MINI PROJECT REPORT (Centrifugal Pump)

KJ Somaiya College of Engineering, Mumbai-77
(Autonomous College Affiliated to University of Mumbai)
DEPARTMENT OF MECHANICAL ENGINEERING
Mini Project Report

on
Analysis of Centrifugal Pump Using

Computational Fluid Dynamics and
Comparison with Literature Data
by
Ishan Shinde
Roll No: 1815125
Hemant Soni
Roll No: 1815129
Yash Telange
Roll No: 1815130
Ashesh Zinjarde
Roll No: 1815136
Guide
Prof. Atul Saraf
Batch 2018 -2022

Certificate
This is to certify that the Mini project report entitled Analysis of

Centrifugal Pump Using Computational Fluid Dynamics and
Comparison with Literature Data is bonafide record of the work done by
Ishan Shinde, Hemant Soni, Yash Telange, Ashesh Zinjarde in the year
2020-21 under the guidance of Prof. Atul Saraf
________________ _____________________
Guide / Co-Guide Head of the Department
_________
Principal
Date: 25/06/2021
Place: Mumbai-77
B.Tech (Mechanical Engineering) Batch: 2018-22 Page 1

Certificate of Approval of Examiners
This is to certify that the Mini project report entitled Analysis of

Centrifugal Pump Using Computational Fluid Dynamics and
Comparison with Literature Data is bonafide record of the work done by
Ishan Shinde, Hemant Soni, Yash Telange, Ashesh Zinjarde
_________________ _________________
Expert / External Examiner Internal Examiner / Guide
Date: 25/06/2021
Place: Mumbai-77

Abstract
This paper deals with the performance prediction of a centrifugal pump and validating data
obtained from Literature data from a variety of research papers with Computational Fluid
Dynamics (CFD) simulations. The next purpose of this paper is to observe and determine the
velocity and pressure contours of centrifugal pump by using CFD simulation after the 3D
modeling of impeller and volute in Vista CPD. The number of impeller blades is between four
to nine and rotational speed of the impeller reaches up to 2940rpm.
3D Navier–Stokes equations were solved using ANSYS CFX. The finite volume method and
an unstructured grid system were used for the numerical solution. The standard k-epsilon
turbulence model was chosen for the turbulence model as it is accurate, robust and mostly a
good choice while dealing with turbulence modelling in pumps and turbines. From the
simulation results it was observed that the pressure increases gradually from pump inlet to
outlet. In addition to this, it was observed that the velocity increases from the impeller inlet
until it enters the volute casing and then it drops to a minimum value at outlet region.
The operating characteristic curves which we have obtained from CFD data match closely (a
maximum of approximately 29.97% error) with the literature data obtained from various
research papers respectively. These curves show that the highest best efficiency point of all the
pumps is 75.648% and optimized head is 42.3156 m at 0.005655 m3/s flow rate.
Key words: Centrifugal Pump, Computational Fluid Dynamics (CFD), Ansys, Vista CPD,
Navier Stokes, Efficiency, Head, Flow rate, Best Efficiency Point , k-epsilon

Contents
List of Figures 6
List of Tables 8
Nomenclature 9
1 Introduction 10
1.1 Introduction 10
1.2 Motivation 10
1.3 Scope 11
2 Literature Survey 12
3 Fundamental Concepts 15
3.1 Centrifugal Pump 15
3.1.1 Operating Characteristic Curves 15
3.2 Basics of Computational Fluid Dynamics 16
3.2.1 Concept of Computational Fluid Dynamics 16
3.2.2 Navier-Stokes Equation 17
3.2.3 Finite Volume Method 18
3.2.4 Grids 18
3.2.5 Turbulence Models 19
3.2.5.1 K-epsilon Model 19
3.2.6 Rotating Frames of Reference 19
3.2.7 Interface Characteristics and Modelling 19
3.2.8 Periodic Interface Model 20
3.2.8.1 Rotational Periodicity 20
3.2.9 Frame Change/Mixing Model 20
3.2.9.1 Frozen Rotor 21
3.2.9.2 Stage 21
3.2.10 Discretization and Solution theory 21

Analysis and Comparison of Literature data with data obtained from software
4 22
simulations and calculations
4.1 General Procedure 22
4.2 General Setup in ANSYS Workbench 23
4.3 Processing Setup and Boundary Conditions 23
4.4 Design Parameters 26
4.5 Visualization and Simulated Results using Contours 30
4.6 Results 32
5 Conclusions and Future Work 51
References 52

List of Figures
No. Title Page No.
3.1 Operating characteristic curves of a pump 15
3.2 Process of Computational Fluid Dynamics 16
3.3 Structured Grids 18
3.4 Unstructured Grids 18
3.5 Control volume definition 21
3.6 Mesh element 21
4.1 Flowchart of work process used to carry out analysis in Ansys 22

Software
4.2 Workflow setup in Ansys workbench 23
4.3 Design parameters of Impeller 23
4.4 Model of Impeller (2D & 3D) 24
4.5 Model of Volute (2D & 3D) 24
4.6 Meshing of Impeller and Volute 25
4.7 Setup and boundary conditions of Centrifugal pump 25
4.8 Solver condition and convergence plot 26
4.9 Velocity contours obtained at 2960 rpm 30
4.10 Pressure contours obtained at 2960 rpm 31
4.11 Head v/s Flow Rate for each set of data [2] 35
4.12 Power v/s Flow Rate for each set of data[2] 35
4.13 Efficiency v/s Flow Rate for each set of data [2] 36
4.15 Power v/s Flow Rate for each set of data [3] 38


List of Tables
No Title Page No
1.1 Comparison of Simulation and Experiment 11
4.1 Design Parameters for Pump 1 [2] 26
4.3 Design Parameters for Pump 3.1 [4] 27
4.9 Head at various flow rates [2] 33
4.10 Efficiency at various flow rates [2] 34
4.11 Head at various flow rates [3] 37
4.13 Head at various flow rates[4] 40

