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Hydraulic components’ matching optimization design and entropy production analysis in a large vertical centrifugal pump

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Abstract

The large vertical centrifugal pump is the core power equipment for long-distance water division and large-scale irrigation projects. The power of the matching motor can reach 40 MW. In view of reducing the operating energy consumption of this kind of pump, the efficiency under the design condition was taken as the optimization objective, and a matching optimization on hydraulic components was proposed in this research. The optimization process was divided into two stages. The first stage focused on improving the configuration of the vane diffuser. In the second stage, the Plackett-Burman test design was used to screen out the optimization design variables of the vane diffuser and the volute, the optimal Latin hypercube sampling method was adopted to generate 106 sample cases, and an automatic numerical simulation optimization platform was built. Then, different approximate models were employed to construct the relationship between the optimization design variables and the objective function, and their fitting accuracy and robustness were compared. Finally, the optimal design parameters were determined by particle swarm optimization, and entropy production theory was used to analyze the internal flow pattern of the model before and after optimization. Results showed that D3, b4, β3, and S8 have the greatest impact on the hydraulic efficiency of the pump. The multilayer backpropagation neural network has a higher fitting accuracy and better robustness compared with the other three approximate models. The efficiency of the optimized model under the design condition is increased by 4.22 %, reaching 90.82 %. Reducing the number of layers and vanes of the diffuser and improving the matching of hydraulic components can dramatically improve the hydraulic performance and hump characteristics of large vertical centrifugal pumps. Entropy production theory is a reliable approach to visualizing flow loss. The turbulent flow dissipation in the vane diffuser can be reduced the most after optimization.

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Abbreviations

Sr :

Strouhal number

Eu :

Euler number

n s :

Specific speed

n :

Rotating speed, r/min

Q :

Flow rate, m3/h

H :

Pump head, m

C H :

Head coefficient

C Q :

Flow rate coefficient

D 2 :

Impeller outlet diameter

g :

Gravity factor, m/s2

b 2 :

Impeller outlet width, mm

η :

Hydraulic efficiency

Τ :

Impeller torque, N

ω :

Impeller rotation angular velocity

ρ :

Fluid density, kg/m3

P tout :

Total pressure at outlet of the pump, Pa

P tin :

Total pressure at inlet of the pump, Pa

h :

Energy head value, m

P out :

Total pressure at outlet of the components, Pa

P in :

Total pressure at inlet of the components, Pa

x :

Optimization design variables

F 1 :

Optimization objective function

S 8 :

Volute throat area, mm2

v 3 :

Average velocity of volute section, m/s

k 3 :

Speed factor

φ 0 :

The angle between the section and the 0 section, °

S φ :

The φ section area of the volute, mm2

R 2 :

Decisive factor

ε :

Turbulence dissipation rate

T :

Temperature

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Acknowledgments

This work was financially supported by the National Natural Science Foundation of China (Grant No. 51979125), Primary Research and Development Plan of Jiangsu Province (Grant No. BE2019089), and Graduate Research and Innovation Projects of Jiangsu Province (Grant No. SJCX21_1682). The research was assisted by the Hang Zhou Jiang He Hydro-Electric Science and Technology Co., Ltd.

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Authors and Affiliations

  1. National Research Center of Pumps, Jiangsu University, Zhenjiang, Jiangsu, China

    Gang Yang, Xutao Zhao, Desheng Zhang, Linlin Geng, Xueqi Yang & Xiongfa Gao

Authors
  1. Gang Yang
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  2. Xutao Zhao
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  3. Desheng Zhang
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  4. Linlin Geng
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  5. Xueqi Yang
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  6. Xiongfa Gao
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Corresponding author

Correspondence to Desheng Zhang.

Additional information

Gang Yang is currently a Master candidate in National Research Center of Pumps, Jiangsu University. His research interests include optimization design, computational flow dynamics, and hydraulic stability of large centrifugal pumps.

Xutao Zhao is currently a Ph.D. candidate in National Research Center of Pumps, Jiangsu University. He received his M.A. degree from Lanzhou University of Technology in 2020. His research interests include the optimization design of centrifugal pumps and the internal flow investigation of axial waterjet pumps.

Desheng Zhang is currently a Professor in the National Research Center of Pumps, Jiangsu University. He received his Ph.D. from Jiangsu University in 2010. His research interests include unsteady cavitating turbulent flows in hydrofoils and pumps and the theory and optimized design of fluid machinery.

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Yang, G., Zhao, X., Zhang, D. et al. Hydraulic components’ matching optimization design and entropy production analysis in a large vertical centrifugal pump. J Mech Sci Technol 35, 5033–5048 (2021). https://doi.org/10.1007/s12206-021-1021-2

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  • DOI: https://doi.org/10.1007/s12206-021-1021-2

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