Centrifugal Pump IST REV 1
Centrifugal Pump IST REV 1
University of Mosul
SUBMITTED BY
SUPERVISIED BY
2023
Abstract
This study focused on designing and, aerodynamically, improving a
petroleum pump, numerically, using ANSYS software i.e. CFX application.
After designing the main two parts of the pump, volute part and rotor part, the
main work aimed for enhancing the pump’s performance by focusing on
improving the rotating part as it has a direct influence on the pump’s overall
efficiency. The study was 3D analysis and the effect of fluid properties was
taken into account by defining the fluid properties. The rotor blade shape was
modified based on changing some of its parameters and the relationships
between head, efficiency and power with the values of the blade angle were
figured out, where the objective was to achieve maximum pump’s efficiency
and reducing the consumed power. The results showed that the twist angle of
24.5o from shroud side and 35.5o from hup side were the ideal value for highest
efficiency of (95.75%).
I
Acknowledgment
For God...
For home...
For those
They were a beacon and a sun that lit up the darkness of our path and the
darkness inside us by knowledge and light.
II
Contents
Content page
Abstract ……………………………………………………………………... I
Contents ……………………………………………………………………..III|
Nomenclature ……………………………………………………………… VI
1.4 What are the main applications for centrifugal pumps ……………….. 7
Conclusion ………………………………………………………………. 28
References ………………………………………………………………. 29
III
Figure Title Page
2 Type of impeller 4
IV
Table Title Page
hup side
V
Nomenclature
Symbols
P Pressure (pa)
V Velocity (m/s)
h Height (m)
VI
CHAPTER ONE
VII
1. Introduction
1.1 Backgrounds
The transfer of liquids against gravity existed from time immemorial. A pump is
one such device that expends energy to raise, transport, or compress liquids.
The earliest known pump devices go back a few thousand years. [1]
The ancient Egyptians invented water wheels with buckets mounted on them to
transfer water for irrigation. More than 2000 years ago, a Greek inventor,
Ctesibius, made a similar type of pump for pumping water. During the same
period, Archimedes, a Greek mathematician, invented what is now known as the
'Archimedes' screw' - a pump designed like a screw rotating within a cylinder.
[1]
1
1.3 Main components of the centrifugal pump
1. Shaft
2. Impeller
3. Casing
4. Stuffing Boxes
5. Wearing Rings
1.3.2 Impeller
The impeller consists of a series of backward-curved vanes. It is mounted to the
shaft of an electric motor. An impeller is a rotating part of the centrifugal pump.
It is enclosed in a watertight casing. The centrifugal pump impeller is divided
into three types [2]:Figure2 shows the impeller types.
2
Figure 2 type of impeller [1].
a) Open Impeller
An open impeller consists of vanes attached to a central hub and mounted
directly on the shaft. The vanes have no walls or cover around them, making
open impellers weaker than closed valves. Still, these are generally quick and
easy to clean and repair.
b) Closed Impeller
The closed impeller has both front and back cover plates. In this, the impeller
vanes are sandwiched between two cover plates. These are installed in radial
flow centrifugal pumps and can be either single or double inlets.
c) Semi-open impeller
Semi-open impellers have a back-wall cover plate that gives mechanical power
to the van, while the other side remains open. Semi-open impellers are used in
medium-sized pumps. This impeller is designed for debris-loading fluid [2].
1.3.3 Casing
The casing is an airtight passage surrounding the impeller. It is designed in such
a way that the kinetic energy of the water discharged at the outlet is converted
into pressure energy before the water leaves the casing and enters the delivery
pipe [2].
3
Figure 3: Volute casing design [2].
The casing works as a cover to protect the system.Figure 3 presents the volute
casing. The casing of the centrifugal pump is further classified into three types.
b) Vortex casing
A vortex casing is a circular chamber introduced between the impeller and
casing. Here the fluid from the impeller has to first pass through the vortex
chamber and then through the volute casing. In such a case, there is a better
conversion done that is velocity energy into pressure, and it has good efficiency
than the volute casing.
