This contribution is dedicated to the memory of late Prof. Maciej Zarzycki, Technical University of Silesia, having passed this week in Gliwice,

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1 This contribution is dedicated to the memory of late Prof. Maciej Zarzycki, Technical University of Silesia, having passed this week in Gliwice, Poland 1

2 PUMPS AS TURBINES FOR HYDRAULIC ENERGY RECOVERY AND SMALL HYDROPOWER PURPOSES IN POLAND Janusz STELLER, Adam ADAMKOWSKI, Zenon STANKIEWICZ Andrzej ŁOJEK, Jan RDUCH, Maciej ZARZYCKI 1. Introduction Why pumps in turbine operation? Fields of application, Problems encountered 1. Research efforts and their results 2. Case study 3. Conclusion 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

3 Pumps as turbines Advantages Low price, high availability Disadvantages Limited efficiency Steep efficiency characterictics Poor or none regulation capabilities Conclusion Application 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. 3

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 4

5 H, m Pumps as turbines -typical operation ranges kw single stage pumps 50 cross-flow turbines Pelton Francis turbines Kaplan turbines Pelton turbines 10 pumps Francis Source: Engeda A., Strate P., Rautenberg M.: Auswahl von Kreiselpumpen als Turbinen. Pumpentagung Karlsruhe 88, Sektion A6, Fachgemeinschaft Pumpen im VDMA, Frankfurt/Main, Oktober cross-flow ,0E-02 1,0E-01 1,0E+00 1,0E+01 1,0E+02 Q, m 3 /s Kaplan Pumps in turbine mode of operation may be applied for heads between 2 and almost 1000 m, with capacities up to almost 2 MW 5

6 efficiency, % Pumps as turbines -typical efficiency characteristics 100 Kaplan Source: Engeda A., Strate P., Rautenberg M.: Auswahl von Kreiselpumpen als Turbinen. Pumpentagung Karlsruhe 88, Sektion A6, Fachgemeinschaft Pumpen im VDMA, Frankfurt/Main, Oktober Pelton Francis propeller turbine cross-flow turbine Surek D.: Parameter und Leistungen rückwärtslaufender Kreiselpumpen mit Frequenzumrichter, Pumpentagung Karlsruhe 92, Fachgemeinschaft Pumpen im VDMA, Frankfurt/Main, Oktober 1992, Beitrag A pump in turbining regime Q T /Q T,opt, % Speed regulation - a remedy to the steep efficiency characteristics 6

7 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 7

8 UM mixed-flow pump - efficiency characteristics of a 5-blade 400UM250 unit in the pumping and turbine modes of operation Pump manufacturer: Leszno Pump Factory opt = 73 % Source : IMP PAN lab 8

9 UM mixed-flow pump in Polanow SHP, Poland 9

10 UM mixed-flow pump - possible modifications of the original design Source : IMP PAN lab 10

11 Temat nr 3 250UM400 pump unit with a Francis runner Jeziorany SHP, H = 12 m 11

12 35D40 mixed-flow pump - efficiency hill in the turbine mode of operation Pump manufacturer: POWEN-WAFAPOMP SA previously: Warsaw Pump Manufacturers Source : IMP PAN lab 12

13 150PJM centrifugal pump - efficiency hill diagrams Source : IMP PAN lab Pump manufacturer: Leszno Pump Factory 13

14 OS multistage radial pumps Manufacturer: POWEN-WAFAPOMP SA previously: Zabrze Mining Machinery Manufacturers, Upper Silesia, Poland Designation Pressure pipe diameter, mm Number of stages speed head discharge rpm H p, m H t /H p Q p, l/s Q t /Qp Lab OS-150A , ,7 IMP PAN OS-80R/ ,6 11 1,65 TU Silesia OS-80M/ ,8 11 1,82 TU Silesia 14

15 OS 150A triple stage pump Manufacturer: POWEN-WAFAPOMP SA previously: Zabrze Mining Machinery Manufacturers, Upper Silesia, Poland pump IMP PAN lab turbine 15

16 OS multistage pumps OS 80R TU Silesia lab Manufacturer: POWEN-WAFAPOMP SA previously: Zabrze Mining Machinery Manufacturers, Upper Silesia 16

17 Typical relationships between pump parameters in the pump and turbine modes of operation low speed single stage impeller pumps Q t /Q p = 1,5 2,4 H t /H p = 1,7 3,7 Sharma formula 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 Q t Q H H p p 0,8 t 1, 2 max, p max, p 17

18 Case study a radial pump used as a turbine for hydraulic energy recovery purposes in a municipal heat plant Location: Lomza Municipal Heat Plant 18

19 Case study a radial pump used as a turbine for hydraulic energy recovery purposes in a municipal heat plant Location: Lomza Municipal Heat Plant 19

20 Case study a radial pump used as a turbine for hydraulic energy recovery purposes in a municipal heat plant Location: Lomza Municipal Heat Plant 20

21 CONCLUSION 1. The experience cumulated so far shows that pumps in turbine operation may be sometimes a reasonable option for the purposes of hydraulic energy recovery in industrial installations and electrical energy generation in some micro hydropower plants. 2. While the simplified formulae used to assess bep parameters in turbining regime basing on the pump mode performance data may be considered a great help when planning a new installation, their limited validity should be always kept in mind. 3. Therefore it is highly desirable to encourage pump manufacturers to test at least some of the offered machines also in turbine mode of operation. Providing access to pump versions modified for the purpose of possible use in turbine mode of operation may further widen their markets and contribute to better utilization of available SHP potential. 4. The success of the energy recovery unit described in the previous section shows open possibilities for more rational energy economics even in case of some critical industrial installations. 21

Design and manufacturing of Crossflow, Pelton, Kaplan and Francis turbines

Design and manufacturing of Crossflow, Pelton, Kaplan and Francis turbines Founded in 1990 as a manufacturer of hydro power plant equipment In 2005, the company underwent complete modernization and extended