Tubular Pump Research Articles

Numerical simulation and experimental study of energy dissipation in a bidirectional axial extended tubular pump with different blade angles

Numerical simulation and experimental study of energy dissipation in a bidirectional axial extended tubular pump with different blade angles

Influence of axial distance between impeller and diffuser on the hydraulic performance and flow loss characteristics of bulb tubular pump

Abstract Bulb tubular pumps used in regional water transfer projects consume substantial power. Optimizing the geometric parameters of tubular pumps is crucial for enhancing efficiency and minimizing hydraulic losses. ANSYS CFX is used to investigate the axial distance between the impeller and the diffuser on the hydraulic performance and flow loss characteristics of the rear-bulb tubular pump, and the numerical simulation results are compared with the experimental data. Then, the entropy production theory is introduced to analyze flow losses. As the axial distance increases, the diffuser’s rectification effect on the flow at the impeller outlet deteriorates, leading to increased flow losses and decreased head and efficiency of the device. Flow losses in the bulb tubular pump are ranked from largest to smallest as follows: impeller, outflow channel, diffuser, inlet channel. The impeller exhibits the highest entropy production ratio, reaching 61.05% at an axial distance of 25 mm. By elucidating the energy loss distribution of each component under varying axial distances, this paper offers insights for the hydraulic optimization design of bulb tubular pumps.

Analysis of static stress and vibration characteristics of the impeller in a tubular pump

Analysis of static stress and vibration characteristics of the impeller in a tubular pump

Coordination of energy loss and fish friendliness for a low-head tubular-pump blade based on a multi-objective optimization model

Tubular pumps and turbines are the water-to-electricity conversion devices widely used in pumped hydro storage systems for low heads and high flow rates. An ecological concern is the high proportion of fish injuries caused by the rotating blades. In this study, a tubular pump blade is retrofitted to balance the energy loss and fish friendliness through multi-objective optimization, combining computational fluid dynamics with a mathematical blade strike model. Sensitivity analysis identifies nine geometric variables out of thirteen for optimizing blade design. An approximation model is developed to implement optimization algorithm and achieve the objective function. By artificially assigning weights to targeted performance metrics, three scenarios are obtained: the optimal efficiency scheme (A), the optimal fish friendliness scheme (C) and the balanced scheme (B). Scheme C achieves a fish survival ratio of 100 % at multiple flow rates (for fish lengths of Lf/D=1/12), but results in a 6.4 % decrease in efficiency compared to scheme A. Additionally, a negative blade attack angle can improve flow pattern. Considerable reduction in fish mortality can be obtained by equipping the rotor with a larger size but lower shaft speed, while also limiting the fish size to pass through the pump running at a reduced flow rate.

Engineering evaluation and reflection on the operation stability of large-scale tubular pump

Engineering evaluation and reflection on the operation stability of large-scale tubular pump

Analysis of the influence of different support types on the operation performance of bidirectional shaft tubular pump

Abstract Because of the particularity of the pump’s bidirectional operation, and the difference of the flow channels on both sides of the pump. The device has a mature impeller and guide vane combination when it is running forward. And when the device runs in reverse, the support on the shaft side acts as the rear guide vane of the impeller, which has great influence on the performance of the device. However, due to the few operating conditions in reverse operation, the importance of support is often ignored. In this paper, the influence of different support types on the bidirectional flow pattern and performance of the device is analyzed by numerical simulation. The results indicate that by optimizing the variation trend of the edge arc radius of the supporting baffle section, it is possible to effectively control the section with poor flow distribution, thereby reducing hydraulic losses. The support adopts three partitions arranged at an interval of 120°, which has little difference in performance during forward operation compared with other schemes. But during reverse operation, it reduces the impact and friction losses of water flow. And it fully utilizes the direct guide vane function of recovering vorticity, resulting in a significant increase in efficiency. At the same time, the accuracy of numerical simulation results is verified by model tests. The stability of positive and negative operating pressure pulsation supporting the inlet and outlet under the optimal scheme is analyzed.

