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Design and analysis of axial inducers performances

Conference Paper · June 1998

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 N° FEDSM 98 - 5118

DESIGN AND ANALYSIS OF AXIAL INDUCERS PERFORMANCES

F. BAKIR, S. KOUIDRI, R. NOGUERA, R. REY
LEMFI - URA CNRS D1504 - Site Paris
ENSAM - 151 Bd de l’hôpital - 75013 PARIS.
e-mail: bakir@cumana.paris.ensam.fr

Abstract
The purpose of this article is a theoretical and experimental characterization of an axial inducer with suction specific speed S = 700.
We first present the design and analysis methodology of the inducer performances (head, efficiency). This method, based on the axial
pumps design methodology, takes into account the inducers specific parameters. The different geometries obtained are compared
with those stemming from other approaches given in the bibliography. We propose then a statistical study which allows the critical
NPSH determination. The relationship which we established, based on the axial velocity in the narrow section formed between two
blades, permits us to calculate the critical NPSH of axial and centrifugal pumps for a wide range of flow rates. The second part of
this article is devoted to the experimental study of an axial inducer designed according to the proposed methodology. We present:
• The description of various visualized cavitation figures.
• The overall measures carried out in order to validate the considered model.

I - INTRODUCTION
450 and the high performance propellers greatly surpass 600.
The inducer is generally placed upstream of a centrifugal or
This device allows higher rotational speeds which make
mixed flow impeller in order to improve the cavitation
pumps more compact and economical. However, the
resistance. The two rotors are on the same drive shaft, turn at
cavitation, can cause operational instabilities and can
the same speed and work in series. Designed to reduce
compromise their use, mainly in partial flow rate ([1], [2] and
cavitation, the inducer, due to the generated pressure rise,
[3]). In fact, the very unstable backflow vortex cavitation is
allows the main impeller to function in best supplied
superimposed upon the blade cavitation (figures 1a and 1b)
conditions. This configuration is usually used in many
and tip vortex cavitation (figure 2) which are present in all
industrial applications: nuclear industry, petroleum, agro-
the flow rates. The effect of the backflow vortex cavitation
business, chemistry, and especially cryogenic propellant
also increases when flow rates decrease (figure 3).
pumping. If the centrifugal pumps suction specific speed S is
limited to 250, the first generation industrial inducers reach

Nomenclature

b height of the fluid passage [m] Ri hub radius [m] ρ liquid density [kg/m3]
N Qn
Cm meridional velocity [m/s] S suction specific speed S = 0.75 [-] σ solidity [-]
Czo aerodynamic camber of blades [-] NPSH gNPSH
De external diameter of the inducer [m] σc cavitation number σ c = [-]
t blade spacing [m] ω2R e 2
Fr Froude number [-] T hub to tip ration [-]
g acceleration due to gravity [m2/s] ω angular velocity of inducer [rad/s]
U translating velocity of blades [m/s] ζ reduced velocity at the throat [-]
h width of the throat [m] W relative velocity [m/s]
H energy head [m] Re Reynolds number [-]
Wc average velocity in the throat [m/s]
i incidence angle [-] Z number of blades [-]
j tip clearance [m] Subscripts
α angle of attack [-]
l blade chord length [m] n nominal (design point)
β relative velocity angle [-] i internal
N rotational speed of inducer [rpm]
βp blade angle [-] e external
NPSH net positive suction head [m] Q
N Qn ϕ flow coefficient ϕ = ωR 3 [-] r rotor
ns specific speed ns = [-] e
Hn 0.75 s stator
pv liquid vapor pressure [Pa] γ stagger angle [-] 1 inducer inlet
Q flow rate [m3/s] λ dynamic depression coefficient [-] 2 inducer outlet
r radius [m] ν kinematic viscosity [m2/s]
Re inducer external radius [m] θ azimutal angle [°]

Copyright 1998 by ASME

 Figure 1b: Development of the vapor pocket up to
Figure 1a: Erosive cavitation - LEMFI Inducer: the trailing edge - LEMFI Inducer:
N = 1450 rpm, Q = 300 m3/h, NPSH=2 m. N=1450 rpm, Q=300 m3/h, NPSH=0.6 m.

