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    Proceedings of ASME Turbo Expo 2016: Turbomachinery Technical Conference and Exposition
    GT2016
    June 13 – 17, 2016, Seoul, South Korea

    Downloaded from http://asmedigitalcollection.asme.org/GT/proceedings-pdf/GT2016/49873/V009T24A009/2431855/v009t24a009-gt2016-56599.pdf by Universitaets Und Landesbibliothek Darmstadt user on 03 November 2024
    GT2016-56599

    A TRANSIENT 3D CFD MODEL OF A PROGRESSIVE CAVITY PUMP


    *
    K.R. Mrinal, Md. Hamid Siddique, AbdusSamad
    Wave Energy and Fluid Engineering Laboratory
    Department of Ocean Engineering
    Indian Institute of Technology Madras, Chennai 600 036, India

    ABSTRACT like natural rubber or nitrile rubber, and a compression fit


    A progressive cavity pump (PCP) is a positive between the rotor and the stator is maintained. In metallic
    displacement pump and has been used as an artificial lift PCP, the stator is metallic (steel or bronze alloy) and
    method in the oil and gas industry for pumping fluid with solid maintains a clearance fit with the rotor. Flow leakage between
    content and high viscosity. In a PCP, a single-lobe rotor the rotor and the stator is one of the main factors which affect
    rotates inside a double-lobe stator. Articles on computational the performance of a PCP. Leakage flow occurs from the
    works for flows through a PCP are limited because of transient outlet to the inlet of the pump because of pressure gradient. In
    behavior of flow, complex geometry and moving boundaries. elastomeric PCP, the leakage is less because of compression
    In this paper, a 3D CFD model has been developed to predict fit. The parameters like length of the pump, clearance between
    the flow variables at different operating conditions. The flow rotor and stator, pressure difference and viscosity affect the
    is considered as incompressible, single phase, transient, and leakage. The leakage causes loss in the discharge resulting in
    turbulent. The dynamic mesh model in Ansys-Fluent for the decrease in overall efficiency [3]
    rotor mesh movement is used, and a user defined function Computational fluid dynamics (CFD) is being used over the
    (UDF) written in C language defines the rotor's hypocycloid years tosolvecomplex fluid flow problems. It plays a vital role
    path. The mesh deformation is done with spring based in design and optimization of fluid machinery systems.
    smoothing and local remeshing technique. The computational Unsteady and dynamic mesh models are used for the moving
    results are compared with the experiment results available in boundary problems such as screw pump, gear pump or
    the literature.Thepump gives maximum flowrate at zero reciprocating pumps [4-5].
    differential pressure. There are limited experimental and numerical studies in the
    area of PCP to study the leakage and performance as
    Keywords: Progressive cavity pump, CFD, transient flow, compared to the other types of pumps. Moineau [6] developed
    dynamic mesh the working principle of PCP in 1930 and introduced a simple
    numerical flow model to find the leakage in PCP based on
    INTRODUCTION Hagen-Poiseuille flow. Robello and Saveth [7] derived an
    A Progressive cavity pump (PCP)isa special type of rotary optimized relationship between pitch and diameter to
    positive displacement pump and consists of a single-lobe rotor maximize the flow rate for a multi-lobe PCP. Later, Gamboa
    eccentrically rotate in a double-lobe stator. Due to the rotation, et al. [8] modeled the leakage in PCP as the combination of
    rotor cavities are formed and a pulsationless flow occurs from Couette flow and Poiseuilleflow. Pessoa et al. [9] used similar
    the suction end to the discharge end. The pump is widely used approach by considering friction factors for predicting the
    for pumping highly viscous crude oils, emulsions, produced flow rate for a given differential pressure. Gamboa et al. [10]
    water and multiphase fluids. The pump is used in petroleum proposed three simplified flow models for understanding the
    industry as an artificial lift technique [1-2]. flow physics in PCP.Asimilar model used by
    PCPis classified into two groups: elastomeric and metallic KarthikeshwaranandSamad [11] predicts leakage for different
    PCP based on the material used for the stator. clearances and fluid viscosities.
    InelastomericPCP,the stator contains elastomeric materials Recently, Paladino et al. [12] presented a 3D transient model
    of PCP using a commercially available CFD package ANSYS-
    *Associate Professor and author of correspondence; E -mail: [email protected]

