Impact of three-dimensional phenomena on the design of rotodynamic pumps

Three-dimensional Navier-Stokes calculations are expected to be increasingly applied in the future for performance improvement of rotodynamic pumps. Frequently such an optimization process involves a preliminary design-based on one-dimensional methods and empirical data-which is subsequently optimized by computational fluid dynamics (CFD). Employing an empirical database is not only necessary in order to provide a good starting point for the CFD analysis but also to ensure that the design has a good chance of fulfilling part load requirements, since recirculating flows at the impeller inlet and outlet are not easily handled by CFD programs. CFD calculations provide the specific work input to the fluid and information on losses and reveal the complex three-dimensional flow patterns. The designer is faced with the task of interpreting such data and drawing conclusions for the optimization of the impeller. It is the purpose of the present contribution to analyse and describe the impact of various geometric parameters and flow features on the velocity distribution in the impeller and their influence on performance and part load characteristics. Criteria are also provided to select the parameters for the preliminary design. Hydraulic impeller losses calculated by CFD programs may often be misleading if the non-uniformity of the flow distribution at the impeller outlet is ignored. Procedures to quantify such mixing losses in the diffuser or volute downstream of the impeller are discussed.