SS symmetry

Article
Study on the Effects of the Wear-Rings Clearance on
the Solid-Liquid Two-Phase Flow Characteristics of
Centrifugal Pumps
Chaoshou Yan, Jianfei Liu, Shuihua Zheng * , Bin Huang and Jiacheng Dai
College of Mechanical Engineering, Zhejiang University of Technology, Zhejiang 310023, China;
yanchaoshou1@163.com (C.Y.); jianfeizjut@163.com (J.L.); huangb1n@126.com (B.H.); Dai_jc123@163.com (J.D.)
* Correspondence: zneu@zjut.edu.cn




Received: 17 November 2020; Accepted: 1 December 2020; Published: 4 December 2020


Abstract: In order to study the wear law of the centrifugal pump flowing surface under different
wear-rings clearance, the McLaury wear model was used to conduct the full-passage numerical
simulation of solid-liquid two-phase flow in a single-stage single-suction centrifugal pump.
The reliability of the numerical calculation method is verified by comparing the experimental
data and numerical simulation results. The clearance is 0.1, 0.15, 0.2, 0.3 and 0.5 mm, respectively.
The results show that the wear of the centrifugal pump blades is mainly concentrated in the end part
and the inlet part of the blade, and the wear of the pressure surface at the end of the suction surface
and the front of the blade is more serious. As the clearance increases, the maximum wear value in the
impeller increases first and then decreases, reaching a maximum at 0.15 mm. With the increase of
the clearance, the wear degree and the wear rate of the volute wall surface first increase and then
decrease, and reach the maximum at 0.2 mm. With the increase of the clearance and the concentration
of the fluid medium, the wear at the clearance of the centrifugal pump is more serious, and the severe
wear area exhibits a point-like circumferential distribution.

Keywords: centrifugal pump; solid-liquid two-phase flow; impeller; clearance; wear; volume fraction

1. Introduction
As a widely used fluid machine, the centrifugal pump is characterized by a simple structure,
stable performance, simple operation, and convenient maintenance. However, the actual operating
environment of the centrifugal pump is mostly in the river basin, and the fluid composition contains
solid phase particles. With the flow of water, the solid particles continuously impinged and cut the
surface of the passing parts of the centrifugal pump, making it lose its body. This impact and cutting
can result in large punctured pits on the blade surface, irregular and serrated leaf blade edges, and the
head and tail of the blade are gradually thinned, which, in turn, leads to blade failure. The wear at
the ring causes the gap to become larger and a groove appears. It usually leads to a decrease in the
operating efficiency of the centrifugal pump and affects the safe operation of the centrifugal pump
and shortens the service life of the centrifugal pump over current components [1]. Studying the wear
law of the over-current components in the centrifugal pump under the sandy water flow is of great
significance for mastering the flow, vibration characteristics, and safe operation of the centrifugal pump
under the solid-liquid two-phase flow.
Wu [2] used the continuum model to calculate the relative velocity and concentration distribution
of solid particles in the pump fluid medium. The results show that the volume fraction and relative
velocity of solid particles at the front of the blade and the rear cover increase with the rise of the solid
particle size. As the particle size increases, the volume fraction of solid particles on the wall of the

Symmetry 2020, 12, 2003; doi:10.3390/sym12122003 www.mdpi.com/journal/symmetry

Symmetry 2020, 12, 2003 2 of 21

pressurized water chamber increases, while the relative speed decreases accordingly. Liu [3] used the
mixture model to simulate the flow field of the centrifugal pump, and studied the trajectory of the
solid phase with the liquid phase in the flow field from four variables: sediment concentration, density,
particle size, and flow. He finds that the nature of the particle itself-density and particle size have a
greater impact on the distribution and movement of the particle. The larger the density and particle
sizes are, the larger the particle is. It is easy to deflect to the working surface under the action of inertial
force. Nonetheless, it cannot simulate the movement trajectory of the particles in the discrete phase in
the flow field. Therefore, if the movement of the particles is to be tracked, the Euler model cannot be
accurately solved [4]. Since the interaction force between the liquid phase and the solid phase in the
solid-liquid two-phase is complex, additional interface force models are usually required. Therefore,
for two-phase fluid media, the two-phase interface force is an important development direction for
future research [5].
For the particle trajectory model, the calculation method is the Euler-Lagrangian method [6]
with regard to the fluid as the continuous phase and the particles as the discrete phase. The flow
field, the physical properties of the fluid medium, and the geometric size of the particles are all
reference factors for the force between the particles. This model also needs to track the particle
motion of solid particles, and then use a statistical average to time-average a large number of particle
motions. The advantage of the particle trajectory model is that it can describe the movement of
solid particles in detail, and can obtain the particle speed, flow field, and wear characteristics at
any point. Its disadvantage is that it needs to track a large number of particle trajectories, which is
time-consuming and requires higher computer requirements. This model is mostly used in systems
with fewer particles to solve the particle trajectory equation [7]. Li [8] used the Euler multiphase flow
model, the extended standard k-ε turbulence equation, and the SIMPLEC(Semi-Implicit Method for
Pressure Linked Equations) algorithm to numerically simulate the solid-liquid two-phase turbulence
in the impeller of the swirl pump, and found that the solid particles are mainly distributed in the swirl
and the working surface of the flow pump. The concentration and particle size of the solid phase
all have an impact on the hydraulic performance of the cyclone pump, which is mainly reflected in
the head and efficiency, and the concentration is more serious. Peng [9] used the Euler-Lagrangian
method to study mud pumps. The two factors of flow and concentration were simulated and calculated
separately, and the wear rate was calculated using the wear prediction model. Chen [10] regarded
quartz sand as a discrete phase to study the solid-liquid two-phase flow of the centrifugal pump,
and assumed that the particle shape was spherical, and used the particle trajectory model to analyze its
trajectory in the flow field and in different processes. Under the condition of the wear of the impeller,
the wear rule of the impeller can be obtained.
When compared with the particle trajectory model, the calculation results of the dual-channel
model can be compared with the measured results in the Euler coordinate system, and the results of
numerical simulation can be used to a greater extent. Therefore, this paper will select the two-fluid
model to analyze the flow field and wear of the centrifugal pump.
In order to link the wear of equipment wall materials with many variables, scholars have proposed
wear equations or wear models under different conditions based on a large number of wear experiments.
Tabakoff [11] used coal ash particles and metal wall collision experiments and observed the resulting
wall wear, and proposed a multi-parameter solid particle wear empirical equation including particle
collision speed and the particle collision angle. The wear rate is defined as the ratio of the mass of
the wall material lost after the impact to the total mass of the colliding particles. This model has
been widely used in the numerical simulation of solid particles at home and abroad to calculate the
wear rate of solid particles on metal walls. McLaury B. S [12] proposed a new type of wear equation,
which includes the effects of the physical properties of the material surface, the incident speed of solid
particles, the incident angle, and the shape of the particles. Oka [13,14] and others also put forward a
prediction equation of the metal wall wear rate with wear-related parameters as variables through a
large number of wear experiments.
Symmetry 2020, 12, 2003 3 of 21

Qian [15] numerically simulated the fluid medium containing solid particles in a double suction
centrifugal pump by numerical simulation of the multi-phase flow model. The results show that,
due to the low flow velocity near the ring, the sediment will not be carried by the high-speed moving
water flow to the outlet of the centrifugal pump, and it is easy to accumulate and form a high particle
concentration fluid, resulting in rapid wear of the ring.
Huang [16] used the experimental method to conduct a wear test on a clean water pump
under different flow rates, different solid particle sizes, and different solid particle concentrations,
and obtained the influence of various parameters on the wear position and extent of the pump impeller.
The experimental results show that the impeller wear is more serious when the fluid flow rate is larger,
the solid particle diameter is larger, and the fluid contains high particle concentration, and the main
wear part is at the impeller inlet turn.
Wang [17] used a particle orbit model to simulate the internal flow field of the centrifugal pump
with different particle sizes. The results show that, with the increase of particle size, the slip speed
of the solid phase of the centrifugal pump over-flow wall increases overall, increased solid phase
concentration of the blade face, the solid phase concentration of the non-working surface decreases,
and the solid phase shifts to the working surface decreases. The solid phase concentration of the
non-working surface decreases, and the solid phase shifts to the working surface. The severely worn
area is in the blade head and the tail of the blade’s non-working surface.
Some other scholars have also done related research [18–20]. The research on the wear
characteristics of centrifugal pump particles mainly focuses on the impeller and the overcurrent
components, while the wear characteristics of the wear-rings particles are relatively less. The wear
characteristics of the wear-rings particles are beneficial for the safe operation of the pump station and
prolong the service life of the centrifugal pump.
In this paper, based on a numerical method and Fluent software, the Euler two-phase mixing
model, k-ε turbulence model, and McLaury wear model were used to study the wear law of the
centrifugal pump flowing surface under different wear-rings clearance.

