Head Curve Research Articles

A stepwise optimization method for topology structure of fluid machinery network

A stepwise optimization method for topology structure of fluid machinery network

A new approach to predict pump transient phenomena in Molten salt reactor Experiment (MSRE) by missing data identification and regeneration

Molten Salt Reactor Experiment (MSRE) is being extensively used for validating the computational tools for Molten Salt Reactors (MSRs). The pump transient tests were performed during the operation of MSRE to obtain the reactivity response to flow perturbation. The transient flow rate during this set of tests is required as input to predict the reactivity response. Since the primary loop of MSRE was not equipped with a flow rate meter, the transient flow rate, which is the crucial factor for the reactivity change in MSRE, is missing. Achieving an accurate simulation of the reactivity response to the MSRE pump transient tests necessitates a precise estimation of the transient flow rate.This paper endeavors to reconstruct the missing flow rate with the aim of offering a valuable input for simulating reactivity responses in the pump transient test series. In order to obtain an accurate transient flow rate, we employed a centrifugal pump transient model based on the affinity laws and solved the model for the MSRE secondary pump to validate the underlying assumptions of the model. In addition, we constructed the homologous pump head curves based on the water test data for the same purpose. The affinity law approximation is proved to be adequate in predicting the MSRE pump startup transient with the root-mean-square error (RMSE) in the normalized flow rate to be 0.03. On the other hand, for the MSRE pump coastdown transient, the preliminary results indicate that neither the affinity law approximation nor the homologous head curve is sufficient to provide acceptable predictions. To overcome this noticeable modeling deficit, we propose an innovative approach based on a straightforward data mining technique to regenerate the MSRE pump coastdown homologous relations using the measured data of the secondary pump. These relations are transferred to the primary pump and used to simultaneously solve for the impeller speed and the flow rate of the pump in the primary pump coastdown. With the new approach, the estimated RMSE in the normalized pump speed for the primary pump coastdown is reduced 0.0052. This excellent agreement validates the accurate calculations for the flow rate during the pump coastdown transient. We also performed an uncertainty analysis to quantify the confidence interval of the predicted quantities, which further justifies the robustness of the proposed approach.

Numerical study on bionic airfoil fins used in printed circuit plate heat exchanger

Abstract Airfoil printed circuit heat exchangers (PCHEs) possess exceptional comprehensive performance. In recent years, extensive research has been conducted on the layout and structure optimization of airfoil fins. As biomimetic technologies gradually mature, bionics has achieved numerous outcomes in optimizing airfoil aerodynamic characteristic. Inspired by the sailfish geometry, four types of bionic airfoils are proposed based on the NACA 0015 airfoil, to enhance the thermal-hydraulic performance of the airfoil PCHEs. The results show that while the four types of sailfish airfoils are effective in terms of drag reduction, their overall performance at the same pumping power is suboptimal, with only one type providing an advantage at the low Re region. Moreover, airfoils with concave head curves further increase the weakening of heat transfer by the velocity boundary layer.

Ctenocephalides orientis and Ctenocephalides felis in Thailand: Head geometry by species, sex and geography.

Fleas in the genus Ctenocephalides serve as biological vectors or intermediate hosts of microorganisms such as bacteria, rickettsia, protozoa and helminths. Ctenocephalides felis has a worldwide distribution, while C. orientis has long been considered as a subspecies of C. felis in Asia. To help the morphological recognition of these two species and further explore their differences, we used the geometric morphometric approach applied to the head. Both sexes were examined. Five anatomical landmarks of the head were used, and to capture the curvature of the front head, 10 semilandmarks were added. There was a consistent difference in species classification accuracy when considering landmarks only versus their combination with semilandmarks, suggesting the importance of the curve of the head as a taxonomic signal. Using or not the labels in the reclassification analyses, the head shape allowed by itself almost perfect recognition of the two species, in both sexes, even after adjustment for prior probabilities. The same approach disclosed a high level of sexual size and shape dimorphism in both species. The contribution of size variation to the discrimination by shape was much more important between sexes (from 27% to 45%) than between species (from 0.7% to 7.1%). Nevertheless, in our data, size never could represent a way to reliably recognise the sex of an individual, even less its species. Geographical variation in head shape could only be explored for the C. orientis sample. No significant correlation of morphometric variation with geography could be detected, which would be consistent with gene flow between Thai provinces. The geometric morphometric approach of the flea head, when it incorporates head curves, is a promising tool for rapid, economical, and accurate species and sex identification. It is, therefore, a useful tool for future epidemiological and demographic studies.

