Numerical and Experimental Study on the Shutdown Transition Process of a Large Axial Flow Pump System Focusing on the Influence of Gate Control
Abstract
:1. Introduction
2. Simulation Method and Experimental Platform
2.1. Physical Model
2.2. Simulation Strategy
2.3. Numerical Models and Method
2.4. Experimental Platform
3. Simulation Model’s Construction and Validation
3.1. Simulation Model’s Construction
3.2. Simulation Model’s Validation
4. Results and Discussion
4.1. The Effect of an Uncontrolled Gate on the Shutdown Transition Process of the LAPS
4.2. Influence of the Gate Closing Speed on the LAPS Shutdown Transient Process
4.3. The Effect of Closing the Rapid-Drop Gate Early on the Shutdown Transition Process of the LAPS
5. Conclusions
- After the power failure of the unit, if the gate could not be closed due to the GGOC, with the increase in the net head, the MBV and the RS of the LAPS after the power failure gradually increased. The backflow rate of the water and the length of time required for the pump to reach the runaway state gradually decreased. When the LAPS was in a power failure at the maximum net head of 5.35 m, the MBV in the LAPS was 1.68Qr, and the length of time required for the water flow to reach the MBV was 44.08 s. The RS of the LAPS was 1.45Qr, and the length of time required for the pump to reach the runaway state was 37.83 s.
- After the power failure of the unit, if the gate was closed simultaneously, the flap valve and overflow hole would not work during the shutdown process. The slower the gate closed, the larger the MBV of the LAPS and the MRS of the LAPS, eventually stabilizing. At the same time, the slower the gate closed, the longer the water stayed backed up, and the longer the pump reversed. When a 30 s shutdown scheme was adopted, the MBV during the shutdown process was 1.63Qr. When the 60 s long shutdown scheme was adopted, the MBV during the shutdown process was 1.67Qr, an increase of 2.45%. When the 150 s long closing scheme was adopted, the MBV during the shutdown process reached 1.68Qr, an increase of 3.07%.
- The shutdown method of closing the gate in advance could significantly improve the violent fluctuation of the KCPs of the LAPS during the shutdown transition and effectively reduced the backflow flow and the reverse speed of the pump during the shutdown process. Taking the total gate closing time of 120 s as an example, when the 25% gate was closed in advance, the MBV and MRS during the shutdown process were reduced by 14.31% and 1.93%. The MBV and MRS were reduced by 96.31% and 100% during the shutdown process when the 100% gate was closed in advance.
- The early closing of the gate will lead to a reduction in the over-flow capacity at the gate, causing a surge in the head and shaft power of the LAPS. If the shutdown method of closing the gate in advance is to be adopted to improve the quality of the shutdown transition process of the LAPS, and the LAPS should be required to be equipped with a flap valve and an overflow hole. If the LAPS is not equipped with flap valves and overflow holes, it can be very dangerous to take the shutdown method of an early gate closure. This can easily cause the motor power to overload or the LAPS to fall into the saddle area of the flow during operation.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Nomenclature
D | Impeller diameter (m) |
Jp | Moment of inertia of pump (kg·m2) |
Jm | Moment of inertia of motor (kg·m2) |
H | Relative elevation of overflow hole (m) |
S | Flap valve area (m²) |
Pm | Maximum motor power (kW) |
Qr | Design flow rate (m3/s) |
Hr | Design net head (m) |
Hm | Maximum net head (m) |
nr | Rated speed (r·min−1) |
Pr | Rated power (kW) |
Nr | Rated torque (N·m) |
g | Local acceleration of gravity (m·s−2) |
f | Friction factor |
ρ | The density of flow (kg·m−3) |
Abbreviations
