Good - and - Bad - of - Mini - Hydro - Power - Vol 1 PDF

GOOD & BAD
of
Mini Hydro Power
Volume 1
Site Identification Civil Works Electro-Mechanical
GOOD & BAD
of
Mini Hydro Power
Klaus Jorde
with the resources of Entec AG
Ekart Hartmann, Heinz Unger
Edited by
Roman Ritter
GTZ
ASEAN-German Mini Hydro Project

(AGMHP)
Imprint
GOOD & BAD

of Mini Hydro Power
Authors:
Klaus Jorde with the resources of Entec AG;
Ekart Hartmann, Heinz Unger
Editing:
Roman Ritter, GTZ
Photos, drawings and graphics provided by:

The Indonesian-German Mini Hydro Power Project (MHPP)
Published by:
The ASEAN Centre for Energy (ACE)
under the direction of its Executive Director, Nguyen Manh Hung,
supported by the ASEAN-German Mini Hydro Project (AGMHP)
Jl. HR. Rasuna Said, Blok X-2, Kav 7-8, Kuningan

Jakarta 12950, Indonesia
Phone : +62 (0)21 527 8027
Fax : +62 (0)21 529 63820
Websites : http://www.aseanenergy.org
http://agmhp.aseanenergy.org
http://www.gtz.de/energy
First published by ACE in June 2009
Photographs, drawings and any other graphical elements are intellectual copyright protected
and therefore must not be extracted separately from this publication.
However, complete chapters of this book may be translated into other languages and thereby
be reproduced for training purposes, provided the publisher is informed of these purposes
and proper acknowledgements are made.
Disclaimer:
The publication has been prepared to illustrate good & bad practice examples in micro and mini hydro power
planning, implementation, operation & management.
While all reasonable care has been taken in the preparation of this publication, the authors, editors, ACE, AGMHP,
Entec AG, GTZ, MHPP, PT Entec Indonesia and any other individuals and parties involved accept no responsibility
for damage, injury or any other undesirable events resulting from its application or interpretation.
The ultimate responsibility for quality, reliability and safety remains with designers, suppliers, installation teams
and operating agencies. It is strongly recommended that any design, construction, electrical or mechanical
installation, operation, maintenance and repair works are carried out and/or supervised and checked by qualified
technicians and engineers only.
ISBN : 978-979-8978-26-5/978-979-8978-27-2
i GOOD & BAD of Mini Hydro Power

Table of Contents
Volume 1
1 SITE IDENTIFICATION 1
1.1 General 2
1.2 Run of River Hydro Power Station 2
1.3 Feasibility 4
1.3.1 Site Identification and Flow Measurement 4
1.3.2 Rough Calculation of Possible Hydro and Electrical Power 6
1.3.3 Estimate Electrical Load 7
1.3.4 How to Measure the River/Stream Flow? 7
1.3.5 Discharge Measurements and Flow Duration Curve 14
1.3.6 Head Measurement 15
1.3.7 General Project Data 24
1.3.8 Synergies, Ownership and Management 26
1.3.9 Energy Supply and Demand 27
1.3.10 Consultants 29
2 CIVIL WORKS 31
2.1 Construction Basics 32
2.2 Individual Components 44
2.2.1 Weir and Intake 44
2.2.2 Sand Trap - Settling Basin 53
2.2.3 Headrace Channel 57
2.2.4 Forebay 70
2.2.5 Trash Rack 75
2.2.6 Spillway 81
2.2.7 Penstock and Support 85
2.2.8 Power House and Tailrace 97
3 ELECTRO-MECHANICAL EQUIPMENT 105

3.1 Basics 106
3.2 Individual Components 111
3.2.1 Turbine 111
3.2.2 Main Elements of a Generator 117
3.2.3 Panel, Controller and Ballast 121
3.2.4 Inside the Power House 129
3.2.5 Power House Wiring 136
3.2.6 Mechanical Transmission 143
3.2.7 Tools and Spare Parts 152
GOOD & BAD of Mini Hydro Power ii

Volume 2
4 TRANSMISSION & DISTRIBUTION 161

4.1 General Basics 162
4.1.1 Basics for Grid Planning, Design & Layout 162
4.1.2 Implications of Productive End Use on Network Design 163
4.2 Major Components 164
4.2.1 Transformer Station 164
4.2.2 Distribution Poles and Lines 168
4.2.3 Wiring connections 170
4.2.4 Maintenance 178
5 HOUSE INSTALLATION 181

5.1 General 182
5.2 Major Elements 183
5.2.1 Service Connection 184
5.2.2 Current Limiting Device 186
5.2.3 Metering 188
5.2.4 House Wiring and Fittings 192
6 MANAGEMENT AND ADMINISTRATION 201

6.1 Community Participation and Mobilisation 202
6.2 Institutional Setup 207
6.3 Capacity Building and Training 210
6.4 Tariff Policy 211
6.5 Financial Management 215
6.6 Monitoring and Documentation 216
7 UTILIZATION OF ENERGY 219
iii GOOD & BAD of Mini Hydro Power

Foreword
The urgent call for reducing the carbon footprint of our economies combined with the worlds
ever growing demand for scaling-up access to energy is a priority challenge on the global
agenda which defines the role for renewables.
Renewable energies offer climate-friendly, low risk technology options for decentralized
power generation. In remote areas, utilizing local renewables to support the development
of poor rural communities is often more economically viable than transporting diesel fuel
or expanding the national electricity grid over long distances. In locations where however
the network infrastructure is already in place, harnessing natural resources for feeding power
into the central grid also offers an important source of local income that contributes to
macroeconomic stability by gaining independence from price-volatile fossil fuels.
In the light of this, the Association of South East Asian Nations (ASEAN) is emphasizing the
need to strengthen the development of renewable energies. Promoting mutual cooperation
for the transfer of knowledge and skills in order to narrow development gaps among the
ASEAN countries, to empower the regions peoples, and ultimately to alleviate poverty is seen
as the way forward.
With this publication, GOOD & BAD of Mini Hydro Power, the ASEAN Centre for Energy (ACE)
aims to provide valuable lessons from experiences gained in one member country for the
dissemination of good practices throughout the whole region. This is intended to support
the capacity development of ASEANs human resources in the sustainable planning, design,
implementation, management, operation and maintenance of mini hydro power (MHP).
The two underlying principles of this book are: a picture is worth a thousand words and the
only real mistake is the one from which we learn nothing. Thus along the sequence from
water to wire contrasting pictures of good & bad examples are provided to illustrate what
actually defines the difference. Each picture is complemented by short explanations so that
the book can serve as a technical training manual that offers direct and easy-to-understand
guidance.
Although MHP is a relatively mature and cost-competitive energy technology, a lot of

mistakes are still being made which lead to increased maintenance cost, reduced power
output, shortened service life or even physical danger. The good news is that in many cases
it is only small changes which need to be made doing things the right way often requires
no more funds than doing them the wrong way. However, what is definitely required is a
proper awareness and expertise among hydro practitioners and their principals for whom,
quite literally, knowledge is power.
Nguyen Manh Hung Roman Ritter

ACE, Executive Director GTZ, Principal Advisor AGMHP
GOOD & BAD of Mini Hydro Power iv

Acknowledgements
This book draws on countless photographs and experiences which have been collected in
practically applying international MHP know-how for the successful improvement of mini
hydro power implementation in Indonesia.
Therefore special thanks go to the Indonesian Directorate General for Electricity and Energy
Utilization (DGEEU) and its Mini Hydro Power Project (MHPP) which has been jointly
implemented for more than 10 years by DGEEU and GTZ, the German Technical Cooperation
Deutsche Gesellschaft fr Technische Zusammenarbeit.
Big thanks also go to the team of authors who made great efforts in bringing together Entecs
expertise in MHP development with the didactical concept of using contrasting pictures
which require only short explanations to point out the decisive difference.
Last but certainly not least, the ASEAN Centre for Energy (ACE) is highly grateful to the German
Federal Ministry for Economic Cooperation and Development (BMZ) for its continuous support
of the ASEAN-German Mini Hydro Project (AGMHP) which provided the necessary resources
for compiling this publication.
Nguyen Manh Hung

ACE, Executive Director
v GOOD & BAD of Mini Hydro Power

1. Site Identification
GOOD & BAD of Mini Hydro Power

Site Identification
1.1GENERAL
Mini hydro power stations (MHP) are installations often referred to as generating less than
1,000 kW electrical energy. The hydraulic sources are:
t 3JWFSTBOETUSFBNT
t 8BUFSTPVSDFT
t 8BUFSTVQQMZNBJOT
t 8BTUFXBUFSTZTUFNT
To create electricity in a small hydro power station the following two questions are essential:
t )PXNVDIXBUFSJTBWBJMBCMFUISPVHIPVUUIFZFBSGPSUIFUVSCJOF PX
t 8IBUJTUIFQPTTJCMFEJFSFODFJOIFJHIU IFBE
1.2 RUN OF RIVER HYDRO POWER STATION
Flow and head are the most important parameters for the design of a hydro power plant.
Typical example of a diversion type run-of-river hydropower plant
t "SVOPGSJWFSIZESPQPXFSQMBOUJTB.)1XJUIPVUBOZSFTFSWPJSPSTUPSBHFDBQBDJUZ
t "EJWFSTJPOUZQFIZESPQPXFSQMBOUJTB.)1XIFSFUIFXBUFSJTEJWFSUFEGSPNUIFSJWFSJOUP
a channel and/or penstock system
2 GOOD & BAD of Mini Hydro Power

Site Identification
t *OHFOFSBM UIFSFBSFUXPUZQFTPG.)1SFHBSEJOHHSJEDPOOFDUJPO
- Isolated MHP
- Grid connected MHP
t *O TPNF BTQFDUT UIF EFTJHO PG BO JTPMBUFE .)1 JT EJFSFOU UIBO UIF POF PG B HSJE
connected. Most components, such as civil works and hydraulic components are the
same
t *OTPNFDBTFT .)1BSFCVJMUBTJTPMBUFE.)1BOEMBUFSBSFDPOOFDUFEUPUIFHSJE
Note:
CHOOSING INCORRECT PARAMETERS AND DEVELOPING THEREWITH A NON-OPTIMIZED

DESIGN RESULTS IN MASSIVE COST INCREASES OR UNSATISFYING PERFORMANCE!
IT IS THEREFORE STRONGLY RECOMMENDED TO CALL AN EXPERIENCED MHP EXPERT
FOR THE DESIGN PHASE!
GOOD & BAD of Mini Hydro Power 3

Site Identification
1.3 FEASIBILITY
The most important information which must be available is the general location and
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head difference which can be utilized. Additionally it is important to know the distance to the
potential electricity consumers and/or the closest power line near by.
1.3.1 Site Identification and Flow Measurement
The following information must be gathered:

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t 5IF PQUJNBM MBZPVU PG UIF XIPMF TDIFNF XJUI JOUBLF IFBESBDF TBOE USBQ QFOTUPDL
powerhouse and tailrace
t 4J[FBOEMFOHUIPGUSBOTNJTTJPOBOEEJTUSJCVUJPOMJOFGSPNQPXFSIPVTFUPUIFVTFSTPG
the electricity
t "EFNBOEGPSFDBTUGPSIPVTFIPMET TNBMMJOEVTUSJFTBOETPDJBMJOGSBTUSVDUVSFGBDJMJUJFTGPS
be connected in the future
Collect river/stream flow data
'PSIZESPQPXFSEFTJHOJUJTWFSZJNQPSUBOUUPIBWFPXEBUBPWFSBTNBOZZFBSTBTQPTTJCMFUP
be sure how much water (in rainy and dry season) is available to run a turbine. These data give
the designer the basic information for the selection of a turbine that works most efficiently.
With this information and the demand of the consumers, the designer can choose the proper
turbine and generator as well as he can define size and length of the grid for an isolated
MHP.
Hydrographs for a 16 year period
5IFHVSFTIPXTEBJMZPXTNFBTVSFEPWFSBQFSJPEPGZFBST5IJTJTBOJEFBMEBUBTJUVBUJPO
In reality, such good data are often not available.

Site Identification
Flow duration curve
"TPDBMMFEPXEVSBUJPODVSWFJTHFOFSBUFECZTPSUJOHBMMNFBTVSFEPXEBUBTJ[FXJTFBOE
printing them over 100% of the time covered by the measurements. The diagram says for
example that during 23% of the time the discharge is higher than 10 m3/s. This curve is the
most important information for the design of the hydropower plant. If it is not based on good
data everything else becomes equally speculative as well.
*G UIF SFRVJSFE NFBTVSFNFOUT BSF OPU BWBJMBCMF UIFO UIF PX TIPVME CF NFBTVSFE BOE
recorded every day during minimum one year in order to get the following curve:
&YBNQMFPGBPXEVSBUJPODVSWFGPSPOFZFBS
5IFPXEVSBUJPODVSWFJTHFOFSBUFEGSPNUIFSJWFSEJTDIBSHFDVSWFCZTPSUJOHBMMUIF
WBMVFT#BTFEPOUIFPXEVSBUJPODVSWF UIFEFTJHOFSFWBMVBUFTUIFBWBJMBCMFDBQBDJUZ5IF
EJNFOTJPOJOHPGUIFQMBOUEFQFOETPOUIFBWBJMBCMFPXPGXBUFSBOEUIFFTUJNBUFEGVUVSF
demand of the customers. Ideally the MHP should allow covering the demand all around the
year. If the demand is higher than the available capacity, alternative energy resources have to
be identified and/or energy efficiency measures have to be taken into consideration.

Site Identification
If you cannot get good measurements over an extended period of time you need the help of
an experienced hydrologist for this analysis.
1.3.2 Rough Calculation of Possible Hydro and Electrical Power
By answering the following questions youll find out, if the scheme is worth to go ahead with
the planning:
)PXNVDIPXJTBWBJMBCMF
.FBTVSFBOEESBXBXBUFSPXDVSWF IZESPHSBQI
BTTIPXO
BCPWF GPS NJOJNVN POF ZFBS 5BLF UIF NJOJNVN PX GPS
ZPVSGVSUIFSDPOTJEFSBUJPOT5IJTJTUIFPXPGXBUFSXIJDI
you have available all year round.
2. How much head is available?

Measure the head from the location of the possible forebay
to the place where the turbine is planned to be placed.
8IFOIFBEBOEEJTDIBSHF XBUFSPX
JTLOPXO JUJTFBTZUPDBMDVMBUFUIFUIFPSFUJDBMIZESP
power:
P = Power in Watt
Q = Minimum available flow
H = Head, difference in height in meter
This formula shows the hydraulic capacity only and refers to 100% efficiency without losses.
Losses in penstock, turbine, gear transmission, generator and electricity transmission reduce
the final electrical power. By calculating losses of 20.30%, the final electrical power will
approximately be:

Site Identification
EXAMPLE:
-FUTVTFUIFPXEVSBUJPODVSWFGPSPOFZFBSPOPOFPGUIFQSFWJPVTQBHFTBTBOFYBNQMF
5IFNJOJNVNUVSCJOFPXXIJDIJTJOEJDBUFEUIFSFJTBSPVOEMT5IJTPXJTFYDFFEFE
EBZTQFSZFBS UIFSFNBJOJOHEBZTUIFPXJTTMJHIUMZTNBMMFSTPUIFIZESPQPXFSQMBOUXJMM
generate less power accordingly. Lets assume that we have a head of 30 m available. In this
case the power generation will be:
So this MHP will generate almost 19 kW.
If the designer chooses a larger turbine, lets say with the design charge of 220 l/s, the MHP
DPVMEHFOFSBUFBSPVOEL8 CVUPOMZGPSBCPVUEBZTFWFSZZFBS EVSJOHIJHIPXT5IF
remainder of the year, around 300 days, the MHP would generate much less power, depending
on the discharge which is available.
1.3.3 Estimate Electrical Load
Try to estimate the required electrical power supply needed for all households, public
infrastructure facilities (e.g. schools, markets, clinics, community buildings, and street
lightings), workshops, etc in the electrical system. For each household calculate around
50150 W for lighting, radio, TV, fan, refrigerator, etc.
8JUIUIFPXPGUIFBCPWFFYBNQMFBSPVOEIPVTFIPMETDBOCFTVQQMJFEBMMZFBSSPVOE
by a possible MHP.
1.3.4 How to Measure the River/Stream Flow
*UTOPUFBTZUPNFBTVSFBOBDDVSBUFPXPGBSJWFSPSTUSFBN
5IFPXNFBTVSFNFOUIBTUPCFUBLFOFWFSZEBZEVSJOHPOFGVMMZFBS'PSUIJTUIFJOTUBMMBUJPO
has to be appropriate and robust. Depending on the size of the river or stream there are
EJFSFOUNFUIPETUPNFBTVSFUIFPX
t #VDLFU.FUIPE
t 'MPBU.FUIPE
t $VSSFOU.FUFS.FUIPE 7FMPDJUZ"SFB.FUIPET
t 4IBSQ$SFTUFE8FJS.FUIPE
t 4BMU$PODFOUSBUJPO.FUIPE

Site Identification
Bucket Method
'PSTNBMMPX BSPVOEMT
POMZ
t *GZPVIBWFPOMZBTNBMMPXZPVDBOEPUIFNFBTVSFNFOUTXJUIUIJTNFUIPE
t *UTJNQPSUBOU UPUBLFBCJHUBOL BSPVOE MJUFS
XJUIESBJOQMVHBUUIFCPUUPN
t 5IFPXUPCFNFBTVSFEJTEJWFSUFEJOUPUIFUBOLPGLOPXOWPMVNF
t 5IFUJNFJUUBLFTUPMMUIFUBOLNVTUCFSFDPSEFE
t #ZEJWJEJOHUIFWPMVNF JOMJUFS
PGUIFUBOLCZUIFMMJOHUJNF JOTFDPOET
UIFPXJO
liter/seconds can be calculated
Note:
THIS METHOD IS VERY ACCURATE IF YOU ARRIVE TO REALIZE SUCH AN INSTALLATION!