Nomenclature
Symbol/
Description Units
Abbreviation
Q Flow Rate m3/s
g Gravitational acceleration m/s2
H Head m
T Torque N-m
ω Angular Velocity rad/s
Z Blade Number -
⍴ Density kg/m3
η Efficiency %
Pin Inlet Static Pressure Pa
Pout Outlet Static Pressure Pa
m Mass Flow Rate kg/s
N Rotational Speed RPM
μ Viscosity kg/m-s
γ Specific Weight N-m3
β1 Inlet Blade Angle of Impeller degrees
β2 Outlet Blade Angle of Impeller degrees
BEP Best Efficiency Point -
CFD Computational Fluid Dynamics -
FVM Finite Volume Method -
RANS Reynolds-Averaged Navier-Stokes -
U Three-Dimensional Velocity Vector m/s
𝝉 Shear Stress N/m2

Chapter 1
Introduction
This chapter presents an overview to the report topic and explains the motivation behind
the work and its scope. CFD analysis is the simulation of conditions within the pump, using
mathematical calculations and computed software algorithms. CFD analysis of pumps is
now an industrial norm because of its advantages over conventional experimental methods.
This report aims to validate the results of other practical experiments by performing
simulation in Ansys CFD software.
1.1 Introduction
Centrifugal pumps are hydraulic machines that convert mechanical energy into hydraulic
energy by applying centrifugal force on the fluid. The fluid enters at the eye of impeller and is
accelerated and pushed outwards by the blades due to centrifugal force, giving velocity to the
fluid which enters into the volute casing, where the kinetic energy is converted into pressure
energy due to an increase in the cross-sectional area of the casing.
Practical analysis of pumps can give the actual values of pressure head, efficiency and power
rating, however, is not easy to carry out in terms of time and cost. Computational Fluid
Dynamics (CFD) software is now commonly used as it has advanced over the years to give
accurate numerical simulations with less labour-intensive methods, reducing time and analysis
cost.
The objective of this report is to determine the operating characteristic curves, optimized head
and efficiency at best efficiency point of centrifugal pumps using CFD. The design parameters
of the pumps have been obtained from literature data and the results mentioned in the literature
data have been compared with the results obtained from the CFD analysis.
1.2 Motivation
Computational fluid dynamics (CFD) analysis has now become a norm in the design of
centrifugal pumps in the industry. Complex internal flows in water pump impellers can be
understood with the aid of CFD tools. Recent advances in both hardware technology to be able
to process the data and compute the results and software technology allowing easier

manipulation of data has made the analysis process much easier using CFD, making the process
less labor intensive, saving time and cost. Advanced solvers contain algorithms which enable
robust solutions of the flow field in a reasonable time. As a result of these factors,
Computational Fluid Dynamics is now an established industrial design tool, which helps to
reduce design time scales and improve processes throughout the engineering world.
There are three methods in study of Fluid dynamics: theory analysis, experiment and simulation
using CFD. CFD has many advantages compared to the experimental method.
Simulation (CFD) Experiment
Cost Cheap Expensive
Time Short Long
Scale Any Small/Middle
Information obtained All types Only at Measured Points
Repeatable Yes To some extent
Safety Completely safe Some risks are present
Table 1.1: Comparison of Simulation and Experiment [1]
1.3 Scope
The report focuses on determination of operating characteristic curves, optimized head and
efficiency at best efficiency point of centrifugal pump using CFD and its comparison with
Literature Data.
It also covers visualization of contours of pressure and velocity variation in centrifugal pumps
at different flow rates using CFD.

Chapter 2
Literature Survey
This chapter presents the information obtained from various literature referred to while
working on the study. The various literature referred have work related to analysis of
centrifugal pumps to obtain their performance results and to get their best efficiency point
and optimized head .
A number of papers showing the effect of discharge on head and efficiency of centrifugal
pumps have been studied. The work in those papers has been carried out experimentally as well
as by simulation.
A five-blade centrifugal pump rotating with 2960 rpm was investigated by Bazin Tsegaye [2]
(Dribssa, Nigussie, Tsegaye. “Performance Analysis of Centrifugal Pump Operating as
Turbine for Identified Micro/Pico Hydro Site of Ethiopia,” 2015) with an objective of plotting
operating characteristics curves of centrifugal pumps. CFD analysis was carried out using
ANSYS software. The results obtained from simulation were then compared with the
experimental data obtained for parameters like head and efficiency. The Best efficiency point
was obtained at 0.025m3/s which is about 59%. The author analyzed the accuracy of the CFD
model using the experimental data as standard. The CFD data was matching satisfactorily with
the Experimental data.
In another research Reza Barmaki and Mir Biyouk Ehghaghi [3] (Reza Barmaki, Mir Biyouk
Ehghaghi “Experimental Investigation of a Centrifugal Pump Hydraulic Performance in
Hydraulic Transmission of Solids,” Mechanics and Mechanical Engineering, Vol.23, Issue 1,
December 2019, pp.259-270) the objective was to plot a operating characteristics curves by
performing an experiment on a centrifugal pump with impeller rotating at 2900 rpm with five
blades and specified motor power. The best efficiency point was obtained at a flow rate of
0.005655 m3/s which was about from CFD was 75.648% and by literature data was about
62.35%. The optimized head at this flow rate is about 42.3156 m. CFD analysis was carried
out by ANSYS software. The experimental set-up results are compared with simulation, which
shows a good agreement with it.

