Rotor-stator Interaction Research Articles

Analysis of pressure pulsation in a multi-stage double suction centrifugal pump

Abstract Pressure pulsation is a common phenomenon, which results from different causes. The intenser pressure pulsation occurs in the pump, the severer the damage to the pump. In the paper, with the assistance of detached eddy simulation method, the characteristic of pressure pulsation in the multi-stage double suction centrifugal pump is studied to understanding the internal flow circumstance. The results reveal that the pressure pulsation intensity reaches the maximum at blade trailing edge, which propagates to the tongue region of forward flow channel and double-volute under the low rates. Furthermore, it can be concluded that the pressure pulsation of region with obvious rotor–stator interaction between rotating impeller and stationary volute is generally larger at low flow rates. The pressure pulsation near the suction side of blade trailing edge shows the feature of broadband frequency and with increasing flow rate the bandwidth of broadband decreases drops rapidly except BP1. Due to the influence of the number of impeller blades, the dominant frequency of monitoring points in the inter-stage flow channel and the volute is basically located at a frequency that is twice the blade frequency. Meanwhile, because of the symmetry of the geometric structure of the reverse flow channel, the pressure pulsation curve changes of its internal monitoring points are similar under the same flow rate.

Unsteady Interaction Between Purge Flow and Secondary Flow in High-Lift Low Pressure Turbine

Abstract The coupling effect between the complex vortex system and the rim purge flow in the endwall region of a high-lift low pressure turbine (LPT) will significantly influence the evolution of secondary flow and the corresponding losses. This paper focused on the unsteady interaction mechanism between the rim purge flow and the secondary flow inside the high-lift LPT under the periodic wake passing. The large eddy simulation (LES) method was used to reveal the influence mechanism of rim purge flow, rotor-stator cavity interaction and unsteady wakes on the secondary flow. Detailed experimental measurement was carried out for the flow field of high-lift LPT under the influences of static purge flow. The results showed that the rim purge flow significantly increased the overturning and underturning downstream of the endwall region, resulting in aggravating secondary loss. The rotating-rim increased the difference of the circumferential velocity between the mainstream and the purge flow, aggravating the Kelvin-Helmholtz (K-H) instability, inducing the K-H vortex structure with stronger energy amplitude, and further increasing the endwall flow loss. The incoming wakes weakened the energy amplitude of the K-H vortex at the rim purge outlet, thinned the thickness of the low-energy fluid at the blade leading edge. Additionally, the interaction between the wakes and the secondary vortices further suppressed the development of the secondary flow. Nevertheless, the incoming wakes caused additional mixing losses and made a negative impact on the overall aerodynamic performance of the high-lift LPT.

Mechanism analysis of the abnormal head-cover vibration of an ultra-high-head pump-turbine operating in pump mode by CFD and FEM

ABSTRACT Hydraulic excitation causes abnormal head-cover vibration in some pump-turbines, particularly as design heads continue to rise. Pump-turbines with heads exceeding 600 m have reported such vibrations in pump mode, and it is urgent to reveal the reasons. A study was conducted on a head-cover of a pump-turbine with a maximum head of 660 m by 3D computational fluid dynamics (CFD) and finite element method (FEM) numerical simulations to investigate the hydraulic excitation source and vibration mechanism. Results show that the intensive vibration is related to the coincidence of frequency and mode between abnormal pressure pulsations with frequency 6–8f n and the low-order wet mode of the head-cover. A new flow pattern termed the rolling vortex was discovered in the vaneless space under high-head pumping conditions. The 6–8f n pressure pulsations result from the interaction between rolling vortices and guide-vanes, similar to the rotor-stator interaction. The flow mechanism of the rolling vortices is that the outflow velocity near the hub at the runner outlet is higher than that near the shroud, due to the positive blade lean angle and the X-shape distorted blades. Suppressing rolling vortices may help eliminate the abnormal head-cover vibration, which will be attempted in further study.

