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Cavitation in Centrifugal Pumps PDF
Cavitation in Centrifugal Pumps PDF
Cavitation in Centrifugal Pumps PDF
Flowserve Pumps
IDP Pumps
F k C.
Frank C Vi
Visser
Tutorial
2
P t 1 – What
Part Wh t iis cavitation
it ti
3
P t 1 – What
Part Wh t iis cavitation
it ti (cont.)
( t)
4
Part 1 – What is cavitation (cont
(cont.))
Cavitation causes or may cause:
• Performance
P f loss
l (head
(h d ddrop))
• Material damage (cavitation erosion)
• Vibrations
• Noise
• Vapor lock (if suction pressure drops
b l
below b
break-off
k ff value)
l )
(Visser et al, 1998)
General Advice: TRY TO AVOID CAVITATION (under normal operation)
5
P t 1 – What
Part Wh t iis cavitation
it ti (cont.)
( t)
Typical cavitation damages
6
Part 1 – What is cavitation (cont
(cont.))
Cavitation behavior is typically expressed in terms of cavitation
parameters.
t
• Cavitation number:
p1 pV
1 ; (Centrifugal Pumps : U Ueye R1T )
2 U
2
7
Part 1 – What is cavitation (cont
(cont.))
In g
general, cavitation performance is related to some “critical” value:
NPSHA (=available) > NPSHc or NPSHR (=critical or required)
Typical “critical”
critical characteristics identified for centrifugal pumps:
• Incipient cavitation (NPSHi)
• Developed p cavitation causing g 3% head drop p ((NPSH3%))
• Developed cavitation causing complete head breakdown
( vapor lock).
8
Part 1 – What is cavitation (cont
(cont.))
Cavitation Phenomena
9
Cavitation Visualization Test Pump
Pump Division
Begin Visual Cavitation
3% head drop
1% head drop
0% h
head
dddrop
Begin visual cavitation
Head (m)
4.05
4.00
3.95
3.90
3.85
3.80
3 75
3.75
3.70
0 10 20 30 40 50 60 70 80 90 100
NPSH (m)
Pump Division
0% Head Drop
3% head drop
1% head drop
0% head drop
Head (m) Begin visual cavitation
4.05
4.00
3.95
3.90
3.85
3.80
3.75
3.70
0 10 20 30 40 50 60 70 80 90 100
NPSH ((m))
Pump Division
1% Head drop
3% head drop
1% head drop
0% head drop
Begin visual cavitation
Head (m)
4.05
4.00
3.95
3.90
3.85
3.80
3.75
3.70
0 10 20 30 40 50 60 70 80 90 100
NPSH ((m))
Pump Division
3% Head drop
3% Head drop
1% head drop
0% head drop
Begin visual cavitation
Head (m)
4.05
4.00
3.95
3.90
3.85
3.80
3.75
3.70
0 10 20 30 40 50 60 70 80 90 100
NPSH ((m))
Pump Division
Recirculation
3% head drop
1% head drop
Recirculation
0% head drop
Begin visual cavitation
Head (m)
4.05
4.00
3.95
3.90
3.85
3.80
3.75
3.70
0 10 20 30 40 50 60 70 80 90 100
NPSH ((m))
Pump Division
Part 1 – What is cavitation (cont
(cont.))
10
Part 1 – What is cavitation (cont
(cont.))
Pumps
u ps run
u ookay,
ay, BUT
U with
t some
so e de
developed
e oped cavitation.
ca tat o
General misconception:
11
Part 2 – Cavitation prediction
• Scaling laws
• Thermodynamic effect
• Ca
Calculating
cu at g incipient
c p e t ca
cavitation
tat o (N
(NPSHi)
S i) from
o CCFD
12
Part 2 – Cavitation prediction (cont
(cont.))
13
Part 2 – Cavitation prediction (cont
(cont.))
Conservative choice:
N < NREF , = 1
N > NREF , = 2
14
Part 2 – Cavitation prediction (cont
(cont.))
Thermodynamic
y effect
(temperature depression)
Cavitation performance
depends on:
• Temperature of liquid
• Type of liquid
NPSHR reduction
(E.g. Stepanoff method, or
Hydraulic Institute correction
chart)
(from Brennen, 1994)
15
Part 2 – Cavitation prediction (cont
(cont.))
Predicting thermodynamic effect
NPSH 3% NPSH 3%, REF NPSH
Equilibrium theory:
L
2
h fg V
NPSH B 2 ;B V
V v fg g C p T VL
Stepanoff (1965
(1965, 1978): B B1 NPSH
2
L g C pT
B1 ; [ m 1
] or [ ft 1
]
V h fg
2
29 4 3 64 4 3
NPSH B1 ; [m 1 ] or NPSH B1 ; [ ft 1 ]
HV HV
Non-equilibrium theory bubble dynamic (CFD) calculations, involving
time-dependent
time dependent two-phase
two phase flow calculations
16
Part 2 – Cavitation prediction (cont
(cont.))
Influence of dissolved and/or entrained gases:
“conceptual effective or artificial” vapor pressure:
PE = PV +
PE = yP
P0 (Ch
(Chen, 1993)
Key characteristic:
Performance (breakdown) comes from gas evolution and gas
expansion, rather than classical vapor formation.