Oğuzcan Mercan [4] (Oğuzcan Mercan. “Centrifugal Pump Design And Performance
Optimization Using Loss Correlations,” Marmara University, 2018) performed the experiment
on centrifugal pump design and the objective was to plot head vs flow rate. Here experiment
was performed on three centrifugal pumps with different flow rates and at speed of 2900 rpm.
Here the maximum head obtained from CFD simulation was 20.71 m for pump 1 with reference
to Experimental data of 20.9m.The number of blades on the impeller were five and six blades.
Here numerical analysis was performed on ANSYS software. Characteristics of three different
pumps are in good agreement with performance curves at off design points of the pumps with
specific speed range between 40 to 180. Therefore, the developed performance prediction code
is highly reliable and consistent.
Mentzos et al. [5] (Mentzos, M., Filios, A., Margaris, P., Papanikas, D., 2005. “CFD
predictions of flow through a centrifugal pump impeller,” Proceedings of International Conf.
Experiments/Process/System Modelling/ Simulation/Optimization. Athens, pp. 1-8.) simulated
the flow through the impeller of the centrifugal pump using finite-volume method along with
a structured grid system for the solution of the discretized governing equations. The CFD
technique was applied to predict the flow patterns, pressure distribution and head-capacity
curve. It was reported that, although the grid size was not adequate to investigate the local
boundary layer variables, global ones were well captured. The proposed approach was
advocated for the basic understanding of the flow at various operating points.
Shah et al. [6] (Shah, S., Jain, S.,Lakhera, V., 2010. “CFD based flow analysis of centrifugal
pump,” Proceedings of International Conferenceon Fluid Mechanics and Fluid Power.
Chennai, India, paper#TM08).carried out a steady state simulation of a 200 m3/hr capacity
centrifugal pump using RANS equations. The non-uniformities were observed in different parts
of the pump at off-design conditions which resulted in the decrease in efficiency. The k-ω SST
turbulence model provided better results compared to the RNG k-ε model. The operating
characteristic curves predicted by the numerical simulation were compared with the results of
model testing and were found in good agreement.
(Department of Mechanical Engineering. "Lab Manual for Energy Conversion-I", Lab Manual,
K. J. Somaiya College of Engineering, Mumbai. 2020) [7]. Here the objective was to conduct
a test on a single stage centrifugal pump and plot the operating characteristic curves of the
pump. The pump speed was set to 1000 rpm and the number of impeller blades were five and

input power was different at different flow rates. These readings were calculated from the
virtual lab of NIT Surathkal [8].
In [9] (Department of Mechanical Engineering. "Lab Manual for centrifugal pump performance
test procedures and techniques", Lab Manual, (mechanical engineering site) experiment, the
aim was to run the pump performance test. Here for experiment purposes the pump used was
of rated speed 1190 rpm and rated power of 304.246 kW with a five-blade impeller. The best
efficiency point from the readings obtained was at 0.5675 m3/s which was about 73.1%.
The objective of this report is to determine the operating characteristic curves, optimized head
and efficiency at best efficiency point of centrifugal pumps using CFD and to visualize the
pressure and velocity variation within the pump using contours.
The results mentioned in the literature data have been compared with the results obtained from
the CFD analysis and validated.
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Chapter 3
Fundamental Concepts
This chapter presents the fundamental concepts and mathematical equations used in
analysis of a centrifugal pump and CFD analysis of flow of the fluid. The concept and
working of a CFD software is explained and the mathematical equations used in analysis
of fluid flow and their use in the CFD software is explained.
3.1 Centrifugal Pump [10]
The hydraulic machines which convert the mechanical energy into hydraulic energy are called
pumps. The hydraulic energy is in the form of pressure energy. If the mechanical energy is
converted into pressure energy by means of centrifugal force acting on the fluid, the hydraulic
machine is called a centrifugal pump. The centrifugal pump works on the principle of forced
vortex flow which means that when a certain mass of liquid is rotated by an external torque,
the rise in pressure head of the rotating liquid takes place. The rise in pressure head at any point
of the rotating liquid is proportional to the square of tangential velocity of the liquid at that
point. Thus, at the outlet of the impeller, where radius is more, the rise in pressure head will be
more and the liquid will be discharged at the outlet with a high-pressure head. Due to this high-
pressure head, the liquid can be lifted to a high level.
3.1.1 Operating Characteristic Curves
If the speed is kept constant, the variation of manometric head, power and efficiency with
respect to discharge gives the operating characteristics of the pump. Fig. 3.1 shows the
operating characteristic curves of a pump.
Fig. 3.1: Operating characteristic curves of a pump

3.2 Basics of Computational Fluid Dynamics [1]
3.2.1 Concept of Computational Fluid Dynamics
Computational Fluid Dynamics (CFD) is the simulation of fluid engineering systems using
modelling (mathematical physical problem formulation) and numerical methods (discretization
methods, solvers, numerical parameters, and grid generations, etc). The process is as in figure
3.2.
Fig. 3.2: Process of Computational Fluid Dynamics
To solve a fluid problem, we should know the physical properties of fluid by using Fluid
Mechanics. Then we can use mathematical equations to describe these physical properties,
which is the Navier-Stokes Equation and it is the governing equation of CFD.
As the Navier-Stokes Equation is analytical, humans can understand it and solve them on a
piece of paper. But if we want to solve this equation by computer, we have to translate it to the
discretized form. The translators are numerical discretization methods, such as Finite
Difference, Finite Element, Finite Volume methods. Consequently, we also need to divide our
whole problem domain into many small parts because our discretization is based on them.
Then, we can write programs to solve them. At the end, we can get our simulation results. We
can compare and analyze the simulation results with experiments and the real problem. If the
results are not sufficient to solve the problem, we have to repeat the process until we find a
satisfactory solution. This is the process of CFD.