2. Method

2.1. Calculation Model

The single-stage single suction centrifugal pump IS80-50-250 is taken as the object of modeling.
The IS pump(Single-stage single-suction centrifugal pump) is designed in accordance with the
performance and size specified by the international standard IS02858. The IS80-50-250 single-stage
single-suction centrifugal pump is widely used in industrial and urban drainage, water supply,
and used in agricultural irrigation and water supply. The representativeness of this pump is selected as
the research object. The main hydraulic design parameters: Q = 50 m3 /h (Q means flow rate), H = 80 m
(H means head), and n = 2900 r/min (n means Rotating speed). Figure 1a shows a schematic diagram of
the pump body and parts of a single-stage single-suction centrifugal pump. Figure 1b is the clearance
diagram of the straight orifice ring of the centrifugal pump, where L represents the clearance length
and d represents the clearance size.
 used in agricultural irrigation and water supply. The representativeness of this pump is selected as
the research object. The main hydraulic design parameters: Q = 50 m3/h (Q means flow rate), H = 80
m (H means head), and n = 2900 r/min (n means Rotating speed). Figure 1a shows a schematic
diagram of the pump body and parts of a single-stage single-suction centrifugal pump. Figure 1b is
the clearance
Symmetry 2020, 12, 2003diagram of the straight orifice ring of the centrifugal pump, where L represents
4 of 21 the
clearance length and d represents the clearance size.

Symmetry 2020, 12, x FOR PEER REVIEW 4 of 21

(a) Single-stage and single-suction centrifugal pump (b) Clearance of wear-rings

Figure
Figure 1. 1.Schematic
Schematic diagram
diagram ofof the
the model
model pump.
pump.

Figure2 2is isthe

Figure the three-dimensionalmodeling
three-dimensional modelingdiagram
diagramofofthe thecomputational
computationalfluid fluiddomain
domainofofthethe
centrifugal
centrifugal pump.
pump. TheThe
fluidfluid domain
domain refersrefers
to the to
areathe
thatarea
the that
fluid the fluidcan
medium medium
reach incan
the reach in the
centrifugal
centrifugal
pump. In the pump.
figure, theIn the figure, the computational
computational fluid domain is fluid domain
composed is composed
of the of the
inlet extension inletthe
tube, extension
cavity,
tube,
the the cavity,
impeller, the impeller,
the volute, and thethe volute,
outlet and the
extension outlet
tube. Theextension
cavity istube. Theinto
divided cavity
theisfront
divided into
cavity the
and
front cavity and the back cavity. The shape of the blade is a twisted blade, the
the back cavity. The shape of the blade is a twisted blade, the balance of the impeller has a balancebalance of the impeller
has the
hole, a balance
volute hole, the volute
is spiral, is spiral,
the section the section
is irregularly is irregularly
rectangular, andrectangular, and the
the outlet section outlet section is
is circular.
circular.

Figure 2. Three-dimensional modeling diagram of the fluid field in a centrifugal pump.

Figure 2. Three-dimensional modeling diagram of the fluid field in a centrifugal pump.
The main parameters of the model pump are shown in Table 1 below.
The main parameters of the model pump are shown in Table 1 below.
Table 1. Main parameters of the model pump.
Table 1. Main parameters of the model pump.
Parameter Value
Parameter
Impeller inlet diameter D1 80 Value
mm
Impeller inlet diameter
Impeller D 1 D2
outer diameter 25080
mm mm
Number
Impeller outer diameter D2Z
of blades 5 mm
250
Angle of
Number of blades Zthe tongue β 24◦ 5
Impeller outlet width b 6.5 mm
AngleBase
of the tongue β
circle diameter D3
24°
260 mm
ImpellerOutlet
outletdiameter
width b D4 50 mmmm
6.5
Base circle diameter D3 260 mm
2.2. Meshing and Boundary Outlet diameter D4
Conditions 50 mm

2.2.The computational
Meshing and Boundarygrid is generated by ICEM (The Integrated Computer Engineering and
Conditions
Manufacturing code for Computational Fluid Dynamics) using a hybrid grid, as shown in Figure 3.
The computational grid is generated by ICEM (The Integrated Computer Engineering and
Both the inlet extension tube and the outlet extension tube are cylindrical cylinders of a regular shape,
Manufacturing code for Computational Fluid Dynamics) using a hybrid grid, as shown in Figure 3.
Both the inlet extension tube and the outlet extension tube are cylindrical cylinders of a regular shape,
which are cut by the O-shape, as shown in Figure 3a. The geometry of the volute and the impeller is
more complicated, and the unstructured mesh is adopted. The geometrical size of the volute tongue
is small and the flow is complicated, while the mesh is encrypted, as shown in Figure 3b and Figure
Symmetry 2020, 12, 2003 5 of 21

which are cut by the O-shape, as shown in Figure 3a. The geometry of the volute and the impeller is
more complicated, and the unstructured mesh is adopted. The geometrical size of the volute tongue is
small and the flow is complicated, while the mesh is encrypted, as shown in Figure 3b,c. The structure
of the anterior cavity and the posterior cavity is relatively simple and adopts a structured grid, as shown
in Figure 3d,e. Finally, the inspection grid quality is above 0.4, which meets the requirements of a
numerical simulation calculation. In addition, check the grid independence, as shown in Figure 4,
when the total number of grids is 2.08 million, the error of the analog head value is within 2%, and the
calculationSymmetry
is not2020,
too12,complicated. Therefore, the total number of grids is 2.08 million. 5 of 21
x FOR PEER REVIEW

(a) Export pipe

(b) Volute (c) Impeller

(d) Anterior cavity (e) Back cavity

(f) Full channel fluid domain grid

Figure
Figure 3. 3. Gridof
Grid of the
the computing
computingmodel.
model.
Symmetry 2020, 12, 2003 6 of 21
Symmetry 2020, 12, x FOR PEER REVIEW 6 of 21

Figure
Figure 4. Grid independence
4. Grid independence verification.
verification.

The Euler model is used to calculate the solid-liquid two-phase flow. The turbulence calculation
The Euler model is used to calculate the solid-liquid two-phase flow. The turbulence calculation
models are standard k-ε models. The sliding grid is used for the part that belongs to the impeller
models are standard k-ε models. The sliding grid is used for the part that belongs to the impeller
fluid domain, and the rest is selected for the stationary coordinate system. The Wen-Yu model is
fluid domain, and the rest is selected for the stationary coordinate system. The Wen-Yu model is
selected. The boundary conditions of the inlet are all speed imports, and the boundary conditions of
selected. The boundary conditions of the inlet are all speed imports, and the boundary conditions of
the outlets are all free flow. The impeller rotation speed is set to 2900 r/min, and the wall roughness is
the outlets are all free flow. The impeller rotation speed is set to 2900 r/min, and the wall roughness
set to 0.04 mm. Among them, the liquid phase in the overflow wall surface and the sandy water flow
is set to 0.04 mm. Among them, the liquid phase in the overflow wall surface and the sandy water
adopt the non-slip wall boundary condition, while the solid phase adopts the free slip wall boundary
flow adopt the non-slip wall boundary condition, while the solid phase adopts the free slip wall
condition. Since the reference pressure has no effect on calculating the external characteristics of the
boundary condition. Since the reference pressure has no effect on calculating the external
centrifugal pump, the reference pressure is set to 0 Pa. The convergence accuracy is set to 10−4 .
characteristics of the centrifugal pump, the reference pressure is set to 0 Pa. The convergence accuracy
is setGoverning
2.3. to 10−4. Equation

The Eulerian
2.3. Governing multiphase flow model is widely used in the simulation of a multi-phase flow.
Equation
In addition, the standard k-ε turbulence model can also obtain more consistent and accurate
The Eulerian multiphase flow model is widely used in the simulation of a multi-phase flow. In
conclusions with experimental data [21–25]. Therefore, the Euler multiphase flow model and the
addition, the standard k-ε turbulence model can also obtain more consistent and accurate conclusions
standard k-ε turbulence model were selected. The k-ε model introduces two new variables in the
with experimental data [21–25]. Therefore, the Euler multiphase flow model and the standard k-ε
Navier-Stokes equation.
turbulence model were selected. The k-ε model introduces two new variables in the Navier-Stokes
Assuming that the total number of phases of the multiphase flow in general is N, then the
equation.
conservation equation of the qth phase is [26,27]:
Assuming that the total number of phases of the multiphase flow in general is N, then the
conservation equation of the qth phase
∂ αq ρisq [26,27]:
 
n
→ .
 X
( ) + ∇· α ρ v
q q q = mPq (1)
∂t + ∇ ∙ 𝛼 𝜌 𝑣 ⃗ = ∑ 𝑚 (1)
P=1

The momentum
The momentum equation
equation is:
is:
⃗
→+∇∙(𝛼 𝜌 𝑣 ⃗𝑣 ⃗) = −𝛼 ∇P + ∇ ∙ 𝜏 +𝐹⃗+ ∑ n 𝐾
𝑣→⃗ − 𝑣 ⃗ + 𝑚 𝑣⃗ (2)
∂ ( αq ρq v q )  → → h i → X →  . →
+ ∇· αq ρq vq vq = −αq ∇P + ∇· τq + Fq + KPq vP − vq + mPq v Pq (2)
𝜏 is the∂t qth phase known as the stress-strain tensor, whichP=1
can be obtained by the following
formula.
h i
τq is the qth phase known as the stress-strain
, ,
tensor, which,
can be obtained by the
following formula. τ , = 𝛼 𝜇 + 𝛼 𝜇 𝛿 (3)
∂uq,j ∂uq,i −2 ∂uq,i
!
Turbulent viscosity: τq,ij = αq µq + αq µq δij (3)
∂x j ∂xi 3 ∂xi
Turbulent viscosity: 𝜇 , =𝜌 𝐶 (4)
Kq2
where αq is the volume fraction of the phase µt,q q,
= uρqisCµthe instantaneous velocity, F is the interphase
(4)
εq
force, g is the acceleration of gravity, ρ is the density, μ is the dynamic viscosity, and λ is the volume
viscosity [28].
Symmetry 2020, 12, 2003 7 of 21

