Detailed Project Report

March 2002






Bilgaon Micro Hydro Power Project
Nandurbar District
Maharashtra



For
Peoples committee
Bilgaon&Maal
Narmada Valley

Bombay Sarvodaya
Friendship Centre
Mumbai
Prepared by
Peoples School of Energy
Alakode, Kannur
Kerala- 670571
Ph:0498-255154,255084

Contents

Preface
Acknowledgement
About the organization
Beginning of the survey
Components of a Micro Hydro Power Project
Geographical & Physiographical features of the area
Scio economic features
Salient features
Site survey
Hydrology & Energy availability
Demand forecasting
Techno ecnomic features
Benefits of the project
Execution of the project
Operation & maintenance
Administration
Detailed design
Detailed Estimation
Maps & Drawings




Preface
The concept of Sustainable Development relies heavily on judicious use of natural resources.
This in other words means maintaining the fragile balance between the resource use and exploitation.
But to strike the balance is rather a difficult task, threshold into consideration, for excessive demands
are made on limited resources. The causes and effects of environmental problem arising from an
imbalanced approach and inappropriate technology such as large macro hydro project are complex,
interlocked and unmeasured. The impacts - frequently synergistic in nature - could sometimes be
irreversible. However, the only solution to these problems is to minimise the impacts: smaller the
project, lesser the impact. This is where Micro Hydro Projects play an important role. They rarely
cause any environmental damage.

Our rulers have so far only tried to build mega projects, which are costly, submerging and
destroying thousands of hectares of forest and agricultural lands with construction activities going on
for several years and decades. There are on going projects continuing with construction actives for
more than 20 years to the half way abandoned ones. The time has come to rethink on these mega
projects which have been going for the last 54years.We have tried to evolve small and decentralised
energy production distribution systems which causes minimum environmental and social impacts.
Our evolution into this understanding was based on the realisation that, the concept, method and the
way of the development model follows so far can not carry the society forward along a sustainable
path, any longer. All the developmental planning targeted towards centralised systems whether in a
capitalistic or communist social settings.
A century has passed witnessing the degradation of our fertile soil, water and biodiversity and
the climate change essential for the life sustaining process. The developmental activities based on
multi crore, technology dependent mega industrial projects poses threat to the very existence of life
forms on the earth. It is this realisation that prompts us to think about the urgent need to initiative
sustainable developmental alternatives instead of the continuing destructive developmental models.
We can only find solutions to the complex energy crisis existing today by adapting agricultural
systems and life styles capable of reconstructing our degraded organic ecosystems. Hence, micro
hydro is a life style and not consumeristic.

Although development of a Micro Hydro Project in Bilgaon was inspired by the Narmada
Bachao Andolan, the benefits of such a venture goes a long way not only in liberating the people of
Bilgaon area from 'darkness', but also in minimising the negative impact upon the local environment.
The development of a technologically, economically and financially viable Micro Hydro System in
Bilgaon - was made possible by adapting Micro Hydro Technology from other Asian countries (such
as Nepal), which was improvised by People School of Energy to suit the local conditions.






Acknowledgement
We express our sincere gratitude to individuals and organizations for helping us to make this
report. The collective desire of the people in Bilgaon and Maal villages for electric power resulted in
assessing and evaluating the potentials, problems, capabilities and demand of the community and its
resources during Aug2000 to March 2002 and hence this report.
The authors of this report PSE expresses gratitude for the sincere and warm support received
from the activists of NBA viz. Pravin, Chambalal, Chokalal, Chetan,Sobha, Sukumar, Jogini, Julab
singh Pavara, Suklal, Phthe Singh, Veer Singh,etc. Ravi and Aravinda from AID India and Daniel from
BSFC.We express our heartful gratitude to Shri. Jeshbhai Patel, Smt. Medha Patkar and Prof
.S.Soundranayakam, IISc, Baglore ,for their constant inspiration and timely advice and above all to the
people of the Bilgaon and Maal villages.

