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EXPERIMENTAL AND COMPUTATIONAL FLUID DYNAMICS (CFD)

INVESTIGATION OF A SINGLE-SHROUDED CENTRIFUGAL PUMP

Technical Report · April 2019

DOI: 10.13140/RG.2.2.19571.81446

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EXPERIMENTAL AND COMPUTATIONAL FLUID DYNAMICS
(CFD) INVESTIGATION OF A SINGLE-SHROUDED
CENTRIFUGAL PUMP

BY

BABATUNDE TAIWO AMOS

MATRIC NO.: 20130838

SUBMITTED TO

THE DEPARTMENT OF MECHANICAL ENGINEERING

FEDERAL UNIVERSITY OF AGRICULTURE, ABEOKUTA.

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE

AWARD OF BACHELOR OF ENGINEERING DEGREE

IN MECHANICAL ENGINEERING.

APRIL, 2019
 Table of Contents

Table of Contents ......................................................................................................................... i

List of Figures ............................................................................................................................ iv

List of Appendices ..................................................................................................................... vi

List of Tables............................................................................................................................. vii

Nomenclature ........................................................................................................................... viii

Declaration ................................................................................................................................. xi

Certification ............................................................................................................................... xii

Dedication ................................................................................................................................ xiii

Acknowledgement .................................................................................................................... xiv

Abstract ..................................................................................................................................... xv

1. INTRODUCTION ................................................................................................................... 1

1.1 Background study ............................................................................................................. 1

1.2 Computational Fluid Dynamics (CFD) ............................................................................ 2

1.3 Scope Of Study................................................................................................................. 4

1.4 Problem Statement ........................................................................................................... 5

1.5 Aim and Objectives of Study ........................................................................................... 5

1.6 Justification ...................................................................................................................... 6

2. LITERATURE REVIEW ........................................................................................................ 7

2.1 Overview .......................................................................................................................... 7

i
 2.2 What Are Turbo Machines? .................................................................................................. 7

2.2.1 What Is a Pump? .............................................................................................................. 7

2.2.2 Rotodynamic Pump .......................................................................................................... 8

2.2.3 Centrifugal Pumps ............................................................................................................ 8

2.3 Review on Design of Centrifugal pump ......................................................................... 13

2.4 Review on the design of impeller and volute ................................................................. 14

2.5 Review on CFD analysis of centrifugal pump ............................................................... 15

2.6 Cavitation ....................................................................................................................... 16

2.7 Pump Performance Curves ............................................................................................. 18

2.8 Pump Efficiencies .......................................................................................................... 19

2.9 Shaft, Bearings and Seals ............................................................................................... 20

3. MATERIALS AND METHODOLOGY............................................................................... 22

3.1 Materials ......................................................................................................................... 22

3.2 Methodology .................................................................................................................. 22

3.2.1 Assumptions Used in the Design ..................................................................................... 22

3.2.2 Theoretical Background Information about Centrifugal Pumps and Computational Fluid

Dynamics ................................................................................................................................... 23

3.2.3 Design Calculations........................................................................................................ 28

3.2.4 Flow Parameters ............................................................................................................. 31

3.3 Methodology for Computational Fluid Dynamics ......................................................... 32

ii
4. RESULTS AND CONCLUSION ......................................................................................... 35

4.1 Results from Theoretical Calculations ........................................................................... 35

4.2 Results from Simulation ................................................................................................. 36

4.3 Results from Experimental Test ..................................................................................... 48

5. CONCLUSION AND RECOMMENDATION .................................................................... 52

5.1 Conclusion...................................................................................................................... 52

5.2 Recommendation ............................................................................................................ 53

REFERENCES .......................................................................................................................... 54

APPENDIX ............................................................................................................................... 56

iii
 List of Figures

Figure 1: (a) front view of the volute and impeller (b) side view of the volute and impeller ........ 9

Figure 2: The closed impeller (Grundfos Research and Technology) .......................................... 11

Figure 3: The Semi-opened or Single Shrouded Impeller [www.alibaba.com] ........................... 12

Figure 4: A volute Casing [www.indiamart.com] ........................................................................ 13

Figure 5: Regions of cavitation in an impeller (Grundfos, 2011) ............................................ 17

Figure 6: Pump Characteristic Sheet (Gould pumps – model 3196) ............................................ 18

Figure 7: Geometry of the Impeller .............................................................................................. 23

Figure 8: The velocity diagram showing (a) cut-off section of the impeller with both inlet and

outlet triangles (b) the inlet triangle (c) the outlet triangle. (Jyh-Cherng Shieh) .......................... 24

Figure 9: Ansys design model for volute casing ........................................................................... 33

Figure 10: Ansys blade gen for impeller model............................................................................ 34

Figure 11: Isometric 3D View of the Blade, Hub and Shroud...................................................... 34

Figure 12: Mesh result from Turbo grid ....................................................................................... 37

Figure 13 : Mesh Elements at 50% Span and Meridional View of the Blade, Hub and Shroud .. 43

Figure 14: Velocity Vectors at 50% Span..................................................................................... 44

Figure 15: Velocity Streamlines at Blade TE ............................................................................... 44

Figure 16: Blade Loading Curves at 20% And 80%..................................................................... 45

Figure 17: Streamwise Plots ......................................................................................................... 45

Figure 18: Efficiency Plot/ Performance Curves .......................................................................... 46

Figure 19: Graph of Momentum and Mass ................................................................................... 46

Figure 20: Turbulence Graph ........................................................................................................ 47

Figure 21: Head Graph.................................................................................................................. 47

iv
Figure 22: Coupling of parts to the motor .................................................................................... 50

Figure 23: Experimental setup for pump ...................................................................................... 50

Figure 24: Setup rig ...................................................................................................................... 51

v
 List of Appendices

Appendix 1: Meshed Zone Of Impeller ........................................................................................ 57

Appendix 2: Solution reports for Pressure distribution and velocity contour .............................. 57

Appendix 3: Turbo grid of CFX ................................................................................................... 58

Appendix 4: Impeller .................................................................................................................... 58

Appendix 5: The volute pattern .................................................................................................... 59

Appendix 6: Sand pore for volute ................................................................................................. 59

Appendix 7: impeller side view .................................................................................................... 60

Appendix 8: Volute casing before machining .............................................................................. 60

Appendix 9: The impeller, volute and volute cover before machining ........................................ 61

Appendix 10: The volute and cover after machining.................................................................... 61

Appendix 11: The impeller in the volute ...................................................................................... 62

Appendix 12: Machined impeller and volute outlet ..................................................................... 62

Appendix 13: Ansys flow chart for the simulation ....................................................................... 63

vi
 List of Tables

Table 1: Calculated Values from Theoretical Knowledge ............................................................ 35

Table 2: Mesh Report for CFX ..................................................................................................... 37

Table 3: Mesh Statistics for CFX................................................................................................. 37

Table 4: Domain Physics for CFX ............................................................................................... 38

Table 5: Boundary Physics for CFX ............................................................................................. 40

Table 6: Boundary Flows for CFX .............................................................................................. 41

Table 7: Performance Results ...................................................................................................... 42

Table 8: Summary Data ................................................................................................................ 42

vii
 Nomenclature

B - Width of Impeller

CFD - Computational Fluid Dynamics

CPD - Centrifugal Pump Design

DNS - Direct Numerical Simulation

Do - Eye diameter (mm)

D1 - Inlet Diameter (mm)

D2 - Outlet Diameter (mm)

g - Acceleration due to Gravity (m/s2)

hs - Suction Head (m)

hd - Delivery head (m)

H/Hmano - Manometric Head (m)

He - Euler Head (m)

Hs - Static Head (m)

Kf - Flow ratio

Ku - Speed Ratio

LES - Large-Eddy Simulation

N - Speed of Electric Motor (r.p.m.)

Ns - Specific Speed (r.p.m)

viii
Nmin - Minimum Starting Speed (r.p.m.)

NPSHA - Net Positive Suction Head Available (m)

NPSHR - Net Positive Suction Head Required (m)

Pi - Power input (KW)

Po - Power output (KW)

Q - Volumetric flow rate (m3/s)

R - Radius of circular arc of vanes

RANS - Reynolds Averaged Navier-Stokes

Re - Reynolds number

T - Torque Transmitted (Nm)

U - Peripheral Speed (m/s)

V - Absolute velocity at inlet (m/s)

Vf - Flow component of velocity (m/s)

Vw - Whirl component of velocity (m/s)

t - Vane thickness (mm)

ts - Shroud thickness (mm)

Z - Number of Vanes

Greek Symbols

ix
α - Inlet Angle (degree)

β - Blade Angle (degree)

η - Efficiency (%)

ε - Energy Dissipation

κ - Turbulent Kinetic Energy

μ - Dynamic Viscosity (Pa.S)

- Head Coefficient

- Specific Weight

ρ - Density (kg/m3)

π - 3.142l

x
 Declaration

I declare that this project on “Design, CFD analysis and testing of a single shrouded Centrifugal

Pump” is an original work done by BABATUNDE TAIWO AMOS, under the supervision of

PROF. M.A. WAHEED, department of Mechanical Engineering, Federal University of

Agriculture Abeokuta.