Figure 2: Tip vortex cavitation - LEMFI Inducer: Figure 3: Backflow vortex cavitation observed in partial
N=1450 rpm, Q=200 m3/h, NPSH=4.5 m. flow rate - LEMFI Inducer:
N=1450 rpm, Q=100 m3/h, NPSH=2 m.
II - INDUCERS DESIGN METHODOLOGY
According to the expected performances, the machine will or
will not be equipped with a stator under which a bearing will
be disposed in order to limit the overhang (figure 4). The
outlet static pressure, the efficiency and the kinematic flow at
the inlet of the main impeller depend strongly on the
presence of this stator. We can find many geometrical
configurations of inducers [4]. At the design stage, the purely
axial machine (single cascade rotor + stator) is accessible. Figure 4: 3D view of cryogenic inducer equipped with stator.

Copyright 1998 by ASME

On the other hand, during the analysis of performances,
inducers configurations with external radius and hub variable
can be taken in account.
The main parameters, used during the inducer design, can be
classified in two categories (rotor only):
- Main parameters:
• Operational parameters: flow rate Q, head H, NPSH ,
rotational speed N.
• Fluid nature.
• Number of rotor blades Zr.
• Aerodynamic camber of the rotor blades Czo.
• Hub to tip ratio T.
• External diameter Re.
• Blade angle at the leading edge βp1 (figure 5c).
• Solidity σ.
• Radially varying work.
• Stagger angle γ (figure 5b).
- Secondary parameters:
• Evolution of the hub.
• Sharpening of the leading edge.
• Type of profile and notably position of the maximal
arrow.
• Tip clearance.
• Slant of the leading edge.
• Blade thickness.
II - 1 - Design methodology
The design methodology which we are suggesting here
allows fixing the main parameters of the inducer. It’s a
classical method equivalent to those found in the
bibliography ([5], [6], [7]).
From the specifications, this methodology can be described
as the following:
• Characteristic of the transported fluid: ρ, ν, pv
• Operational parameters:
Flow rate Q, head H, NPSH, rotational speed N.
Starting with this step, we verify that the suction specific
speed S is compatible with the sought objectives. On the over
hand, we can increase or decrease the rotational speed
according to the geometric characteristics or to the limit
imposed by mechanical behavior of the shaft line. We then
set a certain number of constructive parameters according to
the know Art in that field:
• Number of blades of the rotor Zr: the advisable values
are equal to 3 or 4 (sufficiently low number to limit the
decrease of the passage area of the fluid).
• Blade camber Czo: it is linked to the nominal head wanted
for the inducer. From the point of view of cavitation the high
performance inducer has a cumber of 0.25.
This optimal value constitutes one of the important results of a
series of tests which were done in the laboratory and concerning
different camber values. However, in the case of high pressure
inducers, this value can be increased to 0.4. Over this value, the
suction capacity of the machine can be damaged. If the obtained
head is insufficient, we will need a tandem-bladed rotor.
• Tip to hub ratio T: its value is between 0.3 and 0.6 from the
inlet to the outlet, according to the inducer specific speed ns.
• External diameter De: a value of reference is given in [7]:
 Q 
De = 14.5218  
 (1 − T ² ) N δ 
2k 1 − T²
with δ= and k = 69.2
1+ 1+ 6k 2 S
The choice of the size is essential because it fixes both the value
of the suction capacity using βp1 value (close to 8° in periphery)
and the head produced by the inducer
• Solidity σ: the resistance to the cavitation depends strongly
on the blade length since this one fixes the admissible length of
the vapor pocket before degradation of the outlet pressure. We
retain a value of 1.8 to 2.5 in periphery. In these conditions, θi
angle (figure 5a) is around 300° for the ratio θe / θi equal to 0.7.
The stacking of the trailing edge is made generally radially. The
resolution of the inverse problem necessitates defining a
supplementary condition: the type of incidence law
corresponding to the wanted optimization. Three equivalent
propositions are given here (figure 5c):
A - Optimal incidence law used for the design of axial
machines [6].
B - NASA recommended incidence law, fixing the ratio
i/βp1 to 0.45 for the entire radius [7].
C - The same constant is fixed only to the external
radius. For the rest of the blade, we adopt an incidence law
linked to the facility of the construction of the blade. This
condition often corresponds to a blade ruled surface:
r
= cons tant
tg γ(r )
This design step is described by the chart in figure 6 which
represents the various inducers obtained according to the
incidence law and the retained size.
Copyright 1998 by ASME
 INDUCERS DESIGN METHOD

