Design and Prototyping of Gravitational Water Vortex Turbine 2019

Abstract
The Gravitational Water Vortex turbine (GWVT) is a turbine placed in the centre of vortex which
extracts the kinetic energy of water in the basin. These systems can operate on very low heads
about 0.7m. The construction costs are relatively small because of its simpler construction with no
need of dam structure and the use of locally available materials. The installation of GWVT can act
as an exemplar project that can have huge environmental benefit with no negative environmental
impact. The aim of this thesis is design and prototyping of the gravitational water vortex turbine
(GWVT) for Methara sugar factory. To do this, the model of gravitational water vortex turbine
blade will be developed in CAD software. This model will then be imported to ANSYS workbench.
Finite Element Method analysis will be done after meshing, applying displacement, load and
boundary conditions. The selection of ideal location on the irrigation canal to install GWVT and
the product design has be done and the detail design is in progress.

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Design and Prototyping of Gravitational Water Vortex Turbine 2019

1.1. Introduction
Hydraulic turbines exploiting the energy of water in rivers and reservoirs make a substantial
contribution to the generation of electricity worldwide. The advantages of hydroelectric plants over
fossil fuel plants are a higher life time, an efficiency rate twice as high and lower costs for
maintenance and service. Besides being a renewable and non-polluting source of energy, a
hydropower plant can respond instantaneously to changes in the demand for power of the electric
grid. [21]
Hydropower is currently the most important renewable source of the world’s electricity supply and
there is still a considerable untapped potential in many areas. Continued exploitation of this
resource is likely as a response to the world’s demand for energy. Environmental legislation such
as the Kyoto Protocol is putting increasing pressure on all governments to generate clean energy
from sustainable sources. [20]

1.1.1. Turbines
Turbines are used for hydropower generation. There are basically two types of hydraulic turbines,
the first one is impulse and the second one is reaction type turbines. Impulse turbines work based
on momentum principle; while in the reaction type turbines, the flow is fully pressurized and it
works according to conservation of angular momentum. The potential energy of fluid is converted
to kinetic energy. Francis and Kaplan type turbines are examples of reaction turbines and Pelton
turbine is an example of impulse turbines. [21]
A. Francis Turbines have a runner with fixed blades, usually between seven and thirteen. The
water enters the turbine in a radial direction with respect to the shaft, and is discharged in an
axial direction. Francis turbines are available for 20 to over 900 m of head and can be as large
as 800 MW. [19]
B. Kaplan Turbines are propeller turbines with all of the three to six blades pivoted for pitch
adjustment. The runner design reminds of a boat propeller and may exceed eight meters in
diameter. Kaplan turbines are suitable for heads from 10– 70 m and may yield more than 250
MW. [19]
C. Pelton Turbine is one of the most efficient types of hydraulic turbines; it is a cross-sectional
flow turbo motor machine with partial admission and action. It consists of a wheel (impeller

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Design and Prototyping of Gravitational Water Vortex Turbine 2019

or rotor) outfitted with buckets in its periphery, which are specially designed to exploit large
low flow hydraulic jumps. Hydroelectric plants outfitted with these types of turbines generally
have a large pipe called a pressure gallery to transport the fluid from great heights, often more
than200 m. At the end of the pressure gallery, water is provided to the turbine through one or
several needle valves, called injectors, which are nozzle shaped to increase the speed of the
flow impact upon the buckets. The nozzle or injector launches the water jet directly against a
series of bucket-shaped paddles mounted around the outer border of the runner. The water
provides a driving force on the buckets, exchanging kinetic energy with the wheel by virtue of
its change in the amount of movement. [21]

D. Gravitational Water Vortex Turbine (GWVT) is a new technology in which

Potential energy of water is converted to kinetic energy by a rotation in basin and this kinetic
energy of water is extracted by this turbine in the center of vortex. These systems can operate
on heads as low as 0.7m. The construction costs are relatively small because of its simpler
construction with no need of dam structure and the use of locally available materials. This
makes them suitable on irrigation canals, across cane field of Methara sugar factory. The
installation of GWVT can act as an exemplar project that can have huge environmental benefit
with no negative environmental impact. Moreover, GWVT improves water quality by
oxygenation. Thus, for a sugar factory, like Methara, this technology has a great potential to
overcome the shortage of electricity that was been a bottle neck for increasing productivity.
[17]

