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Numerical Simulation of The Dynamic Effects Due To Impeller-Volute Interaction in A Centrifugal Pump
Numerical Simulation of The Dynamic Effects Due To Impeller-Volute Interaction in A Centrifugal Pump
Introduction transducers, placed on the volute wall, were able to find a spatial
pattern as a function of the flow rate at the blade passing
Flow in centrifugal pumps produces a complex three- frequency.
dimensional phenomenon involving turbulence, secondary flows, Although predictions on the unsteady flow field are always
unsteadiness, etc. 共Brennen 关1兴兲. Moreover, the geometry is com- valuable, numerical simulation of centrifugal pumps is not easy
plex and asymmetric due to the volute shape. The relative move- due to the usual CFD difficulties: turbulence modeling, flow sepa-
ment between impeller and volute generates an unsteady interac- ration, boundary layer, etc. 共Lakshminarayana 关6兴兲. Besides that,
tion which affects not only the overall pump performance 共flow there are also specific problems, as:
structure, losses兲, but is also responsible for pressure fluctuations. —Extremely complex geometry: a great number of cells is
Pressure fluctuations interact with the volute casing or even with needed and, due to skewness, usually unstructured grids give bet-
the circuit and give rise to dynamic effects 共mainly unsteady ter convergence than structured ones.
forces兲 over the mechanical parts 共Adkins et al. 关2兴兲, which are —Energy transfer is generated mainly by the centrifugal force
one of the most important sources of vibration and hydraulic noise in the impeller. A cascade simulation is not valid and these force
共Dong et al. 关3兴兲. Both experimental and numerical approaches source terms must be included in the equations of the moving
have been reported and have contributed to the understanding of zone.
—The interaction between impeller and volute requires an un-
the highly complex flow interactions that occur in a centrifugal
steady solution process to calculate the time dependent terms in
pump.
the equations. In addition, the blade position with respect to the
Some authors 共Kaupert et al. 关4兴兲 have measured the unsteady volute tongue must be taken into account. This can be partially
pressure field inside the impeller of a centrifugal pump using accomplished in a quasi-steady way: calculating the steady solu-
piezoresistive pressure transducers and a telemetry system. They tion with different grid positions. Nonetheless, it is always much
found amplitudes particularly high at the trailing edge of the better if the code is able to perform an unsteady flow calculation
blades 共pressure side兲 and relative values up to 35 percent of the at the same time that slides the impeller grid for each time step.
pump head at off-design conditions. Another important contribu- CFD has proven to be a very useful tool in the analysis of the
tion to the understanding of the relation between unsteady flow flow inside pumps, both in design and performance prediction.
and mechanical problems was pinpointed by visualization 共Chu Much research has been carried out in the last years: Croba et al.
et al. 关5兴兲. In that paper a PIV technique was used to observe the 关7兴 give an updated list of general selected papers while Denus
influence of the blade passing in front of the volute tongue and the et al. 关8兴 give a more extended and specific bibliography. How-
unsteadiness generated. ever, due to the difficulties of the task, most of these studies have
For the present paper, the unsteady pressure fields at the blade been carried out with strong simplifications of the problem either
passing frequency for different operating conditions were mea- in the geometry or in the flow characteristics. Research is slowly
tending toward more complete simulations 共see for example
sured by means of fast response piezo-electric transducers. Those
Miner 关9兴兲 and the approach developed here follows this trend.
A numerical study of a centrifugal pump is used to capture the
Contributed by the Fluids Engineering Division for publication in the JOURNAL
OF FLUIDS ENGINEERING. Manuscript received by the Fluids Engineering Division
effects due to the dynamic interaction between the flow leaving
July 1, 2001; revised manuscript received September 12, 2001. Associate Editor: the impeller and the volute tongue. Calculations have been per-
Y. Tsujimoto. formed with a commercial software package, FLUENT®. This
348 Õ Vol. 124, JUNE 2002 Copyright © 2002 by ASME Transactions of the ASME
code uses the finite volume method and the 3D Navier-Stokes
equations are solved on an unstructured grid. The unsteady flow is
solved using a sliding mesh technique, which has been applied to
turbomachinery flows 共Croba et al. 关7兴兲.
The unsteady pressure fields at the blade passing frequency
obtained both experimentally and numerically are compared and a
high level of concordance is found for a large range of the oper-
ating flow regimes.
