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MODELING and SIMULATION based
DEVELOPMENT of ROTORDYNAMIC PUMPS
Chris DENUS [email protected]
CTD Technology & Consulting
Denus TurboDesign Solutions
CH-8404 Winterthur
Switzerland
Source: „SULZER Horizonte“, 1994
ANSYS-CADFEM Swiss User Meeting
Winterthur,16th June 2016
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This Year‘s CADFEM User Meeting Motto is:
Success of a development project = 10 Simulations + 1 TEST
The purpose of this presentation is to prove the validity of this equation.
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Contents
1. Introduction
2. Sulzer AG contributions to CFD as
applied in turbomachinery
3. Pump Analysis Workflow in ANSYS-CFX
4. Three CFD-based pump projects
5. Conclusions
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1. Introduction
A centrifugal pump
Sulzer Pumps image
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Pump = Hardware + Performance
X * (Design, Build & TEST)
(1830 until 1990‘s)
Sulzer Pumps images
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Pump Users‘ requirements
(Sales/Market requirements)
• short delivery time
• high efficiency
• overall performance according to
specification or to a standard
• simplicity of construction
• reduced and easy maintenance
• durability
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Pump performance requirements (T)
• guaranteed head rise and efficiency level at the
BEP (Hoo, ETAoo, Nq) and at off-design points of
operation
• stable characteristics up to a certain part-load, or
over entire range of flow rate
• Shut-off head, Ho
• SHAPES of Q-H, and Q-ETA curves
• cavitation free operation
• vibration free operation
• remain within certain size envelope
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Pump = Hardware + Performance
Sulzer Pumps images
X * (Design, Build & TEST)
(from 1830 till 1990‘s)
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Pump = Hardware + Performance
successfully applied in pumps since mid-1990‘s:
CAD & CFD
Design Model Simulate Build and TEST
Sulzer Pumps image Sulzer Pumps image
CFD
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Two Sulzer‘s R&D projects and ASME Papers on
Compressor Rotor 37 (1994) & Pump Nq90 (1996)
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WEIR Pumps, ASME J. of Fluids Eng. (1996)
statement on the pump industry needs
„The (pump) industry needs, simply to use,
low labor intensive techniques which
guarantee the optimum solution on the first
time basis“
P.A. Smith, WEIR Pumps (ASME JFE 1996)
The industry needs:
• simple to use,
• low labor intensive techniques,
which
• guarantee the optimum solution,
• on the first time basis
DEC. 1996 11
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Sulzer (Pumps, and Innotec) contributions
to CFD and its applications (1990-2008)
1. CFD software evaluation re. workflow and validation (CFD results vs. test)
2. Pump analysis for Q-H, Q-ETA predictions – „CFD learning curves“
3. H_CFD/H_Test = f(Nq) CFD prediction for pumps / „CFD accuracy diagram“
4. Radial Compressor Impeller internal flowfield (DLR Köln – Eckardt case)
5. Axial Compressor Impeller ASME blind test (NASA Rotor 37)
6. (EPRI project) Radial Pump Stage *)
7. Radial Pump Vaned Diffuser
8. Mixed Flow Pump (Spiral Volute) – Pump Nq90
9. Mixed-Flow Pump (Vaned Diffuser) – STAGE
10. Inlet Sump for Vertical Cooling Pumps
11.*) Rotordynamics ( =>Texas A&M, NASA)
12.Cavitation
13.Erosion
14.CFD „best practises“ and application guidelines
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CFD vs. Experiment: Q-H, Q-ETA
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CFD vs. Experiment
Head prediction error estimation
nq is a pump design factor; nq ≤ 10 for purely RADIAL flow impellers, nq ≥ 200 for AXIAL flow impellers
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CFD vs. Experiment – internal flows in compressors
(DLR-Köln Eckardt‘s impeller)
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Sulzer Pumps Radial Flow BFP stage
for CFD Analysis and Research
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CFD vs. Experiment: Diffuser flow
and the static pressure recovery Cp
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CFD vs. Experiment using LDA
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CFD vs. Experiment:
flow velocities at impeller inlet and outlet
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Texas A&M research re. the secondary flow path
on baseline Sulzer Pumps‘ „EGGER impeller“
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Sulzer-ETHZ Research Pump Nq90
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Sulzer-ETHZ Research Pump Nq90 (grids generated for TASCflow, 1996)
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Sulzer Pumps Mixed-Flow STAGE
CFD performance prediction over entire flow range
Sulzer Pumps images
Source: ASME
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Sulzer Pumps CFD Research on:
A. Shut-off Head (centrifugal pumps)
B. Multiphase Pumps
CFD Model and Results for low
flow conditions of radial flow pump
Sulzer Pumps image
EPFL images
Multiphase Pump CFD
Analysis
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Industrial CAD/CFD/FEA based
development of pumps
Ruhrpumpen image
impeller preliminary design
impeller final design solution
CFD Modeling and Simulation Engine
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3. Pump Analysis Workflow in ANSYS-CFX
3.1 Sulzer – ETH Zürich Research Pump Nq90,
revisited, using ANSYS-CFX
3.2 a double suction pump analysis in ANSYS-
CFX
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3.1 Sulzer-ETHZ Research Pump Nq90, revisited
using ANSYS-CFX
TurboGrid
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3.1 Sulzer-ETHZ Research Pump Nq90, revisited
using ANSYS-CFX
CFX – preprocessing Turbo Tool largely facilitates the
CFD model build for any bladed
component => e.g. Boundary
Surfaces and Conditions assigned
automatically
Grid generated in TurboGrid
using ATM
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3.1 Sulzer-ETHZ Research Pump Nq90, revisited
using ANSYS-CFX
CFX correctly predicted Hoo
and H at several flow rates
CFX predicted Q-H instability at the flow rate it was measured
Structured 250000 grid generated in
TurboGrid using ATM, only small
adjustments were necessary
K-eps Turbulence Model, coverged
solution below 120 iterations
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3.1 Sulzer-ETHZ Research Pump Nq90, revisited
using ANSYS-CFX
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3.2 A double suction pump analysis
using ANSYS-CFX
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A double suction pump analysis in ANSYS-CFX
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A double suction pump analysis in ANSYS-CFX
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4. Three CFD – based pump projects
• SULZER Tehachapi pump
(performance upgrade by HITACHI Power, 2003-4)
• ANDRITZ (Ritz Pumpen/CTD)
• BITTER GmbH
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SULZER – Tehachapi
4 stage pump
Sulzer Pumps image
Allis-Chalmers image
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CTD: Submersible Multistage Pumps
Hydraulic development project done by CTD was entirely CFD-simulations driven.
