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Advances in Mechanical Engineering
Volume 2013, Article ID 385809, 7 pages
http://dx.doi.org/10.1155/2013/385809
Research Article
Performance Optimization in a Centrifugal Pump Impeller by
Orthogonal Experiment and Numerical Simulation
Ling Zhou,1,2
Weidong Shi,1
and Suqing Wu1
1
National Research Center of Pumps & Pumping System Engineering & Technology, Jiangsu University,
Zhenjiang 212013, China
2
Department of Mechanical Engineering & Materials Science, Washington University in St. Louis, MO 63130, USA
Correspondence should be addressed to Ling Zhou; lingzhoo@hotmail.com
Received 29 March 2013; Revised 30 June 2013; Accepted 23 July 2013
Academic Editor: Hirosi Noguchi
Copyright © 2013 Ling Zhou et al. This is an open access article distributed under the Creative Commons Attribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
In order to improve the hydrodynamic performance of the centrifugal pump, an orthogonal experiment was carried out to optimize
the impeller design parameters. This study employs the commercial computational fluid dynamics (CFD) code to solve the Navier-
Stokes equations for three-dimensional steady flow and predict the pump performance. The prototype experimental test results
of the original pump were acquired and compared with the data predicted from the numerical simulation, which presents a good
agreement under all operating conditions. Five main impeller geometric parameters were chosen as the research factors. According
to the orthogonal table, 16 impellers were designed and modeled. Then, the 16 impellers equipped with the same volute were
simulated by the same numerical methods. Through the variance analysis method, the best parameter combination for higher
efficiency was captured finally. Compared with the original pump, the pump efficiency and head of optimal pump have a significant
improvement.
1. Introduction
Pump manufacturing cost and reliability are required by
end users, who push industries to concentrate efforts on
improving pump efficiency with stricter and stricter manu-
facturing constraints [1, 2]. They are involving a large number
of variables in the centrifugal pump design process which
influences the overall pump performance, such as the blade
outlet width, and blade outlet angle blade wrap angle. How to
evaluate these factors and set up the correspondingly values
are more and more challenging and important [3].
Considerable effort has already been invested in studying
the performance optimization in pump [4–7] and turboma-
chines [8–10]. There are various methods to optimize the
design geometry, including global optimization algorithms
based on heuristic algorithms and gradient-based meth-
ods. The global optimization algorithms, such as genetic
algorithms, artificial neural networks, and response surface
method, are prominent in performance improvement quality,
but they also cost huge amounts of computational resources
and are time consuming to obtain an optimal solution [11, 12].
Orthogonal experiment is an optimization method to
research a target which has multiple factors and levels. It
is also well known as the name of the Taguchi method,
which was developed by Dr. Genichi Taguchi of Japan during
the late 1940s [13–15]. His primary aim was to make a
powerful and easy-to-use experimental design and apply this
to improve the quality of manufactured products. In this
optimization method, variables or factors are arranged in an
orthogonal table. Orthogonal array properties are such that
between each pair of columns each combination of levels
(or variables) appears an equal number of times. Due to
an orthogonal layout, the effects of the other factors can be
balanced and give a relative value representing the effects of
a level compared with the other levels of a given factor. In
orthogonal table experiments, some representative tests can
be chosen from overall tests, and it is helpful to find the
optimal scheme and discover the unanticipated important
information. The number of test runs is minimized, while
keeping the pairwise balancing property [16]. It is very
effective for product development and industrial engineering
2 Advances in Mechanical Engineering
and has been successfully applied in numerous research areas
[17–19].
Generally, the orthogonal experiment uses the original
results of the prototype testing. But taking into account the
manufacturing process of, large amount of groups requires
high accuracy and a longer time period, and the error
is also inevitable in the prototype test. If the numerical
simulation methods to predict the pump performance are
adopted, the error will be lower and saves the manufacture
time and cost. With the development of CFD and the great
improvement of parallel computing technology over the past
decade, the numerical optimization based on CFD simulation
is becoming more popular than ever [20–22]. Many relevant
researches have demonstrated that the appropriate numerical
methods could forecast the pump performance precisely [23–
26].
