Search Results (22)

Double-suction centrifugal pumps are extensively employed in industrial applications owing to their high efficiency, low vibration, superior cavitation resistance, and operational durability. This study analyzes how impeller oblique cutting angles (0°, 6°, 9°, 12°) affect a double-suction pump at a fixed 4% trimming ratio and constant average post-trim diameter. Numerical simulations and tests reveal that under low-flow (0.7Q_d) and design-flow conditions, the flat-cut (0°) minimizes reflux ratio and maximizes efficiency by aligning blade outlet flow with the mainstream. Increasing oblique cutting angles disrupts this alignment, elevating reflux and reducing efficiency. Conversely, at high flow (1.3Q_d), the 12° bevel optimizes outlet flow, achieving peak efficiency. Pressure pulsation at the volute tongue (P11) peaks at the blade-passing frequency, with amplitudes significantly higher for 9°/12° bevels than for 0°/6°. The flat-cut suppresses wake vortices and static–rotor interaction, but oblique cutting angle choice critically influences shaft-frequency pulsation. Entropy analysis identifies the volute as the primary loss source. Larger oblique cutting angles intensify wall effects, increasing total entropy; pump chamber losses rise most sharply due to worsened outlet velocity non-uniformity and turbulent dissipation. The flat-cut yields minimal entropy at Q_d. These findings provide a basis for tailoring impeller trimming to specific operational requirements. Furthermore, the systematic analysis provides critical guidance for impeller trimming strategies in other double-suction pumps and pumps as turbines in micro hydropower plants. Full article

This work involves the development of a hydrodynamic fertilizer injector (HFI), which uses an integrated axial-flow turbine (AFT) and a diaphragm pump to absorb liquid fertilizer. Three structural parameters—the number of impellers (M₁), average number of blades per impeller (M₂), and arrangement pattern (M₃)—are considered, and 12 AFT designs are developed. Using a combination of CFD numerical simulations and hydraulic performance testing, the response of the AFT output power (P), blade negative pressure (NP), and fertilizer injection flow rate (Q_inj) to structural parameters and inlet pressure (H) is investigated. The results show that the normalized root mean square error between the simulated outlet flow rate (Q_s) and the measured flow rate (Q_m) is 5.1%, indicating high accuracy in the grid motion simulation method. P increases first and then decreases with the increase in impeller speed (n). The maximum P (P_max) ranges from 150.1 to 201.4 W. P_max increases with H, decreases with increasing M₁ and M₂, and shows little change with M₃. At H = 0.14 MPa, M₁ and M₂ have a significant influence, and at H ≥ 0.14 MPa, M₁ becomes the most significant factor (p < 0.05). Low-speed flow and negative pressure cavitation zones at the leading edge of the blade suction surface cause flow blockage and affect the lifespan of the AFT. These regions decrease in size as H increases but increase with M₁. The negative pressure (NP) decreases as M₂ increases. When M₁, M₂, and M₃ are 2, 3, and identical (D33), the P_max of the AFT is maximized, increasing by 6.7% to 33.5% compared with those of the other combinations. The Q_inj of D33, D34, D43, and D44 at H = 0.12~0.18 MPa range from 288.6 to 847.3 L/h, which is 38.7% to 461.0% higher than that of domestic and international venturi injectors. When considering cavitation issues and the manufacturing cost of the AFT mold, D44 may be chosen. Although its Q_inj is 7.0% lower than that of D33, NP is reduced by 37.9%. These findings provide a basis for the development of the HFI with AFT as the driving unit. Full article

The cavitation phenomenon significantly impacts the performance of pump turbines, necessitating in-depth research on their cavitation characteristics. This study investigates the performance characteristics of a pump turbine through experimental and numerical simulation methods, with consistent results verifying the accuracy of the numerical simulations. The cavitation flow field is numerically analyzed to compare the cavitation distribution and velocity streamlines at different stages of cavitation development. The Q criterion and entropy production method are employed to identify vortex structures and energy loss regions, respectively, exploring the correlation between vortices and energy losses in the cavitation flow field under low-flow pump conditions. The results demonstrate that intensified cavitation generates more multi-scale vortices in the flow field, leading to increased entropy production and reduced energy efficiency. Proper orthogonal decomposition (POD) and dynamic mode decomposition (DMD) methods were subsequently applied to extract vorticity characteristics from transient cavitation flow fields, revealing primary energy loss regions and elucidating the evolution and distribution patterns of vortices. The POD analysis shows that low-order modes represent dominant vortex structures, while intensified cavitation increases both the quantity of vortices and their complexity in scale, distribution, and evolutionary frequency. The DMD results further indicate distinct evolutionary patterns for vortices of different scales. This research provides insights into the instability characteristics of cavitation flow fields in pump turbines under low-flow pump conditions and offers theoretical support for optimizing the design of pump turbines to expand their high-efficiency operational range. Full article

