Analysis of The Flow Field Into A Two Stages and Double Entry Storage Pump Taking Into Account Two Geometries of Stator Blades
Analysis of The Flow Field Into A Two Stages and Double Entry Storage Pump Taking Into Account Two Geometries of Stator Blades
Analysis of The Flow Field Into A Two Stages and Double Entry Storage Pump Taking Into Account Two Geometries of Stator Blades
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Analysis of the flow field into a two stages and double entry storage pump taking into account
two geometries of stator blades
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2010 IOP Conf. Ser.: Earth Environ. Sci. 12 012016
(http://iopscience.iop.org/1755-1315/12/1/012016)
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IOP Publishing
doi:10.1088/1755-1315/12/1/012016
Analysis of the flow field into a two stages and double entry
storage pump taking into account two geometries of stator
blades
G Dunca1, S Muntean2 and E C Isbasoiu1
1
1. Introduction
The centrifugal impeller of a pump interferes with the stator blades which produces pressure fluctuations
downstream the impeller. The pressure fluctuations amplitude can be as high as the total pressure rise inside the
pump in case of small radial gaps between the impeller and stator blades, Arndt et al. [1, 2] Brennen [3] and
Tsukamoto et al. [4]. This leads to noises and vibrations causing unacceptable levels of stress that can affect
machines structure. Barrio et al [5] have studied the influence of the radial gap between the impeller and the tongue
on the dynamic forces generated inside a simple entry and single stage centrifugal pump.
The turbo machines flow is essentially unsteady due to the rotor-stator interaction [6]. On the other hand,
rigorously speaking, the geometrical periodicity of the stator/rotor blade rows cannot be used since there are
differences in flow from one inter-blade channel to another. Spence et al. [9] presented a numerical investigation
of the time variation of pressure within a complete centrifugal pump and the focus is on the variation of the
pressure pulsation close to the impeller outlet in function of the discharge. Computing the real flow (threedimensional, turbulent and unsteady) through a complex storage pump still requires large computer memory and
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
CPU time. However, a simplified simulation technique must be employed to obtain useful results for storage
pump analysis, using currently available computing resources [7, 8]. As a result, with carefully chosen
assumptions, one can devise a methodology for computing the pump flow, such that good and engineering useful
results are obtained.
In this paper, numerical simulations into the storage pump with double entry and two stages centrifugal pump
were carried out in order to investigate the hydrodynamic field for two different geometries of stator blades. The
test case problem is presented in the next section. Next, computational domains, boundary conditions and
numerical method are presented. Velocity and pressure coefficients are plotted for impellers as well as on
original and modified geometry of the first and second stators. The conclusions are drawn in last section.
slide gate
Dn = 1000
pn = 6
discharge
duct
Fig. 1 Centrifugal pump with double entry and two stages installed in the Galceag storage pump
The analyzed pump is a centrifugal pump with double entry and two stages [10]. The pump is a specific
speed of nq = 28.
Fig. 2 Centrifugal pump with double entry and two stages installed in the Galceag storage pump
During the experimental investigation, the pressure was measured using two transducers, one set at the
pumps inlet and the second one set at outlet. The acquired pressure mean values were compared with the
pressure values read by means of two pressure manometers. In order to identify the possible operating disorders,
as well as their causes, the signal for each measurement was processed. A representative sample of data was used
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
and the continuous component of the signal was extracted in order to compute the FFT. This leaded to
indications regarding vibrations and distortions sources.
The sampling period being 0.003 seconds resulted a cutting frequency of 166.5 Hz (the Nyquist frequency)
and a resolution of 0.645 Hz. The results of spectral analyze of the outlet pressure are synthetically shown in
Figure 3, and in Figure 4 the results of spectral analyze of the inlet pressure are shown. For the outlet pressure,
the results show that in the frequency domain of 0163.5 Hz the spectrum is quasi-symmetric around the value
of 100 Hz. The main pressure fluctuations are around 24.914 Hz, 43.12 Hz, 86.722 Hz, 99.258 Hz and
115.371Hz.
