离心泵启动过程瞬态流动的数值模拟和实验研究
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摘要
离心泵启动过程是一类特殊的瞬态过程,利用离心泵的启动可为特殊的应用场合提供瞬时流体动力;同时大功率泵在启动过程中的瞬时特性可能引起设备和管道系统的冲击破坏或过大的负载。目前对离心泵启动过程的内部瞬态流动缺乏系统的研究,如何实现对离心泵启动过程的性能预测、优化和流动控制是一个重要课题。
本文以处在启动过程中的离心泵为研究对象,针对离心泵在启动过程中表现出的特殊瞬态水力性能,建立离心泵启动过程瞬态流动的数值模拟与诊断方法,建立离心泵性能测试实验系统,分别从数值模拟和实验研究的角度探索引起外部非定常效应的内部流动机理。论文的主要内容包括以下五个方面:
第一,为验证基于动网格的有限体积法在求解边界移动引起的非定常流动时的有效性和准确性,对圆柱瞬时平动和旋转平动启动引起的二维非定常不可压黏性流动进行了数值模拟,采用弹簧近似模型和网格重构相结合的方法实现该过程的流场变形。模拟结果与已有的实验和数值结果从定性和定量上均吻合较好,证明该方法在求解边界移动引起的非定常流动时的有效性。
第二,针对单独采用动网格方法模拟叶轮加速启动所引起的网格更新质量下降的问题,提出采用区域动态滑移方法保证叶轮启动过程网格的更新质量,成功的将动网格方法推广应用到离心泵二维和三维模型启动过程的瞬态流动求解。同时,为消除启动过程外部指定非定常进出口边界条件所引起的误差,提出建立离心泵循环管路系统的三维数值模型,通过数值求解的自身耦合性实现了无需指定边界条件即可准确求解启动过程的瞬态流动。
第三,建立离心泵瞬态性能测试实验台,该实验台由动力蓄能装置、模型泵、管路系统、数据采集和电气控制系统五部分组成。对泵启动过程的外特性,如瞬时流量、扬程、转速和轴扭矩的变化进行测试和采集;采用PIV内流测量方法对稳态和瞬态内流场进行拍摄,得到与外特性相对应的稳态和瞬态的速度矢量场,为探索离心泵启动过程瞬态流动机理提供真实的参考依据。
第四,建立与该实验台等效的离心泵循环管路系统三维数值模型,在与启动实验同等边界条件下,求解该数值模型内部瞬态流动。将实验所得结果与数值模拟结果进行对比研究,两者同时在瞬态外特性和内特性上吻合较好。
第五,基于瞬态流动的数值计算结果,采用过流断面和边界涡量流两种涡动力学诊断方法对离心泵启动过程的内部瞬态流动进行诊断。
研究结果显示,泵启动过程无量纲扬程偏离稳态值的外部原因是启动加速度的变化形式,内部原因是水流惯性和瞬时流场结构的不断演化。启动初期瞬时外特性主要表现为低流量下瞬时转速、扬程和功率的快速上升,瞬时无量纲扬程从无穷大快速下降至低于稳态水平;启动中期流量快速增长,引起瞬时功率的增长率高于瞬时扬程;启动后期启动加速度降为零,转速达到稳定值,流量增长减缓,瞬时扬程和功率经过波动冲击达到稳态水平。启动全过程瞬时流量表现出三次曲线的增长特性。阀门全关启动时的电机功率将表现出明显的瞬时冲击。
启动过程内部流动演化呈现强烈的瞬态特性,采用基于准稳态假设的思想对应用于启动过程的离心泵进行设计是不适合的。本文的研究内容和结论可为应用于各种瞬态过程的水力机械瞬时性能预测、设计优化与流动控制提供参考依据。
The startup process of a centrifugal pump is a special type of transient process. The centrifugal pump during starting period can be used to supply instantaneous hydraulic power in some special application areas, while instantaneous performances of high-power pumps during starting period may lead to excessive loads or impact failures of facitilies and piping systems. Due to the lack of systematic study on the transient flow in a centrifugal pump during starting period at present, how to achieve methods of performance prediction, design optimization and flow control of the centrifugal pump during starting period is an important issue.
Taking the centrifugal pump during starting period as the research object of this dissertation, in view of the special transient hydraulic performance casued by the pump's startup process, the methods of numerical simulations and diagnostics on the unsteady flow in the centrifugal pump during startup process were established. A centrifugal pump performance test rig was developed. Numerical simulations and experimental studies were combined to explore the internal transient fluid flow mechanism which is the direct reason for the external transient effects. The major contents of the current dissertation consist of the following five aspects:
First, in order to validate the effectiveness and accuracy of the dynamic mesh based finite volume method in solving the unsteady flow caused by the moving boundary, numerical simulations on the two-dimensional unsteady incompressible viscous flow caused by a circular impulsively started into translation and rotary translation were performed. Spring analogy combined with remeshing method was employed to realize the deformation of the computational domain. Numerical results are compared well with the experimental and numerical results in literature both qualitatively and quantitatively. The dynamic mesh based finite volume method is proved to be feasible in solving the unsteady flow caused by the boundary motion.
