Design Software for Radial & Mixed-flow Pumps

Software Manual 5.0

CFDnetwork Engineering October 2005

 CONTENTS

System Requirements ___________________________________________ 1

Features ______________________________________________________ 1
General _______________________________________________________ 3
Licensing ................ .................. ................. ................. ................. .............. 3
Preferences ............... ................. .................. ................. ................. ........... 4
Approximation functions .............................................................................5
Comparing different designs................. ................. ................. .................. ..8
Remove design steps.................................................................................9
Assembly...................................................................................................9
Graphical dialogs ................ ................. ................. ................. .................. 10
Main window____________ ______________________________________ 12
Project.....................................................................................................12
Project information..............................................................................12
History................................................................................................13
Design information..............................................................................13
3D view ............... .................. ................. ................. ................. ............... 14
Open/ Save design................. ................. ................. ................. ............... 17
Help.........................................................................................................17
Data export..............................................................................................18
Impeller - Meridional section _____________________________________ 21
Main dimensions......................................................................................21
Design point ............... ................. ................. .................. ................. ...21
Assumptions.......................................................................................24
Dimensions ................ ................. ................. .................. ................. ...27
Meridional contour.......................... ................. .................. ................. ...... 30
Blade properties.......................................................................................35
Inlet triangle........................................................................................37
Outlet triangle.....................................................................................38
Meridional flow.........................................................................................42
Impeller - Blade desig n _________________________________________ 43
Mean line.................................................................................................43
Blade profile.............................................................................................47
Blade leading edge ................ ................. ................. ................. ............... 49
Volute _______________________________________________________ 51
Inlet ................ ................. ................. ................. .................. ................. ...51
Geometry.................................................................................................53
Design rule.........................................................................................54
Cut-water ................ ................. ................. .................. ................. ...... 55
Shape of the cross-section................. ................. ................. ............... 56
 Bezier cross-sections ................ ................. ................. ................. ...... 58
End cross-section .................. ................. ................. ................. ......... 59
Diffusor................... .................. ................. ................. ................. ...... 60
Display options ................ ................. ................. .................. .............. 61
References ___________________________________________________ 62
Contact Addresses ____________________________________________ 63
 1

SYSTEM REQUIREMENTS
®
The CFturbo software runs on Windows NT4/ 2000/ XP. A valid license
®
key must be obtained and installed before the first use of CFturbo. The
key is linked to one specific computer and establishes the appropriate
operation on that computer.
Operation is based on the usual standards of the Windows operating
systems. The user interface is in English language. An Online-Help in
German and English is integrated.

FEATURES
®
CFturbo is made to design interactively radial and mixed-flow impellers
and volutes for centrifugal pumps. The software is easy to use and does
enable quick generation and variation of impeller and volute geometries.
Several models can be displayed, compared and modified

simultaneously.
be customized by It the
contains
user innumerous approximation
order to implement functions
user specific that may
knowledge
®
into the CFturbo -based pump design process. In spite of the creation of
semiautomatic proposals, fundamental experiences in pump design are
helpful but not necessary. An experienced pump design engineer should
be able to design new high-quality impellers and volutes more easily and
quickly.

Main features of the program:

§ Approximation functions for characteristic parameters which may
be individually customized by user
§ Calculation of main dimensions of the impeller
§ Calculation and modification of hub and shroud contours as well

§ as leading edge
Calculation using
of blade Bezier
angles splines or
at leading andpolylines
trailing edge in
consideration of obstruction by blades and output deficit (slip);
representation of velocity triangles
§ Meridional flow calculation by streamline curvature method;
display of streamlines and velocity distribution
2

§ Determination of blade mean lines on rotational-symmetric

meridional flow surfaces using Bezier splines or polylines at m,t
plane (conformal mapping); display ofb-distribution
§ Generation of blade profiles by defining blade thickness at 4
points; display of thickness distribution
§ Radius design of blade leading edge by Bezier splines
§ Volute design for various cross section shapes according to the
theory of Pfleiderer or Stepanoff
§ Radial or tangential diffusor with circular or angular cross section
at the pressure side
§ Complete 3D display of designed geometry according to design
progress
§ Design report as text file
§ Geometry export to various CAD and CFD systems
 3

GENERAL

Licensing

Ü Edit | Register

Menu item Register

enables input of licensing
information. The so-called
Machine ID is calculated
®
by CFturbo considering
hardware and operating
system. This Machine ID
number is used to
generate License key for
each of the Design type
(Radial+Mixed Flow Pump
Impeller and/or Volute). A
valid license key is
®
necessary to run CFturbo
on your computer.

Please send the Machine ID to support@cfturbo.com. You could

probably use the Send E-Mail… button if your email softwaredoes allow
it. In this case the text to be submitted is shown in your standard email
program. Alternatively you can copy the relevant data to clipboard by
pressing the Copy to Clipboard button.
You will get a license file that can be opened by pressing the button
Read from file…. The table License Key contains the calculated license
keys. Alternatively the user can insert the the license keys manually. The
item Company is for information only.
If the license key has expired, you can reactivate the program by
entering a new key. A hint with remaining days appears on startup
screen 20 days before expiration of the license. You can inform about
expiration date in the dialogHelp | About CFturbo.
For the input of license information as well as for installation,
System Administrator rights are required.
4

Preferences
Ü Edit | Preferences | General

Menu item Preferences - General is used for global options of the

program.
On tab sheet Units you can select physical
units to be used in the dialogs. Following
units are available:
Head
§ m, ft
§ Geom. length mm, in
§ Flow rate m³/h, ft³/h, gpm, gps
§Density kg/m³, lb/ft³
Stress
§ MPa, PSI
§Pressure MPa, PSI
Power
§ kW, hp

You can simultaneously change all units to

SI or US system by pressing the buttons
above.

On tab sheet Other you can specify length

unit for exporting geometry. Please select
the appropriate units when importing data to
the chosen CAE software.
Furthermore, you can adjust the language of
online help. The standard is English.

Ü Edit | Preferences | Export

On dialog Preferences - Export you can specify how many data points
are to be generated during export. The number of points can be selected
separately in each case for all geometry parts. The available options
depend on active desgn module:
Impeller Meridian: hub/ shroud, leading edge
Blade: mean line, pressure/ suction side, leading edge
 5

Volute - Spiral: cross sections, points per cross section

- Diffusor: cross sections, points per cross section
3 different global pre-settings can be selected.

Approximation functions

Ü Edit | Approximation functions

®
CFturbo uses many approximation functions. These functions are based
on published measurement data of centrifugal pumps that facilitate the
forecast of optimal or accessible values.
In this dialog the approximation functions are graphically displayed and
can be individually customized. Functions for the following physical
quantity are available:
§ Hydraulic efficiency hh
§ Volumetric efficiency hV
§ Side friction efficiency hS
§ Mechanical efficiency hm
§ Pressure number y
§ Intake number
Number
§ of blades z e
§ Wrap angle ju
§ number
Width b 2/d2
Meridional
§ deceleration c m3/cmS
§ Flow angle inflow b0A
§ Flow angle outflow b3
§ Inclination angle hub eH
6

§ Inclination angle shroud eS

§ Inclination angle trailing edge g
§ Blade thickness leading edge s 1
§ Blade thickness trailing edge s 2
§
Blade thickness max. s max
§Cut-water diameter ratio d 4/d2
§
Cut-water width ratio b 4/b2
§
Stepanoff constant k s

On the left at File location, the name of the file is shown that contains all
data of the functions. In general this file is calledFunctions.cftfu, and is
®
located in the installation directory of CFturbo. Modifications to functions
are saved automatically if you leave the dialog window by pressing the
OK-button. In case the user has no write permissions one could choose
a different directory to save the file. Renaming files is possible by using
the Save as-function. By clicking the Open-button a previously saved
functions file can be opened.
®
The user must first select Physical variable. CFturbo ’s internal function
is displayed in the diagram if corresponding check box is active. On
panel Function you can add any functions. Selected function is
®
displayed in the diagram in addition to CFturbo internal function.
®
Function with active check box is used by CFturbo for calculations. If no
 7

function has active checkbox or no additional function is defined at all,

®
then the CFturbo internal function is used.
In panel Points you can edit curve points of selected function. You can
add new points at the end of the table – the points are automatically
sorted by x values. To remove a point you have to delete either x or y
value.

