About the AT Turbocharger

The AT Turbocharger represents a technological breakthrough in Reverse Osmosis energy recovery performance. Advance turbo machine design software, 3D CAD and CAM software plus 5 axis machining now enables PEI to custom design and manufacture complex geometry impellers and casing flow passages that have resulted in Turbos efficiency increases of 40% or more. World class efficiency plus all of the other features and advantages of the Turbo are explained in detail in this manual.
The AT Turbo like its generational predecessors recovers hydraulic energy from the high pressure concentrate (brine) stream in the reverse osmosis (RO) process and transfers that energy to a feed stream. That feed stream may be seawater going into a single stage RO membrane block, or it may be first stage brine stream being boosted in pressure for a second stage membrane block for further recovery of permeate. This unique approach offers many advantages to the RO designer and users. This manual will explain in detail these advantages and innovations that make the AT Turbo the most efficient and cost effective energy recovery unit available today. The manual shows how to estimate Turbo performance as well as how to apply the Turbo to a variety of RO systems.

Table of Contents
Background................................... .2 Design Features.............................3 Construction Features................... .4 Custom Design & Manufacturing....5 Turbo Performance.........................6 Piping & Instrumentation.................9 Pump Selection w/ Turbo...............10 Installation......................................11 Comparison Impulse Turbine vs. Turbo .......12

harnessing the power of...

Comparison PX vs. Turbo............................14 Interstage Boosting........................16 Dual Turbine System......................17

LIQUID ENERGY

AT Turbo Background
Like the previous generation PEI Turbos, the AT Turbo transfer pressure energy from one liquid stream to a second liquid stream. However, with the use of new technology the AT Turbo does this energy transference much more efficiently. The AT Turbo consists of a pump section and a turbine section. Both pump and turbine sections contain a single stage impeller or rotor. The turbine rotor extracts hydraulic energy from the brine stream and converts it to mechanical energy. The pump impeller converts the mechanical energy produced by the turbine rotor back to pressure energy in the feed stream. Thus the AT Turbo is entirely energized by the brine stream. It has no electrical, external lubrication, or pneumatic requirements. Figure 1 illustrates the operation of the AT Turbo in a single stage SWRO system. The feed stream from the high pressure pump provides a flow of 1000gpm (227m3/hr) at a pressure of 588psi (40.5bar) to the pump section of the Turbo. The impeller in the pump section increases the total feed stream pressure to 1000psi (68.9bar). The membrane block produces 400gpm (90.9m3/hr) of permeate and rejects 600gpm (136m3/hr) of brine. The brine, which is now at a pressure of 980psi (67.5bar), enters the turbine section of the AT Turbo. The turbine rotor depressurizes the brine while extracting the energy in the form of high speed rotational torque. The brine, now depressurized to 5psi (brine exhaust can be any value, even hundreds of psi) is exhausted to the discharge piping. It is readily apparent that the reduced discharge pressure of the high pressure pump will have a large effect not only on reducing operating cost, but also on reducing both initial capital and maintenance cost. More details on this important aspect of the AT Turbo Total Life Cycle Cost will be explained later. Also note, the Turbo eliminates the brine control valve, which is another major expense and maintenance item in SWRO plants. Further note, that the Turbo is mechanically independent of the high pressure pump. Thus the Turbo can be used with any type of feed pump and without any modifications to the pump, motor, or base. In a later section of the manual the use of the Turbo in multi stage SWRO systems will be explained and again it will clear that the Turbo is more than just energy recovery. The Turbo, which incorporates a pump with a turbine into a single unit, opens many new possibilities for the RO designer.

Figure 1

Figure 2

Design Features:
The Turbo addresses the major issues facing the RO system designer and user, including simplicity of design and operation, efficiency, reliability, ease of field servicing and versatility of use through the following design features. Type: The Turbo is an integral turbine driven centrifugal pump. The turbine is a single stage radial inflow type. The pump is a single stage centrifugal type with its impeller mounted on the turbine shaft. The unit is entirely energized by the high pressure brine stream. Casing: The US Patent Pending AT Turbo casing consists of an outer pressure casing designed for 1500 psi maximum pressure and inner radially split volute insert casing. The volute insert is designed by CFD software and completely machined on CNC milling machines, thereby achieving the ultimate in dimensional control, surface finish, and hydrualic efficiency. Impellers: The AT Turbos feature custom engineered AND manufactured impellers. Using the most advance computational fluid dynamics pump and turbine design software, 3D CAD and CAM systems and 5 axis milling machines, each impeller design is optimized and manufactured for maximum efficiency. Balancing: The entire rotating assembly is balanced to ISO G3 standards (gyroscope tolerance) on PEIs computer controlled high speed balancer. Bearing: The Turbo uses three bearings all of which is lubricated by the feed or brine flow. The pump and turbine center bearing are the hydrodynamic journal type. The thrust bearing is of the hydrostatic type which utilizes high pressure water in an annular groove to balance net rotor axial thrust. Standard material for all bearings is resin impregnated carbon graphite. Optional material is solid ceramic aluminum oxide. Units equipped with ceramic bearings also use a plasma sprayed ceramic coating on the shaft bearing surfaces. Shaft Seals: Shaft seals or more precisely the lack of shaft seals is one of the outstanding design features that contribute to the Turbos high reliability. Mechanical seals or shaft packings are the most maintenance intensive parts on nearly all pumps and are responsible for the most downtime. And because the Turbos rotor is fully enclosed by the casing, there are no shaft penetrations to the atmosphere, hence no seals. Multiple Turbine Nozzles: The Turbo is equipped with two nozzles and a control valve that allows brine flow and pressure to be regulated without energy wasting throttling or bypassing. See page 8 for additional information on this important feature. Pipe Connections: All feed (pump) and brine (turbine) pipe connections are Victaulic type. For larger units or very high pressure applications ANSI 600# class flanges are available. Unit Base: Turbo bases are available in Delrin plastic, stainless steel, or painted carbon steel. All bases are bolted with SS bolting and are drilled for sole plate bolting. 3

