Computational and experimental study of an industrial centrifugal compressor volute

IntrotctionThe overall performance of a centrifugal compressoris a combination of the dueller, diffuser, and voluteperformances. Each component has to be designedcarefully in order tO' minimize the losses and maximizethe efficiency. In this paper, a centrifugal compressorvolute (or spiral) is stUdied numerically, and the CFDresults are compared with measured data.A volute is used to collect the flow from a vaned orvaneless diffuser and to gUide it Ollt of the compressor.The volute geometry…     

离心式压缩机蜗壳优化设计

基于蜗壳一维气动设计理论,经过参数修正后,获得等内径的不对称圆形蜗壳结构。应用计算流体动力学专业软件NUMECA对流动十分复杂的蜗壳内部流场进行了三维粘性数值计算分析。根据蜗壳内部气流流动特性分析,合理设计并改进蜗壳结构,改进后离心式压缩机整级性能得到提高。     

离心泵叶轮内流场数值模拟及分析

基于计算流体力学,对离心泵叶轮内部流场进行了数值模拟。采用有限体积中心格式、时间推进解法以及N-S方程计算。得到了叶轮压力分布等值线、叶轮相对速度矢量以及二次流分布,并进行详尽的分析,揭示了叶轮内部流动情况,为优化叶轮设计提供了理论依据和技术保障。     

Cavitation in semi-open centrifugal impellers for a miniature pump

Cavitation in miniature pumps was investigated experimentally for two semi-open centrifugal impellers. Although both impellers had the same blade cross-section, one impeller had a two-dimensional blade, while the other had a leaned blade. The flows were also analyzed using a numerical model of the three-dimensional turbulent flow in the pumps near the peak efficiency point using the k-ɛ turbulence model and the VOF cavitation model. The average cavitation performance of each impeller was satisfactorily predicted by the numerical simulations. The results show that the miniature pumps have similar cavitation performances as an ordinary-size pump, with the cavitation performance of the semi-open impeller reduced by increased axial tip clearances. Also, both the hydraulic and cavitation performance of the semi-open impeller were improved by the leaned blade. The results also show that uniform flow upstream of the impeller inlet will improve the cavitation performance of a miniature pump. __________ Translated from J Tsinghua Univ (Sci & Tech), 2006, 46(8): 1451–1454 [译自: 清华大学学报(自然科学版)]     

含气率对混流泵压水室流场的影响分析

为了研究含气率对混流泵压水室内的流场影响,以某厂生产的导叶式混流泵为研究对象,应用商业CFD软件进行数值模拟分析,得到在不同份额含气率条件下压水室内部的流场特性。结果表明:混流泵压水室出口处的流速要比其他位置上的流速大,不符合压水室出口处能量转换的定律,而且随着含气率的增大混流泵压水室在径向流道方向上的压力也在不断增大,并在压水室外壁上出现局部的高压现象,这对混流泵压水室强度有一定的考验。在靠近导叶出口处的压水室内有大量的气体聚集,影响混流泵的运行稳定性。     

Abrasion characteristic analyses of solid-liquid two-phase centrifugal pump

Based on the solid-liquid two-phase mixture transportation test, the renormalization group (RNG) k-e turbulent model was utilized to simulate the solid-liquid two-phase turbulent flow in a centrifugal pump. By comparing the simulated and experimental results, inner flow features were revealed to improve the abrasion characteristic of the solid-liquid two-phase centrifugal pump. The influence of the solid phase on centrifugal pump abrasive performance is small when the particle volume fraction is less than 2.5%. The aggregation degree of the solid particles is enhanced as the particle diameter increases from 0.1 to 1 mm; however, the mixture density on the pressure side is reduced when the particle diameter increases to 1 mm for the impact of inertia. The wear on the hub is most severe for the shear stress on this position; it is also the largest. The wear characteristic is affected greatly by the parameters of the solid phase. The wear chracteristic can be optimized by decreasing the blade outlet angle. In the modified design, the blade angle is different, whereas the other geometric dimensions remain the same. The improved pump is simulated to contrast with the original pump. The results show that the values of mixture density and shear stress both decrease. The wear condition of the blade is improved to a certain extent.     