………………………………………………… …………………………….

Babatunde Taiwo Amos Date

xi
 Certification

This is to certify that BABATUNDE TAIWO AMOS with matriculation number 2013083 of the

Department of Mechanical Engineering, the College of Engineering, Federal University of

Agriculture, Abeokuta, Ogun State, Nigeria has satisfied the requirement of achieving a Bachelor’s

degree in engineering at the above named university.

……………………………….. ..…………..…………..

Prof. M. A. Waheed Date

Supervisor

………………………………….. ………………………..

Dr. S. I. Kuye Date

H.O.D, MCE

…………………………………. …………………………..

Prof O. J. Alamu Date

External supervisor

xii
 Dedication

This research work is dedicated to God almighty, my creator, saviour and Lord. And also

to the 2017/18 set of Mechanical Engineering graduates of the Federal university of Agriculture,

Abeokuta (FUNAAB). The ones we started this journey together and are bringing it to a halt

together in a few more days.

xiii
 Acknowledgement

The completion of this project could not have been possible without the contributions of the people

I know, knew and met whether directly or indirectly before and during my stay in FUNAAB. I

would love to sincerely appreciate and thank them for all of their supports. However, I would like

to express deep appreciation and indebtedness particularly to the following set of people.

First and foremost, I would love to appreciate my supervisor, Prof. M. A. Waheed, whose counsel

led to the success of this undertaking and for his fatherly advice. Sir, I really appreciate your kind

and understanding nature. I would not have been able to achieve this work without your fatherly

support. May God continuously increase you in all ways of life sir. I will also like to extend my

deep indebtedness to all academic and non-academic staffs of the Mechanical Engineering

Department, Federal University of Agriculture, Abeokuta.

I also want to appreciate my head of class (HOC), Soladoye Olaoluwa, Lateef Qudus and my very

good friend, Ofordu Harrison for their supports financially and being accommodating whenever

the needs arises, you guys have made my stay in FUNAAB a very memorable one. Also, my

friends in Electrical and electronics department and Ogunyanwo Temiloluwa, I appreciate you all.

I term them as friends as family.

To my 100L and 200L close colleagues, Bukoye and Emaye Emmanuel, I appreciate the two of

you for assisting me every time I need your help. My roommates, Ogundairo Abayomi and

Oyeleke Ayomide; I thank you guys for accommodating me. Finally, to Akinola Evangeline and

the rest of my friends, I thank you all for always believing in me.

Above all to God, the Great Almighty, the author of knowledge and wisdom, for his countless love

and supplying all my needs and guarding my steps.

xiv
 Abstract

This paper includes the design, CFD analysis and testing of a centrifugal pump. The results were

compared and the values from each result was made for design parameters of head of 10m,

0.0053m3/s, speed of 2000 r.p.m.

From theoretical results, it can be noticed that the design head which is 10m falls within the range

of the Euler head (12.93m) which is the theoretical head. Also, the minimum starting speed for the

impeller to be effective falls between the already designed speed for a 1 horse power electric motor

and the designed required motor power is 0.743KW (approximately 1HP).

The purpose of the simulation is to observe and determine the pattern of velocity profile and

pressure distribution by using CFD simulation program after the 3D design and modelling of the

pump is made using Vista CPD. Basically, this paper revolves around the idea of investigating the

effect and distribution of velocity profile and pressure within a pump having the specifications

given above in the first paragraph. The standard k- ε turbulence model was chosen for turbulence

model. From the simulation results it was observed that the pressure increases gradually from

impeller inlet to outlet. The static pressure on pressure side is evidently larger than that on suction

side at the same impeller radius. In addition to this, it was observed that, the velocity increases

from impeller inlet until it enters the volute casing. It then drops to a minimum value at outlet

region. The table 7 for the simulation result gives a summary of the performance results for the

pump impeller. The second table lists the mass or area averaged solution variables and derived

quantities computed at the inlet, leading edge (LE Cut), trailing edge (TE Cut) and outlet locations.

The flow angles Alpha and Beta are relative to the meridional plane; a positive angle implies that

the tangential velocity is the same direction as the machine rotation. From the performance and

xv
summary tables below, it can be noted that the required motor power from the simulation is also

0.734 KW which is the same as the calculated value.

Conclusively, the pump was designed, simulated, fabricated and tested and each result from the

procedures corresponded. The total cost for the fabrication was estimated to be 60,000 naira for

just a single unit. If this pump was to be produced in mass, cost of production will be minimal

because the patterns required to make the volute and the impeller have already been made (this in

turns reduces the cost of production).

xvi
 CHAPTER ONE

1. INTRODUCTION

1.1 Background study

When building factories and residential housing, the problem of providing or transferring

fluids (water, air, sewages, etc.) from a reservoir to a needed location from other sources (such

wells, streams, atmosphere, etc.) is highly important. The creation of complicated machinery and

engines has been phenomenal ever since the industrial revolution (1760–1040), which was sparked

by Isaac Newton's Newtonian physics/classical mechanics and James Watt's work on engines.

Although some claim that the Egyptians invented the pump approximately 2,000 BC (the Shadoof,

a bucket and rope used to draw water from a well), in 250 BC, Archimedes created the

Archimedean screw, a device that used a large screw to lift water [Wikipedia.com]. Evans, Joe

The centrifugal pump first appeared in the United States in the early 1000s after developing in

Europe in the late 1600s. The centrifugal pump has evolved into the preferred pump for many

applications since the 1940s.

The development of turbo machines in the late 1080s effectively addressed this issue (in

particular, the pumps). Our world has been impacted by pumps in numerous ways. Without pumps,

we would still need to collect our water from the rain or travel long distances to rivers or streams.

Since the invention of pumps, people have been able to dwell on enormous tracts of land that were

previously inhospitable and devoid of any obvious sources of water, moving away from their

traditional locations near rivers, lakes, and springs. Pumps are now indispensable to the modern

way of life because of their increasing utility. Pumps play a significant role in our daily lives.

Pumps are mostly used in household water supply systems from wells and private

boreholes to deliver water to various areas, for irrigation, to reservoirs for firefighting, and for use

1
in residential residences, hospitals, and offices. Pumps facilitate the mitigation of flooding damage

and assist save time and energy.

1.2 Computational Fluid Dynamics (CFD)

According to Miloslav (2006), problems of fluid dynamics play an important role in many

areas of science and technology examples are, airplane industry, mechanical engineering, turbo

machinery, etc.

The image of the flow can be obtained with the aid of

➢ Experiments (e.g. in wind tunnels), which are expensive and lengthy, and most times not a

feasible method,

➢ Mathematical models and their realization with the use of numerical methods on modern

computers. The numerical simulation of flow problems constitutes Computational Fluid

Dynamics (CFD). Its goal is to obtain results comparable with measurements and to replace

expensive and lengthy experiments.

The history of computational fluid dynamics (CFD) began in the early 1970s, according to Blazek

(2001). When used to simulate fluid flows, it soon became an abbreviation for a combination of

physics, numerical mathematics, and, to some extent, computer sciences. The introduction of CFD

was sparked by the development of ever-more-powerful mainframes, and CFD development is

still closely tied to the advancement of computer technology. The simulation of transonic flows

based on the solution of the non-linear potential equation was one of the early uses of the CFD

methodology. Beginning in the 1980s, it was possible to solve Euler equations in both two and

three dimensions (2-D and 3D, respectively). CFD techniques are now often used in the design of

cars, ships, aircraft, and turbomachinery. In addition, CFD is used in astronomy, oceanography,

2
architecture, oil recovery, and meteorology. The Maxwell equations are solved using numerous

numerical methods created for CFD.

In the field of computational fluid dynamics, which is a subfield of fluid mechanics, issues

involving fluid flows are solved and analyzed using numerical analysis and data structures.

Because it defines a large number of single-phase fluid flows, including liquid and gas, the Navier-

Stokes equations serve as the foundation for all CFD issues. Software that enhances the precision

and speed of complicated simulation scenarios, such as transonic or turbulent flows, is the result

of continuous research, according to Mahender et al. (2015).

CFD has been a crucial technique in the design of centrifugal pumps for analyzing fluid

flows around the impeller. The performance of impellers for centrifugal pumps with the same

outlet diameter but varied blade counts was assessed by Chakraborty et al. (2011) using CFD. Both

the traditional k-model and the modified k-model were used in the cavitation investigation.

Researchers have used computational fluid dynamics to make a variety of improvements to

centrifugal pumps, including cavitation analysis and efficiency forecasting. To provide precise

numerical findings, the analysis is conducted using a variety of turbulence models in CFD. CFD

has been quite helpful in the design of diffusers for pumps as well. Reneau et al. discovered that

the intake circumstances have a significant impact on the performance of 2D diffusers, while Goto

and Zangeneh (2010) introduced a novel way for improving a pump diffuser based on a three-

dimensional inverse design method by utilizing CFD.

