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Fluid flow simulation inside 2-stage Horizontal Split casing Pump

Conference Paper · December 2012

DOI: 10.13140/2.1.1705.4721

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 Proceedings of the Thirty Ninth National Conference on Fluid Mechanics and Fluid Power
December 13-15, 2012, SVNIT Surat, Gujarat, India

FMFP2012________
191

Fluid flow simulation inside 2-stage Horizontal Split casing Pump

Vishal Soni Shahil S Charania

CFD Analysis Center, CFD Analysis Center,
R & D, Jyoti Ltd., R & D, Jyoti Ltd.,
Vadodara, Gujarat, India Vadodara, Gujarat, India
soni_vishal2002@yahoo.com shahil_157@yahoo.com

Kiran C Patel Jaymin Desai Vishal Chauhan

CFD Analysis Center, CFD Analysis Center, CFD Analysis Center,
R & D, Jyoti Ltd., R & D, Jyoti Ltd., R & D, Jyoti Ltd.,
Vadodara, Gujarat, India Vadodara, Gujarat, India Vadodara, Gujarat, India
cfx@jyoti.com desai_jaymin@yahoo.com vishu_343@yahoo.co.in

ABSTRACT INTRODUCTION
In present paper, CFD analysis of double stage
Due to the technological advancement in CAD-CAM
horizontal split casing pump is discussed. When the
field, optimization process of some of the machine
requirement of head is high, then it is necessary to
component has become possible with lesser time
use pumps in series connection. Double stage requirement. In addition, the availability of high
horizontal split casing pumps are such pumps in
computing computer machines has made it possible
which the output of first stage is connected to the
to solve complex governing equations with least time
input of second stage. Due to complex geometry and
requirement. At Jyoti Ltd, in our CFD analysis
complex nature of fluid flow inside such pumps, it is
centre, Computational fluid dynamics is used in the
necessary to optimize the hydraulic passages for easy
early stage of design to predict the performance of
and smooth guiding of flow. 3d flow visualization
the Hydro pumps/ Hydro Turbines before actual
using RANS equation helps to get better insight and
testing. In the present paper, we have shown the
understanding of fluid flow behavior inside the pump
design optimization process of 2 Stage HS Pump. In
casing. In present case, performance prediction of
preliminary design, we have carried out CFD
pump is discussed at three different points i.e 80%,
simulation of all components at BEP, part load and
100% and 120% of discharge. over load discharges. From post processing of these
results it was found out that the performance of some
Keywords: CFD, Horizontal split casing pump, components can be improved by some modification
Double Stage, Numerical Simulation, 3D RANS. in their hydraulic passages. Following the post
processing results and experience of our hydraulic

1
engineers, some design modifications were inlet of impellers is not uniform. So at design stage
incorporated followed by their CFD simulations. itself its necessary that the impellers should
incorporate some non-uniform flow behavior instead
TWO STAGE HORIZONTAL SPLIT CASING of uniform axial flow assumption. In addition to this,
PUMP it's also necessary to have optimum location of
Horizontal split casing pumps are used when the tongue in the inlet suction elbow since such tongue
discharge requirement is high compared to head. location influences the fluid flow distribution at
Double stage horizontal split casing pumps are used impeller inlet. In present case, we have also
specifically when along with discharge, head considered the fluid leakage gaps for both the
requirement is also high. Such pumps consists of Impellers. Figure 1 and Figure 2 shows the front and
intake suction elbow, first stage centrifugal impeller, side view of 2stage HS pump.
discharge volute of first stage impeller, crossover
bend connected with second stage suction elbow, Discharge Volute - Stage 2 Discharge Volute - Stage 1
second stage impeller and final discharge volute.
Both impellers are connected on same horizontal Impeller - Stage 2 Impeller - Stage 1
shaft and all components are splitted horizontally
along the axis. In such type of pumps generally the
fluid flows from inlet suction elbow to first stage
impeller.