These 3 buttons are enabling the user to import points from

file (one point per line) or export points to file or to clear the table.
On panel Test you can test the active function. Saving of values is
possible by clicking OK-button.

2 special features are existing:

Functions depending on 2 variables
Functions can depend on 2
variables whereas one serves as
parameter. Separate curves exist
for each particular parameter
value that are used to calculate
function values. These parameter
curves can be added in the

Parameter panel. The

value is displayed parameter
on endpoint of
curve in the diagram.

Following functions with 2 variables exist:

Function depends on curve parameter
Hydraulic efficiency hh specific speed nq flow rate Q
mechanical efficiency hm flow rate Q revolutions n
Range definition
The Pressure number has a
recommended range (see page
24), which means an area that is

defined by adefinition
limit. The higher andof athe
lower
2
parameter curves can be done
as written above.
8

Comparing different designs

Ü Edit | Reference designs

This functionality can be used for simultaneous display of various

designs to compare each other and for purposeful modification.
Using the Add-button any
reference design (*.CFT-
files) can be added. Each
design has its own color
and line width (panel
Options). On panel Hint
some information about
the selected design is
provided.
With the Remove-button
selected reference design
can be deleted from list.
However reference design may be deactivated by the check box at the
beginning of the line.
 9

Reference geometries are displayed in the dialogs with selected color

and line width. Numerical values appear as small hints on input fields
when mouse is moved over it.
Down to the right in the dialog windows you could
completely switch off the display of reference
geometries and start a dialog for new configuration.

Remove design steps

Ü Edit | Remove design steps For impeller design only !

If you make any design changes on the impeller all initial design steps
based upon this status are automatically adapted (automatic update).
This is done to prevent repeating the same design steps.
However, if you would like to start with an
®
automatic generated CFturbo primary
design, certain design steps can be
®
removed manually. Then CFturbo
continues with new primary design data.
For that purpose you have to select the
appropriate design step to be removed
and then press the OK button.

Assembly

Ü Edit | Show assembly

In the assembly dialog it is possible to display impeller and volute

simultaneously. There are the same settings available as shown at the
3D-representaion of the individual components (see 3D view, page 14).
10

Graphical dialogs
All graphical representations are made in diagrams that are automatically
scaled according to displayed objects. All diagrams have a popup menu
(right click on empty diagram area) with basic functions. Alternatively you
can use the buttons on the left side of the diagram:
Zoom window by mouse

Zoom all
Fit view
Lens magnification
Copy to clipboard

Save as WMF, BMP or JPG

Print

Add any polyline from file (x,y points) to compare different curves
 11

or to visualize components
Measure distance

Configure diagram

If the mouse cursor is moved over a graphical object (e.g. polyline,

Bezier point) then this is highlighted by color or by increased line width.
Right mouse click is now related to this object and does open a special
popup menu or a small dialog window for data input.
Bezier splines are used for geometrical contours by default. This
continuous polylines are described by the position of a few Bezier points.
Therefore a simple modification of the curve is possible but on the other
hand the numerical representation of the curve is accurate.
For Bezier curves, a popup menu emerges that permits
the user to switch between Bezier spline and polyline.
Loading and saving of curve points (*.CFTPL) and a reset
of the curve is also performed using this menu.

An alternate method to specifying Bezier

points by the mouse, you may enter the

accurate coordinates
small dialog windowof that
Bezier points inbya
appears
clicking the right mouse button on the
chosen Bezier point. One or two
coordinate values can be entered in
dependence of geometrical boundary
conditions. As a rule these values are
normalized relative values describing the
position of the point between extreme
values left or bottom (0) and right or top
(1). Normalized relative coordinates are giving the advantageous
possibility of an automatic update of the entire design if a parameter is
modified.
Coordinates of mouse cursor are displayed in format x:y bottom left in
the status bar. Position and size of dialogs are saved to restore it in the
same way when they are called again.
®
If CFturbo generates primary design automatically you may seeInitial
design on the top right of the diagram.
If numerical values are entered in tables, then a new value is only
activated and the diagram is updated if the <Enter> key is pressed or a
new cell of the table is selected.
12

MAIN WINDOW
The main window contains important information of the actual project. A
3D-view of the current design state can be displayed.

Menu items and buttons only become active in accordance to the current
design state. The user is able to return to former design status from any
design step in the program. Design step updates dependent on its
modifications are accomplished automatically. Manual removing of
®
complete design steps is possible too in order to continue with CFturbo
using its primary design (see chapter “Remove design steps”, page 9).

Project

Project i nformation
For identification of the project it may be specified:
 13

§ Project name
§ Classification (e.g. version or sub name)
§ User name
§ Comments

This information is not mandatory and should support the identification of

®
CFturbo projects & sessions.
The working directory, the creation date and the date of last modification
are displayed too.

History
The history contains all design steps from opening of the project or
session in chronological order. By pressing buttonRemove selected you
can undo selected design steps. By pressing the buttonClear history
the complete history (and temporary files) can be deleted.

Design information
The right part of main window shows a tabular form summary of the most
important design parameters. You can print these data together with
project information (File | Print) or save to file (see chapter “Data export”,
page 18).
14

3D view

Tab sheet 3D view contains the three dimensional representation of the

current impeller or volute design state.
Above the representation you can find some buttons with the following
functions:
Reset of representation (default position)
Save representation as JPG or BMP
Print representation
X Viewing direction in positive x-axis direction
Y Viewing direction in positive y-axis direction
Z Viewing direction in positive z-axis direction
Define view (see below)
Define point resolution (see Preferences, page 4)
Switch perspective view on/off

Switch coordinate system on/off

 15

The View dialog is to set, save and load special view

points. The corresponding values for rotation, translation
and scaling according to the current state are displayed
and they can be modified.

3D display can be influenced by mouse and keyboard:

Mouse
Left button Middle button/ wheel Right button
Rotation around point
Zoom in/ out Move
of srcin

Keyboard
/ / <Ctrl> / x/ y/ z < > x/ y/ z
Rotation around viewing direction in
x y z positive negative
axis axis direction

In the panel Component all available parts are listed, whereby their
visibility can be switched on or off alternatively. There is shown in detail:

Impeller Volute
Hub Spiral
Shroud Diffusor
Mean surface of blades Connection surface hub
Blades Connection surface shroud
Spiral contour
16

The connection surfaces close the flow area between impeller and
volute. These surfaces have no constructional relevance, but serve the
CFD modelling.

For the marked component in each case the following attributes can be
defined below:

Wire frame display

Surface display

Color selection

Transparency of foreground components

There exist some more features for impellers:

In panel Options the display can be limited to single blade if the blades
overlap too high. Additionally the shown material thickness of hub and
shroud can be adapted only for visualization.
In panel Animation you can generate uniform rotation of impeller around
z axis, whereby velocity can be influenced by track bar.
 17

Open/ Save design

Ü File | Open/ Save/ Save as

®
When opening an existing CFturbo design (*.CFT) you may explicitly
select between current file format or version KREILA4 (*.KRE), but the
different file formats are self-determined. Saving always takes place in
the new format.
To open a list of recently used files can be used by pressing the small
arrow right beside the Open button or by selecting the menu File|Open
recent.
The user can modify filenames by theSave as- function in order to save
modified designs under different file names.

