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Article history:
Received 9 July 2011
Received in revised form 21 March 2012
Accepted 7 July 2012
Available online 20 July 2012
Keywords:
Pump as turbine
Impeller trimming
PAT test rig
Experimental research
Numerical research
a b s t r a c t
Pump manufactures normally do not provide performance curves of their pumps working as turbines,
especially performance curves of trimmed impellers. Impeller trimming is necessary to adapt to a certain
operating condition. Therefore, establishing the correlation of PATs performance curve and impeller
trims is essential. In this paper, a laboratory model of a pump as turbine (PAT) open test rig was set
up. Experimental research was carried out on a single stage centrifugal PAT, performance curves of original impeller, impeller after once and twice trims were acquired. Numerical simulation and analysis
were performed on the PAT. The accuracy of CFD was validated through comparison between numerical
and experimental data. As impeller diameter is cut down, its geometrical parameters of impeller diameter, blade wrap angle, impeller inlet width and blade inlet angle are changed. So, research on effects
of the above four parameters to the performance inuence of PAT were carried out using CFD. Through
analysis of the predicted performance curves, the reasons for the variation of performance curves after
impeller trimming were explored.
2012 Elsevier Ltd. All rights reserved.
1. Introduction
Conserving energy while exploring renewable, environmentally-friendly energy resources is of crucial importance to keeping
up with increasing energy demands. Small hydropower with its
characteristics of available worldwide became attractive to energy
utilization after the oil crisis of the seventies.
Pumps are relatively simple machines, easy to manufacture and
maintain and readily available all over the world. Experiments
have shown that in relatively low power outputs, pumps with high
technological standards in reverse operation can compete with
conventional turbines in respect to maximum efciency [1]. Thus,
PAT is one of the cheap and attractive alternatives in high pressure
uid and small hydropower resources exploration. Research on
PAT was started around 1930 [2]. With increasing energy demands,
it will be more economical to exploit such energy resources in
future.
Pump manufacturers normally do not provide characteristic
curves of their pumps working as turbines. This makes it difcult
to select an appropriate pump to run as a turbine for a specic operating condition. So many research works have been focused on predicting PATs performance based on its pump mode performance
[38] or pump geometric parameters [9]. But the PAT behavior is
very complex and it is difcult to nd just a relation to cover all
pumps behavior in reverse mode [10]. Most recent attempts to pre Corresponding author. Address: Zhenjiang, Xue-fu Road No. 301, Jiangsu
Province, China. Tel./fax: +86 511 88780286.
E-mail address: yangsunsheng@126.com (S.-S. Yang).
0045-7930/$ - see front matter 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.compuid.2012.07.009
dict PAT performance have been made using CFD. However, relatively large deviations from experimental data have been reported
[1013]. Few research works have been focused on the optimization
of PAT [1417]. Yet, no paper has been focused on impeller trimming to the inuence of PAT. Sometimes when the system pressure
head or ow rate drops, trimming impeller is a convenient way to be
adopted. Therefore, it is necessary to focus on effects of impeller
trimming to the inuence of PATs performance.
2. Experimental setup
A laboratory model of a PAT open test rig, as shown in Fig. 1a
was set up at Jiangsu University. High pressure uid required
was supplied by a feed pump. An energy dissipation pump was installed to consume energy generated by PAT and regulate PATs
rotational speed. To measure PATs torque and rotational speed, a
torque meter was put between PAT and energy dissipation pump.
The discharge was measured by a turbine ow meter. Its inlet and
outlet pressure were measured by pressure gauges. After measuring all parameters, PATs head, output power, efciency and performance curve were obtained. The uncertainty of measured pressure
head (H), ow rate (Q), hydraulic power (Ph), generated shaft
power (Pshaft) and efciency (g) were 0.57%, 0.50%, 0.76%,
1.02% and 1.27% respectively.
Fig. 1b shows the open pump test rig established at Jiangsu University. The uncertainty of measured required pressure head (H),
ow rate (Q), hydraulic power (Ph), generated shaft power (Pshaft)
and efciency (g) were 0.14%, 0.50%, 0.52%, 1.08% and
1.20% respectively.