Simulation of Indexing and Clocking with a New Multidimensional Time Harmonic Balance Approach

Alongside the capability to simulate rotor–stator interactions, a central aspect within the development of frequency-domain methods for turbomachinery flows is the ability of the method to accurately predict rotor–rotor and stator–stator interactions on a single-passage domain. To simulate such interactions, state-of-the-art frequency-domain approaches require one fundamental interblade phase angle, and therefore it can be necessary to resort to multi-passage configurations. Other approaches neglect the cross-coupling of different harmonics. As a consequence, the influence of indexing on the propagation of the unsteady disturbances is not captured. To overcome these issues, the harmonic balance approach based on multidimensional Fourier transforms in time, recently introduced by the authors, is extended in this work to account for arbitrary interblade phase angle ratios on a single-passage domain. To assess the ability of the approach to simulate the influence of indexing on the steady, as well as on the unsteady, part of the flow, the proposed extension is applied to a modern low-pressure fan stage of a civil aero engine under the influence of an inhomogeneous inflow condition. The results are compared to unsteady simulations in the time-domain and to state-of-the-art frequency-domain methods based on one-dimensional discrete Fourier transforms.

Broadband Noise Reduction of a Two-Stage Fan with Wavy Trailing-Edge Blades

In this paper, a numerical investigation is performed to study the broadband noise of a fan stage with wavy trailing-edge blades. A study of the wavelength and ratio of amplitude to wavelength (H/L) is conducted to better understand the noise reduction effect of wavy trailing-edge blades. A rotor–stator interaction broadband noise prediction method based on the result of a Reynolds-averaged Navier–Stokes equation is used. The results show that all wavy trailing-edge configurations reduce the sound power level of the fan stage. The noise reduction effect of H20L10 is the best among all the wavy trailing-edge configurations, and the sound power level is reduced by 2.4 dB at 1000 Hz. When the H/L remains unchanged, the noise reduction effect of the wavy trailing-edge configuration increases with the increase in wavelength. When the wavelength remains unchanged, the noise reduction effect of the wavy trailing-edge configuration with an H/L of 2 is the best. The use of wavy trailing-edge configurations reduces the turbulent kinetic energy and turbulent integral length scale upstream of the stator by changing the wake of the rotor, thereby reducing the rotor–stator interaction broadband noise of the fan stage.

Numerical investigation on vortex characteristics in a low-head Francis turbine operating of adjustable-speed at part load conditions

In this paper, the vortex characteristics in a low-head Francis turbine operating of adjustable-speed at part load conditions are numerically investigated. First, the rules of fixed-speed and adjustable-speed operations are introduced in detail, aiming at operating limits extension. Second, comparative analysis on vortex rope is conducted, with emphasis on vortex rope volume, tail water excitation and spontaneous power swing. Finally, inter-blade vortex has been analyzed and successfully demonstrated, and its induced high amplitude pressure fluctuation characteristic is explored. It is found that at deep part load, vortex rope volume and power swing coefficient of adjustable-speed operation decreased by 69 % and 61 % respectively. The amplitude of Rheingans frequency decreased by 17 %, while the amplitude of blade passing frequency increased by 83 %. After decreasing runner speed, inter-blade vortex is stranded at blade suction surface leading-edge. In addition to low-frequency disturbance, pressure fluctuation shows high-frequency wide-band characteristics. It is concluded that adjustable-speed operation has beneficial effects on improvement of cavity cavitation and energy stability. As for hydraulic stability, the Rotor-Stator Interaction effect cannot be ignored. After changing runner speed, the inter-blade vortex becomes more serious, which could provoke low-cycle and high-cycle fatigue of the blades.

Pulsation Stability Analysis of a Prototype Pump-Turbine during Pump Mode Startup: Field Test Observations and Insights

Pump-turbines experience complex flow phenomena and fluid–structure interactions during transient operations, which can significantly impact their stability and performance. This paper presents a comprehensive field test study of the pump mode startup process for a 150 MW prototype pump-turbine. By analyzing pressure fluctuations, structural vibrations, and their short-time Fourier transform (STFT) results, multiple stages were identified, each exhibiting distinct characteristics. These characteristics were influenced by factors such as runner rotation, free surface sloshing in the draft tube, and rotor–stator interactions. The natural frequencies of the metallic components varied during the speed-up and water-filling stages, potentially due to gyroscopic effects or stress-stiffening phenomena. The opening of the guide vanes and dewatering valve inside the guide vanes significantly altered the amplitude of the rotor–stator interaction frequency, transitioning the vibration behavior from forced to self-excited regimes. Interestingly, the draft tube pressure fluctuations exhibited sloshing frequencies that deviated from existing prediction methods. The substantial phenomena observed in this study can help researchers in the field to deepen the understanding of the complex behavior of pump-turbines during transient operations and identify more meaningful research directions.

