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Conceptual Framework of Centrifugal Pumps towards Industrial Revolution

SELVARASU.A,KANTHAVEL.K,KRISHNARAJ.R,KARPAGARAJAN.S,RAVI.G, RAMESH.R

Abs tract-In recent years, researchers have put a considerable eff ort to increase the eff iciency in a centrifugal pump .The current scenariointhe impeller design interest has considerably increased in recent years in various publication, statingthe pump eff iciency, pump perf ormance, impeller design,

modif ication the vane angle through CFD analysis has consideration to elaborate the conceptual f rame w ork of a centrif ugal pu mps.

Ke y words- Centrif ugal pumps, CFD, Eff iciency, Failure analysis, Impeller design, Numerical analysis, Optimization

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Introduction-S.C.M. Yu(2000)Investigated the flow patter ns w ithin the impeller passages of a centr ifugal blood pump of w hich differ ent types of blade geometry have been tested including the r adial straight blade and backward sw ept blade designs. Both designs can achieve a head of about 100 mm Hg at the design point Jong -Soo Choi(2005) exper imented lar ge-scale flow instabilities in a pump r otor and the pr ocess of noise generation on the unsteady flow field and mechanism of a centr ifugal turbomachine has been per for med.The j et-wake flow patter n found in the impeller blade passages induces a str ong vorticity field near the tr ailing edge of each blade.The r otating dischar ge instability in the impeller dischar ge is very similar in its behavior to the phenomenon known as r otating stall fou nd in centr ifugal impellers and diffusers. The sur face pr essur e spectrum measur ed at the trailing edge of each blade r evealed a cluster of peaks, which wer e identified with integer mode number s. Ismaier (2009) pr oposed Centrifugal pumps generate in piping systems noticeable pr essur e pulsations of which the dynamic inter action betw een water hammer and pr essur e pulsations was pr esented. Differ ent measur ements at this testing facility show that pulsating centrifugal pumps can damp pr essur e sur ges generated by fast valve closing.Centr ifugal pumps generate especially in part load and at high pump speed noticeable pr essur e pulsations.

These pr essur e pulsations can interact with pr essur e waves caused for example by fast valve closing AhNemdlh.Dieter-Heinz Hellmann(1999) stated the application of a centr ifugal pump for desalination and

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Selvarasu.A, PG student, Department of Mechanical Engineering, Anna University of Technology, Coimbatore, India, PH -+919786029045. E-mail: sel_va_rasu@yahoo.co.in

Kanthavel.K, Assistant professor, Department of Mechanical

Engineering,Anna University of Technology, Coimbatore, India

Krishnaraj.R, JRF(professional), Department of Mechanical

Engineering,AnnaUniversityof Technology, Coimbatore, India

pow er plants, and the ener gy usage and the maintenance costs dur ing the operation of the pump w as r educed
.Daniel Wolfram(2010)observed that low circumfer ential Mach number the sound of isolated centr ifu gal fan impellers was dominated by distinctive tones at blade passing fr equency (BPF) and integer multiples. This led to the pr eliminary conclusion that the BPF r elated tones ar e exclusively flow-induced. Based on hot-wir e and blade pr essur e fluctuation measur ements and a subsequent corr elation analysis, coher ent flow str uctur es differ ent fr om those associated w ith the pr incipal azimuthal flow pattern due to the blades w er e detected. Mor e likely the vortex structur e detected her e is r elated to the dr aft tub e vortex found in w ater turbines or in the intake of pumps. PunitSingh (2010)concluded that a methodological approach has to be employed for using the optimization r outine in field pr oj ects and to collect accurate operational data. R.Barrio (2011) experienced a significant radial load when operating at off-design conditions. Its average magnitude can be r easonably estimated at the design stage by existing formulas.The total radial load on the impeller of centr ifugal pumps under differ ent operating conditions can be r easonably estimated by means of the numer ical simulation of the unsteady flow w ith an appr opriate CFD code. It was observed that the maximum amplitudeof the unsteady tor que can r each a magnitude of about 45% of theaverage value when operating at the lower flow r ates). Ramazanbavindir (2011) explained the design of water pumping control system in the pr oduction plants and implemented an exper imental setup in a laboratory. These plants contain harsh environments in which chemicals, vibrations or moving parts exist that could potentially damage the cabling or wir es that ar e part of the contr ol system.The pr oposed architectur e and r esults demonstrate the feasibility of using IW LAN pr otocols to communicate effectively w ith PLCs. The system was tested using an industr ial application and it had a very satisfactory per formance. R. Spence(2009) pr oposed numerical model

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of an entir e double entry, double volute centr ifuge pump to conduct a par ametr ic study cover ing four main geometr ic parameters.

