A customized dredge pump is a specialized piece of equipment designed to meet specific requirements in dredging operations. Dredging plays a crucial role in various industries, including construction, mining, offshore operations, and reclamation projects. These pumps are tailored to handle the challenging task of removing sediment, sand, slurry, and other debris from bodies of water such as rivers, lakes, and harbors.
The main advantage of a custom dredge pump is its ability to meet the unique needs of individual projects. These pumps are designed and manufactured with careful consideration of factors like flow rate, discharge pressure, material composition, and operating conditions. By customizing the pump, it becomes optimized for the specific dredging project, resulting in improved efficiency, productivity, and overall performance.
Customized dredge pumps can be equipped with various features and components, including different impeller designs, wear-resistant materials, and specialized sealing systems. Additionally, they can be configured with specific pipeline connections, valves, and control systems to ensure seamless integration into the overall dredging setup.
Tai’an Ocean Pump is a leading customized dredge pump manufacturer. We have produced customized dredge pump for 30 years. Our dredge pump products enjoy high popularity all over the world, and have the characteristics of exquisite workmanship, reliable performance and excellent quality. Our customized dredge pump is very popular in domestic and foreign markets and exported to Brazil, Malaysia, Indonesia, Thailand, South Korea, Nigeria, etc. We have won the trust and good recognition of our customers.
1. What Important Factors You Should Consider When Ordering Customized Dredge Pump
1.1 Wear resistance
Wear ressitance means the dredging ability of the custom dredge pump to resist mechanical friction, and the sharp and irregular gravel can be passed effectively during the dredging process while maintaining high performance and long service life.
1.2 Efficiency
For the abrasion resistance, we use high wear-resistant materials and optimise heat treatment technology, the service life of customized dredge pump has been increased by more the 3 times. For the efficiency, our engineers has also been learning the most advanced technology in the world. Recent research results have proved that our product efficiency has made great progress. Following is how our engineers improve sand dredging pump efficiency.
2. How does the impeller design affect the efficiency of the Customized Dredge Pump?
OCEAN Pump optimizes and improves the dredge pump impeller with the CAD/CAE design method. And use CFD technology to predict and analyze the complex flow phenomenon inside the blade machinery. Such as flow separation, dynamic and static interference and secondary flow, etc. CFD guides the improvement of mechanical parameters of blades by analyzing the three-dimensional flow field distribution. By comparing the influence of different blade geometries on the flow field distribution, the geometric parameters of the blades have been optimized and the customized dredge pump efficiency has been significantly improved. This inverse design method of CFD improves the flow field distribution and reduces the existence of residual vortices inside the impeller. The impeller is optimized by changing parameters such as blade wrap angle and placement angle. The chamfered impeller designed by the impeller maximum diameter design method has the following advantages.
The diameter of the front cover of the impeller is approximately equal to the diameter of the inner wall of the customized dredge pump body. Under the condition of the limited sand dredging machine body diameter, the diameter of the impeller is maximized, thereby increasing the customized dredge pump lift. Although in the structural parameters of the impeller, the impeller diameter D, the outlet width b, and the outlet placement angle β all have a significant effect on the lift, but the largest effect on the lift is D, and increasing b and β will increase the customized dredge pump power at the working condition of low head and big flow, and may cause overload operation, even burn out the motor. So using the maximum diameter of the impeller is the best way to obtain maximum lift. The impeller front cover diameter closes to the customized dredge pump body inner diameter. In this case, when the high-speed liquid flow leaves the impeller and flows into the customized dredge pump cavity, its flow direction will turn sharply from the radial direction to the axial direction by 90 °, thereby causing a large impact loss at the customized dredge pump wall. However, in fact, when the liquid flows out of the impeller, its axial surface speed is small and its peripheral speed is very large, so it generally does not cause an increase in hydraulic loss. In traditional centrifugal sand pumps, there is a large annular space between the impeller outlet and the sand pump wall, but by technology improving, the annular space between the impeller outlet and the customized dredge pump wall is smaller, and the liquid flow speed will be higher in the annular space. In fact, the velocity of the liquid flow when it leaves the impeller and enters the annular space is generally very high, and it is often much higher than the fluid flow velocity in the annular space. Therefore, appropriately increasing the fluid flow velocity in the annular space can effectively reduce the change rate of flow velocity, thereby further reducing hydraulic loss.
The front cover of the impeller is tapered with the pump shaft as the center, so that the flowing liquid tends to move upward at the impeller outlet, which is conducive to improving the efficiency of the customized dredge pump. The front cover of the impeller has a tapered shape, which gradually reduces the width of the axial surface of the impeller flow channel from the inlet to the outlet. This can provide favorable conditions for the design of the shrinkage flow channel, at least it can reduce the degree of flow channel diffusion, and can improve efficiency.
The blade outlet width b2 of the impeller has a great influence on the performance of the customized dredge pump, so appropriately increasing b2 can not only increase the lift, but also improve the efficiency. By optimizing the numerical simulation of the customized dredge pump efficiency, the blade outlet width b2 with the highest efficiency can be selected.
The blade inlet side of the impeller extending to the inlet can make the rear cover streamline of the blade longer. This can not only prevent secondary backflow at the outlet of the impeller, but also improve the lift and efficiency of the customized dredge pump. Because the diameter of the rear cover of the improved pump impeller is smaller than the diameter of the front cover of the impeller, the pressure of the rear cover at the impeller outlet will be lower than the pressure of the front cover. If the pressure at the outlet of the impeller rear cover is too low, secondary backflow may occur, that is, the liquid discharged by the impeller returns to the impeller. If the inlet edge of the impeller blade extends toward the inlet to make the rear cover of the blade flow longer, the pressure at the outlet of the rear cover of the impeller can be increased to prevent secondary backflow at the outlet of the impeller. At the same time, this can also reduce the impact loss of liquid flow at the blade inlet edge and improve the customized dredge pump efficiency.