Axial Compressor Transonic Rotor Shock Interaction With Upstream Stator Row

Abstract Modern multistage axial compressors are designed for high aerodynamic loading and wide range with front stages rotor inlet relative Mach number above one over a large portion of span. Rotor shock waves propagate and reflect in the upstream stator where they provoke extra aerodynamic losses and aeromechanic risks. This paper discusses stator–rotor shock interactions using both steady and unsteady numerical simulations. The computations focus on three different stage designs with the same capacity and total pressure ratio, but different axial gaps and load distribution in stator and rotor. Speedlines from steady and unsteady computations compare the designs, and the detailed flow fields are analyzed at design and close to stall conditions. The steady and unsteady calculations predict similar stage performance, but different stator–rotor loss split. The analyses reveal how the rotor shocks orientation with respect to the upstream stator camber line controls the intensity of shocks interaction with the stator row and its propagation upstream. Finally, the paper indicates the ways to reduce the shock-driven rotor–stator interaction and suggests simple criteria to determine when to switch from steady to unsteady calculations for a reliable transonic stage performance prediction.

Smart Blade Count Selection to Align Modal Propagation Angle with Stator Stagger Angle for Low-Noise Ducted Fan Designs

The rotor–stator interaction noise is a major source of fan noise. Especially for low-speed fan stages, the tonal component is typically a dominant noise source. A challenge is to reduce this tonal noise, as it is typically perceived as unpleasant. Therefore, in this paper, we analytically, numerically and experimentally investigate an acoustic effect to lower the tonal noise excitation. Our study on an existing low-speed fan indicates a reduction in tonal interaction noise of more than 9 dB at the source if the excited acoustic modes propagate parallel to the stator leading edge angle. Moreover, a design-to-low-noise approach is demonstrated in order to apply this effect to two new fan stages with fewer stator than rotor blades. The acoustic design of both fans is determined by an appropriate choice of the rotor and stator blade numbers in order to align the modal propagation angle with the stator stagger angle. The blade geometries are obtained from aerodynamic optimization. Both fans provide similar aerodynamic but opposing acoustic radiation characteristics compared to the baseline fan and a significant tonal noise reduction resulting from the impact of the modal propagation angle on noise excitation. To ensure that this effect can also be applied to other low-speed fans, a design rule is derived and validated.

Application of a new DES model based on Wray-Agarwal turbulence model in flow simulation of a mixed-flow pump

In recent years, it has been demonstrated for many two- and three-dimensional external and internal turbulent flows that the one-equation Wray-Agarwal turbulence model can compute the complex turbulent flow fields with high computational accuracy, excellent computational convergence and efficiency. In this paper, Wray-Agarwal (WA) turbulence model is employed as part of a detached eddy simulation (DES) method to predict the performance of a mixed-flow pump. By comparing the computations with the experimental results, the differences and similarities between the WA-DES model and the Shear Stress Transfer (SST) k-ω model in predicting the internal and external flow characteristics of the pump are analyzed. The results show that both the SST k-ω model and the WA-DES model can reasonably predict the performance of the pump between 0.6 Q and 1.2 Q, where Q is the design flow rate; however, they have their own merits and deficiencies in predicting head and efficiency of the pump at low and high flow rates. For the velocity field in the rotor-stator interaction region, the WA-DES model shows better prediction accuracy since it can accurately predict the large-scale recirculating vortex structure at the inlet of the guide vane. The SST k-ω model over-predicts the separated flow region, which leads to the emergence of a small vortex structure before the backflow region of the pump. Although the turbulent eddy viscosity predicted by the WA-DES model is higher than that of the SST k-ω model and there is small difference in the results for the scale of the tip leakage vortex (TLV) between the two models, the overall simulation results of the WA-DES model for the high turbulent viscosity region and the pressure increase in the impeller are consistent with the SST k-ω model results. The results of this paper demonstrate the potential of WA-DES model for prediction of flows in pumps.