As the core for energy conversion in pumped storage plants, the pump turbine is also a key component in the process of building a clean power grid, owing to its fast and accurate load regulation. This paper introduces the current status of research and development of pump turbines from the perspectives of significance, design and optimization, operational performance, advanced research methods, etc. Internal and external characteristics such as transient flow evolution, structural vibration, flow-induced noise, etc., not only reflect operational performance (hydraulic, cavitation, sediment abrasion, and stability performance, etc.) but also directly affect the safe and efficient operation of the system. It is worth mentioning that the space-time evolution of internal and external characteristics is an emerging research direction, the results of which can be used to predict the operational conditions of pump turbines. Moreover, the development and application of intelligent condition monitoring and fault diagnosis aim to prevent failures and accidents in pumped storage plants. Full article

Recent research has focused on the dynamic control and regulation of hydraulic devices like pumps and turbines to enhance the efficiency of water systems. These devices are adjusted to maintain nearly optimal hydraulic conditions and operating efficiency, although achieving both can be challenging due to factors like machine type and changes in distribution patterns. Incipient cavitation, which can cause mechanical damage and reduce efficiency, presents a specific challenge. It produces a distinct noise which this study aims to detect through a proposed methodology. Using the LES WALE model in OpenFOAM and Lighthill’s acoustic analogy, this research simulates and analyzes the noise generated by the dynamic of a confined flow. This work aims to be the starting point for more complex models. Full article

A pumped storage unit is a crucial guarantee in the pursuit of increased clean energy, especially in the progressively severe circumstances of low energy utilization and poor coordination of the integration of volatile renewable energy. However, due to their bidirectional operation design, pumped turbines possess an S-characteristic attribution, wherein the unsteady phenomena of unit vibration, pressure pulsation, and cavitation erosion happen during the start-up process and greatly impact the stable connection to the power grid. Therefore, a systematic study concentrating on an optimal unified paradigm of a start-up strategy for a pumped storage plant is conducted. Model construction, effective analysis, controller design, and collaborative optimization are sequentially expounded. Firstly, a refined start-up nonlinear model of a pumped storage plant with complex boundary conditions is constructed, wherein the delay time of frequency measurement, saturation, and dead zone features are comprehensively taken account. Furthermore, a variable universe fuzzy PID controller and its operation laws are proposed and specifically designed for the speed governing system of the pumped storage plant; the control quality and anti-disturbance performance are verified by a no-load frequency disturbance experiment. On this basis, taking speed overshoot for stationarity and speed rising time for rapidity, a novel open–close loop collaborative fuzzy control strategy is proposed with rotational speed feedback and a variable universe fuzzy PID control. The experiment results show that the proposed unified paradigm has better control performance in various performance indexes, and more balanced control quality and dynamic performance under various complex start-up conditions, which has great application value for ensuring the unit’s timely response to the power grid regulation task and improving the operating stability of the power system. Full article

Pumps-as-Turbines (PATs) are increasingly used in micro-hydropower applications due to their cost competitiveness that is brought about by lower acquisition, design, operation, and maintenance costs. Despite these, limited research exists that investigates PAT failures. Notably, there is a literature gap concerning cavitation in PATs. As such, this study proposes an improvement to the deviation from the normal distribution (DND) technique to facilitate application in PAT cavitation detection. Probability density functions of vibration signals collected during operation at design speed and various cavitation states are developed and the DND computed using two approaches, i.e., the use of baseline data and the original method, for comparison purposes. Normal probability plots are presented to depict suitability of the two approaches in quantifying the DND. Results show higher deviation when using baseline data, hence, improved detection capabilities with amplification of the slope of the trend line under cavitating conditions when using the proposed DND approach. The proposed method also allows for establishing clear alarm limits for the condition monitoring of PATs in practice. Moreover, the proposed method is validated by application at various PAT operating speeds and cavitation states. The proposed method is found to be responsive, reliable, and independent from operating speed. Full article

