FACULTY OF TECHNOLOGY DEPARTMENT OF MECHANICAL ENGINEERING FINAL YEAR PROJECT PROJECT TITLE: Design and Simulation of a Wind-Solar Hybrid

Energy System for Water pumping NAME: ONGIN TONNY NAME: AKIROR LOUISA PENINAH REG. NO: 07/U/500 REG. NO: 07/U/482 STUD NO.:207000246 STUD. NO: 207000264 _______________________ ____________________________ Students signature Students signature

MAIN SUPERVISOR DR. KARIKO BUHWEZI ___________________ SIGNATURE

CO-SUPERVISOR MR. PAUL I. MUSASIZI ______________________ SIGNATURE

Declaration We dedicate that the work presented in this thesis is authentic and original. Th is report has never been submitted in this university for any award or publicati on. Signed ________________________ __________________________________________ Ongin Tonny Akiror Louisa Peninah We the supervisors have approved this dissertation. It meets the examiners requir ement for the award of the degree of Bachelors of Science degree in Mechanical E ngineering of Makerere University. Supervisor Co-Supervisor ________________________ ________________________________ __ Dr. Bernard Kariko-Buhwezi Mr. Paul I. Musasizi Dedication We dedicate this report to our parents and siblings for their enormous support t hroughout our lives. Acknowledgement I would like to acknowledge the Almighty God for giving us the strength and abil ity to carry out this project. In addition, I would like to acknowledge the marvelous contribution made by the Italian Co-operation towards this research by availing us with the simulation so ftware that was a prerequisite for the successful completion of this research. Special thanks go to our supervisor Dr. Kariko B. Buhwezi for the advice and dir ection offered to me during this research I would also like to extend our many thanks to Mr. Paul Isaac Musasizi for the a cademic and professional guidance offered to me during the entire research perio d spanning two years. Table of Contents Declaration i Dedication ii Acknowledgement iii

Table of Contents iv Table of figures viii Abstract x CHAPTER ONE: INTRODUCTION 1 1.1 Background 1 1.2 Problem statement 2 1.3 Objectives of the project 3 1.3.1 Overall objective: 3 1.3.2 Specific objectives: 3 1.4 Justification 3 1.5 Scope 4 1.6 Expected Long term and Short term results 4 1.6.1 Short term results 4 1.6.2 Long term results 5 1.7 Beneficiaries 5 CHAPTER TWO: LITERATURE REVIEW 6 2.1 Wind Energy Systems 6 2.1.1 Wind Turbine Types and Benefits 6 2.1.2 Wind Turbine Basics 6 2.1.3 Use of Wind Turbines 6 2.1.4 Types of Wind Generators 6 2.15 Wind mill versus wind turbine 7 2.1.6 Benefits of Wind Energy 7 2.1.7 Basic WIND calculations. 8 2.1.8 Blades 8 2.1.9 Increase in the number of blades 9 2.1.10 Increase in height and its effect on Power 2.1.11 Wind Turbine Controls 12 2.1.12 State Machine Model 13 2.2 Solar System Sizing 14 2.2.0 Introduction 14 2.2.1 Major System components 14 2.2.2 Solar PV System sizing 17 2.2.3 Estimating System Output 19 2.3 Hybrid 21 2.3.0 Introduction 21 2.3.1 Solar 21 2.3.2 Wind 21 2.3.3 Inverters and Charge Controllers 22 2.3.4 How Hybrid Solar-Wind Energy works? 22 2.3.5 Connecting the two together 23 2.4 Choice of Site 24 CHAPTER THREE: METHODOLOGY 26 3.0 Introduction 26 3.1 Literature Review 26 3.2 Data Collection 26 3.3 Needs Assessment 27 3.4 Data Analysis 27 3.5 Design Methodology 27 3.5.1 Design methodology followed 27 3.5.2 Process steps: 28 3.5.3 Object Oriented Design 30 3.6 Calculations on the System 30 3.7 CAD Drawings and Simulation 30 3.8 Conclusion and Recommendations 30 3.9 Report and Presentation 30 CHAPTER FOUR: DESIGN AND SIMULATION 31 4.0 Introduction 31 4.1 Investigation of failure of the current system 4.1.1 Review of the current solar PV system 32

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4.1.2 Review of current wind turbine design 36 4.1.3 Possible causes of failure of current system and suggested solutions 37 4.2 Design and simulation of a better wind Turbine 38 4.2.1Solid Edge models of the wind Turbine 38 4.2.2 Simulation of Turbine with SolidWorks 41 4.2.3 Blade Simulation Report 42 4.2.4 Guy pole Segment Simulation Report 47 4.2.5 SolidWorks FloXpress Report 51 4.2.6 Calculating the new height of the tower: 53 4.2.7 Blade Size Considerations 53 4.2.8 Blade diameter 54 4.2.9 Effect of Air density on the Power achievable 54 4.2.10 Mathematical simulation of the Turbine 55 4.2.11 Wind Turbine controls 56 4.2.12 Summary of the design 62 4.3 Design and selection of a suitable Solar PV system 63 4.3.1 New Solar PV system sizing 63 4.3.2 Inverter sizing 64 4.3.3 Battery sizing 64 4.3.4 Solar charge controller sizing 65 4.3.5 Summary of the design 65 4.4 Sizing and selection of a suitable pump 66 4.4.1 Determining flow rate 67 4.4.2 Determine the static head 67 4.4.3 Determining head losses 67 4.4.3 Determining total head 70 4.4.4 Pump selection 71 4.4.5 Summary of Pump sizing 72 4.5 Site Evaluation 73 4.6 Trnsys model of the Hybrid system 74 CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS 75 5.1 Product Description 75 5.2 Summary of results 75 5.3 Statement of modifications, changes and additions 77 5.4 Challenges and limitations 77 5.5 Research contributions 77 5.6 Cost Implications 78 5.7 Conclusion 80 5.8 Recommendations: 80 References 82 Appendix A: Data from Nakasongola 83 Appendix B: Model: H3.1-1000w 85 Appendix B II : New Wind Model 86 Appendix C: Pipe size selection depending on litres produced 87 Appendix D: Pipe specifications (source: DAVIS &SHIRTLIFF Product & Design Manua l 2011 88 Appendix E: Moody chart (Fluid Mechanics by Douglas 2004) 88

Table of figures Figure 1-Picture of the water catchment areas in Nakasongola Figure 2-Decibel Chart 4 Figure 3:Tip Speed Ratio Vs Power Coefficient 10 Figure 5-Selection graph for one, two and three blades 10 Figure 6- Wind Turbine Control diagram 12 Figure 7-solar panels atop a roof 21 Figure 8-Wind turbine 21 Figure 9-Table showing Summary of the Methodology 31

Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure

10-Guy Tower Sub-Assembly 38 11-Tail Wing Sub-Assembly 38 12-Rotor Blade Sub-Assembly (Front) 38 13-Rotor Blade Sub-Assembly (Side) 38 14-Yaw Sub-Assembly 40 15-Wind Turbine Assembly with wind tunnel 40 16-Screenshot of rotor blade showing stress 44 17-Screenshot of rotor blade showing displacement 18-Screenshot of rotor blade showing deformation 45 19-Screenshot of rotor blade showing Factor of Safety 20-Screenshot of tower piece showing stress 49 21-Screenshot of tower piece showing displacement 22-Screenshot of tower piece showing deformation 50 23-Screenshot of tower piece showing Factor of Safety 24-Diagram of Wind Turbine Control 56 25-Response Graph of the Wind Power Model 57 26-Response Graph of Pitch Model 58 27- Response Graph of the Generator Drive Train Model 28-Response Graph of the Speed Control Model 61 29-Bode plot of the Speed Control model 62 30: Pumping system layout 66 31-Summary table for the selected pipe 68 32-Head Vs Flow 71 33-NPSH and ETA% Vs Flow rate 71 34 Trnsys model showing a merged system 74

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Abstract The research undertook to develop design specifications for a solar-wind hybrid energy system to be used for pumping water at low and intermittent speeds throug h simulation. The wind speed regime at Nakasongola was studied and the wind characteristics (s peeds) important to the development of the specifications established. The Rever se Engineering Design methodology was adapted to develop models for simulation e ntwined with Object Oriented Design Simulations were done using SolidWorks to test for the rotor parameters that giv e the best performance at low wind speeds. These simulations included a fluid an alysis which simulated the behavior of the wind around the rotor blades and a st atic stress analysis which was done from the blade and tower segment. Specificat ions for the rotor size and tower height were also generated. A new solar system was developed from these simulations and the new specificatio ns. However, the specifications made can also be adapted for other areas with simila r wind regimes. CHAPTER ONE: INTRODUCTION 1.1 Background The hybrid energy system is the integration of two or more energy production sys tems in order to increase on the reliability and efficiency, for example; wind a nd solar energy systems. Windmills are machines designed to convert wind energy into mechanical energy using rotating blades or sails. They were first built to automate the task of grinding grain and pumping water for irrigation, domestic u se and for livestock. It is from technology that a wind turbine was developed to convert the kinetic energy of the wind, first into mechanical energy then to El ectricity (www.westaustrianvista.com). The solar energy represents the entire el ectromagnetic radiation (visible light, infrared, ultraviolet, x-rays, and radio waves) that strikes the earth which can be converted into usable energy. There is not much in use of wind turbines in Uganda compared to the solar energy system yet they could be a solution to the unreliable supply of power to delive r both piped and natural water for domestic, irrigation and livestock farming. In a few cases where they have been put up, they are either inefficient in opera

tion or fail to work completely from the time of erection. A typical example is of a wind turbine on a farm in Nakasongola that was installed to pump water for livestock and failed to work. Failures of such windmills can be attributed to po or and rudimentary design practices that could have compromised some of the desi gn factors. These two energy systems can naturally work together as the solar hours are usua lly from around 8:00 to 17:00 where as good winds are usually from around 14:00 to 19:00 and morning hours from 9:00 to 12:00. The integration of these two syst ems into a hybrid system could provide the best way to harvest significant amoun t of energy from the natural sources especially in rural areas where national gr id is a dream, with no major impact on the environment. It is within this background that a research program was instituted in January 2 007 funded by the Italian co-operation aimed at availing solar-wind energy techn ology as an alternative solution to power shortage to the local farmers to pump water. If well developed, this technology will go a long way to curb the acute p roblem of insufficient and unreliable supply of electricity even to urban areas by utilizing the abundant solar and wind energy resources. Research was therefor e commenced in 2007/08 to design a rotor that can work effectively in regions wi th low and irregular winds, a typical scenario with Uganda, but no proper design optimization has yet been achieved (Victoria Njuki,2008;Festo Lubwama,2009). Th is project sought to come up with better design optimization for a hybrid wind-s olar energy system that can work in the Ugandan condition. 1.2 Problem statement As a result of the increasing number of farm animals and coupled with the limite d access to clean water and lack of energy to pump water from underground, a win d turbine and 5 solar panels were set up to pump water for farm animals with hel p from the Italian co-operation. However, on erection of the system early 2009 t he wind turbine tower collapsed and one of the three blades broke while the sola r unit remained working but the output from the pump was too little compared to the design capacity (450l/hr compared to 1800l/hr). According to the researchers recent visit to the site; the wind turbine was erect ed but hardly turns, there is no improvement in pump performance as the solar un it seemed to be producing less power than required to run the pump to full capac ity, or probably a faulty operation exist in the pumping unit, therefore the pro blem of water shortage and insufficient energy are still major issues which need to be addressed. Figure 1-Picture of the water catchment areas in Nakasongola This project is therefore motivated by the need to investigate the causes of the continued poor performance of the current systems and to develop a simulated mo del of a reliable hybrid solar-wind energy system that can work well in the loca l conditions, and provide enough energy that can run the pump to supply the desi gned capacity of water for domestic use and possibly provide light at the farm i n the night. 1.3 Objectives of the project 1.3.1 Overall objective: The main objective was to determine the best practice parameters for the solar-w ind hybrid system for the water pump being used. 1.3.2 Specific objectives: The specific objectives were; 1. To investigate the cause(s) of failure of the system in Nakasongola and mitigation. 2. To model and simulate a wind turbine 3. To design and size a solar energy system 4. To size and specify a suitable submersible pump 5. To merge the three systems and come up with a virtual prototype of the h ybrid energy system.