BUT USE IT FOR SMALL FLOWS ONLY!

Site Identification
Float Method
'PSPXMT
Profile
Define the cross section area first. Normally its more difficult than in our example (Cross
section = H x W). Try to divide the whole cross section into several sections, when the profile
is not rectangular, and add the different sections together to define the whole cross section.
Float
For a known length of the stream (L), an average cross section should be available, where a
half filled plastic bottle of water has to be timed over a measured length (L = 1020 m). By
NVMUJQMZJOHDSPTTTFDUJPOBSFBXJUIBWFSBHFPXWFMPDJUZ BOFTUJNBUJPOPGPXSBUFDBOCF
made now. For any case a correction factor of +/- 20% must be applied.

Site Identification
Current Meter Method (Velocity-Area Methods)
t "UBOZQPJOUJOUIFSJWFS UIFWFMPDJUZJTEJFSFOUoGBTUFSPOUIFTVSGBDFBOETMPXFSPO
UIFCPUUPN5IFWFMPDJUZPGUIFPXDBOCFNFBTVSFEBUEJFSFOUEFQUITBOEBUBOZQPJOU
of the rivers cross section by a so called current meter
t 5IF WBMVFT IBWF UP CF BWFSBHFE 5IF WFMPDJUZ NFBTVSFNFOU EBUB BSF UIFO VTFE UP
DBMDVMBUFUIFBDUVBMPX CBTFEPOUIFBSFBPGFBDITFHNFOU
t #FGPSF TUBSUJOH UIF WFMPDJUZ NFBTVSFNFOUT NBSL UIF DSPTT TFDUJPO XJUI B IPSJ[POUBMMZ
laid out piece of steel or timber to get a reference height. Note the location of the cross
TFDUJPOPOBNBQBOEBMTPOPUFEBUFBOEUJNFPGUIFPXNFBTVSFNFOU
Note:
THIS METHOD IS SUITABLE FOR FLOW VELOCITIES RANGING FROM 0.2 - 5 m/s AND WHERE
YOU CAN SAFELY WADE THE STREAM!

Site Identification
Sharp Crested Weir Method
Measuring rod
Why is this a good example?
t 4IBSQDSFTUFEXFJSTXJUIDPOUSPMMFEPXQSPWJEFHPPEPXNFBTVSFNFOUT
But:
t 5IFJOTUBMMBUJPOJTOPUFBTZBOEOFFETBMPUPGTLJMMBOEFYQFSJFODF
t 3FGFSFODFUBCMFTIBWFUPJOEJDBUFSFMBUJPOCFUXFFOIFJHIUIBOEPX2
t 5IFXFJSPOUIFQJDUVSFJTOPURVJUFSFDUBOHVMBS

Site Identification
'PSSFDUBOHVMBSXFJSTXJUICNBOE-JTBQQSPYJNBUFMZoN UIFPXDBOCFSFBEPVU
from following table:
t "OZNBUFSJBMDBOCFVTFEGPSUIFXFJS CVUUIFOPUDITIPVMEIBWFTIBSQFEHFT NFUBMJT

the best)
t 8FJSTBSFBMXBZTPSJFOUFEBUBSJHIUBOHMFUPUIFTUSFBNPX
t *GCJTXJEFSPSOBSSPXFSUIBONZPVDBOTJNQMZNVMUJQMZUIF2WBMVFTJOUIFUBCMFCZ
UIFTBNFSBUJP-FUTTBZGPSBNXJEFXFJSZPVNVMUJQMZUIF2WBMVFTCZBOEGPSB
NXJEFXFJSZPVNVMUJQMZUIF2WBMVFTCZ
t " TIBSQ DSFTUFE XFJS JT BMTP B HPPE EFWJDF UP HFOFSBUF B PX EVSBUJPO DVSWF
(hydrograph) over a longer period of time, e.g. one year. You only need to install a staff
gauge 2-3 m upstream of the weir, read the gauge level every day at the same time,
calculate the discharge based on the table above, and write this into a table

Site Identification
Salt Concentration Method
B
gauging
point of tracer injection point
tracer cloud A
M=V.C1
Distance: injection to gauging point

tracer concentration
FA
FB
tA Time
tB
The figure shows intensity of conductivity
t " CVDLFU XJUI TBMU XBUFS PG LOPXO DPODFOUSBUJPO JT QPVSFE JOUP UIF NJEEMF PG UIF
TUSFBN5IFTBMUDPODFOUSBUFDMPVEXJMMCFTQSFBECZUIFPXPGUIFSJWFS
t 5IF QSPCF JT JOTFSUFE BU MFBTU UJNFT UIF SJWFS XJEUI EPXOTUSFBN UP NFBTVSF UIF
electric conductivity of the stream / salt concentrate mixture. So if the river is 10 m wide,
you should measure at least 200 m downstream
t 5IFTUSFBNPXXJMMCFNFBTVSFEBOEDBMDVMBUFECZUIFDPOEVDUJWJUZNFUFS
Note:
THIS METHOD OF MEASUREMENT CAN ONLY BE USED BY A TRAINED PERSON WITH

PROPER EQUIPMENT!

Site Identification
1.3.5 Discharge Measurements and Flow Duration Curve
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4PZPVPOMZXBOUUPEPUIJTBGFXUJNFTCVUJUNVTUCFBUEJFSFOUPXT MFUTTBZEVSJOHUIF
MPXFTUPXZPVDBOPCTFSWF BOEGVMMSJWFSPXBOEUXPTNBMMFSPXTJOCFUXFFO"UUIFTBNF
time you always measure the stage of the river at the same location and you must install a
permanent staff gauge for this purpose. Then you can develop a relationship between the
stage and the discharge, based in your measurements. It is a simple curve, shown green in
the figure below.
Staff gauge (cm)
Discharge (l/s)
Staff gauge for quick and easy water level reading
The red stars represent the measurements which you have taken. From then on you must
only measure the stage, lets say every day at noon, and your curve will tell you what the
discharge is at the same time. The two blue arrows indicate how this works. If you do this for
POFZFBSZPVIBWFUIFQFSGFDUEBUBGPSBPXEVSBUJPODVSWF
Note:
IF YOU DO NOT UNDERSTAND THIS PROCEDURE YOU MUST HIRE AN EXPERT TO HELP
YOU!

Site Identification
1.3.6 Head Measurement
Head is the difference in height between the water level of the planned forebay and the
planned position of the turbine shaft. There are different ways to measure it.
Level of forebay
Head
turbine
Schematic example of head measurement

Site Identification
Head Measurement by Level
The principles of measurement by the levelling method

Site Identification
Head Measurement by Water Level
This method is similar to the levelling method, except that a water-filled hose is used

Site Identification
Head Measurement by Pressure Gauge
What are the specifics of this simple head measurement method?
t 0OMZBQSFTTVSFHBVHFBOEBDMFBSQMBTUJDIPTFBSFOFFEFE
t 0OMZUXPNBJOFSSPSTDBOBSJTF
- The gauge is not properly calibrated
- There are air bubbles in the hose
t 'JSTU DBMJCSBUF UIF HBVHF TDBMF GSPN B MPX UP B IJHI SFBEJOH EP UIBU UJNFT UP HFU
reliable results
t $IFDL UIF TJ[F BOE MFOHUI PG UIF IPTF CFDBVTF UIF XBUFSMMFE IPTF NVTU CF DBSSJFE
around the entire length from intake to tailrace
t 3FDPSEBMMEBUBPOBDIBSU

Site Identification
Head Measurement by Barometer/Altimeter
Elevation 1 Water level of

forebay
Elevation 2 Turbine inlet
Head is the difference of elevation 1 and 2
An altimeter is based on atmospheric pressure.

The atmospheric pressure is different at different
elevations. It decreases with increasing elevation
above sea level.
When to use an altimeter?
t 6TFUIJTNFUIPEPOMZEVSJOHTUBCMFXFBUIFSDPOEJUJPOT
t .FBTVSFNFOUTTIPVMECFDBSSJFEPVUJOBTIPSUUJNF
t 1FSGPSNUIJTNFBTVSFNFOUTFWFSBMUJNFTBOEUIFODBMDVMBUFUIFBWFSBHFIFBE
t %P OPU VTF UIJT NFUIPE GPS MPX IFBET #FDBVTF CBSPNFUFST IBWF DPOTJEFSBCMF
uncertainties this method should not be used for heads less than about 50 m
t 5IJT NFUIPE JT SFDPNNFOEFE BT B STU RVJDL NFBTVSFNFOU XIJDI MBUFS NVTU CF
validated by more accurate measurements

Site Identification
Head Measurement by Clinometer
Up- and downward

measurements are
possible
Clinometer
4 scales available
What is the use of a clinometer?
t %JFSFOUNFBTVSFNFOUTDBOCFQFSGPSNFEXJUIBDMJOPNFUFS
t 'PSBOHMFNFBTVSFNFOUTUIFDMJOPNFUFSNVTUIBOHWFSUJDBMMZ
t 'PSTMPQF
NFBTVSFNFOUTUIFDMJOPNFUFSNVTUCFIFMEBOEQPJOUFEXJUIUIFiwBU
the bottom/top of the point to be measured
t 'PSEJTUBODFNFBTVSFNFOUUIFDMJOPNFUFSNVTUCFIFMEBOEQPJOUFEXJUIUIFiiBUUIF
bottom/top of the point
t #FTU BOE NPTU BDDVSBUF SFTVMUT BSF PCUBJOFE CZ FJUIFS TUFBEZJOH UIF IBOE PO UIF
forehead or on a pole
t 'SPN UIF NFBTVSFNFOU UIF EJFSFODF JO IFJHIU CFUXFFO UIF UXP QPJOUT DBO CF
calculated

Site Identification
Head Measuring by Level Instrument
b foresight
foresight
a
O% O% O%
backsight
O% Change
Point
La -b Lb -c
Why to use an automatic level instrument?
t .FBTVSFNFOUTBSFGBTUBOEBMTPXPSLGPSMPOHFSEJTUBODFT TVDIBTJOBUUFSSBJOJOTUFFQ
terrain, the instrument has to be set up more often
t 5IFBDDVSBDZPGNFBTVSFNFOUTJTWFSZIJHI JGUIFZBSFEPOFDPSSFDUMZ
t .BLFTVSFUIBUMFWFMJOTUSVNFOUJTTFUVQIPSJ[POUBMMZPOUIFUSJQPE
t -FWFMJOTUSVNFOUTDBONFBTVSFPOMZJOBIPSJ[POUBMMJOFoOPEFFDUJPOJTQPTTJCMF
t 5IF SFTVMU PG NFBTVSFNFOU JT UIF EJFSFODF
in height and distance between the two
points where the rod is set up
t #Z SFDPSEJOH BMM NFBTVSFNFOUT BOE BEEJOH
them up, the distance and the height (which
is the available head) can be calculated
t 5IJTNFUIPEJTTJNJMBSUPUIFPOFVTFEXJUIB
clinometer but more accurate

Site Identification
Land Survey Instruments (Theodolite or Total Station)
Theodolite On site Total Station
Specifics of the high tech instruments:
t "UIFPEPMJUFDBONFBTVSFEJTUBODFT IFJHIUTBOEBOHMFT EBUBBSFSFDPSEFENBOVBMMZ

t " i5PUBM 4UBUJPOw EPFT UIF TBNF CVU UIF TVSWFZ EBUB BSF TUPSFE BVUPNBUJDBMMZ PO B
memory chip
t 5IFTFJOTUSVNFOUTBSFVTFECZQSPGFTTJPOBMMBOETVSWFZPST
t 'PS IFBE DBMDVMBUJPO POMZ TVDI JOTUSVNFOUT BSF OPU SFBMMZ OFDFTTBSZ CVU UIFZ DBO CF
very useful if larger areas have to be surveyed

Site Identification
Head Measurement with High-Tech Instruments
Altimeter Clinometer Leveling Instrument
Theodolite Total Station
These instruments should be used by people who are trained to handle them as well as to analyze
the data of the measurements

Site Identification
1.3.7 General Project Data
Try to get an answer to the following questions:
t 8IFSFJTUIFQSPKFDUBSFBMPDBUFE oEFOFDPPSEJOBUFTCZ(14
t 8IP XJMM CF UIF EFWFMPQFS PG UIF QSPKFDU NFBOT XIJDI PSHBOJ[BUJPO T
TVQQPSU T
UIF
project?
t 'JOEBQFSTPOXJUIJOUIFWJMMBHFGPSDPNNVOJDBUJPOBOZUJNF
t 'JOEBQFSTPOXJUIJOUIFEFWFMPQFSPSHBOJ[BUJPOGPSDPNNVOJDBUJPOBOZUJNF
t )PX JT UIF FMFDUSJDBM JOGSBTUSVDUVSF PG UIF WJMMBHF EFWFMPQFE "TTFTT FYJTUJOH HSJE XJUI
voltage and transformers/medium voltage lines with length and number of wires/low
voltage lines with length and number of wires
t *TUIFSFHPPEBDDFTTJCJMJUZUPUIFOFYUWJMMBHFUPXO NBSLFUBOETVQQMJFST FUD oEJTUBODF
in km and time should be recorded
t *TUSBOTQPSUBUJPOBWBJMBCMF UZQFBOEDPTUPGUSBOTQPSUBUJPO
t "SFUIFSPBETBDDFTTJCMFBMMUIFZFBS
t "SFOFJHICPSJOHWJMMBHFTPSIBNMFUTBMSFBEZDPOOFDUFEUPUIFFMFDUSJDHSJE
t %SBXBOBQQSPYJNBUFNBQPGUIFWJMMBHFBOEJUTMPDBUJPOBOEDPOUFYU

Site Identification
Demographic and Socio-Economic Parameters
t )PXNBOZIPVTFIPMETMJWFJOUIFNBJOWJMMBHFBOEJOJUTTVSSPVOEJOHBSFB
t )PXNBOZQFSTPOTMJWFJOBOBWFSBHFIPVTFIPME
t 8IBUJTUIFQPQVMBUJPOTHSPXUISBUFJOUIJTBSFB
t 8IPIBTFMFDUSJDJUZBMSFBEZ BOEIPXNBOZXBOUUPCFDPOOFDUFEUPBNJOJIZESPQPXFS
system?
t 3BUFQFPQMFTJOUFSFTUBOEVOEFSTUBOEJOHBCPVUUIFXBZUPCFDPNFiFMFDUSJFEw
t 'JOE PVU UIF WBSJPVT TPVSDFT PG JODPNF o BHSJDVMUVSF USBEJOH TVQQMZ PG MBCPS
remittances, etc.
t &TUJNBUFUIFBWFSBHFNPOUIMZJODPNFPGBOBWFSBHFIPVTFIPME
t )PX NBOZ QFSTPOT BSF OPU FNQMPZFE BOE IBWF OP JODPNF PS SFDFJWF TVQQPSU GSPN
others?
t "SFUIFWJMMBHFSTXJMMJOHUPQBZGPSUIFVTFPGFMFDUSJDJUZBOEIPXNVDIDBOUIFZBPSE
monthly?
t "SFUIFSFBOZQVCMJDTVQQPSUTZTUFNTGPSQFSTPOTXJUIMPXJODPNF
t 8IJDIFUIOJDHSPVQTMJWFJOUIFBSFB

Site Identification
1.3.8 Synergies, Ownership and Management
Try to consider following points:
t .BLFOPUFPGBOZSFDFOU POHPJOHBOEGVUVSF JOGSBTUSVDUVSF

EFWFMPQNFOUQSPKFDUT
t $IFDLPVUPUIFSJOWPMWFNFOUTJOUIFWJMMBHF MJLF/(0T HPWFSONFOUPSBJEBHFODJFT
t (BVHFUIFBOUJDJQBUFEMFWFMPGDPNNVOJUZQBSUJDJQBUJPO
t .BLFTVSFUIFSFJTFOPVHIJOWPMWFNFOUJOUBSJTFUUJOH NBLJOHQPMJDZEFDJTJPOTTVDIBT
how to handle payment defaulters etc
t 8IBUJTUIFBWBJMBCJMJUZPGMPDBMQFPQMFXJUINBOBHFNFOUCVTJOFTTTLJMMBTXFMMBTXJUI
civil, electrical and mechanical background?
t 'PSUIFIZESPQPXFSFOUFSQSJTF FYQMPSFBOEQSPQPTFEJFSFOUPXOFSTIJQNPEFMT FH
community-based, private, company-driven)

Site Identification
1.3.9 Energy Supply and Demand
t *T UIFSF BOZ FMFDUSJD HSJE OFBS UIF WJMMBHF GPS DPOOFDUJPO *G TP DIFDL PVU XIBU JT UIF
least-cost option (electricity supply from the existing grid vs. setting up a stand-alone
MHP scheme vs. selling surplus energy from the MHP to the grid)
t -VNQTVNQBZNFOUPSNFUFSFETFSWJDF
t $MVTUFSJOHPSTFQBSBUFJOTUBMMBUJPOT
t 8IBUJTUIFEPNFTUJDEFNBOEPGFBDIIPVTFIPME MJHIUJOH SBEJP 57 GBO SFGSJHFSBUPS
etc ask all households
t $IFDLUIFEFNBOEPGQVCMJDGBDJMJUJFT MJLFTDIPPMT NBSLFU DMJOJD DPNNVOJUZCVJMEJOHT
street lighting, place of worship etc.
t "SF UIFSF BOZ FYJTUJOH PS QSPQPTFE
QSPEVDUJWF BQQMJDBUJPOT JO UIF WJMMBHF NJMM PG BOZ
type, kiosk, manufacturing, cottage industry, etc.?
t 'JOEPVUBUXIBUUJNFBOEIPXMPOHUIFWBSJPVTEFNBOEJTOFFEFE BOEXIFOBOEIPX
long are the peaks of usage
t .BLF B TVNNBSZ PG BMM EFNBOE BOE DBMDVMBUF UIF EBJMZ UIF BOOVBM BOE UIF QFBL
demand for the village
t 'PSUIFEFTJHOBEEPSTPNFPUIFSQFSDFOUBHFGPSGVUVSFFYUFOTJPOTUPUIFTVNNBSZ
demand
Example: see following page!

