Training Case 3 Centrifugal Pump 61

FINETM/Turbo 6.
1-1 - Turbomachines
Training Session
Centrifugal Pump - Practice
Relative Velocity Field
Centrifugal Pump Mesh
Vincent Bouffioux
NUMECA International
Quality
& Engineering
Group
Slide
1
phone: +32-2-627.13.45
e-mail:vincent.bouffioux@numeca.be
NUMECA, a New Wave in Fluid Dynamics
Content
Centrifugal Pump
AutogridTM Software.03
Practice
FINETM Software..24
Practice
CFViewTM Software.48
Practice
Slide 2
AutogridTM
Practice
Centrifugal Pump
Meridional
View
Total
Mesh
Slide 3
Practice
Mesh Generation
Step 1 : Open IGG/Autogrid
Step 2 : Define Blade Geometry
Hub & Schroud Definition
Suction & Pressure Sides definition
Step 3 : Define Blade Topology

H, I or HOH mesh
Blunt
Splitter
Bulb
Propeller
Step 4: Meridional Control ---> Flow Paths

Nbre of points
Tip & Hub Clearance
Step 5 : Mesh Blade-to-blade on Hub & Shroud

Generation of 2D mesh
Step 6 : Volumic Mesh

Generation of the volumic mesh
Checking the negative cells
Checking the grid quality (orthogonality, aspect ratio, grid continuity)
Boundary Conditions Type
No
Step 7 : Save Template & Grid
OK?
Slide 4
Yes
Practice
Step1: Open AutogridTM

1.
Open IGG Session

1
2.
Open Autogrid Window
Slide 5
Practice
Step 2 : Define Blade Geometry
7 blades - 259,161 nodes

Geometry given in meters
Hub and shroud surface expansion = 0.03

Topology
H/I-mesh
Spanwise grid points : 41
Azimuthal grid points : 45
Streamwise grid points : 33 - 65 - 33
Cell width along walls = 1 10-5
Slide 6
Practice
1.
If necessary: in order to see the

Quick Access Pad, select in
File/Preferences/Layout the
Quick Access Pad & Apply
1b
1a
1c
2.
Select Set-Up in the Icon Bar

2
Slide 7
1d
Practice
3a
3b
3c
3.
Slide 8
Activate Select Geometry File in the Set-Up Window
Practice
1.
Activate Surface Edition - Modify Expansion to 0.03
2.
Activate Geometry Characteristics - Modify Nbre of Blades to 7
Slide 9
Practice
Step 3 : Define Blade Topology

1.
Activate Topology in the Set-Up Window
Nbre of points
Clustering
3.
Select H&I Topology

Modify Nbre of pts & clustering - <enter>
4.
Next ---> Flow Paths Created
2.
45
SpalartSpalart-Allmaras
4
shroud
spanwise
streamsurface
blade
hub
Slide 10
streamwise
azimuthal
Practice
Step 4 : Meridional Control

1.
Deactivate Expert Mode
2.
No Tip Clearance
3.
Apply
4.
Next
1
2
4
3
Slide 11
Practice
Flow Paths
2D Mesh
Slide 12
Practice
Step5 : Mesh Blade-to-Blade on Hub & Shroud

1.
Activate Points Distribution

Modify Nbre of points
2.
3.
Apply
Activate Mesh
4.
1
3
Put the Smoothing Step to 20

Activate the Multiblock Smoother
Orthogonality blade-to-blade to 0.0125%
Initial Cell width blade-to-blade to 1e-5
Cst Cells blade-to-blade to 10
B
2-4
Apply
1
Left-click on Projection Point
Left-click value - <enter>
Move Interactively
If necessary
A. Right-Click on the edges to change local Cell
Length or Clustering Expansion Ratio
A
B.
Activate Expert (if necessary)

Adapt Streamwise Clustering
Adapt Streamwise Matching Points (I mesh)
Slide 13
Practice
Blade-to-Blade Shape Control (Optional)

Extension Control
Impose in degree angular (theta)
position of Inlet & Outlet in
Relative or Absolute on both Hub
& Shroud views
2.
Activate Solid Angles
Impose in degree trailing & leading
edge angle in Relative on both Hub
& Shroud views
3.
Update Blade-to-Blade Mesh
Apply & Accept the modifications
1.
If necessary
A.
Activate Expert
Slide 14
Blunt Control
Extension Surface Parameters
Tangent Weight at Leading/Trailing
edge
Practice
Step 6 : Volumic Mesh

