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Procedia Engineering 39 (2012) 212 – 222

XIIIth International Scientific and Engineering Conference “HERVICON-2011”

Automatized Design of the Centrifugal Pumps Setting on the

Base of Mathematic Modeling of Fluid Flow
S. Kostornoya, A. Chaplyginb, A. Kostornoyc, a*
a
Sumy State University, Department of mathematical analysis and optimisation methods, 2 Rimsky-Korsakov Str.,
Sumy 40007, Ukraine
b
Sumy State University, Centre of computer process engineerings, 2 Rimsky-Korsakov Str., Sumy 40007, Ukraine
c
PJSC Sumy Frunze NPO, 58 Gorky Str., Sumy 40004, Ukraine

Abstract

Setting computer-aided design a centrifugal pump is fulfilled on the basis of mathematical model of fluxion of perfect
fluid for an inverse axisymmetric problem and a direct three-dimensional problem in nonstationary statement taking
into account cross effect of all devices. Results of a solution of an inverse problem in the automized condition are
transmitted in the capacity of input data for a solution of a direct problem on the basis of which solution the tentative
estimation of a design solution becomes.

© 2011 Published by Elsevier Ltd. Selection and/or peer-review under responsibility of

Sumy State University Open access under CC BY-NC-ND license.

Keywords: An inverse problem; a direct three-dimensional problem in nonstationary statement; a roll forming of the lobe of the
impellor.

1. Introduction

At the development present stage at the attained level of efficiency of separate types of pumps of the
order of 70-90% the further raise of their efficiency in the conditions of market rationes should be
grounded on the developed theory and methods of hydrodynamic calculations on the basis of program
complexes.

* Corresponding author. Tel.:+38 0542-33-10-50.

E-mail address: kostornoysd@mail.ru.

1877-7058 © 2012 Published by Elsevier Ltd. Open access under CC BY-NC-ND license.
doi:10.1016/j.proeng.2012.07.027
 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222 213

The results gained thus can be used for a purposeful modification and the further perfecting of
hydrodynamic indexes of the pump: energy and cavitational performances, force loadings and
nonstationary performances of a stream that will allow to substitute physical experiment computing and
to divide out lead times.
The explicated new theoretical approach to projection of the setting of the hydraulic machine which
with reference to hydraulic turbines has appeared successful, in the theory of centrifugal pumps and
factory practice of their making is a new scientific direction.

2. Input equations of two-parameter streams in the setting

In orthogonal curvilinear frame q1 , q2 , q3 a stationary stream when each projection of velocity term
V1 , V2 , V3 depends on three coordinates

V1 = f1 (q1 , q2 , q3 ); V2 = f 2 (q1 , q2 , q3 ); V3 = f 3 (q1 , q2 , q3 ) , (1)


term as a three-dimensional three-parametric stream.
Stream which can be referred to such co-ordinate system, and all three builders of a velocity would be
functions of two co-ordinates q1 and q2 and did not depend on the third q3 term three-dimensional two-
parameter. In this case

V1 = f1 (q1 , q 2 ); V2 = f 2 (q1 , q 2 ); V3 = f 3 (q1 , q 2 ) . (2)

Geometrically it means that on all coordinate surfaces q3 = const  the field of velocities is under
& & &
construction equally in relation to a trihedron of unit vectors e1 , e2 , e3 of the frame (fig. 1).



Fig. 1. Curvilinear orthogonal frame

In the setting of the centrifugal pump working with revolutions per minute equal 1500 that matches to
25 turnovers in a second, at engineering and an estimation of a design solution fluxion starts
axisymmetric, rotational which field of velocities equally on each plane transiting through some axis, but
vectors of velocities not bindingly lie in these planes.
Has already transited 2,5 centuries as Leonard Euler in 1754 on the basis of non-viscous liquid
equations of motion has gained the well-known equation and analytical association as which term as the
214 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222

basic equation of the theory of the hydraulic machine, use now at projection and the analysis of their
operation in the capacity of the basic argument.
On the basis of this equation for pumps