Multivariate Regression Models for Predicting Pump-as-Turbine Characteristics

Installing pumps as turbines (PaTs) in water distribution networks can recover otherwise wasted energy, as well as reduce leakage caused by high water pressure. However, a barrier to their implementation is the lack of information on their performance in turbine mode. Previous studies have proposed models to predict PaT characteristics based on pump best efficiency points (BEPs), using regressions with one or two dependent variables, or more complex artificial neural networks (ANNs). While ANNs were found to improve the accuracy of predictions, these models are known to be unstable with small datasets. Other types of regressions with multiple variables have not been explored. Furthermore, because only small datasets are available to train these models, multivariate regression methods could yield better results. The present study develops multivariate regression models to predict BEPs and characteristic curves of PaTs. A database of 145 BEPs and 196 characteristic curve PaT experimental records was compiled from previous literature. Twenty-four types of multi-variate regressions, as well as ANN were compared, with dimensioned and dimensionless versions of the datasets. The multivariate regression models consistently outperformed previous models, including ANN. The R2 of the head and efficiency curves were 0.997 and 0.909, respectively. Results also showed that XGB regressors and a dimensionless dataset yielded the best-fit models overall. The high accuracy of the models, combined with their lower computational cost compared to ANN, make them a robust solution for selecting PaTs in practice.

Loose Belt Fault Detection and Virtual Flow Meter Development Using Identified Data-driven Energy Model for Fan Systems

An energy model that correlates fan airflow, head, speed, and system power input is essential to detect device faults and optimize control strategies in fan systems. Since the application of variable-frequency drives (VFDs) makes the motor-efficiency data published by manufacturers inapplicable for VFD–motor–fan systems, the fan efficiency and drive (belt–motor–VFD) efficiency must be identified for each individual system to obtain accurate energy models. The objectives of this paper are to identify an energy model of existing VFD–motor–fan systems using available experimental data and demonstrate its applications in loose belt fault detection and virtual airflow meter development for optimal control. First, an approach is developed to identify the fan head, fan efficiency, and drive-efficiency curves using available fan head, speed, and system power input as well as temporarily measured airflow rate without measuring shaft power. Then, the energy model is identified for an existing VFD–motor–fan system. Finally, the identified model is applied to detect the slipped belt faults and develop the virtual airflow meter. The experiment results reveal that the developed approach can effectively obtain the energy model of VFD–motor–fan systems and the model can be applied to effectively detect slipped belt faults and accurately calculate the fan airflow rate.

Influence of Blade Exit Angle on the Performance and Internal Flow Pattern of a High-Speed Electric Submersible Pump

The impeller vane exit placement angle has a critical role in the flow characteristics of the fluid inside the lobe, thus having a profound effect on the overall pump performance. The purpose of this study is to investigate the effect of the impeller exit angle on the operating characteristics of a high-speed well submersible pump, and the numerical calculation results of the original model are in good agreement with the experimental results. In this paper, five different impeller vane exit angles, namely 10°, 15°, 20°, 25° and 30°, are selected for numerical analysis based on the original model, and the flow conditions of 0.6 Q, 1.0 Q and 1.4 Q are analyzed for each angle. The results show that the impeller vane exit placement angle not only affects the static pressure distribution, velocity distribution and streamline distribution within the impeller and guide vane, but also has a significant effect on the head curve, power curve and efficiency curve of the well submersible pump. As the flow slip inside the impeller of high-speed well submersible pumps intensifies, the large impeller outlet angle will cause the power of the impeller to increase linearly with the flow rate, thus reducing the pump efficiency. In the low-flow and high-flow conditions, a small outlet angle of 10° will make the efficiency of high-speed submersible pumps higher than in other conditions, and these findings can provide some reference for the optimal design of high-speed submersible pumps.