CFD | Computational fluid dynamics |
LAPS | Large axial flow pump station system |
KCPs | Key characteristic parameters |
RS | Runaway speed |
3D | Three-dimensional |
GOOC | Gate is out of control |
MBV | Maximum backflow value |
MRS | Maximum reverse speed |
TTGC | Total time of gate closing |
References
- Yang, F.; Li, Z.B.; Fu, J.G.; Lv, Y.T.; Ji, Q.W.; Jian, H.F. Numerical and Experimental Analysis of Transient Flow Field and Pressure Pulsations of an Axial-Flow Pump Considering the Pump-Pipeline Interaction. J. Mar. Sci. Eng. 2022, 10, 258. [Google Scholar] [CrossRef]
- Wang, L.; Tang, F.P.; Chen, Y.; Liu, H.Y. Evolution Characteristics of Suction-Side-Perpendicular Cavitating Vortex in Axial Flow Pump under Low Flow Condition. J. Mar. Sci. Eng. 2021, 9, 1058. [Google Scholar] [CrossRef]
- Song, X.J.; Liu, C.; Wang, Z.W. Study on the Vortex in a Pump Sump and Its Influence on the Pump Unit. J. Mar. Sci. Eng. 2022, 10, 103. [Google Scholar] [CrossRef]
- Pu, K.X.; Huang, B.; Miao, H.J.; Shi, P.L.; Wu, D.Z. Quantitative analysis of energy loss and vibration performance in a circulating axial pump. Energy 2022, 243, 122753. [Google Scholar] [CrossRef]
- Zhang, X.; Tang, F. Investigation on hydrodynamic characteristics of coastal axial flow pump system model under full working condition of forward rotation based on experiment and CFD method. Ocean Eng. 2022, 253, 111286. [Google Scholar] [CrossRef]
- Kan, K.; Xu, Z.; Chen, H.X.; Xu, H.; Zheng, Y.; Zhou, D.Q.; Muhirwa, A.; Maxime, B. Energy loss mechanisms of transition from pump mode to turbine mode of an axial-flow pump under bidirectional conditions. Energy 2022, 257, 124630. [Google Scholar] [CrossRef]
- Yang, F.; Li, Z.; Yuan, Y.; Lin, Z.; Zhou, G.; Ji, Q. Study on vortex flow and pressure fluctuation in dustpan-shaped conduit of a low head axial-flow pump as turbine. Renew. Energy 2022, 196, 856–869. [Google Scholar] [CrossRef]
- Song, X.J.; Liu, C.; Wang, Z.W. Prediction on the pressure pulsation induced by the free surface vortex based on experimental investigation and Biot-Savart Law. Ocean Eng. 2022, 250, 110934. [Google Scholar] [CrossRef]
- Qiu, J.T.; Li, N.; Yang, C.J.; Cai, Y.L.; Meng, K.Y. Numerical study on a coupled viscous and potential flow design method of axial-flow pump impeller. Ocean Eng. 2022, 266, 112720. [Google Scholar] [CrossRef]
- Mu, T.; Zhang, R.; Xu, H.; Zheng, Y.; Fei, Z.D.; Li, J.H. Study on improvement of hydraulic performance and internal flow pattern of the axial flow pump by groove flow control technology. Renew. Energy 2020, 160, 756–769. [Google Scholar] [CrossRef]
- Zhang, X.; Tang, F.; Liu, C.; Shi, L.; Liu, H.; Sun, Z.; Hu, W. Numerical Simulation of Transient Characteristics of Start-Up Transition Process of Large Vertical Siphon Axial Flow Pump Station. Front. Energy Res. 2021, 9, 382. [Google Scholar] [CrossRef]
- Fu, S.F.; Zheng, Y.; Kan, K.; Chen, H.X.; Han, X.X.; Liang, X.L.; Liu, H.W.; Tian, X.Q. Numerical simulation and experimental study of transient characteristics in an axial flow pump during start-up. Renew. Energy 2020, 146, 1879–1887. [Google Scholar] [CrossRef]
- Wu, Y.; Liang, X.; Liu, Z.; Liu, M. An Analysis of the Accident Shutdown Characteristics of the Axial Flow Pump under Super Hump Conditions. China Rural. Water Hydropower 2019, 12, 173–175, 180. [Google Scholar]
- Zhou, D.; Zhang, R.; Qu, B.; Wang, X.; Yan, Y. Study on the transition process of stopping the pump of large vertical axial flow pumping station. J. Hohai Univ. 2006, 34, 272–275. [Google Scholar]
- Kan, K.; Zhang, Q.Y.; Xu, Z.; Chen, H.X.; Zheng, Y.; Zhou, D.Q.; Binama, M. Study on a horizontal axial flow pump during runaway process with bidirectional operating conditions. Sci. Rep. 2021, 11, 21834. [Google Scholar] [CrossRef]