Some flow patterns are often difficult to measure directly and
cover a wide range of unsteady very important aspects, such as:
pressure changes in the volute for different flow rates; incidence at
Experimental Results Fig. 1 Pressure taps and angular reference around the volute
for unsteady measurements
The unsteady pressure signals recorded and analyzed by a FFT
procedure describe the dynamic behavior of the flow inside the
volute. In this case, the instantaneous pressure on the volute was wards, spectral analysis 共FFT, with Hanning window兲 of the sig-
measured. First, the experimental routines and measurements nals were performed. A detailed description of such arrangement
chain are described and afterwards a summary of the results is was described in Parrondo et al. 关13兴.
presented in this section.
Results at the Blade Passing Frequency. With the unsteady
Pump Facility and Measurements Chain. The pump was pressure signals measured as a function of the flow rate, different
tested in a hydraulic setup designed according to the international representations were made in order to draw conclusions. In par-
Standards 关10兴. In the circuit, water is pumped from and returned ticular, the study was centered on the fluctuation at the blade
to a 100 m3 reservoir. The flow rate is regulated by a set of passing frequency. With the amplitude and angular phase of that
butterfly valves located close to the reservoir discharge. The pump fluctuation, a filtered signal was recovered 共real signal filtered at
is a single axial suction and vaneless volute casing, Worthington the blade passing frequency兲. This signal produces a clear spatial
EWP-65-200, with seven impeller blades. pattern for each flow rate. Two representative distributions can be
The main dimensions of the pump tested and geometric ar- seen in Fig. 2, namely 20 percent of the nominal flow rate and the
rangements are presented in Table 1. More details about this
pumping facility and test apparatus for static measurements can be
found in González 关11兴. Flow rate uncertainties were found to be
always less than 2.5 percent 共confidence level of 95 percent兲. The
head and efficiency uncertainties were kept under 3 percent and
4 percent respectively, within the same confidence level. All un-
certainty analysis were carried out following the procedures pro-
posed in Kline 关12兴.
On the volute of that pump 共shroud side兲 36 pressure taps were
located 共one each 10 deg兲 in a circumference with R⫽107 mm
共see Fig. 1兲. Four Kistler-601 miniature fast-response piezo-
electric pressure transducers were consecutively installed in the 36
possible taps in order to measure the unsteady pressure signals.
Each transducer was connected to a charge amplifier, which pro-
duced a pressure measurement with an estimated combined uncer-
tainty of less than ⫾1.5 percent. An optic device provides a trig-
gering signal to start all the measurements in the same impeller
position. The resulting pressure signals, as well as the signal from
the tachometer could be digitalized and stored in a PC equipped
with a multi-channel analog-to-digital conversion card. After-
The size of the resulting cells is not enough for a full boundary
layer simulation but it gives correct values for the pump perfor-
mance and allows the analysis the details of the main phenomena
involved.
Surfaces between inlet-impeller and impeller-volute define the
grid interfaces needed for the relative rotation of the impeller. The
sliding mesh technique provided by FLUENT allows that relative
motion of the impeller grid with respect to the inlet and the volute
during unsteady simulation. Grid faces do not need to be aligned
on both sides as an interpolating routine is defined 共a discussion
about this technique was presented in González 关11兴兲.
Mathematical Model. The code solves the fully 3D incom-
Fig. 3 Sketch of the pump unstructured mesh. „Inlet and outlet pressible Navier-Stokes equations, including the centrifugal force
pipe portions are added.… source in the impeller and the unsteady terms.
Turbulence is simulated with the standard k-⑀ model. Although
grid size is not adequate to investigate local boundary layer vari-
nominal flow rate (Q N ). In this figure, the nondimensional mag- ables, global ones are well captured. For such calculations, wall
nitude p A /(1/2 U 22 ) is mapped as a function of the angular posi- functions, based on the logarithmic law, have been used. The time
tion from the volute tongue 共兲 and for a time equal to the passage dependent term scheme is second order, implicit. The pressure-
of one blade channel. Bold arrows represent the angular position velocity coupling are calculated through the SIMPLEC algorithm.
of the seven blades. Second order, upwind discretizations have been used for convec-
The resulting distributions, shown in Fig. 2 characterize the tion terms and central difference schemes for diffusion terms.
dynamic behavior of the impeller-tongue interactions for the dif-
ferent flow rates 共Parrondo et al. 关13兴兲. For the nominal flow rate, Boundary Conditions. The modeled boundary conditions are
a spatial periodic pattern is found for the pressure fluctuations 共at the ones considered with more physical meaning for turbomachin-
any time兲. On the other hand, for off-design conditions a big dis- ery flow simulations, that is, total pressure at the inlet and a vari-
turbance downstream of the tongue location 共⫽30 deg兲 can be able static pressure proportional to the kinetic energy at the outlet.