Variable Speed Control in PATs: Theoretical, Experimental and Numerical Modelling

The selection of pumps as turbines (PATs) for their respective use in energy optimisation systems is a complicated task, because manufacturers do not provide the characteristic curves. For this reason, some research has been carried out to predict them with computational fluid dynamics (CFD) and mathematical models. The purpose of this study is to validate these two prediction methodologies of flow (Q) vs. head (H) curves through numerical modelling using the computational package OpenFOAM, together with a comparison with the experimental data obtained from a PAT for the case in which the nominal rotation speed of the machine varies. Depending on the configuration and working conditions of the PAT, the simulation performed with OpenFOAM was validated by calibrating it with the nominal curve of the pump and with another simulation performed with CFD workbench SOLIDWORKS FloEFD. Subsequently, the second methodology related to the analyses and mathematical models proposed to predict the Q vs. H curves were also validated with new models in OpenFOAM and the experimental data. The results show that these prediction methods are effective when a machine’s operating point is close to the BEP (best efficient point). The absolute error ranges obtained with these two prediction methodologies for rotation speeds of 880 rpm, 1020 rpm, 1200 rpm, and 1500 rpm are between 5 and 24%, 2 and 17%, 0 and 12%, and 1 and 24%, respectively.

The acceleration effect of pump as turbine system during starting period

In order to reveal the influence of starting acceleration on starting process of a pump as turbine system, this paper carries out a numerical calculation of the three-dimensional viscous unsteady flow of pump as turbine circulating piping system under three starting acceleration conditions, and obtains the external and internal flow characteristics of each overflow component during the starting process, and also analyzes the energy loss of each component in the piping system in depth with the help of entropy production method and Q criterion method. The results show that during system start-up, the flow rate and outlet static pressure curves of the pump as turbine are hysteresis relative to the rotational speed, the head curve is similar to a linear rise during slow and medium speed start-up, while it shows a parabolic rise during rapid start-up, the entropy production and vorticity in the impeller domain of the pump as turbine are mainly distributed between the blades, and the distribution decreases during start-up. In addition, the pump similarity law does not apply to the performance prediction during the transient start of the pump as turbine.

Instability characteristics regarding the saddle-shaped region in a reversible mixed-flow pump applied to the low-head pumped storage

The expanding renewable energy has eased the energy crisis but hampers grid stability, which can be offset by scaling up pumped hydro storage. Low-head hydropower resources can be utilized efficiently and economically by a reversible mixed-flow pump (RMFP). However, the saddle-shaped region, a representative unstable feature in the pump mode, severely limits the flexibility and reliability of the RMFP. In this study, external characteristics of the RMFP were experimentally investigated based on a bidirectional test rig. A saddle-shaped region was discovered in the pump head curve formed by the near-rated discharge hump (0.92Qd), valley (0.88Qd), and low-discharge hump (0.71Qd). Transient flows under these feature conditions were simulated using CFD method and compared with the rated discharge condition (1.0Qd). The flow under 0.92Qd was as stable as 1.0Qd but worsened with decreasing discharge. When the discharge decreased to 0.88Qd, the pre-swirl emerged, and the rotating stall occurred and adhered to the blade suction side near the runner shroud. The inflow was blocked by stall vortices, which increased the hydraulic loss and triggered the head drop. When the discharge decreased to 0.71Qd, the inflow collided with stall vortices at the leading edge. This interaction led to the recirculation around the runner inlet, which endowed the inflow with extra energy and triggered the head rise. Overall, this study unveils flow instabilities in the RMFP, which explain the formation of the saddle-shaped region.