1.
3D Mesh Generation
2.
Yes
2
3.
Check Grid Quality & Negative Cells

3
4.
Slide 15
Close the window
Practice
Quality Control Tool

1.
2.
Select 3D View
Deactivate Mesh
2a
3a
3.
2b
To access the Grid Quality analysis tool,

select the "Grid/Grid Quality" menu.
To analyse the ORTHOGONALITY
Select all blocks - <0>

Select the "orthogonality" type in
the "mesh Quality" dialogue box
Click on the "Show chart"/"Hide
chart" to toggle a chart display
Display the range of cells by
clicking directly on the Chart Bar
Orthogonality > 10
3b
3c
3d
3e
3f
3g
Solution
Check Clustering
3h
Check Smoothing
OR
Use I-mesh
Use HOH-mesh
Slide 16
Practice
Slide 17
Practice
To analyse the ASPECT RATIO
(i_direction/j_direction)
Select all blocks - <0>

Select the " Aspect Ratio " type in the "mesh
Quality" dialogue box
Click on the "Show chart"/"Hide chart" to toggle a
chart display
Display the range of cells by clicking directly on
the Chart Bar
Select More Info to see maximum value in the
concerned block.
Aspect ratio < 5000
To analyse the EXPANSION RATIO
select the Expansion Ratio" type in

the "mesh Quality" dialogue box
Click on the "Show chart"/"Hide
chart" to toggle a chart display
Display the range of cells by clicking
directly on the Chart Bar
Select More Info to see maximum
value in the concerned block.
Expansion ratio 3
Slide 18
Practice
Mesh Quality Improvements Mesh Quality at Boundaries
1
2
Mesh Quality Defined at Boundaries

ORTHOGONALITY
ANGULAR DEVIATION (CON - PER)
EXPANSION RATIO (CON - PER)
CELL WIDTH
Slide 19
Practice
Mesh Quality Improvements Negative Cells
2
1
3
Mesh Quality Negarive Cells
Slide 20
Practice
Boundary Conditions Check - Optional

To check or set boundary condition type and
visualize connected patches proceed as follow :
1. Select the "Grid/Boundary Conditions"
menu
2. To set boundary condition type :
Select in the list the patch to visualize

Use "Set Patch Type" to impose the
type of boundary condition
Press Search to detect NMB,
PERNMB, Periodic (PER) & Matching
(CON) Connections
3. To visualize the patches :
2b
3
2c
Select in the list the patch

Press Crtl + Left-Click to cumulatively
visualize other patches
BC Conditions
Inlet
H&I
Topology
BC Conditions Periodic NMB
Slide 21
BC Conditions - Solid
Practice
Step 7 : Save Template & Grid
Slide 22
Save Template as
Save Grid as
Quit Autogrid yes
Interface
Autogrid Files
.bcs
Information generated by IGG for the solver: type of BC
.cgns
Coordinates of all the nodes of the mesh
.geom
Definition of geometry points, curves and surfaces
.igg
Topology and grid information
(Nbr of blocks, nbr of grid points, clustering, BC,)
.meridional
Flow Paths Coordinates used by CFView
.geomTurbo
Geometrical entities used to defined the mesh,
created during Autogrid Session
.trb
Template: Nbre of blades, Topology, Grid Points, Clustering.
Slide 23
FINETM
Practice
Centrifugal Pump
Mass Flow
Slide 24
Global Residual
Interface
Flow Settings
Step 1 : To start FINE Session
To open an Existing project or to create New project
Step 2 : To link/create Mesh .igg
Step 3 : To create/rename Computations
Step4: To impose Flow Settings
No
Step5: To start computation
Step6: To suspend computation
Step7: To restart computation until convergence
Convergence ?
Yes
Step8: Post-Processing: CFViewTM
Slide 25
Practice
Step 1: Start FINE Session

Import Existing Project .iec
1.
Start FINE Session

1
2.
Load Project - File/Open (if necessary)