1.4 Justification With the simulation done, clear specifications are provided so that an appropria te wind turbine can be manufactured and installed. The simulation model, with slight modifications, may be adapted for sites other than Nakasongola. Local manufacturers of wind turbines will have clear specifications and so be ab le to contribute to the provision of indigenous wind turbines in the local marke ts. Imported wind turbines are very expensive costing between $10,000 and $15,000 ea ch for a turbine of 3m to 5m rotor diameter. They are efficient elsewhere but on ce installed in Uganda they fail deliver. The local ones such as those made from Namalere cost about $5,000 but have high failure rates especially for the rotor s. Hence this design once adopted will serve to solve some of these problems. The study shall also be a benchmark for further studies in the design and simula tion of zero-carbon electricity in Uganda for both scholarly and commercial grou nds. Documentation shall be done which will fuel the growth of academic expertis e and knowledge in this field. 1.5 Scope This project involved investigation into the failure of current system, design, modeling and simulation of the solar-wind hybrid energy system and subsequently specify an appropriate pump for the system using data from Nakasongola. 1.6 Expected Long term and Short term results 1.6.1 Short term results An efficient and reliable source of clean water Improvement of livestock health and milk production Improved income of the farm owner(s) This investment will have a negative effect(s) on the environment such as; Noise from the wind turbine Figure 2-Decibel Chart At 250 metres, it produces 54dBs and increases with reduction in distance. The wind turbine blades can kill birds flying around it. 1.6.2 Long term results Increased access to clean water Increases accessibility of clean water to meet the need of local communities of the area at reduced costs compared to the national grid and the thermal energy s ystems. Reduces local air pollution The use of hybrid solar-wind electric systems decreases the amount of local air pollution. With a decrease in the amount of diesel generators, there is a corres ponding reduction in the amount of local pollution produced. Off-sets greenhouse gases wind and Photovoltaic systems produce electric power with no carbon dioxide (CO2 ) emissions. Carbon emission offset is calculated at approximately 6 tons of CO2 over the twenty-year life of one PV system. Conserves energy wind and solar electricity for the Third World is an effective energy conservati on program because it conserves costly conventional power for wealthy areas, lea ving decentralized PV- wind generated power to pump water and serve lighting and basic electrical needs of the majority of the developing Uganda s rural populat ions. Reduces need for dry-cell battery disposal when this hybrid wind-solar energy system is successful, the use of Small dry-ce ll batteries for flashlights and radios will reduce. 1.7 Beneficiaries Villages that experience problems with water pumping for lack of a energy source Academic world The authors of this project

Uganda at large CHAPTER TWO: LITERATURE REVIEW 2.1 Wind Energy Systems 2.1.1 Wind Turbine Types and Benefits With good, consistent wind flow, wind energy is one of the most economical forms of alternative energy available today. If your wind flow fluctuates, wind turb ines can still be an excellent addition to a solar system, providing more consis tent year-round power. Advances in wind turbine technology have focused on impro ving the efficiency of the components and reducing the number of moving parts, r esulting in very reliable and effective turbine designs. Today, wind turbines ar e an essential part of a reliable renewable energy system 2.1.2 Wind Turbine Basics Essentially, a wind turbine (or wind generator) is an alternator attached to a p ropeller. When the wind blows, the propeller turns and the alternator begin prod ucing electricity. The design details that determine which turbines are best sui ted for various wind speeds get more involved, but all wind turbines operate in the same manner. 2.1.3 Use of Wind Turbines Installing a wind turbine is a bit more involved than installing solar panels, b ut they are still relatively easy to incorporate into your alternative energy sy stem. The turbine needs to be mounted in an area free from obstructions to wind flow (nearby buildings, trees, etc.). As a general rule however, the higher in the air you can get your wind turbine t he more effective it will be, so independent, guyed towers are the recommended m ounting system. The wide variety of available tower heights and styles makes it much more likely you will find a mounting kit to suit your needs. 2.1.4 Types of Wind Generators Wind turbines come in a range of output voltages, to match the overall voltage o f your electrical system. While 12 volt is common for small to mid-sized systems , large systems can be designed in 24 or 48 volt configurations. 2.15 Wind mill versus wind turbine Wind Turbines types: - Small (50-400W) turbines, Large (900W+) Turbines and High Voltage Turbines The primary consideration in a wind generator is the average wind speed at the i nstallation site. A different turbine will give optimum performance at a site wi th average wind speeds below 15mph than one at a site with speeds in the low 20m ph range. Generally, low speed generators will either have longer rotor blades o r a larger number of short, wide blades to maximize power drawn from minimal win d. High speed generators may be built of more durable material, and will have na rrow, relatively short blades to minimize potential rotor damage in extremely hi gh winds. Before choosing which type of turbine is best for a particular site, wind speed measurement should be taken for a full year. This is advantageous in that one ca n know the average amount to generate in a particular year since wind/ wind spee ds vary according to the different months. With long term wind measurements an a ccurate average wind speed can be calculated, as well as determining likely maxi mum wind speeds. Armed with this information, a turbine can be chosen that will maximize performance at the average wind speed, as well as one that will withsta nd the likely maximum forces. 2.1.6 Benefits of Wind Energy Like solar power, a wind energy system is an entirely clean source of power. The only potentially hazardous materials involved are the storage batteries. Wind t urbines produce no emissions, use no traditional fuel, and can provide reliable year-round power given the right location. Wind generators require relatively little maintenance, but it is recommended tha t the generator receives annual visual check-ups to ensure the propeller blades haven t been damaged. If the turbine is located in a good spot it s very unlikel

y to be damaged by any flying debris, but a chipped or cracked blade can be a ha zard should it break completely, and a chipped or damaged blade will also negati vely affect the turbine s performance. Wind power can be a wonderful source of power during low-light rainy and cloudy months and even year-round, depending on the site. They can also be configured t o power dedicated water pumping systems, which may be of particular interest to individuals currently without running water. 2.1.7 Basic WIND calculations. Because air has mass and it moves to form wind, it has kinetic energy. Since Energy = Power X Time is a more convenient way to express the mass of flowing air, the kinetic energy equation can be converted into a flow equation: Power in the area swept by the wind turbine rotor: P = 0.5 x x A x V3 whe e: P = powe in watts (746 watts = 1 hp) (1,000 watts = 1 kilowatt) = ai density (about 1.225 kg/m3 at sea level, less highe up) A = oto swept a ea, exposed to the wind (m2) V = wind speed in mete s/sec (20 mph = 9 m/s) (mph/2.24 = m/s) This yields the powe in a f ee flowing st eam of wind. Of cou se, it is impossi ble to ext act all the powe f om the wind because some flow must be maintained th ough the oto 2.1.8 Blades Wind tu bine blades a e being manufactu ed using polyme mat ix composite mate i als (PMCs), in a combination of monolithic (single skin) and sandwich st uctu es . A sandwich st uctu e is a special fo m of laminated composite mate ial compose d of two thin, stiff and st ong face sheets (PMCs in this context) sepa ated by a elatively thick, compliant and lightweight co e mate ial. The esulting assem bly p ovides a st uctu al element with ve y high bending stiffness, st ength and buckling esistance as well as ve y low weight. Todays wind tu bine designs a e mainly based on glass fib e einfo ced composites (GFRPs), but fo ve y la ge blades ca bon fib e einfo ced composites (CFRPs) a e being int oduced in addition to GFRP by seve al manufactu e s in o de to ed uce the weight. 2.1.9 Inc ease in the numbe of blades The majo facto s involved in deciding the numbe of blades includes: 1. the effect on powe coefficient; 2. the design TSR (tip-speed atio); 3. The means of yawing ate to educe the gy oscopic fatigue. When designing numbe of blade, the numbe of blades chosen influence the ae ody namic pe fo mance like coefficient of pe fo mances. Mode n wind tu bines a e neithe built with many oto blades no with ve y wide blades even though tu bines with high solidity (defined as the atio between th e actual blade a eas to the swept a ea of a oto ) have the advantage of enablin g the oto to sta t otating easily because mo e oto a ea inte acts with the wind initially. Since, ou cu ent goal is to conve t the wind ene gy into elect icity, oto s w ill not benefit with high solidity because it is neithe cost effective no effi cient. The numbe of the blades of a tu bine has g eat impact on its pe fo mance . The pictu e below shown COPs between 3,6, and 12 blades with same solidity and s ame speed 5 m/s, f om this pictu e we can concludes that 3 blade have the most e fficient numbe of blades, as we know almost 70% mode n wind tu bine use 3 blade s. Figu e 3:Tip Speed Ratio Vs Powe Coefficient

To calculate Cp (COP) f om equation One, two o th ee blades Figu e 4-Selection g aph fo one, two and th ee blades Pictu e above shown that th ee blades tu bine is mo e efficient to p oduce ene g y, two blades machine tu bine need mo e speed to p oduce ene gy that same with t h ee blades machine tu bine, anothe way to inc ease efficiency is inc ease cho d of blade, two bladed machine with 50 % inc eased cho d have simila efficiency with th ee blade system although not same. 2.1.10 Inc ease in height and its effect on Powe The height of the towe impacts the powe you can ext act f om the wind. The hig he the towe , the less the g ound effects and f iction f om the ea th expe ienc ed by the wind flow. The two most impo tant conside ations in planning the towe height fo a wind tu bine a e avoidance of tu bulent ai flow p oduced nea g ound level by the ou ghness of the te ain ove which the wind flows, and avoidance of excessive g o und d ag which lowe s wind velocity nea the g ound and seve ely est icts the p e fo mance of a wind tu bine. Wind speed inc eases with height. This effect is often efe ed to by the 1/7th law. The exponent is app oximated by 1/7. The fo mula to dete mine the effect of Towe height on wind flow is: Wind Speed Velocity (m/s) = The 1/7th powe law thus implies that doubling the altitude may inc ease wind sp eed by 20% to 60%. And also ecall Betz s law states that the ene gy content of the wind va ies with the cube of the ave age wind speed i.e. doubling wind speed would inc ease the ene gy 8 times. Hence the towe height is c ucial. HINT: If you wind site ave age wind speed is not high enough, then inc ease you towe height until the minimum wind speed is eached. Use this equation to sol ve fo the new towe height that would be equi ed. This equation equi es you h ave a known wind speed at some height Ho. H will be the te m fo you new towe he ight.

