抽芯式斜流泵装置水力与振动特性研究
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摘要
斜流泵是叶片角度全调节的混流泵,其对运行工况的适应性和宽广的高效性,使其得到越来越广泛的应用。进入21世纪以来,在国内大型泵站中,引进了抽芯式斜流泵这种具有优良水力设计的大型混流泵,其最大优点是转子为全抽芯,安装检修十分方便。进水方式采用喇叭口吸水,相应的泵房形式为“湿室型”泵房,可以减小工程投资,但与传统的大型水泵进口采用肘形、钟形或簸箕形进水流道相比,泵吸入口直接从进水池取水,没有条件通过进水流道作流态的进一步调整,同时泵体与水工建筑物之间难以形成固定的结构支撑,因此,泵内流动稳定性很难得到保证,尤其是运行中会产生较强烈的机组振动而导致供水安全隐患。本文针对实际工程中出现的机组异常振动现象,采用数值模拟方法和现场测试手段,对水泵机组振动的原因做了较为全面的分析。
在水力学计算中,使用几种常用的k-ε模型对泵站进水流道进行数值仿真,通过与模型试验数据的对比,得出Realizablek-ω模型最适用于泵站进水池流态的模拟；对不同开机组合条件下泵站进水流态进行的数值仿真,验证了该泵站现有整流装置的有效性,讨论了不同开机组合对进水流态及对水泵机组振动的影响。
分别使用标准k-ε、RNG k-ε、Realizable k-ε及SST k-ω等4种常用湍流模型对斜流泵内部流场进行定常数值模拟,使用RNG k-ε模型和大涡模拟方法进行非定常数值模拟,并将计算得到的结果与水泵实测性能曲线进行对比。分析了不同湍流模型及计算方法对斜流泵内部流场模拟的适用性,结果表明,使用RNG k-ε模型对斜流泵内部流场进行非定常计算所得到的结果精度最高。以此为基础,对斜流泵内部流动特性进行了分析。
分析了不同流量下斜流泵内压力脉动的特性。结果表明,斜流泵内最大压力脉动发生在叶轮出口处,且该处压力脉动幅值沿径向向外侧逐渐增大,指出对叶轮出口位置和叶轮轮缘处的结构设计进行优化是减轻斜流泵内压力脉动强度的有效方法；偏工况运行会导致斜流泵内压力脉动的加剧,且偏离设计工况越远,脉动幅值越大,在偏离设计工况的条件下,斜流泵特别要避免在小流量区内运行；斜流泵内压力脉动的主要频率与其转轮的通过频率相等,故设计时应对斜流泵的转轮等这些主要部件进行模态分析,以避免出现共振产生的条件。通过对转轮的模态进行分析,结果表明水力性能优良的斜流泵内压力脉动不会引发其转轮发生共振或低倍谐共振。
斜流泵机组的振动测试。结果表明,机组振动随其叶片角度的增大而增强,随开机台数的增多而降低,机组对称运行可减弱其振动；机组开机时的冲击力使水泵主轴出现的偏移,导致了机组的异常振动,建议尽量减少机组的启停次数,并采用软启动技术减小机组启动时的冲击力,进而减轻机组运行时的振动。
The all-adjusted mixed-flow pump is more widely used in engineering, which is due to its wide operating-mode adaptability and high efficiency. In the21st century, the core-pulling diagonal-flow pump has been applied to some large domestic pump stations. The greatest advantage of this kind of pump is that it has a fully out-core rotor with excellent hydraulic design facilitate installation and maintenance procedure. The investment is small because of the bell mouth suction and the wet-pit pump house. However, compared with large pump, which have elbow, bell or dustpan-inlet conduits, this kind of pump suction directly pump water from pump sump so that it can not make further adjustment in flow pattern, meanwhile; there is no stable structure support between the pump and hydraulic buildings. Therefore, the flow stability in pump is difficult to be guaranteed, especially that severe-vibration in operation, which induces safety risk in water supply. In this thesis, numerical simulation and field tests are used to overall analyze abnormal vibration of pumps.
In hydraulic calculation, several commonly used k-ε models are used to simulate the inlet flow patterns. Through comparison of simulation data and model experimental data, it is found that Realizable model is more suitable for inlet flow patterns simulation. The effectiveness of rectifying device of the pumping station is validated by the simulation results of inlet flow patterns for different start-up mode of pumping station. The influence of start-up mode on inlet flow pattern and vibration of pump are discussed.
Standard k-ε, RNG k-ε, Realizable k-ε and SST k-ω for the steady numerical simulation are used to simulate the internal flow of the diagonal-flow pump, then RNG k-ε model and large eddy simulation method for the unsteady numerical simulation are used. The simulation results are compared with the measured performance curve of the pump. The applicability of different turbulence models and methods of Numerical calculation is analyzed, the accuracy of the obtained results show that RNG k-ε model is more suitable for this issue, and its internal flow characteristics are analyzed based on that.
The characteristics of pressure pulsation of the diagonal-flow pump are analyzed for different flow volume. The results show that the maximum pressure pulsation occurs at impeller outlet, and the value increases along radial direction. The results show that the structural design optimization of the impeller outlet and rim is an effective method to reduce pressure pulsation strength; the diagonal-flow pump operated on off-design condition leads to internal pressure pulsation intensifies, and the strength of pressure pulsation increases with the increase of deviation. Therefore the diagonal-flow pump should be avoided operating in low flow rate; the frequency of pressure pulsation is equal to the impeller passage frequency, so modal analysis of the main parts, like the impeller wheel, must be conducted to avoid resonance or low power harmonic resonance. The results of modal analysis show that the internal pressure pulsation would not induce the impeller resonance or low power harmonic resonance.