Radial Forces in a Centrifugal Compressor; Experimental Investigation by Using Magnetic Bearings and Static Pressure Distribution

The volute of a centrifugal compressor causes a non-uniform pressure distribution which leads to a radial force on the impeller. This force was measured using magnetic bearings. In addition, the radial force was estimated using the static pressure distribution measured at the impeller outlet. The impeller force was found to be the highest at choke, the lowest at the design flow and moderate at stall. The radial force determined from the pressure measurements was only slightly different from the force obtained from the bearing measurements. The rotational speed was seen to affect the force to some extent.     

Flow structure around the intake of a vertical pump

The flow structure around the intake of a vertical pump is investigated experimentally and numerically in order to obtain a guideline in designing the optimum shape of the intake of vertical pumps, in which their installation area is demanded to be minimum without losing the high performance. We concentrate our attention on the expansion ratio of the intake as a representative characteristic of the shape of the pumps and investigate the effect of the expansion ratio on pump performance. It is concluded that the optimum expansion ratio ranges in 1.1-1.2 if we take into consideration that the area needed for the installation of the pump should be minimum.     

Research on performance of centrifugal pump with different-type open impeller

To investigate the influence of impeller type on the performance and inner flow of centrifugal pump, the numeri- cal simulation and experimental research were carried out on the same centrifugal pump with straight-blade and curved-blade open impeller. Based on SIMPLEC algorithm, time-averaged N-S equation and the standard k-e turbulence model, the numerical results are obtained. The pressure distribution in the different type impellers is uniform, while the low pressure area in straight-blade inlet is larger. The vortexes in the passage of impeller exist in both cases. Relative to curved-blade impeller, there are larger vortexes in most of the flow passages except the passage near the tongue in straight-blade impeller. Also some small backflow regions are found at the blade inlet of two impellers. The characteristic curves achieved by numerical simulation basieaUy agree with those by experiment, and straight-blade open impeller centrifugal pump has a better hydraulic performance.     

Experimental study on a centrifugal pump with an open impeller during startup period

Transient performance of fluid machinery during transient operating periods,such as startup and stopping,has been drawn more attentions recently due to the growing engineering needs.In this paper,the transient behavior of a prototype centrifugal pump with an open impeller during rapid startup period is studied experimentally.The variations of the rotational speed,flow rate,head,and shaft power during rapid startup period are recorded in experiments at different discharge valve openings.In addition,the non-dimensional flow rate and head are also used to analyze the transient behavior.The research result shows that the rise characteristic of the rotational speed is not basically changed by working points,while mainly depends on the startup characteristics of the driving motor.Compared with the rapid rise of the rotational speed,the flow rate rises slowly in the initial stage of startup.Moreover,the flow rate lags behind the rotational speed to rise to final stable value,and the delay becomes more severe with the increase of the discharge valve opening.The shaft power impact phenomenon generally exists in the process of startup.The non-dimensional analysis shows that the non-dimensional head is very high at the very beginning of startup,and quickly falls to the minimum,then gradually rises to final stable value,while the non-dimensional flow rate always shows the rise tendency during whole startup period.In conclusion,it is found from the non-dimensional results that the quasi-steady analysis is unable to accurately assess the transient flow during startup period.     

Influence of blade outlet angle on performance of low-specific-speed centrifugal pump

In order to analyze the influence of blade outlet angle on inner flow field and performance of low-specific-speed centrifugal pump, the flow field in the pump with different blade outlet angles 32.5° and 39° was numerically calculated. The external performance experiment was also carried out on the pump. Based on SIMPLEC algorithm, time-average N-S equation and the rectified k-? turbulent model were adopted during the process of computation. The distributions of velocity and pressure in pumps with different blade outlet angles were obtained by calculation. The numerical results show that backflow areas exist in the two impellers, while the inner flow has a little improvement in the impeller with larger blade outlet angle. Blade outlet angle has a certain influence on the static pressure near the long-blade leading edge and tongue, but it has little influence on the distribution of static pressure in the passages of impeller. The experiment results show that the low-specific-speed centrifugal pump with larger blade outlet angle has better hydraulic performance.     

