低扬程立式泵装置优化水力设计研究
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摘要
我国水资源的时、空分布很不均衡。南水北调东线工程是解决北方地区水资源严重短缺的一项跨流域、跨省市的大型调水工程,其主体工程是泵站,泵装置是泵站的核心。随着我国城市化进程的加速,区域性经济的发展,围绕着城市水环境改善已建设或规划即将建设一批大型泵站。这些泵站的共同特点是扬程较低。
立式轴流泵装置作为一种成熟的泵型已在数百座大型泵站中得到了广泛应用。与其它泵装置型式相比,立式轴流泵装置具有运行稳定、可靠性高、安装检修方便和投资省、维护费用少等优点,并且在设计、制造及运行、管理等方面已积累了丰富的经验。低扬程泵装置中的进、出水流道水力损失在其扬程中占有较大比重,扬程愈低,这种比重愈大；同时,由于立式泵装置中的水流方向要经过两次90°转向过程,低扬程泵站上、下游的水位差较小,使得进出水流道在立面方向的尺寸布置显得比较局促,导致流道水力损失比较大。这两个因素共同起作用,导致提高低扬程立式泵装置效率的困难较大。
泵装置效率决定于水泵效率与流道效率,为提高低扬程立式泵装置的水力性能,本文围绕进、出水流道的优化水力设计及水泵选型所做的工作及主要结论包括：
(1)为了定量研究大型泵装置导叶出口水流速度环量对出水流道水力性能的影响,提出了泵装置导叶出口断面水流的速度环量定量表示方法和平均角速度的实验测量方法,分别运用数值计算和模型试验的方法研究了导叶出口水流的剩余环量对虹吸式出水流道和直管式出水流道水力损失的影响。结果表明：导叶出口水流的环量对出水流道水力损失的影响较为明显,虹吸式出水流道和直管式出水流道最优环量时的水力损失计算值较零环量时的水力损失计算值分别小0.126m和0.180m；存在使得出水流道水力损失最小的最优环量,虹吸式和直管式出水流道的最优环量分别为0.97m2/s和1.31m2/s。
(2)设计制作了不同片数的环量匀化器以改变导叶出口环量的匀化程度,运用模型试验的方法定量研究了不同轴流泵导叶出口环量匀化程度时的出水流道水力损失。结果表明：随着匀化器叶片片数的增加,流道水力损失的变动范围愈来愈小,说明匀化器的片数对导叶出口水流环量的分布有影响,同时也说明环量的分布对出水流道水力损失也有影响,但影响都较小；虹吸式出水流道、低驼峰式出水流道在匀化器叶片数12片时的水力损失与自然状态(叶片数为0片)时相差较小,分别为3.85%、3.73%,说明正常状态下的导叶出口水流的环量己接近于均匀分布。根据这一研究结果,在对出水流道正问题进行分析研究时,其进口的边界条件可预置一定用平均角速度表示的平均环量,平均角速度的大小可通过相关的模型试验测出。
(3)讨论了降低nD值的低扬程泵装置水泵选型设计思路；从理论上推导了降低nD值与增径降速的一致关系;从低扬程泵装置的水泵选型、能量性能及汽蚀性能等3个方面讨论了降低nD值对大型低扬程泵装置水力性能的影响；同时还讨论了泵装置汽蚀性能的考核指标和增径降速对流道控制尺寸及设备投资的影响等问题。结果表明：在设计流量一定的条件下,适当降低nD值可在较低扬程下选用到更为优秀的轴流泵水力模型、同时可提高低扬程泵装置的能量性能、改善泵装置的汽蚀性能;增径降速对流道控制尺寸及机组中心距影响不大,对设备投资的影响需进一步综合比较分析。
(4)采用三维湍流数值计算方法分别研究了中隔墩对肘形进水流道、虹吸式出水流道和直管式出水流道水力性能的影响,并采用流道模型试验的方法对数值计算结果进行了验证。结果表明：模型试验中所观察到的进、出水流道内的流态与数值计算的结果基本相同；中隔墩对肘形进水流道内的水流流态基本无影响,设置中隔墩会使设计流量时的肘形进水流道水力损失数值计算结果增加0.005m；当进水流道进口水流偏斜时,中隔墩对改善水泵入流条件是有利的；由于水泵导叶出口水流具有环量,出水流道内的流态存在偏流现象,出水流道的水力性能受中隔墩的影响较为明显；设置中隔墩会使设计流量时的虹吸式和直管式两种出水流道水力损失数值计算结果分别增加0.024m和0.033m；设计流量时,肘形进水流道、虹吸出水流道和直管出水流道水力损失的模型试验结果分别增加了0.006m、0.023m和0.023m。因此,中隔墩无益于进出水流道的水力性能,在结构允许的条件下大型泵站的进出水流道可取消中隔墩。
(5)长沟站和邓楼站的平均扬程和设计扬程都低于4m,这两座泵站均采用了立式轴流泵装置。为了在低扬程条件下实现较好的水力性能,采用三维湍流数值计算方法分别对长沟站和邓楼站的进、出水流道进行了优化水力设计,用模型试验的方法对优化结果进行了验证：在水泵模型同台测试试验数据和流道优化水力设计基础上对泵装置效率进行了预测,即：泵装置效率由泵段效率和流道效率的乘积得到,其中,泵装置中的泵段效率由同台测试结果修正后得到,流道效率由流道水力损失及泵装置扬程计算得到。进行了泵装置模型试验。研究结果表明：经过优化水力设计的长沟站和邓楼站立式泵装置在4m以下的低扬程条件下得到了优异的水力性能,设计扬程和平均扬程工况点的泵装置效率均达到78%、临界空化余量均小于6m;立式轴流泵装置在低扬程泵站同样具有广阔的应用前景。
The water resources in our country are distributed very unevenly in both time and space. The East Route Project of South to North Water Diversion Project is an inter-basin and across province large water diversion project to resolve the serious shortage of water resources of the north areas in China, the main project of which is pumping station, and the pump system is the core of the pumping station. With the accelerating of China's urbanization, developing of regional economic, a number of large pumping stations will be or plan to be built to improve the water enviorment of the city. The common feature of these pumping stations is lower head.
