© 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
H.E.R.P.S — HYBRID ENERGY RECOVERY PUMP SYSTEM
Hydraulic Energy Recovery Turbine & PMG Generator Unit
HERPS-VOL-09 + HERPS-VOL-10 — Revision D R2.0
The H.E.R.P.S Revision D recovery train converts genuine otherwise-wasted hydraulic pressure into useful electrical energy through a parallel DN300 recovery branch, an axial/Kaplan-inspired reaction turbine, variable-speed permanent-magnet generator and active rectifier.
The direct DN300 process path remains available at all times so that energy recovery cannot compromise required process flow, pressure or primary pump stability.
Engineering Status:
Revision D R2.0 Consolidated Design-Development —
CAD / CFD / FEA / Procurement Input Subject to Validation Gates —
Not IFC
Revision D Energy-Recovery Architecture
Recovery Branch
DN300 Duplex 2205.
Recovery Flow
0–150 L/s, with Qrecovery ≤ Qpump.
Reference Recoverable Head
Up to 6.75 m of genuine otherwise-wasted head.
Reference Hydraulic Power
9.91 kW at 150 L/s and 6.75 m.
Net Electrical Recovery Target
Approximately 8.25 kW nominal target only at the stated true-waste-head condition.
Safe Process Fallback
Full-capacity DN300 direct path remains available whenever recovery is unavailable or inappropriate.
Hydraulic Turbine Core
| Parameter | Revision D R2.0 Baseline |
|---|---|
| Turbine Topology | In-line axial/Kaplan-inspired reaction turbine |
| Runner Type | Fixed-pitch reaction runner |
| Runner Blades | 5 development baseline; CFD sensitivity 4–7 |
| Runner OD | 250 mm nominal development value |
| Runner Hub | Approximately 95 mm |
| Hydraulic Throat | ≥253 mm nominal |
| Minimum Development Tip Clearance | ≥1.5 mm radial |
| Runner Material | Super Duplex 2507 |
| Housing / Guide Material | Duplex 2205 |
Adjustable Guide-Vane Admission System
Guide Vanes
10 adjustable vanes.
Command Range
0–25°.
Primary Function
Meter and condition recovery flow entering the turbine runner.
Control Coordination
Guide position is coordinated with downstream pressure, turbine speed and PMG electromagnetic torque.
Fail Philosophy
Move turbine admission toward safe minimum while the direct process path establishes required flow.
Turbine & Generator Speed Envelope
| Nominal Development Speed | 1,500–1,800 rpm |
|---|---|
| Controlled Development Envelope | 600–2,200 rpm |
| Speed Measurement | ST-D301 — 0–3,000 rpm |
| Preliminary Hardware Overspeed Trip | ≤2,500 rpm pending final D-G5 runaway validation |
DN300 Pressure Boundary & Turbine Cartridge
Inlet / Outlet
DN300.
Pressure Design Class
25 bar(g), 80 °C.
Normal Process Ceiling
≤10 bar(g).
Cartridge Length
Approximately 850–950 mm development envelope.
Outlet Diffuser
DN300 return diffuser with ≤10° included expansion angle where hydraulic expansion is required.
GA-D06 Recovery Train Location
| Interface | Revision D Control |
|---|---|
| Recovery Axis | Y=+950 mm, Z=+850 mm nominal |
| GA-D06 X Zone | 2,500–5,300 mm |
| GA-D06 Y Zone | +700 to +1,250 mm |
| GA-D06 Z Zone | 450–1,450 mm |
| Turbine Cartridge Removal | ≥1,200 mm toward +Y |
| PMG Removal | ≥800 mm local pull/lift or OEM greater |
15 kW Permanent-Magnet Generator
| Generator Parameter | Revision D R2.0 Requirement |
|---|---|
| Type | Permanent-magnet synchronous generator |
| Continuous Rating | 15 kW minimum |
| Optional Rating | 18 kW only if same-envelope fit produces no integration penalty |
| Mechanical Input Region | 8–10 kW nominal target region |
| Efficiency Target | ≥96% at nominal 8–10 kW mechanical input |
| Speed Range | 600–2,200 rpm development range |
| Output | Variable-voltage, variable-frequency three-phase AC |
| Mounting | Horizontal, foot-mounted |
| Cooling | OEM air-cooled baseline or approved equivalent |
20 kW Active Rectifier
| Parameter | Revision D R2.0 Requirement |
|---|---|
| Type | Controlled active rectifier / generator converter |
| Continuous Rating | 20 kW minimum |
| AC Input | Variable-frequency 3-phase PMG output |
| DC Output | 750 VDC nominal common link |
| Controlled DC Window | 650–800 VDC |
| Efficiency Target | ≥98.5% nominal |
| Preliminary Hardware OVP | ≥820 VDC, final coordination validation-controlled |
Recovered Energy Routing
Mechanical turbine output drives the PMG through a flexible coupling. The PMG produces variable-voltage, variable-frequency three-phase AC, which is converted by the active rectifier into the H.E.R.P.S 750 VDC common link.