2.1.11 Wind Tu bine Cont ols Figu e 5- Wind Tu bine Cont ol diag am These explo e the fundamental concepts and cont ol methods/techniques fo wind t u bine cont ol systems. Wind tu bine cont ol is necessa y to ensu e low maintena nce costs and efficient pe fo mance. The cont ol system also gua antees safe ope ation, optimizes powe output, and ensu es long st uctu al life. Tu bine otati onal speed and the gene ato speed a e two key a eas that you must cont ol fo p owe limitation and optimization. The following models can be gene ated fo the tu bine cont ol; Wind Powe Model Pitch Model: Gene ato D ive T ain Model: Speed Cont ol Model State Machine Model 2.1.12 State Machine Model The open-loop cont ol of the wind tu bine contains diffe ent states, fault handl ing, and b aking p ocedu es. Fo modeling and simulating ene gy captu e and swit ching behavio of the system, only the ve states feathe ed, spinning, un-up, pa t-load, and full-load, and thei t ansitions need to be conside ed. The following desc iptions give a sho t ove view of these ve states.

1) State Feathe ed: The tu bine is stopped due to a fault, manual stop, o calm. The oto blades a e in feathe ed pitch position. If the wind is st ong enough, the e will be a state t ansition to the spinning mode. 2) State Spinning: The oto blades a e in xed-spinning position. The oto and g ene ato spin at diffe ent speeds depending on the wind speed. If wind is availa ble in the allowable ange fo load ope ation, the e will be a state t ansition to un-up. 3) State Run-Up: The oto is accele ated th ough speed cont ol, adjusting the b lades towa ds the minimum blade angle. If the speed has eached the cut-in speed and the e is enough powe in the wind, the tu bine switches to the g id. 4) State Pa t-Load: Once switched to the g id, speed cont ol is done by the to que cont olle following the cont ol law p esented in Section II-B. If wind spee d dec eases and the gene ato acts as moto fo too long, the tu bine would cutout off the g id. 5) State Full-Load: At highe wind speeds, the pitch cont olle becomes active i n addition to the to que cont olle to limit the powe . 2.2 Sola System Sizing 2.2.0 Int oduction Sola photovoltaic system o sola powe system is one of enewable ene gy syste m which uses PV modules to conve t sunlight into elect icity. The elect icity ge ne ated can be sto ed o used di ectly, fed back into g id line o combined with one o mo e othe elect icity gene ato s o mo e enewable ene gy sou ce. Sola PV system is ve y eliable and clean sou ce of elect icity that can suit a wide ange of applications such as esidence, indust y, ag icultu e, livestock, etc.

2.2.1 Majo System components Sola PV system includes diffe ent components that should be selected acco ding to you system type, site location and applications. The majo components fo so la PV system a e sola cha ge cont olle , inve te , batte y bank, auxilia y ene gy sou ces and loads (appliances). PV modules Elect icity is gene ated by sola cells. Individual sola cells a e g ouped tog ethe into a sola panel o module. Then seve al sola modules a e g ouped togethe to fo m a PV a ay. Sola cha ge cont olle Regulates the voltage and cu ent coming f om the PV panels going to batte y and p events batte y ove cha ging and p olongs the batte y life. Wo king and the need fo a sola cha ge cont olle Sola cha ge cont olle s a e an essential element to any sola elect ic panel sy stem. At a most basic level cha ge cont olle s p event batte ies f om being ove cha ged and p event the batte ies f om discha ging th ough the sola panel a ay at night. A cha ge cont olle is an essential pa t of nea ly all powe systems that cha ge batte ies, whethe the powe sou ce is PV, wind, hyd o, fuel, o utility g id. Its pu pose is to keep you batte ies p ope ly fed and safe fo the long te m. Cha ge Cont olle Types Cha ge cont ols come in all shapes, sizes, featu es, and p ice anges. They ang e f om the small 4.5 amp cont ol, up to the 60 to 80 amp MPPT p og ammable cont olle s with compute inte face. Often, if cu ents ove 60 amps a e equi ed, tw o o mo e 40 to 80 amp units a e wi ed in pa allel. The most common cont ols use d fo all batte y based systems a e in the 4 to 60 amp ange, but some of the ne w MPPT cont ols such as the Outback Powe FlexMax go up to 80 amps. Cha ge cont ols come in 3 gene al types (with some ove lap): Simple 1 o 2 stage cont ols which ely on elays o shunt t ansisto s to cont o l the voltage in one o two steps. These essentially just sho t o disconnect th e sola panel when a ce tain voltage is eached. Fo all p actical pu poses thes e a e dinosau s, but you still see a few on old systems. Thei only eal claim t o fame is thei eliability - they have so few components, the e is not much to b eak.

3-stage and/o PWM such Mo ningsta , Xant ex, Blue Sky, Steca, and many othe s. These a e p etty much the indust y standa d now, but you will occasionally still see some of the olde shunt/ elay types a ound, such as in the ve y cheap syste ms offe ed by discounte s and mass ma kete s. Maximum powe point t acking (MPPT), such as those made by Xant ex, Outback Powe , Mo ningsta and othe s. These a e the ultimate in cont olle s, with p ices to match - but with efficiencies in the 94% to 98% ange, they can save conside ab le money on la ge systems since they p ovide 15 to 30% mo e powe to the batte y. Fo mo e info mation, see ou a ticle on MPPT. The Basic Functions of a Cont olle Cha ge cont olle s block eve se cu ent -Blocking Reve se Cu ent Photovoltaic panels wo k by pumping cu ent th ough you batte y bank in one di ection. At night, the panels may pass a bit of cu ent in the eve se di ection, causing a slight discha ge f om the batte y. The potential loss is mino , but i t is easy to p event In most cont olle s, cha ge cu ent passes th ough a semiconducto (a t ansisto ) which acts like a valve to cont ol the cu ent. It is called a "semiconducto " because it passes cu ent only in one di ection. It p events eve se cu ent wi thout any ext a effo t o cost. And in some cont olle s, an elect omagnetic coi l opens and closes a mechanical switch. This is called a elay. The elay switch es off at night, to block eve se cu ent. Cha ge cont olle s p event batte y ove cha ge- P eventing Ove cha ge When a batte y eaches full cha ge, it can no longe sto e incoming ene gy. If e ne gy continues to be applied at the full ate, the batte y voltage gets too hig h. Wate sepa ates into hyd ogen and oxygen and bubbles out apidly. The e is ex cessive loss of wate , and a chance that the gases can ignite and cause a small explosion. The batte y will also deg ade apidly and may possibly ove heat. Exce ssive voltage can also st ess you loads o cause you inve te to shut off. P eventing ove cha ge is done by educing the flow of ene gy to the batte y when the batte y eaches a specific voltage. When the voltage d ops due to lowe sun intensity o an inc ease in elect ical usage, the cont olle again allows the m aximum possible cha ge. This is called "voltage egulating." It is the most esse ntial function of all cha ge cont olle s. Some cont olle s egulate the flow of ene gy to the batte y by switching the cu ent fully on o fully off. This is ca lled "on/off cont ol." Othe s educe the cu ent g adually. This is called "puls e width modulation" (PWM). Both methods wo k well when set p ope ly fo you typ e of batte y. A good cha ge cont olle is not expensive in elation to the total cost of a pow e system. Inve te Powe p oduced by the PV a ay is di ect cu ent, o DC powe . That powe needs to be conve ted to alte nating cu ent, o AC powe , befo e it can be connected to the g id o load. The inve te is the hea t of the system and is esponsible fo pe fo ming this conve sion safely and efficiently. The Utility Mete The utility mete tells you how much powe is being gene ated, used and its supp ly. The mete t acks the amount of each. Batte y Sto es ene gy fo supplying to elect ical appliances when the e is a demand. The batte y type ecommended fo use in sola PV system is deep cycle batte y. D eep cycle batte y is specifically designed to be discha ged to low ene gy level and apid echa ged o cycled cha ged and discha ged day afte day fo yea s Batte ies a e an integ al pa t of any automotive, RV, ma ine o home powe elect ical system. A sto age batte y bank is what enables a powe system to delive a constant leve l of powe to the elect ical system. Without sto age batte ies, the enti e elect ical system would be limited by the immediate output of the alte native ene gy gene ato s. At night, a sola - un pump would have no elect ical powe available to un. A wind-powe ed system would be subject to constant powe fluctuations as the wind speed inc eased, d opped o disappea ed enti ely.

Steps in PV sizing Calculate the daily load ene gy demand in watt-hou s pe day fo each appliance used The daily load ene gy demand is the amount of ene gy equi ed each day to powe the load. Powe f om a ay This is the atio of the ene gy equi ed to sunshine du ation pe day Batte y sizing The batte y should be la ge enough to sto e sufficient ene gy to ope ate the app liances at night and cloudy days. To find out the size of batte y, calculate as follows: Calculate total watt-hou s pe day used by appliances Divide the total watt-hou s pe day used by 0.8 (given efficiency) fo batte y l oss Divide the answe obtained in item by the no mal batte y voltage (eg. 12v) Multiply the answe obtained by days of autonomy Sola A ay design and sizing Once the pump powe consumption was known, the co esponding sola ating was al so known; sola system design involved the following activities dete mination of the daily amp-hou equi ements obtaining the peak sun hou s of the p oject a ea sola a ay sizing sola batte y bank sizing etc Sola cha ge cont olle sizing The sola cha ge cont olle is typically ated against Ampe age and Voltage capa cities. Select the sola cha ge cont olle to match the voltage of PV a ay and batte ies and then identify which type of sola cha ge cont olle is ight fo y

By unning the output of enewable powe gene ato s th ough cha ge cont olle s a nd into a batte y bank, powe can be available 24 hou s a day, ega dless of wea the . Sola panels o wind gene ato s can delive powe to the batte y bank ega dless of cu ent powe usage, so excess powe can be sto ed du ing low use time s (gene ally the middle of the day and middle of the night) and be available du ing high use times (usually mo ning and evening). Batte ies supply DC powe , so if powe is needed fo an AC powe system o a mix ed AC/DC system, the batte y powe will need to be un th ough an inve te to ch ange 12VDC o 24VDC powe into VAC cu ent. Batte y Cha ging & Maintenance In an alte native ene gy system, batte y cha ging is usually accomplished th oug h cha ge cont olle s attached to the va ious powe gene ato s. A good quality ch a ge cont olle will use a th ee stage, pulse width modulated cha ging system. T his allows the batte y to eceive the highest cha ging cu ent du ing the bulk s tage of cha ging, with a second lowe abso ption level to b ing the cha ge to ma ximum voltage, and a thi d "float" cha ging cu ent to maintain the batte y cha ge. A good quality cha ge cont olle will maximize cha ging efficiency and minim ize lead sulfate build up, inc easing the batte y s useable lifespan. Lead acid batte ies will lose thei cha ge if they a e left unused fo an extend ed pe iod of time. Sola panels a e available fo this pu pose, and will delive a low level of cu ent to the batte y while exposed to sunlight. Fo batte ies o vehicles sto ed indoo s, plug-in cha ge maintaine s a e also available. Load Elect ical appliances that connected to sola PV system such as lights, compute , pump, etc. Auxilia y ene gy sou ces Diesel gene ato o othe enewable ene gy sou ces 2.2.2 Sola PV System sizing The design of a PV system usually sta ts with the anticipated load. The load and the pe iod in use, meteo ological conditions and equi ed availability dete min e the size of all components. So the fi st step is to find out the total powe a nd ene gy consumption of all loads that need to be supplied by the sola PV.