About the Organisation
Peoples School of Energy
Objectives
1. To propagate among the public the energy related knowledge systems.
2. To equip people to assess the activities and projects of any agency related to energy.
3. To evolve decentralized energy programmes to help the decentralized political process.
4. To co ordinate the present energy studies, activities and analyse the energy relations of
development.
5. To take up Micro Hydro Power Projects and give technical training for its regular functioning.
6. To publish News letters, phamlets, mazines and books related to energy.

Activities
1. Ashan kavala Miro Hydro project (1kW) for an individual completed in 1997,Kannur
dist.Kerala.
2. Pathanpara Micro Hydro Project (4 kW), in Kannur Dist. Kerala, a community project with
complete peoples participation and investment for the first time in Kerala, benefiting 80
families, completed in 1997.
3. Eruvatty Micro Hydro Project (3kW) in Kannur Dist. Related with peoples planning process
using government money ,completed in 1998, benefiting 27 families.
4. Domkhedi Micro Hydro Project ( 300 W ) in the Narmada valley, Maharashtra completed in
2000, benefiting 8 tribal families going to be submerged in the ongoing Sardar Sarovar Project.
5. Malur Micro Hydro Project( 6 kW) in Kannur Dist. With Peoples Planning Process completed
in March 2002, benefiting 45 families.
6. Conducted an Independent Study on the Proposed Athirappilly Hydro Electric Project
(163 MW) in the Chalakudy River, Kerala, 2001.
7. Conducted an Independent Assessment of the Problems associated with Kavarakundu Micro
Hydro Project (Implementing agency IRTC-Technical Wing of Kerala Sastra Sahithya
Parishat) in Malampuzha grama panchayath, Plalakkad dist. Kerala,2002
Beginning of the survey
We were first invited by the people of Bilgaon (by seeing the success of Domkhedi Micro
Hydro Project) to discuss the possibility of a Micro Hydro Project in their village on September 2000.
we went to the village and met few persons from the local area and decided to conduct a formal
meeting to discuss about the feasibility of the project. The people themselves initiated to conduct the
meeting in the same evening. The meeting decided to conduct a feasibility survey in the next day itself.
The survey itself lasted 3days and an average number of 10 volunteers participated in each day. The
flow, head, distance to each pada were taken.
During December 2000,we submitted a preliminary feasibility report. During our visit in
August 2001 people from the adjoining village (Maal) also showed their interest to join the project.
The villagers asked us to prepare a detailed project report covering all the related aspects of the project.
So we decided to conduct a detailed survey during the first week of March .the survey lasted unto the
last week of March 2002 and hence this report.