Site Identification

Site Identification
1.3.10 Consultants
MANY FACTS HAVE TO

BE CONSIDERED BEFORE
STARTING WITH HYDRO
108&345"5*0/%&4*(/
When to look for consultants?
If communities intend to implement an electrical system they are well advised to ask a
consultant for support:
t "IZESPQPXFSTUBUJPOJODMVEJOHBOFMFDUSJDBMTZTUFNJTBDPNQMFYTVCKFDUBOEUIFIFMQ
of a reliable professional is very important. Only with such a professional you prevent
mistakes in calculation, design, construction and operation
t *GBOFMFDUSJDBMTZTUFNTIPVMECFJOTUBMMFEUIFTPVSDFGPSUIFFOFSHZIBTUPCFTFMFDUFE
very carefully. Hydro, wind or solar potential will be checked in detail. The professional
consultant will recommend the most appropriate energy system
Note:
SUCH SYSTEMS SHOULD NOT HARM THE ENVIRONMENT!

THIS FACT BECOMES MORE AND MORE IMPORTANT EVEN MHP IF NOT DESIGNED, BUILD
AND OPERATED PROPERLY, CAN HARM THE ENVIRONMENT IN CERTAIN CASES!

Civil Works
2. Civil Works

Civil Works
2.1 CONSTRUCTION BASICS
This chapter will provide general advice for construction and show a number of good and
bad examples to illustrate what makes the important difference.

Civil Works
+ +
Cement Sand Gravel
+ =
Good quality concrete
Water
How to make concrete
What has to be considered for good workmanship?
t 5IF RVBMJUZ PG DPODSFUF EFQFOET PO UIF DPSSFDU QSPQPSUJPOT PG BMM UIF JOHSFEJFOUT JF
cement, sand, gravel and water
t /PUFOPVHIDFNFOUJOUIFNJYNBLFTXFBL MPXTUSFOHUIDPODSFUF
t 5PPNVDIXBUFSBMTPNBLFTQPPSRVBMJUZDPODSFUF
t *UJTJNQPSUBOUUPNFBTVSFBOEBEEBHHSFHBUFTQMVTTBOETFQBSBUFMZGPSNBLJOHEFOTF
concrete of good quality
t 6TFPOMZDMFBOBHHSFHBUFT
Note:
THERE IS NEVER AN ALTERNATIVE TO GOOD QUALITY WORKMANSHIP!

Civil Works
Measure & mix the ingredients

with care
Let the concrete slip into the

formwork
Construction of anchor block
t (PPEQSFQBSBUJPOJTFTTFOUJBMGPSHPPEDPODSFUF
t %POPUESPQUIFDPODSFUFJOUPUIFGPSNXPSLGSPNBOZIFJHIU CVUMFUJUTMJQ
t .BYJNVNESPQPGDPODSFUFJTN PUIFSXJTFUIFBHHSFHBUFTHFUTFQBSBUFE
t "WPJEDPMEKPJOUTEVSJOHDPODSFUJOHEPPOFTFDUJPOJOPOFMJGU
t .BLFTVSFDPODSFUFMMTBMMWPJET VTFBWJCSBUPS TUJSEVSJOHQPVSJOH LOPDLPOGPSNXPSL
from outside etc

Civil Works
Corner bracing
Supports all around

the formwork
Puddle flange welded on pipe
Anchor block ready for concreting
t 5IFCPBSETPGUIFGPSNXPSLBSFPGHPPERVBMJUZ
t 5IF TVQQPSUT BSF GBTUFOFE UP UIF GPSNXPSL BOE CSBDFE BHBJOTU UIF HSPVOE UP BWPJE
movements during placing the concrete
t 1VEEMFBOHFTBSFXFMEFEUPUIFQFOTUPDLQJQFUPCFUUFSBODIPSJU
t 3FJOGPSDFNFOUJTJOQMBDFBOESFBEZGPSDPODSFUJOH
t 'PSNXPSLNVTUCFXFMMYFECFDBVTFJUJTJNQPTTJCMFUPIPMEJUVQXIFOUIFDPODSFUFJT
being poured into the formwork
t #FGPSF QPVSJOH DMFBSMZ NBSL UIF OFDFTTBSZ UPQ PG DPODSFUF TVSGBDF UP HFU FOPVHI
coverage of reinforcement, at least 3 cm
t 7JCSBUFDPODSFUFXFMMoUIJTXJMMHJWFDPODSFUFUIFEFOTJUZBOEMMBMMWPJETTPJUIBTUIF
strength and quality to fulfill the task of an anchor block

Civil Works
Earthing cable connected to

reinforcement
Earthing cable
Steel base fixed to rods
Construction details of equipment foundation
t 5IFGPVOEBUJPOTPGUVSCJOFBOEHFOFSBUPSNVTUCFCVJMUXJUIDBSF
t "TUBCMFGPVOEBUJPOBWPJETNPWFNFOUTPGUIFFRVJQNFOUXIJDIJTBCTPMVUFMZOFDFTTBSZ
for a trouble-free operation of the plant
t 5IFHFOFSBUPSTIPXOJOUIFQJDUVSFJTQSPQFSMZGBTUFOFEBOEBEKVTUFECZUVSOCVDLMFTUP
keep the equipment stable and horizontal while the concrete is being placed
t "OBCTPMVUFMZIPSJ[POUBMCBTFJTFTTFOUJBMGPSBTNPPUIUSBOTNJTTJPO
t 5IFFBSUIJOHDBCMFJTDPOOFDUFEUPUIFSFJOGPSDFNFOUPGUIFCBTFBOEXJMMCFMBUFSBMTP
connected to the equipment itself. This is very important to avoid short circuits during
operation
t *OPSEFSUPHFUHPPERVBMJUZDPODSFUF UIFDPODSFUFNVTUCFWJCSBUFEBGUFSCFJOHQPVSFE

Civil Works
Screw thread on steel rod
Equipment base
25 mm
Sheet metal packing 16 mm
-FWFMPGDPODSFUFPPS
Steel plate must overlap hole in concrete

by at least 30 mm all around
)PMFJODPODSFUFPPSBQQSPYYEJOEJBNFUFS
It must not be larger at the top than the bottom
Small plates welded to screw rod and

washer (to prevent rotation)
Thick washer (approx, 4d x 5 mm thick)

welded to rod
'BTUFOJOHPGFRVJQNFOUUPDPODSFUFPPSXJUIPVUCVJMEJOHBGPVOEBUJPO
t *G OP OFX GPVOEBUJPO JT UP CF CVJMU FRVJQNFOU DBO BMTP CF YFE UP UIF DPODSFUF BT
shown above and described below
t 5IJT NFUIPE JT BMTP BQQMJDBCMF XIFO B GBTUFOJOH CPMU CFDPNFT MPPTF BOE NVTU CF
repaired
t %SJMM B WFSUJDBM IPMF JO UIF DPODSFUF PPS BOE NBLF TVSF UIBU UIF UPQ EJBNFUFS JT OPU
larger than the diameter of the bottom of the hole
t 'PSHSPVUJOHVTFPOMZIJHIEFOTJUZNPSUBS OPOTISJOL BOETMPXTFUUJOH
t 1PVS NPSUBS STU BOE UIBO JOTFSU CPMU WFSUJDBMMZ TFU FRVJQNFOU PO UPQ o EVSJOH UIJT
operation the mortar is still soft and all parts are adjustable

Civil Works
Earthing cable
Earthing rod
Earthing must be done properly for the sake of safety
t &BSUIJOHJTBTBGFHVBSETZTUFNGPSQFPQMFBOENBDIJOFT
t &BSUIJOHDBCMFNVTUIBWFBHPPEDPOOFDUJPOUPUIFFBSUIJOHSPE
t 6TF0/-:BQQSPWFEFBSUIJOHDMBNQT
t -FOHUIPGFBSUIJOHQPMFEFQFOETPOUIFDPOEVDUJWJUZPGUIFHSPVOECVUNVTUCFBUMFBTU
3 m long
t &BSUIJOHTIPVMECFMBJEBSPVOEUIFQPXFSIPVTFBUUIFGPVOEBUJPOMFWFM
t $POOFDUBMMSFJOGPSDFEDPODSFUFGPVOEBUJPOT QPXFSIPVTFBOEQPXFSFRVJQNFOU
BOE
any other electrical equipment to the earthing ring
t -JHIUOJOHDPOEVDUPSUPCFDPOOFDUFEUPFBSUIJOHSJOHo 1 m above ground
t 5IJTDPOOFDUJPOXJMMCFVTFEUPNFBTVSFUIFSFTJTUBODFGPSOEJOHPVUJGUIFFBSUIJOHJT
still functioning as it should be
Note:
EARTHING IS A SAFEGUARD FOR PEOPLE AND MACHINES!

NO EARTHING oDEADLY DANGER!

Civil Works
Washed out
%FBMJOHXJUITVSGBDFXBUFSIFSFVODPOUSPMMFEXBUFSPX
t 1SPQFSESBJOBHFPGBMMTUSVDUVSFTJTOFDFTTBSZGPSMPOHFSMJGFFYQFDUBODZ
t 5IFCBTFPGTUSVDUVSFT FHGPVOEBUJPOPGQPXFSIPVTF QFOTUPDLTVQQPSUTFUD DBOCF
easily destroyed by water, unless they have a stable concrete foundation
t 'MPXJOHTVSGBDFXBUFSXJMMXBTIPVUTPJMBOEDBVTFFSPTJPOVOEFSOFBUITUSVDUVSFTBOE
foundations - keep an eye on surface water where it comes from and where it goes
t 8BUFSEJTDIBSHFJTBOJNQPSUBOUTVCKFDUPGDPOTUSVDUJPOoEPOPUOFHMFDUJU
Note:
WATER CAN BE A HAZARD TO STRUCTURES!

Civil Works
Material is not suitable
No concrete foundation
Wall is too high

compared to thickness
Big structure without static design
t 'PSBMMTUSVDUVSFT FTQFDJBMMZGPSCJHPOFT JUJTFTTFOUJBMUPIBWFBTUBUJDTUSVDUVSBMEFTJHO

before construction works starts
t $IPPTFNBUFSJBMBDDPSEJOHUPEFTJHOBOESFRVJSFETUSFOHUI
t $BSSZPVUXPSLTWFSZDBSFGVMMZBOEGPMMPXUIFBEWJDFPGUIFFOHJOFFS
t 8FBLBOEVOTUBCMFXBMMDPOTUSVDUJPOTDBOCFBIB[BSEUPQFPQMFXIFODPMMBQTJOH
t 5IF PPE GPMMPXJOH B CSPLFO SFUBJOJOH XBMM JT WFSZ EBOHFSPVT UP QFPQMF XIP MJWF
downstream

Civil Works
Mesh width ~ 5cm
Good design
Max water level
Max water pressure
Gabion used for weir construction
t 5IF EJNFOTJPO PG UIF MPXFTU SPX PG HBCJPOT NVTU CF MBSHFS UIBO UIF NBY XBUFS
pressure, e.g. if the water is 1 m deep, the lowest gabion should be 1.2 m
t "MMTUFQTPGUIFHBCJPOXFJSNVTUCFBCPWFXBUFSQSFTTVSFMJOF
t 5PSFBDICFUUFSTUBCJMJUZPGUIFDPOTUSVDUJPO EJHUIFMPXFTUHBCJPOJOUPUIFSJWFSCPUUPN
t 5JFUIFHBCJPOFOETJOUPUIFSJWFSCBOLTPSJOUPXJOHXBMMT
t "TBMUFSOBUJWFUPBTUSBJHIUBMJHONFOUTFUUIFHBCJPOTJOBOVQTUSFBNDVSWF
t 'PS CFUUFS GSJDUJPO UIF MFOHUI PG UIF VQQFS HBCJPO TIPVME CF PG UIF MFOHUI PG UIF
lower one
t .BLFTVSFUIBUUIFNBYJNVNTJ[FPGUIFXJSFNFTIJTDN EFOJUFMZTNBMMFSUIBOUIF
smallest cobbles in the gabions
t $POOFDUBMMHBCJPOTUPFBDIPUIFS
t 6TFPOMZXJSFNBUFSJBMUIBUEPFTOPUSVTU TVDIBTHBMWBOJ[FEPSFQPYZDPBUFE

Civil Works
Sand bags are not

enough support
Headrace channel too close to a steep slope
t 5IFTJEFXBMMTPGBDIBOOFMNVTUCFBCMFUPXJUITUBOEUIFXBUFSQSFTTVSF
t 5IFXBUFSQSFTTVSFJTBUUIFIJHIFTUBUUIFCPUUPNPGUIFDIBOOFM
t #VJME UIF DIBOOFM BT B SJHJE CPY BOEPS EJH UIF DIBOOFM JO EFFQFS XJUI FOPVHI
undisturbed material remaining on the down slope side
t *G UIFSF JT OP PUIFS BMJHONFOU QPTTJCMF VTF NBUFSJBM XIJDI DBO XJUITUBOE UIF XBUFS
pressure o use concrete on a good base foundation
t 5IFBSFBBSPVOEUIFDIBOOFMTIPVMECFXFMMESBJOFEUPMJHIUFOBOZXBUFSQSFTTVSFBOE
keep the slope from sliding

Civil Works
Broken channel invert caused by erosion and sliding
t "DIBOOFMVTVBMMZDPOTJTUTPGUXPTJEFXBMMTBOEBOJOWFSU CFE
t *G B DIBOOFM IBT OP VQTMPQF SFUBJOJOH XBMM XBUFS XJMM TFFQ UISPVHI VOEFSOFBUI UIF
channel and erode and damage the bed
t 5IFNPOFZTBWFECZOPUCVJMEJOHBOVQTMPQFXBMMXJMMIBWFUPCFTQFOUGPSSFQBJSTPGUIF
channel this becomes more expensive because the channel invert must be repaired
too
t *U JT B HPPE JOWFTUNFOU UP CVJME B SFUBJOJOH XBMM PO UIF VQTMPQF TJEF VOMFTT UIFSF JT B
stable rock face where only a thin liner is needed
t 6QTMPQFSFUBJOJOHXBMMTBMTPIFMQUPQSFWFOUUIBUFSPEFENBUFSJBMESPQTJOUPUIFDIBOOFM
t .BLF TVSF UIBU UIF TMPQF BSPVOE UIF DIBOOFM JT XFMM ESBJOFE UP LFFQ UIF TMPQF GSPN
sliding, place drainpipes underneath the channel

Civil Works
2.2 INDIVIDUAL COMPONENTS
2.2.1 Weir and Intake
Weir or diversion
structure
Side spillway
Sluice gate
Flushing gate
Intake orifice
Sand trap
Optional: Gravel trap

with flushing gate Optional: coarse trash rack
Intake gate or stop log

on sill Headrace
Main elements of a weir and intake structure
Main functions and design principles of weir & intake structure:
*OUBLF NVTU EJWFSU UIF SFRVJSFE TUSFBN PX JOUP UIF IFBESBDF DIBOOFM BU BMM UJNFT BOE
all water levels in the river
Intakes should if possible be located on the outer side of a river bend to minimize
sediment in headrace
1SPWJTJPOT TIPVME CF NBEF UP FYDMVEF MBSHF PBUJOH EFCSJT PBUJOH CBS PS TVCNFSHFE
JOUBLFPSJDF
BOEDPBSTFHSBWFM CPUUPNTJMM
GSPNUIFPXEJWFSUFEJOUPUIFIFBESBDF
5IF TMVJDF HBUF NVTU CF JOTUBMMFE DMPTF UP UIF JOUBLF PSJDF JO PSEFS UP BMMPX VTIJOH PG
sediments depositing in front of the intake orifice

Civil Works
Intake gate
Sluice gate
Wing wall
Flow to sand trap

Weir
Intake orifice
3D sketch of weir and intake
Main elements of an intake:
This drawing shows a typical combination of weir and intake including a sluice gate which
can be used to remove deposited sand and gravel from the intake. The main function of the
intake is to allow a certain amount of water into the sand trap and headrace and to keep
TFEJNFOUTBOEPBUJOHEFCSJTBXBZGSPNUIFIFBESBDFTZTUFN&YDFTTXBUFSNVTUCFSFUVSOFE
into the river.

