [6]
 21

2.8 Effect of Turbine Materials on Power Generation efficiency from free water
vortex hydro power plant

This study was done by P. Sritram. From this article paper is made and experiment effect
of turbine with different material such as steel and aluminum. The focus of this paper is
to get out the torque, electric power and electricity production efficiency of steel and
aluminum turbine. From the result the production efficiency respectively of aluminum
turbine was higher than the steel turbine. It showed that light weight of water turbine can
increase the torque and power generation efficiency [7].

2.8.1 Instruments for Experimentation and Experimental Methodology

The block diagram in Figure 2.18 shows the process operation from free water vortex
hydro power plant in the laboratory to generated electrical power. The turbine for this
system is made by steel and aluminum.

Figure 2.18: The block diagram process of free vortex hydro power plant [7]

Figure 2.19: The prototype of free vortex hydro power plant in laboratory [7]
 22

2.8.2 The Comparative Property Of Steel And Aluminum Material

Table 2.6: A comparative between Steel (Fe) and Aluminum (Al) materials [7]

a) A drawing of turbine b) Turbine blade

Figure 2.20: Figure of water turbine [7]

a) Steel turbine b) Aluminum turbine

Figure 2.21: The turbines were set in the small generator from the free water vortex
hydro power plant [7]
 23

2.8.3 Result Of Experimentation Between Steel And Aluminum Turbine

Table 2.7: The result of experimentation output torque power and efficiency [7]

Figure 2.22: The total efficiency of both turbine [7]

 24

2.9 Developing a Portable Hydroelectric Generator Using Axiomatic

Design Method

This study was done by H. soewardi. The purpose of this study is to redesign the
portable hydroelectric power generator that can satisfy requirements. The designed
developed to satisfy user requirement. It is also durable, waterproof, attractive,
lightweight, small in size and portable. The design generator by using a spiral shape of
hydro turbine can produced more energy [8]. This prototype project could generate
energy up to 500 Watt per hour. This hydroelectric generator is more effective, more
efficient and safer generator.

2.9.1 Design of Portable Hydroelectric Generator

Figure 2.23: Virtual design for portable hydroelectric generator [8]

 25

Table 2.8: Marginal homogeneity and Wilcoxon signed rank test [8]

2.10 A feasibility study of small hydro power for selected locations in Egypt

The article was done A.Y. Hatata [9]. This article explains the small-hydro turbine
efficiency, output power and energy by the procedure for evaluating small- hydro energy
by using flowchart. Then, examined different types of small-hydro turbines and different
types of generators for the selected sites. This turbine is called ‘mixed flow turbine’, as
the water enters through the outer periphery of the runner in the radial direction and can
be used on sites with rang of net heads from 1.5 to 20 m and peak flow rates from 3 m3
/s to 30 m3 /s. For these ranges, the power output is ranging from 75 kW up to 1 MW.
The main disadvantage of Kaplan turbines is that they are expensive.
There are three types of Kaplan turbines; vertical axis, horizontal axis (also
called S-turbines) and bulb turbines. Vertical-axis turbines are preferred in sites with a
small footprint, whereas horizontal axis or ‘Sturbines’ are suitable for a larger system
footprint. Vertical turbines are designed for the water-energy utilization at relatively low
heads. These turbines are usually provided with a gear drive connecting them to the
generator. Bulb Kaplan turbines are located within the main flow. The horizontal axis
and bulb turbines are technically slightly more efficient than vertical axis because the
inlet flow does not have to change direction which leads to a decrease in the hydraulic
losses. The application heads range from 1.5 m to 25 m with an output up to 50 MW.
 26

From the summarized previous works, several related kinds of research are
explained and it shows that most of them implemented their project using water
generator as the primary source to save electricity usage. Some of the advantages of
using water generator as the primary source are free and clean energy, user friendly and
cheaper [9]. However, this project uses a combination of solar water generator and
batteries to store the system charge. Research has been done to identify the appropriate
components and to ensure that this project is successful.

2.10.1 The Block Diagram

The figure 2.24 shows the block diagram of small hydro power for selected location in
Egypt. The electricity is generated from the water depend on the amount of water pump
to running the turbine. The turbine used is Francis turbine. The generator will produce
electricity the connected to inverter to convert DC supply into AC supply. Then, the
battery will store the energy from the generator.

Figure 2.24: Block diagram of project [9]

 27

2.10.2 Prototype of Superficial Hydro Power Plants

Figure 2.25: The Francis turbine used in the project [9]

Figure 2.26: The design turbine [9]

 28

2.10.3 Result of Project

Table 2.9 shows the result of operating working to charge the battery. The battery that
has average output current of 7A has an average of 2 hours to charge the battery.

