Optimization of a Centrifugal Pump Impeller by Controlling Blade Profile

Parameters
Md. Hamid Siddique, K.R. Mrinal, Abdus Samad*
Wave Energy and Fluid Engineering Laboratory, Department of Ocean Engineering,
Indian Institute of Technology Madras, Chennai 600 036, India
ABSTRACT
A multi-surrogate based optimization is a technique for
the optimization of a turbomachinery impeller shape, which
reduces the total design time. Computational analysis and
surrogate-based optimization methodology have been
implemented for the shape optimization of a centrifugal
impeller blade in this problem. Geometric parameters such as
impeller inlet and two-point control Bezier curve blade profile
were selected as design variables. The objective was to
maximize the total head as well as the efficiency of the pump
using surrogate based optimization methods. A sample space
was created for the design variables based on the sensitivity
of the variable to the objective function and literature survey
give a range of sample space. A three-dimensional Reynoldsaveraged
Navier-Stokes equations were solved to analyze the
performance of the pump and the results were validated with
experimental results. The simulations were done at different
design points within the sample space to train the surrogate
and to find the design optimum point using genetic algorithm.
The shape of the impeller was optimized, to decrease the
input power and improve the total head by varying the inlet
and exit angles of the impeller.
Keywords: Centrifugal pump, Multi-objective optimization,
Kriging.
Nomenclatures
Abbreviations
CAD Computer aided design
C.P Cluster Points
DOE Design of experiment
Exp Experimental
GA Genetic algorithm
KRG Kriging
LHS Latin hypercube sampling
LE Leading edge
NSGA Non-dominating sorting of genetic algorithm
POD Pareto optimal design
RANS Reynold -averaged Navier-Stokes
Ref Reference
RMSE Root mean square error
VFD Variable frequency drive
Symbols
A,B,C,D E Cluster points
C1, C2 Control points
D Diameter in mm
g Acceleration due to gravity
H Head in meter
k Turbulent kinetic energy
N Number of basis functions
Q Volume flowrate
t Thickness in mm

z Blade number
1, 2 Coordinates in z- direction
Blade angle
Turbulent Dissipation
Efficiency
R Residual
Z Random sample component
m Trend component
Subscript
1 Inlet
2 Outlet
h Hub
*Associate Professor and corresponding author: Email: samad@iitm.ac.in

Proceedings of ASME Turbo Expo 2016: Turbomachinery Technical Conference and Exposition
GT2016
June 13 17, 2016, Seoul, South Korea

GT2016-56604
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s Shroud
S Shaft
surr Surrogate
1 INTRODUCTION
A centrifugal pump is a type of turbomachinery, which is
used to elevate or transport fluid from one place to another
with the help of energy source. It is being used almost
everywhere as a means to lift water in households or to
discharge sewage, transport chemical or oil through pipelines.
Due to its extensive use in most of the transportation system,
energy consumption of this pump is a recognizable entity in
an energy system [1, 2].
Impeller and casing are the main parts of a centrifugal
pump, where a rotary motion of the impeller creates suction at
the inlet of the pump. The centrifugal force created by the
impeller increases the velocity of the fluid, and the casing or
the diffuser converts the kinetic energy of the fluid into the
potential energy. The ideal case happens only when the fluid
gets no resistance, no flow separation, or no reverse
circulations. In real case; inlet angles, outlet angles, wrap
angle, blade height, number of blades, blade width and the
blade profile plays a vital role in the performance of the
pump. The complex geometry and a large number of
parameters affect the performance and take a long simulation
time [3]. Some parameters are sensitive to cavitation;
whereas, some are sensitive to pressure loss or performance
depletion.
An extended leading edge (LE) toward the inlet shows a
favorable effect on the pump performance, and a larger inlet
blade angle favors reduction in cavitation [4]. Yokoyama [5]
reported that the inlet geometry is important for a low specific
speed pump. The change in blade position at inlet also affects
the pump performance [4, 6- 8].
Chen et al. [9] introduced the concept of the Bezier curve
to modify the blade profile. Flow pattern study across the
blade profile was done [10, 11]. Heo et al. [1] showed that the