Civil Works
NO side walls
NO intake structure
NO sluice gate
Only earth channel as

headrace
Most elements of a proper weir and intake structure are missing
How can I improve it?
t #VJME B XFJS FRVJQQFE XJUI PWFSPX TQJMMXBZ TMVJDF HBUF BOE JOUBLF HBUF UP UIF
headrace or a properly dimensioned intake opening with stop log grooves
t 5IFIFBESBDFTIPVMECFCVJMUPGDPODSFUF NBTPOSZPSTJNJMBSNBUFSJBM
t 4JEFBOEXJOHXBMMTVQBOEEPXOTUSFBNPGUIFXFJSBSFFTTFOUJBM
Why?
t 5IFSJWFSCFEVQTUSFBNPGUIFXFJSNVTUCFVTIFESFHVMBSMZUPQSFWFOUTFEJNFOUTGSPN
entering the headrace
t "O FMFWBUFE JOUBLF HBUF PS JOUBLF PQFOJOH JT OFFEFE UP DPOUSPM UIF PX JOUP UIF
headrace and prevent sediments from entering
t *GUIFSFJTOPHBUF TUPQMPHTDBOCFVTFEUPDMPTFUIFPQFOJOHGPS0.
t 8JUIPVUQSPQFSTQJMMXBZUIFXFJSTUSVDUVSFNBZCFFSPEFEBOEEBNBHFEEVSJOHPPET
t 8JUIPVUXJOHXBMMTBOETJEFXBMMTUIFSJWFSCBOLTXJMMCFFSPEFE

Civil Works
Cover over both gates
Sluice gate
Intake gate
Weir
Side walls on
both sides
Headrace
Stilling basin to forebay /
powerhouse
Main elements of a weir and intake structure
t "MMFMFNFOUTOFDFTTBSZGPSBXFMMGVODUJPOJOHJOUBLFBSFJODMVEFEJOUIJTTUSVDUVSF
t 5IFNBJOFMFNFOUTBSFXFMMBSSBOHFE
t 5IFRVBMJUZPGDPOTUSVDUJPOJTHPPE
t 5IFTUSVDUVSFJTXFMMNBJOUBJOFE
t (BUFTBOEBDDFTTUPUIFHBUFTJTDPWFSFECZBSPPG

Civil Works
Dam structure has

shifted already
Rocks and plastic sheets

do NOT make a good dam
Gabions cannot with-

stand flood flows
Examples of unsuitable dam materials

Civil Works
Concrete weirs can last for a long time
Why are these good examples?
t $PODSFUFDPODSFUFNBTPOSZJTUIFQSFGFSSFENBUFSJBMGPSCVJMEJOHXFJST
t .BTTDPODSFUFXJMMXJUITUBOEUIFIJHIIZESBVMJDMPBETEVSJOHPPET
t $PODSFUFJTBTUSPOH EVSBCMFNBUFSJBM BMTPSFTJTUBOUUPDIFNJDBMT
t $PODSFUFDBOCFVTFEGPSBOZUZQFPGXFJS

Civil Works
Columns on both
sides missing
An unstable construction
t #VJMEDPODSFUFDPMVNOTPOCPUITJEFT
t 4VQQPSUUIFGSBNF ZPLF
PGUIFHBUFTPMJEMZ
Why?
t 5IFHBUFTMJEFTJOTJEFUIFGSBNF
t *G UIF GSBNF HFUT CFOU PS UXJTUFE UIF HBUF XJMM OPU NPWF BOZNPSF t PX DBOOPU CF
controlled
t 5IFGSBNFDPVMEBMTPHFUCFOUPSUXJTUFECZBPPEJOUIFSJWFSPSTPNFPUIFSJODJEFOU
TVDIBTPBUJOHEFCSJT

Civil Works
Solid columns
The columns are good supports for the gate
t 5IFGSBNFPGUIFHBUFTIPVMECFCVJMUBTBTPMJEXBMMPSJOTUSPOHDPMVNOT
t 5IFTUFFMGSBNFNVTUCFLFQUTUSBJHIUBMMUIFUJNFUPMFUUIFHBUFTMJEFJOUIFSBJMT
t 5IFHBUFNVTUCFBCMFUPCFNPWFEUPDPOUSPMUIFPXUPUIFTBOEUSBQBOEGVSUIFSPO
to the headrace and forebay

Civil Works
5 1
3
6
Points for operation and maintenance
What must I do to keep system running well?
1 Daily : Keep the intake orifice clean

2 8FFLMZ $IFDLGPSEFQPTJUT JGUIFSFBSFBOZ VTIBUJOUBLFHBUF
3 Monthly : Flush through sluice gate to clean upstream basin
4 As needed : Apply grease on wheels and threads of the gates
5 %VSJOHBGUFSPPE $IFDLGPSCBOLFSPTJPOCFIJOEXJOHXBMMT
6 %VSJOHBGUFSPPE $IFDL GPS FSPTJPO BOE EBNBHF JO TUJMMJOH CBTJO BOE on
downstream banks
Note:
IF ANY PROBLEMS ARE FOUND, REPAIRS MUST BE MADE IMMEDIATELY!

Civil Works
2.2.2 Sand Trap - Settling Basin
Weir or diversion
structure
Sluice gate Side spillway
Flushing gate
Intake orifice
Optional: Gravel trap

with flushing gate
Sand trap
Intake gate or stop
Optional: coarse
log on sill
trash rack
0.25 0.60 0.25 0.10 Headrace
Cross Section A-A'

0.20
0.80
Side spillway
0.20
Long Section
0.25 0.80 0.25
A'
2.00 5.00 1.00
Spillway Trash rack if penstock follows

From Intake Headrace or
Penstock
0.80
Bottom outlet with gate for flushing
Intake channel
A'
Main construction details of a sand trap/settling basing

Civil Works
NO flushing gate
Headrace
Shrubs need cutting
NO Spillway
NO bank
protection
Vortices erode
bank
Intake structure
There are a number of problems with this intake
t #VJMEBDPODSFUFXBMMGVSUIFSCBDLPOUIFIJMMTJEFCBOL
t $VUCBDLBMMTISVCTBOENBJOUBJOSFHVMBSMZ
t 4QJMMXBZTIPVMECFMPDBUFEBUUIFFOEPGUIFTBOEUSBQ /05JOUIFIFBESBDFtrap
Why?
t 0OHPJOHTDPVSJOHCZXBUFSXJMMDBVTFUIFCBOLUPFSPEF
t 4FUUMJOHPVUPGTFEJNFOUXJMMCFMFTTFFDUJWFJGPXJTOPUMJOFBS
t 4FEJNFOUT GSPN CBOL FSPTJPO XJMM TJMU VQ UIF IFBESBDF BOE XJMM IBWF UP CF NBOVBMMZ
SFNPWFECFDBVTFUIFSFJTOPVTIJOHHBUF

Civil Works
Gate Sluice gate Weir Wingwalls
Transition
Spillway
Sandtrap
Grooves for Overflow channel

Headrace to
stop logs
forebay
This picture shows all main elements of a well designed water intake with sandtrap
t 5IFUSBOTJUJPOJTJNQPSUBOUUPDBMNBOETMPXEPXOUIFPXWFMPDJUZ
t 4FEJNFOUTTFUUMFPVUNPSFFBTJMZXIFOUIFWFMPDJUZJTMPXBOEUIFPXJTMJOFBS
t 5IFTQJMMXBZDPOUSPMTUIFNBYJNVNWPMVNFPGPXJOUPUIFIFBESBDF
t 4UPQ MPH HSPPWFT BMMPX UIF JOTFSUJPO PG CPBSET UP CMPDL UIF PX GPS DMFBOJOH BOE
repairing the headrace
But:
t 'PSBTBOEUSBQ UIFCBTJOJTUPPTIPSU UIFPXWFMPDJUZJTUPPIJHIBOEUIFTBOENBZOPU

settle down
t *G UIF TBOE TFUUMFT EPXO UIFSF JT OP VTIJOH HBUF BOE UIF TBOE NVTU CF SFNPWFE
manually

Civil Works
5
5
2
2
Issues for operation and maintenace of a sandtrap
What must I do to keep the system running well?
1 3FNPWFBOZSFNBJOJOHTFEJNFOUNBOVBMMZBGUFSVTIJOHUIFTBOEUSBQ
2 Clean concrete surface from vegetation
3 Repair broken parts of the sandtrap
4 Check gates and/or stop logs to be ready for use (not shown in the picture)
5 Remove all grass, shrubs, debris and dirt and do it regularly
Note:
SEDIMENT PARTICLES MAY DAMAGE PENSTOCK AND TURBINE!
CHECK AT LEAST ONCE A MONTH!

Civil Works
2.2.3 Headrace Channel
Simple earth channel Lined channel - masonry
Concrete lined channel Sealed channel Clay or

concrete slurry
Cover of channel where rock

PXBOEFSPEFENBUFSJBM
cannot be halted
Retaining wall
Drainage below channel
is needed on water-
Covered channel because of rockfalls or eroded material saturated slopes
Examples of headrace channels
What do I have to consider regarding headrace channels?
t "WPJEFBSUIDIBOOFMTJGQPTTJCMFBUBMMo higher maintenance and higher risk of erosion

material which could reach the turbine
t $VUTMPQFTCBDLGSPNDIBOOFMUPBWPJEFSPEFENBUFSJBMPSSPDLTGSPNESPQQJOHJOUPUIF
headrace channel
t 3FUBJOJOHXBMMTNVTUBMXBZTCFESBJOFEXFMMXJUIXFFQJOHIPMFTUPBWPJETMJEJOHTMPQFT
t $PWFSFEDIBOOFMDPVMEBMTPCFSFQMBDFECZBCVSJFEQJQFo high costs
t ,FFQBSFBBMPOHUIFDIBOOFMGSFFPGWFHFUBUJPOo cut back regularly

Civil Works
Erosion material will

fall into headrace
Avoid steep eroding banks along headrace channel
t %POPUCVJMEIFBESBDFDIBOOFMDMPTFUPTUFFQFSPEJOHTMPQFT
t $VUCBDLTMPQFTTPUIFSFJTOPFSPTJPONBUFSJBMDBSSJFEJOUPDIBOOFM
t $IFDLIFBESBDFDIBOOFMSFHVMBSMZ BOEDMFBOBTOFFEFE
t *O TFDUJPOT XIFSF FSPTJPO NBUFSJBM DBOOPU CF QSFWFOUFE DPWFS UIF DIBOOFM FH XJUI
wooden boards
t 3FNPWFFSPTJPONBUFSJBMBOETFEJNFOUTGSPNUIFDIBOOFM
Why?
t 4UFFQCBOLTXJUIPVUWFHFUBUJPOtNPSFFSPTJPONBUFSJBMJOUIFDIBOOFM
t &SPTJPONBUFSJBMDBOTJMUVQBOEFWFOUVBMMZCMPDLUIFDIBOOFM
t &SPTJPONBUFSJBM TFEJNFOU
BMTPSFEVDFTUIFPXDBQBDJUZ
t &SPTJPONBUFSJBMDPVMEEBNBHFUIFUVSCJOFJGOPUDBVHIUJOUIFTBOEUSBQ

Civil Works
Cut back slope from

edge of channel
BUT : remove debris

from this ditch
Area is free of shrubs
The channel should be free of vegetation and away from steep slopes
t 5IFBSFBBMPOHUIFIFBESBDFDIBOOFMJTGSFFPGWFHFUBUJPOo less debris from vegetation

in the channel
t *GTUFFQTMPQFTBSFBXBZ PSDVUCBDL
GSPNUIFFEHFPGUIFDIBOOFMUIFSFJTMFTTSJTLPG
dirt and sediment dropping into the headrace
t 1SPQFS NBJOUBJOFE HSBTT JT B HPPE DIPJDF GPS FBSUI TMPQF JU TUBCJMJ[FT UIF CBOLT BOE
reduces erosion
t *OTQFDUJPOGPSPQFSBUJPOBOENBJOUFOBODFBMPOHUIFDIBOOFMXJMMCFFBTZ
But:
t 5IF EJUDI CFUXFFO UIF DIBOOFM BOE UIF TMPQF NVTU CF DMFBOFE GSPN EFCSJT BOE LFQU
open

Civil Works
Vegetation like a jungle
Headrace channel must be free of vegetation
t $IFDLIFBESBDFSFHVMBSMZBOEDVUCBDLWFHFUBUJPO
t 3FNPWFQMBOUT MFBWFT EFCSJT FUDGSPNUIFDIBOOFMSFHVMBSMZ
Why?
t 7FHFUBUJPO JO UIF IFBESBDF SFEVDFT UIF PX WFMPDJUZ BOE DBQBDJUZ XIJDI XJMM DBVTF
NPSFTFEJNFOUBUJPOJOUIFDIBOOFMBOEMFTTPXUPUIFQPXFSIPVTF
t 5PPNBOZMFBWFTJOUIFIFBESBDFNBZDMPHUIFUSBTISBDL

Civil Works
Free of vegetation
Vegetation well cut along the left bank
t 5IFBSFBBMPOHIFBESBDFDIBOOFMJTLFQUGSFFPGEJTUVSCJOHWFHFUBUJPO
t (SBTTBOETISVCTBSFDVUUPLFFQQBUIBOEMFGUDIBOOFMCBOLGSFF
Note:
THE SLOPE ON THE RIGHT SIDE IS VERY STEEP AND EROSION MATERIAL WILL EASILY DROP
IN THE EARTH CHANNEL. MAINTENANCE IS VERY IMPORTANT IN THIS SECTION OF THE
HEADRACE!
TRY TO STABILIZE THE STEEP SLOPE WITH VEGETATION AND/OR OTHER BIO-ENGINEERING
MEASURES!