Table 2.9: Result of working to charging the battery [9]

 29

2.11 Previous Project Comparison

Table 2.10: Comparison between related work pervious project

No Title Year Advantages Disadvantages Hardware Comments
used
1. Mini-Hydro Turbine: solution 2017 1. The turbine blades has 1. Complex design of 1. Pelton Turbine Finding the process to generating
to Power Challenges in an high efficiency blade turbine. 2. Alternator as electricity and idea to make design for
Emerging Society with 2. Generated high DC output 2. Need water height generator turbine
Abundance of Water [2] 3. Suitable for abundance water for pressure to 3. DC and
4. Suitable in cities area. generating current. AC load
3. Not operation when
no abundance water.

2. Ultra Low Head Hydroelectric 2017 1. Can be distributed widely 1. The design of 1. Kaplan Finding the suitable turbine of low head
[3] and implemented near human prototype is complex. Turbine hydro generator based on the comparison to
activities. 2. High cost to install. 2. Squirrel Cage the other type of turbine.
2. Environmentally friendly Induction Motor
4. Corrosion resistant material
5. High efficiency.
6. Least amount of
maintenance.
 30
3. Local Installation Method for 2012 1. The design project can 1. The quality of 1. Pico-Hydro Finding ways to reduce the turbine
Low Head Pico-Hydropower suitable to install in 3 method generic turbines is low turbine. efficiency to generate high output.
In The Lao PDR [4] (Laying, Angle and standing 2. Turbine efficiency 2. Shaft
installation) is often very low 3. Generator
2. Portable 3. Not used for
3. Cheap to install long lifespan.
4. Limited of use for load.

6. Preliminary Design of A Mini 2014 1. Can generate electricity 1. Not available for 1. DC generator. Try to change the concept household mini
Hydroelectric System [5] from water waste pipeline in domestic in-house use 2. Shaft. hydro generator into conceptual hydro
house. 2. Produce least 3. Butterfly generator for river installation.
2. Provide an economical potential power source. blade.
way to produced electrical 3. Complex design and to 4. Pipe.
without affecting the install.
environment.
7. Design and Analysis of Small 2016 1. Much higher total efficiency. 1. Pump has to run at 1. Cross-flow Finding ways to use the concept water head
Hydro Power for Rural 2. Simple design, requires the same rotational turbine system. and pressure in the project.
Electrification [6] fewer components speed as turbine. 2. Valve.
3. Cheaper if existing 2. Operation of system is 3. Pump.
pumps can be driven. dependent on reliability or 4. Coupled shaft.
both turbine. 5. Piping water
3. The turbine has to be flow.
situated next to the pump.
8. Effect of Turbine Materials On 2018 1. Has high speed of 1. The speed of steel 1. Tank Try to compare the Aluminum and steel
Power generation Efficiency aluminum turbine rotation turbine is least rotation. 2. Whirlpool blade material with other material that has
From Free Water Vortex 2. Aluminum turbine has 2. The steel blades least 3. Steel and more light weigh, strong and can produced
Hydro Power Plant [7] high torque and power torque and power values. Aluminum blade high torque, power and efficiency to
values. 3. The Steel Turbine has turbine. generate electricity.
3. The Aluminum turbine high low total efficiency. 4. Generator
total efficiency. 5. Water pump
31
 32
9. Developing a Portable 2018 1. The design of portable 1. More complex 1. Battery Finding the ways to make design of
Hydroelectric Generator Using hydroelectric generator is more to design. 2. Turbine from prototype based on the existing virtual
Axiomatic Design [5] durable, waterproof, lighter 2. Not easy to iron metal. design of portable hydroelectric generator.
and easier to carry. maintenance. 3. Housing from
2. Has energy storage. Plastic
3. Has long lifespan.
10. A Feasibility Study of Small 2019 1. Can store electricity 1. The design to big 1. Francis Finding the technique of proposed system
Hydro Power For Selected to appliances purpose. for installation. turbine to time taken generating electricity and
Location In Egypt [9] 2. The frictional losses are less. 2. Need high water 2. Battery system working to charging the battery.
3. Fairly high head without flow pressure. 3. Generator
increasing the speed of the 3. Difficult to repair 4. Inverter
turbine. and inspection.
4. Produced high electricity.
 33

2.12 Main part in Portable Hydro Generator System

Portable Hydro Generator has 4 main parts which are 12V DC motor as the primary
source for this project that get from water flowing. Then, 12V Smart charge controller to
keep the batteries from overcharging and monitor the voltage and current coming to the
battery from source that generated from 12V DC motor, 12V battery as to store energy
in the lead-acid and as for power supply to electrical equipment (load). Lastly, Inverter
to converted direct current (DC) that produced from the battery into alternating current
(AC) for electrical equipment that use AC load supply. Torque is apply to shaft, the
rotor will turns and generated a current in the coil by the magnetic field.

