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International Journal of Applied Research ISSN 0973-4562 Volume 13, Number 5 (2018) pp. 9-14 © Research India Publications. http://www.ripublication.com Horizontal Axis Water : Generation and Optimization of Green

Disha R. Verma1 and Prof. Santosh D. Katkade2 1Undergraduate Student, 2Assistant Professor, Department of Mechanical Engineering, Sandip Institute of & Research Centre, Nashik, Maharashtra, (India) 1Corresponding author

energy requirements. Governments across the world have been Abstract creating awareness about harnessing green energy. The The paper describes the fabrication of a Transverse Horizontal HAWT is a wiser way to harness green energy from the water. Axis (THAWT). THAWT is a variant of The coastal areas like Maldives have also been successfully Darrieus Turbine. Horizontal Axis Water Turbine is a turbine started using more of the energy using such . The HAWT has been proved a boon for such a country which which harnesses electrical energy at the expense of water overwhelmingly depends upon fossil fuels for their . As the name suggests it has a horizontal axis of electrification. This technology has efficiently helped them to rotation. Due to this they can be installed directly inside the curb with various social and economic crisis [2]. The water body, beneath the flow. These turbines do not require complicated remote households and communities of Brazil any head and are also known as zero head or very low head have been electrified with these -kinetic projects, water turbines. This Project aims at the fabrication of such a where one unit can provide up to 2kW of electric [11]. Horizontal Axis Water Turbine and testing its electrical power Their governments also claim to have remarkable reduction in generation. The HAWT was manufactured using galvanized their recurrent costs. These turbines could be used in local iron blades of NACA 0018 hydrofoil blade profile. The actual river bodies and lakes wherever there is a good flow of water. performance of the turbine could be estimated in the However, these turbines are still in a developmental phase and laboratory testing. Hydro-kinetic energy has a very crucial task have not been fully commercialized yet, due to their lack of to perform in the near future as far as sustainable energy reliability and low power density [1]. Horizontal axis turbines have some beneficial features which make them more suitable harnessing is concerned. The need for harnessing more green than vertical axis turbines since they are easier self-starting, energy is need of the current era and the future decades to have less fluctuation, higher efficiency and larger speed come. operation. The performance of the hydro turbines depends is Keywords: Transverse Horizontal Axis Water Turbine, mainly influenced by the rotor. Secondarily it depends upon hydrofoil, kinetic energy, green energy, zero head, etc. the shaft, gear box, and the generator characteristics [6].

Introduction Transverse Horizontal Axis Water Turbine (THAWT) is a Literature review hydrokinetic turbine which has a close resemblance with wind Rajendra Prasad A. et al produced electrical power up to 160 turbines. They operate on the science based on producing watts using the developed turbine. Since the initial results are torque from water [6]. These on the principle of turning encouraging it was proposed to fabricate large diameter and directional power into rotational power by using a certain longer length turbines to harvest more power to make a green amount of surface area to come into contact with the fluid energy farm. Since stream flow velocities would be increased movement over a period of time in order to harness energy as by 3 to 4 times in shrouded turbines, it is proposed to develop much power as possible. ‘Horizontal Axis Water Turbine’ is a such turbines for future works to establish a green energy farm rotary having a horizontal axis of rotation used for at the site[1]. generation using the kinetic (flow) energy of R. A. McAdam et al demonstrated that in a series of scale water. Water Current Turbine (WCT), Ultra-low-head Hydro model experiments the truss variant of the THAWT produces Turbine, Free Flow/Stream Turbine, Zero Head power with a kinetic efficiency close to that of the conventional parallel- bladed device. Results show that both the parallel and truss-bladed devices are capable of producing Hydro Turbine or River In-stream Hydro Turbine are some power at efficiencies greater than the Lanchester-Betz limit other names used for this turbine [1]. [3]. Hydrokinetic energy refers to the energy generated from the M.J. Khan et al concluded that the Axial turbines are mostly moving water of the oceans currents, tidal, rivers and artificial being considered for placement at the bottom of a channel, water channels. The world is witnessing the depletion of the whereas vertical turbines are being designed for either floating fossil fuels on a rapid scale. These conventional sources of or near-surface mounting arrangements. In the presence of a energy have been fulfilling more than 80% of the world’s wide variety of terminologies attributed to the fundamental process of kinetic energy conversion from water streams, the