ou application. Make su e that sola cha ge cont olle has enough capacity to h andle the cu ent f om PV a ay. Fo the se ies cha ge cont olle type, the sizing of cont olle depends on the t otal PV input cu ent which is delive ed to the cont olle and also depends on P V panel configu ation (se ies o pa allel configu ation). Acco ding to standa d p actice, the sizing of sola cha ge cont olle is to take the sho t ci cuit cu ent (Isc) of the PV a ay, and multiply it by 1.3 2.2.3 Estimating System Output PV systems p oduce powe in p opo tion to the intensity of sunlight st iking the sola a ay su face. The intensity of light on a su face va ies th oughout a da y, as well as day to day, so the actual output of a sola powe system can va y substantial. The e a e othe facto s that affect the output of a sola powe sys tem. These facto s need to be unde stood so that the expectations of ove all system o utput and economic benefits unde va iable weathe conditions ove time a e eal istic. Facto s Affecting Output A. Standa d Test Conditions Sola modules p oduce dc elect icity. The dc output of sola modules is ated by manufactu e s unde Standa d Test Conditions (STC). These conditions a e easily ec eated in a facto y, and allow fo consistent compa isons of p oducts, but n eed to be modified to estimate output unde common outdoo ope ating conditions. STC conditions a e: sola cell tempe atu e = 25 oC; sola i adiance (intensity) = 1000 W/m2 (often efe ed to as peak sunlight int ensity, compa able to clea summe noon time intensity); sola spect um as filte ed by passing th ough 1.5 thickness of atmosphe e (ASTM Standa d Spect um). The efo e the pa ticula sola module output ated at 120 Watts of powe unde S TC, this module will often have a p oduction tole ance of +/-5% of the ating, w hich means that the module can p oduce 114 Watts and still be called a 120Wpmodul e. To be conse vative, it is best to use the low end of the powe output spect um as a sta ting point (114 Watts fo a 120Wp module). B. Tempe atu e Module output powe educes as module tempe atu e inc eases. When ope ating on a oof, a sola module will heat up substantially, eaching inne tempe atu es of 50-75 oC. Fo c ystalline modules, a typical tempe atu e eduction facto ecom mended by the CEC is 89% o 0.89. So the 120Wp module will typically ope ate at about 101.46 Watts (114 Watts x 0. 89 = 101.46 Watts) in the middle of a day, unde full sunlight conditions. C. Di t and dust Di t and dust can accumulate on the sola module su face, blocking some of the s unlight and educing output. Although typical di t and dust is cleaned off du in g eve y ainy season, it is mo e ealistic to estimate system output taking into account the eduction due to dust buildup in the d y season. A typical annual d ust eduction facto to use is 93% o 0.93. So the 120Wp module ope ating with some accumulated dust may ope ate on ave age at about 79 Watts (101.46 Watts x 0.93 = 94.4 Watts). D. Mismatch and wi ing losses The maximum powe output of the total PV a ay is always less than the sum of th e maximum output of the individual modules. This diffe ence is a esult of sligh t inconsistencies in pe fo mance f om one module to the next and is called modul e mismatch and amounts to at least a 2% loss in system powe . Powe is also lost to esistance in the system wi ing. These losses should be kept to a minimum bu t it is difficult to keep these losses below 3% fo the system. A easonable ed uction facto fo these losses is 95% o 0.95. E. DC to AC conve sion losses The dc powe gene ated by the sola module must be conve ted into common househo ld ac powe using an inve te . Some powe is lost in the conve sion p ocess, and

2.3 Hyb id 2.3.0 Int oduction Small powe systems that use both wind and sola photovoltaic powe gene ation o ften wo k bette than eithe one alone. Sola /wind hyb ids use sola panels and small wind tu bine gene ato s to gene ate elect icity in both g id-tied and stan d-alone systems. 2.3.1 Sola Figu e 6-sola panels atop a oof Sola PV panels conve t sunlight into elect icity and send it into the home th o ugh a cha ge egulato that feeds batte ies o an inve te unit that conve ts th e DC output f om the sola panels to AC house cu ent. 2.3.2 Wind Figu e 7-Wind tu bine A hyb id powe system also uses a wind tu bine gene ato to conve t the mechanic al ene gy of the windmill into elect icity. Acco ding to the U.S. Depa tment of Ene gy, hyb id systems a e mo e efficient because they complement each othe . In summe the winds a e usually slow and the sola panels a e most efficient. The wind tu bine is mo e efficient in winte when winds a e usually st onge and the e is less sunlight. 2.3.3 Inve te s and Cha ge Cont olle s The elect icity f om a hyb id system must be conve ted into usable AC cu ent be fo e it ente s you home. The cu ent f om the wind tu bine and sola panel is un th ough cha ge cont olle s and inve te s to t ansfo m it into usable AC elect icity. 2.3.4 How Hyb id Sola -Wind Ene gy wo ks? A hyb id sola windmill gene ato is often a eliable enewable powe sou ce. It uses sola technology joined with wind ene gy to gene ate a stand-alone ene gy sou ce that is both dependable and consistent. Sola ene gy and wind powe will be the two most available easons fo powe on the ea th. Both a e enewable ene gy sou ces which might be plentiful th oughout the yea in all of the a eas. While sola powe o wind powe alone can fluctuate, when used togethe they fea tu e a eliable sou ce of ene gy. In seve al a eas when the sun is st ongest the wind speed is low then when the wind speed is highest sunshine can often be the weakest such as winte . The ight solution is to combine these two kinds of pow e s to p oduce a constant ene gy flow. This hyb id system balances you fluctuat ions in powe to give a mo e even flow. The hyb id sola wind gene ato uses sola powe systems that collect light and conve t it to ene gy in addition to wind tu bines that collect ene gy th ough th e wind. Sola wind cha ge cont olle s egulate the cha ging with the ene gy befo e it is sto ed in the batte y banks. An inve te , found in the batte y bank, ch anges the existing f om DC to AC. AC, o alte nating cu ent, is the type of pow e found in most homes and businesses. The hyb id sola wind gene ato p ovides low p iced powe . The elect icity is e

the e a e additional losses in the wi es f om the ooftop a ay down to the inv e te and out to the house panel. Mode n inve te s commonly used in esidential PV powe systems have peak efficiencies of 92-94% indicated by thei manufactu e s, but these again a e measu ed unde well-cont olled facto y conditions. Actua l field conditions usually esult in ove all dc-to-ac conve sion efficiencies of about 88-92%, with 90% o 0.90 a easonable comp omise. The efo e the 120Wp module output, educed by p oduction tole ance, heat, dust, wi ing, ac conve sion, and othe losses will t anslate into about 68 Watts of AC powe delive ed to the house panel du ing the middle of a clea day (120 Watts x 0.95 x 0.89 x 0.93 x 0.95 x 0.90 = 80.68Watts). Hence fo an a ay fo 5 panels, total peak powe will be 403.4 Watts. To t y and optimize this, an inve te and a sola cha ge cont olle a e necessa y.

liable as it combines sola and wind powe togethe . The ope ating costs a e low in cont ast to non- enewable sou ces. The application of the two sou ces sola and wind togethe assist with offe a stable ene gy supply fo the batte ies. Wh en utilizing exclusively among the sou ces alone the batte ies may become unde c ha ged, once the sou ce doesnt p oduce enough ene gy to keep batte y cha ge. 2.3.5 Connecting the two togethe When installing the cont ols and wi ing of a wind gene ato , it is impo tant to unde stand two fundamental diffe ences between wind tu bines and sola panels: Cu ent Rectifie s: Sola panels p oduce di ect cu ent (DC) elect icity equi ed by powe sto age b atte ies, and can be connected di ectly to the batte y bank without causing ha m . Wind gene ato s do not p oduce DC elect icity, so a device called a " ectifie " is used to conve t the tu bine s output cu ent to DC. Some tu bines have a ectifie built in. In most cases though, the ectifie is supplied as a sepa ate component that must be installed between the wind tu bine and the batte y. Often, the ectifie is combined with a cha ge cont olle into one complete wind tu bine cont ol unit. Load Dive sion: Sola panels a e "passive" elect icity p oduce s. Even though the sun is shining , they only p oduce elect icity when a cha ge is needed by the batte y. Wind gen e ato s a e "active" elect icity p oduce s. If the wind is blowing, they will p oduce cu ent whethe the batte y bank needs the cha ge o not. In o de to p ev ent damage to the wind tu bine, all of the elect icity it p oduces must be "used " in some way. When the system batte ies need cha ging cu ent, they p ovide an elect ical load to use the wind tu bines elect icity. If the batte ies a e fully cha ged, the tu bine s output must be "dive ted" to anothe elect ical load. A load dive ting cha ge cont olle egulates wind gene ato output so you batte ies eceive cha ging cu ent when they need it, and any excess elect icity gene ated by the wind tu bine is dive ted to an alte nate load when the batte ies a e fully cha ged. Some wind tu bines have cha ge cont ol featu es built-in, dive ting thei own ex cess cu ent and allowing it to dissipate as heat th ough the wind tu bine housi ng. In most tu bine systems howeve , the cha ge cont olle is an exte nal unit, and while DC ectifie s a e always included as pa t of a basic wind tu bine pack age, the load dive ting cont olle may not be. Some load-dive ting cha ge cont olle s come with a heat-sink esisto to attach as the dive sion load. When the batte ies each full cha ge, the load-dive ting cont olle will simply send elect icity to this esisto , whe e the ene gy will be eleased as heat. Some wind tu bines have dive sion featu es built into the t u bine body itself, and the tu bines oute shell acts as a heat sink fo the exce ss powe . Many cha ge cont olle s allow you to use the dive ted cu ent fo othe uses, such as unning a wate heating coil, a ventilating fan o a space heati ng system, making the wind gene ato an even mo e useful and efficient sou ce of powe . Once a load-dive ting cha ge cont olle is attached between the wind tu bine and the sto age batte ies, you elect ical system can be connected to the batte ies , eithe di ectly fo a matching-voltage DC system, o th ough an inve te fo a n AC o mixed AC/DC system. 2.4 Choice of Site In o de to know if a wind powe ed system is eithe feasible o cost competitive you need to have some facts and figu es. Because of the site p epa ation and wo k that needs to go into a wind towe , you need to have done extensive esea ch befo e installation. Unless you have a pa ticula ly good wind site, it is ecommended that eithe you have a hyb id system (i.e. wind and sola o wind and diesel) o no wind system at all. Wind is the fuel that d ives a wind tu bine and the efo e the tu bine needs to b e placed whe e the wind is. No matte how efficient and well designed the tu bin

e itself may be, if not placed in the ight location, the tu bine will be useles s. The efo e, p ope site selection is essential in building efficient wind fa m s. Reduced tu bulence: Wind tu bines need ai that moves unifo mly in the same di e ction. Eddies and swi ls, tu bulence in sho t, do not make good fuel fo a wind tu bine. The oto cannot ext act ene gy f om tu bulent wind, and the constantly c hanging wind di ection due to tu bulence causes excessive wea and p ematu e fai lu e of the tu bine. This means that tu bines need to be placed high enough to c atch st ong winds, and above tu bulent ai . To dete mine you sites, ave age wind speeds you can look at efe ence, o you c an make di ect measu ements. To measu e wind speeds (and di ection) using an ane momete equi es you set up a Meteo ological Towe called a Met-Towe . Typically , youll choose a height fo you Met-Towe to measu e as close to the Hub Height of the wind gene ato you wish to use.