1.
2.
Select Existing project

Open Existing project
3.1
2.1
3.2
2.2
OR
3.
New Project - File/New (if necessary)

1.
2.
Slide 26
Create New Project

Set a Name to the Project
Practice
Step2: Link/Create Mesh

1.
If New Project
1. Open (Create) Grid File
2. Select Grid File .igg - Open
3. Select Grid Type & Units: Cylindrical/3D/Meter - OK
1.3
1.1
2.
1.2
If Existing Project
1. Mesh Properties (Units,) accessible in Menu Mesh/Properties - Close
2. Mesh Path accessible in Icon Bar
2.1
2.2
Slide 27
Practice
Step3: Create/Rename Computation

1.
If Rename Computation
1. Select Computation (highlighted in blue)
2. Right-click Rename OR Rename in Computation Menu
3. Type New Name - <enter>
1.1
2.
1.3
1.2
If New/Duplicate Computation
2. Right-click New/Duplicate OR New in Computation Menu
2.1
2.2
3.
If Remove Computation
2. Right-click Remove OR Remove in Computation Menu
3. OK
3.1
3.2
Slide 28
3.3
Practice
Step4: Define/Check Flow Settings

Steady flow in a Centrifugal Pump
3D
Internal Flow
Cylindrical Coordinates
Fluid
Liquid : Tref = 293 K and Pref = 100 000 Pa
Cp = 4200 J/(kg.K), Pr = 7.02, = 1.141001 10-6 m2/s (Sutherland Law),
density = 1000 kg/m3, compressibility = 1e-11 1/Pa, dilatation = 6.4e-5 1/K
(Boussinecq Law)
Boundary conditions
Inlet :
Axial Flow Magnitude = 1.842 m/s - Static Temperature = 293 K

Turbulent Viscosity = 0.001 m2/s
Outlet : Static Pressure = 320,000 Pa

Walls : Adiabatic with pressure extrapolated from the flow field. The blade walls
and part of shroud/hub are rotating.
Numerical Model
Multigrid : 3 grid levels (250 FMG cycle, coarse grid convergence criteria -3)
Multigrid sub-iterations : 1 3 6
CFL number = 3
Turbomachinery initial solution

Inlet static pressure = 150,000 Pa , Turbulent Viscosity = 0.0003 m2/s
Slide 29
Practice
Configuration - Fluid Model
1.
Select Configuration/Fluid Model

1. Select Existing Fluid
OR
2. Create New Fluid by Add Fluid to List
1.1
Slide 30
1.2
Practice
Configuration - Flow Model
2.
Select Configuration/Flow Model

1. Select Steady Time Configuration
2. Select Spalart-Allmaras Turbulent Model
3. Define Reference Scales
Length = 1.0 m
Velocity = 10.0 m/s
Density = 1000.0 kg/m3
Temperature = 293 K
Pressure = 100,000 Pa
2.1
2.2
2.3
Slide 31
Practice
Configuration Rotating Machinery
3.
Select Configuration/Rotating Machinery
1. Select Blocks & Groups

2. Define Rotational Speed: = 1,200 rpm
3.1
3.2
Slide 32
Practice
Boundary Conditions
4
4.
Select Boundary Conditions

1. Select Inlet
1. Open Mesh by Mesh/View On/Off
2. Move Cursor
3. Impose Inlet Boundary Conditions
4.1.1
Axial Flow Magnitude = 1.842 m/s

Static Temperature = 293 K
Turbulent Viscosity = 0.001 m2/s
4.1
4.1.2
INLET
4.1.3
Slide 33
Practice
2.
Select Outlet: Impose Static Pressure = 320,000 Pa

4.2
3.
Right-click
OUTLET
Check Periodic Connections Nothing has to be changed
4.3
PERIODIC
Right-click
Slide 34
Practice
4.
Select Solid: Impose Adiabatic Solid Boundary Conditions: part of shroud/hub &
blade rotating
4.4
Right-click
SOLID Hub
Right-click
SOLID Blade
Slide 35
Practice
4.4
Right-click
SOLID - Shroud
Slide 36
Practice
Numerical Model
5.
Select Numerical Model
1. Select Spatial Scheme: Central