Crossover Elbow

Inlet Suction
Elbow

Outlet Discharge
Volute
Figure 1: Front View of 2 Stage HS Pump
Generally the suction elbows are curved in shape and
the fluid has to follow the curved shape of the conduit
and then has to divide uniformly at the impeller inlet.
But due to inherent complex shape and due to curved
shape of such elbows, the flow distribution at the
Figure 2: Side View of 2 Stage HS Pump
MESHING
For solving the governing PDE’s of fluid flow, it’s
necessary to discretize the domain of interest in small
number of elements. This successive division of
domain in small number of elements is called
meshing or discretization. According to the

2
complexity of domain we can select triangular or
hexagonal meshing elements. On one side hexagonal
elements requires less node points and good solution
accuracy while on other hand, the time required to
mesh a domain with hex element is comparatively
higher. Sometimes it becomes impossible to have
complete hexa-mesh in all domains when domain
itself is very complex in shape. However, we can also
compromise sometimes with a good combination of
hexa and tetra meshing (Hybrid Meshing). Now a
days, due to the availability of automated mesh
generation tools, it has become quite easy to generate
faster automated tetra mesh with good overall
meshing quality. In addition to the tetra elements, to
capture boundary layer effects well within viscous
flow, we can also define prism layers next to walls.
Based on the expertise and solution accuracy, we can
choose between hexa and tetra meshing. In present
case, all domains are discretized with automated tetra
meshing. We have used ANSYS ICEM CFD V12.1
for meshing. About 6 Million Nodes are generated in
all domains. Table 1 shows the meshing details of
different parts of HS pump. Figure 4 (a), (b), (c), and
(d) shows the meshing of all components of 2 Stage
HS pump. Figure 4(b) shows zoomed view of
impeller with prism layer.
Table 1: Detail of Meshing in Different Domains
Tetrahedral Meshing with Prism Layers
Part Name Nodes
Intake Suction Elbow 882982
Stage 1 Impeller 430638
Leakage 1 + Leakage 2 1106000
Discharge volute stage1 and Suction 964675
elbow stage 2
Stage 2 Impeller 430638
Leakage 3 + Leakage 4 1106000
Discharge Volute 532817
PROBLEM DEFINITION
As shown in Fig. 3 is the assembly of 2-stage HS
pump. In present case, the CFD simulations are
carried out at three different discharge values i.e at
part load, BEP and at over load point. At the inlet of
pump, constant atmospheric static pressure condition
is applied while at outlet, mass flow values are
3
applied based on operating condition. Full pump
system is analyzed on two Quad core processors,
with 32 Gb RAM. All simulations are carried out
using incompressible fluid water with all physical
quantities at 25 degree temperature. The interaction
between rotor and stator is treated using frozon rotor
interface while static components are treated using
general interface. ANSYS CFX V12.1 best
turbomachinery practice guide suggests SST
turbulence model to predict viscous loss behavior in
such type of centrifugal machines. Final simulations
are carried out using high-resolution numerical
scheme. Also as shown in the Fig.3, for simulation
purpose, separate inlet and outlet pipes are considered
so that fully developed flow enters the pump casing.
To check the reliability of CFD results, all
simulations are repeated with different mesh size and
a mesh dependency test is carried out for further
reliability of CFD results.
Inlet
Inlet Pipe
Outlet Pipe
Outlet
Figure 3: Meshing first stage Inlet Suction Casing.
RESULTS AND DISCUSSION
As discussed earlier, the fluid flow inside intake
suction elbow is very complex, which in turn affects
the performance of Impeller. The main function of
Intake suction elbow is to provide uniform flow at
impeller inlet. Figure 5 shows the velocity vectors at
the inlet of Impeller at BEP. As can be seen from Fig.
When such discharge volutes smoothly guide the
5, if the tongue region is not provided in such fluid flow, the design can be fixed with no further
casings, then a situation may prevail in which fluid
optimizations.
flow from both side collides and two vortices with From CFD simulations, the hydraulic design of first
corresponding opposite sense of rotation will be stage inlet suction elbow, impeller and first stage
generated. Such generation of vortex may damage thedischarge volutes found satisfactory. Further detailed
impeller and chances of cavitations increases in such
investigation of velocity vectors in second stage
situation. Hence, by placing a tongue region we aresuction casing as shown in Fig. 7 reveals that there is
intentionally preventing the flow from interacting quite a huge amount of low velocity zone created
with each other and preventing the vortex generation.
with non-uniform fluid flow distribution. The low
The location of tongue also plays a major role while
velocity region leads to flow separation and localize
distributing the flow at impeller inlet. CFD is used as
vortex generation, which further deteriorates the
virtual tool to optimize all components of 2 stage HS
second stage impeller performance. The position of
pump with several different combinations and designtongue plays an important role here in providing
modifications. Preliminary CFD simulation is carried
uniform flow at inlet of the impeller. Same trend is
out at BEP point and by looking at the velocity vector
observed for all cases at 80 and 120% discharge.
plots, it's evident that the flow distribution is almost
From careful examination at this section, it was found
uniform at Impeller Inlet. Hence the design of intake
that the fluid entering from cross over elbow tends to
suction casing for first stage impeller can be fixed for
move on straight path following its shape but it
all other modifications. In addition to this at 80%experiences initially the separation due to transition
and 120 % of discharge, the first stage intake suction
of shape and then the blockage due to early arrival of
casing design proves to be sufficient. tongue region in suction casing. Due to sudden
collision of flow with Tongue (Wall), there is high-
Figure 6 shows the velocity vectors in first stage pressure zone (Stagnation Pressure), and low velocity
discharge volute at 100 % discharge and it can be zone created. As a result, flow tends to follow this
seen that the flow angle and cutwater angle are shortest possible path with high velocity compared to
showing good agreement. the remaining part of the suction casing. Also in the
remaining part of suction casing, the sections are
more diverging in radial direction, which leads to