Othe Facto s Affecting Site Selection: T anspo tation and oad system that exists between the tu bine manufactu e s and the site. Soil composition and p esence of ock dete mine the tole ance fo placement of t owe foundations, oads and c ane pads. Wind tu bines cause noise and sometimes visual pollution and hence need to be pl aced away f om civilization. Ecology of p oposed site locations. Fo example, wind fa ms should not be built in the mig ato y path of bi ds o in a eas that a e ecognized by thei wildlife , plant life o unique geog aphical featu es. P oximity to t ansmission g id affects the economic viability. Site te ain The mo e emote and complex the te ain is the highe the developme nt cost is likely to be. Location whe e the e is constant wind th oughout the yea . Density and f equency of flying insects-They affect the leading edge of tu bine blades and the eby educe the pe fo mance of the tu bine. The e will be an inc e ase in maintenance costs if blades need to be washed egula ly Cost of land Exposu e to ext eme wind speeds o othe climatological events such as cyclones. CHAPTER THREE: METHODOLOGY 3.0 Int oduction This chapte is devoted to the p esentation of the p og ess of events in the des ign, simulation and investigation into the failu e of the sola -wind hyb id ene gy system. The c ite ion fo development of the simulation model is the hea t of this chapte . 3.1 Lite atu e Review A comp ehensive lite atu e eview on the existing Wind Tu bine design technology and sola d iven pumps we e done f om the following sou ces Reading epo ts and ecommendations of p evious esea che s Field visits to Nakasongola dist ict whe e a hyb id wind-sola wate pumping sys tem is installed Visiting expe ts such as Davis and Shi tliff Uganda Limited and obtaining info m ation f om them in a face-to-face discussion. Inte net sea ches on sola -wind hyb id ene gy system design, pump selection, sol a module sizing and othe accesso ies. Text books, p ofessional magazines and jou nals on sola -wind hyb id ene gy syst em design. 3.2 Data Collection Data on the wind speeds, sola adiation and othe weathe conditions we e colle cted f om the weathe station installed at Nakasongola. This data we e downloade

d f om the weathe station onto a compute via Unive sal Se ial Bus. Info mation on the wate depth, wate equi ements, distance of the of wate sto age tank f om the well and pipe diamete and app oximate length we e also obtai ned. 3.3 Needs Assessment F om the lite atu e eviewed and f equent visits and analysis, the following nee ds have been ealized: The powe output f om wind tu bine is fa below 1000W The sola PV system cannot fully sustain the system The e a e f equent p oblems and e o s f om the inve te Pump output is below the designed and desi ed output Review choice of site 3.4 Data Analysis Diffe ent data was collected namely weathe data including sola adiation, wind velocity and wind di ection Wate mete measu ements f om Nakasongola. Estimations These we e done on the field visits mainly to Nakasongola but also to Mukono. 3.5 Design Methodology Mechanical design is the design of things and systems of a mechanical natu e; p oducts, st uctu es, devices and inst uments (Shigley, 1986). Fo the most pa t m echanical enginee ing design utilizes mathematics, the mate ials sciences and en ginee ing mechanics sciences. 3.5.1 Design methodology followed Using the Nakasongola Sola -Wind hyb id installation as a case study The p ocedu e followed was; data containing the ave age wind speeds, tempe atu e s and adiation in the a ea was got. This data was used to dete mine ce tain pa amete s used in the windmill design. Afte all the pa amete s had been asce tain ed, the p ototype of the windmill was then made using SolidWo ks. P ototyping wa s not done ea lie befo e installation due to the high costs of mate ials, fab i cation and testing. The lack of p ototyping led to the failu e o b eakdown of t he windmill. This failu e was eithe att ibuted to the use of inco ect data on the wind speeds, o basic inaccu acies and assumptions made du ing design and se lection. A sola system of five panels was set up to eplace it to un the wate pump system Below is the detailed theo etical and technical design of a sola -wind hyb id en e gy system that has developed using the Reve se Enginee ing Design P ocess entw ined with Object O iented Design Reve se enginee ing is taking apa t an object to see how it wo ks in o de to du plicate o enhance the object. (Tech Ta get, 2007) Reve se enginee ing initiates the edesign p ocess, whe ein a p oduct is obse ved, disassembled, analyzed, te sted, "expe ienced," and documented in te ms of its functionality, fo m, physica l p inciples, manufactu ability, and ability to be assembled. The intent of this p ocess is to fully unde stand and ep esent the cu ent instantiation of a p o duct. Based on the esulting ep esentation and unde standing, a p oduct may be evolved, eithe at the subsystem, configu ation, component, o pa amet ic level. (P of. K istin L. Wood, 1995) 3.5.2 P ocess steps: 1. P edict p oduct behavio : Examine the p oduct and develop a black box model. Desc ibe global black box functionality; that is inputs, outputs and functional equi ements. Gathe custome equi ements on the p oduct and develop specificat ions. Dete mine and list p ima y distinguishing featu es between the design unde stud y compa ed to benchma k designs. Hypothesize which p oduct featu es cause each p oduct objective to be satisfied. State a p ocess desc iption p oviding the functional steps. List assumed physical p inciples gove ning the p oduct.

2.

ocess.

P oduct function sha ing and compatibility analysis. Identify components that sha e functions. Pe fo m a compatibility analysis between the solution p inciples and associated sub functions; include geomet y, o ientation, motion and ene gy domain. 3. Mathematically model p oduct (Modeling): Fo each design objective identify the associated physical p inciple. Identify the balance elation fo the physical p inciple. C eate an enginee ing model of each p oduct objective using the balance elation . Dete mine met ics fo each objective using the enginee ing model. Alte natively a physical model may be developed that will be physically tested. 4. Solve p oduct model (Simulation): Apply enginee ing analysis, simulation and/ o nume ical design techniques. Change mate ials, dimensions and othe pa amete s to explo e the design space. Alte natively test with physical model. 5. C eate evolved p oduct va iant design: Recommend pa amet ic edesign based on the esults of the p evious step. P ototype, implement and test new design. 3.5.3 Object O iented Design Object-o iented design is a design methodology that puts emphasis on defining ob jects and how they collabo ate to fulfill the design equi ements. (La man, 2005 ) Object Modeling is the cent al technique in Unified Modeling Language (UML). I t is a notation allowing the specification of classes, thei att ibutes and meth ods, inhe itance, and othe mo e gene al elationships between classes (CollinsCope, 2001). This methodology is typically used fo softwa e design, but it has been p oven that this softwa e development p ocess can be used fo ha dwa e desi gn. (Te y Bahill, 2002) 3.6 Calculations on the System Calculations fo the diffe ent pa amete s/dimensions of the diffe ent systems we e made based on the data analysis and the data collected. These calculations in cluded flow ate, pump powe equi ed, oto diamete and numbe of oto blades ; batte y size, numbe of panels, numbe of batte y; pump specifications 3.7 CAD D awings and Simulation Pa amete ized CAD d awings of the windmill oto we e made. The d awings we e be made using Solid Wo k design softwa e and then simulated using diffe ent softwa e such as FloXp ess and SimulationXp ess. The simulation model was developed using Solid Wo ks and it was subjected to the analyzed data collected f om Nakasongola. This simulation involved changing dif fe ent pa amete s of the windmill with the aim of obtaining optimum windmill pe fo mance. 3.8 Conclusion and Recommendations Recommendations fo the design specifications of the enti e system expected to p e fo m efficiently at the site in Nakasongola we e made. These ecommendations w e e based on the pa amete s used in the simulation that esulted in optimum wind mill pe fo mance. 3.9 Repo t and P esentation This involved w iting down of a detailed epo t on the p oject communicating the esults of the p ojects and the steps that we e taken to come to a conclusion o f the best design. A p esentation was also done. CHAPTER FOUR: DESIGN AND SIMULATION 4.0 Int oduction This chapte cove s detailed design of the system step-by-step achieving eve y o

Disassemble p oduct: Disassemble the p oduct and c eate a mate ial o components list. Develop a featu e list fo each component with associated featu e definitions. Lea n and document actual p oduct function. Develop a detailed function st uctu e of the p oduct based on the disassembly p

bjective in o de as summa ized in the table below Objectives How to achieve them Tools To investigate the cause(s) of failu e of the system in Nakasongola and mitigati on. Collect data Obtain equipment specifications Deduce possible causes Mitigation Daily measu ements f om the pump. Data f om weathe console Inst uction manuals fo all the equipment Lite atu e Review To model and simulate a wind tu bine Collect data Recalculation of its potential powe in the given site CAD modeling FEA analysis and expe imentation Suggest imp ovements and p ove thei wo th Lite atu e Review Inst uction manual fo the Anhui 1000W wind gene ato Solid Edge V20 Solid Wo ks To design and size a sola ene gy system Collect data Sizing of the sola system Suggest imp ovements and p ove thei wo th Lite atu e Review Inst uction manual fo the sola panels and batte y To design and select a suitable subme sible pump Collect measu ement Recalculate using data Select the app op iate pump Suggest imp ovements and p ove thei wo th Lite atu e Review Specifications and selection manuals of subme sible pumps To me ge the th ee systems and come up with a vi tual p ototype of the hyb id en e gy system Combine the th ee systems Specify specifications in the new design TRNSYS 16 Meteono m Figu e 8-Table showing Summa y of the Methodology 4.1 Investigation of failu e of the cu ent system This sub-chapte will cove the analysis of the cu ent system in t ying to iden tify the causes of its failu e and suggest easonable solutions that will be add essed in this p oject. 4.1.1 Review of the cu ent sola PV system These we e d awn using back technology unning f om DC/AC inve te that comes wi th the Wind tu bine. The e a e five pieces of 120Wp 12 V Yingh sola panels. The input being 60VoHs Isc-maximum cu ent=7.6A Peak voltage=17.5V Numbe of cells=36 Model=Multi- o polyc ystalline. Step 1: Sola PV system sizing Dete mining powe consumption demands The fi st step in designing a sola PV system is to find out the total powe and ene gy consumption of all loads that need to be supplied by the sola PV system as follows: Calculating total Watt-hou s pe day used. Take note of the Watt-hou s needed fo the pump to get the total Watt-hou s pe day. Total DC load = 370*7=2590 Wh/day Calculating total Watt-hou s pe day needed f om the PV modules. Multiply the Watt-hou s pe day times 1.3 (the ene gy lost in the system) to get the total Watt-hou s pe day which must be p ovided by the panels. Total PV panels ene gy needed = 2590*1.3=3367 Wh/day

Step 2. Size the PV modules Diffe ent size of PV modules will p oduce diffe ent amount of powe . The peak watt (Wp) p oduced depends on size of the PV module and climate of site location. We have to conside panel gene ation facto which is diffe ent in each site locati on. Fo Uganda, the panel gene ation facto is 5. To dete mine the sizing of PV modules, calculate as follows: Calculating the total Watt-peak ating needed fo PV modules Divide the total Watt-hou s pe day needed f om the PV modules (f om item 1.2) b y 5 to get the total Watt-Peak ating needed fo the PV panels needed to ope ate the pump Total Watt-Peak ating=3367/5=673.4W Calculating the numbe of PV panels fo the system Divide the answe obtained in item 2.1 by the ated output Watt-Peak of the PV m odules available to you. The system will be powe ed by 12 Vdc, 120 Wp PV modules. Inc ease any f actional pa t of esult to the next highest full numbe and that will be the numbe of PV modules equi ed. Total Watt-Peak ating=673.4/120=5.61167= app ox. 6. But 5 we e used The minimum numbe of PV panels is 5modules. So this system should be powe ed by at least 6 modules of 120 Wp PV. If mo e PV modules a e installed, the system will pe fo m bette and batte y lif e will be imp oved. Step 3. Inve te sizing An inve te is used in the system whe e AC powe output is needed. The input ating of the inve te should neve be lowe than the total watt of ap pliances. The inve te must have the same nominal voltage as you batte y. Fo stand-alone systems, the inve te must be la ge enough to handle the total a mount of Watts you will be using at one time. The inve te size should be 25-30% bigge than total Watts needed. Total Watt of the pump=0.37kW The inve te size =app ox. 25-30% of 0.37kW=92.5-111W Step 4. Batte y sizing The batte y type ecommended fo using in sola PV system is deep cycle batte y. Deep cycle batte y is specifically designed fo to be discha ged to low ene gy level and apid echa ged o cycle cha ged and discha ged day afte day fo yea s. The batte y should be la ge enough to sto e sufficient ene gy to ope ate the appliances at night and cloudy days. To find out the size of batte y, calculate as follows: Calculate total Watt-hou s pe day used by the pump. F om above, it is 2590Wh/day Divide the total Watt-hou s pe day used by 0.85 fo batte y loss. 2590/0.85=3047.059Wh/day Divide the answe obtained in item 4.2 by 0.6 fo depth of discha ge. 3047.059/0.6=5078.43Wh/day Divide the answe obtained in item 4.3 by the nominal batte y voltage. 5078.43/12=423.20Ah/day Multiply the answe obtained in item above with days of autonomy (the numbe of days that you need the system to ope ate when the e is no powe p oduced by PV p anels) to get the equi ed ampe e-hou capacity of deep-cycle batte y. Batte y Capacity (Ah) = 423.20*1=423Ah Step 5. Sola cha ge cont olle sizing The sola cha ge cont olle is typically ated against Ampe age and Voltage capa cities.

