International Journal of Applied Power Engineering (IJAPE)

Vol. 14, No. 1, March 2025, pp. 90~100

ISSN: 2252-8792, DOI: 10.11591/ijape.v14.i1.pp90-100  90

Innovation of control valve motorization method for regulating

turbine rotation in micro hydro generators

Supri Hardi, Nelly Safitri, Yaman, Radhiah, Jamaluddin

Electrical Engineering Department, Politeknik Negeri Lhokseumawe, Lhokseumawe, Indonesia

Article Info ABSTRACT

Article history: The method of transferring the main load to the dummy load is still used in
micro hydropower plants. Because the turbine and generator are constantly
Received Jan 10, 2023 operating at maximum capacity, the load transfer system, also known as the
Revised Mar 20, 2024 electronic load control (ELC) system, is ineffective and inefficient. The
Accepted Apr 26, 2024 researcher devised a method for controlling the pressure/flow rate on the
branch pipe by using a control valve motorized (CVM). Control valve
motorized (CVM) is responsible for the opening and closing of branch
Keywords: pipelines using an electric motor. The goal is to achieve voltage and
frequency stability by using CVM to adjust the flow/pressure of water in the
Control valve motorized branch pipe. The method involves designing and testing the CVM system
Pelton turbine module via a Pelton turbine module connected to the generator. The results of testing
Pressure the Pelton turbine module with a pressure of 4 kg/cm2 on a 34-inch pipe
Proportional integral derivative show that the turbine rotates at 800 rpm. Brushless direct current (BLDC)
Voltage and frequency stability generator with 12 poles and a Pelton turbine. The proportional integral
derivative (PID) controller control parameters are calculated by the control
system using the Nichols-Ziggler method, with tuning results of PB 130%,
Ti 2.8 seconds, and Td 0.7 seconds. A frequency of 50 Hz and a voltage of
61 volts is produced by controlling the set point (SP) at 55% of the process
variable (PV) and the manipulated variable (MV) to CVM at 38%,
respectively. The conditions are implemented by varying the load on the
system by connecting and disconnecting the load; the system remains stable
for 5 seconds.
This is an open access article under the CC BY-SA license.

Corresponding Author:
Nelly Safitri
Electrical Engineering Department, Politeknik Negeri Lhokseumawe
Banda Aceh-Medan St. Km. 280 Buketrata, Lhokseumawe, Aceh, Indonesia
Email: [email protected]

1. INTRODUCTION
A micro hydro power plant is a small-scale power plant that employs the head and flow rate of water
as the driving force, such as an irrigation canal, river, or natural waterfall. The phrase "micro hydro" is made
up of the words "micro," which means "tiny," and "hydro," which means "water." Generator rotation
irregularity brought on by changes in the linked load is a frequent issue in the micro hydro power plant. As a
result, the system frequency fluctuated, which increased the risk of electrical equipment damage [1]-[3].
The generator's rotational speed has a significant impact on the electrical frequency and voltage that it
produces. Any technologies that have been developed regarding micro hydropower plants can be seen
through reference [4]-[9].
Electronic load controllers (ELCs) are now being developed for micro hydropower plants to ensure
voltage and frequency stability [10]-[15]. The micro hydro power plant's ELC is used to change the load to a
heater with a resistance of 1–5 Ohms as a dummy load. The ELC's basic operating principle is to transfer the

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Int J Appl Power Eng ISSN: 2252-8792  91

