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Computers & Fluids 67 (2012) 7278

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Computers & Fluids


j o u r n a l h o m e p a g e : w w w . e l s e v i e r . c o m / l o c a t e / c o m p fl u i d

Effects of impeller trimming inuencing pump as turbine


Yang Sun-Sheng , Kong Fan-Yu, Jiang Wan-Ming, Qu Xiao-Yun
Research Center of Fluid Machinery Engineering and Technology, Jiangsu University, Zhenjiang, Jiangsu 212013, China

a r t i c l e

i n f o

Article history:
Received 9 July 2011
Received in revised form 21 March 2012
Accepted 7 July 2012
Available online 20 July 2012
Keywords:
Pump as turbine
Impeller trimming
PAT test rig
Experimental research
Numerical research

a b s t r a c t
Pump manufactures normally do not provide performance curves of their pumps working as turbines,
especially performance curves of trimmed impellers. Impeller trimming is necessary to adapt to a certain
operating condition. Therefore, establishing the correlation of PATs performance curve and impeller
trims is essential. In this paper, a laboratory model of a pump as turbine (PAT) open test rig was set
up. Experimental research was carried out on a single stage centrifugal PAT, performance curves of original impeller, impeller after once and twice trims were acquired. Numerical simulation and analysis
were performed on the PAT. The accuracy of CFD was validated through comparison between numerical
and experimental data. As impeller diameter is cut down, its geometrical parameters of impeller diameter, blade wrap angle, impeller inlet width and blade inlet angle are changed. So, research on effects
of the above four parameters to the performance inuence of PAT were carried out using CFD. Through
analysis of the predicted performance curves, the reasons for the variation of performance curves after
impeller trimming were explored.
2012 Elsevier Ltd. All rights reserved.

1. Introduction
Conserving energy while exploring renewable, environmentally-friendly energy resources is of crucial importance to keeping
up with increasing energy demands. Small hydropower with its
characteristics of available worldwide became attractive to energy
utilization after the oil crisis of the seventies.
Pumps are relatively simple machines, easy to manufacture and
maintain and readily available all over the world. Experiments
have shown that in relatively low power outputs, pumps with high
technological standards in reverse operation can compete with
conventional turbines in respect to maximum efciency [1]. Thus,
PAT is one of the cheap and attractive alternatives in high pressure
uid and small hydropower resources exploration. Research on
PAT was started around 1930 [2]. With increasing energy demands,
it will be more economical to exploit such energy resources in
future.
Pump manufacturers normally do not provide characteristic
curves of their pumps working as turbines. This makes it difcult
to select an appropriate pump to run as a turbine for a specic operating condition. So many research works have been focused on predicting PATs performance based on its pump mode performance
[38] or pump geometric parameters [9]. But the PAT behavior is
very complex and it is difcult to nd just a relation to cover all
pumps behavior in reverse mode [10]. Most recent attempts to pre Corresponding author. Address: Zhenjiang, Xue-fu Road No. 301, Jiangsu
Province, China. Tel./fax: +86 511 88780286.
E-mail address: yangsunsheng@126.com (S.-S. Yang).
0045-7930/$ - see front matter 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.compuid.2012.07.009

dict PAT performance have been made using CFD. However, relatively large deviations from experimental data have been reported
[1013]. Few research works have been focused on the optimization
of PAT [1417]. Yet, no paper has been focused on impeller trimming to the inuence of PAT. Sometimes when the system pressure
head or ow rate drops, trimming impeller is a convenient way to be
adopted. Therefore, it is necessary to focus on effects of impeller
trimming to the inuence of PATs performance.
2. Experimental setup
A laboratory model of a PAT open test rig, as shown in Fig. 1a
was set up at Jiangsu University. High pressure uid required
was supplied by a feed pump. An energy dissipation pump was installed to consume energy generated by PAT and regulate PATs
rotational speed. To measure PATs torque and rotational speed, a
torque meter was put between PAT and energy dissipation pump.
The discharge was measured by a turbine ow meter. Its inlet and
outlet pressure were measured by pressure gauges. After measuring all parameters, PATs head, output power, efciency and performance curve were obtained. The uncertainty of measured pressure
head (H), ow rate (Q), hydraulic power (Ph), generated shaft
power (Pshaft) and efciency (g) were 0.57%, 0.50%, 0.76%,
1.02% and 1.27% respectively.
Fig. 1b shows the open pump test rig established at Jiangsu University. The uncertainty of measured required pressure head (H),
ow rate (Q), hydraulic power (Ph), generated shaft power (Pshaft)
and efciency (g) were 0.14%, 0.50%, 0.52%, 1.08% and
1.20% respectively.

