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Alok Chaudhari et al IJMEIT Volume 2 Issue 12 December 2014 Page 952
IJMEIT// Vol. 2 Issue 12//December//Page No: 952-963//ISSN-2348-196x 2014
Design of Diversion Based Mini Hydro Power Plant with Involving
Environment Analysis and Effect of Roughness Factor on Hydraullic
Turbine
Authors
Alok Chaudhari1, Antriksh Verma
2, Abhishek Singh Jatav
3
Abstract
Environmental factor is one of the major concern to the present generation. Due to the increase demand of
the electric energy hydro power plants are made because of its non-polluting behavior. Here some changes
are mention so that the environmental and social factors are eliminating with the development of small
hydro power plant. These changes are done only for achieving the concept of “Aviral Dhara” of the Ganga
River. The constant energy generation is also comes in this category which is achieved by using this new
type proposed scheme of small hydro power plant. The new hydro scheme is based on the diversion basis
without using any barrage to the river. By using the natural head and with small length of the penstock, the
energy losses are removed which directly related to the cost effective of this type of hydro power project.
Here also the roughness factor is mentioned by which the turbine efficiency is increased.
Keywords: Hydro energy, Hydro Power Plant, Environmental Aspects, Turbine Testing, Roughness Factor
INTRODUCTION
The major part of world’s economy depends upon
the energy which is from renewable energy
sources in order to produce different forms of
energy. Some are depend on the fossil fuel but
limitation of fossil fuels on the earth and recent
price hikes of these fuels in last two decades is
kind of a concern for the energy sector across the
world. Hydro energy is comes in this category
which most efficient and non-polluting to the
environment. It is also one of the most available
energy sources in the earth especially in the
mountainous region of the earth. This new type of
proposed hydro power scheme is designed in that
way which perform the efficiently without
damaging the environment or by using the natural
flow of water.
Classification of hydro power plants:
There are various ways of classification of hydro
power plants they are follows
a) Availability of head
1. High head power plant.
2. Medium head power plant.
3. Low head power plant.
b) According to availability of water
1. Hydro power plant with storage
reservoir.
2. Run of river plant with or without
poundage.
3. Pump storage hydro power plant.
4. Mini & micro hydro power plants.
High head power plant
This type power plant operating under the head of
110 m or above to it they are known as High head
power plant. In that type of power plant river
water is stored in between mountain region
especially when the heavy rainfall season begins
or also when the snow melts that time flow rate is
high. When the reservoir cross its limits then there
is another system known as spillway is design so
that the extra water is given out from that spill
way. Here tunnel is provided which act like a
penstock and is from where the water is discharge
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in the high rate to the hydro turbine these all are
done with the help of regulating valve and then
water is flow to the turbine. Just because of the
large head here the Pelton wheel is used as the
prime mover.
Fig: High head power plant
Medium head power plant
Such type of hydropower plant are found in the
large number because of the low initial cost as
compare to high head and also the efficiency is
almost or greater than the high head. The main
advantage over high head is that it can run in the
heads up to 50mt to 100mt.hence it can be used in
any ways or medium head is present almost all the
maximum sites. Because of the medium head here
we use Francise turbine as a prime mover. For
stopping the air bubble in the penstock we made a
forebay tank which is just used before the
penstock act as a reservoir as well as surge tank.
Low head power plants
These are constructed where the head is available
below the 50 meter. In that condition the dam is
constructed across the river and the side way
bypass channel is made from the divergence of the
river is constructed and here a forebay is provided
before the power house. After the passage through
the turbine this water again meets to the main
river from where it is actually diverted. Just
because of the head is low so here Kaplan turbine
or Francise turbine are used as the prime mover.
Hydro power plant with storage reservoir
This one of the most common power plant used in
the worldwide or also in the India. Here the
simple process is used water is stored in the
reservoir especially during the rainy season and
then producing electricity which is used
throughout the year. It has the benefit over the
other power plant is that the reservoir is used in
many application such as for Irrigation, drought
remedies, and also for agricultural system.
Run of river plant with or without pondage
These are used using the actual flow of the river,
here without pondage water is used as the flow
rate and all are depend on the discharge of the
river. On the other hand with the pondage a small
reservoir is located and then the small diversion
made from which the turbine is run. The main
advantage among the run off river plants is that a
continuous generation of electricity is achieved
without any disturbances but all that the only
disadvantage is that the continuous flow of water.