2.12.1 DC Motor

A generator is a device that converts mechanical energy from motive power into
electrical energy for use in an electric field. DC motors are highly efficient, which is true
sometimes when they are used as generators. The fundamental calculations for speed
and voltage, as well as current and torque, are very simple. Permanent magnet
synchronous motors (PMSM) and Brushless DC motors (BLDC) can be operated as
generators [10]. The Permanent Magnet Synchronous Motor (PSMS) is more costly than
Brushless DC Motor (BLDC). The permanent magnet synchronous motor (PSMS) has
higher and smooth torque with higher efficiency 92% to 97% compared to the Brushless
DC motor (BLCD) has 85% to 90% efficiency [11]. Then, permanent Magnet
Synchronous Motor (PSMS) is more low noise compared to other motor. Permanent
Magnet Synchronous Motor (PSMS) has been selected for this project. The advantages
of Permanent Magnet Synchronous Motor (PSMS) is the higher maximum achievable
speed then Brushless motor (BLDC) and no torque ripple at the commutation. The 12V
DC motor with maximum 1.5A capacity can generate 18W of power it depend on
current coil of rotor can carry and the gauge of coil. If the coil is more in the DC motor
it can generate more current. It has great benefit of being in generate electricity for this
project.
 34

2.12.2 Smart Charger Power Controller

The portable hydro generator charge controller’s core function is the efficient transfer of
power from a hydro module to a battery or charge. There are two different solar charge
regulators, each with different technology; maximum power point monitoring (MPPT)
and pulse width modulation (PMW). Their performance is very different from each
other; for example, the MPPT charge controller is expensive than the PMW controller.
The MPPT regulator is performing better than the PWM charge regulator. This can be
seen in Figure 2.1. The PWM charge controller operates by making a direct connection
from the power source to the battery, while the MPPT charge controller measures the
voltage of the panel and converts it to the battery voltage [12].

.
Figure 2.27: MPPT and PWM graph [13]

The Maximum Power Point Tracker (MPPT) system transfers energy from DC to DC
and then ensures that it supports the power output between the voltage of the power
source and the voltage of the battery bank. As a result, the MPPT charge controller
decreases the high-power voltage from the power source to the low voltage needed to
charge the battery. This is illustrated in Figure 2.2.
 35

Figure 2.28: MPPT performance match between the charger and the battery [13]

2.12.3 12V Battery

12V battery is a technical standpoint, consists of one or more cells that allow a chemical
reaction to creating the flow of electrons in a circuit. Battery is not generated with their
own energy or power. The battery is simply energy storage devices to store the energy
that can use when need it. For rechargeable storage battery it has two primary types are
currently used nowadays is lead acid and lithium-ion. Lead-acid battery is most common
variety for 12V battery type. The battery is use battery water to keep the battery is
functioning correctly. The battery water will create a chemical reaction to allows for
energy to be stored. The life span of lead-acid battery generally can stand within 2 to 5
years depend on use and maintenance of the battery and the lead-acid battery is cheaper
than lithium-ion battery. The lithium-ion 12V battery is new technology for battery. It is
work using lithium salt to create more efficient electricity storage than the battery lead-
acid battery. The life span of this battery is more times longer than the lead-acid battery.
The cost of lithium battery is expensive and more costly than the lead –acid battery. The
 36

lead-acid battery has been selected for this project. The advantages of lead-acid battery
is low maintenance and cost is more cheaper than the lithium-ion battery to be used for
this project.

2.12.6 Inverter

Inverter is a devices used for convert electrical power of direct current DC into
alternating current AC but it cannot generate electrical power. There are three type of
inverter, square wave inverter, modified sine wave inverter and sine wave inverter are
commonly used for powering AC load [14]. Then, each of inverter has with different
technology. The sine wave inverter is been selected on this project. Sine wave inverter is
more costly than the other type inverter but it has highly safety to use and supported
household appliances in universal AC power source operating at 60Hz for example
laptop, refrigerator and etc. The square wave inverter is less expensive and can be used
in this project but it has many disadvantages. Many devices that square wave inverter
supply in household get heated up and unsafe to use for appliances and less reliable. For
the modified sine wave inverter it is better than the square wave but it can be utilized for
simple system only. It cannot support many household appliances like sine wave
inverter. The main purpose of sine wave inverter in this project is to take DC power
supplied from the 12V battery and transform it into AC power source operating at 60Hz
for example the power available at an ordinary household electrical applied.
 37

2.13 Summary

This chapter discusses in detail the previous work on portable water hydro generator
featured on irrigation system as well as generated electricity. The review shows that the
portable hydro generator can be adapted to all water motion such as water from a river
flowing to generated electricity. It can be observed that most water generator turbine
show good result in renewable energy. It is desirable to modify with the use of the
hardware discussed to implement this project. All components that choose indicate that
it can support nature of the hardware from renewable energy without any defects.
 3

CHAPTER 3

METHODOLOGY

3.1 Introduction

This chapter deals with the creation of the project from the selection of a correct project
title to the end. To archive the project goals, every flow takes one step closer. This
chapter describes each flow that is designed to create a Portable Hydro Generator step
by step.
Before starting the project, the overall idea of the project must be gathered which
can be found through any other sources, such as journals, previous projects and the
internet. Those are essential steps to locate an acceptable publication or study to
determine all water motion from a river flowing to the water turbine fit this project.
Final decision will then be to develop a small hydro generator to generated electricity.