Components of a Micro Hydro Power Project
In general, the larger the scale of a system, the more the number of components. The basic
components can be briefly described:
Intake: This is where the water from the river/spring is diverted from its main course. Generally a
weir is used to divert water through an opening in the riverside (the intake opening) into an open
channel.
Head race channel: leads the water from the intake to the head of the penstock.
Desilting basin : This is a small tank designed to desilt the water.
Forebay Tank: Water from the headrace flows to this tank at the head of the penstock. Here it
collects and serves as a buffer to control sudden flow and pressure variations. The tank should be
designed to hold the volume of water needed to operate the turbine-generator for the number of
hours the system will be operating. Measures such as trash rake/wire mesh are needed to prevent
silt, leaves and other debris from entering the pipeline.
Penstock: This is the pipeline supplying water from the forebay to the turbine. It should be well
supported every 20 feet for Mild Steel / Cast Iron Pipes or be buried under a thin layer of soil to
protect it from physical damage and also from chemical action of sunlight on some materials like
PVC etc.
Turbine: This is the mechanical device that rotates when driven by water issuing from pipes.
There are several kinds of turbines that can be used, e.g. Pelton wheel, cross flow turbines, pumps
as turbines and standard reaction turbines. Each kind of site is suited to a particular kind of turbine.
Therefore the choice of turbine is site-specific.
Generator: Electricity is generated when the turbine drives the generator. There are basically two
kinds of generators that can be used for AC power. Regular Synchronous Generators are the
simplest option, but in the lower ranges of power (<10kW) it may be difficult to source them. In
this case, three phase induction motors can be used in reverse as generators with the help of a
capacitor bank.
Governor: This device ensures that the generator is not affected when the load on it changes. It can
be hydraulic, in which case the flow of water is regulated when the load changes; or electronic, in
which case ballast or dump load is activated when the load changes. The type of governor used
depends on the generator. In electronic control, the synchronous generator requires an Electronic
Load Controller (ELC) whereas with an induction generator, Induction Generator Controller (IGC)
is required. When this equipment is not used, effectively the load on the machine cannot be
changed, which means that all appliances must be kept on for the entire time and switched off only
when the system is shut down. The other option is to manually control the flow so that the voltage
and frequency are kept constant when the load is changed.
Distribution System: The electricity generated in the power house is supplied to the house holds
through local grids. This consists of weather proof Aluminium cables as conductors and locally
available wooden poles as electric posts.
Geographical & physiographical features of the area
The project area consists of Bilgaon and Maal villages of Dadgaon tehsil Nandurbar district,
Maharashtra. The nearest all weather road reaches upto Dhadgaon which is 60 km north of
Akkalkuwa. There is a seasonal road reaches upto Bilgaon, which is 18 km north of Dhadgaon. The
Maal village is about 3km west of Bilgaon.
The project area lies in the Central Highlands, which are the northern extention of peninsular
plateau. Between latitude 21and 24 degrees N , a series of mountain ranges run aligned west east
across the plateau. The main range is Satpuras, extending as the Mahadev Hills and Maikala ranges to
the Chotanagpur plateau. The Satpuras are about 900 km long with an elevation between 500 and
1000m and consists of several ranges, the name signifying Sapt (seven) Pura(folds). To the north of
Satpuras are the Vindyas, traversing nearly the entire peninsula for about 1,050 km with an average
elevation of 300 m asl. The scared river Narmada flows in between Satpura and Vindya ranges. The
Central Highlands separate the Indo-gangetic plains from the peninsular plateau.
The project area lies in the northern slope of the sixth fold of the Satpura range called as
Thoranmaal mountains. The Udai river on which the proposed project is planned Joins the Narmada at
Bushagaon. The Thoranmaal range divides the Narmada and Tapi river drainage basins. The towns
Akkalkuwa, Thaloda, Shahada are all in the southern slope of the Thoranmaal mountains and lies in
the Tapi river basin.
Scio economic features
The Bilgaon and Maal villages of Dhadgoan tehsil belongs to Adivasi settlements. They
belongs to Powra tribal community . Their langague is powari in devnagari script. They are
relatively autonomous and fully dependent on agriculture for their livelihood. They have been
cultivating the valley and the banks of the Narmada for time immemorial, living along with the forest.
Devising their own technologies and equipments, seeds and manure, they have been growing all the
necessary grains, pulses, vegetables, and allied crops complemented by the shrubs , fruits ,fishes and
meat from the forest and river. The forest has been fulfilling 75-85% of the needs of the people
regarding fodder, fuel, fruits, building materials, logs and so on. The major crops of the area are Jovar,
Bajra and Mucca.
The tribes have their own social, cultural and political norms and systems, their own languages,
their own mythology. Women in these tribal communities are relatively high status, more freedom and
decision making power than in the rural or urban societies. The women participate equally in economic
activities and have the same status as men in marriage, inheritance and other cultural practices
Salient features

Name of the project : Bilgaon Micro Hydro Power Project
Name of the stream : Udai river
Location
Village : Bilgaon
Tehsil : Dhadgaon
District : Nandurbar
State : Maharashtra
Watershed particulars
Topo sheet No. : 46 K/ 5
Latitude : 21 45 - 22 N
Longitude : 74 15 -74 30 E
Elevation above msl : 158 m
Average annual rainfall : 600 mm
Watershed area of the stream : 50 sq.km

Accessibility
There are seasonal roads upto Bilgaon which is 18 km north of Dhadgaon . Geeps are playing in
between these places. The nearest railway station is at Nandurbar and is 60 km from Dhadgaon. There
are buses from Akkalkuwa and Shahada and will take 2 and 3 hours respectively to reach Dhadgaon.