Fig: Run of river plant
Pump Storage hydro power plant
Here the concept is totally change and here we
made two reservoir first is head water reservoir
and the second is tail water reservoir. Actually this
type of power plant is used with the
interconnected with the storage type power plant
and during the night time when demand is almost
low then the access electricity is used to run the
reversible turbine this is used when the
interconnected is used otherwise simple Francise
turbine with the another type of design of the
blade used.
The advantage of that power plant is that:
High operating efficiency.
At low cost sudden increase in the peak
load.
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Independence of the condition of the
stream flow.
Mini & Micro Hydro Power Plant
As per the name suggest these power plants are
smaller in size and the main advantage is over
large hydel plants is that it overcomes all the
problems which is actually comes from the large
hydropower plants. The natural water source in
the hilly region used easily for converting that in
to the electricity and the main effect is that there is
no any ecology harmful effect to the environment
and to the natural vegetation. Mini hydro plants
operated under the low head of range between
10mt to 20mt. Producing about 2MW. With the
study of the survey it is found that the potential
energy which is actually generated from these two
types of hydel power plant is about 24,000MW.
The main advantage of this type is that less
harmful effects to the environment.
Base Load hydro Plants
This type of power plant used as the transferring
the constant power to the grid without any
disturbances. Because of the sufficient power
supply base load plants have their extensive
properties of the supply electricity.
Peak Load Hydro Plants
These types of power plants actually uses even the
demand of the electricity is high and also when
the load is more to the plant than the nominal
load. In the interconnected system like as the
thermal and hydro plants operated to meet the
base & peak load during the time of the various
seasons of the demand.
Hydraulic Turbine & There Classification
The main principle of the any type of turbine is
that the conversion of the one form of energy to
another form. In case of the hydraulic power plant
potential energy of the water is converted into the
mechanical energy by the device which is known
as the hydraulic turbine. In this process the head
energy of the water is converted in to the shaft
work and finally with the help of electric
generator it is converted in to the electrical
energy, when the turbine is coupled to the
generator within the same shaft. As per the new
invention of the turbine blades and design
parameters new turbine developed which produces
large amount of output and the efficiency is
almost high in all the respects.
Head & discharge of available water
The most important parameter in the selection of
the turbine is about the measurement of the head
of the water flow. The new term gross head is
used which basically meaning the difference in the
water level from the surface of the water between
the head race and tail race. While the net head is
define as the difference between the gross head
and head loss due to friction. On the basis head
turbines are also classified as:
I. Low head Based turbine
Head is in the range of 3mt -15mt.
Need a high discharge rate.
Kaplan Turbine or Propeller Turbine is
generally used.
II. Medium Head Based Turbine
Here head in the range of 16mt -75mt.
High or Medium discharge rate needed
Kaplan Turbine or Francise Turbine is
generally used.
III. High Head Based Turbine
Head is used within the range of 76mt
-500mt.
Medium or low discharge rate needed.
Francise Turbine or Pelton Turbine is
used.
IV. Very High Head Based Turbine
Head is greater than 500mt.
Here only low discharge rate is used.
Only Pelton Turbine is used.
Advantage of runoff river plant
It is non-polluting, renewable energy
sources, and environment friendly process
of energy.
Like as the all hydropower project run off
river plant uses the natural potential
energy by eliminating the process of the
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coal burning, natural gases, or any other
pollution creating techniques to generates
the electricity.
Because of the low area required these
plants are easily setup near the load Centre
and hence reduces the transfer lining cost
and also another benefit is that it also
developed according the demands of the
load.
Here the generation of the electricity is
continuous.
It followed the approach of the demand of
the power without any disturbances.
Maintenance and operating cost are low.
Life cycle period of the power plant is
almost high or can say that it is long
lasting technique.
Capacity factor of the micro hydel power
plant is high as compared to the other
renewable sources.
No fuel requirement it is the best
advantages.
It has the high efficiency about 60prcnt -
70prcnt
OVERVIEW OF HYDROPOWERPLANT
The hydro power plant consists of many parts and
these parts are the basic parts of the power system
but they are divided in four basic sub parts. All
these four components are totally defining all the
parts of the hydro power plants.