where αq2020,
Symmetry is the
12, xvolume REVIEWof the phase q, u is the instantaneous velocity, F is the interphase
fraction
FOR PEER 7 of 21
force, g is the acceleration of gravity, ρ is the density, µ is the dynamic viscosity, and λ is the volume
2.4. Wear[28].
viscosity Model
In the wear calculation of solid-liquid two-phase flow in the centrifugal pump, the velocity of
2.4. Wear Model
fluid medium and the concentration distribution of solid particles are important parameters to study
In the wear
the internal flowcalculation
field. Theof solid-liquid
McLaury modeltwo-phase
is widelyflow
usedin the centrifugal the
in calculating pump, the velocity
solid-liquid of fluid
two-phase
medium
flow wear andinthehydraulic
concentration distribution
machinery, and of
thissolid particles
wear modelare important
considers parameters
the effects oftospeed
study and
the
internal flow field.
concentration. The McLaury
Therefore, based model
on the iswear
widely usedproposed
model in calculating the solid-liquid
by McLaury, two-phaselaw
the distribution flowof
wear
wearin hydraulic
rate machinery,
of centrifugal pump and this wear
overcurrent model considers
components the effects
is obtained throughof speed and concentration.
the following calculation.
Therefore, based on formula
The calculation the wearformodel proposed
this model is as by McLaury,
follows [12]: the distribution law of wear rate of
centrifugal pump overcurrent components is obtained through the following calculation.
WR = 2 . 17 × 10 −7
× ( BH )
The calculation formula for this model is as follows [12]: p p
−0.59
F v 2.41
F (ϕ ) (5)

F (ϕ ) WR
−7 −0.59 2.41
= 5.4=ϕ2.17 10ϕ 2 ×+ (10
− 10×.11 BH ) ϕ3 −
.93 F(4ϕ+) 1.42ϕ 5
Fp6v.p33ϕ (5)
(6)

F(ϕ) = 5.4ϕ − 10.11ϕ2 + 10.93ϕ3 − 6.33ϕ4 + 1.42ϕ5 (6)

ER = q mWR Acell (7)
ER = qm WR/Acell (7)
where WR is the weight loss rate of grinding, BH is brinell hardness of the wall material, and FP is the
where WR
particle is thecoefficient.
shape weight lossTherate of grinding,
solid BH is brinell
phase is angular hardness
particles, and Fof
P =the
1 iswall material,
taken. and FvPpisisthe
In addition, the
particle
speed of shape coefficient.
the solid phase,The
m/s,solid
φ isphase is angular particles,
the solid-phase incident and
angle, = 1 isER
FP rad, taken.
is theInwear rate, vqpm is
addition, is the
the
speed of the solid phase, m/s, ϕ is the solid-phase incident angle, rad, ER is the
solid phase mass flow rate, kg/s, and Acell is the area of the grid wall of the calculation unit. When wear rate, q m is the
the
solid phase
material of mass flow rate, kg/s,
the centrifugal pumpand Acell is the area
is unchanged, of the
it can grid from
be seen wall of
thethe calculation
formula that unit. When
the wear ratetheis
material
related toof the
the incident
centrifugal pump is
collision unchanged,
velocity, it can
incident be seenangle,
collision from the
andformula
mass flow that rate
the wear
of therate is
solid
related
phase. to the incident collision velocity, incident collision angle, and mass flow rate of the solid phase.

2.5.
2.5. Verification
Verification ofofaaNumerical
NumericalSimulation
SimulationMethod
Method
The
Themodel
modelpump
pumpwithwithaa ring
ring gap
gap of
of 0.15-mm
0.15-mm was
was verified
verified by
by numerical
numerical simulation
simulationexperiments
experiments
at different flow rates. Figure 5 below is a schematic diagram of a centrifugal
at different flow rates. Figure 5 below is a schematic diagram of a centrifugal pump pump
test test bench.
bench. The
The test bench mainly includes water tanks, test pumps, pressure gauges, torque meters, flow
test bench mainly includes water tanks, test pumps, pressure gauges, torque meters, flow meters, and meters,
and piping
piping systems.
systems.

Figure 5. Centrifugal pump test bench. 1-Water-sealed valve, 2-voltage stabilizer, 3-experimental
Figure4-torque
pump, 5. Centrifugal pump test
meter, 5-motor, bench.
6-flow 1-Water-sealed
meter, valve,
7-Flow control 2-voltage
valve, 8-waterstabilizer, 3-experimental
tank, 9-digital indicator,
pump, 4-torque meter, 5-motor, 6-flow
10-pressure gauge, and 11-outlet valve. meter, 7-Flow control valve, 8-water tank, 9-digital indicator,
10-pressure gauge, and 11-outlet valve.

Figure 6 shows the external characteristic curve of the centrifugal pump test bench and the
numerical simulation when the water medium is clean. Except for the 0.6 working condition, the
simulated head increases and the hump phenomenon occurs. Under other conditions, the simulated
 Symmetry 2020, 12, 2003 8 of 21

Symmetry 2020, 12, x FOR PEER REVIEW 8 of 21

Figure 6 shows the external characteristic curve of the centrifugal pump test bench and the
head and the test head have a tendency to decrease with the increase of flow, and the drop gradient
numerical simulation when the water medium is clean. Except for the 0.6 working condition,
of head gradually increases. While the simulation efficiency and test efficiency graphs first increase
the simulated head increases and the hump phenomenon occurs. Under other conditions, the simulated
with the increase of flow, and then decrease, because this model pump designed is biased toward
head and the test head have a tendency to decrease with the increase of flow, and the drop gradient
large flow conditions, the efficiency value reaches the maximum value under 1.2 operating
of head gradually increases. While the simulation efficiency and test efficiency graphs first increase
conditions, which is slightly greater than the efficiency value under standard conditions. According
with the increase of flow, and then decrease, because this model pump designed is biased toward
to Figure 6, the simulated values of head and efficiency are slightly larger than the experimental
large flow conditions, the efficiency value reaches the maximum value under 1.2 operating conditions,
values. This is due to the insufficiency and roughness of the centrifugal pump wetted parts
which is slightly greater than the efficiency value under standard conditions. According to Figure 6,
manufacturing process under actual conditions.
the simulated values of head and efficiency are slightly larger than the experimental values. This is
Compare the magnitude of the corresponding simulation and test values in the curve in the
due to the insufficiency and roughness of the centrifugal pump wetted parts manufacturing process
figure below. The error values are all within 5%, which meets the calculation requirements.
under actual conditions.

Experimental head
Simulated head
90 Experimental efficiency 90
Simulated efficiency

80 80

70 70
Hm/m

η/%
60 60

50 50

40 40

0.4 0.6 0.8 1.0 1.2 1.4

Q/Qd

Figure 6. Simulation of the external characteristics of the centrifugal pump-experimental value curve.
Figure 6. Simulation of the external characteristics of the centrifugal pump-experimental value curve.
Compare the magnitude of the corresponding simulation and test values in the curve in the figure
3.below. The
Results error
and values are all within 5%, which meets the calculation requirements.
Discussions

3. Results and Discussions

3.1. Effects of Wear-Rings Clearance on External Characteristics of Centrifugal Pump
3.1.As
Effects
shown of Wear-Rings
in Figure 7,Clearance on External Characteristics
in the performance of Centrifugal
curve of the centrifugal pumpPump under the condition of
sand concentration under a different opening ring clearance d, three
As shown in Figure 7, in the performance curve of the centrifugal pump under working conditions: 0.8q,of1.0q,
the condition sand
and 1.2q are selected for numerical simulation analysis of the centrifugal pump. Flow-head
concentration under a different opening ring clearance d, three working conditions: 0.8q, 1.0q, and 1.2q are curve and
flow-efficiency curve are
selected for numerical significant
simulation performance
analysis curves of
of the centrifugal centrifugal
pump. Flow-headpumps.
curveAccording to the
and flow-efficiency
curve of the wear-rings clearance d and the head of the centrifugal pump in the
curve are significant performance curves of centrifugal pumps. According to the curve of the wear-ringsupper part of Figure
7,clearance
it can bedseen that,
and the under
head of thethe same clearance,
centrifugal pump in the head of
the upper small-flow
part of Figure 7,isitthe
canhighest, the head
be seen that, underofthe
large-flow is the lowest, and the head declines faster. The head in the small-flow
same clearance, the head of small-flow is the highest, the head of large-flow is the lowest, and the head is more similar to
the standard.
declines The
faster. head
The headof in
thethecentrifugal
small-flowpump
is more in similar
small-flow
to theis standard.
the highest Thewhen
headdof = the
0.1 centrifugal
mm. The
head
pump ofinthe centrifugal
small-flow pump
is the highesttends
when toddecrease
= 0.1 mm.asThe thehead
clearance increases in
of the centrifugal the same
pump tends toconditions.
decrease as
When
the clearance increases in the same conditions. When d = 0.5 mm, the downward trend of head inflow,
d = 0.5 mm, the downward trend of head in large-flow is the fastest. The larger the the
large-flow
more
is theclear the The
fastest. impact of the
larger the flow,
changethe in clearance
more clear the onimpact
the external characteristics
of the change of the
in clearance oncentrifugal
the external
pump. The larger the clearance, the more energy leaked, making the head decrease
characteristics of the centrifugal pump. The larger the clearance, the more energy leaked, making the head faster.
The efficiency
decrease faster. graph of the centrifugal pump is located at the bottom of Figure 7. In the figure,
the abscissa represents the gap of the mouth ring, the ordinate H represents the head, and η represents
the efficiency. The efficiency of the centrifugal pump under the sandy condition increases with the
increase of the flow no matter how the clearance changes. This may be because the research object
Symmetry 2020, 12, x FOR PEER REVIEW 9 of 21