Civil Works
Velocity is too fast
Eroded slope
Earth channel can erode easily when velocity is too high
t -JOFUIFDIBOOFMXJUINBTPOSZPSDPODSFUF JGQPTTJCMF
t #VJMEESPQTJOUIFDIBOOFMUPSFEVDFUIFWFMPDJUZPGUIFPX
t 1SPUFDUUIFESPQTXJUISJQSBQBHBJOTUCFEFSPTJPO
t 1SPUFDUUIFPVUFSDVSWFPGFBSUIDIBOOFMTXJUISPDLT SJQSBQ
UPSFEVDFFSPTJPO
t 1SJPSUPDPOTUSVDUJPO ESBXBMPOHJUVEJOBMTFDUJPOUPEFUFSNJOFUIFPQUJNBMTMPQFCBTFE
on the proposed channel material
Why?
t 5IFTMPQFPGUIFDIBOOFMEFUFSNJOFTUIFWFMPDJUZPGUIFPX
t 5IF GPSDF PG PXJOH XBUFS DBO DBVTF FSPTJPO EFQFOEJOH PO UIF DIBOOFM NBUFSJBM BOE
slope
t $IBOOFMTXJUIUPPTUFFQTMPQFTPXUPPGBTUBOEUIVTXJMMFSPEFGBTUFS
t $IBOOFMTXJUITMPQFTUPPBUXJMMCFCMPDLFECZTFUUMFETFEJNFOUT
t #VJME DIBOOFM TMPQF BDDPSEJOH UP SFDPNNFOEFE WFMPDJUJFT JO DIBOOFMT VOOFDFTTBSZ
drops reduce the available head for MHP:
- Earth channel : < 0.4 m/s
- Masonry lining : < 2.0 m/s
$PODSFUFMJOJOH NT
.JOJNVNWFMPDJUZ NTUPBWPJETFEJNFOUBUJPO

Civil Works
Slope is set back
Headrace channel is free of vegetation
t 4JEFTMPQFJTXFMMCBDLGSPNFEHFPGDIBOOFM
t 5IFSFJTOPWFHFUBUJPOHSPXJOHJOUPUIFDIBOOFM
t "TBDPOTFRVFODFZPVDBOFYQFDU
- less debris in the channel
- a clean trash rack
- well operating turbine
- efficient electricity generation
- happy consumers

Civil Works
Slopes are too steep
Suggested retaining wall
Headrace in a deep and steep cut section
t *GUIFDVUJTOPUTUBCMF CVJMESFUBJOJOHXBMMTUPQSFWFOUFSPTJPONBUFSJBMGSPNGBMMJOHJOUP
the channel
t $PWFSUIFIFBESBDFXJUIQSFGBCDPODSFUFTMBCTPSXPPEFOCPBSET
t 3FQMBDFUIFPQFOIFBESBDFDIBOOFMXJUIBCVSJFEQJQF
Why?
t %FFQBOETUFFQDVUTXJMMBMXBZTCFQSPOFUPCBOLFSPTJPO
t &YDFTTJWFNBJOUFOBODFPGTUFFQCBOLTNBZCFWFSZDPTUMZ
t 4UFFQCBOLTNBZTMJEFBOECMPDLDIBOOFMDPNQMFUFMZ
Note:

Civil Works
Slopes are set back

from headrace
Retaining wall
Space to walk
Retaining wall stabilizes the toe of the slope
t "SFUBJOJOHXBMMSFEVDFTUIFOBUVSBMBOHMFPGSFQPTFPGUIFTMPQF
t -FTTFSPTJPONBUFSJBMXJMMGBMMJOUIFIFBESBDF
t .BJOUFOBODF PG UIF IFBESBDF JT FBTJFS o less sediment, which however still must be
removed
t 5IFSFBSFOBSSPXXBMLXBZTBMPOHUIFDIBOOFMGPSFBTJFSNBJOUFOBODF

Civil Works
Shaky supports
This a not a good creek crossing
t 3FQMBDFUIFXPPEFOTVQQPSUTXJUIDPODSFUFDPMVNOTVQQPSUT
t 4FUUIFTVQQPSUTPOHPPEGPVOEBUJPOT FTQFDJBMMZVOEFSXBUFS
t "EEBODIPSCMPDLTPOCPUITJEFTPGUIFTUSFBNUPTVQQPSUUIFQJQF
Why?
t 1JQFDSPTTJOHTOFFETUBCMFTVQQPSUT PUIFSXJTFUIFQJQFNBZCVDLMFBOEDPMMBQTF
t 8PPEFOTVQQPSUTNBZSPUSBUIFSRVJDLMZXJUIUJNF UIFQJQFXJMMTJOLBOEXJMMFWFOUVBMMZ
fail
t "TJOLJOHQJQFDBVTFTUIFBOHFDPOOFDUJPOTUPDPNFMPPTF

Civil Works
Spillway
Strong supports
Stable abutments
Storm water creek
Well-built pipe crossings in a headrace
t 5IF DPOOFDUJPO PG UIF PQFO IFBESBDF DIBOOFM UP UIF QJQF DSPTTJOH JT B TPMJE DPODSFUF
structure
t 5IFTQJMMXBZVQTUSFBNPGUIFQJQFJOMFUJTBHPPETPMVUJPOUPEJTDIBSHFFYUSBPPEXBUFS
it does not seem to affect the stability of the abutments
t 5IFTJ[FPGUIFDSPTTJOHQJQFJTMBSHFFOPVHIUPDBSSZUIFPXJOUIFIFBESBDF UIFSFGPSF
the pipe cross section equals the wetted area of the channel
t 5IF QJQF JOMFU TIPVME IBWF B TNPPUI SPVOEFE USBOTJUJPO UP SFEVDF IFBE MPTTFT BOE
backwater effects
t 5IF TQJMMXBZ JT MPDBUFE VQTUSFBN PG UIF DSPTTJOH QJQF JG UIFSF JT UPP NVDI CBDLXBUFS
effect, the water will be spilled in a controlled way

Civil Works
3
2
1 Remove sediment and rocks from the channel

2 Cut grass and shrubs, and remove debris do it regularly
3 Check slopes for erosion
Repair broken parts of the headrace
Check functionality of stop logs and spillways - if existing
Note:

CHECK REGULARLY AS NEEDED!

Civil Works
2.2.4 Forebay
River
Spillway
Flushing gate
Headrace
Penstock to
Forebay power house
Trash rack
Main elements and functioning principles of a forebay:
t " GPSFCBZ GVODUJPOT JO B TJNJMBS NBOOFS BT B TBOE USBQ UIF PX TMPXT EPXO TP
sediments can settle down
t 5IFUSBOTJUJPOBUUIFCFHJOOJOHPGUIFGPSFCBZBOEUIFXJEUIPGUIFGPSFCBZBSFFTTFOUJBM
GPSTMPXJOHEPXOUIFPXWFMPDJUZ
t 4FEJNFOUTDBOTFUUMFPVUJOTMPXPXJOHXBUFSPOMZ
t 5IFUSBTISBDLBUUIFFOEQSFWFOUTEFCSJTGSPNPXJOHJOUPUIFQFOTUPDL
t 5IFGPSFCBZQSPWJEFTTVCNFSHFODFGPSUIFQFOTUPDLJOMFUUPQSFWFOUBJSGSPNFOUFSJOH
t 5IF TQJMMXBZ BMMPXT FYDFTT BOE PPE PXT UP PX CBDL UP UIF SJWFS FTQFDJBMMZ VOEFS
rapid shut down conditions following load rejection
t 5IFVTIJOHHBUFJTFTTFOUJBMGPSDMFBOJOHUIFGPSFCBZPGTFEJNFOUTBTSFRVJSFE

Civil Works
Main elements of a forebay
Ventilation pipe Inlet gate
Service area
Transition to
Penstock Trash rack forebay
Overflow channel
Flush gate
Headrace
Spillway
The drawing shows a typical forebay which marks the transition between the open headrace
channel and the penstock. The water level in the forebay determines the head which is
available for power generation. The trash rack in the forebay and the forebay itself is the last
QPJOU UP SFNPWF BOZUIJOH UIBU DPVME EBNBHF UIF UVSCJOF GSPN UIF XBUFS TVDI BT PBUJOH
debris or sediment. Also it provides a controlled way of escape over the spillway for surplus
water in case of a load rejection or when too much water enters the open channel part of the
headrace.

Civil Works
Horizontal bars are Flushing gate is

difficult to clean missing
Overflow spillway
NOT to the hillside!
Gradual transition would

Bottom sill is be better
missing
Forebay without sedimentation
t .BLFHSBEVBMUSBOTJUJPOXJUIBOBOHMFPG SBUJP
PSMFTT
t 1MBDFUIFUSBTISBDLPOUPQPGBTJMMBUUIFCPUUPNPGUIFGPSFCBZ
t *OTUBMMBVTIJOHHBUFBUUIFCPUUPNPGUIFGPSFCBZBOEDPOOFDUJUXJUIUIFTQJMMXBZ
t .BLF TQBDJOH XJEUI PG USBTI SBDL CBST EFQFOEFOU PO UVSCJOF NBOVGBDUVSFST
requirements
Why?
t "WPJEFEEJFTBOEEFBE[POFTJOUIFGPSFCBZ
t 'MPXBQQSPBDIJOHUIFUSBTISBDLTIPVMECFTUFBEZ MJOFBS
t 8BMM TJMM
XJMMIPMECBDLUIFTFUUMFEPVUTFEJNFOUT
t 'MVTIJOHHBUFBMMPXTUPFNQUZBOEDMFBOUIFGPSFCBZ
Note:
SEDIMENT REACHING THE TURBINE CAN DAMAGE THE RUNNER!

Civil Works
Inlet gate to penstock

Vent pipe of
penstock
Gate for flushing
Trash rack
min. 2x width of
Spillway headrace
Width of headrace
Ratio 1:2
Groove for stop logs
Forebay with sedimentation basin
t 'PSFCBZXJUITFEJNFOUBUJPONVTUCFXJEFSBOEEFFQFSUIBOUIFIFBESBDF
t 8JEUIPGGPSFCBZTIPVMECFBUMFBTUUJNFTUIFXJEUIPGUIFIFBESBDFDIBOOFM
t -FOHUIPGUSBOTJUJPOTIPVMECFBCPVUUJNFTUIFXJEUIPGIFBESBDF PSUIFBOHMFPGUIF
transition should be around 25 degrees (a ratio of 1:2)
t 4UPQMPHHSPPWFTBMMPXUIFJOTFSUJPOPGCPBSET MPHT
UPCMPDLUIFPXXIFODMFBOJOH
and repairing the forebay

Civil Works
2.2.5 Trash Rack
Service area (platform)

Trash Rack
Forebay
Flow 4 x DN
DN Penstock
20cm
20cm min. high sill (low wall)
Main design principles of a trash rack:
t 5IFBOHMFPGBUSBTISBDLUPUIFIPSJ[POUBMTIBMMCFUP
t 5SBTISBDLTIPVMECFYFEUPUIFTJEFXBMMTBOEUPUIFTJMMXBMMBTXFMMCVUJOTVDIBXBZ
that the trash rack can be removed for service
t 6TF 0/-: WFSUJDBM CBST XIJDI DBO CF TVQQPSUFE CZ IPSJ[POUBM CSBDJOH BU UIF CBDL TP
that rack can be cleaned easily
t 5IF CBST NVTU CF EFTJHOFE UP XJUITUBOE UIF XBUFS QSFTTVSF PG B DPNQMFUFMZ DMPHHFE
rack with maximum water level upstream and no water downstream
t 5IFTQBDFCFUXFFOCBSTTIPVMECFIBMGPGUIFTQBDFCFUXFFOUVSCJOFSVOOFSPSHVJEF
vane blades, in accordance with the turbine manufacturer. Here are some examples:
$SPTTPXUVSCJOF FH5
NN
Pelton turbine: 0.5 times nozzle diameter
t 5SBTI SBDL TIBMM CF EJWJEFE JOUP TFDUJPOT TP UIBU JU DBO CF SFNPWFE SFQBJSFE BOE
transported more easily
t 1SPWJEFBTFSWJDFBSFBGPSFBTJFSDMFBOJOH JODMVEJOHBQMBUGPSNUPTUBOEPO

Civil Works
Outlet drain should be Width not according

at bottom level to requirements
Penstock inlet is too

close to the bottom
Avoid horizontal
bars
min. 20 cm
Angle should be 70 Sill (low wall or step)
Trash rack on top of a sill (low wall)
t 6TFUSBTISBDLTXJUIWFSUJDBMCBSTPOMZ
t 4QBDFCFUXFFOCBSTTIPVMECFIBMGUIFTJ[FPGBQBSUJDMFXIJDIDBONPWFUISPVHIUIF
turbine without doing any damage
t 1MBDFUSBTISBDLBUBOBOHMFPGBSPVOEUPUIFCPUUPN
t 'JYUSBTISBDLXJUICPMUTUPUIFTJEFXBMMTBOEUPUIFCPUUPNXBMMoCVUJUTUJMMTIPVMECF
removable
t 'PSMBSHFSUSBTISBDLT EJWJEFJUJOTFQBSBUFTFDUJPOT
t )FJHIUPGTJMM MPXXBMM
CFBNJOJNVNPGDN
Why?
t 7FSUJDBMCBSTNBLFDMFBOJOHUIFUSBTISBDLFBTJFS
t 5SBTISBDLQMBDFEBUBOJODMJOFEBOHMFXJMMOPUDMPHBTFBTJMZXJUIEFCSJT
t "QMBDFUPTUBOEBTTFSWJDFBSFBXJMMNBLFUIFNBJOUFOBODFFBTJFS

Civil Works
Trough for debris

Service area
Use rake for easy

cleaning
Trash rack at a
good angle
%FCSJTDBVTFTIFBEMPTTFTBOEPSSFEVDFTUIFXBUFSPXJOUPUIFQFOTUPDL
t 5SBTISBDLJTNPVOUFEBUBOBOHMFPGBCPVUGSPNUIFIPSJ[POUBM
t 5SBTISBDLJTYFEUPUIFXBMMTCVUJUTIPVMETUJMMCFSFNPWBCMF
t 5IFUSBTISBDLIBTWFSUJDBMCBSTXIJDINBLFTJUFBTJFSUPDMFBO
t 5IFHBQTCFUXFFOCBSTBQQFBSUJHIUFOPVHIUPLFFQEBNBHJOHEFCSJTBXBZGSPNUIF
turbine
t -BSHFTFSWJDFBSFBBOEBQMBDFUPTUBOEGPSFBTZNBJOUFOBODF
t %FCSJTDBOCFDMFBOFEBOEUFNQPSBSJMZTUPSFEJOUIFTFSWJDFBSFB

Civil Works
A too small open area

causes head loss &
penstock inlet is not
enough submerged
The gaps are too narrow

and rack is not fixed at
an angle of about 70
Horizontal support
should be at the rear
side of the rack
Trash rack to be bolted

& fixed to the side walls -
not just leaning on them
4PNFCBETBNQMFToBWPJEUIFN

Civil Works
Rack properly fixed to

the walls
Service area for

maintenance
Trash rack fixed on top of

a bottom sill or step, with
service opening
4PNFHPPEFYBNQMFToEPMJLFUIJT

Civil Works
Service area
Trough for debris removal
1 Remove all debris and rubbish a rake is a good tool for this job
2 Trough at the top end of the trash rack makes the removal of debris easier
o store organic debris on a compost pile
Note:
DEBRIS MAY DAMAGE THE TURBINE!

CHECK AT LEAST TWICE A DAY AND EVEN MORE OFTEN DURING STORMS OR FLOODS!

Civil Works
2.2.6 Spillway
This drawing shows an example of a forebay and a stepped spillway which allows excess
XBUFSUPPXCBDLUPUIFSJWFSPWFSUIFTQJMMXBZXJUIPVUEPJOHEBNBHFUPUIFQFOTUPDLPS
its supports. The steps in the spillway reduce the velocity of the water and cause energy
dissipation. This is very important to prevent damage from the spill to the powerhouse and
other structures.

Civil Works
Spillway and tailrace to

the river
Power house
Penstock
Overflow spillway needs

drops
8BUFSDBSSJFTIJHIFOFSHZXIFOPXJOHEPXOBTUFFQTMPQF
t #VJMEPCTUBDMFTJOUPUIFTQJMMXBZUPSFEVDFUIFWFMPDJUZBOEEJTTJQBUFUIFXBUFSTFOFSHZ
t *U XPVME FWFO CF CFUUFS UP CVJME ESPQT JO UIF TQJMMXBZ XIJDI JT UIFO DBMMFE B TUFQQFE
spillway
Why?
t 5IF EZOBNJD GPSDF PG XBUFS JT WFSZ IJHI XIFO PXJOH EPXO B TUFFQ TMPQF t JU DPVME
damage and destroy even concrete structures

Civil Works
Multiple drops
Energy dissipation is happening at every step
t "TUFQQFETQJMMXBZSFEVDFTUIFWFMPDJUZBOEEJTTJQBUFTUIF JOUIJTDBTFIBSNGVM
FOFSHZ
of the water step by step

Civil Works
2.2.7 Penstock and Support
A thrust block is an anchor which is

used before the power house Intake Gate
Vent
Pipe
Restrained
Power house
Expansion joint
Slide Block
Serrations (small grooves) ensure proper key

between anchor and foundation
Main design principles for a stable penstock:
t 4FUBODIPSCMPDLBUFBDIDIBOHFPGEJSFDUJPOoIPSJ[POUBMBOEWFSUJDBMoPGUIFQFOTUPDL
t 4VQQPSUFBDIQJFDFPGQJQFXJUIB TMJEF
CMPDL
t 'BTUFOUIFQFOTUPDLUPUIFTVQQPSUTXJUITUFFMTUSBQT
t &OTVSF UIBU BMM CMPDLT IBWF B TPMJE BOE TUBCMF GPVOEBUJPO XIJDI EFQFOET PO HSPVOE
material and slope
t #FGPSFQFOTUPDLFOUFSTQPXFSIPVTFUIFSFNVTUCFBUISVTUCMPDLUPBCTPSCBMMEZOBNJD
water forces in the pipe
t 1FOTUPDLJOMFUNVTUCFDNBCPWFCPUUPNJOWFSU BOEXBUFSEFQUIBCPWFJOMFUTIPVME
be 4 times the diameter of the penstock pipe

Civil Works
Anchor block Is
missing
NO base for a
solid support
A tree is NO pipe support
Penstock must have solid supports at regular intervals
t 6TFDPODSFUF PSTUFFM
TVQQPSU TFUPOBTPMJEGPVOEBUJPO
t 5IFSF NVTU CF BO BODIPS CMPDL BU FWFSZ IPSJ[POUBM BOE WFSUJDBM CFOE JO UIF QFOTUPDL
pipe
t 1JQFNVTUCFYFEUPUIFTVQQPSUTXJUITUFFMTUSBQT
Why?
t 5SFFTBOEUSVOLTSPUBOEMPTFUIFJSTUSFOHUI
t "ODIPSCMPDLTSFTJTUUIFIZESBVMJDGPSDFTBUCFOETJOUIFQJQF
t 8FBLPSVOTUBCMFTVQQPSUTNBZDBVTFUIFQFOTUPDLUPNPWFXIJDIDPVMEDBVTFVOEVF
stress on the pipe o risk of major failure
t "CSFBLJOB IJHI
QSFTTVSFQFOTUPDLDPVMEDBVTFTFSJPVTXBUFSEBNBHF
Note:
PVC PENSTOCKS HAVE TO BE COVERED TO AVOID PVC MATERIAL BECOMING BRITTLE AND
EVENTUALLY FAILING!