Operation and Construction Features

Besides its outstanding efficiency, the AT Turbocharger brings many benefits, some obvious, and others not so obvious, however, they all add up to increase total value to the RO designer and user. Consider the following Turbo characteristics: 1. Fexibility of installation, can be placed next to RO block, greatly reduces brine piping cost no double shaft motors, brine sumps, extended bases and foundations. 2. Significantly reduces high pressure pump size (number of stages), motor size, motor starter, switch gear and transformers 3. Able to discharge brine against backpressure no brine sump or pump 4. Brine is not exposed to atmosphere, thereby minimizing odor and corrosion 5. Reduces load on high pressure pump resulting in greater pump reliability shorter and stiffer shafts for centrifugal pumps, reduced frame and crankshaft loading and cooler oil temperatures for positive displacement plunger pumps. 6. Can be used with any type of high pressure feed pump. 7. Turbos are very compact, small space and foundation requirements 8. Turbo do not generate flow or pressure pulsation 9. Low noise and vibration operation Turbo also reduces high pressure pump noise 10. No shaft seals very high reliability 11. No oil or grease lubrication bearings are water lubricated 12. Brine pressure and flow regulated with Turbo auxiliary nozzle and valve, no energy wasting throttling or bypassing

Materials of Construction
The standard and optional material of construction for AT Turbocharger are: Part Casing Standard Duplex Stainless Steel Alloy 2205 AL6XN Resin/ Carbon Graphite Ceramic: Aluminum Oxide Optional Super Austenitic Stainless Steel AL6XN

Impellers Bearings Retaining Rings External Bolting

SS316 Passivated SS304

Duplex alloy 2205 is a superior material for crevice and pitting corrosion resistance in high chloride environments. Alloy 2205 has twice the tensile strength of SS316L . The welding characteristics of 2205 are very good and post weld heat treatment to maintain corrosion resistance is not required. The nominal composition of Alloy 2205 is: Cr Ni Mo N Fe 22% 5% 3% 0.15% balance

TESTING
All Turbochargers are individually tested for performance, mechanical integrity, and hydrostatic pressure. All data acquisition is by electronic instrumentation and computer interface. Test data is documented to identify the unit test and test conditions. The complete test report becomes a part of the units job history file.

Custom engineering impellers utilizing turbomachine design software.

Customer Specific Hydraulic Design And Manufacturing

In the past, every Turbo was designed and manufactured to achieve its best efficiency point (BEP) at the customers specific duty point. Casing hydraulic passages (volute, diffuser, and nozzles) were machined to the correct dimensions for duty point operation. The cast impellers were trimmed for maximum efficiency at the design reject ratio. The AT Turbo, however, goes much beyond that already high level of custom engineered equipment produced by PEI. Now, thanks to a highly disciplined design process which includes computational turbo machine software, 3D CAD and CAM software and 5 axis CNC milling machines, PEI can create a completely unique turbochargers with turbine rotor and pump impellers designed with complex 3D blade geometry. The results of this process, plus the inherent efficiency advantage of high speed operations, are simply the most efficient pumps and turbines available today.

HAAS 5 axis machining center.

DATA: Customer Requirements

Generate hydraulic design

Generate CNC program

3D machining accomplished through use of Master Cam software and 5 axis machining center.

Machine volute inserts*

Machine AT 3D impellers

Hydro & Performance Test

OK TEST YES
Machined wax turbine impeller for investment casting.

NO

Unit ready for shipping

*Custom Machined Volute Insert technology patented by Pump Engineering, Inc.