efficiency of a centrifugal pump is more sensitive to the

impeller geometry than the volute shape. Li [12] developed
the singularity method to design impellers to control the blade
shape. Therefore, in this study parameters like inlet blade
angles and the blade profile shape were selected which have a
dependency on each other.
Numerical optimizations are the decision-making
processes [13]. Surrogate models like Kriging (KRG) are
being widely used in optimization for global optimization. It
reduces the number of real function calculation [14,15]. KRG
model is an alternative to traditional second-order polynomial
response-surface model used in multi-disciplines [16-19].
KRG is more flexible to approximate linear and nonlinear
multimodal function as compared to other meta-models [15,
20].
A design problem can have either single-objective or
multi-objective. The problem becomes challenging when the
objectives conflict with each other. In that case the optimal
solution of an objective function is different from that of the
others [21]. Due to multiplicity in solutions, these types of
problems can be solved using evolutionary algorithms, which
use a population approach in its search procedure [21, 22].
Genetic algorithm (GA) is an evolutionary algorithm, which
provides satisfactory parameters used to estimate the
uncertainty related to search procedure. Grapsas [24]
successfully showed an improvement of efficiency of an
impeller with the use of evolutionary algorithms.
In this paper, the performance of centrifugal pump was
optimized via numerical modeling assisted by KRG model to
improve head and efficiency. Simulations were done to obtain
pump's performance at 15 off-design points, constructed by
varying inlet blade angles and the blade profile shape control
points. A detailed description of the methodology and results
are presented in the paper.
2 EXPERIMENTAL SETUP
Tests for performance of the pump was carried out in a
closed loop test facility developed in the department of Ocean
Engineering, Indian Institute of Technology Madras. A
schematic diagram of the test facility is shown in Fig. 1 and
the real test facility is as shown in Fig. 2.
The experimental setup includes a centrifugal pump
whose suction side was connected to a water tank having a
capacity of 160 liter followed by a gate valve and a suction
pressure gauge. The pump was coupled with a 3-phase
induction motor connected to a variable frequency drive.
Similarly, the delivery side of the pump has a Bourdon type
pressure gauge and a turbine type digital flow meter with
measurement accuracy of 1%. To complete the loop, the
delivery pipe was discharged back to the water tank.
1. Tank 2. Gate valve
3. Suction pressure gauge 4. Suction line
5. Pump 6. Motor
7. Delivery pressure gauge 8. Flow control valve
9. Delivery line 10. Flow meter
Figure 1: Line diagram of the experimental test facility

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Figure 2: Test facility

Table 1: Centrifugal pump specification

Parameters Dimensions
Shaft diameter, DS 24 mm
Inlet diameter, D1 55 mm
Outlet diameter, D2 142 mm
Inlet Blade angle, 1s 11o
Inlet Blade angle, 1h 31.5o
Outlet Blade angle, 2 36o
Blade number, z 5
Blade thickness, t 2 mm
1 4.5mm
2 4.5mm
Figure 3: Meshing

During the tests, a fully flooded criterion was

maintained throughout with suction head above atmosphere to
avoid priming. The pump was allowed to run at a constant
speed of 1340 rpm with the help of 3-phase induction motor.
The changes of pressure on the suction side and the delivery
side at different flowrates were recorded by controlling the
flow control valve. The input power was measured using an
energy-meter built inside the variable frequency drive (VFD),
and the flowrates were measured using digital turbine type
flowmeter, thereafter the efficiency of the pump was
calculated.
3 CFD MODELING
A computational technique was used to solve the 3D
Reynold-averaged Navier-Stokes (RANS) equations for
finding the performance of the pump. The flow domain
contains casing and the impeller geometry. The impeller
designed in BladeGen module of ANSYS 14.5 has
specifications shown in table 1. An unstructured grid system
was generated as shown in Fig. 3. A frozen rotor interface
[25] has been used and an automatically generated contact
element was used between the impeller and casing interface.
The flow in passages is governed by mass and momentum
conservation equations. The assumptions for the analysis are
steady state and incompressible flow. Atmospheric pressure at
the inlet and the mass flow rate at the outlet of the pump were
set as the boundary condition. The working fluid was water at
25oC and the solid surfaces for impeller were taken as rough
surface of mean height 1mm, with no slip boundary
conditions. The other details like convergence criteria and
simulation time are shown in table 2.
The standard k- turbulence model with scalable wall
functions were employed to calculate turbulent flow. The
model uses two partial differential equations; one for
calculating turbulent kinetic energy, k, and another for
turbulent kinetic energy dissipation rate, , to get length and
time scale information of local eddy viscosities [26, 27].
The blade profile is modified in BladeGen module of
ANSYS 14.5 as shown is Fig. 5 using the Bezier curve
equation shown in Eq. (2). It is a three degree polynomial
controlled by points C1, C2, C3 and C4 in which C1 and C4
were fixed and the blade profile was only controlled by points