Influence of gate cutoff effect on flow mode conversion and energy dissipation during power-off of prototype tubular pump system

Understanding the cutoff effect of gates is essential for enhancing the overall quality of the pump system's power-off process, minimizing energy losses, and reducing potential risks associated with hydraulic transients. In this study, both numerical simulations and experimental investigations were conducted on the power-off process of a tubular pump system, considering scenarios with and without gate functionality. The simulations utilized a dynamic mesh method to model gate movement, incorporated the torque balance equation to determine the real-time impeller speed, and applied the 3D-VOF method for free surface modeling in reservoirs. Power-off experiments were performed on a model pump system and a prototype pump system to validate the numerical simulation results. To elucidate the mechanism of the gate's cutoff effect, flow modes during the power-off process were categorized based on the four-quadrant static test results of the pump, revealing the deviations between transient and static characteristics. By comparing the transient flow structures of the pump system under different gate operating states, specific energy dissipation behaviors during gate cutoff were analyzed. The research findings enhance the understanding of hydraulic transients, which is essential for developing more sustainable and resilient energy systems.

Study on the Structural Characteristics of Bulb Tubular Pumps Based on Fluid–Structure Interaction

As a special type of through-flow device, bulb turbine pumps have been widely used in the Eastern Route of the South-to-North Water Diversion Project due to their compact structure, flexible installation process, easy maintenance, high efficiency, and strong adaptability. Therefore, structural improvements to enhance their safety and stability through fluid–structure interaction analysis have significant engineering value. This paper conducts static and transient fluid–structure interaction analyses of the bulb turbine pump structure. The results show that the rotor structure experiences the greatest deformation under low-flow conditions, with maximum deformation (2.13 mm) occurring at the leading edge of the impeller inlet and decreasing radially along a gradient distribution. The damping effect of water changes the mode shapes of the rotor structure, and although the vibration modes under wet conditions are similar to those in the air, the frequencies decrease to varying degrees. In transient analyses under different conditions, the total deformation of the rotor system is greater than in static analyses, showing significant regularity. Under low-flow conditions, the deformation of the pressure surface at the inlet and outlet of the blade tip is greater than that of the suction surface, with a maximum total deformation of 3.656 mm. The maximum total deformation under design flow is 3.337 mm; under high flow, it is 2.646 mm. The total deformation of the casing mainly occurs on both sides of the internal bulb body bottom support, with a maximum deformation of 2.0355 mm and an equivalent stress maximum of 44.848 MPa. The equivalent stress and total deformation distribution of the support structure are similar, located at the top support and trailing edge, with a maximum value of 22.94 MPa at the trailing edge. The research results provide technical references and theoretical foundations for the structural optimization of bulb turbine pumps.

Locomotion and strike damage of fish passing through a fish friendly tubular pump using computational fluid dynamics and discrete element coupling method

The tubular pump is a typical water transfer apparatus designed for extremely low heads and large flow rates. It serves as the core equipment in pumping stations situated at lakes, rivers, and canals. An adverse effect on the ecological environment stems from fish injury and mortality primarily caused by blade strikes. The present work combines computational fluid dynamics and the discrete element method to simulate the dynamics of fish passing through a simplified blade, allowing us to establish a safe margin of the strike force to further assess fish damage in a more complex tubular pump system. The results indicated that strikes on fish alter their motion state in terms of direction and magnitude, inducing chaotic movements that heighten the risk of subsequent strikes with downstream components. Fish tend to align their velocities with the surrounding fluid due to flow-induced drag after multiple contacts with solid structures. The knife-shaped leading edge, and particularly the blade tip side, emerged as the primary factor in creating strike damage, and the adoption of a slanted and blunt leading edge can effectively reduce fish damage. In addition, decreasing the shaft speed, increasing the flow rate, and restricting the fish size were identified as measures conducive to fish survival in running pumps. The study further suggested that using fewer but larger pumps operating at lower shaft speeds would contribute to better fish friendliness, which can also ensure a sufficient delivery head and mass flow rate.

Simulation analysis of runaway process of tubular pump and comparison of site test

Abstract To investigate the transient characteristics of tubular pumps during runaway, we developed a three-dimensional model of the pump and its flow channel. Using this model, we conducted a CFD simulation to analyse the three-dimensional transient process of the tubular pump’s runaway, and obtained the internal and external characteristic parameters of the pump. By comparing the results of the site test and the numerical simulation, we verified the correctness of the speed, flow, pressure pulsation, and eccentric zone during the runaway process of the numerical simulation. This verification provides technical support for the subsequent pump station operation.