AT TURBO PERFORMANCE
Generally, an energy recovery turbine (ERT) is rated as having a certain efficiency based on the conversion of hydraulic energy into mechanical shaft energy. However, in reverse osmosis where the process is driven by pressure energy, the shaft energy generated by the ERT is normally transferred to the feed pump which then converts that energy back into pressure energy in the feed stream. The most accurate measure of ERT efficiency for an RO system is the ratio of hydraulic energy returned to the feed stream to the amount available in the brine stream. This ratio is called the Hydraulic Energy Transfer Efficiency (HETE), or nte and is defined as: Nte = Hout / Hin [1] Where Hout = Hydraulic energy transferred to the feed stream Hin = Hydraulic energy available in the brine stream The Hydraulic Energy Transfer Efficiency provides the truest method to evaluate and compare the energy recovery effectiveness of all energy recovery devices, including impulse turbines, flow work exchangers, as well as the Turbo. Unlike conventional ERTs, the energy transfer efficiency of the Turbo is independent of pump efficiency. The reason for this is that the Turbo contains its own pump, so the complete energy transference occurs within the Turbo. So unlike an impulse turbine or reverse running multistage pump, the Turbos rotor speed is completely independent of the motor/ high pressure pump. This means the Turbo can be designed for high speed operation which is the most efficient and cost effective design. Pump efficiencies of 90%+ are possible for larger AT Turbos. The useful work of the AT Turbo is expressed as the Boost Pressure. This is the pressure rise that occurs between the Turbos pump inlet and pump discharge. To apply the Turbo to an RO system, the boost pressure needs to be calculated. Use Figure 3 to find the approximate Hydraulic Energy Transference Efficiency for the Turbo. For example, at a feed flow rate of 1000gpm the AT Turbo displays an nte of about 73%. FIG 3 AT Turbo Hydraulic Energy Transfer Efficiency (nte) Knowing nte makes calculation of the Turbo pressure boost, P, very simple: Now substituting numerical data into our formula for the 1,000gpm (227m3/hr) example as follows: Qf = 1,000gpm (feed flow) Qb = 600gpm ( brine flow) Qp = 225gpm(product flow) y = 40% (recovery ratio) Rr = 60% (reject ratio) Pm = 1,000psi (membrane pressure) Pbr = 980psi (brine pressure) Pe = 5psi (brine exhaust pressure) P = ( .73 ) ( 600gpm/1000gpm ) * ( 980psi 5psi ) = 427 psi A design objective is to make P as large as possible to obtain maximum energy recovery. Equations [ 2 ] and [ 3 ] indicate that increasing Pbr will accomplish that. Since Pbr is usually a given value based on membrane design, try to keep turbine exhaust pressure to a minimum safe level. Although the AT Turbo can discharge brine at a high pressure, this exhaust pressure does reduce the available recoverable energy. In this example the use of the AT Turbo reduced the high pressure feed pump discharge pressure from 1000psi to 588 psi. Thus not only will the AT Turbo system be the most energy efficient, but it will contribute considerable capital cost savings as well. A Note on Energy Efficiency Comparisons When comparing the stated efficiency of the Impulse Turbine and Reverse Running Pump Turbines with the Turbos Hydraulic Energy Transfer Efficiency, be aware that their efficiencies are given as the ratio of mechanical shaft output to brine energy input. To get a true comparison of Hydraulic Energy Transfer Efficiency to mechanical efficiency, multiply the Impulse Turbine efficiency by the feed pump efficiency and any other component such as a V belt speed reducer, Variable Frequency Drive or part load reduction of motor efficiency. As an example, a 86% efficient Impulse Turbine coupled to a 77% efficient centrifugal pump would have combined efficiency Hydraulic Energy Transfer Efficiency of 66.2%. Further if a full sized motor were used, there would be a reduction in motor efficiency due to part load operation that would now bring nte to 64.8%. Thus the 64.8% nte of the Impulse Turbine/Pump and not the 86% mechanical efficiency, is the true measure of Energy Recovery Turbine efficiency.

P = (Nte) (Rr) (Pbr Pe)

[2]

Where Rr = ratio of brine flow to feed flow Pbr = brine pressure at turbine inlet Pe = exhaust pressure of Turbo (brine pressure leaving Turbo) The brine pressure drop, Pbr is defined as: Pbr = Pbr Pe [ 3 ]

HTC-AT Efficiency Chart

Efficiency (%)

Feed Flow (gpm)

HTC-AT Efficiency Curve

Figure 3

1000 gpm 1000 psi 600 gpm 980 psi 71% nte 1000 gpm 585 psi Pump Power = 420 hp 1000 gpm 30 psi High Pressure 4 stage pump 77% efficiency 600 gpm 5 psi AT 900 Turbo (placed next to membrane rack for reduced piping)

500 hp motor

Turbo Transfer efficiency = 71% nte

Figure 4

Extra high pressure brine piping 600 gpm 980 psi 1000 hp Motor motor net power 467 hp

1000 gpm 1000 psi Pump Power = 761 hp High Pressure 7 stage pump 77 % efficiency 1000 gpm 30 psi

Pelton Impulse Turbine 86% efficiency 294 hp Output

PIT Transfer efficiency = .86 (PIT n) x .98 (*) x .77 (pump n) = 64.8% nte

Figure 5 7

* percentage reduction of motor efficiency due to part load operation

AT Turbocharger Auxiliary Nozzle and Valve

All AT Turbocharers (see Fig 6) are equipped with a Main Nozzle and a secondary Auxiliary Nozzle (AN) and Auxiliary Nozzle Control Valve (ANCV). The Main Nozzle is sized to provide a concentrate system resistance (concentrate pressure) equal to the maximum design pressure at the design concentrate brine flow rate. The auxiliary nozzle is sized to about 20-25% of the area of the Main Nozzle. The ANCV controls flow to AN in the turbine casing. The ANCV will provide a 20-30% pressure range at a constant brine flow. Note that the ANV does not bypass flow around the Turbo. It is a unique way to achieve variable area Auxiliary Nozzle nozzle flow without the energy wasting throttling and Valve bypassing valve arrangements needed by constant Auxiliary Nozzle speed reverse running pump turbines. The ANCV can be supplied either as a manual or as a power actuated unit.