Civil Works
Penstock
Drainage of
surface water
Pipe supports regular

spacing
Steel strap
The penstock pipe sections are well supported
t &WFSZQJQFTFDUJPOJTXFMMTVQQPSUFE
t 1JQFJTYFEUPUIFDPODSFUFTVQQPSUTXJUITUFFMTUSBQT
t $PODSFUFJTUIFCFTUNBUFSJBMGPSQJQFTVQQPSUT
t 1JQFJTBCPVUNFUFSBCPWFUIFHSPVOE
t 1SPQFSUSFODIESBJOBHFo important for long-term stability of supports
Note:
STEEL PENSTOCKS REQUIRE EXPANSION JOINTS BETWEEN ANCHOR BLOCKS AND FOR
SECTIONS LONGER THAN 30 m o INSTALL EXPANSION JOINTS DOWNSTREAM OF ANCHOR
BLOCKS!

Civil Works
Broken anchor block
Missing expansion
joint possibly caused
broken support
Penstock
Unsolid foundation
Expansion joint must be installed in penstock after each anchor block
t #VJMEBOFXBODIPSCMPDLXJUIBTPMJEGPVOEBUJPO
t "GUFSFBDIBODIPSCMPDLUIFSFNVTUCFBOFYQBOTJPOKPJOUPOUIFQJQF
Why?
t *GUIFSFJTOPFYQBOTJPOKPJOUUIFQJQFDBOOPUBCTPSCUIFMPOHJUVEJOBMNPWFNFOUTPGUIF
pipe due to hydraulic forces and temperature changes
t "CSFBLJOB IJHI
QSFTTVSFQFOTUPDLDPVMEDBVTFTFSJPVTXBUFSEBNBHFBOEXBTIPVU
the supports and even damage the powerhouse
Note:
RISK OF FAILURE!

Civil Works
Expansion joint
Steel strap to fix the

pipe to the support
Anchor block
Pipe support
An anchor block with an adjacent expansion joint
t 5IFBODIPSCMPDLBCTPSCTUIFXFJHIUBOEIZESBVMJDGPSDFTPGUIFQJQFTFDUJPOBCPWFUIF
anchor block
t &YQBOTJPOKPJOUTBMMPXGPSMPOHJUVEJOBMNPWFNFOUTPGUIFQJQFTFDUJPOEPXOTUSFBNPG
the anchor block
t 1JQFDBOFYQBOEPSDPOUSBDUBTBSFTVMUPGUFNQFSBUVSFDIBOHFTBOEIZESBVMJDGPSDFT

Civil Works
Pipe sealed with tape
NO straps
Support is broken -
strap is not fixed
NOT a proper joint
Several examples of poorly installed penstocks
t %PQFSJPEJDJOTQFDUJPOBOENBJOUFOBODFUPOEBOEYQSPCMFNT
t "EETUFFMTUSBQTUPYUIFQJQFUPUIFTVQQPSUT
t 3FQMBDFQJQFTFDUJPOTXIFOQJQFJTMFBLJOHPSDSBDLFE
t 6TFBOHFEUUJOHTGPSQJQFDPOOFDUJPOT
t 3FQMBDFGBVMUZ FYQBOTJPO
KPJOUT
Why?
t -FBLJOHPSGBVMUZQJQFTBOEKPJOUTDPVMEDBVTFBCVSTUQJQFBOETFSJPVTXBUFSEBNBHF
oNO electrical power generation would result
t 8BUFSJOUIFQPXFSIPVTFPSBUUIFUSBOTGPSNFSDBODBVTFFMFDUSJDBMTIPDLT
t *NQSPQFSMZTVQQPSUFEBOEYFEQJQFDPVMEGBJM SFTVMUJOHJOMPTTPGQPXFSBOESFRVJSJOH
costly repairs

Civil Works
Penstock
Steel straps
Pipe supports
A well built and properly maintained penstock
t 5IFSFBSFTVQQPSUTGPSFBDIQJQFTFDUJPOEVFUPUIFQJQFTIJHIXFJHIU
t 4UFFMTUSBQTGBTUFOUIFQJQFUPUIFDPODSFUFTVQQPSUT
t 5IFSFJTBEFRVBUFHSPVOEDMFBSBODFPGBCPVUDN
t 5IFSFBSFOPTJHOTPGNPWFNFOUT EFGPSNBUJPOPSDSBDLT
t 5IFQJQFJTXFMMQBJOUFEBTQSPUFDUJPOBHBJOTUDPSSPTJPO
t (SBTT PUIFSWFHFUBUJPOBOEEJSUIBWFCFFODMFBSFEBXBZGSPNQFOTUPDL

Civil Works
Base not well founded on

solid ground
PVC penstock well Cover is not

covered sufficient
Support leans on poor NO base for a support

base
4PNFCBEFYBNQMFTPGQFOTUPDLTVQQPSUToUPCFBWPJEFE

Civil Works
Some good example of penstock supports

Civil Works
NO ventilation pipe
Inlet gate
NO service area for

trash rack
Penstock inlet gate without required ventilation pipe
t *OTUBMMBWFOUJMBUJPOQJQFJOUIFQFOTUPDLEPXOTUSFBNPGUIFHBUF
Why?
t 5IF WFOUJMBUJPO QJQF BMMPXT BJS UP FOUFS UIF QFOTUPDL XIFO UIF QFOTUPDL JT SBQJEMZ
emptied. Without ventilation pipe the penstock could easily be damaged by a vacuum
collapse of the pipe
t *GQFOTUPDLJTFRVJQQFEXJUIBOJOMFUHBUFUIFSFNVTUCFBWFOUJMBUJPOQJQF
Note:
A PENSTOCK WITH INLET GATE REQUIRES A VENTILATION PIPE!

Civil Works
Ventilation pipe Inlet gate
Penstock Service area
Forebay with trash rack

and spillway
Penstock inlet gate and ventilation pipe
t 1FOTUPDLQJQFTXJUIBOJOMFUHBUFNVTUIBWFBWFOUJMBUJPOQJQF
t %JBNFUFSPGWFOUJMBUJPOQJQFEFQFOETPOQFOTUPDLEJBNFUFS
Note:
THE VENTILATION PIPE PREVENTS A VACUUM COLLAPSE OF THE PENSTOCK PIPE WHEN IT
IS EMPTIED!

Civil Works
1 4
3
5
1 Check for rust and condition of paint clean and re-paint as needed
2 Check pipe supports and anchor blocks for deformation, settlings or any other
movements repair cracks with cement grout
3 $IFDLUJHIUOFTTPGOVUTCPMUTPGBOHFTBOETUSBQToUJHIUFOBTOFFEFE
4 Check all joints, especially expansion joints, for leaks fix if needed
5 Remove grass, shrubs and dirt do it regularly
Note:
CHECK PENSTOCK AT LEAST EVERY THREE MONTHS!

Civil Works
2.2.8 Power House and Tailrace
Tailrace
The drawing shows a typical setup for a small powerhouse and a short tailrace which takes the
XBUFSCBDLUPUIFSJWFSPODFJUIBTPXOUISPVHIUIFUVSCJOF5IFQPXFSIPVTFNVTUDMFBSMZ
TJUXFMMQSPUFDUFEBOEBCPWFQPTTJCMFPPEXBUFSMFWFMTJOUIFSJWFSTPJUDBOOPUHFUEBNBHFE
The tailrace is a part of the hydraulic system of the MHP and needs to function well just like
the headrace. It must not be blocked or full of vegetation or debris. Usually the tailrace is very
short but there are also MHP with tailraces several hundred meters or even kilometres long.
This depends on the specific situation or topography.

Civil Works
Broken roof and

windows
Dirty walls and windows
This power house is NOT a safe place for valuable equipment
t 1BJOUUIFXBMMTBTXFMMBTUIFXPPEFOQBSUTMJLFXJOEPXTBOEEPPS
t 'JYUIFSPPG
t ,FFQUIFPPSUJEZ
t $MFBOUIFPVUTJEFXPSLJOHTQBDF
Why?
t 5IFQPXFSIPVTFQSPUFDUTDPTUMZNFDIBOJDBMFMFDUSJDBMFRVJQNFOU
t *UQSFWFOUTBDDFTTCZVOBVUIPSJ[FEQFSTPOT
t "EWFSTFXFBUIFSDPOEJUJPOTDPVMEEBNBHFUIFFRVJQNFOU

Civil Works
Penstock with anchor

block and supports
Power house holds
costly equipment
Tailrace to the river

Safe access for the
operators
A well built and maintained power house located at a suitable place
t "MMJNQPSUBOUFMFNFOUTIBWFCFFODPOTJEFSFE
t "MMOFDFTTBSZGFBUVSFTIBWFCFFOJODMVEFE
t 5IFCVJMEJOHJTXFMMNBJOUBJOFEBOENBLFTBOFBUJNQSFTTJPO
t 5IFIPVTFJTXFMMBDDFTTJCMFXIJDIJTJNQPSUBOUQBSUJDVMBSMZEVSJOHOJHIUIPVST

Civil Works
Step-up transformer for

medium voltage transmission
Power house in the river

o NOT a good place !
Wall
5IJTQPXFSIPVTFQSPWFE/05UPCFPPEQSPPG
t #VJME B SFUBJOJOH XBMM BSPVOE UIF CVJMEJOH BOE CBDLMM UIF BSFB UP QSPUFDU UIF
GPVOEBUJPOTPGUIFQPXFSIPVTF5BLFDBSFUPOPUCMPDLUIFPXPGUIFSJWFSCZUIFXBMM
Why?
t 5IFSF JT DPTUMZ NFDIBOJDBM FMFDUSJDBM FRVJQNFOU JO UIF QPXFS IPVTF UIBU NVTU CF
QSPUFDUFE&WFOXJUIBSFUBJOJOHXBMM UIJTQPXFSIPVTFJTOPUPPEQSPPGCFDBVTFJUJT
located too low in the river. Waterproof doors and temporary sand bags can help possibly
JODBTFPGBTNBMMFSPPE#FUUFS DMPTFUIFXJOEPXBOEEPPSPQFOJOHXJUIDPODSFUFBOE
CVJMEBOFXBDDFTTWJBUIFSPPG,FFQQVNQTSFBEZJOUIFQPXFSIPVTFJODBTFPGBPPE
to protect the equipment
t "TUIFQJDUVSFJOUIFSJHIUDPSOFSTIPXT BTFWFSFPPEXIJDIPDDVSSFETIPSUMZCFGPSF
completion of this book has caused serious damage unfortunately even to a second
turbine which was installed at the same location

Civil Works
Penstock
Retaining walls protect the
power house area against
erosion and floods
Tailrace
A well located and properly built power house
t 5IFQPXFSIPVTFJTXFMMQSPUFDUFEBHBJOTUPPETJOUIFSJWFSCFDBVTFJUTJUTBCPWFPPE
water level
t 5IFXBUFSJOUIFUBJMSBDFSFUVSOTUPUIFSJWFSXJUIBTNBMMESPQBOEEPFTOPUFSPEFUIF
river bank
t 5IFQPXFSIPVTFJTBTPMJEBOEOFBUMPPLJOHTUSVDUVSF

Civil Works
Power house
Penstock
Support does NOT

replace a thrust
block
Thrust block
missing
Joint between
house and pipe is
missing
Pipe support does NOT replace the need for a thrust block
t #VJMEBDPODSFUFUISVTUCMPDLBSPVOEUIFQFOTUPDL
t -FBWFBKPJOUCFUXFFOUIFCMPDLBOEUIFCVJMEJOH
t *OTUBMMBOFYQBOTJPOKPJOUBIFBE VQTUSFBN
PGUIFUISVTUCMPDL
Why?
t " UISVTU CMPDL BCTPSCT UIF QFOTUPDLT XFJHIU BOE IZESBVMJD GPSDFT PG UIF XBUFS JO UIF
penstock
t "OFYQBOTJPOKPJOUBCTPSCTQJQFFYQBOTJPOEVFUPUFNQFSBUVSFDIBOHFT BOEBMTPUIF
hydraulic forces in the pipe between anchor blocks

Civil Works
Power House
Turbine Trust block
Thrust block
Power House
Penstock
Solid thrust block prevents the penstock from moving
t 5IFUISVTUCMPDLBTTVSFTUIBUUIFQFOTUPDLJTYFEBOEEPFTOPUNPWFBOEQVTIPSQVMM
the house wall
t *UJTCFUUFSJGUIFUISVTUCMPDLJTTFQBSBUFEGSPNUIFIPVTF
t %SBJOBHFEJUDIFTBSPVOEUIFCVJMEJOHLFFQTVSGBDFXBUFSBXBZGSPNUIFQPXFSIPVTF

Civil Works
1 Keep tailrace clean and free of debris

2 Check for erosion in the river
Note:
ONLY FREE FLOW IN THE TAILRACE KEEPS THE TURBINE RUNNING!

CHECK AND CLEAN AS NEEDED!

Electro-Mechanical Equipment
3. Electro -Mechanical
Equipment
3. Electro-Mechanical
Equipment

3.1 BASICS
to Panel
Automatic voltage
regulator (AVR)
Turbine Generator
Mechanical Flywheel
transmission
Typical electro-mechanical elements of a Micro Hydro Power Plant
t 5VSCJOF
t .FDIBOJDBMUSBOTNJTTJPOHFBS
t (FOFSBUPS
t 5VSCJOFDPOUSPMMFS
t $POUSPMBOEQPXFSDBCJOFU

Generator
Belt drive in a cage Turbine
Coupling
Bearings
Adjustable steel
base
What are the main challenges to set up these machines?
It is most important that the electro-mechanical components and their baseframe are sitting
on a solid and stable foundation and that the shafts of all components are perfectly aligned
as required.

Runner TURBINE
GENERATOR Bearing
Pulley
Gen. Shaft Turbine Shaft
Inter line coupling

Puley
Slide rails
Axial alignment
H = Horizontal deviation Subframe
V = Vertical deviation
Perfectly aligned shafts are essential for good operation
What should be considered for good workmanship?
t 5IFJOTUBMMBUJPOPGUVSCJOFBOEHFOFSBUPSNVTUCFEPOFXJUIDBSF
t .BLF TVSF UIBU UIF TIBGUT PG UVSCJOF BOE HFOFSBUPS BSF QFSGFDUMZ QBSBMMFM UP UIF
IPSJ[POUBMBOEUPUIFWFSUJDBMQMBOF
t 5IJTQBSBMMFMBMJHONFOUJTWFSZJNQPSUBOUGPSBTNPPUIUSBOTNJTTJPOBOEMPOHFSMJGFUJNF
t #FMUQVMMFZTSFRVJSFBYJBMBMJHONFOU
t 5IFBEKVTUNFOUTPGUIFTIBGUTNVTUCFEPOFXJUIBMPUPGDBSF
t 4VCGSBNFOFFETUPCFBEKVTUBCMF JOPSEFSUPBMMPXQSFDJTFBMJHONFOU
t 'PSCFMUUJHIUFOJOH UIFTVCGSBNFTIPVMEBMXBZTCFNPWFEJOQBSBMMFM
t .JTBMJHONFOUDBVTFTUSBOTNJTTJPOQSPCMFNTUIFSFXJMMCFBMPUPGXFBSBOEUFBSPOCFMU
and bearings they may have to be replaced much sooner
t $BSF TIPVME CF UBLFO EVSJOH DBTUJOH PG UIF DPODSFUF GPVOEBUJPO UP HFU JU QFSGFDUMZ
horizontal to make adjustments of the equipment bases at a later stage easier

Belt driven Generator
Both shafts must be horizontal and TURBINE

paralell to each other
Both pulleys must be in the same

plane
Direct driven Generator Misalignments
Induction motor and

gearbox used as alternator
Generator
Gearbox Turbine
In-line coupling
Turbine runner
Shafts must be on the same axis

3.2 INDIVIDUAL COMPONENTS
3.2.1 Turbine
Guide vane
Runner blades
.BJOFMFNFOUTPGBDSPTTPXUVSCJOF
Note:
THE GUIDE VANE REGULATES THE FLOW TO THE TURBINE!

Bolt slot not covered

and washers are too
small
Bolt slots
Washers should be
of this size
Incorrect size of washers
t 6TFUIFDPSSFDUTJ[FPGXBTIFST JOUIJTDBTFMBSHFS
t 5IFFEHFTPGUIFXBTIFSTNVTUCFQBSBMMFMUPUIFCPMUTMPUBOENVTUDPWFSJUDPNQMFUFMZ
Why?
t #PMUTDPOOFDUUIFUVSCJOFUPUIFTUFFMCBTFBOEYJUTQPTJUJPO
t 5IFXBTIFSTEJTUSJCVUFUIFMPBEFWFOMZPOUIFTUFFMCBTF
Note:
WASHER SIZE SHOULD BE TWICE THE DIAMETER OF THE HOLE!

