Proceedings of International Conference on Integrated Renewable Energy for Regional Development
Keywords: design, development, diffusion, electric, energy, micro-hydro, rural, water
ABSTRACT
Maximizing and integrating utilization of potential natural resources of
Indonesia archipelago are necessary for generating rural electricity. Indonesia is a
tropical country, consist of about 3,000 islands and most of which are mountainous area
and lots of water resources for an electric generator. Therefore a micro-hydro as a
renewable energy is very compatible to be developed in Indonesia.
Most of Indonesian people live in a remote village and harnessing the power of falling
water by means of micro-hydropower plants is one way of providing affordable energy for
the development of rural areas.
Design and engineering development of water turbine and penstock are adapted with
local material availability and local manufacturer capability. The development covers
redesign of turbine components, such as shaft, bearing adjuster and runner. Especially for
the penstock, the usage of local material is very important, such as an asphalt drum that is
covered by fibber cement, the combination of its an appropriate solution. Therefore, the
usage of software such as AUTO-Cad, FEMAP, UNA and ANSYS in the design simulation
is very fruitful.
Technology diffusion of the micro-hydropower plants is done through pilot project,
workshop and training. DATD has conducted of more than thirty pilot micro-hydropower
plant projects throughout Indonesia, and trained thirty field instructors and thirty
technicians of Man Power Department.
INTRODUCTION
In mountainous area, hundreds of water wheels in irrigation canals that made by
carpenters are used for rice milling and electric generator. At North Coast of Java, some
traditional mariculture farmer lifted water by using fabric windmill. Indication has shown
that Indonesia is a potential natural resource for power generating.
As an example, at Kampung Pasanggrahan, Neglasari Village, District of
Tasikmalaya, Mr. Abdul Rozak installed a water wheel for electric generating, the
electrical output is 2,000 Watt and presented on Figure 1. He was a receiver of an
Environment Award ‘Kaplataru’, in 1987. The initiative encourages his neighbors to make
and install the same water wheels, so in the village appears about thirty water wheels for
electricity [Pikiran Rakyat], 1997].
2
The small size of micro hydro has no adverse on the environmental impact; it is an
environment friendly renewable indigenous resource. Even though, the contribution of
micro-hydropower plant to the overall energy supply is small, it may induce associated
economic activities, employment and income generation to improve the quality of life.
Micro-hydropower plant may contribute to the alleviation of poverty; at the same time
preserve the environment.
DATD is concerned to the rural electrification, because electricity is not to fulfill basic
needs only, but also to create income generation through the development of production
units.
Figure 1. Water Wheels for Village Electrification.
The micro hydropower plant may have the following advantages:
· To build up of local-know for manufacturing, assembling, and operating of micro
hydropower.
· To supply low-cost energy by appropriate solutions.
· To promote a regional consultant.
· To create job opportunity.
Cross flow turbine is nominated to be developed because of its simplicity on the
design and manufacturing, locally manageable, and compatibility to the natural resources.
3
The design development of DATD’s cross flow turbine is based on the GTZ’s design. The
redesign is fitted to the local condition, especially on the local manufacturing capability.
REQUIREMENT & OPPORTUNITY
More than 60% of Indonesia’s rural house holds, some 60 millions people are still
not electrified and forced to rely on kerosene lamps, automobile batteries and dry cells for
light and power.
The aim of the rural electrification program is to promote rural community
development. Referring to the President Director of PT Perusahaan Listrik Negara (PLN =
Electric State Company) statement, the company has a main duty as a national agent of
development by distributing electric power to the rural area, when signed a MOU with
Andalas University for surveying villages with multiplier effects [Kompas, 1997]. The
government encourages using of seasonable micro hydro electricity for income generating
effort. In 1997, PT PLN is going to electrify 5,000 villages, based on the state budget of
about Rp 1,000 millions, -. PT PLN is still committed to the rural electrification, but grid
extension programs have been costly and natural restriction.
Electrification has been restricted because of the archipelago nature of Indonesia.
The country consists of about 3,000 islands; this makes expansion of public grid on a
national or multi province basis tremendous difficult and expensive. Even, rural demand is
small scale, it caused economics problem.
GOVERNMENT NEW REGULATION FOR SMALL POWER PLANT
A consideration of micro hydropower plant is reliable energy supply to remote rural
areas, which won’t be connected to the grid in the near future. PLN’s new regulation will
remit the consideration, because PLN may buy the electricity produced by micro
hydropower plant, and integrate to the regional or national grid.
The new regulation will eliminate the decrease of micro hydropower plant and give
opportunity to integrate to the PLN’s grid. Referring the new regulation, a small-scale
electric power plant could be proposed by private company and cooperation; it indicates a
business opportunity for a medium manufacturer.
Since 1992, about twenty private companies have installed electric power plant and signed
MOU for selling the electricity to the government with price about USD 0.60/kWh.
4
Table 1. Private’s Electric Power Plant.