2. Select CFL Number: 3
3. Define Multigrid Parameters
4.
Number of Grid Level

Current Grid Level
Define Preconditioning Parameters

5.1
5.2
5.3
Slide 37
5.4
Practice
Initial Solution
6.
Select Initial Solution

1. Select Blocks & Groups
2. Select for turbomachinery
3. Define Initial Static Pressure: 150,000 Pa
6.1
6.2
6.3
Slide 38
Practice
Outputs
Define group of variables (temperature, pressure,
density, turbulent viscosity, wall distance, Y+,)
that will be visualized in CFView
7.1
Slide 39
Practice
Computation Steering Control Variables
8.
Select Computation Steering/Control Variables

1.
2.
3.
4.
5.
Number of iterations MultiGrid

MultiGrid Convergence Criteria
Save Solution
Memory Requirements
Expert Parameters
8
8.1
8.3
8.2
8.4
8.5
Slide 40
Practice
Computation Steering Convergence History
Slide 41
Practice
Step 5: Start Computation

1.
Select Solver/Start in the Menu Bar in order to start the

computation
2.
Start Euranus Solver

1
3.
Select Convergence History in the Computation Steering
4.
Select Monitor (Additionnal Tool) to check for each block:
Global Residual per block per equation

BUT also:
Mass Flow Inlet/Outlet
Slide 42
Practice
Step 6 & 7: Suspend/Restart Computation

1.
Select Solver/Suspend in the Menu Bar in order to suspend the

computation and to check the solution in CFView before starting a longer
calculation
1
2.
Create a new computation and select it

2.1
2.2
3.
Change the Initial Solution type to from file - Open the run file of the
computation suspended before.
3.1
4.
Deactivate the FMG option - Start the flow solver

4
Slide 43
3.2
Convergence History
Convergence Criteria
Global Residual
Image of the evolution of the calculation on the whole domain starting from the
initial solution (global residual reference set at 1). To decrease the level of the
Global Residual to 3 order of magnitude and to reach a level of Global Residual
is also recommended.
Block Residual
Image of the evolution of the calculation on each block for each equation starting
from the initial solution (residual reference set at 1). To decrease the level of the
Residual to 3 order of magnitude and to reach a level of the Residual in each
block is also recommended. Nevertheless, some differences may appear
between blocks due to their respective mesh quality.
Mass Flow
The most important criteria to respect. Due to the discretization, 0.5% of error
may be accepted between mass flows. Furthermore, both mass flow profiles
have to present at convergence no more oscillating aspects.
Local Value
FINE provides the capability to check pressure, velocity, evolutions locally in
the flow field iteration per iteration. Convergence is reached when the evolution is
stabilised. If some oscillations are still present in the evolution, the amplitude is
defining the quantity precision or natural unsteady aspects.
Global Value
FINE provides the capability to check global quantity evolutions in the whole flow
field iteration per iteration. Convergence is reached when the evolution is
stabilised. If some oscillations are still present in the evolution, the amplitude is
defining the quantity precision or natural unsteady aspects.
.
Slide 44
Convergence History
Level has been

reached in all the
evolutions
No Level has been

reached in all the
evolutions
Parameters
1. Check Mesh Quality
Clustering (Nbre of cells) Orthogonality Aspect Ratio Expasion Ratio
2. Check Boundary Conditions Initial Condition

(Pini Poutlet natural flow)
3. Check Numerical Parameters

CFL - Multigrid Parameter Preconditioning Parameter Turbulent Parameter
.
Slide 45
Practice
Step 8: Post-Processing: CFViewTM

1.
Convergence of Computation in Monitor
2.
Open CFViewTM Tool on Menu Bar/Modules to

visualize converged solution
2.1
Slide 46
2.2
Interface
FINE-Euranus Files
Quantity Files
.cgns
Solution, used for restarting solution, CFView results
.mf
Averaged Quantities at inlet & outlet
.res
Numerical Control Files
Residual values for each iteration of a computation
.log
All information about the current computation: error, warning,...
.steering
All information about Convergence History Data in Task Manager
.std
All information about the current computation: start, kill, iteration,
.wall
Forces and Torques on solid patch if requested by the user
.run
All settings of the active computation
Slide 47
CFViewTM
Practice
Centrifugal Pump
Hub/Blade
Relative Velocity
Slide 48
Interface
CFView Visualization
Step 1 : Open File .run
Step 2 : Select Area of Interest: surface, plane,...
Step 3 : Define New Quantity or Select Quantity
Step 4 : Select Representation
Step 5 : Adapt Representation
Step 6 : Save Output
Slide 49
Practice
Step1: Import File .run

