Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
By
Bilal Waseem
ME-04
Report submitted to the faculty of PIEAS in partial fulfillment of
requirements for the degree of MS Mechanical Engineering
Abstract
Centrifugal pumps are very important component of any industrial setup. These pumps
must be operated carefully because issues such as cavitation have the potential to put
these turbo machines out of order. The work conducted in this research comprises of the
use of CFD tools to analyze the flow characteristics inside a centrifugal pump. ANSYS
CFX has been used to carry out the CFD simulations of the pump impeller under
different flow rates and pressure and velocity profiles have been determined inside the
impeller. These profiles will provide information about phenomena such as flow
separation and flow recirculation. Using the pressure profile, the head to flow rate
characteristic curve will be developed and compared with the data provided by the actual
impeller that has been modeled. Afterwards, the blade length will be shortened and its
effects on the characteristic curves will be studied. The results obtained from this
research are then planned to be carried on to a separate research work in the future, where
cavitation phenomena will be studied in detail and it will be investigated how the
shortening of blades affects the pump performance with reference to cavitation.
ii
Table of Contents
1
Introduction ................................................................................................................. 1
1.1
1.1.1
1.1.2
Impeller ......................................................................................................... 2
1.1.3
Volute............................................................................................................ 2
1.1.4
Discharge ...................................................................................................... 2
Literature Review........................................................................................................ 3
4.1
4.2
Meshing..................................................................................................................... 14
5.1
Element Size....................................................................................................... 14
5.2
5.3
6.2
Analysis Type..................................................................................................... 19
6.3
6.4
6.4.1
6.4.2
6.5
Initialization ....................................................................................................... 21
6.6
Boundary Conditions.......................................................................................... 21
iii
6.6.1
Inlet ............................................................................................................. 21
6.6.2
Outlet........................................................................................................... 21
6.6.3
Wall ............................................................................................................. 21
Results ....................................................................................................................... 23
7.1
7.2
Pressure Contours............................................................................................... 24
7.3
References ................................................................................................................. 27
Vita............................................................................................................................ 28
iv
LIST OF FIGURES
Figure 1: Components of centrifugal pump ........................................................................ 1
Figure 2: Views of actual impeller...................................................................................... 6
Figure 3: Sketch for hub geometry ..................................................................................... 8
Figure 4: Developing the blade geometry........................................................................... 9
Figure 5: 3D blade profile ................................................................................................. 10
Figure 6: Blade profile of all 6 blades .............................................................................. 10
Figure 7: Isometric view of impeller ................................................................................ 11
Figure 8: Side view of impeller ........................................................................................ 11
Figure 9: Top view of Impeller ......................................................................................... 12
Figure 10: Isometric view of fluid domain ....................................................................... 13
Figure 11: Side view of fluid domain ............................................................................... 13
Figure 12: Mesh with 9 mm element size ......................................................................... 16
Figure 13: Mesh view from a slice plane .......................................................................... 16
Figure 14: Close up of inflation layers around blades ...................................................... 16
Figure 15: Inlet and outlet faces........................................................................................ 17
Figure 16: Hub face .......................................................................................................... 17
Figure 17: Blade and shroud faces .................................................................................... 18
Figure 18: Inlet and outlet boundaries .............................................................................. 22
Figure 19: Pressure contours - top and bottom view ........................................................ 25
Figure 20: Velocity streamlines ........................................................................................ 26
Figure 21: Velocity vectors............................................................................................... 26
LIST OF TABLES
Table 1: Dimensions of impeller......................................................................................... 5
Table 2: Operating conditions........................................................................................... 19
Table 3: Basic settings ...................................................................................................... 20
Table 4: Mesh independence ............................................................................................ 24
1 Introduction
A centrifugal pump is a work consuming type of turbo machinery. It converts rotational
kinetic energy to hydrodynamic energy of fluid flow. An engine or electric motor
provides rotational energy. The fluid enters the inlet of a rotating impeller along its axis
of rotation, gets accelerated and then enters a volute where its kinetic energy is converted
into higher pressure as the fluid passes through the increasing area of volute.
