Small Hydro Ee eee eee eS SSeS Eee CS eee eee eee See eee eee ee ee Eero eee Using Pumps as Hydroturbines Running a pump in reverse to operate as a turbine is sometimes feasible, offering equipment cost savings. However, operation and control differences need to be thoroughly explored before installing a PAT. By Paul N. Garay Wien cnosin dra easipmest for a small hydropower facility, one option to consider is the use of a pump-as-turbine (PAT), Standard pumps to use as turbines at mini-hydro plants as large as 2 MW are available, but the ‘most usual PAT installation is at proj- ects up to a maximum of about 500 kW per unit. Although performance and flow control are less than ideal, con siderable equipment cost savings are sometimes possible. There are, how- ever, many potential pitfalls. Proj- ect developers need to thoroughly understand the PAT technology before beginning on this journey. ‘This article provides some of the background necessary to further con- sider a PAT installation at_ yout site. ‘More detailed analyses with worked ‘examples are given in my book, Pump Application Desk Book." This article focuses on using PATS as hydroturbines. Making a Case for PATs Hydraulic turbines are similar in ‘many respects to the pumps that are widely used in industrial processes. Whereas a hydraulic turbine extracts energy from water as it flows through the turbine runner, a pump adds ener~ gy to the water passing through the pump impeller. In fact, if you were to track the water particles flowing through @ pump impeller on fim and then run the film in reverse, you would be simulating the flow through a tur- bine runner (expect for flow separation Paul Garay, PH, is a senior pro: fessional associate with FMC As- ‘sociates, a division of Parsons Brinckerhoff Quade & Douglas, Ine,, in San Franciseo, California. ‘52, HYDRO REVIEWIOCTOBER 1990 Cornell Bump Company installed thase PATS atthe Portwood hydroslectic project in ceitral Galina In'965. The fact fe comprised of one 25 KW unl (leet of photo) and four ‘Te:RW unis. An eduction erator sts ontop of the PAT. The units ae mounted on & ‘Bretvnick plete over ap Water ontors tha PAT horzorialy dough the pump stand is {clecsed verbally info the pt through a daft ubo, Project savor is gold to Southern Calor Edison Company-The fst four yoars of power sale revenues wore enough to pay back tne ‘original nvastmert. and some othe: minor differences). If follows, then, that 2 standard produc- tion pump may be adapted to produce power wherever a reasonable amount Of fluid head exists. A standard pump may be operated fm reverse mode (both fhid direction and direction o° rotation) with efficien- cy Within plus or minus two percent- age points of Lie corresponding pump efficiency. The standard pup curves ‘may also be used to define operation as a PAT. Small PAT units can be economically incorporated into several situations: —at the traditional streams and res cervoirs (and from less familiar sources where pressure is reduced); —at wastewater discharge at_pres- sures —at pressure reduction at the termi- nation of distribution systems; and —in pipeline service (pressure let down) on the downside of a high mountain range to keep the line full and avoid excessive pressures. Furthermore, pressure letdown in chemical processes, such as those at refineries, are also ‘excellent locations for application of a PAT.Comparing a PAT to a Turbine One of the primary differences when using a pump as a hydroturbine is in terminology: a turbine runner corre sponds to a pump impeller; a Francis turbine to either a radial Dow or mixed Sow pump; a Kaplan, tubular, or bulb ‘turbine to'an axial flow or propeller pump; and turbine setting to net posi- tive Suction head. Another general difference is in relative scale. Pumps that are considered fairly large would correspond to turbines used for small- scale hydropower. For example, many of the pumps sold are below 100 kW, which “is in the micro-hydropower range. A primary advantage of using a PAT instead of a hydroturbine is the poten- tial cost savings. Due to the large number of standard pumps produced, a standardized pump converted to a turbine can be significantly less ex- pensive than a specifically designed hydraulic turbine, In addition to low cost, the PAT has several other advantages. ‘These. in ‘clude simplified control due to the absence of biade pitch change, simpli- fied installation, ready adaptation to chemical or hot process fluids, and reduced delivery time. Obviously, these factors alee can comiribnte te cost savings. Pumps-as-Turbines: Dealing with Dissimilarities Although there are divect_ parallels between the operation of PATS. and hydraulic turbines, differences in op- eration and control factors do exist and should be considered before in- stalling a PAT. Each