CFD simulation, which also provides helpful information about the centrifugal pump,

allows one to observe the flow conditions inside a centrifugal pump. A centrifugal pump's

performance can be anticipated using simulation, which lessens or does away with the necessity

3
for testing during the design of the pump. CFD makes it easier to critically examine the turbulent,

three-dimensional, extremely complicated flow of the pump.

Labor will be saved as a result of the CFD study, and it also hastens the design cycle.

Different types of pumps are currently designed hydrodynamically using CFD analysis. The fluid

flow in a machine can be accurately predicted by numerical simulations, which makes it possible

to evaluate a design's performance in detail. Software such as AnsysFluent, ProLB, OpenFOAM,

SimiFlow CFD, Autodesk CFD, Symscape, Applied Flow Technology (AFT), Intelligent Light,

etc. can be used to perform CFD analysis. Ansys Fluent is the program utilized in this research

project to analyze the flow around the impeller. The following turbulence models are employed in

CFD, according to Bengte et al. (2012): Direct Numerical Simulation (DNS), Large Eddy

Simulation (LES), Standard -, Standard -, Spalart-Allmaras model, and Zero-equation model.

1.3 Scope Of Study

The research work in this report focuses mainly on the design and fabrication of single shrouded

(semi-opened) impeller type centrifugal pump and numerical analysis of flow around the impeller

using technique of computational fluid dynamics. Igor (2001) noted that in designing centrifugal

pumps, engineers strive to develop specific internal geometry that will produce head and flow with

low energy loss. Each pump is designed for a specific head versus flow rate for the given impeller

speed. This is done by;

➢ Assuming a suitable value for total head, discharge and speed of motor.

➢ Modeling the 3D and 2D geometry of the impeller using Ansys Vista CPD.

➢ Modeling the geometry of the volute casing using Ansys Vista CPD.

➢ Carry out flow analysis around the impeller by CFD using Ansys Fluent.

4
 ➢ Carry out a comprehensive test to check for flow rate and velocity of fluid as the pump is in

operation.

The CFD analysis of the impeller involves solving all flow governing equations such as the 3D

Navier-Stokes equations, continuity equation and Cauchy or momentum equation.

1.4 Problem Statement

The design and production of pumps has been a thing which is not taken so serious in Nigeria

due to design constraint and limited research interest. Pumps have been mainly imported into

Nigeria at very high price which is considerably a disadvantage to the citizens of the country. To

cap it all, the pump is a very crucial machinery used in industries in moving different kinds of fluid

and all these industries import the pumps.

1.5 Aim and Objectives of Study

The aim of this project is to design and fabricate a working centrifugal pumping machine and

also to model the semi-opened impeller used in the fabrication using Ansys fluent.

The specific objectives of this project are:

• To fabricate a working pumping machine

• To carry out CFD simulation of the centrifugal pump with its casing and impeller inside

using the sliding mesh method to rotate the impeller inside to see the effect of the fluid

entering the casing.

• To compare the calculated values calculated using Euler theorem for pumps and values

from CFD.

• To carry out flow test on the fabricated pump and then compare with theoretical values and

CFD values.

5
 1.6 Justification

The need for a more efficient and less costly pump has been of great concern to thermo-

fluid engineers. Several models and analysis has been carried out on different kind of pumps in

order to find a better means of fluid transportation. Diving into this kind of project can help

increase the country’s economy by reducing costs in importing them. This project is entailed with

basic design analysis that will yield a more effective and less costly design of centrifugal pumps

for supply of liquid (water) to houses or farms.

6
 CHAPTER TWO

2. LITERATURE REVIEW
2.1 Overview

A detailed review of the literature on the improvement in design of an impeller,

construction of a pump and CFD analysis of the impeller and pump is presented as follows. Also,

the basic description of the centrifugal pump will be reviewed.

2.2 What Are Turbo Machines?

Energy is transferred between a rotor and a fluid by turbo machines. Steam turbines, gas

turbines, turbo-compressors, water turbines, pumps, and other similar devices are examples of

turbo machines. A rotor with blades around its circumference, commonly referred to as the

impeller, is their primary characteristic. A force between the working fluid and the blades converts

energy.

A compressor transfers energy from a rotor to a fluid, whereas a turbine transfers energy

from a fluid to a rotor. Euler's pump and turbine equation for compressible fluids and Newton's

second rule of motion regulate these two fundamental subcategories of turbo machines.

2.2.1 What Is a Pump?

A mechanical device known as a pump gives a fluid in a fluid system energy. By

transforming the mechanical energy to transfer the fluid to an elevated height, it helps to improve

the fluid's pressure energy, kinetic energy, or both. From a hydrodynamic perspective, the turbine

has flow from the high-pressure side to the low-pressure side, whereas the pump transports fluids

from a low-pressure side to a high pressure side. Positive displacement pumps and rotodynamic

pumps are two different types of pumps.

7
Principle of operation

When the pump is running, there is a rise in fluid pressure from the pump's inlet to its exit.

The fluid is forced through the system or plant by the pressure differential. By transferring

mechanical energy from the motor to the fluid through the rotating impeller, the centrifugal pump

raises pressure. From the inlet, fluid travels along the impeller's blades to the impeller's center and

then out. As a result of the centrifugal force, the fluid moves more quickly, and the kinetic energy

is converted to pressure (Grundfos, 2011).

2.2.2 Rotodynamic Pump

The rotodynamic pump is a type of pump which increases energy level due to combination

of centrifugal energy, pressure energy, and kinetic energy. It is classified into:

• Axial flow pumps: Energy transfer occurs when the flow is in its axial direction.

• Mixed flow pump: Energy transfer occurs when the flow comprises radial as well as axial

components.

• Radial flow pumps: energy transfer occurs mainly when the flow is in its radial path. It

is commonly called centrifugal pumps (which is the main concentration of this report).

2.2.3 Centrifugal Pumps

A centrifugal pump is a rotodynamic pump that uses a rotating impeller to increase the pressure of

a fluid; the fluid enters the pump near the rotating axis streaming into the rotating impeller. Paul

(2001) noted that all impeller pumps are rotodynamic, including those with radial-flow, mixed-

flow, and axial-flow impellers: the term “centrifugal pump” tends to encompass all rotodynamic

pumps.

Centrifugal pumps are designed using the Bernoulli equation and the Euler pump equation given

as;

8
 𝑣1 2 𝑃1 𝑣2 2 𝑃2
𝑍1 + + = 𝑍2 + +
2𝑔 𝜌𝑔 2𝑔 𝜌𝑔

(𝑉𝑤2 𝑈2 − 𝑉𝑤1 𝑈1 )
𝐰𝐨𝐫𝐤𝐝𝐨𝐧𝐞 𝐩𝐞𝐫 𝐬𝐞𝐜𝐨𝐧𝐝 𝐩𝐞𝐫 𝐮𝐧𝐢𝐭 𝐰𝐞𝐢𝐠𝐡𝐭 =
𝑔

Figure 1: (a) front view of the volute and impeller (b) side view of the volute and impeller

R.K Rajput (2011) classified centrifugal pumps on the basis of characteristics features;

1. Types of casing:

i. Volute pumps

ii. Turbine or diffusion pump

iii. Vortex casing

2. Working head:

i. Low lift centrifugal pumps: they work against heads up to 15m

ii. Medium lift centrifugal pumps: used to build up heads as high as 40m

iii. High lift centrifugal pumps: used to deliver liquids at heads above 40m

9
 3. Number of impellers per shaft:

i. Single stage: uses one impeller

ii. Multi-stage: uses two or more impellers

4. Number of entrances to the impeller:

i. Single entry or single suction pump

ii. Double entry or suction pump

5. Impeller type:

i. Closed or shrouded impeller

ii. Open impeller

iii. Semi-open or single shrouded impeller

The main parts of the centrifugal pump are;

1. Impeller

2. Casing

3. Suction pipe

4. Delivery pipe

5. Shaft and electric motor

1) Impeller: A wheel (or rotor) having a set of backward-curving vanes is known as an

impeller (or blades). The shaft on which it is placed is often linked to an electric motor.

The impeller is a crucial component of centrifugal pumps; its design and diameter

determine how well the pump works. According to Houlin et al. (2010), the blade number

of the impeller is a significant design factor for pumps that has a significant impact on

their features. The following types of impellers are available:

10
 i. Shrouded or closed impeller: The vanes in this kind of impeller have metal cover plates

or shrouds on both sides. It is highly efficient and offers the liquid superior guiding. It is

used when the liquid that needs to be pushed is clean and largely debris-free.