1.1.2 Impeller
The impeller is the main rotating component of centrifugal pump. Fluid enters through its
eye, gets caught up in its blades and is whirled tangentially and radially outward. It can
be classified in multiple ways:
1. Based on flow direction
a. Radial flow
b. Axial flow
c. Mixed flow
2. Based on suction type
a. Single-suction: Liquid inlet on one side.
b. Double-suction: Liquid inlet to the impeller symmetrically from both sides
3. Based on mechanical construction
a. Closed: Shrouds or sidewall enclosing the vanes.
b. Open: No shrouds or wall to enclose the vanes.
c. Semi-open or vortex type
1.1.3 Volute
This is the stationary component. It receives the fluid being pumped by the impeller. It
reduces the velocity of fluid because its area keeps increasing from the point where fluid
enters it to the point where it leaves. This reduced velocity results in conversion of kinetic
energy into potential energy thus increasing the pressure of the fluid.
1.1.4 Discharge
This component is basically the ending part of the volute. From here onward, the fluid is
not further pressurized. It connects the pump to the piping system.
2 Literature Review
S. Rajendran and Dr. K. Purushothaman analyzed centrifugal pump impeller using
Ansys CFX. The impeller was six blade closed type impeller, rotating at 925 rpm with a
flow rate of 12.5 litres per second. Unstructured tetrahedral mesh was used for
simulation, using k-epsilon turbulence model with 5% turbulence intensity. CFD
simulation predicted the discharge head of 9.4528 m at design point (1).
Neelambika and Veerbhadrappa used CFD to analyze the effect of varying the inlet
and outlet blade angles on the efficiency of a mixed flow pump impeller. They concluded
that by increasing the blade exit angle and decreasing the inlet angle, efficiency increased
by about 18%. Variation in exit angle improved the efficiency more significantly that the
variation in inlet angle (2).
Kiran Patel and N. Ramakrishnan investigated the flow in a mixed flow pump. The
original geometry was simulated using steady state conditions. Performance curves
obtained from the simulation matched the original curves with only 5 to 10 % difference.
The recirculation at design point was reduced by matching stator blade angle with respect
to flow angle and changing hub curve profile. This improved the efficiency by 1% (3).
S. C. Chaudhari, C. O. Yadav and A. B. Damor studied the effect of change in inlet
and outlet blade angle and number of blades on the discharge head of the mixed flow
pump impeller. CFD simulation was carried out using k-epsilon turbulence model with
5% intensity. Several different blade angles and different blade numbers were simulated
and the best geometry showed an improvement of 10.29 m in discharge head (4).
Liu Houlin, Wang Yong, Yuan Shouqi, Tan Minggao, and Wang Kai studied the
effect of blade number on characteristics of centrifugal pumps. Impellers with 4, 5, 6 and
7 blades were simulated and it was found that discharge head increased with increasing
number of blades. The low pressure region at the inlet of impeller increased with the
number of blades (5).
K.M. Pandey, A.P. Singh and Sujoy Chakraborty investigated the effect of blade
number on performance of centrifugal pump at 2500 rpm. It was found that discharge
head increased while efficiency decreased with increase in blade number (6).
4
Miguel Asuaje, Farid Bakir, Smaine Kouidri, Frank Kenyery and Robert Rey
carried out numerical simulation of centrifugal pump. Three different turbulence models
were compared, namely k-epsilon, k-omega and sst models. It was found that discharge
head was almost same with a difference of less than 0.02%. Further simulations were
done under quasi-unsteady case with k-epsilon model. Frozen rotor interface was used
between inlet-impeller domains and impeller- volute domains (7).
Lamloumi Hedi, Kanfoudi Hatem and Zgolli Ridha studied the three dimensional
flow in centrifugal pump using k-epsilon turbulence model with structured grid. Frozen
rotor interface was used to model the inlet-impeller interface and impeller-volute
interface (8).
Suthep Kaewnai, Manuspong Chamaoot and Somchai Wongwises used CFD
simulation to compare the effect of different turbulence models (k-epsilon, k-omega and
RNG k-epsilon) and turbulence intensities (1%, 5% and 10%) using structured grid.
Different turbulence models gave very similar values of discharge head and variation of
turbulence intensity also did not have any significant effect on the result. The increase in
surface roughness increased the pressure loss (9).
H. L. Liu, M. M. Liu, L. Dong, Y. Renand H. Du studied the effect of turbulence
models and computational grids on numerical simulation of centrifugal pump. K-epsilon
EARSM model was found to give the best results (10).
3 Problem Statement
This thesis is based on an industrial centrifugal pump of mixed flow type. The pump
under consideration has been facing cavitation issues at the suction of impeller and also at
the surface of blades near the trailing edge. The objectives of this thesis are:
1. Modeling CAD geometry of impeller from the actual impeller in use.
2. Using CFD simulation to visualize the flow inside the impeller. These simulations
will show the variation of pressure and velocity under different flow rate
conditions.