Help

Ü Help

The following features can be used in the help menu:

Help topics Help for main window, index of whole help
®
CFturbo website Show www.cfturbo.com in the web browser
Check for updates Check for available updates
® ®
About CFturbo Information about CFturbo incl. licenses
18

Data export
Ü File | Export

Export submenu offers file formats of several CAE programs to export

designed geometry. Thus a smooth further processing of the geometry
data is possible.
Menu Description

Design *.CFT-REP
report -
TEXT Short design information as text file
Summary of most important design parameters

Geometry – *.CFT-GEO
TEXT
Text file containing geometry data of the design for any
further processing
Impeller:
Meridional section: z, r of hub, shroud, leading edge
Blade mean lines, x, y, z (cartesian coordinates),
Blade profiles: r (radius), t (angle)
Volute:
Spiral cross sections,
Diffusor cross sections x, y, z (cartesian coordinates)
Outline: x, y (cartesian coordinates)

BladeGen *.rtzt ANSYS CFX-BladeGen 4.1

Program for three-dimensional blade design and
(Impeller automatic impeller performance evaluation with CFD
only)
§ File | Open: select file type „Meanline File (*.rtzt)“
§ select file
 19

TurboGrid *.curve ANSYS CFX-TurboGrid 1.6

Software to generate high-quality grids for turbo-
(Impeller machinery
only)
3 files will be generated: hub.curve, shroud.curve,
profile.curve
§ Application Launcher: select directory, start

§ TurboGrid
File | New: select template
§ define z axis as rotational axis, input number of
blades, select XYZ coordinate system
§ Grid | Create

Gridgen *.curve Gridgen 15 (Pointwise)

Software to generate high-quality grids for turbo-
machinery
A model file and a curve file for each component are
generated.
Import by Glyph-script “CFturboImport.glf“

RBS-Q3D *.RBS RBS-Q3D

Input file for program RBS-Q3D (quasi-three-dimensional
(Impeller
frictional flow) of TU Dresden, which can be used for
only) approximate flow calculation

Fluent *.tur GAMBIT (Fluent)

Input file for the Fluent preprocessor GAMBIT for meshing
(Impeller with G/Turbo
only)

IGES *.igs common format

File contains designed geometry as B-Splines

PRO/E *.ibl PRO/Engineer Version 2001

File contains hub, shroud, blade profiles
§ File | New | <name> (if no file is open)
§ Insert | Datum | Curve | From file
§ Define coordinate system (e.g. with menu) | Select
§ select *.ibl file
20

Uni- *-ug.dat Unigraphics V16-18, NX

graphics
4 files will be generated: *hub-ug.dat, *shroud-ug.dat,
*skl-ug.dat, *blade-ug.dat
§ File | New | <name> (if no file is open)
§ Application | Modeling
For hub and shroud:

§ Insert | Curve | Spline | Through points

§ Points from file
§ select *.dat for hub and shroud
For blade surfaces:
§ Insert | Free form feature | Through points
§ Row degree <= number of blade profile sections;
Column degree <= Row degree-1
§ Points from file
§ select *.dat for blade surfaces

SolidWorks *.swb SolidWorks 2004, macro file

Macro generates hub, shroud and blade surfaces
§ Tools | Macro | Run: select *.swb

AutoCAD *-ACAD.txt AutoCAD 14

§ Tools | Applications: install xyz2spline.fas(or load
“xyz2spline.lsp“)
§ start Plug-in: xyz2spline, select *-ACAD.txt

OneSpace *-OSD.txt OneSpace Designer (Solid Designer)

Designer
one file per curve will be generated (hub, shroud,
n * mean line, n * blade profile);
Import by script "curves_points.lsp"

Rhino3D *-Rhino.txt Rhinoceros command file

Rhinoceros is a 3D modeler designed by Robert McNeel
(Impeller
& Associates
only)
§ Tools | Commands | Read from file...: select *-
Rhino.txt
§ generates hub, shroud contours and blade profiles
 21

IMPELLER - MERIDIONAL SECTION

Main dimensions

Ü Meridian | Main dimensions

The Main Dimensions menu item is used to define main dimensions of

the impeller. Main Dimensions are forming the most important basis for all
following design steps.

b2

The real flow in a pump impeller is turbulent and 3

three-dimensional. Secondary flows, separation 2
and reattachment in boundary layers, cavitation, d2
transient recirculation areas and other features
may occur. Nevertheless it is useful - and it is
common practice in the pump design theory - to
simplify the realistic flow applying representative
streamlines for the first design approach.
Employing 1D-streamline theory the following
cross sections are significant in particular:
suction area (index S), just before leading edge
(index 0), at the beginning (index 1) and at the 1
end of the blade (index 2) and finally behind the dS 0
trailing edge (index 3).
S

dN

Design point
In the left-hand side of the dialog window you have to enter the design
point data. The essentialBasic values are:
Flow§ rate Q
Head § H
§ Number of revolutions n
§ Density of the fluid r
22

On panel Inflow you may define the inflow swirl at hub and shroud.
There are two possibilities:

Œ Flow angle • Swirl number

aS = arctan(cmS cuS ) dr = 1 - cuS uS

Positive swirl aS < 90° dr < 1

Negative swirl aS > 90° dr > 1
No swirl aS = 90° dr = 1

Negative swirl is increasing the head and may often have no good affect
to the suction behavior of the pump. Inflow through a straight pipe usually
leads to swirl-free flow.
dr and aS relate as follows:
c mS 4Q
dr = 1 - = 1-
us tan aS p 2
(d
S
2
- dN2 )d n tan a S
The conversion dr 1 aS is only valid for certain diameters dN and dS.
Conversion is updated if these diameters are modified.
 23

Furthermore, you can define rotational direction of the impeller seen from
the drive side (looking at the backside of hub)
At the lower end of each column some related values are computed - just
for information:

Specific speed nq points to pump type and general shape of

(metric units) impeller:

3
nq = n [min-1]× Q m s
[ ]
(H [m])3 4
10… 50 Radial impeller
50…170 Mixed-flow impeller
150…400 Axial impeller
Specific speed NS Q [gpm ]
(US-units) Ns = n [rpm]
(H [ ft ])3 4
„Type number“ ws Q nq
(ISO 2548) ws = 2 p n × 3 4
=
(g H) 52 .9

Specific energy Y Y = gH
Pressure difference Dp Dp = r g H
Pump output PQ PQ = rgHQ

In general for cost reasons single-stage & single-intake pumps are

preferred covering a range of about 10 < nq < 400.
In exceptional cases it may become necessary to design an impeller for
extremely low specific speed values (nq < 10). These impellers are
characterized by large impeller diameters and low impeller widths. The
ratio of free flow cross section area to wetted surfaces becomes
unfavorable and is causing high frictional losses. To prevent this one
may increase either rotational speed n or flow rate Q if possible. An
alternative solution could be the design of a multi-stage pump reducing
the head H of the single-stage.
If especially high specific speed values (nq > 400) do occur one can
reduce rotational speed n or flow rate Q if feasible. Another option would
be to operate several single-stage pumps - having a lower qn- in parallel.
®
Please note: CFturbo is preferably used between 10 < nq < 150 – radial
and mixed-flow impellers.
24

Assumptions
At the middle column of the Main Dimension dialog window you have to
put in or to modify Assumptions resulting from approximation functions
in dependence on specific speed qn or flow rate Q (see chapter
"Approximation functions“, page 5).
The panel Characteristic numbers allows to define alternative values in
each case for the calculation of all impeller main dimensions: suction
diameter dS, impeller diameter d2 und impeller width b2:
For dS calculation
- Ratio between meridional inflow velocity and
specific energy
Intake number e
e = c0 2 Y ~ b0a
- 0.05…0.4 (rising with n q)
- high ’ smaller dimensions,

lower friction losses

- < 20° ’ prevent the risk of cavitation
Inflow angle b 0a
- > 15° ’ with regard to efficiency

- 12°...17° ’ recommended for good suction

capability
- small friction and shock losses
Minimal relative - only if no cavitation risk !
velocity w - fdS=1.15...1.05 standard impeller, nq=15...40
- fdS=1.25...1.15 suction impeller

nSS = n [min-1]×
[
Q m3 s ]
(NPSHR [m])3 4
Suction number - Standardsuction impeller u 1<50 m/s 160...220
nSS - Suction impeller, axial inflow u 1<35 m/s 220...280
- Suction impeller, cont. shaft u 1<50 m/s 180...240
High pressure pump
- u 1>50 m/s 160...190
Standard
- inducer u 1>35 m/s 400...700
Rocket- inducer >>1000
2 2
c1m w
NPSHR = lc + lw 1
2g 2g
- lc suction pressure coefficient for absolute
velocity c (inflow acceleration and losses)
1.1 axial inflow
Min. NPSH
1.2…1.35 radial inflow casing
- lw suction pressure coefficient for relative
velocity w (pressure decrease at blade
leading edge)
0.10…0.30 standard impeller
0.03…0.06 inducer
 25