3.2.2 Navier-Stokes Equation
Applying the mass, momentum and energy conservation, we can derive the continuity
equation, momentum equation and energy equation as follows.
Continuity Equation
Momentum Equation
Where
I: Local change with time

II: Momentum convection
III: Surface force
IV: Molecular-dependent momentum exchange (diffusion)
V: Mass force
Energy Equation
I : Local energy change with time

II: Convective term
III: Pressure work
IV: Heat flux (diffusion)
V: Irreversible transfer of mechanical energy into heat

General Form of Navier-Stokes Equation
To simplify the Navier-Stokes equations, we can rewrite them as the general form.
When Φ = 1 ,Uj ,T we can respectively get the continuity equation, momentum equation and
energy equation.
3.2.3 Finite Volume Method
If we use finite difference and finite element approach to discretize the Navier-Stokes equation,
we have to manually control the conservation of mass, momentum and energy. But with a finite
volume method, we can easily find out that, if the Navier-Stokes equation is satisfied in every
control volume, it will automatically be satisfied for the whole domain. In other words, if the
conservation is satisfied in every control volume, it will be automatically satisfied in the whole
domain.
That is the reason why finite volume is preferred in computational fluid dynamics.
3.2.4 Grids
There are three types of grids: structured grids, unstructured grids and block structured grids.
The simplest one is structured grid (fig 3.3). This type of grid, all nodes have the same number
of elements around it. We can describe and store them easily. But this type of grid is only for
the simple domain.If we have a complex domain, we can use an unstructured grid (fig 3.4).
Generally, an unstructured grid is suitable for all geometries.Block structure grid is a
compromise of structured and unstructured grid. The idea is, firstly, divide the domain into
several blocks, then use different structured grids in different blocks.
Fig. 3.3: Structured Grids Fig. 3.4: Unstructured Grids

3.2.5 Turbulence Models
Turbulence is the time-dependent chaotic behavior seen. It is a complex process, mainly

because it is three dimensional, unsteady and consists of many scales which reduces mesh size
and can be practically used. To enable the effects of turbulence to be predicted, a large amount
of CFD research has concentrated on methods which make use of turbulence models. Some of
the turbulence models that are used to describe turbulence in a flow are described below.
1. The k-epsilon Model
2. The Renormalization Group (RNG) k-epsilon Model
3. The k-omega and Shear-Stress-Transport SST Models
4. The Reynolds Stress Model
3.2.5.1 The k-epsilon Model
Within CFX, the k-ε model provides good predictions for many flows of engineering interest.
It is the most well-known turbulence model that has been used in most general purpose CFD
codes and is considered as a standard model. It has proven to be stable and numerically robust
and has a well-established regime of predictive capability. For general purpose simulations,
this model offers a good compromise in terms of accuracy and robustness. The k-ε model is an
appropriate choice for modelling turbulence in liquid pumps and turbines.
3.2.6 Rotating Frames of Reference (RFR)
Rotating Frames of Reference (RFR) are useful for rotating fluid machinery applications, such
as pump impeller or turbine blade problems. CFX enables the user to specify a domain that is
rotating about an axis. When a Rotating Frame of Reference is specified, angular velocity input
is required.
The velocity in the rotating frame of reference is defined as:
3.2.7 Interface Characteristics and Modelling
Domain interfaces provide a way of connecting meshes or domains together. Depending on the
type of domains defined, the different model connection across the interface is used. Type of

interface may be categorized into Fluid-Fluid, Solid-Solid, Porous-Porous, Fluid-Solid, Fluid-
Porous and Solid-Porous.
Domain interface are used in the following situations:
▪ Domains can be connected together with a domain interface. This is often useful for
connecting static domains together with non-matching grids.
▪ A domain may contain multiple mesh blocks. Non-matching interfaces can be
connected together using a domain interface.
▪ Domains that have a change in the reference frame (such as rotor-stator) can be
connected together.
▪ If the flow field is repeated in multiple identical regions, then only one region needs to
be solved, but the boundaries are specified as periodic.
3.2.8 Periodic Interface Model
The periodic condition is most common for a fluid-fluid interface that allows a simplified
geometry to be used if the full problem has multiple identical regions .It ensures that the flow
out of one side of the interface automatically appears on the other side. The two types of
periodic interface model in Ansys CFX:-
▪ Rotational Periodicity
▪ Translational Periodicity
3.2.8.1 Rotational Periodicity
Rotational periodicity is the most common case of periodic interface which is used to model a
single flow passage for a domain having identical flow passage in the domain; for example, the
analysis of a centrifugal pump impeller. In this interface model, the two sides of the periodic
interface can be mapped by a single rotational transformation about an axis.
3.2.9 Frame Change/Mixing Model
There are three types of frame change/mixing models available in ANSYS CFX:
▪ Frozen Rotor
▪ Stage
▪ Transient Rotor-Stator

3.2.9.1 Frozen Rotor
Frozen Rotor analysis is most useful when the circumferential variation of the flow is large
relative to the component pitch. This model assumes the frame of reference and/or pitch is
changed but the relative orientation of the components across the interface is fixed. The two
frames of reference connect in such a way that they each have a fixed relative position
throughout the calculation.
This model produces a steady state solution to the multiple frame of reference problems, with
some account of the interaction between the two frames. This model requires the least amount
of computational effort of the three frame change models.
3.2.9.2 Stage
The Stage model is an alternative to the Frozen Rotor model for modeling frame change.
Instead of assuming a fixed relative position of the components, the stage model performs a
circumferential averaging of the fluxes through bands on the interface. Steady state solutions
are then obtained in each reference frame. To obtain best results, it is required to obtain an
approximate solution using a Frozen Rotor interface and then restart with a Stage interface.
3.2.10 Discretization and Solution Theory
ANSYS CFX uses an element-based finite volume method, which first involves discretizing
the spatial domain using a mesh. The mesh is used to construct finite volumes, which are used
to conserve relevant quantities such as mass, momentum, and energy.
Figure 3.6 shows a typical two-dimensional mesh. All solution variables and fluid properties
are stored at the nodes (mesh vertices). A control volume (the shaded area) is constructed
around each mesh node using the median dual (defined by lines joining the centres of the edges
and element centres surrounding the node).
Fig. 3.5: Control volume definition Fig. 3.6: Mesh element

