Off-design Flow Rates Research Articles

Impact of extracorporeal blood pump gap sizes on the performance and hemocompatibility under off-design operation.

Hemocompatibility remains the dominant challenge in rotary blood pumps, and more information on the relationship between individual pump design features, hemodynamics, and blood trauma in various operation conditions is necessary. The study evaluated the variation of gap sizes in extracorporeal blood pumps concerning their influence on blood compatibility, particularly during off-design conditions. We developed a parametric generic blood pump framework for in-silico and in-vitro design feature analysis. Thirty-six designs with varying axial and radial gap sizes between 0.5 mm and 3 mm were generated. CFD was applied to calculate and compare device hemodynamics and evaluate the performance and hemocompatibility during off-design and target operation conditions. The following quantities were analyzed: pressure difference, hemolysis potential, residence times, hydraulic efficiency, and recirculation ratio. The in-vitro prototype showed excellent agreement with in-silico predictions regarding hydraulic performance (R2 = 0.996 with a RMSE = 2.07). Our results show a modest impact of gap size variations ±10% on key metrics. Domain-resolved analyses revealed a significant contribution of the gap regions to the device's overall hemolytic performance, with an increasing contribution for off-design flow rates. Overall elevated hemolysis levels were identified if at least one gap size was held minimal. We introduced and showed the feasibility of a parametric rotary blood pump framework to systematically investigate design feature impact. Results suggest, larger and uniformly sized gaps being overall beneficial regarding hemocompatibility.

Analysis on flow structure in a vortex pump under all flow rates

Abstract Vortex pumps are usually designed based on its inner flow model. Currently, the flow models of vortex pump just consider flow rate at the design condition, which results in low efficiency under off-design flow rates in practical engineering. Therefore, the main objective of this article is to build a flow model that takes into account the impact of flow rates. To reveal the flow mechanism of vortex pump, we provide refined flow field simulations for a vortex pump. Performance experiments were conducted to validate the numerical simulation method. The study found that the vortex structure in the non-blade cavity can be regarded as a Rankine-like vortex. The inflow range is limited to the hub diameter (45 mm), smaller than the volute inlet diameter (85 mm). The action radius of the forced vortex gradually decreases from the impeller side to the inlet side. The maximum radius of the forced vortex on the impeller side is determined by the impeller diameter. As the flow rate increases, the action radius of the forced vortex on the inlet side gradually increases, while the axial length of the vortex in the inlet pipe gradually decreases. Based on the study of internal flow, a new flow model is proposed.

Unsteady Pressure Pulsations in Pumps—A Review

Unsteady pressure-pulsation-induced severe vibration and high alternating stress can cause some unexpected results, including impeller crack and structural damage of the entire pumping system. In the present paper, a review on pressure pulsations in pumps is carried out based on the published studies. A comprehensive view on pressure pulsations from several aspects is discussed in detail. The contents of the studies include the mechanism of rotor–stator interaction; a prediction model and experimental and numerical investigations of pressure pulsations; unsteady rotating-stall-induced pressure pulsations at off-design flow rates; the relationship between pressure pulsation and the internal flow structure and cavitation; and the reduction in pressure pulsation caused by some effective approaches. It is concluded that unsteady pressure pulsation in pumps is closely associated with complex flow structures, for instance flow separation, cavitation, and rotating stall. The rotor–stator interaction mainly dominates pressure pulsation characterized by the discrete components in pressure spectrum. To reduce pressure pulsation, some effective approaches are proposed, such as increasing the rotor–stator gap, staggered blade, and blade modification. Finally, several suggestions for future works are given and discussed considering the current research. The review contributes to better understanding of pressure pulsations in centrifugal pumps, and may also benefit engineers in controlling pressure pulsations in some fields, such as pumps in nuclear reactor.

