Water turbine system for electricity generation in pipelines

Abstract

A water turbine system for generating electricity from water flow within a supply pipeline is disclosed. The system comprises a turbine unit with a fixed tubular body fluidly connected to the pipeline, rotatably housing a turbine. The turbine has radially arranged vanes configured to rotate under water flow, transferring rotational energy to a ring gear. The ring gear couples with an external pinion gear, which is operably connected to an electrical generator. The gear ratio between the ring gear and the pinion gear allows the generator to achieve sufficient rotational speed for consistent electricity output. The system may further include a water flow conditioning unit upstream of the turbine unit, designed to impart rotation to the water flow, enhancing the turbine's efficiency.

Description

Water Turbine System for Electricity Generation in Pipelines Field of the Invention

[0001] This invention relates generally to energy recovery systems for fluid networks. More specifically, the invention pertains to water turbine systems adaptable to existing or new water supply systems designed for integration within pipelines or closed conduit water supply systems, where they can harness kinetic energy from water flow to generate electricity.Background of the Invention

[0002] Traditional hydroelectric systems typically require substantial infrastructure, including dams, reservoirs, and large-scale water diversions, to facilitate energy generation. These installations rely on substantial elevation differences and high water volumes to produce sufficient power output. The construction and operation of such systems are often complex, involving large structural components and extensive environmental and logistical considerations.

[0003] These systems are generally located in open-flow environments with natural or artificial head (elevation drop) to harness gravitational potential energy, and they operate best where continuous, high-volume water flow is available. As a result, traditional hydroelectric systems are not readily adaptable for use in smaller, confined, or low-head water environments, such as those found in closed conduit systems or pipelines, where space is limited and high water flow rates or elevation drops may not be available.

[0004] In closed or controlled water systems, where the emphasis is often on maintaining consistent pressure and flow characteristics, conventional hydroelectric methods are unsuitable due to their scale and operational requirements, and because any appreciable disruption to flow can diminish downstream pressure. Within such networks there is a practical limit to the number of energy-recovery units that can be introduced before cumulative pressure losses begin to reduce supply to dwellings to an unacceptable level, making traditional approaches impracticable in this context.

[0005] Consequently, alternative methods of energy capture and conversion in confined or pressurised flow environments are needed which are distinct from traditional hydroelectric approaches, which are tailored to open environments and rely heavily on natural watercourse characteristics and substantial civil infrastructure. Summary of the Disclosure

[0006] The described water turbine system generates electricity from water flow in supply pipelines such as municipal water supply systems, and comprises a turbine housed within a fixed tubular body fluidly connected to the pipeline. Multiple units could be inserted in a water mains system in different locations which feed into an existing electrical grid. The number of installed units may be optimised to maximise power generation depending on the volume, flow rate and / or head height of the water supply system.

[0007] The turbine's vanes are radially arranged to rotate under water flow, allowing continuous energy capture with minimal disruption to water velocity within the pipeline. The turbine is coupled to a circumferential ring gear that drives an external pinion gear, which rotates at a higher speed than the ring gear, efficiently transferring torque to an electrical generator to achieve a minimum armature speed to produce saturation of the coils during flux cycles and maintain a minimum satisfactory power output. The substantial gear ratio between the ring gear and the pinion gear ensures that the generator reaches its required rotational speeds to produce consistent electricity output, even under variable water flow conditions.

[0008] The system's vane design and radial arrangement maximise fluid coupling, creating optimal torque while preserving water flow consistency. This design prevents significant reductions in water pressure or velocity, ensuring the system's integration into existing water infrastructure with minimal impact on overall flow rates. In certain configurations, a water flow conditioning unit can be positioned upstream of the turbine to introduce a rotational component to the incoming water flow, enhancing the turbine's rotational velocity and torque and thereby improving overall system efficiency.

[0009] According to one aspect, there is provided a water turbine system comprising a turbine unit with a fixed tubular body fluidly connected to a water supply pipeline and arranged to rotatably retain a turbine having a radial arrangement of vanes. The turbine is configured to rotate under water flow within the pipeline and to drive a ring gear coupled to an external pinion gear interfacing with an electrical generator. This arrangement enables the extraction of usable rotational energy from a confined, pressurised water environment while maintaining the hydraulic characteristics of the pipeline.