Chapter 4
Analysis and Comparison of Literature data with data obtained
from software simulations and calculations
This chapter presents the details of the work carried out for the analysis its results. The
workflow used in the software is shown, along with the setup of the models and initial
conditions used for analysis. At the end, the simulated results are visualized and are
tabulated and plotted for comparison with the literature data.
4.1 General Procedure
For the analysis of each model the workflow shown below was followed. All work was carried
out in the Ansys Software package. The 2D models of the Impeller and Volute were created in
Vista CPD. The 3D model of the impeller and volute were created in BladeGen, then the model
mesh was generated using Turbo Mesh. After that, in CFX Pre, boundary conditions were set
according to the requirements of each case. The data was then sent into CFX Solver, which
processed the data and calculated all the parameters and results as required. Then, finally, all
results were tabulated and visualized using CFX Post.
Fig. 4.1: Flowchart of the work process used to carry out analysis in Ansys Software

4.2 General Setup in Ansys Workbench
Fig. 4.2: Workflow setup in Ansys workbench
4.3 Processing Setup and Boundary Conditions
Fig 4.3: Design parameters of Impeller

Fig. 4.4: Model of Impeller (2D & 3D)
Fig. 4.5: Model of Volute (2D & 3D)

Fig. 4.6: Meshing of Impeller and Volute
Fig. 4.7: Setup and boundary conditions of Centrifugal pump

Fig. 4.8: Solver condition and convergence plot
4.4 Design Parameters
4.4.1 FROM [2]:
Parameter Value
Speed 2960 rpm
Number of Impeller Blades 5
Outlet blade angle 40 degree
Blade thickness 4.2 mm
Pump Inlet Condition Static Pressure
Pump Outlet Condition Mass Flow Rate
Table 4.1: Design Parameters for Pump 1

4.4.2 FROM [3]:
Parameter Value
Speed 2900 rpm
Outlet blade angle 22.5 degree
Blade thickness 3 mm
Pump Outlet Condition Static Pressure
4.4.3 FROM [4]:
Parameter Value
Speed 2900 rpm
Pump Inlet Condition Mass Flow Rate
Table 4.3: Design Parameters for Pump 3.1
Parameter Value
Speed 2900 rpm

Blade thickness 3.5 mm
Parameter Value
Speed 2900 rpm
4.4.4 FROM [7]:
Parameter Value
Speed 1000 rpm

4.4.5 FROM [11]:
Parameter Value
Speed 1750 rpm
Pump Outlet Condition Mass Flow Rate
4.4.6 FROM [9]:
Parameter Value
Speed 1190 rpm

4.5 Visualization of Simulated Results Using Contours
--- Velocity Contours ---
(a) (b)
(c) (d)
(e) (f)
Fig. 4.9: Velocity contours obtained at (a) 0.005m3/sec; (b) 0.010m3/sec; (c) 0.015m3/sec; (d)
0.020m3/sec; (e) 0.025m3/sec and (f) 0.030m3/sec at 2960 rpm (Pump1)

--- Pressure Contours ---
(a) (b)
(c) (d)
(e) (f)
Fig. 4.10: Pressure contours obtained at (a) 0.005m3/sec; (b) 0.010m3/sec; (c) 0.015m3/sec;
(d) 0.020m3/sec; (e) 0.025m3/sec and (f) 0.030m3/sec at 2960 rpm (Pump1)

4.6 Results
The results procured from the literature data and the results from the CFD simulation are
tabulated and compared below.
CFD Formulae
1] Calculation of Head:
Head = (massFlowAve(Total Pressure in Stn Frame)@S1 Outlet -
massFlowAve(Total Pressure in StnFrame) @R1 Inlet) / (ave(Density)@S1
Outlet*g)
2] Calculation of Efficiency:
Angular velocity = (2*pi*N)/60
Input Power = Torque*Angular velocity
Output Power = ave(density)@S1 Outlet*g*mass flow rate*head
Efficiency = (Output Power)/(Input Power)
S1- Volute
R1- Impeller
N- Rotating speed
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4.6.1 FROM [2]:
Head (m)
Flow Rate Flow rate
Error (%)
(kg/s) (m3/sec) Lit. Data CFD
5 0.0050 54.128 60.650 12.05
7 0.0070 - 58.195 -
8.5 0.0085 - 56.385 -
10 0.0100 53.516 56.010 4.66
15 0.0150 52.497 55.989 6.65
17 0.0170 - 55.879 -
18.5 0.0185 - 53.037 -
20 0.0200 50.968 52.675 3.33
22 0.0220 - 51.713 -
23.5 0.0235 - 50.067 -
25 0.0250 48.420 49.880 3.01
26 0.0260 - 48.545 -
27 0.0270 - 46.271 -
28 0.0280 - 44.475 -
29 0.0290 - 43.250 -
30 0.0300 39.960 41.920 4.90
Table 4.9: Head at various flow rates
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Flow Flow Power (W) Efficiency (%) Error
Rate Rate
(%)
(kg/s) (m3/sec) Input Output Lit. Data CFD
5 0.0050 12028.262 2974.882 20 24.732 23.662
7 0.0070 - 3996.312 - - -
8.5 0.0085 - 4701.696 - - -
10 0.0100 14523.148 5494.581 37 37.833 2.252
15 0.0150 15146.265 8238.781 48.44 53.442 10.326
17 0.0170 - 9319.074 - - -
18.5 0.0185 - 9625.401 - - -
20 0.0200 16047.147 10334.835 57 64.402 12.987
22 0.0220 - 11160.721 - - -
23.5 0.0235 - 11542.172 - - -
25 0.0250 15916.960 12233.071 61 76.855 25.994
26 0.0260 - 12381.989 - - -
27 0.0270 - 12255.799 - - -
28 0.0280 - 12216.393 - - -
29 0.0290 - 12304.192 - - -
30 0.0300 19518.253 12337.056 50 63.207 26.415
Table 4.10: Efficiency at various flow rates
NEXT PAGE →

