For widely used multistage centrifugal pumps, their former structures are so bulky that nowadays growing interest has been shifted to the development of more compact structures. Following this trend, a compact pump structure is provided and analysed. To maintain the pump’s pressure recovery, as well as to meet the water flow from the impeller, a circumferential twisted return guide vane (RGV) is proposed. To validate this design method, the instantaneous CFD simulations are performed to investigate the rotor-stator interventions. Within the impeller, the pressure fluctuation is cyclic symmetry, where the impeller frequency dominates. At the zone where flow leaves impeller for RGV, the pressure fluctuation is nonperiodic, the impeller frequency is major, and the rotation frequency is secondary. Within RGV, the periodic symmetric fluctuation is recovered, where the rotation frequency is governing. The fluctuation decreases from seven cycles within impeller to two cycles within RGV, indicating that the flow from impeller is well handled by RGV. To examine the pump’s performance, a prototype multistage pump is designed. The testing shows that the pump efficiency is 57.5%, and the stage head is 9 m, which is comparable to former multistage centrifugal pumps. And this design is more advantageous in developing compact multistage centrifugal pumps.

https://downloads.hindawi.com/journals/ijrm/2013/683713.pdf

A New Proposed Return Guide Vane for Compact Multistage Centrifugal Pumps

Submersible pumps are now in high demand due to the sporadic occurrence of recent torrential rains. The current study was carried out to investigate the hydraulic characteristics of a submersible axial-flow pump with a swept impeller and to optimize the impeller and diffuser shapes of the pump to enhance the hydraulic performance. Three-dimensional Reynolds-averaged Navier–Stokes equations were solved with the shear stress transport turbulence model. The governing equations were discretized using the finite volume method, and unstructured tetrahedral and hexahedral meshes were used in the grid system. The optimal grid system was selected through a grid dependency test. A performance test for the submersible axial-flow pump was carried out experimentally, and the results of the numerical analysis were validated against the experimental results. The hydraulic efficiency and the total head were used as objective functions. For the first optimization, a multi-objective optimization was carried out to simultaneously improve the objective functions through a hybrid multi-objective evolutionary algorithm coupled with a response surface approximation by varying the swept angle and pitch angle of the blades of the rotating impeller. The second multi-objective optimization was performed using two design variables, i.e., the inlet angle and the length of the diffuser vanes, to simultaneously increase the objective functions. Clustered optimum designs in the Pareto optimal solutions yielded significant increases in the objective function values as compared with the reference design.

https://www.mdpi.com/1996-1073/13/12/3053/pdf

Hydrodynamic Optimization for Design of a Submersible Axial-Flow Pump with a Swept Impeller

For radial multistage pumps with stationary vaned diffusers the diameter of the pump casing is much larger than the diameter of the impeller. In the case of submersible pumps, where just a limited space for installing the pump is available, smaller stator diameters need to be realized resulting in a loss in efficiency. Improving the design of these pumps and in order to save space and to decrease costs, alternative stators are being developed at the Institute of Turbomachinery and Fluid mechanics at University of Kaiserslautern. With respect to space, the optimum is a pump stage with a stage diameter equal to the outer impeller diameter. For realizing this concept, it is necessary for the flow to exit the radial impeller in axial dir ection before entering the stator. The advantage of this design is that when keeping the stage diameter constant, a much larger impeller diameter and thus a much higher hydraulic head can be realized. On the other hand, when keeping the hydraulic head or the specific speed constant, the diameter of the pump casing can be much smaller. In previous work, it was possible to increase the pump efficiency of these pump stages to values being comparable to conventional stators. In this paper the comparison to a conventional pump stage and the numerical analysis of the rotor-stator interaction of a pump stage with a small stage diameter is presented.

http://www.wseas.us/e-library/conferences/2006elounda2/papers/538-151.pdf

Rotor-Stator-Interaction of a Radial Centrifugal Pump Stage with Minimum Stage Diameter