For d2 calculation
- dimensionless expression for the specific
energy
2
y=Y u2 2
Pressure 0.7 ...1.3 radial impeller
coefficient y 0.25...0.7 mixed-flow impeller
0.1 ...0.4 axial impeller
- high ’ small d2, flat charactersitic curve
- low ’ high d2, steep charactersitic curve
- 6°...13°: recommended for stable
Outflow angle b3
performance curve (with nq rising)

for b2 cal culation

Outlet width ratio
- 0.04...0.30 (with n q rising)
b2/d2
Mer. deceleration
- 0.60...0.95 (with n q rising)
cm3/cmS

In panel Efficiency you have to specify several efficiencies:

§ Hydraulic efficiency hh
§ Volumetric efficiency hv
§ Side friction efficiency hS
§ Mechanical efficiency hm
The first three values form the internal efficiency because these losses
result in dissipating energy from the fluid:

hi = hh × hv × hS
Internal and mechanical efficiency form the overall efficiency (pump/
coupling efficiency):

PQ
h= = hi × hm PQ: pump output, see above
PD PD: power demand (coupling/ driving power)

The obtainable overall efficiency correlates to specific speed and to the

size and the type of the impeller as well as to special design features like
bypass installations and auxiliary aggregates. Efficiencies calculated by
approximation functions (please see page 5) are representing the
theoretical reachable values and they should be corrected by the user if
more information about the impeller or the whole pump are available.
26

The hydraulic efficiency (or blade efficiency) describe the energy losses
within the pump caused by friction and vorticity. Friction losses mainly
srcinate from shear stresses in boundary layers. Vorticity losses are
caused by turbulence and on the other hand by changes of flow cross
section and flow direction which may lead to secondary flow, flow
separation, wake behind blades etc.. The hydraulic efficiency is the ratio
between specific energy Y and the energy transmitted by the impeller
~
blades Y :

Y
hh = ~ » h » 0.85 K 0.93
Y

The volumetric efficiency is a quantity for the deviation of effective flow rate Q
~
from total flow rateinside the impeller Q which also includes the circulating
flow within the pump casing:
Q
hv = ~ » 0.93 K0.99 (rising with impeller size)
Q

The side friction efficiency contains losses caused by rotation of fluid

between hub/ shroud and housing:

PS 0.5 K 0.985 for nq < 40

hS = 1 - »
P 0.985K 0.995 for nq > 40

The mechanical efficiency mainly includes the friction losses in bearings

and seals:
Pm
hm = 1 - » 0.95 K 0.995 (is rising with impeller size)
P

Hydraulic and volumetric efficiency are most important for the impeller
~ ~
dimensioning because of their influence to Y and/or Q . Mechanical and
side friction efficiency are affecting only the required driving power of the
pump.
Please note about the required consistency for Q- and H- values and for
hh und hV too: they refer to the same control volume of the viewed fluid
domain. For example if the head H is representing the desired head after
the outlet of the spiral casing the assumed hydraulic efficiencyhh must
contain all hydraulic losses which occur at the flow through the impeller
and through the volute. Clearly distinguish if you look at the whole pump
stage or just viewing to the impeller alone!
 27

Finally the blade number z has to be set as an assumption: the number

is usually between 3 and 10. Many blades - causing low blade loading -
are related to higher friction losses. By choosing of fewer blades -
leading to a higher blade loading - the hydraulic losses may rise due to
increased secondary flow and stronger deviation between blade and flow
direction.
In the lower area of the Assumptions column you will find again some
calculated values for information:

Required driving PQ
PD =
power h
Power loss PL = PD - PQ = PD (1 - h)

Internal efficiency hi = hh × hv × hS
PQ
Overall efficiency h= = hi × hm
PD

Dimensions
In the panel Shaft/ hub, the required shaft diameter is computed and the
hub diameter is determined by the user.
Dimensioning of the shaft diameter is made under application of strength
requirements. It is a result of torque M = P w to be transmitted by the
shaft and the allowable torsional stress t of the material.

You can directly enter allowable stress or

select the value from a list by pressing
button right beside the input area.
In a small dialog window you can see
some materials and its allowable stress.
The list can be extended or reduced by
and button. You can confirm selected
value by pressing the OK-button.
At File location the file containing material
properties is shown. The file is srcinally
called Stress.cftst and is located in the
®
installation directory of CFturbo .
Modifications of the list will be saved if the
user is leaving the dialog window by
28

clicking the OK-button. In case there are no write permissions the user
can choose another directory to save the file. Renaming of files is
possible by Save as- functionality. By clicking the Open-button a
previously saved file can be opened.

To consider a higher load, e.g. due to operating conditions away from the
design point, a safety factor SF may be specified leading to a modified
proposed shaft diameter dw.

8 r Q Y × SF
dW ³ 3
p2 n t h

The hub diameter dN is usually selected as small as possible and

depends on the kind of connection of hub and shaft.

The main dimensions of a designed impeller - suction diameter d S,

impeller diameter d2, outlet width b2 - can be seen on Main dimensions
panel. They can be recomputed by pressing theCalculate-button. The
computation is based on "Euler's Equation of Turbomachinery", on the
continuity equation and the relations for the velocity triangles.

You may accept the proposed values or you can modify them slightly,
e.g. to meet a certain normalized diameter.
Regarding the impeller size one should try to attain d 2 values as low as
possible. But there is a limit for a specified task: lower impeller diameters
are leading to higher blade loading - up to blade anglesb 2 which may not
be suitable anymore.

You can select a value for the diameters dS and d2 from standard
specifications. For that purpose you have to press the button right
beside the input field.
The small dialog gives you the possibility to select a diameter from
several standard specifications. If material, standard name and pressure
range are selected the lower panel shows all diameters of the chosen
standard. One diameter is highlighted as a proposal. Nominal diameter,
outside diameter and wall thickness for the marked entry is displayed.
Using of and buttons additional standard specifications and user
defined diameters can be added or existing parameters can be removed
from the list.
 29

At File location the name of the file

containing the diameters is shown. The
file is srcinally called Diameter.cftdi and
is located in the installation directory of
®
CFturbo . Modifications of the list will be
saved if the user is leaving the dialog
window by clicking the OK-button. In case
there are no write permissions the user
can choose another directory to save the
file. Renaming of files is possible bySave
as- functionality. By clicking the Open-
button a previously saved file can be
opened.

In the lower area you will find some calculated values for information
which result from calculated or determined main dimensions:

2
§ Pressure coefficient y = gH u2 2

QhV
cmS =
p 4 (dS - dN2 )
§ Average inlet velocity 2

Q hV
§ Average outlet velocity cm3 =
pd2b2

c m12 w12
NPSHR = lc + lw resp.
2g 2g
§ NPSH value

NPSHR = H × (n q nSS )4 3
§Outlet width ratio b 2/d2

§ Meridional deceleration dcm = cm3 c mS

2
§ Estimated axial force Fax = 0.9 r gH× p 4 dS - dN2
30

Meridional contour

Ü Meridian | Contour

The design of the meridional contour is the second important step to

design the impeller.
th
Hub and shroud are represented by 4 order Bezier-splines. The curve is
determined by five Bezier points. Points 0 and 4 are defining the
endpoints of the curves while the other three points determining the
shape of the curve. The middle point (2) can be moved without any
restrictions whereas points 1 and 3 have only one degree of freedom.

