The impeller, which is the main energy conversion component of a pump as turbine (PAT), is designed for pumping mode, and its internal flow characteristics are quite complicated even at the best efficiency point (BEP) of the turbine mode. This study aims to investigate the flow separation characteristics in a PAT impeller under the BEP condition by numerical method. The hydraulic performance and transient pressure characteristics of PAT predicted numerically were verified through experimentation. The surface friction lines and flow topological structure were applied to diagnose the flow separation at the surface of the blade. The relationship between flow topological structure and vortex in the impeller and static pressure at the blade were analyzed. Analysis results show that the backflow and open flow separation are observed significantly in the leading region and near the shroud of the trailing region of suction side. The passage vortex always appears near the spiral node. The saddle point and spiral node correspond to the peak position of adverse pressure and the lowest position between two peak values of the static pressure of the blade, respectively. The inflow conditions of blade and shape of the trailing edge significantly influence the flow separations in the impeller.

Multi-stage pump as turbine (PAT) has a wider range of heads and application intervals compared to single-stage PAT. In our research, we have conducted experimental and numerical simulation studies on this issue. In this paper, based on experimental research, numerical simulation is applied to calculate the multi-stage PAT flow field. The flow characteristics of multi-stage PAT under different working conditions are studied using the entropy production theory. Finally, the Pearson correlation coefficient is used to evaluate the relationship between the hydraulic loss and entropy production of the impellers and guide vanes. The entropy production theory is used to determine the location where the multi-stage PAT energy loss occurs compared with the traditional pressure drop assessment method. The results show that the trend of the numerical simulation results is consistent with the experimental results. The energy loss in the multi-stage PAT is calculated combined with the impeller and guide vane which accounts for 69.1–73% of the total energy loss under all flow conditions. The total entropy production rate of each component under design flow conditions is listed in decreasing order: impeller, guide vane, front and back chamber, a balance disk, and inlet and outlet volute. The first stage component has a larger energy loss compared with the rest of the stages. The magnitude of energy loss is closely related to physical quantities such as flow field velocity and skin friction coefficient. Furthermore, the distribution of streamlines and vortex cores at the impellers reflects that flow domain stability increases from the first stage impeller to the fifth stage impeller. The correlation between entropy production and hydraulic loss was evaluated by the Pearson correlation coefficient. Therefore, using the entropy production theory can effectively identify the characteristics of the flow field and the location of energy losses. It provides a reference for the targeted optimization of multi-stage PAT.

The outlet duct is the only outlet flow component of the pump as turbines (PATs). The flow state within it not only affects its operation stability but also influences the safe operation of downstream process equipment. The undesirable flow phenomenon of the vortex is the main reason for pressure pulsations and vibrations; therefore, it is important to adopt simulation and experimental methods to reveal the vortex-pressure fluctuation interaction characteristics in the outlet duct of PATs. Firstly, the spatial and temporal evolution of the vortex in the outlet duct under different operation conditions were compared based on the Q-vortex identification criterion. Subsequently, the frequency components corresponding to local high amplitude vorticity and pressure pulsations were clarified. Finally, the relationship between vortex evolution and the pressure pulsations in the outlet duct was established. The results showed that the flow rates of the turbine significantly affected the spatial and temporal evolution of the vortex rope in the outlet duct. The front chamber leakage flow and vortex shedding from the blade trailing edge also influenced the vortex distribution characteristics in the outlet duct. The dominant frequency of the pressure pulsation in the outlet duct was 6 f_n under different operating conditions, and the amplitude of the pressure pulsation increased with the flow rates. The effect of vortex evolution on the local pressure pulsation characteristics decreased with increasing flow rates. The results can be used to improve and stabilize the operation and further optimization of PATs.