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    The Suction Performance of Centrifugal Pumps Possibilities and Limits of Improvements PDF

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    THE SUCTION PERFORMANCE OF CENTRIFUGAL PUMPS POSSIBILITIES AND LIMITS OF IMPROVEMENTS by Peter Hergt Senior Research Engineer Alexander Nicklas Head of Hydraulic Development Department Gerhard Mollenkopf Head of Experimental Research of New Teetmologies and S. Brodersen “Head of Hydraulic Research and Development KSB Aktiengeslischatt Frankenthal, Germany Peter Hergt is Senior Research Engineer and Vice Director of the “New Techno- ‘ogies” division, He received his Engineering Diploma in 1960 from the Technical University of | Karlsruhe, Germany. After joining KSB. Aktien: gesellschaft, Frankenthal, Germany, in 1960 he dealt with hydraulic. basic research. Between 1975 and 1988, Mr Hergt was head of the Central Hydraulic Research and Development Department ‘and was responsible fr the hydraulic design of all purps within the KSB program. Gerhard Mollenkopf is head of Experi mental Research of the New Technologies division of KSB Aksiengesellschaft, Fran Kenthal, Germany. His responsibilities Include’ customer support im examining pump problems in situ Dr Mollentopf Joined KSB's research center in 1971 and was involved inthe desis and construction Of she experimental research center. Dr Mollenkopf received his PhD. at the University of Munich witha dissertation on cavitation problems in water turbines Alexander Nicklas heads the Hydraulic Development Department of the New Technologies division of KSB Aktien: gesellschaft, Frankenthal, Germany Wis responsbilites are the development and ‘improvement of hydraulic products, with ‘major emphasis on heavy-duty pumps for power engineering applications. Mr Nicklas joined KSB's fluid dynamics ‘research center in 1974 with responsibility {for the development of improved vane pro: {files to reduce the risk of cavitation damage o boiler feed pumps. He has many years’ experience in the hydraulic improvement of ‘multistage pumps and in fundamental research In the field of 1B cavitation erosion. Mr Nicklas received his Mechanical Engineering degree at Darmstadt Technical University, Germans: where hydraulic machinery and plant engineering were the major fields of his studies. ABSTRACT Following a brief description ofthe general suction performance of pumps and starting from an impeller designed for standard requirements, it will be discussed by which modifications and up {o which limi he swcion performance can be improved. {n this context, it willbe shown thet the well-known measures — eg, enlargement of the impeller inlet diameter, reduction of the vane number or installation of an inducer ~ may result in some restrictions conceming the possible operational range and may pose @ risk of cavitation erosion, These undesirable consequences can, however, be avoided or at least moderated by modifications "upstream ofthe impeller. ‘The suction performance can also be improved by using double suction instead of single suction pomps. It is explained why the resulting. improvement may nat be as substantial as could be assumed 2 fist glance Pumps with inlet velocities exceeding 25 t 30 mvs that are expected to nun for 10,000 br and more without cavitation damage cannot operate at NPSH values corresponding 1 3.0 percent head trop, even if highly cavitation-resistant material is used. I. is demonstrated that the design parameters of thei impellers difer from those used for ‘normal impellers, If NPSHA is not sufficient, a booster pump has to be provided, or the rotational speed has to be reduced. As the later isan expe sive alternative, the question arses what the minimum booster pomp head is. Some infarmation regarding this issue is given. Te ill also be demonstrated that there is an upper limit of the rotational speed of the main pump beyond which an economical solution is impossible. INTRODUCTION ‘A major factor in plant engineering, be it for process circuits, water supply, oF power generation applications, is the NPSH required by the pump used, which greatly influences the system's esign and cost. It goes without saying tha large, low-speed ‘machines, possibly connected in parallel or in muldstage design, svi eet low NPSH requirement are a safe solution in terms of rs PROCEED! plant cost and operating reliability, but such machines come expen: sive and the system will ot operate economically. With a view 10 ‘optimizing cost on the one hand and ensuring operating reliability and