Influence of operating parameters on blade wear characteristics of helical vane multiphase pump

To address blade wear of helical vane multiphase pumps during sand-containing crude oil transportation in desert oilfields, a self-developed multi-stage pump was studied via numerical simulation (Discrete Phase Model, DPM) and experimental verification. The effects of flow rate, rotational speed, and oil content on internal wear mechanisms were investigated, and a multivariate nonlinear regression model for maximum wear rate was established using the Levenberg–Marquardt algorithm. Results show pitting wear dominates the blade surface, with the blade tip and diffuser outer edge as primary wear-prone regions. Increased flow rate aggravates wear: the impeller hub wear rate first rises then declines, while the rim wear rate increases monotonically. Reduced rotational speed significantly mitigates wear in the impeller’s mid-span and mid-streamwise regions, synchronously decreasing diffuser tip wear. Higher oil content reduces maximum wear, most notably at the diffuser tip; impeller rim/tip wear first decreases then increases. Minimum wear occurs at low flow rate, low rotational speed, and high oil content. The regression models exhibit R 2 > 0.8, indicating excellent fitting accuracy and reliable predictive capability. This work provides critical technical support for the optimal design and on-site condition regulation of helical vane multiphase pumps.