3.2 Block Diagram

A block diagram is used to represent the layout and structure of the system that is
involved. The design of the project will be described and highlighted in each chapter.
 38

Figure 3.1 illustrates the block diagram of the project.

Water Flow
Spiral
Turbine
12V
Blade
DC Pole
Double Double Pole DC12V- 240V MCB
12V
Motor (40A) DC Fuse Block
DC12V- 240V
MCB Smart
Charger
(40

DC Load
Double Pole
DC12V- 240V
MCB
(40
Double Pole DC12V- 240V MCB
Inverter
(40A)
Battery

Home
applianc
es
Figure 3.1: The block diagram of the project
 39

The low head portable hydro generator must have water flow from the river to
generate the electricity. The river water flow is the important element to be considered
in this project. The pressure from river water flow will moving the spiral blade turbine
inside the PVC pipe. The spiral blade turbine material is using PVC that custom made to
be a spiral blade. Then, the DC motor will rotate at the same time with the help of a belt
that has been connected to the spiral blade pulley and will generate electricity energy
from the river water flow current.
The electricity energy that produced from DC motor will connect with DC Main
Circuit Breaker (MCB) before connected to 12V Smart Charger Controller. The DC
Main Circuit Breaker (MCB) used in this system for safety and protection requirement
in this project. Besides, it is used for over-current protection within appliances or
electrical equipment from being damaged and allow for battery bank to supply close or
trip (switch) power to the breaker control circuit. The 12V Smart Charger Controller
used in the circuit to keep the battery from overcharging by regulating the voltage and
current coming from the hydro generator to the battery, the operation is for control
charging and discharging the battery. When the battery in low condition the smart
charger control will automatically allow the current pass through battery for charging, if
the battery in full charging the smart charger controller will cut-off the current and the
battery will discharging.
The battery function is to stores energy electricity that produced from hydro
generator and to supply all DC electrical power when the hydro generator is not running.
The battery will supply the DC fuse block and inverter. The DC fuse block will protect
the circuits in an application from wiring malfunctions before connecting to DC load
appliances such as USB port for charging smartphone, DC light and other DC electrical
services. Then, the inverter uses as to convert the Direct Current (DC) produced from
the battery into standard Alternating Current (AC source) for home appliances
application such as hand drill, laptop, fan and other home appliances electrical
equipment that use AC supply.
 40

3.3 Flowchart

The flow chart in Figure 3.2 shows the operation of the Portable Low Head Hydro
Generator that generated electricity from beginning to end process. The flow chart in
Figure 3.3 and Figure 3.4 shows the process analysis of DC output and time taken for
charging and discharging battery that generated by the portable low head hydro
generator from different gradient angle.

3.3.1 Low Head Portable Hydro Generator

Figure 3.2: Flowchart of whole process low head portable small hydro generator.
 41

3.3.1.2 Explanation of Operation Low Head Portable Hydro generator.

The river water flow is the important element to be in hydro generator to generate
electrical energy. Firstly, select the suitable river area that had huge current water flow
to get maximum efficiency to generate electricity. Therefore, the pressure from river
water flow will moving the spiral blade turbine that inside the PVC pipe. Then, at the
same time the DC motor will also rotate with the help of belt that has been connected to
the spiral blade turbine pulley and will generate electricity energy from the river water
flow current by different gradient angle that has select.
When the DC motor produced electricity energy, the alternator will connect to
Main Circuit Breaker (MCB) before connected to the 12V smart charger controller. The
circuit breakers are used to prevent the 12V smart charger controller from excessive
electrical current which can cause it to damage and overheat. Then, the 12V smart
charger controller will connect to the battery and can set the level of battery for
operation charging and discharging. The charging is operation when the level of battery
in low condition and the discharging will operation when the battery is on fully charge
condition to keep the battery from overcharging and protect the life span of battery.
Next, the battery is use as a power supply for 12V smart charger controller, DC
load and inverter to convert DC into AC power for home appliances. It is also for store
the energy that produced from the hydro generator when running. However, before
battery connected to the DC and AC load it must have connected to the Main Circuit
Breaker (MCB) to protect the load appliances from short circuit or safety requirement
before turn it on.
 42

3.3.2 Process of Analysis The DC Output.

Figure 3.3: Flowchart of measured the DC output low head portable small hydro
generator.

3.3.2.1 Explanation Process of Analysis the DC Output.

The flowchart in Figure 3.3 shows the process of analysis the DC output from the low
head portable small hydro generator. The process can be observed after the alternator
generated the electricity from different gradient angle. The output of voltage (V), speed
 43

(RPM), current (A) and power (W) will be measured from the gradient angle
0𝑜, 15𝑜, 25𝑜and 35𝑜 to get the data to be observed and make analysis.

