CHINESE JOURNAL OF MECHANICAL ENGINEERING

Vol. 30,aNo. 1,a2017 ·103·

DOI: 10.3901/CJME.2016.1024.125, available online at www.springerlink.com; www.cjmenet.com

Cavitation Optimization for a Centrifugal Pump Impeller

by Using Orthogonal Design of Experiment

PEI Ji1, *, YIN Tingyun1, YUAN Shouqi1, WANG Wenjie1, and WANG Jiabin2
1 National Research Center of Pumps, Jiangsu University, Zhenjiang 212013, China
2 Shandong Shuanglun Co., Ltd., Weihai 264203, China

Received April 25, 2016; revised September 30, 2016; accepted October 24, 2016

Abstract: Cavitation is one of the most important performance of centrifugal pumps. However, the current optimization works of
centrifugal pump are mostly focusing on hydraulic efficiency only, which may result in poor cavitation performance. Therefore, it is
necessary to find an appropriate solution to improve cavitation performance with acceptable efficiency. In this paper, to improve the
cavitation performance of a centrifugal pump with a vaned diffuser, the influence of impeller geometric parameters on the cavitation of
the pump is investigated using the orthogonal design of experiment (DOE) based on computational fluid dynamics. The impeller inlet
diameter D1, inlet incidence angle Δβ, and blade wrap angle φ are selected as the main impeller geometric parameters and the orthogonal
experiment of L9(3*3) is performed. Three-dimensional steady simulations for cavitation are conducted by using constant gas mass
fraction model with second-order upwind, and the predicated cavitation performance is validated by laboratory experiment. The
optimization results are obtained by the range analysis method to improve cavitation performance without obvious decreasing the
efficiency of the centrifugal pump. The internal flow of the pump is analyzed in order to identify the flow behavior that can affect
cavitation performance. The results show that D1 has the greatest influence on the pump cavitation and the final optimized impeller
provides better flow distribution at blade leading edge. The final optimized impeller accomplishes better cavitation and hydraulic
performance and the NPSHR decreases by 0.63m compared with the original one. The presented work supplies a feasible route in
engineering practice to optimize a centrifugal pump impeller for better cavitation performance.

Keywords: cavitation optimization, computational fluid dynamics, orthogonal design of experiment, range analysis

performance. LUO, et al[12], analyzed the effects of impeller


1 Introduction
Cavitation physics play an important role in the design
and operation of many liquid handling turbomachines. In
particular, cavitation can give rise to erosion damage, noise,
vibration and hydraulic performance deterioration[1–5].
Accordingly, a large body of research has been performed
toward understanding the physics of, designing away from,
and designing to accommodate the effects of
cavitation[6–10].
In the past decades, improving the cavitation
performance of pumps by optimizing impeller geometry
has been successfully achieved in several studies. XIE, et
al[11], applied a numerical method to optimize slots on
impeller blades near the pump inlet in six groups of
hydraulic models. The simulation results showed that the
used of slotted impellers could improve the cavitation
* Corresponding author. E-mail: jpei@ujs.edu.cn
Supported by National Science & Technology Pillar Program of China
(Grant No. 2014BAB08B01), National Natural Science Foundation of
China(Grant No. 51409123), Jiangsu Provincial Natural Science
Foundation of China(Grant No. BK20140554), and Training Project for
Young Core Teacher of Jiangsu University, China
© Chinese Mechanical Engineering Society and Springer-Verlag Berlin Heidelberg 2017
inlet geometry on centrifugal pump cavitation performance
by using computational fluid dynamics(CFD). The pump
cavitation performance can be significantly improved with
new impellers designed by properly extending the blade
inlet toward the pump inlet or enlarging the blade inlet
angle. WANG, et al[13], studied the effect of varying the
vane wrap angle on cavitation performance and determined
that there is an optimal value for vane wrap angle to obtain
the best cavitation performance. TAO, et al[14], applied a
genetic algorithm to modify the leading edge ellipse ratio
and blade thickness on the leading 20% meanline. By using
CFD simulation, optimization was completed with obvious
improvements on the cavitation inception performance.
However, It can be seen that these findings of cavitation
characteristics in the centrifugal pump are based on single
factor, and in the practical application, cavitation is the
outcome of combined action of multiple factors.
Meanwhile, the orthogonal design of experiment is one
of the most popular and efficient optimization methods
used to achieve the design objective, which has many
factors. YUAN, et al[15], applied the orthogonal
experimental method to investigate the impact of varying
the main parameters of the splitter blades on the pump
 PEI Ji, et al: Cavitation Optimization for a Centrifugal Pump Impeller
·104· by Using Orthogonal Design of Experiment