availability on the other, the plant designer needs a thorough "understanding ofthe caitation-dependent operation limi. ‘An outline is provided of the characteristic properties of cen- teifugal pumps in this respect and their application limits as defined by the latest findings inthe field of fuid dynamics. On the one hand it describes the basic phenomena that oecur in an impeller, if the system NPSH falls below a specific pump- and load-dependent value. On the other hand, itis to demonstrate Which NPSHeq Value ‘eanaot be underrun in a specific case and with a specific pump. ‘A brief description of the interelations between the impeller’s ‘geometry and its cavitation and operating characteristics is to help the operator retrace the steps taken and gain a better understanding ofthe factors limiting the operating range GENERAL REMARKS ON THE HYDRODYNAMIC CAVITATION CHARACTERISTICS OF CENTRIFUGAL PUMPS: Discharge Head In Figure 1, the NPSH curves for incipient cavitation (1), 0 per- ‘cent, 3.0 percent and total head breakdown (bd) are shown. The lt- ter is characterized by a steep head drop at constant flow rate and is normally not measured. Although the numerical values apply to a specific pump and cannot be easily generalized, a few universal ‘conclusions can be drav: NPSH TNPSHildes, ak rt 0 Figure 1. Typical NPSH Curves of Pumps. + NPSH; has a minimum atthe point fr which the has been designed (Qu) This need ot necessarily cone with the pump's best efficiency pont (ne. + The curves defined on the basis of the head drop exiterion lie far below the NPSH, curve and havea diferent shape. aluation of umerous ets showed tha he following approx imate ranges can be given for Q/Qgq = 1.0. OF THE THIRTEENTH INTERNATIONAL PUMP USERS SYMPOSIUM NPSHJNPSHs = 2.0 for special vane profiles += 4 106 for standard designs = 8 1010 for impellers with alow number of vanes (2 = 3) NPSHYNPSHs = 1.11013 NPSHyy/NPSH; = 0.8 100.9 for standard impellers = 1.0 for impellers with high 8, (NSS) + NPSH increases sharply and almost linearly with Q in the off design operating ranges. Aer point X, which mass the onset ofrecelaion a the impel let (Gg), NPSHY ceases fuer caves). ies cling the detcopment of eceeulason ve led spaeam st temple Sch coments aro exanple al nbs seed tb sublte th chuacense eave 8 bead rmedily Sram as Pu, Talia ie witoo any inser ified vpszeam of he impelr NPS ps chal Qt eve ously cone {ponds at fhe eign pte reason for phenomenon thatthe cviaon sont moves om herd fon the hs tren her the way love lowe The curves shown in Figue we pil fer ovetang impels snd seal alb for impels sete shat ed ough he Impaler eye (nutaage or ube pups), as gy © 60" tNy 3100) and By, 06, Inpetrs wiper specie Spend ng > 7, and DYD, > Of sometines exit pa the Npsti cha NPOt, ces car ake es Pie 1 ints low cans in head ay ees cin tone ib eave thor compared ih oer Now rages At desched by Koay {Il tht se eat of evo ace shange ine fow theogh he impeller combi wih oot trary Wanfomaaion Acute Reasuonene pial ‘eval thse pump’ characte cues to have daconluiie at Ox tent toviaing cones [3 “The basic covelton teen the development ofthe eiation tone and deceasig NSPH (opi aed n Fight 2. Staring iow elas sone abe wh decreasing Dye slow tnd then ever more rp, mere ores fllowing 9 hyperbolic ine, The slo ofthe picketed bute length Igh = 10 foun coveponds a3 0 percent head ro. lnaeordance with pe Ierviy gro at ow flow (Q1Qqe 75) sa at gh tov an each i I (conesponding A WH" pce Town compared wi eden pit Tn Fie Sauahercorlaton sown, The ead ltd the head fo oncviaing operation (He) ated piste sel Tecan tne Rag Are sign pot Chee H rains Comply wnafecd upto appetinatl gt © 825 and then seorasescontnoualy Ar ow Row. reas uae wp fo ig 06, and then drops lave sap Thi oud ive the iRpreion of ream sey at ow tom, wihchs nt wae howe teas willbe sown at ‘Al previous data fered 0 pelle wit vanes symneical- \vlapedar ett bin eure 4 Ite vane upered ty Inte ei o he suction GS) oon he pressure ie (3), Ih wl area ifn eff on Gye and weaker, yet cep tl elect on oy shown in Figure. Sharpening offine me's reser de dott improve the i, vale a large Dewy, By alo ineeses ental. Ta im put pump a ik ied enema Rave to Ds en Ime ecoet Sharpening cn he son sds tues he , aes, "HE SUCTION PERFORMANCE OF CENTRIFUGAL PUMPS POSSIBILITIES AND LIMITS OF IMPROVEMENTS s 35 20 ‘it 1,08, \ a = a I 19 : Ns = 1550 jj 0,75, 1,0 Sul. 050 /0¢es = 19 as 025 =a 7 a IM . er pnt 0 025 050 075 100 135° («150 o on 02 03 04 0s Figure 2. Cavitation Zone Length Iq (Related to Pitch 1) vs Ca tation Coeficient 6, 1.00, 7 at