About the AT Turbocharger

The AT Turbocharger represents a tech-

nological breakthrough in Reverse Os-
mosis energy recovery performance.
Advance turbo machine design soft-
ware, 3D CAD and CAM software plus
5 axis machining now enables PEI to
custom design and manufacture com-
plex geometry impellers and casing flow
passages that have resulted in Turbo’s
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 Table of Contents
boosted in pressure for a second stage membrane block for further
recovery of permeate. Background................................... .2

This unique approach offers many advantages to the RO designer Design Features.............................3
and users. This manual will explain in detail these advantages and
innovations that make the AT Turbo the most efficient and cost ef-
Construction Features................... .4
fective 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. 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

LIQUID ENERGY Dual Turbine System......................17

1
 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 require-
ments.

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

2
 Figure 2

Design Features:
The Turbo addresses the major issues facing the RO system type. The thrust bearing is of the hydrostatic type which
designer and user, including simplicity of design and opera- utilizes high pressure water in an annular groove to
tion, efficiency, reliability, ease of field servicing and versatil- balance net rotor axial thrust. Standard material for
ity of use through the following design features. all bearings is resin impregnated carbon graphite.
• Type: The Turbo is an integral turbine driven cen- Optional material is solid ceramic aluminum oxide.
trifugal pump. The turbine is a single stage radial in- Units equipped with ceramic bearings also use a
flow type. The pump is a single stage centrifugal type plasma sprayed ceramic coating on the shaft bearing
with its impeller mounted on the turbine shaft. The surfaces.
unit is entirely energized by the high pressure brine • Shaft Seals: Shaft seals or more precisely the lack
stream. of shaft seals is one of the outstanding design fea-
• Casing: The US Patent Pending AT Turbo casing tures that contribute to the Turbo’s high reliability. Me-
consists of an outer pressure casing designed for chanical seals or shaft packings are the most main-
1500 psi maximum pressure and inner radially split tenance intensive parts on nearly all pumps and are
volute insert casing. The volute insert is designed responsible for the most downtime. And because the
by CFD software and completely machined on CNC Turbo’s rotor is fully enclosed by the casing, there
milling machines, thereby achieving the ultimate in are no shaft penetrations to the atmosphere, hence
dimensional control, surface finish, and hydrualic ef- no seals.
ficiency. • Multiple Turbine Nozzles: The Turbo is equipped
• Impellers: The AT Turbo’s feature custom engineered with two nozzles and a control valve that allows brine
AND manufactured impellers. Using the most ad- flow and pressure to be regulated without energy
vance computational fluid dynamics pump and tur- wasting throttling or bypassing. See page 8 for addi-
bine design software, 3D CAD and CAM systems tional information on this important feature.
and 5 axis milling machines, each impeller design is • Pipe Connections: All feed (pump) and brine (tur-
optimized and manufactured for maximum efficiency. bine) pipe connections are Victaulic type. For larger
• Balancing: The entire rotating assembly is balanced units or very high pressure applications ANSI 600#
to ISO G3 standards (gyroscope tolerance) on PEI’s class flanges are available.
computer controlled high speed balancer. • Unit Base: Turbo bases are available in Delrin plas-
• Bearing: The Turbo uses three bearings all of which tic, stainless steel, or painted carbon steel. All bases
is lubricated by the feed or brine flow. The pump and are bolted with SS bolting and are drilled for sole plate
turbine center bearing are the hydrodynamic journal bolting. 3
 Operation and Materials of Construction
Construction Features
Besides its outstanding efficiency, the AT Turbocharger The standard and optional material of construction for AT Tur-
brings many benefits, some obvious, and others not bocharger are:
so obvious, however, they all add up to increase total
value to the RO designer and user. Consider the fol- Part Standard Optional
lowing Turbo characteristics: Casing Duplex Stainless Super Austenitic
Steel Stainless Steel
1. Fexibility of installation, can be placed next to Alloy 2205 AL6XN
RO block, greatly reduces brine piping cost
– no double shaft motors, brine sumps, ex- Impellers AL6XN
tended bases and foundations.
2. Significantly reduces high pressure pump size Bearings Resin/ Ceramic:
(number of stages), motor size, motor starter, Carbon Graphite Aluminum Oxide
switch gear and transformers
3. Able to discharge brine against backpressure Retaining Rings SS316 Passivated
– no brine sump or pump
4. Brine is not exposed to atmosphere, thereby External Bolting SS304
minimizing odor and corrosion
5. Reduces load on high pressure pump – Duplex alloy 2205 is a superior material for crevice and pitting
resulting in greater pump reliability – shorter corrosion resistance in high chloride environments. Alloy 2205
and stiffer shafts for centrifugal pumps, has twice the tensile strength of SS316L . The welding char-
reduced frame and crankshaft loading and acteristics of 2205 are very good and post weld heat treat-
cooler oil temperatures for positive ment to maintain corrosion resistance is not required. The
displacement plunger pumps. nominal composition of Alloy 2205 is:
6. Can be used with any type of high pressure
feed pump. Cr 22%
7. Turbos are very compact, small space and Ni 5%
foundation requirements Mo 3%
8. Turbo do not generate flow or pressure N 0.15%
pulsation Fe balance
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 TESTING
All Turbochargers are individually tested for performance,
mechanical integrity, and hydrostatic pressure. All data acqui-
sition is by electronic instrumentation and computer interface.
Test data is documented to identify the unit test and test con-
ditions. The complete test report becomes a part of the unit’s
job history file.

