Design of a low-cost hydraulic turbine based on flat sheet metal construction

Abstract

The main objective of this project is the design, sizing, and theoretical validation of a low- cost Pelton turbine, designed to be manufactured using accessible manufacturing processes, specifically laser cutting and welding of S355 flat steel sheet. The turbine is oriented towards micro-hydropower projects, a sector frequently limited by the high investment costs associated with conventional technology. The methodology employed begins with the development of a calculation code in MATLAB, where the project scope (generation up to 250 kW) is divided into five working zones based on head and flow rate values, and the turbine's geometric parameters are determined. Based on these parameters, and through parametric design in SolidWorks, a family of turbines is generated covering the entire range while maintaining geometric similarity. Finally, a static structural analysis is performed using ANSYS under the effect of centrifugal, gravitational loads, and the jet impact force. The results obtained confirm the geometric feasibility of the proposed solution, and the presented design is concluded to be valid as a conceptual model. The project does not include experimental testing, which remains as future work to validate its long-term viability and commercial implementation. The project is presented as a foundation for a technology with great potential to reactivate the exploitation of currently neglected renewable resources.