Investigation of hydrodynamic lubricant film breakdown between the journal and bearing in a high-speed coolant pump of electric vehicles

The high-speed coolant pump is essential for electric vehicle thermal management, ensuring optimal module temperatures. The pump impeller and bearing are combined into a rotor and then fit on a fixed shaft with a clearance, aiming to generate a complete lubricant film between the stationary journal and rotating bearing during pump operations. However, during the pump durability test under off-design conditions, severe wear occurred on both the journal and bearing. A novel simulation method based on computational fluid dynamics and dynamic mesh is developed to investigate the lubrication failure. User-defined functions are programmed to articulate the simultaneous rotation and whirl of the bearing, and the effects of temperature and cavitation are considered. Both the pump and bearing simulations closely align with experimental results. When the radial force of the pump rotor is steady, the bearing only rotates without whirling, and the bearing load capacity can counteract the maximum radial force of the rotor. However, the rotor experiences fluctuating radial forces over time, primarily attributed to elevated pressure levels at the volute tongue caused by the rotor–stator interaction. This phenomenon results in the bearing to rotate and whirl simultaneously. The load capacity generated by the backward whirl of the bearing is greater than that of the forward whirl. Nevertheless, the bearing whirl initiates a decline in the extremum values of lubricant film pressure. Subsequently, both load capacity and minimum film thickness exhibit a continuous decrease, eventually culminating in the breakdown of the complete lubricant film and resulting in contact wear failure. These new findings contribute to proposing measures to reduce wear under unsteady excitations.

Rotor–stator interaction investigations in variable speed reversible pump-turbine at higher head

Efficiency and grid stability can be improved by variable speed operation using doubly fed induction machine technology for pumped storage plants experiencing significant head variations. With the higher penetration of intermittent and variable renewable energy sources, viz., solar and wind, the grid may be stabilized by operating the reversible pump-turbines (RPTs) in off-design conditions. In a turbine mode, the RPT is more susceptible to fatigue and vibrations when operating at a higher head as a result of hydraulic instability generated by rotor–stator interaction (RSI); therefore, its performance becomes even more critical. The powerhouse structural components, including floors and columns, could experience intense vibrations because of this instability. Therefore, it is essential to investigate the RSI in the variable speed RPTs at the higher head. These investigations present the results of a numerical analysis of RSI and its associated pressure fluctuations in the variable speed RPTs at the higher head. The high-head scaled model of variable speed RPT was used, and the numerical simulations were executed by utilizing the shear stress transport k-ω turbulence model. The numerical analysis was performed at the best efficiency point and high-head operating conditions having optimized rotational speed. The results show that the main source of pressure fluctuations in the variable speed RPT at all operating conditions is RSI, where the dominant frequencies are blade passing frequency (9fn) and its harmonics. It is also found that the variable speed operation lowers the pressure fluctuations in the RPT.

Optimization of low-temperature multi-stage submersible pump based on blade load

The multi-stage submersible pump is a power conveyor for low-temperature media, which is conveyed by the rotating of centrifugal impellers. In this study, the impellers of a multi-stage submersible pump were optimized to improve the efficiency under the premise of the constant total blade load and head. Based on the analysis of performance and flow for each stage of the 18-stage submersible pump, the optimization scheme composed of the first stage, the middle stage, and the last stage was determined. The blade outlet angle, average blade wrapping angle, and blade wrapping angle difference were selected as optimization parameters through Plackett–Burman experimental design and significance analysis, and the blade profile was redrawn by changing the blade load distribution. The performance prediction model was built based on the Kriging response surface model, and then, the global optimal blade profile was found by non-dominated Sorting Genetic Algorithm II. The efficiencies of the 3-stage submersible pump and 18-stage submersible pump with optimized impeller increased by 2.35% and 2.01%, respectively. Under the design condition, the flow rate loss and pressure pulsation at the impeller outlet decreased and the stator–rotor interaction between the impeller and guide vane was weakened. This will lead to a reduction in unstable flow such as secondary flow and vortices, and an improvement of flow stability at the impeller outlet.