Civil Structured
There are various structures for the layout of the
hydropower plant and these are actually depends
on the site location. Some possibility regarding to
that type are discussed below but our area of
concerned is not on that type these are
Low head with the barrage in the river.
Low head by using the channel duct.
High head without using channel.
High head with using channel.
After knowing the different structures one thing
should be noted that according to this different
essential factors which should be kept in mind
before designing the mini hydro power plant.
These factors include the following results.
Fig: Diversion based hydro power plant
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Hydraulic System
It consist basically the intake structure but due the
design only the Mechanical device and the
channels from which the water is passes through
the inlet turbine is comes in this category it mean
the hydraulic turbine. Which convert the kinetic
energy of the water to the mechanical energy and
thus rotating the turbine blade further converted in
to the electricity?
Electricity Generating System
It is also known as the electrical equipment
system it includes the Generator, the processing
and monitoring equipment, with the switch gear
and the transformer here the mechanical energy is
converted in to the electric energy.
Consumer System
It is the final component which consist the means
of distribution system and the appliances or we
can say that the electric load devices like Radios,
Television, Heaters, and Motors etc.
Use of available head
The head or net head or the gross head is from
which the power delivered to turbine is the main
criteria before set up the design. The power
generated through the turbine is directly
proportional to the head of the plant site location.
So the generated power is direct belongs to the
head.
LOW HEAD DIVERSION SCHEME
Sediment
The flowing of the water is the main key of the
hydro power project the only thing is the sediment
or the sand of the river level which is the main
drawback of the project site so before going water
in to the turbine the problem is removed by
applying the some devices or uses the hole casing
before going to the intake. Sediment also blocks
the intake of weirs and causes the channel many
harmonies.
On our proposed model we made a sediment
chamber just before going to the turbine inlet the
diagram shown below is based on the
sedimentation treatment scheme this basic design
which we use in our proposed system.
In the new type of scheme of hydropower plant
which is based on the diversion based of the river
flowing water the above factor play a vital role
and on the basis of these parameters the design is
done and all the civil structures are made so that
the problems are resolved.
PROCEDURE OF TURBINE TESTING
The turbine setup test consists of a dynamometer
which is coupled to the turbine through the
instruments of torque transducer. This torque
transducer is coupled in between the
dynamometer which is used to indicate the torque
applied by the dynamometer. Now the non-contact
type tachometer is used which measure the
rotation speed of the turbine, in this process the
outlet is freely allowed to flow on the sump
without any draft tube. Here an electromagnetic
flow meter is used which is used to measure the
flow rate through the turbine. A precision pressure
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gauge is connected for measuring the head of the
water at inlet of the turbine.
The testing was done with different guide vane
opening at 25%, 50%, 75%, and 100%. In the
starting phase of testing turbine was allowed to
run in its runway speed by some time and then run
way data collected during this time the
dynamometer is physically condition connected
and that is in operating condition. And during the
switched off condition the dynamometer is freely
rotating with the turbine speed.
At each step the head, discharge, speed and torque
which are produced by turbine are noted down
and from these data Hydraulic power and water
power is calculated and the overall efficiency is
noted down.
MEASURING INSTRUEMENT USED IN TURBINE TESTING
Sl. No EQUIPMENT SPECIFICATIONS PURPOSE
1 Pump Flow - up to 450 m3/sec
Head – up to 100m
Water supply
to test rig.
2 Electromagnetic
Flow meter
Size - 6"
Flow Range 15 -600m3/sec
Uncertainty - +/- 0.4121 m3/sec
Flow Measurement
3 Precision Pressure
Gauge
Range 0 – 100 m
Uncertainty - +/- 0.03% of reading
Head measurement
4 Torque Transducer Range 500 - 1000kN-m
Uncertainty - +/- 0.31 of FS
Torque Measurement
5 Tachometer Range 0-1000 RPM
Uncertainty - +/- 0.4RPM
Turbine Shaft
Speed measurement
Impact on places of cultural and religious
importance
India is the land of the religious country and the
one truth is that about river water from the
religious culture point of view. The main activities
is that the bathing in the river water on the
auspicious day, shaving the of infant popularly
known as Mundan, Shradha ceremonies etc. for
these functions the flowing water is concerned and
from there point of view the only flowing water is
pure and if the flow is blocked than according to
that it losses its purity.
