Hindawi Publishing Corporation

Advances in Mechanical Engineering

Volume 2014, Article ID 139868, 7 pages
http://dx.doi.org/10.1155/2014/139868

Review Article
End Suction Centrifugal Pump Operating in Turbine Mode for
Microhydro Applications

Mohd Azlan Ismail,1 Al Khalid Othman,2 Shahidul Islam,2 and Hushairi Zen2
1
School of Engineering and Information Technology, University Malaysia Sabah, 88450 Sabah, Malaysia
2
Faculty of Engineering, University Malaysia Sarawak, 94500 Sarawak, Malaysia

Correspondence should be addressed to Mohd Azlan Ismail; lanz mr@ums.edu.my

Received 15 January 2014; Accepted 10 February 2014; Published 19 March 2014

Academic Editor: Mario L. Ferrari

Copyright © 2014 Mohd Azlan Ismail et al. This is an open access article distributed under the Creative Commons Attribution
License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly
cited.

This paper reviews the current research works on the end suction centrifugal pump coupled with induction generator running in
turbine mode for microhydro application. The information can be used by practicing engineers, researchers, and plant managers to
understand the potential of pump running as turbine. Review on experimental and simulation works was carried out encompassing
end suction single stage low specific speed which is less than 10 kW. This is followed by review of their efficiency improvement
through modifications. The results show that centrifugal pump can operate in turbine modes without any modification on
mechanical components. However, to achieve the best efficiency point (BEP), it requires higher flow rate and head than pumping
rating. Efficiency improvement is viable through geometric modification to improve hydraulic characteristic. The studies also show
that pump as turbine (PAT) can be directly coupled with modified induction motor as generator by adding capacitor and electric
control system, regulating voltage and frequency at the output terminal. It was found that PAT offers the best low cost solution for
microhydro application especially for third world countries that do not have local microhydro manufacturer.

1. Introduction energy from the gravitational force over height difference is

Hydropower is a well-known renewable energy source gen-
erating clean, secure, and predictable electric power. It has
zero carbon emission, low operational cost, and virtually
zero greenhouse gas emission. With the technology of over
one hundred years, hydropower is considered as the most
established technology to provide energy in a small or large
scale. By far, hydropower is the largest renewable energy
produced accounting for 90% of the total renewable energy
worldwide [1]. In 2010, hydropower has been utilized in
150 countries with installed capacity of 860 GW and Europe
having the highest installed capacity followed by East Asia
and Oceania [2].
While large hydropower plants feed the national grid,
typical off-grid microhydro is the most popular solution
for electrification among rural communities which supplies
power in the range of 5–100 kW which usually use a run-of-
the-river to divert some of the water from the river before
dropping into a pressurized penstock. The water potential
converted to rotational mechanical energy. A hydro turbine is
used to transform energy from the flowing water to mechan-
ical rotational energy and then a generator transforms the
rotational mechanical energy to electrical energy regulated
by electric control system. Microhydro configurations vary
depending on the topography and hydrological site condi-
tions [3].
The main components that comprise typical microhydro
schemes are electromechanical equipments, civil structures,
and energy distribution systems [4]. An optimum opera-
tional design, smart selection of equipment, and reduced
professional consultation input can lower the overall cost [5–
7]. It is important to pay attention to actions to reduce the
whole microhydro cost because it is always the main concern
for small communities especially in rural areas. In order to
minimize the overall cost, microhydro system must be in the
optimal operation and component selection. Furthermore,
the microhydro must be reliable, robust, and manageable with
minimum technical knowledge by local communities.
2 Advances in Mechanical Engineering

1000

10

10
10
10

00

00
500 Gate valve Flow meter

0k
kW

0k
kW
W

W
200 Pelton wheel
Pressure gauge
100 1 kW
Francis turbine
Head (m)

Crossflow turbine

Single stage radial Kaplan turbine PAT

10 flow PAT

Archimedean Auxiliary pump Water tank

screw turbine
1 Figure 2: Laboratory schematic test rig for PAT.
0.001 0.01 0.1 1.0 10 100
Flow rate (m3 /s)