i 0 /Qgeg=1.0 0.75 \ \ 095 ‘ nq =30 : n=] iit 090, e 0 0% «05 075 400 «25 «80 Figure 3. Pump Head Related to Cavitation Free Operation (cf) Plotted Against Dimensionless Cavitation Zone Length Ip/t at Design Point and Low Flow Operation. Figure 4. Different Vane Leading Edge Contours, PS = Pressure Side, Suction Side. in particular at low flow and improves, though just slightly, 6, for very low flowrates. a ‘However, cutting back the vane inlet edge by some millimeters and then tapering the vane from the suction or the pressure side is ‘a measure that can be taken onsite, if the desired changes in the cavitation performance are within the range shown in Figure 5. Figure 5. Covtaton Coefficient o, for Different Vane Leading Edge Contours (Figure 4) Plotted Against Flowrate Number nds Efficiency ‘The change in efficiency with deereasing NPSH depends on the type of blading (solidity) and the operating point, although exact correlation have not yet been established. ‘Often the head drop is accompanied by a slight rise in the power input (0 percent < APS 1.5 percent), which results ina somewhat higher efficiency reduction than head drop. CAVITATION EROSION Whelter appreciable damage occurs or not depends on the hydrodynamic cavitation intensity (ICD on the ene hand and the ‘material's cavitation erosion resistance (CR) on the other ‘As far as materials are concerned, the euthors have at least a ‘general idea of tbe quantitative relationships between the erosion Velocities of different materials. In Table 1, these ratios are listed fora few selected materials, Table 1. Material Relative Erosion Grey cast iron (GCI) 92 Bronze G-CuSn10 33 Bronze CuAIONi 13 A743 CF-8M, 316 ss 40 A361 CD 4M CU 07 Tiatve os Stelite 6 0.05 ‘This means that in some cases a change ofthe impeller material can eliminate or atleast moderate erosion problems. An impeller made of G-CuSn10 will have a lifetime approximately thees times Tonger than that of « GCI impeller 6 PROCEEDINGS OF THE THIRTEENTH INTERNATIONAL PUMP USERS SYMPOSIUM, ‘What is harder to asses isthe effect of hydrodynamic cavitation imensity, which has not yet been exactly defined with all its influ- ‘encing parameters. Although the authors do know that the follow- ing parameters affect cavitation intensity, there is not enough data ‘of their influence forgiven fluid properties: + the flow velocity atthe location where cavitation occurs + the cavitation zone volume othe cavitation zone Yength + the pressure gradient atthe end ofthe cavitation zone + the model size Since local flow velocity and the pressure gradient at the end of the eavittion zone for a given impeller geometry are a function of the inlet flow ange, these two variables include the influence of the relative load point "AS local flow velocity is not known in most cases, it is re- placed by the average inflow velocity wy, which is an acceptable ‘approximation provided a uniform design concept is used. For ‘comparative studies the rate of erosion Fy is taken to be - depend ing on this velocity and the cavitation zone or bubble length Ip Bg = CUlp)*(0)® a for given material and fluid properties. The constant C includes the local velocity peak and the pressure gradient influene, ic, iis function of the operating point. According to an EPRI repo [4] it Js possible 1 seta = 2.8 and b= 6, which gives Ba =C(p)? (07 )8 @) ‘Systematic pump test series have shown that the erosion rate with = 21 is elie up 0 = Wg Lo oes ton Ind up wigg= 2m er sts eel 6s This ding and the above edn il Figure 6, whch applies to Q = Que For Hipaer ny aluona! conesions wring own practical pe toce wee mae, Like te consi CS the teal vloes ra int of the operating Po an tut eased fot OZb ube lover ol le ——" Beers Figure 6. Admissible Dimensionless Cavitation Zone Length Iy/t {for Different Materials as a Function of he Relative Inlet Velocity WO = Qies What is very difficult is the prediction of potential cavitation damage at Q'< Qj is for flowrates with recirculation at the inmpller inlet, ‘Although the vane cavitation zone moves into the impeller hub area (i.e, into an area of lower velocities w,) as destrbed for ‘example by Schiavello and Sen [5}, erosion phenomena may also ‘occur inthis region as 8 consequence of considerable inlet flow Geviations on te vane suetion side and marked pressure gradients, Hence, if an impeller shows cavitation erosion in the corner ‘between the hub and the vane suction side, it will have run at Q 0.5 Odes ‘The aviation 2ones inside the vortex region depend on the recirculation intensity and are difficult wo predict