- Pu, K.X.; Miao, H.J.; Li, J.H.; Huang, B.; Yuan, F.X.; Wu, P.; Wu, D.Z. Numerical Investigation and Experiment on Natural Circulation Resistance and Energy Characteristics in a Circulating Axial Pump. J. Fluids Eng. Trans. Asme 2022, 145, 011208. [Google Scholar] [CrossRef]
- Dai, J.; Liu, X.Q.; Huang, C.B.; Xu, X.M.; Bu, G.; Zhong, Z.Y.; Xu, F.; Dai, Q.F. Experiment on Pressure Pulsation of Axial Flow Pump System with Different Runaway Head. Processes 2021, 9, 1597. [Google Scholar] [CrossRef]
- Xu, Z.; Zheng, Y.; Kan, K.; Huang, J. Runaway characteristics of bidirectional horizontal axial flow pump with super low head based on entropy production theory. Trans. Chin. Soc. Agric. Eng. 2021, 37, 49–57. [Google Scholar]
- Dai, J.; Dai, Q.; Li, H.; Wang, W.; Liang, H.; Guo, Z. Calculation of Two-way Vertical Axial Flow Pumping Station Runaway Transient Hydrodynamic Process. China Rural. Water Hydropower 2018, 12, 129–133. [Google Scholar]
- Zhang, Y.; Xu, Y.; Zheng, Y.; Rodriguez, E.F.; Liu, H.; Feng, J. Analysis on Guide Vane Closure Schemes of High-Head Pumped Storage Unit during Pump Outage Condition. Math. Probl. Eng. 2019, 2019, 8262074. [Google Scholar] [CrossRef]
- Chen, S.; Yan, D.; Jang, L.; Lu, W.; Wang, L. Numerical calculation of hydraulic transient for a low-head pump station during its suspending period. Trans. Chin. Soc. Agric. Mach. 2004, 35, 58–60. [Google Scholar]
- Zhang, L.; Zhou, D.; Chen, H. CFD simulation of shutdown transient process of pumped storage power station under pump conditions. J. Drain. Irrig. Mach. Eng. 2015, 33, 674–680. [Google Scholar]
- Lu, W.; Guo, X.; Zhou, X. Theoretical study on stop gate breaking flow in large pumping station. Trans. Chin. Soc. Agric. Mach. 2005, 36, 56–59. [Google Scholar]
- Kan, K.; Zheng, Y.; Chen, H.; Zhou, D.; Dai, J.; Binama, M.; Yu, A. Numerical simulation of transient flow in a shaft extension tubular pump unit during runaway process caused by power failure. Renew. Energy 2020, 154, 1153–1164. [Google Scholar] [CrossRef]
- Xue, H.; Zhang, C.; Li, Y. Analysis of transient flow in vertical mixed-flow pumping system during pumpstopping period by closing valve in two-phase mode. J. Drain. Irrig. Mach. Eng. 2015, 33, 953–959. [Google Scholar]
- Gou, D.; Guo, P.; Luo, X. Three-dimensional coupling numerical study on power-off and runaway transition process of pump in pumped storage power station. Chin. J. Hydrodyn. 2018, 33, 28–39. [Google Scholar]
- Zhou, D.; Chen, H.; Zhang, L. Investigation of Pumped Storage Hydropower Power-Off Transient Process Using 3D Numerical Simulation Based on SP-VOF Hybrid Model. Energies 2018, 11, 1020. [Google Scholar] [CrossRef] [Green Version]
- Li, Z.; Bi, H.; Bryan, K.; Wang, Z.; Yao, Z. Three-dimensional transient simulation of a prototype pump-turbine during normal turbine shutdown. J. Hydraul. Res. 2017, 55, 520–537. [Google Scholar] [CrossRef]
- Sun, Y.; Yu, G.; Liu, C. Research on Closing Control of the Sluice Gate for Sudden Power Off of Large Pump. Adv. Sci. Lett. 2011, 4, 2316–2320. [Google Scholar] [CrossRef]
- Jing, S. Numerical Simulation of Dynamic Behavior with Ripid-Drop Gate in Vertical Axial Pumping Station during Its Suspending Period; HoHai University: Nanjing, China, 2006. [Google Scholar]
- Wang, C.-N.; Yang, F.-C.; Nguyen, V.T.T.; Nhut, T.M.V. CFD Analysis and Optimum Design for a Centrifugal Pump Using an Effectively Artificial Intelligent Algorithm. Micromachines 2022, 13, 1208. [Google Scholar] [CrossRef]
- Nguyen, V.T.T.; VO, T.M.N. Centrifugal Pump Design: An Optimization. Eurasia Proc. Sci. Technol. Eng. Math. 2022, 17, 136–151. [Google Scholar] [CrossRef]
- Liu, Y.; Zhou, J.; Zhou, D. Transient flow analysis in axial-flow pump system during stoppage. Adv. Mech. Eng. 2017, 9, 1–8. [Google Scholar] [CrossRef] [Green Version]
- Wu, Z. Research on Hydraulic Transient Characteristics of Large-scale Siphon Flow Channel Pump Unit; Yangzhou University: Yangzhou, China, 2021. [Google Scholar]
