Experimental and CFD modeling of a progressive cavity pump (PCP) using overset unstructured mesh part 1: Single-phase flow

Abstract

Progressive Cavity Pumps (PCP) are integral in industries for transporting high-viscosity fluids due to their efficacy. Nevertheless, their computational modeling via Computational Fluid Dynamics (CFD) poses challenges, primarily attributed to meshing algorithms and computational demands. This research underscores that structured meshes are not imperative for assessing PCP efficiency, given that operational parameters reflect a 10% accuracy when juxtaposed with experimental data. An overset mass conservation model was harnessed to rectify mass conservation errors and the computational burden from interpolation. The overset grid methodology emerged as a favorable technique for PCP modeling, with its applicability critically analyzed. Experimental data comparison revealed that variables like volumetric flow rate, power consumption, and efficiency were accurately depicted with a marginal error of less than 10%. Interestingly, while high-viscosity oils resonated with the Hagen-Poiseuille flow equation in clearance zones, water showcased elevated velocities, inducing a non-linear pressure profile. Analysis of slip components indicated that high-viscosity oils offered superior efficiencies due to augmented slip resistance. Thus, CFD modeling of PCPs across different viscosity spectrums is feasible without mandating operations to enhance mesh quality. This study pioneers in offering insights into PCP dynamics, emphasizing the accuracy and optimization potential of the overset unstructured mesh approach.