Turbine Impeller Brine

AT Turbocharger Installation and PID

Primary Nozzle

For single stage seawater RO systems, the Turbo is located Figure 6 hydraulically between the discharge of the high pressure feed pump and the membrane block. Its actual physical location can be optimized to reduce the length of both brine and feed piping. A brine control valve is not needed when using the Turbo. Brine pressure and flow can be trimmed through use of the Auxiliary Nozzle Control Valve (ANCV).

Volute

Figure 7

Fig. 7 is a preferred PI&D arrangement of a turbo installation for non VFD driven centrifugal feed pump motors. Note that a flow control valve (FCV) is used to throttle pressure for membrane recovery control. The FCV is used in conjunction with the ANCV to achieve the proper flow capacity and pressure. The FCV is opened or closed to maintain the required flow rate, while the ANCV is open to operate the membrane at a lower pressure and closed to operate the membrane at a higher pressure.

Piping and Instrumentation Diagrams

Figure 8
Two Stage - Brine staged utilizing AT Turbo as interstage booster pump.

Figure 9
Second Pass - utilizing AT Turbo as interstage booster pump.

Figure 10
Single stage SWRO with PD pump.

Feed Pump Selection with the AT Turbo

Pump selection with the TurboTM is easy, although a few guidelines should be followed. Always use the highest expected pressure conditions in calculating TurboTM pressure boost. This would typically be the pressure at the end of the membrane life with the highest expected TDS feed at the lowest expected temperature. If the recovery or feed flow may vary significantly, it is a good idea to check with PEI to ensure the TurboTM can efficiently accommodate the conditions. Positive Displacement Pumps With positive displacement (PD) pumps such as reciprocating plunger types, flow rate is established by pump displacement and RPM. Membrane pressure is controlled by adjustment of the ANCV on the TurboTM. PD pumps do not need any type of feed pressure control device such as a feed throttle valve. Due to the very high reliability of the TurboTM, the PD pump and motor can be rated to deliver the required pump discharge pressure allowing for the TurboTM boost. Such downsizing of the pump and motor will save considerable capital and maintenance costs and energy use. CAUTION! Always use good pulsation dampening on the feed pump discharge. Severe flow and pressure pulsations can be damaging to pressure gauges, flow meters, piping and possibly the TurboTM. See PEIs installation manuals for additional information Centrifugal Pumps These pumps must be sized for maximum pressure conditions. When the required membrane pressure is lower than the rated pump discharge pressure excess pump delivery pressure must be eliminated. A feed throttle valve is the most common way to regulate this pump pressure. This valve is partially closed during initial operation of the plant. As the membrane pressure requirement increases with plant age, the valve is opened to obtain increased pressure to the RO train. Another way is to use a variable speed pump drive such as a variable frequency drive (VFD). The pump speed is adjusted as required to obtain the desired pump pressure. The advantage of this technique is that the pump power consumption is minimized and the expensive control valve can be eliminated. Centrifugal Pump Example The goal of this analysis is to find the performance requirements of the feed pump. Operating conditions are indicated in Figure 11 including the projected lowest and highest membrane pressure. Figure 11 indicates a TurboTM transfer efficiency of 64%. Using end of life conditions, equation [3] calculates the TurboTM boost (i.e. the pressure rise between points 2 and 3) as 352 psi. The required feed pump discharge pressure, Pp, is: Pp = Pm Ptc = 950 386 = 564 psi Thus, the feed pump must be sized to deliver 550 psi outlet pressure. For start-up conditions, the TurboTM boost is 348 psi which yields a TurboTM feed inlet pressure of 536 psi. Note that the feed throttle valve must be adjusted to destroy about 61 psi of feed pressure. If a VFD were used, the control valve would be eliminated and the feed pump power consumption would be reduced. For this example, the pump for start-up condition without the VFD would require 184 hp. With a VFD, the input power drops to 176 hp. Please contact PEI with questions about feed pump selection.

Feed Throttle Valve

Start-up
1 2 2 3 4 5 Flow Pressure (gpm) (psi) 420 30 420 564 420 502 420 850 280 830 280 5

End of Life
Flow Pressure (gpm) (psi) 420 30 420 564 420 564 420 950 280 920 280 5