Model tests and model calculations are the most basic means currently available to study the characteristics of the axial-flow pumps and Kaplan turbines in a systematic manner. Large and medium-sized turbine units and axial-flow pumps must rely on model tests and model calculations to ensure the performances of prototype units before designing. The conversions between models and prototypes are mainly carried out through similarity criteria. However, it is difficult to meet all the similarity criteria in the model tests and the similarity conversions, and the hydraulic and cavitation performances of the model and the prototype are often different. In this paper, numerical calculations of shroud clearance cavitation are performed on both the prototype and model using different cavitation coefficients. The results indicate that the prototype and model have a similar clearance cavitation flow regularity when the cavitation coefficient changes, but they have different energy characteristics and cavitation characteristics. In cavitation conditions, the prototype has higher energy characteristics than the model and the critical cavitation coefficient is similar to the model. When the cavitation coefficient is higher than the critical cavitation coefficient, compared to the model, the blade cavitation performance of the prototype is worse, and the clearance cavitation and runner chamber cavitation are more serious. If the cavitation coefficient decreases to the device cavitation coefficient, the runner chamber of the prototype will cavitate, even though the model has not cavitated yet. The comparison of shroud clearance cavitation between the prototype and the model can be used as a reference for the accuracy of similarity conversion results between the model and the prototype. It also has a positive impact on the design and operation of the prototype. Full article

In many industrial processes that include fluid flow, cavitation erosion of different engineering structures (pumps, turbines, water levels, valves, etc.) during their operation is expected. Metallic, ceramic, and composite materials are usual candidates considered for application in such extreme conditions. In this study, the idea is to synthesize refractory ceramic material based on talc with the addition of zeolite for utilization as protective coatings in cavitating conditions. Two talc-based refractories with zeolites from two Serbian deposits were produced. The behaviors of the samples in simulated cavitation conditions were examined by an advanced non-destructive methodology consisting of monitoring mass loss and surface degradation using image analysis compiled with principal component analysis (PCA), interior degradation by ultrasonic measurements, and the microstructure by a scanning electron microscope (SEM). Lower mass loss, surface degradation level, and modeled strength decrease indicated better cavitation resistance of the sample with Igros zeolite, whereby measured strength values validated the model. For the chosen critical strength, the critical cavitation period as well as critical morphological descriptors, Area and Diameter (max and min), were determined. A Young’s elasticity modulus decrease indicated that surface damage influence progressed towards interior of the material. It can be concluded that the proposed methodology approach is efficient and reliable in predicting the materials’ service life in extreme conditions. Full article

The purpose of this paper is to study the mechanism and improve the prediction accuracy of transient torque converter cavitation flow by the application of scale-resolving simulation (SRS) methods with particular focus on cavitation vortex flow. Firstly, the numerical analysis of the entire internal flow field of the torque converter was carried out using different turbulence models, and the prediction accuracy of the hydraulic characteristics of the adopted models was analyzed and validated via test data. Secondly, the cavitation and turbulence behavior in the internal flow field were analyzed, and the blade surface pressure according to different turbulence models was compared and validated through test data. Finally, the transient cavitation characteristics of the flow field were studied based on the stress-blended eddy simulation (SBES) model. The prediction accuracy of the cavitation flow field simulation of the torque converter is significantly improved using the SRS model. The maximum error of capacity constant, torque ratio and efficiency are reduced to 3.1%, 2.3%, and 1.3% at stall, respectively. The stator is more prone to cavitation than pump and turbine. The SBES model has the highest prediction accuracy in multiple measurement points, and the maximum deviation can reach 13.32% under stall. Attached cavitation bubbles and periodic shedding cavitation can be found in the stator, and the evolution period is about 0.0036 s, i.e., 279 Hz. The prediction accuracy of different models was compared and analyzed, which has important guiding significance for the high-precision prediction and analysis of fluid machinery. Full article

