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Annex. 6.2
Integral pump and motor can be purchased for use as a turbine and generator set
Low cost
There are several practical benefits of being able to use a direct drive pump as turbine (PAT), i.e. one
which the pump shaft is connected directly to the generator, as explained in the next section.
Pump suppliers usually stock a number of different pumps designed to be suitable for a wide range of
heads and flows.
The actual range of heads and flows for which a PAT is suitable is explained in a
later section.
The simplicity of the PAT means that it does have certain limitations when compared with more
expensive types of turbine.
The main limitation is that the range of flow rates over which a particular
limitation are covered at the end of this chapter. Therefore, the selection of applicable pump should be
selected upon referring hereunder.
2.
However, in some circumstances there are advantages to fitting a belt drive to a PAT.
Lower cost (in the case of a mono-bloc design) because of simpler construction, fewer bearings,
etc.
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The use of combined pump-motor units is recommended for micro-hydro schemes that are to be used
only for the production of electricity, and where the simplest installation possible is required. There
are, however, some limitations to using such integral units, as listed below:
3.
Given the right conditions, pumps as turbines can be used over the range normally covered
by multi-jet Pelton turbines, cross flow turbines and small Francis turbines. However, for high head,
low flow applications, a Pelton turbine is likely to be more efficient than a pump, and no more
expensive.
The chart in Fig. 6.A2.1 shows the range of heads and flows over which various turbine options may be
used.
The range of Pelton and cross flow turbines shown is based on information from the range of
turbines manufactured in Nepal, and is compared with the range of standard centrifugal pumps running
with a four-pole (approx. 1500 rpm) generator. The range of PATs can be extended by using either a
two-pole (approx. 3000 rpm) or a six-pole (approx. 1000 rpm) generator, as shown in Fig 6.A2.2. This
500
400
300
200
150
100
70
H(m)
50
40
30
20
Key
10
Crossflow
Turbines
PAT
5
2
10
15
20
30
40
60
Q(/s)
Fig. 6.A2.1
- 6-35 -
H(m)
500
400
300
200
100
70
50
40
30
20
4 pole limit
(c. 1500 rpm)
10
5
2
Fig. 6.A2.2
4
6
8
10
15 20 30 Q(/s)
Head-flow Ranges for Direct Drive Pumps as Turbines
The use of a pump as turbine has greatest advantage, in terms of cost and simplicity for sites where the
alternative would be either a cross flow turbine, running at relatively low flow, or a multi-jet Pelton
turbine.
For these applications, shown by the hatched area on Fig. 6.A2.2, a cross flow turbine would
expensive to manufacture than larger ones because of the difficulty of fabricating the runner.
Therefore, a cross flow installation would require a large turbine running at slower speed than an
equivalent PAT, resulting in the need for a belt drive to power a standard generator. A Pelton turbine
for this application would require three or four jets, resulting in a complicated arrangement for the
casing and nozzles, although it would be more flexible than a PAT for running with a range of flow rates.
A small Francis turbine could also be used in this range, but would be even more expensive than cross
flow turbine.
What dictates the use of a pump as turbine is that it requires a fixed flow rate and is therefore suitable
for sites where there is a sufficient supply of water throughout the year. Long-term water storage is not
generally an option for a micro-hydro scheme because of the high cost of constructing a reservoir.
Due to somewhat difficulty of selection of PAT (Pump As Turbine), it is recommended that the
client should confirm its performance to the designer or pump manufacturer in advance, including
the characteristics of the pump and its induction motor as the characteristics of pumps differ
according to the manufacturer.
Table 6.A2.1 Centrifugal Pump manufactured by Southern Cross for PAT is attached hereunder
for reference only.
The engineer, who wants to know more detailed design, shall continue the study to the following
chapters hereunder.