seen. Therefore, it can be observed how the tongue has no dy- The flow rate is changed by modifying the static pressure to ki-
namic effect for flow rates near the nominal one, whereas it affects netic energy ratio at the outlet condition, which simulates different
quite severely the pressure fluctuations for off-design conditions. closing positions of a valve. Some tests were carried out using a
The relative blade to tongue effect for a blade passing period is fixed flow rate at the inlet. Although it provides a better stability
also made visible. and faster convergence, this condition was found to be less physi-
cally correct, because the pressure fluctuations obtained were
Model Description and Computational Method quite different to the measured ones. Also, nonslip boundary con-
ditions have been imposed over the impeller blades and walls, the
Geometry and Grid. A geometrical discretization of the cen- volute casing and the inlet pipe wall.
trifugal pump is made for the numeric treatment. Structured hexa- Total pressure at the inlet and variable static pressure at the
hedral cells are generated to define the inlet and outlet zones outlet conditions allow simultaneous unsteady pressure and veloc-
共34883 cells and 44684 cells, respectively兲 while unstructured tet- ity fluctuations at the domain boundaries. Again, a constant veloc-
rahedral cells are used to define the impeller and volute 共162974 ity or pressure boundary condition would not be able to capture
cells and 89712 cells, respectively兲. In the volute, a mesh refine- both unsteady fluctuations at the same location. The influence of
ment zone is defined near the tongue. Once the geometry is de- the pump circuit itself has not been included in this simulation.
fined, the model is ready to be simulated. A view of the generated Studies about such interactions have been performed by Longatte
grid can be seen in Fig. 3, while a detail of the impeller grid is et al. 关14兴.
shown in Fig. 4. In the two grid interfaces between a stationary and moving
partly smooths out the wake. This has been generated by taking
and three off-design ones 共two higher and a lower one兲. The head from each time step the data around the volute some millimeters
obtained in these points matches very well with the experimental above the impeller near the frontal case of the volute. If a fixed
ones. The efficiency correspondence is also very good, if one abscissa 共angular position兲 is selected, the ordinate represents the
considered the unavoidable simplifications that are behind the nu- pressure change in time; if a fixed ordinate 共time instant兲 is cho-
merical simulation. More details on the flow structure analysis and sen, the abscissa shows the pressure around the volute at that
static comparison between numerical results and experimental instant. The time range represented is only a blade passage. In this
data were already presented in Blanco et al. 关15兴. figure it can be observed how the wakes advance around the vo-
lute. In such representation, the wave generated by the blades
Comparison of the Fluctuating Fields 共shown in Fig. 2兲 is superimposed to the average pressure distri-
The results of the numerical simulation were recorded for the bution around the volute. At the angular positions opposite to the
same locations considered in the experiments. Pressure fluctua- tongue 共 around 180 deg兲, the blade passage in front of the
tions with time are compared in Fig. 8 using both techniques tongue has little effect, while near the tongue, the blade wave is
共average value subtracted兲. This signal corresponds to a circum- more or less smoothed depending on the blade position with re-
ferential position opposite to the tongue. Agreement between the spect to the tongue. This tendency depends strongly on the con-
numerical and experimental data is fairly good, although the nu- sidered flow rate 共Fig. 9 corresponds to nominal conditions and
merical result is obtained for a complete revolution of the impeller the pressure fluctuations are kept below 5 percent of the average
once the periodic state is achieved and the experimental signal is value of the static pressure for this flow rate兲.
an instantaneous measurement. These experimental results have
not been phase averaged and therefore include random fluctua- Pressure Fluctuations Inside the Volute. Pressure at differ-
tions. ent flow rates is obtained numerically in the 36 points at R
As an example of the numerical instantaneous results, the static ⫽107 mm, on the shroud wall of the volute, corresponding to the
pressure in the intersection between the center plane and a cylin- same locations for which experimental data was available. After
der with R⫽107 mm, for different time steps with nominal flow recording the pressure at that points, FFT was performed and rel-
rate, is shown in Fig. 9. The displacement of the wake at the outlet evant amplitudes and phases were obtained for the different fre-
of the blades is clear in angular positions far from the tongue. quencies and particularly for the blade passing frequency. The
Approaching the tongue, the circumferential pressure distortion
Fig. 8 Pressure fluctuations in the volute wall in a angular Fig. 10 Comparison of the pressure fluctuations at the blade
position opposite to the tongue at a radius RÄ107 mm passing frequency for Q Ä0.5 Q N . Tongue at Ä0 deg.