This chapter deals with one-dimensional calculation procedures and design methods for impellers, volute casings, diffusers and inlet casings. For developing these components, the main dimensions and blade angles are calculated in a first step. Subsequently, the hydraulic contours are designed based on certain rules and methods. Many pump manufacturers employ computer programs for this work, and the drawings are generated on 2D-CAD systems. However, these methods are also increasingly replaced by 3D-CAD systems with which fully three-dimensional geometry models of a component can be created, Fig. 2.2A and Fig. 7.45. The complex hydraulic channels can be evaluated better with such models than with the conventional two-dimensional representations in various sections and views. Even more importantly, 3D-CAD systems provide the capability to directly manufacture the hydraulic components (or the casting patterns) by NC milling, stereo lithography or other fast-prototyping processes, [7.1]. The advantages of such processes are evident in terms of geometrical accuracy and lead times (not in the least also for model tests with milled or stereo-lithographed components). Since manual designs on the drawing board are rather the exception, the subsequent discussion of the design methods emphasizes the fundamental aspects of the design processes rather than a very detailed description of geometrical operations.

Design of the hydraulic components

Gemas dem Stand der Technik stutzt sich die hydraulische Auslegung der verschiedenen Arten von Lauf- und Leitradern, Spiralen und Einlaufgehausen auf empirische Methoden wie sie in diesem Kapitel beschrieben werden. Der so entstandene Erstentwurf wird dann mittels CFD analysiert und optimiert. Selbst dann ist die Genauigkeit der Vorausberechnung der Forderdaten (insbesondere bezuglich Wirkungsgrad und NPSH) nicht immer zufriedenstellend; denn die dreidimensionale Stromung durch die Pumpe hangt ab von den komplexen Formen der Stromungskanale von Einlaufgehause, Laufrad und Leitvorrichtung. Erschwerend kommt hinzu, das die Wechselwirkung zwischen dem Hauptforderstrom und der Radseitenraumstromung einen unerwartet grosen Einflus auf Kennlinie und Wirkungsgrad ausuben kann (ein Beispiel findet sich in Kap. 9.1). Es ist stets zu bedenken, das die Kombination aller Parameter und 3D-Geometrien die Stromungsformen bestimmt – und folglich die Forderdaten und Verluste. Um die Genauigkeit der Vorausberechnung zu verbessern, wird ein systematisches Vorgehen bei der hydraulischen Auslegung empfohlen. Hierzu wird in Kapitel 7.14 ein neuartiges Konzept fur eine rein analytische Beschreibung der Laufradgeometrie vorgestellt. Vor Beginn der Hydraulikentwicklung sollten alle Anforderungen an die Pumpe und die konstruktiven Randbedingungen sorgfaltig analysiert und dokumentiert werden (siehe „hydraulische Spezifikation“ in Kap. 17).

Berechnung und Entwurf der hydraulischen Komponenten

For radial multistage pumps with stationary vaned diffusers the diameter of the pump casing is much larger than the diameter of the impeller. In the case of submersible pumps, where just a limited space for installing the pump is available, smaller stator diameters need to be realized resulting in a loss in efficiency. Improving the design of these pumps and in order to save space and to decrease costs, alternative stators are being developed at the Institute of Turbomachinery and Fluid mechanics at University of Kaiserslautern. With respect to space, the optimum is a pump stage with a stage diameter equal to the outer impeller diameter. For realizing this concept, it is necessary for the flow to exit the radial impeller in axial direction before entering the stator. The advantage of this design is that when keeping the stage diameter constant, a much larger impeller diameter and thus a much higher hydraulic head can be realized. On the other hand, when keeping the hydraulic head or specific speed constant, the diameter of the pump casing can be much smaller. In this paper, the numerical calculation of the flow through the pump stage with minimum stage diameter is presented. Fully transient calculations with the sliding mesh method are performed. The numerical model consisting of the complete impeller with side gaps and stator is validated by measurements of characteristic curves and hot-wire data. After discussing the deficit of the initial stator layout, an optimized stator with a pump efficiency comparable to a conventional stator is presented. All results are compared to characteristic curves of a pump stage with conventional stator.Copyright © 2006 by ASME

Numerical Investigation and Optimization of a Stator for a Radial Submersible Pump Stage With Minimum Stage Diameter

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Numerical Investigation and Optimization of a Stator for a Radial Submersible Pump Stage With Minimum Stage Diameter