shifted the highest efficiency point to a large flow to ensure the efficiency at high flow conditions.
When the clearance increases, the efficiency decreases in the three flow conditions.
Symmetry 2020, 12, 2003 9 of 21

Head: 0.8Q 1.0Q 1.2Q

80 90%
Efficiency: 0.8Q 1.0Q 1.2Q
85%

80%
70
75%
Hm/m

η%
70%

65%
60
60%

55%

50 50%
0.1 0.2 0.3 0.4 0.5
d/mm

Figure 7. Performance of the centrifugal pump with sediment under different wear-rings clearances.

Figure 7. Performance
The efficiency of the
graph centrifugal
of the pumppump
centrifugal with sediment under
is located different
at the bottom wear-rings
of Figureclearances.
7. In the figure,
the abscissa represents the gap of the mouth ring, the ordinate H represents the head, and η represents
3.2.
theUnsteady Clearance
efficiency. Flow Analysis
The efficiency of the centrifugal pump under the sandy condition increases with the
increase
In orderof to
thestudy
flow the
no matter
working how the clearance
condition changes. Thispump
of the experimental may be in because the research
most working hours,object
the
shifted the highest efficiency point to a large flow to ensure the efficiency at
internal flow field of the centrifugal pump is analyzed under the standard working condition,high flow conditions.
i.e., Q
When
= 50 theFigure
m3/h. clearance increases,
8 shows the efficiency static
the instantaneous decreases in thedistribution
pressure three flow conditions.
diagram of the centrifugal
pump under different clearances under standard working conditions, and studies the pressure
3.2. Unsteady Clearance Flow Analysis
distribution in the centrifugal pump under a different clearance with sandy water. As can be seen
from the In pressure
order to nephogram
study the working
of the crosscondition
sectionof ofthethe experimental
centrifugal pump pump in in most6,working
Figure the pressurehours,
the internal
distribution of flow field channel
each flow of the centrifugal
in the impeller pump is is
veryanalyzed
regularunder the standard
and symmetrical working
in the center,condition,
except
thei.e.,
flow = 50 m3near
Q channel /h. Figure 8 shows
the tongue. There theis instantaneous static pressure
a pressure accumulation near distribution diagramand
the septum tongue, of athe
small pressure drop occurs in the diffusion tube area connected to it. At the same time, the internalthe
centrifugal pump under different clearances under standard working conditions, and studies
pressure
flow distributionisinbasically
field distribution the centrifugal
the samepump whileunder a different
the clearance clearanceand
is different with
thesandy
internalwater. As can
pressure
of be
theseen from the
centrifugal pumppressure nephogram
impeller increasesof thethe
with cross section
radial of theThis
gradient. centrifugal
is because pump in Figure 6,
the centrifugal
the generated
force pressure distribution
by the rotationof each flow
of the channeldoes
impeller in the impeller
work for theis fluid
very regular and symmetrical
in the impeller passage. The in the
center,
larger theexcept
radius,the theflow channel
greater near the tongue.
the centrifugal There isby
force suffered a pressure
the fluid,accumulation
and the more near workthe septum
is done.
Thetongue, and a small
more kinetic energypressure drop to
is converted occurs in the
pressure diffusion
energy, tube area
the higher connected
the static pressureto it.value
At the same
is. The
time, the
pressure nearinternal flow
the inlet fieldimpeller
of the distribution
is theis basically
lowest and the same while
pressure the clearance
distribution is different
is relatively and the
uniform,
internal
while pressurenear
the pressure of the
thecentrifugal
outlet of the pump impeller
impeller increases
is higher. with the
However, theradial gradient.
pressure This is because
distribution is not
the centrifugal
uniform. force generated
This non-uniformity by the rotation
is mainly caused by of thetheimpeller
geometric does work for the
asymmetry fluid
of the in theand
volute impeller
the
passage.
static The larger
interference. Thethe radius,onthe
pressure thegreater
working thesurface
centrifugal of theforce
blade suffered
is higherby than
the fluid,
that onandthe
thenon-more
work issurface,
working done. Thewhich more kinetic caused
is mainly energy by is converted
the inertialtoforce pressure energy,force
and viscous the higher the static
of the fluid pressure
in the flow
value is.
passage. Thealso
It can pressure
be seennear thethe
from inlet of the
figure impeller
that is the lowest
the pressure gradient andof the pressure
middle sectiondistribution
of the is
relatively
impeller uniform,
gradually while thewith
decreases pressure near theofoutlet
the increase of the impeller
the clearance. From theis higher. However,
blade inlet the outlet,
to blade pressure
thedistribution is not uniform.
clearance increases, This non-uniformity
the pressure in the area near is the
mainly
blade caused by the geometric
inlet increases, and the asymmetry
pressure in of thethe
volute
area nearand thetheblade
static outlet
interference. The pressure
decreases. Then the onheadthe working
tends to surface of the corresponding
decrease, blade is higher than to the that
on the non-working
relationship surface, which
between clearance and headis mainly caused
in Figure 7. by the inertial force and viscous force of the fluid
in the flow passage. It can also be seen from the figure that the pressure gradient of the middle section
of the impeller gradually decreases with the increase of the clearance. From the blade inlet to blade
outlet, the clearance increases, the pressure in the area near the blade inlet increases, and the pressure
Symmetry 2020, 12, 2003 10 of 21

in the area near the blade outlet decreases. Then the head tends to decrease, corresponding to the
Symmetry 2020,
relationship 12, x FORclearance
between PEER REVIEW
and head in Figure 7. 10 of 21

(a) d = 0.1 mm (b) d = 0.15 mm (c) d = 0.2 mm

(d) d = 0.3 mm (e) d = 0.5 mm

Figure Figure 8. Instantaneous
8. Instantaneous static pressure
static pressure distribution
distribution of centrifugal
of centrifugal pumpspumps
under aunder a different
different clearance.
clearance.
Figure 9 is the static pressure distribution diagram of section y = 0 containing sand water at the same
time inFigure
different
9 isclearance
the static under thedistribution
pressure design condition.
diagram sectionyy==00can
Theofsection be moresand
containing comprehensive
water at the
tosame
see the pressure changes in the whole passage of the centrifugal pump,
time in different clearance under the design condition. The section y = 0 can be more mainly including the
front chamber andtothe
comprehensive seeback
the chamber, which is in
pressure changes easy
thetowhole
ignorepassage
when studying the internal
of the centrifugal flow of
pump, the
mainly
centrifugal
including pump.
the front Aschamber
can be seen
and from the figure,
the back chamber, the which
pressure insidetothe
is easy impeller
ignore when has a change,
studying the
but the range of change is relatively small. From the change of clearance from 0.1 mm
internal flow of the centrifugal pump. As can be seen from the figure, the pressure inside the impeller to 0.5 mm, it can
behas
clearly seen but
a change, thatthe
therange
pressure gradient
of change of the front
is relatively cavity
small. is small
From when the
the change clearancefrom
of clearance is 0.10.1mm.mm
The
to 0.5 mm, it can be clearly seen that the pressure gradient of the front cavity is small when of
change of clearance of the front wear-ring mainly has a significant impact on the pressure the
the front cavity
clearance is 0.1and
mm. theThe
overall pressure
change is basically
of clearance of theconsistent with the
front wear-ring pressure
mainly has at the outlet of
a significant the
impact
impeller. As the clearance
on the pressure becomes
of the front cavitylarger
and the and the pressure
overall pressure gradient increases,
is basically the pressure
consistent with thenear the
pressure
inlet
at the outlet of the impeller. As the clearance becomes larger and the pressure gradient increases,the
wear-ring of the front chamber decreases and the low-pressure area gradually expands. Since the
clearance
pressuresize
nearofthethe rearwear-ring
inlet ring remains
of theunchanged,
front chamber the decreases
pressure in thethe
and back chamber decreases
low-pressure area graduallyin a
small range Since
expands. but doesthe not change size
clearance significantly. Withring
of the rear the remains
increase of clearance, the
unchanged, the high-pressure
pressure in the areabackin
the volute gradually decreases and the change is clear. Therefore, when the clearance
chamber decreases in a small range but does not change significantly. With the increase of clearance, between the front
wear-ring increases,area
the high-pressure the main
in theeffect
volute ongradually
the front cavity
decreasesis relatively large, soisthat
and the change clear.the average pressure
Therefore, when the
ofclearance
the front between
cavity decreases and the pressure gradient increases.
the front wear-ring increases, the main effect on the front cavity is relatively large,
so that the average pressure of the front cavity decreases and the pressure gradient increases.