Electrical Power output : 15 KW
Head : 8 m
Design flow : 390 liters per second
Water intake : Udai River, above Bardhariya water fall in Satpura
Ranges

Beneficiaries : At least 306 unelectrified Adivasi households in Bilgaon &
Maal villages plus one residential school holding 300
Students.
Site Survey

The availability of head, identification of suitable locations for water intake, forebay tank and
power house and measurement of flow in the stream were carried out in the site survey in September
2000 and 2002, an anticipation of flow was also made in consultation with local people and assessed
the flow in the stream by area - velocity method and bucket method. The entire area was scouted by the
team and the distribution network were finalized.

Hydrology & Energy availability

The entire catchment area of sq.km receives an average annual rainfall of 600mm . the Udai
river originates from the Thoranmaal mountains has a sq. km. of this ---sq.km. consists of dry
deciduous forest and the rest as cultivated area. From the starting point to the project site the stream
traverse --- km. The breadth of the stream at the project site is 90m . The maximum Flood discharge
through the stream will be 260 cu.m /sec (Aug-Sep) . The least flow will be 0.02 cu.m/sec (May June
).the depth of water varies from 3m to 0.3m .

Stream flow particulars & power generation profile
Months Anticipated
Minimum flow
Litres/sec (lps)
Remarks Possible
generation
(15kW) per day
Possible Power
generation per
month
kWh(units)
January 180 11hrs 3960
February 80 4 hrs 54 mins 2058
March *40 2 hrs 27 mins 1029
April 30 1 hr 50 mins 825
May 20 1 hr 13 mins 565
June15 20 1 hr 13 mins 547
July,
August,
September
October
*600 lps Amble water is
available
24hrs 11160
11160
10800
11160
November 550 24hrs 10800
December 400 24hrs 11160
Total - 75224units
Flow measured in 5
th
September2000 - 745 lps
Flow measured in 16
th
march 2002 - 40 lps

Flow requirement for Power



Demand forcasting
The electricity demand of the area was assessed by conducting a meeting in the village itself.
A simultaneous maximum demand of 12 kW is anticipated. Considering the future demands,
maximum power generations fixed to be 15 kW. To meet the excess power requirement for summer
months (March, April, May and up to June15) a diesel engine (15kW) can also be provided.
Power 15 kW 10 kW 5 kW
Flow
requirement
390 lps 254 lps 130 lps
Technical features

Civil
Gross head : 8 m
Design flow : 390 lps
Electrical power output : 15 kW
Type of system : Run-off the river
Intake : Weir
Length = 90m Height = 2.0 m
Top width = 1.0m Bottom width = 1.5m
Diversion system : Concrete channel
Length = 66 m bed width = 1 m
Height = 0.65m bed slop = 1 in 714
Forebay : concrete tank holding 20,000 liters
Penstock : Material Mild Steel
Diameter =400mm Thickness = 8mm
Length = 18 m
Power house : Surface, 8m x 5m x 3m.
Mechanical
Turbine : 19 kW mechanical output cross flow Turbine

Electrical
Generator : 19 kVA, 3 phase, 50 Hz, synchronous Generator.
Control panel : Distribution bus bar, switch gears, meters & indicators.
Safety measurements : Three phase electronic load governor, over voltage & short
circuit protection system.
Distribution network : Through local grids using weather proof cables and locally
available wooden poles.
Area of supply : 15 sq. km
Maximum feeder length : 4 km
Energy and cost
Annual energy production : 40,000 units
Load factor : 0.6
Plant factor : 0.4
Cost of production : 6,00,000
Cost of production /kW : 40,000
Operation &Maintenance cost :
Unit energy cost :
Cost of distribution : 4,00,000
Diesel Engine (15kW) : 50,000
Total project cost : 10,50,000
Execution of the project

The execution of the project should be through the direct responsibilities of the beneficiaries.