65
60
55
HEAD (m)
50
45
CFD Literature Data

40
35
5 7 8.5 10 15 17 18.5 20 22 23.5 25 26 27 28 29 30
FLOW RATE (kg/s)
Fig. 4.11: Head v/s Flow Rate for each set of data
25000
20000
POWER (W)
15000
10000
5000
Output Power Input Power
0
5 7 8.5 10 15 17 18.5 20 22 23.5 25 26 27 28 29 30
FLOW RATE (kg/s)
Fig. 4.12: Power v/s Flow Rate for each set of data

90
80
70
EFFICIENCY (%)
60
50
40
30
20
CFD Literature Data
10
0
5 10 15 20 25 30
FLOW RATE (kg/sec)
Fig. 4.13: Efficiency v/s Flow Rate for each set of data
NEXT PAGE →

4.6.2 FROM [3]:
Head (m)
Flow rate Flow rate
Error (%)
(kg/sec) (m3/sec) Lit. Data CFD
4.828 0.004828 38.13 44.029 15.46
5.655 0.005655 34.96 42.315 21.04
6.433 0.006433 31.98 36.878 15.31
6.906 0.006906 30 33.794 12.64
7.147 0.007147 28.01 32.526 16.12
7.539 0.007539 24.99 31.055 24.27
8.269 0.008269 21.97 27.699 26.07
50
45
40
35
HEAD (m)
30
25
20
15
10
CFD Literature Data
5
0
4.828 5.655 6.433 6.9055 7.147 7.539 8.2694
FLOW RATE (kg/sec)

Flow rate Flow Rate Power (W) Efficiency (%) Error
(kg/sec) (m3/sec) Input Output Lit. Data CFD (%)
4.828 0.004828 2990 2083.224 60.2 69.673 15.73
5.655 0.005655 3100 2345.088 62.35 75.648 21.32
6.433 0.006433 3290 2324.933 61.09 70.666 15.67
6.906 0.006906 3330 2286.992 60.84 68.678 12.88
7.147 0.007147 3430 2278.196 57.05 66.419 16.42
7.539 0.007539 3510 2294.478 52.47 65.369 24.58
8.269 0.008269 3570 2244.754 49.74 62.878 26.41
4000
3500
3000
POWER (W)
2500
2000
1500
1000
500
0
4.828 5.655 6.433 6.9055 7.147 7.539 8.2694
FLOW RATE (kg/s)

80
70
60
EFFICIENCY (%)
50
40
30
20
CFD Literature Data
10
0
4.828 5.655 6.433 6.9055 7.147 7.539 8.2694
FLOW RATE (kg/sec)
NEXT PAGE →

4.6.3.1 FROM [4]:
Flow rate Flow rate Head (m) Output Error

(l/min) (m3/sec) Lit. Data CFD Power (W) (%)
390 0.0065 20.90 24.89 1587.43 19.11
600 0.0100 15.85 20.60 2020.86 29.97
850 0.0142 6.51 7.58 1053.15 16.41
30
25
20
HEAD (m)
15
10
5
CFD Literature Data
0
390 600 850
FLOW RATE (l/min)
2500
2000
POWER (W)
1500
1000
500
Output Power
0
390 600 850
FLOW RATE (l/min)

4.6.3.2 FROM [4]:

(l/min) (m3/sec) Power (W) (%)
Lit. Data CFD
150 0.0025 11.53 13.94 341.984 20.94
300 0.0050 8.99 11.23 550.728 24.89
450 0.0075 4.07 4.43 326.076 8.89
16
14
12
10
HEAD (m)
8
6
4
CFD Literature Data
2
0
150 300 450
FLOW RATE (l/min)
600
500
400
POWER (W)
300
200
100 Output Power
0
150 300 450
FLOW RATE (l/min)

4.6.3.3 FROM [4]:

(l/min) (m3/sec) Lit. Data CFD Power (W) (%)
60 0.001 9.78 8.36 82.057 14.47
120 0.002 7.90 7.17 140.685 9.23
180 0.003 5.46 4.65 137.002 14.74
12
10
8
HEAD (m)
2
CFD Literature Data
0
60 120 180
FLOW RATE (l/min)
160
140
120
100
POWER (W)
80
60
40
20 Output Power
0
60 120 180
FLOW RATE (l/min)

4.6.4 FROM [7]:
Head (m)
Flow rate Flow rate
Error (%)
(kg/sec) (m3/sec) Lit. Data CFD
10.429 0.01043 6.23 6.0378 3.08
10.000 0.01000 - 6.6385 -
9.862 0.00986 7.03 6.7481 4.001
9.500 0.00950 - 7.2356 -
9.331 0.00933 7.63 7.3091 4.20
9.000 0.00900 - 7.6453 -
8.734 0.00873 8.23 7.9291 3.66
8.400 0.00840 - 8.3875 -
8.113 0.00811 9.03 8.7732 2.84
7.800 0.00780 - 8.9753 -
7500 0.00750 - 9.3758 -
7.336 0.00734 9.73 9.6192 1.14
7.000 0.00700 - 9.7535 -
6.500 0.00650 - 9.8668 -
6.231 0.00623 10.23 10.1321 0.96
5.800 0.00580 - 10.2784 -
5.500 0.00550 - 10.5234 -
5.257 0.00526 10.83 10.7183 1.03