叶片厚度分布对两级离心泵空化性能的影响

针对叶片厚度分布对两级离心泵空化性能的影响,通过对第一级叶轮叶片的厚度分布进行优化,研究其对泵外特性、压力脉动以及流体激励力的影响。结果表明：采用线性厚度分布的对称叶片时,前缘厚度对空化性能的影响最大,叶片越薄,泵的抗空化能力越强;随着尾缘变厚,压力脉动幅值向叶轮进口方向偏移,且随着叶片厚度减小,压力脉动幅值相应减小。第一级叶轮流道内的压力脉动主频为干涉叶频,保留高幅低频的宽频特征,所受空间三向力的脉动主频为2倍叶频,轴向力较小,脉动幅值较低,径向力的主要信号成分是叶频和2倍叶频。     

Investigation of flow dynamics and decrease of vortex noise inside volute of centrifugal fans

The characteristics of three-dimension flow dynamics inside the volute of a G4-73No.8D centrifugal fan was simulated numerically using a computational fluid dynamics(CFD) technique. The generation, evolution, and noise of the vortex were investigated when cylinder-shaped and cone-cylinder-shaped anti-vortex rings were added separately. Numerical results showed that large-scale vortices were broken effectively and the flow fields inside the fan were more uniform with the two anti-vortex rings installed. Experimental results indicated A-sound level and spectrum noise of the refitted fan decreased and the two anti-vortex rings were effective in decreasing vortex noise. The cone-cylinder-shaped anti-vortex ring was more effective than the cylinder-shaped one in breaking large-scale vortexes and decreasing vortex noise. __________ Translated from Proceedings of the CSEE, 2006, 26(17): 117–121 [译自: 中国电机工程学报]     

Three-Dimensional Viscous Numerical Simulation of Tip Clearance Flow in Axial-Flow Pump

The blade tip clearance flow in axial-flow pump is simulated based on three-dimensional N-S equations, RNG k -e turbulence model, and SIMPLEC algorithm. It shows that numerical results agree well with experiment data measured by 5-hole probe through validation. Flow fields at the blade tip and velocity distribution at the exit of rotor are analyzed in detail. The numerical results show that the increase in tip clearance reduces hydro-head, especially at small flow rate. Experiment equipment is also introduced.     

Accuracy details in realistic CFD modeling of an industrial centrifugal pump in direct and reverse modes

Numerical computation of the flowfield inside a pump is herein used as a numerical laboratory, subject to the limitations of modeling assumptions and to experimental verification. A numerical computation of the flow inside a real industrial centrifugal pump is performed that includes a very sophisticated geometry. Conversely to other computations, in this test case no simplification of the geometry was introduced. Numerical computations are ob- tained using Spalart-Allmaras turbulence model. A detailed analysis of the turbulent flowstructure is performed for the design point and two off design conditions. Additional computations were performed in order to compare the numerical and experimental pump characteristics; these were obtained under normalized testing conditions. Further computations are presented for the pump working in reverse turbine mode （PAT）. Detailed analyses of the flow allow a comparison of the internal flow losses when the pump is operating in direct and reverse mode. This is also useful to help in the selection of an adequate pump geometry that can work in both modes with best efficiency.     