3.3.3 Process of Time Taken For Charging and Discharging Battery.

Figure 3.4: Flowchart of the time taken for charging and discharging battery process.
 44

3.3.3.1 Explanation Process of Time Taken for Charging and Discharging Battery.

Figure 3.4 shows the flowchart process of the time taken for charging and discharging
battery. When the DC motor is generates electricity, the battery will store the energy and
used as power supply to turn on the 12V smart charger controller. Therefore, the 12V
smart charger controller used to keep the battery from overcharging by regulating the
voltage and current coming from the hydro generator to the battery and will show the
level of battery. It also can be set the voltage for charging and discharging. When the
charger controller is set to 12.5V, the battery will automatically charging. Then, if the
battery is set to 14.4V, the battery will discharging and cut-off the current pass through
the battery. From the process, it can make analysis for the time taken for battery to
charging and discharging by different gradient angle from 0𝑜, 15𝑜, 25𝑜and 35 . The data
of time taken will be record for how long of each gradient angle take for charging and
discharging battery.
 45

Project Development Process

The first step in the development project process is to identify the components used for
the project. The size of alternator, the battery and others. This is important to ensure the
smooth flow of the project in hardware development.

3.3.4 Hardware Development

Table 3.1 shows the list of the component for electrical parts and mechanical parts.

Table 3.1: List of Component

Component Item Description
Mechanical Component DC Motor 12V
Battery 12V
DC Main Circuit Breaker 2 Pole
(MCB) Max current : 40A
Operating voltage :
DC12V – 240V
DC Fuse Block Operating Voltage : 12V
Electrical Component Smart Charger Control Operating voltage :12V
Auto charge and discharge
current : 30A
USB Output : 5V/2.1A
3.0 Quick Charger USB Ports Operating Voltage :
DC 12V/24V
USB socket output:
Dual DC 5V/2.1A
Power Outlet : DC 12V
Inverter Operating Voltage : 12V
Input Voltage Range :
9.5V – 15.5V
Output Voltage :
220V
Output Voltage Range :
110V±10% / 220V±10%
Frequency : 50Hz/60Hz
 46

3.3.5 Design of Project

Figure 3.5: Side view of project

28CM

1 Meter
Figure 3.6: Top view of project
 47

Figure 3.7: Front and behind view of project

 48

3.3.6 Design of Circuit Diagram

Figure 3.8: Low head portable small hydro generator connection circuit

3.3.6.1 Front View

b) Side View
Figure 3.9: Panel box for circuit connection
 49

3.4 Costing of Project

The materials used for this project and the prices of each item are list in Table 3.2

Table 3.2: List of material

No. Item Details Quantity Price

1 DC Motor

Rated Voltage: 12V

Maximum Current :10Amp 1 RM100
Speed: 1800rpm
Rotation: Bidirectional

2 Battery

Voltage : 12V
Capacity : 20 Ah 1 RM120
Rechargeable

3 12V Smart Charger Control

Output : 5V/2.1A
Operating Voltage : 1 RM25
12V/24V
Auto Rated Charge
Discharge Current :
10A/30A
 50

4 DC MCB

Double Pole
Max current : 40A
Operating voltage : 4 x RM16
DC12V – 240V 4 =
RM64

5 3.0 Quick Charger USB port

socket outlet

Operating Voltage :
DC 12V/24V
USB socket output: 1 RM30
Dual DC 5V/2.1A
Power Outlet : DC 12V

6 Inverter

Operating Voltage : 12V

Input Voltage Range :
9.5V – 15.5V
Output Voltage : 1 RM75
220V
Output Voltage Range :
110V±10% / 220V±10%
Frequency : 50Hz/60Hz
 51

7 DC Fuse Block

Operating Voltage : 12V 1 RM60

8 Cable

5xRM2.50
+
Size Cable :1.5mm(5meter) 1 5mxRM4
Size Cable :2.5mm(5meter) 1 +
Size Cable :6mm(2meter) 1 2mxRM25
Size Cable :4mm(1meter) 1 +
1mxRM32
=
RM114.50

9 PVC Pipe

Size : 8 Inches (3 meter) 1 3mxRM12

Size : 6 Inches (5 meter) 1 +
5mxRM8
=
RM76
 52

10 PVC End Cap

2xRM3
Size : 2 Inches 2 =
RM6

11 Block Bearing

2xRM7
Bore Size : 8mm 2 =
RM14

12 Timing Belt

Size Belt : 10mm 5 RM30

Meter
 53

13 Distribution Box Panel

Size :
32”(W) x 13”(H) x 8”(D) 1 RM165

14 PVC Junction Box

Size :
6”(W) x 4”(H) x 3”(D) 1 RM8

TOTAL RM887.50
 54

3.5 Summary

This chapter has described in detail the methodology for small hydro generator. For
the hardware development in this project, the portable water generator was analyzed
based on it spiral water turbine structure that joint with DC motor to get maximum
energy that produce from current river and battery charge controller to transfer of
power from river to a battery or charge. For a DC motor, based on a water flow from
river and its operating to generated electricity. The cost of each component with their
properties also attached.
 5