owing to the com- plexity of flow details involved. They may cause erosion damage both on the vanes (in particular the vane pressure side) and on the elements upstream ofthe impeller. Measurements on a number of ‘pumps revealed thatthe NPSH value for incipient cavitation in the recirculation regime is lower for undisturbed flow, for example, through a Tong eylindrical suction pipe, than for vane cavitation. Referred to curve b in Figure 5, the following would apply: 0S d= 04 8160/8 13 Gy)e=06 ‘The cavitation zone length IB/ atthe vanes would then already range at about 0:35, PERFORMANCE OF STANDARD IMPELLERS Most ofthe pumps produced today have to meet a variety of aif ferent requirements. While, for example, cavitation is of minor sig- nificance for primary circulating pumps in power statins, but a major factor for booster pump operation, common industrial or ‘Water supply pumps must cater forthe most varied egplications. As well as good (even though not exceptional) suction characteristics, they need to achieve high efficiency and a long service life. The suction behavior is just one parameter, che pump designer is expected to arrive at an optimum compromise between efficiency, ‘operating behavior and suction characteristics ‘The impeller eye diameter may be defined with the following equation derived from the afiiy law Q~ a Dj v=DyD, eo inserting the flowrate Q in m/s and the speed n in spm. 5 is then the inlet diameter in m of « geometically similar pump with Q ms and a= I pm. Keeping te efficiency in mind, Bis chosen tobe relatively small (also see Enlarging the Inlet Diameter, since small inlet diameters permit to use small sealing clearance diameters and thus, at cleat- ance width prescribed by the production process, result in lower internal leakage losses and higher efficiency From Equation (3) and from t8 Bp = n/t it can easily be derived, that the inlet flow angle fy is defined by: Boras 2 ‘This angle, and consequently, the vane inlet angles become rel- atively large (B= 20° -22°) The small inlet diameter reduces fric~ tion losses in the vane passage due to the lower relative velocity ‘The NPSH required calculated usin the approach suggested by PMteideres (6) nes =a, Soa, © ag ith 2, = 11-12 and yy according to Figure 7 then yields suc- tion specific speed values En one OO Nps o ranging at about 220 (NSS ~ 1,000), fis taken tobe 8= 4:3 m au, ‘THE SUCTION PERFORMANCE OF CENTRIFUGAL PUMPS POSSIBILITIES AND LIMITS OF IMPROVEMENTS ” of 03 02 fo Co) a imme el o 5 0 68 mM 8 » Figure 7 Cofiint by vs Vane Inlet Ansle By METHODS OF IMPROVING THE SUCTION CHARACTERISTICS IN THE DESIGN FLOW RANGE If the NPSH, value coresponding to the above-mentioned S. value of 220 (NSS = 11,000) isnot sufficient, performance can be improved in a number of ways, which can also be combined as described below. Enlarging the Impeller inlet Diameter In Figure 8, a statistical evaluation of suction specific speeds S, asa function ofthe inlet number 8 along withthe results ofa sys tematic test series are presented. The results are plotted in Figure 9 ‘of the systematic test series in dimensionless form ws the elative flowrate. Based on these curves with tg By according to Equation (4) and x0 18200 » - NSS tg q (8) 300 e 15600 with w= 1.1 representing a 10 percent incidence and q = 0.9 rep- * Tesening the ro of tet t toll ial area (vane blockipe), Equation (5) yells a Ay curve as shown in Figure 7 Gk = 1-1). oo 13000 Here he reference velocity isthe relative velocity atthe lne ia meter, which has a decisive influence on he suction characteristics nd the cavitation erosion poteatal location of highest relative 200 10400 Velocity). This simpleton does not quite give an adequate {ccount ofthe changes inthe vlocy triangles ean from the increase in diameter Figure 1 0 rc) T T (NPSH3) 6 100 sm ~ statistic (NPSH3)6=4,5 Ad © systematic test + 4-—+ P 200 45 tes ° ° | f 3 + 5 $ Figure 8, Suction Number S, vs Specific Inlet Number 6. ‘Aimed at ensuring low-loss energy transfer, the numberof vanes of standard impellers ranges between 5.0 and 8.0 in the low to ‘medium specific speed range, ie, itis higher than that of suction stage impellers (se Reducing the Number of Vanes) 'NPSH plated against the flowrate yields a curve similar to that itustated in Figure 1. Under Enlarging the Impeller Diameter, it willbe shown that higher suction specific speeds S, require small- cr vane angles and lower meridional velocities afd, thus, larger Suction diameters, This fact contradicts the interrelations described above for achieving high efficiency. Optimum