Application is Unique Will the PAT drive a mechanical unit or an electrical generator? Will it supply electric power to an isotated station or a grid? The problems of variable speed and control, a8 well a3 torque performance, will difer with each application. Know how the PAT will be used before exploring opera- tonal problems. Setting Limits on Output Figure 1 gives head-discharge curves for a typical pump and its PAT appli- cation. Note that the flow is consid- erably higher for a turbine than for the corresponding pump. This increased flow, possibly accompanied by an in- creased head, results in considerably increased power transferred through the pump. shaft. As a result, the output of the PAT must be limited to the power that can be safely handled by the shaft, bearings, and couplings, In this case, considerable advantage may be gained by utilizing an ANSI pump or one designed to American Petroleum Standard API 610, “Cen. Uifugal Pumps for Refinery Service.” Pumps that meet the API standard are designed with large, stiff shafts and are very heavy-duty. Note also that tae head at PAT best cease aS Excellent for restoring dams, tunnels, Sewer lings and ether concrete structures. ct eri er oi steer corms arate SE ayo z See cece meas cates Bos ehenereerst sense Shotorete jor maved. ‘construc: stv na mich a HALL efficiency point (BEP) in Figure 1 is considerably higher than at the purmp’s BEP and increases to the right of the BEP. The standard pump pressure rating must be adequate to withstand the additional pressure. Dealing with Increased Speed Figure 2 gives the relationship be- tween turbine speed and discharge capacity, efficiency, and power output. Itcan be seen that the runaway speed of the PAT can be much greater than the BEP speed at which the pump was Strong, Qualty and srngthgroster Aigo shes ful sccesibe. Our re tupment goes ere eroded. No delays geting to job site moans less lost time. ures tant niko poured concroto, Store cre reid tne one Exeaient cary Strength, tetra mc eary ruetutal roquroments are met without delay, ‘aloning ther phases of Songtucton work t poe hod ahead of schede, nero sex nse SE arg vegetarian Mares, iy areas te Seay pee ally HYDRO REVIEW/OCTOBER 1860 63Pump are Twine RPM = Conetnt Pump BEP Faw cat Bet Eficenoy Point (SEP) Hea Etilancy, Power 5 é "Flow Percent of Purp Best Enlany Poet (BEP) Flom “Tutine Speed Figur 1 Portormance ofa pump and a purp-asurbine (PAT) at [cdrnicalroratona’ speeds, (Coutouy Power & Frcs Vel 10, NO. 1) Figure 2: Relationship btwoen tubne speed and discharge capac, Percy ate owol cts (Couey Power Pade Val 10:89) designed to run. In some cases, the bearings may have to be redesigned {for increased speed. Dealing with Higher Pressure Normally, pumps experience low pressure at the intake and high pres sure at the discharge. The PAT will conversely see highest pressure at its intake and lowest pressure at its dis- charge, However, the reduction of pressure in the PAT may not neces- sary be the reverse of the pressure build-up in the pump. It is possible that ‘the PAT discharge may experience pressures higher than those for which the seal was designed. If so, the criginal seal at that point must be redesigned. Potential for Vibration With a PAT, the reverse rotation and the turbulence of the reversed flow may generate vibrations not ex- perienced by the pump. This can be especially critica in the case of vertical submerged pumps, which may have a long drive shaft extending up to the drive motor above the floor. The necessity for this precaution, how- ever, is not accepted by some pump designers. Using An Irrigation Pump Irvigation-type pumps used as PATS often were originally driven by a long shaft, with shaft. sections threaded together. Usually, threads are in such a direction that the shaft sections will nol unscrew. However, in opposite rotation the threads may require pin- ning or replacement. Checking Hydraulic Balance As is the case with pumps, the Evaluations Consulting Service: m FERC Relicensing Hydroacoustic Fisheries @ Fish Diversion Screen Evaluations Hydroacoustic Equipment: ‘m Automatic Fish Counter/Tracker @ Digital Chart Recorder m Target Strength Processor = Digital Echo Integrator ‘54 HYDRO REVIEWIOCTOBER 1990 Hydroacoustic Technology, Inc. {6869 Woodlavin Avenue NE, Suite 110 Seale, WA 98115 (208) 527-3383 FAX (206) 527-3384 ‘MCLE 421 ON READER SERVICE CARO‘operation of a PAT should be limited to the center section of the efficiency curve for continuous operation. The inherent radial and longitudinal balance designed into a pump may not be as precise in the reverse operation. In high pressure, multiple stage units, the provisions for hydraulic balance should be checked against the condi- tions acting in reverse operation. Cavitation Possibilities Cavitation, always 2 