International Conference on recent innovations in engineering & technology

Development of a tool for selection of KSB Pump as

Turbine products

Sangram Nangare Tejas Paliwal Sanmay Aphale Akash Talware

UG Student UG Student UG Student UG Student
Department of Department of Department of Department of
Mechanical Mechanical Mechanical Mechanical
Engineering,PVPIT, Engineering,PVPIT, Engineering,PVPIT, Engineering,PVPIT,
Bavdhan, Pune-21 Bavdhan, Pune-21 Bavdhan, Pune-21 Bavdhan, Pune-21
Mail2sangramnan Paliwaltejas11@g sanaphale@gmail.c Attalware7@gmail.
gare@gmail.com mail.com om com

ABSTRACT
Turbine a rotary mechanical device plays a vital role in
generation of electricity. In combination with a generator the
turbines are used for generating electrical power. A
standardized centrifugal pump can be run in reverse and used
as a turbine without having to make any changes to the design
of the casing or the impeller geometry. Selection only requires
a few rules with regard to volume flow rate (Q), head (H) and
rotational speed (n) to be observed. A combined method using
statistical and numerical models in Microsoft- Excel and its
visual basic applications has been developed by the authors for
selecting a pump running as turbine according to the customer’s
requirement.
Keywords
Hydropower, Experimental measurements, Pump as turbine,
Raster, Data Analysis Case study.
This tool will input the two basic quantities at first i.e. the head
and the flow rate as provided by the customer. Along with these
two quantities, the customer also has a choice of considering
parameters like efficiency and cost if needed. Based on all these
parameters combined, the tool will give an exact solution or the
exact series of Pump as Turbine which tends to be the perfect
fit for the customer according to their requirement.
3. DEVELOPMENT OF TOOL
3.1 Data Collection
When the data collection was taken in consideration, we were
required few inputs regarding the mathematical equations
involved in the performance prediction of the PAT. A sample
data was taken from KSB, a leading PAT manufacturer for a
series of PAT products. This data was in the form of
successively calculated readings of head observed at a given
flow (80% to 120%).

1. INTRODUCTION The obtained data for one PAT is mentioned below.

For more than 35 years now, PAT has became a more popular Table 1. Sample Data of calculated readings of PAT
amongst small scale and medium scale capacity Pump/Turbine
users. As the demand increased for this product the Q/Qo (%) Flow Q(m3/s) Head H (m)
manufacturer’s have chosen to increase the number of their 80% 70.4064 18.1698
products with the same working and different capacities, sizes
etc. As each one of them results in different properties, there 90% 79.2072 20.78092
comes a need of selection tool which is flexible for the selection
100% 88.008 23.866
of the best product according to customer’s requirement. So
rather than choosing the best product manually, the automated 110% 96.8088 27.42491
tool which is developed in Microsoft Excel will give the best
and accurate results to save time and testing cost too. 120% 105.6096 31.45881

2. BACKGROUND
The raw data received for the various series of Pump as Consider table 1, similar data of 5 different PAT products is
Turbines in terms of flow rate, head, efficiency and various considered for the raster formation and tool development.
parameters is segregated into excel sheets. This segregated data
is further sorted into the data which is actually required and to
be used for the automation of selection process of Pump as
Turbines. Hence to handle this data effectively, the use of Excel
VBA is done. It not only simplifies the data sorting work, but
also eliminates the need of using other complicated software in
order to automate the process.

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3.2 Graphical representation & Table 2. Sample Data of calculated readings of PAT
Interpolation of Data PAT Flow Q Head H
The above data is plotted on a curve which basically shows
A 70.4064 18.1698
the performance curve of respective PAT product.
79.2072 20.78092
88.008 23.866
96.8088 27.42491
105.6096 31.45881
B 71.2984 26.22334
80.2107 29.11664
89.123 33.987
98.0353 38.85517
106.9476 44.38039
C 92.376 44.95807
103.923 51.1628
115.47 58.85
127.017 67.84556
138.564 76.84565
D 113.6264 27.53416
127.8297 31.40609
142.033 35.988
156.2363 41.28112

Fig 1: Raster of PAT’s 170.4396 47.28427

The reason why Interpolation was necessary is the range and E 153.208 43.74205
tendency of curve. In our case the performance calculated from 172.359 49.59973
the formulae is to be represented on scatter chart in order to see
how it tends to perform as we increase its efficiency. While 191.51 56.54
calculating the values the values of calculated flow and head
were having large decimal numbers and weren’t giving the 210.661 64.562
accuracy of the answer. 229.812 73.667
Interpolation was carried out to increase its accuracy while
showing the values on curve which will help to balance the
performance level throughout the experiment. As we see above,
the interpolated curve is giving much more accuracy with a
balancing in the graph. From this idea we used Gauss
elimination method formula based Curve fitting tool. This tool
was developed in Visual Basic Application – Excel. The tool
interpolated the readings to its maximum expected accuracy.
As we consider the best suitable output from the product, we
considered the best/maximum efficiency point region with near
most 4 readings. After studying the data, it is observed that the
best efficiency point comes in the range of 80% to 120% for all
products and for the series.
Hence we took all the readings of the products from the range
of 80% to 120% respectively.

