Optimization of a High Pressure Industrial Fan

Fans are used in industrial refineries, power generation, petrochemistry, pollution control, etc. These fans can perform in sometimes extreme, mission-critical conditions. The design of fans has historically relied on turbomachinery affinity laws, resulting in oversized machines that are expensive to manufacture and transport. With the increasingly lower CPU cost of fluid modeling, designers can now turn to CFD optimization to produce the necessary machine performance and flow conditions while respecting manufacturing constraints. The objective of this study is to maximize the pressure rise across an industrial fan while respecting manufacturing constraints. First, a 3D scan of the baseline impeller is used to create the CFD model and validated against experimental data. The baseline impeller geometry is then parameterized with 21 free parameters driving the shape of the hub, shroud, blade lean and camber. A fully automated optimization process is conducted using Numeca’s Fine™/Design3D software, allowing for a CPU-efficient Design Of Experiment (DOE) database generation and a surrogate model using the powerful Minamo optimization kernel and data-mining tool. The optimized impeller coupled with a CFD-aided redesigned volute showed an increase in overall pressure rise over the whole performance line, up to 24% at higher mass flow rates compared to the baseline geometry.

Numerical study on the transient behavior of a radial pump during starting time

This paper presents a fast simulation model for predicting the dynamic response of a motor-pump system to startup event. The purpose is to analyze the effect of the impeller acceleration time, the final flow rate and the impeller geometry on the pump transient flow during starting operations. The motor speed and torque variations were predicted by simulating the transient law of the three-phase induction motor by adopting the d-q axes theory. The pump model was built by solving the unsteady flow governing equations with the method of characteristics (MOC). The whole model was validated with available tests from literature. Accordingly, the computation of impeller acceleration, the motor torque, the unsteady pressure and flow rate was made for various starting conditions. The results have revealed that during its starting time, the pump hydraulic transients are well influenced by the motor speed acceleration, the flow inertia and the impeller geometry. Through the analysis of the simulation results, the conclusion was that the accuracy of the present method is reasonable, and it can be used for assisting pumping system design.

Influence of input parameters in radial compressor design algorithm on the efficiency and its sensitivity analysis

Nowadays there are lots of methods using three-dimensional or quasi three-dimensional CFD analysis. Unfortunately, this approach is still very demanding, so that quick preliminary design algorithms have still its importance, even though simplified analytical model of radial compressor gives less accurate results. Obtained results can be used in later stages of the radial compressor (RC) design, such as definition of spatial impeller geometry and CFD computation. The article presents the influence of input parameters in the radial compressor design algorithm on the efficiency. The assembled mathematical model of RC is derived from the basic laws of continuum mechanics and can be used for a quick assessment of the preliminary design concept of the RC. A sensitivity analysis is performed on input parameters to select parameters that have the dominant effect on the monitored performance indicators. On the basis of the sensitivity analysis, a multicriteria optimization process was assembled to increase the performance parameters.

A New Approach to Modeling Slip and Work Input for Centrifugal Compressors

A new method of modeling slip factor and work input for centrifugal compressor impellers is presented. Rather than using geometry to predict the behavior of the flow at the impeller exit, the new method leverages governing relationships to predict the work input delivered by the impeller with dimensionless design parameters. The approach incorporates both impeller geometry and flow conditions and, therefore, is inherently able to predict the slip factor both at design and off-design conditions. Five impeller cases are used to demonstrate the efficacy of the method, four of which are well documented in the open literature. Multiple implementations of the model are introduced to enable users to customize the model to specific applications. Significant improvement in the accuracy of the prediction of slip factor and work input is obtained at both design and off-design conditions relative to Wiesner's slip model. While Wiesner's model predicts the slip factor of 52% of the data within ±0.05 absolute error, the most accurate implementation of the new model predicts 99% of the data within the same error band. The effects of external losses on the model are considered, and the new model is fairly insensitive to the effects of external losses. Finally, detailed procedures to incorporate the new model into a meanline analysis tool are provided in the appendices.

Development of a standard range of waterjets for vessels with high seakeeping performance

Object and purpose of research. The object of the research is a fundamentally new waterjet, intended for installation on ships of increased seakeeping performance with discrete-variable bottom deadrise. The purpose of the research is to develop and experimentally test the impeller and water duct for a variety of waterjet design possible for installation aboard vessels with large deadrise operating in severe weather conditions. Materials and methods. Test data for waterjet impellers obtained at KSRC Cavitation Tunnel for Special Propulsors. Main results. The study made it possible to select optimal impeller geometry and develop the shapes for water inlets and water ducts of three waterjet designs with partial-pressure water inlets: two waterjets with isolated single-elbow water ducts and inlets on the bottom section with medium deadrise, "II"design; two waterjets with combined water duct and inlets on the bottom section with maximum deadrise and double jet, “X” design; single waterjet with bifurcating two-elbow water duct and a pair of water inlets on the bottom section with maximum deadrise, “Y” design. Conclusion. The studies have shown that developed waterjet impeller features good hydrodynamic and cavitation characteristics, and possible air suction creates a smooth, rather than sharp, force decrease.