• Tangential direction

• Radial direction

• Axial direction

Figure 2: The closed impeller (Grundfos Research and Technology)

ii. Open impeller: The vanes are open on both sides since they lack a base plate and neither

a crown plate. Pumping liquids with suspended solid matter requires the employment of

such impellers (e.g., sewage, paper pulp etc.).

iii. Semi-open or single shrouded impeller: A semi-open impeller has vanes that only have

the base plate attached to them, not the crown plate. Even if the liquid has some debris in

it, this impeller can still be used. Due to the fact that there is only one shroud, it often runs

11
 more efficiently than an equivalent enclosed one. Semi-open impellers have the benefit

over open ones in that the axial orientation of the impellers can be changed to account for

wear.

Figure 3: The Semi-opened or Single Shrouded Impeller [www.alibaba.com]

2) Casing: The fluid emerging from the impeller is conducted to the pump discharge port or entry

to another stage by the collecting configuration, which can employ one or more of the

following elements in combination:

➢ Volutes, which can be used for designs of all specific speeds.

➢ Diffuser or stator vanes, which are often more economical of space in high-specific-speed

single-stage pumps and in multistage pumps, and for the latter.

Generally, the most efficient impeller has a steady internal relative flow field as it rotates

in proximity to these configurations. This is assured by all of these elements because they are

designed to maintain uniform static pressure around the impeller periphery. For this project, the

volute casing is used for collection of fluid.

12
Figure 4: A volute Casing [www.indiamart.com]
2.3 Review on Design of Centrifugal pump

The design and performance analysis of the centrifugal pump were described in Khin Choet

al. (2008) research. They were able to conclude from their design that input characteristics

including supply head, discharge, power, and speed of the electric motor are taken into account

while designing centrifugal pumps. After the design phase of the project was complete, a

performance analysis was conducted. This analysis included shock losses, impeller friction losses,

volute friction losses, disk friction losses, recirculation losses, and actual head losses. Graphs were

created for each loss. Theoretical head, slip, shock losses, recirculation losses, etc. parameters were

computed by adjusting volume flow rate to determine characteristic curves of centrifugal pumps.

Mohammed (2013) used the fundamental theories of turbomachines to carry out a one-

dimensional flow process for an analytical investigation of centrifugal pump performance. In order

to determine pump performance parameters for various discharge coefficients, the Euler equation

and the energy equation were modified. Estimates were made for the volute loss and fluid slippage

13
loss at impeller exit. By using Wiesner's empirical equation and the slip factor technique, the fluid

slippage is modeled. The volute loss model accounts for friction loss related to the velocity of the

volute throw, diffusion friction loss resulting from circulation related to the volute flow, loss due

to the disappearance of radial flow at the volute outlet, and loss within the pump volute throat.

Appropriate models take into account models for impeller hydraulic friction power loss, disk

friction power loss, internal flow leakage power loss, and inlet shock circulation power loss.

A single stage centrifugal pump was designed, built, and tested by Imhadeet et al. in 2017.

The test revealed that the built-in single-stage centrifugal pump can generate a head of around 30m

as opposed to the predicted 27m; this was an increase of roughly 3m above the planned head H. A

9m3/hr volumetric discharge was also attained. However, it was noted that if the intended pump

were tested at the design speed and power with all relevant parameters prepared by direct

measurement, it would perform better. The pump's performance was noted to be extremely smooth,

with no vibration and noise coming from the motor and pump, respectively. This ensured the

pump's dependability while in use.

2.4 Review on the design of impeller and volute

Shuweiet.al (2016) carried out a research on the effect of impeller inlet geometry on cavitation

performance of centrifugal pumps based on radial basis function. The research carried out was

able to make them have the following conclusions;

a) That it was crucial to consider while constructing a pump the impact of various blade leading

edge shapes on cavitation. The blade along the shroud had transferred energy into the fluid

before it entered the impeller. As a result, the cavitation performance increased and the flow

state at the impeller entry was enhanced. The cavitation performance of a centrifugal pump is

slightly influenced by the position of the blade leading edge along the hub. The cavitation

14
 performance can be marginally improved by using the proper FS angle along the hub, but when

the FS angle was large, the entry was severely blocked and the cavitation performance was

decreased.

b) The blades stress distribution can be used to assess cavitation performance. Higher suction side

pressure and greater cavitation performance were related to decreased blade load near the inlet.

c) Because of the vortex that emerges from the impeller, the falling-off and collapsing of the

bubbles, and the decreased cavitation performance, the blade passing frequency and second

harmonics of the blade passing frequency in the volute are more extreme. The intensity of the

pressure pulsation can be used to determine the cavitation's status. The FS blade along the

shroud had lower pressure pulsation amplitude and vorticity strength than other blade samples,

which improved cavitation performance.

d) The Radial Basis Function-based cavitation performance response model was developed,

allowing for the precise prediction of the impact of the shape of the blade leading edge on the

cavitation performance of centrifugal pumps.

2.5 Review on CFD analysis of centrifugal pump

Mohammed et al. (2010) used the CFD code ANSYS CFX to numerically analyze the flow

through the blade passage in order to look for the development of cavitation in centrifugal pumps.

The head stayed steady as NPSH declined, and at the critical point, the head will rapidly shrink

(they were able to create a head drop curve with a knee shape).

A generic three-dimensional simulation of turbulent fluid flow was developed by

Jafarzadeh et al. (2011) to forecast the velocity and pressure fields for a centrifugal pump.

Research on the impact of the number of blades on the efficiency of pumps using head coefficient

as the selection criterion revealed that the impeller with 7 blades has the highest head coefficient

15
when compared to 5 and 6 blade pumps at all ranges. Additionally, they found that the separation's

beginning is significantly influenced by the blades' relationship to the volute's tongue.

Salem (2013) provided details on the experimental work carried out to use acoustic signals

to detect centrifugal pump cavitation. Analyses of head, efficiency, and flow rate are represented

visually with the signal amplitude.

Pande et al. (2015) predicted the velocity and pressure fields for a centrifugal pump using

a general three-dimensional simulation of turbulent fluid flow. The governing equations of the

flow field were solved using CFD. In order to investigate the pump cavitation at the pressure drop

zone on the blade, this study proposed a finite volume approach. It was quickly discovered that

there was a sizable increase in residuals and that the absolute pressure is low enough to cause

cavitation.

Using numerical simulation techniques, Alex et al. (2016) investigated the impacts of the

centrifugal pumps blade number, inlet pressure, and exit pressure. They were able to come to the

conclusion that while there is an optimal blade number for the model pump to be 7 and 5 blades,

the head required for the pump is quite large for seven impeller blades, and that the change

regulations of efficiency and NPSHR are complex, that there is an optimal value for the best

efficiency and cavitation characteristics.

2.6 Cavitation

Cavitation, according to Grundfos (2011), is the formation of vapor bubbles in regions

when the local pressure decreases to the fluid vapor pressure. The amount of cavitation is a

function of the pump's internal pressure. Cavitation typically results in a lowered head, loudness,

and vibration. Cavitation first develops at the pump's low-pressure region, which is typically the

blade edge at the impeller input. In the construction of centrifugal pumps, cavitation must be

16
avoided because it is a very destructive phenomenon. It will cause hydraulic machinery to work

less effectively and cause vibration, noise, corrosion, and damage to the flow passage components

(impeller and casing). Mohammed (2010) conducted study on cavitation and found that the phrase

refers to a dynamic process that involves bubbles forming inside the liquid, growing, and then

collapsing as the liquid runs through the pump. The two types of bubbles that often occur inside

the liquid are:

a) Vapor bubbles: These are formed due to the vaporization of a process liquid that is being

pumped. The cavitation condition induced by formation and collapse of vapor bubbles is

commonly referred to as Vaporous Cavitation.

b) Gas bubbles: These are formed due to the presence of dissolved gases in the liquid that

is being pumped (generally air but may be any gas in the system). The cavitation condition

induced by the formation and collapse of gas bubbles is commonly referred to as Gaseous

Cavitation

Figure 5: Regions of cavitation in an impeller (Grundfos, 2011)

17
2.7 Pump Performance Curves

The pump performance curves show the performance of a pump by showing pump head, power,

efficiency and NPSHR plotted over flow rate at a given speed in RPM.

: Pump Performance Curve (Binamaet al.2016 pp.52)

Figure 6: Pump Characteristic Sheet (Gould pumps – model 3196)

18
2.8 Pump Efficiencies

1. Hydraulic efficiency: This is the ratio of the head developed (manometric head) by the pump

to the head delivered to the liquid. Mathematically,

𝐻
𝜂ℎ = 𝐻+𝐻
𝑙

0.12𝑉2 2
Where 𝐻𝑙 = ℎ𝑒𝑎𝑑 𝑙𝑜𝑠𝑠 = 2𝑔

2. Manometric efficiency: This is the ratio of manometric head to Euler head. Mathematically,

𝐻𝑚𝑎𝑛𝑜
𝜂𝑚𝑎𝑛𝑜 =
𝐻𝑒

𝑉𝑤2 × 𝑈2
𝐻𝑒 = 𝐸𝑢𝑙𝑒𝑟 ℎ𝑒𝑎𝑑 =
𝑔

3. Volumetric efficiency: This is the ratio of liquid discharge per second from pump (Q) to

quantity of liquid passing per second through impeller.

