Recently, contra-rotating reversible pump-turbines (CR RPTs) have been proposed to increase the efficiency of low-head pumped hydropower storage applications, which are promising to provide energy storage for non-mountainous regions. To study the control architectures for these systems, a dual-rotor hardware-in-the-loop (HIL) emulator test-setup is developed. The HIL test-setup employs two induction machines controlled by separate regenerative variable frequency drives to emulate the torques on the two runners. A quasi-steady-state RPT model is developed based on 380 steady-state computational fluid dynamics (CFD) simulations and compared to three transient CFD simulations to analyse the dynamics. Furthermore, the runner torques are adapted to account for the lower friction and higher inertia of the HIL test-setup compared to the prototype CR RPT, ensuring accurate emulation. Finally, it is shown how precise calibration of the drive torque response averts torque errors related to the machine model estimator used in direct torque control. The developed emulator setup offers a cost-effective and controlled environment to optimise and validate control architectures for the novel CR RPT, providing a higher fidelity than theoretical simulation by including the physical effects of the drivetrain, electrical machines and converters that are not entirely captured in mathematical models.

In an effort to make pumped hydropower storage (PHS) technology feasible for regions with a flat topography, recent research shows promising results using a contra-rotating reversible pump-turbine at low-head. In this study, the impact of dual variable speed and inlet valve control is analyzed to evaluate the effect of these three degrees of freedom (DOFs) on the system efficiency and operating range. To this end, analytical models are described to assess pump-turbine performance, conduit losses and electromechanical losses. Methodologically, optimal efficiency maps are computed for every combination of the three DOFs to evaluate individual and combined effects on the overall efficiency. Furthermore, three energy storage cycles are analyzed to further study the performance in realistic use-cases. Key conclusions include an increase in round-trip efficiency by combining variable speed ratio and inlet valve control of 5.6% and 2.0% compared with only variable speed ratio control and variable inlet valve control, respectively. Furthermore, it is shown that using only 1 DOF significantly limits the operating range, with the addition of a variable inlet valve granting a higher impact than a variable speed ratio. Combining inlet valve and speed ratio control leads not only to the highest efficiency, but also the largest operating range, with a maximum round-trip efficiency of 67.5% and an energy storage capacity of 58.6 Wh/m ². The results confirm that exploiting both dual variable speed operation and inlet valve control yields the maximum efficiency and operating range, and is thus the preferred topology for contra-rotating reversible pump-turbines in low-head operation.