Now coming to the non-religious tourism based
around the water ,adventures sports, trekking eco
friendly environment and eco-tourism are some
other areas which are totally depends on the river
water not only water but the river flowing water.
All are the human needs every want to do enjoy
the natural beauty and all these are depend on the
water.
The study about that topic is concerned and
focused on some areas which are belonging to
both religious and nonreligious view.
Aviral Dhara or Uninterrupted flow of
Ganga or river.
Diversion of river by constructing the
barrage and leaving the large area with
little or no water.
Effects on the pure factory quality of water
by constructing hydro power plants.
Effects on the non-religious tourism based
around the river water.
All the data for study is qualitative in nature not
concerning the quantitative. Our study mainly
concerned with the interviews conducted with the
members of the religious community, business
class’s communities, political communities,
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village’s residents which are besides the river and
staffs of power companies. According to these
studies we find some results that are summarized
below.
By conducting the interviews there find some
positive economic benefits for local people like
they have some opportunities for starting hotels,
guest houses near the project area not only this the
companies those are taking the power house
project give the job opportunities to the local
village people, and also with the help of
government providing some money schemes for
those who were living near by the project area
site.
For the people who are strongly devoted to the
god according to their view economic
consideration are worth less when it is compared
to the flowing water river they are not agreed to
compromise there natural heritage by assured
them a good environment livelihood
opportunities.
The local people facing the adverse impact of
hydro project construction activities for example
damages to houses, properties, agricultural fields,
farming lands, water sources, cultivation land etc.
Those who were totally depend on the farming by
providing some money and resettle the case;
environmental issue is concerned is taken by the
help of the people hearing.
The Ganga as Goddess and Aviral Dhara
For those people who really believe that the
Ganga is a goddess and believed that its flow
never be interrupted or we can say that the Aviral
Dhara of the Ganga. All these people are totally
opposing the hydro project in the region of
Uttarakhand. They also oppose the diversion of
the river because as there mythology all are
factors which impure the water of the river. Just
because of that when the river is diverted the total
area which is in contact in the area of the
diversion side is going totally in the dry region or
very much less water is present there just
therefore affect the local people and also all the
animal which are living at that places are also very
much affect.
Harkipedi in Haridwar is only one of the religious
places which are accepted by the Hindu by the
diversion in the upper channel of the Ganga River.
The actual flow of Ganga is on the other side.
Sadhu Samaj accepted the diversion river.
Aviral dhara concept of the Hindu mythology has
the greater significance during the period when
Tehri dam is in its construction phase. That time
with the support of government all the issued are
taken away as per government rule.
Environmental impact
Environment it is one the basic needs to the
people who lived in this earth now going to those
area where the hydro project are developed just as
talking in Uttarakhand . The total change in
environment is now seen the monsoonal rain is
affected due to the construction of the large
reservoir of dams especially the Tehri dam and the
Srinagar project by which the whole area is
affected near the dam site. Because by
constructing the reservoir they actually stopping
the river flow and thus the large amount of water
is collect at particular place resulting the high
evaporation rate at that particular site which affect
the rate of cloud formation and also affected the
dew point temp as a result the heavy rainfall is
measured at that area and most of the time the fog
is seen which affect the natural ecosystem to
whole of the reservoir side area.
So from the good environmental point of view
there should be a proper measure taken place
Incomplete hydro project schemes should
be completed without doing any further
delay
A well planned environmental assessment
is done before constructing the hydro
project.
Environment is more important than the
development there should be a proper
focuses is done on these system.
People of Uttarakhand must have right to
use the river water for their use and
drinking purpose.
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Political issues are not going to take as a
personal issue every government should
think about the environment not to the
profit to their personal use.
Surface finishing processes
Mechanical surface finishing process
It is the broad range in the industrial process that
is done on the surface of a manufactured item to
achieve the certain property. Finishing process
may be used to improve the corrosion resistance,
wear resistance, remove burrs, and other surface
defects it is also used i widely for removing the
surface friction. In many case these finishing
process are used to restore the original dimension
shapes.