Parametric Analysis and Optimization Design of the Twin-Volute for a New Type of Dishwasher Pump

To improve the hydraulic performance of a new type of dishwasher pump and solve the multi-parameter optimization problem, a genetic algorithm was introduced to optimize the special design of the twin-volute structure. Six curvature radii of the twin-volute structure were defined as the optimization parameters, and 100 groups of design samples were generated based on the Latin hypercube sampling (LHS) method. The pump head and the efficiency were taken as the optimization objectives, i.e., to improve the efficiency as much as possible while ensuring that the head would not be lower than 2 m. The important parameters were identified via sensitivity analysis, and the optimization problem was solved in detail by using the multi-objective genetic algorithm (MOGA). The results showed that the external profile of the first to the fourth section of the twin-volute structure had the most significant effect on the pump head and efficiency. The response surface method (RSM) was used to select the intervals of optimization, and a comparative simulation of the pump schemes before and after optimization was performed. The head curve did not significantly change before and after optimization. By contrast, the efficiency of the dishwasher pump significantly increased, showing an increase of 2.7% under the design point. Compared with the original model, the impeller of the optimal model pump had a lower overall distribution of turbulent kinetic energy, reduced the vorticity in the twin-volute inlet area, and increased the pressure in the flow channel. Our research results confirm that the combination of RSM and MOGA can effectively solve the problem of optimization for new types of dishwashers and can provide a reference for the development of subsequent hydraulic models.

Study on external performance and internal flow characteristics in a centrifugal pump under different degrees of cavitation

Cavitation as a form of unsteady flow within centrifugal pumps can cause the reduced performance of pumps, disordered internal flow regimes, and flow loss. The present criterion used for determining the occurrence of cavitation is a 3% head drop. However, in most cases, pump cavitation already occurs with less than a 1%–2% head drop due to significant changes in the internal flow status. To examine changing patterns in internal flow characteristics as the degree of cavitation deepens in the early stage of cavitation in centrifugal pumps when the head curve does not show significant fluctuation, this paper focuses on a low specific speed centrifugal pump to analyze distributions of total internal pressure, speed, bubble volume, vortex structure, and entropy generation across different degrees of cavitation and obtain internal flow characteristics and flow loss patterns of pumps, with an aim of providing preferences for anti-cavitation hydraulic design of centrifugal pumps.

Investigation on Stall Characteristics of Centrifugal Pump with Guide Vanes

Stall usually occurs in the hump area of the head curve, which will block the channel and aggravate the pump vibration. For centrifugal pumps with guide vanes usually have a clocking effect, the stall characteristic at different clocking positions should be focused. In this paper, the flow field of the centrifugal pump under stall conditions is numerically simulated, and the rotor–stator interaction effects of the centrifugal pump under stall conditions are studied. The double-hump characteristic is found in the head curve by using SAS (Scale Adaptive Simulation) model. The hump area close to the optimal working condition is caused by hydraulic loss, while the hump area far away from the optimal working condition point is caused by the combined action of Euler’s head and hydraulic loss. The SAS model can accurately calculate the wall friction loss, thus predicting the double-hump phenomenon. The pressure fluctuation and head characteristics at different clocking positions under stall conditions are obtained. It is found that when the guide vanes outlet in line with the volute tongue, the corresponding head is the highest, and the pressure fluctuation is the lowest. The mechanism of the clocking effect in the centrifugal pump with guide vanes is obtained by simplifying the hydrofoil. It is found that when the downstream hydrofoil leading edge is always interfered with by the upstream hydrofoil wake, the wake with low energy mixes the boundary layer with low energy, which causes small-pressure pulsation. The results could be used for the operation of centrifugal pumps with guide vanes.

Hydraulic Optimization and Experimental Measurement of Low Specific Speed Centrifugal Fire Pump