In this study, in order to improve the performance of
the original pump, orthogonal experiment method was used
combining with the numerical simulation. The original pump
was tested and compared with the numerical results to prove
the numerical accuracy. The primary and secondary factors
of the design parameters were acquired by way of variance
analysis. Meanwhile, the optimal design parameters for better
efficiency and head were presented, respectively.
2. Geometry and Experiment
2.1. Geometric Model. A typical centrifugal pump was chosen
as the research model. The main original parameters of the
investigated pump at the design operation condition are
summarized in Table 1. Figure 1 gives the general views of the
solid model of the impeller and volute.
2.2. Performance Experiment. The original pump was
tested in centrifugal pump performance test platform.
The schematic arrangement of the test rig facility and
test equipment are shown in Figure 2, which have the
identification from the technology department of Jiangsu
province, China. The test rig precedes the requirement of
national grade 1 precision (GB3216-2005) and international
grade 1 precision (ISO9906-1999) [27].
Test facilities and measurement methods abide by the
relevant measurement requirements. The pump inlet and
outlet pressure is measured by a pressure transmitter with
0.1% measurement error. The overall measurement uncer-
tainty is calculated from the square root of the sum of the
squares of the systematic and random uncertainties [28], and
the calculated result of expanded uncertainty of efficiency is
0.5%. The performance of the original pump under multiflow
rates was tested by experiments. Detailed experiments results
were presented in Table 2.
3. Numerical Simulation Methods
3.1. Meshes. The computational domain was modeled as the
real machine, which include the impeller, volute, lateral cavity
with seal leakage, balancing hole, inlet section, and outlet
Table 1: Specification parameters of the original pump.
Description Parameter Value
Design flow rate (m3
/h) 𝑄des 40
Head (m) 𝐻 30
Rotating speed (r/min) 𝑛 2850
Specific speed (m3
/h, m, r/min) 𝑛𝑠 23.4
Nondimensional value Ω𝑠 0.444
Impeller diameter (mm) 𝐷𝑖 168
Impeller blades number 𝑍𝑖 6
Impeller blade outlet width (mm) 𝑏2 11
Impeller inlet diameter (mm) 𝐷1 70
Impeller blade warp angle (∘
) 𝜑 120
Impeller outlet blade angle (∘
) 𝛽2 12
section. Unstructured grids were used in the volute, and
all the other flow passages were meshed with structured
girds. Considering that the wall functions were based on
the logarithmic law, the maximum of the nondimensional
wall distance was targeted to 30 < 𝑦+
< 80 in the mesh
process. The total grid elements in the entire flow passages
are approximately 1.6 million. Figure 3 gives a general view of
the mesh in the impeller and the whole computation domain.
3.2. Methods and Boundary Conditions. The fully 3D incom-
pressible Navier-Stokes equations are performed in ANSYS-
CFX 13.0 code. The finite volume method has been used
for the discretization of the governing equations, and the
high resolution algorithm has been employed to solve the
equations. Turbulence is simulated with the shear stress
transport (SST) 𝑘-𝜔 turbulence model. The space and pres-
sure discretization scheme are set as second order accuracy.
In the steady state, the simulation is defined by means of
the multireference frame technique, in which the impeller is
situated in the rotating reference frame, and the volute is in
the fixed reference frame, and they are related to each other
through the “frozen rotor.” The grids of different domains
are connected by using interfaces. At such interfaces, the
flow fluxes are calculated based on the linear interpola-
tion between the two sides, with fully implicit and fully
conservative in flow fluxes. The boundary conditions are
considered with the real operation conditions, as summarized
in Table 3. Mass flow rate is specified in the pump inlet,
and pressure outlet boundary is used at the pump exit. A
smooth nonslip wall conditions have been imposed over all
the physical surfaces, expect the interfaces between different
parts. Maximum residuals are set to 10−5
, and the mass
flow value and static pressure value at the pump inlet and
outlet are also monitored. When the overall imbalance of the
four monitors is less than 0.1% or the maximum residuals
are reached, the simulation was considered as steady and
convergence.