1.1.2. Methara Sugar Factory

The factory is found in Oromiya Regional State at 200 Kilo Meters distance from Addis Ababa.
Same as Wonji Shoa Sugar Factory its construction was carried out by H.V.A. Company of the
Netherlands. The factory started sugar production in 1970. Formed as Share Company between the
then Ethiopian government and the constructing company, it was the third sugar mill to the nation.
It currently has more than 10,000 hectares of land covered with sugarcane. Its average production
capacity is 136,692 tons of sugar a year. Through an expansion project conducted, it came up with
an ethanol producing plant by the end of 2010. Currently the factory’s ethanol plant has a capacity
of producing 12,500 Meter Cube ethanol a year. It also generates 9 Mega Watt electric power and

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satisfy its own power demand by itself. It is a factory which has applied Kaizen appropriately and
has won trophies at national competition. [23]

1.2. Problem Statement

Electricity shortage creates a vast problem in sugar producing industries, since plants in each sugar
production steps are operated by electrical energy supplement. This problem has been an enemy
of Ethiopian sugar industries for years. It arises due to age depreciation of cogeneration plant of
factories as they are using electric produced by this plant for the whole operation of sugar
production.
Our country Ethiopia utilizes sugar product that has produced mainly by Methara, Wonji and
Fincha sugar factories which have production rate of 1.1M, 0.8M and 0.7M quintals of sugar per
year respectively. This dependency of the country on the above aged factories is emerged due time
delay of construction of new sugar factories, planned by Ethiopian Sugar Corporation. Methara
sugar factory, which has the highest sugar production capacity from the listed three, executes its
production process mainly with the aid of two juice extracting plants named as mill and diffuser
plants. Each of this plant has a capacity of 3000 quintals of sugar production from 4992 tons of
cane supplied. These two huge plants electrically supported by steam driven power turbines from
the cogeneration plant circuit. There are three turbines existed in Methara sugar factory which
individually generates 3.3MW power. For the sake of bad luck, one had burnt out due to mis
handling of the overall session. So, the factory management had decided to bypass the diffuser
plant until they get another additional power source.
During our internship program we had observed that loosing 3000 quintals of sugar per day is not
a simple issue to ignore. So as a mechanical engineering student we are intended to propose a
document that is set to design gravitational water vortex turbine which can produce 15kW of
power. This turbine will be mounted on four different places at the irrigation canal in a cascaded
manner. These four turbines together generate 60kW power that will enough to run the diffuser
plant and produce that expected 3000 quintals of sugar. . [31]

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1.3. Literature Review

1.3.1. Introduction
The huge importance of hydroelectric power plant has been an incentive for conducting
various researches from different perspectives to fulfill the growth of industry all over the
world. The eventual sophistication of science and technology permitted researchers to focus
on the design, failure analysis and development of better material and processes that could
maximize the efficiency of the hydro power turbines
Many researches have been studied on factors that have adverse effect on efficiency of turbine
blades. Since the last century, fatigue crack propagation has been a great interest in
researching of failure of the pelton turbine blades.
The problems in the turbine blade do not only affect the efficiency of the power plant but also
pose a threat to the life of the operational and maintenance personnel. Of all problems, crack
propagation by fatigue load is one of the severe problems which can fractures the blade and
even the turbine. Understanding the possible problem will assist in preventing such losses and
catastrophes.
A large number of researches and papers have been written on gravitational water vortex
turbine, also on micro hydro powers we focused on our interst and reviewed same.
Some of the researchers’ achievements related to my thesis objective are:

1.3.2. On Micro Hydropower

Prof Dr. P.S. Pingle and Urmila Zope, [10] works on Micro hydropower turbines designs and
this paper discusses review of work performed on generation of hydroelectric power by using
various water turbine including already existing and also newly designed turbine. This paper
is a comprehensive review of different types of water turbines developed by different
researchers as per need for production of electricity from small rivers and streams inorder to
meet the need of electricity for rural area peoples in India. (2014)
Abdul Muis, Priyono Sutikno, Aryadi Soewono, Firman Hartono, [11] works on the design
optimization of axial hydraulic turbine for very low head application. This Study is conducted
on axial hydraulic turbine for very low head application which operates on low speed. Design
optimization is generated by optimizing the blade airfoil and blade cascade during

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development of the turbine blades. Blade airfoil is optimized to obtain optimum value of ratio
of Lift coefficient Cl and Drag Coefficient Cd in the range of turbine operation. Numerical
analyses are conducted to determine the performance of the designed turbine. The results of
numerical simulations show that the turbine can be operated at a maximum efficiency of 91%
at various ranges of flow rates. (2014)

