A municipality receiving its water supply from a high elevation spring sought to replace an energy wasting pressure reducing valve with a hydro turbine. MSI was tasked with designing the turbine to capture power over a challenging range of operating conditions.
A Francis style hydro turbine was chosen as a design normally well-suited for varying flows, but generally less effective with variations in head pressure. The challenge was to come up with a single turbine capable of high efficiency for both current and future head conditions.
After extensive iterative design and analysis consisting of finite element analysis (FEA) and computational fluid dynamics (CFD), MSI developed a runner with high efficiency across the operating range of head and flow pressures. Cavitation was also a concern, given the wide operating range. The model predicted cavitation would not be a problem, and the turbine performed as expected.
A major pump OEM called on MSI to help resolve multiple pump driveshaft failures for an ore mining company in East Africa.
To identify potential opportunities for early bearing failure, MSI performed experimental modal analysis (EMA) and operational deflection shape (ODS) tests on a prototype unit for the manufacturer.