Fo the se ies cha ge cont olle type, the sizing of cont olle depends on the t otal PV input cu ent which is delive ed to the cont olle and also depends on P V panel configu ation (se ies o pa allel configu ation). Acco ding to standa d p actice, the sizing of sola cha ge cont olle is to take the sho t ci cuit cu ent (Isc) of the PV a ay, and multiply it by 1.3 Sola cha ge cont olle ating = Total sho t ci cuit cu ent of PV a ay *1.3 Sola cha ge cont olle sizing PV module specification Pm = 120 Wp Vm = 17.5 Vdc Im = 6.6 A Voc = 20.7 A Isc = 7.5 A Sola cha ge cont olle ating = (4 st ings x 7.5 A) x 1.3 = 39 A So the sola cha ge cont olle should be ated 40 A at 12 V o g eate In conclusion: The efo e the sola a ay should be made of 5 and mo e panels, the batte y bank of 5 batte ies of capacity 423 Ah o mo e, A sola cha ge cont olle of 40A at 12V. 4.1.2 Review of cu ent wind tu bine design F om the basic wind powe equation; P = 0.5 x x A x Cp x V3 x Ng x Nb whe e: P = powe in watts (746 watts = 1 hp) (1,000 watts = 1 kilowatt) = ai density (about 1.225 kg/m3 at sea level, less highe up) A = oto swept a ea, exposed to the wind (m2) Cp = Coefficient of pe fo mance (.59 {Betz limit} is the maximum theo etically p ossible, 0.35 fo a good design) V = wind speed in mete s/sec (20 mph = 9 m/s) Ng = gene ato efficiency (50% fo ca alte nato , 80% o possibly mo e fo a pe manent magnet gene ato o g id-connected induction gene ato ) Nb = gea box/bea ings efficiency (depends, could be as high as 95% if good) Tu bine powe being p oduced p esently P=0.5 x 1.225kg/m3 x (3.1*3.1)/4 x 0.35 x 2.853 x 0.95 P=35.6W Results This ower out ut is way below 1000W. This is because as er manufacturers design , the rated s eed used was 9m/s and the cut-in s eed is 3m/s hence site wind s e ed cannot start the wind turbine. To try and o timize this system, variations in the height, rotor diameter and ch anges in air density are used. 4.1.3 Possible causes of failure of current system and suggested solutions Possible cause: 1 The ower out ut from wind turbine is far below 1000W(rated ca acity) Suggested solutions: Increasing of blade size and length, Increase of tower height, effect of air density Review choice of site Look at factors used to consider and mark against the current site. Possible cause: 2 The solar PV system su ly insufficient ower which cannot fully sustain the sys tem Suggested solution: Resize to cater for the auxiliary and extra ower needed Possible cause: 3 The frequent roblems and errors from the inverter

Suggested solution: Resize the inverter and include a solar charge controller Possible cause: 4 Pum out ut is below the designed and desired out ut ossibly due to flow losses Suggested solutions: Calculate the actual ower out ut being sent to the out ut Calculate losses and if ossible minimize the losses. Check for any blockages along the i e length Review um selection 4.2 Design and simulation of a better wind Turbine This sub-cha ter includes the solid Edge models and SolidWorks simulation models of the new system that will work effectively. 4.2.1Solid Edge models of the wind Turbine CAD modeling of the Wind Turbine assembly Sub-assemblies: Figure 9-Guy Tower Sub-Assembly Figure 10-Tail Wing Sub-Assembly Figure 11-Rotor Blade Sub-Assembly (Front) Figure 12-Rotor Blade Sub-Assembly (Side) Figure 13-Yaw Sub-Assembly Assembly with tunnel Figure 14-Wind Turbine Assembly with wind tunnel

4.2.2 Simulation of Turbine with SolidWorks The simulation was carried out to establish the forces that result from the blad e, tower and the entire wind turbine assembly. Procedures Followed in the SolidWorks SimulationX ress Pre aring the art Starting SolidWorks SimulationX ress A lying fixtures to kee the art from moving when loads are a lied To simulate loading, a ly forces, ressures or both. Choose the a ro riate material Model is now ready to solve. Meshing is done The simulation is run Assessing the safety of the design Evaluating the accuracy of results Documenting your roject Procedure followed in SolidWorks FloX ress Starting SolidWorks FloX ress Pre aring the geometry(assembled model) for calculation Defining the boundary conditions e.g. inlet and outlet volume rate Mesh is generating and Flow simulation is done. Viewing results Documenting your roject The analysis was then carried out to establish the forces, dis lacements, deform

ations and Factor of Safety that result from the loading and constraining of the arts and system 4.2.3 Blade Simulation Re ort 1. File Information Model name: rotor-2may Model location: C:\Users\louisa\Deskto \ roject 2010\Tonny documents\solidedge\ rotor-2may.SLDPRT Results location: C:\Users\louisa\A Data\Local\Tem Study name: SimulationX ress Study (-Default-) 2. Materials No. Body Name Material Mass Volume 1 SolidBody 1(Hole2) 201.0-T43 Insulated Mold Casting (SS) 2.32908 kg 0.000831814 m^3 3. Load & Restraint Information Fixture/Restraint Fixed-1 <rotor-2may> on 2 Face(s) fixed. Load Force-1 <rotor-2may> on 1 Face(s) a ly normal force 5000 N using uniform dis tribution 4. Study Pro erty Mesh Information Mesh Ty e: Solid Mesh Mesher Used: Standard mesh Automatic Transition: Off Smooth Surface: On Jacobian Check: 4 Points Element Size: 16.932 mm Tolerance: 0.84662 mm Quality: High Number of elements: 2569 Number of nodes: 4864 Time to com lete mesh(hh;mm;ss): Com uter name: Louisa-PC

00:00:02

5. Results 5a. Stress Name Ty e Min Location Max Location Stress VON: von Mises Stress 0.0910506 N/mm^2 (MPa) (74.9998 mm, -33.0074 mm, -1.31075 mm) 523.716 N/mm^2 (MPa) (0.00793393 mm, 2.3164 mm, -17.9221 mm)

Figure 15-Screenshot of rotor blade showing stress The blade above under stress is bound to fail at the region shaded in green; wit

h that having the highest stress Figure 16-Screenshot of rotor blade showing dis lacement Dis lacement from the original increases away from the joint towards the blade t i ; blue region undergoing the least dis lacement and red region the highest dis lacement.

Figure 17-Screenshot of rotor blade showing deformation The joint is fixed; the above icture shows how far the blade deforms from the o riginal osition ( arallel to the x-axis) Figure 18-Screenshot of rotor blade showing Factor of Safety F.O.S is 1 and lower for the s ot in red. The blade has a yield strength that is midway the stress range that it will ex e rience, hence with higher stress it is bound to fail along the inner art of the blade length. The dis lacement and deformation is large and greater as the leng th of the blade increases. Hence for the new system with long blades, it ought t o be made of lighter material and fastened firmly on to the rotor to avoid layi ng. 4.2.4 Guy ole Segment Simulation Re ort 1. File Information Model name: Tower Model location: C:\Users\louisa\Deskto \ roject 2010\Tonny documents\solidedge\ Tower.sld rt Results location: C:\Users\louisa\A Data\Local\Tem Study name: SimulationX ress Study (-Default-) 2. Materials No. Body Name Material Mass 1 SolidBody 1(Im orted1) 6061 Alloy 3.58835 kg 0.00132902 m^3 Volume

3. Load & Restraint Information Fixture Fixed-1 <Tower> on 2 Face(s) fixed. Load Force-1 <Tower> on 2 Face(s) a ly normal force 1 N using uniform distribution

4. Study Pro erty Mesh Information Mesh Ty e: Solid Mesh Mesher Used: Standard mesh Automatic Transition: Off Smooth Surface: On Jacobian Check: 4 Points Element Size: 10.997 mm Tolerance: 0.54985 mm Quality: High Number of elements: 9900 Number of nodes: 17922

Time to com lete mesh(hh;mm;ss): Com uter name: Louisa-PC

5. Results 5a. Stress Name Ty e Min Location Max Location Stress VON: von Mises Stress 1.24736e-009 N/mm^2 (MPa) (-79.8254 mm, -5.23235 mm, 194.999 mm) 3.06619e-005 N/mm^2 (MPa) (-9.84466 mm, -10.8719 mm, -145.341 mm)

Figure 19-Screenshot of tower iece showing stress The blade above under stress is bound to fail at the region shaded in green; wit h that having the highest stress. That region coincides with the bottom art of the segment which is attached to the to of the next tower segment Figure 20-Screenshot of tower iece showing dis lacement Dis lacement from the original increases from to to the bottom of the tower seg ment; blue region undergoing the least dis lacement and red region the highest d is lacement Figure 21-Screenshot of tower iece showing deformation The joint is fixed at the to ; the above icture shows how the segment deforms f rom the original osition to form a cu sha e at the bottom art of the segment

Figure 22-Screenshot of tower iece showing Factor of Safety F.O.S is 4 throughout the segment. The guy ole segment is bound to fail at each of their bottom arts. The F.O.S i s low and ought to be increased e.g. by change of the material or structure. The refore for the increase of blade diameter, it is not wise to use the already exi sting guy ole system. With increase in length, the number of su ort cables sho uld be increased. 4.2.5 SolidWorks FloX ress Re ort SolidWorks FloX ress is a first ass qualitative flow analysis tool which gives insight into water or air flow inside your SolidWorks model. To get more quantit ative results like ressure dro , flow rate etc you will have to use Flow Simula tionModel Model Name: C:\Users\louisa\Deskto \ roject 2010\Tonny documents\solidedge\wind tunnel assembly.SLDASM Fluid: Air Inlet Volume Flow 1 Ty e Volume Flow Rate Faces <1 > Value Volume Flow Rate: 5080 mm^3/s, Tem erature: 293.2 K Environment Pressure 1 Ty e Environment Pressure Faces <1 >

00:00:04

Value

Environment Pressure: 101325 Pa, Tem erature: 293.2 K

Results Name Unit Value Maximum Velocity

mm/s

6223.28 ossible is 6.223m/s.