Effects of pre-whirl and blade profile on the hydraulic and cavitation performance of a centrifugal pump

The effects of pre-whirl and modified blade profile on the hydraulic performance and cavitation flow of the centrifugal pump are investigated quantitatively with the numerical simulations. The results show that the hydraulic efficiency of the off-design flow rate can be improved with the positive pre-whirl angle owing to significantly reduced friction loss, whilst the negative and positive pre-whirl can give rise to the higher and lower head coefficient respectively compared with that of no pre-whirl condition. Besides, the pre-whirl design is confirmed to have the ability to improve the cavitation performance of centrifugal pump, while the positive and negative pre-whirl are more suitable for the larger/design and smaller flow rates in the centrifugal pump, respectively. Additionally, the head coefficient, hydraulic efficiency and torque of the centrifugal pump are improved obviously with the redesign blade profile, while the cavitation number corresponding to the original head drop and the critical cavitation number of the modified impeller are both decreased gradually by up to 45.7% and 43.1% respectively as the ratio of tangent line (t) and the circle arc line (c) is increased. In addition, the much smaller low-pressure zone and cavitation area of modified impellers confirm that the suction performance of an impeller can be improved effectively with the modification method of the blade profile adopted in this study, which makes for the lesser cavitation damage and longer impeller lifetime.

Numerical Investigation on Blockage-Related Cavitation Surge and Pressure Gain of a Mixed-Flow Pump With Influence of Blade Leading Edge Shape on Suction Performance

Abstract The blade leading edge is a design variable that can affect the local flow patterns and pressure peaks, implying a direct effect on the cavitation performance. This study was conducted to analyze the effect of the blade leading edge shape on the cavitation and noncavitation states. A total of four sets, including the square shape, were selected under the definition of ellipse ratio, and the main focus was on the cavitation state rather than the noncavitation state. In the noncavitation state, the square set denoted a remarkable negative influence, while the other three sets obtained almost the same performance despite different ellipse ratios. In the cavitation state, the square set obtained a relatively low net positive suction head required, related to the inlet flow pattern with the cloud cavity. The other three sets contained the sheet cavity, and their suction performance tended to improve as the cavity blockage decreased. As a parallel focus, an in-depth analysis of cavitation surge and pressure gain was presented with the head drop slope for the other three ellipse sets. The numerical results included the off-design flow rate points and were validated through an experimental test.

Numerical Analysis of Flow Characteristics of the Low-Speed Centrifugal Compressor Stage Comprising Wedge Diffuser

Wedge type diffusers are used generally in the highly loaded stages of smaller jet engines as it is compact in size. Low speed centrifugal compressor (LSCC) is selected for this present study as experimental details are available. A centrifugal compressor stage comprising wedge type diffuser is used in this numerical investigation in which studies are carried out at design mass flow rate (30kg/s) and off-design mass flow rates (23.64kg/s and 36.36kg/s) at constant rotational speed of 1920 rpm. Single passage approach is chosen to model the computational domain which is meshed with unstructured grid. Turbulence model chosen is kω-SST. The investigation revealed the jet-wake structure along the pressure side and suction side of the impeller and its subsequently mixing at impeller exit vaneless diffuser region. Diffusion process in the LSCC is observed to be effective as the outlet values of absolute velocity are lesser compared to its inlet values. Highest static pressure rise is observed for design mass flow rate and followed by below and above off-design mass flow rates.

LES study on the influence of the diffuser inlet angle of a centrifugal pump on pressure fluctuations

Large-Eddy Simulations are conducted on a centrifugal pump at design and reduced flow-rates for three diffuser geometries, to investigate the effect of changing the diffuser inlet angle on the overall performance and the pressure fields. In particular, pressure fluctuations are investigated, which affect the unsteady loads acting on the pump, as well as vibrations, noise and cavitation phenomena. The considered modification of the diffuser geometry is targeted at decreasing the incidence angle at the off-design flow-rate by rotating the stationary blades of the pump around their leading edge. Results are compared against those of an earlier study, where the same modification of the diffuser inlet angle was achieved by increasing also the radial gap between impeller and diffuser, whose blades were rotated relative to their mid camber location. The comparisons across cases demonstrate that the radial gap between the trailing edge of the impeller blades and the leading edge of the diffuser blades has a more profound influence on pressure fluctuations, compared to the angle of incidence on the diffuser blades of the flow coming from the impeller.