serious com sideration in’ pump operation, is also a possibilty in the operation of a PAT. Sufficient back pressure at the turbine outlet must be maintained to prevent cavitation-erosion, Normally, in high pressure units, the loss of efficiency Gue to back pressure is minor. How: ever, in low pressure units, it may be significant. A saving feature with low pressure units is that cavitation is not as destructive as it may be for high pressures. Some efficiency improve- ment is possible by using a draft tube at the discharge. In this arrangement, the water should discharge in a full column, filing the tube, Since the area of the draft tube exceeds that im- mediately below the discharge, the water is decelerated so that a part of its kinetic energy is regaines, thereby adding to the differential head acting fon the impeller/runner. Range of Control ‘The PAT does not have the range of control that is possible in a hydraulic fuurbine with variable pitch and adjust- able gates. Control is by throttling and bypassing. Figure 3 gives the perform- racteristics of 2 PAT. The heavy line is the rotational speed of the PAT at various differential heads. Note that below a differential head ‘equal to 50 percent of the design head, torque becomes negative, That indi cates the turbine will require power from the grid to maintain the rotational speed. A variable speed motor (gen- erator) will improve this situation. The synchronous generator which it drives will supply an output to a variable frequency inverter, such as is used for changing drive motor speeds by vary- ing the supply frequency. ‘The inverter will operate in a reverse mode—taking whatever hertz is available, converti it to DC, and then converting the DC to a 60 Hz output. (Por a more de- tailed discussion, see articles in the Journal of Energy Fngineering GSLOPE and G TILT mean =e iy bo eRe Ur) Oe CaPLICy De R ay ‘Suite 200, 9636 - 51 Avenue Edmonton, Alberta Phone (403) 434-4452 CANADA T6E 6AS Fax (403) 437-7125 ‘GCLE 170 ON RENDER SERVICE CARD Dam Deformation Specialists Surveying Engineers offering: | = Dam Deformation Monitoring and Analysis = Hydrographic Surveys and Reservoir Mapping a HighPrecision Engineering Surveys = GPS and Geodetic Control! Surveys COLERS& COLANTONIO ? Contact: Mark W. Rohde See Te: (617) 740-2208 Visit us at ASDSO, Booth 105 Cone. a8 on nEAoen sevice caRD HYDRO REVIEWOCTOBER 1990 551 The Market for Pumps-as-Turbines Pump manufacturing companies that market pumps for use as hydraulic ‘turbines say demand for equipment from small hydro develspers peaked in the early 1980s. And, they are hopeful that the interest may be renewed during this decade. Some companies are already séeing an increased interest {in small hydro development in the Canacian provinces of Byilish Columbia and ‘Ontatio. Depending on future prices ofall and federal incentivas for renewable ‘energy, a revived interest in. small hydro in the U.S. could cccur in the next few years. omell Pump Company in Portland, Oregon, is actively marketing pumps- as-turbines (PATs) for use as hydraulic turbines and installs ‘our or tive such systems a year, Comell's largest hydro installation is a 1.5 MW faclty with 7 PAT units operating at 900 feet of head. William Nicholas, Cornell sales ‘representative, says he anticipates placing 26 to 30 PATs at small hydro sites, in British Columbia in the next three years. He says these Canadian ‘developers are opting for PATS Instead of the more expensive conventional turbines. Comell is also marketing its PAT Intomatlonally, especially in thicd-world countries with interest in small hydro development. Dresser Pump, a division of Dresser Industries, Inc., Liberty Corner, New Jersey, says it wil specially design a pump to operate as\a tydraulic turbine, but hasn't seen a market for the product in the last few years. A. Agostinell, Vice president of engineering al Dresser Pump, says the compary in the past has sold pumps as turbines for small private hydro projects ip to 800 kW in she. Both Pacific Pump Company and Worthington Pump have. been incor- porated into Dresser Pump Division. ‘Other companies that produce pumps, such Fiygt and BWIP Intemational, Inc. have chosen to design special turbines to market for small hydroolectric. applications. They wil sell a standard pump to uso as a hydioelectric turbine but are not actively marketing PATS. Flyat Corporation based in Norwalk, Connecticut, has been manufacturing pumps for 70 years. In tho mid and late 1970s, Flvat exserinented with flow propeller pumps as hydroturbines. However, the company decided instead 10 design its own submersible hydroturbine, Stefan Abslin, marketing and ‘engineering manager. for propeller pumps and hydroturbines, says Flygt began marketing its new turbine in 1983 and now has over 100 installations ‘across