primary load to a dummy load [16]-[20]. The generator and turbine operate at their highest capacity
continually as a result of the ELC system. The ELC method is less effective and efficient, according to
researchers. Researchers consider introducing a fresh idea to enhance the ELC system. The novel technique
that will be investigated is controlling the turbine's spin using a control valve motorized (CVM). The novel
technique that was investigated is controlling the rotation of the turbine using a control valve motorized
(CVM). A turbine rotation control system that designed and tested by researchers with CVM controlled by a
proportional integral derivative (PID) controller. The CVM system was developed as a voltage and frequency
stabilizer for micro hydro generators. PID controller parameter values greatly affect the level of stability of
the controller performed by CVM. The expected goal of the results of this study is to obtain voltage and
frequency stability by adjusting the flow rate to the turbine with CVM.
Pelton type turbine is used, has input energy (Pin) in the form of water pressure on a turbine driving
the turbine blade and producing kinetic energy (Pm) in the form of rotation. Turbine efficiency is defined as
the ratio of input energy to generated kinetic energy. Turbine efficiency should be between 80% and 90%.
Turbine blades, penstock pipes, nozzles, and water guides are some of the components that influence the
value of low turbine efficiency [10], [21]-[27]. The turbine's mechanical energy then rotates the generator,
converting mechanical energy to electrical energy.
The rotation control system in large-scale generators employs a hydraulic valve with governor control
[13], [28]-[32]. The turbine is set to rotate at a constant rate, which requires controlling the control valve so that
the flow to the turbine is always stable [1], [15], [33]. The synchronous generator, AVR excitation, and
automatic governor control (AGC) are the three main components of the generation system [1], [6], [17]-[20],
[29], [30]. The turbine system, generator system, and control system are the three main components of a
hydroelectric energy generation system. The advantages and disadvantages of these types of turbines,
particularly for a very specific design, can be used to determine the type of turbine to be used. In the early
stages, the type of turbine can be considered by taking into account the special parameters that affect the turbine
operating system, as in reference [30], [32]. As the load influences the generator's rotation speed. Consequently,
frequency control is required in the working environment. Currently, ELCs are frequently used to develop
various knowledge such as vehicle steer control also to ensure voltage and frequency stability. As a result,
researchers were eager to experiment with PID controllers to optimize the AVR based on CVM. A CVM is used
because it is simpler than a control valve, which needs pressurized air or a source of hydraulic pressure to
operate. This study was carried out by designing and implementing the CVM method to control the rotation
of the Pelton turbine which is coupled to the generator in a micro hydro generator. A control valve that may
be opened to a different degree and is driven by an electric motor is known as a control valve motorization
(CVM). The signal given at 0–10 volts determines the proportion of CVM valve opening.
Sections in this study are as follows: i) Section one introduces CVM and the method that can be
used to regulate the rotation of the Pelton turbine due to generate voltage in the micro hydro power plant
system; ii) Section two proposes and explains the innovative method in regulating the rotation of Pelton
turbine due to generate voltage in the micro hydro power plant system; iii) Section three simulating and
analyzing the proposed system to see the plant responds and also determining the PID parameters (stable and
unstable conditions) and addressing it to the load changes circumstances; iv) and The final section is
concluding the behavior of the proposed system.

2. METHOD
The generator system is the load that the turbine must drive in order to produce a voltage at a
specific frequency [34]-[37]. According to (1), the need for generator rotation must be met based on the
number of poles and the desired frequency. At the same point, the turbine rotates the rotor magnetic field,
which induces a magnet to the stator coil and results in the induced voltage [30], [32]. The (2) describes how
much voltage is produced.

(120.𝑓)
𝑁𝑠 = (1)
𝑃

Where 𝑁𝑠 is synchronous rotation (rpm); 𝑓 is frequency (Hz); and 𝑃 is the number of poles.

𝐸 = 4.44 × 𝑓 × 𝑁 × 𝜙 (2)

Where 𝐸 is induced voltage (volts); 𝑓 is frequency (Hz); 𝑁 is the number of turns; and 𝜙 is flux magnetic
field excitation (wb).

Innovation of control valve motorization method for regulating turbine rotation … (Supri Hardi)
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The rotation control system is used on the turbine to adjust the flow rate by adjusting the CVM
opening. The turbine power is related to the flow rate Q in the penstock, as shown in (3).

𝑃 = 9.81 × 𝑄 × 𝐻 × 𝜂_𝑡𝑢𝑟𝑏𝑖𝑛𝑒 (3)

Where 𝑃 is turbine power (kW); 𝑄 is water discharge (m3/s); and 𝐻 is effective head height (m).
CVM can adjust the flow rate based on the generator power requirements. The flow rate control
system is made up of three major components: sensors, controllers, and actuators. Electrical signal standards
include current signals 0-20 mA and 4-20 mA, as well as voltage signals 0-5 volts and 0-10 volts. The
industry standard signal ranges from 4-20 mA [38]-[40]. The shape of this signal must be understood so that
no errors occur during the system control process. Signal standardization is very important, so the industry's
instrumentation equipment must be recalibrated so that the signal matches the real-time in the field [17].
The design process involves creating a generating plant module with a Pelton turbine operating at a
specific turbine rpm and water pressure [21]-[27]. The PID control parameters are then calculated and
determined [20], [31], [41], [42]. PID control parameters are calculated and determined based on the Ziegler-
Nichols in Table 1.
The test procedure involves measuring the outcomes of the power plant design and testing using the
PID control settings that have been determined to see how the CVM control reacts to the Pelton turbine.
Figure 1 illustrates the system design of Pelton turbine. The turbine rotation is carried out in accordance with
Figure 2 to measure and record control response data using LabSoft [16], [18], [19], [42]-[44].