performance and they observed that the splitter blades fluid domain boundary to precisely fit the fluid domain
could make the Q-H curve flat and that the pump with along the boundary. The computational domain, comprising
splitter blades could operate under overload conditions. the inlet, impeller, diffuser, and volute, consists of 1 060 291
YAN, et al[16], optimized the cavitation performance of a grids. The details of the layout of the mesh are shown in
large-scale axial-flow pump with the orthogonal Fig. 2.
experimental method and numerical simulations. The
results showed that when the flow line of suction surface Table 1. Main geometrical and design parameters
of the centrifugal pump
φ=0.7, the cavitation persistence length can be rapidly
decreased and the cavitation volume fraction can be sharply Parameter Value
Impeller inlet diameter D1/mm 189
cut. SHEN, et al[17], applied the orthogonal experimental
Impeller outlet diameter D2/mm 357.7
method to optimize the parameters of a compound impeller. Impeller outlet width b2/mm 34.3
Through the test of specimen of the best design scheme, it Inlet incidence angle φ/(°) 120
demonstrated that the excellent selection by using Blade wrap angle Δβ/(°) 5.5
numerical simulation of whole flow field was non-overload Impeller blade numbers Zi 5
and high efficiency. Diffuser inlet diameter D3/mm 360.5
Diffuser outlet diameter D4/mm 502.6
In this study, CFD technology was used to evaluate the
Diffuser inlet width b3/mm 38.5
impact of impeller inlet diameter D1, inlet incidence angle Diffuser throat width a3/mm 58.8
Δβ, and blade wrap angle φ on the cavitation performance Diffuser inlet angle α3/(°) 9.7
of a centrifugal pump. The orthogonal DOE was used to Diffuser blade numbers Zd 7
study the cavitation characteristics of the pump and to Volute inlet diameter D5/mm 588
Volute inlet width b5/mm 175
obtain the optimal parameter combinations for pump design.
Design flow rate Qd/(m3 • s–1) 0.086 7
Finally, the internal flow in the optimized impeller was also Design head Hd/m 37
analyzed and compared with the original one. Rotating speed n/(r • min–1) 1490
Specific speed ns 113.7
2 Numerical Simulation

2.1 Geometry model

The 2D sketch of the model pump is shown in Fig. 1.
The hydraulic components of the pump consist of the
impeller, diffuser, and volute. To be specific, the impeller
shown is shrouded with five twist and backswept blades
with specific speed, ns=3.65nQd0.5/Hd0.75=113.7. To
eliminate the radial force, the diffuser is shrouded with
seven radial vanes which are fixed on the pump through (a) Meridional plane
bolts. The annular volute is designed to keep the pump
operating safely. The design parameters and the main
geometric parameters are shown in Table 1.

(b) Self-adapted grids

Fig. 1. 2D sketch of the model pump

2.2 Mesh generation

A grid generation method based on a binary tree
algorithm is used to generate the adaptive Cartesian grid for (c) Grids of the impeller
numerical simulation[18–20]. The density of the coarse grids Fig. 2. Grids of computational domains
increased based on the dichotomy method in the region
requiring high geometric precision by using this technique. 2.3 Boundary conditions
The grid is laid out in accordance with the surface of the In a complete pump model, there are rotating parts and
 CHINESE JOURNAL OF MECHANICAL ENGINEERING ·105·

stationary parts. The grid solution has to take into account ¶

 vd + ò  ((v - v ) • n) vd =
the relative motion of fluid domains. To resolve relative ¶t ò (t ) 
mesh motion problems, an advanced implicit approach  (2)
without interpolation is used. In this approach, the program ò ò
 • nd - pnd + ò
fd ,

