Centrifugal pumps are widely used in various fields and have enormous energy-saving potential. In order to predict efficiency quickly and accurately, firstly, by establishing a hydraulic loss model for centrifugal pump impellers, the functional relationship between impeller hydraulic loss and hydraulic efficiency is constructed to establish the objective function. Secondly, calculate the main dimensions of the impeller using the velocity coefficient method and establish the objective function variables of the number of blades Z and outlet placement angle β2. And the velocity coefficient k0. Then, the method of mathematical statistics, namely response surface analysis, is used to solve the relationship between hydraulic efficiency and dependent variables within the range of variables, which plays the role of predicting hydraulic efficiency. Finally, the accuracy of the predictions is verified by numerical simulation. The results show that the hydraulic efficiency of a high specific speed centrifugal pump reaches its maximum at 1000m3/h operating conditions with a blade number of 3, a speed coefficient of 3.9 and an outlet angle of 30°. The study provides a new direction for the hydraulic design of high specific speed centrifugal pumps to achieve more accurate predictions of high specific speed centrifugal pump efficiency. 

https://www.tandfonline.com/doi/pdf/10.1080/19942060.2023.2227686?needAccess=true&role=button

Automatic optimization of centrifugal pump for energy conservation and efficiency enhancement based on response surface methodology and computational fluid dynamics

This study aims to develop a rapid optimization design method for the centrifugal pump with high efficiency and low noise. The improved delayed detached eddy simulation and Powell's vortex sound method were employed to calculate the flow and sound field. The prediction models of hydraulic loss and noise based on vortex characteristic quantities were built using linear regression (LR) and artificial neural network (ANN) methods respectively. The Kriging surrogate model and the NSGA-II genetic algorithm were utilized for minimizing the entropy production rate and average total sound pressure in the pump, where the objectives of the training dataset for Kriging model were calculated by prediction model (scheme I) and conventional unsteady numerical simulation (scheme II). Results show that the structure and performance of optimized pumps under both schemes are nearly identical, but the computational cost of scheme Iis much lower than that of scheme II. The shear of the optimized pump is significantly reduced and the rigid rotational strength is enhanced, leading to head and efficiency improved by 3.2 % and 3.7 % respectively, under the design flow condition. The average total sound pressure level is reduced by 1.07 % due to the fluctuation suppression of shear and rigid vorticity. 

Optimization of a centrifugal pump with high efficiency and low noise based on fast prediction method and vortex control

The centrifugal pump is one of the most widely used types of power machinery in the field of ship and ocean engineering, and the shape of the impeller blade trailing edge has an important influence on their performance. To reveal the mechanism of the effect of different trailing edges on external performance, the internal flow of 16 types of impeller blade trailing edges of a centrifugal pump, consisting of Bezier trailing edges, rounding on the pressure side, cutting on the suction side, and the original trailing edge is studied by numerical simulation. The reverse flow, shaft power, and energy loss distribution in the impeller and diffuser along the streamwise direction are analyzed by calculating them on each micro control body sliced from the fluid domain. The entropy production theory and Ω-vortex identification method are used to display the magnitude and location of energy loss and the vortex structure. Finally, a static structural analysis of the impeller with different trailing edges is performed. The results show that different impeller trailing edges can clearly affect the efficiency of the pump, i.e., the thinner the trailing edge, the higher the efficiency, with the thickest model reducing efficiency by 5.71% and the thinnest model increasing efficiency by 0.59% compared to the original one. Changing the shape of the impeller trailing edge has a great influence on the reverse flow, shaft power, and energy loss near the impeller trailing edge and diffuser inlet but has little influence on the leading part of the impeller. The distribution of local entropy production rate, energy loss, and reverse flow along the streamwise direction shows similar rules, with a local maximum near the leading edge of the impeller due to the impact effect, and a global maximum near the impeller trailing edge resulting from strong flow separation and high vortex strength due to the jet-wake flow. Thinning the impeller trailing edge and smoothing its connection with the blade can reduce the vortex strength and entropy production near the impeller trailing edge and diffuser inlet, improve the flow pattern, and reduce energy loss, thus improving the pump efficiency. In all models, the maximum equivalent stress is less than 6.5 MPa and the maximum total deformation is less than 0.065mm. The results are helpful for a deeper understanding of the complex flow mechanism of the centrifugal pump with different blade trailing edges.

