Part load flow in radial centrifugal pumps

Centrifugal pumps are required to sustain a stable operation of the system they support under all operating conditions. Minor modifications of the surfaces defining the pump's water passage can influence the tendency to unstable system operation significantly. The action of such modifications on the flow are yet not fully understood, leading to costly trial and error approaches in the solution of instability problems. The part-load flow in centrifugal pumps is inherently time-dependent due to the interaction of the rotating impeller with the stationary diffuser (Rotor-Stator Interaction, RSI). Furthermore, adverse pressure gradients in the pump diffuser may cause flow separation, potentially inducing symmetry-breaking non-uniformities, either spatially stationary or rotating and either steady or intermittent. Rotating stall, characterized by the presence of distinct cells of flow separation on the circumference, rotating at a fraction of the impeller revolution rate, has been observed in thermal and hydraulic turbomachines. Due to its complexity, the part-load flow in radial centrifugal pumps is a major challenge for numerical flow simulation methods. The present study investigates the part-load flow in radial centrifugal pumps and pump-turbines by experimental and numerical methods, the latter using a finite volume discretization of the Reynolds-averaged Navier-Stokes (RANS) equation. Physical phenomena of part load flow are evidenced based on three case studies, and the ability of numerical simulation methods to reproduce part-load flow in radial centrifugal pumps qualitatively and quantitatively is assessed. A numerical study of the flow in a high specific speed radial pump-turbine using steady approaches and the hypothesis of angular periodicity between neighboring blade channels evidences the relation of sudden flow topology changes with an increase of viscous losses, impacting on the energy-discharge characteristic, and thus increasing the risk of unstable operation. When the flow rate drops below a critical threshold, the straight through-flow with flow separation zones attached to the guide vanes changes to an asymmetrical flow. Energy is drawn off the mean flow and dissipated in a large vortex-like structure. Besides flow separation in some diffuser channels, time-dependent numerical simulations of the flow in a double suction pump evidence a flow rate imbalance between both impeller sides interacting with asymmetric flow separation in the diffuser. Viscous losses increase substantially as this imbalance occurs, the resulting segment of positive slope in the energy-discharge characteristic is found for a flow rate sensibly different from measurements. Different modes of rotating stall are identified by transient pressure measurements in a low-specific-speed pump-turbine, showing 3 to 5 zones of separated flow, rotating at 0.016 to 0.028 times impeller rotation rate, depending on discharge. For operating conditions where stall with 4 cells is most pronounced, velocity is measured by Laser-Doppler methods at locations of interest. The velocity field is reconstructed with respect to the passage of stall cells by definition of a stall phase obtained from simultaneous transient pressure measurements. Time-dependent numerical simulation predicting rotating stall with 4 cells shows velocity fields that are in reasonable agreement with the measured velocity fields, but occurring at a sensibly higher flow rate than found from experiments. In consideration of the quantitative shortcomings of the numerical simulation, a novel modelling approach is proposed: Replacing the costly 3-dimensional simulation of the major part of the impeller channels by a 1-dimensional model allows a significant economy in computational resources, allowing an improved modeling for the remainder of the domain at constant computational cost. The model is validated with the challenging cases of rotating stall and impeller side flow rate imbalance. The satisfying coherence of the results with the simulation including the entire impeller channels qualifies this approach for numerous turbomachinery applications. It could also provide improved, time-dependent boundary conditions for draft tube vortex rope simulations at reasonable computational cost. Parameter studies modifying deliberately some quantities of mean flow and turbulence at the modeled boundary surfaces can be implemented in the framework of the method.