Fig. 12 Comparison of the pressure fluctuations at the blade Fig. 14 Comparison of the pressure fluctuations at the blade
passing frequency for Q Ä Q N . Tongue at Ä0 deg. passing frequency for Q Ä1.5Q N . Tongue at Ä0 deg.
Nomenclature
b2 ⫽ impeller width at outlet
D2 ⫽ impeller diameter at outlet
f BP ⫽ blade passing frequency
H, H N ⫽ pump head and pump head at best efficiency point
共nominal兲
p, p A ⫽ pressure, pressure amplitude at the blade passing fre-
quency
Q, Q N ⫽ flow rate and flow rate at nominal point
R ⫽ radial coordinate
uជ ⫽ flow velocity
U2 ⫽ peripheral velocity at impeller outlet
2 ⫽ impeller blade angle 共outlet section兲
⫽ flow coefficient ⫽Q/( D 2 b 2 U 2 )
⫽ density of the fluid 共water in this paper兲
⫽ angular position around impeller
, S ⫽ rotating speed, specific speed S⫽ Q N 1/2/(gH N ) 3/4
⫽ head coefficient ⫽gH/(U 2 2 /2)
References
关1兴 Brennen, C. E., 1994, Hydrodynamics of Pumps, Oxford University Press and
CETI Inc.
关2兴 Adkins, D. R., and Brennen, C. E., 1988, ‘‘Analysis of Hydrodynamic
Radial Forces on Centrifugal Pump Impellers,’’ ASME J. Fluids Eng., 110, pp.
20–28.
关3兴 Dong, R., Chu, S., and Katz, J., 1997, ‘‘Effect of Modification to Tongue and
Impeller Geometry on Unsteady Flow, Pressure Fluctuations and Noise in a
Fig. 16 Polar representation of the fluctuating force „numeri- Centrifugal Pump,’’ ASME J. Turbomach., 119, pp. 506 –515.
关4兴 Kaupert, K. A., and Staubli, T., 1999, ‘‘The Unsteady Pressure Field in a High
cal result…, Q Ä1.3 Q N . Force at the blade passing frequency.
Specific Speed Centrifugal Pump Impeller. Part I: Influence of the Volute,’’
ASME J. Fluids Eng., 121, pp. 621– 626.
关5兴 Chu, S., Dong, R., and Katz, J., 1995, ‘‘Relationship Between Unsteady Flow,
Pressure Fluctuations, and Noise in a Centrifugal Pump-Part B: Effects of
Conclusions Blade-Tongue Interactions,’’ ASME J. Fluids Eng., 117, pp. 30–35.
关6兴 Lakshminarayana, B., 1991, ‘‘An Assessment of Computational Fluid Dy-
The impeller-volute interaction in a centrifugal pump is suc- namic Techniques in the Analysis and Design of Turbomachinery-The 1990
cessfully predicted by a numerical model developed using a finite Freeman Scholar Lecture,’’ ASME J. Fluids Eng., 113, pp. 315–352.
volume commercial code. Both experiments and numerical pre- 关7兴 Croba, D., and Kueny, J. L., 1996, ‘‘Numerical Calculation of 2D, Unsteady
Flow in Centrifugal Pumps: Impeller and Volute Interaction,’’ Int. J. Numer.
diction show the presence of a spatial fluctuation pattern at the Methods Fluids, 22, pp. 467– 481.
blade passing frequency as function of the flow rate. That fre- 关8兴 Denus, C. K., and Göde, E., 1999 ‘‘A Study in Design and CFD Analysis of a
quency is predominant in what refers to the dynamic effects inside Mixed-Flow Pump Impeller,’’ ASME-FEDSM-99-6858.
the pump and conditions the possible limitations in what refers to 关9兴 Miner, S. M., 2000, ‘‘Evaluation of Blade Passage Analysis Using Coarse
Grids,’’ ASME J. Fluids Eng., 122, pp. 345–348.
the use of the dynamic data for design purposes. Unsteady forces 关10兴 British Standard BS-5316 Part-2, 1977, ‘‘Acceptance Tests for Centrifugal,
have been calculated using the numerical results. Mixed Flow and Axial Pumps.’’
Considering the model results obtained, secondary flow pattern 关11兴 González, J., 2000, ‘‘Modelización Numérica del Flujo no Estacionario en