Energy Characteristics in the Flow Channel of the Shaft-Type Tubular Pumping Station Considering Tides

The shaft-type tubular pumping station has the remarkable characteristics of a large flow rate and high efficiency. It can realize the functions of irrigation, pumping, and drainage through pumping and generating conditions considering tides. Moreover, it is widely used in the plain area of eastern China and the tidal area along the marine region. Due to the different topological features of the airfoil of the impeller, the energy evolution characteristics of the shaft-type tubular pumping station during pumping and generating conditions remain unclear. The entropy generation theory was introduced to numerically simulate the flow pattern and energy characteristics in the shaft-type channel, impeller, and straight channel in operation conditions. The results show that the flow pattern is stable when the shaft-type channel and the straight-type channel are used as the inlet channel under pumping and generating conditions, and a low-pressure region occurs in the contraction section of the shaft-type channel. The velocity of sections of the inlet and outlet and the middle section of the impeller in the generating condition is larger than that in the pumping condition. In addition, the difference in the static pressure on the blade surface nearby the hub is large. With a change in the position of the wingspan, the difference gradually decreases from the small flow condition to the large flow condition. There is a high-entropy production rate zone in the channel contraction section and the shaft-type wall surface of the shaft-type flow channel. When the straight-type channel is used as the outlet flow channel, a high-entropy production region appears near the inlet water surface. In the pumping condition, a high-entropy production area is found at the inlet of the impeller, the blade groove channel, and the inlet of the guide vane. In the generating condition, a high-entropy production area is found at the out-of-impeller outlet, the blade groove channel, and the outlet of the guide vane. These research achievements have some reference value for the design of the shaft-type tubular pumping station considering tides and the study of hydraulic performance, along with the energy characteristics of the channels.

Pressure Pulsation Characteristics on the Bulb Body of a Submersible Tubular Pump

Submersible tubular pumps are an ideal choice for pump stations that require high flow rates and low lift. These pumps combine the unique features of submersible motors with axial flow pump technology, making them highly efficient and cost-effective. They have found extensive applications in China’s rapidly developing water conservancy industry. In this research, we focus on investigating the pressure pulsation characteristics of the internal bulb body in a specific pump station project in China. To conduct our analysis, we utilize a model of the submersible tubular pump and strategically position 18 monitoring points. These monitoring points cover various sections, including the impeller inlet and outlet, guide vane outlet, as well as the inlet, middle, and outlet sections of the bulb body segment. To calculate the unsteady flow of the system, we employ numerical simulation techniques. By combining the outcomes of model tests, we determine the pressure pulsation characteristics. The comparison of results reveals a remarkable similarity between the efficiency–head curves obtained from the numerical simulation and the model test. While the model test yields slightly higher head results, the numerical simulation indicates slightly higher efficiency values. This finding lends strong support to the reliability of numerical simulation results, which can provide valuable insights for the design and optimization of submersible tubular pumps. Overall, submersible tubular pumps demonstrate their suitability for pump stations with high flow rates and low lift requirements. The study of pressure pulsation characteristics within the bulb body contributes to a better understanding of their performance and facilitates their further application in the field of water conservancy engineering.

Energy loss mechanism of a full tubular pump under reverse power generation conditions using entropy production theory

This paper investigates the energy dissipation mechanism of the internal flow field of the full tubular pump during reverse power generation and pump conditions, utilizing CFD and model test methods to research the device’s hydraulic characteristics, internal flow field and entropy production. The results indicate that the reverse power generation and pump conditions’ performance curves have opposite trends. Under PRPG conditions, the flow uniformity and weighted average angle of the impeller inlet flow field are smaller and the inlet flow field is poor. The stator-rotor gap flow under PRPG conditions increases with the increase in total flow, the gap flow under the design flow is 2.88 L/s, and the torque is 7.35 N·m. Under the PRPG condition, the turbulent and wall entropy production ratio increases gradually with the flow increase. Under the design flow rate, the entropy production rate of the impeller is 55.07%, and the entropy production rate of the impeller is the largest among the components under different flow rates. The entropy production of the outlet channel rises significantly with the flow rate. The research results of this paper provide a theoretical basis for the distribution of energy loss in reverse power generation of the full tubular pump.