[0010] In accordance with certain embodiments, the gear ratio between the ring gear and the pinion gear may be in excess of 80:1, facilitating elevated rotational speeds at the generator and promoting consistent electrical output even under fluctuating flow conditions. In some forms, the tubular body may have a diameter substantially matching that of the water supply pipeline, allowing the system to be installed with minimal disruption to flow profile and without introducing appreciable pressure loss.

[0011] In further embodiments, the vanes may occupy a longitudinal extent greater than the internal diameter of the tubular body, improving fluid engagement within the restricted space of the pipeline. Inner surfaces of the vanes may include formations which enhance coupling with the moving fluid to increase torque without materially impeding flow. The turbine may incorporate four vanes radially arranged within a cylindrical body, with the formations positioned on the inner surfaces between the vanes to further promote efficient transfer of kinetic energy.

[0012] In some forms, the tubular body may comprise two half-cylinder portions that mate together with longitudinal flanges, allowing straightforward assembly and maintenance. These flanges may additionally provide mounting points for the external pinion gear, enabling compact integration of the mechanical and electrical components within the pipeline environment.

[0013] In accordance with another embodiment, a water flow conditioning unit may be positioned upstream of the turbine to impart rotation to the incoming water, encouraging the turbine to accelerate more readily and thereby improving energy capture. The conditioning unit may be configured to impart rotation in the samedirection as the turbine, and may include vanes of fixed pitch extending longitudinally along the length of the unit beyond its internal diameter, supported between semicylindrical portions clamped together with flanges. This upstream conditioning promotes smoother, more uniform flow into the turbine, supporting stable rotational behaviour.

[0014] These and other forms described herein allow the system to operate efficiently within pressurised water networks while maintaining flow continuity, enabling distributed energy recovery across multiple locations in a water mains system without undue reduction in downstream water pressure.

[0015] Other aspects of the invention are also disclosed.Brief Description of the Drawings

[0016] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0017] Figure 1 shows a water turbine system configured to generate electricity from water flow through a supply pipeline.

[0018] Figure 2 shows a cross-sectional view of the turbine unit, detailing the turbine's rotation within a tubular body with flanges for watertight attachment.

[0019] Figure 3 shows an embodiment of the turbine with vanes featuring inner cup formations to increase backpressure and torque.

[0020] Figure 4 shows the turbine with the vanes and cup formations in greater detail, illustrating their arrangement to maximise water force.

[0021] Figure 5 shows a cross-sectional view of the water flow conditioning unit, depicting the fixed vanes configured to impart rotation to water flow upstream of the turbine.

[0022] Figure 6 shows the turbine unit's flanges in detail, highlighting their watertight attachment to the pipeline.

[0023] Figure 7 shows an inner tubular body of the water flow conditioning unit, with vanes clamped in place by internal projections.

[0024] Figure 8 shows a top view of the water flow conditioning unit, illustrating the longitudinal flanges used to assemble the unit's semicylindrical portions.

[0025] Figure 9 shows an end view of the turbine unit without cup formations, highlighting the longitudinal flanges as mounting points for the pinion gear.

[0026] Figure 10 shows an end view of the turbine unit, depicting the vanes rotating around a central axis and their radial arrangement within the cylindrical body.

[0027] Figure 11 shows a top cross-sectional view of the turbine unit, illustrating the mating of the two half-cylinder portions with longitudinal flanges.Description of Embodiments

[0028] Figure 1 shows a water turbine system 100 configured to generate electricity from water flow 101 within a water supply pipeline 102, such as those found in municipal water supply systems. Multiple systems 100 can be installed along the pipeline 102, enhancing electrical output and providing redundancy if one or more systems 100 experience a failure.

[0029] The system 100 comprises a turbine unit 103 with a turbine 104, comprising vanes 109 and a ring gear 105. The ring gear 105 engages a smaller pinion gear 106, which is operably coupled to an electrical generator (not shown). The gear ratio between the ring gear 105 and the pinion gear 106 may be more than 80:1 such as approximately 100:1 or more, enabling sufficient rotational speed to drive the electrical generator at its minimum operational threshold.

[0030] Figure 2 provides a cross-sectional view of the turbine unit 103 in greater detail, showing the turbine 104 rotatably positioned within a tubular body 107, which preferably matches the diameter of the pipeline 102 to maintain consistent water velocity. The tubular body 107 may include flanges 108, as shown in Figure 6, to ensure watertight attachment to the pipeline 102 and integration with other components of the system 100.