(c) Stage 2 Intake Suction casing

(a) Intake Suction Elbow (b) Impeller Stage 1 and 2 (d) Exit Discharge Volute
and stage 1 Discharge Volute

Figure 4: Meshing of Different components of 2 Stage HS Pump

4
 Due to shifting of the location of tongue, the fluid is
not able to cover some more portion of suction
casing. It can be seen from the velocity vectors of
Fig. 8 that the region of low velocity zone is greatly
reduced and the distribution of fluid flow becomes
uniform.

Figure 5: Velocity Vectors at first stage Inlet Suction

Elbow at 100%Q.

the further separation of flow and finally induce

losses. The design of impeller for both stages is the
same but due to unsuitable inlet condition at second
stage impeller; the head generated is not similar as
first stage.
Figure 7: Velocity Vectors at Second Stage Suction
To improve the suction inlet condition at second
inlet at 100%Q for Case -1
stage Impeller, the geometry of second stage suction
Velocity vectors in Fig. 9 at 100 % Q shows that the
cutwater angle in second stage discharge volute is in
line with the incoming fluid flow. Hence the water is
delivered smoothly through the main exit diffuser and
there is no back flow observed.

Figure 6: Velocity vectors at First stage Discharge

Volute
elbow is revised in which the position of tongue is
shifted without any modification in rest of geometry. Figure 8: Velocity Vectors at Second Stage Suction
inlet at 100%Q for Case -2

5
 is identical. Case 2 consist of modified second stage
suction elbow.

1.05
Case-1 - Impeller 2
1

Head, Non dimensional

0.95 Case-2 - Impeller 2
0.9
0.85
0.8
0.75
0.7
0.65
0.6
80 90 100 110 120
Figure 9: Velocity Vectors in Exit Discharge volute at Q, %
100% Q
Chart 2: Non Dimensional Head comparison for stage
Chart 1 shows non-dimensional head generated by 2 Impeller.
stage 1 impeller for case-1 and case-2. All head
values are normalized by the stage 1 impeller head at Chart 2 shows the non-dimensional head generated
by stage 2 impeller for both cases. Its also evident
100% Q.
from the chart that for case-1, due to the sudden
expansion observed in the passage of stage 2 suction
1.08 elbow, there was improper distribution of fluid flow
1.06 at impeller inlet and hence the impeller was not
Case -1 - Impeller 1
Head, Non Dimensional

1.04 performing well resulting into low head generated.