1.3.3. On Gravitation water vortex turbine (GWVT)

Yasuyuki Nishi and Terumi Inagaki, [6] works to clarify the performance and flow field of a
gravitation vortex type water turbine and conducted experiments and numerical analysis,
taking the free surface into consideration. (2017)

Nauman Hanif, [6] Khan studies a simple methodology that has been used to investigate the
parameters that result in the formation and strengthening of vortex and an efficient generation
of energy using a strong artificial air-core vortex. The analysis of the vortex formation at
different basin parameters led to the reduction of the flow-rate in order to increase the
efficiency of the plant. (2016)

S. Wanchat and R. Suntivarakorn, [3] studies on the analysis and design of a basin structure
which has the ability to form a gravitational vortex stream. (2011)

Anjali Mohanan M, [9] determine and prove the possibility of using a gravitational vortex
turbine for free flowing water. (2018)

Ajay Kumar Jha, [8] presents about the technical feasibility of innovative low head turbine
technology, Gravitational Water Vortex Hydropower Plant fitted zwith conical basin. (2018)

1.3.4. On suitable turbine blade type

Saeed Badshah and Noor Rahman,[14] works on the modeling and Analysis of the runner of
a low head Kaplan for a specific site at RD 216+852 Jhang branch Canal in Punjab, Pakistan
where the net head and rated flow of water is 1.16m and 7.07m3/s respectively. (2014)

Pankaj p. amonkar, abhay u. naik, sagar devashetty and Vinod kolar, [15] works on structural
analysis on micro-hydro Kaplan turbine blade and review of analysis and Design work
performed on Micro Hydro Kaplan Turbine. (2016)

Chamil Abeykoon and Tobi Hantsch, [16] works on the design and analysis of a Kaplan
turbine runner wheel and they concluded that the efficiency of a turbine is highly influenced

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by its runner wheel and this work aims to study the design of a Kaplan turbine runner wheel.
First, a theoretical design was performed for determining the main characteristics where it
showed an efficiency of 94 %.( 2017)

Lie Jasa, Putu Ardana, Ardyono Priyadi, Mauridhi Hery Purnomo, [12] worked on the
investigation of curvature angle of the blade of banki's water turbine model for improving
efficiency by means particle swarm optimization. The blade curvature angle in a Banki’s water
turbine model is investigated using the particle swarm optimization algorithm to obtain the
highest output power, speed, and efficiency in the water turbine. (2017)

Salman Habib, [13] works on Power generation from canal system using adjustable Twisted
Blade Turbine. The results shown in this paper were evaluated on the wet area angles of 150
to 200. Our calculations propose that these angles can be varied to 280. And the turbine
efficiency was assumed to be 35%, however, with better engineering skills these results can
be improved to at least 59%.

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1.4. Objective
1.4.1. General Objective:
The general objective of this thesis is:
 To design gravitational water vortex turbine and produce a prototype.

1.4.2. Specific Objective:

The specific objectives are:
 Detail design of Basin.
 Detail design of Turbine.
 Prototyping of the Gravitational water vortex turbine.

1.5. Research Methods and Methodology

The methods and methodologies employed to achieve the above objective are:

a) Literature Review
Literature review of relevant material on different methods of designing gravitational water
vortex turbine and will be done. The review will be based on literatures available from
electronic media, journals, and books. Besides, secondary data, from previous related
research studies, existing statistical data, etc. will be used.

b) Data Collection
The geometrical specifications will be collected from plantation department office of Methara
sugar factory since issues concerning irrigation canal design data are their responsibilities.

c) Modelling and Simulation of Gravitational water vortex Turbine Blade

Having modelled the 3D model of the turbine blade using Solid Work software, the Finite
Element Method Simulation will be done by using ANSYS Workbench software.

d) Results, Discussion, Conclusion, Recommendation and Future work

Discussion and conclusion will be drawn based on the analysis done on the method and
recommendations will be given after concluding the result. Finally; based on the limitations
and scope of the thesis, future work will be forwarded for further study

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1.6. Scope and Limitations

Scope
This thesis is intended to analyse the design and prototyping of GWVT which is used for Metahara
sugar factory diffuser plant. But, due to wideness of the research area and shortage of budget and
other undefined problems, which need further studies; this research paper will focus to answer the
following statements.

• Discuss the gravitational water vortex turbine (GWVT) used in hydropower plants.