Figure 1: Range of application for different PAT for hydropower [12,
44, 45].
2. Pump as Turbine (PAT)
The electromechanical unit is one of the most expensive
components in microhydro system. Generally, microhydro
manufacturers offer high efficiency turbine performance;
however, they are expensive and unaffordable particularly
for rural communities. The use of PAT for microhydro
offers low cost solution as a substitution for commercial
microhydro turbine. Domestic and industrial end suction
centrifugal pumps cover a wide range of flow and head are
readily available and mass produced in many countries. The
advantages of PAT compared to commercial turbines are
simple constructions, know-how knowledge which is readily
available, and low operating and initial cost thus making the
technology more affordable, and these advantages are the
reasons why there are a large number of PATs installed in
rural areas [8, 9].
Pump as turbine (PAT) as an unconventional type of
turbine does not have a flow regulating mechanism; therefore,
each pump running in the turbine mode has single best
efficient point (BEP), in which the flow rate and head are
fixed for a particular point. The application of PAT is suitable
for radial and mixed flow serving low specific speed turbine
which is normally covered by a single jet Pelton wheel,
multijet Pelton wheel, and crossflow turbine in the range
of 13 to 100 m of head [10–12] as shown in Figure 1. Axial
flow pumps which are not covered in this paper are prone to
cavitation and are more expensive; thus they reduce the cost-
benefit factors.
3. Research Review
3.1. Experimental Analysis of PAT. Pump manufacturers only
supply pump mode performance curve and this makes it diffi-
cult to predict the turbine mode performance. Many attempts
have been made to predict turbine mode performance by
using analytical model but the percentage of deviation is
relatively large compared to the actual performance [13–16].
To attain a definite characteristic pump in turbine mode, the
pump is required to be tested over a range of heads and
flows shown in Figure 2. A feed pump producing greater head
and flow is used to supply inverse flow to the studied pump.
The characteristic can be obtained at constant rotational
speed controlled by electrical control equipment. The review
on present PAT experimental works is presented in the
following.
Derakhshan and Nourbakhsh (2008) had tested four
industrial centrifugal pumps with specific speed between
14 and 60 (m,m3 /s) to derive a prediction model for the
best efficient point based on pump hydraulic characteristic
[16]. The test showed that centrifugal pump can operate in
turbine mode without mechanical problem. Based on the
experimental data, all centrifugal pumps give lower BEP
running in turbine mode compared to pump mode. The
efficiency in turbine mode was reported to be between 60
and 80%. The authors suggested that bigger pump impeller
performs better in turbine mode.
Raman et al. (2013) had carried out experimental inves-
tigation of a centrifugal pump with specific speed of 15.36
working in turbine mode [17]. Calgon (HES 40–200) end
suction centrifugal pump with head and flow of 22 m and
8.31 l/s was used for the test. 5 kW, 230 V synchronous AC
generator was directly coupled to the pump. Control panel
measured the rotational speed, generator voltage, current,
and frequency of the system. The experiment shows that
the best efficient point (BEP) was found at higher head and
flow than in the pump mode. The efficiency was recorded at
39%, head and flow of 30 m and 13.52 l/s, respectively. The
efficiency in pump mode was reported at 59% and the lower
efficiency suggests higher hydraulic loss in the turbine mode.
Fernández et al. (2004) presented a performance study
of a centrifugal pump in order to justify the feasibility of
using pump in turbine mode by determining pump and
turbine performance and radial thrust and prediction of
pump-turbine characteristic curves [18]. The pump used for
the study had a single axial suction and spiral volute casing
with an impeller of 200 mm. The pump was tested using
hydraulic setup standard ISO3555:1977. The best efficiency
point in turbine mode was reported at 58% corresponding
to flow coefficient and head coefficient of 0.015 and 0.011,
respectively.
Nautiyal et al. (2011) studied the performance character-
istics of a centrifugal pump running in pump and turbine
mode. A Kirloskar (KC100-65-315) pump with specific speed
of 18 was selected for the test [19]. The pump ratings for head,
Advances in Mechanical Engineering
Inlet
Impeller
Volute
Outlet
Figure 3: PAT computer aided design model.
flow, and power are 32.8 meter, 14.8 l/s, and 8.18 kW, respec-