V22 − V12 W12 − W22 U 22 − U12

H T = U 2Vu 2 − U1Vu1 = + + , (3)
2 2 2

where: H T - theoretical pressure created by the impellor; V - absolute velocity; W - relative velocity;
U - radial velocity; Vu - projection of absolute velocity to an radial direction.
Noted expression (3), analyses a role centrifugal and a Coriolis force in the impellor in terrain
clearance, portable and relative motions and their effect on the basic parameter-theoretical pressure Hɬ
depending on geometrical and kinematic parameters of the impellor.
& & & &
Considering properties of the Coriolis force defined by expression F = 2ω × W  ω - angular velocity
vector, and centrifugal, transiting through a spin axis, the equation (3) can be presented in an aspect

( )
H T = H Cor + H c = u22 − u12 + (W1u u1 − W2u u2 ) , (4)

in which the first item defines a quantity the energies, transmitted by an inertia Coriolis force, and second
- circuital forces in relative motion. As centrifugal forces do not create gyration moment about the axis,
and Coriolis velocities of relative motion and force of a viscous friction when there are losses on the basis
of (4) it it is possible to consider that efficiency of an energy transfer as the impellor of centrifugal type
above, than axial for which u2 = u1 = u , H Cor = 0 are perpendicular. At introduction of the relative sizes
of geometrical and kinematic parameters of the setting and execution of matching transformations, shares
of the energy, transmitted a fluid a centrifugal sprocket by means of Coriolis and circuital forces will be

H Cor 1 − D12
= hCor = , (5)
HT K z (1 − q) − ϕD12

Hc 1 − D12
= hc = 1 − , (6)
ɇɌ K z (1 − q) − ϕD12

V1u Í
where: ϕ = - the relative curling of a stream on an input in a centrifugal sprocket; K Z = T -
U1 H T∞
coefficient of effect of a finite number of blades; q = (V2 m u 2 )ctgβ 2 - Account parameter; β 2 - angle of
installation of blade on an exit from the impellor.
On the basis of the reduced simplified theoretical results it is possible to make following estimations to
geometrical and kinematic parameters of the setting at projection of impellors and to explain expediency
of application of two-dimensional analytical methods at projection of more high-speed, and methods of
conformal representations and one-dimensional for the low-speed hydraulic machine.
So from formulas (5) and (6) follows that values hCor ɢ hc are defined by D1 , q and ϕ (value K z can
be accepted to stationary values). Ration D1 = 1 matches to the axial sprocket which specific operation
 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222 215

H T forms only by circuital forces: hc = 1;  hCor = 0 . Therefore for such pumps the lobe roll forming has
essential value as the circuital flow is defined by velocity allocation on a profile. With decrease D1 and
magnification q and ϕ the share of the energy transmitted by means of circuital forces hc is diminished
and the share of the energy transmitted by means of Coriolis force hCor increases. For pumps with ration
D1 < (0,5 − 0,6) ; q > 0 that matches to impellers with angle β 2 ∠900 , value hc becomes subzero, and
hCor > 1 . In this case in the course of a flow of blades energy of a fluid is diminished, instead of
transmitted it. The impellor transfers energy fluids only by means of a Coriolis force, cancelling the
energy which is selected from a fluid by means of circuital forces. For such pumps critical buckling of a
profile of blade and conditions flows (angles of attack) practically do not render appreciable effect on
exterior indexes and in such pumps it is possible to use the technological profiles of blades delineated by
arcs of a circle or in the form of plates.

3. The common differential equations of two-parameter streams of perfect fluid.

The model of two-parameter streams is of special interest at study of circuital and screw streams in the
setting of the hydraulic machine. Expression (2) equivalently following requirement

∂V1 ∂V2 ∂V3
= = =0. (7)
∂q3 ∂q3 ∂q3

From this it follows that the functional determinant from velocity components on co-ordinates is
identically equal to null, owing to key properties of identifiers [1].
It means that between functions V1 , V2 , V3 there is a relation independent of variables q1 , q2 , q3 , for
example,

V3 = f (V1 ,V2 ) . (8)

The gained result for a two-parameter stream when one of velocity components is bound to two others
a functional connection, usually is not considered in inverse problems of the theory of the hydraulic
machine. The further examination of two-parameter streams we will spend in an orthogonal curvilinear
frame.
& & & &
Making velocities V on unit vectors e1 , e2 , e3 we will mean through V1 , V2 , V3 . Components of an
&
angular velocity of gyration (curl) Ω in the same directions we will mean Ω1 , Ω 2 , Ω 3 . Generally:

& & & & &

Ω = rotV = e1Ω1 + e2 Ω 2 + e3Ω 3  (9)