• Design of the basin, vortex and the turbine.

• Discuss the performance of gravitational water vortex turbine (GWVT).

• Modelling gravitational water vortex turbine (GWVT) using modelling software (Solid
Work).

• Simulating the modelled GWVT by finite element software using ANSYS workbench.

• Prototyping of the GWVT

• Concluding and recommending the result based on the analysis.

Limitations
The experimental method is quite expensive to perform different testing like corrosion, erosion, wear,
surface finish and etc. Moreover, the experimental set ups are not available in developing countries
such as Ethiopia. For this reason, this thesis paper is limited to analytical and finite element methods.
Gravitational water vortex turbine (GWVT) are subjected to a combination of stresses caused by
centrifugal force and cyclic loads. The centrifugal force is induced by the fast rotating body and is
related to the runner speed and mass. A gravitational water vortex turbine (GWVT) operating with
cyclic load in corrosive and erosive environment at elevated temperature is inevitable to experience
instability, become corroded, eroded and creeped. Even though they are critical problems, the
following are not addressed in this paper due to the problems mentioned earlier.

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• Vibration of the bucket.

• Corrosion and Erosion problems,
• Wear problem,
• Thermal load/ creep effect
• Surface finish of the material, etc...

1.7. Significance of the Study

The outcome of this thesis is very significant to sugar factories with severe power shortage like
Metahara sugar factory and for the electrification of the rural population living by river side
throughout the country also the outcome of this thesis will be used as a spring board for farther studies
and researches on Gravitational Vortex Turbine.
As the experimental method is quite expensive, modelling and simulating using FEM analysis
software’s can reduce the cost and also the required result can be found with a short period of time.

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Chapter 2
Product Design and Development
2.1 Introduction
GWVT is a new technology in which potential energy of water is converted to kinetic energy by a rotation
in basin and this kinetic energy of water is extracted by this turbine in the center of vortex. These systems
can operate on heads as low as 0.7m. The construction costs are relatively small because of its simpler
construction with no need of dam structure and the use of locally available materials. This makes them
suitable on irrigation canals, across cane field of Metahara sugar factory. The installation of GWVT can
act as an exemplar project that can have huge environmental benefit with no negative environmental
impact. Moreover, GWVT improves water quality by oxygenation.

2.2 Current Existing Platforms in Ethiopia

The design and development of micro power generation have started a few years ago following the
county’s plan utilize the water and other energy resources found in the country for the production of
electricity. There are different kinds of micro power generation technology in the country. Mainly these
are: -
 Cross flow turbine
 Cross flow turbine is the suitable primarily water turbine for the microhydro industry
because of its simple structure and high possibility of applying to small hydropower. It is
assembled with few components, and can work effectively at the comparatively low head
and low discharge in the onshore and offshore without nature disruptions.
 The crossflow turbine has been installed in many places in the country. Wolisso hulluka
river project [30], Jimma zone kersa-minko project are examples of places where crossflow
turbine exists.
 Small wind turbines
 Wind energy is rapidly emerging as one of the most cost-effective forms of renewable
energy with very significant increases in annual installed capacity around the world.
Considering the substantial wind resource in the country, the government has committed
itself to generate power from wind plants. This development of wind power is a part of the
current energy sector policy of the country that aims at a five-fold increase in renewable
energy production.
 The wind turbines has been installed three places in ethiopia. These are Adama wind farm
1 & 2 and Ashegoda wind farm. And also the fourth wind farm is in progress.

 Solar photovoltaic cell

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 Ethiopia is thought to have about 5 MW of off-grid solar. Almost all current solar power
is used for telecommunications. Other uses include village well pumps, health care and
school lighting. A current government initiative plans to bring solar power to 150,000
householdsThe first phase included 1 MW of panels. The first large installation of solar
was a village grid of 10 kW in 1985, expanded to 30 kW in 1989. A solar panel assembly
plant opened in Addis Ababa in early 2013 capable of making 20 MW of panel per year.

Figure 2.1. Cross flow turbine manufactured in Ethiopia for low head power generation.