- 6-36 -
Flow as pump(Q)
(rpm)
1400
1400
1400
(rpm)
1470
1470
1470
(l/sec)
3.1
2.6
2.5
(m)
9.5
7.5
6.0
(%)
56
54
50
(l/sec)
5.7
4.9
5.0
(m)
23.1
19.1
16.7
(kW)
0.5
0.4
0.3
65 x 50 160-L
65 x 50 160-M
65 x 50 160-S
1400
1400
1400
1470
1470
1470
5.5
4.5
4.0
9.0
7.5
6.0
65
60
57
9.0
7.8
7.2
18.3
16.8
14.3
0.7
0.6
0.4
80 x 65 160-L
80 x 65 160-M
80 x 65 160-S
1420
1420
1420
1491
1491
1491
9.5
7.5
6.8
9.5
7.5
6.0
78
74
68
13.4
11.0
10 .6
15.5
13.1
11.6
1.1
0.7
0.6
80 x 50 200-L
80 x 50 200-M
80 x 50 200S
1420
1420
1420
1491
1491
1491
10.0
9.0
8.0
15.5
12.0
9.0
72
69
68
15.0
14.0
12.6
27.9
22.7
17.3
2.1
1.5
1.0
100 x 80 160-L
100 x 80 160-M
100 x 80 160-S
1420
1420
1420
1491
1491
1491
18.0
16.0
15.0
9.5
6.5
5.0
80
77
75
24.9
22.8
21.8
15.1
10.8
8.6
2.1
1.3
1.0
100 x 65 200-L
100 x 65 200-M
100 x 65 200-S
1420
1420
1420
1491
1491
1491
18.5
16.0
14.0
15.0
11.5
9.0
78
75
70
26.1
23.3
21.5
24.5
19.7
16.7
3.5
2.4
1.8
100 x 65 250-L
100 x 65 250-M
100 x 65 250-S
1450
1450
1450
1523
1523
1523
20.0
18.5
16.5
24.0
19.0
15.0
78
76
73
28.2
26.6
24.5
39.2
32.0
26.5
6.0
4.5
3.3
1440
1440
1440
1512
1512
1512
38.0
34.0
30.0
14.5
10.0
8.0
85
81
78
50.0
46.5
42.3
21.4
15.6
13.1
6.3
4.1
3.0
1450
1450
1450
1523
1523
1523
40.0
36.0
33.0
24.0
19.0
14.0
81
80
78
54.7
49.6
46.5
37.5
30.1
22.9
11.6
8.4
5.8
1460
1460
1460
1523
1523
1523
70.0
70.0
50.0
23.0
17.0
13.0
88
83
80
89.6
93.8
69.0
32.5
25.8
20.0
17.9
14.0
8.0
- 6-37 -
Speed as turbine
50 x 32 160-L
50 x 32 160-M
50 x 32 160-S
Pump Type
Efficiency as pump
Speed as pump
4.
dealing with low flow rates is to use intermittent operation. By using a special intake and a small
storage tank it is possible for a PAT to run intermittently.
arrangement.
If the flow rate increases, it is not possible to generate more power using only one pump. A second
pump could be installed but the additional cost of installing more than one unit may outweigh the
advantage of buying a pump instead of a conventional turbine.
This
can limit the range of flows over which the pump can run. Care must be taken to avoid overloading
(either electrical or mechanical) of the generator. The electrical output of an induction generator
should normally be limited to 80% of the rated power output as motor.
5.
is the performance curve, which shows how the head and flow delivered by the pump are related. As the
flow delivered by the pump increases, the delivery head decreases. The head-flow curve of each pump
is often available from the pump manufacturer.
The other piece of information that you need to know for your pump is the point at which it works most
efficiently.
This is called the best efficiency point. The pump efficiency, plotted against the flow rate,
is shown in Fig. 6.A2.3. The maximum value of efficiency varies according to the type and size of
pump, but is typically 40% to 80%. The best efficiency point (bep) occurs at a particular value of flow
rate.
- 6-38 -
max
Qbep
Fig. 6.A2.3
Qp
The efficiency values can be shown on the head-flow curve, as shown in Fig. 6.A2.4.
Information
60
50
Qbep
Fig. 6.A2.4
70
Hbep
65
50
%
60
%
65
%
Hp
Qp
If you have no efficiency data for the pump, but do have a curve showing input power against flow rate,
then it is possible to calculate the values at the best efficiency point. The relationship between head,
flow-rate input power and efficiency is given by the following equation:
Efficiency () =
where:
H Q 9.81
100
Pin
(1)
H is head (m)
Q is flow rate (1/2)
Pin is mechanical input power (W)
9.81 is acceleration due to gravity (m/s2)
is pump efficiency as a percentage.
- 6-39 -
The steps for calculating the value of maximum efficiency are as follows:
1.
Use the head-flow curve to obtain the head and flow rate at best efficiency point (bep).
2.
Use this flow rate on the power input-flow curve to get Pin.
3.
Note that, especially for pumps with integral motors, the power curve may show electrical power
consumption rather than mechanical input power. In this case, use Appendix D to estimate the
efficiency of the motor.
Pin = Pelec
Where:
motor
(%)
100
(2)
Pin =
Pelec
motor(%)
75
= 1050
= 788W
100
100
- 6-40 -
Hp
(m)
18
Pelec
(W)
16
14
1000
12
10
750
8
500
6
4
250
2
5
10
15
20
Qp (m3/hr)
10
15
20
Qp (m3/hr)
Hsite
hf
e
ur v
TC
A
P
Site Curve
Operating
Point
Fig. 6.A2.6
The speed of the turbine will vary according to the load that is put on it, and there is a different
head-flow curve for each speed.
labeled N=100% is for the normal operating speed (the same as in Fig. 6.A2.8).
N=130% and N=80% are for speeds 30% higher and 20% lower than normal operating speed. Note
that for each speed, the operating point it given by the intersection of the turbine curve with the site
curve.
If a load, which is higher than design load, is put on the turbine, the speed goes down.
shown in Fig. 6.A2.7, this causes a slight increase in flow rate, which is usually the case for
centrifugal pumps running as turbines.