3. The results of CFD simulation will be compared with the data provided by the
vendors of the actual pump.
4. Characteristic curves will be developed and compared with those provided by
vendor.
5. The blade length will be reduced and its effect on the performance of pump will
be studied.
The pump under consideration has a best efficiency point at 508 litres per second with
efficiency of 88%. At this flow rate, the discharge head produced by the pump is about 51
m.
Physical dimensions shown in table 1 were taken from the actual impeller but blade
angles could only be measured approximately because the impeller was of closed type.
Entity
Value
Inlet diameter
29.7 cm
Outlet diameter
48.1 cm
16 cm
9 cm
25 degrees (approx.)
Shaft diameter
7.8 cm
6
The purpose of this research is to study the flow in the impeller with the existing
conditions and then to investigate the effects of shortening the length of blades.
Figures show the different views of the actual impeller.
Figure 3 shows the sketching procedure employed for the development of blades. The
yellow curve is lower edge of blade. This is the edge that is attached to the hub. The
black dots are 3D points from where the upper edge of the blade will be passed. This
edge will be attached to the shroud.
From the 3D curve and 3D points shown in figure 3, the complete blade profile was
generated and it is shown in figure 4.
10
As this is a six blade impeller, each blade covers an angle of 150o. Finally the impeller
geometry was replicated six times to finally obtain the complete blade geometry as
shown in figure 5.
11
After the development of hub and blade profile, shroud was developed and the figure 6, 7
and 8 show the final geometry of impeller.
12
13
14
5 Meshing
A fine mesh is important for CFD simulation. Mesh should be fine enough to be able to
capture all the details in critical areas. As the mesh grows finer, the number of cells
where computation is to be done, increases. Thus the computational effort increases and
simulation takes longer time to find a converged solution.
In complex geometries such as the impeller under consideration, it is a general practice to
use tetrahedral elements. The most critical area in the impeller is the area occupied by
blades and so it is necessary to refine the mesh in these regions. In this work,
unstructured grid has been used to generate a free mesh and then inflation layers have
been added on the blade surfaces.
15
wall to the first mesh node. To use a wall function approach for a particular turbulence
model with confidence, we need to ensure that our y+ values are within a certain range.
For good approximation of wall effects, it is advisable to use y+ of less than 2 (11). In
this thesis, desired value of y+ has been set to 2 and then from this dimensionless
number, the actual distance of the first node away from the wall has been estimated. The
procedure employed is as follows:
1. Compute the Reynold number Re:
.
For the design point of 417 litres per second, using inlet velocity of fluid as the
and diameter of inlet as
0.65]
1
.
2
.
.
16
17
18
19
Entity
Value
Rpm of impeller
1480 rpm
10 m
Flow rate
20oC
It is to be mentioned here that uptill now, only a flow rate of 417 lps has been used for
simulations. The future work will consist of simulation done on flow rates ranging from
zero to 660 lps.
20
Table 3: Basic settings
Entity
Characteristic or Value
Domain type
Fluid
Fluid
Water
Morphology
Continuous fluid
Reference pressure
0 kPa
Domain motion
Rotating
Angular velocity
1480 rpm
21
As this research is being conducted primarily to predict the regions where the flow
separates from the blades and accurate results are also required in the free stream, so the
turbulence model chosen for this research is the SST model.
6.5 Initialization
To reduce the computational efforts and to obtain convergence as quickly as possible, it
is essential to initialize the solution properly. If the initial conditions are poor, the solver
takes a long time in finding a converged solution. In this step, an initial guess value is
given for the velocity of flow. The better the guess, the lesser are the computational
efforts. When the simulation work was started, initialization was left to the solver itself
using automatic option. This resulted in severe problems at the inlet and many a time, the
solver returned an error and did not solve the case. Finally the inlet velocity was
initialized using the velocity at inlet and this solved the problem.
6.6.2 Outlet
Mass flow rate has been applied as the outlet boundary condition. For the simulation that
has been done thus far, a mass flow rate of 415 kg/s has been used.
6.6.3 Wall
All the six blades, the hub and shroud have been included as wall boundary condition.
The walls have been modeled as smooth walls with no slip condition.
Figure 14 shows the regions where inlet and outlet boundary conditions have been set.
22
23
7 Results
The simulation setup that was set up in the previous chapter, was solved using CFX
solver. The importance of correct setup cannot be denied but it is equally important to
present the results of an analysis. One must have a clear idea of what the purpose of
simulation is and what physics is aimed to be studied. At the end of the day, it is the
results that are presented and these results give the information needed from the analysis.
