H.E.R.P.S — HYBRID ENERGY RECOVERY PUMP SYSTEM

Hydraulic Energy-Recovery Turbine Assembly

HERPS-VOL-09 — Revision D R2.0

The H.E.R.P.S Hydraulic Energy-Recovery Turbine Assembly is the pressure-energy recovery subsystem of the Hybrid Energy Recovery Pump System. Revision D R2.0 establishes a DN300 parallel pressure-reduction recovery branch incorporating an in-line axial/Kaplan-inspired reaction turbine, adjustable guide vanes, variable-speed permanent-magnet generator interface, pressure housing, diffuser, instrumentation, isolation, check and direct-path fallback functions.

Engineering Status: Consolidated Design-Development — CAD / CFD / FEA / Procurement Input Subject to Revision D Validation Gates. Not Released for Construction.

Revision D Energy-Recovery Architecture

The Revision D turbine architecture operates as a parallel pressure-reduction energy-recovery branch. The full-capacity direct hydraulic path remains available whenever energy recovery is unavailable, unnecessary, outside the validated operating envelope, or isolated for maintenance.

Recovery Architecture

Parallel pressure-reduction energy-recovery branch with full direct process path continuously available.

Recovery Branch

DN300 turbine inlet and outlet interface.

Recovery Flow

0–150 L/s, with recovery flow never permitted to exceed measured pump flow.

Reference Recoverable Head

Up to 6.75 m of genuine otherwise-wasted plant head, dependent on actual site and process conditions.

Reference Hydraulic Recovery

9.91 kW hydraulic power at 150 L/s and 6.75 m recoverable head.

Nominal Electrical-Recovery Target

Approximately 8.25 kW at the stated genuine waste-head condition, subject to validation and selected generator equipment.

Fundamental Energy-Recovery Rule

The primary pump exists to satisfy the required plant hydraulic duty. Energy recovery must never compromise required downstream pressure, process flow or pump stability.

The recovery turbine is permitted to extract energy only from pressure that would otherwise be dissipated by the plant. H.E.R.P.S does not intentionally increase the pump pressure setpoint merely to create additional turbine power.

The governing hydraulic relationship is:

Qpump = Qdirect + Qrecovery

Recovery flow must never exceed the measured pump flow.

Revision D Turbine Design

Turbine Topology

In-line axial/Kaplan-inspired reaction turbine with a fixed-pitch runner, adjustable guide vanes and variable-speed permanent-magnet generator.

Runner

Five-blade nominal Revision D development configuration with an approximately 250 mm runner outside diameter.

Runner Hub

Approximately 95 mm nominal development baseline.

Hydraulic Throat

At least 253 mm nominal for the current 250 mm runner development configuration, maintaining the required radial clearance.

Guide Vanes

Ten adjustable guide vanes with a 0–25° command range.

Cartridge Length

Approximately 850–950 mm development envelope, subject to package, OEM and coordinated CAD control.

Turbine Materials & Pressure Boundary

Runner Material

Super Duplex 2507.

Housing / Guide Material

Duplex 2205.

Pressure-Boundary Class

25 bar(g), 80 °C design class with a normal process pressure ceiling of 10 bar(g).

Outlet

DN300 return diffuser, with an included expansion angle limited to 10° or less where hydraulic expansion is required.

Final pressure-housing wall thickness, reinforcement, flange and joint loads, bolting and hydrotest requirements remain controlled by the applicable Revision D pressure-boundary validation process.

Speed & Performance Development Envelope

Nominal Development Speed

1,500–1,800 rpm.

Controlled Development Envelope

600–2,200 rpm.

Turbine Efficiency

≥88% nominal development target with a 90% stretch objective.

Preliminary Hardware Trip

≤2,500 rpm until prototype/runaway validation releases the final hardware trip setting.

Permanent-Magnet Generator Interface

Mechanical energy recovered by the hydraulic turbine is coupled to the H.E.R.P.S electrical recovery architecture through a variable-speed permanent-magnet generator and active rectifier.

Generator

15 kW permanent-magnet generator.

Optional Generator Rating

18 kW where accommodated within the same compliant equipment envelope and selected OEM frame.

Generator Efficiency Target

≥96% nominal, OEM controlled.

Active Rectifier

20 kW minimum with a nominal efficiency target of ≥98.5%.