Design models were systematically developed and evaluated. The process resulted
in the design solution which:
- did not require any optimization by testing
- all performance targets were achieved by the design selected for the manufacturing
and were confirmed by the first test made, on each of the FOUR different pump
sizes.
The performance targets included:
A. Hoo, Qoo (very strict requirement on exact values of Qoo (and Hoo in a certain
range)
B. Shapes of Q-H, and Q-ETA characteristics, with ETA values prescribed over a
certain range Q range
C. Excellent hydrodynamic stability in tested pump assemblies with up to twelve
stages; the tests were confirmed at the end client’s own facilities and these
pumps performed better than comparable pumps delivered for this client.
D. Fulfilment of manufacturing related constraints
E. Fulfilment of requirements related to multistage applications.
Andritz image
Note: the pumps operate flawlessly for the
5th year now, in major power stations in
Germany
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CTD: Submersible Multistage Pumps
Andritz and VDMA
images
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Computable pump performance curves
WILO image
WILO image
TU-Graz image
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CTD in Automotive
• SUTER Racing (CH-Turbenthal)
• RICARDO (UK)
• Pierburg (D-Neuss)
• BITTER (A)
• ….
Radial Flow (2D) Mixed Flow (3D) 3D2
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Impellers – design and manufacturing problem
efficiency
manufacturing costs
curvature of the impeller blades
„one“-dimensional (1D) two-dimensional (2D) three-dimensional (3D)
impeller style
open half-open closed
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1985 2005
> 2016
?
?
?
„1D“ 2D 3D
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New generation impeller for automotive cooling
BITTER 3D2 impeller
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1
Ruhrpumpen image
evaluation of numerical simulation
experimental validation
fabrication of prototype
preparation for production
experience, measurements,
empirical values
BITTER images
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Spezifische Drehzahl
KFZ/NFZ Haupt-Kühlmittelpumpen
NFZ: 50 m³/h =
833 l/min
KFZ: 20 m³/h =
333 l/min
125 m³/h = 2083 l/min 250 m³/h = 4167 l/min 630 m³/h = 10500 l/min 2000 m³/h = 33333 l/min
Bitter 3D² Laufräder
BITTER pump development technology
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BITTER GmbH 3D² Impellers – projects summary;
shown in frames are detailed developments incl. optimization by
prototyping and testing
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Automotive pump – inlet conditions
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Automotive pump – inlet and outlet system
configurations (installed conditions)
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Zufluss: CV1 – CV3
Laufrad und Ablaufgehäuse: CV3 – CV4
Abfluss: CV4 – CV6
Zentrales Element einer Kreiselpumpe ist das
Laufrad. Aber auch Ablaufgehäuse und Zu- und
Abströmbedingungen beeinflussen den
Wirkungsgrad.
Im Bild links verursacht die ungünstige Zu- und
Abströmung, vorgegeben durch den Einbauraum des
Kunden, eine Wirkungsgradeinbusse von 11 %.
Häufig ist Optimierungspotential vorhanden, das
aber auch Änderungen beim Kunden verursacht.
CV1
CV2
CV
3
CV
5
CV6
CV
4
Inlet
Outlet
CV: control volume, Kontrollvolumen bei Strömungssimulationen
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BITTER CFD Model for integrated pump & impeller
development. Integrated = PUMP + SYSTEM
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Pump & System Modeling for CFD at BITTER
Strömungssimulationen
Berechnete Drosselkurven, CV1-CV6 (inkl. Zu- und Abströmung) Konstruktion entsprechend Auslegung
Laufrad und Ablaufgehäuse
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5. Conclusions
• CFD, thanks to extensive development accompanied by validation
effort, proves to be reliable and cost-effective pump development
technology
• CFD is a core performance analysis and predictive technology. It is
an integral part of the Design Cycle, human centric, or AI-based
• It allows to:
1. improve even best-in-class pump design solutions from the past
2. develop new pumps for increasingly demanding applications and
challenging, multi-objective, performance targets
3. innovate, in which the design solutions combine
• optimized blading hydrodynamics,
• integrated pump and system approach,
• specialized and cost effective manufacturing technology
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