On the scale effect of energy conversion in large-scale bulb tubular pump: Characteristics, mechanisms and applications

Bulb tubular pump is a special pump type with considerable application potential in low-head energy engineering. The energy performance of a large-scale bulb tubular pump can only be estimated based on its hydraulic model according to the conventional similarity law. However, engineering experience shows that this approach may cause significant errors, but the reason is still unclear due to the lack of understanding the scale effect of its energy conversion. In this paper, the characteristics, mechanisms and applications of the scale effect of energy conversion in large-scale bulb tubular pump are comprehensively studied. Progressive characteristics of energy conversion are quantified and a special scale effect is found. Hydraulic efficiency and head exhibit a feature of first increasing and then decreasing as the geometric scale increases, and the critical scale is 16. The competition between viscous effect and gravity effect is the origin of this special scale effect. When the bulb tubular pump exceeds a certain size, gravity-induced pressure polarization oscillation and partial flow separation are rapidly highlighted, destroying the hydraulic consistency and leading to a surge in energy loss and hydraulic instability. According to these findings, an improved similarity conversion mode is proposed for the bulb tubular pump, and the hydraulic efficiency drift with the geometric scale is determined by combining the dynamic weights of gravity effect and viscous effect. More importantly, this indicates the existence of a theoretical limit of pump size to balance the economy and safety, which should be paid attention to in energy engineering.

Comparative study on stator corner separation vortex characteristics in axial-flow pump and tubular pump: To understand the effects of guide-vane cone diffusion on horn-like vortices

The guide-vane cone diffusion is a typical structural difference between an axial-flow pump and a tubular pump, which is shown as low diffusivity and high diffusivity respectively, but it is still unclear how this structural difference affects the vortex characteristics in stator corner separation flows. In this paper, a comparative study of stator corner separation flows in an axial-flow pump and a tubular pump was conducted, and the effects of guide-vane cone diffusion on vortical structures were clarified. Firstly, for the apparent vortical features, compared with the guide-vane of axial-flow pump with low diffusivity, the horn-like vortex in the guide-vane of tubular pump with high diffusivity has the features of smaller scale, weaker swirling strength, shorter evolution cycle and lower pressure fluctuations. Secondly, for the vortex dynamics mechanism, the guide-vane cone diffusion of tubular pump can cause additional pressure energy recovery, which leads to higher adverse pressure gradients, so it is easier to induce additional shroud backflow near the suction surface. In this coupled flow field of main flow, namely hub corner separation flow and shroud backflow, the streamwise periodic oscillation of the pressure function gradient ωS ·▽(▽p/ρ) is found, and it induces the unique vortex-street-like distributions of the deformational vorticity ωS and the rigid vorticity ωR . This physical effect causes a mutual competition between the horn-like vortex near the hub corner and the opposite backflow vortex near the shroud side. It is this competition effect originating from the guide-vane cone diffusion that greatly suppresses the development of the horn-like vortex in a tubular pump.

Optimization of low-head shaft tubular pumping systems based on entropy production theory

In order to improve the operation efficiency of low-head tubular pump, this paper studies the influence of shaft type in the shaft tubular pump on the flow characteristics and energy characteristics of the pump. To optimize the shaft structure of shaft tubular pumping systems and realize the efficient use of energy, numerical simulation and model test was employed to study the optimization of the entire pumping system. In this paper, the CFD method was used to numerically simulate the whole pumping system, and the effect of changing the shaft length, shaft head profile, and shaft tail profile on the internal flow and entropy production characteristics of the inlet passage and impeller position were analyzed. It is found that the tapered tail profile can make the inlet passage overflow area change more smoothly and thus make the flow pattern more favorable. The wall entropy production dissipation at the inlet passage position dominates the total entropy production, and the high-value area of mainstream entropy production at this position is distributed periodically. The mainstream entropy production dissipation at the impeller section accounts for a relatively large proportion. After the entropy production dissipation analysis, it is believed that the tapered can reduce the entropy production dissipation of the pumping systems. The change of the shaft tail profile will make the entropy production dissipation change more noticeable compared with other optimization factors. Therefore, the tapered tail profile with better transition in the actual project is recommended.