Simulation of shear-driven flows

Roland Bouffanais

The research work reported in the present dissertation is aimed at the analysis of complex physical phenomena involving instabilities and nonlinearities occurring in fluids through state-of-the-art numerical modeling. Solutions of intricate fluid physics problems are devised in two particularly arduous situations: fluid domains with moving boundaries and the high-Reynolds-number regime dominated by nonlinear convective effects. Shear-driven flows of incompressible Newtonian fluids enclosed in cavities of varying geometries are thoroughly investigated in the two following frameworks: transition with a free surface and confined turbulence. The physical system we consider is made of an incompressible Newtonian fluid filling a bounded, or partially bounded cavity. A series of shear-driven flows are easily generated by setting in motion some part of the container boundary. These driven-cavity flows are not only technologically important, they are of great scientific interest because they display almost all physical fluid phenomena that can possibly occur in incompressible flows, and this in the simplest geometrical settings. Thus corner eddies, secondary flows, longitudinal vortices, complex three-dimensional patterns, chaotic particle motions, nonuniqueness, transition, and turbulence all occur naturally and can be studied in the same geometry. This facilitates the comparison of results from experiments, analysis, and computation over the whole range of Reynolds numbers. The flows under consideration are part of a larger class of confined flows driven by linear or angular momentum gradients. This dissertation reports a detailed study of a novel numerical method developed for the simulation of an unsteady free-surface flow in three-space-dimensions. This method relies on a moving-grid technique to solve the Navier-Stokes equations expressed in the arbitrary Lagrangian-Eulerian (ALE) kinematics and discretized by the spectral element method. A comprehensive analysis of the continuous and discretized formulations of the general problem in the ALE frame, with nonlinear, non-homogeneous and unsteady boundary conditions is presented. In this dissertation, we first consider in the internal turbulent flow of a fluid enclosed in a bounded cubical cavity driven by the constant translation of its lid. The solution of this flow relied on large-eddy simulations, which served to improve our physical understanding of this complex flow dynamics. Subsequently, a novel subgrid model based on approximate deconvolution methods coupled with a dynamic mixed scale model was devised. The large-eddy simulation of the lid-driven cubical cavity flow based on this novel subgrid model has shown improvements over traditional subgrid-viscosity type of models. Finally a new interpretation of approximate deconvolution models when used with implicit filtering as a way to approximate the projective grid filter was given. This led to the introduction of the grid filter models. Through the use of a newly-developed method of numerical simulation, in this dissertation we solve unsteady flows with a flat and moving free-surface in the transitional regime. These flows are the incompressible flow of a viscous fluid enclosed in a cylindrical container with an open top surface and driven by the steady rotation of the bottom wall. New flow states are investigated based on the fully three-dimensional solution of the Navier-Stokes equations for these free-surface cylindrical swirling flows, without resorting to any symmetry properties unlike all other results available in the literature. To our knowledge, this study delivers the most general available results for this free-surface problem due to its original mathematical treatment. This second part of the dissertation is a basic research task directed at increasing our understanding of the influence of the presence of a free surface on the intricate transitional flow dynamics of shear-driven flows.

EPFL2007

Numerical Analysis of Flow Phenomena Related to the Unstable Energy-Discharge Characteristic of a Pump-Turbine in Pump Mode

François Avellan, Olivier Braun

Regions of positive slope in the pressure-discharge characteristics are one of the major concerns in design and operation of centrifugal pumps, as they are limiting the admissible operating range to values above the critical discharge. The industrial pump turbine of specific speed ν=0.42 (nq=66 min-1) proposed as QNET-CFD test case TA6-04 shows a marked saddle in the energy-discharge characteristic associated to a sudden drop of efficiency versus discharge at part load. The pump-turbine consists of a shrouded impeller with five blades, a diffuser with 22 guide and stay vanes and a spiral casing. CFD flow simulations on a reduced model were carried out with a finite volume Navier-Stokes code (CFX-5.7) using block- tructured hexahedral meshes and the Menter-SST Turbulence model. Control of numerical quality has been performed. Reduced models with relatively low computational effort (mixing plane interface) already permit to capture the drop in efficiency and energy coefficient to analyze the flow phenomena inducing the drop of the energy coefficient Ψ that occurs at partial discharge. Analysis of local flow patterns and energy and velocity distributions at the rotor-stator interface that are related to the onset of recirculation are presented.

2005

Numerical simulation of three-dimensional free surface flows

Vincent Maronnier, Marco Picasso, Jacques Rappaz

A numerical model is presented for the simulation of complex fluid flows with free surfaces in three space dimensions. The model described in Maronnier et al. (J. Comput. Phys. 1999; 155(2):439) is extended to three dimensional situations. The mathematical formulation of the model is similar to that of the volume of fluid (VOF) method, but the numerical procedures are different. A splitting method is used for the time discretization. At each time step, two advection problems-one for the predicted velocity field and the other for the volume fraction of liquid-are to be solved. Then, a generalized Stokes problem is solved and the velocity field is corrected. Two different grids are used for the space discretization. The two advection problems are solved on a fixed, structured grid made out of small cubic cells, using a forward characteristic method. The generalized Stokes problem is solved using continuous, piecewise linear stabilized finite elements on a fixed, unstructured mesh of tetrahedrons. The three-dimensional implementation is discussed. Efficient postprocessing algorithms enhance the quality of the numerical solution. A hierarchical data structure reduces memory requirements. Numerical results are presented for complex geometries arising in mold filling. Copyright (C) 2003 John Wiley Sons, Ltd.

2003

Simulation of shear-driven flows

Roland Bouffanais

EPFL2007