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S.-S. Yang et al. / Computers & Fluids 67 (2012) 7278

Nomenclature
b2
D1
D2
D3
D4
Dh
e
H
n
ns
P
Q

L
z

impeller inlet width (mm)


impeller outlet diameter (mm)
impeller diameter (mm)
volute base circle diameter (mm)
volute inlet diameter (mm)
impeller hub diameter (mm)
blade thickness (mm)
head (m)
rotational speed (r/min)
p
n

length of impeller wear ring, mm


blade number

Greek symbols
/
blade wrap angle ()
b
blade angle ()
g
efciency
Subscriptions
1
variable at low pressure end
2
variable at high pressure end
H
hydraulic
b
balancing hole

specic speed, ns H3=4


power (kW, W)
volume ow rate (m3/h, m3/s)

a
Valve

Turbine flow meter

Valve
Pressure gaugue

Motor

Feed pump

PAT

Consume Pump

Torque meter

Turbine flow meter

valve

Pressure gaugue

pump

motor

Fig. 1. (a) An open PAT test rig and (b) an open pump test rig.

3. PAT main geometric parameters

4. Numerical investigation

The focus of the investigation is a single stage centrifugal PAT. Its


rated speed is 1500 r/min in both turbine and pump modes. As
impeller is trimmed, its geometrical parameters of impeller diameter (D2), impeller inlet width (b2), blade wrap angle (u) and blade
inlet angle (b2) will be changed. Table 1 lists the main geometric
parameters of the designed PAT and the varied impeller parameters
after trimming. Fig. 2 shows the tested PAT and impellers.

CFD code ANSYS-CFX which utilizes a nite-element based nite-volume method to discrete the transport equations was used
for numerical research. The uid was split into ve component
parts; they were PATs volute, impeller, front and back chambers
and outlet pipe. This separation allowed each mesh to be generated
individually and tailored to the ow requirements in that particular component. To get a relatively stable inlet and outlet ow, four

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S.-S. Yang et al. / Computers & Fluids 67 (2012) 7278

Table 1
Main geometric parameters of the designed PAT.

u ()
b2 ()
b2 (mm)
u ()
b2 ()
b2 (mm)
u ()
b2 ()
b2 (mm)

D2 = 235

D2 = 215

102
6
4
39
15
266
65
30
6
75
97.52
24.27
14.38
88.06
28.22
15.30
79.16
31.28
16.98

62.5
62.0
61.5

(%)

D1 (mm)
z
e (mm)
b1
L (mm)
D3 (mm)
D4 (mm)
Dh (mm)
zb
Db (mm)
D2 = 255

63.0

61.0
60.5
60.0
59.5
59.0
0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

mesh number (million)


Fig. 3. PATs efciency versus mesh number curve.