9 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 5 (2018) pp. 9-14 © Research India Publications. http://www.ripublication.com term ‘Hydrokinetic’ energy conversion can be used as long as the generator will indicate the electricity produced by the sufficient caveats are given for diverse fields of application mechanical work of the turbine. such as, rivers, artificial channels, tides, and marine currents 3. If we see a greater picture, the paper aims at reducing the [4]. use of non-renewable sources and finding an efficient way Kamal A. R. Ismail, et al in their paper, have proposed a cheap too harness green energy and contribute to good health of hydrokinetic turbine system whose blades are easy to design, the environment and the society at large. manufacture, replace when necessary and its operation is independent of the flow of direction. The effects of the number Construction of blades, blade profile and water flow velocity on the turbine torque and power coefficients were presented and discussed. Fozur blade profiles were investigated, that is, flat plate, circular arc, NACA 0018 and NACA 1548. CFD simulations showed that circular arc profiles are more efficient and produce more power [9]. Edwin Chica et al stated that the effect of the material and the blade structure shape on its structural behavior were presented and discussed. Safe working stresses and strains were identified and checked. There is a good comparison between the turbine design power and obtained from numerical simulation [13]. Figure 1: Constructional Details of HAWT Ridway Balaka et al stated that the selection of the blade number is very important aspect in design. This study deals The construction of a Horizontal Axis Water Turbine is easy. with the findings of effect of the blade number on the It is shown in the figure 1 above. The main component of the performance of the horizontal axis river turbine for low speed Horizontal Axis Water Turbine is the Rotor which is made of Condition. The high bladed turbines have the higher up six blades (even number is for balancing purpose) of performance than those with lower number. The high hydrofoil NACA 0018 mounted on the two endplates. There is performance of the high bladed turbine at a low rotation a frame to support the rotor assembly. There is a spur gear pair operation requires a high gearing ratio for the mechanical to increase the rotor output. The rotor is connected to the gear system [14]. pair by a shaft. The output velocity of the spur gear pair is then Himanshu Joshi et al concluded that to draw the attention to a fed to the output shaft and thereby connected to the generator new method of generation which doesn’t require or any other output measuring device. The figure 2 shows the construction of large and tunnels to store energy. The actual fabricated setup picture and table 1 shows the different turbine can be assembled vertically, horizontally or in any components, materials used and its fabrication details. other cross flow combination using a common shaft and generator for an array of multiple turbines. This helps in Table 1: Materials and Fabrication reducing the construction, expansion and maintenance costs Part Material Qty. Method of for any such power generating unit. The NACA 0018 Fabrication hydrofoil used as the blade profile is symmetric and has an 18% width-to-thickness ratio [15]. NACA Galvanized 6 General A. Rubio-Clemente et al stated that a horizontal axis 0018 Iron with Engineering hydrokinetic is designed and verified with the Hydrofoi protective Methods help of the momentum theory, the blade element momentum l Blade paint coating theory and numerical simulation. Focuses on the description of Shaft Mild Steel 2 General Purpose the steps involved in the design and numerical simulation of a Bright small horizontal axis hydrokinetic turbine rotor used [16]. Bearing Pedestal type 3 Purchased

readymade Problem statement 1. Various kinds of turbines which extract End Plate Mild Steel 2 General Purpose require a certain amount of head. machines 2. Also, they require large complicated arrangements and Spur Cast Iron 1 Milling process setup. Gear with a machine 3. The depleting quantity of fossil fuels and its continued usage Frame Mild Steel 1 Welding the is a great threat to the environment. structure

Objectives 1. The work is to fabricate a working Transverse Horizontal Axis Water Turbine. 2. Testing it for the shaft power it gives in terms of watts, the generator power in terms of voltage. Voltage produced by

10 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 5 (2018) pp. 9-14 © Research India Publications. http://www.ripublication.com

1. The of water is converted to kinetic energy when it flows through the river. 2. Kinetic energy of moving water is converted into rotational (mechanical) energy by a water turbine. 3. Rotating water turbine drives a generator that turns into electrical energy. Horizontal Axis Water Turbines are used in seas and oceans in a large scale, which are various HAWT units joined together. Single units can be used in local river bodies and rivers according to the geography of the river.

