Most multi-phase pumps used in crude oil production have been developed to satisfy certain pressure specifications. In the design of these pumps, the flow characteristics of the posterior stage are different from those of the prior stage. For this reason, the design of the second stage needs to be supplemented. To optimize performance in this stage, multi-objective optimization to simultaneously increase pressure and efficiency is reported in this article. Flow analyses of the single and multiple phases of the multi-phase pump were conducted by solving three-dimensional steady Reynolds-averaged Navier–Stokes equations. For the numerical optimization, two design variables related to the blade inlet angle were selected. The impeller and the diffuser blades were optimized using a systematic optimization technique combined with a central composite method and a hybrid multi-objective evolutionary algorithm coupled with a surrogate model. The selected optimal model yielded better hydrodynamic performance than the base model, and reasons for this are investigated through internal flow field analysis.

Pump-turbines are often used to provide a stable power supply with a constant frequency in response to intermittent renewable energy resources. However, existing pumped-storage power stations often operate under off-design conditions because of the increasing amounts of inconsistent renewable resources that have been added to the grid. Under off-design low flow rate conditions, inter-blade vortex and vortex rope phenomena usually develop in the runner and draft tube passages, respectively, in turbine mode. These vortices cause complicated flow patterns and pressure fluctuations that destabilize the operation of the pump-turbine system. Therefore, this study investigates the influence of correlation between the inter-blade vortex and vortex rope phenomena under low flow rate conditions. Three-dimensional steady- and unsteady-state Reynolds-averaged Navier–Stokes equations were calculated with a two-phase flow analysis using a shear stress transport as the turbulence model. The inter-blade vortices in the runner passages were captured well at the low flow rate conditions, and the vortex rope was found to develop within a specific range of low flow rates. These vortex regions showed a blockage effect and complicated flow characteristics with backflow in the passages. Moreover, higher unsteady pressure characteristics occurred at locations where the vortices were especially pronounced.

S-shaped characteristics in turbine mode are prone to instabilities in associated transient processes. A single value of the speed factor corresponds to multiple values of the discharge factor, having the possibility of changing the operating point among the turbine, turbine brake, and reverse pump modes. Because of this characteristic, the S-shaped curves induce instability in transient processes. Understanding the hydraulic behavior of a turbine on the four-quadrant characteristic is important since it provides detailed performance information through the whole discharge range of the turbine. This study was numerically and experimentally investigated the scale effect on the S-shaped characteristics in the turbine transition region. The four-quadrant characteristic curves (full- and laboratory-scale) in the turbine mode were predicted by numerical simulations. To verify the predicted results, a laboratory-scale experiment was performed in the turbine, turbine brake, and reverse pump modes. Although the full-scale experiment was performed in the normal operating head range, the scale effect can be validated by comparing steady operating points between the two models. Based on the verified results, the internal flow and pressure pulsation characteristics were determined at the operating point in a specific transition region.