the country, The turbine is designed for 50 to 800 KWN of capacity por Unt. Fiygt’s largest instalation is at Twin Branch, a 28 MW hydro facity ‘Outside South Bend, Indiana, owned by Amorican Electric Power. ‘Abelin says he does got requests for PATS periodically. Although Flyot is not actively selling PATS now, It might consider pursulng that market in the future. Abolin believes the most feasible use of a pump as a hydraulic turbine 'g in situations where eficiency is not of vital importance. ‘H you've got a situation where there's opportunity for eneray production but you're. not fecovering anything at all, recovering something would bo better than BWIIP Intemational, Inc. in Long Beach, California, developed the Byron Jackson TKW turbine in the eatly 19808 when the federal government was: providing incentives. for alternative energy development. Tho turbine Is recommended for hydropower sites between 60 KW and 5 NW In size, One: turbine unit can generate up to 1.5 MW of capacly. According to Johnny. Johnson, manager/vertical producis, BW/IP has installed cbout 100 TKW. turbines. The largest installation was for Los Angeles Department of Wator {and Power for use af pressure reducing stations throughout lis system, Johnson says BW/IP has sold some PATS, but the number of installations: has dropped recently. BW/IP has no plans to actively marset PATS in the future, Because of the stringent environmental regulations in the U.S., Johnson says very few run-of-tiver hydro facifties are being installed. Since PATS aro most effective in a run-ot-tiver scheme, the decrease in this type of plant is. Toflected in the drop in PAT use. Although there is increased interest in small hydro development in Canada, Johnson says the interest (1 PATS has not accelerated yet —Marla Bares ‘56 HYDRO REVIEW/OCTOBER 1990 and Hydro Review.**) ‘Three general areas to consider when implementing a pump as a tur bine are the type of generator to use, flow control, and speed control. Using an Induction Generator Drive with a PAT ‘Typically, a “ake what you cat philosophy ‘guides PAT operation and lends itself to the use of induction generators for power production. In- duction generators are especially use- ful when the PAT is used as a pressure reducer to maintain a controlled pres- sure ot flow downstream, The PAT can run at nearly constant’ speed, but with variable torque by controling the flow or by accepting what flow is availible. This is one of the main advantages of the induction generator set. It allows you to recover every possible kilowatt from your system ‘even when the flow fluctuates over a fairly wide range, This would be ex- tremely difficult to do with a synchro- hows generator where stable control becomes very difficult at tight loads and reverse power cannot be tolerated atall ‘According to the characteristics of an induction generator/motor, as the torque changes, the generator output changes. At about 102 percent of rated speed, the generator is at full capacity. When’the turbine loses power, it will slow down to synchronous speed, at which point no power is produced by the generator. If the turbine is cut back still more, due to loss of flow or throttling, the generator will drive the turbine. ‘To limit this loss, a reverse power relay can be used fo open the generator breaker so the turbine is operating at no load, A time delay relay is used to open the breaker after a pre-set period of operation in the motoring condition. The reverse pow- cer relay also controls warning lights to indicate motoring or generating, oper- ation. This makes the application very flexible and independent of an opera tor, Ifreduced flow is just @ temporary swing, the unit will briefly motor and then ‘automatically revert back to generating as flow increases, Basic protection is provided by the circuit breaker against overcurrent, Addi- tional protection can be provided by monitoring stator temperature in the generator and providing an over-tem- perature trip of alarm relay, ‘The in- duction generator has additional con-trols, such as_ over/under voltage relay, under frequency relay, and automatic reclosure of an opened breaker. The limitations on the use of an induction generator are simple but significant. It doesn’t have an exicter, so it can't operate in isolation. Instead, it has to be connected to a much larger power source in order to oper- ate because it draws its excitation from the connected power system. ‘This excitation produces the magnetiz~ ing current in the field of the gener- ator, which allows it to generate and produce power. Without it, the gen- erator ean't produce. This parasitic excitation has two very significant effects on the gener- ator’s operationone positive and one negative. First, the induction gener ator cannot be’ used in isolation from the grid, Therefore, it cannot be used for standby power.’ If standby power as well as energy production are re- ‘quired from the generator set, a syn- chronous generator should be used. ‘This is the biggest disadvantage of an induction generator. Second, because the induction generator cannot generate without excitation from the grid, it will not continue to operate in the event of & failure in the distribution system. Consequently, the induction generator inherently camot feed a fault condi- tion, This is a large advantage, ‘The control system for an induction generator is simple. From the elec- trical end, basically all that is necded is a circuit breaker. This provides the means to switch the generator on and off line as required and gives. pro- tection against overcurrent. Because the generator is not self-excited, there is no power until the breaker is closed. Simply bring the PAT up to approxi- ‘ately synchronous speed and close the breaker. No sophisticated paral- leling equipment is required. Once the breaker is closed, the generator is excited at the same phase, voltage, and frequency as the grid to which it is connected, This is done automatically, without special controls Since the induction generator vill ‘use excitation from the grid, the power factor of the grid is reduced. ‘When povrer factor is a consideration, the induction generator needs to op” erate in a grid with several times the capacity of the generator. Flow Control Tn many cases, flow varies accord- ing to the season or to the process load. Best efficiency will be obtained by using multiple turbines. For exam- ple, when the projected yearly flow varies from 2,030 to 6,000 gallons per minute, a 40 LW and a 60 kW PAT. may be pairec to efficiently handle these flows. Depending upon dis charge, severd variations are por sible—you coull run the 40 percent uit, the 60 fercent unit, or both Systems with steep head curves (a large head loss component) lend themselves to variable speed turbines. Flow changes, if required, can be ‘accommodated with multiple steep head Gow specific speed) turbines in parallel, a shown in Figure 4. A valve may be provided in series with the turbines. Fach turbine is connected to a generator thet is wound for two speeds. The speeds of the turbine- generator would be automatically con- trolled based on the upstream pres- OVER 800 HYDRO/ELECTRIC PROJECTS ON) OILES BEarincs SHOULDN'T YOURS? ‘THE LEADER IN SELF-LUBRICATING BEARINGS OILES AMERICA CORPORATION 14941 Cleat St., Plymouth, Ml 48170 (313) 459-2940 FAX: (313) 459-0080 ‘rNcL 240 ON READER SERVICE CARD HYDRO REVIEW/OCTOBER 1990 573 a O 6 20. 40 60 80 100 120 140 160 180 Dea mt pn Figure 3: Typeal punp-as tubne perormerce curves as a percent of design pont, (Cou {e9y Ghombal Engineering F028, 1970) . eee sure and the point where the turbine curve crosses the system head-dis- charge curve. The flow control valve ‘would then break down the diferentia pressure between the system head and the turbine curve to maintain a constant flow. This variable speed-type setup. works best with very steep system curves. When the system head-discharge curve is horizontal, infinitely variable slow is required, and so a single con- stant speed PAT may be utilized in series with a control valve. If flow in excess of the turbine capacity is re- uiced, a bypass valve rust be used, as ilustrated in Figure 5. An improved utilization of the flow is achieved with multiple constant speed turbines, as ra Flow Contci vole | (reset dood Ne pant shown in Figure 6 where acceptable efficiency is maintained over a wide range of flows. Speed Control ‘The problem of speed control of a water turbine is complex. If the horse- power output ot the PAT could be changed at the same rate at which the horsepower absorbing this load changes, there would be no speed control prob- lem, For each existing load, the output ‘would match it so -hat there would be neither @ surplus or a shortage be- tween the two. Tt should be noted that when the available head la) is changed, both the discharge and the ‘output of the PAT changes. These changes must be considered for each case. The control of a PAT, therefore, is a combination oF throttling and by- passing. The optimum arrangement is to provide for use of all the power the PAT can provide. Control is then only a matter of throttling, If all the power can't be used, the bypass is required. Fluid input to the PAT may be controlled with 2 oneumaticaly_actu- ated liquid flow conzol valve. Butterfly valves are commonly applied due to their relatively low cost. The butterfly will cause considerable fuid turbulence downstream. Inasmuch as it is desir- able to provide smooth flow to the Figure 4: Schematic tagram for multe weed tien” sem wh vy toon ‘September 1982) . a ‘58 HYDRO REVIEW/OCTOBER 1990, PAT, the