Flow rate Flow Rate Power (W) Efficiency (%) Error
(kg/sec) (m3/sec) Input Output Lit. Data CFD (%)
10.429 0.01043 2040 651.236 31.25 30.28 3.10
10.000 0.01000 - 652.850 - - -
9.862 0.00986 1920 674.321 35.43 34.003 4.03
9.500 0.00950 - 669.075 - - -
9.331 0.00933 1920 675.003 36.38 34.847 4.21
9.000 0.00900 - 679.392 - - -
8.734 0.00873 1824 691.163 38.66 37.247 3.65
8.400 0.00840 - 698.223 - - -
8.113 0.00811 1776 686.772 40.46 39.314 2.83
7.800 0.00780 - 689.824 - - -
7500 0.00750 - 692.302 - - -
7.336 0.00734 1680 669.772 41.68 41.208 1.13
7.000 0.00700 - 629.156 - - -
6.500 0.00650 - 619.375 - - -
6.231 0.00623 1560 584.820 40.10 39.703 0.99
5.800 0.00580 - 567.790 - - -
5.500 0.00550 - 552.786 - - -
5.257 0.00526 1440 617.712 38.78 38.388 1.01
NEXT PAGE →

12
10
8
HEAD (m)
4
CFD Literature Data
2
FLOW RATE (kg/sec)
2500
2000
1500
POWER (W)
1000
500
FLOW RATE (kg/sec)

45
40
35
30
EFFICIENCY (%)
25
20
15
10
CFD Literature Data
5
0
10.4289 9.86196 9.3313 8.7343 8.11274 7.33648 6.2314 5.2573
FLOW RATE (kg/sec)
NEXT PAGE →

4.6.5 FROM [11]:
Flow Rate Head (m) Output Power

Error (%)
(m3/sec) Lit. Data CFD (W)
0.0100 6.09 7.4051 726.472 21.48
0.0075 7.62 8.1117 596.818 6.45
0.0050 8.68 8.5609 419.915 1.37
0.0025 9.60 8.8162 216.217 8.16
12
10
8
HEAD (m)
4
CFD Literature Data
2
0
0.01 0.0075 0.005 0.0025
FLOW RATE (m3/sec)
800
700
600
500
POWER (W)
400
300
200
Output Power
100
0
0.01 0.0075 0.005 0.0025
FLOW RATE (m3/sec)

4.6.6 FROM [9]:
Head (m)
Flow Rate Flow rate
Error (%)
(m3/hr) (m3/sec) Lit. Data CFD
934.390 0.295 50.048 41.771 16.54
1136.76 0.316 48.585 40.273 17.11
1589.42 0.442 45.141 36.914 18.22
2042.99 0.567 39.685 31.707 20.1
2433.87 0.676 33.162 28.431 14.27
2723.45 0.756 29.626 26.066 12.02
2948.53 0.819 26.609 24.307 8.65
60
50
40
HEAD (m)
30
20
10
CFD Literature Data
0
934.39 1136.76 1589.42 2042.99 2433.87 2723.45 2948.53
FLOW RATE (m3/hr)

Flow Flow Power (W) Efficiency (%) Error
Rate Rate
(%)
(m3/hr) (m3/sec) Input Output Lit. Data CFD
934.39 0.295 300740.76 106355.4 42.3 35.36 16.39
1136.76 0.316 300740.76 124751.0 49.9 41.48 16.87
1589.42 0.442 301710.00 159879.1 64.7 52.99 18.09
2042.99 0.567 301561.03 176515.9 73.1 58.53 19.92
2433.87 0.676 326276.14 188561.5 72.4 57.79 20.17
2723.45 0.756 335289.55 193446.2 71.9 57.69 19.75
2948.53 0.819 347824.91 195300.5 69.3 56.15 18.97
400000
350000
300000
250000
POWER (W)
200000
150000
100000
50000
0
934.39 1136.76 1589.42 2042.99 2433.87 2723.45 2948.53
FLOW RATE (m3/hr)

80
70
60
EFFICIENCY (%)
50
40
30
20
CFD Literature Data
10
0
934.39 1136.76 1589.42 2042.99 2433.87 2723.45 2948.53
FLOW RATE (m3/hr)
NEXT PAGE →

Chapter 5
Conclusions and Future work
This chapter presents a summary of the results found from the study and the conclusions
drawn. It also gives details on the future work that can be carried out related to the report.
Conclusions
▪ By comparison of literature data and simulation data we found deviations in their values
which were expected as the CFD software does not consider mechanical and volumetric
losses that exist within the real existing pump.
▪ The simulated data comply with the literature data to a close extent so we can conclude that
simulated data were successfully validated with literature data.
▪ From pressure contours we conclude that pressure increases from pump inlet to outlet
which supports the fact that fluid kinetic energy gets converted into pressure energy as it
moves from pump inlet to outlet.
▪ Numerical results also proved that head decreases and efficiency increases till best
efficiency point and further efficiency and head both decreases.
Future Work
▪ Effect of variation in impeller eye diameter, vane exit angle, width and thickness of blade
at exit on performance of centrifugal pump can be analysed.
▪ This research could also be further extended to predict the performance of the pump in
turbine mode using published empirical formulas and compare the results with CFD
simulation results.
▪ Same analysis can be performed for different numbers of impeller blades(more than 5) and
rotating speed to obtain corresponding optimum performance for different centrifugal
pumps studied in this paper.
▪ Three-dimensional unsteady flow patterns in centrifugal pumps can be used to establish the
correlation between the pump characteristics and efficiency numerically.
▪ Further research can be extended to investigate vibration analysis of centrifugal pumps by
integrating the CFD data with an accurate pump FEA model.