Fig. 4. Mesh within PAT.

respectively. For other models simulation, the mesh number was


almost the same.
Care was taken in the PAT outlet pipe mesh generation in order
that the mesh between the interface of outlet pipe and front chamber leakage was almost the same. The y+ near the boundary wall
was around 40. Due to the complexity of generating structured
mesh based on geometry, great efforts had been taken in the mesh
generation of volute. Fig. 4 gives a general view of the generated
meshes.
4.2. Solution parameters

Fig. 2. (a) PAT and (b) three impellers.

times of the pipe diameter had been extended in the PAT inlet and
outlet section.
4.1. Mesh generation
ICEM-CFD was used to generate structured hexahedral grid for
each component part [18]. A grid independent test of the PAT with
impeller diameter of 235 mm showed that when mesh numbers
were around 1 million, the variation of efciency was within
0.5% as indicated in Fig. 3. The nal mesh number of volute, impeller, front chamber, back chamber, outlet pipe and total number
were 479710, 378222, 134956, 129700, 174720, and 1297308

The turbulence selected was ke model. The advection scheme


was set to high resolution. The convergence criterion was 105.
The uid selected was ideal water at 25 C. All the wall surface
roughness within the control volume was set to 50 lm. The inlet
and outlet boundary condition were set to static pressure inlet
and mass ow rate outlet [18]. By changing the mass ow rate,
PATs performance curves were acquired. The simulation type used
in this paper was steady state simulation. The relative position of
impeller blades in relation to volute tongue is shown in Fig. 4.
As the motion of the impeller blades relative to the stationary
volute was central to the investigation, the analysis must involve
multiple frames of reference. The volute and outlet pipe were set
in stationary frame and the impeller was set in rotary frame. The
interfaces between two stationary components, rotary and stationary components were set to general grid and rotor stator interface
respectively.

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S.-S. Yang et al. / Computers & Fluids 67 (2012) 7278


Table 2
BEPs of impellers in both modes.

6. Validation of CFD results

Items
PAT

255
235
215
255
235
215

Pump

Q (m3/h)

H (m)

Pshaft (kW)

g (%)

ns

95.23
86.14
93.63
52.12
51.71
49.80

39.17
32.40
37.52
18.07
17.17
13.75

6.15
4.56
5.63
4.19
3.83
3.13

62.95
59.98
58.84
61.15
63.08
59.55

15.58
17.09
15.96
20.59
21.31
24.71

Exp P
CFD P

Exp H
CFD H

Exp
CFD

64

14
52

13

60

48

12

56

44

52

40

11

48

36

44

32

40

28

36

24

32

20

10

Pshaft (kW)

H (m)

Experimental research on original impeller and impeller after


once and twice trims were carried out on turbine and pump
modes. Fig. 5 shows the performance curves of the three tested
impellers in both modes. Table 2 lists their BEPs.
Table 2 shows that PATs efciency is decreased with the trimming of impeller diameter. As impeller is cut from 255 mm to
215 mm, PATs BEP shifts from 95.23 m3/h to 86.14 m3/h and then
moves back to 93.63 m3/h and its efciency at BEP is dropped by
4.11%. Fig. 5a indicates that PATs QH curve becomes increasingly
steep and QPshaft curve moves almost parallel down when impeller is trimmed.
As impeller is trimmed from 255 mm to 215 mm, PATs geometric parameters of impeller diameter, blade wrap angle, impeller inlet width and blade inlet angle are changed. To get a more clear
result of these parameters affecting PATs performance, effects of
these four parameters to the inuence of PAT are carried out separately using CFD.

(%)

5. Experimental results of impeller trimming

9
8
7
6
5
4

To validate the accuracy of numerical result, experimental and


numerical performance curves of the impeller with diameter of
235 mm are presented in Fig. 6. Table 35 lists their experimental
and numerical results. In the process of numerical simulation, leak-

65

70

75

80

85

90

95

100

105

110

115

120

3
2
1
125

Q (m3/h)

PAT 215
PAT 235
PAT 255

66
64

PAT 215 P
PAT 235 P
PAT 255 P

PAT 215 H
PAT 235 H
PAT 255 H

Fig. 6. Experimental and numerical performance curves.

12

56
52

62

10

48

60

Table 3
Experimental and numerical efciency.