Custom engineering impellers utilizing turbomachine design

software.

4
Customer Specific Hydraulic Design
And Manufacturing
In the past, every Turbo was designed and manufactured to
achieve its best efficiency point (BEP) at the customer’s spe-
cific 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 cus-
tom engineered equipment produced by PEI.

Now, thanks to a highly disciplined design process which in-

cludes computational turbo machine software, 3D CAD and
CAM software and 5 axis CNC milling machines, PEI can cre-
ate a completely unique turbochargers with turbine rotor and HAAS 5 axis machining center.
pump impellers designed with complex 3D blade geometry.
The results of this process, plus the inherent efficiency ad-
vantage of high speed operations, are simply the most effi-
cient pumps and turbines available today. DATA: Customer
Requirements

Generate hydraulic design

Generate CNC program

Machine volute inserts*

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

Machine AT 3D impellers

Hydro & Performance Test

OK NO
TEST

YES

Unit ready for shipping

Machined wax turbine impeller for
investment casting.

*Custom Machined Volute Insert technology

patented by Pump Engineering, Inc. 5
 AT TURBO PERFORMANCE
Generally, an energy recovery turbine (ERT) is rated as hav- Now substituting numerical data into our formula for the
ing a certain efficiency based on the conversion of hydraulic 1,000gpm (227m3/hr) example as follows:
energy into mechanical shaft energy. However, in reverse os-
mosis where the process is driven by pressure energy, the Qf = 1,000gpm (feed flow)
shaft energy generated by the ERT is normally transferred to Qb = 600gpm ( brine flow)
the feed pump which then converts that energy back into pres- Qp = 225gpm(product flow)
sure energy in the feed stream. y = 40% (recovery ratio)
Rr = 60% (reject ratio)
The most accurate measure of ERT efficiency for an RO sys- Pm = 1,000psi (membrane pressure)
tem is the ratio of hydraulic energy returned to the feed stream Pbr = 980psi (brine pressure)
to the amount available in the brine stream. This ratio is called Pe = 5psi (brine exhaust pressure)
the Hydraulic Energy Transfer Efficiency (HETE), or nte
and is defined as:
∆P = ( .73 ) ( 600gpm/1000gpm ) * ( 980psi – 5psi ) = 427 psi
Nte = Hout / Hin [1]
Where Hout = Hydraulic energy transferred to the feed stream A design objective is to make ∆P as large as possible to ob-
Hin = Hydraulic energy available in the brine stream tain maximum energy recovery. Equations [ 2 ] and [ 3 ] indi-
cate that increasing ∆Pbr will accomplish that. Since Pbr is
The Hydraulic Energy Transfer Efficiency provides the tru- usually a given value based on membrane design, try to keep
est method to evaluate and compare the energy recovery ef- turbine exhaust pressure to a minimum safe level. Although
fectiveness of all energy recovery devices, including impulse the AT Turbo can discharge brine at a high pressure, this ex-
turbines, flow work exchangers, as well as the Turbo. haust pressure does reduce the available recoverable energy.

