H.E.R.P.S — Hybrid Energy Recovery Pump System

Revision D System Overview

H.E.R.P.S — the Hybrid Energy Recovery Pump System — is a skid-mounted industrial water-pumping architecture developed around a horizontal three-stage variable-speed centrifugal pump and a controlled parallel hydraulic energy-recovery branch.

The primary function of the machine is pumping. The energy-recovery subsystem is secondary to that duty and is designed to recover energy only where the plant process provides a genuine otherwise-wasted pressure reduction. The recovery architecture therefore supplements the overall energy-management system without replacing the external energy required to drive the primary pump.

Revision D integrates the hydraulic, rotating, electrical, thermal, energy-storage, controls, structural and site-interface disciplines into one coordinated engineering-development platform.

Key Revision D System Data

Three-Stage Centrifugal Pump System

The primary hydraulic machine is a horizontal three-stage centrifugal pump developed around the rated 150 L/s at 80 m TDH operating duty. Variable-speed control allows the pump operating point to be matched to actual process demand rather than relying exclusively on throttling.

• Three hydraulic stages arranged within the integrated pump assembly
• Variable-speed operation
• DN350 principal suction interface
• DN300 common discharge architecture
• Integrated shaft, bearings, seals and pressure-boundary systems
• Condition monitoring and protective instrumentation
• Controlled alignment with the main motor and coupling system

Direct & Energy-Recovery Hydraulic Paths

Downstream of the main pump, Revision D provides both a direct hydraulic process path and a parallel recovery path.

The direct path remains available for essential pumping operation even when the recovery subsystem is unavailable, isolated, under maintenance or not economically useful. This prevents the primary plant pumping duty from becoming dependent upon the energy-recovery turbine.

The recovery path diverts only the permitted portion of actual pump flow through the turbine where recoverable pressure head genuinely exists.

The governing hydraulic conservation relationship remains:

Q_pump = Q_direct + Q_recovery

Hydraulic Energy-Recovery Turbine

The recovery subsystem converts otherwise-wasted hydraulic pressure reduction into rotational mechanical energy through a dedicated hydraulic turbine.

The turbine is mechanically coupled to a permanent-magnet generator, allowing genuine recovered hydraulic energy to be converted into controlled electrical energy for the machine's DC energy-management architecture.

Recovery operation remains subordinate to hydraulic process requirements, safe pumping operation and validated available head. Additional pump head is not intentionally created merely to increase electrical recovery.

Main Motor & Variable-Speed Drive

Revision D uses a high-efficiency synchronous reluctance motor architecture with regenerative AFE/VFD power electronics to provide controlled variable-speed operation of the main pump.

• 160 kW-class main motor architecture
• Liquid-cooled motor configuration
• Regenerative AFE/VFD architecture
• Variable-speed hydraulic duty control
• Integrated motor, coupling and shaft alignment
• Electrical, thermal and mechanical protection

Integrated Electrical Energy Management

The H.E.R.P.S electrical architecture coordinates the main regenerative drive, recovery generator, active rectification, common DC link, bidirectional conversion, battery storage and transient-energy support within one controlled electrical platform.

• 400 VAC-class plant electrical interface
• Regenerative AFE/VFD main-drive architecture
• Recovery PMG and active rectifier
• 750 VDC nominal common DC link
• Bidirectional DC/DC conversion
• LiFePO₄ battery energy-storage system
• Supercapacitor transient-energy subsystem
• Controlled precharge, discharge and isolation
• Electrical fault protection and monitoring

Battery Energy Storage System

Revision D incorporates a dedicated LiFePO₄ BESS arranged across two cabinet zones and interfaced with the common DC system through controlled bidirectional power conversion.

The battery system provides managed stored-energy capability and operates under dedicated battery-management, isolation, monitoring and protection functions. It is not presented as the permanent source of the main pump's operating energy.