Second, according to the problem that using dynamic mesh method alone to deal with the changing of fluid domain due to the accelerated impeller may lead to the deterioration of the updating mesh quality, the dynamic slip region (DSR) method was put forward to guarantee the updating mesh quality. The DSR method was successively applied to solve the two-dimensional and three-dimensional transient flows in the centrifugal pump during starting period. Furthermore, to eliminate the errors introduced by externally prescribed unsteady inlet and outlet boundary conditions during starting period, the three-dimensional cycling pipe system along with the whole pump model was set up, and then the transient flow was solved exactly via numerical self-coupling computation process without specifying any boundary conditions.
Third, a centrifugal pump performance test rig was originally designed and built up. The rig was composed of power storage device, pump, piping system, data acquisition and electric control system. Instantaneous explicit characteristics such as flow rate, head, rotational speed and shaft torque of the pump during starting period were tested and collected experimentally. Particle image velocimetry (PIV) technique was employed to record the two-dimensional instantaneous flow field. Evolutions of the velocity vector field corresponding with the explicit performance under same condition were given. The experimental results can served as the realistic references in exploring the transient flow mechanism during starting period.
Fourth, three-dimensional numerical model of cycling pipe and pump system equivalent with the real test rig was established. The transient flow in the numerical system model was solved under the experimental rotational speed history. Comparisons of the explicit and internal results between numerical simulation and experiment were satisfactory.
Fifth, based on the numerical calculation results of the transient flow, unsteady vortex dynamics diagnostics on the pump were performed by analyzing the total pressure flux distribution in the flow cross section and the axial component of boundary vortex flux on the blade surface.
Research results indicate that, during starting period, the explicit factor of unsteady non-dimensional head deviation from the steady-state level is the form of start acceleration, while the fluid inertial and evolution of flow structure are the internal factor. Transient characteristics in the early stage of the starting period show rapid rises of rotational speed, head and power with low flow rate, non-dimensional head suddenly falls below the steady-state level from infinity; in the mid-stage flow rate rises rapidly, lead to the increase rate of power exceeds that of head; in the later stage, start acceleration abruptly decreases to zero, rotational speed turns to stable, the increase of flow rate slowdowns, head and power come to the steady-state level after fluctuation and impact. During the whole process of the starting period, the flow rate-time curve shows like cubic trait. The motor power shows clear instantaneous impact when the valve was completely closed.
The evolutions of the internal flow field present strong transient effects. That applying the quasi-steady assumption to the design of a centrifugal pump used in the startup process is not appropriate. The content and conclusions of the current dissertation can provide references for the performance prediction, design optimization and fluid control of the hydraulic machinery used in a variety of transient process.
本文以处在启动过程中的离心泵为研究对象,针对离心泵在启动过程中表现出的特殊瞬态水力性能,建立离心泵启动过程瞬态流动的数值模拟与诊断方法,建立离心泵性能测试实验系统,分别从数值模拟和实验研究的角度探索引起外部非定常效应的内部流动机理。论文的主要内容包括以下五个方面:
第一,为验证基于动网格的有限体积法在求解边界移动引起的非定常流动时的有效性和准确性,对圆柱瞬时平动和旋转平动启动引起的二维非定常不可压黏性流动进行了数值模拟,采用弹簧近似模型和网格重构相结合的方法实现该过程的流场变形。模拟结果与已有的实验和数值结果从定性和定量上均吻合较好,证明该方法在求解边界移动引起的非定常流动时的有效性。
第二,针对单独采用动网格方法模拟叶轮加速启动所引起的网格更新质量下降的问题,提出采用区域动态滑移方法保证叶轮启动过程网格的更新质量,成功的将动网格方法推广应用到离心泵二维和三维模型启动过程的瞬态流动求解。同时,为消除启动过程外部指定非定常进出口边界条件所引起的误差,提出建立离心泵循环管路系统的三维数值模型,通过数值求解的自身耦合性实现了无需指定边界条件即可准确求解启动过程的瞬态流动。
第三,建立离心泵瞬态性能测试实验台,该实验台由动力蓄能装置、模型泵、管路系统、数据采集和电气控制系统五部分组成。对泵启动过程的外特性,如瞬时流量、扬程、转速和轴扭矩的变化进行测试和采集;采用PIV内流测量方法对稳态和瞬态内流场进行拍摄,得到与外特性相对应的稳态和瞬态的速度矢量场,为探索离心泵启动过程瞬态流动机理提供真实的参考依据。
第四,建立与该实验台等效的离心泵循环管路系统三维数值模型,在与启动实验同等边界条件下,求解该数值模型内部瞬态流动。将实验所得结果与数值模拟结果进行对比研究,两者同时在瞬态外特性和内特性上吻合较好。
第五,基于瞬态流动的数值计算结果,采用过流断面和边界涡量流两种涡动力学诊断方法对离心泵启动过程的内部瞬态流动进行诊断。
研究结果显示,泵启动过程无量纲扬程偏离稳态值的外部原因是启动加速度的变化形式,内部原因是水流惯性和瞬时流场结构的不断演化。启动初期瞬时外特性主要表现为低流量下瞬时转速、扬程和功率的快速上升,瞬时无量纲扬程从无穷大快速下降至低于稳态水平;启动中期流量快速增长,引起瞬时功率的增长率高于瞬时扬程;启动后期启动加速度降为零,转速达到稳定值,流量增长减缓,瞬时扬程和功率经过波动冲击达到稳态水平。启动全过程瞬时流量表现出三次曲线的增长特性。阀门全关启动时的电机功率将表现出明显的瞬时冲击。
启动过程内部流动演化呈现强烈的瞬态特性,采用基于准稳态假设的思想对应用于启动过程的离心泵进行设计是不适合的。本文的研究内容和结论可为应用于各种瞬态过程的水力机械瞬时性能预测、设计优化与流动控制提供参考依据。
The startup process of a centrifugal pump is a special type of transient process. The centrifugal pump during starting period can be used to supply instantaneous hydraulic power in some special application areas, while instantaneous performances of high-power pumps during starting period may lead to excessive loads or impact failures of facitilies and piping systems. Due to the lack of systematic study on the transient flow in a centrifugal pump during starting period at present, how to achieve methods of performance prediction, design optimization and flow control of the centrifugal pump during starting period is an important issue.