Thus the differential equation of streamlines of a fluid looks like

H1dq1 H 2 dq2 H 3dq3

= = , (10)
V1 V2 V3

216 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222

2 2 2
§ ∂x · § ∂y · § ∂z ·
where H i = ¨¨ ¸¸ + ¨¨ ¸¸ + ¨¨ ¸¸ , i = 1,3 - coefficients (parameters of Lame).
© ∂q i ¹ © ∂q i ¹ © ∂q i ¹
For a frame we will accept requirements

∂H1 ∂H 2 ∂H 3
= = =0, (11)
∂q3 ∂q3 ∂q3

which geometrical meaning consists that on each surface q3 = const a normal line to it has in all points
one and too a direction, that is coordinate surfaces q3 = const are planes. Surfaces q1 = const and
q2 = const depend from q2 or q1 and are surface of revolutions on which meridional lines also are lines
q3 = const , parallels: q1 = const or q2 = const . From the told follows that the set of surfaces q3 = const
represents a pencil of planes, and a bundle axis are the common axis of orthogonal surface of revolutions
q1 = const and q2 = const .
Introducing the accepted requirements (7) and (11) into the equations for a curl and continuity, we will
gain for a two-parameter vortex flow of expression for curl and equation of continuity components
identical to an axisymmetric flow case when curl builders also do not depend on coordinate q3 . Thus in
an equation of continuity instead of three terms remains two. For example, if to take the differential
equation of streamlines (10) on surfaces q3 = const :

H1dq1 H 2 ∂q2
= or − H1V2 dq1 + H 2V1dq2 = 0 , (12)
V1 V2

∂ ∂
and a continuity equation in an aspect: (H 2 H 3V1 ) = (− H 3 H1V2 ) then H 3 serves as an integrating
∂q1 ∂q2
factor of the equation (12) which left part after multiplication on H 3 will be represents a total differential
∂ψ ∂ψ
of flow function ψ : dϕ = dq1 + dq2 , so
∂q1 ∂q2

∂ψ ∂ψ
H 2 H 3V1 = , H 3 H1V2 = − . (13)
∂q2 ∂q1

If requirements (11) are fulfilled completely, ψ = ψ (q1 , q2 ) . Function ψ as it is accepted for two-
dimensional streams, term as a flow function. The flow function of a two-dimensional stream defines all
field of velocities, and a flow function of a two-parameter stream two of three components of a velocity
define only.
Having introduced a relation (13) into expressions for Ω 3 , we will gain

1 1 ª ∂ § H 2 ∂ψ · ∂ § H 2 ∂ψ ·º
Ω3 = − « ¨¨ ¸¸ + ¨¨ ¸¸» . (14)
2 H1 H 2 ∂q H H ∂
¬« 1 © 3 1 1 ¹
q ∂q2 © H 3 H 2 ∂q2 ¹¼»
 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222 217

After the prestress analysis the differential equations of a two-parameter stationary stream in the
Lambs form in an orthogonal curvilinear frame look like the following

& &
Ω × V = − grad E , (15)

p V2
where a mechanical energy of a mass unit of fluid E = U + + ,  U - a potential of exterior
ρ 2
volume forces; p - pressure; ρ - a density.
Let's introduce into system (15) requirements (7) and (11) and we will guess that E does not depend
from q3 then the energy distribution in a stream submits to the same requirement to what builders of a
velocity of a two-parameter stream submit. Therefore last equation (15) will look like V1Ω 2 − V2 Ω1 = 0 or
Ω1 Ω 2
= , and will mean that on co-ordinate surface q3 = const , the curl component is parallel a making
V1 V2
∂ ( H 3V3 ) ∂ψ ∂ ( H 3V3 ) ∂ψ
velocity. Substituting in this equation of expression (13), we will gain: − = 0,
∂q1 ∂q2 ∂q2 ∂q1
∂ ( H 3V 3,ψ )
that is functional determinant from product H 3V3 and flow functions ψ : = 0. 
∂q1q2
From this identity follows that between product H 3V3 and flow function ψ there is a relation which is
not dependent on variables q1 and q2 :

