The design scheme of open intake will often increase the shaft length and the height of wet-pit pump house when the range of intake water level varies relatively large. And if the pump house is far away from the discharge bay, a longer discharge pipe may be inevitable, and the arrangement of full passage model pumping system may exceed the allowed size of a specific test bench. Aiming at a long-shaft vertical pumping system with open intake design, larger water level variation and longer discharge pipe, a methodology of performance prediction for the pump and pumping system was proposed by combining numerical simulation and non-full passage model test because of less experiment funds, shorter research periods and restricted test bench. Through numerical simulation, the hydraulic losses and drag coefficients of sump and discharge pipe were calculated and followed by the experiment design and model test of non-full passage pumping system. Based on the calibration accuracy of measurement instruments and test results, the experimental uncertainties were analyzed. Through combination of numerical simulation and non-full passage model test, the prediction of model pump and pumping system performance was realized. The performance of prototype pump and pumping system was obtained by applying the similarity law of pump. When operated under the designed head of 13.59 m, the flow rate and efficiency of the prototype pumping system reached 11.86 m 3 /s and 86.56%, respectively, exceeding the requirements stipulated in the bidding documents and showing that it possessed greater pumping capacity and higher efficiency. The methodology proposed in this paper can be referenced and applied to the engineering design of similar pump stations.
Axial-flow pumps are widely used in every sector of China. After many years of operation, the aging of mechanical and electrical facilities poses threats to their steady and safe operation. Taking the technical innovation of an axial-flow pump station as an example, the study is focused on the pump selection and performance prediction. The pump similarity law and specific speed were applied to guide the pump selection based on the designed head and discharge. The performances of pump models were compared and it is suggested for the technical innovation that when the selected model pump is adopted, the impeller diameter is kept at 3100 mm and the rotational speed is reduced from 150r/min to 136.4r/min to improve its cavitation performance. A threedimensional pumping system model was established by using software Pro/E and CFD analyses were conducted to predict the hydraulic performance of the pumping system for the evaluation of technical innovation. It is shown through the comparison of computed results with model test results that the designed flow rate corresponding to the designed head can be fully satisfied with the selected pump and stronger pumping capacity can be prospected at the designed and mean lifting head. The pumping system model tests, in comparison between the original and the selected model pump, indicate that when the innovated pump station operates under characteristic heads, the pumping system efficiency can be raised by more than 3 percentages, and the cavitation allowance can be decreased by 0.90m; thus, better engineering and economic benefits can be prospected through the technical innovation.
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