44

56
54

36

52

32

50

28

48

24

Pshaft (kW)

40

H (m)

(%)

58

Q/QBEP(%)

0.81

0.90

1.00

1.14

1.27

Exp
CFD
Error

52.25
56.14
7.44

56.31
60.67
7.74

59.98
63.03
5.09

58.80
62.18
5.74

56.70
60.13
6.05

46

20
70

75

80

85

90

95

100

105

110

115

2
120

Q (m3/h)

PUMP215
PUMP235
PUMP255

70

PUMP215H
PUMP235H
PUMP255H

PUMP215P
PUMP235P
PUMP255P

0.81

0.90

1.00

1.14

1.27

Exp (m)
CFD (m)
Error (%)

24.79
25.42
2.54

27.96
29.16
4.29

32.40
33.71
4.04

38.85
40.43
4.07

47.27
49.24
4.17

Table 5
Experimental and numerical shaft power.

20

H (m)

40

16
14

Pshaft (kW)

18

50

(%)

Q/QBEP

24
22

60

Table 4
Experimental and numerical head.

Q/QBEP

0.81

0.90

1.00

1.14

1.27

Exp (kW)
CFD (kW)
Error (%)

2.47
2.72
10.12

3.33
3.74
12.31

4.56
4.98
9.21

6.20
6.70
8.06

8.29
8.87
7.00

3
12
30
10
2
20

8
10

20

30

40

50

60

70

80

90

100

Q (m3/h)
Fig. 5. (a) Performance curves of impellers in turbine mode and (b) performance
curves of impellers in pump mode.

age ow through the balancing holes and mechanical seals is neglected, so the simulated efciency includes volumetric loss
through the wear ring and mechanical loss caused by disc friction.
As illustrated in Fig. 6, numerical predicted performance curves
well reect the tendency of PATs experimental results. Numerical
predicted efciency, pressure head and shaft power are higher than
those of experimental results. The maximal relative error of predicted g, H and Pshaft to experimental data are 7.44%, 4.29% and

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S.-S. Yang et al. / Computers & Fluids 67 (2012) 7278

12.31%. This over predict of efciency, pressure head and shaft


power may attribute to the neglection of leakage loss through balancing holes and mechanical loss caused by mechanical seal and
bearings. According to the comparison between experimental
and CFD results, it is reasonable to believe that CFD can be used
in the prediction of PATs performance.

Table 6
BEPs of impellers with three diameters.
D2 (mm)

Q (m3/h)

H (m)

Pshaft (kW)

g (%)

255
235
215

80.0
72.5
60.0

31.82
27.46
21.48

4.72
3.67
2.32

68.15
67.73
65.98

7. Impeller diameter
90 H
110 H
130 H
150 H

90
110
130
150

70
69
68

90 P
110 P
130 P
150 P

48

H (m)

64

32

63

28
4

62
24

61

20

55

70

18

75
70

16

65

65

H (m)

55
50
45

50
45
40

40

30

30

25

25

20

20

15
70

80

90

100

110

120

90

95

100 105

110 115

H (m)

Pshaft (kW)

g (%)

150
130
110
90

70.00
72.50
75.00
80.00

26.89
27.46
28.29
30.64

3.45
3.67
3.90
4.49

67.42
67.73
67.51
67.29

11
13
15
17

64

11 P
13 P
15 P
17 P

11 H
13 H
15 H
17 H

12

52
48

62

44

H (m)

61
60
59

40

10

Pshaft (kW)

63

36

130

Q (m3/h)
Fig. 7. Performance curves of impellers with three diameters.

12
10

58
32

56

35

35

85

57

Pshaft (kW)

55

80

14

60

60

75

Q (m3/h)

(%)
215 CFD P
235 CFD P
255 CFD P

70

u ()

66

215 CFD H
235 CFD H
255 CFD H

65

Table 7
BEPs of impellers with different blade wrap angles.

In the research of impeller inlet width to the performance inuence of PAT, impellers with inlet widths of 11 mm, 13 mm, 15 mm
and 17 mm were numerically investigated. The selected impeller
diameter was 235 mm; all other specications remain the same

215 CFD
235 CFD
255 CFD

60

Fig. 8. Performance curves of impeller with different blade wrap angles.