Grinding and polishing
Grinding is the process which is done on the
surface of the parts such that its finishing is done
and also to minimizing the losses. Here a grinding
wheel is covered in rough particle which cuts the
chip from the metallic particles from work piece
making face flat or smooth Surface Grinders a
machine tool use to provide the surface finishing.
Mechanical stainless steel polishing is the
abrading process which is used to remove the
lines or also to the smooth grinding lines,
scratches, tool marks, parting lines, and other
types of surface defects which affect the
performance of the metallic parts. By using this all
the problems are removed and thus obtaining the
fine surface.
Abrasive Blasting
It is the operation which is forcibly applied or
stream of abrasive material against a rough
surface to smoothen it this process remove surface
contaminants. After that a pressurized fluid or an
air or some time it uses the centrifugal wheel is
used to propel the blasting material.
Buffing
Buffing is in category of the finishing process for
smoothing the work piece surface by using an
abrasive or leather strop. Technically buffing uses
a loose abrasive applied to the work wheel. When
it is compare to polishing it is less effect it leads to
a smoother and bright surface.The actual meaning
of buffer that is soft thick undyed leather which is
made up from the skin of buffalo.
Filing
It is the material removal process which is
generally used in manufacturing. It is most widely
used for finishing operation. Filing is based on
function by removing some excess material and
deburring the surface. The common material
which is used in filing that is sand paper.
A burr is a raised edge or small pieces of material
remaining attached to a work piece after a
modification process. It is usually an unwanted
piece of material and is removed with
a deburring tool in a process called 'deburring'.
Burrs are most commonly created
after machining operations,suchas grinding, drillin
g, milling, engraving or turning.
Sanding
Sanding is done to make the surface smoother,
consistent and also for removing the machining
marks or we can say that making the grain or in
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the directional way. For doing sanding in the
machine parts “wet or dry” sandpaper are used
which content liquid resistant sheet blended with
silicon carbide abrasive. In this process the light
oil, kerosene or water as a sanding fuel are used
for doing the frictionless less and smooth works.
Cross sanding, power back sanding, contour block
sanding these are some technique which is used in
sanding process done on the lathe. Most
commonly used hand sanding and lathe power
sanding are used for getting the better finish
products.
Effect of surface roughness on turbine
efficiency
As the flow over a flat plate, all the energy losses
is directly depend on the Reynolds number and
relative surface roughness. The efficiency of the
turbine is thus affected by these parameters in
number of various ways.
The energy losses in turbine consist of:
Head losses in hydraulic passages.
Volumetric as well as mechanical losses.
By the study it is found that these losses are the
function of relevant Reynolds number and
roughness of the hydraulic passage,
The power developed by turbine is calculated as
Turbine power =
+ PM
PM= represent the all mechanical losses
mec= mechanical efficiency
vol=
hydraullic=
Here the quantities of volumetric efficiency and
hydraulic efficiency depend on the surface
roughness and Reynolds number.
Therefore the generalize form of the efficiency
equation in terms of the surface roughness is
given as:
ῆ=
Turbine efficiency associated with roughness of
different manufacturing process
Turbine
efficiency
Roughness
Pressure die casting 86.0 1.7
Investment casting 85.0 3.2
Milling 85.0 4.5
Laser 80.0 6.9
Electron beam 78.0 6.9
Oxyacetylene
welding
60.0 18
Sand casting 60.0 25
Flame casting 60.0 38
TABLE: Turbine efficiency with different
manufacturing process
Friction factor
The loss in the flow through the pipe when using
penstock is the major drawback of the hydro
power project which directly affect the turbine
efficiency and thus resulting the poor efficiency of
overall. So if in place of the pipe if we uses the
channel for the passage of the water by reducing
the surface roughness of the channel using with
fine frame of work this directly decrease the
losses with the cost and also by this the overall
efficiency is improved.
The losses in the pipe are derived by the Darcy
Friction factor which is one of the major losses
seen in the penstock uses hydro power plant.
hf=
Where,
f=friction factor
L=length of pipe
v=velocity of jet
d=diameter of pipe
g= acceleration due to gravity
The surface can be improved by various
manufacturing process or also by surface coating
to have the following advantage:-
By using this various friction losses,
hydraulic losses, and mechanical losses are
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reduced which are contributing towards
the improved efficiency of the turbine
Smooth surface has the ability to better
efficiency and also take the longtime of
repair.