CHAPTER 4

RESULT AND DISCUSSION

4.1 Introduction

This chapter explained the results and finding for Development of Portable Low Head
Small Hydro Generator for Rural Electrification. After the development and completion
of the project, it will then be evaluated in order to measure the how fast hydro generator
alternator is operating at a given time in rpm to get the maximum output current that
produced to charging battery and to get the duration of battery to full charging. Then,
ensure whether it had met the outlined objectives successfully. The performance of the
prototype was observed by testing the system in the rural area that near with the river.
 56

4.2 Hardware Prototype

Figure 4.1 (a),(b) and (c) show the hardware prototype of the Portable Low Head Small
Hydro Generator for Rural Electrification. The portable low head small hydro generator
is produced electricity by water flowing in the hole of PVC pipe and the PVC pipe is
design with different gradient at an angle 0𝑜to 35𝑜 degrees. The portable low head small
hydro generator uses spiral blade turbine with special aerodynamic design to rotate the
alternator to get maximum rpm to produced high output current and voltage to charge
the battery. Figure 4.1 (a) shows a portable low head small hydro generator prototype,
while Figure 4.1 (b) shows a wiring connection of main power supply for store energy
and supply the load. An example the inverter that converted the DC supply from battery
to AC supply load equipment like hand drill, fan, laptop and other AC equipment. Then,
DC fuse block is use to supply the DC load electrification in example for DC lighting,
USB charging port for smart phone and spare port for backup inverter. Figure 4.1 (c)
shows the holes for each degree gradient that can be changed according to the river
water flow current.

(a)
 57

(b)

Angle 350

Angle 250

Angle 150

Angle 0 0

(c)
Figure 4.1: A hardware prototype (a) a portable low head small hydro generator
prototype (b) a wiring connection of main power supply for store energy and
supply the load (c) different gradient angle hole.
 58

Figure 4.2 (a) and (b) show the testing DC output measured of the prototype by using
Digital Multimeter when in the river. Figure 4.2 (a) shows the testing for output voltage
and Figure 4.2 (b) shows the testing for output current of portable low head small hydro
generator.

(a)

(b)
Figure 4.2: Measured testing by Digital Multimeter on river (a) output voltage (b)
output current
 59

Figure 4.3 shows the portable low head small hydro generator speed measured by using
Tachometer when testing in the river.

Figure 4.3: The measured speed of turbine hydro generator by using Tachometer.
 60

Figure 4.4 and Figure 4.5 shows the overall system diagram. It displays complete
components in developed a portable low head small hydro generator for rural
electrification.

Output DC Motor
Cable

PVC Pipe

Turbine
Blades

Frame
Project

Figure 4.4: The hydro generator components.

 61

12V Smart
Charger
Controller

MCB

Inverter

DC Fuse
Block

12V
Battery

DC Load

AC Load
Socket

Figure 4.5: Wiring Components in panel box

 62

4.3 DC output of speed, voltage, current and power of small hydro

generator with different angle.

The test was conducted to determine the output speed (RPM), voltage (V), current (A)
and generator power (W) of low head small hydro generator with different gradient
angle. The output speed (RPM) of hydro generator was measured using a Tachometer.
Then, the output voltage (V), current (A) and generator power (W) of hydro generator
was measured by using a digital multimeter. The test was conducted on 23 rd May 2022
until 29 May 2022 for one week and the data output produced from of low head small
hydro generator was measured with four different gradient angles; 0𝑜to 35𝑜 angle. The
hardware for the low head small hydro generator was assembled at river Kampung
Chegor, Kuala Pilah, Negeri Sembilan.
The data from the evaluated results are shown in Table 4.1. The data of low head
small hydro generator was collected at a specific point value.

Table 4.1: DC output of portable hydro generator

PRIME MOVER SIDE GENERATOR SIDE
GRADIENT GENERATOR VOLTAGE CURRENT GENERATOR
ANGLE SPEED (V) (A) POWER
𝑜
(𝑛 ) (RPM) (W)

0𝑜 1469.1 1.56 0.95 1.48

15𝑜 1934.4 1.77 1.35 2.39
25𝑜 2117.2 2.16 1.60 3.46
35𝑜 2795.8 3.74 2.53 9.46
 63

4.3.1 The result of output voltage low head small hydro generator.

As shown in Figure 4.2 and Figure 4.3, the reported data is plotted. From the graph, it
can be observed that the gradient angle 35𝑜 has high speed (RPM), the low head small
hydro generator will generated its highest voltage i.e., 3.74V. It also produces high
current (A) and Alternator Power (W) to charging and supply the load. Then, the other
three gradient angle also generating voltage but not highest and not as good as in the
gradient angle of 35𝑜. Whereas the low head small hydro generator at angle 0𝑜 is
generating the lowest voltage i.e., 1.56V.