Unlike conventional ERTs, the energy transfer efficiency of In this example the use of the AT Turbo reduced the high
the Turbo is independent of pump efficiency. The reason for pressure feed pump discharge pressure from 1000psi to 588
this is that the Turbo contains its own pump, so the complete psi. Thus not only will the AT Turbo system be the most en-
energy transference occurs within the Turbo. So unlike an ergy efficient, but it will contribute considerable capital cost
impulse turbine or reverse running multistage pump, the savings as well.
Turbo’s rotor speed is completely independent of the motor/
high pressure pump. This means the Turbo can be designed A Note on Energy Efficiency Comparisons
for high speed operation which is the most efficient and cost When comparing the stated efficiency of the Impulse Turbine
effective design. Pump efficiencies of 90%+ are possible for and Reverse Running Pump Turbines with the Turbo’s Hy-
larger AT Turbos. draulic Energy Transfer Efficiency, be aware that their effi-
ciencies are given as the ratio of mechanical shaft output to
The useful work of the AT Turbo is expressed as the “Boost brine energy input. To get a true comparison of Hydraulic
Pressure”. This is the pressure rise that occurs between the Energy Transfer Efficiency to mechanical efficiency, multi-
Turbo’s pump inlet and pump discharge. To apply the Turbo ply the Impulse Turbine efficiency by the feed pump efficiency
to an RO system, the boost pressure needs to be calculated. and any other component such as a V belt speed reducer,
Variable Frequency Drive or part load reduction of motor effi-
Use Figure 3 to find the approximate Hydraulic Energy Trans- ciency. As an example, a 86% efficient Impulse Turbine
ference Efficiency for the Turbo. For example, at a feed flow coupled to a 77% efficient centrifugal pump would have com-
rate of 1000gpm the AT Turbo displays an nte of about 73%. bined efficiency Hydraulic Energy Transfer Efficiency of
66.2%. Further if a full sized motor were used, there would be
FIG 3 AT Turbo Hydraulic Energy Transfer Efficiency (nte) a reduction in motor efficiency due to part load operation that
Knowing nte makes calculation of the Turbo pressure boost, would now bring nte to 64.8%.
∆P, very simple:
∆P = (Nte) (Rr) (Pbr – Pe) [2] Thus the 64.8% nte of the Impulse Turbine/Pump and not the
86% mechanical efficiency, is the true measure of Energy
Where Rr = ratio of brine flow to feed flow Recovery Turbine efficiency.
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 ]

6
 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 600 gpm

500 hp motor 585 psi 5 psi
Pump Power = 420 hp

AT 900 Turbo
1000 gpm (placed next to membrane
30 psi rack for reduced piping)

High Pressure
4 stage pump
Turbo Transfer efficiency = 71% nte Figure 4
77% efficiency

Extra high pressure brine piping

600 gpm
980 psi
1000 gpm
1000 hp Motor 1000 psi
motor net power High Pressure
Pelton Impulse
467 hp 7 stage pump
Turbine Pump Power = 77 % efficiency
86% efficiency 761 hp
294 hp Output
1000 gpm
30 psi

PIT Transfer efficiency = .86 (PIT n) x .98 (*) x .77 (pump n) = 64.8% nte Figure 5

* percentage reduction of motor efficiency due to part load operation 7

 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
speed reverse running pump turbines.
Auxiliary Nozzle

The ANCV can be supplied either as a manual or Turbine

as a power actuated unit. Impeller
Brine

AT Turbocharger Installation and PID Primary Nozzle

Volute
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).