Vertical axial-flow pump system, as a mature type, has been applied widely by hundreds of large pumping stations. Compared with other types of pump system, it has many advantages, such as running stably, high dependability, installing and maintaining easily, low capital investment, less maintenance charge, etc. Furthermore, a wealth of experience has been accumulated in designing, manufacturing, running, managing, etc. The hydraulic losses of the inlet and outlet conduits for a low head pump system account for a larger proportion in its head, the lower the head, the larger the proportion. At the same time, the flow in a vertical pump need to turn90degrees twice, while the water-head between the upper and lower reaches for a low head pumping station is smaller. This leads to the arrangement of inlet and outlet conduits in elevation of the direction more haste, which leads to a bigger conduit hydraulic loss. So, it is difficult to improve the pumping system efficiency for a low head vertical pumping station when the two factors act together.
The pump system efficiency depends on pump efficiency and conduit efficiency. To increase the hydraulic performance of low head vertical pump system, focus on the optimal hydraulic design of inlet and outlet conduit and pump type selection, the main works and main conclusions including:
(1) In order to study influence of the velocity circulation at the guide vane outlet on the hydraulic performance of outlet conduit for a large pump system quantitatively, it was put forward that the method to calculate velocity circulation and the method to measure the average angular velocity for the flow at the guide vane outlet of the pump system. The methods of both numerical simulation and model test were applied to research the circulation influence of circulation on the hydraulic losses for both siphon and straight outlet conduits. The results indicate that the hydraulic losses of the outlet conduits were obviously influenced by the circulation at the guide vane outlet, the hydraulic losses of the siphon and straight conduit under the condition of the optimal circulation were0.126m and0.180m lower than those under the condition of zero circulation, respectively; there is optimal circulation for the hydraulic loss of the outlet conduit to be minimized, the optimal circulations for siphon and straight outlet conduit are0.97m2/s and1.31m2/s respectively. The research results above could be helpful to optimal hydraulic design both for outlet conduit and guide vane of a axial-flow pump.