3.3. Performances Comparison. Through the numerical sim-
ulations under different flow rates, the detailed pump per-
formance was obtained and compared with the experiments
results, as shown in Figure 4. The comparison between test
Advances in Mechanical Engineering 3
(a) Impeller (b) Volute
Figure 1: Solid model of the impeller and volute.
Pressure transmitter
Tank
Computer
Data acquisition instrument
Motor
Pump
Power distributing cabinet
Turbine flowmeter Gate value
Figure 2: Test rig.
Table 2: Experiment results of the original pump.
𝑄 (m3
/h) 𝐻 (m) 𝑃𝑠 (kW) 𝑃 𝑚 (kW) 𝜂 (%)
51.66 22.01 5.32 6.74 58.15
46.90 24.74 5.17 6.54 61.18
44.58 25.98 5.06 6.40 62.38
40.59 27.63 4.90 6.21 62.27
37.68 28.98 4.78 6.05 62.23
34.10 30.23 4.62 5.85 60.77
30.88 31.18 4.45 5.64 58.88
27.10 32.35 4.26 5.40 55.98
24.05 33.20 4.10 5.19 53.06
20.63 33.77 3.87 4.89 49.09
16.98 34.50 3.66 4.63 43.64
14.39 34.93 3.49 4.42 39.23
0.00 35.18 2.55 3.23 0.00
results and the numerical results has a good agreement,
especially for the shaft power. In most cases, both the head
and pump efficiency of simulation results are higher than
experimental values. At design flow point, the simulation
head is 29.21 m and pump efficiency is 64.11%; compared with
the experimental head of 28.63 m and efficiency of 62.91%,
the error is 2% and 1.9% in percent, respectively. For all the
studied flow rates, the numerical results are consistent with
the changing trends of the experimental data. It is clearly
proven that the numerical methods used in this study could
simulate the pump performance accurately.
4. Orthogonal Experiments
4.1. Orthogonal Experiment Design. The effect of many differ-
ent parameters on the overall performance characteristic in a
condensed set of experiments can be examined by using the
orthogonal experimental design. Once the parameters affect-
ing a process that can be controlled have been determined,
the levels at which these parameters should be varied must
be determined. Determining what levels of a variable to test
requires an in-depth understanding of the process, including
the minimum, maximum, and interval for each level [13, 14].
In this study, according to the manufacturers’ require-
ments, the optimization just focuses on the impeller with
an identical volute casing. Based on the impeller design
experience, five important impeller geometrical factors were
selected, namely, impeller outlet width 𝑏2, impeller inlet
diameter 𝐷1, impeller blade wrapping angle 𝜑, impeller blade
outlet angle 𝛽2, and impeller blade inlet angle 𝛽1. Since the
volute is keeping in the same geometry, the impeller param-
eters should stay in a reasonable range to match the volute.
Therefore, according to the original pump characteristics and
impeller design experience, four levels were chosen for each
factor, as summarized in Table 4.
As long as the number of parameters and the number
of levels are decided, the proper orthogonal table could
be selected. Many predefined orthogonal tables have been
given in the relative reference [13, 14]. These tables were
created using an algorithm Taguchi developed and allows for
each variable and setting to be tested equally. In the preset
study, the orthogonal tables L16 (45
) are used to arrange
the experiments; five factors are evaluated each time and
each factor takes four levels, and the detailed experimental
programs are presented in Table 5.
4.2. Orthogonal Experiment Results. According to the pre-
vious test scheme, the 16 impellers were designed and
assembled with the same volute, respectively. Then, the 16
pumps were simulated in the ANSYS-CFX with the same
computational methods of the original pump. Table 6 gives
4 Advances in Mechanical Engineering
(a) Overall view (b) Impeller
Figure 3: Mesh sketch.
Table 3: Boundary conditions.
Position Boundary condition
Inlet Mass flow inlet
Outlet Pressure outlet boundary
Walls Nonslip wall
Impeller Rotating reference frame
Volute Stationary reference frame
Interface General connection
Wall function Automatic near-wall treatment
Simulation results
Experiment results
0
10
20
30
40
50
60
70
16
20
24
28
32
36
40
Q (m3
/h)
0 10 20 30 40 50 60
Ps(kW)𝜂(%)
2
3
4
5
H(m)
Figure 4: Experiment and simulation results comparisons of the
original pump.
the predicted pump head and efficiency of the 16 programs at
the design flow rate.