Operation and Maintenance
The O&M is the responsibility of the beneficiaries.

Benefits of Bilgaon 15 kW Micro Hydro Project

1. Lighting

It can provide electric light to 161 houses in Bilgaon and 145 houses in Maal village. The school and
other public utilities in the village can also be provided with electricity.

2. Irrigation

Irrigation can be made to atleast 20 hectares of land on the vicinity of the project site. The people of
other places can also use electric pumps to irrigate atleast 80 hacters in a restricted manner to ensure
that adverse effects will not be created to the ecology and sociology of the society.


3. Drinking Water

Fetching drinking water from the rivers is a laborious job of the village women. The project can
provide drinking water to the hamlets in the vicinity of the project site. This will relieve the work load
of the village women a lot.

4. Grinding Unit

Much physical labour of the women is being put into use to grind the foodgrains by traditional
methods. The diesel units are only accessible to the wealth due to exorbitant rates. So one or two
community controlled grinding units can be stated in the village which will in turn reduce the work
load of the women-fold in addition to financial benefits.

5. Oil Extracting Unit

One or two oil extracting units can be started with the electricity generated from the project. Oil
extraction is a very difficult task in the village now.

6. Community Recreation Centres

One or two community recreation centres having facilities like radio, TV, etc. can be started with the
electricity.

7. Employment Opportunities

Direct employment opportunities as detailed below will be generated by the project.

a. Operators to operate the systems - 2 nos
b. Maintaining staff to maintain the lines and wires - 2 nos
c. Office staff to collect charges and keep accounts - 2 nos
d. Grinding Units - 2 nos
e. Oil extraction units - 2 nos

Total - 10 nos

Administrative Plan of the Project

The decision making body of the project (General council) will include 161 households in
Bilgaon and 145 households in Maal village,one representative of Ashramschool in Bilgaon, and two
or three representatives of the project implementation agency (PIA).

Three different committees to handle Technical, Financial and Administrative aspects of the
project is needed. The formation and representation to these committees can be made as follows:

Total houses (306) in the two Bilgaon and Maal village can be divided into clusters of 10
houses each(Pada). Four member from each village is selected to the committees making the total
strength of each committee 9. In addition to the 31 elected members one member from PIA should be
there in each committee making the strength 32.

Nine elected members and the representative of the PIA from each committee will form the
executive body of the project. The number of members will be so. From the executive body office
bearers of the project can be selected, if needed.

To settle the issues which may cause a division in the society, an elders council can be formed.
The elders council will comprise of village elders, members of the local bodies and the representative
of the PIA, nominated for the purpose. The number of members in the elders council can be fixed as
15. The decision of the elders council will be final in all disputes.

A graphical representation of the administrative structure is as follows:































Technical
Committee
5++ +1 P!A

Administrative
Committee
5++ +1 P!A
Financial
Committee
5++ +1 P!A
Executive
Committee
9 + 3 P!A
One representative
from one Pada
(10 Households)
cost estimate

Weir & intake - 1,00,000
Channel & forebay - 50,000
Anchor blocks - 20,000
Power house - 20,000
Penstock - 1,20,000
Turbine - 85,000
Generator - 50,000
Control Panel - 60,000
Design & supervision - 25,000
Installation charges - 25,000
Distribution (approx.) - 4,00,000
Transportation - 20,000
Overheads - 25,000
Diesel Engine (15kW) - 50,000
Total - 10,50,000 ( Ten Lakh fifty thousand rupees only)


Share by the beneficiaries:
Labour manual and skilled total by the villagers and volunteers.
Part contribution to capital cost by the Ashram school
Periodic contribution for tear and wear, receiving cost per family to be decided.
Management of the project and regular maintenance voluntary work by the peoples
committee.





