tively. A synchronous generator of 12.5 kVA was coupled to
the pump to measure power output running at 1500 rpm. The
efficiency of pump operating in turbine mode was found to
be 8.53% lower than the best efficiency in pump mode.
3.2. Numerical Analysis on PAT. The computer fluid dynamic
(CFD) analysis provides great tools in the designing and
performance analysis of fluid dynamics in turbo machinery.
This tool allows researchers, engineers, and plant managers
to test hydraulic performance in virtual condition. With
the advancement in numerical algorithms and computing
power, CFD plays a significantly large role in the discipline
of fluid dynamics and turbo machinery. CFD allows various
parameters investigation such as flow visualization, hydraulic
optimization, off-design operation, and cavitation analysis
which are impossible to perform by experimental work.
Moreover, CFD can provide a pinpoint insight for local flow
phenomenon and allow for the alteration on corresponding
parameters for optimization purpose. An example of PAT
computer design model is shown in Figure 3.
Natanasabapathi and Kshirsagar (2004) had conducted a
simulation study on PAT using ANSYS CFX (V5.6) on newly
developed unstructured mesh geometry replacing complex
blocked mesh [20]. Unstructured mesh was used to match the
pump complex geometry. The flow domain was divided into
three individual parts as casing, runner, and draft tube. Total
pressure boundary condition and average static pressure were
set at the inlet and outlet, respectively. Comparison between
experimental data and simulation shows good agreement for
head drop across the turbine; however, there was a deviation
in the efficiency for discharge. Further enhancement by
additional interface ring between the casing and runner leads
to considerably reduced error.
Yang et al. (2012) presented a computational fluid dynam-
ics analysis on reverse mode performance prediction using
commercial flow solver, ANSYS-CFX software [21]. The
control volumes domains were divided into five component
parts: inlet pipe, front, back chambers, impeller, and volutes.
Each part used different types of mesh, tailored to suit flow
pattern and requirements. Structured hexahedral grid was
3
used to generate meshes for each individual component.
Comparison of experimental and simulation results shows
that both performance curves are in good agreement. The
relative error between both results at BEP for efficiency, head,
and power is −3.02%, −0.78%, and −0.78%, respectively. The
study highlighted the importance to establish performance
prediction model using theoretical analysis, empirical corre-
lation, and simulation results.
Fernández et al. (2004) investigated three-dimensional
flow simulation for end suction centrifugal pump installed
with an impeller size of 200 mm operating in turbine mode
by using commercial Fluent software [18]. Specially refined
mesh was used at critical flow domain in the pump such as
leading and trailing edges of the impeller and volute tongue.
Uniform velocity distribution was set at the inlet and constant
static pressure at the outlet. Turbulence effect of standard
k-epsilon was used together with standard wall function.
Good agreement and trend between numerical computation
prediction and experimental analysis were observed. How-
ever, the numerical analysis yielded higher performance as
predicted. The reason can be explained by leakage loss that
was excluded in the simulation work. Once validated, the
simulation model was later used to investigate hydraulic flow
and radial force.
Rawal and Kshirsagar (2007) conducted numerical simu-
lation on a single stage, mixed flow pump having an impeller
size of 236 mm operating in turbine mode [22]. The flow
domains considered for the simulation consist of casing,
impeller, and draft tube. Unstructured tetrahedral mesh was
used for all flow domains taking advantage of adjusting mesh
density at critical flow zone. The boundary condition at the
inlet was specified as known uniform pressure exerted by
fluid flow from the penstock. The wall interface was set to
no-slip boundary condition over wetted surface. K-epsilon
turbulence model was used in this simulation. The simulation
results match well with the experimental results for low
flow range but perform poorly beyond the best efficiency
flow range. The disparities between the simulation and the
experiments were from frictional losses in mechanical system
and leakage loss which was excluded in the simulation.
Derakhshan and Nourbakhsh (2008) conducted a simu-
lation in pumping and turbine for an industrial centrifugal
pump with specific speed of 23.5 using 3D full Navier-Stokes
equation and FineTurbo V.7 flow solver [23]. Two different