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.

8
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.

9
 Feed Pump Selection with the AT Turbo
Pump selection with the TurboTM is easy, although a few guide- operation of the plant. As the membrane pressure require-
lines should be followed. Always use the highest expected ment increases with plant age, the valve is opened to obtain
pressure conditions in calculating TurboTM pressure boost. This increased pressure to the RO train.
would typically be the pressure at the end of the membrane
life with the highest expected TDS feed at the lowest expected Another way is to use a variable speed pump drive such as a
temperature. variable frequency drive (VFD). The pump speed is adjusted
as required to obtain the desired pump pressure. The advan-
If the recovery or feed flow may vary significantly, it is a good tage of this technique is that the pump power consumption is
idea to check with PEI to ensure the TurboTM can efficiently minimized and the expensive control valve can be eliminated.
accommodate the conditions.
Centrifugal Pump Example
Positive Displacement Pumps The goal of this analysis is to find the performance require-
With positive displacement (PD) pumps such as reciprocat- ments of the feed pump. Operating conditions are indicated
ing plunger types, flow rate is established by pump displace- in Figure 11 including the projected lowest and highest mem-
ment and RPM. Membrane pressure is controlled by adjust- brane pressure.
ment of the ANCV on the TurboTM. PD pumps do not need
any type of feed pressure control device such as a feed throttle Figure 11 indicates a TurboTM transfer efficiency of 64%. Us-
valve. ing “end of life” conditions, equation [3] calculates the TurboTM
boost (i.e. the pressure rise between points 2 and 3) as 352
Due to the very high reliability of the TurboTM, the PD pump psi. The required feed pump discharge pressure, Pp, is:
and motor can be rated to deliver the required pump discharge
pressure allowing for the TurboTM boost. Such downsizing of Pp = Pm – Ptc
the pump and motor will save considerable capital and main- = 950 – 386 = 564 psi
tenance costs and energy use.
Thus, the feed pump must be sized to deliver 550 psi outlet
CAUTION! Always use good pulsation dampening on the pressure.
feed pump discharge. Severe flow and pressure pulsations
can be damaging to pressure gauges, flow meters, piping and For start-up conditions, the TurboTM boost is 348 psi which
possibly the TurboTM. See PEI’s installation manuals for addi- yields a TurboTM feed inlet pressure of 536 psi. Note that the
tional information feed throttle valve must be adjusted to “destroy” about 61 psi
of feed pressure.
Centrifugal Pumps
These pumps must be sized for maximum pressure condi- If a VFD were used, the control valve would be eliminated
tions. When the required membrane pressure is lower than and the feed pump power consumption would be reduced.
the rated pump discharge pressure excess pump delivery For this example, the pump for start-up condition without the
pressure must be eliminated. VFD would require 184 hp. With a VFD, the input power drops
to 176 hp.
A feed throttle valve is the most common way to regulate this
pump pressure. This valve is partially closed during initial Please contact PEI with questions about feed pump selec-
tion.

Feed Throttle
Valve
’ Start-up End of Life
Flow Pressure Flow Pressure
(gpm) (psi) (gpm) (psi)
1 420 30 420 30
Feed ηte = 64% AT TurboTM 2 420 564 420 564
Pump ηp = 72% 2’ 420 502 420 564
ηm = 93% Figure 11 3 420 850 420 950
4 280 830 280 920
5 280 5 280 5

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 de-
signed 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 dis-
placement 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 (lead-
ing 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 Capacity: 2,641,000 gpd (10,000m3/d)

290C Summer Conditions - 0 years 140C Winter Conditions - 3 years

Feed 3986 gpm (906 m3/hr) 3986 gpm (906 m3/hr)

Flow
Pump 920 psi (63.4 bar) 1085 psi (74.8 bar)
Pressure
Membrane 885 psi (61 bar) 1050 psi (72.4 bar)
Pressure
Concentrate 2232 gpm (507 m3/hr) 2232 gpm(507 m3/hr)
Flow
Concentrate 865 psi (59.7 bar) 1030 psi (71bar)
Pressure

