Thaka.AiReviewed 16 October 2026 · schematic not to scale
Use the complete Pico Power Pack fabrication drawings and village-design manuals with a qualified workshop and electrical designer.
- 1Measured natural head / flow
- 2Wheel / runner and supported shaft
- 3Guarded transmission and matched generator
- 4Rated load and simultaneous V/A measurement
Site and operating requirements
- Survey net head, usable seasonal flow, flood level, debris and legal access. Select a design for that measured resource.
- Obtain complete shaft, bearing, mounting, guard and electrical drawings. A photograph is not a tolerance or load specification.
Tools and measuring equipment
- Tape/level and safe survey tools, timer and measured collection vessel for suitable small flows, tachometer and rated load/meter set; workshop tools follow the full drawings.
Output and operating conditions
Manual example: 50 m net head, 5 L/s, 160 mm Pelton runner, 14.2 mm nozzle → estimated 1.3 kW electrical. This is not a guarantee for another site.
Documented manual example. Full tolerances, complete drawings, protection and current local approval are required; the short list below is not a fabrication drawing.Parts, quantities and dimensions
| Part | Quantity | Specification / dimensions |
|---|---|---|
| Pelton runner | 1 | Manual pitch-circle options 120 / 160 / 200 mm; example 160 mm. Use its specified bucket material and drawings. |
| Generator and nozzle | 1 + 1 | Example: 2.2 kW four-pole induction motor as generator; 14.2 mm nozzle. Not a permanent universal pairing. |
| Intake, penstock, casing and frame | site sized | Pressure-rated pipe, supports and losses must be designed from the survey. Obtain all drawing sheets from the author’s index. |
| Controller, ballast and protection | engineered set | Full manual electrical/distribution design; earthing, overspeed control and protection by qualified personnel. |
Preparation and component checks
- Create a drawing register: runner pitch circle, bucket detail, nozzle, shaft, bearing seats, casing and frame. Keep one selected revision; have the workshop sign dimensional and material inspection.
- The 50 m / 5 L/s example is separate from your site. Calculate pipe pressure/losses and obtain controller, ballast and protection settings from the electrical designer.
Procedure
- 1
Survey dry-season usable flow and net head; confirm land/water/environmental permissions.
- 2
Use the manual’s selection and design process to choose the runner, nozzle, generator and penstock.
- 3
Have the workshop fabricate from the full dimensioned drawings and inspect material, alignment and pressure ratings.
- 4
Commission with the electrical designer: protection, load regulation, earthing, flow and measured output tests.
Safety and inspection
Pressurised water, rotating machinery and mains voltage require competent design. The manuals are historical; apply current local requirements.
Verify the result
A documented Kenya scheme supplied 1.1 kW to 65 households with tightly limited lighting/radio loads, not unrestricted appliances. Household count alone is not a sizing method.
Measurement log
- Gross/net head, seasonal flow, nozzle diameter, runner diameter/rpm, generator nameplate, loaded electrical power, controller setpoints and shutdown test results.
Maintenance and repeat checks
- Inspect intake screens and leaks from a safe isolated position. Use the designer’s bearing, belt and electrical maintenance schedule; inspect after floods and record every repair.
Troubleshooting
- No output, abnormal heat, noise, vibration or leaks
- Stop and isolate first. Check the documented input, load compatibility, alignment and connections; keep guards fitted and refer specialist systems to their installer.