65

(%)

Q (m3/h)

9. Impeller inlet width

60

59

Numerical simulation of the PAT with blade wrap angles of 90,


110, 130 and 150 were carried out. The blade inlet angle (b2),
blade outlet angle (b1), impeller inlet width (b2) and impeller diameter (D2) of the investigated impellers are 20, 19.5, 14.38 mm and
235 mm respectively. Other geometric parameters are the same as
listed in Table 1. Fig. 8 shows the predicted performance curves.
Table 7 lists the BEPs of different schemes.
Table 7 shows that the ow rate at BEP is increased by 10 m3/h
as blade wrap angle decreases from 150 to 90. There is an optimal
blade wrap angle for this PAT to achieve the highest efciency. Its
highest efciency is reached when the blade wrap angle is 130,
which is 0.44% higher than that of 90. Fig. 8 shows that PATs
QH curve and QPshaft curve moves down with the decrease of
blade wrap angle.

50

Pshaft (kW)

36

65

60

75

40

66

8. Blade wrap angle

80

10

44

67

(%)

Numerical simulation of PAT with impeller diameters of


255 mm, 235 mm and 215 mm were performed. The blade inlet
angle (b2), blade outlet angle (b1), blade wrap angle (/) and impeller inlet width (b2) of the investigated impellers were 20, 19.5,
130 and 14.38 mm respectively. Other geometric parameters were
the same as listed in Table 1. Fig. 7 is the predicted performance of
the three impeller diameters. Table 6 lists their BEPs.
Table 6 indicates that the ow rate at the BEP is decreased by
20 m3/h and efciency at the BEP is decreased by 2.17% as impeller
diameter decreases from 255 mm to 215 mm. Fig. 7 shows that
PATs QH curve grows increasingly steep and QPshaft curve becomes relatively at as impeller diameter is decreased.

28

55
75

80

85

90

95

100

105

110

115

120

Q (m3/h)

Fig. 9. Performance curves of impellers with different impeller inlet widths.


6
4
2
140

as listed in Table 1. Fig. 9 shows the CFD results comparison of


impellers with different inlet widths. Table 8 lists their BEPs.
As is indicated in Table 8, the ow rate at the BEP is increased by
10 m3/h as impeller inlet width increases from 11 mm to 17 mm.
The highest efciency is reached when the inlet width is 13 mm,
which is 1.27% higher than that of 11 mm. Fig. 9 shows that with
the increase of impeller inlet width, PATs high efciency operating

S.-S. Yang et al. / Computers & Fluids 67 (2012) 7278


Table 8
BEPs of impellers with different inlet widths.
b2 (mm)

Q (m3/h)

H (m)

Pshaft (kW)

g (%)

11
13
15
17

82.50
85.00
87.50
92.50

33.07
33.50
34.41
36.60

4.60
4.89
5.14
5.75

61.86
63.13
63.05
62.33

74

20H
25H
30H
35H

20
25
30
35

72
70

20P
25P
30P
35P

60

12

68

10

H (m)

(%)

64

40

62

Pshaft (kW)

50
66

6
60
30

58

56
54
60

70

80

90

100

110

120

20
130

Q (m /h)
Fig. 10. Performance curves of impellers with different blade inlet angles.

Table 9
BEPs of impellers with different blade inlet angles.
b2 ()

Q (m3/h)

H (m)

Pshaft (kW)

g (%)