DC Link

750 VDC nominal common link.

Direct Path & Energy-Recovery Flow Routing

The Revision D hydraulic arrangement retains separate direct and recovery functions so that process duty remains the governing requirement under every operating condition.

L-D301 — Energy-Recovery Branch

DN300 Duplex 2205, 25 bar design class, carrying 0–150 L/s through the recovery turbine path.

L-D302 — Warm-Up / Minimum-Flow Trim

DN100 316L/2205, 25 bar, with flow up to 20 L/s for controlled turbine-admission functions.

L-D201 — Common Discharge

DN300 common high-pressure source carrying the rated 150 L/s system flow.

L-D202 — Direct Pressure-Control Path

DN300 full-capacity process path providing the preferred low-loss route and safe fallback whenever recovery is unavailable.

Recovery Control Strategy

  1. Establish sufficient direct-path capacity to guarantee required plant pressure and flow before admitting recovery flow.
  2. Coordinate guide-vane position and permanent-magnet generator electrical torque to recover available energy while remaining within downstream-pressure, pump-flow, cavitation and turbine speed limits.
  3. If available recoverable head falls below the stable turbine operating region, unload the generator, reduce turbine admission and transfer flow to the direct path.
  4. On overspeed, generator/rectifier fault or recovery-valve fault, establish the safe direct-path condition, close turbine admission and unload or isolate the generator through the validated shutdown sequence.
  5. Never increase the pump pressure setpoint solely to increase turbine electrical output.

Turbine Instrumentation

PT-D301 / PT-D302

Recovery pressure measurement before and after the turbine, 0–25 bar(g).

FT-D301

Recovery-flow measurement, 0–180 L/s, with ≤0.5% target.

ST-D301

Turbine speed measurement, 0–3,000 rpm, including independent trip input.

Condition Monitoring

Turbine bearing and structural vibration monitoring, temperature monitoring and stored baseline signatures.

Electrical KPIs

Recovered electrical power, DC voltage/current and generator/rectifier operating status.

Calculated KPIs

Recovery efficiency, recoverable-head margin, valve loss, net recovered power and whole-machine energy performance.

Package Integration & Service Access

The nominal Revision D recovery turbine / PMG axis is positioned at Y=+950 mm and Z=+850 mm within the coordinated H.E.R.P.S package. Hydraulic and service access is located toward the +Y side.

GA-D06 Zone

X=2,500–5,300 mm;
Y=+700 to +1,250 mm;
Z=450–1,450 mm.

Turbine Cartridge Removal

Minimum 1,200 mm withdrawal clearance toward +Y.

PMG Removal

Minimum 800 mm local pull/lift clearance or greater where required by the selected OEM.

Support Philosophy

Turbine, valves and piping are independently supported so turbine and pump nozzles do not carry unrelated pipe or valve dead load.

Revision D Validation & Design Freeze

Revision D R2.0 defines the coordinated design-development baseline, but does not fabricate or invent engineering values that remain subject to CFD, prototype testing, rotordynamics, fatigue analysis, bearing analysis, pressure-code verification, transient analysis, HAZOP, OEM data or final coordinated CAD.

Final blade surfaces, guide-vane hydraulic geometry, shaft and bearing dimensions, runaway speed, pressure-housing wall thickness, purchased valve dimensions, actuator envelopes and final recovery-branch fitting coordinates remain controlled by their applicable Revision D validation gates.

NOT IFC: This material represents consolidated engineering design-development information and is not released for construction or manufacturing.

HERPS-VOL-09 — HYDRAULIC ENERGY-RECOVERY TURBINE ASSEMBLY

HERPS VOL 09 Hydraulic Energy-Recovery Turbine Assembly Revision D R2.0
© Paul Smith — Alpha & Omega Limited — PlatformClouds.com — Conceptual Engineering Preview — Not Approved for Manufacturing

HERPS-VOL-09-HYDRAULIC-ENERGY-RECOVERY-TURBINE-ASSEMBLY-REV-D-R2.0.webp

Engineering Development Notice

H.E.R.P.S Revision D R2.0 is a consolidated engineering design-development platform. Values identified as validation-controlled, OEM-controlled or site-controlled must be finalized through their governing engineering validation, equipment-selection and site-integration processes before construction or manufacture.