Conceptual investigation

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TOTAL NO OF PUBLICATIONS=60

CFD Analysis

A.D Gosman(1998)CFD codes to effectively harness the pow er of the new generation in parallel computer s[19]. A. Lucius(2010) et al calculate r otating stall in a pump for part load conditions. W hich is a state of the art eddy viscosity model[50]. K.K. Singh(2007) et al simulated continuous flow pump-mixer employing top shr ouded Rushton turbines w ith trapezoidal blades. W hich concluded that CFD simulations can closely pr edict the single-phase head and pow er characteristics of pump- mixer . An insight has been provided into the pumping action of the impeller [12]. R. Spence(2009) et al studied double volute centr ifugal pump to conduct a parametr ic study four main geometr ic parameters[1]. Wei Zhang(2010) et all analyzed of tr ansportation equation of turbulence fluctuant velocity in the r otating frame intr insic mean spin tensor is instead of mean vorticity tensor . Consider ing the transportation of fluctuation velocity and Reynolds str ess [9]. pr esented advancement numer ical solvers, physics modeling, user inter faces, CAE integration and computer hardwar e.

Governing equations

Katharine H(2011)et all the Navier–Stokes equations using CFD fluent , wher e is the fluid density, it is the velocitycomponent in solved the xidir ection (i=1,2), p is the pr essur e, ij is the str ess tensor , and r epeated indices w er e equated as


These ar e solved using a commercial CFD package Fluent
4[10]

Pump efficiency

Khin Cho Thin (2008) et al determine the power efficiency r equir ed to shaft using

The hydraulic efficiencies w her e

=1- [54]

E. M. Kraeva(2010)compar ed the density for the magnitude pow er consumption of pump due to the [52]


the pump efficiency determined was changes of fluid viscosity with the normal par ameter s

η

Antonio de la Torre(2008)define the differ ence betw een total absolute pr essur e in the pump suction flange and the vapour pr essur e of the pumped liquid based is onset of cavitation, head dr at 0% to 3% and formulated cavitation criteria NPSHRvalues can be defined as follows:[21]

pump performance

The per formanceflows a significant r ole in or der to plot the efficiency curve in order to compar e the theor etical and experimental calculating consider ing var ious losses J.P. Boylan(1998)innovated solar pump system using a modular centr ifugal pump w ith var iable speed and number of activated stages (DSP) has been pr oposed [34]. . Khin Cho Thin (2008) et al showedlooses of centr ifugal pump with the valuesQ and H deter mine var ious operating points. Centr ifugal pumps ar e fluid-kinetic machines designed for pow er incr ease within a r otating impeller Somelooses of centr ifugal pump with the values Q and H ar e determined for the var ious operating points. [54]. P. Thanapandi and Rama Prasad(1995) studied to theor etical and experimental on the tr ansient character istics of a centr ifugal pump during starting and stopping periods. Which experiments w er e conducted on a volute pump for normal starting and stopping transients for two cases. Dynamic character istics of the pump dur ing the operating transients have been studied and the natur e of change of parameters during tr ansients was conducted [11]. Wen- GuangLi(2000)tested centrifugal pump per formances using water and viscous oil as w or king fluids of w hich centr ifugal

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pump's per for mance goes down when the pump handles
high viscosity wor king fluid. The flow patter ns near the
impeller outlet ar e less affected by the viscosity of the fluids in best efficiency and part loading points, but the flow patter ns near the impeller inlet ar e gr eatly affected by the viscosity’s.*20+. TahsinEngin(2006) et al designed to thr ee centr ifugal fan impeller s made of ceramic mater ials
Exper iments have been conducted on a specifically designed test facility allowing that gases w ith t emperatur es up to 1050 ºC. The effect of impeller geometry, shaft speed, gas temper atur e, and the tip clearance on the overall per formance of the tested impellers have been investigated [55].

N. Tauveron, I. Dor(2010 ) investigated var ious technologies centrifugal cir culator s with a vane less diffuser when have significant properties in term of simplicity, cost, ability to operate over a w ide range of conditions (according to general consideration and histor ical development and choices)[42]. N. Tauveron, I. Dor(2010)experimented and simulated r esults of inter nal and external character istics at steady oper ation fr om shutoff condition to design condition, DES and sliding mesh w er e used to explor e the transient character istic of the pr ocess when valve was rapidly opened [48].

Theoretical Head:

N. Tauveron, I. Dor(2010) subj ected in the Euler

head is deter mined fr om zer o to maximum theor etically attainable flow using.[54]
The theor etical head: Hth = 1/gU2Vu2 (27)
wher eU2and Vu2 ar e outlet tangential velocity and whirl
velocity. Whirl velocity: Vu2 = U2 – Vm2 cotβ2 (28)wher eVm2andβ2 ar e outlet flow velocity and outlet blade angle.