Data
•Functionning parameters : • Know Art :
- flow rate Q
- Blade number ZR= 3 or 4
- Head H
- NPSH - blade camber CZ 0=0.25
- Rotational speed N
• Fluid parameters :
- Hub to tip ratio T=Ri / Re = 0.4
- Tip radius Re }
- Density ρ
- Kinematic viscosity ν
- Blade solidity at tip radius σe = 2
- Angular ratio θe /θi =0.7 }
- vapor pressure pv
Choice of incidence law
A : incidence ≡ ηmax
i i
B: = 0. 45 C: = 0.45 + ruled surface
β p1 βp1
r r=Re

CALCULS •••

Figure 5a: Meridian view and face view of the inducer - Suction specific speed S (satisfactory)

- Radial definition of the blade :

• Blade solidity σ(r) (satisfactory)
• Stagger angle γ(r) (Blade swirl correct )

Hub to tip ratio modification

at impeller inlet

• Radial equilibrium
• Performances analysis by stream tube
(Control of Head, Efficiency, critical NPSH)

Flow rate 370 m3/h

Nominal head 10.5 m
NPSH 0.5 m
Rotational speed 1450 rpm
Figure 5b: Main definitions of Figure 5c: Geometrical Number of blades 3
the rotor blade cascade definitions of the leading edge.
Aerodynamic camber 0.25
Tip to hub ratio 0.494 Hub Tip
II - 2 - Analysis of performances in noncavitating regime σ 3 2,5
External diameter 312.8 mm γ 70,55 76,25 type A
The machine, designed from the previously described
methodology, is then analyzed in a first optimization step in
order to clarify the following aspects:
• The carrying out of a first study of performance
sensitivity relative to the choice of the design parameters.
• To know the evolution of the characteristics around
the design point.
In this step of analysing performances, the developed method Hub Tip
Hub Tip
σ 3 2,5
σ 3 2,5
takes into account the following points [6]: γ 71,22 79,08 type B
γ 68.67 79,08 type C
0
• The radial equilibrium allowing the definition of
Figure 6: Planning of the inducer’s design and general forms
the stream tubes.
obtained in cylindrical hub for an identical specification.
• The wall boundary layers (hub, tip).
III - GLOBAL PERFORMANCE ESTIMATION IN
• The tip clearance loss characterized by the increase
CAVITATING REGIME
of the average drag coefficient of the blade. This loss can
Working close to the nominal flow rate, the onset of cavitation
become significant if the ratio j/b> 0.01.
(first bubble apparition) can be satisfactorily predicted whether
we are treating the problem with a refined blade to blade flow
analysis or by global methods using the diffusion factor [8]. The
blade cavitation has been the subject of many studies, essentially