As already mentioned, the purpose of these simulations is to obtain the characteristic
curves of the concerned impeller. Uptill now, the pressure curve is under development.
For this curve, it is required to run the simulations at various flow rates and determine the
pressure at the putlet face of impeller. This means that the primary output parameter in
the analysis is the outlet pressure. Pressure is presented in the form of contours in CFX.
These contours show regions of different pressure ranges. From these contour, one can
get the idea about where the pressure gradients are high or low, and where the pressures
are critically low or high.
At the same time, the velocity of water is also needed. From the velocity results, CFX can
produce the streamlines to show the path along which the fluid moves inside the fluid
domain. This fluid path is of importance as it gives an idea of the various phenomena
occuring inside the impeller e.g flow separation along blade surfaces, flow recirculation
etc. These phenomena must be predicted because the ultimate goal of this research work
is to find possible measures to reduce the issue of cavitation and these phenomena have a
close relation to cavitation.
The results presented in this report are only for a flow rate of 417 lps. The pressure at the
inlet of the impeller has been taken as 199 kPa (absolute).
24
affect the results. If the mesh is grown finer beyond this point, it will only increase the
computational time but the results will not be affected.
For this study, pressure at the outlet of impeller was set as the parameter of interest and
different mesh sizes were simulated under identical boundary conditions and turbulence
model.
Table 4: Mesh independence
Serial no.
No. of elements
Pressure (bar)
15
110516
6.73428
10.2
204715
6.80756
9.8
225176
6.77522
251497
6.77470
From this analysis, it was found that the mesh size does not affect the results by much.
This is because inflation layers have already been added in the critical area around the
blade surface. The mesh in the remaining domain does not affect the result significantly.
25
26
27
8 References
1. Analysis of Centrifugal Pump Impeller Using Ansys-CFX. Purushothaman, S.
Rajendran and Dr. K. Purushothaman. ISSN:2278-0181.
2. CFD Analysis of Mixed Flow Impeller. Neelambika, Veerbhadrappa. ISSN: 23217308.
3. CFD Analysis of Mixed Flow Pump. Kiran Patel, N. Ramakrishnan.
4. A comparative study of mix flow pump impeller CFD analysis and experimental data
of submersible. S. C. Chaudhari, C. O. Yadav and A. B. Damor. ISSN 2321-8843.
5. Effect of blade number on characteristics of centrifugal pumps. Liu Houlin, Wang
Yong, Yuan Shouqi, Tan Minggao, and Wang Kai. s.l. : Chinese Journal of
Mechanical Engineering, 2010, Vol. 23.
6. Numerical studies on effects of blade number variation on performance of centrifugal
pumps at 2500 rpm. K.M. Pandey, A.P. Singh and Sujoy Chakraborty. s.l. : Journal of
Environmental Research And Development, 2012, Vols. 6, No. 3A.
7. Numerical modelization of the flow in centrifugal pump: Volute influence in velocity
and pressure fields. Miguel Asuaje, Farid Bakir, Smaine Kouidri, Frank Kenyery
and Robert Rey. s.l. : International Journal of Rotating Machinery, 2005.
8. Simulation study and Three-Dimensional Numerical Flow in a Centrifugal Pump.
Lamloumi Hedi, Kanfoudi Hatem and Zgolli Ridha. s.l. : International Journal of
Thermal Technologies, 2012, Vols. 2, No.4. ISSN 2277 - 4114.
9. Predicting performance of radial flow type impeller of centrifugal pump using CFD.
Suthep Kaewnai, Manuspong Chamaoot and Somchai Wongwises. s.l. : Journal of
Mechanical Science and Technology, 2008.
10. Effects of computational grids and turbulence models on numerical simulation of
centrifugal pump with CFD. H. L. Liu, M. M. Liu, L. Dong, Y. Renand H. Du. s.l. :
IAHR Symposium on Hydraulic Machinery and Systems, 2012.
28
9 Vita
The author of this report was born on May 07, 1990 in the city of Sahiwal, Pakistan.
He received his early education, Matriculation (2006) and Intermediate - Pre Engineering
Group (2008) from Divisional Public School and Inter College, Sahiwal. In 2008, he
went to National University of Sciences and Technology (NUST), Islamabad for
professional education in the field of Mechanical Engineering. After graduating from
NUST in 2012, he joined Pakistan Atomic Energy Commission (PAEC) as a
postgraduate fellow and is currently completing his course work in the field of
Mechanical Engineering at Pakistan Institute of Engineering and Applied Sciences
(PIEAS).