Net Theoretical Head

If the slip factor is known, the net theor etical head may be obtained fr om Euler ’s head. It is possib le to r elate thetheor etical char acter istic obtained fr om Euler ’s equation
to theactual character istic for var ious losses r esponsible for thediffer ence. The use of the slip factor which varies with flow rate enables the net theor etical head curve to obtained. Atflow r ates below design flow rate, separation occurs on thesuction side of the blade.
The net theor etical head is calculated by:

H
The whir l velocity at the outlet is;
Vu2 = U2σ – Vm2 cotβ2 (30)
wher e, σ is the slip value. Slip value is obtained by using the follow ing equation Specific speed is used to classify impellers on the basis of their per for mance, and pr oportions r egar dless of their actual size or the speed at which they oper ate.[54]
Specific Speed: =3.65n

Experimental

M. J. Tummers(1997) et al measur ed the mean velocities, Reynolds str esses, and triple-velocity corr elations w er e measur ed in an adver se pr essur e gradient wake, using LDA[57]. Ramazanbavindir (2011) explained water pumping contr ol system that is designed for production plants and implemented in an experimental setup in a laboratory. These plants contain harsh envir onments in which chemicals, vibrations or moving par ts exist that could potentially damage the cabling or w ir es that ar e part of the control system[6]. F. JiménezEspadafor(2000) et al analysed the failur e mode of the six impellers of a centr ifugal pump in an irr igation system used for str eet washing for the r esults show a ver y high level of tor sional vibrations induced by sever e pulsations of engine tor que.

Daniel Wolfram(2010) et al detected the draft tube vortex found in water turbines based an flow indused[25]. Daniele Fiaschi(2005) et al subj ected to an innovative solar pumping system using a modular centrifugal pump with var iable speed and number of a ctivated stages (DSP) has been proposed and discussed Centr ifugal Pump, SCP) [35]. Chi Nan Pai(2010) et almeasur ed the pulsatile flow rate thr ough a maglev CBP dur ing ventr icular assistance and developed a disturbance force observer to estimate the radial thr ust[41]. N.R. Sakthivel(2010) et al deal w ith the vibration based fault diagnosis an mono block centr ifugal pump thr ough six classical statement viz., normal, bear ing fault, impeller fault, seal fault, impeller and bear ing fault together , cavitation [51].

Failure analysis

OM PRAKASH(1996)et al explained an eight -stage feed pump in a ur ea-manufactur ing plant started show ing a high over all vibr ation level. Chemical examination of impeller mater ial did not show any ser ious irr egularity r egar ding its chemical composition wher e as metallographic examination confirmed that the impellers w er e not subj ected to pr oper heat tr eatment and formed that high level of vibr ation was due to the imbalance caused as a r esult of the br eakage of the impeller s [28]. G Das(1999) et al subj ected to an analysed the pr ematur e

failur e of tw o counter shafts used in centr ifugal pumps for lifting slurry thus Chemical analysis, micr ostr uctural char acterization, fact gr aph, hardness measur ement, tensile and Charpy impact t ests w er e used for the analysis wher e shafts "consisting of ferrite-pearlite for A and temper ed bainite for B w er e made of EN13 steel The mater ials did not show significant inclusions or segr egation but Shaft B impr oper heat tr eatment r esulted in low values of str ength

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[27]. F. Berndt(2001) et al contr ibuted towar ds pump failur es indicating the effect of pump per formance[60].

Fluid dynamics

B. Baudouy(1998) et al studied the hydraulic char acteristics of a var iable speed liquid helium centr ifugal pump in He I near saturated conditions (4.2 K and 100 kPa) ar e pr esented.W e have the hydraulic per formances of thr ee pump housings, for a simple housing and two inducer housings in He I. The use of an inducer avoids the pr ecipitous decr ease in the pr essur e head at low mass flow rate as exhibited by a simple housing pump [31]. A. Ismaier(2009) et al determined the Centrifugal pumps generate in piping systems noticeable pr essur e pulsations. Thus the dynamic inter action betw een water hammer and pr essur e pulsations for w hich differ ent measur ements at this testing facility show that pulsating centrifugal pumps can damp pr essur e sur ges generated by fast valve closing. [30]. Wu Dazhuan(2010) et al exper imental and simulated r esults of inter nal and external character istics at steady operation fr om shutoff condition to design condition, DES and silding mesh w er e used to explor e the tr ansient char acteristic of the pr ocess w hen valve w as r apidly opened. [48]. Jorge Parrondo (2011)et al subj ected to Conventional centr ifugal pumps w ith volute casing generating fluid-dynamic noise particular ly at the so-called blade-passing fr equency, which is attr ibuted to the inter action of the flow exiting the pump impeller w ith the volute tongue. R.Barrio(2011) et al explained the impeller of a centr ifugal pump significant radial load when operating at off-design conditions. Its average magnitude can be r easonably estimated at the design stage by existing formulas.The total radial load on the impeller of centr ifugal pumps under differ ent operating conditions can be r easonably estimated by means of the numerical simulation of the unsteady flow with an appr opr iate CFD code[22].