10 DC Ouput Of Hydro Generator

9 9.46
8
Voltage (V), Current (A) & Power

7 Voltage (V)
Current (A) Power (W)
6
5
4
3
2
1 3.46 3.74
0
2.39 2.16 2.53
1.56 1.77
1.48 1.6
1.35
0.95

Gradient 0Gradient 15Gradient 25Gradient 35

Different Gradient Angle
Figure 4.6: The voltage, current and power generator performance of a low head small
hydro generator with different gradient angle
 64

Speed Of The Hydro Generator

3000

2500 2798.5

2000
Speed Generator
2117.2
1934.4
1500
1469.1 Speed (RPM)
1000

500

0
Gradient 0 Gradient 15 Gradient 25 Gradient 35
Different Gradient Angle

Figure 4.7: The generator speed performance of a low head small hydro generator with
different gradient angle
 65

4.4 The time taken of low head small hydro generator for charging and
discharging battery with different gradient angle.

Table 4.2 shows the data collected from observing the time taken of low head small
hydro generator for charging and discharging the battery with capacity 20Ah. The time
taken of hydro generator to charging and discharging battery was measured by using a
12V smart charging controller. The results were demonstrated hourly, the voltage level
in the battery is increasing. As for charging, if the level battery is low than 12.5V, the
12V smart charging controller will automatically charge the battery. If the battery level
is full in 14.4V (fully charge), the 12V smart charging controller will be cut-off
(discharge) automatically.
From this test, it can be concluded that the time taken of low head small hydro
generator water flow with gradient angle 35𝑜 is performed better than the other rest
gradient angle, for charging and discharging battery. With gradient angle 35 , the
battery will charge quickly during high peak angle, which means when the gradient
angle is increase the value of voltage also is increase. This is because, if gradient angle
is more slope, the hydro generator will generate more electricity to save time to charge
and discharge the battery.
 66

Table 4.2: The data of hydro generator to charge and discharge battery.
Time Output voltage
taken Gradient Gradient Gradient Gradient
(Hours) angle angle angle angle
( 0𝑜 ) ( 15𝑜 ) ( 25𝑜 ) ( 35𝑜 )
1 hour 12.50V 12.50V 12.50V 12.50V
2 hour 12.60V 12.65V 12.69V 12.70V
3 hour 12.70V 12.78V 12.82V 13.00V
4 hour 12.82V 12.92V 13.01V 13.22V
5 hour 12.92V 13.03V 13.16V 13.45V
6 hour 13.01V 13.12V 13.31V 13.7V
7 hour 13.11V 13.22V 13.44V 13.99V
8 hour 13.22V 13.4V 13.59V 14.28V
9 hour 13.33V 13.54V 13.75V 14.40V
10 hour 13.46V 13.63V 13.89V Discharging
11 hour 13.52V 13.71V 14.05V Discharging
12 hour 13.62V 13.82V 14.07V Discharging
13 hour 13.72V 13.92V 14.33V Discharging
14 hour 13.82V 14.05V 14.40V Discharging
15 hour 19.94V 14.21V Discharging Discharging
16 hour 14.03V 14.33V Discharging Discharging
17 hour 14.13V 14.40V Discharging Discharging
18 hour 14.23V Discharging Discharging Discharging
19 hour 14.33V Discharging Discharging Discharging
20 hour 14.40V Discharging Discharging Discharging
21 hour Discharging Discharging Discharging Discharging
 67

4.4.1 The result of the battery for charging and discharging.

Based on Figure 4.8, once the small hydro generator output power is obtained, it is made
to store in the lead-acid for the future work. For battery protection, the power generated
by the hydro generator is made to pass through the smart charger controller and then
towards the battery. The smart charger controller is function to detect and control the
level of the battery. If the battery is lower than 12.5V, the smart charger controller will
allow the current for charging. When the battery is in fully charge condition 14.4V, the
smart charger controller will cut-off and discharging the current through to the battery.
According to this test, the time taken to fully charging to charge the battery of
small hydro generator depends on the gradient angle. With gradient angle 35𝑜 is much
faster to charge battery than the other gradient angle. The time required to charging
fully battery in gradient angle 35𝑜 is for 9 hours. This is because small hydro generator
with the gradient angle 35𝑜 will generated voltage and current more efficient compared
to other gradient angle. When the angle small hydro generator is more gradient the
water flow inside the PVC pipe is more pressured and faster to run the turbine. Then,
the generator will produce high output voltage and current to charging the battery.
Meanwhile, after 9 hours charging the battery, smart charger controller will operation
to discharging (cut-off) the battery from over charging and keep the battery from being
damaged.
The result time taken of low head small hydro generator shows for charging and
discharging battery, depending on the gradient angle of the small hydro generator has
been test. The gradient of this project is affecting of required time taken through to
charge the battery. Hence, for future work, the test must be conducted simultaneously
to compare the required time taken to charge the battery with the same gradient angle
that has selected.
 68

15
Time Taken For Charging And Discharging Battery
14.5

14

13.5
Battery

13

12.5

12

11.5

123456789 10 11 12 13 14 15 16 17 18 19 20 21
Time taken (Hours)