C2 and C3. A basic Bezier curve equation is as shown in the

equation below.
C(t) =
=0 i Bi
n(t) (1)
Table 2: Meshing and boundary conditions

Parameter Description
Flow domain Impeller and casing
Mesh Unstructured
Interface Frozen rotor
Nodes 177,000
Elements 860,342
Turbulence model k-
Inlet Pressure
Outlet Mass flow rate
Residual convergence value 1x10-5
Time taken for simulation 6 hrs
Number of Iteration 450
Mass imbalance 0.0002%
Fluid nature Water
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where, t varies from 0 to 1, n=3 is the degree of the Bezier

curve and B(t) is the blending function, So, the 3rd degree
equation can be written as,
C(t) = (1-t)3 +3t(1-t)2C1 + 3t2(1-t)C2 + t3C3 (2)
The design variable for the study was varied in terms of 1
and 2, which are the z-axis coordinates of the control points
C2 and C3.
4 OPTIMIZATION METHODOLOGY
The optimization procedure, shown in Fig. 4, is followed
in this work. To perform the optimization, problem
formulations were done in which the objective function, the
design variables, and the design spaces were defined. Latin
hypercube sampling scheme (LHS) were used to obtain 15
design points within a design space defined by the variable
limits. Geometries were made and CFD simulations were
performed at the sample points. The performance results were
used to construct an approximate KRG surrogate model over
the entire design space. Search for the optimum value was
done using genetic algorithm (GA) and a Pareto optimal curve
was obtained. To cross validate the surrogate predicted
results, clustering from the Pareto curve was done and then
CFD simulations were done at those points.
4.1 Design of Experiment(DOE)
Design of experiment (DOE) is the planning stage of any
optimization problem. The major steps include variable
selection based on variable sensitivity towards an objective
function. After the variable selection, finding of design space
was done. The wrong selection of design space may give
multiple optimization runs [28]. To avoid that, initially some
simulations were done at the lower and upper bounds of the
variables.
The design variables are inlet blade angles 1h, 1s, and the
coordinates of the control points C2 and C3. These inlet blade

angles were selected based on the preliminary calculations

and prior literature search [5, 29] having lower bound and
upper bound as shown in Table 3. The other two variables
(C1, C2) are the Bezier curve control points for the profile
modification shown in Table 3. The technique used for
controlling these Bezier control points is already discussed in
the above section, and the control points are shown in Fig. 5.
Once the off-design variables were obtained, CFD
simulations were done to get the performance at those points.
Table 3: Design space

Inlet blade angles Lower bound Upper bound

1h 20o 40o
1s 10o 20o
C1 4 45
C2 4 15
Figure 4: Optimization methodology flow diagram
Figure 5: Impeller control points

4.2 Construction of surrogate

There are a number of surrogate models successfully
adapted for surrogate based optimization [20]. Based on
reliability and precision to handle uncertainty for
turbomachinery problems [13, 15], KRG surrogate model has
been selected in this study. The model [16] is an interpolating
meta-modeling technique that employs a trend model R(x) to
capture large-scale variations and a systematic departure Z (x)
to capture small-scale variations. The KRG model in its basic
formulation is given by,
R(x) = Z(x) m(x) (3)
where, R(x) is a residual component, Z(x) is the random
sample component and m(x) is a tread component. The KRG
Problem definition
Design of Experiment (DOE)
Numerical simulations at sample locations
Construction of Surrogate(KRG)
Generation of Pareto optimal
curve
Further analysis
Yes
No
Setting design space
Is RMS error within limit?

-1 1
-2 2
Inlet
Outlet
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prediction is based on a large volume of data. The data

obtained in this work at the off-design points within the
design space were used to predict the performance of the
pump at the unsampled locations of the design space. In order
to search the regression KRG model, an estimation of error in
the model is required and these errors were cross validated
using CFD simulations.
4.3 Multi-objective optimization

