TECHNICAL NOTE

Correlation between cavitation type and cavitation erosion in centrifugal pumps

W. K. Chan
School of Mechanical and Production Engineering, Nanyang Technological Institute, Singapore

This technical note presents results of cavitation experiments conducted on a centrifugal pump in a closed circuit. We observed that erosion depends not only on the difference between the NPSH available and the NPSH required but also on the type of cavitation formed on the impeller blades. In addition, at different rotation speeds we found that the same cavitation forms have different erosive effects: The sheet cavity at 1,450 rpm and 8.8 m NPSH provokes a larger erodid surface than the sheet cavity at 1 ,150 rpm and 5.5 m NPSH. Results also indicate that bubble cavitation causes small pittings downstream of its inception, cloud cavitation causes erosion in a randomly distributed manner, and sheet cavitation acts as a protective layer to the surface where it is attached. We observed erosion downstream of the sheet cavity.

Keywords: net positive suction head (N PSH); cavitation; erosion

Introduction Traditionally, the criterion for prediction of the onset of cavitation erosion relies heavily on the detection of a drop in head or e!?iciency-3 and also on the detection of acoustic signatures4*5 associated with cavitation inception. However, investigators generally felt that the shape and location of cavitation bubbles- played an important part in determining the erosion observed. A knowledge of the relationship between the onset of cavitation and the NPSH of the fluid system gives the designer an initial estimate of the NPSH required to avoid cavitation completely. However, the major concern still lies in the quantitative determination of the influence of the various modes of cavitation on erosion. To completely avoid cavitation is unrealistically costly, so the ability to predict the inception of cavitation erosion-and also the subsequent evolution of erosion with the various modes of cavitation-is vital. A method has been devised, to detect the inception of cavitation erosion. The present work extends previous work to correlate the results of cavitation and erosion observed in a centrifugal pump. Types of cavitation The different modes of cavitation observed in a centrifugal impeller pump can be characterized as incipient, cloud, and sheet cavitation. Incipient cavitation Incipient cavitation marks the inception of cavitation. Small streamlets of bubbles appear on the leading edge of the impeller. Experimental studies4.5*7 on cavitation detection by acoustic signals show a sharp increase in noise emission (in the highAddress reprint requeatato Dr. Chan at the School of Mechanical and Production Engineering, Nanyang Technological Institute, Nanyang Avenue, Singapore 2263. Received 6 March 1989; accepted 3 January 1990 0 1990 Butterworth-Hcinemann Int. J. Heat and Fluid Flow, Vol. 11, No. 3, September 1990

frequency range, 20-80 kHz) owing to the collapse of these bubbles. Figure 1 shows incipient cavitation at an NPSH of 15.7m. Cloud cavitation As the NPSH available decreases, the bubbles increase both in quantity and size, and they tend to gather to form a cloud or mass of bubbles. Depending on the geometry of the impeller, cloud cavitation resides either near to the hub or near the shroud. The group of bubbles is never steady, and at the trailing end of the cloud, bubbles detach from the main mass. At this stage erosion is normally observed downstream of the cloud. Figure 2 shows this type of cloud cavitation. Sheet cavitation With a further reduction in the NPSH, a cavity sheet clings to the surface of the impeller. The sheet is transparent and largely

Figure 1 Bubble cavitation at 1,460 rpm, 160 Ls-, and NPSH = 15.7m

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Cevitation type 8nd erosion in centrifuge/ pumps: W. K. Ghan

after $ hour of testing. Subsequently, measurements are taken at intervals of f hour. This procedure ensures that localized cavitation erosion is detected right from the start, because ~ut~uous operation under the experimental condition will cause the eroded area to increase in depth only and not in planform area. In addition the cavitation form is also recorded and photographed. The general trend of cavitation evolution and the corresponding erosion zones are shown in Figures 5 and 6. They show the surface areas eroded after 24 hours and 4 hours of testing, respectively. The total surface area eroded, S, is

Figure 2 13m

Ckud

~v~tation at 1,45Orpm, 160 Ls-, and NPSH-

Figure 4

Sheet cavitation at 1,450 rpm, 160 Ls-, and NPSW =7 m

Figure 3 llm

Sheet cavitation at 1,45Orpm,

16OLs-,

and NPSH=

covers the impeller blade. Figure 3 shows the unsteady nature of the sheet, which results in a large roll up of the bubbles as the sheet attains a certain critical dimension. The subsequent detachment, lasting for a few milliseconds, leaves the impeller blade free of any form of cavitation before the next sheet forms. Incidentally, this type of cavity is observed at an NPSH of nearly a 3% drop in head. Studies4** have indicated the likelihood of severe erosion when pumps are operating at a 3% drop in head. With any further decrease in NPSH, the frequency of the formation and detachment of the sheet becomes so rapid that visual observation is no longer possible. What can be observed is only a constant cavity sheet covering a large portion of the impeller blade. Pumps operating under this condition, i.e., at or below a 3% drop in head, arc subject to a risk of severe erosion, noise, vibration, and drastic drop in performance.10*2*13*14Figure 4 shows development of the cavity sheet as the NPSH is reduced.