As one of the core components of the fire-fighting water-supply system, the performance of a fire pump directly determines the extent of damage caused by the fire. Compared with conventional pumps, the design requirements of fire pumps not only need to ensure that the head of the pump is at 0Qd, 1.0Qd, and 1.5Qd and its efficiency is at 1.0Qd but also consider the cavitation performance at each flow rate, which presents a greater challenge for the design of high-performance fire pumps. By optimizing the design of a centrifugal fire pump with a specific speed of 24.7, numerical calculations were performed to obtain the best optimized scheme Y4. The results show that at the design flow rate the best optimized scheme improves the efficiency by 9.17% compared with the original scheme, and the head meets the design requirements of the fire pump while avoiding the hump phenomenon. Through a comparative analysis, it was found that the optimized scheme Y4 can reduce the pressure pulsations at the outlet of the pump and improve the cavitation performance at each flow rate. The experiment verifies that the head of the best optimized scheme at the design flow rate is 74.43m, the pump efficiency is 40.22%, and there is no hump in the head curve, which can meet the design and use requirements of the fire pump. The maximum reduction in the outlet pressure pulsations coefficient in the best optimized scheme was 47.12% on average. Compared with the original scheme, the critical net positive suction head (NPSHr) of the best optimized scheme was reduced by 21.5%, 17.6%, 15.7%, and 16.8%, respectively.

Optimization design of hump phenomenon of low specific speed centrifugal pump based on CFD and orthogonal test

Aiming to eliminate the hump phenomenon in a low specific speed centrifugal pump, its structural parameters were optimized using the computational fluid dynamics method. Based on the k - varepsilon turbulence model, a 3D steady analysis of the internal flow field was carried out. The L_{9} left( {3^{4} } right) orthogonal table was established, and four structural parameters, including the impeller outlet diameter, impeller outlet width, number of blades, and blade outlet angle, were selected as influencing factors. Nine orthogonal test schemes were developed and the results were analyzed through the weight matrix analysis method, obtaining the weight of the selected factors on the test results. The optimal scheme was selected according to the weight and the weight matrix analysis results have shown that the impeller outlet width had the dominant influence on the head, shaft power, and efficiency. Further, the blade number was the main influencing factor for shaft power and efficiency. The centrifugal pump flow control test bench was built to carry out the numerical simulation and test all the prototype and optimization pump indexes. Through the external characteristic test, it can be seen that the beta_{2} Z^{0.773} of the optimized pump is 87.889, which is 24.89% lower than that of the prototype pump, which effectively optimizes the hump phenomenon of the centrifugal pump. The experimental results have shown that in underrated working conditions, the working performance of the optimized pump was improved significantly. The head size was reduced by 1.424%, and the efficiency was increased by 7.896%. By optimizing the structural pump parameters, its jet-wake hydraulic loss was reduced, and the head curve hump phenomenon was effectively eliminated. All the performance indexes of the optimized pump were higher than those of the prototype, verifying both the accuracy and reliability of the orthogonal test and weight matrix analysis method. Finally, obtained results provide a reference for the structural design of high-performance centrifugal pumps.

PROAD (Process Advisor): A health monitoring framework for centrifugal pumps

PROAD is an automated framework developed using multi-pronged approach that integrates process, vibration, and spectral data for performance monitoring, prescriptive maintenance, and fault diagnosis of centrifugal pumps. Data input to PROAD is through robust interactive templates. A clustering algorithm is implemented within PROAD that computes deviation of pump head (as a function of flowrate) w.r.t. vendor-supplied head curve for fresh pump. Head deviations over time are analyzed using regression techniques to predict remaining useful life of pump w.r.t. threshold limits. Data from vibration sensors are analyzed to prescribe spectral checks and data obtained from spectral checks are then examined to diagnose mechanical faults. Based on performance and diagnostic metrics, color-coded health status, report, and plots are displayed for each pump. We have tested PROAD on industrial data and it successfully diagnosed a pump with severe bearing damage. PROAD can be easily implemented in industries for health monitoring of centrifugal pumps.

The external characteristics and inner flow research of rim-driven thruster

In order to have a more comprehensive grasp of the performance of the rim-driven thruster, the external characteristics are studied by experiment and carry out numerical simulation to study inner flow characteristics. The test results for the rim-driven thruster find that the head curve had a hump shape. The head is the largest while the flow rate Q = 600 m3/h. The numerical simulation is carried out to reveal the cause of the hump of head. The results show that large-scale backflows gradually appear near the wall in front of the impeller inlet, the central area of the impeller outlet, and the two sides of the central low-pressure zone with the reducing of the flow rate, which can cause a large flow loss and result in a drop in head. The discrepancy between the pressure surface and the suction surface of blade decreases rapidly in the range of r/ R = 0.2–0.5, which is another major factor leading to the drop in head under small-flow conditions. Structurally, there is no blade in the impeller center and there are the large backflows in the middle of impeller, which causes much volume loss and is a main cause of the decreasing of head under small flow rate.