butterfly valve should have at least ten diameters of straight pipe between it and the turbine. The situa tion may also be improved by installing flow straighteners downstream of the butterty ‘A more desirable control valve. is ‘one in which @ rubber sleeve is com- pressed by hydraulic or pneumatic pressure, thus providing a streamlined Circular orifice to restrict the flow. With this type of valve, however, sufficient hydraulic or” pneumatic pressure must be available to com- press the sleeve agzinst the internal pressure, The actuating fluid should have a pressure at least 30. percent higher than the pressure of the fluid which is being controlled. Gate and slobe valves, of course, may be used if sufficient length of straight. pive available downstream. ‘The flow control valve is usually placed upstream of the PAT to limit pressure at the mechanical seals which are exposed to PAT outlet pressure. This low sealing pressure usually means lower initial cost and reduced maintenance. ‘Most valves do not have a linear output. Therefore, valve actuators should be fitted with positioners to ‘ensure that the valve aetion accurately follows the control signal. Further more, positioners are useful in that they ‘can be adjusted to cause the valve to respond in a linear fashion. Bypass valves, however, are not as critical. In some’ instances, three-way valves may be used to combine bypass and throttle functions. In this case, a decision should be made regarding whether power output or bypass flow shall take precendlence. The head-ca- pacity curve of a PAT drops. with decreasing flow. Therefore, in design- ing a process to accept 2 PAT, the control valves or regulators required are sized similarly to those for a pump. That is, the regulator must throttle, or dissipate, any difference between the total design head available from the process and that which the PAT. is capable of absorbing at any given flow rate. The total design head across. a PAT is fixed at any given flow rate. It, of course, varies with flow but cannot. be otherwise adjusted. A splt-range positioner is commonly used to regulate flow to the PAT and its bypass. Once design flow to the PAT has been reached, it is not possi- ble to increase this flow without also increasing the available inlet pressure. ‘Therefore, a bypass must be used to allow excess flow from the source to leave.a | Maximum Syst N00) 150" flow [head Maximum ie \ curve flow = 80 130 3 a Bypass g capacity 2 co 2 110} Turk jeer £ 7 bs ae Paot § 90 efficeney 3 5 a i Control oo 19; Turbine. valve head beac~copacity dissipation ° = ale Rosie 20°24 28 32 36 40 44 48 Capacity, cubic foot per second ‘gure: Vara fom cytom with constant nea uliig a snl constantspood tine Mesy Power Enginsering, Soptember 1902) Controllers for the PAT have be- ‘come sophisticiated. Microprocessors may be used for large systems, but ‘many controllers are available ‘with several inputs as well as outputs. Inputs may be required such as downstream flow (with set points), required power (with set point), tur- bine speed, and developed power, With appropriate algorithms, the con- troller will contral PAT power output, bypass flow, and will incorporate over: speed safety functions and features. Pneumatic activation of control NEW CONCEPTS IN DAM RESTORATION Time-saving, trouble-saving, innovative solutions have made Nicholson nationwide leader in geotechnic ‘construction. al Nicholson's Rock Anchors, Diaphragm Walls and Grouting technologies are ideal forthe rehabilitation of concrete and earth embankment dams. Our experts can cost- NICHOLSON effectively restore these structurestomeet CONSTRUCTION current federal or state safety standards. Call Nicholson... Where innovation gets down to earth, CIRCLE 109 ON READER SeAVICE CARD (60 HYDRO REVIEW/OCTOBER 1000 OF AMERICA P.0.Box300 PA 5017 4800 Bidgevil ara valves is preferred a pneumatic actu- ator can “dither” continually without any problem, An electrically-actuated valve is most reliable when motion is not continuous, especially in re- verse/ahead valve adjustment. The controller should be electronic because of its versatility. Between the pneu- ‘mutic operator and the electronic con- troller, there should be interposed an “UP Converter.” This device receives fan electronic signal and converts the signal to pneumatic pressure suitable to appropriately move the valve actu- ator. Sophisticated electronic control Jers are almost mandatory when the PAT is being supplied with a fluid other than ambient temperature _ water. Temperature, pressure, viscosity, and other parameters unique to the fluid may be measured and controlled to censure optimum and safe operation of the PAT.) Any control should be programmed so that the head and discharge do not drop below the point of zero pawer ‘output, such that negative