BOLT SLOTS ALLOW A PRECISE ALIGNMENT OF THE EQUIPMENT!

Correct size
Turbine
Inclination
Steel base,
horizontally
Turbine housing
Tapper washer
compensates inclination
Tapper washer Base
t 5IFXBTIFSTIBWFDPSSFDUEJNFOTJPOTBOEBSFDFOUFSFEUPUIFIPMF
t 5IF UBQQFS XBTIFS JT OFDFTTBSZ UP DPNQFOTBUF UIF TMPQF PG UIF TUFFM TFDUJPO XJUI UIF
horizontal steel base
t 4DSFXTIBWFUPCFJOTUBMMFEWFSUJDBMMZ

Debris between the guide

vanes and runner blades
Clogged runner and guide vanes
t 1SFWFOUEFCSJTGSPNHFUUJOHJOUPUIFQFOTUPDLCZJOTUBMMJOHBOFUSBTISBDLBDDPSEJOHUP
the requirements of the turbine manufacturer
t $MFBOBOENBJOUBJOUIFUSBTISBDLSFHVMBSMZ
Why?
t %FCSJTJOUIFUVSCJOFCMBEFTJOJUJBMMZSFEVDFTUIFQFSGPSNBODFPGUIFUVSCJOFCVU
eventually will clog and damage the turbine
t &TQFDJBMMZ'SBODJTBOEQSPQFMMFSUVSCJOFTBSFTVTDFQUJWFUPHFUCMPDLFECZEFCSJT

No debris all
clean
A turbine in good condition thanks to a functional sand trap and trash rack
t 5IFQFSGPSNBODFPGUIFUVSCJOFJTOPUJOVFODFECZEFCSJT
t 5IF USBTI SBDL JT CVJMU BDDPSEJOH UP UIF SFDPNNFOEBUJPO PG UIF UVSCJOF TVQQMJFS BOE
keeps the turbine clean
t 5IBOLTUPBTBOEUSBQOPBCSBTJPOJTWJTJCMFPOUIFUVSCJOFSVOOFS
Note:
PROTECT THE TURBINE AND IT WILL KEEP RUNNING FOR A LONG TIME!
CLEAN TRASH RACK AND SAND TRAP REGULARLY!

3.2.2 Main Elements of a Generator
Cable in ducts to
panel AVR
Ventilation grating
Shaft of generator
connected with pulley
The drawing depicts a synchronous generator with an AVR (Automatic Voltage Regulator).
In island mode, the AVR controls the generator voltage which is the system voltage as well.
In grid-connected mode, the AVR is not able to change the system voltage but by adjusting
the excitation current it can determine the reactive power characteristics. Asynchronous
generators do not have an AVR.

Very messy cable

connections
AVR dismantled
Belt without cover
Power cable not

Protection missing protected
Generator and AVR in bad condition
t 3FQMBDFBMMNJTTJOHQBSUTPGUIFHFOFSBUPSBOE"73
t .BLFQSPQFSDBCMFDPOOFDUJPOTJOBDDPSEBODFXJUITBGFUZSFHVMBUJPOT
t 1PXFSDBCMFNVTUCFMBJEJOBEVDU
t $POOFDUHFOFSBUPSBOEDPOUSPMMFSUPBOFBSUIJOHTZTUFN
t 5SBOTNJTTJPOCFMUNVTUCFQSPUFDUFEXJUIBDBHF
Why?
t 5IF QSFTFODF PG VOUSBJOFE QFSTPOT JO UIF QPXFSIPVTF JT QPTTJCMF 5IFZ NVTU CF
protected from the dangers of electricity and mechanical power.
t 4BGFUZSFHVMBUJPOTBMXBZTNBLFTFOTFBOEIBWFBSFBTPO UIFZIFMQUPQSFWFOUBDDJEFOUT
and injuries
t (PPEBOEDPOTDJFOUJPVTPQFSBUJPOBOENBJOUFOBODFXPSLXJMMMFBEUPHPPEPQFSBUJPO

AVR
Belt cover
Generator
Earthing
connection
Sledge
Well protected
power cable
Adjustment screws
Generator well installed
t 5IFFRVJQNFOUJTJOTUBMMFEJOBDDPSEBODFXJUITBGFUZSFHVMBUJPOT
t 1PXFSDBCMFJTQSPUFDUFECZBFYJCMFQJQF
t (FOFSBUPSBOEDPOUSPMMFSBSFDPOOFDUFEUPUIFFBSUIJOHTZTUFN
t 5IFCFMUJTQSPUFDUFEXJUIBDPWFS
t 5IFSFJTFOPVHITQBDFUPTIJGUUIFHFOFSBUPSJOUPUIFSJHIUQPTJUJPO5IFCFMUDBOCF
tightened by moving it on the sledge on the frame
t 5IFPPSJTDMFBO BMMPXJOHUPEFUFDUXBUFSMFBLBHFTPUIFSJSSFHVMBSJUJFTJNNFEJBUFMZ

3.2.3 Panel, Controller and Ballast
A safe place for all electrical devices
The control cubicle provides a safe place, dry and free of dust, for the electrical devices and
also protects people working in the powerhouse from electrical shocks.
Boxes are not covered
Wires are not insulated
Mouse in panel
Alignment of cables and

components is confusing
Bad example of wiring and electric components
t .PVOUFMFDUSJDDPNQPOFOUTBOEXJSJOHJOBXFMMBSSBOHFETDIFNF
t &MFDUSJDBMDPNQPOFOUTNVTUCFJOTUBMMFEJOBMPDLBCMFNFUBMDBTF
t 1SFWFOU QVCMJD BDDFTT UP FMFDUSJD DPNQPOFOUT XJSJOH o JODMVEJOH BDDFTT GPS BOJNBMT
which can bite away the insulation of cables
Why?
t *NQSPQFSMZCVJMUQBOFMTBSFBQPUFOUJBMTPVSDFGPSUFDIOJDBMGBJMVSFT
t &WFOFYQFSUTDBOVOEFSTUBOE BOEUIFSFBGUFSY
BTZTUFNPOMZXIFOJUJTXFMMBSSBOHFE
t #BSFXJSFTBSFEBOHFSPVT
Note:
RISK OF INJURY & DEATH!

All elements are

well arranged
Panel of control
cubicle
All cables are

labeled
Example of a well arranged control cubicle
t $MFBSBSSBOHFNFOUPGBMMDPNQPOFOUTNBLFTNBJOUFOBODFTJNQMFBOEGBTU
t $BCMFTBOEEFWJDFTBSFQSPQFSMZMBCFMFE
t 3FQBJSTBSFRVJDLBOEFBTZUPEP
t 8PSLJOHPOUIFDVCJDMFJTTBGFS
Note:
DURING OPERATION THE PANEL MUST BE CLOSED AND SHOULD BE LOCKED!

Ventilation
Wires are not protected

against contact risk of
electric shock
Never touch the

glowing rods
Unprotected ballast presents a real hazard
t 3FJOTUBMMCBMMBTUBUBXFMMWFOUJMBUFEQMBDF
t "UUBDICBMMBTUIJHIFSoPVUPGSFBDIPGQFPQMF
t .PVOUBTBGFUZDBHFBSPVOEUIFCBMMBTU
t *OTUBMMBIFBUTIJFMEBHBJOTUUIFXPPEFOXBMMBOEDFJMJOHCPBSET
Why?
t )PUCBMMBTUJTBSFIB[BSEFTQFDJBMMZGPSXPPEFOCPBSET
t 1MBTUJDDBCMFDPBUJOHTNBZNFMU
t *GUIFCBMMBTUJTJOTUBMMFEUPPMPXTPNFCPEZNBZUPVDIJUBOEHFUCVSOFE
Note:
RISK OF INJURY!

Protected and
shaded by roof
Inner cage
Outer cage
Well protected ballast at outer wall of the power house
t 5IFSPPGQSPUFDUTUIFCBMMBTUJOTUBMMBUJPOBHBJOTUSBJO
t #BMMBTUJTXFMMWFOUJMBUFE
t 5IFPVUFSDBHFQSFWFOUTBDDFTTCZVOBVUIPSJ[FEQFSTPOT
Note:
IN CASE OF LOW LOAD IN THE VILLAGE (WITH MOST APPLIANCES SWITCHED OFF) THE
CONTROLLER DIVERTS ELECTRICITY TO THE BALLAST WHERE IT IS CONVERTED TO HEAT!
RODS ARE GLOWING HOT!

Distance too short
Ceiling
The distance between ceiling and the top edge of ballast must be at least 50 cm
t *OTUBMMCBMMBTUMPXFS PSJGUIBUJTOPUQPTTJCMF PVUTJEFPGUIFQPXFSIPVTF

t 1SPUFDUUIFCBMMBTUXJUIBTBGFUZDBHF
t 1SPWJEFWFOUJMBUJPOGPSUIFHMPXJOHSPET
Why?
t *GUIFFMFDUSJDJUZEFNBOEJTMPX UIFFYDFTTFOFSHZJTTFOUUPUIFCBMMBTU5IFSPETHFUWFSZ
hot and enough space to the roof plus a good ventilation is required to convey the heat
Note:
RISK OF FIRE!

Roof
Ballast in a cage
Cable duct should be guided

inside the cage
Power cable ducts
Penstock
A good installation of ballast
t #BMMBTUJTXFMMQSPUFDUFEJOBTUFFMDBHF
t #BMMBTUJTQSPQFSMZWFOUJMBUFEBTJUHFUTWFSZIPU
t *OTUBMMBUJPOVOEFSUIFSPPGJTBHPPESBJOQSPUFDUJPO
t 5IFXJSJOHUPUIFCBMMBTUJTSVOUISPVHIEVDUT
t 6OBVUIPSJ[FE QFSTPOT IBWF OP BDDFTT UP UIF CBMMBTU BOE DPVME OPU CF CVSOFE CZ UIF
glowing rods
Note:
CABLE DUCTS SHOULD BE GUIDED INSIDE THE CAGE TO PREVENT DAMAGE OF THE
CABLES!
IF THESE CABLES ARE INTERRUPTED THE TURBINE CANNOT BE CONTROLLED ANYMORE!

2
3
Keep panel clean of dust and grease

Check all electrical devices and control instruments for functionality
Make sure that all cable connections are okay
Note:
ONLY PROPERLY WORKING DEVICES PRODUCE ELECTRICITY!

CHECK AT LEAST ONCE A WEEK!

3.2.4 Inside the Power House
Tailrace to river
Thrust block
Electro-mechanical
equipment
Penstock
Panel
Tool & spare part

cabinet

Turbine & generator

are crammed in the
corner of power house
Main equipment is too close to walls
t "UUIFEFTJHOTUBHFFOPVHITQBDFNVTUCFQMBOOFEBSPVOEUIFUVSCJOFBOEHFOFSBUPS
t 5SZUPSFBSSBOHFFRVJQNFOUPSFOMBSHFQPXFSIPVTFUPNBLFNPSFSPPNBSPVOENBJO
equipment
Why?
t "EFRVBUFXPSLJOHTQBDFJTSFRVJSFEGPSTFSWJDFBOENBJOUFOBODF
t 'PSEJTBTTFNCMZPGUIFUVSCJOFTIBGU BDFSUBJONJOJNVNTQBDFJTOFFEFEEFQFOEBOUPO
the length of the shaft

B C
Here is adequate space around the equipment
t 5IFSFJTTVDJFOUTQBDFGPSPQFSBUJPO NBJOUFOBODF SFQBJSBOEBTTFNCMZEJTBTTFNCMZ

work around the generator and turbine
t 3FDPNNFOEFETQBDF
- A = minimum 1.5 m when also entrance area
- B = minimum 1.0 m
- C = minimum 1.5 m or at least length of turbine shaft plus 0.5 m
t "SFB BSPVOE BMM FMFDUSPNFDIBOJDBM FRVJQNFOU JT LFQU DMFBO o no greasy and/or wet
surfaces
Note:
WATER CONDUCTS ELECTRIC CURRENTS VERY WELL!

HAZARD FOR OPERATOR!

Panel and boards

Walls are damaged
are greasy
and dirty
Floor is slippery &

dirty
Oil and grease are
everywhere on
equipment
A poorly maintained, run-down power house
t $MFBOVQUIFQPXFSIPVTF
t $MFBOIBOETUIPSPVHIMZBGUFSNBJOUFOBODFXPSLXJUIHSFBTFPJM
t 8JQFPPSFWFSZUJNFBGUFSXPSLJOHJOUIFQPXFSIPVTF
Why?
t &YQFOTJWFFRVJQNFOUNVTUCFLFQUDMFBOUPXPSLXFMM
t 8PSLJOBDMFBOFOWJSPONFOUJTNVDITBGFSBOEBMTPFOKPZBCMF
t 0JMDPVMESFBDIXBUFSBOETPJMBOEQPMMVUFJU
t %JSUBOEHSFBTFDBODBVTFUIFFMFDUSJDBMFRVJQNFOUUPGBJM
Note:
A GREASY FLOOR IS SLIPPERY AND UNSAFE!

Panels
Tool shelf
AVR
Generator
Turbine
Penstock
All equipment is well arranged, clean and well maintained
t 0QFSBUJPOBOENBJOUFOBODFJTFBTJFSXIFOBMMFRVJQNFOUJTXFMMBSSBOHFE
t "MMFRVJQNFOUoUPPMT TQBSFQBSUTFUDoJTXJUIJOFBTZSFBDI
t $MFBOMJOFTTBOEUJEJOFTTBTTVSFUIBUOPUIJOHJTMPTUPSEBNBHFECZEVTUPSMUI
t "DMFBOPPSQSFWFOUTJUGSPNCFDPNJOHTMJQQFSZBOENBLFTXPSLTBGFS

A power house is NO stage for a

show or family visits
Belt drive in
operation !!!
Power house is NO stage for a show or family visits
t ,FFQPVUBMMQFSTPOTXIPIBWFOPCVTJOFTTJOUIFQPXFSIPVTF FTQFDJBMMZDIJMESFO
t *GVOBVUIPSJ[FEQFSTPOTFOUFSUIFQPXFSIPVTF TUPQNPWJOHFRVJQNFOUJNNFEJBUFMZUP
avoid accidents
t "DUJOBDDPSEBODFXJUIBMMTBGFUZSFHVMBUJPOTBOEQSPDFEVSFT
Why?
t "QPXFSIPVTFJTOPUUIFQMBDFGPSWJTJUTPSNFFUJOHTXIFOGBTUNPWJOHFRVJQNFOUJTJO
operation and electricity is generated
Note:
BE AWARE THAT AN UNPROTECTED ROTATING BELT DRIVE, FLYWHEEL AND TURBINE-

GENERATOR SHAFTS ARE DANGEROUS FOR (UNAUTHORIZED) PERSONS o CLOTHES CAN
EASILY BE CAUGHT!
A RISK TO EVERYBODYS HEALTH!

3 1
,FFQPPSBOEXBMMTDMFBOBOEUJEZ
Clean all parts of the equipment after maintenance
At the end of maintenance work put all removable parts back in place again
Note:
ONLY CLEAN EQUIPMENT WORKS WELL!

CLEAN AT LEAST AFTER EACH MAINTENANCE ROUTINE!

3.2.5 Power House Wiring
Nail!!
Wires!!!
Never bridge fuses oJUJTGBSUPPEBOHFSPVT
t /&7&3SFQMBDFGVTFTXJUIBXJSFPSPUIFSNFUBMMJDPCKFDU
t *OTFSUBMMGVTFTSFRVJSFEJOUIFQBOFMBOELFFQQBOFMDMPTFEEVSJOHUIFPQFSBUJPO
t *UJTPQFSBUPSTSFTQPOTJCJMJUZUPIBWFGVTFTJOTUPDL
Why?
t 'VTFTJNQMFNFOUJNQPSUBOUFMFDUSJDTBGFUZGVODUJPOT
t #SJEHFEGVTFTDBVTFTIPSUDJSDVJUBOEDBOJOKVSFUIFPQFSBUPSPSCVSOEPXOUIFQPXFS
house
Note:
DEADLY DANGER!

Devices of power and control cubicle
t $MFBSMBZPVUPGBMMXJSFTBOEEFWJDFT XIJDINBLFTUIFTFBSDIGPSGBJMVSFTNVDIFBTJFS
t 5IFDVCJDMFJTLFQUDMFBO
t &WFSZEFWJDFJTMBCFMFE GBDJMJUBUJOHBOFBTZVOEFSTUBOEJOHPGUIFTZTUFN
Note:
CLOSE CUBICLE DURING OPERATION!