𝑄
𝜂𝑣𝑜𝑙 =
𝑄+𝑞

Where q = leakage (but assuming no leakage) = 0

Therefore, volumetric efficiency = 100%

4. Mechanical efficiency: this is given by the expression;

𝜔𝑄(𝑉𝑤2 × 𝑈2 )
𝜂𝑚𝑒𝑐ℎ =
𝑃𝑖 × 𝑔

𝑔𝐻𝑄
5. Overall efficiency:𝜂𝑜 = 𝜂𝑚𝑎𝑛𝑜 × 𝜂𝑣𝑜𝑙 × 𝜂𝑚𝑒𝑐ℎ = 𝑃𝑖

19
6. Net Positive Suction Head (NPSH): Grundfos (2011) defined NPSH as a term describing

conditions related to cavitation, which is undesired and harmful.

The NPSH is classified into two, the Net Positive Suction Head Available (NPSHA) and

Net Positive Suction Head Required (NPSHR).

2.9 Shaft, Bearings and Seals

The centrifugal pump's fundamental and crucial components are the shafts, bearings, and seals. To

transmit, sustain, and enable efficient operation of the centrifugal pump, these three are

incorporated into the design of the centrifugal pump.

A spinning machine component known as a shaft transfers power from one location to another.

The shaft connects the impeller to the driving unit, which in a centrifugal pump is often an electric

motor but can also be a gas turbine. Shafts can be categorized based on;

a. Machine shafts: These shafts form an integral part of the machine itself. The crank shaft and

camshaft are examples of machine shaft.

b. Transmission shaft: These shafts transmit power between the source (usually an electric

motor) and the machines or elements absorbing power.

Shafts are known to be subjected to different stresses such as the bending stress and shear stress

(which is due to transmission of torque from the source). Considering only shear stress, the torque

transmitted from the source is given by;

𝑇 = 𝜏 × 𝜋 × 𝑑3

Where T = torque transmitted

𝜏 = 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡

d = diameter of the shaft.

20
 To support the shaft while transmitting power, there is a need for the use of bearing(s) to

support the shaft to reduce deflection and vibration.

Bearings: Bearing a machine element which permits rotational motion between surfaces in contact

while carrying load. Bearings are classified according to;

a. Direction of load carried: (i) Radial bearing, (ii) Thrust bearing

b. Nature of contact: (i) Sliding contact bearing, (ii) Rolling contact bearing

Basically, in the design of centrifugal pumps, Radial ball bearings (a type of bearing

which supports radial load and allows rolling contact) are used.

Mechanical Seals: Mechanical seals are materials fixed in a mechanical element to make them

air-tight. In centrifugal pumps, mechanical seals are used to protect the bearings against fluid and

prevent leakage, there are several seals fitted into the casing and impeller. Nowadays, rotary pumps

are equipped with mechanical seals. A mechanical seal consists of primary and secondary sealing.

In most cases the primary part, which is fitted to the casing, is made of a hard material like silicon

carbide or tungsten carbide.

21
 CHAPTER THREE

3. MATERIALS AND METHODOLOGY

3.1 Materials

The following materials are used in the construction of the centrifugal pump;

• Aluminum for impeller

• Aluminum for volute casing

• Mechanical seals

• Shafts and bearings will not be used in this design in other to reduce construction cost and

to maximize space.

The following are the software packages used in the design and simulation of the pump;

• Ansys Fluent for simulation

• Ansys Vista CPD

3.2 Methodology

All formulae used in the calculation are derived from the velocity triangle.

3.2.1 Assumptions Used in the Design

i. Liquid enters the impeller eye in radial direction.

ii. The whirl component of velocity (Vw1) at inlet is zero.

iii. The flow component of velocity (Vf1) at inlet equals absolute velocity at inlet (V1).

iv. No energy loss in the impeller due to friction and eddy formation.

v. No loss due to shock at entry.

vi. There is uniform velocity distribution in the narrow passages formed between two

adjacent vanes.

22
 vii. The liquid is incompressible

viii. The fluid is a Newtonian fluid

ix. The fluid’s physical and thermal properties are constant with temperature.

3.2.2 Theoretical Background Information about Centrifugal Pumps and Computational

Fluid Dynamics

Basic design terms and formulae

Figure 7: Geometry of the Impeller

23
Figure 8: The velocity diagram showing (a) cut-off section of the impeller with both inlet
and outlet triangles (b) the inlet triangle (c) the outlet triangle. (Jyh-Cherng Shieh)

• Suction Head (hs): It is the vertical height of the center line of the pump above the water

surface in the sump.

• Delivery Head (hd): It is the vertical height between the center line of the pump and water

surface in the tank to which water is delivered.

• Static head (Hs): Static head is the vertical distance between the liquid level in the sump

and the delivery tank. Mathematically, the static head is given by;

Hs = hs+hd

24
• Total dynamic head for a vertical pump with pumping element submerged, the total

𝑉𝑑 2
dynamic head is defined as; 𝐻 = 𝐻𝑑 + 𝐻𝑠 + 2𝑔

• Peripheral speed (U):[newregiston.co.jp] this is the speed that a point in the

circumference moves per second. It has component in both inlet and outlet of the impeller.
𝜋𝐷2 𝑁
Outlet peripheral speed,𝑈 = 60

𝜋𝐷1 𝑁
Inlet peripheral speed, 𝑈1 = 60

• Manometric head (Hmano): this is the head which the centrifugal pump has to work.

𝑈2 2 − 𝑈1 2
𝐻𝑚𝑎𝑛𝑜 =
2𝑔

• Diameter of pipe: this has both the suction and delivery pipe diameters.

4𝑄
Diameter of suction pipe, 𝑫𝒔 = √𝜋𝑉 where Vs is the suction velocity usually 1.5-3ms-
𝑠

4𝑄
Diameter of delivery pipe, 𝑫𝒅 = √𝜋𝑉 where Vd is the delivery velocity usually slightly
𝑑

≥ Vs

• Speed ratio (Ku): the speed ratio of peripheral speed at exit (U2) to the theoretical velocity

of jet corresponding to the manometric head (Hmano). It is given by the formula.𝑘𝑢 =

𝑈2
0.95 ≤ 𝐾𝑢 ≤ 1.25
√2𝑔𝐻𝑚𝑎𝑛𝑜

• Flow velocity (Vf):For this design, there are two flow velocities which are;
𝑄
Velocity of flow at inlet,𝑉𝑓1 = 𝜋𝐷
1𝐵1

25
 𝑄
Velocity of flow at outlet, 𝑉𝑓2 = .
𝜋𝐷2𝐵2

where B1 and B2 are width of impeller at inlet and outlet respectively.

• Flow ratio (Kf): this is the ratio of the velocity of flow at exit to the theoretical velocity of

the jet corresponding to manometric head (Hmano). It is given by the formula; 𝐾𝑓 =

𝑉𝑓2
Kf ranges from 0.1-0.25
√2𝑔𝐻𝑚𝑎𝑛𝑜

• Inlet angle (α): this is the angle in which the fluid enters into the volute casing. By

assumption(i), α= 90o

• Outlet blade angle (𝛽2): this is the angle in which the fluid leaves the volute. It is given

𝑉𝑓2
by; tan 𝛽2 = 𝑈
2 −𝑉𝑤2

• Inlet blade angle (𝛽1): this is the angle in which the fluid enter the vanes of the impeller.
𝑉𝑓1
It is given by; tan 𝛽1 = 𝑈1

• Absolute velocity (V): This can be defined as the common uniform linear velocity of the

various components of a physical system (the water in this case). For this design, there are

two absolute velocities which are;

V1 = absolute velocity of water at inlet=Vf1; according to assumption(iii)

V2 = absolute velocity of water at outlet

• Whirl component of velocity (Vw): this is the tangential (horizontal) component of

absolute velocity of jet, in the direction of the jet. For the design, the following are the

whirl component of the impeller;

Vw1 = whirl velocity at inlet; but according to assumption (ii), Vw1=0

𝑉
𝑓2
Vw2 = whirl velocity at outlet = 𝑈2 − 𝑡𝑎𝑛𝛷

26
 𝑊(𝑉𝑤2 𝑈2 −𝑉𝑤1 𝑈1 )
• Work done by the impeller on the liquid per second = 𝑔

• Euler momentum equation: work done per second per unit weight

(𝑉𝑤2 𝑈2 −𝑉𝑤1 𝑈1 )
= 𝑔

6.5(𝐷2 +𝐷1 )
• Number of vanes, using Pfleider’s equation, 𝒁 = [sin(𝛽1 + 𝛽2 )]
2(𝐷2 −𝐷1 )

Where β1 and β2 are inlet and outletblade angles respectively given by;