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2.3 Assessment of the Market Opportunity

Ethiopia is located in east Africa with total area of 1.1 million sq. kilometres and a population of more
than 90 million and is endowed with enormous renewable energy resources that include 45,000 MW
hydropower, 10,000 MW geothermal power, 1,350,000 MW wind, and massive solar and biomass
potential. Biomass covers 90% of the total energy consumption, mainly used for cooking in the
household. The energy consumption of the country is 45 kWh/capita which is the lowest when compared
to averages of 578 and 2752 kWh/capita for Africa and the world, respectively The total electric access
rate is around 41% and less than 10% of the rural people connected to the national grid. The government
has taken different measures to increase electrification access in the country of which formulation of
energy policy in 1994 is one of the positive drives. The policy encourages the use of indigenous resources
and renewable energy to secure energy supply and reduce use and dependency on fossil fuel. The policy
puts hydropower resource development as top priority due to availability of high potential site suitable to
generate electricity at relatively lower cost. The country generates around 91% of its power from large
scale hydropower and small scale hydropower development gets little attention from the government side
and contributes a small portion in the energy pool of the country.

Researches shows that Small scale hydropower is estimated to be 10% of the total hydropower potential
of the country. As feasibility study, the government identified around 299 hydropower potential sites
within eleven river basins with a total potential of 7877 MW including both large and small hydropower.
The potential for small scale hydropower lies in western and southwestern Ethiopia, where annual rainfall
ranges from 300 mm to over 900 mm especially in Omo Gihbe basin and Abay basin. In the past majority
of small scale hydropower schemes in the country were abandoned due to the encroachment of the national
grid with cheaper and more reliable electricity. Currently only one small and two mini hydropower (MHP)
schemes are functional under EEPCOs Self-Contained System (SCS), namely, Sor (5 Mw), Yadot
(350 kW), and Dembi (800 kW), with a cumulative installed capacity of 6.15 MW. Moreover, another
four new small hydropower schemes (Gobecho I = 7 kW, Gobecho II = 30 kW, Hagara Sodicha = 55 kW,
and Ererte = 33 kW) have been installed in the southern part of Ethiopia in Sidama zone with the help of
the German Cooperation Organization (GIZ) as pilot project in 2011.
Among the reasons for the highest market opportunity in Ethiopia are:
 The availability of many water resources in the country year to year.
 The shortage of electricity in the country have become problem to the peoples.
 Most rural part of the country don’t have electricity access.
 The cost of electricity have become problem to the people.
 Competition in the market is very low.

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2.4 Mission Statement of the Project

This project is dedicated for the design of a gravitational water vortex turbine that will satisfy the needs
of Methara sugar factory of Ethiopia. The mission statement of the project is summarized in Table 1.2.
Mission Statement: A row sowing machine
Product Description  A gravitational water vortex turbine from Methara
irrigation canal
Benefit Proposition  Electricity can produced from the turbine which runs
different plants
 Saves electricity cost of the factory
 Durable and efficient
 Affordable price
Key Business Goals  Serve as platform for future derivatives
Primary Markets  Methara sugar factory
Secondary Markets  Government. (i.e. to produce electricity from lakes,
rivers, and etc.)
 Different factories that have irrigation canals.
Assumptions and  New product to the country
Constraints  Environmental friendly
 A simple design
 Blades and shaft manufactured in Ethiopia
 Components are easily purchased from the inside market
Stakeholders  Sugar factories
 Agricultural development centers that have irrigation
canal
 Small scale manufacturing enterprises
 Distributors and resellers
 Government

Table Summary of the mission statement of the project.

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2.5 Concept Development

2.5.1 Customer Selection Matrix
This customer matrix (Table) identified the intended customer contacts (lead users, users and research and
development centers).
Type of Lead Users Users Retailer or Service Centers
Customers Sales Outlet
Market
Segments

Methara sugar factory 5 2 0 0

(Heavy-duty use)
Rural towns peoples 5 3 0 0
(Frequent use)
Factories having 0 4 0 0
irrigation canal
(Occasional use)
Government 0 3 5 3
(Occasional use)

Table 2.1. Customer selection matrix

2.5.2 Customers Need Raw Data
We have conducted a survey on the real customers need by going to their working place and individual
interview. We have collected the following raw data.
Customer name: Ato. Arefayni Nigusse (power plant division head in Methara sugar factory)
Address: Methara
Question /prompt: Basic needs related gravitational water vortex turbine?
Response:
 Maintained easily.
 Should operate for long time
 Do not corrode easily
 The product price must be affordable.
 Should be strong.
 Don’t be affected by temperature.
 Environmental friendly.

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Customer name: Ato. Fahmi Dawud (technical manager in Methara sugar factory)
Address: Methara
Question /prompt: Basic needs related to gravitational water vortex turbine?
Response:
 Last longing machine.
 Gives higher output.
 Light weight, easily operated.
 Will be our preference if it can have no harm on aquatic life like fishes.
 Should be strong.
 It should occupies smaller space.
 Maintained easily.