Numerical investigation of no-load startup in a high-head Francis turbine: Insights into flow instabilities and energy dissipation

The presented paper numerically investigates the internal flow behaviors and energy dissipation during the no-load startup process toward a Francis turbine. Passive runner rotation is implemented through the angular momentum balance equation accompanied by dynamic mesh technology and user defined function. Three phases of rotational speed are identified: stationary, rapid increase, and slow increase. Head exhibits a monotonic decrease, rapid rise and fall, and eventual fluctuation. Flow rate shows quasi-linear increase. The pressure fluctuations in the vaneless region are primarily dominated by the frequencies induced by Rotor-Stator Interaction and a broad frequency range below 50 Hz, and below 30 Hz in the draft tube. Runner inlet experiences positive to negative incidence angles, causing intense flow separation and unstable structures. Draft tube exhibits large-scale recirculation and evolving vortex structures. Energy loss analysis based on the entropy production method highlights the runner and draft tube as primary contributors. The energy loss within the runner exhibits an initial increase, subsequent decrease, and then a rise again during the stationary and rapid speed increase phases. While the draft tube shows a rapid increase during the phase of rapid speed increase. Turbulent fluctuations significantly contribute to entropy production loss, with trends matching total entropy production. Maximum energy loss locations correspond to runner inlet and draft tube wall, emphasizing the importance of unstable flow and vortex generation. This study establishes foundational insights into unstable hydrodynamics and energy dissipation modes during hydraulic turbine no-load startup, paving the way for further research.

The impact of blade inlet angle (β2) influence on pump‐as‐turbine performance by using entropy production theory

AbstractThe effect of the blade inlet angle on the pump‐as‐turbine (PAT) has not been adequately investigated. The hydraulic performance of PAT was analyzed using an available test rig. The accuracy of the numerical data was established by the comparative analysis of the experimental data. The study demonstrated that as the blade inlet angle increases, so does hydraulic performance, but only to a certain degree. The required pressure head and the shaft power increased with the increase in blade inlet angle. As compared to the volute and outlet pipe, the hydraulic power loss within the impeller accounts for a large portion of the total power loss. The impeller power loss decreases and increases at low and high flow rates, respectively, as the blade inlet angle increases. The fluid angle of attack decreases as the blade inlet angle increases at high flow, allowing the impeller power loss to drop and performance to increase. To visualize PAT internal energy loss, the distribution of the variable of pressure, velocity, and entropy dissipation theory was applied. The impeller had the highest energy loss of the PAT geometrical parameters. The shock loss, flow separation, and asymmetric volute structure are the primary causes of impeller loss. The unsteady simulation results showed that rotor–stator interaction greatly influences the gap between the volute tongue and the impeller tip. The research results provide a reference for the design of the PAT.

Study on mechanism of unsteady gas-liquid two-phase flow in liquid-ring vacuum pump

To investigate the gas-liquid two-phase flow mechanism in liquid-ring vacuum pump, the large-eddy simulation coupled with volume-of-fluid method (LES-VOF) was used to numerically simulate the unsteady gas-liquid flow characteristics in pump. The structure of gas-liquid flow within pump and its dynamic evolution characteristics were studied, and the hydraulic excitation characteristics induced by gas-liquid flow were analyzed. The result shows that the channel vortex inside the impeller on the pump suction side gradually flows out of the flow passage with the rotation of the impeller, and continuously mixes with the wake vortex at the outlet of the impeller and the separation vortex at the inner wall of the casing. The evolution and development of vortex structures with different intensities and scales near the inner wall of the suction side casing have a relatively large contribution to pressure fluctuation. The wake vortex at the impeller outlet of the exhaust side gradually enters the flow passage and dissipates gradually with time. There is an obvious high-intensity backflow vortex in the exhaust section due to the pressure difference between the flow channels near the leading edge of the exhaust port, which leads to obvious rotor-stator interaction in the exhaust section.