Therefore maximum velocity

4.2.6 Calculating the new height of the tower:

H=58.978m = a rox. 60m That will need (58.978-14) =44.978 extra meters. 4.2.7 Blade Size Considerations For a given survivable wind s eed, the mass of a turbine is a roximately ro or tional to the cube of its blade-length. Wind ower interce ted by the turbine is ro ortional to the square of its blade-length. The maximum blade-length of a t urbine is limited by both the strength and stiffness of its material. Labor and maintenance costs increase only gradually with increasing turbine size , so to minimize costs, wind farm turbines are basically limited by the strength of materials, and siting requirements. For HAWTs, tower heights a roximately two to three times the blade length have been found to balance material costs of the tower against better utilization of the more ex ensive active com onents. 4.2.8 Blade diameter The ower from the wind increases as a function of the cube (third ower) of the wind velocity. Increasing the diameter of the rotor increases the ower out ut as a square function. Power from the wind can be derived by the formula: W = 14.3 PAV3 where: P = air density (2.3 x 10-3) value at sea level A = area swe t by turbine blades (sq. meters)= radius (m) squared x 3.14 16 (B) V = wind velocity in k h Power from a 30 k h wind will be 10% less at an elevation of 1,000 meters, 25% l ess at 3,000 meters. 4.2.9 Effect of Air density on the Power achievable The Power in the Wind is also affected by air density. The altitude is vital as you estimate the erformance of wind hardware at your site. The standard density for air is 1.226 kg/m3 and corres onds to a tem erature of 15o C. The Air Density changes with altitude using a formula: Air Density ( ) = 1.226 (1.194 x 10-4) z where air density is in kg/m3 Z is the altitude of your site in meters. Higher altitudes will lower air ressure reducing the air density, which in tur n affects the out ut of your wind generator. An altitude of 1000 meters will reduce the air ressure nearly 10% and therefore the ower by nearly 10%. Hence for Nakasongola, the guyed tower is at 14metres above the ground The air density at that height = 1.226-(1.194 *10^-4)* 1,160 =1.0875 kg/m3.

4.2.10 Mathematical simulation of the Tu bine

Wind Specifications at a height sizes; 1. P=0.5 x 1.0875kg/m3 x P = 124.2W 2. P=0.5 x 1.0875kg/m3 x P = 279.2W 3. P=0.5 x 1.0875kg/m3 x P = 344.7W 4. P=0.5 x 1.0875kg/m3 x P = 389.6W

of 60m, wind speed of 3.5m/s and diffe ent oto (2.258x2.258) x 0.35 x 3.53x 0.95 (3.386x3.386) x 0.35 x 3.53x 0.95 (3.7625x3.7 625) x 0.35 x 3.53x 0.95 (3.7625x3.7625) x 0.35 x 3.53x 0.95

Power roduced (W)

Standard value for rotor of this size (r = 3.1m) with new tower Standard value for rotor of smallest diameter Gives results that are most favorable for start u at low wind s eeds Hence if ro erly used on a favorable day i.e. s eeds of 3.5 and more, it can r un the submersible um of 370W rating. 4.2.11 Wind Turbine controls Figure 23-Diagram of Wind Turbine Control The wind-turbine model contains three sub-models described as follows. Wind Power Model: The ower Pmech extracted from wind can be described by [11] with the air density , the wind speed v, the oto adius , and the Cp value of the blades depending on the blade angle and the tip speed ratio = where vR is the rotor speed. A sing e wind speed v, representative for the who e wind e d acting on the ades is taken as mode input. The measured wind speed vm, measured on top of the nac e e, is smoothened y a ow-pass ter with time constant wind resul ing in he re presen ing wind speed ransfer func ion;

For a ime cons an wind 12 s, real measuremen s.

he model ou pu s showed he bes correla ion wi h

Figure 24-Response Graph of he Wind Power Model Conclusion from he graph: A he design speed of 3.5m/s, he sys em will be s able because of he nega ive roo aking 50s o reach and main ain op imum speed. demand dem y a rst-order ag with time constant ac ua or. values for he blade angle , the maximum chan s ew constraints.

Pi ch Model: The blade angle fo ows the pitch pi ch, which depends on he pi ch S roke cons rain s give he limi ge of the ade ang e is given y

Results for Blade length simulations Blade Length (function of rotor radius) Length (m) ge increase (%) 1.500r 2.258 124.2 112.0 2.000r 3.1 234 300 2.250r 3.386 279.2 377.3 2.500r 3.7625 344.7 489.2 2.658r 4 389.6 566

Percenta

Figure 25-Response Graph of Pitch Mode Conc usion from the graph: At various ang es of pitch ang es,the system remain sta e ecause of the negati ve root taking an even shorter time to reach and maintain optimum speed when 45o is taken. HENCE THIS PROVIDES THE BEST CONTROL STRATEGY FOR THIS APPLICATION. Generator Drive Train Mode : For ca cu ating the generator speed n, this su -mode imp ements the drive equat ion with its driving and raking torques, the generator/inverter mode , and the mechanica (friction) and e ectrica osses. TGen =

Approx. 20Nm. Figure 26- Response Graph of the Generator Drive Train Mode Conc usion from the graph: From the graph, it is noted that at a generator torque, the system wi sta e and takes a short time of 25s to ui d up.

Speed Contro Mode C osed- oop generator speed contro is done y the PID pitch contro er and the PI torque contro er, dependent on the state the tur ine is operating in. The PI torque contro er is on y active during a oad period (whi e the tur ine is con nected to the grid and produces e ectrica power). Otherwise, the torque demand is set to zero. Torque Contro : The transfer function G(s) of the PI torque contro er in Zieg erNicho s structur e is given y G(s) = With the contro parameters kp (proportiona gain) and i (in egra or ime cons an ). Bo h con rol parame ers are no cons an and hey vary be ween differen s a es he urbine is opera ing. he roo is equal o zero; hence his model is n ime cons an s and K chosen.

Pi ch Con rol: Similar o he above, he ransfer func ion G(s) of he PID pi ch con roller in ZieglerNichols s ruc ure is given by G(s) = Wi h he deriva ive erm d, his usually includes a low-pass l er wi h ime cons a n o avoid large s eps in he con rol variable caused by he deriva ion of he con rol error. Figure 27-Response Graph of he Speed Con rol Model Conclusion from he graph: Cri ical s abili y is also realised. Figure 28-Bode plo 4.2.12 Summary of of he Speed Con rol model he design

I is cri ically s able because o advisable for he par icular

remain

4.3 Design and selec ion of a sui able Solar PV sys em 4.3.1 New Solar PV sys em sizing The solar panels are of a peak power ra ing of 120Wp,12 V. The inpu being 60VoHs Isc-maximum curren =7.6A Peak vol age=17.5V Number of cells=36 Model=Mul i- or polycrys alline. Power requiremen calcula ions Tha place requires power as follows Appliances/day Quan i y Power from each Hours of opera ion Wa er pump 1 370W 5 Ligh s 4 75W 3 Radio 1 40W 6 Phone charging 2 60W 2 Consump

5 1,850W/day 900W/day 240W/day 2 240W/day 3,230W/day

Specifica ions Ba ery efficiency = 80% Vol age regula or = 90% Ba ery size = 12V Sys em efficiency = (ba ery efficiency x vol age regula or)x100% = (0.85x0.9) x100% = 76.5% To al energy required = Sunshine dura ion = Power from array = The number of PV panels for he sys em; N= 4.3.2 Inver er sizing To al power required = 3230W The inver er size =approx. 125 - 130% of 3230W = 4040 - 4200W 4.3.3 Ba ery sizing Energy demanded = 3230Wh/day Ba ery size = 0.6 is he dep h of discharge, implying ha he ba ery canno be used beyond 6 0% of discharge Ac ual ba ery size = 1x528 = 528Ah 4.3.4 Solar charge con roller sizing PV module specifica ion Pm = 120 Wp Vm = 17.5 Vdc Im = 6.6 A

If he average global radia ion Appliances/day Quan i y ion/day Wa er pump 1 370W Ligh s 4 75W 3 Radio 1 40W 6 Phone charging 2 60W To al energy consump ion/day

is 5572Wh/m2/day Power from each Hours of opera ion

Ro or diame er Number of blades Turbine heigh Power ou pu 3blades 60m 400W minimum

8m

Voc = 20.7 A Isc = 7.5 A Solar charge con roller ra ing = (4 s rings x 7.5 A) x 1.3 = 39 A So he solar charge con roller should be ra ed 40 A a 12 V or grea er 4.3.5 Summary of he design Solar sys em efficiency To al energy required Sunshine dura ion Number of PV panels The Ba ery size The inver er size Solar charge con roller ra ing 4222Wh/day 5.572 hrs 6 panels 528Ah/day 4040 - 4200W 40 A a 12 V or grea er 4.4 Sizing and selec ion of a sui able pump The s eps o selec ing a pump ha works: Figure 29: Pumping sys em layou

76.5%

4.4.1 De ermining flow ra e Firs find ou he consump ion ra e. Find ou he pumping hours per day o mee demand Then de ermine he flow ra e. The ank capaci y = 10,000l = 10m3 The pump is o run 6hrs/day o fill he ank The flow ra e Q = 10m3/6hrs = 1.7m3/hr 4.4.2 De ermine he s a ic head Take measuremen s of he heigh be ween he suc ion ank fluid surface and he d ischarge pipe end heigh . S a ic head 30.2m Discharge head=35.2 To al dynamic head=36m 4.4.3 De ermining head losses De ermine he fric ion head The fric ion head depends on; The flow ra e, The pipe size and The pipe leng h. Fric ion head, Fh= (f.v2.105).l/(D.2g) Where D= diame er of he pipe =average flow veloci y in he pipe for laminar flow

For urbulen flow For Re<2000 he flow is laminar and Re> 4000 he regime is Bu urbulen .

Manufac urers recommenda ions: A DAVIS & SHIRTLIFT Uganda, he available submers ible pumps are from DAYLIFF TAIFU as he manufac urer, for heir submersible pum ps, he recommended pipe size is . From he pipe specifica ion in Appendix C, a pipe whose nominal bore is inch w ill have an ou side diame er of 42.9mm, he choice be ween classes A, B or C dep ends on he maximum pressure head, from he previous calcula ion of ideal pump p ressure head Nominal bore(in) Diame er ou side (mm) kg/m) Max. pressure head 42.9 2.6 2.6 85 he selec ed pipe Wall hickness(mm) Weigh (

Figure 30-Summary able for Therefore,

o de ermin

Where Re= Reynolds number =densi y of wa er =pipe diame er =dynamic viscosi y aken as 0.00038kg/s De ermina ion of pipe roughness Since he flow is urbulen , i implies ha e pipe Rela ive roughness = Where k for commercial s eel is 0.000045

here is a rela ive roughness of

Using he moody char , he fric ion fac or can now be de ermine For Reynolds less han 2000 he flow is laminar. For Reynolds number is above 4000 he regime is urbulen . De ermining Fric ion Losses Fric ion losses can be evalua ed using Darcy equa ion as below Where = fric ion head loss =pipe diame er =pipe leng h = fric ion fac or =flow veloci y From he moody char (Appendix E), he fric ion fac or can be es ima ed a 0.025

De ermining Minor Losses Due To Bends

I s es ima ed ha here will a c ion sys em Hence o al losses due o bends

leas be 10 bends of 90 degree each in he conne

De ermining Reynolds number Since fric ion fac or is a func ion of Reynolds number, i s necessary e whe her he flow will be urbulen or laminar

he s a ic head can

4.4.4 Pump selec ion You can selec he pump based on he pump manufac urers ca alogue informa ion usi ng he o al head and flow required as well as sui abili y o he applica ion. Figure 31-Head Vs Flow Figure 32-NPSH and ETA% Vs Flow ra e 4.4.5 Summary of Pump sizing The Pump specifica ions should be; Power inpu Pump discharge Pipe size To al head 0.37kw 1.8m3/s 5/4 inches 60m