1.
Load Project from FINE Interface

1. Select the CFView item in the Menu Bar/Modules or in Icon Bar that
automatically open the .run associated to the active computation
1.1
1.2
2.
Load Project from CFView

1. Open .run associated to the computation of interest.
2.1
2.2
Slide 50
Practice
Step2: Select/Create Area of Interest

1.
Select Area
1. Select the Geometry/Select Surfaces item in the
Menu Bar
2. Select the area of interest & Apply
1.2
1.1
1.3
2.
Create Area before Select Area (if Area not existing)

1. Select theGeometry/Create... item in the Menu
Bar
2. Create thanks to Cutting Plane or I,J,K Surface
3. Plane or Surface is highlighted
4. Save - Apply - Close
2.3
2.1
Right-click
1.1
2.1
2.4
Quick Access Pad/Surfaces

Select Surfaces
1.2
Slide 51
Show Wireframe
Create IJK Surface/Cutting Plane
Practice
Step3: Select/Define Quantity

1.
Select Quantity
1. Select the Quantity/ Field Data/... item in the Menu Bar
2. Select the quantity of interest
3. Quantity Selected & its Range appear in the Selection Area
1.1
2.
1.3
1.2
Create Quantity
1. Select the Quantity/ Field Data/Define New Quantity item in the

Menu Bar
2.2.1
2. Create New Quantity
3. Apply
2.1
2.2.2
2.3
2.2.3
Quick Access Pad/Quantities

Select Quantity (dubble-click)
Slide 52
Create New Quantity
Practice
Step4: Select Representation

1.
Select Representation: Representation item in the Menu Bar

1
2.
Scalar Representation
1.
2.
3.
4.
5.
6.
Local value
2.1
Isolines
Contour
Cartesian Plot
2.2
Integral
IsoSurface
2.4
2.2
2.6
2.1
2.4
2.3
2.5
2.6
2.5
3.
Quick Access Pad/Representation
1.
2.
3.
4.
Streamlines
3.3
Vector field
Local Vector
Integral
3.1
3.1
3.2
Vector Representation
3.2
3.3
3.4
3.4
Quick Access Pad/Representation
Slide 53
Practice
Step5: Adapt Representation

1.
Scalar Adapt Representation

1. Scalar Range
2. Icon Bar
3. Quick Access Pad
1.1
Quick Access
Pad/Representation
1.3
1.2
2.
Vector Adapt Representation

1. Vector Range/Vector Type
2. Icon Bar
3. Quick Access Pad
2.1
2.3
2.3
2.1
Quick Access
Pad/Representation
2.2
Slide 54
Practice
3.
Refresh Graphics Area - Update

1. Undo
2.
3.
4.
5.
Select the Area of Interest (step2)

Select the Quantity of Interest (step3)
Delete
Select Representation to delete
Right-click
3.2
3.1
3.4
3.5
3.3
Slide 55
Practice
Step6: Save Output

Save Image: Open File/Print Select format Select name
1.3
1.2
1.1
Save Macro File: Start File/Macro/Record
1.4
2.1
2.2
2.3
Save Template File

Scalar
Quantity
3.2
Scalar Quantity
Cartesian Plot
3.1
Save Cartesian Plot/Iso Surface

4.2
Slide 56
4.1
Practice
Task1: Check Y+
Mesh well-adapted to the Turbulent Model ?
SpalartSpalart-Allmaras
1.
2.
Open .run
Check Y+ close the Solid Wall
1.
Create Surfaces close to the Solid Wall

HOH Mesh: I=2, J=2, J=Jmax-1
H/I Mesh: I=2, I=Imax-1, J=2, J=Jmax-1
2.
3.
4.
5.
6.
2.3
2.4
Select Created Surfaces