The default Revision D architecture does not directly grid-tie the recovery PMG. Recovered energy is routed internally through the common DC architecture.
Grid export is disabled by default and would require a separately engineered and approved interconnection and protection system.
Variable-Flow Recovery Control
- Establish sufficient direct-path flow to guarantee required plant pressure and process flow.
- Admit hydraulic flow into the DN300 recovery branch only when genuine recoverable pressure is available.
- Coordinate guide-vane position with PMG electromagnetic torque.
- Maximize recovered electrical power only within downstream-pressure, flow-conservation, cavitation and turbine-speed limits.
- Reduce or terminate recovery when available waste head falls below the approved stable turbine region.
- On turbine overspeed, PMG/rectifier fault or recovery-control fault, establish the safe direct path, reduce/close turbine admission and unload/isolate the generator branch.
The control system may not increase the main pump pressure setpoint solely to create additional turbine recovery.
Turbine & Generator Instrumentation
| Tag / Measurement | Revision D Requirement |
|---|---|
| PT-D301 / PT-D302 | Recovery pressure before/after turbine — 0–25 bar(g) |
| FT-D301 | Recovery flow — 0–180 L/s |
| ST-D301 | Turbine speed — 0–3,000 rpm independent trip input |
| Vibration | Turbine bearing / support vibration monitoring |
| Temperature | Bearing / PMG and required recovery-train temperatures |
| Electrical KPIs | PMG power, DC voltage/current and rectifier status |
Recovery-Train Materials
| Component | Revision D Material |
|---|---|
| Runner | Super Duplex 2507 |
| Housing / Guide System | Duplex 2205 |
| DN300 Wetted Recovery Parts | Duplex 2205 baseline |
| DN100 Trim | 316L / Duplex 2205 |
| Coupling Guard | 304 stainless steel |
| Structural Supports / Rails | S355 structural steel family |
Turbine / PMG Installation Sequence
- Confirm released turbine hydraulic, pressure-boundary and rotordynamic interfaces before irreversible manufacture.
- Fabricate and inspect the DN300 recovery spools, pressure parts and structural supports.
- Manufacture only CFD/prototype-released runner, guide-vane, throat and diffuser geometry.
- Manufacture released shaft, bearing and coupling interfaces and complete balance/runout verification.
- Assemble the guide system, runner, shaft, bearings, pressure housing and diffuser.
- Mount the turbine cartridge on the recovery rails within GA-D06.
- Mount the selected 15 kW PMG and establish preliminary cold alignment.
- Install the DN300 recovery isolation/check/admission piping and DN100 trim circuit with independent supports.
- Install recovery pressure, flow, speed, vibration, temperature and electrical instrumentation interfaces.
- Complete DN300 piping connection and repeat turbine/PMG alignment and nozzle-strain verification.
- Install and terminate the 20 kW active rectifier, generator isolation/protection and 750 VDC interface.
- Verify bonding, insulation, speed feedback, safe-state logic and direct-path transfer before wet recovery testing.
- Conduct controlled turbine/PMG recovery testing only within the released flow/head/speed/cavitation operating map.
Revision D Validation Status
The Revision D documents deliberately do not treat final blade surfaces, shaft geometry, bearing sizes, bearing preload, pressure-wall thickness, runaway speed, final overspeed trip, PMG electromagnetic construction, generator shaft extension, winding and pole data, rectifier semiconductor topology, cable sizes or final protection settings as already frozen.
Those values remain controlled by CFD, prototype testing, rotordynamics, shaft-fatigue analysis, bearing-life analysis, pressure-code/FEA, electrical studies, HAZOP, final CAD, selected-vendor data and FAT/SAT.
Revision D R2.0 Consolidated Design-Development — Not IFC — Not Shop Release.
VOLUME 09 — HYDRAULIC ENERGY RECOVERY TURBINE ASSEMBLY
VOLUME 10 — RECOVERY PMG / ACTIVE RECTIFIER / GENERATOR DRIVE
© Paul Smith — Alpha & Omega Limited — PlatformClouds.com —
Conceptual Engineering Preview — Not Approved for Manufacturing
HERPS-VOL-10-RECOVERY-PMG-ACTIVE-RECTIFIER-AND-GENERATOR-DRIVE-REV-D-R2.0.webp