[0031] The vanes 109 are pitched to rotate the turbine 104 under water pressure flowing through the tubular body 107. In certain embodiments, the vanes 109 may have a fixed helical pitch and may extend longitudinally along the tubular body 107, maximising fluid coupling force within the confines of the tubular body.

[0032] Figures 3 and 4 illustrate an embodiment in which the inner surfaces of the vanes 109 include cup formations 110. The cup formations 110 may be oriented so that they do not face axially along the direction of water flow. By presenting a surface that is offset from the principal flow axis, the formations 110 impose an orthogonal force component on the passing water, creating a lateral pressure differential that contributes to rotational movement of the turbine 104. Each cup formation 110 may further include a direct trailing outlet, allowing water entering the leading side of the cup to be redirected and discharged rearward in a defined manner. As water is briefly captured within the cup and then expelled through the trailing outlet, a reaction force is generated in a tangential direction, reinforcing the turning moment applied to the turbine. This combination of non-axial orientation, asymmetric pressure build-up and controlled discharge promotes rotation by establishing a consistent force imbalance between opposing sides of each vane.

[0033] Alternative vane configurations may be adopted to achieve more predictable or efficient rotational behaviour. In some embodiments, the vanes 109 may employ directional blade profiles shaped or angled to impose a tangential force on the turbine when struck by the flow. In other embodiments, helically pitched vanes may be used to guide water along a spiral path, naturally imparting rotational momentum as the flow advances through the turbine. Further configurations, such as curved blades, swept-back profiles or aerofoil-inspired geometries, may be utilised to convert the linear flow into rotational energy in a more continuous and controlled manner, selected according to the anticipated operating conditions within the pipeline.

[0034] Figure 10 displays an end view of the turbine unit 103, showing the vanes 109 rotating around a central axis 113. In this embodiment, the turbine 104 has four vanes, a configuration that provides adequate torque from the water flow 101 while minimising obstruction to water flow.

[0035] The turbine 104 is defined by a cylindrical body 113 with radially arranged vanes 109. Cup formations 110 are positioned on the inner surfaces of the cylindrical body 113 between the vanes 109. Figure 10 also shows that the tubular body 107 is composed of two half-cylinder portions 112, joined with longitudinal flanges 111.

[0036] Figure 11 presents a top cross-sectional view of the turbine unit 103, showing the joining of the two half-cylinder portions 112 with longitudinal flanges 111, which also serve as mounting points for the pinion gear.

[0037] In a preferred embodiment shown in Figure 1, the system 100 further includes a water flow conditioning unit 114 positioned upstream of the turbine unit 103. The conditioning unit 114 is designed to impart rotational motion to the water flow 101 before it reaches the turbine 104, potentially in the same rotational direction as the turbine 104, thereby increasing the rotational force. The water flow conditioning unit 114 may feature fixed vanes 115, which, for example, can impart a clockwise rotation to the water flow 101 when viewed from the unit’s entrance. This preconditioned clockwise water flow aligns with the turbine’s clockwise rotation, boosting operational speed and torque.

[0038] Figure 5 shows a cross-sectional view of the water flow conditioning unit 114, with fixed vanes 115 inside. The arrangement of the conditioning unit 114 is similar to the turbine unit 104 and may include four vanes 109, which could be fixed or variably pitched, extending along the length of the unit 114 beyond its internal diameter. The conditioning unit 114 is constructed from two semicylindrical portions 116, which are clamped together with flanges 117. The conditioning unit 114 also features end flanges 108 for coupling its inlet to the pipeline 102 and its outlet to the turbine unit 103.

[0039] Figures 7 and 8 illustrate that the water flow conditioning unit 114 may include an inner tubular body 119 with vanes 115 clamped between the semicylindrical portions 116, as depicted in Figure 7. The inner tubular body 119 and vanes 115 can be secured by internal projections 118.

[0040] Figure 9 shows an end view of the turbine unit 103 without the cup formations 110, highlighting how the vertically oriented longitudinal flanges 111 serve as mounting points for the pinion gear 106.

[0041] In an exemplary embodiment, the ring gear 105 of the turbine unit 103 is constructed from titanium to ensure maximum durability and longevity in the demanding environment of an in-pipe turbine system, as this component is subjectedto continuous water flow and substantial rotational stress and is comparatively difficult to access or replace once installed. Titanium offers excellent resistance to corrosion and mechanical wear, allowing the ring gear 105 to maintain its structural integrity over prolonged operational periods. In contrast, the pinion gear 106 may be formed from a comparatively softer compound so that, during prolonged engagement with the ring gear 105, any operative wear preferentially occurs on the pinion gear 106. This arrangement reduces wear on the titanium ring gear 105 and materially increases the service life of the exit turbine 104, as replacement or maintenance of the pinion gear 106 involves significantly less work than replacing the ring gear 105 within the turbine unit 103.