- Liu, Y.; Zhou, D.; Zheng, Y.; Zhang, H.; Xu, J. Numerical simulation of starting process of axial flow pump with quick-stop gate. South--North Water Transf. Water Sci. Technol. 2017, 15, 167–172. [Google Scholar]
- Yu, Y.; Wei, C. Determination of the Area of Flap Valve in Rapid-Drop Gate of Large Vertical Axial Flow Pumping Station. South--North Water Transf. Water Sci. Technol. 2010, 8, 6–8. [Google Scholar]
- Lee, B.R.; Yun, T.J.; Oh, W.B.; Lee, C.W.; Kim, H.H.; Jeong, Y.J.; Kim, I.S. Study on Floodgate Resonance Avoidance Using FSI Analyses. Trans. Korean Soc. Mech. Eng. A 2021, 45, 223–230. [Google Scholar] [CrossRef]
- Zhou, D.; Wu, Y.; Zhang, R. Research on start-up transient of vertical axia-l flow pump station. J. Hydroelectr. Eng. 2007, 26. [Google Scholar]
- Li, J.; Chai, L. Cut-off flow technique with loose-leaf rapid-drop gate at low-head pumping stations. Engineering J. Wuhan Univ. 2004, 37, 36–39. [Google Scholar]
- Fujun, W.; Mianmian, B.; Ruofu, X. Analysis on hydraulic transients of pumping station with Flowmaster. J. Drain. Irrig. Mach. Eng. 2010, 28, 144–148. [Google Scholar]
- Hu, X. Research of Hydraulic Transients Process in Pump Station System Based on Flowmaster; Xihua University: Chengdu, China, 2012. [Google Scholar]
- Geng, T. Numerical Simulation of Hydraulic Transient Process of Francis Turbine Generator Based on Flowmaster; Xihua University: Chengdu, China, 2020. [Google Scholar]
Geometric Parameter | Value | Hydraulic Parameter | Value |
---|---|---|---|
Impeller diameter, D | 1.86 m | Design flow rate, Qr | 12.79 m3·s−1 |
Moment of inertia of pump, Jp | 425.80 kg·m2 | Design net head, Hr | 4.55 m |
Moment of inertia of motor, Jm | 3350 kg·m2 | Maximum net head, Hm | 5.35 m |
Relative elevation of overflow hole, H | 5.9 m | Rated speed, nr | 214.3 r·min−1 |
Flap valve area, S | 3.5 m2 | Rated power, Pr | 735.38 kW |
Maximum motor power, Pm | 1000 kW | Rated torque, Nr | 32771.25 N·m |
Serial Number | Real Physical Model | Components of Simulation Model | Transient Simulation Implementation Method |
---|---|---|---|
1 | Inlet channel | Flow resistance components and rigid pipes | - |
2 | Pump | Axial flow pump | Pump speed controller |
3 | Outlet channel | Flow resistance components and rigid pipes | - |
4 | Overflow hole | Rigid pipes and check valve | - |
5 | Rapid-drop gate | Sluice | Gate controller |
6 | Flap valve | Clapper | - |
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content. |
© 2023 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
Share and Cite
Zhang, X.; Hu, C.; Tang, F.; Yang, F.; Song, X.; Liu, C.; Shi, L. Numerical and Experimental Study on the Shutdown Transition Process of a Large Axial Flow Pump System Focusing on the Influence of Gate Control. J. Mar. Sci. Eng. 2023, 11, 280. https://doi.org/10.3390/jmse11020280
Zhang X, Hu C, Tang F, Yang F, Song X, Liu C, Shi L. Numerical and Experimental Study on the Shutdown Transition Process of a Large Axial Flow Pump System Focusing on the Influence of Gate Control. Journal of Marine Science and Engineering. 2023; 11(2):280. https://doi.org/10.3390/jmse11020280
Chicago/Turabian StyleZhang, Xiaowen, Chongyang Hu, Fangping Tang, Fan Yang, Xijie Song, Chao Liu, and Lijian Shi. 2023. "Numerical and Experimental Study on the Shutdown Transition Process of a Large Axial Flow Pump System Focusing on the Influence of Gate Control" Journal of Marine Science and Engineering 11, no. 2: 280. https://doi.org/10.3390/jmse11020280
APA StyleZhang, X., Hu, C., Tang, F., Yang, F., Song, X., Liu, C., & Shi, L. (2023). Numerical and Experimental Study on the Shutdown Transition Process of a Large Axial Flow Pump System Focusing on the Influence of Gate Control. Journal of Marine Science and Engineering, 11(2), 280. https://doi.org/10.3390/jmse11020280