/pdf/cfd-simulation-of-centrifugal-pump-with-different-impeller-1a6gvln4.pdf

CFD Simulation of Centrifugal Pump with Different Impeller Blade Trailing Edges

Axial flow pumps (AFPs) are widely employed in urban flood control and drainage systems due to its high discharge at relatively low heads. As off-design condition becomes more common in real operations, we proposed an enstrophy dissipation-based hybrid optimization (EDHO) approach, which combines both the advantage of sparrow search algorithm and Non-dominated Sorting Genetic Algorithm III (NSGA-ΙΙΙ) to enlarge the Preferred Operating Range (POR) of a slanted axial flow pump (SAFP). The overall hydraulic performance was optimized with the proposed EDHO approach with a special focus on energy loss mechanism. According to the analysis, eddy dissipation occupied the most energy loss under partial loads, while shear dissipation also contributed a lot under overload conditions especially around impellers. It is demonstrated that the POR of SAFP was significantly improved after optimization. In particular, the available operation interval was broadened, and the corresponding head and efficiency were remarkably increased by refining the impeller and diffuser profiles. In contrast with NSGA-II, NSGA-III, and multi-objective evolutionary algorithm, the novel hybrid algorithm showed significantly better convergence performance, solution diversity, and stability.

Investigating the hydraulic performance of slanted axial flow pumps using an enstrophy dissipation-based hybrid optimization approach

/pdf/structural-optimization-of-multistage-centrifugal-pump-via-2nef3m8i.pdf

Structural optimization of multistage centrifugal pump via computational fluid dynamics and machine learning method

It is important to reduce carbon emissions caused by the energy consumption of pumps. This study used a centrifugal pump with a specific speed of 89.6 as the research object to improve pump efficiency. The adaptive single-objective method was adopted as the automatic optimization tool with computational fluid dynamics, which includes optimal space-filling experimental design, Kriging response surface, and mixed-integer sequential quadratic programming. Eight geometric parameters from the meridian section and the plan of the impeller and diffuser were chosen as the design variables. The maximum efficiency under the design flow conditions was set as the optimization target. The Spearman correlation coefficient analysis results show that the sensitivity of each variable to efficiency and head. Compared with the original scheme, the optimal scheme showed a 2.75% increase in efficiency and a 1.17 m increase in head under the design flowrate. The internal flow field after optimization was also improved. An external characteristic experiment of the original and optimized pumps was performed to validate the numerical results. This automatic optimization method presents great potential to improve the hydraulic performance of centrifugal pumps at a lower cost.

https://doi.org/10.1080/19942060.2022.2143901

Automatic optimization of centrifugal pump based on adaptive single-objective algorithm and computational fluid dynamics


 Trimming the impeller diameter of a centrifugal pump is the easiest and most economical way to adjust its efficient operating range based on its original performance. Three impellers obtained by trimming the diameter are investigated. Energy performance, internal flow field and entropy production analysis have been discussed with different cases. The results shown that trimming the impeller diameter causes a great change in the energy performance of centrifugal pumps. The turbulent kinetic energy (TKE) distribution and entropy production also change significantly. The best efficiency point (BEP) shifts to low flow rate with trimming impeller diameter. The BEP shift rate were 6.67% and 20% for trimming amounts of 5.15% and 10.29%, respectively. As the impeller diameter decreases, the backflow phenomenon that occurs at the diffuser inlet at low flow rate improves. The ratio of mechanical energy to kinetic energy and pressure energy is not constant for pumps with different impeller diameters. The energy performance changes are mainly caused by flow changes inside the impeller, chamber and diffuser. The results could be referred to the design and selection of centrifugal pumps.

Influence Mechanism of Trimming Impeller Diameter in a Centrifugal Pump by Computational Fluid Dynamics Investigation

Axial force is one of the main factors which affect the pump safety and reliability during the operation of pumps, especially in multi-stage centrifugal pumps. 150QJ20 type deep-well centrifugal pump (DCP) is selected as an example to research the pump performance and axial force with the numerical simulation and experiment method. The numerical simulation results were compared with experimental measurements, and such result was analyzed. The results show that the change trend of the pump performance and axial force acquired by numerical and experiment is similar. At rated operating point, the error of axial force between the numerical simulation and experimental measurements is less than 3%. This confirmed the feasibility of predict the pump performance by numerical simulation method.

Performance Predication and Axial Force Study on Deep-Well Centrifugal Pump

A new control method based on speed sensorless active disturbance rejection control (SS-ADRC) is proposed for overcoming the shortage of traditional PID control method in the application of the multi-motor synchronization system. By using the extended state observer (ESO), the internal and external disturbances in the system are compensated. According to the data driving principle, the formula of speed identification is inferred. Disturbances can be estimated online through ESO, and then speed value can also be identified by ESO. The simulation results show: the control system have strong decoupling ability, accurate speed identification ability, and good dynamic performance.

Three-Motor Synchronization Control Strategy Based on the New Speed Sensorless Active Disturbance Rejection Control

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