Components and description 1. Rotor The most vital component for harnessing energy in this system

is rotor. Rotor are responsible for converting kinetic energy of Figure 2: HAWT fabricated setup (Front view) water into rotational energy. The turbine used in this system is horizontal axis kinetic turbine. The rotor axis is orthogonal to Working the water flow but parallel to the water surface. This turbine A Turbine is basically a component design to convert kinetic consists of 6 number of hydrofoil shape blades. Blades were energy of water to rotational energy which in turn produces made of Standard hydrofoil shape of NACA0018 [13]. electricity. When water (fluid) strikes on the turbine blades, it Galvanized iron material is used for blades as it is cost pushes the blades and makes them rotate, harnessing kinetic effective and is light in weight. A non-corrosive enamel energy (energy of flow) and converting it into mechanical coating was given to the blades to prevent corrosion due to energy. More and more kinetic energy is harnessed if there is water. The blades are welded helically to end plates on either more pressure of the flow of water. side. Central shaft used is made with mild steel bright Kinetic energy of a mass in motions is given by, material. 1 E = m푣2 ------(1) 2

The power in the water is given by the rate of change of energy: 푑퐸 1 푑푚 P= = 푣2 -----(2) 푑푡 2 푑푡

As mass flow rate is given by:

푑푚 푑푥 푑푥 = ρA ------{ =푣} 푑푡 푑푡 푑푡 Figure 3: Fabricated Rotor we get, 푑푚 2. Gear pair = ρA푣 푑푡 The gear box used in setup is single stage gear box. The type of gear used is spur gear. The gear ratio between gear and Hence, from equation (2), the power can be defined as: pinion is 30:1[1]. The gear is in line with the central shaft of P= 1ρA푣3 the rotor. Pinion meshes with gear to transmit power to the 2 generator. Bearings are used to support shafts on both the The power captured by the rotor of the and the sides. The type of bearing used are pedestal type bearing. total power available is not the same That is why the coefficient of performance comes into picture, 1 3 Pavail= *ρ*A*푣 *Cp 2 where, Pavail =Power available ρ = Density of Water A= Swept Area= πdl V= Free stream velocity Cp= Coefficient of Performance Water carries a lot of energy even when it flows at low speed and is heavy thus, these turbines can also be relatively slow [6].

Hydroelectricity energy conversion can be well understood in Figure 4: Spur Gear Pair three simple steps.

11 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 5 (2018) pp. 9-14 © Research India Publications. http://www.ripublication.com

3. Frame high turbulence in the system. Hence, here we used 6 number The frame provides support for rotor and gear pair assembly. of blades for the turbine. Rotor and the spur gear pair are mounted on the frame. The The shape of the blade is the most major character which material used for the frame is mild steel. Different sections of influences on the turbine performance. Thus, we are used mild steel bars with trapezoidal cross-section are welded NACA0018 standard profile for turbine blades. This turbine together. There are mountings for rotor, gear pair and motor gives good performance in hydrokinetic turbine field and is each. It has a base and supports the rotor center shaft. Frame closely related to hydrofoil NACA0015 [31]. could be provided with hooks for holding purposes. [1] Specifications Table 2: Technical specifications for turbine rotor design Sr. Component Parameter Value No. 1 Fluid Density(Kg/m3) 997 Properties Kinematic 1.1 Viscosity (106m2s−1)

Mean 1-2.5 Figure 5: Supporting Frame Velocity(m/s) 2 Turbine No. of blade 6 Blade Hydrofoil Selection Diameter of 0.65 rotor(m) Length of 1 rotor(m) Hydrofoil Blade NACA0018 profile [13] Chord 0.012 Length(m) Aspect 8.33 Ratio(l/C) Angle of 10 attack(deg) Figure 6: NACA0018 Hydrofoil Blade profile

The most important thing is to choose the blade profile as it is the most crucial part of the whole system, after dimensioning Advantages of all components. The blades of a type device are of 1. Horizontal Axis Water Turbine does not require any hydrofoil shape and the rotor is moved due to the tangential HEAD. [1] forces induced in the blades. To optimize the performance of 2. HAWT is a self-cleaning machine that is it can clean the the turbine, we need to choose the number of blades debris which causes power loss like leaves, on its own. effectively. Number of blades influence the balancing of the 3. It is easier and self-starting. rotor. Turbine runs on a higher rpm with lesser number of 4. It has negligible torque fluctuation. blades, due to light weight. Also, large number of blades leads 5. HAWT has higher efficiency and larger speed operation. to the small chord length and low Reynolds number which is 6. It has a high-speed uniform spinning in relatively slow not good for turbine. Although, 2 to 6 blades can be used. To fluid flow (low pressure fluids). decide the shape of hydrofoil to be used as blade profile is 7. It has unidirectional rotation in reversible fluid currents. another very important task. The commonly used blade 8. No visible signs of in water for high rotating profiles in transverse horizontal axis turbines are: NACA speed [8]. 0012, NACA 0015, NACA 0018, and NACA 63-018 [13]. 9. It has a low price, and good regulation, these turbines are Water turbines have higher solidity than wind turbines and mostly used in mini and micro hydropower units of less solidity values may range from 0.15 to 1.6 [17]. Due to the than two thousand kW.[18] similar blade profiles of NACA0015 and NACA0018, the later 10. Under varying load, the horizontal axis water turbine has a one was used for the blades of this turbine. The maximum flat efficiency curve. Particularly with small run-of-the- efficiency is reached by high bladed turbines at a higher value river plants, the flat efficiency curve yields better annual than the value at which the maximum efficiency is achieved by performance than other turbine systems, as small rivers' the lower bladed turbines. In one of the researches, it is found water is usually lower in some months. that odd number of blades on the turbine is more efficient [20]. On the other side, a very large number of blades can produce