efficiency and opt ‘mum suction characteristics, especially at below-design flows, are therefore mutually exclusive and cannot be combined in one pump. ‘Another characteristic feature of standazd impellers is their e004 offslesign efficiency compared with suction stage impelles. One reason for this is that with reduced inet diameter, the inet recit- calation develops at lower QQ (also see section 6) and the ener- 2 imparted by the impeller to the recireuatory flow atthe inlet Pig = kn -Df~ 8 o is considerably smaller than in suction stage impellers (8 = 4.7 52m). Le FT => 0 des 0 0,25 0,50 075 1,00 125 Figure 9. NPSH Plowted Against Flowrate for Different Specific Inlet Numbers 5(m) According to Equation (3). on Figure 10. Standard and Suction Impeller, Corresponding Velocity ‘Triangles. 8 PROCEEDINGS OF THE THIRTEENTH INTERNATIONAL PUMP USERS SYMPOSIUM A larger diameter Dy results in a higher elative velocity inthe died vane area (Figure 10), which however increases slighty less than inary with he cicumferential speed or Dy, snes the merc ional velocity is reduced atthe same time (assumption: y= const. along the leading edge). The lower meridional velociy causes a reduction of relative velocity in the previous inlet area (cone sponding othe standard impeller area), which in tur reduces the risk of cavitation erosion. This small improvement is indvecly Jnclued i the 2, obained fom the measurements. Fr meridion- al section design small curvatures ae recommended, lage radi and vanes extending far into the impeller ee. This wil est in reduced local vane ieultion and lower velocity peaks, Which wil hve a positive effect on the complete NPSH, to NPSH ange and on cavitation erosion ‘Considering the characteristics of the limit curve shown in Figure 6 it can be concluded that a further enlargement of D will not yield any Turherpereptible reduction in NPSH. An impeller ‘ith large diameter Di, of course, more likely tobe affected by cavitation erosion. In principle, these impellers ate also prone 10 recreation, since the inception point Qre may be lead quite close to Qi, as was shown by Fraser [T} However, onthe one hand the coresponding conelations have not yet been clearly defined, and on the ther hand, methods ae available hat permit Safe operation even below Qj ee Improvements inthe Low-Flow Range) ‘Apart fom the lower efficiency of suetion impellers at reduced flowrates previousley mentioned, the more or less unsteady power consuinpion caused by inlet recirculation can lead to vibrations Sependine onthe overall design of the pump. In order to obtain first information about the rik of trouble, iis recommended to evaluate 6 from Equation (3) with Q= Que For 8 < 45, the riskis limited. For 8 46 the risk increases, ifthe pump is un below 0.7 Qi This i trv for low to medium specific speeds and for pumps tbove a erin size Reducing the Number of Vanes A reduction inthe number of vanes enlarges the fiee flow cross section area and, thus, improves NPSH, (Figure 11). Taree or four ‘vanes are, however, the minimum so as to avoid excessive loads on the vanes (see Discharge Head). In order be able to maintain the original discharge head, the impellers equipped with the full ber of vanes from the mide ofits passage tothe outlet ares. hich ‘means thatthe impeller has, fr example, three Tong and tree short ‘vanes (called splitters). It must be kept in mind that a reduced num ber of vanes will increase the risk of low-frequency pressure fluctuations in the low flow range (See Swift Contra). (NPSHS)7_ INPSHI)7 des WS ate ——_ Fr 0s eT —> Q/Ades | ° 0 02 05001008180 Figure 11 Influence of Vane Number 2 on NPSH. Double-Suction Impellers Should the suction impeller’s NPSH, value sil be insufficient fora very small NPSHA, double-suction impellers (Figure 12) can be used. The overall inlet area is approximately 20 percent larger than that ofa single-suction impeller and NPSH, can be reduced bby 30 percent on average. These values result from applying the following equations as Epf4a):d,=6: (24) :8-coan Ly snd by variation ofthe hub ratio v = Dy/D, (Table 2) ‘The improvement resulting from the assumption that Oy, can be atributed to the lower relative velocity level Figure 12. Typical Double Suction Pump. Initially, the above considerations (Table 2) did not tke into account that NPSH might increase due to the hub. In Figure 13, it is illustrated tat the hub ratio Dy/D, has a significant eect on the NPSH, value. I this is allowed for, the values given in the las line are derived. In addition, it must be Kept in mind thatthe improve- ment