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 concen-
trate 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
Pump hp
2936 with PIT
2750

2500
Flow

2250
2176
2109
2039
2000 1969
1899
1830 Net Motor hp
1750 1763
with PIT
1650

1500 Pump hp
750 with HTC
800 850 900 950 1000 1050
Membrane Pressure (psi)

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 Pelton Impulse Turbine (PIT)

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

PX High Pressure Pump: For the Turbo example, first calculate AT Turbo boost
Q = 49.5 x 1.04 (internal leakage factor) = 51.5gpm pressure utilizing the following forumula:
P = 995psi (1,000psi – 20psi suction pressure +
15psi Salinity Mixing Factor) Reject Ratio x AT Turbo HTE x Brine Diff. Pres. = Turbo Boost
Reciprocating Plunger .55 x .60 x 995 psi = 322 psi Boost
Pump Efficiency = .84 (including V belt drive losses)
40hp motor efficiency = .90 The high pressure pump differential pressure then is:
Total Pump Motor Power*
= 51.5 x 995 x .0005831/.84/.90 x .746 = 29.48 kW 1000psi (membrane pressure) – 20psi(suction pressure) –
322psi (turbo boost pressure) = 658psi
Booster Pump: Q = 61.5gpm
P = 75psi Reciprocating Plunger Pump Efficiency =. 85 (including V
Pump used for this application will be a multistage centrifu- belt losses).
gal with BEP efficiency of .52. 7.5 hp motor efficiency = .88
Total Pump Motor Power = 61.5 x 75 x .0005831/.52/.88 x 60hp electric motor efficiency = .92
.746 = 4.38kW
Total Pump Motor Power = 111 x 658 x .0005831/.85/.92 x
Total energy usag: 33.86kW .746 = 40.62kW
Permeate Energy Rate: 3.04kW/m3 or 11.40kW/1,000gals 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. Addi-
tional 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 AT Turbocharger System

PX High Pressure Pump: For the AT Turbo example, first calculate the Turbo Boost
Q = 347gpm x (430 x .04) (internal leak factor) = 364gpm Pressure by:
P = 1045psi (1050psi – 20psi (suction pressure + 15psi Reject Ratio x AT Turbo HTE x Brine Differential Pressure
Salinity Mixing Factor)
The most reasonable choice for a high pressure feed pump .55 x .721 x 1025psi = 406.5 psi
is a multistage centrifugal. A well designed segmental ring
type such as, Flowserve 4x11 A, will display an efficiency of The high pressure pump differential pressure then is:
64.2%. 1050psi (membrane pressure) – 20psi (suction pres-
Total Pump Motor Power = sure) – 406.5 psi (turbo boost pressure) = 623.5 psi
364 x 1045 x .0005831/.70 /.93 x .746 = 277 kW
High Pressure Pump: Because the feed flow is higher (771gpm
Booster Pump selection would be an API 610 class single vs 347gpm) with the AT Turbo system a more efficient feed
stage centrifugal rated for 1,000psi suction pressure and pump is available. A typical axial split case multistage volute
with an efficiency of .72 pump displays an efficiency of .79 at this flow rate. 400hp Elec-
Booster Pump: Q = 771gpm tric Motor efficiency = .94
P = 75psi
Booster Pump Motor Power = Total Pump Motor Power:
424 x 75 x .0005831/.72 / .92 x .7457 = 20.87kW 771 x 623.5 x .0005831/.79 /.94 x .7457 = 281.48kW
Total energy usage: 298 kW
Permeate Energy Rate: 14.3 kW/1,000gals or 3.85kW/m3 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

3986 Permeate
High Pressure 885
Pump 84% eff.
1499 gpm
865 psi M
3986
3986 gpm 667 P T P T
30 psi Interstage HTC

Net Motor hp 1442

M Reverse
Running
Pump
Turbine

653 gpm Control Valve

PIT 865 psi

Figure 16 (right) and illustrates another DTS de-
sign utilizing the BCS two stage design with a
84% eff. reverse running pump as the secondary turbine.
Other design options include using an additional
Figure 15 (left) and illustrates the DTS for
TurboCharger to lower first stage pressure re-
maximum energy recovery in SWRO
quirements.
plants.