Unsteady flow fluctuations in a centrifugal pump measured by laser Doppler anemometry and pressure pulsation

Turbulent flow generated by the intense rotor–stator interaction is detrimental to the safe running of the centrifugal pump. In order to gain more insight into unsteady velocity pulsation characteristics, this research applies the laser Doppler anemometry technique to capture velocity signals at various flow rates. Besides, pressure transducers are arranged on the model pump to sample transient pressure pulsation signals. The study paid particular attention to pulsation signals in the diffusion section of the volute. Results show that at low flow rates, a prominent hump phenomenon generated within the pump head curve, which indicates the development of rotating stall in the model pump. As noted from the spectra, the discrete blade passing frequency and impeller rotating frequency dominate the velocity and pressure spectra. Root mean square values of velocity signals increase rapidly at off-design flow rates, especially within the rotating stall region, and a similar trend is observed for pressure amplitude at the blade passing frequency. From the measuring point (P3) at the inlet of the discharge channel upstream of the volute tongue to the point (P10) at the volute outlet, pressure amplitude rises significantly. Meanwhile, the minimum point of pressure amplitude vs flow rate occurs around 0.4ΦN, and again, the findings show differences for comparisons between measuring points in the core flow region of the volute. This resulting phenomenon can be attributed to flow patterns in the diffusion section.

Analysis of the Pressure Pulsation and Vibration in a Low-Specific-Speed Centrifugal Pump

Abstract Unsteady pressure pulsation and fluid force induced by flow instabilities in the centrifugal pump is an important cause of vibration, which is detrimental to the safe operation of the pump. In this study, we numerically investigated the pressure pulsation and radial force in a low-specific-speed centrifugal pump by using the detached-eddy simulation method. We also performed a vibration displacement experiment on the shaft of the centrifugal pump. The vortex identification method was introduced to clarify the internal correlation between unsteady flow structures with pressure pulsations. The results showed that the pressure pulsations at the impeller outlet were closely associated with the periodic vortex shedding from the blade pressure surface. The rotor–stator interaction between a relatively big trailing vortex core and volute tongue generated larger pressure pulsation and radial force in the pump at a low flow rate. Under a large flow rate, the trailing vortex core was easily broken and dispersed, and this resulted in smaller pressure pulsation and radial force compared with that at a low flow rate. Under the design flow rate, the pressure pulsation intensity and the radial force in the impeller were smaller than that under the off-design flow rate. Compared with the spectra between the radial force on the impeller and radial displacement on the shaft, they both presented higher amplitude at the shaft frequency. The vibration of the pump shaft was closely related to the radial force on the impeller.

Математическая модель Метода универсального моделирования 9-й версии: особенности и результаты идентификации

The Universal modeling method is a complex of computer programs for calculating the characteristics and optimal design of centrifugal compressors based on mathematical models of efficiency and head. Practical experience allows improving the mathematical models that underlie the Method. Determining the non-incidence inlet in a blade cascade is an important part of calculating the compressor gasdynamic characteristics. In the 8th version of the Universal modeling method, a formula is used to calculate the direction of the critical stream line, containing an empirical coefficient X. The practice of application has shown that the value of the empirical coefficient changes the amount of losses in the impeller in off-design flow rates. A new scheme for modeling velocity diagrams is proposed. It is made for the stage operation mode corresponding to the zero incidence angle. The successful use of the model for the impeller made it possible to extend it to the vane diffuser and return channel. Several other improvements are made too. A new mathematical model is developed for calculating the flow parameters in the exit nozzles of centrifugal compressor stage. The mathematical model for calculating the flow parameters in the vaneless diffusers is modernized. The applicability boundary of the new model is expanded to a range of diffusers of low consumption stages with a relative width of up to 0,006. The resulting mathematical model is identified by the test results of two family model stages and plant tests of industrial compressors