4 3
3

2
1
0

0 1 2
 31

Point 1 is only movable on the straight line between points 0 and 2, point
3 between point 2 and 4. Therefore no curvature is occurring at the end
of the curves. In conjunction with a continuous curvature gradient small
velocity gradients can be expected. The two straight lines are defining
the gradients in the end points of the curves.
For an automatic primary design of the contours the following values are
used:
§ Main dimensions (see page 27): d N, dS, d2, b2
§ Inclination angle g of trailing edge to horizontal
(see Approximation functions, page 5)
§ Inclination angle e of hub and shroud to vertical
(see Approximation functions, page 5)
§ Axial extension Dz = (d2a - dS ) (nq 74 )1.07 + b2 2 cos g

Point 1 is primary placed at 3/4 of the axial distance of points 0 and 2,

point 3 at 2/3 of the radial distance of points 2 and 4.
The manipulation of the contours can be achieved by shifting the
positions of the Bezier points. As an alternative the position of Bezier
points can be realized by input of numerical values (see page 10).
Trailing edge can be rotate by moving Bezier points 4. If <Ctrl> key is
pressed simultaneously the whole trailing edge can be moved in axial
direction with constant inclination angle (change axial extension).
Inclination angle of trailing edge can be numerically determined by
clicking the right mouse button on it.
In the design process for the meridional contours the user should try to
create curvatures which are as steady as possible in order to minimize
local decelerations. The maximum values of the curvature should be as
low as possible and should entirely disappear at the end of the contours.
These requirements are met very well by Bezier curves showing the
above mentioned limitations. Local cross section 2 pr × b should grow
from the suction to the impeller diameter as uniformly as possible.
The points of maximum curvature are marked on hub and shroud while
their numerical values are displayed in theMax. curvature section.
There are two different options to define hub and shroud contours that
can be selected in the right-hand part of the dialog in theEdit section:
ΠHub, Shroud Direct design of the two contours
• Cross section Design of center line; the contours result from
given cm course between suction (dS) and outlet
(d2) cross sections
32

In the first case hub and shroud can be designed separately or in the
coupled mode. If you hit the Coupled check box hub and shroud will be
modified simultaneously considering the same relative positions of the
Bezier points.
In the second case only the geometric center line of the flow channel will be
modified. The contours result in specifying a relative shape of the meridional
velocity cm. It may either be linear or could be loaded from a file.
On the left side you can see an
#
# Cross section progression
example example of cm progression.
# Beginning/end tangential,
# linear in the middle section All lines starting with a # symbol
# Spline interpolation between are comments. All other lines
# 9 points contain the numerical values. The
0.00 0.00000 first value of each line is the
0.04 0.01728 relative meridional coordinate x
0.08 0.03830
along the center line, with x=0 at
0.12 0.06368
0.16 0.09404
the suction cross and x=1 at the
0.20 0.13000 outlet cross-section. The second
0.24 0.17164 value is the relative meridional
0.28 0.21687 velocity cm,rel, which allows to
0.32 0.26314 compute the related absolute
0.36 0.31018 value:
0.40 0.36000
0.44
0.48
0.41404
0.47102 cm = c m,0 + c m,rel × (c m,3 - c m,0 )
0.52 0.52898
0.56 0.58596
0.60 0.64000 The meridional velocity is used
0.64 0.68982 to determine the width b vertical
0.68 0.73686 to the flow direction:
0.72 0.78313
0.76 0.82836 Q
b=
0.80 0.87000 2pr × c m
0.84 0.90596
0.88 0.93632
0.92 0.96170
0.96 0.98272 These considerations are based
1.00 1.00000
on the assumption of a constant
meridional velocity cm over the

cross section.
non-radial areaThis willimpeller.
of the becomes less applicable to wider impellers at the

th
The leading edge is designed too by a 4 order Bezier spline. Regarding
the Bezier points, the statements made above are applicable in a similar
way. The only difference is the manipulation of the end points. For the
leading edge there is no restriction on hub and shroud contour. The
 33

position of the leading edge always appears at the same relative position
®
in a primary CFturbo design but this not mean to be a suggestion.
Leading edge can be designed as a straight line by selectingLeading
edge straight in panel Edit (controlled by 2 Bezier points). If the edge
additionally should be parallel to z-axis thenLeading edge parallel to z
has to be selected (controlled by 1 Bezier point).
For radial impellers having nq » (10…30) rpm the leading edge is often
designed parallel to the axis. As the trailing edge is parallel to the axis
too for such applications 2D-curved blades can be created. At higher
specific speed nq the leading edge often is extended into the impeller
suction area. Various diameters result in different leading edge blade
angles - therefore 3D-curved blades are created. This leads to improved
suction capacity, better performance curves and higher efficiencies.
The position of the leading edge should be chosen in a way that enables
the transmission of energy should be about equal on all meridional flow
surfaces. A criterion is the approximately equal static moment S =ò r dx
of the meridional streamlines on hub and shroud between leading and
trailing edge. In the Static moment section the corresponding numerical
values are displayed. Both ends of the leading edge should be
perpendicular to the meridional contours of hub and shroud if possible.
To obtain equal static moments on hub and shroud the trailing edge is
often not parallel to axial direction - particularly at higher specific speeds
(mixed-flow impellers).

In panel Extension on exit an extension downstream of the trailing edge

can be modeled. This may be necessary for further processing in other
CAE-systems, e.g. CFX-BladeGen. The values Exit diameter d2a and
Exit width b2a refer to cross section behind trailing edge and can be
determined in different ways. The designed outflow area is displayed.

In panel Show progressions the following curves can be displayed:

Curvature Static moment Area progression
34

In the Options panel some graphical representations can be activated

for illustration:
Grid Width lines Area circles
for later blade for calculation of hub for calculation of cross
design and shroud section area

In the Information panel you can find some numerical values of above
mentioned quantities.
 35

Blade properties

Ü Meridian | Blade properties

When starting blade design, the number and the meridional position of blade
profile sections must be specified as well as the blade angles. Blade
angles b B1 and b B2 are calculated from the velocity triangles, whereby the
blade blockage of the flow channel and the slip velocity is considered.

Procedure for calculation of blade angles:

Œ
Defining the Blade
(TE) in panel blade thickness
thicknessvalues
s at leading (LE) and trailing edge

• Estimation of slip velocity in panel 2: Deviation flow – blade:

fully automatic by selecting WIESNER theory or input of
coefficient a when selecting PFLEIDERER theory or manual
selection of angular deviation b2B - b2 resp. velocity ratio
cu 2 cu 2 ¥ byselecting Self
36

Ž Panel Blade angle B:

§ Specifying number of blade profile sections for further blade
design using the vertical track bar
§ Calculation of blade angles using values from Œ and • by
pressing button Calculate B
§ Manual adaptation of calculated blade anglesif required

Calculation or input
profiles. Further of blade
blade designangles can beaccording
is realized executedtoforthe
2 up to 11 blade
defined blade
profile number.
Blade angles are computed under consideration of the equations listed
below. They remain unchanged by default if they are determined once. If
main dimensions or meridional contours are modified or, on the other
hand, values of blade thickness or slip velocity are renewed, a
recalculation of blade angles should be executed by pressing button
Calculate B.
On panel Blade lines all meridional lines are displayed which will be
used for blade design. The number of lines can be adjusted with track
bar on panel Blade angle B.
Velocity triangles of inflow and outflow are displayed. Continuous lines
represent flow velocities on hub (blue) and shroud (green). Velocities
directly before and behind blade area can be displayed optionally
(dashed lines) to show influence of blockage in the flow domain.
Furthermore the blade angles can be displayed by thick lines in order to see
the incidence angle on the leading edge and the flow deviation caused by
slip velocity on trailing edge.