Select Quantity Y+
Select Color Contour Representation
Adapt Representation Range on Selected Surfaces
Check range of Y+
1< Y+ <10 for Baldwin-Lomax OR Spalart-Allmaras OR k-epsilon Y-S
1< Y+ <50 for Standard k-epsilon
2.5
Full Range
2.5
0 < Y+ < 10
Slide 57
Practice
Task2: Visualize Wheel
9.
UpDate if Necessary Delete/All & <b>

Select All Geometry
Desactivate Boundaries (b)
Select Hub, Pressure, Suction (Apply)
Activate Boundaries (b) &/or Mesh (g)
Set Material on Selected Surfaces: Render/Shading
Adapt Material
Set Nbre of Repetition: 7 blades
Set Repetition <R>
10.
Save output File/Print to save an image
1.
2.
3.
4.
5.
6.
7.
8.
8&9
Slide 58
Practice
Task 3: Relative Velocity at Mid-Span

1.
2.
Deactivate Repetition <R>

Select Turbomachine Module
1. Define Hub/Shroud Patches
2. Define Meridional Patches
3.
4.
5.
6.
7.
8.
9.
Create Turbomachines Views

Create Mid-Spanwise Surface in B2B View
Select Created Surface in 3D View
Select Static Pressure Quantity
2.2
Select Color Contour
Adapt Representation
2.3
Activate Repetition <R>
2.1
2.2
2.2.1
2.3
2.3.1
2.3.2
2.2.2
2.3.3
Slide 59
Practice
Meridional Average
3D View
5
Blade-to-Blade View
Meridional
View
4.1
4.2
4.3
9
6
7
8
Slide 60

Training Case 3 Centrifugal Pump 61

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FINETM/Turbo 6.

Relative Velocity Field

Centrifugal Pump Mesh

NUMECA, a New Wave in Fluid Dynamics

NUMECA, a New Wave in Fluid Dynamics

NUMECA, a New Wave in Fluid Dynamics

Step 3 : Define Blade Topology

Step 4: Meridional Control ---> Flow Paths

Step 5 : Mesh Blade-to-blade on Hub & Shroud

Step 6 : Volumic Mesh

Step 7 : Save Template & Grid

NUMECA, a New Wave in Fluid Dynamics

Step1: Open AutogridTM

Open IGG Session

Open Autogrid Window

NUMECA, a New Wave in Fluid Dynamics

Step 2 : Define Blade Geometry

7 blades - 259,161 nodes

Hub and shroud surface expansion = 0.03

NUMECA, a New Wave in Fluid Dynamics

If necessary: in order to see the

Select Set-Up in the Icon Bar

NUMECA, a New Wave in Fluid Dynamics

Activate Select Geometry File in the Set-Up Window

NUMECA, a New Wave in Fluid Dynamics

Activate Surface Edition - Modify Expansion to 0.03

Activate Geometry Characteristics - Modify Nbre of Blades to 7

NUMECA, a New Wave in Fluid Dynamics

Step 3 : Define Blade Topology

Activate Topology in the Set-Up Window

Select H&I Topology

Next ---> Flow Paths Created

NUMECA, a New Wave in Fluid Dynamics

Step 4 : Meridional Control

Deactivate Expert Mode

NUMECA, a New Wave in Fluid Dynamics

NUMECA, a New Wave in Fluid Dynamics

Step5 : Mesh Blade-to-Blade on Hub & Shroud

Activate Points Distribution

Put the Smoothing Step to 20

Left-click value - <enter>

Activate Expert (if necessary)

NUMECA, a New Wave in Fluid Dynamics

Blade-to-Blade Shape Control (Optional)

NUMECA, a New Wave in Fluid Dynamics

Step 6 : Volumic Mesh

Check Grid Quality & Negative Cells

Close the window

NUMECA, a New Wave in Fluid Dynamics

Quality Control Tool

To access the Grid Quality analysis tool,

Select all blocks - <0>

NUMECA, a New Wave in Fluid Dynamics

NUMECA, a New Wave in Fluid Dynamics

Select all blocks - <0>

Aspect ratio < 5000

To analyse the EXPANSION RATIO

select the Expansion Ratio" type in

NUMECA, a New Wave in Fluid Dynamics

Mesh Quality Defined at Boundaries

NUMECA, a New Wave in Fluid Dynamics

Mesh Quality Negarive Cells

NUMECA, a New Wave in Fluid Dynamics

Boundary Conditions Check - Optional