Multi-factor orthogonal optimization and experimental performance study of flow passages in a vertical mixed-flow...

Area of Science:

• Fluid dynamics
• Mechanical engineering
• Hydraulic machinery

Background:

• Traditional methods for optimizing pump flow passages are inefficient and lack engineering adaptability.
• These methods often ignore complex parameter interactions and rely on empirical data.

Purpose of the Study:

• To develop and validate a multi-factor interactive flow passage optimization methodology for vertical mixed-flow pump units.
• To enhance the efficiency and operational stability of these pumps through advanced simulation and experimental design.

Main Methods:

• Coupling orthogonal experimental design with Computational Fluid Dynamics (CFD) simulations.
• Establishing a multi-indicator quantitative evaluation system (hydraulic loss, velocity uniformity, weighted average angle).
• Systematic testing of key parameter combinations on a large-scale drainage pumping station.

Main Results:

• The optimal intake flow passage scheme reduced hydraulic loss to 0.104 m and improved outlet velocity uniformity to 97.06%.
• The optimized discharge flow passage exhibited smooth flow patterns, avoiding flow separation and ensuring spatial compatibility.
• Model tests confirmed pump unit efficiency reached 77.34% at a flow rate of 11.38 m3/s, with CFD-experimental error below 5%.

Conclusions:

• The proposed methodology offers a scientifically efficient and engineeringly feasible approach for flow passage optimization in vertical mixed-flow pumps.
• The optimized designs significantly reduce flow impact losses and enhance overall pump performance.
• This study provides a validated technical pathway for improving similar hydraulic machinery.