Influence Analysis of Impeller-Guide Vane Matching on Energy and Pressure Pulsation in a Tubular Pump Device

Tubular pump devices offer advantages such as low hydraulic losses, a simple structure, and easy maintenance. They find extensive application in areas such as irrigation, flood control, and water diversion. The performance and security of the pump are directly impacted by the contact between the impeller and guide vane. The matching relationship between the number of impeller blades and guide vanes significantly influences this interaction in tubular pump devices. To explore this impact, a Very-Large-Eddy Simulation turbulence model was employed to simulate the 3D flow fields of six different number matching relationships in a shaft tubular pump device. The analysis focused on the energy performance of the different schemes, the flow distribution of the guide vanes, and the velocity circulation at the guide vanes’ outlet. Entropy theory and energy gradient theory were employed to understand how the number matching relationship influences energy performance. Additionally, pressure pulsations were analyzed at the impeller and guide vanes for different matching configurations. The results indicate that although increasing the number of impeller blades can lead to higher water circulation, increased energy, and potentially unstable water flow, an increase in impeller blades number results in improved flow distribution in each guide vane groove, leading to an overall enhancement in the efficiency of the pump device. Similarly, increasing the number of guide vanes may increase the non-uniformity of the guide vane flow rate, but it also enhances the ability of the guide vanes to regulate water circulation and recover energy, thereby benefiting the overall efficiency.

Research on identification of the hydraulic and structural vibration sources in a tubular pumping station

The hydraulic and structural vibration sources of pumping station are investigated in current research. Based on a vertical shaft tubular pumping station project in an eastern province of China, a three-dimensional fluid-solid coupling model of the pumping station is established, including the fluid in the flow channel, concrete structure, and hydraulic machinery. Two-way fluid-structure interaction (FSI) method is used to calculate the coupled vibration responses of the pumping station. Based on the FSI simulation results, the hydraulic and structural vibration sources of the pumping station are explored from the frequency perspective based on the Fourier transform theory and the vibration energy transmission perspective based on the time-delayed transfer entropy method. Research results show that the fluid pulsation generated by the rotation of the impeller is the main hydraulic vibration source, and the rotating impeller is the main structural vibration source that causes the vibration of the unit and the concrete structure. This research could provide a scientific basis for structural vibration control, vibration reduction, and isolation design of the pumping station.

Research on Optimization of the Bulb Form of the Bulb Tubular Pump Device for a Low-Head Agricultural Irrigation Pumping Station

A bulb tubular pump unit is a horizontal tubular pump unit composed of a water pump and bulb with an electric motor installed. Electric motors, transmission equipment, and bearings are usually placed in the bulb. The bulb is located in the flow channel and has a relatively narrow space. Therefore, the shape of the bulb has a significant influence on the flow pattern and pump efficiency in the flow channel. In this study, the CFX 19.2 software was employed to optimize the bulb hydraulically according to its geometry and parameters. The research results indicate that the flow pattern at the tail of the elliptical bulb was better, the hydraulic loss at the bulb section was small, and the device efficiency was higher than that at the tail, which was round. The streamlined support had small flow resistance, minimal hydraulic loss, and a high pump unit head and efficiency. Nine schemes were selected, and the geometrical characteristics and parameters of the bulb were determined as follows: the shape of the tail of the bulb was oval, the bulb ratio was 0.96, and the shape of the support parts was streamlined. The results hold important reference significance to improve efficiency and broaden the operating conditions of bulb tubular pump devices.

Study on the Energy Loss Characteristics of Shaft Tubular Pump Device under Stall Conditions Based on the Entropy Production Method

This study aimed to reveal the energy loss characteristics of each part of the shaft tubular pump device (STPD) under stall conditions. Numerical simulations were conducted by using the SST k-ω turbulence model with curvature correction, and the reliability of the simulation results was verified by a model test. The entropy production method was used to evaluate and visualize the energy loss. The results show that turbulent entropy production (TEP) is the main source of energy loss in each component of the STPD, and the TEP increases significantly with the deterioration of stall. The energy loss in the impeller is mainly concentrated near the shroud and hub, while in the guide vanes it is mainly concentrated near the shroud and suction surface of the blades. In addition, with the deterioration of stall, the energy loss in the inlet of the impeller and guide vanes increases significantly. Influenced by the backflow from the impeller, there is a significant amount of energy loss at the outlet segment of the inlet passage, and the location of the high-energy-loss region is consistent with the backflow region. Affected by the flow separation vortex at the tail of the guide vanes, the energy loss in the outlet passage is mainly concentrated at the inlet segment.