Copyright 1998 by ASME

in 2D potential flow, attempting to describe the vapor pocket - The average velocity of the liquid over the liquid-vapor
growth along the flow passage. The shape of the attached interface, tending to convey the cavity downstream up to the
cavity is thus obtained by an iterative process, as the limit of throat and then to the exit of the impeller.
the isobar p=pv in the pressure field among the rotor blades. This concept leads to the exclusion of the relative velocity
We should point out that an empirical model of the cavity obtained from the composition of velocities W1, and to use in its
wake or a closure law should be used in this procedure [5]. place, the average velocity Wc between the blades which takes
According to several authors, the fall of the static head into account, implicitly, the thickness of the blades at the leading
characteristic produced by the inducer occurs when the cavity edge.
reaches the throat formed between two adjacent blades where Configuration B: Q > Qn
it is rapidly conveyed up to the trailing edge (figure 5b). By The operation above the nominal flow rate often allows the
keeping this same criterion for the calculated cavity, a good observation of two cavities simultaneously in the same flow
approach to the critical NPSH in the range of incidence close passage: one attached to the suction side and the other to the
to nominal point (design) can be obtained. On the other hand, pressure side of the adjacent blade. Then it is said that the
below and above the nominal flow rate, the complexity of the blockage phenomenon has been attained which is accompanied
phenomena involved does not allow us to visualize a with a sudden increase of the critical NPSH (figure 7).
sufficiently reliable model to estimate the critical NPSH. It is
required then, to use models and empirical correlations Determination of λTo generalize this phenomenon of bubble
obtained from experiments. The existence of such models is entrainment linked at the same time to the viscous effects and to
justified equally to facilitate the previous step (1D procedure) free surface flows (liquid-vapor interface), we have defined a
where a first optimized general geometry of the machine is reduced velocity ξ, that takes into account the Reynolds R e and
achieved by means of a simple relationship and taking into Froude Fr numbers under the form:
account sufficiently the constructive parameters to be reliable. Wc l Wc
ξ = R e Fr R e= Fr =
ν g l
III - 1 - Selected model
Regardless of the model employed, the general form of the
critical NPSH is given by the classic relationship:
Cm1 2 W1 2
NPSH X = +λ
2g 2g
where x: represents the percentage of static height loss;
depending on the case, 3, 5, 20% or more could be used.
Cm1: meridional velocity at the impeller inlet.
W1: relative velocity at the impeller intake or, otherwise, the
average velocity in the throat formed between two continuous
blades.
λ: coefficient of dynamic depression depending, according to
the authors, on the bellow elements.
The available models found in literature are generally old and
use fixed values for λ (0.12 to 0.24) depending exclusively on
the type of machine. In more recent models, developed at the
same time as the cryogenic inducers, we take into account the
angle of incidence, the width of the section at the average
radius or the transverse section of the flow passage, the
number and the length of the blades, the thickness and the Figure 7: Cavitation above nominal flow rate corresponding
sweep of the leading edge and possibly its wedge angle. We to blockage – LEMFI inducer:
should distinguish two different configurations of the flow; A N = 1450 rpm, Q = 420 m3/h, NPSH=2.4 m.
and B:
Configuration A: Q < Qn Many available experimental results for various types of
It refers to the partial flow operation with recirculation, for machines allowed to trace the evolution of the dynamic
which the model of attached bubble has been described. It is depressure coefficient λ as a function of the reduced velocity at
in this case that the majority of experimental results are the throat ξ: 25 centrifugal pumps with specific speed ns going
available. The importance of this model of the cavity and its from 15 to 80; 6 classic axial machines and 6 inducers. The
evolution up to the throat formed between two blades, figure 8 shows the evolution of some of these pumps whose main
depends mainly on two phenomena: characteristics are reproduced in table 1 as follows (all these tests
- The operational flow rate that fixes, by means of the angle were done with water):
of incidence, the thickness and the length of the cavity.

Copyright 1998 by ASME

With the exception of two cases, figure 8 only contains points IV - EXPERIMENTAL STUDY
of operation in partial flow rate. Above the nominal flow rate,
Although the application of inducers is widespread nowadays,
the slope is inverted and we can observe an increase of λ with
several aspects of their operation and their behavior remain
ξ. This last tendency materializes the blocking effect that
misunderstood and far from being modeled. To appreciate some
consists in a sign change of the slope of the function λ(ξ). of the phenomena that constrain the reliability of these devices,
The shape of this characteristic allows some remarks their maximal attainable performances and their application
confirmed experimentally: limits, it is always necessary to resort to experimentation.
- For the points corresponding to the same operational The chosen design for the LEMFI inducer corresponds to the best
conditions of the same pump, the similarity of the cavitation compromises between hydraulic performances, manufacture and
phenomena evolves less rapidly than the square of the constraints associated with the existing experimental circuit. This
rotational speed. inducer was built from one piece of aluminum manufactured by a
- The critical NPSH decreases with the kinematic viscosity of numerical controlled machine tool with 5 axes. A sanding of the
the liquid. hub and blades was done, followed by surface treatment
- Large size machines present better performances in (anodization), in order to provide a better resistance to the
cavitation that a scaled down prototype. electrochemical corrosion and erosion by cavitation to the
impeller (figure 9).
Pumps ns De (mm) N (rpm)
Inducers cryogenic 90 168 5000 - 6000
7000 - 9000
LEMFI Inducer 140 235 1450
Industrial Inducer 100 130 3575
Axial pumps 180 240 1450
Centrifugal pumps 15 400 1450
32 408 1470
45 340 1480
80 500 1000