torque or drag of the runner occurs, a8 illus trated in Figure 3, In the case of the PAT driving an induction generator or an auxiliary driven machine, the generator or the ‘machine will drive the PAT and con sume excess power. With an induction generator, the controller should open the breaker. With a driven machine Using the turbine and an auxiliary drive for power, the drag on the auxiliary driver can be reduced by using an ‘overrunning clutch on the output shaft Of the PAT to release the driver when it is not required, Selecting the Right PAT It is a reasonably simple matter to approximate the horsepower which can be recaptured from the potential energy available in a given situation. The key to proper machine selection is to remember that a good centrifugal Pump operating with high efficiency may be expected to display good performance when the direction of flow is reversed and the pump is used as a driver. Pump performance curves are readily available, so if you can evaluate flows and pressure drops in terms of pump performance, selection of a pump for use as a turbine can be provided by any pump supplier Both pump and turbine efficiencies may be considered identical with little error, so the relation of performance flbetween the two at their respective BEPs and at the same speed can be expressed as: Developed bhp tuthine ~ Required bhp pump, or QxH, xexSp.Gr 3960 H, x Sp.Gi 3960 xe where: ‘Qis flow in gallons per minute; His total diferential head (pressure drop) in feet of liquid; and wage’ Be else ofthe pump atts BEP. Subscript “p” refers to operation of a pump; “t” refers to the same ma- chine operated as 2 turbine. Further, Q,xe = Q, and Hxe =H, a Recent investigation indicates that the above relationships are sufficiently accurate for actual pump selection from pump performance curves. for application as a hydraulic turbine. It ‘can be assumed that the BEP for both pump and turbine is approximately equal For preliminary planning, assume an efficiency which may be eclected from pump curves for available pumps. Calculate Q, and H, and select a pump with a BEP'as close to these values as possible. If the pump selected has a BEP that varies significantly from the selected efficiency, use an appropriate new value of eficiency for re-selection and refinement of the data. Generally, 4 pump can be converted to a PAT Q, and H, fall within 20 percent of the BEP of the pump selected. Conclusions A pump-as-lurbine is often a real- istic option fer a small hydropower facility (or for a turbine to replace pressure letdewn systems in an in- dustrial process). Considerable cost savings can be realized, but ideal performance and flow control probably will have to be sacrificed. By under- standing come of the challenges in- volved in operation and control, a pump-as-turbire can be used more effectively. a Mr. Garay may be contacted at Parsons Brinckerhoff, 1068 Mis- sion Street, San Francisco, CA 94103; (415) 364-6776. Notes: ' Garay, P., Pump Application ‘Desk Book. Fairmont Press: Lik burn, Geo:gia, 1990, Chapter 21, pp. 367-386, * Farell, C. and J. Gulliver, “Hydro- mechanics of Variable Speed Tur- bines,” Jeurnal of Energy En gineering, Vol. 113 (), 1987, pp. 1-13. ° Sheldon, LH. and T.H. Logan, “Variable-Speed Pump/Turbines, Hydro Review, Vol. 8 (4), 1989, pp. 72-82. HX Hosey & Associates ‘Ernenirg Eetorvrtay, 6 Ragan Saves Can Fish:Pass ‘An Eicher Fish Screen may provide acon effective alternative to conventional sereens and may be practical where conventional screens wenot, ‘An Eleher Fish Sereen consiss of fa wire screen placed in apenstock at shallow angle to the flow. The sexcened fish ate safely bypassed sound the turbine, “The ish sereen is mounted ona pivot Which allows itt be positioned in a “ishing” position, cleaning postion or, in neve position. Hosey & Associates experience in the design, constuction and testing of conventional and Eicher Fish Sereens means our engineers end Tiologiss may have a solaion for your Fish passage projects 16 24 Effective and Bconomical Screens Will Pass [| Minithum / Turbine /System Your Fish Safely Aa i fl 1 head / efficiency T System / 9 Pr 2 Or eee . een Turbines & 6o- s110P 1 & 2 head Maximum = 3 4 Turbines 1, flow e ial 2 & 3 head Pats 5 e Tyrbings Turbines EB Hosey & Associates a yrange orbines, Teer ennerceann Feet tee eee NEW LOCATION o T. : 1 T (206) 882-2455 FAX: (206) 863-7555 32 40 8 ‘Capacty,cubie foot per second Figure 6: Vatiabe flow system with constant head uilzing mulipl constant speed turbines. Tis provides a higher average efcency than the use ofa sanletrbme. Courosy Power Engineering, September 1882) ost Otics Sox c-66900 Befieroo, Rashungion 2009 520 Corporate Center pass adr ave NE Sule 200 Beliewe, Washingian S800 CCRCLE 140 OW READER SERVICE CARD HYDRO REVIEW/OCTOBER 1990 61