4.5 Si e Evalua ion As realized above in he Causes of Failure (refer o 4.1), choice of a si e and si e evalua ion is qui e impor an . Selec ion Cri eria Nakasongola Cos of land Affordable Densi y and frequency of flying insec s Low Exposure o ex reme wind speeds or o her clima ological even s such as cyclones Fair Transpor a ion and road sys em Poor Soil composi ion and presence of rock Good Noise and some imes visual pollu ion Low Loca ion Remo e Ecology of proposed si e loca ions. Low Proximi y o ransmission grid Remo e

4.6 Trnsys model of he Hybrid sys em Figure 33 Trnsys model showing a merged sys em CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS 5.1 Produc Descrip ion Fea ures: S reamlined hree-bladed glass fiber reinforced blades have he advan ages of grea in ensi y, fa igue resis ance and high efficiency. The Hummer-pa en ed genera or charac erizes i s high efficiency and good low-spe

4.4.3 De ermining o al head The o al head is he sum of he s a ic head (remember ha be posi ive or nega ive) and he fric ion head. To al head = 60m minimum

ed-performance. The speed regula ing sys em adjus s au oma ically o wind speed. The whole sys e m is easy o ins all and convenien o main ain. Con rolling, inver ing and disc harging are in egra ed. Blade is designed according o airfoil s ruc ure and made of glass fiber reinfor ced plas ic Yaw shaf is made of reinforced aluminum, ligh and s rong. Genera or is ex reme ligh and small, low in noise, running in high efficiency. Inver er is hree-in-one ype, in egra ing rec ifier, con roller and inver er. Con rol sys em has he func ion of charging, discharging and unloading. LED indica es kinds of informa ion simul aneously. 5.2 Summary of resul s The aim of he research presen ed in his repor was o develop design specifica ions for a solar-wind hybrid energy sys em o be used for pumping wa er a low and in ermi en wind speeds hrough simula ion. This research was mo iva ed by he need o op imize he design of he hree sec ions, he windmill, he solar sys em and he pump hrough he use of CAD modelin g and simula ion. The specifica ions developed were for he differen sys ems ha would work wi h he low wind speeds in Nakasongola. They included specifica ions on blade leng h, number of ro or blades and heigh of he ower for he windmill; specifica ions of he solar charge con roller o purchase and size & capaci y of ba ery; pump specifica ions as indica ed in he able below.

OBJECTIVES RESULTS/FINDINGS 1) Inves iga ion of causes of failure of curren sys em Possible causes Sugges ed solu ions The power ou pu from wind urbine is far below 1000W(ra ed capaci y) Increase of ro or diame er Increase of ower heigh The solar sys em canno fully sus ain he sys em Resized o for he auxiliary and ex ra power requiremen Frequen problems and errors from he inver er Resized and solar c con roller recommended Pump ou pu below he designed ou pu Reduced head losses Increased power inpu o he pump Turbine failed o deliver as required Resized he urbine Reviewed choice of si e 2) Model and simula ion of a wind urbine Design parame er Design v alue Ro or diame er Number of blades Turbine heigh Power ou pu 8m 3blades 60m 400W 3) Design and sizing of a solar sys em Solar sys em efficiency To al energy required Sunshine dura ion Number of PV panels The Ba ery size The inver er size Solar charge con roller ra ing 76.5% 4222Wh/day 5.572 hrs 6 panels 528Ah/day

5)

5.3 S a emen of modifica ions, changes and addi ions There have been a number of modifica ions and addi ions o he new sys em as bel ow; 6 solar panels should be used ins ead of 5 6 ba eries o be connec ed ins ead of 5 A charge con roller should be included A wind urbine of diame er 8m ins ead of 3.1m A heigh of he urbine should be 60m ins ead of 14m 5.4 Challenges and limi a ions S udying of he sof ware and finally confiden ly using i in he research. This was in ended o use improved me hods in design ha are be er han he rudimen ary means ha were more cos ly and gave difficul o predic performance of he sys ems. There are limi ed sof ware capabili ies which have hindered explora ion of some sec ions of he projec . 5.5 Research con ribu ions Developed compu er models necessary for parame erising he wind genera or, solar sys em and he pump Mi iga ion and improvemen on he men ioned models in Nakasongola and Mukono Correla e power and pump ou pu so o vary sui ably. Comprehensive repor on recommenda ions and designing usable o modify he hybri d energy sys em Capaci y building 5.6 Cos Implica ions PROJECT COST ESTIMATES I em Descrip ion QTY Ra e (UGX) Amoun (UGX) 1 DAYLIFF TAIFU solar powered submersible pump( full se ) 1 2,713,50 0 2,713,500 2 YL 120 MULTICRYSTALLINE solar panels 6 900,000 5,400,000 3 Energy S orage VRLA ba ery( op ional) 6 950,000 5,700,00 0 4 30A ba ery charge con roller 1 361,800 361,800 5 Wind urbine 1 7,000,000 7,000,000 6 Ins alla ion cos Whole 1,000,000 SUB TOTAL 22,175,300 7 5% con ingency and varia ions 1,108,765 GRAND TOTAL 23,284,065 The above figures were ob ained from DAVIS AND SHIRTLIFF as he key suppliers of solar panels, ba eries and charge con rollers. Payback period= inves men made/ne annual cash inflow Wind Power in kWh/pa =390(W/day)* 365 (day/yr)*12(hrs) =1708200Wh/yr =1708.2kWh/yr (Wind is assumed o be presen for 12hours a day for he new sys em)

4)

Power inpu

4040 - 4200W 40 A a 12 V or grea er Sizing and selec ion of a sui able pump Pump discharge Pipe size To al head 0.37kw 1.8m3/s 5/4 inches 60m Merging he hree sys ems in an hybrid sys em

Solar Power in kWh =4222(Wh/day)*365(day/yr) =1541030Wh/yr =1541.03kWh/yr. To al hybrid power=1708.2kWh/yr+1541.03kWh/yr =3249.23kWh/yr Therefore aking he new urbine of a 60m heigh urbine genera ing a 3249.23 kW hrs/pa a an average wind speed of 3.5m/s and given he curren cos of elec ric i y a around 358/= per kWh he payback ime would be calcula ed as follows: 3249.233*358.2 = 1,163,874.186 saved per year (excluding main enance) Therefore he number of years required o payback = 24,000,000 / 1,163,874.186 =20.6 years. 21 years migh be close o or exceed he life expec ancy of he urbine. This figure was arrived a using a wind speed of 3.5m/s. however, wind speeds in Nakasongola mos imes goes beyond 3.5m/s. herefore he implemen a ion of his projec can be far beneficial han is depic ed in his piece of work. 5.7 Conclusion The analysis of he wind speeds and solar po en ial hroughou he area show ha here are o her periods when here is reasonable average wind veloci y and sol ar po en ial for low power genera ion. A compara ive s udy of he hybrid wind-so lar elec rici y produc ion agains power diesel genera or or ex ending he main grid favors he hybrid sys em whose energy uni cos is lower besides being envi ronmen ally friendly. Therefore as s a ed above, he use of wind-solar hybrid en ergy sys em is a viable inves men wi h non-carbon emission and hence should be fur her implemen ed. 5.8 Recommenda ions: The recommenda ions are based on; Wind Turbine Blade leng h = 4m Number of ro or blades=3 Heigh of he ower=approx. 60m Solar PV Panels Number of panels = 6 Solar charge con roller =40A a 12V Capaci y of VRLA ba ery=540Ah Pump specifica ions Power = 0.37kw Discharge = 1.7m3/s Pipe size = 5/4 inches To al head = 60m This projec once implemen ed, will be; ligh weigh , highly efficien and easy o main ain. I can be economically used in; Homes, Farms Telecommunica ions S a ion TV Transfer S a ion Moni oring S a ion (mili ary, hydrology, observa ory) Wa er-pumping S a ion and may o her places Fur her s udies and research can s ill be under aken in his area as one of he safes sources of energy rural par s of Uganda can adop for a sus ainable devel opmen .

References 1. www.dasolar.com 2. EWEA European Wind Energy Associa ion h p://www.ewea.org/ 3. AWEA American Wind Energy Associa ionh p://www.awea.org/ www.allwindenergy.com 4. Anhui Hummer China h p://www.chinahummer.cn/ 5. Davis &Shir liff Uganda h p://www.dayliff.com 6. California energy commission, a guide o pho ovol aic (PV) Sys em design and ins alla ion, June 2001, 500-01-020, consul an repor -gray Davis, governor 7. PV ins alla ion guide -a guide o pho ovol aic (PV) sys em design and in s alla ion. Prepared for: California Energy Commission Energy Technology Develop men Division 1516 nin h s ree Sacramen o, California 95814. Prepared by: Endec on Engineering 347 Norris cour , san Ramn, California 94583 8. Final year projec repor , (Vic oria Njuki,2008); 9. Final year projec repor , (Fes o Lubwama,2010). 10. Appendices Appendix A: Da a from Nakasongola Da a depic ing wind specifics Da a depic ing solar specifics

Appendix B: Model: H3.1-1000w The main echnical da a of H3.18-1000w wind urbine genera ors sys em is : Ra ed power(W) 1000 Maximum ou pu powerW 2000 Charging vol age(V) DC 60 Blade quan i y 3 Ro or blade ma erial GRP Ro or blade diame er 3.1 S ar -up wind speed (m/s) 3.0 Ra ed wind speed (m/s) 9.0 Ra ed ro a ing ra e (r/min) 500 Wind energy u ilizing ra io (Cp) 0.45 Genera or ou pu Single-phase frequency conversion AC Ou pu AC frequency (Hz) 0~400 Ra ed charging curren (A) 15 The maximum charging curren (in a shor ime )(A) 30 Genera or efficiency >0.8 Tower diame er(mm) 89*2000*3.5 (4pcs) Tower heigh (m) 8 Weigh of genera or (kg) 15 Ba ery 12V 150Ah/ 200Ah 5pcs Appendix B II : New Wind Model Produc Specifica ions Ra ed power(W) 400 Maximum ou pu power (W) 2000 Charging vol age(V) DC 60 Blade quan i y 2.8 Ro or blade ma erial GRP Ro or blade diame er 8 S ar -up wind speed (m/s) 3.0 Ra ed wind speed (m/s) 3.5 Ra ed ro a ing ra e (r/min) 500

Wind energy u ilizing ra io (Cp) 0.45 Genera or ou pu Single-phase frequency conversion AC Ou pu AC frequency (Hz) 0~400 Ra ed charging curren (A) 15 The maximum charging curren (in a shor ime )(A) 30 Genera or efficiency >0.8 Tower diame er(mm) 89*2000*3.5 (4pcs) Tower heigh (m) 60 Weigh of genera or (kg) 25 Ba ery 12V 150Ah/ 200Ah 5pcs Appendix C: Pipe size selec ion depending on li res produced Pipe size Li res Per Hour Li res Per Minu e 1/2" 480 8 3/4" 900 15 1" 1,500 25 1 1/4" 2,700 45 1 1/2" 3,600 60 2" 5,400 90 3" 13,500 225 4" 21,000 350 6" 42,000 700 Appendix D: Pipe specifica ions (source: DAVIS &SHIRTLIFF Produc l 2011 Appendix E: Moody char (Fluid Mechanics by Douglas 2004)

& Design Manua