2.5.3 Customer Need Statements and Interpreted Needs

Customer needs are expressed as written statements and are the result of interpreting the need
underlying the raw data gathered from the customers. Each statement or observation may be translated
into any number of customer needs. Multiple analysts may translate the same interview notes into
different needs, so it is useful to have more than one team member conducting the translation process.
Below we provide five guidelines for writing need statements.

 Express the need in terms of what the product has to do, not in terms of how it might do it.
 Express the need as specifically as the raw data
 Use positive, not negative, phrasing.
 Express the need as an attribute of the product.
 Avoid the words must and should.

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Question/Prompt Customers Statements Interpreted Needs

Basic needs I need to get available power from the The GWVT has higher efficency
irrigation water
I need to mount it in smaller place. The GWVT occupies less space.
The price need to be affordable. The GWVT has less cost.
I want to be able to maintain the The GWVT can easily be
turbine by myself. maintained.
I need to have a long-lasting turbine. The GWVT has high durability.
I need to have high strength turbine The GWVT has high strength.
I need to have turbine that can’t The GWVT is corrosion resistant.
corrode.
I need to have environmental friendly The GWVT is recyclable.
turbine.
I need to operate it easily. The GWVT is easily operated
I need to have turbine that cannot be The GWVT is thermal resistant.
affected by higher temperature.
I need to have turbine that don’t harm The GWVT is fish friendly.
aquatic life.
Likes-existing _ _
product
(if ever used one)
Dislikes-existing _ _
product (if ever
used one)
Suggested _ _
improvements

Table 2.2. Customer need statement and interpreted needs.

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2.5.4 Relative Importance of the Needs

The outcome of this step is a numerical importance weighting for a subset of the needs. There are two
basic approaches to the task:
(1) Relying on the consensus of the team members based on their experience with customers, or
(2) Basing the importance assessment on further customer surveys.
The obvious trade-off between the two approaches is cost and speed versus accuracy: the team can make
an educated assessment of the relative importance of the needs in one meeting, while a customer survey
generally takes a minimum of two weeks. In most cases we believe the customer survey is important and
worth the time required to complete it.
In Table different interpreted customer needs have given relative importance based on the customer’s
preference.
Importance ratings for the customer needs are indicated by the numbers ranging from 1 to 5. 5
representing critically important need and relative importance decreases as the number decrease. Latent
needs are denoted by !.

Need Interpreted customer needs Relative

No. importance
1 The GWVT has higher efficiency 5
2 The GWVT has high durability. 5
3 The GWVT has high strength. 5
4 The GWVT can easily be maintained. 4
5 The GWVT less cost. 4
6 The GWVT has occupies less space. 3
7 The GWVT is corrosion resistant. 3
8 The GWVT is recyclable. 3
9 The GWVT is easily operated 3
10 The GWVT is thermal resistant. 2
11 The GWVT is fish friendly. 2!

Table 2.3. Customer need statement and interpreted needs

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2.5.5 List of Matrices for the Gravitational Water Vortex Turbine.

The most useful metrics are those that reflect as directly as possible the degree to which the product
satisfies the customer needs. The relationship between needs and metrics is central to the entire concept
of specifications. The working assumption is that a translation from customer needs to a set of precise,
measurable specifications is possible and that meeting specifications will therefore lead to satisfaction of
the associated customer needs.
A few guidelines should be considered when constructing the list of metrics:
 Metrics should be complete.
 Metrics should be dependent, not independent, variables
 Metrics should be practical.
 Some needs cannot easily be translated into quantifiable metrics.
 The metrics should include the popular criteria for comparison in the marketplace.

Metric Need Metric Imp. Units

No. Nos.
1 1,3,7,10 Efficiency 5,5,3,2 -
2 2,3 Design life 5 Years
3 3,7,10 Material strength 5,3,2 MPa
4 4,5,9 Maintainability 4,4,3 %
5 4,5 Price of the turbine 4 ETB
6 6 Space occupied 3 m3
7 2,7 Corrosion resistance 5,3 Mils/year
8 5,8 Recycling 4,3 ETB
9 1,9 Reliability 4,3 %
10 2,10 Thermal resistance 5,2 (m2K)/W
11 11 Fish friendly 2! -

Table 2.4. List of matrices for the GWVT

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10

11
1

9
METRIC

Corrosion resistance
Price of the turbine

Thermal resistance
Material strength

Space occupied
Maintainability

Fish friendly
Design life

Reliability
Efficiency

Recycling
NEEDS
1 The GWVT has higher * *
efficiency
2 The GWVT has high * * *
durability.
3 The GWVT has high * * *
strength.
4 The GWVT can easily be * *
maintained.
5 The GWVT has less cost. * * *
6 The GWVT occupies less *
space.
7 The GWVT is corrosion * * *
resistant.
8 The GWVT is recyclable *
9 The GWVT is easily * *
operated
10 The GWVT is thermal * * *
resistant.
11 The GWVT is fish *
friendly.