The frequency at 1000 rot/min motor rotational speed is:
fm =
1000
= 16.666 Hz,
60
(1)
and the fundamental frequency is 100 Hz which corresponds to the above frequency multiplied by the impellers
number of blades (7 blades):
f =
N
1000
n =
7 = 116.62 Hz.
60
60
(2)
The pressure spectrum in the inlet duct (Fig. 4) has higher amplitude at 26.426 Hz, 29.648 Hz, 43.184
Hz and 48.984 Hz in the range 0163.5 Hz. The pumps inlet hydraulic circuit generates these frequencies and
they cannot be correlated with the pumps specific frequencies. It can be considered that these frequencies
(24.914 Hz and 43.12 Hz), which are present also in the outlet pressure spectrum, derive from the inlet hydraulic
circuit and are sent through the pump in the outlet hydraulic circuit.
Because a detailed experimental analysis inside the pump would have been difficult, in order to obtain
distinct results regarding the possible sources of these vibrations, a numerical analysis of the flow inside the
centrifugal pump was realized, taking into account the two different geometries of the stators blades.
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
Original geometry
Modified geometry
Cutwater diameter
modified geometry
1132
Cutwater diameter
1104
Impeller diameter
1100
Fig. 7 Two geometries for the stators blades: original (with gray) and modified (light blue).
In the present investigation a full 3D, steady, turbulent and incompressible fluid flow is considered. Thus the
upper equations can be written
G
V = 0
G
G G p
G
+ V
V V = f
(3a)
(3b)
These equations are applied in this form in the suction elbow, stators and volute. For impellers analysis, a
steady relative flow is assumed, in a rotating frame of reference with angular speed = k :
W = V r
The following boundary conditions are considered in our computation for each domain:
(4)
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
Boundary condition
velocity components and turbulent quantities
pressure field
wall
periodicity for all quantities
Mixing interface method for coupling velocity and pressure fields from consecutive components is used. In
the mixing plane approach, each fluid zone is treated as a steady-state problem. Flow-field data from adjacent
zones are passed as boundary conditions that are spatially averaged or mixed" at the mixing plane interface.
This mixing removes any unsteadiness that would arise due to circumferential variations in the passage-topassage flow field, thus yielding a steady-state result. Despite the simplifications inherent in the mixing plane
model, the resulting solutions can provide reasonable approximations of the time-averaged flow field [12, 13].
Four mixing interface planes (two annular sections between suction elbow and first impeller and first stator
and second impeller as well as two cylindrical sections between impellers and stators, labeled MI in Figure 5) are
used in order to compute the flow through the entire storage pump. An iterative process is employed to obtain the
absolute velocity and pressure continuity across all mixing interfaces. It starts by computing the suction elbow,
with a constant suction elbow outflow pressure. The resulting outflow velocity components are circumferentially
averaged and corrected to preserve the prescribed discharge, then used as inflow condition on the impeller
computational domain. The same procedure is applied for coupling the first impeller domain with the first stator
domain (R1-St1), the stator domain with the second impeller domain (St1-R2) and the second impeller domain
with volute domain that includes the second stator (R2-St2). The volute computation is performed with inflow
velocity profile on the inlet section and constant pressure on the outlet section displaced in the downstream duct.
After coupling all components downstream, a new pressure profile is obtained on the inlet section of the volute
domain. Consequently, the flow in the second impeller is computed taking into account the new pressure profile
from volute domain. After the coupling between the volute and second impeller, other computational domains
are connected upstream in order to obtain continuous pressure field. Then, computing the suction elbow with a
new outflow pressure is performed, and so on. The iterating process is stopped when no significant changes in
pressure field occur from the previous iteration for all mixing planes. The convergence of the iterative scheme is
investigated. It is found that relaxation must be employed in order for the iterative process to converge. Excellent
convergence of the iterative mixing interface algorithm is achieved, with no more than 5-6 iterations. Threedimensional turbulent computation is performed using the FLUENT 6.3 code and SST k turbulence model
[14, 15].