Clean energy liquid oxygen is more and more widely used in aerospace, but the research on the thermodynamic characteristics of liquid oxygen is still less. In this paper, a method for correcting the local saturated vapor pressure by thermodynamic effect is proposed, so we establish the Zwart modified cavitation model considering the thermodynamic characteristics. We choose the turbine pump inducer as the research object, and select liquid water and liquid oxygen at different temperatures as the fluid medium. Based on two different Zwart cavitation models, the cavitation flow characteristics of liquid water at different temperatures of 298 K, 320 K and 350 K are numerically simulated and analyzed, and the cavitation flow characteristics of liquid oxygen at different temperatures of 85 K, 90 K and 95 K are also numerically simulated and analyzed. According to the analysis of the simulation results, for liquid water at the temperature of 298–350 K, since the change range of its thermophysical parameters is very small, the inhibition of cavitation is not obvious, and the thermodynamic characteristics are not significant. For liquid oxygen, the cavitation effect is obvious at different temperatures. When the temperature increases gradually, the thermodynamic effect of liquid oxygen becomes more obvious, which can effectively inhibit the cavitation phenomenon of the inducer in the steady-state cavitation flow. Full article

For Francis pump turbines, the pressure pulsation characteristics of the draft tube are some of the key concerns during the operation of the units. The pressure pulsation characteristics of the draft tube are directly related to the draft tube spiral cavitating vortex rope. In this paper, the velocity distribution in the draft tube of a Francis pump turbine is tested by means of laser Doppler velocimetry. The velocity pulsation was found to be directly related to the pressure pulsation, while the velocity pulsation was also influenced by the cavitation coefficient. The main frequency of the velocity pulsation was close to the main frequency of the pressure pulsation and became larger as the cavitation factor increased. Full article

Korto’s multidimensional method for vibro-acoustical diagnostics and monitoring of turbine cavitation is based on a high number of spatially distributed sensors and the signal and data processing that systematically utilises three data dimensions: spatial, temporal, and operational. The method delivers unbiased data on cavitation intensity and rich diagnostical data on cavitation mechanisms. It is applicable on Kaplan, Francis, bulb, and reversible pump turbines, as well as pumps. In this paper, the theory of the method is introduced, and its application is illustrated on a prototype and three models of a Kaplan turbine. In the considered case, two distinct cavitation mechanisms responsible for the two erosion patches found in an overhaul are vibro-acoustically identified, quantified, and analysed. The cavitation quality of the models is compared. Cavitation as a source of vibration is discussed. Full article

The self-oscillation of the cavitating vortices is one of the dangerous phenomena of hydraulic turbine operation near full-load conditions. This work is an attempt to generalize data and expand insight on the phenomenon of self-excited oscillations by comparing the experimental results obtained on a simplified turbine and scaled-down pump–turbine models. In both cases, a series of high-speed imaging was carried out, which made it possible to study these phenomena with high temporal resolution. The high-speed imaging data was subjected to additional processing such as binarization, cropping, and scaling. For a simplified turbine model, the volume of the vapor cavity was calculated based on the assumption of the axial symmetry of the cavity, after which fast Fourier transform (FFT) analysis was carried out. A proper orthogonal decomposition (POD) analysis was also performed to examine individual modes in the original digital imaging data. For the pump–turbine, visualization data on the cavitation cavity oscillations were supplemented by pressure measurements in the draft tube cone to determine the frequency characteristics. Based on obtained experimental data, an improved one-dimensional model describing the oscillations of the cavitation cavity arising behind the hydraulic turbine runner is proposed. Full article

The low carbon martensitic stainless AWS 410NiMo steel has in its chemical composition 13% chromium, 4% nickel, and 0.4% molybdenum (wt.%) and is used in turbine recovery, rotors, and high-pressure steam pump housings due to its resistance to impact at low temperatures, as well as to corrosion and cavitation. Those applications of the AWS 410NiMo steel frequently demand repair, which is performed by welding or cladding. Arc welding is a well-established technique for joining materials and presents several parameters that influence the mechanical performance of the weld bead. Although numerous welding processes exist, optimizing welding parameters for specific applications and materials is always challenging. The present work deals with a systematic study to verify the correlation between the pulsed fluxed core arc welding (FCAW) parameters, namely pulse current and frequency, welding speed, and contact tip work distance (CTWD), and the bead morphology, microstructure formation, residual stress, and hardness of the martensitic clad. The substrate used was the AISI 1020 steel, and the AWS 410NiMo steel was the filler metal for clad deposition. From the initial nine (9) samples, three (3) were selected for in-depth characterization. Lower heat input resulted in lower dilution, more elevated hardness, and lower compressive residual stresses. Therefore, the results highlight the need for selecting the proper heat input, even when using a pulsed FCAW procedure, to achieve the desired performance of the clad. In the present case, a higher heat input appears to be more advantageous owing to the lower convexity index, smooth hardness transition between fusion and heat-affected zones in addition to more elevated compressive stresses. Full article