Bilgaon Micro Hydro Power Project
Detailed Project Design
BILGAON MICRO HYDRO POWER PROJECT


Maximum power generated = 15 KW
Power out put = Efficiency x g x Net head x flow
P
o
= x g x H
net
x Q
The flow required to produce the required power Q = P
o
/ x g x H
net


Where H
net
= Net static head = 8 m

= Overall efficiency = 50%

g = acceleration due to gravity = 9.81 m/sec
2

Q = flow in m
3
/sec

P
o
= power out put in KW

Q = 15x 10
3
/ 0.50 x 9.81 x 8 = 382.26 lps


So the entire civil works should be designed to carry the required flow
(ie 390lps).

Design of intake

Considering entrance losses and trash rack losses, the intake should be designed to carry a flow
of 780 lps.

Effective head from the centre line of intake = h
e
= 0.5m.
Velocity of water flow through intake = V =c
d
2gh
e


= 0.6 2 x 9.81 x 0.5
= 1.88 m / sec
Where c
d
= Coefficient of discharge = 0.6
Design flow through intake = 0.08m
3
/ Sec
Area of cross section of the intake = Q / V = 0.78 / 1.88
= 0.414 m
2


Length and height of the intake = 0.65 m x 0.65 m > 0.414 m
2


Therefore provide a square intake with length and height 0.65m each. The quantity of water
flowing through the intake can be regulated by gate opening.

Design of weir

The forces acting on a weir built on a impervious foundation may be static or dynamic.

Static forces
1. Normal water pressure on the upstream face of the weir.
2. Normal water pressure on the downstream face of the weir.
3. The weight of the water supported by the crest and the weight of the weir.
Dynamic forces
1. Erosive or the scouring forces on the downstream side of the weir produced either by high
velocity or by the impact of water pouring over the weir.
2. The force of impact of floating matter against the crest on the upstream side of the weir.
Conditions for stability of weirs

1. There must be no tension in the masonry or in the contact plane between weir and the
foundation.
2. There must be no overturning.
3. There must be no tendency to slide on the joint with the foundation or any horizontal plane
above the base.
4. The maximum toe and heel pressures in foundations should not exceed the prescribed safe
limits.

Failure by crushing is not considered here, as it generally does not occur, being a low structure.

Condition of maximum stress on weir

In the case of a dam the condition for maximum stress is when the water level above the base is
maximum. i.e. when the head is maximum. But in case of a weir, when the discharge increases the near
water level also builds up and the difference between them will become less and less. So, the weir is
subjected to maximum head when the water level on the upstream side is maximum and no water
passes over the crest..
Design of Channel

Design discharge of the channel Q = 390 lps
Length of the channel L = 65 m
Cross sectional area of the channel A = Q / V = 0.39 / 1.0
= 0.39 m
2

V = max. velocity permissible through the channel = 1.0 m/s

Cross sectional dimensions of the channel

From economic consideration
Top width T = 2d
Area A = T x d = 2d
2


Depth d = 0.39/2 = 0.44 m

Provide a free board of 15cm
Total depth D = 0.60 m
Base width B = 0.44 x 2 = 0.88 m ~ 0.9 m
Hydraulic radius R = wetted area = A/P = 0.90 x 0.45
wetted perimeter 0.90 + 0.45 x 2
= 0.225