(2) The uniformity devices with different vane numbers are designed to change the uniformity degree of velocity circulation at the guide vane, the model test method is applied to study the influence of the distributing of velocity circulation at the guide vane outlet on the hydraulic loss of outlet conduit for axial-flow pump quantitatively. The results indicate that with the vane number increasing, the changing range of hydraulic loss for outlet conduit becomes smaller and smaller. This account for that the vane number has effect on the distributing of flow velocity circulation and the distributing of flow velocity circulation has effect on the outlet conduit hydraulic loss, the influence degree are both small. The hydraulic loss discrepancy between uniformity device with12vanes and natural state (uniformity device with0vanes) for siphon and low-hump outlet conduits are3.85%and3.73%respectively. This account for that the flow velocity circulation obtained under normal state is close to even distribution. According to the research result, it is feasible to preset an average circulation at the inlet of outlet conduit when numerically simulating the outlet conduit, and the average circulation could be expressed by an average angular velocity. The angular speed could be measured by relevant model test.
(3) In order to improve the hydraulic performance of a low head pump system, the design thinking of reducing nD value for the pump system was discussed. The consistency between reducing nD value and increasing impeller diameter while reducing pump speed was derived. The influence of reducing nD value on pump type selection, energy performance and cavitation performance for the pump system was discussed. Meanwhile, examination index for.the cavitation performance of the pump system and the influence of increasing impeller diameter while reducing pump speed on conduit control size and equipment investment was also discussed. The research results indicate that under the condition of a certain design discharge to decrease nD value suitably is beneficial for pump type selection and improvement of both energy and cavitation performance for the pump system. Therefore it is more suitable for a large low head pumping station with long running operation time to adopt a lower nD value.
(4) The method of3D turbulent numerical calculation is applied to study the influence of the middle division pier on hydraulic performance for elbow inlet conduit, siphon outlet conduit and straight outlet conduit respectively, and the calculation results were verified by conduit model experiments. The research results indicate that the flow patterns in both inlet and outlet conduits observed by the model test are consistent with those by the numerical simulation method; the middle division pier almost has no influence on the flow patterns for the elbow inlet conduit, and the hydraulic losses obtained by numerical calculation will be increased by0.005m under the condition of design discharge; the middle pier is helpful to improve the flow patterns at the outlet of inlet conduit when the flow direction is defluxion at the inlet; due to the flow circulation at the outlet of the pump guide vane, the flow patterns in the outlet conduit are obviously asymmetrical and easily affected by the middle division pier, as a result, the hydraulic losses obtained by numerical calculation will be increased by0.024m and0.033m respectively under the condition of design discharge. The model test results are0.006m,0.023m and0.023m for elbow inlet conduit, siphon outlet conduit and straight outlet conduit respectively, under the condition of design discharge. Therefore, the middle division pier is not conducive to the hydraulic performance of the inlet and outlet conduits. The middle division pier for a large pumping station with low head could be cancelled if its structural design condition may be satisfied.
(5) The design head and average head of Changgou and Denglou pumping stations are both lower than4m, the vertical pump system has been adopted by the two pumping stations. To obtain better hydraulic performance under the condition of low head, numerical simulation method is applied to optimal hydraulic design the inlet and outlet conduits for the two pumping stations. The conduit model test method was applied to verify the optimal result. The pump system efficiency was forecasted based on the test data for pump models on the same test bed and research results of the optimum hydraulic design for conduits. The pump system efficiency may be obtained by multiplying pump segment efficiency with conduit efficiency, where the pump segment efficiency in the pump system may be modified according to the results obtained through the pump model tests on the same test bed, and the conduit efficiency may be calculated according to the conduit hydraulic loss and pump system head. The model test of pump system was carried out. The research results indicate that the excellent hydraulic performance are obtained for the vertical pump systems of Changgou and Denglou pumping station under the condition of low head of less than4m. The efficiencies of the two pump systems reach78%and the NPSHc are lower than6m at both design head and average head working points. The vertical pump system also has a wide application prospect in low head pumping stations.