Feed Pump

te = 64% p = 72% m = 93%

AT TurboTM

Figure 11

10

Installation
Characteristics of the AT Turbo that effect its installation in typical SWRO plant are as follows: Compact Size and Weight Because of its high speed operation, an AT Turbo is much smaller than an equivalent capacity motor driven pump, as much as five to tens times smaller. For instance a 100gpm Turbo ways 40lbs vs 400lbs or more for a high pressure pump. This factor makes it ideal for skid mounted or containerized system, where space restrictions are always an important consideration. Flexible Installation Location The Turbo is mountable in any orientation. Units up to the AT 100 can be supported by its piping. For larger system that have separate pump rooms, the Turbo ability to downsize the pump, motor, and associated electrical equipment will result in a smaller building. Additionally, the Turbo can be located anywhere between the high pressure pump discharge and the feed header to the membrane block. By placing the Turbo next to the membranes, considerable savings of high pressure super alloy piping can be made. Piping and Foundations Victaulic pipe connections are standard on the AT Turbo from model AT 25 through model AT 2400. ANSI 600lb class flanges however are available on all AT Turbo models and are standard equipment on models AT3600 and larger. Because of their relatively small size and vibration free operation foundation requirements are very modest and are primarily designed to support piping loads that the Turbo may be carrying. Low Noise and Pulsation Free Flow Highly efficient hydraulic design of the AT Turbo significantly minimizes noise generation to such an extant that it is not audible over the background noise of a typical SWRO plant. In addition, because the Turbo downsizes the high pressure pump and motor size and pressure requirements, there is a noise reduction associated with this equipment. The high speed centrifugal principle of Turbo operation assures pulsation free smooth flow to the membranes. Pressurized Brine Discharge The AT Turbo can discharge brine (concentrate) against practically any level of backpressure. So there is never any need for brine disposal pumps or gravity flow piping or trenches. AT Turbo Recommended Requirements Pressure gauges or transducers should be installed near each Turbo pipe connection to permit monitoring of Turbo performance. Suction Stabilizers and Discharge Pulsation Dampeners should always be used with reciprocating positive displacement pumps Perform all pipe cleaning and flushing before final installation and start up of the Turbo

Maintenance and Overhaul

The AT Turbo has no scheduled maintenance requirements. There are no shaft couplings to align, no shaft seals (leading cause of pump failure), no lubrication system or lubricants (second leading cause of pump failure), and no external auxiliary services such as cooling water or pneumatic requirements. See the Installation and Operation Manual for complete information.

Overhaul and Repair

Thanks to its relative small size and single stage design, even the largest Turbo can be completely inspected and/or overhauled in a few hours. All bearings are slip fit and O ring mounted, making their removal and installation a quick, simple, and straightforward job. PEI stocks all parts necessary for any repairs that may occur.

11

Comparison of the AT Turbo and Pelton Impulse Turbine

As explained in the AT Turbo Performance section of this manual, Hydraulic Energy Transfer Efficiency is the only accurate method of comparing Energy Recovery Devices. In this section,AT Turbo performance will be compared to a Pelton Impulse Turbine performance for a relatively large SWRO train size of 2,641,000gpd (10,000m3/d). The comparison will cover the entire hydraulic operating envelope from minimum to maximum membrane pressure requirements. Example RO System Conditions: Fluid: Seawater TDS 38,000 Temperature: 14 290 C 290C Summer Conditions - 0 years Feed Flow Pump Pressure Membrane Pressure Concentrate Flow Concentrate Pressure 3986 gpm (906 m3/hr) 920 psi (63.4 bar) 885 psi (61 bar) 2232 gpm (507 m3/hr) 865 psi (59.7 bar) Capacity: 2,641,000 gpd (10,000m3/d) 140C Winter Conditions - 3 years 3986 gpm (906 m3/hr) 1085 psi (74.8 bar) 1050 psi (72.4 bar) 2232 gpm(507 m3/hr) 1030 psi (71bar)

From the above membrane manufacture recommended design data, the extremes of throttle pressure is 200psi (maximum pump discharge pressure 1085psi minimum membrane pressure 885psi). This total pressure range defines the basic Hydraulic Operating Envelope. At those times of reduced pressure operation, the excess pressure will be throttled by flow control valve. Presented below are the performance factors for an AT 3600 Turbocharger and a Pelton Impulse Turbine and centrifugal high pressure pumps AT 3600 + pump Pelton Impulse Turbine+ pump Feed Pump Flow 3986 gpm (906 m3/hr) 3986gpm (906 m3/hr) Turbo Boost Pressure (max) 433psi (29.9 bar) Feed Pump Discharge Pressure 652psi (45 bar) 1085 psi (bar) Feed Pump Efficiency .85 .85 Motor Efficiency .95 .95 Pelton Impulse Turbine Efficiency n/a .89 Hydraulic Transfer Efficiency .78 .748 The graph below depicts the performance of the AT 3600 and the Pelton Impulse Turbine over the Hydraulic Operating Envelope defined above. Note that the pressure throttling significantly diminishes the amount of recoverable concentrate energy available to the Impulse Turbine. In fact, the pump discharge pressure throttling energy loss can be 20% or more of total pumping energy and represents the greatest source of loss and inefficiency in most SWRO high pressure circuits equipped with Impulse Turbines.

12

Figure 12
3250

3000

2936
2750

Pump hp with PIT

2500

Flow

2250

2176 2109 2039 1969 1899 1830 1650

2000

1750

1763

Net Motor hp with PIT Pump hp with HTC

1500 750

800

850

900
Membrane Pressure (psi)

950

1000

1050

Pressure Throttling with a Turbocharger

Another advantage of feed stream pressure boosting with the Turbo is a reduction in throttling pressure differential. Taking the above example, where there is 200psi difference between minimum and maximum membrane operating pressure, the AT Turbo reduces the amount of throttling from 200psi to 130psi. Because Turbo Boost Pressure (TBP) is a function of Brine Differential Pressure (BDP), the TBP in the example decreases from 433psi at a BDP of 1030psi to 364psi at a BDP at 865psi. The reduction in throttling pressure differential results in lower noise, less wear, and cavitation in the flow control valve.