12 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 5 (2018) pp. 9-14 © Research India Publications. http://www.ripublication.com

Results A) Analytical Results 'Voltage shown on Multimeter' Vs 'Time' The analytical results for power output were obtained for two 13.4 different conditions: 13.2 1. Constant velocity (V= 2 m/s) 13 2. At optimum Tip Speed Ratio (TSR) and maximum 12.8 Coefficient of performance 12.6 12.4 1) Constant Velocity 12.2 Constant Values for Calculation 12 1. Area, A = πdl =2.04 m2 4.00pm 4.15pm 4.30pm 4.45pm 5.00pm 2. Density of Water (ρ)= 997kg/m3 The analytical results are calculated by the formula given Voltage by, 1 3* Figure 7: Graph of electrical voltage reading on multimeter Pavail= *ρ*A*푣 Cp 2 with respect to time (Voltage Vs Time) Where, Pavail =Power available 푣 = Free stream velocity The above graph 1 shows the relation between the voltage and Cp= Coefficient of Performance time. The voltage readings were taking for one hour and they were around 12.5 Volts which are shown in table 5.

Table 3: Power Output at Constant Velocity Blade Angular TSR Cp Power Conclusions Speed Velocity (W) A Horizontal Axis Water Turbine of diameter 650 mm and (rpm) (rad/s) length 1000 mm was fabricated using Galvanized Iron blades 20 2.1 0.682 0.03 244.06 of hydrofoil NACA 0018 Blade profile. IP class 65 generator, 40 4.2 1.36 0.12 976.26 Direct Drive, Rotary Flux 500-Watt Permanent Magnet 60 6.3 2.04 0.3 2440.6 Generator was used to demonstrate the electric power. The 80 8.4 2.73 0.13 157 experimental result was nearly 44% of the analytical ideal 100 10.47 3.4 0.31 630 results obtained. The project aimed at voltage generation 2) At optimum TSR and maximum Coefficient of helpful for the electrification. The large-scale production of performance such Horizontal Axis Turbines would give greater scope for it. Output can be increased by manufacturing these turbines with Table 4: Power Output at optimum TSR and larger dimensions. Two Phillips Compact Fluorescent Lamps maximum Coefficient of performance of 80W and 85W capacity were lit using the turbine power that is power up to 165 watts was produced using this fabricated Velocity Power Power O/P setup. The Horizontal Axis Water Turbines are really worked (m/s) (W) using upon in many parts across the globe because of its unique Efficiency advantages. However, due to the fewer past studies over river 0.5 40.67 14.23 applications, they lack the complete satisfaction of the 1 325.42 113.897 understanding of the required parameters as compared to 1.5 1098.2 384.37 Ocean based applications. The fabrication and usage of 2 2603.4 911.19 Horizontal Axis Water Turbines in rivers and local water 2.5 5084.68 1779.6 bodies, portraying on to a larger picture about this in the near future would prove to be a boon to the green energy farms and 1. TSR = 1.9 its special applications with multiple product variations. 2. Cp = 0.32[6]

B) Experimental Results References

Table 5: Multimeter readings in volts [1] Rajendra Prasad A, Krishnaraj S, Ramachandran S, Vasudevan N and Suresh S M. “An approach to Time Multimeter reading development to of green energy farm using horizontal (in volts) axis Water Turbine”, International Journal of Mechanical 4.00pm 12.52 Engineering and Technology (IJMET), Volume8, Issue7, 4.15pm 13.20 July2017. 4.30pm 12.82 [2] Van Alphen K, Kunz HS, Hekkert MP. “Policy measures 4.45pm 12.56 to promote the widespread utilization of renewable 5.00pm 12.45

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