Table 1. PID control parameter of Ziegler-Nichols

Controller Kp Ti Td
Proportional 𝑇𝑔 ∞ 0
𝑇𝑢
PI 0.9 𝑇𝑔 3.3 Tu 0
𝑇𝑢
PID 1.2 𝑇𝑔 2 Tu 0.5 Tu
𝑇𝑢

Figure 1. Pelton turbine generator system design

Figure 2. Rotation control block diagram

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Figure 2 shows that the turbine rotation sensor by the tacho generator provides a linear signal of
0-10 volts through a cable conductor from the field to the panel. Then the signal from the controller is sent
again to the servo motor actuator with a signal of 0-10 volts. Before the actuator in the form of a servo valve,
the 0-10 volts electrical signal is changed by a converter with a 24 volts DC source voltage to rotate the
valve. The responses to be recorded are the setpoint, variable process (VP), and the control response
manipulated variable (MV) through the interface to the computer.
A technique for managing the load involves using CVM and a PID controller to direct water flow or
pressure in the penstock toward the Pelton turbine. Construction is needed, and the associated expenses are
higher because a larger valve size is employed to directly set the pressure or flow in the quick pipe. Only
50% of the primary penstock's size is used in the procedure for rerouting pressure or flow from it. Figure 3
illustrates the Pelton turbine which is coupled to the generator in a micro hydro generator.

Figure 3. Micro hydro generator

3. RESULTS AND DISCUSSION

The experiment was carried out on a tiny Pelton turbine plant that was pumped with 4 BAR
compressed water. Pelton turbine paired with a 2 kW, 12 pole, 500 rpm, 50 volts, and 50 Hz permanent
magnet generator. At a turbine speed of 0-1000 rpm, the turbine speed is measured using a 0-10 volts signal.
used as a controller MEP-SD multi channels digital instrument is the model name. For intelligent style, use a
control valve with a 24-volt DC source, a run time of 55-100 seconds, and an input signal of 0-10 volts. The
recorder system connects the plant to the computer via the Labsoft interface, which measures and records
control response data on process variable (PV) and manipulated variable (MV). A technique for controlling
loads involves using a CVM and PID controller to direct the flow or pressure of water in the penstock
towards the Pelton turbine. Construction is required, and the associated costs are higher because larger valve
sizes are used to directly regulate pressure or flow in the rapid pipe. Only 50% of the main penstock size is
used in the procedure to divert pressure or flow from it. Figure 3 illustrates a Pelton turbine coupled to a
generator in a micro hydro power plant.

3.1. Proposed system’s general description

The water pressure coming out of the turbine is 1 ATM = 10322 kg/m2. The density of water is
1 g/cm , which is 1000 kg/m3, so the weight of water is 1000 kg/m3 × 9.8 m/s2 = 9800 Kg/m2s2. The results of
3

the measurements carried out are the water pressure in the penstock measuring the pressure gauge leading to
the turbine Pelton of 4 kg/cm2 with a height of 3.03 m. We got the plant response as shown in Figure 4. The
responses that can be analyzed are the delay time (td), rise time (tr), top time (tp), set time (ts),
and overshoot (mp) values that occurred. The Td value = 1 s, Tr = 2.5 s, Tp = 3.5 s, ts = 7 s, mp = (35-30)/30
×100% = 16.67% (can be seen in Figure 5).
Figure 6 shows that the turbine rotation sensor by the tacho generator provides a linear signal of
0-10 volts through the cable conductor from the field to the panel. Then the signal from the controller is sent
again to the servo motor actuator with a 0-10 volts signal. Before reaching the actuator in the form of a servo
valve, the 0-10 volts electrical signal is converted by a converter with a 24-volt DC source voltage to rotate
the valve. The responses to be recorded are setpoint, variable process (VP), and control response (MV) via
the interface to the computer.