[0042] T o further enhance the efficiency of water flow through the turbine system 100, the interior lining of the tubular body 107 may include a thick Teflon coating. This Teflon lining substantially reduces friction between the flowing water 101 and the interior surfaces of the tubular body 107, resulting in near-zero friction. In embodiments, enhanced friction reduction may be achieved and longevity of the system increased 100 by baking an outer shell of the exit turbine 104 mating with the Teflon coating in enamel. The reduction in friction minimises energy loss as water flows through the turbine unit 103, maximising the transfer of kinetic energy to the turbine 104 and improving overall system efficiency.

[0043] Additionally, the lengths of the turbine unit 103 and / or the water flow conditioning unit 114 may be adjusted according to the rotational force applied to the turbine 104, depending on specific operational needs. By configuring the length of these tubes, the system 100 can be tailored to different flow conditions, allowing for an increase or decrease in the generated torque as required.

[0044] In an exemplary method of use, water flow 101 from the supply pipeline 102 is directed through the fixed tubular body 107 of the turbine unit 103. As water flows through the tubular body 107, it exerts pressure on the radially arranged vanes 109, causing the turbine 104 to rotate. This rotational energy is transferred to the ring gear 105, which engages the external pinion gear 106, thereby driving the generator at a suitable speed to produce electricity.

[0045] In configurations that include the water flow conditioning unit 114, water flow is pre-conditioned with rotational movement in the same direction as the turbine 104 before it reaches the turbine unit 103. This pre-conditioned flow increases the rotational velocity and torque applied to the turbine 104, enhancing the efficiency of electricity generation. The generated electricity can then be used directly or fed into an external grid, depending on the application requirements.

[0046] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practise the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed as obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention.

Claims

Claims1. A water turbine system comprising a turbine unit, the turbine unit comprising a fixed tubular body fluidly connected to a water supply pipeline and rotatably retaining a turbine, the turbine having a radial arrangement of vanes configured to rotate under water flow through the water supply pipeline, wherein the turbine rotates a ring gear coupling with an external pinion gear, the pinion gear operably interfacing with an electrical generator.

2. The water turbine system of claim 1, wherein a gear ratio between the ring gear and the pinion gear is in excess of 80:1.

3. The water turbine system of claim 1, wherein the tubular body has the same diameter as the water supply pipeline.

4. The water turbine system of claim 1, wherein the vanes of the turbine are helically pitched.

5. The water turbine system of claim 1, wherein the vanes of the turbine occupy a length along the tubular body greater than an internal diameter of the tubular body.

6. The water turbine system of claim 1, wherein inner surfaces of the vanes of the turbine have formations installed thereon.

7. The water turbine system of claim 1, wherein the turbine comprises four vanes.

8. The water turbine system of claim 1, wherein the turbine comprises a cylindrical body having the vanes radially arranged therein, and wherein the formations are arranged on inner surfaces of the cylindrical body between the vanes.

9. The water turbine system of claim 1, wherein the tubular body comprises two halfcylinder portions which mate together with longitudinal flanges.

10. The water turbine system of claim 9, wherein the longitudinal flanges mount the pinion gear.

11. The water turbine system of claim 1 , further comprising a water flow conditioning unit located upstream of the turbine unit and configured to impart rotation to water flow upstream of the turbine.

12. The water turbine system of claim 11 , wherein the water flow conditioning unit is configured to impart rotation in the same rotational direction as the turbine.

13. The water turbine system of claim 11 , wherein the vanes of the water flow conditioning unit are of fixed pitch.

14. The water turbine system of claim 11 , wherein the vanes of the water flow conditioning unit extend along a length of the water flow conditioning unit greater than an internal diameter of the water flow conditioning unit.

15. The water turbine system of claim 11 , wherein the water flow conditioning unit comprises two semicylindrical portions which clamp together with flanges.

16. A method of generating electricity from a water supply pipeline using the water turbine system of claim 1, the method comprising directing water flow through the water supply pipeline to cause rotation of the turbine, transmitting the rotation of the turbine through the ring gear and pinion gear, and operating the electrical generator to produce electricity.

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