HTC AT vs. Pelton Impulse Turbine a side by side comparison

HTC AT Benefits Feed pump and motor layout not affected. HTC AT can be located anywhere, including next to the RO trains, reducing the amount of high pressure piping. The HTC AT is able to discharge brine against any backpressure and a brine disposal pump or sump is not needed. The turbo boost pressure provided by the HTC AT reduces the discharge pressure the main feed pump must produce thereby allowing for a pump with fewer stages. Motor size reduced by 30% - 50%. Smaller transformer and motor starter or VFD The HTC AT is maintenance free! All three bearings are process lubricated. No increase in power over complete membrane pressure envelope. Brine flow and pressure can be regulated with reduced energy-wasting throttling or bypassing. Small footprint and Victaulic pipe connections ensure easy installation. Pelton Impulse Turbine (PIT) PIT is connected to pump a modified base plate, second shaft and coupling are required. PIT must be located next to the pump. Pump room must accommodate longer base plate and heavier pumping equipment. Brine sump with pump or gravity flow piping required. Level switches, alarms and valves may be needed too. Must develop full membrane pressure with main feed pump requiring maximum number of pump stages. Full size motor with a double extended shaft may be required. No size reduction in transformer or starter. Oil/grease lubricated bearings need periodic inspection and maintenance. Brine disposal pump requires additional maintenance. Large number of pump stages increases the cost of spare parts. Double extended shaft motor may be difficult to replace on an emergency basis.

13

Comparisons of the AT Turbo and the Pressure Exchanger

The Hydraulic Energy Transfer Efficiency of the Pressure Exchanger in RO service can be determined by analysis of the efficiencies of all the components that are part of the high pressure circuit. Fig 14 shows the PX system. Note that its basic design is comprised of the PX device, a high pressure pump, a booster pump. Additional and necessary components such as high pressure flow meters and valves have a minor effect on overall HETE, so for sake of simplicity will not be considered in the energy analysis. The PX Exchanger system uses two pumps. One pumps capacity equals the permeate flow plus an additional flow equal to the internal leakage losses of the PX, typically 3 4% of brine flow. This pump has to achieve the full membrane pressure required by the feed water salinity plus an additional pressure head required by the increase in feed salinity due to brine mixing in the PX device. The second pump is a booster pump whose capacity equals the brine flow and whose head rise equals the membrane pressure loss (20 50psi) plus the inlet and outlet pressure losses of 20 25psi per each end of the PX device, giving a total differential pressure of 60 100psi.

Example 1
50,000gpd SWRO plant (49.5gpm permeate, 111gpm feed) operating at 45% recovery at a membrane pressure of 1,000psi

PX Pressure Exchanger System

PX High Pressure Pump: Q = 49.5 x 1.04 (internal leakage factor) = 51.5gpm P = 995psi (1,000psi 20psi suction pressure + 15psi Salinity Mixing Factor) Reciprocating Plunger Pump Efficiency = .84 (including V belt drive losses) 40hp motor efficiency = .90 Total Pump Motor Power* = 51.5 x 995 x .0005831/.84/.90 x .746 = 29.48 kW Booster Pump: Q = 61.5gpm P = 75psi Pump used for this application will be a multistage centrifugal with BEP efficiency of .52. 7.5 hp motor efficiency = .88 Total Pump Motor Power = 61.5 x 75 x .0005831/.52/.88 x .746 = 4.38kW Total energy usag: 33.86kW Permeate Energy Rate: 3.04kW/m3 or 11.40kW/1,000gals

AT Turbocharger System
For the Turbo example, first calculate AT Turbo boost pressure utilizing the following forumula:
Reject Ratio x AT Turbo HTE x Brine Diff. Pres. = Turbo Boost

.55 x .60 x 995 psi = 322 psi Boost The high pressure pump differential pressure then is: 1000psi (membrane pressure) 20psi(suction pressure) 322psi (turbo boost pressure) = 658psi Reciprocating Plunger Pump Efficiency =. 85 (including V belt losses). 60hp electric motor efficiency = .92 Total Pump Motor Power = 111 x 658 x .0005831/.85/.92 x .746 = 40.62kW Permeate Energy Rate is 13.67kW/1,000gal or 3.64kW/m3

Thus the HETE of the PX Exchanger device is .658. Compare this number to the advertised claims of 94% efficiency for the PX. The difference between the claimed efficiency and true HETE is in the losses due to internal leakage and inefficiencies of the booster pump. Additional losses will be produced by valve(s) necessary to control the PX.