Supercapacitor Transient-Energy System

A high-power supercapacitor subsystem complements the BESS by handling rapid short-duration charge and discharge events.

This allows transient-energy buffering to be separated from the longer-duration storage duty of the battery system and supports controlled DC-link behaviour during rapidly changing operating conditions.

Integrated Thermal Management

The Revision D machine incorporates a dedicated thermal-management rack serving the main motor, drive electronics and other defined thermal loads.

• 40 kW installed radiator heat-rejection architecture
• Dual EC variable-speed radiator fans
• 40 kW 316L plate heat exchanger
• Duty / standby variable-speed circulation pumps
• DN40 316L main coolant supply and return
• Reservoir, expansion and filtration equipment
• Flow, pressure, temperature and level instrumentation
• Independent BESS cabinet thermal-management boundary

PLC, HMI, SCADA & Instrumentation

H.E.R.P.S uses an integrated automation architecture to coordinate hydraulic operation, motor control, recovery operation, electrical-energy management, thermal systems, alarms, trips and machine diagnostics.

• Central PLC control
• Local operator HMI
• SCADA integration
• Distributed and remote field I/O
• Pressure, flow, temperature and vibration instrumentation
• Motor and rotating-equipment monitoring
• BESS and DC-system monitoring
• Alarm and first-out event recording
• Operating permissives and interlocks

Functional Safety & Hardwired Protection

Protective functions are not dependent solely on ordinary supervisory software. Revision D incorporates independent hardwired safety and trip functions alongside PLC-based control.

• Emergency stop architecture
• Independent protective trips
• Overspeed and abnormal-condition protection
• Electrical isolation
• Pressure-system protection
• Thermal protection
• BESS protection
• Controlled operating modes
• Industrial cybersecurity architecture

Integrated Structural Skid

The mechanical, hydraulic, electrical and thermal systems are coordinated on a common structural base designed to preserve equipment alignment, support operating loads, accommodate lifting and transport requirements and maintain service access around the machine.

Foundation anchoring, grout, structural interfaces, lifting points, equipment supports and final site connection requirements are controlled through the dedicated structural and foundation engineering volumes.

Serviceability & Maintainability

Revision D incorporates service access as part of the package architecture rather than treating maintenance as an afterthought.

• Pump inspection and maintenance access
• Motor and coupling service access
• Recovery turbine and PMG access
• Thermal-rack servicing
• Electrical cabinet access
• BESS cabinet servicing
• Valve and instrumentation accessibility
• Defined component-removal paths
• Inspection and spare-parts planning

Engineering Validation & Design Freeze

Revision D distinguishes between internally reconciled design interfaces, design-development baselines, validation-controlled values, OEM-controlled purchased equipment and site-controlled installation values.

Final hydraulic surfaces, pressure-boundary thicknesses, supplier equipment dimensions, protection settings, certified battery construction and site foundation details are therefore frozen only through their applicable engineering validation processes.

The overall H.E.R.P.S design-development architecture is coordinated, but it is not represented as fabrication-final or issued for construction until the applicable Revision D validation gates have been completed.

H.E.R.P.S Energy-Recovery Principle

H.E.R.P.S is an energy-recovery pumping system, not a self-powering or perpetual-energy machine.

Hydraulic recovery is permitted only where pressure would otherwise be dissipated by the plant process. The system does not intentionally create additional pump head solely to drive the recovery turbine.

This design rule protects the underlying thermodynamic and hydraulic energy balance and keeps the primary pumping function independent of the optional recovery subsystem.

Revision D Engineering Status

This page provides a public engineering overview of the H.E.R.P.S Revision D R2.0 architecture. It intentionally does not replace the detailed purchaser-controlled engineering volumes, released manufacturing data, supplier-certified equipment records, validation calculations or final signed as-built configuration.

Status: Master Design-Development — CAD / CFD / FEA / procurement inputs remain subject to the applicable Revision D validation gates. Not released for construction.