The results of diagonal-flow pump vibration tests show that the vibration amplitude of pumps enhance with the increase of its blade angle, and decrease with the increase of the operation units, and the symmetrical layout of operation pumps can reduce the vibration amplitude. The impact force which is due to the start of pump makes the spindle deviate, and leads to the abnormal vibration of pumps. In order to reduce the vibration of pumps, the frequency of starting and stopping should be reduced as far as possible, and the soft start technology should be used to decrease the impact force.
在水力学计算中,使用几种常用的k-ε模型对泵站进水流道进行数值仿真,通过与模型试验数据的对比,得出Realizablek-ω模型最适用于泵站进水池流态的模拟；对不同开机组合条件下泵站进水流态进行的数值仿真,验证了该泵站现有整流装置的有效性,讨论了不同开机组合对进水流态及对水泵机组振动的影响。
分别使用标准k-ε、RNG k-ε、Realizable k-ε及SST k-ω等4种常用湍流模型对斜流泵内部流场进行定常数值模拟,使用RNG k-ε模型和大涡模拟方法进行非定常数值模拟,并将计算得到的结果与水泵实测性能曲线进行对比。分析了不同湍流模型及计算方法对斜流泵内部流场模拟的适用性,结果表明,使用RNG k-ε模型对斜流泵内部流场进行非定常计算所得到的结果精度最高。以此为基础,对斜流泵内部流动特性进行了分析。
分析了不同流量下斜流泵内压力脉动的特性。结果表明,斜流泵内最大压力脉动发生在叶轮出口处,且该处压力脉动幅值沿径向向外侧逐渐增大,指出对叶轮出口位置和叶轮轮缘处的结构设计进行优化是减轻斜流泵内压力脉动强度的有效方法；偏工况运行会导致斜流泵内压力脉动的加剧,且偏离设计工况越远,脉动幅值越大,在偏离设计工况的条件下,斜流泵特别要避免在小流量区内运行；斜流泵内压力脉动的主要频率与其转轮的通过频率相等,故设计时应对斜流泵的转轮等这些主要部件进行模态分析,以避免出现共振产生的条件。通过对转轮的模态进行分析,结果表明水力性能优良的斜流泵内压力脉动不会引发其转轮发生共振或低倍谐共振。
斜流泵机组的振动测试。结果表明,机组振动随其叶片角度的增大而增强,随开机台数的增多而降低,机组对称运行可减弱其振动；机组开机时的冲击力使水泵主轴出现的偏移,导致了机组的异常振动,建议尽量减少机组的启停次数,并采用软启动技术减小机组启动时的冲击力,进而减轻机组运行时的振动。
The all-adjusted mixed-flow pump is more widely used in engineering, which is due to its wide operating-mode adaptability and high efficiency. In the21st century, the core-pulling diagonal-flow pump has been applied to some large domestic pump stations. The greatest advantage of this kind of pump is that it has a fully out-core rotor with excellent hydraulic design facilitate installation and maintenance procedure. The investment is small because of the bell mouth suction and the wet-pit pump house. However, compared with large pump, which have elbow, bell or dustpan-inlet conduits, this kind of pump suction directly pump water from pump sump so that it can not make further adjustment in flow pattern, meanwhile; there is no stable structure support between the pump and hydraulic buildings. Therefore, the flow stability in pump is difficult to be guaranteed, especially that severe-vibration in operation, which induces safety risk in water supply. In this thesis, numerical simulation and field tests are used to overall analyze abnormal vibration of pumps.
In hydraulic calculation, several commonly used k-ε models are used to simulate the inlet flow patterns. Through comparison of simulation data and model experimental data, it is found that Realizable model is more suitable for inlet flow patterns simulation. The effectiveness of rectifying device of the pumping station is validated by the simulation results of inlet flow patterns for different start-up mode of pumping station. The influence of start-up mode on inlet flow pattern and vibration of pump are discussed.
Standard k-ε, RNG k-ε, Realizable k-ε and SST k-ω for the steady numerical simulation are used to simulate the internal flow of the diagonal-flow pump, then RNG k-ε model and large eddy simulation method for the unsteady numerical simulation are used. The simulation results are compared with the measured performance curve of the pump. The applicability of different turbulence models and methods of Numerical calculation is analyzed, the accuracy of the obtained results show that RNG k-ε model is more suitable for this issue, and its internal flow characteristics are analyzed based on that.
The characteristics of pressure pulsation of the diagonal-flow pump are analyzed for different flow volume. The results show that the maximum pressure pulsation occurs at impeller outlet, and the value increases along radial direction. The results show that the structural design optimization of the impeller outlet and rim is an effective method to reduce pressure pulsation strength; the diagonal-flow pump operated on off-design condition leads to internal pressure pulsation intensifies, and the strength of pressure pulsation increases with the increase of deviation. Therefore the diagonal-flow pump should be avoided operating in low flow rate; the frequency of pressure pulsation is equal to the impeller passage frequency, so modal analysis of the main parts, like the impeller wheel, must be conducted to avoid resonance or low power harmonic resonance. The results of modal analysis show that the internal pressure pulsation would not induce the impeller resonance or low power harmonic resonance.
The results of diagonal-flow pump vibration tests show that the vibration amplitude of pumps enhance with the increase of its blade angle, and decrease with the increase of the operation units, and the symmetrical layout of operation pumps can reduce the vibration amplitude. The impact force which is due to the start of pump makes the spindle deviate, and leads to the abnormal vibration of pumps. In order to reduce the vibration of pumps, the frequency of starting and stopping should be reduced as far as possible, and the soft start technology should be used to decrease the impact force.
引文
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