(4

(4

NPSH= 11.5m

Results and discussion

A closed-circuit fluid system, as described in References 8 and 9 is designed to provide clear visualization of the impeller in motion. The impeller blades are painted with a microionized lead paint to provide accelerated erosion testing. Experiments are conducted at 1,450 and 1,150 rpm at selected flow rates that are in similitude. Surface erosion measurements of impeller blades are taken

(4

Figure 5 1601s

Cavitation forms and cavitation erosion at 1,450 rpm and

Int. J. Heat and Fluid Flow, Vol. 1 I, No. 3, September 1990

Cavitation type and erosion in centrifugal pumps: W. K. Chan

(a) ~ (b)~ (c) (d)

S=3~3 NPSH=12m S-~2 NPSH =11.1m NPSti=9.1m .5 NPSI-1=7.2m

no increase in the extent of surface area eroded. Localized erosion downstream from a sheet cavity can thus be expected. Plausibly, bubbles grow and form a sheet of cavity, then detach and collapse downstream from the sheet. The N P S H corresponding to this form of sheet cavitation is slightly above the N P S H at a 3% drop in head. A subsequent decrease in the N P S H at a constant flow rate causes a larger sheet of cavity and a higher frequency of cavity shedding. The probability is greater that a higher frequency of cavity shedding will result in erosion of a larger surface area. Experimental results 11 have already indicated that the eroded zones increase from the point of cavitation inception to a maximum and then fall to a minimum before increasing again. The NPSH corresponding to the minimum eroded surface area is only slightly higher than the NPSH at a 3% drop in head. Hence pumps operating at a 3% drop in head are subject to a greater risk of severe erosion. We also observed that, by reducing the rotational speed from 1,450rpm to 1,150rpm, only small surface areas are e r o d e d - even at an NPSH of 5.3 m, where the sheet cavity covers a large portion of the impeller blade. Thus the same form of cavity observed at different rotational speeds have different erosion effects on the impeller blades.
Conclusion

(O)~ ~~3 NpsH-'-5"3m

Figure 6 1271s
Cavitation forms and cavitation erosion at 1,1 50 rpm and

Experimental studies conducted on a centrifugal pump illustrated different phases of cavitation forms and the corresponding zones of erosion. Bubble cavitation is virtually nondamaging, whereas cloud cavitation causes unpredictable erosion. An impeller blade covered by sheet cavitation is protected against erosion, but from the zone downstream the sheet is susceptible to intensive erosion damage. However, pumps operating close to the N P S H at a 3% drop in head are likely to suffer erosion, the extent of which is determined by the frequency of cavity shedding and the subsequent location of the bubble implosion.

References
1 2 3

recorded in square mm on the right, while the corresponding cavitation form is traced on the left. The numbers indicate the location and distribution of cavitation erosion. As the intensity of cavitation at 1,150rpm is expected to be less severe than that at 1,450rpm, the duration of the tests at 1,150rpm is extended to 4 hours, whereas that at 1,450rpm is restricted to 2 hours. At both speeds, bubble cavitation does not cause severe surface erosion. In fact, the surface areas eroded at 1,450rpm and 1,150rpm are 0 m m 2 and 3mm 2, respectively. The latter is the result of paint removed at the leading edge and thus should not be considered as erosion caused by bubble cavitation. Based on our experimental results, the major limitation of the present technique concerns the proper application of paint on the impeller blades. Improper application leads to removal of small surface areas of paint (about 1-2 mm 2) from the leading edge. Aside from this limitation, the observations of surface eroded closely resemble those obtained from ultrasonic testing, i.e., pitting rather than peeling of the paint. Our results also indicate that cloud cavitation causes sporadic zones of erosion. Although the eroded surface area is not very extensive, prediction of the location of the eroded surface area is difficult. The reason is that bubble implosion occurs in a random manner downstream from the cavitation zone. Figures 5 and 6 also illustrate the phenomena of blade protection by sheet cavitation. We observed no erosion under the sheet cavity in the experiments. However, severe localized erosion downstream from the sheet cavity is shown in Figure 5(d) and (e). In fact, the eroded surface area shown is achieved in just 20 minutes of testing; prolongation of the test to 2 hours yielded

4 5 6

8
7 9 10 11
12 13

14

Decprose, W. M. and Merry, H. Scaling for performance prediction. Stirlino, September 6-8, 1977, 123-130 Frederic, G. Machinery detection and control of cavitation in pumps. Prec. 5th Conf. on Fluid Machinery, Budapest, 1975, 273-284 Grist, E. NPSH requirements for avoidance of unacceptable cavitation erosion in centrifugal pumps. Paper presented at Institution of Mechanical Engineers Conf.-~Cavitation, Edinburgh, 1974 McNulty, P. J. and Pearsall, I. S. Cavitation inception in pumps. J. Fluids Eno., 1982, 104, 99-104 Sebestyen, G. Y. et aL Investigation of cavitation in pumps by direct and indirect methods. Acta Tech. Sci. Hunoaricae, 1971, 71(3-4), 431-474 Thiruvengadam, A. Cavitation erosion. Appl. Mech. Rev., 1971, 24(3), 245-253 Hammitt, F. G. Cavitation erosion: The state-of-the-art and predicting capability. AppL Mech. Rev., 1979, 32(6), 665-675 Chan, W. K. Detection of cavitation erosion in centrifugal pumps. Int. J. Heat and Fluid Flow, 1988, 9(1), 74-77 Chan, W. K. Visualization et erosion de la cavitation dans une roue de pompe centrifuge. These Dr-Ing., ENSAM, 1984 Pearsall, H. Off design performance of pumps. Von Karman Institute Lecture Series, Brussels, 1978 King, N. W. Measurement of cavitation erosion in a centrifugal pump as a function of speed, NPSH and flow rate. Cavitation Symposium, Institution of Mechanical Engineers, Edinburgh, 1983 Wood, G. M., Kulp, R. S., and Altieri, J. V. Cavitation damage investigation in mixed flow liquid metal pumps. Cavitation in Fluid Machinery, ASME, 1965 Wood, G. M. and Whippen, W. G. Cavitation effects in pumps and turbomachinery. Paper presented at ASME Cavitation State of the Art Symposium, 1969 Karassik I. J. Centrifuoal Pump Clinic, Marcel Dekker, 1981

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