first finds the common overlapped area between

æ ¶u ¶u j ö÷ 2 ¶u
mismatched interfaces. After that, this area is treated as the  ij =  ççç i + ÷÷ -  k  , (3)
common face connecting cells on both sides of the interface. çè ¶x j ¶xi ÷÷ø 3 ¶xk ij
During the simulation process, this face is treated no
differently than an internal interface face between two where n is surface normal, p is static pressure, t is time, ν is
neighboring cells in the same grid domain. Therefore, the fluid velocity, νσ is mesh velocity, Ω(t) is control volume as
solution will be fully conservative and fully implicit, and a function of time, ρ is average local fluid density, σ is
all high order schemes will also automatically apply. An surface of control volume, μ is dynamic viscosity.
example of this type of matching is shown in Fig. 3. By the
implicit and conservative coupling of the two volumes, the 2.4.2 Turbulence model
solution becomes faster, more robust, and more accurate in Standard k-ε was selected in present study. The k and ε
terms of the conservation of mass, momentum, and equations are, respectively:
energy[21–24]. Meanwhile, the total pressure is used in the
inlet and the flow direction is normal to the boundary. The ¶
 k • d + ò  ((v - v ) • n) kd =
mass flow rate is specified in the outlet. All solid walls are ¶t ò (t ) 
no slip and the high resolution algorithm is employed to æ ö
t ÷
solve the equations. The maximum residuals are set to 10-4, ò ççççè +  ø÷÷÷(k • n) d + ò (Gt -  ) d ,
k
(4)
and the values of head, efficiency and power are monitored.  

Table 2 lists the working fluid parameters in the centrifugal

¶
 • d + ò  ((v - v ) • n)  d =
¶t ò (t )
pump.


æ ö æ 2ö
çç + t ÷÷( • n) d + ççc G  - c   ÷÷ d , (5)
ò çèç  k ø÷÷ ò çèç 1 t k 2 k ÷÷ø
 

where c1=1.44, c2=1.92, σk=1.0, σε=1.3, k is the turbulent

kinetic energy, ε is dissipation rate of the turbulent kinetic
energy, μt is the turbulent viscosity, Gt is the turbulent
generation term.

2.4.3 Cavitation model

Fig. 3. Mismatched grid interface between impeller and diffuser The cavitation model used is a mathematical formulation
describing the conversion between the liquid and vapor
Table 2. Working fluid parameters phase. The constant gas mass fraction model, is frequently
Parameter Value used to describe cavitation flow in centrifugal pumps. It
Working fluid Water assumes that the mass fraction of non-condensable
Dynamic viscosity μ/(μPa • s) 1.003 gas present in the liquid is constant at the boundaries and
Density ρl/(kg • m–3) 998 throughout the domain[25]. The equations for modeling the
Liquid bulk modulus B0/GPa 2.15 vapor in the constant gas mass fraction model are:
Liquid reference pressure pref/Pa 101 325
Saturation pressure pv/Pa 3610 ¶
 f v d + ò  ((v - v ) • n) f v d =
¶t ò (t ) 
2.4 Mathematical Models æ
ç t ÷ö
ò çççè D f +  f ÷÷÷÷ø • (f v • n) d +
2.4.1 Governing equations
(6)
The vapor/liquid two-phase mixture model used to
ò ( Re - Rc ) d + ò (Sv ) d ,
describe cavitation assumes the fluid to be homogeneous,
1
implying that the multiphase fluid components have the é 2 ( P - Pv )ù 2
same velocity and pressure. The continuity and momentum Re = Ce • l  v êê ú (1- f v - g f ) , (7)
ú
equations for the mixture flow are as follows: ë 3 l û
1

¶ é 2 ( P - Pv )ù 2
 d + ò  (v - v ) • nd = 0 , Rc = Cc • l  v êê ú fv ,
¶t ò (t )
(1) ú (8)

ë 3 l û
 PEI Ji, et al: Cavitation Optimization for a Centrifugal Pump Impeller
·106· by Using Orthogonal Design of Experiment

where Dv is diffusivity of vapor, Cc is cavitation become larger. When total pressure is as low as 23 kPa,
condensation coefficient, Ce is cavitation evaporation much larger cavities appear and result in blocking the
coefficient, fv is mass fraction of the vapor, gf is mass passages between blades, seriously aggravating the
fraction of the free gas, Rc is vapor condensation rate, Re is decrease of the pump performance.
vapor generation rate, Sv is source of vapor, ρl is liquid
density, ρv is vapor density.
In addition to the above, the constant gas model solves
the following equation for the free gas: gf=constant. In this
paper, three-dimensional steady simulations were
conducted to predict the cavitation performance of the
pump by using constant gas mass fraction model with
second-order upwind.