* Total Pump Motor Power hp = Q x P x .0005831/ pump efficiency/ motor efficiency/

vfd efficiency (if used) Where Q = Pump Capacity in gpm P = Differential Pressure Rise in psi .0005831 = Water Horsepower Constant

14

Figure 13

Figure 14

Example 2
500,000gpd SWRO plant (347gpm permeate, 771gpm feed) operating at 45% recovery with a membrane pressure of 1,050psi

PX Pressure Exchanger System

PX High Pressure Pump: Q = 347gpm x (430 x .04) (internal leak factor) = 364gpm P = 1045psi (1050psi 20psi (suction pressure + 15psi Salinity Mixing Factor) The most reasonable choice for a high pressure feed pump is a multistage centrifugal. A well designed segmental ring type such as, Flowserve 4x11 A, will display an efficiency of 64.2%. Total Pump Motor Power = 364 x 1045 x .0005831/.70 /.93 x .746 = 277 kW Booster Pump selection would be an API 610 class single stage centrifugal rated for 1,000psi suction pressure and with an efficiency of .72 Booster Pump: Q = 771gpm P = 75psi Booster Pump Motor Power = 424 x 75 x .0005831/.72 / .92 x .7457 = 20.87kW Total energy usage: 298 kW Permeate Energy Rate: 14.3 kW/1,000gals or 3.85kW/m3

AT Turbocharger System
For the AT Turbo example, first calculate the Turbo Boost Pressure by: Reject Ratio x AT Turbo HTE x Brine Differential Pressure .55 x .721 x 1025psi = 406.5 psi The high pressure pump differential pressure then is: 1050psi (membrane pressure) 20psi (suction pressure) 406.5 psi (turbo boost pressure) = 623.5 psi High Pressure Pump: Because the feed flow is higher (771gpm vs 347gpm) with the AT Turbo system a more efficient feed pump is available. A typical axial split case multistage volute pump displays an efficiency of .79 at this flow rate. 400hp Electric Motor efficiency = .94 Total Pump Motor Power: 771 x 623.5 x .0005831/.79 /.94 x .7457 = 281.48kW Permeate Energy Rate:13.52kW/1,000gals or 3.57kW/m3

In the above example the HTE of the PX Pressure Exchanger is .647. It is clear in the second example the AT Turbo is more efficient. However, efficiency is just one of many factors to consider in energy recovery equipment selection. Capital cost, reliability, maintainability, ease and simplicity of operation and control are other important factors, and in some cases more important than efficiency alone. In all these areas, the AT Turbo is superior to the PX device.

15

The Dual Turbine System:

A Cost Effective and Reliable Method of Eliminating Pressure Throttling in RO Systems
In the comparison of AT Turbo and Pelton Impulse Turbine performance (page 12-13), the effects of feed stream throttling were clearly noted. This type of energy loss is especially prominent with SWRO plants that see wide annual salinity and/or temperature changes. There are a number of ways to minimize these losses. Permeate throttling can reduces these losses somewhat. Using variable frequency drives (VFD) with centrifugal pumps to change motor driver speed, hence pump discharge pressure is a more effective method to minimize pressure throttling. However VFD equipment for large plants is very expensive and VFD generate their own losses of 2-3%. Additionally, as speed is changed to accommodate pressure changes, pump capacity also changes, which may result in unacceptable capacity to the membrane To address the problem of pressure throttling in SWRO plants, PEI has developed the Dual Turbine System (DTS) for both single stage and two stage plants.

1834 gpm 0 psi High Pressure Pump 84% eff. 3986 667 3986 885 1499 gpm 865 psi
Permeate

M P T
Interstage HTC

3986 gpm 30 psi

P T

Net Motor hp 1442

Reverse Running Pump Turbine Control Valve

PIT

653 gpm 865 psi 84% eff.

Figure 15 (left) and illustrates the DTS for maximum energy recovery in SWRO plants.

Figure 16 (right) and illustrates another DTS design utilizing the BCS two stage design with a reverse running pump as the secondary turbine. Other design options include using an additional TurboCharger to lower first stage pressure requirements.

16

The Dual Turbine System (continued)

Fig. 15 shows a parallel flow arrangement of a AT Turbo as a feed pressure booster and a smaller Pelton Impulse Turbine as a secondary ERT. Fig 16 is a similar arrangement, but with the AT Turbo being used as a interstage booster pump. In both cases the method of operation is the same. At those times when Turbo boost pressure plus high pressure pump discharge pressure is in excess of membrane requirements, a valve will open to divert flow from the turbine of the AT Turbo to the Impulse Turbine. Thus the AT Turbo becomes a controllable variable speed pump, providing only sufficient pressure for the membrane process. The high pressure pump runs at constant speed and output at its Best Efficiency Point. The Impulse Turbine recovers the concentrate energy not required by the Turbo.

Figure 17
3200

2950

2936

Pump hp with PIT

2700

2450

Flow

Net Motor hp with PIT

2176 2109 2039 1969 1899 1830 1763

2200

1950

1700 1450 1200

1261

1650

Pump hp with HTC

1317 1377 1440 1507 1577 1650

750

800

850

900
Membrane Pressure (psi)

Net Motor hp with DTS

950

1000

1050

All pressure throttling is eliminated without resort to expensive VFD. The Impulse Turbine is of modest size (specific size depends on flow conditions) and inexpensive compared to pressure throttling losses or a VFD. There are many variations to the basic DTS design. For instance reverse running pumps or additional Turbos can be in the place of the Impulse Turbine. However in most cases the Impulse Turbine is a good choice because of its excellent part load efficiency. For a complete Dual Turbine energy analysis, please contact Pump Engineering.