Experience of designing a low-pressing turbocharger compressor using the modern version of a Universal modelling method

The paper presents the joint experience of the NPO “Turbotekhnika” and the R&D Laboratory “Gas Dynamics of Turbomachines” of SPbPU for designing a centrifugal compressor operating at pressure ratio 1.61 and a mass flow rate of 0.62 kg/s. The design was executed using the Universal modelling method and the inviscid quasi-three-dimensional calculation program 3DM.023. At the first step, by the preliminary design program, the stage dimensions were determined. The expected gas-dynamic characteristics are calculated. At the final design step, stator elements were offered by NPO “Turbotekhnika” and the configuration of the impeller blades was optimized based on the non-viscous quasi-three-dimensional calculations. NPO “Turbotekhnika” designed, manufactured and tested the 140E compressor at blade velocities 150, 200, 250 and 300 m/s. A comparison and analysis of experimental and calculated characteristics is presented. The design pressure ratio was calculated almost exactly for the design flow rate at a blade velocity of 300 m/s. The expected efficiency was confirmed. The mathematical model slightly overestimates the efficiency and the pressure ratio for the off-design flow rates.

Multi-condition optimization and experimental verification of impeller for a marine centrifugal pump

In order to improve the performance of marine centrifugal pump, a centrifugal pump whose specific speed is 66.7 was selected for the research. Outlet diameter D2, outlet width b2, blade outlet angle β2, blade wrap φ and blade number z of the impeller were chosen as the variables. The maximum weighted average efficiency and the minimum vibration intensity at the base were calculated as objectives. Based on the Latin Hypercube method, the impeller was numerically optimized. The numerical results show that after optimization, the amplitudes of pressure fluctuation on the main frequency at different monitoring points decrease in varying degrees. The radial force on impeller decreases obviously under off-design flow rates and is more symmetrical during the operation of the pump. The variation of the axial force is relatively small, which has no obvious relationship with the rotating angle of the impeller. The energy performance and vibration experiment was performed for verifying. The test results show that the weighted average efficiency under 0.8Qd, 1.0Qd and 1.2Qd increases by 4.3% after optimization. The maximal vibration intensity at M1-M4 on the pump base reduced from 0.36 mm/s to 0.25 mm/s, decreasing by 30.5%. In addition, the vibration velocities of bracket in pump side and outlet flange also have significant reductions.

Performance improvement of an axial-flow pump with inlet guide vanes in the turbine mode

The axial pump operating in the pump-as-turbine mode is a practical and cost-saving alternative suitable for low-head pico hydropower in rural and remote areas that bypasses the need for expensive turbines. Their pump characteristics, however, indicate that efficiency is low in off-design flow rates. Using the computational fluid dynamics, the adjustable inlet guide vanes with five angles (±20°, 0°, ±10°) in front of the impeller of the axial pump have been redesigned and installed specifically to increase the operating range of high efficiency in the pump-as-turbine mode. To validate the simulation method, a prototype of the axial pump was built to measure in the pump mode the pump characteristics including head and efficiency. The results obtained show that the computational fluid dynamics calculated results are in qualitative agreement with the experimental data. In the pump-as-turbine mode, the adjustable inlet guide vanes were found to affect the performance of the axial pump. The most important aspect is that the adjustable inlet guide vanes widen the efficiency range if the inlet guide vane angle is adjusted for different flow rates. For the same situation with negative angles, the efficiency values at the BEP are higher than those with positive angles, where the efficiency around the angle − 10° is the highest. The main reason is that the direction of flow at the impeller-zone exit is guided by the adjustable inlet guide vanes to reduce the energy loss, which can be supported in the view of vector field and energy losses of different parts of pump.