2.5 Comparison of performance

The pump model was tested in the open test rig in the lab
of National Research Center of Pumps, Jiangsu University,
and testing precision is superior to the national grade 1. Fig.
4 shows the open test rig. The pressures at the pump inlet
and outlet were measured by pressure sensors with a
measurement error of 0.1%. Flow rates were measured with
a LWGY-200A turbine flow meter with a 0.5%
measurement error.

Fig. 5. Comparison of the pump performance

between the experiment and CFD

Fig. 4. Open test rig

By running the numerical simulations for five different

75 kPa 65 kPa
flow rates, the predicted pump performance curve is
obtained. To verify the accuracy of the simulation, the
pump performance was tested in the open test rig. A
comparison of the experimental and numerical results is
shown in Fig. 5. The numerical results are consistent with
the experimental results well. At the design point, the head
and the net positive suction head required(NPSHR)
calculated are 37.82 m and 2.95 m, respectively, while the
32.5 kPa 23 kPa
experimental head and NPSHR are 37.9 m and 2.93 m. It is
clear that the numerical simulation can predict the Fig. 6. Vapor volume fraction distribution of original impeller
performance characteristics of the model pump accurately respectively under 75, 65, 32.5 and 23 kPa
and the optimization can be achieved by using CFD.
Fig. 6 shows the vapor volume fraction distribution for 3 Orthogonal Array Experiment
total inlet pressures of 75 kPa, 65 kPa, 32.5 kPa, and 23
kPa. As can be seen from the figure, small cavities occurs To achieve the best cavitation performance of the
in the suction side of the blade leading edge when total centrifugal pump, the main parameters should be selected
inlet pressure is 75 kPa, which is called cavitation inception. carefully and exactly. According to the empirical design of
With total inlet pressure further decreasing, the cavities the impeller and previous studies on cavitation performance,
 CHINESE JOURNAL OF MECHANICAL ENGINEERING ·107·

three main impeller geometrical parameters are selected: Table 5. Orthogonal experimental scheme
the impeller inlet diameter D1, the inlet incidence angle Δβ, Trail Parameter combination Head NPSHR Efficiency
and the blade wrap angle φ. The geometry of the diffuser No. A B C H/m /m ρ/%
and volute remain the same. Table 4 lists the different 1 182 3 110 38.42 2.73 72.02
parameters of the impeller. And a flow chart of the 2 182 5.5 120 38.24 2.68 71.37
optimization process is shown in Fig. 7. 3 182 8 130 37.67 2.67 72.46
4 189 3 120 38.03 2.42 71.77
Table 4. Parameters of the impeller 5 189 5.5 130 37.61 2.48 72.47
6 189 8 110 38.01 2.61 71.15
Trail Impeller inlet Inlet incidence Blade wrap 7 196 3 130 37.67 2.42 72.46
No. diameter D1/mm angle Δβ/(°) angle φ/(°) 8 196 5.5 110 37.69 2.32 70.62
1 182 3 110 9 196 8 120 37.63 2.61 71.38
2 182 5.5 120
3 182 8 130
The analysis results for pump NPSHR are described in
4 189 3 120
5 189 5.5 130 Table 6. To obtain a low NPSHR according to the Δmax-min
6 189 8 110 value, which is equal to difference between maximum and
7 196 3 130 the minimum values of the NPSHR, the effect of the main
8 196 5.5 110 parameters on the NPSHR is A > B > C, namely impeller
9 196 8 120
inlet diameter is the most important factor of NPSHR,
followed by inlet incidence angle, blade wrap angle. Thus,
the order of main parameter for the efficiency is C > B > A.
In this paper, mainly considering the lower NPSHR, the
final optimal combination of the main parameter for low
NPSHR is A3, B2 and C3, namely D1=196mm, Δβ=5.5°,
φ=130°.