Table 1: Main characteristics of the pumps used for the

correlation λ(ξ)

8
Log(10 λ) De termina tion of th e function λ = f( ξ)

cen trifuga l p ump n s1 5

cen trifuga l p ump n s3 2 Figure 9: LEMFI inducer.

cen trifuga l p ump n s4 5

cen trifuga l p ump n s8 0 The table 2 below, reproduces the values of the main constructive
6 a xia l p ump s N1 ....N 6

4 in du stria l ind ucers

parameters of the LEMFI inducer. Following the selected
4 L EMF I ind ucer nomenclature, it corresponds to an inducer of type A (figure 6).
C ryog en ic in du ce r

Flow rate 300 m3/h

Nominal head 4.3 m
NPSH 0.5 m
Rotational speed 1450 rpm
0
Blades number 3
Aerodynamic camber 0.25
Tip to hub ratio 0.494
Tip diameter 235 mm
6PQx ilam4
Log(ξ )
Tip clearance 0.4 mm
-4
Type A Hub Tip
4 6 8 10 12
Solidity 3.44 2.5
Figure 8: Evolution of the dynamic depression coefficient λ as
Stagger 65.9 74.0
a function of the reduced velocity at the throat ξ.
Table 2: Main constructive parameters of the LEMFI inducer.

Copyright 1998 by ASME

IV-1- General overview of the experimental facilities
A: Inducer D: Motorized valve
B: Storage tank E: Circulation pump
The centrifugal and axial pump test facilities at LEMFI-Paris C: Vacuum pump F: Ultrasonic flowmeter
is composed of two independent but interconnected loops. The
axial pump loop (figure 10), which was used in this study, has
the following main parts:

- Two storage tanks with a capacity of 4 m3 each, connected

by a pipe of 350 mm in diameter. They can be loaded and
emptied by means of two electrical control valves.
- A liquid ring vacuum pump is used to control the pressure
at the free surface inside the storage tanks.
- A 22 kW direct current motor "Brook Hansen" powered by
a variable frequency controller was used to drive the tested
inducer.
- A motorized control valve serves to adjust the inducer flow
rate in a precise manner. Figure 10: General schematic of the experimental pump loop
- The inducer equipped with a transparent acrylic cover. at "LEMFI-Site Paris".
- A circulation centrifugal pump installed in series with the IV-2- Main experimental results for the LEMFI inducer
impeller in order to overcome the circuit losses.
- Various measurement instruments and devices: Figure 11 shows the global characteristics of head, efficiency
and critical NPSH (5%) as a function of the flow rate. We
• Ultrasonic flowmeter "A500 - Sparling Meter Flow" show in this same figure, the predicted performance curves
calibrated. obtained from the program POMAX [6]. We can observe the
• Metallic manometers backed up by piezoresistive sensors. excellent agreement between the calculated results and the
• Two piezoelectric pressure sensors KISTLER type 601A, tests taking into account the precision of the critical NPSH.
disposed over the transparent cover, one at 20 mm This comparison leads to the following two remarks:
upstream from the leading edge of the impeller and the
- The correlation for the critical NPSH underpredicts in partial
other at 150 mm downstream from the trailing edge. The
flow rates. The experimentally observed increase was not
signal generated by these sensors was amplified and
predicted by the model.
then processed by a spectrum analyzer LECROY
- Outside the partial flow rate range, the comparison of the
(type 930 4A). A digital interface with a computer
calculation with the tests is satisfactory and specially, the
allowed the post-processing and storage of these signals.
estimate of the blockage corresponding to the sudden increase
• An accelerometer "Bruel & Kjaer" with a sensibility of
above the nominal flow rate.
3.5 mV/(m/s2) was placed over the transparent cover.
10 100 10
Head (m) efficiency (%) NPSH (m)
LEMFI Inducer
LEM FI Inducer N =145 0 rpm
N=145 0 rpm
NPSH cavitation inception
experimental
8 80 8 experimental critical NPSH
theoritical
theoritical critical NPSH

6 60 6

4 40 4

2 20 2

design point

Flow rate (m3/h) Flow rate (m3/h)

0 0 design point
0
100 200 300 400 500 100 200 300 400 500

Figure 11: Global characteristics of the LEMFI inducer: N = 1450 rpm.