The numerical investigations are performed for one operating regime near to the best efficiency point with
parameters from Tab. 2:
Table 2 Parameters of the operating point investigated
Parameter
Value
1000
3
247
7269.2
4. Numerical results
Hydrodynamic field into the storage pump is computed. As a result, the pressure coefficient and the velocity
coefficient distributions are obtained. A correct evaluation of this minimum pressure level is crucial in evaluating
the storage pump cavitational behavior.
The pressure coefficient is defined according to the eq. (5) and absolute velocity coefficient in eq. (6):
cp =
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
p p ref
gH
v
cv =
2 gH
trailing edge
(5)
(6)
z = 10%
shroud
z = 50%
z = 90%
suction side
inlet
section
hub
pressure
side
leading edge
Fig. 8 Shroud-to-hub sections at 10%, 50% and 90% selected for plotting the numerical results.
Figure 8 presents the shroud-to-hub sections selected in order to plot the numerical results. The absolute
velocity coefficient distribution on the mixing plan section at the first impeller outlet (corresponding to a radius
of R=0.555 m) is presented in Fig. 9. On this section three analysing section were made, corresponding to three
values of the axial coordinate, one next to the shroud, z = 10% , one in the middle of the mixing section,
z = 50% and one next to the hub, z = 90% . The distribution of this velocity coefficient is plotted in terms of
the angular coordinate of the impeller outlet section. One can observe that the non-uniformity is more significant
near the shroud due to the meridian shape of the channel, Fig. 9(right). However, these circumferential nonuniformities are not passed downstream in the stator due to mixing interface technique [12]. It can be seen that
there is a pronounced non-uniformity of the velocity field at the impeller outlet corresponding to the wake jet
phenomenon [13], as Prof. Brennen has shown [3].
z10%
suction side
cv [-]
pressure
side
z50%
cv [-]
z90%
impeller
blade
suction side
Fig. 9 Absolute velocity coefficient distribution on the outlet section of the first impeller (R1)
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
0.9
1.8
0.8
1.6
0.7
1.4
0.6
1.2
0.5
PS
Cp [-]
Cp [-]
The pressure coefficient distribution in seven shroud-to-hub sections on the first impeller is presented in Fig.
10. One can observe a uniform pressure coefficient distribution on the first impeller blade, excepting the leading
edge. That means the impact flow is on the blade pressure side (PS) near the leading edge. The same conclusion
can be drawn for the second impeller from Fig.11.
0.4
10%
SS
SS
0.8
Shroud
0.3
PS
Shroud
0.6
10%
30%
50%
0.2
30%
0.4
50%
70%
0.1
90%
90%
Hub
0.2
0.4
0.6
0.8
1.2
1.4
Hub
0
0
70%
0.2
1.6
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
l/D2 [-]
l/D2 [-]
Figure 12 shows the pressure coefficient distribution on the first blade row of the first stator with original
geometry. One can see in Fig. 12 the loading near to the leading edge on the first blade of the first stator (St1).
Moreover, it can be seen that the loading near to the shroud is less than the loading to the hub that means the
different flow impact along to the leading edge. Indeed the flow to the outlet is leaned according to the trailing
edge of the first impeller generating different flow impact on the straight first stator blade. It can be observed in
Fig. 13 that the pressure has lower values near the leading edge in the middle section (50%) on the modified
blade geometry of the first stator (St1_mod), which indicates a different attack angle on the stator inlet. However,
this difference is not so clear near the hub. Nevertheless, the new geometry of the first stator blades increases the
gap between the first impeller outlet (R1) and the first stator inlet (St1). Consequently, the impeller-stator
interaction (R1-St1) is mitigated.
The same analysis is performed for impeller-stator interaction between second impeller (R2) and the second
stator (St2) presented in Figs. 14 and 15. In this case the benefit is clearer than for the first one. One can observe
an improved pressure coefficient distribution near to the leading edge of the second stator new geometry
(St2_mod plotted in Fig. 15) than the same distribution computed on the original geometry (St2 from Fig. 14).
Consequently, it can be stated that the flow incidence on the reshaped blade of the second stator is improved.