Taking the centrifugal pump during starting period as the research object of this dissertation, in view of the special transient hydraulic performance casued by the pump's startup process, the methods of numerical simulations and diagnostics on the unsteady flow in the centrifugal pump during startup process were established. A centrifugal pump performance test rig was developed. Numerical simulations and experimental studies were combined to explore the internal transient fluid flow mechanism which is the direct reason for the external transient effects. The major contents of the current dissertation consist of the following five aspects:
First, in order to validate the effectiveness and accuracy of the dynamic mesh based finite volume method in solving the unsteady flow caused by the moving boundary, numerical simulations on the two-dimensional unsteady incompressible viscous flow caused by a circular impulsively started into translation and rotary translation were performed. Spring analogy combined with remeshing method was employed to realize the deformation of the computational domain. Numerical results are compared well with the experimental and numerical results in literature both qualitatively and quantitatively. The dynamic mesh based finite volume method is proved to be feasible in solving the unsteady flow caused by the boundary motion.
Second, according to the problem that using dynamic mesh method alone to deal with the changing of fluid domain due to the accelerated impeller may lead to the deterioration of the updating mesh quality, the dynamic slip region (DSR) method was put forward to guarantee the updating mesh quality. The DSR method was successively applied to solve the two-dimensional and three-dimensional transient flows in the centrifugal pump during starting period. Furthermore, to eliminate the errors introduced by externally prescribed unsteady inlet and outlet boundary conditions during starting period, the three-dimensional cycling pipe system along with the whole pump model was set up, and then the transient flow was solved exactly via numerical self-coupling computation process without specifying any boundary conditions.
Third, a centrifugal pump performance test rig was originally designed and built up. The rig was composed of power storage device, pump, piping system, data acquisition and electric control system. Instantaneous explicit characteristics such as flow rate, head, rotational speed and shaft torque of the pump during starting period were tested and collected experimentally. Particle image velocimetry (PIV) technique was employed to record the two-dimensional instantaneous flow field. Evolutions of the velocity vector field corresponding with the explicit performance under same condition were given. The experimental results can served as the realistic references in exploring the transient flow mechanism during starting period.
Fourth, three-dimensional numerical model of cycling pipe and pump system equivalent with the real test rig was established. The transient flow in the numerical system model was solved under the experimental rotational speed history. Comparisons of the explicit and internal results between numerical simulation and experiment were satisfactory.
Fifth, based on the numerical calculation results of the transient flow, unsteady vortex dynamics diagnostics on the pump were performed by analyzing the total pressure flux distribution in the flow cross section and the axial component of boundary vortex flux on the blade surface.
Research results indicate that, during starting period, the explicit factor of unsteady non-dimensional head deviation from the steady-state level is the form of start acceleration, while the fluid inertial and evolution of flow structure are the internal factor. Transient characteristics in the early stage of the starting period show rapid rises of rotational speed, head and power with low flow rate, non-dimensional head suddenly falls below the steady-state level from infinity; in the mid-stage flow rate rises rapidly, lead to the increase rate of power exceeds that of head; in the later stage, start acceleration abruptly decreases to zero, rotational speed turns to stable, the increase of flow rate slowdowns, head and power come to the steady-state level after fluctuation and impact. During the whole process of the starting period, the flow rate-time curve shows like cubic trait. The motor power shows clear instantaneous impact when the valve was completely closed.
The evolutions of the internal flow field present strong transient effects. That applying the quasi-steady assumption to the design of a centrifugal pump used in the startup process is not appropriate. The content and conclusions of the current dissertation can provide references for the performance prediction, design optimization and fluid control of the hydraulic machinery used in a variety of transient process.
引文
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