Manufacturing Hydraulic Components for the Primary Double Entry S-Pump Model

The article describes a new design of the primary pump to run in powerful units (more than 1 GW) of power plants. The new construction has some advantages such as compactness, theoretical lack of radial and axial forces, and high efficiency in a wide range of flow. The abovementioned advantages can be possible owing to applying an innovative shape of the pump flow path. An impeller with the guide vanes forms the three-row single stage in the each row axial double entry blade system. The inlet and outlet parts have a shape of the involute that can ensure (according to calculated data) the efficiency and stability in a wide range of flow because of a lack of the spiral parts. The results of numerical calculations of the pump working flow theoretically confirm that demanding parameters of the pump (H=286 m; Q=1,15 m3 /s) can be obtained with competitive efficiency. To verify the proposed advantages of the construction, there was decision made to conduct the real physical experiment. For this purpose the small model of a real pump was designed with parameters H=14 m, Q=13 l/s. Construction of the pump model has a cartridge conception. In addition, there is a possibility for quick replacement of the some parts of the blade system in case of operational development of the pump. In order to obtain hydraulic characteristics of the pump to say nothing of the electromotor the torque gauge coupling is used. Numerical calculations for the pump model were also performed which confirm the operability. For manufacturing of the blade system the new perspective technology is applied. The main hydraulic components (impellers and guide vanes) are made of ABS plastic by using 3D-printer. According to this technology parts are made layer by layer by means of welded plastic filament. Using this method the satisfactory tolerance (approximately ±0,3 mm) of the parts was obtained. At that moment, it is possible to create the parts with the maximum size no higher than 150 mm. Immersing finished parts in acetone vapor enable us to increase the surface strength and reduce roughness. At this stage of the work some plastic parts are ready for assembling operation. Now manufacturing of other plastic parts of the blade system is under way along with pre-production of the rotor and stator components.

s-pump, involute, 3D-printer, ABS plastic, numerical calculation, impeller, guide vanes, multi-row pump, physical experiment, manufacturing, prototyping

1. Kuptsov S.Yu., Morgunov G.M. Results of the numerical simulation of the flow path of the primary double entry s-pump. Gidromashiny, gidroprivody i gidropnevmoavtomatika: 17-aya Mezhdunarodnaya nauchno-tekhnicheskaya konferentsiya studentov i aspirantov. Dekabr' 2013 g: Sbornik dokladov [Hydraulic machines, hydraulic drive, hydraulic and pneumatic automation. 17th international science technical conference for students and graduate. Collection of reports. Moscow, BMSTU Publ., pp. 78-85. (in Russian)

2. Morgunov G.M. Vane machines for liquids and gases with increaseed density of the efficiency. Vestnik MEI = Herald of the MPEI, 2007, no. 4, pp. 5-13. (in Russian).

3. Kuptsov S.Yu., Morgunov G.M. Involute shaped inlet for pump installations. Radioelektronika, elektrotekhnika i energetika: Dvadtsataya mezhd. nauch. tekhn. konf. studentov i aspirantov: Tez. dokl. T. 4 [Electronics, Electrical and Power Engineering. 20th international science technical conference for students and graduate. Collection of reports], Moscow, Publishing house MPEI, 2014, vol. 4, 190 p. (in Russian).

4. Morgunov G.M. Pump paradigm of feed system on power unit. Teploenergetika = Thermal Engineering, , 2013, no. 2, pp. 118-128 (in Russian).

5. Bushziper P. Conception of the SULZER feed pump construction. Vestnik SUSU = Bulletin of the South Ural State University, 2005, iss. 1, pp. 65-72 (in Russian).

6. ANSYS CFX-Solver Modeling Guide. Release 14.5, October 2012.

7. Funaba Y., Sato T., Suzuki S., Terunuma A., Nagahara T. Unsteady Fluid Flow Analisis as Applied to the Internal Flow in a Pump using ANSYS CFX . Hitachi Plant Technologies, Ltd. 2006 Ansys – Simulation Driven Product Development: website. Available at: http://www.ansys.com/staticassets/ANSYS/staticassets/resourcelibrary/confpaper/2006-IntANSYS-Conf-235.pdf, accessed 17.07.2015.

8. Kulebiakin A.A., Orehovskya N.A. New technology. Development of the 3D-printing: prospects and consequences. Molodezhnyi nauchno-tekhnicheskii vestnik MGTU im. N.E. Baumana = Youth Science and Technology Herald of the Bauman MSTU, 2015, no. 3 (in Russian).

9. Matushkin L.B., Permiakov N.V. Applying of the 3D-printing in providing of professionally oriented stuff training for nanoindustry. Biotekhnosfera = Biotechnosphere, 2013, no. 3(27), pp. 38-47. (in Russian).