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

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PUMPS AS TURBINES FOR HYDRAULIC ENERGY RECOVERY AND SMALL HYDROPOWER PURPOSES IN POLAND Janusz STELLER, Adam ADAMKOWSKI, Zenon STANKIEWICZ Andrzej Ĺ OJEK, 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


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.

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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

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Pumps as turbines -typical operation ranges 1000

100

200

500

1000 kW

single stage pumps cross-flow turbines

50 Pelton

20

Francis turbines Kaplan turbines

100

H, m

Pelton turbines

pumps 10 Francis cross-flow

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

1 1 1,0E-02

2

1,0E-01

Kaplan 5

10 1,0E+00

1,0E+01

1,0E+02

Q, m 3/s

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


Pumps as turbines -typical efficiency characteristics 100 Kaplan Pelton 80

Source:

Surek D.: Parameter und Leistungen rückwärtslaufender Kreiselpumpen mit Frequenzumrichter, Pumpentagung Karlsruhe’92, Fachgemeinschaft Pumpen im VDMA, Frankfurt/Main, Oktober 1992, Beitrag A5-01

efficiency, %

Engeda A., Strate P., Rautenberg M.: Auswahl von Kreiselpumpen als Turbinen. Pumpentagung Karlsruhe’88, Sektion A6, Fachgemeinschaft Pumpen im VDMA, Frankfurt/Main, Oktober 1988

cross-flow turbine 60

Francis

40

propeller turbine

20

pump in turbining regime 0 0

20

40

60

80

100

QT/QT,opt, %

Speed regulation - a remedy to the steep efficiency characteristics

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Main research directions ď Ž

identifying home manufactured impeller pumps suitable for energy generation purposes

ď Ž

determining performance characteristics for specified series of types and establishing general relationships between bep parameters in both modes of operation

ď Ž

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 characteristics of a 5-blade 400UM250 unit in the pumping and turbine modes of operation Pump manufacturer

:

Leszno Pump Factory

ď ¨opt = 73 %

Source : IMP PAN lab

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UM mixed-flow pump in Polanow SHP, Poland

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UM mixed-flow pump

- possible modifications of the original design

Source : IMP PAN lab

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Temat nr 3

250UM400 pump unit with a Francis runner Jeziorany SHP, H = 12 m

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35D40 mixed-flow pump

- efficiency hill in the turbine mode of operation

Pump manufacturer:

POWEN-WAFAPOMP SA

Source : IMP PAN lab

previously:

Warsaw Pump Manufacturers 12


150PJM centrifugal pump

Source : IMP PAN lab

- efficiency hill diagrams

Pump manufacturer:

Leszno Pump Factory

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OS multistage radial pumps

Manufacturer:

POWEN-WAFAPOMP SA previously:

Zabrze Mining Machinery Manufacturers, Upper Silesia, Poland Designation

Pressure pipe diameter, mm

Number of stages

OS-150A

150

OS-80R/3 OS-80M/2

speed

head

discharge Lab

rpm

Hp, m

Ht/Hp

Qp, l/s

Qt/Qp

3

1450

62

1,27

40

2,7

IMP PAN

80

3

1450

60

1,6

11

1,65

TU Silesia

80

2

1450

30

2,8

11

1,82

TU Silesia 14


OS 150A triple stage pump Manufacturer:

POWEN-WAFAPOMP SA previously:

Zabrze Mining Machinery Manufacturers, Upper Silesia, Poland

pump

IMP PAN lab

turbine

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OS multistage pumps OS 80R

TU Silesia lab Manufacturer:

POWEN-WAFAPOMP SA previously:

Zabrze Mining Machinery Manufacturers, Upper Silesia 16


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 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

Qp Qt  0,8  max, p

Hp H t  1, 2  max, p

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Case study

a radial pump used as a turbine for hydraulic energy recovery purposes in a municipal heat plant

18 Location: Lomza Municipal Heat Plant


Case study

a 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 study

a 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 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


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