(a) d = 0.1 mm (b) d = 0.15 mm (c) d = 0.2 mm

pressure near the inlet wear-ring of the front chamber decreases and the low-pressure area gradually
expands. Since the clearance size of the rear ring remains unchanged, the pressure in the back
chamber decreases in a small range but does not change significantly. With the increase of clearance,
the high-pressure area in the volute gradually decreases and the change is clear. Therefore, when the
clearance between
Symmetry 2020, 12, 2003the front wear-ring increases, the main effect on the front cavity is relatively 11
large,
of 21
so that the average pressure of the front cavity decreases and the pressure gradient increases.

Symmetry 2020, 12, x FOR PEER REVIEW 11 of 21

(a) d = 0.1 mm (b) d = 0.15 mm (c) d = 0.2 mm

(d) d = 0.3 mm (e) d = 0.5 mm

Figure 9. Static pressure distribution diagram of section y = 0 under different clearances.

Figure
Figure 10 10shows
showsthe thepressure
pressure distribution
distribution of the circular
of the circularsection withwith
section the same diameter
the same at theat
diameter same
the
time
sameoftime different fluid medium
of different with different
fluid medium wear-rings
with different clearance.clearance.
wear-rings As shown Asinshown
the figure,
in thewhen the
figure,
clearance
when the increases, the orificethe
clearance increases, ring pressure
orifice ring near the front
pressure near cavity
the front drops,
cavityand the overall
drops, and thepressure
overall
distribution of wear-rings
pressure distribution is more uniform.
of wear-rings is more Whenuniform. clearance
When d is 0.1 mm
clearance d isand0.10.15
mmmm, andthe 0.15geometric
mm, the
size of the size
geometric wear-rings is too small,iswhich
of the wear-rings is easily
too small, which affected
is easily by affected
the rotating impeller
by the rotating front cover plate
impeller front
and
cover theplate
stationary
and the front pump cover.
stationary When clearance
front pump cover. When d = 0.2 mm, the
clearance d =geometric
0.2 mm, size of the wear-rings
the geometric size of
is
theless than 0.1 mm.
wear-rings Inthan
is less addition,
0.1 mm.0.15Inmm is less affected
addition, 0.15 mmby is the
lessrotating
affectedsurface
by the of the impeller
rotating surface andof the
stationary surface of the front pump cover, but the size change is still relatively
impeller and the stationary surface of the front pump cover, but the size change is still relatively large large compared with
the interface
compared withof the
thefront
interfacecavity.of Therefore, the pressure
the front cavity. Therefore, drops thesomewhat,
pressure dropsbut thesomewhat,
pressure near but the
front
pressurecavity
nearis higher
the front than thatisnear
cavity the wear-rings.
higher than that near When the clearance
wear-rings. d is 0.3 mm
When and 0.5dmm,
clearance is 0.3it mm
can
be
andseen0.5 that
mm,the it overall
can be pressure
seen thatdistribution
the overall of the outlet
pressure ring is symmetric
distribution because
of the outlet ring theisgeometrical
symmetric
size of the
because theinterface
geometrical between size the front
of the cavity between
interface and the wear-rings
the front cavity is similar,
and theandwear-rings
the influence on the
is similar,
wear-rings is reduced. The fluid in the front cavity presents different
and the influence on the wear-rings is reduced. The fluid in the front cavity presents different flow flow characteristics under the
influence of theunder
characteristics flow inthe theinfluence
wear-rings. of Since
the flowthe front
in thecover plate is aSince
wear-rings. rotating
the surface
front cover whileplate
the front
is a
pump
rotating cover is static,
surface whilethe theflow
frontinpump
different
cover positions
is static, in
thetheflowfront cavity presents
in different positions different flow cavity
in the front states.
The non-uniform
presents differentpressure
flow states. distribution caused bypressure
The non-uniform the clearance makes the
distribution axialby
caused force
theof the wear-rings
clearance makes
non-uniform,
the axial forcewhile of thethewear-rings
annular force of the orificewhile
non-uniform, ring has theaxial
annularsymmetry.
force ofTherefore,
the orifice thering
non-uniform
has axial
axial force can
symmetry. be ignored.
Therefore, When the clearance
the non-uniform is small,
axial force can be theignored.
high energy
Whenfluid the leaked
clearance from the outlet
is small, the
pipe
high is less likely
energy fluidto enter from
leaked the inlet
the of the impeller
outlet pipe is lessthrough
likelythe wear-rings,
to enter the inlet which
of the reduces
impeller thethrough
energy
leakage. Therefore,
the wear-rings, which it reduces
is relatively advantageous
the energy leakage. to choose aitsmall
Therefore, clearance
is relatively of the wear-rings
advantageous to choose to
improve the efficiency.
a small clearance of the wear-rings to improve the efficiency.
Symmetry 2020, 12, 2003 12 of 21

Figure 10. Pressure distribution of the circumferential section under a different clearance.

The axial direction of the centrifugal pump is the z-axis. In order to study the flow state of the
front cavity when the clearance size changes, the circumferential axial surface at z = −15 mm in the
front pump cavity is intercepted. Figure 11 shows the velocity cloud diagram of the front cavity axial
surface when the clearance size is different. It can be seen from the figure that the clearance of the
wear-rings affects the velocity distribution of the liquid in the front chamber of the centrifugal pump.
When the clearance d is 0.1 mm, the velocity gradient changes greatly and the average velocity is low.
With the gradual increase of clearance, the change of velocity of the axial plane tends to be stable.
When the maximum clearance value is 0.5 mm, the change of velocity gradient is minimal, and the
average velocity increases. On the whole, the velocity distribution is relatively uniform and increases
along the radius. However, due to the asymmetry of the volute structure, a low speed zone will appear.

Figure 11. Distribution of liquid velocity on the axis of the front pump cavity under a different clearance.

Figure 12 shows the flow diagram at the anterior cavity. It can be seen that vortexes tend to
appear near the front cover plate because the front pump cover is a stationary surface while the front
cover plate is a rotating surface. The influence of the centrifugal force on the media near the rotating
surface is relatively large. Therefore, the velocity at the cover plate is relatively greater than that of
 Symmetry 2020, 12, 2003 13 of 21

the front pump cover at the same radius. As a result, vortexes are more likely to form on the front
cover. With the increase of the gap, it can be seen that the vortexes in the front cavity tend to decrease.
When the clearance is 0.5 mm, the vortex at the front cover plate is the smallest, and the average
velocity increases, making the leaking medium flow more into the inlet of the impeller through the
Symmetry 2020, 12,
wear-rings, x FOR PEER
causing REVIEW
energy loss. 13 of 21

(a) d = 0.1 mm, (b) d = 0.15 mm, (c) d = 0.2 mm, (d) d = 0.3 mm, and (e) d = 0.5 mm

Figure
Figure12.12.Streamline of liquid
Streamline velocity
of liquid velocity y = 0 cross-section
at y =at0 cross-section in the front cavity
in the under
front a different
cavity under a
clearance.
different clearance.