Analysis of Pressure Pulsation and Structural Characteristics of Vertical Shaft Cross-Flow Pumps

In order to study the pressure pulsation characteristics and structural dynamic response characteristics of a vertical shaft cross-flow pump, this study used a computational fluid dynamics (CFD) numerical simulation method to analyze the pressure pulsation characteristics of the inlet passage, impeller, and guide vane positions of the vertical shaft cross-flow pump device. At the same time, this study analyzed the equivalent stress–strain characteristics of the impeller and guide vane of a vertical shaft cross-flow pump based on fluid structure coupling technology and comprehensively analyzed the deformation modes of the impeller blades and guide vanes under dynamic water flow. This research shows that due to the influence of rotor–stator interaction, the amplitude of pressure pulsation at the interface between the impeller and guide vane of the pump device is the largest and that the main frequency distribution at this position is relatively complex. The non-uniformity of stress distribution at the impeller position gradually decreases with an increase in the radial distance. The high stress and strain zones of the impeller and guide vane are concentrated at the root of the blade. This study can provide reference for hydraulic optimization design and stable operation of similar pump devices.

On the application of a soft-vane cascade model in rotor-stator interaction noise prediction

On the application of a soft-vane cascade model in rotor-stator interaction noise prediction

Numerical Investigation of Unsteady Rotor–Stator Interaction Mechanism and Wake Transportation Characteristics in a Compressor with Non-Uniform Tip Clearance Rotor

This study aims to numerically investigate a transonic compressor by solving the unsteady Reynolds-averaged Navier–Stokes equations. The flow mechanisms related to unsteady flow were carefully examined and compared between rotors with non-uniform tip clearance (D1) and small-value tip clearance (P1). The unsteady flow field near the 50% and 95% blade span characterized by unsteady rotor–stator interaction was analyzed in detail for near-stall (NS) conditions. According to the findings, the perturbation of unsteady aerodynamic force for the stator is much bigger than that of the rotor. At the mid-gap between the rotor and stator, the perturbation of tangential velocity of the D1 scheme in the rotor and stator frame is reduced. At the rotor’s outlet region, the perturbation intensity is divided into three main perturbation regions, which are respectively concentrated in the TLV near the upper endwall, the corner separation at the blade root, and the wake of the whole blade span. Through the analysis of the wake transportation characteristics, it was found that when the wake passes through the stator blade surface, the wake exerts a substantial influence on the flow within the stator passage. It further leads to notable pressure perturbations on the stator’s surface, as well as affecting the development and flow loss of the boundary layer. The negative jet effect induces opposite secondary flow velocity on both sides of the wake near the stator’s surfaces. Therefore, the velocity at a specific point on the stator’s suction surface will decrease and then increase. Conversely, the velocity at a particular point on the pressure surface will increase and then decrease.

Enhancing low-pressure stage steam turbine using the TDLD criterion and the TOPSIS analysis

The liquid phase in the wet steam flow causes thermodynamics losses and affects steam turbine blade durability. The main objective of the present research is the design of the rotor stagger angle and different operating conditions in the low-pressure stage of the steam turbine. A two-phase Eulerian-Eulerian model and the SST k − ω model are used to simulate the viscous wet steam flow inside the steam turbine stage. Frozen rotor methodology is employed for modeling the stator-rotor interaction. The effects of different rotor stagger angles and different outlet pressure levels on the wet steam flow parameters are studied to introduce an improved case. The turbine stage efficiency, droplet average radius, liquid mass fraction, and degree of reaction (TDLD) are considered as design criteria. The search for the improved value of pressure ratio and rotor stagger angle is performed using the TDLD criterion by TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution). The improved case is selected with a rotor stagger angle of 64 degrees and outlet pressure of 6.5 kPa, at which the turbine stage efficiency (TSE) is increased by 21.3% compared to [Formula: see text]. Also, the liquid mass fraction (LMF) and the degree of reaction (DOR) reduced by 39.53 and 26% relative to [Formula: see text], and [Formula: see text], respectively. In addition, droplet average radius (DAR) increases by 26.14% compared to [Formula: see text].