5
CHAPTER TWO
6
2. Literature review
E.C. Bacharoudis et al. (2008) in this study, the performance of impellers with
the same outlet diameter having different outlet blade angles is thoroughly
evaluated. The One-dimensional approach along with empirical equations is
adopted for the design of each impeller. The predicted performance curves
result through the calculation of the internal flow field. Head-discharge curve
play important role into different outlet angles. The influence of the outlet blade
angle on the performance is verified with the CFD. The performance curve
becomes smoother and flatter with the increase with the increase outlet blade
angle. At nominal capacity, when the outlet blade angle was increased from 20°
to 50°, the head was increased by more than 6% but the hydraulic efficiency
was reduced by 4.5%. However, at high flow rates, the increase of the outlet
blade angle caused a significant improvement of the hydraulic efficiency [5].
LIU Houlin, et al. (2010) add verb they found that the blade number play the
important role during designing the pump which affects the characteristics of
the pump. The model pump has a design specific speed of 92.7 and an impeller
with 5 blades. The blade number is varied to 4, 6, 7 with the casing and other
geometric parameters keep constant. The inner flow fields and characteristics of
the centrifugal pumps with different blade number are simulated and predicted
in non- cavitation and caviation conditions by using commercial code FLUENT.
Using rapid prototyping the impeller with different blade numbers is made.
With the increase of blade number, the area of low pressure region at the
suction of blade inlet grows continuously, and the uniformity of static pressure
distribution at screw section become worse and worse while at diffusion section
become better and better. The head of model pump is increase with the increase
with pump but there is variation with efficiency and cavitation is complicated.
These results are important to design of the centrifugal pump [6].
Neelambika,et al. a (2014) a detailed CFD analysis was done to predict the flow
pattern inside the impeller which is an active pump component. The optimum
inlet and outlet vane angles are calculated for the existing impeller by using the
empirical relations.This study was divided in to three cases. In the first case,
outlet angle is increased by 5°. From the outlet flow conditions, obtained from
the CFD analysis, it is evident that the reduced outlet recirculation and flow
7
separation cause the improved efficiency. By changing the outlet angle the
efficiency of the impeller is improved to 59%. In the second case,the inlet angle
is decreased by 10%. The efficiency of the impeller in this case is 61%. From
this analysis it is understood that the changes in the inlet vane angle did not
change the efficiency of the impeller as much as the changes in outlet angle. For
existing impeller, the head and efficiency are found out to be 19.24 m and 55%
respectively. The impeller 1, the percentage increase in the head and efficiency
are 3.22% and 7.27% respectively. The impeller 2, the percentage increase in
the head and efficiency are 10.29% and 10.91% respectively.For the impeller 3,
the percentage increase in the head and efficiency are 13.66% and 18.18%
respectively. Based on the above, it is concluded that impeller 3 gives better
performance [8].
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CHAPTER THREE
9
3. Methodology
A centrifugal pump is a machine used to transfer fluid from one place to
another. The basic principle behind the working of a centrifugal pump is the
transfer of kinetic energy from the impeller to the fluid. This energy transfer
results in an increase in the fluid's pressure and its flow rate.
The design of a centrifugal pump is an iterative process that involves several
steps. The first step is to determine the design flow rate and the required head.
This can be done by analyzing the system in which the pump will operate and
the required operating conditions. The next step is to select the type of impeller
that will be used in the pump. Impellers are designed to convert the kinetic
energy of the fluid into pressure energy. The type of impeller chosen depends on
the required head, the fluid properties, and the flow rate.
Once the impeller type is selected, the next step is to determine the impeller
geometry. This includes the diameter, the number of blades, the blade angle, and
the blade thickness. The geometry of the impeller is critical in determining the
pump's performance, including its efficiency, head, and flow rate [3].
