H.E.R.P.S — Variable Flow Turbine Generator Unit
Volume 14 — Energy Recovery Core (Full Dimensions Blueprint)
Hybrid Energy Recovery Pump System (H.E.R.P.S)
System Overview
Volume 14 provides the complete dimensional, mechanical and performance specification for the Variable Flow Turbine Generator Unit — the core of the H.E.R.P.S energy recovery architecture. This subsystem converts hydraulic energy into electrical power using a mixed‑flow turbine, variable guide vane system and high‑efficiency permanent magnet generator.
Turbine Assembly — Overall Dimensions
- Inlet: 180 mm
- Diffuser: 250 mm
- Turbine Housing: 620 mm
- Rotor Assembly: 520 mm
- Bearing Housing: 220 mm
- Coupling: 180 mm
- Generator: 650 mm
- Outlet: 200 mm
- Overall Length: 2830 mm
- Diameter: Ø420 mm
Turbine Cross Section (A‑A)
- Width: 620 mm
- Depth: 480 mm
- Height: 560 mm
Component Materials
- Inlet Housing — SS 316
- Diffuser — SS 316
- Rotor — SS 304
- Shaft — Alloy Steel
- Seal Ring — Buna‑N
- Bearing Housing — Cast Steel
- Bearing — SS 316
- Coupling — Alloy Steel
- Generator — Cast Iron
- Outlet Housing — SS 316
- Wear Ring — SS 316
- Wire Ring — SS 316
Turbine Specifications
| Parameter | Value |
|---|---|
| Inlet Type | Variable Mixed Flow |
| Rated Flow Range | 250–1250 L/s |
| Rated Head Range | 40–250 m |
| Rated Power | 42.5 kW |
| Peak Efficiency | 94.25% |
| Rotor Diameter | Ø420 mm |
| Speed Range | 1500–3600 RPM |
| Max Inlet Pressure | 25 bar |
| Max Outlet Pressure | 30 bar |
| Rotation Direction | Clockwise (view from generator) |
Rotor & Blade Details
- Rotor Diameter: Ø420 mm
- Blade Material: SS 316
- Number of Blades: 12
- Blade Angle (Inlet): 35°
- Blade Angle (Outlet): 30°
- Blade Thickness: 4 mm
- Tip Clearance: 1.5 mm
- Dynamic Balance Grade: G2.5
Guide Vane (Variable Flow System)
- Diameter: Ø420 mm
- Number of Vanes: 12
- Adjustment Range: ±30°
- Vane Material: SS 304
- Actuation Type: Hydraulic
- Actuation Pressure: 19.0 MPa
- Control Signal: 4–20 mA
Generator Specifications
- Type: Permanent Magnet
- Max Power Rating: 250 kW
- Voltage: 400 V AC (3‑Phase)
- Rated Speed: 1500–3600 RPM
- Power Factor: 0.95 Lagging
- Frequency: 50 Hz
- Cooling Method: Air Cooled
- Weight: ~450 kg
Coupling & Torque Transfer
- Type: Flexible Disc Coupling
- Max Torque: 16,000 Nm
- Speed Range: 1500–3600 RPM
- Angular Misalignment: ±1.0°
- Axial Misalignment: ±1.5 mm
- Material: Alloy Steel
- Safety Factor: 2.0
Turbine Performance Curves (Typical)
- Efficiency vs Flow
- Power Output vs Flow
- Head vs Flow
Bypass & Relief System
TD (Inlet) → Bypass Valve → Relief Valve → Outlet
Key Connections
- Inlet Flange: DN150 (PN25)
- Outlet Flange: DN150 (PN25)
- Drain Connection: 1/2” BSP
- Pressure Tap: 1/4” BSP
- Temperature Sensor Port: M10×1
- Vibration Sensor Port: M12×1.25
Bearing Housing Details
- Height: 260 mm
- Width: 110 mm
- Base Width: 320 mm
- Base Depth: 160 mm
Bearing Specifications
- Type: Angular Contact Ball Bearing
- Arrangement: Back‑to‑Back (DB)
- Diameter: Ø60 mm
- Dynamic Load Rating: 42.5 kN
- Static Load Rating: 19.0 kN
- Lubrication: Grease (NLGI 2)
Shaft Details (Turbine Section)
- Length: 520 mm
- Diameter: Ø60 mm
- Keyway: 14 mm W × 9 mm D
- Material: AISI 4140 Alloy Steel
- Heat Treatment: Quenched & Tempered
- Surface Finish: Ra 0.8 µm
- Balancing Grade: G2.5
Engineering Notes
- All dimensions in millimeters
- General tolerance: ±0.25 mm
- Angular tolerance: ±0.5°
- Surface finish: Ra ≤ 3.2 µm
- Welding: Full penetration (ISO 15614‑2)
- Assembly integrates with Volume 1 master blueprint
Blueprint Access & Licensing
Volume 14 of the H.E.R.P.S Variable Flow Turbine Generator Unit is part of the complete engineering blueprint package available exclusively through BlueprintsMarket.com.
Contact Blueprints Market for licensing, integration support or enterprise‑level deployment.