𝑉 𝑉𝑓2
➢ 𝛽1 = tan−1 𝑈1 . and 𝛽2 = tan−1 𝑈
1 2 −𝑉𝑤2

𝑉𝑓2
• Flow coefficient, 𝐶𝑓 = 𝑈2

𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 ℎ𝑒𝑎𝑑 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 𝑔×𝐻

• Head coefficient, ψ = ≡ 𝜂×𝑈 2 0.5 ≤ 𝜓 ≤ 0.6
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝐸𝑢𝑙𝑒𝑟 ′ 𝑠 ℎ𝑒𝑎𝑑 2

(𝑅2 )2 −(𝑅1 )2
• Radius of circular arc of impeller blade, 𝑅 = 2(𝑅2 cos 𝛽2 −𝑅1 cos 𝛽1 )

3.2.3 Flow Equations

• Bernoulli Equation

• Euler pump equation

• Navier-Stokes equations in x, y and z direction respectively are;

𝜕𝑢 𝜕𝑢 𝜕𝑢 𝜕𝑢 𝜕𝑃
𝜌[ +𝑢 +𝑣 +𝑤 ]=− + 𝜌𝑔𝑥 + 𝜇[∇2 𝑢]
𝜕𝑡 𝜕𝑥 𝜕𝑦 𝜕𝑧 𝜕𝑥

𝜕𝑣 𝜕𝑣 𝜕𝑣 𝜕𝑣 𝜕𝑃
𝜌[ +𝑢 +𝑣 +𝑤 ]=− + 𝜌𝑔𝑦 + 𝜇[∇2 𝑣]
𝜕𝑡 𝜕𝑥 𝜕𝑦 𝜕𝑧 𝜕𝑦

𝜕𝑤 𝜕𝑤 𝜕𝑤 𝜕𝑤 𝜕𝑃
𝜌[ +𝑢 +𝑣 +𝑤 ]=− + 𝜌𝑔𝑧 + 𝜇[∇2 𝑤]
𝜕𝑡 𝜕𝑥 𝜕𝑦 𝜕𝑧 𝜕𝑧

𝜕2 𝜕2 𝜕2
Where ∇2 = 𝜕𝑥 2 + 𝜕𝑦 2 + 𝜕𝑧 2

27
 • Continuity equation

𝜕𝑢 𝜕𝑣 𝜕𝑤
+ + =0
𝜕𝑥 𝜕𝑦 𝜕𝑧

• Cauchy or momentum equation

𝜕
[𝜌 𝑣⃗] + ∇[𝜌 𝑣⃗𝑣⃗] = ∇[𝜎𝑖𝑗 ] + 𝜌𝑔⃗
𝜕𝑡

𝜕 𝜕 𝜕
Where, ∇= 𝜕𝑥 + 𝜕𝑦 + 𝜕𝑧

𝜎𝑥𝑥 𝜎𝑦𝑥 𝜎𝑧𝑥

𝜎𝑖𝑗 = [𝜎𝑥𝑦 𝜎𝑦𝑦 𝜎𝑧𝑦 ]
𝜎𝑥𝑧 𝜎𝑦𝑧 𝜎𝑧𝑧

3.2.3 Design Calculations

Impeller Design

For the design of the centrifugal pump, a minimum head of10m is to be supplied at a discharge

rate, Q of 25m3/hr. and speed motor, N of 2000 r.p.m. The density of water is 1000 Kg/m3 and the

acceleration due to gravity, g is 9.81m/s2.

19
❖ Discharge, Q = 3600 𝑚3 /𝑠 = 0.0053 𝑚3 /𝑠

❖ Speed of motor (single phase), N = 2000 rpm

❖ Manometric head, H = 10m

❖ From performance curve, 𝜂𝑜 = 70%

❖ Density of fluid (water), ρ = 1000 kg/m3

❖ Dynamic viscosity of water, 𝜇 = 8.90 × 10−4 𝑃𝑎. 𝑠 𝑎𝑡 25𝑜 𝐶

❖ Acceleration due to gravity, g = 9.81m/s2

❖ Vane thickness, t = 5mm

28
 ❖ Shroud thickness, ts = 7mm
𝑄 1⁄
➢ Eye diameter, 𝐷𝑜 = 𝑘𝑜 (𝑁) 3 where ko is taken to be 4.5

0.0053 1⁄
𝐷𝑜 = 4.5( 2000 ) 3 = 0.062 𝑚 ≅ 62 𝑚𝑚

𝑄 1⁄
➢ Inlet diameter, 𝐷1 = 1.1 𝑘𝑜 (𝑁) 3

0.0053 1⁄
𝐷1 = 1.1 × 4.5 × ( ) 3 = 0.069 𝑚 ≅ 70 𝑚𝑚
2000
𝜋𝐷1 𝑁
➢ Inlet velocity, 𝑈1 =
60

𝜋×0.069×2000
𝑈1 = = 7.2m/s
60

4𝑄
➢ Absolute velocity at inlet, 𝑣1 = 𝜋 𝐷 2
1

4 × 0.0053
𝑣1 = ≅ 1.46 𝑚/𝑠
𝜋 0.0692

From velocity triangle,

𝑣
➢ Inlet angle at inlet, 𝛽1 = tan−1 𝑈1
1

1.46
𝛽1 = tan−1 ≅ 11.5°
7.2

➢ Radial velocity at inlet, 𝑣𝑟1 = √𝑣1 2 + 𝑈1 2

𝑣𝑟1 = √1.462 + 7.22 ≅ 7.35 𝑚/𝑠

𝑣𝑟1 = 𝑣𝑟2

➢ Let the head coefficient, CH = 0.6

Then Power output of the pump, 𝑃𝑜 = 𝑔𝐻𝑄 (𝑘𝑊)

𝑃𝑜 = 9.81 × 10 × 0.0053 ≅ 0.51993 𝑘𝑊

29
 𝑔𝐻
Then, outlet velocity, 𝑈2 2 =
𝜂𝑜 ×ψ

9.81 × 10
𝑈2 2 = = 192.35
0.7 × 0.6

𝑈2 = √192.35 ≅ 15.28 𝑚/𝑠

60𝑈
➢ Outlet diameter, 𝐷2 = 𝜋𝑁

60 × 15.28
𝐷2 = = 0.146 𝑚 ≅ 146 𝑚𝑚
𝜋 × 2000

𝑉𝑓2
➢ If 𝐾𝑓 = and taking Kf = 0.15
𝑈2

∴ 𝑡ℎ𝑒 𝑓𝑙𝑜𝑤 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑎𝑡 𝑜𝑢𝑙𝑒𝑡 𝑉𝑓2 = 𝑈2 × 𝐾𝑓 = 15.28 × 0.15 ≅ 2.292 𝑚/𝑠

➢ Whirl velocity at outlet,𝑉𝑤2 = 𝑈2 − √𝑉𝑟2 2 + 𝑉𝑓2 2

𝑉𝑤2 = 15.28 − √7.352 − 2.2922 ≅ 8.3 𝑚/𝑠

➢ Absolute velocity at outlet, 𝑉2 = √𝑉𝑤2 2 + 𝑉𝑓2 2

𝑉2 = √8.32 + 2.2922 ≅ 8.61 𝑚/𝑠

𝑉𝑓2
➢ Outlet blade angle, 𝛽2 = tan−1 𝑈
2 −𝑉𝑤2

2.292
𝛽2 = tan−1 ≅ 18.2°
15.28 − 8.3

6.5(𝐷2 +𝐷1 )
➢ Number of vane blades, 𝒁 = [sin(𝛽1 + 𝛽2 )]
2(𝐷2 −𝐷1 )

6.5(0.146 + 0.069)
𝒁= [sin(11.5° + 18.2°)] = 4.5
2(0.146 − 0.069)

30
 𝑍 ≅ 4 𝑏𝑙𝑎𝑑𝑒𝑠

(𝑅2 )2 −(𝑅1 )2
➢ Radius of circular arc of vanes, 𝑹 = 2(𝑅2 cos 𝛽2 −𝑅1 cos 𝛽1 )

(0.073)2 − (0.0343)2
𝑹= = 0.056 𝑚
2(0.073 cos 15.4° − 0.0343 cos 11.5°)

𝑅 ≅ 56𝑚𝑚

𝑉𝑤2 ×𝑈2
➢ Euler head, 𝐻𝑒 = 𝑔

8.3 × 15.28
𝐻𝑒 = ≅ 12.93 𝑚
9.81

𝑸
➢ Width of impeller at inlet, 𝑩𝟏 = 𝑽
𝒇𝟏 ×𝝅×𝑫𝟏

0.0053
𝐵1 = = 0.017 𝑚
1.46 × 𝜋 × 0.069

𝐵1 = 10.7 𝑚𝑚

𝑄
➢ Width of impeller at outlet, 𝐵2 = 𝑉
𝑓2 ×𝜋×𝐷2

0.0053
𝐵2 = = 0.0050 𝑚
2.292 × 𝜋 × 0.146

𝐵2 = 5 𝑚𝑚

➢ From performance curve, using an overall efficiency of approximately 70%, then;