立式轴流泵装置作为一种成熟的泵型已在数百座大型泵站中得到了广泛应用。与其它泵装置型式相比,立式轴流泵装置具有运行稳定、可靠性高、安装检修方便和投资省、维护费用少等优点,并且在设计、制造及运行、管理等方面已积累了丰富的经验。低扬程泵装置中的进、出水流道水力损失在其扬程中占有较大比重,扬程愈低,这种比重愈大；同时,由于立式泵装置中的水流方向要经过两次90°转向过程,低扬程泵站上、下游的水位差较小,使得进出水流道在立面方向的尺寸布置显得比较局促,导致流道水力损失比较大。这两个因素共同起作用,导致提高低扬程立式泵装置效率的困难较大。
泵装置效率决定于水泵效率与流道效率,为提高低扬程立式泵装置的水力性能,本文围绕进、出水流道的优化水力设计及水泵选型所做的工作及主要结论包括：
(1)为了定量研究大型泵装置导叶出口水流速度环量对出水流道水力性能的影响,提出了泵装置导叶出口断面水流的速度环量定量表示方法和平均角速度的实验测量方法,分别运用数值计算和模型试验的方法研究了导叶出口水流的剩余环量对虹吸式出水流道和直管式出水流道水力损失的影响。结果表明：导叶出口水流的环量对出水流道水力损失的影响较为明显,虹吸式出水流道和直管式出水流道最优环量时的水力损失计算值较零环量时的水力损失计算值分别小0.126m和0.180m；存在使得出水流道水力损失最小的最优环量,虹吸式和直管式出水流道的最优环量分别为0.97m2/s和1.31m2/s。
(2)设计制作了不同片数的环量匀化器以改变导叶出口环量的匀化程度,运用模型试验的方法定量研究了不同轴流泵导叶出口环量匀化程度时的出水流道水力损失。结果表明：随着匀化器叶片片数的增加,流道水力损失的变动范围愈来愈小,说明匀化器的片数对导叶出口水流环量的分布有影响,同时也说明环量的分布对出水流道水力损失也有影响,但影响都较小；虹吸式出水流道、低驼峰式出水流道在匀化器叶片数12片时的水力损失与自然状态(叶片数为0片)时相差较小,分别为3.85%、3.73%,说明正常状态下的导叶出口水流的环量己接近于均匀分布。根据这一研究结果,在对出水流道正问题进行分析研究时,其进口的边界条件可预置一定用平均角速度表示的平均环量,平均角速度的大小可通过相关的模型试验测出。
(3)讨论了降低nD值的低扬程泵装置水泵选型设计思路；从理论上推导了降低nD值与增径降速的一致关系;从低扬程泵装置的水泵选型、能量性能及汽蚀性能等3个方面讨论了降低nD值对大型低扬程泵装置水力性能的影响；同时还讨论了泵装置汽蚀性能的考核指标和增径降速对流道控制尺寸及设备投资的影响等问题。结果表明：在设计流量一定的条件下,适当降低nD值可在较低扬程下选用到更为优秀的轴流泵水力模型、同时可提高低扬程泵装置的能量性能、改善泵装置的汽蚀性能;增径降速对流道控制尺寸及机组中心距影响不大,对设备投资的影响需进一步综合比较分析。
(4)采用三维湍流数值计算方法分别研究了中隔墩对肘形进水流道、虹吸式出水流道和直管式出水流道水力性能的影响,并采用流道模型试验的方法对数值计算结果进行了验证。结果表明：模型试验中所观察到的进、出水流道内的流态与数值计算的结果基本相同；中隔墩对肘形进水流道内的水流流态基本无影响,设置中隔墩会使设计流量时的肘形进水流道水力损失数值计算结果增加0.005m；当进水流道进口水流偏斜时,中隔墩对改善水泵入流条件是有利的；由于水泵导叶出口水流具有环量,出水流道内的流态存在偏流现象,出水流道的水力性能受中隔墩的影响较为明显；设置中隔墩会使设计流量时的虹吸式和直管式两种出水流道水力损失数值计算结果分别增加0.024m和0.033m；设计流量时,肘形进水流道、虹吸出水流道和直管出水流道水力损失的模型试验结果分别增加了0.006m、0.023m和0.023m。因此,中隔墩无益于进出水流道的水力性能,在结构允许的条件下大型泵站的进出水流道可取消中隔墩。
(5)长沟站和邓楼站的平均扬程和设计扬程都低于4m,这两座泵站均采用了立式轴流泵装置。为了在低扬程条件下实现较好的水力性能,采用三维湍流数值计算方法分别对长沟站和邓楼站的进、出水流道进行了优化水力设计,用模型试验的方法对优化结果进行了验证：在水泵模型同台测试试验数据和流道优化水力设计基础上对泵装置效率进行了预测,即：泵装置效率由泵段效率和流道效率的乘积得到,其中,泵装置中的泵段效率由同台测试结果修正后得到,流道效率由流道水力损失及泵装置扬程计算得到。进行了泵装置模型试验。研究结果表明：经过优化水力设计的长沟站和邓楼站立式泵装置在4m以下的低扬程条件下得到了优异的水力性能,设计扬程和平均扬程工况点的泵装置效率均达到78%、临界空化余量均小于6m;立式轴流泵装置在低扬程泵站同样具有广阔的应用前景。
The water resources in our country are distributed very unevenly in both time and space. The East Route Project of South to North Water Diversion Project is an inter-basin and across province large water diversion project to resolve the serious shortage of water resources of the north areas in China, the main project of which is pumping station, and the pump system is the core of the pumping station. With the accelerating of China's urbanization, developing of regional economic, a number of large pumping stations will be or plan to be built to improve the water enviorment of the city. The common feature of these pumping stations is lower head.