Table 2.5. The needs-metrics matrix.

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2.5.6 Ideal and Marginally Acceptable Values

The team synthesizes the available information in order to actually set the target values for the metrics.
Two types of target value are useful: an ideal value and a marginally acceptable value. The ideal value is
the best result the team could hope for. The marginally acceptable value is the value of the metric that
would just barely make the product commercially viable. Both of these targets are useful in guiding the
subsequent stages of concept generation and concept selection, and for refining the specifications after
the product concept has been selected.

Metric Need Metric Imp. Units Marginal Ideal value

No. Nos. value
1 1,3,7,10 Efficiency 5,5,3,2 - >60% >90%
2 2,3 Design life 5 Years >7 >10
3 3,7,10 Material strength 5,3,2 MPa - -
4 4,5,9 Maintainability 4,4,3 - >85% >95%
5 4,5 Price of the turbine 4 ETB - -
6 6 Space available 3 m3 <3 <2.3
7 2,7 Corrosion resistance 5,3 Mils/year - -
8 5,8 Recycling 4,3 ETB - -
9 4,9 Reliability 4,3 - >95% >99%
10 2,10 Thermal resistance 5,2 (m2K)/W - -
11 11 Fish friendly 2! - - -

Table 2.6. Target specifications

No Metric Unit Target value

1 Efficiency % 80%
2 Design life Years 8
3 Material strength MPa -
4 Maintainability % 90%
5 Price of the turbine ETB -
6 Space available m3 2.5
7 Corrosion resistance Mils/year -
8 Recycling ETB -
9 Reliability % 97%
2
10 Thermal resistance (m K)/W -
11 Fish friendly - -

Table 2.7. Target values

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2.6 Concept Generation and Selection

2.6.1 Concept Generation
1) Clarification of the Problem

Accept Convert potential

Energy
external energy to rotational
energy kinetic energy

Apply rotational
energy to the Generate
generator electricity

Water Water rotates the

Water
creates turbine
vortex

Figure 2.2. Function diagram of the GWVT

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2) Search Externally

Twisted blade
Figure 2.3. Different blade types suited for GWVT

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Circular centered
3) Explore Systematically
Circular offsetted
Vortex
Circular with guider

Rectangular
Electricity
generation
Kaplan

Turbine
Twisted

Rectangular

Helical

Figure 2.4. Concept classification tree for the GWVT.

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- Platform

Figure 2.5. Cross flow turbine manufactured in Ethiopia for low head power generation.
Features:
 Steel material
 Water guided to the blade through guide vanes.
 Having more than 20 blades
 The blades attached to the shaft by welding.
 The generator lies parallel to the shaft in axial direction.
 Semicircular types of blades.

Advantage:
 Simpler design.
 Less manufacturing cost.
 Occupies less space
Disadvantage:
 They are low speed turbines. i.e. their speed can’t increased.
 There is harm on aquatic life even it can kill them.
 Lower efficiency.

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 Since the blades are welded there is difficulty of maintenance.

Concept 1: With Kaplan Type Blade
Description: we used Kaplan blade in this part because Kaplan blades are more important in case of low
head and high flow rate power generation. The Kaplan blades are attached to the shaft by a pin in which
it makes its maintenance simple. And the flowing water still generates vortex which will help to drive the
blades.
Components:
 Kaplan blade
 Shaft
 bearing
 pin
 casing
Advantages:
 Higher efficiency.
 Ease of maintenance.
 Less space occupied.
 No harm on aquatic life.
 No need of guide vanes since the water creates vortex by it self.
Disadvantages:
 High manufacturing cost.
 Complex design and manufacturing of blades.

