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基于端壁射流的轴流泵扩稳试验研究

Experimental study on stability enhancement of axial flow pump based on endwall injection

  • 摘要: 为探索可有效抑制轴流泵失速的流动控制方法,该研究针对某轴流泵开展了稳态端壁射流和脉冲端壁射流的试验研究,分析了射流量、喷嘴数量和脉冲射流频率对轴流泵性能的影响规律,并结合压力脉动测试揭示了端壁射流提高轴流泵稳定性的机理。研究结果表明,端壁射流通过有效抑制/消除轴流泵的旋转失速起到大幅提升轴流泵稳定性的作用,射流量、喷嘴数量和脉冲射流频率对轴流泵性能具有较大影响。在稳态射流作用下,轴流泵的失速裕度随着射流量和喷嘴数量的增加而增大,存在最优的射流量和喷嘴数量参数使轴流泵设计点效率最高。相比于稳态射流,脉冲射流可使用稳态端壁射流50%的射流量起到起到更大的扩稳效果,同时进一步提高轴流泵的设计点效率;在本文研究范围内,脉冲射流的扩稳效果随射流频率的增加而增大,当射流频率为0.5 Hz时,脉冲射流使用4.2%的射流量将轴流泵失速裕度提高53.9%,设计点效率提升3.52%。端壁射流在不降低轴流泵设计点效率的同时可大幅提高轴流泵的运行稳定性,可成为保障轴流泵高效、稳定运行的关键技术手段。

     

    Abstract: Axial flow pumps serve as the core equipment for waterjet propulsion systems and water diversion projects. Research indicates that under low-flow conditions, flow separation-induced stall phenomena induce hump-shaped characteristics in head-flow curves. The presence of such unstable flow features poses significant operational risks to pump systems. This study proposes a flow control method based on endwall injection to suppress rotating stall in an axial flow pump. Experimental studies were conducted in terms of steady-state endwall injection and pulsed endwall injection for the axial flow pump. The influence of injected flow rate, injector numbers and pulsed injection frequency on the performance of the axial flow pump was analyzed. The injected flow rate was normalized against the design flow rate of the axial flow pump. In the experiment, the tested range of injected flow rate spanned from 2.6% to 10.48%. The number of injectors varied between 1 and 6, while the pulsed injection frequency covered a range of 0.05 Hz to 0.5 Hz. The mechanism by which the endwall injection improved the stability of the axial flow pump was revealed using pressure pulsation testing. Experiments were performed on a closed-loop axial flow pump test rig at the State Key Laboratory of Water Engineering Ecology and Environment in Arid Area, Xi’an University of Technology. The test pump was designed with a flow rate of 168 m³/h, head of 3.12 m, and rotational speed of 1800 r/min. The research results indicate that the injected mass flow rate, injector number, and pulsed injection frequency have a significant impact on the performance of the axial flow pump. When the steady-state endwall injection is performed, the stall margin of axial flow pump increases with the increase of injected mass flow rate and injector numbers. The pump efficiency exhibits negligible sensitivity to the injected mass flow rate when the injected mass flow rate is below 5% of the design flow. When the injected mass flow rate exceeds 8.4%, a measurable efficiency enhancement emerges. Parametric studies reveal a non-monotonic relationship between the injector number and pump efficiency, peaking at four injectors. Considering both the efficiency under the design point and stall margin, the optimal injector number is four, achieving a 1.83% improvement in the pump efficiency and 39.4% enhancement in the stall margin using an injection flow rate of 5.6%. Experimental studies on pulsed endwall injection were conducted using six injectors. Compared to steady-state endwall injection, the pulsed endwall injection achieves greater stability enhancement with reduced injected flow. The injection frequency significantly impacts the pump performance, with the stall margin generally increasing as the injection frequency rises. However, further increases in injection frequency exert little influence on the pump stability when the injection frequency exceeds 0.25Hz. Maintaining elevated injection frequency can significantly improve the pump efficiency. However, beyond a critical injection frequency threshold of 0.17 Hz, further increases in injection frequency exert negligible influence on the pump efficiency. Comprehensive consideration of both the pump efficiency and stall margin of the axial flow pump suggests that the injection frequency should exceed 0.25 Hz. When the injection frequency is 0.5 Hz, the pulsed endwall injection demonstrates superior stability enhancement compared to steady-state endwall injection. The use of 4.2% injection flow rate in the pulsed injection mode improves the stall margin of axial flow pump by 53.9% and the efficiency under the design point by 3.52%. Mechanistic analysis revealed that head decline initiates with rotating stall onset, where stall cell propagation velocity reaches 72% of impeller rotational speed. Endwall injection effectively delays stall inception caused by the rotating stall. Endwall injection with optimized parameters can completely suppress rotating stall and eliminate associated hump-shaped characteristics in head-flow curves, thereby substantially improving operational stability. In conclusion, endwall injection demonstrates dual-benefit capability by maintaining the pump efficiency under the design point while enhancing the operational stability significantly, thereby establishing itself as a critical flow control strategy for achieving high-efficiency and high-stability operation in axial flow pumps.

     

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