Impeller design

John S. Anagnostopoulos(2009 ) calculated a numer ical methodology of the flow field in a centr ifugal pump impeller and pr edicted of the pump per formance curves and developed, r egulated, and tested against exper imental and statistical data, with encouraging r esults using Navier– Stokes equations in thr ee dimensions [2]. AndrzejMisiewicz(2011) et al show ed the influence of lar ge angles of the inlet of impeller on the pump cavitation per formance. [53]. Hongmin Li(2010) pr esented a ther mal fluid analysis on the air cooling of a permanent magnet electric motor with a centr ifugal impeller . Heat tr ansfer analysis on the armatur e sur face shows that the armatur e body has a flat temperatur e distribution in the radial

dir ection[15]. Mario Savar(2009) et al pr oposed the method for pump impeller tr imming found good exper imental confirmation despite some theor etical constr aints. Dimensional head-dischar ge diagrams show a high coincidence when pr esented in non-dimensional form. The exper imental r esults for a range of seven examined impeller diameters ar e pr esented by a single cur ve with a high head corr elation coefficient R2=0.9895[33]. PunitSingh, Franz Nestmann(2011) et al developed a subj ected to the theor etical model specifically for the PAT optimization study under the backgr ound of some assumptions was very useful in isolat ing the important inter nal hydraulic var iables[36]. S.C.M. Yu(2000) et al focused on the flow patterns within the impeller passages of a centr ifugal blood pump. Four differ ent types of blade geometry have been tested including the radial straight blade and backward swept blade designs. Both designs can achieve a head of about 100 mm Hg at the design point [44].

Numerical Analysis

M.A.Langthjem (2004) et a r elined discr ete vortex method for simulation of the flowwith a centr ifugal pump is the one of the simplest methods capable of captur ing the essential featur es of this kind of r otational flow . concer ned with the simulation of the flow in a flat, ‘two-dimensional’ laboratory centr ifugal pump. [4]. LI Yao -jun, WANG Fu- jun (2007) pr edicted the thr ee-dimensional turbulent flows generated by an axial-flow pump equipped w ith an inducer simulated using the multiple r efer ence fr ame appr oach. The effects of angular alignment of inducer and impeller blades and the axial gap between inducer and impeller have been examined [40]. RaúlBarrio(2010) et al simulated numer ically unsteady flow (URANS + kepsilon model) w ith an appr opr iate CFD code has pr oven to be a good methodology to investigate the dynamic character istics of the flow in the near -tongue r egion of a vane less centr ifugal pump [39]. A. Rossetti et al (2010)experimented and numer ical analyzed tw o miniatur e tw o stage pumps with an over all dimension of 10mm wher e the innovative design integr ated a bladed first stage w ith a bladeless second stage. The Rotary Shaft Pump design, which integrates the impeller in the shaft, was used as first stage for w hich the second stage was designed as bladeless centr ifugal disk pump [3]. Amy l. Throckmorton(2010) et al states Curr ently available mechanical cir culatory support systems ar e limited for adolescent and adult patients w ith a Font an physiology. The per for mance evaluation using CFD, theexper imental testing of a pump pr ototype, and bloodbag

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testing in this study indicated an acceptable design fr om which to build upon and optimize [59]. Bao -ling Cui(2011) et al based Navier-Stokes equations and the Spalart - Allmarasturbulence model, thr ee dimensional turbulent flow fields in centrifugal pump with long-mid-short blade complex impeller for calculating and numer icallyanalysing. [58]. Optimization

M.M.A. Shahin(1990) et al calculated to the optimization technics for centr ifugal pump staling

 Slient featur es of micr o computer pr ogram
 Data information
 Parametric characteristics
 Relation and interaction of curvatur e
 Cost estimation

PunitSingh(2010) et al advised for a methodological approaching in or der to attend gr eater accurate [7].

Performance

P. Thanapandi and Rama Prasad(1995) studied to a theor etical and exper imental on the tr ansient char acteristics of a centr ifugal pump dur ing starting and stopping periods. Exper iments have been conducted on a volute pump for normal starting and stopping transients for two cases thr ough dynamic characteristics of the pump dur ing the operating transients [11]

Conclusion

The sur vey very clear ly indicates that r esear chers
have shown consider able efforts on centr ifugal pumps based on its per formance characteristics and efficiency determination, v ery few papers wer e published on cfd analysis on pumps and ther e is no consistent papers on
scada applications in pump theory,consider amount of effor t has to be made on abr asive slurries, the r equir ement of longer life and r eliability have to be balanc ed by the constr ain of high initial cost and efficiency.

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