3.3.Wear
3.3. WearCharacteristics
CharacteristicsAnalysis
Analysisofofthe
theImpeller
Impellerwith
witha aDifferent
DifferentClearance
Clearance
Figure1313below
Figure belowshows
showsthe thedistribution
distributiondiagram
diagramofofthe thesolid
solidcontent
contentinside
insidethethecentrifugal
centrifugalpumppump
atatthe
thesame
sametimetimeunder
underdifferent
differentwear-rings
wear-ringsclearance.
clearance.As Asshown
shownininthe thefigure,
figure,thethesand
sandaccumulates
accumulates
in the inlet area of the blade, especially near the head of the blade. With
in the inlet area of the blade, especially near the head of the blade. With the increase of clearance, the increase of clearance,
the
the sediment
sediment concentration
concentration in theininlet
the inlet
area area
tendstends to decrease
to decrease gradually.
gradually. DueDue to large
to the the large proportion
proportion of
of sand, under the action of centrifugal force and fluid reflux on the blade
sand, under the action of centrifugal force and fluid reflux on the blade working face, the volume working face, the volume
fractionofofsand
fraction sandininthe
theflow
flowpassage
passageofofthe theimpeller
impellerisisalmostalmost00ininaacertain
certainrangerangenear
nearthethemiddle
middleofof
theblade
the bladeworking
workingface.face.However,
However,the thesand
sandcontent
contentinina asmallsmallpartpartofofthe
thetail
tailofofthe
theworking
workingface faceisis
significantly higher than that in the middle. The average sediment concentration
significantly higher than that in the middle. The average sediment concentration near the non- near the non-working
face of the
working faceblade
of theisblade
higher, amongamong
is higher, which,which,
the surface of theofnon-working
the surface the non-working face face
has has
a relatively
a relativelylow
sediment
low sedimentconcentration,
concentration, whilewhile
the tailthe
of the
tailnon-working
of the non-workingface has a face
higher sediment
has a higher concentration.
sediment
When the clearance becomes larger, the average content of sand near the
concentration. When the clearance becomes larger, the average content of sand near the non-working non-working face decreases
anddecreases
face the low content
and the area
low becomes
contentlarger. The sandlarger.
area becomes in the The
volute accumulates
sand in the volute in the outermost edge
accumulates in theof
the volute, and the content increases gradually from the first section to the
outermost edge of the volute, and the content increases gradually from the first section to the eighth eighth section. The sand
concentration near the tongue of the volute is low, and the average content
section. The sand concentration near the tongue of the volute is low, and the average content of sand of sand is higher the closer
isthe diffusion
higher tube ofthe
the closer thediffusion
volute is tube
to theofoutlet. Whenisthe
the volute to clearance
the outlet.ofWhen
the wear-rings increases,
the clearance of thethe sand
wear-
concentration near the tail of the non-working face of the volute tongue and
rings increases, the sand concentration near the tail of the non-working face of the volute tongue and blade decreases, and the
volume fraction of sand from the diffusion tube to the outlet decreases
blade decreases, and the volume fraction of sand from the diffusion tube to the outlet decreases significantly when the clearance
is 0.3 mm and
significantly 0.5 mm.
when the clearance is 0.3 mm and 0.5 mm.

(a) d = 0.1 mm (b) d = 0.15 mm (c) d = 0.2 mm

outermost edge of the volute, and the content increases gradually from the first section to the eighth
section. The sand concentration near the tongue of the volute is low, and the average content of sand
is higher the closer the diffusion tube of the volute is to the outlet. When the clearance of the wear-
rings increases, the sand concentration near the tail of the non-working face of the volute tongue and
blade decreases, and the volume fraction of sand from the diffusion tube to the outlet decreases
Symmetry 2020, 12, 2003 14 of 21
significantly when the clearance is 0.3 mm and 0.5 mm.

Symmetry 2020, 12, x FOR PEER REVIEW 14 of 21

(a) d = 0.1 mm (b) d = 0.15 mm (c) d = 0.2 mm

(d) d = 0.3 mm (e) d = 0.5 mm

13. Solid volume fraction at z = 0 cross section of the centrifugal pump.
Figure 13.
Figure

Figure 14 below shows the distribution of the solid phase of the blade and the velocity flow
diagram of the middle section of the impeller under different clearance clearance conditions when the solid
phase concentration is 50 kg/m kg/m33 under rated conditions. It can be seen from the solid phase volume
distribution of ofthe
theblade
bladeinin thethe figure
figure that
that thethe
solidsolid
phase phase is more
is more distributed
distributed in thein the head,
blade blade upper
head,
upper edge,
edge, and tailand
of tail
the of the suction
blade blade suction surface.
surface. The solidThedistribution
solid distribution
on the on the pressure
pressure surfacesurface
is much is
much
smallersmaller
than thatthan onthat
the on the suction
suction surface. surface.
This is This is related
related to the
to the flow flowinside
state state the
inside the centrifugal
centrifugal pump.
pump.
AccordingAccording to the velocity
to the velocity flow diagram
flow diagram of the section
of the middle middle of section of the impeller,
the impeller, it can beitseen
can that
be seen
the
that
solidthe solidflow
phase phase flow velocity
velocity at thehead
at the blade bladeishead
small,is while
small,the
while the velocity
velocity increasesincreases along
along the the
radial
radial direction,
direction, and the and the velocity
velocity at the at the blade
blade tail reaches
tail reaches the maximum.
the maximum. As theAsarea
the becomes
area becomes
largerlarger
after
after entering
entering the diffusion
the diffusion tube,
tube, the thephase
solid solid phase
velocityvelocity decreases.
decreases. Where the Where
solidthe solidvolume
phase phase volume
fraction
fraction
is small, is small,
there is athere
vortexis ainvortex in the impeller
the impeller passage.passage.
It can be It can be speculated
speculated that the
that the vortex vortex
causes thecauses
solid
the solid particles to be affected by centrifugal force, resulting in
particles to be affected by centrifugal force, resulting in the decrease of solid phasethe decrease of solid phase particle
concentration. The distribution range of the solid phase volume fraction of the blade increases when
the clearance of the wear-rings increases from 0.1 mm mm to to 0.15
0.15 mm.
mm. When the gap of the wear-rings wear-rings
continues to increase
continues increase to to 0.2 mm, 0.3 mm, and 0.5 mm, it is clear that the distribution range of the solid
phase significantly
significantly decreases.
decreases.

(a) 0.1 mm (b) 0.15 mm (c) 0.2 mm

is small, there is a vortex in the impeller passage. It can be speculated that the vortex causes the solid
particles to be affected by centrifugal force, resulting in the decrease of solid phase particle
concentration. The distribution range of the solid phase volume fraction of the blade increases when
the clearance of the wear-rings increases from 0.1 mm to 0.15 mm. When the gap of the wear-rings
continues
Symmetry to12,
2020, increase
2003 to 0.2 mm, 0.3 mm, and 0.5 mm, it is clear that the distribution range of the15solid
of 21
phase significantly decreases.

Symmetry 2020, 12, x FOR PEER REVIEW 15 of 21

(a) 0.1 mm (b) 0.15 mm (c) 0.2 mm

(d) 0.3 mm (e) 0.5 mm

Figure 14.
Figure 14. Distribution of solid
Distribution volume
of solid and flow
volume velocity
and flow in the in
velocity middle section under
the middle sectiona under
different
a
clearance.clearance.
different

Figure
Figure1515shows
showsthe thewear
wear rate distribution
rate distribution of the impeller
of the under
impeller underdifferent wear-rings
different clearances
wear-rings under
clearances
standard working conditions and soli d concentration of 50 kg/m 3 . It can3 be seen that the wear on the
under standard working conditions and soli d concentration of 50 kg/m . It can be seen that the wear
suction surface surface
on the suction of the blade
of theisblade
more isserious than that
more serious on the
than thatpressure surface. surface.
on the pressure The wear Theonwear
the suction
on the
surface is mainly concentrated in the head, middle, and tail of the blade,
suction surface is mainly concentrated in the head, middle, and tail of the blade, while while the wear on the pressure
wear on
surface is mainly
the pressure concentrated
surface is mainlyinconcentrated
the tail. The severe
in the wear at the
tail. The tail ofwear
severe the blade
at themay
tail be dueblade
of the to themay
greater be
absolute
due to the velocity
greaterof the fluid, and
absolute the mutual
velocity of the interference
fluid, and the is more significant.
mutual The blade
interference head
is more is significantly
significant. The
worn
bladebecause
head isof the positive worn
significantly impactbecause
angle ofofsolid
theparticles
positiveaccompanied
impact angleby offluid
solidflow. Whenaccompanied
particles the clearance
of
bythe wear-rings
fluid flow. When changes from 0.1 of
the clearance mm thetowear-rings
0.15 mm, the blade from
changes shows0.1 more
mmwear.
to 0.15When
mm, it increases
the from
blade shows
0.15
moremm to 0.2
wear. mm,it0.3
When mm, andfrom
increases 0.5 mm,
0.15 the
mmwear degree
to 0.2 mm, tends
0.3 mm,to decrease.
and 0.5 mm, The maximum wear rate
the wear degree tends of
the clearance from 0.4 mm to 1.2 mm is 4.16 × 10 −3 kg/(m2 ·s), 5.67 × 10−3 kg/(m2 ·s), 5.58 × 10−3 kg/(m 22 ·s),
to decrease. The maximum wear rate of the clearance from 0.4 mm to 1.2 mm is 4.16 × 10 kg/(m ·s), −3
−3 kg/(m22 ·s), and 3.55−3 10−3 kg/(m 2 ·s), respectively.
5.67 ×× 10 −3 kg/(m
5.34 ·s), 5.58 × 10 ×kg/(m 2·s), 5.34 × 10−3 kg/(m2·s), and 3.55 × 10−3 kg/(m2·s), respectively.

(a) 0.1 mm (b) 0.15 mm (c) 0.2 mm

due to the greater absolute velocity of the fluid, and the mutual interference is more significant. The
blade head is significantly worn because of the positive impact angle of solid particles accompanied
by fluid flow. When the clearance of the wear-rings changes from 0.1 mm to 0.15 mm, the blade shows
more wear. When it increases from 0.15 mm to 0.2 mm, 0.3 mm, and 0.5 mm, the wear degree tends
to decrease.
Symmetry The
2020, 12, maximum wear rate of the clearance from 0.4 mm to 1.2 mm is 4.16 × 10−3 kg/(m
2003 16 of·s),
2
21
5.67 × 10 kg/(m ·s), 5.58 × 10 kg/(m ·s), 5.34 × 10 kg/(m ·s), and 3.55 × 10 kg/(m ·s), respectively.
−3 2 −3 2 −3 2 −3 2

(a) 0.1 mm (b) 0.15 mm (c) 0.2 mm

(d) 0.3 mm (e) 0.5 mm

Symmetry 2020, 12, x FOR PEER REVIEW 16 of 21
Figure 15.
Figure 15. Wear
Wear rate
rate distribution
distribution of
of the
the impeller
impeller under
under aa different
differentclearance.
clearance.