H 3V3 = Φ (ψ ) , (16)

where Φ(ψ ) - an arbitrary function.
Having increased the equations (15) accordingly on V1 , V2 , V3 and having combined them, at the made
suppositions concerning energy, components of a velocity and coefficients of Lame, the total of right
V ∂E V2 ∂E
members of the equations with matching factors addresses in null: 1 + = 0 . From this
H 1 ∂q1 H 2 ∂q2
∂E ∂ψ ∂E ∂ψ ∂ ( E ,ψ )
equation follows that − = 0, or = 0. 
∂q1 ∂q 2 ∂q 2 ∂q1 ∂q1 q 2
Thus, between a store of energy of a mass unit of fluid Å and flow function ψ also there is a
functional connection without means q1 and q2 . We will note it as follows:

E = − F (ψ ). (17)

Function − F (ψ ) is taken with the sign reversed as a matter of convenience the further
transformations.
From the equation (17) by means of relations (13), (15) and (16) it is possible to gain following
expression for an energy differential, having equated its differential dE = − F (ψ )dψ , establishing
communication between functions ψ and Φ :
218 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222

∂ § H 2 ∂ψ · ∂ § H1 ∂ψ · H1 H 2
¨¨ ¸¸ + ¨ ¸+ ⋅ Φ(ψ ) ⋅ Φ′(ψ ) + H1H 2 H 3 F ′(ψ ) = 0. (18)
∂q1 © H 3 H1 ∂q1 ¹ ∂q2 ¨© H 2 H 3 ∂q2 ¸¹ H3

Thus, the erected two-parameter vortex flow of non-viscous liquid in considered co-ordinate system is
defined by the following set of equations: (13), (16), (17), (18). The gained equations at the made
suppositions quite substitute themselves a prototype system.
Let's mark that the equation (18) in system is its basic equation. It displays that in the selected
orthogonal curvilinear frame the problem solution about a two-parameter vortex motion of non-viscous
liquid at the additional supposition (17) concerning an energy distribution is led to a solution of a partial
equation of the second order of elliptic type, generally - non-linear.
This equation links three functions: flow function ψ , function Φ(ψ )  expressing the law of a
modification builders V3 , and function F (ψ ) expressing a distribution law of energy. Two of these three
functions are arbitrary. The most rational path the problem solution will be following: to assign arbitrary
functions Φ(ψ ) and F (ψ ) and to search for function ψ ; then the mathematical problem will be reduced
to integration of one partial equation. If Φ (ψ ) = 0 at any value of function F (ψ ) , streamlines lie on
surfaces q3 = const .

4. Roll forming of the blade of the impellor

Problem of build-up of the blade of the impellor of a centrifugal pump, according to Euler's basic
equation for the hydraulic machine reduce to a solution of some inverse axisymmetric problem in which
the shape of a rotational current surface of a current of a stream, average on environing coordinate and a
time is defined. Using fluid equations of motion in a curvilinear orthogonal frame, the problem of build-
up of the lobe is reduced to a solution of system of differential partial equations of the second order of
hyperbolic type (19) or (19 ')

∂ϕ V r − r 2ω ½
= u 2 °
H1∂q1 r V1 °
¾, (19)
∂ϕ ∂ (Vu r ) ∂ϕ ∂ (Vu r ) ∂ (H1V1 ) ∂ § p V2 ·
= 0°
1 ¨ +
⋅ − ⋅ + − ⋅ ¨ρ − ωVu ¸¸
H1∂q1 H 2 ∂q2 H 2 ∂q2 H1∂q1 H1 H 2 ∂q2 H 2V1 ∂q2 2 °
© ¹ IN ¿

∂ ϕ
2
∂ ϕ
2
a + 2b = f, (19 ')
∂q1
2
∂q1∂q2

∂ϕ 1 ∂ϕ
where: a = , b=− ;
∂q2 2 ∂q1




 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222 219

2
H1 ­ ∂ § r 2Vm ·§ ∂ϕ · ∂ §¨ r 2Vm ·¸ ∂ϕ ∂ϕ ∂ (r 2 ) ∂ϕ
f = ® ¨ ¸¨ ¸ − + ω −
¨ ¸¨ ¸ ∂q1 ¨© H1 ¸¹ ∂q1 ∂q2
r 2Vm ¯ ∂q2 © H1 ¹© ∂q1 ¹ ∂q2 ∂q1

∂ (r 2 ) ∂ϕ ∂ ( H1Vm ) H1 H 2 ª ∂ (rVU )âõ (ψ ) ∂G (ψ ) º ½°
−ω + + «ω − ω âõ » ¾ = 0,
∂q1 ∂q2 ∂q2 Vm ¬ H 2 ∂q2 H 2 ∂q2 ¼ °¿

where: Vu - an environing component of a velocity; ϕ - co-ordinate of meridional cut of the blade.