derived on the basis of these simple relationships will not ‘uite be achieved in practice owing to + loses in the ilet bend, + distoed inlet flows tothe impeller (90 degrees bending around the shaft) ‘Therefore, the values of double-suetion impellers can be increased by approximately 5 percent. ‘Maximum values referred tothe total flowrate therefore only range at 350 (NSS = 18,000) (v < 0.45). In extreme cases, a du- ble-Suction pump with thick hub will nt give better results than a single-stage pump without hub, atleast as far as the NPSH, value Js concerned. NPSH, valves are improved due tothe reduced rl tive velocity level When considering multistage or double-suction pumps with thick hubs, particular attention must also be paid to the specific speed ny, since excessive Dy/D2 mtios ean lead to an extremely short outer streamline snd relatively high vane loads. Criticl ng values already strat ng = 35 (Ng = 1800), when v > 0.65. rom the above it can be concluded that the improvement ofthe INPSH value that can be achieved by replacing an overhung sve- THE SUCTION PERFORMANCE OF CENTRIFUGAL PUMPS POSSIBILITIES AND LIMITS OF IMPROVEMENTS » tion impeller pump by a double-ssction pump might be very limit. ed, However, the lower inlet velocity and a higher stiffness af the ror with its two bearings offer certain advantages as far as relia- bility is concerned, 20 10 5 | 0 05 Figure 13. Influence of the Hub/Tip Ratio Dy/D, at the Impeller Inlet on NPSH, Test Results with an Overhung Impeller Table 2 a> owe > ingle | wo | oa | oso | avo neste, | 079 | 000 | 069 Joy NPSHss NPSHy 0.98 O77 063 [corecion ese san gue 13 Inducers General Remarks If the NPSHA value is so low that even the use of a suction impeller or double-suetion pump does not yield satisfactory per- formance data, the designer of a pump station has to look for meth- d$ of raising the uid’ energy level upstream of the impeller One method consists in installing a separate booster pump (see Booster Pumps); another method, often used for single-stage volute casing pumps, is iting an axial impeller stage, a so-called inducer, just before the main impeller. Indcers typically are axial for mixed-flow impeller stages without diffusers, which are arranged on the pump impeller shaft and therefore have tne same speed and direction of rotation. The fact that he inducer is cose to {he impeller and in particular the swirling flow downstream of the inducer (= inflow to pump impeller) influence the impeller’ oper ating characteistics, which means that the flow conditions are rither more complex than those for booster pump configurations. “The inducer is not expected to increase the pumps discharge hea. ‘The primary objective isthe suppression of cavitation phenomena in the impeller; the inducer itself works in & distinct cavitation regime with a head drop of considerable proportion referted to the inducer’s discharge head. The NPSH requites by the inducer for ‘proper pump operation is markedly lower than the pur impeller's PSH, value This situation i illustrated in Figure 14 Hing NPSHinp Hep F ao Figure 14, Head and NPSH Curves of a Pump with Indwcey vs Flowrate for Different Operating Conditions. (Q-H), Impeller only; (Q-H); = inducer only: (Q-H anya = impeller and Inducer with three percent head drop; (Q-H),x= inducer with head drop of more than three percent (= x percent): NPSH inp ae = NPSH of the impeller with axial inlet flOW; NPSHS imp pont [NPSH of the impeller with preswirl caused by an inducer AA schematic pressure (energy) carve is shown in Figure 15 along 4 hypothetical streamline through the pump, with and itkout inducer, thus highlighting the benefit gained by using an inducer (ANPSHD, Lh | ened) Figure 15, Pressure Distribution Along the Flow Path Through a Standard Pump with (Right) and Withowt Inducer (Left) ‘When designing an inducer or a pump fitted with an inducer, di ferent approaches are exuice forthe 1W0 cases outlined below: + An inducer is tobe fited upsteam of an existing pump impeller Q> Qj, Le there ino evidence of inlet recrculs tion atthe impeller vanes, or Q < Qhg with increasingly intensive recirculation towards Q = 0. It must also be examined whether the ‘actual cavitation intensity would in fact cause erosion damage oF not. If nt, further investigation isnot required, since according to Stoffel and Jaeger {11} the impeller design has but a minor infl- fence on the mechanical operating behavior If cavitation erosion is a problem, vane profiles, as illustrated in Figure 4 improve condition inthe Ques > Q> Qie range €0 8 lim: ited extent