Power Plant Capacity (MW) Price (USD/kWh) Operated
PLTGU Sengkang 80 6.55 cents 1997
PLTGU Pare-pare - 6,33 cents 1997
East Java Power Corp. - 5.67 cents 2000
As an example, a survey of the micro hydropower plants condition at Subang district
presented that some of its stopped by the extension of regional grid. The survey is
conducted by DATD and presented in Table 2.
Table 2. Micro Hydropower Plants Condition at Subang District.
Location Manufacturer Capacity [kVA] Year Condition
Cinta Mekar PTP - ITB 10 89/90 stopped - grid: 90/91
Bunihara PTP - ITB 10 90/91 damaged - over load
Jambe Air PTP - ITB 50 91/92 stopped - grid: 95/96
Bojongloa PTP - ITB 20 92/93 stopped - grid: 95/96
Curug Agung Mandiri 15 92/93 running
Cibeusi Mandiri 10 93/94 running
Cupu Nagara Mandiri 30 94/95 stopped - grid: 96/97
Bantar Sari Mandiri 20 95/96 running
Table 3. Mini-hydropower plant - West Java.
Company River District Capacity
[MW]
Operation Schedule
PT. Kwarsa Hexagon Cibuni Cianjur 2 x 3.00 -
PT. Wirabuana Prajaraya Cibuni Cianjur 2 x 2.00 2000
Cikaingan Garut 2 x 6.00 2000
PT. Bangun Swadaya Listrindo Ciarinem Garut 1 x 1.50 1998
Cikandang Garut 2 x 2.00 1998
Ciberang Lebak 2 x 2.75 1998
Succeeding the new regulation, a small-scale electric power plant is proposed by
private company and cooperation; it indicates a business opportunity for a medium
manufacturer. In Java, the power plant will be connected to the Java - Bali Inter-connection
System. The proposed mini-hydropower plants in West Java are presented in Table 3.
HYDROPOWER
The topography of the most Indonesian tropical island promises the suitability of
hydropower generation. To study the useable of flow available from a stream for power
generation, Pusat Penyelidikan Masalah Kelistrikan – PLN (Center for Study of
Electricity) conducted at various areas in Indonesia [Sularso, 1983].
5
Data survey is presented in the diagram of the application of various turbine types
based on the head, and it is shown in the Figure 2.
Figure 2. The application of various type of turbine vs. power head.
The small size of micro hydro has no adverse on the environmental impact; it is an
environment friendly renewable indigenous resource. Even though, the contribution of
micro-hydropower plant to the overall energy supply is small, it may induce associated
economic activities, employment and income generation to improve the quality of life.
Micro-hydropower plant may contribute to the alleviation of poverty; at the same time
preserve the environment.
TURBINE COMPATABILITY
DATD has been concerned with the problems of establishing a suitable
technology to enable any remote area with suitable water resource, to have its own
individual micro hydro scheme.
The objective is to produce a set of designs in which each one:
· Is a properly engineered system requiring no further professional involvement in the
installation.
· Has a cost of the energy produced those compares favorably with any alternatives.
The design philosophy was to match the technology to the capabilities of rural
commercial and industrial resources and the needs of remote farming areas in the country.
6
Remoteness usually means many kilometers from assistance, and for that reason, the
installation needs to be extremely reliable with maintenance and repairs as far as possible
within the means of the consumer.
The design approach has been to use the best of technical resources to produce the
simplest of solutions. It is hoped that the technology will be transferable to sites in
developing countries.
Table 4. Matrix of Turbine Selection
Type Operation
Head Capacity
Power Design Manufacturing Construction Workshop
Facility Skill
Pelton H L S - B E E E G Sp
Francis M MB S - B D D : casting C G Sp
Kaplan L B S - B MD MD C G Sp
Turgo MH L S E E : casting C G Sp
Crossflow M L S E VE VE Si N
L = low, M = medium, MB = moderate big, MD = moderate difficult, MH = moderate high,
B = big, H = high, S = small, Si = simple, Sp = special, E = easy, D = difficult,
C = complicated, G = good, N = no need.
CROSSFLOW TURBINE
The classical approach to turbine selection is using a machine of the highest
practicable specific speed; it leads to the smallest and fastest machine. For the low head
application, the result would be a turbine based on the propeller, i.e.: Kaplan and the cross
flow turbine. The Kaplan turbine is discouraging by complex in shape and manufacturing.
The cross flow turbine tends to be favored for its simplicity, but being an
impulse turbine and not a reaction turbine, runs relatively slowly with the consequent
transmission problems involved in increasing the speed to a synchronous generator speed.
Modified Cross flow Turbine
The modified of GTZ’s cross flow turbine is shown in cross sectional view in Figure
3. The range of power output is decided by the size of the turbine, which is in wide range
of 150 - 700 mm. The specification of the cross flow turbine is presented in Table 5.
Design Development
Turbine design is a tailor made approach, its depends on the site condition and
performance requirements. The working load determines a strength analysis of turbine
components, i.e. head and capacity of water. Shaft, runner, runner blade, bearing, housing
and penstock need a specific and repetitive design calculation, thus an application of
computer in the design simulation is beneficiary.