types of mesh grid were used for two flow domains developed
by IGG5.5 for the volute and Autogrid5 for the impeller. The
simulation model excluded flow domain between impeller
hub and casing which excludes leakage loss, disc friction,
and mechanical loss. However, these losses were estimated
using Thorne and Stephanoff method and then added to the
simulation power input. The simulation shows that BEP of the
pumping mode gives good match but the turbine operation
was not in good coincidence with the experimental data.
3.3. PAT Performance Improvement. Pump has low efficiency
in turbine mode and geometric modification of the impeller
can lead to an increase in efficiency. Modifications works
on PAT were reported through rounding impeller blade and
4 Advances in Mechanical Engineering
Figure 4: Rounding of blade profile and shrouds at impeller inlet
[25–27].
shrouds, installing splitter blades, enlargement of suction
eye, and using fixed guide vane. To further understand the
internal hydraulic characteristic, Singh and Nestmann (2011)
had divided pump control volume into five different flow
zones so it can be treated and optimized individually [24].
The control volume domain was enclosed between the inlet
and outlet of the pump. By treating the zone as individual
section, the alteration can be performed based on local losses.
The aim of the experiment is to minimize modification in
order to maintain cost-benefit of PAT. Among all geometrical
modifications, rounding centrifugal tip is the most beneficial,
reducing shock loss at the turbine inlet and increasing
efficiency up to 2.4% as shown in Figure 4 [25]. In many cases,
average modification work may potentially improve turbine
mode efficiency between 2 and 3%. Conversely, the effect
must be validated through experimental analysis because
there are a large variety and number of pumps operating at
various ranges of head and flow.
Singh (2005) had conducted an experimental investiga-
tion on the effect of impeller rounding for radial flow and
mixed flow pump in turbine mode [26]. The modification
gives a positive impact on the overall best efficient perfor-
mance with a raise between 1 and 3%. The reason for the
efficiency increase is from the reduction of loss coefficient due
to rounding effect.
Suarda et al. (2006) had carried out experimental analysis
on the effect of rounding off the impeller tips [27]. The
modification was performed by grinding the pump impeller
tips to rounded shape, eliminating excessive turbulence at the
inlet. A centrifugal pump with specific speed of 𝑁𝑠 = 18
and power input of 400 W, head of 13 m, and flow of 2.2 l/s
was used in the test. Based on the rotational power generated
from the turbine shaft, it was found that the performance
after modification had increased at 7.55% compared to the
original impeller. Further examination shows that the turbine
can rotate at 1500 rpm at high efficiency and therefore can be
coupled directly with induction generator without belting.
Derakhshan et al. (2009) had performed a modification
by rounding the blades leading edges and shroud [25]. The
modification involves rounding up the impeller tips and
shrouds by half of the blade thickness eliminating the sharp
edges at pump inlet in turbine mode. An industrial pump
with a specific speed of 𝑁𝑠 = 23.5, flow rate of 120 l/s, and
head of 25 m was chosen for the test. The modification gives a
9.4% power increase. However, the authors suggested that the
percentage increase of turbine mode could be from reduced
inner flow separation or rearrangement of inlet velocity
triangle leading to change in the shock loss component.
Sun-Sheng et al. (2012) had studied the effect of splitter
blades to a centrifugal pump in turbine mode [28]. A
complete microhydro test rig with an electric eddy current
dynamometer to regulate and measure the studied pump was
constructed to test centrifugal pump with specific speed of
37.5. By introducing splitter blades to the impeller, the fluid
flow inside the pump changed. The authors had proposed
that by adding splitter blades there is a substantial decrease
in pressure fluctuation between impeller blades and pressure
gradually decreases along the outlet pipe. The splitter blades
reduce the original pressure head and flow rate but increase
the turbine mode performance by additional 6.66% from its
original condition.
Patel et al. (2013) examine the effect of fixed guide vanes
with NACA-4418 profile to part load operating conditions
[29]. A smaller impeller size was used to make additional
space by replacing 250 mm diameter impeller with 200 mm
impeller. The installation of guide vanes at an angle of 75∘
helps guide the flow tangential with the impeller and thus
reduces the loss of kinetic energy. The variation flow velocity