only. ‘A marked improvement compared with standard profiles is described by Hergt [12]. A special vane design at the inlet helps keep the valve for incipient cavitation in the lw flow range atthe design point level (Figure 20) : 2 i | | i sie 7 7 onree eat 0 os 10 15 Figure 20. Cavitation Coefficient 6 vs Flowrate for Improved Vane Profile 2 PROCEEDINOS OF THE THIRTEENTH INTERNATIONAL PUMP USERS SYMPOSIUM Although these measures only alter NPSH, with NPSH remaining more or less constant, they do affect cavity growth in Such away thatthe aviation 2one length redvced on account of aviation reson effects is reached at lower NPSH valves com- jared wih standard profiles (Fgure 21). This means dat the car {ation erosion at any NPSHA between NPSH, and NPSHY wil be less pronounced Before discussing potential measures for improving operation at Q> Qj it would have tobe examined whether a specific machine eater this regime a all. other words the rectelation inception point Qj fora given geometry woul have tobe localized, Various "tempts have been made o solve this sue (eg, 13, 14, and 15), which othe knowledge ofthe authors have not yi Viele sais: factory results however. Staring from very generalizing hypothe- ses that only considera few of te posible influencing parame relationships have been derived by Fraser [7] t0 compute the onset Of revteulation using only & few geometric pump parameters. ‘These were further simplified [13], where the ertical value vy is corelated dieetly with he suction specific speed (N85), The statements thatthe higher Sy ithe aver the Fla- tive flowrate a recoulation onsets ie, the smaller the safe ope= ating region (Figare 22). The endencyiustrated in his figure can be confirmed with ena but appre the comelatons as such ae not so easy to define special profile normal profile a5 10 Figure 21. Canty Lenh vs NPSH for Diferen Vane Profiles 100 9 lg (” 90 |-Odes: — 4 A 8 10 | # Fe Ns Spt Cc CT) Figure 22. Onset of Inlet Recirculation Og /Oaeq V8 Specific Suc- tion Speed. In Figure 22, which was taken ftom Stoffel and Herp [16 sev ‘eral measurements done in-house at KSB have been plotted. Curve ‘A.was obtained in a set of experiments in which four impellers di fering only in inlet diameter and corresponding vane angle were tested, The trend is very’ similar tothe original curve, but the level isclferet. This results from the conclusion, which was fr exem- le also raven by Schiavelio [14] end Sen {15}, hat Bis only one ‘of many parameters which determine Qhg. Another parameter apparent in Schiavelo (14) and Sen's (15] Work i the location of te leading edge relative tothe axial direction, which according to ‘ur ovin measurements may lead to differences in Qe of upto 40 percem, Keeping other parameters constant. In this light, itis understandable that a curve given by Palgrave [17] ranges at a completely ditferent level ‘Nonetheless it ean be assumed that at a given flowrate, Q, and speed, larger inlet diameters (higher 8 and solr B) will result in higher Qj values and according #9 Equation (Pp ~ 8) also in intensified rcireulatory ows. Although cavitation within the recirculation zone stars to devel- ‘ap ata markedly lower NPSH,, valve than Vane cavitation, a ills- trated in Figure 5, ite is known about is intensity. Therefore, itis recommended to take appropriate measures to improve conditions in general. Diffuser Upstream of the Impeller Hergt, Jaberg, an Amann (18) demonstrated that a diffuser fit ted upstream of the impeller has a major influence on the recireu- lation zone length, The correlation ilustrated in Figure 23 is ‘between the diffuser and recirculation zone lengths, Lp, and Lyg, respectively. Ata flowrate corresponding t0 Cyx/ty = Ot, the fol Towing epplies: 035 030 025 020 0.5 0.10 0.05 st 7 Se =o 1.306 Sikes 0 a 1S 20 25 ° Figure 23, Influence ofthe Length Lp of an Inlet Diffuser on the Extension of the Recirculation Zone [yg ‘The axial extension of the inlet reciteulation zone is Lyg= 2.5 Dj sithout and 0.8 Dy witha diffuser having a length of Lp = 0.778 -Dy I has been additionally demonstrated by Hergt and Hellmann (19) that the diffuser considerably influences the velocity distribu tion within and outside the recirculation 2one, The axial and tan- ‘ential velocity components within the backflow are much smaller than without the diffuser. In contrast, the flow approaching the impeller has higher tangential component resulting ina smaller angle of incidence near the hub. Hence, the ratio of the power transferred in the recirculatory flow at Q=0 with and without diffuser is Pia =03 