Innovation of control valve motorization method for regulating turbine rotation … (Supri Hardi)
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Figure 4. Plant responds

Figure 5. Determined of Tu and Tg

Figure 6. Simulation via Luecas Nuelle module and the wiring in panel

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3.2. PID control parameters determination and applications

The parameters that must be calculated for PID control are the values of Kp, Ti, and Td. Following the
Nichols-Ziggler method using the reaction curve in Figure 5, where Tu = 1.4 and Tg = 2.2. The magnitude of
the PID control parameters is Kp = 1.2×1.4/2.2=0.764 or proportional band (PB)=1/0.764×100%=130.89%,
Ti = 2×1.4=2.8 s, and Td = 0.5×1.4=0.7 s. Applying PID control parameter values by setting parameter
values that have been calculated on the controller tool [21]-[25]. The steps are: i) running the turbine until it
reaches a stable condition, ii) analyzing control response, iii) providing turbine and generator loads,
iv) analyzing changes in response that occur, v) changing the PB values to 100% and 200%, vi) perform
analysis from points 2 to 4, and vii) make another load changes.
The experiment initially takes the turbine and generator worked under zero load conditions with a set
point at 51% or at a frequency of 51 Hz or a rotation of 510 rpm, with a voltage of 61 volts.
Control parameter settings according to the calculation PB = 130%, Ti = 2.8 s, and Td = 0.7 s. Figure 7 shows the
MV response, which is the output from the controller where the observed values td = 1 s, tr = 2.5 s, tp = 5.5 s,
ts = 17.5 s, and mp = (61-51)/51×100%=19.6%. At 43 seconds, the load is carried out in the form of a 3×5-watt
lamp. In this condition, the frequency and voltage drop to 50 Hz and 60 volts, respectively. The normal voltage
and frequency then return to the setpoint values of 51 Hz and 61 volts automatically after 20 seconds.
As the experiment continues, 2 sets of PB (100% and 50%, respectively) have been simulated to see
the response of the plant as other control parameter settings are still the same. Figures 8 and 9 illustrate the
responses as the PB value on the PID control changes. Whereas at Kp 1 (PB 100%) the steady state time
reaches 35 seconds, it is only 28 seconds with Kp 2 (PB 50%). The overshoot for Kp 1 is negligible, however
for Kp 2 (50%) it is 19.6%. The static state time is only 5 seconds when loading and unloading is being done.

Figure 7. Plant responds as loaded condition

Figure 8. Plant responds at PB 100%

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Figure 9. Plant responds at PB 50%

3.3. Load changes

In terms of speed, when a load change of 3×10 watts and 3×25 watts, respectively is made, it
reaches a steady state, and the overshoot response that occurs is shown in Figures 10 and 11, respectively. In
both Figures 10 and 11, it can be seen in the load changes of 3×10 watts and 3×25 watts, the zero load
condition reaches a steady state for 12 seconds and 13 seconds, respectively, with an overshoot of 19.6%.
The condition is carried out by loading a steady state time of about 5 seconds with an overshoot almost equal
to zero. Then the load was released again during a steady state for 9 seconds with an overshoot of 4% and
16%, for a 3×10 watts and a 3×25 watts load, respectively.

3.4. Unstable PID control parameter values

Unstable control systems are unavoidably the result of inappropriate control parameter settings. It is
possible to see unstable system conditions when the response oscillates constantly and causes unstable
voltage and frequency. Figure 12 illustrates this situation, which happens with a Kp = 3, Ti = 4, Td = 1, and a
load of 3×10 watts.

3.5. System performance analysis

An intriguing finding emerged from all the tests run, in which the controller itself may adjust the
PID control parameters. The turbine is first operated normally, and then the self-tuning setting is activated.
After that, the controller performs its own calculations for roughly 60 seconds until the system is steady.
According to the results of the controller's self-tuning, the PID control parameters were set to PB = 127.8%,
Ti = 25 s, and Td = 6 s, as shown in Figure 13.

Figure 10. 3×10 watts load condition responds

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Figure 11. 3×25 watts load condition responds

Figure 12. Unstable plant responds

Figure 13. PID parameter setting

In order to avoid huge input values to the controller using a potentiometer, restrictions on sensor
settings are implemented. Since the voltage sensor can generate signals greater than 10 volts, this is done.
A controller whose maximum sensor signal is 10 volts should not experience this. By changing the
potentiometer, the sensor signal limit is restricted to a value of 6 volts. The set point value of 55% VP is at
55% and the MV value to the CVM setting is at position 38% in the response, resulting in a frequency of
50 Hz and a voltage of 61 volts. The issue is that when the load is connected, it disturbs the system, and
releasing the load, the system remains stable, with a duration of about 5 seconds. The parameter calculated
values manually compared to self-tuning have slight differences, particularly the PB value of 127.8%, with
130%, as well as the calculated Ti and Td values, which are 1/10 multiplication of the self-tuning values.
Table 2 lists the changes that occurred during the tuning point when Ti is 2.8 seconds and Td is 0.7 seconds.