Due to the orthogonal features, the importance order of
each factor could be found through the analysis. These 16
test sets have tested all of the pairwise combinations of the
independent variables. This demonstrates significant savings
in testing effort over the all combinations approach. Variance
analysis method (i.e., range analysis method) was used to
clarify the significance levels of different influencing factors
Table 4: Orthogonal experimental factors.
Factors
Name A B C D E
Notation 𝑏2/mm 𝐷1/mm 𝜑/∘
𝛽2/∘
𝛽1/∘
Levels
1 8 64 100 10 0
2 9.5 66 115 15 6
3 11 68 130 20 12
4 12.5 70 145 25 18
Table 5: Orthogonal experiment scheme.
No. A B C D E
1 8 64 100 10 0
2 8 66 115 15 6
3 8 68 130 20 12
4 8 70 145 25 18
5 9.5 64 115 20 18
6 9.5 66 100 25 12
7 9.5 68 145 10 6
8 9.5 70 130 15 0
9 11 64 130 25 6
10 11 66 145 20 0
11 11 68 100 15 18
12 11 70 115 10 12
13 12.5 64 145 15 12
14 12.5 66 130 10 18
15 12.5 68 115 25 0
16 12.5 70 100 20 6
on the diameter and morphology of obtained fibers [13, 14],
and those most significant factors could be disclosed basing
the result of range analysis. The average values of each level for
each factor were named as 𝑘𝑖, which is calculated as follows
𝑘𝑖 =
1
𝑁𝑖
𝑁𝑖
∑
𝑗=1
𝑦𝑖,𝑗. (1)
Advances in Mechanical Engineering 5
Table 6: Numerical simulation results of the 16 programs under
design point.
No. 𝐻/𝑚 𝜂/%
1 27.89 64.57
2 28.19 65.93
3 28.04 66.40
4 27.24 63.23
5 30.14 66.38
6 30.00 67.13
7 30.07 66.94
8 30.05 66.81
9 32.05 66.94
10 31.36 66.93
11 31.30 66.38
12 30.67 66.82
13 31.87 67.42
14 30.74 67.49
15 32.98 65.84
16 32.54 64.42
Table 7: Range analysis of pump efficiency.
A B C D E
𝑘1 65.032 66.328 65.625 66.455 66.037
𝑘2 66.815 66.870 66.243 66.635 66.058
𝑘3 66.767 66.390 66.910 66.032 66.942
𝑘4 66.293 65.320 66.130 65.785 65.870
𝑅 1.783 1.550 1.285 0.850 1.072
Table 8: Range analysis of pump head.
A B C D E
𝑘1 27.840 30.488 30.433 29.843 30.570
𝑘2 30.065 30.073 30.495 30.353 30.713
𝑘3 31.345 30.597 30.220 30.520 30.145
𝑘4 32.033 30.125 30.135 30.567 29.855
R 4.193 0.524 0.360 0.724 0.858
The variances between each factor were defined as 𝑅 to
analyze the difference between the maximal and minimal
value of the four levels for each factor:
𝑅 = max (𝑘1, 𝑘2, . . . , 𝑘𝑖) − min (𝑘1, 𝑘2, . . . , 𝑘𝑖) , (2)
where 𝑖 is number of levels, 𝑗 is number of factors, 𝑦𝑖,𝑗 is the
performance value for factor 𝑗 in level 𝑖, and 𝑁𝑖 is the total
number of levels, that is, 𝑁𝑖 = 4 in this study.
The analysis results for pump efficiency were shown in
Table 7 and Figure 5. As seen from Table 7, we find that the
factor influence of the pump efficiency decreases in the order:
A > B > C > E > D according to the 𝑅 values. The impeller
blade outlet width was found to be the most important
determinant of efficiency. When the factor A employs the
64.0
64.5
65.0
65.5
66.0
66.5
67.0
67.5
8
9.5
11
12.5
64
66
68
70
100
115
130
145
10
15
20
25
0
6
12
18
Efficiency(%)
A B C D E
Figure 5: Level influence of each factor for pump efficiency.