Figure 16
Figure 16 shows
shows thethe experimental
experimental resultsresults of
of blade
blade wear
wear in in the
the same
same type
type of
of the
the centrifugal
centrifugal pump
pump
by other researchers [28], which are like the numerical simulation results in this
by other researchers [28], which are like the numerical simulation results in this paper. The wear is paper. The wear is
mainly distributed
mainly distributedininthe
thetail
tailofofthe
thesuction
suction surface,
surface, thethe
tailtail
of of
thethe pressure
pressure surface,
surface, andand
the the
headhead of
of the
the blade as well as the wear on the suction surface that is more severe than that
blade as well as the wear on the suction surface that is more severe than that on the pressure surface. on the pressure
surface.

Figure 16. A sketch map of the actual wear of a blade at a high concentration.
Figure 16. A sketch map of the actual wear of a blade at a high concentration.
3.4. Wear Characteristics’ Analysis of the Volute Wall under a Different Clearance
3.4. Wear Characteristics’ Analysis of the Volute Wall under a Different Clearance
Figure 17 shows the wear rate distribution of the volute wall under different wear-rings clearance
Figure working
in standard 17 shows the wearwith
conditions ratethe
distribution of the volute
solid concentration wall 3under
of 50 kg/m different
. The volute wallwear-rings
surface is
clearancefree
basically in standard working
of wear when conditionsofwith
the clearance the solid concentration
the wear-rings is 0.1 mm and of0.15
50 kg/m 3
mm with. Theonly
volute wall
a slight
surface is basically free of wear when the clearance of the wear-rings is 0.1 mm and
erosion at the tongue. When the clearance of the mouth ring is 0.20 mm, the wear of the volute wall 0.15 mm with
only a slight
becomes veryerosion at the
clear. The tongue.
wear rate When
is at a the
highclearance
level, andof the
the wear
mouthdamage
ring is 0.20 mm,and
is dense the wear of the
significant.
volute
The wall
areas becomes
with verywear
a higher clear. Theare
rate wear rate three
mainly is at aparts:
high level,
areasand theII,wear
I and whichdamage is dense and
are symmetrically
significant. The areas with a higher wear rate are mainly three parts: areas
distributed on the volute wall surface, and the outer wall area III of the outlet flow sectionI and II, which are
of the
symmetrically distributed on the volute wall surface, and the outer wall area III of the outlet flow
section of the volute. In these areas, especially area III, there are a large number of turbulent states
and high-pressure regions. The motion of particles shows a disordered and a random motion state.
The collision between particles and the wall surface, the collision between particles and particles, and
the interaction between particles and fluid make the wear more severe on the wall. As the clearance
 Figure 17 shows the wear rate distribution of the volute wall under different wear-rings
clearance in standard working conditions with the solid concentration of 50 kg/m3. The volute wall
surface is basically free of wear when the clearance of the wear-rings is 0.1 mm and 0.15 mm with
only a slight erosion at the tongue. When the clearance of the mouth ring is 0.20 mm, the wear of the
volute wall
Symmetry 2020, becomes
12, 2003 very clear. The wear rate is at a high level, and the wear damage is dense and
17 of 21
significant. The areas with a higher wear rate are mainly three parts: areas I and II, which are
symmetrically distributed on the volute wall surface, and the outer wall area III of the outlet flow
volute. In these areas, especially area III, there are a large number of turbulent states and high-pressure
section of the volute. In these areas, especially area III, there are a large number of turbulent states
regions. The motion of particles shows a disordered and a random motion state. The collision between
and high-pressure regions. The motion of particles shows a disordered and a random motion state.
particles and the wall surface, the collision between particles and particles, and the interaction between
The collision between particles and the wall surface, the collision between particles and particles, and
particles and fluid make the wear more severe on the wall. As the clearance increases from 0.20 mm
the interaction between particles and fluid make the wear more severe on the wall. As the clearance
to 0.50 mm, the peak wear rate ranges from 2.03 × 10−5 kg/(m2 ·s), 1.78 × 10−5 −5kg/(m2 ·s), 1.40 × 10−5
increases
2 from 0.20 mm to 0.50 mm, the peak wear rate ranges from 2.03 × 10 kg/(m2·s), 1.78 × 10−5
kg/(m 2·s). In turn, the size of areas I, II, and III was significantly reduced, and the wear changes from
kg/(m ·s), 1.40 × 10−5 kg/(m2·s). In turn, the size of areas I, II, and III was significantly reduced, and the
sheet to a random pitting corrosion with a high wear rate.
wear changes from sheet to a random pitting corrosion with a high wear rate.

(a) 0.1 mm (b) 0.15 mm (c) 0.2 mm

(d) 0.3 mm (e) 0.5 mm

Figure 17. Wear rate distribution of the volute wall under a different clearance.

3.5. Wear Characteristics Analysis of Wear-Rings under Different Clearances

Figure 18 shows the distribution diagram of a solid phase volume fraction of the wear-rings at
the same time. The solid at the wear-rings is mainly formed by the accumulation of fluid leaking
from the front cavity of the volute to the inlet of the impeller. By analyzing the volume fraction
distribution diagram of a solid, the leakage of the inlet fluid from the front cavity of the volute through
the wear-rings to the impeller can be more intuitively understood.
According to the pressure distribution state at the wear-rings in Figure 10, it can be clearly seen
from the solid phase volume fraction distribution diagram of the wear-rings when the clearance is
0.1 mm, the solid phase volume fraction at the inlet of the wear-rings and the impeller is higher, and the
solid phase volume fraction at the left wear-ring in the interface is also relatively high. The solid phase
concentration of the connected part of the wear-rings and the front cavity is higher, but the volume
fraction of the solid phase in the left anterior cavity of the connected part is lower. This is because,
when the clearance of the wear-rings is small, the pressure difference between the front cavity of the
volute and the inlet of the impeller is large, and the fluid flow rate is fast, so that the solid particles
cannot be taken away to accumulate. Then, before the liquid in the front cavity of the volute enters the
wear-rings, there is a process of a sudden reduction of the flow area. Due to the great difference in flow
velocity, solid particles accumulate on the boundary of the suddenly narrowed wear-rings, resulting in
a high solid phase concentration and linear shape between the wear-rings and the front cavity. With the
increase of clearance, the pressure difference between the wear-rings near the front cavity and the inlet
of the impeller decreases, the flow rate slows down, and the solid volume fraction at the junction of
 Symmetry 2020, 12, 2003 18 of 21

Symmetry 2020, 12, x FOR PEER REVIEW 17 of 21

the wear-rings and the front cavity decreases. The solid volume fraction at the wear-rings near the
Figure 17.
front cavity increase Wear ratewhile
gradually, distribution
the solidof the volutefraction
volume wall under a different
at the clearance.
junction of the wear-rings and
the inlet decrease clearly. This is because, when the fluid flows out of the wear-rings after a sudden
3.5. Wear Characteristics
expansion tube, the flow Analysis of Wear-Rings
rate here compared tounder DifferentofClearances
the junction the impeller inlet and the wear-rings is
greater.
Figure 18 shows the distribution diagram of a solid phase volume takes
When the clearance increases and the flow rises, it significantly away
fraction the wear-rings
of the solid particles
at
thatsame
the should
time.have
The accumulated there, so is
solid at the wear-rings that the solid
mainly formedparticle
by theconcentration
accumulation decreases. When
of fluid leaking the
from
clearance
the of theofwear-rings
front cavity the volute isto0.5
themm,
inletthe solid
of the volumeBy
impeller. fraction at the
analyzing thejunction
volumeof the wear-rings
fraction and
distribution
the inlet of
diagram of athe impeller
solid, is significantly
the leakage smaller
of the inlet fluidand
fromshows a banded
the front cavitydistribution,
of the volutewhile the solid
through phase
the wear-
concentration
rings near the
to the impeller canfront cavity
be more of the wear-rings
intuitively is significantly higher.
understood.

(a) d = 0.1 mm (b) d = 0.15 mm (c) d = 0.2 mm (d) d = 0.3 mm (e) d = 0.5 mm
Figure
Figure18.
18.Solid
Solidvolume
volumefraction
fractionofofaacircumferential
circumferentialsection
sectionof
ofwear-rings.
wear-rings.