Copyright 1998 by ASME

Characteristics in Cavitating Regime. Explanation of cavitation figures
We have done the tests in cavitating regime for 6 different The cavitation images observed during the tests of the inducer
flow rates around the nominal value (figure 12). These results were characteristic, and in general resemble those presented in
show an inducer having adequate characteristics, and the literature [1]. We have already presented in figures 1, 2, 3 and
responding to what we can expect from this kind of device: 7 the most representative images of cavitation that we observed.
- Good suction capacity, since its required NPSH is less than
1 m, over a large range of flow rates, when the suction
specific speed S is greater than 700 (figure 13).
- Delayed appearance of the first cavities around the nominal
flow rate.
8.0 6PQ8cavasm e

Head (m)
LEMFI Inducer
N=1450 rpm

Q=180 m3/h
6.0

Q=220 m3/h

Q=260 m3/h
Figure 14 : critical NPSH (20%) - LEMFI Inducer:
Q=300m3/h
4.0 N = 1450 rpm, Q = 100 m3/h, NPSH = 1.6 m.
Q=340 m3/h

2.0 Q=380 m3/h

Q=420 m3/h

NPSH (m)
0.0
0.0 2.0 4.0 6.0 8.0 10.0

Figure 12: Determination of the critical NPSH for various

flow rates – LEMFI inducer N = 1450 rpm.
0.04
σc
LEMFI Inducer 5% 1450 rpm
LEMFI Inducer 20% 1450 rpm Figure 15 : critical NPSH (20%) - LEMFI Inducer:
Cryogenic inducer 5% 5000 rpm N = 1450 rpm, Q = 300 m3/h, NPSH = 0.51 m.
Cryogenic inducer 5% 6000 rpm

Cryogenic inducer 5% 7000 rpm

0.03
Cryogenic inducer 20% 9000 rpm

0.02

S = 702

0.01

S = 758

φ
0.00

0.1 0.2 0.3 0.4 0.5 Figure 16 : critical NPSH (20%) - LEMFI Inducer:
Figure 13: Comparison of cavitating performances for two N = 1450 rpm, Q = 420 m3/h, NPSH = 2.4 m.
inducers.

Copyright 1998 by ASME

We can thus identify depending on the flow rate:
- Stable cavities developed on the opposite faces of the blades
at flow rates above the nominal point.
- The onset of appearance of backflow cavitating vortices
propagating upstream from the inducer's inlet at partial flow
rates (backflow vortex cavitation).
For the critical NPSH corresponding to 20% decrease in head,
the associated cavitating figures are very different depending
on flow rate. As shown in the following figures, the blockage
condition could occur upstream, in the flow passage or at the
exit of the impeller, when the flow rate increases (figure 14,
15 et 16).
CONCLUSION
An efficient quick method for the design and performance
analysis of inducers in cavitating regime was presented. The
development of this model allowed the optimization of a
design program which constitutes an indispensable tool in the
conceptual stage and which could also be used before the
utilization of 2D and 3D analysis codes.
A correlation based on the velocity in the flow passage
section has been established in order to predict the critical
NPSH. This correlation was built from experimental results
obtained from inducers, axial and centrifugal pumps.
The quality of comparisons between calculations and
experiments were globally satisfactory. The results obtained
during measurements tests have shown that the inducer
exhibited good global characteristics in spite of the following
drawbacks: cylindrical hub, blunt blade leading edges, slow
rotational speed and absence of a stator.
Additionally, this inducer, having a very stable operation at
partial flow rate, has been the subject of several previous
research studies in our group.
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Acknowledgments
This study has been accomplished in relation and with the
support of the Centre National d'Etudes Spatiales- Evry. The
LEMFI inducer has been built by the CER-ENSAM de Lille.
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Copyright 1998 by ASME