inside the casing decreases, which leads to improvement of
part load operating condition.
Many researchers have reported that the efficiency of
pump in turbine mode can be improved by simple modifi-
cation such as rounding impeller tips, installation of splitter
blades, and reducing impeller size. Other pump modifica-
tions such as trimming the impeller diameter can alter the
pump characteristic to match the operation condition. In
some cases, minor modification to the pump impeller con-
tributes to huge hydraulic improvement leading to increased
efficiency.
3.4. Induction Generator. The use of induction motor as
generator is usually employed for installed powers below
30 kW. It has been known that an induction motor which
is normally coupled directly with PAT can be modified as
AC generator and largely used in microhydro applications.
Converting induction motor to induction generator is viable
by carefully adding capacitor and wiring modification on
the motor winding. The application of induction motor as
generator is well proven in many microhydro sites [30].
Selection of appropriate capacitance for operating voltage
and frequencies can be achieved in many ways. Listed are
some of the methods to determine capacitance to initiate self-
excitation.
Generally, minimum and maximum capacitance value
can be derived from fundamental equations derived from
equivalent circuit [31–33]. Brennen and Abbondanti (1977)
had proposed an exciter scheme based on static reactive
power generator with fixed capacitor and thyristor control
inductors [34]. Harrington and Bassiouny (1998) had pro-
posed using complex impedance matrix analysis loaded with
an inductive load which involves algebraic equation solved
by iterative approach [35]. The value of capacitor excitation at
Advances in Mechanical Engineering
Induction Consumer
generator load
Capacitor ELC with
bank dummy load
Figure 5: Schematic diagram of three-phase ELC [46–48].
no load and the desired rate of operation can be determined
iteratively.
Different from synchronous generator, induction genera-
tor does not have a voltage regulator. The generated frequency
and voltage depend mainly on the power factor of the
load, rotational speed from the turbine, excitation from the
capacitor, and the load current applied to the terminal [30].
Induction Generator Controller (IGC) as power electronic
device is used to regulate voltage and frequency output main-
taining good power quality [36, 37]. The most popular IGC
for microhydro application is Electric Load Controller (ELC).
This type of IGC uses solid state electronic controller regulat-
ing voltage and frequency, maintaining constant applied load
at generator terminal by dummy load. The function of ELC is
to eliminate hydraulic control mechanism and let the turbine
and generator run at their optimum operating speed.
The philosophy of ELC for rural electrification is to
generate stable voltage and frequency using unsophisticated
solid state electrical circuit maintaining a constant load at
generator terminal. Since the possibility of sensitive elec-
tronic equipment is low and common loads are from resistive
loads such as fan and lighting [38], the complexity of the
control system is kept at a minimum level. This approach
can be achieved by generating moderate power quality.
With emphasis on optimum solution for remote microhydro,
uncontrolled rectifier with a chopper controller dump load is
the most favourable induction generator [30, 39]. This control
system uses unsophisticated electric circuit with only one
dump load and requires no batteries or inverters, which is
deemed as simple, cheap, rugged, and reliable, as shown in
Figure 5. This system offers satisfactory performance under
transient and steady state, for balanced and unbalanced
resistive load. An uncontrolled rectifier converts AC voltage
to DC voltage and then it is filtered by filtering capacitor
producing a variable unity power factor load. An insulated-
gate bipolar transistor (IGBT) based chopper operates as
load diverter, dumping excessive current to the dummy load
maintaining constant applied load at the generator terminal.
Induction generators which are coupled with pump were
found to be the best electric generators with PAT. With wiring
modification and ELC, the system exhibit reliable, simple, and
excellent for microhydro application.
3.5. Cost Analysis on PAT. One of the major cost analysis
evaluations is to rationalise installation investment of PAT
[40]. This will help users to assess the cost-benefit factor of
PAT compared to commercial hydro turbine in a range of the
5
operating period. For economic justification, PAT offers low
initial cost at low efficiency but commercial hydro turbine has