References
[1] Wangda Zuo. “Introduction of Computational Fluid Dynamics,” Joint Advanced Student
School (JASS), 2005.
[2] Dribssa, Nigussie, Tsegaye. “Performance Analysis of Centrifugal Pump Operating as

Turbine for Identified Micro/Pico Hydro Site of Ethiopia,” 2015.
[3] Reza Barmaki, Mir Biyouk Ehghaghi. “Experimental Investigation of a Centrifugal Pump
Hydraulic Performance in Hydraulic Transmission of Solids,” Mechanics and Mechanical
Engineering, Vol.23, Issue 1, December 2019, pp.259-270.
[4] Oğuzcan Mercan. “Centrifugal Pump Design And Performance Optimization Using Loss
Correlations,” Marmara University, 2018.
[5] M. Mentzos, A. Filio, P. Margaris, D. Papanikas. “CFD predictions of flow through a

centrifugal pump impeller,” Proceedings of International Conf. Experiments/Process/System
Modelling/Simulation/Optimization. Athens, 2005 pp. 1-8.
[6] S.R. Shah, S.V. Jain, V.J. Lakhera. “CFD based flow analysis of centrifugal pump,”
Proceedings of International Conferenceon Fluid Mechanics and Fluid Power. Chennai, India,
paper#TM08, 2010.
[7] Department of Mechanical Engineering. "Lab Manual for Energy Conversion-I", Lab
Manual, K. J. Somaiya College of Engineering, Mumbai, 2020.
[8] Department of Civil Engineering. “Performance Characteristics of Centrifugal Pump”,

Virtual Lab, NIT Surathkal https://fmc-nitk.vlabs.ac.in/fluid-machinery-lab/exp/centrifugal-
pump/index.html
[9] Department of Mechanical Engineering. "Lab Manual for centrifugal pump performance
test procedures and techniques", Lab Manual, mechanicalengineeringsite.com

[10] R.K. Bansal. “A Textbook of Fluid Mechanics and Hydraulic Machines,” Revised 9th ed.,
Laxmi Publications Pvt. Ltd., New Delhi, 2010.
[11] José David Villegas Jiménez. "Numerical simulations on a centrifugal pump operating in
turbine mode," Bachelor's thesis, Universidad EAFIT, 2010.
[12] Mechanical Engineering Department “Laboratory Manual and Test Data,” Addis Ababa
University
[13] Raghavendra S Muttalli, Shweta Agrawal, Harshala Warudkar. “CFD Simulation of

Centrifugal Pump Impeller using ANSYS-CFX,” International Journal of Innovative Research
in Science, Engineering and Technology, Vol. 3, Issue 8, August 2014
[14] Nilesh Patil, G.S.Joshi, V.R.Naik. “Validation in the improved performance of Centrifugal
pump using CFD,” International Research Journal of Engineering and Technology (IRJET),
Vol. 4, Issue 6, June 2017.
[15] Khin Cho Thin, Mya Mya Khaing, Khin Maung Aye. “Design and Performance Analysis
of Centrifugal Pump,” World Academy of Science, Engineering and Technology 22 2008
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KJ Somaiya College of Engineering, Mumbai-77

(Autonomous College Affiliated to University of Mumbai)

DEPARTMENT OF MECHANICAL ENGINEERING

Mini Project Report

Analysis of Centrifugal Pump Using

Batch 2018 -2022

DEPARTMENT OF MECHANICAL ENGINEERING

This is to certify that the Mini project report entitled Analysis of

B.Tech (Mechanical Engineering) Batch: 2018-22 Page 1

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate of Approval of Examiners

This is to certify that the Mini project report entitled Analysis of

B.Tech (Mechanical Engineering) Batch: 2018-22 Page 2

B.Tech (Mechanical Engineering) Batch: 2018-22 Page 3

3.1 Centrifugal Pump 15

3.1.1 Operating Characteristic Curves 15

3.2 Basics of Computational Fluid Dynamics 16

3.2.1 Concept of Computational Fluid Dynamics 16

3.2.2 Navier-Stokes Equation 17

3.2.3 Finite Volume Method 18

3.2.5 Turbulence Models 19

3.2.5.1 K-epsilon Model 19

3.2.6 Rotating Frames of Reference 19

3.2.7 Interface Characteristics and Modelling 19

3.2.8 Periodic Interface Model 20

3.2.8.1 Rotational Periodicity 20

3.2.9 Frame Change/Mixing Model 20

3.2.9.1 Frozen Rotor 21

3.2.10 Discretization and Solution theory 21

B.Tech (Mechanical Engineering) Batch: 2018-22 Page 4

4.1 General Procedure 22

4.2 General Setup in ANSYS Workbench 23

4.3 Processing Setup and Boundary Conditions 23

4.4 Design Parameters 26

4.5 Visualization and Simulated Results using Contours 30

5 Conclusions and Future Work 51

B.Tech (Mechanical Engineering) Batch: 2018-22 Page 5

No. Title Page No.

3.1 Operating characteristic curves of a pump 15

3.2 Process of Computational Fluid Dynamics 16

3.3 Structured Grids 18

3.4 Unstructured Grids 18

3.5 Control volume definition 21

3.6 Mesh element 21

4.1 Flowchart of work process used to carry out analysis in Ansys 22

4.2 Workflow setup in Ansys workbench 23

4.3 Design parameters of Impeller 23

4.4 Model of Impeller (2D & 3D) 24

4.5 Model of Volute (2D & 3D) 24

4.6 Meshing of Impeller and Volute 25

4.7 Setup and boundary conditions of Centrifugal pump 25

4.8 Solver condition and convergence plot 26

4.9 Velocity contours obtained at 2960 rpm 30

4.10 Pressure contours obtained at 2960 rpm 31

4.12 Power v/s Flow Rate for each set of data[2] 35

B.Tech (Mechanical Engineering) Batch: 2018-22 Page 6

B.Tech (Mechanical Engineering) Batch: 2018-22 Page 7

4.1 Design Parameters for Pump 1 [2] 26

4.2 Design Parameters for Pump 2 [3] 27

4.3 Design Parameters for Pump 3.1 [4] 27

4.4 Design Parameters for Pump 3.2 [4] 28

4.5 Design Parameters for Pump 3.3 [4] 28

4.6 Design Parameters for Pump 4 [7] 28