7
Figure 3. The Modified of GTZ’s Crossflow Turbine.
Table 5. Turbine Specification
POWER INPUTS RANGE UNIT
· Head 2.5 - 100 [m]
· Capacity up to 350 [liters/second]
POWER OUTPUT
· Power 2-70 [kWatt]
The design development of the cross flow turbine component based on the CAE, i.e.:
AutoCAD for drafting and FEMAP-UNA or ANSYS for stress analysis. Creating
geometry of Finite Element Modeling, the existing geometry from the CAD system are
imported through a DXF (AutoCAD format) interface.
Advantages of application CAE for the design development are:
· organizing and handling time-consuming and repetitive calculations.
· it allows the designer to analyze complex problems faster and more completely
· it possible to carry out more iterations of design.
8
Component Modification
The modification of the cross flow turbine component is based on the
availability of local materials and the existing tool and skill of local workshop.
The modified components are:
· Housing: the thickness of material and the limited of bending machine capability to
form the cover and sidewall of housing fit to the design requirement caused the
material is cut off to pieces and connected by welding process.
· Valve adjustment stand: tearing the U profile to make more clearance modified spindle
support and guide of valve adjustment stand.
· Bearing block: the original design of bearing block is consisted of three pieces, and the
modified component is one piece to get stiff component and avoid welding process
· Penstock: to consider easy forming of the penstock shape, a full-scale drawing is made
for a pattern, and the material is torn in the section of square form
STUDY OF DIFFUSION AND DISSEMINATION
To increase the diffusion of micro-hydropower plant for rural electricity, DATD
carried out training course for trainers and technicians of Man Power Department, installed
and studied the impact of micro-hydropower plant in collaboration with Man Power
Department.
This time, micro hydro, which is developed by DATD, has been widely spread in
various areas in Indonesia for rural electrification and rural industry in collaboration with
district government.
The dissemination of Micro-hydropower covers some activities, i.e.:
· micro-hydro power pilot training on micro-hydropower plant
· diffusion of micro-hydropower plant
· study of implication micro-hydropower plant
LESSON LEARN OF THE INSTALLATION OF MICRO HYDRO IN WAMENA
There are two units of micro hydro that have been installed in Jaya Wijaya, one
is in Anggruk sub district and another is in Makki sub district. Due to the remoteness and
low skill of the rural people where the micro hydro was installed, so that in arranging the
component; some modification and simplification in the design of micro hydro are
necessary to be paid attention. From the field experience is obtained that the participation
9
of the local people plays very important role. Beside the local people, the formal and nonformal
organization are also are important to be taken into account. To maintain the micro
hydro that has been installed, training to the group of the local people is necessary to be
done.
The use of the micro hydro in both places as mentioned above is focused to
operate the equipment of the clinic health. Beside that purpose, the micro hydro is also
used for house and street lighting.
REFERENCES
Adhikari, D., 1993, Experience in Small Hydro Power Rural Electrification in Muktinath-
Nepal, SHP News (4): 19-20.
Burgoine, D., Rodrigue, P., Tarbell, J.C., 1994, Siphon Penstock Installation at
Hydroelectric Project, SHP News (3): 34-38.
Cavallo, A.J., Hock, S.M., and Smith, D.R., 1993, Wind Energy: Technology and
Economics, Renewable Energy: Sources for Fuels and Electricity, Island
Press, Washington D.C.
Djunaedi, I.,Hidayat,D.D.,Abbas, A., 1997, Preliminary Study of Design, Installation
and Performance Test of Maki-Micro Hydropower Plant, Technical Report,
DATD, Subang.
Djunaedi, I., 1997, Preliminary Analysis of Wind Energy in Wamena, Technical Report,
DATD, Subang.
Djojodihardjo, H., 1984, Penilaian Potensi Energi Angin dengan Kasus Khusus Indonesia
dan Prospek Pengembangannya, Proceedings: Kursus Teknologi Energi
Terbarukan, Bandung.
Duffie, J. A.,William, A.B., 1980, Solar Engineering of Thermal Process, John Wiley
and Sons.
Eldrige, F. R., 1980, Wind Machines, 2nd ed., Van Nostrand Reinhold New York.
Inversin, A. R., 1993, A Method for Estimating a Flow Duration Curve at an Ungaged
Site, SHP News (4): 21-25.
Rosenblum, L., 1982, Practical Aspect of PV Technology, Application and Cost, NASA
Lewis Center Research.
Stevens, M.J.M., Smulders, P.T., 1979, The Estimation of Parameters of the Weibull
Wind Speed Distribution for Wind Energy Utilization Purposes, Wind
Engineering 3(2): 19-27.
10
Sugiarmaji, H.P.S., 1984, Pengembangan Teknologi Konversi Energy Angin di
Indonesia, Proceedings : Kursus Teknologi Energi Terbarukan, Bandung.
Tarigan,I. , Mulyadi, D., 1988, Photovoltaic Design Using Loss Energy Probability
Method, Telaah, Vol. 11, (1,2 ) : 1-11.
