Development and Optimized Design of Propeller Pump System & Structure with VFD in Low-head Pumping Station

Compared with vertical-installed pumps, the propeller (bulb tubular) pump systems can achieve higher hydraulic efficiencies, which are particularly suitable for low-head pumping stations. More than four propeller pumping stations are being, or will be built in the first stage of the S-to-N Water Diversion Project in China, diverting water from Yangtze River to the northern part of China to alleviate water-shortage problems and develop the economy. New structures of propeller pump have been developed for specified pumping stations in Jiangsu and Shandong Provinces respectively and Variable Frequency Drives (VFDs) are used in those pumping stations to regulate operating conditions. Based on the Navier-Stokes equations and the standard k-e turbulent model, numerical simulations of the flow field and performance prediction in the propeller pump system were conducted on the platform of commercial software CFX by using the SIMPLEC algorithm. Through optimal design of bulb dimensions and diffuser channel shape, the hydraulic system efficiency has improved evidently. Furthermore, the structures of propeller pumps have been optimized to for the introduction of conventional as well as permanent magnet motors. In order to improve the hydraulic efficiency of pumping systems, both the pump discharge and the motor diameter were optimized respectively. If a conventional motor is used, the diameter of the pump casing has to be increased to accommodate the motor installed inside. If using a permanent magnet motor, the diameter of motor casing can be decreased effectively without decreasing its output power, thus the cross-sectional area is enlarged and the velocity of flowing water decreased favorably to reduce hydraulic loss of discharge channel and thereby raising the pumping system efficiency. Witness model tests were conducted after numerical optimization on specific propeller pump systems, indicating that the model system hydraulic efficiencies can be improved by 0.5%similar to 3.7% in different specified operational conditions.