Figure 2.6. Kaplan turbine blade

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Concept 2: With Rectangular Type of Blade

For this part we choose the rectangular type of blade. Because rectangular blades are easy to design and
manufacture. The blades are attached to the shaft by a pin in which it makes its maintenance simple. And
the flowing water still generates vortex which will help to drive the blades.
Components:
 Rectangular blade
 Shaft
 bearing
 pin
 casing
Advantages:
 Simple design
 Ease of maintenance.
 Less space occupied.
 No harm on aquatic life.
Disadvantages:
 High manufacturing cost.
 Smaller efficiency
 Complex design and manufacturing of blades.

Figure 2.7. Rectangular blade

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Concept 3: Twisted Type of Blade

For this part we choose the twisted type of blade. The blades are attached to the shaft by a pin in which
it makes its maintenance simple. And the flowing water still generates vortex which will help to drive
the blades.

Components:
 Twisted blade
 Shaft
 bearing
 pin
 casing
Advantages:
 Ease of maintenance.
 Less space occupied.
 No harm on aquatic life.
Disadvantages:
 High manufacturing cost.
 Smaller efficiency
 Complex design of blades.

Figure 2.8. Twisted blade

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2.6.2 Concept Selection

Concept Weight
CRITERIA

of
Maintenance

Efficiency
Durability

Percentile
occupied
Strength

Weight
Space
Ease

Sum
Cost

Cost - 1 0 0 0 3 4 4/34 11.76

Ease of 2 - 0 0 0 2 4 4/34 11.76

Maintenance
Strength 3 3 - 0 0 3 9 9/34 26.47

Durability 2 1 1 - 0 3 7 7/34 20.59

Efficiency 3 2 1 1 - 3 10 10/34 29.41

Space 0 0 0 0 0 - 0 0/34 0
occupied
Total 34 99.99

Table 2.8. Concept weighting

Concept Rating
SELECTION PRODUCT CONCEPTS
CRITERIA ALT 1 ALT 2 ALT 3 PLAT FORM
COST -- - -- 0
EASE OF ++ ++ ++ 0
MAINTENANCE
STRENGTH ++ 0 + 0
DURABILITY +3 + + 0
EFFICENCY +3 + ++ 0
SPACE OCCUPIED + + + 0
TOTAL +9 +4 +5 0

Table 2.9. Concept rating

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Concept Scoring
CONCEPTS
ALT 1 ALT 2 ALT 3
CRITERIA

WEIGHT

WEIGHT

WEIGHT

WEIGHT
RATING

RATING

RATING
SCORE

SCORE

SCORE
COST 11.76 5 0.588 6 0.7056 5 0.588
EASE OF 11.76 7 0.8232 7 0.8232 7 0.8232
MAINTAINANCE
STRENGTH 26.47 9 2.3823 5 1.3235 7 1.8529
DURABILITY 20.59 8 1.8531 5 1.0295 7 1.4413
EFFICENCY 29.41 9 2.6469 4 1.1764 6 1.7646
SPACE OCCUPIED 0 7 0 7 0 7 0
TOTAL 100 8.2935 5.0582 6.47
RANK 1 3 2
CONTINUE YES NO NO

Table 2.10. Concept scoring

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2.7 Product Architecture

2.7.1 Functional and Physical Elements
1) Functional elements of the GWVT
 Accept external energy
 Convert potential energy to rotational kinetic energy
 Apply rotational kinetic energy through the shaft to the generator
 Water creates vortex
 Water rotates turbine
2) Physical elements of the GWVT
 Components:
 Kaplan blade
 Shaft
 bearing
 pin
 casing

 Chunks:
 Power train – turbine, shaft,
 Feeding mechanism – basin, vortex
 Chassis – shaft, casing, basin hole

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2.7.2 Architecture Establishment

Step 1: Create a schematic of the product.

Accept external
energy Water

Water creates
Convert potential vortex
energy to rotational
kinetic energy

Water rotates the

Apply rotational shaft
energy to the to the
generator through the
shaft

Flow of energy
Flow of mass
Figure 2.9. Schematic of the GWVT

Step 2: Cluster the elements of the schematic.

Accept external
energy Water flows

Water creates
Convert potential vortex
energy to rotational
kinetic energy
Water rotates the
shaft
Feeding mechanism
Apply rotational
energy to the
generator by shaft

Power train Provide structural Direction control

support to the
GWVT
Figure 2.10. Schematic of the GWVT Chassis

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Step 3. Create a rough geometric layout.

c c
a a
Basin Shaft blade s Basin
s blad
wall i wall
i e
n n
g g

Generator

Figure 2.11. Geometric layout.

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