73
Nomenclature
b2
D1
D2
D3
D4
Dh
e
H
n
ns
P
Q
L
z
Greek symbols
/
blade wrap angle ()
b
blade angle ()
g
efciency
Subscriptions
1
variable at low pressure end
2
variable at high pressure end
H
hydraulic
b
balancing hole
a
Valve
Valve
Pressure gaugue
Motor
Feed pump
PAT
Consume Pump
Torque meter
valve
Pressure gaugue
pump
motor
Fig. 1. (a) An open PAT test rig and (b) an open pump test rig.
4. Numerical investigation
CFD code ANSYS-CFX which utilizes a nite-element based nite-volume method to discrete the transport equations was used
for numerical research. The uid was split into ve component
parts; they were PATs volute, impeller, front and back chambers
and outlet pipe. This separation allowed each mesh to be generated
individually and tailored to the ow requirements in that particular component. To get a relatively stable inlet and outlet ow, four
74
Table 1
Main geometric parameters of the designed PAT.
u ()
b2 ()
b2 (mm)
u ()
b2 ()
b2 (mm)
u ()
b2 ()
b2 (mm)
D2 = 235
D2 = 215
102
6
4
39
15
266
65
30
6
75
97.52
24.27
14.38
88.06
28.22
15.30
79.16
31.28
16.98
62.5
62.0
61.5
(%)
D1 (mm)
z
e (mm)
b1
L (mm)
D3 (mm)
D4 (mm)
Dh (mm)
zb
Db (mm)
D2 = 255
63.0
61.0
60.5
60.0
59.5
59.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
times of the pipe diameter had been extended in the PAT inlet and
outlet section.
4.1. Mesh generation
ICEM-CFD was used to generate structured hexahedral grid for
each component part [18]. A grid independent test of the PAT with
impeller diameter of 235 mm showed that when mesh numbers
were around 1 million, the variation of efciency was within
0.5% as indicated in Fig. 3. The nal mesh number of volute, impeller, front chamber, back chamber, outlet pipe and total number
were 479710, 378222, 134956, 129700, 174720, and 1297308
75
Items
PAT
255
235
215
255
235
215
Pump
Q (m3/h)
H (m)
Pshaft (kW)
g (%)
ns
95.23
86.14
93.63
52.12
51.71
49.80
39.17
32.40
37.52
18.07
17.17
13.75
6.15
4.56
5.63
4.19
3.83
3.13
62.95
59.98
58.84
61.15
63.08
59.55
15.58
17.09
15.96
20.59
21.31
24.71
Exp P
CFD P
Exp H
CFD H
Exp
CFD
64
14
52
13
60
48
12
56
44
52
40
11
48
36
44
32
40
28
36
24
32
20
10
Pshaft (kW)
H (m)
(%)
9
8
7
6
5
4
65
70
75
80
85
90
95
100
105
110
115
120
3
2
1
125
Q (m3/h)
PAT 215
PAT 235
PAT 255
66
64
PAT 215 P
PAT 235 P
PAT 255 P
PAT 215 H
PAT 235 H
PAT 255 H
12
56
52
62
10
48
60
Table 3
Experimental and numerical efciency.
44
56
54
36
52
32
50
28
48
24
Pshaft (kW)
40
H (m)
(%)
58
Q/QBEP(%)
0.81
0.90
1.00
1.14
1.27
Exp
CFD
Error
52.25
56.14
7.44
56.31
60.67
7.74
59.98
63.03
5.09
58.80
62.18
5.74
56.70
60.13
6.05
46
20
70
75
80
85
90
95
100
105
110
115
2
120
Q (m3/h)
PUMP215
PUMP235
PUMP255
70
PUMP215H
PUMP235H
PUMP255H
PUMP215P
PUMP235P
PUMP255P
0.81
0.90
1.00
1.14
1.27
Exp (m)
CFD (m)
Error (%)
24.79
25.42
2.54
27.96
29.16
4.29
32.40
33.71
4.04
38.85
40.43
4.07
47.27
49.24
4.17
Table 5
Experimental and numerical shaft power.