    1 Copyright © 2016 by ASME


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    CFX. A numerical PCP model [13] for Newtonian fluid unstructured mesh generation is flexible for complex shape
    predicts the flow rate used simplified form of Navier-Stokes geometry and dynamic mesh applications. The domain was

    Downloaded from http://asmedigitalcollection.asme.org/GT/proceedings-pdf/GT2016/49873/V009T24A009/2431855/v009t24a009-gt2016-56599.pdf by Universitaets Und Landesbibliothek Darmstadt user on 03 November 2024
    equation and the results are close to the experimental results. discretized using octree approach, which generates tetrahedral
    Berton et al. [14] presented a full transient 3D model mesh. The octree method is robust, generates mesh using top-
    considering both Newtonian and non-Newtonian fluids. The down meshing approach, and does not require any surface
    recent studies [15-16] considered the deformation of stator mesh to generate the volume mesh. The computational domain
    (elastomeric PCP) and developed model for predicting the is discretized by a mesh consisting of 2,285,938 elements as
    flow variables. The main difficulties in 3D modeling arise shown in the fig.2.
    because of the transient flow, complex geometry and the
    moving boundaries. Table 1.Geometrical details of PCP
    In this paper, a 3D CFD unsteady model of PCP has been
    developed to predict the flow rate at the zero differential Parameters Dimensions
    pressure with different speeds. The CFD results are validated Eccentricity (E) 4.039mm
    with the experimental results and detailed analysis has been Rotor diameter 39.878mm
    presented. Stator diameter 40.248mm
    Stator pitch 119.99mm
    PCP GEOMETRY Number of stages 3
    The operating principle of PCP was first described by
    Moineau [6]. The work was based on the geometry with the
    hypocycloidal design of the rotor-stator profile. A PCP
    consists of a single threaded rotor and a double threaded Ps Stator
    stator. The rotor cross section is circular which is
    perpendicular to the axis along the length. The center of each Rotor
    successive circular section lies along the helix and it is called
    the axis of the rotor. The center of the rotor cross section is
    offset from the axis of the rotor at a distance called the
    eccentricity (e). The cross section of stator (fig.1) has two
    semicirclesjoined by two tangential lines and the center to
    center distance is4e[1,17].
    Due to rotation of rotor, cavities are formed progressively,
    andone cavity openswhile another closes. The fluid gets Axis
    transferred from the closing cavity to the opening cavity and
    pressuredifferential increases. The pressure capacity of PCP Pr
    depends upon the number of the cavities. The leakage flow or
    back flow occurs from a higher pressure cavity to a lower Axis
    pressure cavity and reduces the overall efficiency.
    Figure 1.PCP geometry: rotor and stator
    COMPUTATIONAL MODEL
    The CFD analysis was done in a three-stage metallic PCP,
    and it was validated with experiment results [3, 10]. Details of
    the pump specifications are given in Table 1. The 3D
    geometry of the pump was created in pre-processor CAD
    software. A full pitch was considered for the analysis, and a
    clearance between the stator and the rotor was taken as 0.5mm
    instead of actual clearance 0.385mm. This small increase in
    clearance was due to the thin-section meshing difficulty and
    also to avoid negative volume cell formation during mesh
    movement. The increase in clearance may lead to increase in
    the leakage and decrease in the discharge of the pump. The
    rotor pitch length is one half of the stator pitch length, and one
    stage equals to one stator pitch.
    In this analysis, the fluid domain was discretized and the
    flow equations were solved by numerical method. The domain
    was extracted for fluid flow and the solid body (rotor) was Figure 2. Unstructured mesh in the fluid domain
    kept as a hollow helical cylinder. The unstructured mesh was
    generated in the meshing software ANSYS-ICEM CFD. The

    2 Copyright © 2016 by ASME

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