1.4
1.4
1.2
1.2
PS
PS
0.8
Cp [-]
SS
Cp [-]
SS
0.8
0.6
Shroud
0.6
Shroud
10%
10%
0.4
30%
30%
0.4
50%
50%
0.2
70%
70%
0.2
90%
90%
Hub
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Hub
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
l/D2 [-]
l/D2 [-]
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
PS
2.0
1.8
SS
1.6
SS
1.6
1.4
1.4
1.2
1.2
Cp [-]
Cp [-]
PS
2.0
1.8
1.0
0.8
1.0
0.8
Shroud
0.6
10%
10%
30%
30%
0.4
Shroud
0.6
50%
0.4
50%
70%
70%
0.2
0.2
90%
90%
Hub
0.0
Hub
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.1
0.2
0.3
0.4
l/D2 [-]
0.5
0.6
0.7
0.8
0.9
l/D2 [-]
PS
1.8
SS
1.6
PS
1.4
PS
Cp [-]
1.2
PS
SS
1
0.8
SS
PS
0.6
SS
R1
St1_1
St1_1_mod
St1_2
SS
0.4
R2
0.2
St2
St2_mod
0
0
l/D2 [-]
Fig. 16 Pressure coefficient distribution along the mean streamline of the entire storage pump hydraulic
passage
Pressure coefficient distribution along the mean streamline for the entire analysed hydraulic passage is
presented in Fig. 16. For the first impeller, the minimum pressure coefficient is above critical value avoiding any
cavitational risk into the storage pump.
5. Conclusion
The paper presents a computing methodology as a first step in the three-dimensional numerical analysis of
the flow into a hydraulic passage of the two stages and double entry storage pump. First, the 3D geometry of the
hydraulic passage (suction elbow, first impeller, first stator with two cascades, second impeller, second stator and
volute) is reconstructed. Consequently, the 3D computational domains for each part are generated. Second, the
3D turbulent steady flow is performed in the hydraulic passage of storage pump using the commercial FLUENT
code. The impeller-stator (between the first impeller and first stator as well as between second impeller and
second stator) and stator-impeller (between the first stator and second impeller) interactions are taken into
account with mixing interface method. The hydrodynamic flow field from the inlet to the outlet is obtained. Thus,
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
the blade geometries of the first and second stator cascades are modified. As a result, the 3D flow around
modified geometry is computed. The hydrodynamic field for modified geometry is analyzed against original one.
Comparing the results obtained for the two geometries of the stators, it can be seen that they have different
behaviour during the pumps operation, due to the different conditions at the outlet of the two impellers situated
upstream each of the analysed stators. It can be considered that, although the same geometry modification was
realized for both the stators, the effects on the flow parameters are different, only for the second stator being
possible to observe a net improvement of the blade load. The cavitational behaviour was not studied. After this
methodology is validated, an unsteady analysis will be the subject of a further study, in order to properly study
the impeller-stator interaction phenomenon inside the double entry and two stages pump.
Acknowledgments
Dr. Sebastian Muntean was supported by the Romanian Academy program Hydrodynamics Optimization
and Flow Control of the Hydraulic Turbomachinery in order to Improve the Energetic and Cavitational
Performances. Numerical computations have been performed at the Numerical Simulation and Parallel
Computing Laboratory from the Politehnica University of Timisoara, National Center for Engineering of
Systems with Complex Fluids.
G
V
G
w
Nomenclature
p
cp
cv
g
References
[1]
IOP Publishing
doi:10.1088/1755-1315/12/1/012016
[13] Dunca G, Muntean S and Isboiu E C 2009 3D Numerical Analysis of the Impeller - Stator Interaction
into a Storage Pump The International Conf. on Energy and Environment, CIEM2009
[14] Menter F R 1994 Two-equation eddy-viscosity turbulence models for engineering applications AIAA
Journal 32(8) 269 289
[15] Menter F R, Kuntz M and Langtry R 2003 Ten Years of industrial Experience with the SST Turbulence
Model Proc. of the Turbulence, Heat and Mass Transfer 4 625-632
10