If there is no load, the speed of the turbine increases to a maximum, which is known as runaway.
The curve of maximum speeds is also shown on Fig. 6.A2.7 (labeled N=max). In the case illustrated,
the actual speed at runaway is (by extrapolation) approximately 140% of normal operating speed.
- 6-41 -
14
N=
Site Curve
0%
13
N=
N=
ma
x
10
N=
0%
Fig. 6.A2.7
6.
80
N=
0%
maximum efficiency. The head and flow corresponding to the maximum efficiency will define the best
efficiency point.
Sometimes, no curve is available that shows either input power or electrical power consumption.
this case, some information may be obtained from the pump nameplate.
In
nameplate may consist of a single value for head and for flow (which is not always the head and flow
for best efficiency pump operation) or a range of heads and flows. One approximation for the best
efficiency conditions can be made by using:
Qbep = 0.75 Qmax;
Hbep = 0.75Hmax
(3)
A useful check can be made on these estimates by an alternative method, which is based on physical
measurements of some parts of the pump.
7.
turbine performance curve and the site curve in Fig. 6.A2.6 gives the head and flow at which the turbine
will actually operate. This is known as the operating point.
- 6-42 -
Limit of
PAT operation
0
Qt
Fig. 6.A2.8
- 6-43 -
normally determined by the minimum flow rate, i.e. the flow that is available throughout the year. The
head is determined by the vertical height between the intake from the stream and the turbine outlet, less the
head loss in the penstock for this particular flow rate. A pump needs to be selected for which the head and
flow, at the turbine best efficiency point, are as close as possible to the site conditions.
This section gives the calculations needed to get the turbine head and flow at best efficiency point for
a particular pump. The running conditions in terms of head and flow, for best efficiency as a turbine, are
very different from the rated pump output, although the PAT efficiency will be approximately the same as
for pump operation.
Friction and leakage losses, within a centrifugal pump, result in a reduction of head
greater than the theoretical values, in order to make up for the losses. The following equations are given
in the literature to predict turbine head and flow for constant speed:
Q1 =
where
Qbep
max
H1 =
Hbep
max
1 = max
(4)
Qbep is the flow rate and pump best efficiency point (bep)
Hbep is the head at pump bep
max is the pump maximum efficiency
and
that the head ratio is usually greater than the flow ratio between turbine and pump modes. The prediction
can be improved by using different powers ofmax for the head and flow ratios, following a method
proposed by KR Sharma of Kirloskar Co., India.
equations are:
Q1 =
Qbep
max
0.8
H1 =
H bep
max 1.2
1 = max
(5)
The following example shows how to calculate the head and flow needed by the turbine when the
turbine speed is the same as the pump speed.
- 6-44 -
Q1 =
H1 =
Qbep
max
0.8
H bep
max
1. 2
20
20
=
= 29.3 l/s
0.8
0.682
0.62
16
16
=
= 28.4 m
1.2
0.563
0.62
Often the turbine speed will not be the same as the rated pump speed and it is necessary to use
additional equations to take into account different running speeds of turbine and pump.
Before
Q1 (at N = N1) =
N1
Q1 (at N = Np)
Np
H1 (at N = N1) = (
(6)
N1 2
) H1 (at N = Np)
Np
(7)
Q1 =
Qbep
H bep
N1
N
; H1 = ( 1 ) 2
0.8
1. 2
N p max
Np
max
(8)
An example of carrying out this calculation is given on the next page. It must be stressed that,
although this method is more accurate than the equation normally given in the literature (4) it is still
only approximate. The actual values of Qt and Ht may be as much as 20% of the predicted value for
the dep.
This may or may not have a significant effect on the PAT output, depending on the
- 6-45 -
performance characteristics.
the pump is tested as a turbine to find out what power will be produced at the available head and flow.
The method for testing is described in the next section.
Example 3: Calculation of turbine best efficiency point at 1550 rpm.
The head available at a particular site is 26m, and the flow is 7 l/s. It has been suggested that the
pump looked at in Example 2 could be used as a turbine for this site.
The induction motor is to be used as a generator directly driven from the turbine. The turbine
speed is therefore fixed by the generator speed.
speed is calculated to be 1550 rpm.
Q1 =
H1 =
Qbep
1550
3.89
N1
= 6.52 l/s
0.8
N p max
1450
0.57 0.8
(
H bep
1550 2
11.8
N1 2
)
)
= (
= 26.5 m
1. 2
Np
max
1450
0.57 1.2
These values of head and flow are close to the site conditions, and the pump is therefore suitable.
Due to some difficulty of selection of PAT (Pump As Turbine), it is recommended as sample for brief
selection to refer to the attached Table 6.A2.1 of Centrifugal Pump Manufactured by Southern Cross
for PAT attached hereunder,.
The client is requested to ask the designer the detail design with technical explanation for the selected
pump for PAT, referring to the characteristics of the actual pump because that of each type turbine is
different by manufacturer.
- 6-46 -