0.51993
Therefore, the required motor power, 𝑃𝑖 = = 0.743𝑘𝑊 ≅ 1ℎ𝑝
0.7

3.2.4 Flow Parameters

❖ Pressure rise in meter in the impeller (using Bernoulli equation),

31
 𝑃1 − 𝑃2 𝑉2 2 − 𝑉1 2
= 𝐻𝑒 + − 𝐻𝑙𝑜𝑠𝑠
𝜔 2𝑔

8.612 − 1.462 0.12 × 8.612

= 8.77 + − = 11.986 𝑚
2 × 9.81 2 × 9.81

𝑃1 − 𝑃2
≅ 11.99 𝑚
𝜔

❖ Pressure rise in casing =𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑟𝑖𝑠𝑒 𝑖𝑛 𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 − 𝐻 = 11.99 − 10

= 1.99m

𝑁×√𝑄 2000×√0.0053
❖ Specific speed, 𝑁𝑠 = 3 = 3
(𝐻)4 (10)4

𝑁𝑠 = 25.89 𝑟𝑝𝑚

𝟏𝟐𝟎×𝜂𝑜 ×𝑉𝑤2 ×𝐷2 𝟏𝟐𝟎×𝟎.𝟕×𝟖.𝟑×𝟎.𝟏𝟒𝟔

❖ Minimum starting speed, 𝑵𝒎𝒊𝒏 = =
𝝅(𝑫𝟐 𝟐 −𝑫𝟏 𝟐 ) 𝝅(𝟎.𝟏𝟒𝟔𝟐 −𝟎.𝟎𝟔𝟖𝟐 )

𝑁𝑚𝑖𝑛 = 2696.5 𝑟𝑝𝑚

NOTE: The deign type of this centrifugal pump is going to be a closed one where there will not

be need for any external shaft but just the shaft of the electric motor will be used thereby reducing

the cost of fabrication and no need to use bearing for this type of model.

3.3 Methodology for Computational Fluid Dynamics

The simulation is carried out using Ansys Vista CPD. The boundary conditions are used in

the setup interface of the Ansys CFX. The following steps are taken in the simulation exercise:

a. Specification of design parameters such as the head, discharge, efficiency, number of

impeller vanes and flow rate are specified in the Vista CPD interface and the calculation

for the geometry of impeller and volute casing is automatically done.

32
 b. Then the Blade gen interface is opened and design parameters are adjusted to fit design for

the blade. The geometry for the volute is then modeled in the Ansys Modeler interface.

c. The data from blade gen is then transferred to the Turbo Mesh interface for Turbo grid.

The mesh geometry is the unsuspended for meshing to be carried out dynamically.

d. The Turbo grid data is then transferred to CFX interface where the flow is setup, the

solution (simulation) is done and the results are being computed. The total number of

Iterations used in the simulation is 200 and the standard κ-ε model is used for solving the

RANS equations.

e. The graph parameters for input and output are then specified and the graphs for each inputs

and outputs are displayed.

The Ansys flow chart for this process is represented in Figure Appendix 13.

Figure 9: Ansys design model for volute casing

33
Figure 10: Ansys blade gen for impeller model

Figure 11: Isometric 3D View of the Blade, Hub and Shroud

34
 CHAPTER FOUR

4. RESULTS AND CONCLUSION

The various parameters/results gotten from each procedure in this project are compared in this

chapter. The calculated result, the results from simulation and the results carried out from

experimental test are to be analyzed.

4.1 Results from Theoretical Calculations

After the design calculations, the following parameters shown in the table below were gotten;

Table 1: Calculated Values from Theoretical Knowledge

Parameters/symbols Calculated values Unit

Discharge, Q 0.0053 m3/s

Supply head, H 10 M

Hydraulic efficiency,𝜂𝑜 70 %

Motor speed, N 2000 r.p.m

Density, ρ 1000 Kg/m3

o
Temperature, T 25 C

Dynamic viscosity, μ 0.00089 Pa.s

Acceleration due to gravity, g 9.81 m/s2

Vane thickness, t 5 mm

Shroud thickness, ts 8 mm

Blade height 11 mm

Eye impeller diameter, Do 62 mm

Inlet diameter, D1 70 mm

35
 Outlet diameter, D2 146 mm

Inlet angle,𝛽1 11.5 Degree

Outlet angle, 𝛽2 18.2 Degree

Number of vanes, Z 4

Radius of blade, R 56 mm

Euler head, He 12.93 M

Required motor power, Pi 0.743 KW

Pressure rise 11.99 m

Pressure rise in casing 1.99 m

Specific speed, Ns 25.89 r.p.m

Minimum starting speed, Nmin 2696.5 r.p.m

From the above table 1, it can be noticed that the design head which is 10m falls within the range

of the Euler head (12.93m) which is the theoretical head. Also, the minimum starting speed for the

impeller to be effective falls between the already designed speed for a 1 horse power electric motor

and the designed required motor power is 0.743KW (approximately 1HP).

4.2 Results from Simulation

The following tables and figures are extracted from the Ansys turbo grid, CFX setup, solution and

report. The results give a clear interpretation of the simulation and images from each interface

during the simulation. A region S1 is added to the setup in order for the volute casing to be

considered during the simulation.

36
Table 2: Mesh Report for CFX
Domain Nodes Elements

R1 264300 244470

S1 66956 184888

All Domains 331256 429358

Figure 12: Mesh result from Turbo grid

Table 3: Mesh Statistics for CFX

Domain Maximum Edge Length Ratio

R1 207.282

S1 277.089

All Domains 277.089

37
Table 4: Domain Physics for CFX
Domain - R1

Type Fluid

Location Passage

Materials

Water

Fluid Definition Material Library

Morphology Continuous Fluid

Settings

Buoyancy Model Non Buoyant

Domain Motion Rotating

Alternate Rotation Model True

Angular Velocity 2.0000e+03 [rev min^-1]

Axis Definition Coordinate Axis

Rotation Axis Coord 0.3

Reference Pressure 0.0000e+00 [atm]

Turbulence Model SST

Turbulent Wall Functions Automatic

Domain - S1

Type Fluid

38
Location B75

Materials

Water

Fluid Definition Material Library

Morphology Continuous Fluid

Settings

Buoyancy Model Non Buoyant

Domain Motion Stationary

Reference Pressure 0.0000e+00 [atm]

Turbulence Model SST

Turbulent Wall Functions Automatic

Domain Interface - R1 to R1 Periodic 1

Boundary List1 R1 to R1 Periodic 1 Side 1

Boundary List2 R1 to R1 Periodic 1 Side 2

Interface Type Fluid Fluid

Settings

Interface Models Rotational Periodicity

Axis Definition Coordinate Axis

Rotation Axis Coord 0.3

39
Mesh Connection Automatic

Domain Interface - R1 to R1 Periodic 2

Boundary List1 R1 to R1 Periodic 2 Side 1

Boundary List2 R1 to R1 Periodic 2 Side 2

Interface Type Fluid Fluid

Settings

Interface Models Rotational Periodicity

Axis Definition Coordinate Axis

Rotation Axis Coord 0.3

Mesh Connection Automatic

Domain Interface - S1 to R1

Table 5: Boundary Physics for CFX

Boundary List1 S1 to R1 Side 1

Boundary List2 S1 to R1 Side 2

Interface Type Fluid

Settings

Interface Models General Connection

Frame Change Stage

Frame Type Rotating

40
 Downstream Velocity Constraint Constant Total Pressure

Pitch Change Automatic

Mesh Connection GGI

Table 6: Boundary Flows for CFX

Location Type Mass Flow Momentum

X Y Z

R1 Blade ( R1 ) Boundary 0.0000e+00 3.8840e+01 -3.0262e+01 1.4246e+01

R1 Hub ( R1 ) Boundary 0.0000e+00 1.7772e+00 -3.3819e+00 -1.5102e+02

R1 Inlet ( R1 ) Boundary 1.3057e+00 5.4893e-03 1.4145e-03 9.5727e-01

R1 Shroud ( R1 ) Boundary 0.0000e+00 -4.4593e+00 1.1590e+01 1.3641e+02

S1 Default ( S1 ) Boundary 0.0000e+00 -9.2997e+00 2.3160e+02 -3.9554e+00

S1 Outlet ( S1 ) Boundary -5.2995e+00 1.5763e+00 -2.1730e+02 1.7685e+00

S1 to R1 Side 1 ( S1 ) Boundary 0.0000e+00 0.0000e+00 0.0000e+00 0.0000e+00

S1 to R1 Side 2 ( R1 ) Boundary 0.0000e+00 0.0000e+00 0.0000e+00 0.0000e+00

The tables 7 and 8 below gives a summary of the performance results for the pump impeller. The

second table lists the mass or area averaged solution variables and derived quantities computed at

the inlet, leading edge (LE Cut), trailing edge (TE Cut) and outlet locations. The flow angles Alpha

and Beta are relative to the meridional plane; a positive angle implies that the tangential velocity

is the same direction as the machine rotation.