20
H (m)
40
16
14
Pshaft (kW)
18
50
(%)
Q/QBEP
24
22
60
Table 4
Experimental and numerical head.
Q/QBEP
0.81
0.90
1.00
1.14
1.27
Exp (kW)
CFD (kW)
Error (%)
2.47
2.72
10.12
3.33
3.74
12.31
4.56
4.98
9.21
6.20
6.70
8.06
8.29
8.87
7.00
3
12
30
10
2
20
8
10
20
30
40
50
60
70
80
90
100
Q (m3/h)
Fig. 5. (a) Performance curves of impellers in turbine mode and (b) performance
curves of impellers in pump mode.
age ow through the balancing holes and mechanical seals is neglected, so the simulated efciency includes volumetric loss
through the wear ring and mechanical loss caused by disc friction.
As illustrated in Fig. 6, numerical predicted performance curves
well reect the tendency of PATs experimental results. Numerical
predicted efciency, pressure head and shaft power are higher than
those of experimental results. The maximal relative error of predicted g, H and Pshaft to experimental data are 7.44%, 4.29% and
76
Table 6
BEPs of impellers with three diameters.
D2 (mm)
Q (m3/h)
H (m)
Pshaft (kW)
g (%)
255
235
215
80.0
72.5
60.0
31.82
27.46
21.48
4.72
3.67
2.32
68.15
67.73
65.98
7. Impeller diameter
90 H
110 H
130 H
150 H
90
110
130
150
70
69
68
90 P
110 P
130 P
150 P
48
H (m)
64
32
63
28
4
62
24
61
20
55
70
18
75
70
16
65
65
H (m)
55
50
45
50
45
40
40
30
30
25
25
20
20
15
70
80
90
100
110
120
90
95
100 105
110 115
H (m)
Pshaft (kW)
g (%)
150
130
110
90
70.00
72.50
75.00
80.00
26.89
27.46
28.29
30.64
3.45
3.67
3.90
4.49
67.42
67.73
67.51
67.29
11
13
15
17
64
11 P
13 P
15 P
17 P
11 H
13 H
15 H
17 H
12
52
48
62
44
H (m)
61
60
59
40
10
Pshaft (kW)
63
36
130
Q (m3/h)
Fig. 7. Performance curves of impellers with three diameters.
12
10
58
32
56
35
35
85
57
Pshaft (kW)
55
80
14
60
60
75
Q (m3/h)
(%)
215 CFD P
235 CFD P
255 CFD P
70
u ()
66
215 CFD H
235 CFD H
255 CFD H
65
Table 7
BEPs of impellers with different blade wrap angles.
In the research of impeller inlet width to the performance inuence of PAT, impellers with inlet widths of 11 mm, 13 mm, 15 mm
and 17 mm were numerically investigated. The selected impeller
diameter was 235 mm; all other specications remain the same
215 CFD
235 CFD
255 CFD
60
65
(%)
Q (m3/h)
60
59
50
Pshaft (kW)
36
65
60
75
40
66
80
10
44
67
(%)
28
55
75
80
85
90
95
100
105
110
115
120
Q (m3/h)
Q (m3/h)
H (m)
Pshaft (kW)
g (%)
11
13
15
17
82.50
85.00
87.50
92.50
33.07
33.50
34.41
36.60
4.60
4.89
5.14
5.75
61.86
63.13
63.05
62.33
74
20H
25H
30H
35H
20
25
30
35
72
70
20P
25P
30P
35P
60
12
68
10
H (m)
(%)
64
40
62
Pshaft (kW)
50
66
6
60
30
58
56
54
60
70
80
90
100
110
120
20
130
Q (m /h)
Fig. 10. Performance curves of impellers with different blade inlet angles.
Table 9
BEPs of impellers with different blade inlet angles.
b2 ()
Q (m3/h)
H (m)
Pshaft (kW)
g (%)
20
25
30
35
72.50
72.50
75.00
75.00
27.46
27.69
28.90
29.27
3.67
3.70
4.01
4.06
67.73
67.64
67.94
67.90
77
78
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