Numerical values of velocity components and flow angles are displayed

in a table on the right side of the dialog window. A short description is at
mouse cursor too:
§d Diameter
§ a Angle of absolute flow to circumferential direction
§ b Angle of relative flow to circumferential direction
§ u Circumferential velocity
§ cm Meridional velocity ( c m = wm )
§ cu Circumferential component of absolute velocity
§ c Absolute velocity
§ wu Circumferential component of relative velocity ( w u + cu =u )
§ w Relative velocity
§ t Obstruction by blades (see below)
 37

§i Incidence angle i = b1B - b1

§ d Deviation angle d = b2B - b2
§ wR Deceleration ratio of relative velocity w R = w2 w1

Inlet triangle

The inlet triangle is defined by inflow parameters

and geometrical dimensions on leading edge.
Between inlet area and leading edge the swirl is
constant because transmission of energy from
rotating impeller to fluid occurs in blade area only.
Cross sections 0 and 1 (see “Main dimensions",
page 21) are different only due to blockage of the
flow channel by blades t(1) in section 1. This
results in an increased meridional velocity cm.
c m1
tan b1 =
w u1

c m1 = c m0 t1
t1 pd1 s1
t1 = with t1 = , s1 =
t1 - s1 z sin b1

c m0 = Q (pd1b1)
w u1 = u1 - c u1

u1 = pd1n
rS rS
cu1 = c uS = uS (1 - dr ) constant swirl before blade
r1 r1

Selected blade angle b 1B does only indirectly influence the velocity

triangle due to blade blockage. Differences between selected blade angle
b1B and flow angle b1 is referred as the incidence angle i: i = b1B - b1
In general an inflow without any incidence is intended (i=0). If¹i0 the flow
around the leading edge shows high local velocities and low static
pressure:
i>0: b1 < b1B Þ stagnation point on pressure side
i<0: > Þ suction side
38

A small incidence angle i can be profitable for best efficiency point.

®
Calculation of b1B inside CFturbo gives inflow without incidence.
Because of cavitation b1B should be as small as possible; with regard to
efficiency not smaller then 15…18°.
If the radius of leading edge varies from hub to shroud the blade angle
b1B does not remain constant. A higher radius on shroud results in a
lower value for b 1B – the blade is curved on leading edge.

Outlet triangle
The outlet triangle is determined by
geometrical dimensions of flow channel
and selected blade angle b2B. The blade
angle b 2B strongly affects the trans-
mission of energy in the impeller there-
fore is has to be chosen very carefully.
Similar to the inlet the velocity triangles
in cross sections 2 and 3 are different
due to blockage of the flow channel by

blades t2 in section 2.
c
tan b2 = m2
w u2

cm2 = c m 3t2
t2
t2 =
t2 - s2
p d2 s2
with t2 = , s2 =
z sin b2

c m3 = Q (pd2b2 )
w u2 = u2 - c u2
u2 = pd2n
Y hh + u12 (1 - dr )
cu 2 =
u2
~ Y gH
from: Y = = = u 2 c u3 - u 1c u0
hh hh
 39

For determination of b 2B it is important to be aware about the deviation

between flow angle and blade angle. The direction of the relative flow w2
at impeller outlet does not follow exactly with the blade contour at angle
b2B. The flow angle b2 is always smaller than blade angleb 2B due to the
slip velocity. This difference is called deviation angled:

d = b2B - b2
The deviation angle should not exceed 10°…14°, in order to limit
increased turbulence losses by asymmetric flow distribution.
A reduced flow angle b 2 results in smaller circumferential component of
absolute speed cu2, which is - according to Euler's equation - dominant
for the transmission of energy. Blade angleb 2B is estimated by cu 2¥ for
blade congruent flow (see figure). Therefore an estimation of slip is
necessary. Slip can be estimated by empirical models. Two different
®
possibilities are available in CFturbo :

ΠTheory of decreased output byPFLEIDERER

Reduced energy transmission is expressed by decreased output
coefficient p:

p= Y
~¥
~ -1
Y
This coefficient can be empirically calculated in dependence of
experience number y’:
2
r2
p = y'
zS
r2

with S =
ò rdx
r1
static moment from leading to trailing edge

y' = a (1 + b2 60° ) experience number

Design coefficient a is supposed to be:

Radial impeller with guided vanes : a = 0.6
with volute : a = 0.65…0.85
with plain diffusor : a = 0.85…1.0
Mixed flow/axial impeller : a = 1.0 …1.2
(for sufficiently high Re;y ’ strongly grows with small Re).
40

More descriptive is the decreased output factor kL:

~
1 Y D (rc u )
kL = = ~ = (kL=1 for flow congruent to blade)
1+ p Y¥ D (rc u )¥
Circumferential component of the flow, which is congruent to blade,
can be calculated as follows:

cu2 r1
2
æ 1 ö
cu2¥ = kL - r2 èç kL - ÷ø p ( - d )
1 2 n1 r

• Outflow coefficient by WIESNER

Outflow coefficient g is defined for decreased energy transmission:

c u2 ¥ - c u2
g = 1- (g=1 for flow congruent to blade)
u2

Difference c u2¥ - cu2 is called slip velocity.

The smaller the outflow coefficient, the higher is the deviation of flow
compared to the direction given by blade.
Wiesner has developed an empirical equation for the estimation of
outflow coefficient:

æ sin b2B ö
g = f1 ç 1 - ÷k
ç z 0 .7 ÷ w
è ø
with correction values
ìï 0.98 for radial impellers üï
f1 = í ý
ïî1 .02 + 1.2 × 10 -3 (nq - 50 ) for mixed flow impellers ï
þ
ì1 for d1m d2 £ eLim ü
ï ï
kw = í æ d1m d2 - eLim ö3 ý
1 - ç
ï ç 1- e ÷
÷ ï
è Lim ø
î þ
d1m = 0.5 * (d1,Shroud + d1,Hub )
2 2

æ 8.16 sin b2B ö

eLim = expç - ÷
è z ø
 41

Circumferential component of blade congruent flow can be calculated

as follows:

cu2¥ = c u2 + (1 - g )u2

Blade angle b 2B must be determined to reach the desired energy

transmission - respectively the required head - under consideration of

slip velocity.
15°…45°, Commonused
commonly blade anglesb2B for pumps are within the range of
20°…27°.

Radial pumps with low specific speed nq usually have similar values for
b2B. The blades for this type of impellers are often designed with a
straight trailing edge (b2B=const.).
42

Meridional flow

Ü Meridian | Flow

The meridional flow is computed by a streamline curvature method. The

flow domain is divided into thin layers of 11 meridional flow surfaces.
There a two-dimensional flow computation is possible with sufficient
accuracy. The calculation is made on 35 quasi-orthogonal lines - from the
suction area up to the extension area behind the trailing edge. The leading
and trailing edges are two of these quasi-orthogonal lines.
Since this design program is supposed to deliver just a rough estimation
of the meridional flow the influence of friction is neglected. Furthermore
®
rotational symmetry has been assumed. After completing the CFturbo-
based pre-design process, one should use an appropriate CFD-code for
flow recomputation of the impeller or of the whole pump stage.
After calculation the meridional contour as well as the cm and w
distribution is represented showing 6 streamlines and 35 quasi-
orthogonal lines. You could adjust the size of the diagrams by mouse.
 43

IMPELLER - BLADE DESIGN

Mean line

Ü Blade | Mean line

The blade mean lines are designed on the number of meridional flow
surfaces which were determined in “Blade properties” (page 35).
The spatially curved meridional
flow surfaces are mapped to a
plane by coordinate transfor-
mation. This coordinate system
has the angle in circumferential
direction t as abscissa and the
dimensionless meridional exten-
sion m as the ordinate. Both r
quantities are created by the z t

reference of absolute
to local radius r: distances
m
dM dT
dm = dt =
r r

This conformal mapping allows

the uniform handling of various
impeller types (radial, mixed-
flow, axial). It should be noted
that for each meridional flow
surface a separate m-coordi-
nate is existing.
rd
In general the mean lines are represented by 3 order Bezier splines.
Boundary conditions are:
§ Blade angles bB1, bB2 (see Blade properties, page 35)
§ Meridional extension dm (see Meridional contour, page 30)
§ Wrap angle j
44

®
CFturbo 's primary design is fixing point 0 (leading edge) for all cross
sections due to wrap angle and meridian coordinate m=0, while point 3 is
determined by the meridian coordinate of the trailing edge (dm) and t=0.
The wrap angle j is initially constant for all cross sections (see
Approximation functions, page 5), but it can be modified individually. In
general j should be in the range of 70…150° (with nq decreasing). Wrap
angle tremendously influences blade angle progression -bB along mean
line. Beta-progression can be viewed in a separate diagram.
Two points in the middle, 1 and 2, must be on a straight line at an angle
of b B1 or bB2 to the horizontal in order to fulfill the boundary condition
( tan bB = dm dt ). The primary design shows points 2 at 1/4 of the wrap
angle, and points 1 at 3/4.