Figure 19 to
According below shows the
the pressure velocity cloud
distribution state at diagram at the wear-rings
the wear-rings in Figure 10, under
it canrated conditions
be clearly seen
Symmetry 2020, 12, x FOR PEER REVIEW 18 of 21
and different
from the solid clearance
phase volume conditions
fraction when the solid diagram
distribution concentration 50 kg/m3 . when
of theiswear-rings Whenthe theclearance
clearanceisis
0.1
0.1
mm, mm,
mm, the
thethe velocity
solid
velocity phasedistribution is
volumeisfraction
distribution relatively
relatively at theuniform.
inlet ofWith
uniform. With
the theclearance
clearance
wear-rings
the andofof thethe
the wear-rings
impeller
wear-rings increasing,
is higher, and
increasing,
the
the velocity at the wear-rings increases gradually, and the velocity gradient near the front cavity is
the velocity
solid phase at the wear-rings
volume fraction increases
at the gradually,
left wear-ring and
in the
the velocity
interface gradient
is also near
relatively the front
high. Thecavity
solid is
relatively
phase fast.
concentration
relatively However,
fast. However,of thethe velocity
velocity distribution
connected
the in
in the
part of the wear-rings
distribution the front
frontandcavity
theis
cavity not
not uniform,
isfront cavity is which
uniform, which is
higher, caused
isbut the
caused
by
by the
the asymmetry
volume fraction of the
asymmetry of
of the
solid
the volute
phase
volute structure.
in the left
structure. It anterior
It can be
can be seen from
cavity
seen Figure
of the
from 10
10 that
connected
Figure vortexes
that part are
are likely
is lower.
vortexes This is
likely to
to
occur
occur in
because, the
the front
in when the cavity,
front clearance
cavity, and
andof the
thethevortexes
wear-rings
vortexes decrease when
is small,
decrease when the
the clearance
pressure
the clearance increases.
difference
increases. When
When the
between thevortex
the front
vortex
decreases,
cavity of thethe
decreases, the solid
volute phase
solidand
phase theback-flow
inlet of thecan
back-flow be
be reduced,
impeller
can is large,
reduced, so that
so and the
thatthe mass
thefluid
massflow flow
flowratethrough the
is fast,
through thesoclearance
that the
clearance
increases,
solid particles
increases, and the
the velocity
andcannot be taken
velocity finally
away
finally increases.
to accumulate. Then, before the liquid in the front cavity of the
increases.
volute enters the wear-rings, there is a process of a sudden reduction of the flow area. Due to the
great difference in flow velocity, solid particles accumulate on the boundary of the suddenly
narrowed wear-rings, resulting in a high solid phase concentration and linear shape between the
wear-rings and the front cavity. With the increase of clearance, the pressure difference between the
wear-rings near the front cavity and the inlet of the impeller decreases, the flow rate slows down, and
the solid volume fraction at the junction of the wear-rings and the front cavity decreases. The solid
volume fraction at the wear-rings near the front cavity increase gradually, while the solid volume
fraction at the junction of the wear-rings and the inlet decrease clearly. This is because, when the fluid
flows out of the wear-rings after a sudden expansion tube, the flow rate here compared to the junction
of the impeller inlet and the wear-rings is greater. When the clearance increases and the flow rises, it
(a) 0.1 mm (b) 0.15 mm (c) 0.2 mm (d) 0. 3 mm (e) 0.5 mm
significantly takes away the solid particles that should have accumulated there, so that the solid
particle concentration decreases. Figure 19.When Velocity the clearanceunder
nephogram different
of thea different
wear-rings clearance.
is 0.5 mm, the solid volume
clearance.
fraction at the junction of the wear-rings and the inlet of the impeller is significantly smaller and
showsFigure
Figure
a banded 20
20 below
below shows
shows the
distribution, the
whilewear
wear distribution
distribution
the solid phase at the wear-rings
atconcentration
wear-ringsnearin
in rated conditions
cavitywith
conditions
the front with
of the thewear-
solid
phase 3
phase isconcentration
concentration of
of 50
50 kg/m
kg/m and under different different clearance
clearance conditions
conditions of of the
the wear-rings.
wear-rings. It can be
3
rings significantly higher.
seenFigure
from the 19 below shows the velocity cloud diagram at the wear-rings under ratedisconditions
figure that, when the clearance is 0.1 mm, the area with severe wear the wear-rings and
near the front cavity, which is linearly distributed. In the middle
different clearance conditions when the solid concentration is 50 kg/m3. When the clearance of the wear-rings, there is a is
point-
0.1
like circumferential distribution with severe wear at the center of the point and uneven distribution.
With the increase of the clearance, the wear area near the front cavity gradually widens and presents
a zonal distribution, and the severe wear area in the middle of the wear-rings expands from a point-
 (a) 0.1 mm (b) 0.15 mm (c) 0.2 mm (d) 0. 3 mm (e) 0.5 mm
Figure 19. Velocity nephogram under a different clearance.
Symmetry 2020, 12, 2003 19 of 21
Figure 20 below shows the wear distribution at the wear-rings in rated conditions with the solid
phase concentration of 50 kg/m3 and under different clearance conditions of the wear-rings. It can be
seen
seen from
from the
the figure
figure that,
that, when
when the the clearance
clearance isis 0.1
0.1 mm,
mm, the
the area
area with
with severe
severe wear
wear is
is the
the wear-rings
wear-rings
near the front cavity, which is linearly distributed. In the middle of the wear-rings,
near the front cavity, which is linearly distributed. In the middle of the wear-rings, there is there is a point-like
a point-
circumferential
like circumferentialdistribution
distribution withwith
severe wear
severe at the
wear center
at the centerofofthe
thepoint
pointand
anduneven
uneven distribution.
With
Withthetheincrease
increaseofofthe
theclearance,
clearance,thethewear
weararea
areanear
nearthe
thefront
frontcavity
cavitygradually widens
gradually widens and
and presents a
presents
zonal distribution, and the severe wear area in the middle of the wear-rings expands
a zonal distribution, and the severe wear area in the middle of the wear-rings expands from a point- from a point-like
circumferential distribution
like circumferential to a round-like
distribution circumferential
to a round-like distribution.
circumferential distribution.

(a) 0.1 mm (b) 0.15 mm (c) 0.2 mm (d) 0.3 mm (e) 0.5 mm

Figure 20.
Figure 20. Distribution map of the
the wear
wear rate
rate under
under different
different clearances.
clearances.

4.
4. Conclusions
Conclusions
Based
Based onon the
the combination
combination of of theoretical
theoretical analysis
analysis and
and numerical
numerical simulation,
simulation, the
the reliability
reliability of
of the
the
numerical
numerical calculation
calculation method
method waswas verified
verified by
by comparing
comparing the
the experimental
experimental data
data with
with the
the numerical
numerical
simulation
simulationresults.
results. Euler
Euler two-phase
two-phase flow
flow mixing
mixing model,
model, k-ε
k-ε turbulence
turbulence model,
model, and
and the
the McLaury
McLaury wearwear
model
model were used to calculate the wear rate of the centrifugal pump, and the flow lines and
were used to calculate the wear rate of the centrifugal pump, and the flow lines and particle
particle
velocity
velocity of
of the
the impeller
impeller are
are studied
studied under
under the
the conditions
conditions of
of different
different wear-rings
wear-rings clearance
clearance andand fluid
fluid
medium
medium particle concentration. In addition, the wear of the impeller blade and wear-rings are
particle concentration. In addition, the wear of the impeller blade and wear-rings are also
also
studied
studied by
by the
the velocity
velocity of
of the
the distribution
distributionofofsolid
solidparticles.
particles. The
The conclusions
conclusions are
areas
asfollows.
follows.
(1) The wear of the centrifugal pump blade is mainly concentrated in the end and the
(1) the inlet
inlet of
of the
the
blade because the tip of the blade is moving at a higher speed and the solidsolid particles
particles at
at the
the front
front
of the blade have a better positive impact angle. Under the influence of vortexes, the wear at the
end of the blade suction surface is very severe, while, that at the front of blade, is more serious.
(2) With the clearance changing, the maximum wear of the blade changes. When the clearance
increases from 0.1 mm to 0.15 mm, the maximum wear in the impeller increases. When the
clearance increases from 0.15 mm to 0.5 mm, the maximum wear in the impeller decreases because
of the leakage of the wear-rings and energy loss.
(3) It can be found through the analysis of the solid distribution and pressure distribution at the
wear-rings that the solid distribution presents different distribution states with the change of the
clearance. In general, the larger the clearance is, the higher the solid concentration is. The analysis
of the impeller’s front cavity shows that the pressure of the front cavity is affected by the change
of the clearance, which influences the flow of the fluid and the movement of solid particles in the
front cavity.
(4) As the clearance of the wear-rings increases, the wear of the centrifugal pump becomes more
significant, and the severe wear area presents a point-like circumferential distribution.

The conclusions are also limited to centrifugal pumps similar in structure and purpose to the
model pumps studied in this article. Other types of pumps need to be further studied for their
related characteristics, which can provide a certain method reference for other types of centrifugal
pump-related research.
Symmetry 2020, 12, 2003 20 of 21

Author Contributions: Writing—original draft preparation, writing—review and editing, visualization, C.Y.;
software, J.L.; project administration, funding acquisition, S.Z.; methodology, B.H.; resources, J.D. All authors
have read and agreed to the published version of the manuscript.
Funding: The authors gratefully acknowledge the financial supports given by the National Nature Science
Foundation of China (No. 51976193).
Conflicts of Interest: The authors declare no conflict of interest.

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