Gradient 0 Gradient angle 15 Gradient angle 25 Gradient angle 35

Figure 4.8: The time taken for small hydro generator to charging and discharging
battery.
 69

4.5 Summary

In summary, the performance of portable low head small hydro generator by hardware
development was successfully analyzed and discussed with adequate data and accurate
graphical representations. All results are presented to support each other and reach a
mutual agreement, which then helps identify minor offences to improve future work.
 7

CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1 Conclusion

In conclusion, a portable low head hydro generator for rural electrification successfully
developed. This system was developed six main parts, which is using 12V DC motor to
generate electricity, using material PVC to design the turbine blade and using 12V smart
charger controller that determine the optimum charge current and terminate charge of
battery. Then, using 12V battery to store energy and convert into electrical energy.
Using inverter to convert the battery supply into AC supply for home appliances load.
Also, the hydro generator has different gradient angle that can adjust their degree
according to change of river water flow and as to proven the DC output of hydro
generator performance.
From this project, it also shown that the application of available technologies and
exploit the opportunity of generating electric power from low head sites by using the
portable low head hydro generator. Therefore, the hydro generator has four different
gradient angles (0𝑜, 15𝑜, 25𝑜 and 35𝑜) to generate electricity according to the level of
river water flow, resulting in DC output voltage, current, power and improved the time
taken of generator for charging and discharging battery. The hydro generator with
gradient angle 35𝑜 constantly more significant to generate electricity and has faster time
taken to charging battery than the other gradient angle. The different gradient angle will
be affecting the hydro generator speed to generated electricity and the time taken for
battery to charging and discharging process.
 71

As a result, a hydro generator with a higher gradient angle will produce higher of
efficiency to generate electricity and can decrease the time taken for charging and
discharging battery. Changing the suitable gradient angle for the generator with
unchanged size and figures could increase the efficiency of electricity. The electricity
that will generate from the portable low head small hydro generator has no limitation to
store energy to produce electricity. It is because the hydro generator will generate
electricity in day and night as long as the current of the river flows for used of their
home or other appliances. The other advantage of this project is to develop a sustainable,
environmentally friendly alternative renewable production that can contribute green
environment.

5.2 Recommendation for future improvement

There are some limitations for this project. It is also possible to implement the low head
portable small hydro generator in the small current river. This project can also show the
hydro generator hardware function and get the same result as the expectation results.
Measurements of hydro generator with different gradient angle are vital, especially in
charging and discharging battery system as project data to collect DC output that can be
more accurate. During this project was implemented, the hydro generator will produced
electricity depend the level of current river water flow. The prototype can be adjusts
their gradient angle hole based on the river water flow. The high output of this hydro
generator was found when the current river water flow is fast and depends on their
gradient angle. This project system can also be improved in the future by adding IoT
system to the panel box for control the load system by using smartphone. Furthermore, it
also can monitor the output of hydro generator to make change locations that can
generate electricity more efficiently and be as data storage to easy collect data to make
improvements in the future.
 72

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 74

APPENDIX A

GANTT CHART PSM 1

WEEK
ACTIVITIES 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Consultation with supervisor

Project Title, Objectives and Scopes

Preparation for Project Introduction (Chapter 1)

Research on Literature Review (Chapter 2)

Determine the Methodology of the Project

(Chapter 3)
Discuss the Component and Hardware to use
(Chapter 3)
Simulation (Preliminary Result)

Report checking by Supervisor

Submission of report PSM1 to Supervisor

Submission of report PSM1 to panels

Preparation for presentation

PSM1 Presentation

Remark:
Planning
Actual
 75

APPENDIX B

GANTT CHART PSM 2

WEEK
ACTIVITIES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Consultation with supervisor

Purchasing all of the component needed

Software and Hardware Development for

Solar Tracking and Water Pump
Troubleshooting and Testing

Data Collection

Preparation for Chapter 4 (Result and

Discussion)
Thesis Development and improvisation

Preparation for Technical Report

Thesis, Technical Report, Video

Presentation with Poster submission
Preparation for presentation

PSM2 Question and Answer Session

E-Report submission

Remark:

Planning

Actual
 76

VITA

The author was born in Kuala Pilah on 9 November 1998. He went to Sekolah
Menengah Kebangsaan Datuk Undang Abdul Manap, Johol, Kuala Pilah, Malaysia, for
him secondary school. Then she pursues him study at Politeknik Ibrahim Sultan at Pasir
Gudang, Johor, from 2016 until 2018. After that, he further him study at Universiti Tun
Hussien Onn Malaysia in Bachelor of Electrical Engineering Technology (Electrical
Power) with Honours from 2019 until 2022. Him final year project title is “Development
of Portable Low Head Small Hydro Generator For Rural Electrification”, making him
contribution to developing and constructing the portable low head small hydro generator
hardware method. By applying the control elements in him discipline course, he
responded to developing the suitable and best plan to design a portable low head small
hydro generator for rural electrification successfully.