Table 6. Range analysis of net positive suction head required

NPSHR/m
A B C
Levels
Impeller inlet Inlet incidence Blade wrap
diameter angle angle
Fig. 7. Schematic map of optimization process 1 2.696 2.572 2.554
2 2.503 2.492 2.571
3 2.451 2.630 2.523
4 Results and Discussion Δmax-min 0.245 0.138 0.048
Rank 1 2 3
4.1 Orthogonal experiment results based on the CFD
Impellers for 9 cases were designed using the CFturbo 4.2 Final optimization
9.0 software to export the 3D computational domain. The According to the best combination of the main
mesh was generated with the similar number of grids for parameters (D1=196 mm, Δβ=5.5°, φ=130°), the
the different impeller cases[26–27]. optimized impeller is designed and simulated using the
Table 5 lists the predicted head, efficiency and NPSHR same method. The predicted performance is compared with
of the 9 schemes under the design condition. The range the original one in Fig. 8. For the design condition, the
analysis method was applied to identify the influence of the NPSHR of the optimized pump decreases by 0.63 m, which
main parameters on the objective function. The sum values significantly improves the cavitation performance. And
of each level for each factor are defined as Ki, and the efficiency calculated is 72.39%, higher than the original
average values are defined as ki, Ki and ki are calculated one.
using Eqs. (9) and (10):

Ni
K i = å yi j , (9)
i =1

1
ki = Ki , (10)
Ni

where i is the number of level, j is the number of factor, yi,j

is the value of NPSHR, which corresponds to factor j in Fig. 8. Comparison of the pump cavitation performance between
level i. N is the total number of levels. the original and optimized impellers at design point
 PEI Ji, et al: Cavitation Optimization for a Centrifugal Pump Impeller
·108· by Using Orthogonal Design of Experiment
4.3 Analysis of the internal flow
The relative velocity vector and pressure distribution are
compared between the original and optimal impellers at
design point when total inlet pressure is 101 325 Pa, as
shown in Fig. 9. As can be seen from the figure, direction
of relative velocity is changed at the leading edge of blade
in the optimal impeller, making fluid more smoothly enter
the impeller compared with original impeller. Meanwhile,
the optimal impeller obviously improves pressure distribution,
compared to the original one. In the optimal impeller,
pressure at the inlet of blade is higher than original one,
which means that cavitation performance is improved.
Fig. 9. Comparison of relative velocity vector and pressure
In this study, numerical simulation of cavitation was
performed by changing the total inlet pressure, and then the
vapor volume fraction distributions for the optimal and
original impellers were compared. Fig. 10 shows that when
the inlet pressure of the pump dropped to 32.5 kPa, critical
cavitation occurred in the original impeller. However, the
vapor volume fraction of optimal impeller was lower than
for the original impeller at the same time, which means that
optimal impeller provided a better cavitation performance.
5 Conclusions
(1) The numerical simulation agrees well with the
experimental results, and cavitation is observed at the
suction side of the blade inlet, which meets the actual
phenomenon.
(2) An L9(3*3) orthogonal array was designed to
evaluate impeller inlet diameter D1, inlet incidence angle
Δβ and blade wrap angle φ using the orthogonal DOE, and
the optimal combination for pump cavitation (D1=196 mm,
Δβ=5.5°, φ=130°) was obtained. The results show that D1
has the greatest influence on the cavitation performance.
The final optimized impeller accomplished better cavitation
performance and the NPSHR decreases by 0.63m compared
with the original one.
(3) Internal flow of original and optimal impeller was
analyzed. Direction of relative velocity vector is changed at
the leading edge of blade in the optimal impeller, making
fluid more smoothly enter the impeller. And in the optimal
impeller, pressure at the inlet of blade is higher than
original one, which means that cavitation performance is
improved.
(a) Original impeller (b) Optimal impeller
Fig. 10. Comparison of vapor volume fraction
distribution in the impeller
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Biographical notes
PEI Ji, born in 1984, is currently an associate professor at
National Research Center of Pumps, Jiangsu University, China.
His research interests include optimization theory, flow instability
and fluid-structure interaction in centrifugal pumps.
Tel: +86-13776474939; E-mail: jpei@ujs.edu.cn
YIN Tingyun, born in 1993, is currently a master candidate at
National Research Center of Pumps, Jiangsu University, China.
His research interests include unsteady cavitation and cavitation
optimization of centrifugal pumps.
E-mail: tingyun_YIN@ujs.edu.cn
YUAN Shouqi, born in 1963, is currently an professor at National
Research Center of Pumps, Jiangsu University, China. His
research interests include energy saving irrigation and theory and
design of pumps.
E-mail: shouqiy@ujs.edu.cn
WANG Wenjie, born in 1990, is currently a PhD candidate at
National Research Center of Pumps, Jiangsu University, China.
His research interests include hydraulic optimization of
centrifugal pumps.
E-mail: wenjiewang@ujs.edu.cn