Bad cable
connections
No cable extention
like this!
Good cable
connections
Bad cable connections are a source for major damages
t 0/-:VTFDBCMFTIPFTGPSDBCMFDPOOFDUJPOToUIFSFJT/0BMUFSOBUJWF
Why?
t &MFDUSJDBMXJSFTIBWFUPCFDPOOFDUFEQSPQFSMZUPBWPJEMPTTFT
t #BEDPOOFDUJPOTDBVTFJNQSPQFSPQFSBUJPOBOEDBOCFUIFSFBTPOPGTIPSUDJSDVJUT
t 4IPSU DJSDVJUT BSF IB[BSEPVT GPS PQFSBUJPO BOE FRVJQNFOU BOE MFBE UP VOOFDFTTBSZ
interruptions in operation

Proper cable
connections
A proper and
simple way to fix
cables
Cables are properly fixed with cable shoes
t $BCMFTIPFTBSFBDDPSEJOHUPDBCMFEJBNFUFSBOEBSFYFEXJUITDSFXT
t $BCMFDPOOFDUJPOTDBOOPUNPWFCFDBVTFUIFZBSFYFEUPUIFXBMMCFGPSFFOUFSJOHUIF
panel
t /PUFOTJPOPODBCMFT

Use earthing
clamps only
Earthing connection will probably not work
t 5IFFBSUIJOHSJOHNVTUCFDPOOFDUFEUPBMMNBJOJOTUBMMBUJPOTJOUIFQPXFSIPVTFoFH
reinforcement of foundations of power house, equipment and all the other pieces
t 6TFFBSUIJOHDMBNQTGPSBOZDPOOFDUJPOUPUIFFBSUIJOHTZTUFN
Why?
t 5IFFBSUIJOHTZTUFNJTBTBGFHVBSETZTUFNGPSJOTUBMMBUJPOT BQQMJBODFTBOEQFPQMFJOUIF
power house
t 5IFEJTUBODFCFUXFFOUIFFBSUIJOHSJOHoXIJDIJTMBJEBSPVOEUIFQPXFSIPVTFoBOE
the installations has to be at least 1 m and must be done with earthing clamps
t 5IJTBCPWFUIFHSPVOEDPOOFDUJPOJTFTTFOUJBMUPNFBTVSFUIFSFTJTUBODFJOPSEFSUP
find out if the earthing system functions properly

Equipment base of
steel
Earthing
connection Earthing cable
Reinforcement of
foundation
Reinforcement of foundation & steel base connected to earthing rod
t 3FJOGPSDFNFOU PG UIF GPVOEBUJPO CBTF BOE UIF FRVJQNFOU TUFFM CBTF NVTU CF
connected to the earthing system with earthing clamps
t 5IJT DPOOFDUJPO BWPJET TFWFSF EBNBHF UP QFPQMF BOE FRVJQNFOU JO DBTF PG
malfunctioning of a device
t &BSUIJOH TZTUFN QSPUFDUT BMM NBDIJOFT BOE FRVJQNFOU XJSJOH QPXFS IPVTF BOE UIF
people working there against lightning and stray currents
Note:
NO EARTHING A DEADLY DANGER!

3.2.6 Mechanical Transmission
Generator
Belt drive in a cage
Turbine
Coupling
Bearings
Adjustable steel
base
The mechanical transmission links the turbine to the generator. It is also often called speed
increaser. It is needed because the generator usually runs at a much higher rotational velocity
UIBOUIFUVSCJOF5IFSFBSFEJFSFOUUZQFTPGUSBOTNJTTJPOTJOUIFDBTFPG.)1XJUIDSPTTPX
turbines, belt drives are very commonly used. They are not suitable for turbines and generators
with more than 100 - 200 kW.
Cover has been

removed
Turbine is running
Flywheel and belt are not protected in a cage
t 1VUUIFTBGFUZDPWFSCBDLPWFSUIFZXIFFMBOECFMUCFGPSFSFTUBSUJOHPQFSBUJPO
t 'PMMPXBMMTBGFUZSFHVMBUJPOTBOEQSPDFEVSFT
Why?
t 6OQSPUFDUFEGBTUNPWJOHQBSUT XIFFMTBOEESJWFCFMU
BSFBIB[BSEUPUIFPQFSBUPS BOE
everybody else entering the powerhouse)
Note:
FAST MOVING PARTS A SERIOUS HEALTH HAZARD!

Panel
All fast moving
parts are covered
Turbine
AVR
Generator
Flywheel and drive
belt
Flywheel, drive belts and couplings covered by safety covers
t 5IFTBGFUZDPWFSTQSFWFOUBDDJEFOUTXIFOUIFUVSCJOFJTSVOOJOH
t 'MPPSJTDMFBOBOEUJEZ
t 5IFSFJTFOPVHIXPSLJOHTQBDFBSPVOEUIFFRVJQNFOU

Use drive belts of Turbine

same length (=
same tension)
Generator shaft
Fast moving parts!
Tension of drive belts is very important for efficient transmission
t *GUIFUFOTJPOPGUIFESJWFCFMUTGFFMTPSMPPLTJOTVDJFOU UJHIUFOUIFNCZTIJGUJOHUIF
QPTJUJPOPGUIFZXIFFMBOEHFOFSBUPSTVCGSBNF
t 6TFPOMZESJWFCFMUTPGUIFTBNFNBOVGBDUVSFSBOETBNFBHFo buy and replace all belts
at the same time
t "MXBZTLFFQQVMMFZTBOEESJWFCFMUTGSFFGSPNBOZHSFBTF
Why?
t 'PSBOFDJFOUUSBOTNJTTJPOJUJTFTTFOUJBMUPIBWFFRVBMUFOTJPOPOBMMESJWFCFMUT
t "XFMMSVOOJOHHFOFSBUPSQSPEVDFTNPSF

Drive belts are

aligned and
properly tightened
Fast moving parts!
Tension of all belts must be the same
t "QSPQFSMZBMJHOFEBOEUFOTJPOFEUSBOTNJTTJPOMFBETUPBIJHIFDJFODZ
t 6OFWFO UFOTJPO PG UIF ESJWF CFMUT MFBET UP NPSF TUSBJO PO UIF NPSF UJHIUFOFE POFT
reduces efficiency and can cause additional strain on bearings
Note:
OPERATOR MUST CHECK TENSION OF DRIVE BELTS BEFORE START-UP!
PULLEY AND BELT MUST BE KEPT FREE FROM GREASE!

Must be on same
level
Same distance all

around!
Coupling 2
Coupling 1
Precise work is required when coupling is being adjusted
t 5IFEJTUBODFBOEFMFWBUJPOCFUXFFOQBSUTPGUIFDPVQMJOHNVTUCFUIFTBNFtFRVBM
pressure is necessary to ensure long service life of the coupling
Why?
t 1SPQFSDPVQMJOHBMJHONFOUJTWFSZJNQPSUBOUBTJUFYUFOETUIFTFSWJDFMJGFTJHOJDBOUMZ
t .JTBMJHONFOUMFBETUPVOOFDFTTBSZBOEQSFNBUVSFEBNBHFPGUIFDPVQMJOH

both sides on same level
same distance all

around
Connection adjustment check
t 5IFSFRVJSFEEJTUBODFTPGUIFDPVQMJOHFMFNFOUTBSFSFTQFDUFEFYBDUMZ
t *U JT WFSZ JNQPSUBOU UIBU UIF BMJHONFOU PG UIF DPOOFDUJPO JT EPOF DBSFGVMMZ PUIFSXJTF
the seal will soon be destroyed and has to be replaced more often o avoidable costs
Note:
EVERY INTERRUPTION OF THE OPERATION CAUSES A POWER OUTAGE FOR THE CONSUMERS
AND MEANS NO INCOME FOR THE MHP!

.PSFHSFBTFPOUIFPPSUIBOJOUIFCFBSJOH
t )BOEMFHSFBTFXJUIDBSF
t 1SFTTHSFBTFPOMZJOUIFOJQQMFTXIFSFJUJTOFFEFE
t $MFBOBMMFRVJQNFOUBOEPPSBGUFSHSFBTJOH
t ,FFQUIFPPSDMFBOBOEUJEZ
Why?
t 0/-:UIFNPWJOHQBSUTPGUIFFRVJQNFOUOFFEMVCSJDBUJPO
t (SFBTFPOUIFPPSJTBTFSJPVTSJTLGPSUIFPQFSBUPSBOEBOZCPEZFMTFJOUIFQPXFS
house oPPSTCFDPNFTMJQQFSZ
Note:
SLIPPERY POWERHOUSE HIGH RISK OF INJURIES!

When grease
appears - it is
greased enough
Grease properly applied
t "MMNPWJOHQBSUTPGBNBDIJOFOFFEHSFBTFGPSHPPEPQFSBUJPO
t "QQMZHSFBTFVOUJMJUTUBSUTUPPP[FPVUoUIFOJUJTFOPVHI
t $MFBOPTVSQMVTHSFBTF
t 1SFWFOUHSFBTZPPSToBMXBZTDMFBOVQBGUFSMVCSJDBUJOHNBDIJOFT
Note:
TOO MUCH GREASE CAN TEMPORARILY LEAD TO AN INCREASED BEARING

TEMPERATURE!
IT IS ADVISABLE TO GREASE CAREFULLY AND OBSERVE THE BEARING TEMPERATURES!

3.2.7 Tools and Spare Parts
Greasy spare parts
What a mess !
Spare parts and tools have to be cleaned and stored well organized
t 4UPSFTQBSFQBSUTJOBDBCJOFUPSUPPMCPYBOELFFQJUMPDLFE
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Why?
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t 5IFPQFSBUPSTIPVMELFFQBXSJUUFOJOWFOUPSZPGBMMUPPMTBOETQBSFQBSUT BOEVQEBUFJU
regularly
t 5IJTXJMMTBWFNPOFZCFDBVTFPOMZXIBUJTOFFEFEXJMMCFQVSDIBTFE
t 5IF DPOEJUJPO PG UIF UPPMT BOE TQBSF QBSUT TIPXT UIF RVBMJUZ PG UIF PQFSBUPS BOE IJT
work

Various wrenches
Screwdrivers
Pliers
Compartments for
small spare parts
Well stored tools always within easy reach
t 'PSGSFRVFOUXPSLUPPMTTIPVMECFXJUIJOFBTZSFBDIPGUIFPQFSBUPS
t 5PPMTBSFTUPSFEPOUIFUPPMCPBSETBOETIFMWFTBGUFSVTF
t 5IFUPPMCPBSETBOETIFMWFTBSFDMFBOoUIJTJTBMTPHPPEGPSBTBGFXPSLJOHFOWJSPONFOU
t 8PSLJTQSPCBCMFNPSFFOKPZBCMFXIFOUPPMTBSFBUIBOEBOEDMFBO

Proper tools & lubricants: essential for operation & maintenance

1 Electrical tools are essential for electrical maintenance

2 Various accessories for effective maintenance
3 Equipment for lubrication and grease must be available
4 Common electrical spare parts must be stocked
5 Common mechanical spare parts must also be stocked
Note:
KEEP TOOLS AND SPARE PARTS CLEAN AND COMPLETE ALL THE TIME!
GOOD TOOLS MAKE THE JOB EASY!
SPARE PARTS IN STOCK SHORTEN MAINTENANCE WORKS!
CHECK COMPLETENESS OF TOOLS AND SPARE PARTS AT LEAST AFTER EACH MAINTENANCE
ROUTINE!

Just any tree trunk

may not be strong
enough test it first!
Use snaplinks
instead of knots
Heavy and costly equipment must only be moved with a lot of care
t 6TFQSPQFSMJGUJOHFRVJQNFOU
t "MUFSOBUJWFMZ VTFBTVDJFOUMZTUSPOHUSFFUSVOL TUSVDUVSBMQJFDFPGXPPEPSTUFFM PSB
heavy steel pipe (but test it first for its strength)
t 6TFTOBQMJOLTJOTUFBEPGLOPUTCFDBVTFTOBQMJOLTEPOPUPQFOEVSJOHMJGUJOH
Why?
t )ZESPQPXFSFRVJQNFOUTJTDPTUMZBOEIBSEUPSFQMBDF
t *NQSPQFSMJGUJOHPGIFBWZFRVJQNFOUNBZQVUUIFXPSLUFBNBUSJTL
Note:
RISK OF INJURIES!

Wall-mounted type
of crane
Mobile crane for

larger equipment
Two types of lifting equipment for heavy loads in larger power houses
t 4USPOHMJGUJOHFRVJQNFOUJTFTTFOUJBMGPSCPUI JOTUBMMBUJPOBOENBJOUFOBODF
t 5IFNPWFNFOUBOEPSUSBOTQPSUPGIFBWZFRVJQNFOUNVTUCFEPOFXJUIBMPUPGDBSF
and with regard to all necessary safety procedures

Weak-looking
branches
Three tree trunks tied together as a tripod look rather weak
t 1SFGFSBCMZSFQMBDFUIJTLJOEPGUSJQPECZVTJOHTUFFMTFDUJPOTPSQJQFT
t *GJUDBOCFBPSEFEBOENBOBHFE VTFBDSBOF PSTJNJMBSFRVJQNFOU GPSNPWJOHIFBWZ
loads
t 6TFTOBQMJOLTJOTUFBEPGLOPUTGPSTBGFMJGUJOH
Why?
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damaged and hurt operator
Note:
RISK OF INJURY!

Tripod made of
steel Solid steel top
Strong chain and

hook
BUT: worker should also

wear safety shoes
Strong tripod used for lifting a heavy piece of equipment
t "TUFFMUSJQPE NFFUJOHBMMTBGFUZSFRVJSFNFOUT JODMVEJOHBTUSPOHTUFFMDIBJOBOEIPPL

is used for lifting and transport
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But:
t 5IFGFFUPGUIFXPSLFSBMTPOFFEQSPUFDUJPO

ISBN 978-979-8978-26-5
ISBN 978-979-8978-27-2 (Vol.1)
ASEAN-German Mini Hydro Project (AGMHP)

ASEAN Center for Energy
Jl. HR. Rasuna Said Blok X-2, Kav. 7 - 8, Kuningan
Jakarta - Indonesia

Good - and - Bad - of - Mini - Hydro - Power - Vol 1 PDF

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GOOD & BAD

ASEAN-German Mini Hydro Project

GOOD & BAD

Photos, drawings and graphics provided by:

Jl. HR. Rasuna Said, Blok X-2, Kav 7-8, Kuningan

First published by ACE in June 2009

i GOOD & BAD of Mini Hydro Power

3 ELECTRO-MECHANICAL EQUIPMENT 105

GOOD & BAD of Mini Hydro Power ii

4 TRANSMISSION & DISTRIBUTION 161

5 HOUSE INSTALLATION 181

6 MANAGEMENT AND ADMINISTRATION 201

7 UTILIZATION OF ENERGY 219

iii GOOD & BAD of Mini Hydro Power

Although MHP is a relatively mature and cost-competitive energy technology, a lot of

Nguyen Manh Hung Roman Ritter

GOOD & BAD of Mini Hydro Power iv

Nguyen Manh Hung

v GOOD & BAD of Mini Hydro Power

GOOD & BAD of Mini Hydro Power

1.2 RUN OF RIVER HYDRO POWER STATION

Typical example of a diversion type run-of-river hydropower plant

2 GOOD & BAD of Mini Hydro Power

CHOOSING INCORRECT PARAMETERS AND DEVELOPING THEREWITH A NON-OPTIMIZED

GOOD & BAD of Mini Hydro Power 3

1.3.1 Site Identification and Flow Measurement

The following information must be gathered:

Collect river/stream flow data

Hydrographs for a 16 year period

4 GOOD & BAD of Mini Hydro Power

Flow duration curve

GOOD & BAD of Mini Hydro Power 5

1.3.2 Rough Calculation of Possible Hydro and Electrical Power

2. How much head is available?

6 GOOD & BAD of Mini Hydro Power

So this MHP will generate almost 19 kW.

1.3.3 Estimate Electrical Load

1.3.4 How to Measure the River/Stream Flow

GOOD & BAD of Mini Hydro Power 7

THIS METHOD IS VERY ACCURATE IF YOU ARRIVE TO REALIZE SUCH AN INSTALLATION!

8 GOOD & BAD of Mini Hydro Power

GOOD & BAD of Mini Hydro Power 9

Current Meter Method (Velocity-Area Methods)

10 GOOD & BAD of Mini Hydro Power

Sharp Crested Weir Method

Why is this a good example?

GOOD & BAD of Mini Hydro Power 11

t "OZNBUFSJBMDBOCFVTFEGPSUIFXFJS CVUUIFOPUDITIPVMEIBWFTIBSQFEHFT NFUBMJT

12 GOOD & BAD of Mini Hydro Power

Salt Concentration Method

Distance: injection to gauging point

The figure shows intensity of conductivity

THIS METHOD OF MEASUREMENT CAN ONLY BE USED BY A TRAINED PERSON WITH

GOOD & BAD of Mini Hydro Power 13

1.3.5 Discharge Measurements and Flow Duration Curve

Staff gauge (cm)

Staff gauge for quick and easy water level reading

14 GOOD & BAD of Mini Hydro Power

1.3.6 Head Measurement

Schematic example of head measurement

GOOD & BAD of Mini Hydro Power 15

Head Measurement by Level

The principles of measurement by the levelling method