41
Table 7: Performance Results
Rotation Speed 209.4400 [radian s^-1]

Reference Diameter 0.1346 [m]

Volume Flow Rate 0.0052 [m^3 s^-1]

Head (LE-TE) 13.1345 [m]

Head (IN-OUT) 13.0477 [m]

Flow Coefficient 0.0103

Head Coefficient (IN-OUT) 0.1611

Shaft Power 734.2430 [W]

Power Coefficient 0.0018

Total Efficiency (IN-OUT) % 91.0132

Static Efficiency (IN-OUT) % 60.1131

From the performance and summary tables below, it can be noted that the required motor power

from the simulation is also 0.734 KW which is the same as the calculated value.

Table 8: Summary Data

Quantity Inlet LE Cut TE Cut Outlet TE/LE TE-LE Units

Density 997 997 997 997 1 0 [kg m^-3]

Pstatic -1122.5 -2402.9 80279.5 82560.8 -33.41 82682 [Pa]

Ptotal -25.301 -441.47 127977 127546 -289.89 128419 [Pa]

42
 Quantity Inlet LE Cut TE Cut Outlet TE/LE TE-LE Units

Ptotal (rot) -74.283 -1437.7 -5878.7 -7156.6 4.089 -4441 [Pa]

U 4.93 5.6952 14.093 14.6608 2.4745 8.3978 [m s^-1]

Cm 1.4812 1.9669 0.9925 1.0806 0.5046 -0.9744 [m s^-1]

Cu 0.0097 0.8503 9.3881 7.458 11.0409 8.5378 [m s^-1]

C 1.4838 2.6572 9.4603 7.5452 3.5603 6.8031 [m s^-1]

Distortion
1.0011 1.5923 1.0358 1.1364 0.6505 -0.5565
Parameter

Flow Angle:
0.3788 39.8166 85.8824 86.2699 2.157 46.066 [degree]
Alpha

Wu -4.9203 -4.845 -4.7049 -7.2028 0.9711 0.1401 [m s^-1]

W 5.1658 5.3105 4.8485 7.3214 0.913 -0.462 [m s^-1]

Flow Angle:
-71.297 -22.121 21.4964 32.9113 -0.9718 43.617 [degree]
Beta

Figure 13 : Mesh Elements at 50% Span and Meridional View of the Blade, Hub and
Shroud

43
Figure 14: Velocity Vectors at 50% Span

Figure 15: Velocity Streamlines at Blade TE

44
Figure 16: Blade Loading Curves at 20% And 80%

Figure 17: Streamwise Plots

45
Figure 18: Efficiency Plot/ Performance Curves

Figure 19: Graph of Momentum and Mass

46
Figure 20: Turbulence Graph

Figure 21: Head Graph

47
It can be noted from the figure 21 above that at the start of simulation (that is at the start of pump),

there was a radical drop in head. This is due to the fact that the pump has not gained enough kinetic

energy to move the fluid. But later on, there was a rise until it got to the original head specified

and then the head supply was constant throughout the operation.

From the simulation results it can be observed that the pressure increases gradually from

impeller inlet to outlet. The static pressure on pressure side is evidently larger than that on suction

side at the same impeller radius. In addition to this, it was observed that, the velocity increases

from impeller inlet until it enters the volute casing. It then drops to a minimum value at outlet

region.

4.3 Results from Experimental Test

Procedure followed in the pump performance tests and calculations made with the data collected

during the tests are given below.

Test Procedure

During the pump tests performed in the content of this study, the procedure given below is

followed.

1. The pump is assembled and prepared for the test. If a special problem on the pump is to be

observed, the required preparation is made, like painting the close surfaces of impeller, volute

and suction flange, while observing a possible rubbing problem.

2. Test setup is assembled and the pump is primed by filling the column pipe with water.

3. The motor is connected to the electric source.

4. The direction of rotation is checked by starting and stopping the pump instantaneously. If

required, the electrical connections are reversed in the sense of phase sequences in order to

reverse the direction of rotation.

48
5. The inlet pipe is then dipped to the pool of water and connected to the discharge pipe.

6. Suitable manometer and flow meter are chosen according to the maximum expected head

and flow rate of the pump, respectively. The chosen manometer is connected to the

discharge pipe. Required vane adjustments are made in order to direct the flow through

the collector pipe to the chosen flow meter.

7. The pump is started.

8. Nominal discharge pipe diameter at pressure reading location is recorded.

9. For a number of data points that is sufficient to inspect the hydraulic and power consumption

characteristics of the pump, no reading is taken for a while that is sufficient for the system to

reach equilibrium. The flow rate the pump delivers and the power given to the electric motor

are recorded.

10. Vertical distance between the manometer and the water surface is measured and recorded.

The results for the experiment is tabulated below.

49
Figure 22: Coupling of parts to the motor

Figure 23: Experimental setup for pump

50
Figure 24: Setup rig
After the centrifugal pump has been setup as shown in figures 23 and 24, the pump was tested. It

supplied to a head of 3m at start of motor afterwards, it the head supplied increased to 5m.

Observations

i. While the pump was running, there was no noise or vibrations from the coupling

ii. The suction part was well sealed and a foot valve was used and the discharge port leaked a

little (due to casting error) but was later properly sealed.

iii. Though the pump operated at a desired rate, there is need for adjustment at the discharge.

51
 CHAPTER 5

5. CONCLUSION AND RECOMMENDATION

5.1 Conclusion

From the theoretical calculations done in chapter 3 above, the results obtained were desirable. An

efficiency of 70% at a theoretical head of 12.93m was gotten which is very close to the design

head (i.e., 10m) taken as a design point. The pressure rise in the impeller is 1.99m while that in the

volute is 11.99m which also obeys the Bernoulli principle for centrifugal pumps (the pressure at

the inlet of pump must be lesser than that at the outlet, in order to meet the required design head).

From the simulation result in chapter 4, the theoretical head was 13.12m and an hydraulic

efficiency of 60.1% was obtained at an overall efficiency of 91%. The pressure rise in the impeller

was given as 1.33m which tallies with the pressure rise for the theoretical results. Also, from figure

17 in chapter 4, the streamwise pressure curve increased as it moves from the inlet to the outlet

and the velocity also increases. From figure 18, the performance curve shows the efficiency to fall

in between the purple curve and the yellow cure at the rated discharge (this means that the

discharge is at normal operating condition). From figure 21, the head curve showed that at the start

of the pump, there was an initial drop in the head supplied before rising to the normal supply head

which is 10m. The discharge then remained constant after about 20-time step. Simulation result is

used to predict the performance of a centrifugal pump to replace or reduce the experiments in the

process of pump design. CFD reduces the difficulty of critical analysis of highly complex flow in

the pump which is turbulent and three dimensional in nature.

From the results from the theoretical and the simulation, the centrifugal pump was casted and

tested. The pump was made to work for 30 minutes to check for the head discharge. The pump

52
discharged to a maximum head of 8m and had no vibration. The pump when initially started gave

a low supply of head before rising. This conformed with the result from the head graph from the

simulation in figure 21.

Comparison between the simulated results and the theoretical results shows a great agreement in

the design. Conclusively, the pump was designed, simulated, fabricated and tested and each result

from the procedures corresponded. The total cost for the fabrication was estimated to be 60,000

naira for just a single unit. If this pump was to be produced in mass, cost of production will be

minimal because the patterns required to make the volute and the impeller have already been made

(this in turns reduces the cost of production).

5.2 Recommendation

The need for a better design of centrifugal pumps and other type of turbomachines requires a great

deal of theoretical calculations but with the aid of simulation and CAD software, the design and

production will be made easier and at an effective rate in shorter period of time. Therefore,

Engineers need to be equipped with basic knowledge of these software so as to make fabrication

and production in the industry faster and easier because Numerical simulations provides quite an

accurate information on the fluid behavior in the machine, and thus helps to obtain a thorough

performance evaluation of a particular design. Also, according to theoretical knowledge obtained

in this research, a project on connection of centrifugal pumps in series and parallel should be

considered because it was observed to be more efficient but production and usage of these

configurations have not been implemented here in Nigeria.

53
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APPENDIX

56
Appendix 1: Meshed Zone Of Impeller

Appendix 2: Solution reports for Pressure distribution and velocity contour

57
Appendix 3: Turbo grid of CFX

Appendix 4: Impeller

58
Appendix 5: The volute pattern

Appendix 6: Sand pore for volute

59
Appendix 7: impeller side view

Appendix 8: Volute casing before machining

60
Appendix 9: The impeller, volute and volute cover before machining

Appendix 10: The volute and cover after machining

61
Appendix 11: The impeller in the volute

Appendix 12: Machined impeller and volute outlet

62
 Appendix 13: Ansys flow chart for the simulation

63

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