3. Test Data
3.1 Calculation formula of head
pd, ps is the static pressure of the liquid at the customized dredge pump outlet and inlet. vd, vs is liquid speed at the pump outlet and inlet. zd, zs is distance from customized dredge pump outlet, inlet to optional measurement datum.
3.2 Calculation formula of efficiency
ρ is the density of pumped liquid, kg/m3. Q is customized dredge pump flow, m3/s. H is customized dredge pump head, m. g is gravitational acceleration. P is shaft power, kw.
Pg is effective power, kw.
3.3 Conversion of standard performance
nsp is required revolutions, n is measured motor revolutions, QT is flow at specified revolutions. Q is the measured flow.
HT is the head at the specified revolutions; H is the head at measured revolutions.
PT is the input power at the specified revolutions; P is the measured power. ρsp is the density of the specified liquid. ρ is the density of the test liquid.
ηT=η
ηT is the efficiency at specified revolutions. η is the efficiency at the measured revolutions.
3.4 Identify key factors
According to the professional knowledge and the special structural design requirements of the new customized dredge pump, the following seven sets of geometric parameters are taken as test factors: β2 (outlet placement angle), D2min (impeller rear cover outer diameter), b2 (outlet width), D1 (number of blades), Z( Blade inlet diameter), Δβ1 (blade inlet angle of attack), the specific position is shown in the figure.
2D hydraulic diagram of impeller
Test purpose: To propose an optimal design scheme for model sand pump flow Q = 2200m3 / h, head H = 30m, rotation speed n = 730r / min, and specific speed ns = 128. The two-stage full-flow field numerical simulation was performed for the sand pump with a small flow of 2100m3 / h, a rated flow of 2200m3 / h, and a large flow of 2300m3 / h. The total number of mesh divisions was 870,000 and the accuracy of the residual convergence was 10-4. Using standard model, SIMPLEC algorithm. Impeller and guide vane surface roughness is 0.025mm, axial clearance of impeller inlet seal end face is completely sealed.
4. Customized dredge pump optimization scheme analyse
Based on the simulation results, the pressure distribution and speed distribution of the three operating conditions of the customized dredge pump optimization scheme are analyzed.
4.1 Pressure analysis:
Figure 1 static pressure cloud diagram of the middle section of the impeller under three operating conditions
Figure 1 shows the static pressure cloud diagram of the middle section under the three working conditions of the impeller. It can be seen that the static pressure in all three operating conditions increases uniformly from the inlet of the impeller to the outlet. The pressure at the tail end of the blade reaches the maximum. The pressure on the back of the blade near the inlet area reaches minimize.
4.2 Speed analysis
Figure 2 Vector diagram of the relative velocity of the impeller in three operating conditions
4.3 Turbulent kinetic energy distribution diagram
Figure 3 Turbulent kinetic energy distribution of the impeller in three operating conditions
Figure 2 shows a vector diagram of the relative velocity of the middle section of the impeller in three operating conditions, and Figure 3 shows the turbulent kinetic energy distribution diagram of the impeller in three operating conditions. The liquid velocity distribution in the impeller is uniform, without significant backflow and vortex, and the overall symmetry is obvious. Make the X = 0 section of the whole flow channel, and get the velocity vector diagram and turbulent kinetic energy distribution diagram at the rated flow shown in Figure 2. There is no obvious backflow and vortex in the entire flow channel. The impeller outlet speed is the largest, and the speed gradually decreases after passing through the impeller, which is in line with the actual situation. The impeller outlet is cut obliquely, so the outlet speed is directed to the rear cover, and there is no obvious impact on the inner wall of the customized dredge pump. It can be seen that increasing the diameter of the front cover of the impeller does not increase the impact loss at the impeller outlet.
OCEAN Pump used the CFD software Fluent to perform numerical simulation on the pump model, obtained the relationship between the primary and secondary order of several design parameters of the splitter blades: β2 (outlet placement angle), D2min (outer diameter of the rear cover of the impeller), b2 (outlet width), Z (number of blades), D1 (blade inlet diameter), Δβ1 (blade inlet punch angle), and predicted its hydraulic performance. By producing sand pump sample and comparing test results, we learned that numerical simulation can better predict hydraulic performance. This provides the basis for our design and improvement.
After new technical improvements, OCEAN Pump made customized dredge pump sample for test. After clear water tests and mixed liquid test, the efficiency of the dredge pump was increased by 3% compared to the previous, which is a very big improvement. OCEAN Pump engineers has been pursuing technological advances without a break.
Conclusion
The design and optimization of customized dredge pumps play a crucial role in achieving efficient and effective dredging operations. These specialized pumps are tailored to meet the unique requirements of each project, taking into account factors such as flow rate, discharge pressure, material composition, and operating conditions. By customizing the pump design, it becomes optimized for the specific dredging task, resulting in improved efficiency, productivity, and overall performance.
The use of advanced technologies, such as CAD/CAE design methods and CFD analysis, enables engineers to optimize the impeller design and enhance the flow field distribution within the pump. This leads to increased lift, reduced hydraulic losses, and improved overall efficiency. Additionally, the selection of wear-resistant materials and the implementation of heat treatment technology extend the service life of the customized dredge pump.
OCEAN Pump always pays attention to customer needs, and always improves and updates our products to meet customer requirements and local construction environment, and customize personalized products for customers. We are committed to providing perfect and unique dredging pumps, perfect customer service, and unremittingly meeting customer needs. Customer satisfaction is our most important business reputation. We are always your best partner. If you have any questions about the customized dredge pump and sand dredger, please feel free to consult our engineers.