Energy Rate 750 psi - 1050 psi DTS 2.26 - 2.95 kW/M3 PIT 3.90 - 3.16 kW/M3
17

AT Turbocharger for SWRO Interstage Booster Pump Application

Today, with the use of high pressure membranes (100bar), it is now possible to design two stage seawater reverse osmosis system with recovery ratios of 60% and higher. This type of plant has become known as the BCS or Brine Conversion System. Higher recoveries in SWRO plants can save capital and operating cost on intake and outfall structures and piping, pretreatment system size and chemical usage. In additional this type of plant can be highly energy efficient when an AT Turbocharger is used as the interstage booster pump. Fig 18 shows a flow schematic for a two stage 60% recovery system. As indicated in the schematic, an interstage booster pump is required to increase the pressure from the 1st stage to the 2nd stage. The reason for the increased interstage pressure is to compensate for the increased salinity of the 2nd stage feed (which is the 1st stage concentrate).

Figure 18

Example: Two stage SWRO plant of 60% recovery and capacity of 150,000gpd (174gpm feed flow) The feed salinity will be 35,000ppm and temperature will be 280C. The above schematic indicates the flows and pressures of this design. The AT 100 model turbocharger provides a boost pressure of 497psi (34.2bar) with a HETE of .60. The feed pump is a PD pump at 87% 3 efficiency. In this example the permeate energy rate is 11.15kW/1,000 gal or 2.97kW/m . Advantages of AT Turbo as an Intersatge Booster Pump AT Turbo is more efficient than a motor driven pump No high pressure mechanical seals Combines booster pump and ERT in one unit The Turbo easily handles very high suction pressure No electric motor or controls

With larger BCS systems, the AT turbo efficiency is such that more boost pressure can be produce than what the 2nd stage membrane requires. A new and patented Dual Turbine System is described in the previous section that can eliminate all pressure throttling in both two stage BCS and single stage SWRO plants

18

TURBINE C L PUMP C L FEED OUT BRINE IN

YT

CP YC YP ZP ZT

BRINE OUT DP D FEED IN J F E

DT

HH E

MODEL CP 13.56 3.00 3.31 3.75 4.00 4.50 4.88 5.38 6.63 6.88 8.00 8.88 9.38 6.38 5.88 6.13 7.00 7.63 7.75 9.06 9.63 2.62 5.31 5.62 YC YT YP J 1" 1-1/4" 15.00 1-1/2" 16.69 2" 2" 3" 3" 4" 23.38 23.88 21.56 18.63 18.00

PIPE SIZE BRINE FEED

F 4.31 4.88 5.25 5.44 5.75 6.75 5.38 4.62 5.00 5.63 6.13 6.25 6.94

D 3.75 4.19 5.19 5.25 5.50 6.50 11.75 7.31

E 1.88 1.63 1.63 2.81 3.13 3.25 3.44

ZT 4.62 5.63 6.50 6.63 7.63 7.63 2.59

ZP 4.62 5.63 6.50 7.13 7.63 8.63 3.25

HH

DT 17/32 .968 17/32 1.22 17/32 1.50 17/32 1.78 17/32 1.88 21/32 2.25 21/32 9.63

DP 1.31 1.56 1.88 2.13 2.31 2.65 9.63

HTC AT-50

1"

HTC AT-100

1-1/4"

HTC AT-150

1-1/2"

HTC AT-225

1-1/2"

HTC AT-300

2"

HTC AT-450

2"

HTC AT-600

3"

HTC AT-900

3"

11.13 5.63

13.00 8.19

4.25

3.09

3.81

21/32 9.63

11.50

19

20
FEED OUT CP YC YP BRINE IN ZT ZP DP D HH FEED IN F E E CP 30.06 33.13 37.69 42.38 46.56 53.50 53.38 9.00 7.75 6.50 YC YT YP J F D 14.81 8.19 17.00 9.75 19.63 12.88 22.50 15.00 26.63 15.50 14.00 19.00 20.50 11.13 30.38 18.00 14.75 17.75 20.88 10.12 31.50 20.50 E 5.25 5.88 6.75 8.25 9.25 ZT 3.56 4.34 5.19 6.25 7.28 10.25 8.50 11.38 9.00 ZP 4.38 5.56 6.31 7.69 8.88 HH 29/32 DT DP 13.13 13.13 1-1/32 13.13 15.63 1-1/32 18.00 21.00 1-9/32 19.50 24.00 1-9/32 22.50 26.50 10.38 1-9/32 24.50 29.00 12.25 1-5/8 28.00 36.00 4" 6" 6" 8" 8" 10" 12" 10.56 13.00 6.94 11.13 14.25 6.56 13.75 14.94 8.50 10.13 15.00 17.25 9.13 12.06 16.50 18.00 9.31

YT

DT

BRINE OUT

MODEL

PIPE SIZE BRINE FEED

HTC AT-1200 4" HTC AT-1800 4"

HTC AT-2400 6" HTC AT-3600 6"

HTC AT-4800 8" HTC AT-7200 8"

HTC AT-9600 10"