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Table 2. Changes of PID control parameters at fix turning point initial time
Controller parameter (PB) Time delay (Td) Time rise (Tr) Time peak (Tp) Time setting (Ts) Overshoot percentage (mp)
% (s) (s) (s) (s) %
130 1 2.5 5.5 17.5 19.6
100 1.2 4 7.2 35 12.3
50 1.5 2.7 7.5 28 20

4. CONCLUSION
The proposed system is designed using the CVM method to control the rotation of the Pelton turbine
which is coupled to the generator in a micro hydro generator. A rotation of 750 rpm is produced by the
measurement of a pressure of 4 kg/cm 2, a potential energy of 4 kg, and a height of 3 meters. A 2 kW BLDC
generator is linked with this rotation. Tacho generator sensor input 0-10 volts linearly, a 24-volt DC voltage
source as a CVM voltage source, and a 0-10 volts analog input and output controller are all included in the
control panel installation. The tuning results of the PID controller control parameters are determined at
Ti 2.8 seconds, and applied for PB 130%, 100%, and 50%, respectively. However, the unstable system has
occurred at PB 33%. As the two sets of PB were simulated, 100% and 50%, respectively, the results show
that the steady-state time reaches 35 seconds with Kp 2 (PB 50%), but only 28 seconds with Kp 1. When
loading and unloading occurred, at a static state time is only 5 seconds, the system reached a steady state
condition, and the overshoot response occurred. Controlling the set point values at 55%, causes the CVM to
be set at 38%, resulting in a frequency of 50 Hz and a voltage of 61 volts. The condition is that the system is
disturbed by connecting and disconnecting the load; however, the system remains stable for approximately
5 seconds.
The CVM is used to regulate water pressure in the Pelton turbine in this latest design. This system is
more effective and efficient if the electrical energy produced is stable under varying load situations. As a
result, with ready-to-use modules, this system may be deployed in the field. The control response shows that
the control system is stable.

ACKNOWLEDGEMENTS
Author thanks to Pusat Penelitian dan Pengabdian kepada Masyarakat (P3M) of Politeknik Negeri
Lhokseumawe who in most cases, sponsored and financially supported acknowledgments.

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Innovation of control valve motorization method for regulating turbine rotation … (Supri Hardi)
100  ISSN: 2252-8792

BIOGRAPHIES OF AUTHORS

Supri Hardi, S.T., M.T. currently works as a lecturer and researcher at the
Electrical Engineering Department, Politeknik Negeri Lhokseumawe. Completed his master's
degree at the University of North Sumatera in 2008. His area of interest is power system, power
electronics, and electrical machinery. He can be contacted at email: [email protected].

Dr. Nelly Safitri, S.S.T., M.Eng. Sc. currently works as a lecturer and researcher at
the Electrical Engineering Department, Politeknik Negeri Lhokseumawe. Completed her master's
and doctoral degree at the Curtin University of Technology, Western Australia in the Electrical
and Computer Engineering Department in 2007 and 2016, respectively. Her area of interest is
renewable energy, power system, and smart grid. She can be contacted at email:
[email protected].

Yaman, S.T., M.T. currently works as a lecturer and researcher at the Electrical
Engineering Department, Politeknik Negeri Lhokseumawe. Completed his master's degree at
Gadjah Mada University in Yogyakarta, Indonesia in 2010. His area of interest is power system
distribution and electrical machinery. He can be contacted at email: [email protected].

Radhiah, S.T., M.T. currently works as a lecturer and researcher at Electrical

Engineering Department, Politeknik Negeri Lhokseumawe. Successfully completed her master
degree at the University of North Sumatra in Indonesia in 2008. Her area of interests is power
system, power electronics, and electrical machinery. She can be contacted at email:
[email protected].

Ir. Jamaluddin, M.T. currently works as a lecturer and researcher at the Electrical
Engineering Department, Politeknik Negeri Lhokseumawe. He successfully completed his
master's degree at Bandung Institute of Technology in Indonesia in 2003. His area of interest is
control system, power electronics, and distributed control systems. He can be contacted at email:
[email protected].

Int J Appl Power Eng, Vol. 14, No. 1, March 2025: 90-100