Vertical axial-flow pump system, as a mature type, has been applied widely by hundreds of large pumping stations. Compared with other types of pump system, it has many advantages, such as running stably, high dependability, installing and maintaining easily, low capital investment, less maintenance charge, etc. Furthermore, a wealth of experience has been accumulated in designing, manufacturing, running, managing, etc. The hydraulic losses of the inlet and outlet conduits for a low head pump system account for a larger proportion in its head, the lower the head, the larger the proportion. At the same time, the flow in a vertical pump need to turn90degrees twice, while the water-head between the upper and lower reaches for a low head pumping station is smaller. This leads to the arrangement of inlet and outlet conduits in elevation of the direction more haste, which leads to a bigger conduit hydraulic loss. So, it is difficult to improve the pumping system efficiency for a low head vertical pumping station when the two factors act together.
The pump system efficiency depends on pump efficiency and conduit efficiency. To increase the hydraulic performance of low head vertical pump system, focus on the optimal hydraulic design of inlet and outlet conduit and pump type selection, the main works and main conclusions including:
(1) In order to study influence of the velocity circulation at the guide vane outlet on the hydraulic performance of outlet conduit for a large pump system quantitatively, it was put forward that the method to calculate velocity circulation and the method to measure the average angular velocity for the flow at the guide vane outlet of the pump system. The methods of both numerical simulation and model test were applied to research the circulation influence of circulation on the hydraulic losses for both siphon and straight outlet conduits. The results indicate that the hydraulic losses of the outlet conduits were obviously influenced by the circulation at the guide vane outlet, the hydraulic losses of the siphon and straight conduit under the condition of the optimal circulation were0.126m and0.180m lower than those under the condition of zero circulation, respectively; there is optimal circulation for the hydraulic loss of the outlet conduit to be minimized, the optimal circulations for siphon and straight outlet conduit are0.97m2/s and1.31m2/s respectively. The research results above could be helpful to optimal hydraulic design both for outlet conduit and guide vane of a axial-flow pump.
