The Design Report we compiled can be seen below:
Final Microhydro Design Implementation Report
Compiled by Joseph Baker
Eng 101
12/6/10
Background and Introduction:
This project was designed to meet the electrical needs of a missionary station in Papua New Guinea. After determining the energy needs of the system, our team designed a complete microhydro power production proposal. Our team actually produced and tested part of this design. This section of the project will be covered in the Implemented Design Elements section. Some elements of our project could not be practically produced and tested in our limited time frame. These components will be outlined in the Proposed Design Elements section. At the end of this report, our calculations and results will be summarized in the Analysis section.
Implemented Design Elements:
1. General Layout
a. We basically followed the general design of our initial proposal.
2. Mounting Plate
a. A 18” x 19” x 1/8” aluminum sheet was used to mount the alternator, turbine, and nozzle.
b. After measuring our components, we marked the sheet and had openings depicted in the following diagram machined.
3. Alternator
a. To produce the needed power, we decided on the Windblue DC-520 Permanent Magnet Alternator.
b. This is a rebuilt automotive alternator that uses permanent magnets to produce 3-phase power.
c. This alternator can be found at Windbluepower.com
4. Turgo Turbine
a. We chose to use a turgo turbine due to our given head and flow rates.
b. In order to provide adequate torque to turn the alternator, we chose the 32-spoon, 9.74 inch turgo turbine sold at h-hydro.com.
5. Nozzle Design
a. We designed nozzle to power our turbine from 3/4” plumbing fittings.
b. The main parts of this design were a brass ball valve and threaded ¾” pipe fittings.
c. The threaded coupling at the base of the assembly allows for interchangeable nozzle heads based on flow rates.
d. We achieved maximum power output in our 12gpm experiments using a 1/4” nozzle head.
e. Our nozzle was designed to shoot water at a 20 degree angle with the turbine. While this is a commonly recommended angle, a shallower angle would actually be slightly more efficient.
6. Rectifier and Charge Controller
a. In order to convert the 3-phase power from the alternator into DC current, we used the rectifier which came with the alternator we ordered at Windbluepower.com
b. In order to regulate the charge to the batteries and prevent overcharging, our circuit incorporated a charge controller (model number NC25A-12V) available at Windbluepower.com. When the batteries are fully charged current will automatically be directed to a divert load which can be harnessed for applications such as a water heater.
c. All components were assembled on a panel which was designed and labeled to be disassembled and reassembled as needed.
7. Wiring
a. We used about 15 ft. of 16 gauge wire, most of this ran to and from the battery for sensing how charged the battery was.
b. We used about 10-12 ft. of 12 gauge wire. This ran to and from the battery for charging and from the rectifier to the terminal board.
c. For the load, we used about 10 ft. of 22 gauge wire, but they were part of the light set already.
d. We used an 8 ft. 10 gauge extension cord that ran from the generator to the terminal board.
Proposed Design Elements:
1. Water Collection
a. A rock weir will be used to collect water.
2. Piping
a. Approximately 200 feet of 4in. PVC pipe will be used between the water source and the turbine.
b. The 4in. PVC pipe will constrict to 3/4" PVC before the ball valve.
3. Housing
a. The housing will be built from locally available materials.
b. This housing will be secured to prevent theft.
4. Water Heating
a. A heating element can be wired to the divert load and used to heat water for the missionaries.
5. Interrupted Current Alarm
a. An alarm will be wired into the circuit board that will sound when current is interrupted.
b. This will both prevent theft and serve as an indicator if something is malfunctioning.
Analysis:
1. Cost Summary
2. Calculations and Predictions
a. Assuming the turbine moves at half of the speed of the water exiting the nozzle, we predicted that the turbine should rotate at almost 1000 RPMs.
b. The following chart shows the expected power output of the alternator we used as different speeds.
3. 3. Experimental Results
a. Our experiment was performed with a water source with a flow rate of approximately 12 gpm and a pressure of approximately 45psi.
b. The expected results are shown in the theory section of the following table. These predictions assume 14psi. However, our experiment used a higher pressure than this, so theoretical wattage is actually higher than the values shown.
c. The measured wattage numbers separated by a slash indicate wattage output during charging (left) and divert (right).
how do you cool the Alternator???
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