3.3 Raster Formation

Raster means a combined graphical representation of multiple
series of Pump as turbines in a single graph which will contain
all the data under

Fig 1: Raster of PAT’s

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3.3 Selection Process

Considering required inputs given by Customer
Flow = 100; Head = 60
Selection process for PaT depends on Customer’s requirement.
Table No. 4.2.3 Lines Locating point of operation
Customer has to provide the information regarding the flow rate
and head available at the mounting place. According to these
requirements we will put the given values in our Raster in order X Y
to get a marking point in it. This point will be nearer to the
specific two to three curves and these curves will be taken in Horizontal 110 110
consideration for the selection of desired product. This selected Line
product will have best combination of all input values such as
Flow rate, head, efficiency, Input and output diameter etc. Also 0 50
the tool is generated with inbuilt programming developed in
VBA-Excel which will convert the Raster according to change
in input Speed of shaft at input in rpm.
Vertical 50 50
4. EXPERIMENTATION Line
4.1 Experimentation Procedure
First interpolate the readings and Form the Raster in MS- 0 110
Excel. Consider the equations of curves. Substitute the values
X= Flow Rate Y= Head in the equations to get the Y intercept
of curve with the given point. Subtracting this all Y intercepts
from the given Y value. The minimum value of the Y Substituting X= 110 Y= 50 in above equations (Table 4.2.1) to
intercept will represent the near most Curve to the required get Y-intercepts
point. If two curves are nearby to the point, then both products
represented by Curves will be suitable for that requirement Table No. 4.2.4 Lines Locating point of operation
and then the process will consider costing and budget of the
customer.
Curve Y-Intercepts
4.2 Experimentation Calculation A 33.64814
Considering The Equations of the curves
B 46.61093

Table No. 4.2.1 Polynomial Equation of plotted curves in C 55.246

Raster
Curve Equation D 26.65953
A y = 0.0031x2 - 0.1613x + 14.354
E 34.50175
B y = 0.0018x2 - 0.1526x + 22.139

C y = 0.0037x2 - 0.1568x + 27.768

Y Difference= (Y-Y Intercept)
D y = 0.0015x2 - 0.1745x + 35.845
At Y= 50
E y = 0.0018x2 - 0.1526x + 22.139
Table No. 4.2.4 Lines Locating point of operation
Consider Condition
Curves y difference
Flow= X=110, Head=Y= 50
A 16.35186
Table No. 4.2.2 Point of Operation
B 3.389066
X Y
C 5.245998
110 50
D 23.34047

E 15.49825

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 International Conference on recent innovations in engineering & technology
5. RESULTS
Out of the Y distances calculations, the smallest value
determines the near most curve to the requirement of the
customer. It also predicts that the performance of the product
matches with the customer’s requirement. Thus the tool
predicts the most approximate solution according to input data.
Visually it is seen that curve C is nearby to the point but by
calculations it is seen that curve B is the most preferred solution
in this case.
Table No. 5.1 Results
Curve(Y-
REQUIRED
Yintercept)
B 3.389066
C Point
B
Fig No. 5.1 Lines Locating point of operation
6. FUTURE SCOPE
The tool can be used for different series of PATs.
The tool can be made more user friendly by programming it in
other languages like Python, JAVA etc.
The empirical correlation developed in the present study is
applicable in the specific range of diameter and rotational
speed. More detailed investigations may be carried out to apply
the correlation in the wider range.
Majority of the research on PAT focuses on water as the
working fluid. But, PAT also found applications for energy
recovery in petroleum industries, gas scrubbing, sewage
treatment plants etc. Hence, the effects of viscosity and density
of fluid on PAT performance may be studied. Mathematical
modelling of PAT working under different operating
conditions may be carried out.
6. ACKNOWLEDGMENTS
Authors are thankful to Prof Dr K.A. Sorate, HoD Mechanical,
PVPIT Bavdhan campus, Pune for guidance. We are also
thankful to Campus director Prof S.R.Thithe and Principal Prof
C.M.Sedani for kind support and help.
Authors like to appreciate the sincere efforts and valuable
guidance of Mr. Shailendra Ukirde, KSB Tech Pvt, Ltd.,Pune.
7. REFERENCES
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3,238,534',"HYDRAULIC PUMPS AND REVERSIBLE
PUMP TURBINES" ,Patented March 1, 1966.
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