10
Where P is the pressure (in pascals), ρ is the density (in kilograms per cubic
meter), V is the velocity (in meters per second), g is the gravitational
acceleration (in meters per second squared), and h is the height (in meters)
3.1.3.1 Head:
It is the height of the column of fluid at a certain level and it is measured in
meters. It is also called the column of water corresponding to the fluid energy
(Pressure energy + Kinetic energy + Potential energy) at a certain point.
Component of Head:
1- Static Section Head (hs)
The vertical distance between the free surface of the fluid to be
pumped and the center of the pump
11
b) Pressure loss in connections such as elbow joints, valves, and
others. (shock)
v2
hsh = K (5)
2g
5- Pump head: the total head which a pump operates is based on.[9]
H = hs + hv + hf + hsh (6)
12
3.1.6 Specific Speed:
Specific Speed: The specific speed is a dimensionless parameter used to classify
pumps based on their flow rate, head, and rotational speed. It is given by:
N√Q
Ns = 3 (11)
(H) ⁄4
Where Ns is the specific speed, N is the rotational speed (rpm), Q is the flow
rate (m3/s), and H is the head (m).
13
3.2 Software Numerical
Considering that the impeller is open type and the casing is spiral type
They are the most suitable for oil pump design, as they are suitable for complex
oil properties
Operation Condition
1 Liquid Hydrocarbon
2 Capacity 252 m3/hr.
3 Head 38.5 m
4 Density 654.78 Kg/m3
5 Speed 1500 [ rpm]
6 Temp. 45 C
7 Pressure outlet 3 bar
Table-1- Operation condition for centrifugal pump
14
3.2.3 Parameter changed
Figure 5 and Figure 6 show the torsion of the blade when the angle is changed
15
3.2.3 Procedure
1. Start Workbench
2. Create "Vista CPD" from toolbox
3. Create Volute
16
4. Bladegen
5. Transfer data to Turbo Grid, then transfer the data to ICEM CFD:
17
9. Result
18
Figure 13: Toolbox of the workbench showing the complete steps of the
designed pump.
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CHAPTER FOUR
20
4. Result and Discussion
From the figure (14) it can be noticed that there is a relationship which is taken
in consideration between the impeller’s blade angle and the pump head. The
chart shows that whenever we decrease the blade angle then we get a shorter
head and vice versa. The evidence of our context is as we see in the figure. We
made many empirical runs and we figured out that the best angle is 24.5 where
we get the maximum head. From this point we can give an advice of taking this
angle in your designs
43.5
43
42.5
42
head (m)
41.5
41
40.5
40
19.5 20.5 21.5 22.5 23.5 24.5 25.5 26.5 27.5
blade angle
Figure 14: Variation of head with the change in blade angle (shroud) and head.
From the figure (15) it can be seen that there is a relationship which is taken in
consideration between the impeller’s blade angle and its own efficiency. The
chart shows that whenever we decrease the blade angle then we get worse
efficiency for the impeller and vice versa. The evidence of our context is as we
see in the figure. Moreover, we made many empirical runs and we figured out
that the best angle is 24.5 where we get an ideal efficiency. From this point we
can give an advice of taking this angle in your designs
21
Effiecnecy
96
95.5
95
94.5
Effiecnecy
94
93.5
93
92.5
92
19.5 20.5 21.5 22.5 23.5 24.5 25.5 26.5 27.5
blade angle
Figure 15: Variation of head with the change in blade angle (shroud) and
efficiency.
Now we’ll speak about the most important section per any project (the cost)
which is here represented in the pump’s power after a long time of empirical
runs we figured out the chart (16) and it gives a perceive that it’s whenever we
decrease the impeller’s angle then we’ll need less amount of the provided power
Power
20.4
20.3
20.2
20.1
power (KW)
20
19.9
19.8
19.7
19.6
19.5
19.5 20.5 21.5 22.5 23.5 24.5 25.5 26.5 27.5
bade angle
Figure 16: Varation of head with the change in blade angle (shroud) and power.