However, the methods stated in such operations, at doubtless methodical and theoretical worth, owing to
great volume of computing operations in practice of engineering calculations and experimental researches
it is difficult to implement. Us more well-founded method of solution of an inverse problem generally an
axisymmetric vortex flow is offered.
Matching simplification of a solution of the equations in the given operation is attained by introduction
of a side condition (16) between components of velocities for a case of the difficult laminar flow since
magnitude Vu r varies only along a streamline. Therefore in the capacity of a requirement which are
establishing communication between components of velocity V1 , V2 and V3 it is possible to accept a
kinematic orthogonality condition of streamlines and whirl lines:

V rotV = V1Ω1 + V2 Ω 2 + V3Ω 3 = 0 . (20)

In the selected curvilinear orthogonal frame V2 = 0; H 3 = r ; V3 = Vu the equation (20) looks like

1 ∂
V1 (Vu r ) − Vu ∂ (H1V1 ) = 0 . (21)
r ∂q2 H1 ∂q2

Solving the equation (21) rather Vu r , we will gain

Vu r = H1V1Φ(q1 ) , (22)

where: Φ(q1 ) - an arbitrary constant function.
For search of function Φ(q1 ) use the boundary conditions usually accepted at projection of the lobe on
the given meridional stream when along one line q2 = const the law of modification Vu r is set equal
( )
Vu r q10 . Then at known association H1V1 along a line taking into account association (22) equation (21)
establishes communication Vu r and H1V1 in the difficult stratified stream:

( ) ( )
H 1V1
Vu r = Vu r q10 . (23)
H1V1 q10
220 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222

( )
At a matching select of value Vu r q10 , for example, from a requirement of deriving of a uniform
distribution of pressure along a matching streamline and boundary conditions for magnitude of circulation
on an input in the impellor and an exit from it, the equations (19) and (19') define a blade face.
On the basis of the featured mathematical models which explicitly are stated in operations [5-7] the
program complex of a solution of inverse and direct problems of the theory of the hydraulic machine is
developed for engineering of centrifugal pumps. Screenshot of a program complex are presented on fig.
2-5. The results of computer-aided engineering of a centrifugal pump with parameters Q = 365 m 3 hour ,
H = 30,66 m , n = 1470 min −1 are presented on them.

Fig. 2. Calculation and build-up of meridional equally velocity stream

 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222 221

Fig. 3. Roll forming of the impellor’s blade

Fig. 4. 3-D impellor model (without a coating disk)

222 S. Kostornoy et al. / Procedia Engineering 39 (2012) 212 – 222

Fig. 5. 3-D impellor model

References

[1] S. Kostornoy. Build-up of the blade of a radial-axial turbine. The Hydraulic machiner, Kharkov, Vol.2, (1968), pp. 116-122.
[2] S. Kostornoy. The select of the shape of fluxion of a fluid at a roll forming of lattices. The Hydraulic machiner, Kharkov,
Vol 5 (1971), pp. 8-12.
[3] S. Kostornoy, A. Chaplygin. Engineering of spiral taps of centrifugal pumps of a trapezoid shape with the rounded angles.
The Visnyk of the Sumy State University, Sumy, ʋ3, Vol 1 (2010), pp. 105-115.
[4] S. Kostornoy, A. Chaplygin. The automized calculation meridional Equally velocity and a potential stream in axisymmetric
channels of the arbitrary shape The Visnyk of the Sumy National Agrarian University, Sumy, 2(22) (2010), pp. 161-168.
[5] A. Kostornoy. Examination of nonstationary hydrodynamic processes in the centrifugal pump impellor. The collector of
proceedings Perfection Turbine installation by methods of mathematical and physical model operation, National academy of
sciences of Ukraine, Institute of problems of machine industry, Kharkov, Vol.2 (2006), pp. 577-581.
[6] A. Kostornoj, N. Martynova. Calculation of a nonstationary flow of high-drag bodies a method of hydrodynamic
singularities. The Visnyk of the Sumy State University, Sumy, ʋ 2 (2007), pp. 42-51.
[7] A. Kostornoj, N. Martynova. Working of the setting of a centrifugal pump a method of mathematical model operation. The
Visnyk of the Sumy State University, Sumy, N4 (2008).