For continuous transition between the separate mean lines (blade surface),

the matching points of each mean line have to be Coupled linear.

Individual mean lines can be designed separately. If the linear coupling
mode is active you can move and rotate the connecting line. The
positions of Bezier points of all mean lines are modified correspondingly,
to get uniform profiles. If you select a point of the inner cross sections
you can move the entire connecting line. On the other hand, if you select
any point of the inner or outer cross sections, you can move this point
along the related straight line. This line is given bybB1 or b B2 (rotation of
 45

the connecting line). Points 0 (leading edge) and 3 (trailing edge) can
only be moved horizontally (m=const). Points 3 can be moved
interactively (move/ rotate trailing edge). Points 0 (leading edge) can
moved only by modifying wrap angles in tableBoundary conditions.
Additionally you can use option Coupled in t-direction. This results in
smooth transition of connection lines in t direction regarding t difference
between inner and outer mean line. This option makes sense only if
different wrap angles for the mean lines are used.

You can display bB progression

along every mean line in a
separate diagram by pressing
button Show Beta progression.
Too high local extreme values
should be avoided if possible.

Alternatively to the Bezier splines, the mean lines can also be

represented as simple polylines. For this purpose you may read any
curve coordinates from file.

The blades of a pump impeller representing a deceleration cascade for

the relative velocity. Therefore the risk of flow separation exists. The user
should try to obtain a continuous, smooth change of flow direction, as
well as the cross section graduation of the flow channel should be as
steady as possible.
46

You can click on the button Frontal view to represent the designed
mean lines in a frontal view, including diameters d
N and d2.
 47

Blade profile

Ü Blade | Profile

To create blade profiles the orthogonal blade thicknesses are used

located at leading edge, at trailing edge, after 1/3 and after 2/3 of the
blade. The primary CFturbo®-design is suggested typical values in
dependence of the impeller diameter d2 (see Approximation functions,
page 5). Blade thickness is interpolated linear between these 4 values.

In the Blade thickness table the corresponding blade thickness values

are indicated. Considering impeller manufacturing a certain thickness
distribution across the flow direction may be implemented, e.g. to ensure
the molding process. The blade thickness values can be setconstant,
linear changing from leading to trailing edge or completelyuser defined.
The orthogonal blade thickness values are converted into thickness
values referred to the circumferential direction. By adding half the
thickness to both sides of the blade mean line the pressure and suction
sides of the blades will be created. The profile can be represented then
in m,t - coordinates.
48

You may display thicknessprogression along mean lines in a separate

diagram by pressing button Show thickness progression.

By clicking to the Frontal view button the designed blade profiles in

frontal view are shown, including diameters dN and d2.
 49

Blade leading edge

Ü Blade | Leading edge

The previously designed blade has a blunt leading edge. To complete

the blade design the leading edge should be radiused. For this purpose
4th order Bezier splines are used.

4
2
3

Points 0 and 4 representing the transition between the blade sides and
the rounded leading edge. You can move these points only along the
corresponding blade side. Bezier points 1 and 3 can only be moved on
straight lines which correspond to the gradient of the curve in points 0 or
4, respectively in order to guarantee smooth transition from the contour
to the leading edge. Bezier point 2 is not restricted to move - it has the
most influence to the shape of the leading edge.
In addition the m-value of the leading edge (corresponding to the radius)
is represented. When designing the leading edge, you should make sure
that the smallest radius of the rounded leading edge does not deviate too
much from the value given in the meridian section.
50

There are two different possibilities to determine the shape of the leading
edge. In the Edit panel on the right top of the dialog window you can
select between:
§ Coupled linear only leading edges of hub and shroud will be
fixed, while anything between will be linearly
interpolated
§ Uniform when designing leading edge on hub or shroud
then Bezier points of all other leading edges
have the same relative positions
You could click on the Frontal view button to show the designed blade
profiles with their rounded leading edges in a frontal view, including
diameters dN and d2.
 51

VOLUTE

Inlet

Ü Volute | Inlet definition

The first design step of

the volute is to define
the inlet side. To do
this, input the impeller
data in the dialog box
on the left hand side.
If the impeller was
already designed using
®
CFturbo , the data can
be transferred directly
from the corresponding

(Load
CFT file CFT
Impeller file).from

General data:
Flow§ rate Q
Head § H
Pump
§ revolutions n
§ Density of the pumped fluid r

Impeller outlet parameters:

§
Impeller diameter d 2
§Impeller outlet width b 2
§ Angle of absolute flow a3
§ Axial position (centre of b 2) z
The axial position, z, ensures correct positioning relative to the impeller
concerned.
52

Additionally, the direction of rotation of the impeller, seen from the drive
side (looking at the backside of hub), must be defined.
Various calculated values are shown, for information purposes, in the
bottom box:

Specific speed nq (SI units)

see section
Specific speed NS (US units) Design point
page 21
Type number ws (ISO 2548)

Meridional component of the absolute velocity cm3 = Q (pd2b2 )

Circular component of the absolute velocity cu3 = cm3 tan a3

Data concerning the volute are entered in the dialog box on the right
hand side.
General data:
§ Volumetric efficiency hv
Flow§ factor F Q
(for overdimensioning, particularly for a better degree of efficiency
at overload operation)
Volute inlet:
Inlet
§ diameter d 4
Inlet§width b 4
§ Axial displacement Dz
(relative to the centre of the impeller outlet)
For hv and FQ, standard values of 1.0 are used. d4 and b4 are determined
using the ratios d4/d2 and b4/b2, which are calculated from functions
dependent on the specific speed nq (see section Approximation function).
Clicking on the Calculate-button, to the top right, recalculates the
standard values.
A short distance between the impeller and the cut-water is desirable for
reasons of flow. For acoustic and vibration reasons, however, a certain
minimum distance is necessary. The inlet width b 4 should be chosen
such that the width/height ratio at the end cross-section of the volute is
close to 1. The ratio b4/b2 can be varied within a relatively wide range
without significant negative effect on the efficiency. For radial impellers
with open impeller sides, values up to b4/b2=2 are possible. At higher
specific speeds (wider impellers), however, high width ratios have a
negative effect on flow (intensive secondary flows, turbulence losses). In
this case, b4/b2 should be between 1.05 and 1.2.
 53

Various calculated values are shown, for information purposes, in the

bottom box.

Calculated internal flow rate Qi Qi = FQ × Q hv

Inlet diameter ratio d4 d2

Inlet width ratio b4 b2

Geometry

Ü Volute | Geometry

The geometry of the volute can be designed and calculated in this dialog
box. The wrap angle (standard: 360°) and the starting angle (standard:
0°= horizontally to the right of the centre) can be defined under
Extension.
54

Design rule
The flow rate through a cross-section, A, of the circumferential angle,j,
is generally calculated as:
ra (j )

Qj = ò cudA = ò c b(r)dr
r4
u

Using Qj = Qi × j (2p ) , results in an equation to calculate the

circumferential angle, j, dependent on the outer radius ra:
ra (j )
2p
j=
Qi ò c × b(r )dr
r4
u

b(r) is a geometrical function which is defined according to the shape of

the cross-section. The velocity cu is chosen in accordance with the
design instructions. Under Design rule, two alternatives can be selected.

ΠPfleiderer

Experience has shown that the losses can be greatly minimised if the
volute housing is dimensioned such that the fluid flows in accordance
with the principal of conservation of angular momentum. The cross-
section areas are therefore designed in accordance with the principal of
conservation of angular momentum, i.e. angular momentum exiting the
impeller is constant. In addition, an exponent of angular momentum, x,
can be chosen so that the principle c u × r x = const. is obeyed. When x=1,
 55

the angular momentum is constant. For the extreme of x=0, the circular
component of the absolute velocity cu remains constant at the impeller
outlet.
ra (j )
x
2pcu4r4 b(r )
j=
Qi ò
r4
rx
dr

The integral can be explicitly solved for simple cross-section shapes

(rectangles, trapezoids, circles). For other, arbitrary, shapes, it can be
solved numerically.