Performance analysis of mini centrifugal pump with splitter blades

Design method for a mini centrifugal pump is not established because the internal flow condition for these small-sized fluid machines is not clarified and conventional theory is not suitable for small-sized pumps. Then, a semi-open impeller for the mini centrifugal pump with 55mm impeller diameter is adopted in this research to take simplicity and maintenance into consideration. Splitter blades are adopted in this research to improve the per- formance and internal flow condition of mini centrifugal pump having large blade outlet angle. The performance tests are conducted with these rotors in order to investigate the effect of the splitter blades on the performance and internal flow condition of the mini centrifugal pump. A three dimensional steady numerical flow analysis is con- ducted to analyze rotor, volute efficiency and loss caused by a vortex. It is clarified from the experimental results that the performance of the mini centrifugal pump is improved by the effect of the splitter blades. Flow condition at outlet of the rotor becomes uniform and back flow regions are suppressed in the case with the splitter blades. Further, the volute efficiency increases and the vortex loss decreases. In the present paper, the performance of the mini centrifugal pump is shown and the flow condition is clarified with the results of the experiment and the nu- merical flow analysis. Furthermore, the performance analyses of the mini centrifugal pumps with and without the splitter blades are conducted.     

Study on the Effects of Flow in the Volute Casing on the Performance of a Sirocco Fan

The flow at the exit from the runner blade of a centrifugal fan with forward curved blades (a sirocco fan) sometimes separates and becomes unstable. We have conducted many researches on the impeller shape of a sirocco fan, proper inlet and exit blade angles were considered to obtain optimum performance. In this paper, the casing shape were decided by changing the circumferential angle, magnifying angle and the width, 21 sorts of casings were used. Performance tests, inner flow velocity and pressure distributions were measured as well. Computational fluid dynamic calculations were also made and compared with the experimental results. Finally, the most suitable casing shape for best performance is considered.     

Numerical simulation of air flow through turbocharger compressors with dual volute design

In this paper, turbocharger centrifugal compressors with dual volute design were investigated by using Computational Fluid Dynamics (CFD) method. The numerical simulation focused on the air flow from compressor impeller inlet to volute exit, and the overall performance level and range are predicted. The numerical investigation revealed that the dual volute design could separate the compressor into two operating regions: “high efficiency” and “low efficiency” regions with different air flow characteristics, and treating these two regions separately with dual diffuser design showed extended stable operating range and improved efficiency by comparing with conventional single volute design. The “dual sequential volute” concept also showed the potential to further extend the stable operating range by closing one of the volutes at low air flow rates. Furthermore, by comparing with other alternate designs such as variable diffuser vanes and variable inlet guide vanes, the operation of the dual sequential volute also features relatively simple control and calibration.     

半开式离心泵内部流场的数值模拟研究

采用标准k-epsilon,SST以及DES 3种湍流模型对小流量工况下半开式离心泵的流量-扬程曲线和内部流场进行了数值模拟。为了验证模拟结果,应用二维粒子图像测速技术(PIV)对离心泵的内部流场进行了实验测量。研究证明:对于半开式离心泵流量-扬程曲线的预测,3种数值方法都能比较准确的进行预测;而对于内部流场的预测,标准k-epsilon和SST湍流模型不能得到准确全面的结果,而DES方法则可以较为准确的预测出内部流场细节。     

Investigation of the flow in the impeller side clearances of a centrifugal pump with volute casing

The paper is concerned with the fluid flow in the impeller side clearances of a centrifugal pump with volute cas-ing.The flow conditions in these small axial gaps are of significant importance for a number of effects such as disk friction,leakage losses or hydraulic axial thrust to name but a few.In the investigated single stage pump,the flow pattern in the volute turns out to be asymmetric even at design flow rate.To gain a detailed insight into the flow structure,numerical simulations of the complete pump including the impeller side clearances are accom-plished.Additionally,the hydraulic head and the radial pressure distributions in the impeller side clearances are measured and compared with the numerical results.Two configurations of the impeller,either with or without balancing holes,are examined.Moreover,three different operating points,i.e.:design point,part load or overload conditions are considered.In addition,analytical calculations are accomplished to determine the pressure distri-butions in the impeller side clearances.If accurate boundary conditions are available,the 1D flow models used in this paper can provide reasonable results for the radial static pressure distribution in the impeller side clearances.Furthermore,a counter rotating wake region develops in the rear impeller side clearances in absence of balancing holes which severely affects the inflow and outflow conditions of the cavity in circumferential direction.