Pion ‘THE SUCTION PERFORMANCE OF CENTRIFUGAL PUMPS POSSIBILITIES AND LIMITS OF IMPROVEMENTS 2 ang that ofthe circulating volume flows (Qwair 9 5 (ine ‘This means that a diffuser reduces the recirculation intensity substantially. The conclusion, corroborated by practical exper ence, is that the cavitation risk i considerably lower, The diffuser clfect i also reflected in the values for incipient cavitation, i paz- ticular at Q-< Qj, as illustrated in Figure 24 125 oy 4 1,00 without diffuser /] aa NO 0.75 ‘x Ta hae | 050 02s Su. a — > Cm/uy 0 005010 01S 020025 Figure 24, Comparison of 6, and 03 without and witha Diffuser (2a= 14 degrees) Swirl Controt Another effect caused by recirculation, which may result in a reduced operating range, is shown in Figure 25, where the differ ence between the local static pressure immediately upstream of the Impeller and the pressure far upsteamn at Q = O is plotted. Owing tothe circumferential component in the recirculation zone the pres- sure dectesses ragily inwards end reaches considerably negative values near the hub, IF NPSHA is low, this may cause the medium toevaporate neat the hub (pipe center), which in tum may bring on the well-known phenomenon of low-frequency auto-oscilltion with considerable head fluctuations. Although the low pressure recovers with increasing flowrate, it only eaches zero level at Q= x. ‘Various methods of preventing auto-osillation are available, which, inthe final analysis, are all based on eliminating the cir- ccumferental component of the recirculating flow. A solution was suggested in Kasztejn, eta, [20]. The recirculating flow from the impeller is led into ring element equipped with Vanes ending in sual direction. The flow is deswirled and reintroduced into the impeller, Since the flow does no longer have a circumferential component, the low pressure area in the center disappears and auto-oscilltion is prevented. ‘A special solution examined by the authors is illustrated in Figure 26, Itiffers from Kesztena, et al (20), in the method ofre- introducing the recirculating Mow and the use of a diffser ‘Although a direct comparison has not been made ye, itis expect: ced tobe slightly more effective. ‘The same conceptional approach can be applied without great effort and outlay to can-type pumps, which aze mostly installed vertically Figure 27), Just upstream of the impeter, the inet pipe 10 Ew Prot Peo % 05 Pip Feo Muy mir) os 19 mr /ry Figure 25, Tal and Static Pressure Distribution Upstream ofthe Impeller at Shutoff Point. Figure 26. Pump Provided with Annular Slot and Vanes Upstream ofthe Impeller Figure 27. Inlet Pipe with Sorin Front of a Pump. Py PROCEEDINGS OF THE THIRTEENTH INTERNATIONAL PUMP USERS SYMPOSIUM 'is equipped with an diagonal slot allowing the recirculating flow to escape into the clearance between can and suction pipe. With an adequately dimensioned slot, this method eliminates auto-oscill tion almost completly ‘These measures can obviously only be effective, if the wcireu- lating flow enters the slot or the ring element. Some impellers, for example, those with inlet edges approximately parallel tothe axis show comparatively short axial extensions of the recirculation zone, which may not be influenced by the measures mentioned above, However, all the negative consequences of inlet reci= culation, eg. those explained in Figure 25, will be much Tess pronounced Recirculation Suppression Sometimes, a pump is found to peste in the low flow range ost ofthe time after it has been commissioned. In these cases, simple method of adapting the impeller tothe actual operating con ditions i avaiable. I consists in reiting aring hat duces the inlet diameter (Figure 28 (a). This rng extends int the vaned part, ef the impelier and “cuts ofa paral low impeller, soto speak Qrgis shifted to lower flowrates and the recirculatory flow i ess intensive, In some cases, an orifice was fitted upstream of the impeller (Figure 28 ()). An onfce is very easy to instal and has a smilar effec, bu itis les effective. Alsiough it does not prevent recirclaton, it keeps the axial extension ofthe recirculation zone short and reduces the pover consumption. o> D- a) b) Figure 28. Orifice within the Impeller Bye (a) or in Front of t (bh SUMMARY + On the basis ofa brief explanation of the basic flow pkenomena ‘within an impeller, the general cavitation performance of & pump is described, + limits of the suetion capability as a function of the particular impeller design and the overall pump design (single-suction,

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