17
Part 2 – Cavitation prediction (cont
(cont.))
T i l approach:
Typical h
Create 3D geometry model/grid of impeller passage
Solve flow field with CFD code (non-cavitating)
Calculate incipient NPSH from CFD pressure field (next slide)
18
Part 2 – Cavitation prediction (cont
(cont.))
Streamline through point of minimum pressure
p01,i pV
NPSH i
g
p01,i p1,i 12 U 2
p1,i p1 ( pmin pV )
p01 pmin
NPSH i
g
So: NPSHi follows from pmin and p01 of calculated pressure field, and
does not require pV to be known!
19
Part 2 – Cavitation prediction (cont
(cont.))
Running simulations for several flow rates produces NPSHi curve:
(from Visser
Visser, 2001)
20
Part 2 – Cavitation prediction (cont
(cont.))
Note: CFD calculated characteristic is for impeller flow!
21
Part 2 – Cavitation prediction (cont
(cont.))
• physically unrealistic
unrealistic, but it gives
• first “indication” of cavitation area, and
• first approximation of cavity bubble length
22
Part 2 – Cavitation prediction (cont
(cont.))
pV* pV ( p1 p1, A )
p1 12 U 2
( p1, A 12 U 2 pV )
p01 g NPSHA
p01 NPSPA
23
Part 2 – Cavitation prediction (cont
(cont.))
Example:
Cavitation on blade
suction side
24
Part 2 – Cavitation prediction (cont
(cont.))
Putting
g LCAV = m L(p<p
(p pV), m=O(3),
( ), one can get
g some impression
p of
expected cavitation erosion rate
n
LCAV
Güli h (1986
Gülich (1986, 1988
1988, 1989)
1989): E C
L
A
2 3
U e
6 3
A 8TS
2
CAV ,10
E Ln E E L L
n
or CAV 2 1 2 1 (*)
with n = 2.83 for blade suction side and
n = 2.6
2 6 for blade pressure side
Equation
q ((*)) is especially
p yppowerful when comparing
p g designs
g and
evaluate susceptibility to cavitation erosion (in a relative sense).
• Still it p
provides important
p information of an impeller
p design
g
regarding cavitation performance.
26
Part 2 – Cavitation prediction (cont
(cont.))
CFD Cavitation models
• Bubble dynamic
y models
– Rayleigh-Plesset equation
– Vapor-liquid interaction (time-dependent mass & heat transfer)
– Closer to reality
– More complicated and more “CPU-expensive”
– E.g. Volume of Fluid (VOF) model
27
Part 2 – Cavitation prediction (cont
(cont.))
Example:
Equilibrium
q model
CFX-TASCflow
(CEV-model)
NPSHA = 15.5
15 5 m (51 ft)
NPSHi = 28 m (92 ft)
N = 2980 RPM
Q = 400 m3/h
(1760 USGPM)
m3
Cavitation on blade
suction side
28
Part 2 – Cavitation prediction (cont
(cont.))
Application:
With CFD cavitation
it ti models
d l one can predict
di t NPSH3% from
f CFD
calculated head drop curves
30
References
Brennen, C.E.
H d d
Hydrodynamics
i off PPumps.
Oxford University Press (1994)
Chen, C
Chen C.C.
C
Cope with dissolved gases in pump calculations.
Chemical Engineering, vol. 100 (1993), pp. 106-112.
Gülich, JJ. F
Gülich F. and Pace
Pace, S.
S
Quantitative Prediction of Cavitation Erosion in Centrifugal Pumps.
Proceedings of the 13th IAHR Symposium (1986), Montreal, Canada.
31
References (cont
(cont.))
Gülich, J. F. and Rösch, A.
Cavitation Erosion in Centrifugal Pumps.
World Pumps, July 1988, pp. 164-168.
Gülich, J. F.
Guidelines for Prevention of Cavitation in Centrifugal Feedpumps.
EPRI Final Report GS-6398, (1989).
Gülich, J. F.
Beitrag zur Bestimmung der Kavitationserosion in Kreiselpumpen auf Grund der
Blasenfeldlänge und des Kavitationsschalls
Kavitationsschalls.
Thesis, Technische Hochschule Darmstadt, Germany, 1989.
Stepanoff, A
Stepanoff A.J.
J
Pumps and Blowers – Two-Phase Flow.
John Wiley & Sons (1965), Krieger Publishing (1978)
32
References (cont
(cont.))
Visser, F.C., Backx, J.J.M., Geerts, J., Cugal, M. & D. Miguel Medina Torres
Pump impeller lifetime improvement through visual study of leading-edge cavitation.
Proceedings of the 15th International Pump Users Symposium, Turbomachinery
Laboratory,Texas
y, A&M University,y, College
g Station,, Texas,, USA,, pp.
pp 109-117.
Also in: Pumping Technology, vol. 2 (1998), pp. 149-157.
Visser, F
Visser F.C.
C
Some user experience demonstrating the use of CFX-TASCflow computational fluid
dynamics for cavitation inception (NPSH) analysis and head performance prediction
of centrifugal pump impellers. FEDSM2001-18087
Proceedings of the 4th ASME International Symposium on Pumping Machinery,
May 29 – June 1, 1 2001,
2001 New Orleans
Orleans, Louisiana
Louisiana, USA
USA.
33