high efficiency at higher cost. The main function of economic
benefit analysis is to justify the financial investment benefit to
the project. The main economic evaluation aspect is price of
unit energy cost ($/kWh) which is a financial indicator for
the hydro scheme. In a microhydro scheme, the initial and
operation cost vary and are site specific. Typical microhydro
system costs include but are not limited to mechanical
components, control system, electric distribution system, and
civil structures. However, reviewed cost analysis in this study
is focussed on electromechanical components supposing that
other expenses are identical for any microhydro system. Case
studies comparing commercial turbines with PAT have been
reported in academic literature but in very small numbers.
Motwani et al. (2013) had carried out a cost analysis for
commercial justification of centrifugal pump in turbine mode
for hydropower application [41]. The performance charac-
teristic of 3 kW PAT was determined through experimental
analysis. It was found that the highest efficiency in turbine
mode is around 60%. A conventional hydro turbine, Francis
turbine, having an efficiency of 80% was chosen for the
economic comparison analysis. The parameters considered
in this cost analysis were initial cost of the project, capital
recovery factor, annual expenses, discount rate, annual life
cycle cost, annual energy generated, and cost of electricity
generated per unit. Based on the study, the ratio of Annual
Life Cycle cost and the cost of electricity generated per unit
between Francis turbine and centrifugal pump in turbine
mode were found to be 6.8 and 5.07, respectively. The study
had also signified that the cost of electricity generation
($/kWh) for centrifugal pump in turbine mode is 5 times
cheaper compared to Francis turbine.
Chuenchooklin (2006) explained the implementation of
centrifugal pump in turbine mode to generate power for
electrification of Thailand conservation area [42]. A centrifu-
gal pump, model Mono flo MF 65–16 with 3 horse power
(hp), was used for the project. PE pipe with inner diameter
of 100 mm was used as the system penstock. An electric
controller system was installed to regulate the voltage output
to 220 V by using parallel system together with series of
running capacitors. The cost of the project was approximately
USD 4000. It was found that 45% of the expense is for
penstock, 37% for electric control, and 18% for PAT and
induction generator. The electricity energy production was
reported to be 8760 kWh per year and, with energy price of
0.75 cent per kWh, the payback period will be in 6 years.
Arriaga (2010) presented a pico hydro development status
in Lao PDR and proposed the use of PAT as a cost-effective
solution for electrification for isolated communities [43].
Three power generation options were considered including
PAT, commercial Vietnamese crossflow, and PV panels. Cost
estimation model divided the expenditure into three cate-
gories including energy generation equipment, civil works,
and energy distribution system. The analysis shows that a
2 kW PAT system offers a 53% cost reduction for energy
generation equipment compared to Vietnamese crossflow
turbine. PAT offers the lowest installation cost per kW
compared to commercial crossflow turbine and PV panel.
6 Advances in Mechanical Engineering
4. Conclusion
This paper reviews previous research works on radial flow
and end suction centrifugal pump operating as turbine
for standalone microhydro application. Experimental and
simulation works show that, by inversing the fluid flow, end
suction centrifugal pump can work well in turbine mode.
However, BEP for turbine mode is slightly lower than the
pump mode. Efficiency improvement is viable by modifica-
tion of the pump impeller and it was found that rounding
impeller tips contribute the highest efficiency improvement.
Induction motors which usually come with pump can be
modified into induction generator by adding capacitor. ELC
can be used to regulate voltage and frequency producing
satisfactory power quality by maintaining shaft rotational
speed. The use of induction generator further reduces the
overall cost and justifies the economic feasibility of PAT as
practical options. With low initial cost, energy generation
cost is 5 times lower and the payback period is shorter
than commercial hydro turbines. Moreover, the know-how
maintenance knowledge is readily available in local areas.
This further reduces maintenance and operational cost of the
system.
Conflict of Interests
The authors declare that there is no conflict of interests
regarding the publication of this paper.
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