(2) The uniformity devices with different vane numbers are designed to change the uniformity degree of velocity circulation at the guide vane, the model test method is applied to study the influence of the distributing of velocity circulation at the guide vane outlet on the hydraulic loss of outlet conduit for axial-flow pump quantitatively. The results indicate that with the vane number increasing, the changing range of hydraulic loss for outlet conduit becomes smaller and smaller. This account for that the vane number has effect on the distributing of flow velocity circulation and the distributing of flow velocity circulation has effect on the outlet conduit hydraulic loss, the influence degree are both small. The hydraulic loss discrepancy between uniformity device with12vanes and natural state (uniformity device with0vanes) for siphon and low-hump outlet conduits are3.85%and3.73%respectively. This account for that the flow velocity circulation obtained under normal state is close to even distribution. According to the research result, it is feasible to preset an average circulation at the inlet of outlet conduit when numerically simulating the outlet conduit, and the average circulation could be expressed by an average angular velocity. The angular speed could be measured by relevant model test.
(3) In order to improve the hydraulic performance of a low head pump system, the design thinking of reducing nD value for the pump system was discussed. The consistency between reducing nD value and increasing impeller diameter while reducing pump speed was derived. The influence of reducing nD value on pump type selection, energy performance and cavitation performance for the pump system was discussed. Meanwhile, examination index for.the cavitation performance of the pump system and the influence of increasing impeller diameter while reducing pump speed on conduit control size and equipment investment was also discussed. The research results indicate that under the condition of a certain design discharge to decrease nD value suitably is beneficial for pump type selection and improvement of both energy and cavitation performance for the pump system. Therefore it is more suitable for a large low head pumping station with long running operation time to adopt a lower nD value.
(4) The method of3D turbulent numerical calculation is applied to study the influence of the middle division pier on hydraulic performance for elbow inlet conduit, siphon outlet conduit and straight outlet conduit respectively, and the calculation results were verified by conduit model experiments. The research results indicate that the flow patterns in both inlet and outlet conduits observed by the model test are consistent with those by the numerical simulation method; the middle division pier almost has no influence on the flow patterns for the elbow inlet conduit, and the hydraulic losses obtained by numerical calculation will be increased by0.005m under the condition of design discharge; the middle pier is helpful to improve the flow patterns at the outlet of inlet conduit when the flow direction is defluxion at the inlet; due to the flow circulation at the outlet of the pump guide vane, the flow patterns in the outlet conduit are obviously asymmetrical and easily affected by the middle division pier, as a result, the hydraulic losses obtained by numerical calculation will be increased by0.024m and0.033m respectively under the condition of design discharge. The model test results are0.006m,0.023m and0.023m for elbow inlet conduit, siphon outlet conduit and straight outlet conduit respectively, under the condition of design discharge. Therefore, the middle division pier is not conducive to the hydraulic performance of the inlet and outlet conduits. The middle division pier for a large pumping station with low head could be cancelled if its structural design condition may be satisfied.
(5) The design head and average head of Changgou and Denglou pumping stations are both lower than4m, the vertical pump system has been adopted by the two pumping stations. To obtain better hydraulic performance under the condition of low head, numerical simulation method is applied to optimal hydraulic design the inlet and outlet conduits for the two pumping stations. The conduit model test method was applied to verify the optimal result. The pump system efficiency was forecasted based on the test data for pump models on the same test bed and research results of the optimum hydraulic design for conduits. The pump system efficiency may be obtained by multiplying pump segment efficiency with conduit efficiency, where the pump segment efficiency in the pump system may be modified according to the results obtained through the pump model tests on the same test bed, and the conduit efficiency may be calculated according to the conduit hydraulic loss and pump system head. The model test of pump system was carried out. The research results indicate that the excellent hydraulic performance are obtained for the vertical pump systems of Changgou and Denglou pumping station under the condition of low head of less than4m. The efficiencies of the two pump systems reach78%and the NPSHc are lower than6m at both design head and average head working points. The vertical pump system also has a wide application prospect in low head pumping stations.
引文
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