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

Pump hp
2950
2936 with PIT
2700

2450 Net Motor hp

with PIT
Flow

2200 2176
2109
2039
1899
1950 1969 1830
1763

1700
Pump hp
1650
with HTC
1450
1577 1650
1377 1440 1507
1200
1261 1317
Net Motor hp
750 800 850
with DTS
900 950 1000 1050
Membrane Pressure (psi)

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 PIT
2.26 - 2.95 kW/M3 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 · Combines booster pump and ERT in one unit
· AT Turbo is more efficient than a motor driven pump · The Turbo easily handles very high suction pressure
· No high pressure mechanical seals · 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
 CP
YC
YT YP ZP ZT
TURBINE CL

PUMP CL

FEED OUT BRINE IN

BRINE OUT
DP DT

D
HH
FEED IN

J F E E

PIPE SIZE
MODEL BRINE FEED CP YC YT YP J F D E ZT ZP HH DT DP
HTC AT-50 1" 1" 13.56 2.62 5.31 5.62 4.31 4.62 3.75 1.88 4.62 4.62 17/32 .968 1.31
HTC AT-100 1-1/4" 1-1/4" 15.00 3.00 5.88 6.13 4.88 5.00 4.19 1.63 5.63 5.63 17/32 1.22 1.56
HTC AT-150 1-1/2" 1-1/2" 16.69 3.31 6.38 7.00 5.25 5.63 5.19 1.63 6.50 6.50 17/32 1.50 1.88
HTC AT-225 1-1/2" 2" 18.00 3.75 6.63 7.63 5.44 6.13 5.25 2.81 6.63 7.13 17/32 1.78 2.13
HTC AT-300 2" 2" 18.63 4.00 6.88 7.75 5.75 6.25 5.50 3.13 7.63 7.63 17/32 1.88 2.31
HTC AT-450 2" 3" 21.56 4.50 8.00 9.06 6.75 6.94 6.50 3.25 7.63 8.63 21/32 2.25 2.65
HTC AT-600 3" 3" 23.38 4.88 8.88 9.63 5.38 11.75 7.31 3.44 2.59 3.25 21/32 9.63 9.63
HTC AT-900 3" 4" 23.88 5.38 9.38 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 BRINE IN ZT ZP

YT YC YP

DT DP

D
BRINE
OUT
HH
FEED IN

J F E E

PIPE SIZE
MODEL BRINE FEED CP YC YT YP J F D E ZT ZP HH DT DP
HTC AT-1200 4" 4" 30.06 6.50 10.56 13.00 6.94 14.81 8.19 5.25 3.56 4.38 29/32 13.13 13.13
HTC AT-1800 4" 6" 33.13 7.75 11.13 14.25 6.56 17.00 9.75 5.88 4.34 5.56 1-1/32 13.13 15.63
HTC AT-2400 6" 6" 37.69 9.00 13.75 14.94 8.50 19.63 12.88 6.75 5.19 6.31 1-1/32 18.00 21.00
HTC AT-3600 6" 8" 42.38 10.13 15.00 17.25 9.13 22.50 15.00 8.25 6.25 7.69 1-9/32 19.50 24.00
HTC AT-4800 8" 8" 46.56 12.06 16.50 18.00 9.31 26.63 15.50 9.25 7.28 8.88 1-9/32 22.50 26.50
HTC AT-7200 8" 10" 53.50 14.00 19.00 20.50 11.13 30.38 18.00 10.25 8.50 10.38 1-9/32 24.50 29.00
HTC AT-9600 10" 12" 53.38 14.75 17.75 20.88 10.12 31.50 20.50 11.38 9.00 12.25 1-5/8 28.00 36.00