• Stepanoff
Alternatively, it can be beneficial to design the volute with a constant
velocity in all cross-sections of the circumference. According to
Stepanoff, this constant velocity can be determined empirically:
cu = ks 2gH . The constant ks can be determined dependent on the
specific speed nq (see section Approximation function).
ra (j )
2pk s 2gH
j=
Qi ò b(r)dr
r4

By clicking on Default, you can return to the standard values for each
design instruction.

Cut-water
The cut-water can be designed in theCut-water section:

Inner radius r4 Informative, see section Inlet, page 51

Thickness (src.) e Thickness of the cut-water at the start of the
volute
Thickness (calc.) Realised thickness of the cut-water; deviates
by jC,0<>0
Position jC,0 Angular position of the cut-water (standard:
0°=start of volute); jC,0<>0 indicates a
rounding-off between the actual volute and the
diffusor
56

Position min. Minimum necessary angular position to

prevent overlap of the actual volute and the
diffusor

Compensation jC Angle, above which cut-water correction

begins (standard: 270°); only possible when
jC,0=0

The cut-water does disturb the

flow, since the cross-section of the
flow is narrowed suddenly by the
thickness of the cut-water. To
weaken this negative influence,
the cut-water can be corrected.
This is achieved by assuming that
from the angle jC the inner radius
r4 increases linearly to a value of
r4+e at the end cross-section of
the volute. This results in larger
volute cross-sections in this area,
so that the narrowing of flow
caused by the cut-water becomes

less significant.
By clicking on Default, you can return to the standard values for the cut-
water.

Shape of the cross-section

The shape of the cross-section of the volute can be selected under
Cross sections. In general, very small cross-sections width should be
avoided. The achievable cross-section shape strongly depends on
manufacturing and the space available.
 57

Rectangle (exact)
most simple cross-section shape; cannot be
achieved in cast parts; only sensible for low
specific speeds, since otherwise the cross-
section becomes too large

Trapezoid (exact)
cannot be achieved in cast parts; the angled
can be specified; results in a flatter cross-
section than a rectangular cross-section, with
less intense secondary flow

Circle ( symmetric)
simple geometry with a beneficial stress
distribution; does not develop on rotation
surfaces

Circle ( asymmetric)

more favourable secondary flow structure than

with a symmetrical circle cross-section; often
with semi-axial impellers

User defined (Rectangle type)

analogous with Rectangle; with chamfers
(cast radii)

User defined (Trapezoid type)

analogous with Trapezoid; with chamfers

(cast radii)
58

Bezier cross-sections
The shape of a User defined cross-section is described by a Bezier
spline. A special dialog box is used for this purpose and it can be opened
by clicking on the Design cross sections button.

4 3 2

One half of the shape of the cross-section is described using a 4th

degree Bezier polynomial. Points 0 and 4 are the end points and cannot
be changed. Point 1 can be moved along a straight line which
corresponds to the cone angle of the cross-section (0° for a rectangle
type, d for a trapezoid type). Point 3 can only be moved in the horizontal
direction in order to guarantee a smooth transition between the two
symmetrical halves. The intersection of the two lines which points 1 and
3 are on is designated by the letter S and plays an important role in the
positioning of Bezier points 1 and 3. Point 2 can be moved freely and
therefore he has the major influence on the shape of the cross-section. In
the first design, point 2 is identical with point S.
The basic shape of the cross-section can be selected in the upper right-
hand corner of the dialog box, rectangular or trapezoid. Only the end
cross-section of the volute is designed, all other cross-sections result
from this. Under the heading Inner point position, you can select
whether positioning of the inner points 1 and 3 should be relative
(0=point 0 and 4; 1=point S) or absolute (distance from point S). The
numeric values of the positions can be changed by right-clicking on
 59

points 1 or 3. If the option Show all points under the heading Options is
selected, the different positioning methods become apparent.
The minimum curvature radius of the designed contour is shown in the
box to the bottom right.

End cross-section
Some informative values relating to theend cr oss-section are shown in
the lower part of the left-hand area:

Radius r5
Height H5
Width B5
Side ratio H5/B5
Equivalent diameter D5
Area A5
Average velocity c5

In addition, the volute cross-sections can be viewed Show ( cross

sections) and the area distribution displayed S
( how area distribution).
60

Diffusor
The options for the diffusor geometry are found to the right. In general, 2
basic shapes are differentiated:
Tangential diffusor Radial diffusor

The tangential diffusor is easier to manufacture, the radial diffusor has

the advantage of minimising tangential forces.
The tangential diffusor has the added advantage that the angle deviation
from the tangential direction,g, (standard: 0°) can be defined. In the case
of a radial diffusor, either the anglee between the outlet branch and the
line connecting impeller-centre and outlet branch centre, or the radius RN
of the diffusor curvature can be selected.
The end cross-section of the diffusor can be either round or rectangular.
The diameter D6 can be directly defined or selected from standard tables
(see page 27). In the case of a rectangular end cross-section the height
H6 and width B6 can be chosen.
The length, L, of the diffusor can also be defined. The following values
are shown for information purposes:

Equivalent diameter D6 Diameter of the equivalent circle at the

diffusor outlet

Cone angle J cone angle from D5 to D6 over the length L

Allowable cone angle Jmax = 16 .5° (D5 2) L

Deceleration ratio AR = D52 D6 2

By clicking on Default, you can return to the standard values for the
diffusor geometry.
 61

Display options
Under Display options, changes can be made which affect only the
graphics:

Cross section visualization Number of angle lines shown

Show – refers to the image of volute + diffusor
Section lines radial angle lines
Cut-water compensation cut-water compensation as a larger inner
radius
Cut-water srcinal srcinal cut-water geometry where
jC,0<>0
Show in cross section – refers to the image of the cross-section
Cut-water section cut-water cross-section
Equivalent diameter equivalent diameter D6 (dashed line)
Outlet branch outlet branch as an area
Filled cross-sections filled cross-sections
62

REFERENCES
Werner Fister
Fluidenergiemaschinen Bd. 1 und 2, Springer-Verlag, 1984 und 1986

Gotthard Will
Kreiselpumpen, in: Taschenbuch Maschinenbau, Band 5,
Edited by Hans-Joachim Kleinert, Verlag Technik Berlin, 1989

Joachim Raabe
Hydraulische Maschinen und Anlagen, VDI-Verlag, 1989

Kurt Holzenberger, Klaus Jung

Kreiselpumpen Lexikon, KSB AG, 1989

Carl Pfleiderer, Hartwig Petermann

Strömungsmaschinen, Springer-Verlag, 1991

Walter Wagner
Kreiselpumpen und Kreiselpumpenanlagen, Vogel-Verlag, 1994

Johann F. Gülich
Kreiselpumpen, Springer-Verlag, 1999

John Tuzson
Centrifugal pump design, John Wiley & Sons, 2000
 63

CONTACT ADDRESSES

Development, Sales, Support

CFDnetwork Engineering
www.cfdnetwork.com
Bismarckstr. 2
80803 München, Germany
Phone: (+49) 89 30 76 10 69
Fax: (+49) 89 30 76 10 72
Moritzburger Weg 67
01109 Dresden, Germany
Phone: (+49) 351 803 97 13
Fax: (+49) 351 801 29 55
Solitudestr. 197
70499 Stuttgart, Germany
Phone: (+49) 711 887 31 33
Fax: (+49) 711 887 31 34

Sales Partner

ANSYS CFX (Worldwide)

North America www-waterloo.ansys.com/cfx/local/na
Great Britain www-waterloo.ansys.com/cfx/local/uk
France www-waterloo.ansys.com/cfx/local/france
Germany www.cfx-germany.com
Italy www.enginsoft.it
Japan www.cfx-ap.com
China www.atechina.com
www.ansys.com.cn

Impact Technologies, LLC, Rochester, (for USA) www.impact-tek.com

PUNTO Engineering Ltd., Ankara, (for Turkey) www.punto.com.tr