An experimental performance comparison of Newtonian and non-Newtonian fluids on a centrifugal blood pump

The use of substitute fluid with similar rheological properties instead of blood is important due to ethical concerns and high blood volume consumption in pump performance test before clinical applications. The performance of a centrifugal blood pump with hydrodynamic journal bearing is experimentally tested using Newtonian 40% aqueous glycerin solution (GS) and non-Newtonian aqueous xanthan gum solution of 600 ppm (XGS) as working fluids. Experiments are performed at four different rotational speeds which are 2700, 3000, 3300, and 3600 rpm; experiments using GS reach between 8.5% and 37.2% higher head curve than experiments using the XGS for every rotational speed. It was observed that as the rotational speed and flow rate increase, the head curve difference between GS and XGS decreases. This result can be attributed to the friction reduction effect when using XGS in experiments at high rotation speed and high flow rate. Moreover, due to different fluid viscosities, differences in hydraulic efficiency were observed for both fluids. This study reveals that the use of Newtonian fluids as working fluids is not sufficient to determine the actual performance of a blood pump, and the performance effects of non-Newtonian fluids are remarkably important in pump performance optimizations.

Fluid dynamics of dredging

Centrifugal pumps are used for pumping slurry from the dredge cutter head or drag head located in front of the suction pipe inlet to the final placement site or dredge hopper. Cavitation is an important phenomenon that must be avoided on the suction side of the pump that is quantified by the net positive suction head. The settling velocity is important for determining whether the sediment settles to the bottom of the pipeline. There is a critical velocity for the slurry in the pipeline that must be maintained such that the dredged sediment remains in suspension and minimizes contact with the pipe wall to keep friction losses at a minimum. Friction losses and minor losses are calculated and input to the energy equation to determine the system head curve over a range of flow rates. The system head curve and pump head characteristic curve are used to evaluate the dredge pump head and flow requirements needed to satisfactorily transport the dredged sediment to the placement location. A submerged ladder pump is installed on the ladder or drag arm to avoid cavitation, and booster pumps are added along the discharge pipe to ensure the transport of slurry over long distances greater than a mile or 1.6 kilometers.

Maximizing the performance of pump inducers using CFD-based multi-objective optimization

Pump inducers are usually employed within a limited flow rate range since the performance is known to drop out significantly far from their design point. Therefore, finding an optimal geometry that ensures efficient operation for a relatively wide range of flow rates is challenging. The present study tackles this problem using multi-objective optimization to identify optimal inducer configurations, delivering high performance for a wide flow range. 3D RANS single-phase turbulent simulations were performed using the k-omega turbulence model. The optimization was done by employing the Non-dominated Sorting Genetic Algorithm (NSGA-II) coupled with computational fluid dynamics (CFD). An established in-house flow optimization library (OPAL++) was used to automatically control the numerical simulations. The objective is to optimize the inducer geometrical parameters to simultaneously maximize the efficiency and pressure head curves, considering different flow rates, i.e., 80% (part-load), 100% (nominal), and 150% (overload) of the optimal flow rate for the considered pump. The optimization involves 8 most relevant design parameters, i.e., the axial blade length, blade sweep angle, blade pitch, hub taper angle, tip clearance gap, blade thickness at the hub, blade thickness at the tip, and the number of blades. A total of 5178 simulations over 37 generations have been needed to get a Pareto front containing 5 optimal configurations. This article discusses quantitatively the influence of each geometrical parameter on flow behavior and inducer performance. The results reveal in general that blade length, blade sweep angle, tip clearance gap, and blade thickness should be kept low for the considered application; inducers with high hub taper angles and 3 blades lead to optimal performance.