Channel bed slope S = nv
2
R
2/3


= 0.015 x 1.0
2
= 0.00164
(0.225)
2/3


Head loss = Channel bed slope x Length of the channel
= 0.00164x 65 = 0.11m



0.2 0.80m 0.2



0.60 m



.05 6mm 300 mm c/c

3, 8mm 200 mm c/c

1.30 m



Design of settling tank

Rated flow through the channel (Q) = 390 lps
For low head power plants
d
limit
= 0.2 to 0.5mm
Select d
limit
= 0.2mm

In practice for a limited grain size of 0.2mm, a flow velocity of 0.2 m/s has proved to be
suitable
V
d
= 0.2 m/s

Determination of sand trap dimensions

Length of the sand trap
L = V
d
. h .
V
s
0.04 V
d

Where V
s
= sinking velocity = 0.028
h = settling depth = 0.5 m
L = 0.2 x 0.50 = 5m
0.028 0.04 x 0.2
Width of sand trap

B = Q . t
d

L.h
Where Q = discharge in m
3
/sec = 0.39 m
3
/sec
t
d
= time of passage (sec) = L = 5.0 /0.2 = 25 sec
V
d

Width of the sand trap B = 0.39 x 25 = 3.90 m
5 x 0.5

Collection tank capacity

The depth of the collection tank is specified on the basis of a reasonable emptying frequency.
After periods of heavy rainfall when the silt load (or turbidity) is a maximum, a reasonable emptying
frequency might be up to twice daily.
Consider the water caries a severe silt load of 0.5 kg/m
3
If 100% of the silt is deposited in the
collection tank then.

Rate of silt deposited = silt load x rated flow through the canal
= 0.5 x 0.39
= 0.195 kg/s
Silt deposited in 12 hours = 12 x 3600 x 0.195
= 8424 kg

Taking the density of sand as 2600 kg/m
3
and estimating the packing density of the deposit as
50% then.
Volume of silt deposited = 8424 / 0.5 x 2600
= 6.48 m
3

Depth of the collection tank = Volume / Area
= 6.48 / 5 x 3.9
= 0.33m
Provide depth of the collection tank as 0.35m

In order to achieve uniform approach of water over the whole chamber width the transition
section is to be designed according to the condition

Transition length l = B-B 1/3 L
2 tan
= 3.90 0.90 = 1.5 m < 1/3 L =1.67 m
2 tan 45
0






45
0
45
0


0.90m 3.90 m 0.90 m





1.50 m 5m 1.50 m





0.45 m
0.5 m



0.35 m
Design of flood spillway

The flood spillway can be sized on the basis of the head race water depth of 0.45 m. at normal
flows. The height of the spillway crest (h spillway) should be aligned to the normal flow surface level
or water depth.
h spillway = h
h
(normal) = 0.45 m.

The spillway length (L spill way) is found from the standard weir equation. It must be long
enough to pass the spill flow (Q spill) with the available excess head of water behind it. The spillway
length is not found from crest flood conditions but from miner floods. When the head race flow has
only risen by 15 % above its normal value.

Standard weir equation (Q) = C
w
x L
weir
(h
over top
)
1.5


In this case
Q
spill
= Q
minorflood
Q
gross
= C
w
x L
spillway
x (h
minor flood
h
spillway
)
1.5

Adopt a value for weir coefficient for spillway of (C
w
=1.6)

L
spillway
= (Q
minor flood
Q
gross
)/ 1.6 (h
minor flood
h
spillway
)
1.5


For a minor flood flow of 15% above normal flow.
Q
minor flood
= 1.15 x Q
gross
= 1.15 x 0.39= 0.45 m
3
/Sec.
If we assume that the minor flood water travels at the same velocity as normal flows, the water
depth for this increased flow will also be increased by the same ratio.
h
minor flood
= 1.15 x h
spillway
= 1.15 x 0.45 = 0.52 m.
L
spillway
= (0.45 0.39) / 1.6 (0.52 0.45)
1.5
= 0.54 m.