22
Blade Angle Head Efficiency Power
degree (m) % (KW)
20.5 40.44 92.63 19.62
Table-2-:Charging of Head, Efficiency and Power values with blade angle from
shroud side
23
It is very clear from the chart (17) that there is a changeable head curve where
we got the maximum head at the angle 35.5 and the minimum one was at 38.5.
Head
43.3
43.2
43.1
43
42.9
head (m)
42.8
42.7
42.6
42.5
42.4
42.3
32 33 34 35 36 37 38 39
blade angle
Figure 17: Variation of head with the change in blade angle (hup) and head.
It's evident from the figure (18) that there is a random change with the
efficiency curve where we got the maximum efficiency at the angle 35.3 and the
minimum one was at 38.5 ..
Efficiency
96
95.8
95.6
95.4
Effiecnecy
95.2
95
94.8
94.6
94.4
94.2
32 33 34 35 36 37 38 39
blade angle
Figure 18: Variation of head with the change in blade angle (hup) and
efficiency.
24
When we made run it was seen that there is a random change with the power
curve where we got the maximum power at the angle 35.5 and the minimum
one was at 37.5 Figure (19)
Power
20.28
20.26
20.24
20.22
power (KW)
20.2
20.18
20.16
20.14
20.12
20.1
32 33 34 35 36 37 38 39
blade angle
Figure 19: Variation of head with the change in blade angle (hup) and power.
25
Blade Angle Head Efficiency Power
degree (m) % (KW)
Table-3- Charging of Head, Efficiency and Power values with blade angle from
hup side.
26
CHAPTER FIVE
27
5. Conclusions and Recommendations
5.1 Conclusions:
The main outcomes of this project can be summarised as follow:
1. The 3D pump was successfully designed and modelled using the CFX
application in Ansys by starting with the mean line design in VISTA
CPD.
3. We figured out that the blade angle from the shroud side has a serious
effect on the rotor efficiency value .Where the hub has less impacting on
the rotor efficiency value.
5.2 Recommendations:
1. Including the effect of the volute and/ or the stator within the analysis of
the pump’s model to have more accurate results.
28
References
[1] Paresh Girdhar. “Practical Centrifugal Pumps”.(2004)
https://books.google.com.eg/books?hl=ar&lr=&id=3RjnmvQSFvcC&oi=
fnd&pg=PP1&dq=info:waFQ5ADZbY4J:scholar.google.com/&ots=8zY9
inDV5I&sig=Psgyhi8OrTomVEodnr27-
PndVNk&redir_esc=y#v=onepage&q&f=false
[2] https://www.michael-smith-engineers.co.uk/resources/useful-
info/centrifugal-pumps
[3] Imad Touma Bani Karsh. “ Centrifugal pump design”.(2014).
https://books-library.net/files/download-pdf-ebooks.org-ku-17324.pdf
[4] . A. Omar, A. A. Ali, and A. M. Al-Sammarraie, "Numerical Analysis and
Design of an Oil Pump Impeller," Journal of Fluid Engineering, vol. 141,
no. 9, pp. 091102-1-091102-12, Sep. .2019
[5] E.C. Bacharoudis, A.E. Filios, M.D. Mentzos and D.P. Margaris
(2008),”Parametric study of centrifugal pump by varying the outlet blade
angle”, The open mechanical engineering journal, 2008, 75-83.
[6] LIU Houlin, WANG Yong, YUAN Shouqi, TAN Minggao, and WANG
Kai (2010),”Effects of blade number of characteristic of centrifugal pump
”,Chinese journal of mechanical engineering,2010.
[7] Sambhrant Srivastavaa, Apurba Kumar Roy and Kaushik Kumar, (2014)
“Design of a mixed flow pump impeller and its validation using FEM
analysis”, Science Direct, Procedia Technology 14, PN 181 – 187.
[8] Neelambika, Veerbhadrappa (2014) “CFD analysis of mixed flow
impeller”, International journal of research engineering and techn
[9] Centrifugal pump design https://books-library.net/files/book-
library.online_nooa0b96e9e4911b0e-18731.pdf
29