The entire component will remain safe due
to surface coating on them.
Cost required for smoothing the surface is
not so much high when compared with the
efficiency.
Some of the process is provide for smoothing the
surface of the component parts these are the
techniques from where the friction factor is
removed by optimizing the cost and thus increases
the overall efficiency.
RESULT AND DISCUSSION
Results of the turbine testing at different guide
vane opening
After performing the testing in the turbine it was
found that the guide vane perform the role in
determining the efficiency the test result at
different guide vane openings, here only the 20mt
head is taken when this is going through the
60m3/sec is taken because this is the head and
discharge where the efficiency is going to be good
and because of the low head scheme and
according to the area of the channel section we
take these two parameter for our designing
At 25%, the guide vane data was collected
for the head of 10 to 30mt and speed range of
120rpm to 200rpm and the maximum efficiency
obtained was 47%
At 50%, the guide vane data was collected
for the head of 10 to 30mt and speed range of
120rpm to 200rpm and the maximum efficiency
obtained was 59%
At 75%, the guide vane data was collected
for the head of 10 to 30mt and speed range of
120rpm to 200rpm and the maximum efficiency
obtained was 73%
At 100%, the guide vane data was
collected for the head of 10 to 30mt and speed
range of 120rpm to 200rpm and the maximum
efficiency obtained was 80%
From testing performance we taken the head of
20mt with the discharge of 60m3/sec and on the
behalf its and testing result we find
Hydraulic power = 11760kW
Mechanical power = 9417.69kW
Overall efficiency (ῆ) = 80%
Overall efficiency at different head:
Discharge
(Q) m3/sec
Head (m) Number of
rotation
(rpm)
Water
Power(kw)
Shaft
Power(kw)
Overall
Efficiency(ῆ)
60 20 147 11760 9417.69 0.80
60 25 172 14700 11907.87 0.81
60 30 196 17640 14664.23 0.82
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Graph: Efficiency v/s Gross head
Overall efficiency at different flow rate:
Discharge
(Q) m3/sec
Head (m) Number of
rotation
(rpm)
Water
Power(kw)
Shaft
Power(kw)
Overall
Efficiency(ῆ)
60 20 147 11760 9417.6 0.80
55 20 141 10780 8516.3 0.79
50 20 136 9800 7644 0.76
Graph: Efficiency v/s Discharge
CONCLUSION
From the social and religious point of view
interrupted flow should be avoided by using our
type proposed scheme. Hydropower generation is
one of the major energy sources in among the all
the other energy sources and one of the largest
electricity production medium without involving
the damage to the environment and thus we can
say that the it is one the best sources from the
pollution control strategies and thus the generation
of the small hydro power project is one of the best
achievements from the energy point of view. The
74
75
76
77
78
79
80
81
20 25 30
EFFI
CIE
NC
Y %
GROSS HEAD
Efficiency
74
75
76
77
78
79
80
81
60 55 50
EFFI
CIE
NC
Y %
DSCHARGE
Efficiency
Alok Chaudhari et al IJMEIT Volume 2 Issue 12 December 2014 Page 963
IJMEIT// Vol. 2 Issue 12//December//Page No: 952-963//ISSN-2348-196x 2014
only problem is that the high initial cost and also
the religious problem but that were the major
problem when compared to the generation of
electricity. With the increasing demand of the
regular supply of electricity many new hydro
power plants developed but they were totally
disturbed the natural environment cycle not only
this during the high monsoonal time they play an
major problem to those area which were in the
surrounding region of that hydro power plant
region.
The total production from our proposed hydro
project is approx. 9.5MW. Which is sufficient for
supplying the energy for supplying the energy for
rural area? The main advantage is that this hydro
project analyzing the cost or when compared to
the other small hydro schemes which are already
establishing at the nearby sites this estimated
project gave the many benefit in respect to the
cost and by analyzing all the cost of the power
plants equipment it is best suitable in all respect.
Because of the construction work is totally
negligible and also the use of the local labour of
this project gives the opportunity to the village
people to work there and earn money. By using
our scheme the constant energy production of
electricity is achieved. This is one of the main
advantages of this small hydro power project.
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