Case-2 - Impeller 1
1.02
1 1.15
Case-1 Case-2
0.98 1.1
Head, Non-Dimensional

0.96
1.05
0.94
0.92 1

0.9 0.95
80 90 100 110 120 0.9
Q, %
0.85

Chart 1: Non Dimensional Head comparison for stage 0.8

1 Impeller. 80 90 100 110 120
Q, %
It can be also be observed that in both cases since Chart 3: Non Dimensional net-head generated by
there in no modification in geometry of stage 1 inlet pump system.
suction elbow, the head generated by stage 1 impeller

6
After modifying the location of tongue in intake
suction elbow i.e. case-2, there is significant
improvement observed in impeller heads. About 2 to
16 % rise in head observed in case-2 from 80 - 120 %
Q compared to case-1.
Improvement in the second stage impeller
performance leads to overall improvement in pump
performance and as a result the overall head
generated by pump system increases. Chart 3 gives
information about the net head generated by pump
system for both case-1 and case-2. For 80, 100 and
120 % Q, rise in net head is observed in case-2
compared to case-1. This rise in net head is
contributed by the improved performance of second
stage impeller.
1.06
Case-1
1.04
Efficiency, Non-Dimensional
CONCLUSION
In the present paper, the CFD simulations were
carried out for 2 stage HS pump to predict its
performance at BEP, part load and at over load
points. From preliminary analysis, it was found out
that lesser net heads were generated by the system
then required. Detailed investigation with further post
processing leads to the fact that the distribution of
flow at inlet of second stage impeller was non-
uniform. In HS pumps, uniform suction inlet
conditions are very important for better performance
of impellers. Modification in the design of second
stage suction intake elbow results in more uniform
distribution of flow, which in turn leads to
improvement in the performance of second stage
Impeller. At BEP about 8 % rise in head is observed
for second stage impeller. Along with single stage
head improvement, net head of complete system also
improved with corresponding rise in efficiency for all
discharge values.
Case-2

FUTURE WORK
1.02 As discussed above, we have analyzed whole pump
1 system at three different discharge points. All results
presented in this paper are purely from CFD
0.98 simulations. Along with this, validation of the CFD
0.96 result is required by actual testing of pump system.
0.94
ACKNOWLEDGMENTS
0.92 The authors of the paper are greatly thankful to Jyoti
0.9 Ltd. for their immense support throughout the
80 90 100 110 120
research work and facilitating CFD Analysis Center
with latest software & state of the art hardware
Q, %
resources.

Chart 4: Non Dimensional Hydraulic Efficiency of NOMENCLATURE

pump system. BEP - Best Efficiency Point
CFD – Computational Fluid Dynamics
Chart 4 indicates the Non-dimensional Hydraulic
PDE - Partial Differential Equation.
efficiencies for both cases. All hydraulic efficiency
values are normalized by the case-1 efficiency value Q - Discharge
at 100% Q. It can be seen that rise in efficiency is RANS - Reynolds Averaged Navier Stokes Equation.
observed for all discharge values in case-2. SST - Shear Stress Transport.

7
REFERENCES
 Books
Gulich, J.F., 2010, Centrifugal Pumps, Springer -
Verlag, Berlin, Germany, Chap. 7.

Lobanoff, V.F., Ross R.R., Centrifugal Pumps,

Design and Application, Second Edition,
Butterworth-Heinemann, USA, Chap. 7.

 Journal articles
Sallaberger, M., Sebestyen, A., Pinkas, W., Modern
pump Impeller design with consideration of non-
uniform inlet flow fields.
Van den Braembussche, R.A., Flow and Loss
Mechanisms in Volutes of Centrifugal Pumps,
Educational Notes RTO-EN-AVT-143, Paper 12.
Neuilly-sur-Seine, France.
 Help Files
ANSYS Inc, Documentation of ANSYS CFX,
Release 12.1, 2009.

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