1
This contribution is dedicated to the memory
of late Prof. Maciej Zarzycki,
Technical University of Silesia,
having passed this week in Gliwice, Poland
PUMPS AS TURBINES FOR HYDRAULIC ENERGY RECOVERYAND SMALL HYDROPOWER PURPOSES IN POLAND
Janusz STELLER, Adam ADAMKOWSKI, Zenon STANKIEWICZ
Andrzej ŁOJEK, Jan RDUCH, Maciej ZARZYCKI
The Szewalski Institute of Fluid-Flow Machinery of the Polish Academy of Sciences
ZRE Gdansk Sp. Z O.O
Technical University of Silesia, Institute of Power Industry Machinery and Equipment
1. IntroductionWhy pumps in turbine operation? Fields of application, Problems encountered
1. Research efforts and their results
2. Case study
3. Conclusion
3
Pumps as turbines
Advantages
Low price, high availability
Disadvantages
Limited efficiency
Steep efficiency characterictics
Poor or none regulation capabilities
ConclusionApplication of pumps in turbine operation instead of
single or double regulated hydraulic turbines may be
economically justified in case of stable hydrological
conditions, low capacities and discharges.
4
Pumps as turbines- typical application fields
oil and chemical industry- decompression processes for gas/liquid separation
and washing/clearing chemical media
- hydrocarbon synthesis
by means of hydro-cracking technique
pressure pipelines in heating,
fuel supply and reclamation systems
micro hydropower plants
5
Pumps as turbines-typical operation ranges
1
10
100
1000
1,0E-02 1,0E-01 1,0E+00 1,0E+01 1,0E+02
Q, m3/s
H,
m
single stage pumps
cross-flow turbines
Francis turbines
Kaplan turbines
Pelton turbines
1000 kW500200100
50
20
10521
pumps
Kaplancross-flow
Francis
Pelton
Source: Engeda A., Strate P.,
Rautenberg M.: Auswahl von
Kreiselpumpen als Turbinen.
Pumpentagung Karlsruhe’88,
Sektion A6, Fachgemeinschaft
Pumpen im VDMA,
Frankfurt/Main, Oktober 1988
Pumps in turbine mode of operation may be applied for heads
between 2 and almost 1000 m, with capacities up to almost 2 MW
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Pumps as turbines-typical efficiency characteristics
Source:
Engeda A., Strate P.,
Rautenberg M.: Auswahl von
Kreiselpumpen als Turbinen.
Pumpentagung Karlsruhe’88,
Sektion A6, Fachgemeinschaft
Pumpen im VDMA,
Frankfurt/Main, Oktober 1988
Surek D.: Parameter und
Leistungen rückwärtslaufender
Kreiselpumpen mit
Frequenzumrichter,
Pumpentagung Karlsruhe’92,
Fachgemeinschaft Pumpen
im VDMA, Frankfurt/Main,
Oktober 1992, Beitrag A5-01
Speed regulation
- a remedy to the steep efficiency characteristics
0
20
40
60
80
100
0 20 40 60 80 100
QT/QT,opt, %
eff
icie
ncy,
%
pump in turbining regime
propeller turbine
Francis
Kaplan
cross-flow
turbine
Pelton
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Main research directions
identifying home manufactured impeller pumps
suitable for energy generation purposes
determining performance characteristics for
specified series of types and establishing
general relationships between bep parameters
in both modes of operation
low-cost modifications of the flow part
geometry aimed at enhancing performance
characteristics in turbine mode of operation
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UM mixed-flow pump- efficiency characteristicsof a 5-blade 400UM250 unit in the pumping and turbinemodes of operation
opt = 73 %
Source : IMP PAN lab
Pump manufacturer:Leszno Pump Factory
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35D40 mixed-flow pump- efficiency hill in the turbine mode of operation
Pump manufacturer:
POWEN-WAFAPOMP SApreviously:
Warsaw Pump Manufacturers
Source : IMP PAN lab
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150PJM centrifugal pump- efficiency hill diagrams
Pump manufacturer:
Leszno Pump Factory
Source : IMP PAN lab
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Designation Pressure
pipe
diameter, mm
Number
of stages
speed head discharge
Labrpm Hp, m Ht/Hp Qp, l/s Qt/Qp
OS-150A 150 3 1450 62 1,27 40 2,7 IMP PAN
OS-80R/3 80 3 1450 60 1,6 11 1,65 TU Silesia
OS-80M/2 80 2 1450 30 2,8 11 1,82 TU Silesia
OS multistage radial pumps
Manufacturer:
POWEN-WAFAPOMP SApreviously:
Zabrze Mining Machinery
Manufacturers, Upper Silesia, Poland
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OS 150A triple stage pump
Manufacturer:
POWEN-WAFAPOMP SApreviously:
Zabrze Mining Machinery
Manufacturers, Upper Silesia, Polandpump
turbine
IMP PAN lab
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OS multistage pumps
Manufacturer:
POWEN-WAFAPOMP SApreviously:
Zabrze Mining Machinery
Manufacturers, Upper Silesia
TU Silesia lab
OS 80R
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Typical relationships between pump parameters in the pump and turbine modes of operation
low speed single stage impeller pumps
Qt/Qp = 1,5 2,4 Ht/Hp = 1,7 3,7
Sharma formula
8,0max, p
p
t
2,1max, p
p
t
HH
Source:
Schmiedl E.: Serien-Kreiselpumpen
im Turbinenbetrieb. Pumpentagung
Karlsruhe’88, Sektion A6,
Fachgemeinschaft Pumpen im VDMA,
Frankfurt/Main, Oktober 1988
Williams A.: Pumps as turbines.
A user’s guide. Intermediate
Technology Publications, London, 1995
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Case studya radial pump used as a turbine for hydraulic energy recovery purposes
in a municipal heat plant
Location: Lomza Municipal Heat Plant
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Case studya radial pump used as a turbine for hydraulic energy recovery purposes
in a municipal heat plant
Location: Lomza Municipal Heat Plant
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Case studya radial pump used as a turbine for hydraulic energy recovery purposes
in a municipal heat plant
Location: Lomza Municipal Heat Plant
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CONCLUSION
1. The experience cumulated so far shows that pumps in turbine operationmay be sometimes a reasonable option for the purposes of hydraulicenergy recovery in industrial installations and electrical energy generationin some micro hydropower plants.
2. While the simplified formulae used to assess bep parameters in turbiningregime basing on the pump mode performance data may be considered agreat help when planning a new installation, their limited validity shouldbe always kept in mind.
3. Therefore it is highly desirable to encourage pump manufacturers to testat least some of the offered machines also in turbine mode of operation.Providing access to pump versions modified for the purpose of possible usein turbine mode of operation may further widen their markets andcontribute to better utilization of available SHP potential.
4. The success of the energy recovery unit described in the previous sectionshows open possibilities for more rational energy economics even in caseof some critical industrial installations.