Multi-objective optimization problems deals with more

than one objective function. These types of problems often
conflict each other since improving one can degrade another.
Therefore, for this type of problem no single optimal solution
can be the best for other objectives [30]. For solving these
type of problems where many solutions exist within the
search space, a set of optimal solutions known as Pareto
optimal solutions is generated and the curve joining these
solutions are known Pareto-optimal front [21].
The genetic algorithm used as search algorithms in this
work is an evolutionary algorithm inspired by the biological
evolution, such as inheritance, mutation, selection, and
crossover. The algorithm includes crossover and mutation,
which helps in varying chromosomes and maintaining genetic
diversity in the population, respectively. The generations
continue till a termination point reaches. A fixed number of
generations were used in this case.
In this work, both the objective functions, namely head
(H) and efficiency () of the pump were maximized. The
Pareto optimal front formed first by regression of the data
point on the entire sample and then with the help of Nondominated
sorting of genetic algorithm (NSGA-2) [21] a set
of Pareto optimal solutions was formed.
5 RESULTS AND DISCUSSION
5.1 Validation of numerical analysis
For the simulations, Ansys-CFX package was used to
analyze the performance of the pump. The validation of the
numerical analysis is done by comparing the CFD simulation
results with experimental results. Figure 6 shows the pump
performance curves obtained from the CFD simulation and by
experimental test. The head at design point predicted by CFD
was 5.27m which is slightly higher than the experimental
head, which is 4.95m. Again, efficiency at design point for
CFD results was 61.58% compared to experimental result,
which is 58.53% at the design point. Both the errors are
within the limit of 10% and are acceptable for the study [31].
5.2 Optimization and optimal solutions validations
Further simulations were performed to get pumpperformance
at other design and off-design points. The head
and the efficiency obtained at the design points were used to
construct KRG model to get approximation results over the
entire design space. A Pareto optimal curve shows the
maximization of head and efficiency of the pump (Fig. 7). To
check the reliability of the estimated surrogate predicted
points, clustering is done and five different points were
obtained. The points were checked through CFD simulation,
and RMS errors were calculated as shown in Table 4. If errors
are high, the DOE steps are repeated for better accuracy.
To compare the base design and an optimal design, cluster
point A is considered. The change in shape of the impellers is
shown in Fig. 8 and the performance curves for both the
impellers are compared in Fig. 9(a) &(b).
5.3 Fluid flow behaviors of the optimized design
Figure 10(a) shows the comparison of pressure
distribution over the impeller. It is clear that the maximum
head generated by the pump for optimized design is higher

than the base design at the design point.

The reason for the increase in total head can be explained
by Fig. 10(b), which shows an increase in impeller peripheral
velocity in the optimized design. Higher velocity increases the
total kinetic energy of the fluid, which gives rise to potential
energy in the casing/diffuser.
Figure 10(c) shows the comparison of streamlines for both
base design and the optimum design. The streamlines were
captured at a place perpendicular to the axis of the inlet to the
pump. A clear indication of minimization of recirculation is
seen between the blades of the impeller. The decrease in
recirculation is also one of the reasons for the improvement of
efficiency of the pump.
Figure 6: Comparison of CFD and experimental results
Figure 7: Pareto optimal points

0
2
4
6
8
0
20
40
60
80
0123
H

Q x 10-3 m3/s
-EXP
-CFD
H-CFD
H-EXP
64.4
64.6
64.8
65
5.72 5.74 5.76 5.78 5.8

H
POF(KRG)

Cluster points
B
C
D
E
A
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Table 4: Validation of surrogate predicted point

Model
C.P
surr Hsurr CFD HCFD
CFD
-

POD
HCFDHPOD
RMSE
KRG
A 64.83 5.74 64.81 5.75 -0.02 0.01 0.01
B 64.76 5.76 64.84 5.74 0.08 -0.02 0.06
C 64.72 5.76 64.93 5.74 0.21 -0.02 0.15
D 64.71 5.77 64.40 5.64 -0.31 -0.13 0.24
E 64.55 5.78 64.43 5.64 -0.12 -0.15 0.13
Figure 8: Comparison of base and optimal impeller designs
a) Efficiency
b) Head
Figure 9: Head and efficiency comparison of base design and
optimized design
a) Pressure
b) Velocity
c) Streamlines

Base design point Cluster Point A

Figure 10: Flow comparison of the reference and the optimized
pump at a plane located at 50% of the blade height

6 CONCLUSION
Shape optimization using CFD technique and a surrogate
approximation model coupled genetic algorithm is done in
this work. Four design variables were considered to construct
KRG surrogate model. The pump performance in terms of
head and efficiency was defined and maximized in this
problem.
The inlet blade angles with blade profile plays an
important role in the improvement of the centrifugal pump
performance. By this shape optimization, the efficiency and
the head of the pump are improved by 3.2 % and 8.9%
respectively.
20
45
70
0.5 1 1.5 2 2.5

Q x 10-3 m3/s
Cluster pt A
Ref point CFD
3.5
5
6.5
0.5 1 1.5 2 2.5
H
Q x 10-3 m3/s
Cluster pt A
Ref point CFD
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Comparing the flow in the impellers, the optimized

impeller has improved streamlines and low flow circulation
which reduces the total energy loss.
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