Design of penstock
Material of the penstock Mild steel

Length of penstock (Lp) = 18 m
Flow through the penstock pipe Q
p
= 390 lps
Gross head (Hg) = 9 m
Pipe inner diameter D
i
= 400 mm
Thickness of the Pipe t = 8 mm
Equivalent sand grain roughness K
s
= 0.02mm
Young's modulus of elasticity E = 2.1 x 10
10
kg/m
2
Bulk modulus of elasticity of water K= 2.14 x 10
8
kg/m
2

No. of bends = 2
Angle of bends = 20
0
, 45
0


Hydraulic Design

Area of cross section of the pipe Ap = ( / 4) D
i

2

= ( / 4) x ( 0. 4)
2

= 0.126 m
2

Velocity of the flow through the pipe V
p
= Qp / Ap
= 0.39 / 0.126
= 3.09 m / sec
Reynolds number Re = Vp D
i
x 10
6

= 3.09 x 0.4 x 10
6
= 1.24 x 10
6

Relative roughness K
r
= K
s
/ D
i

0.02 / 400 = 0.00005

Friction factor from moody's chart f = 0.011
Head loss due to friction H
f
= fL 0.083 Q
2
D
i

5


= 0.011x 18 x 0.083 x ( 0.39)
2
(0.4)
5

= 0.244 m
Considering 2 bends 45
0
, 20
0
, entrance losses and valve losses
H
turbulence
= K V
2
/ 2g
H
turbulence
= ( 0.23 + 0.15 + 0.8 + 0.14) 3.09
2

2 x 9.81
= 0.64 m
Total head loss H
loss
= H
f
+ H
turbulence

= 0.24+ 0.64 = 0.88m
Net head H
net
= Hg - H
loss
= 9 0.88 = 8.12 m
Structural design

Minimum thickness of pipe (Di in cm) = t mini = 10 (Di + 50) / 400

= 10 (40 + 50)
400
= 2.25 mm

Corrosion allowance C
a
= 1.5 mm
Effective thickness of pipe t
e
= t C
a

= 8 1.5
= 6.5 mm > 2.25 mm

Surge wave velocity C = 1 / sqrt [(Pw/g) (1/K + Di /E x t
e
)]

= 1 / sqrt [(1000 / 9.81) (1 / 2.14 x 10
8
+ 400 / 2.1 x 10
10
x 6.5)]

= 1125.09 m/sec.

H
surge
= CV
p
/ g = 1125.09 x 3.09 / 9.81
= 354.38 m
H
max
= H
g
+ H
surge
= 9 + 354.38
= 363.38 m

Hoop stress = 0.1 x H
max
x D
i

2 x t
e


= 0.1 x 363.38 x 400
2 x 6.5
= 1118.11 kgf / cm
2


< 1.5 yield stress i.e. 1500 Kgf/ cm
2
hence safe

SUMMARY
MATERIAL OF PENSTOCK = MILD STEEL
OUTSIDE PIPE DIAMETER = 400 mm
WALL THICKNESS = 8 mm
INTERNAL DIAMETER = 416 mm









Strengths, weakness and Threat analysis
Strengths
v The concerned people have got the history of taking spontaneous collective action for common
needs.
v Moderately educated, skilled and motivated human power available from the project area.
v All the materials are procured and processed within India, from reputed manufacturers.
v The environmental impact of the project will be minimal.

Weaknesses

v Lack of awareness/information about the technology and its potential among concerned officials and
politicians.
v The incapacity of the public and others to have an in-depth and comprehensive vision about the
project.
v The nature of technology, which is only getting matured.

Opportunities

v The value addition possible on farm products.
v Promotion of small-scale industries.
v Mechanizations of artisans work.
v The protection of agriculture from wild animals.
v The irrigation potential of the water released from the powerhouse
v Environmental issues reach the people from an abstract form to a hard reality which makes it possible
to start real soil water conservation measures, since the streams are becoming very critical for the
community.
v Whole village is becoming energy sufficient using renewal energy source.