Automatic optimization of a centrifugal pump based on impeller–diffuser interaction

In this study, a centrifugal pump has been optimized using the genetic algorithm coupled with computational fluid dynamics considering the flow physics for various impeller–diffuser configurations. During the automatic optimization process, the population was selected from a pool of pump geometries generated by four design variables; namely the relative diffuser vane angle, number of diffuser vanes, number of impeller blades, and the impeller wrap angle. The genetic algorithm was combined with a flow solver and a computer aided design software which was used also to create the mesh for the generated geometry. Two objective functions were adopted for the optimization: maximum pressure increase and minimum relative flow angle, which is an indication of reverse flow in the impeller. The iteration history of the optimization for the design (2.4 kg/s) and off-design (3.6 kg/s) flow rate showed that the optimization has been converged to an impeller–diffuser configuration within approximately 250 computational fluid dynamics analyses. Three geometries from each optimization with the highest pressure increase were studied for various mass flow rates and the results were compared with those of the original pump. The results show that the first optimization indicates a significant improvement of pressure increase at design flow rate (15.5%) but decrease at larger flow rates. The second optimization which was required after the results of the first optimization enhanced the head for the entire mass flow rates with an average increase of 25.74%.

Performance Enhancement of a Low-Pressure Ratio Centrifugal Compressor Stage with a Rotating Vaneless Diffuser by Impeller Disk Extended Shrouds

Numerical simulations have been carried out to examine the performance and flow parameters of forced rotating vaneless diffuser obtained by the extension of impeller disks of a low-pressure ratio shrouded type centrifugal compressor stage with diffuser diameter ratio 1.40. Four different levels of shroud extensions (i.e., impeller disks alone) forming the rotating vaneless diffusers are analyzed at four different flow coefficients. The extension of impeller disks alone by 40% of impeller exit diameter leads to a fully forced rotating vaneless diffuser thereby replacing the existing stationary vaneless diffuser. The comparative studies are performed using the same impeller with a stationary vaneless diffuser also having a diffuser diameter ratio of 1.40. Static pressure rise in ES40 is found to be higher than SVD by around 9.84% at design flow coefficient and also at above off-design flow rates. Energy coefficient is highest for ES40, followed by ES30 compared to SVD. For ES40, the static pressure recovery coefficient also is higher compared to SVD. The efficiency of ES40 is lesser by around 5.40% to 3.43% compared to SVD, at design as well as at above off-design flow coefficients. The stagnation pressure losses for ES40 drastically reduced compared to SVD. The comparison of stagnation pressure contours and absolute velocity contours near the hub and shroud walls of ES40 and SVD configurations shows that the rotating diffuser walls as in ES40 causes further addition of energy to the fluid. This adds up the kinetic energy level of the fluid which due to better diffusion, results in gain of static pressure rise. Moreover, there is a net increase in stagnation pressure distribution at the exit of diffuser due to rotating vaneless diffuser. Also, the presence of a fully rotating vaneless diffuser (ES40) smooth out the distorted entry flow profiles, thereby improving the performance of the centrifugal compressor stage.

Numerical and In Vitro Experimental Investigation of the Hemolytic Performance at the Off-Design Point of an Axial Ventricular Assist Pump.

The ventricular assist pumps do not always function at the design point; instead, these pumps may operate at unfavorable off-design points. For example, the axial ventricular assist pump FW-2, in which the design point is 5 L/min flow rate against 100 mm Hg pressure increase at 8,000 rpm, sometimes works at off-design flow rates of 1 to 4 L/min. The hemolytic performance of the FW-2 at both the design point and at off-design points was estimated numerically and tested in vitro. Flow characteristics in the pump were numerically simulated and analyzed with special attention paid to the scalar sheer stress and exposure time. An in vitro hemolysis test was conducted to verify the numerical results. The simulation results showed that the scalar shear stress in the rotor region at the 1 L/min off-design point was 70% greater than at the 5 L/min design point. The hemolysis index at the 1 L/min off-design point was 3.6 times greater than at the 5 L/min design point. The in vitro results showed that the normalized index of hemolysis increased from 0.017 g/100 L at the 5 L/min design point to 0.162 g/100 L at the 1 L/min off-design point. The hemolysis comparison between the different blood pump flow rates will be helpful for future pump design point selection and will guide the usage of ventricular assist pumps. The hemolytic performance of the blood pump at the working point in the clinic should receive more focus.