20
25
30
35

72.50
72.50
75.00
75.00

27.46
27.69
28.90
29.27

3.67
3.70
4.01
4.06

67.73
67.64
67.94
67.90

range gradually increases, its QH curve and QPshaft curve are


dropped.
10. Blade inlet angle
Blade inlet angle (b2) of 20, 25, 30 and 35 are simulated
using CFD. The blade outlet angle (b1), blade wrap angle (/), impeller inlet width (b2) and impeller diameter (D2) are 19.5, 130,
14.38 mm and 235 mm respectively. Other geometric parameters
are the same as listed in Table 1. Fig. 10 shows the predicted performance curves. Table 9 lists the BEPs of different schemes.
Table 9 demonstrates that as blade inlet angle increases from
20 to 35, the ow rate at the BEP is increased by 2.50 m3/h, the
required pressure head is increased by 1.81 m and the variation
of efciency is at a neglectable level. Fig. 10 illustrates that PATs
QH and QPshaft curve gradually increases as blade inlet angle is
increased. However, the amplitude of increase is minor.
11. Conclusions
Experimental and numerical investigation into impeller trimming to the inuence of pump as turbine were carried out on a single stage centrifugal PAT.
An open PAT test rig was built in laboratory; a single stage centrifugal PAT with original impeller and impeller after once and
twice trims was tested. The results in both turbine and pump

77

modes are presented. Experimental results show that PATs ow


rate at the BEP shifts from 95.23 m3/h to 86.14 m3/h and then
moves back to 93.63 m3/h, its efciency at the BEP is dropped by
4.11% as impeller is cut from 255 mm to 215 mm. PATs QH curve
becomes steep and QPshaft curve moves almost parallel down.
CFD technology was used to explore the reasons for the performance variation when impeller diameter is trimmed. The validity
of CFD result was rst proved through comparison between experimental and numerical results. Results show that numerical results
are slightly higher than those of experimental, due to the neglection of volumetric leakage loss through balancing holes and
mechanical seals caused by mechanical seal and bearings. The
maximal deviation of efciency, head and shaft power over the
operating range of 0.811.27QBEP are 7.74%, 4.29% and 12.31%
respectively. The numerical prediction method adopted could be
used as a helpful reference in the accurate performance prediction
of PAT.
Effects of impeller parameters including D2, /, b2 and b2 to the
performance inuence of PAT were carried out using CFD. Through
CFD analysis, the following conclusions were acquired.
 As impeller diameter decreases from 255 mm to 215 mm, the
ow rate and efciency at the BEP are decreased by 20 m3/h
and 2.08%. PATs QH curve grows increasingly steep and Q
Pshaft curve becomes relatively at as impeller diameter is
decreased.
 The optimal blade wrap angle for this PAT to achieve the highest
efciency is 130. The ow rate at the BEP is increased by
10 m3/h as blade wrap angle decreases from 150 to 90. PATs
QH curve and QPshaft curve move down with the decrease of
blade wrap angle.
 The highest efciency is reached when impeller inlet width is
13 mm. With the increase of impeller inlet width, PATs ow
rate at the BEP and its high efciency operating range are
increased; its QH curve and QPshaft curve slightly decrease.
 As blade inlet angle increases from 20 to 35, the ow rate at
the BEP is increased by 2.50 m3/h, the required pressure head
is increased by 1.81 m and the variation of efciency is at a neglectable level. PATs QH and QPshaft curves slightly increases
as blade inlet angle is increased.
As impeller is trimmed, PATs impeller geometric parameters of
D2 and / will decrease, b2, and b2 will increase. The decrease of D2
will offset the ow rate at the BEP to the left side of its performance
curve, the decrease of / and increase of b2 and b2 will move its ow
rate at the BEP to the right. So the performance change of PAT
when its impeller is trimmed is the combined effects of these four
geometric parameters.
Acknowledgements
Special thanks are given to the project entitled, A Project
Funded by the Priority Academic Program Development of Jiangsu
Higher Education Institutions (PAPD), national science and technology support program entitled Research on the Key Technology and
Engineering Application Project of Typical Centrifugal Pump
(2011BAF14B03) and Doctoral innovation foundation of Jiangsu
University entitled Research on High Pressure Fluid Power Recovery
Device of Pump as Turbine (CX10B_012X).
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[18] Help Navigator, ANSYS CFX, Release 12.0 CFX-Solver modeling Guide.

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