Reverse engineering of impellers to reduce pipe network pressure and enable sustainable power generation using pumps as turbines (PATs)

• Design a 3D pump model from scratch using Catia software and compare design parameters with theoretical calculations and CFTurbo software, analyze pump velocity triangle values as a part of design requirements • Ansys software simulation utilized dynamic mesh option with 6 DOF rotation movement around the x-axis • Determine the transition equations from pump to turbine to conduct numerical analysis of a pump operating as a turbine, in order to obtain theoretical performance curves for the Pump-As-Turbine (PAT) system. • The new PAT model was implemented in the Seri Aman water district network to reduce pressure and convert to mechanical energy during low consumption periods, avoiding the energy waste associated with PRV valves. A pump working as a turbine is a hydraulic machine type that can operate as both a pump and a turbine (PAT) by reversing the flow direction. The PAT could be an effective method for meeting global energy demands, particularly in rural and isolated areas. Furthermore, the operating costs of micro-hydropower systems are lower compared to conventional hydrodynamic turbines, although they require a high initial investment. The pump-as-turbine has been applied in various engineering fields, including irrigation, sewage, reverse osmosis, water piping networks, storage, and pressure-reducing valves. Reducing pressure in a pipe distribution system also decreases leaks within piping systems. To estimate the performance of a pump-as-turbine (PAT), the influence of pump design parameters and its best efficiency point should be identified. Current research focuses on designing a 3D centrifugal pump from scratch by applied reverse engineering for existing pump’s impeller part and extract power from pipe distribution system. The extracted dimensions by reverse engineering were validated in two steps, results of pump design equations, and the result of CFTurbo software. Numerical simulations were carried out for a 3D centrifugal pump operating as a turbine at its best efficiency point in terms of velocity and head using pump to turbine transformation equations. Subsequently, simulations were conducted based on data collected from a water company, using the pump-as-turbine during low water consumption periods. This approach reduces pressure within the Seri Aman pipe distribution system, allowing for the transfer of mechanical power that could be used to produce electricity.