Output power analyses for the thermodynamic cycles of thermal power plants

Thermal power plant is one of the important thermodynamic devices, which is very common in all kinds of power generation systems. In this paper, we use a new concept, entransy loss, as well as exergy destruction, to analyze the single reheating Rankine cycle unit and the single stage steam extraction regenerative Rankine cycle unit in power plants. This is the first time that the concept of entransy loss is applied to the analysis of the power plant Rankine cycles with reheating and steam extraction regeneration. In order to obtain the maximum output power, the operating conditions under variant vapor mass flow rates are optimized numerically, as well as the combustion temperatures and the off-design flow rates of the flue gas. The relationship between the output power and the exergy destruction rate and that between the output power and the entransy loss rate are discussed. It is found that both the minimum exergy destruction rate and the maximum entransy loss rate lead to the maximum output power when the combustion temperature and heat capacity flow rate of the flue gas are prescribed. Unlike the minimum exergy destruction rate, the maximum entransy loss rate is related to the maximum output power when the highest temperature and heat capacity flow rate of the flue gas are not prescribed.

Internal Flow of Contra-Rotating Small Hydro-Turbine at Off-Design Flow Rates

Internal Flow of Contra-Rotating Small Hydro-Turbine at Off-Design Flow Rates

Numerical Simulation of Internal Flow and Performance Prediction of Tubular Pump with Adjustable Guide Vanes

Aiming at the performance defect of tubular pump with fixed guide vanes, a design scheme of tubular pump with adjustable guide vanes is proposed, so that the inlet setting angle of guide vanes can be flexibly adjusted to coordinate with the operation conditions of pump, to ensure the inlet setting angle of guide vanes changing with the outlet flow angle of the impeller. The three-dimensional time-averaged incompressible Navier-Stokes equations are adopted to numerically simulate the internal flow field of a tubular pump with fixed and adjustable guide vanes, respectively. Computed results indicate that with the design of adjustable guide vanes and at off-design flow rates the flow conditions inside the diffuser of tubular pump can be improved effectively, and its hydraulic losses can be reduced. When the impeller blade angles are fixed the best efficiency points are within 0.51% while adjusting setting angles of guide vanes within a certain range. Under off-design conditions the hydraulic efficiency of tubular pump with adjustable guide vanes can be obviously improved by 1.70% at 0.75 Q0 and 2.19% at 1.20 Q0, when the blade angle is 0 degrees and the angle of guide vanes is adjusted to be 2 degrees smaller and larger, respectively.

Experimental study on the flow of a mixed flow pump impeller

Mixed flow pump is wildly used in many field, the performance of the whole pump is affected by the flow in the impeller to a great extend. To make clear the flow phenomena in the mixed flow impeller at design and off-design flow rate condition, a mixed flow unshrouded impeller was manufactured and the flow in the impeller at design and off-design flow rate was experimental measured by Particle Image Velocimetry (PIV) in this paper. In the experiment test device, the volute was specially design and manufactured by transparent material. According to the experimental result, the distribution of time-average relatively velocity showed the velocity near blade pressure surface at design flow rate decreases and then increases from inlet to outlet of the impeller, and that near blade suction surface increase and then decreases. The velocity near the suction surface decrease from hub to casing, and the minimal velocity appears near the casing and suction surface. Near the impeller outlet, the relative velocity near blade pressure surface varies a little alone the span direction; Back-flow phenomena were found at passages outlet near casing and mid-span sections at partial flow rate. To clarify the effect of volute geometry on the velocity distribution, the flow in different impeller passages relatively to the volute tongue was test and the result showed that the velocity distribution in different passages was similar.