26
27
28
29
30
31
32
33
Head(m)
8
9.5
11
12.5
64
66
68
70
100
115
130
145
10
15
20
25
0
6
12
18
A B C D E
Figure 6: Level influence of each factor for pump head.
value of 11 mm, the pump has the highest efficiency. Factor
D has the lower significant influence on the pump efficiency
compared with the other factors. The reason maybe is that the
volute in this paper is changeless. For all the five factors, their
changing trends all have an obvious peak value; it means that
each factors has a best value or levels for the better efficiency.
Accordingly, the best program of optimized pump efficiency
is A3, B2, C3, D2, and E3, namely, 𝑏2 = 11 mm, 𝐷1 = 66 mm,
𝜑 = 130∘
, 𝛽2 = 15∘
, and 𝛽1 = 12∘
.
Table 8 is the range analysis of the head; the levels of
influence are indicated in Figure 6. According to the 𝑅 values,
factor influence rank is A > E > D > B > C for the head. The
primary factor that impacts the pump head is impeller outlet
width. The best parameters combination for higher head is
A4, B3, C2, D4, and E2, namely, 𝑏2 = 12.5 mm, 𝐷1 = 68 mm,
𝜑 = 115∘
, 𝛽2 = 25∘
, and 𝛽1 = 6∘
.
4.3. Optimal Pump Performance. In this study, we focus on
the pump efficiency improvement, so the optimal impeller
design was adopted as A3, B2, C3, D2, and E3 (i.e., 𝑏2 =
11 mm, 𝐷1 = 66 mm, 𝜑 = 130∘
, 𝛽2 = 15∘
, and 𝛽1 = 12∘
) based
on the results of the orthogonal experiment. Then, the final
optimized impeller was designed and assembled with the
same volute and simulated by the same numerical methods.
Figure 7 compares the pump efficiency and head between the
optimal pump and original pump, which are both predicted
by the numerical methods.
At the design flow rate, the optimal pump has 67.55%
efficiency and 30.93 m head. Compared with the original
6 Advances in Mechanical Engineering
15
20
25
30
35
40
Original pump
Optimal pump
0 10 20 30 40 50 60
Q (m3
/h)
H(m)
(a) Head
30
40
50
60
70
Original pump
Optimal pump
0 10 20 30 40 50 60
Q (m3
/h)
𝜂(%)
(b) Efficiency
Figure 7: Predicted performance comparison between the original and optimal pumps.
pump with 64.11% efficiency and 29.21 m, the increase is 5.4%
and 5.9% in percent separately. In the pump operating flow
range (0.8∼1.2 times design flow rate), the optimal pump
has an obvious performance promotion. However, due to the
influence of the volute, the optimal pump did not present a
similar improvement in the smaller or larger flow area. It is
indicated that the best way to optimize the pump drastically
should be considering the design of the impeller and volute
at the same time.
5. Conclusions
How to improve the impellers performance by changing their
geometric characteristics is always challenging. In the present
study, a centrifugal impeller was optimized by the orthog-
onal experiment method. The geometric parameters of the
original pump were distributed clearly. Detailed numerical
methods for pump performance prediction were presented,
such as meshes, boundary conditions, and turbulence model.
The original pump was manufactured and tested in a cen-
trifugal pump test rig. Then, the numerical results of the
original pump were compared with the experimental ones,
and the comparisons between the two methods have a good
agreement.
Five main impeller geometric characteristics were chosen
as the research target to carry out the orthogonal exper-
iment. The best programs for pump efficiency and head
were obtained through the variance analysis method. The
performance comparisons between the original pump and
optimal pump show a remarkable improvement. The results
also demonstrated that the impeller outlet width has the
largest effect on both pump efficiency and head. But the
optimal pump did not present an obvious improvement in
the smaller or larger flow area. Therefore, the best way to
optimize the pump performance should consider the impeller
and volute together in the design process.
Notation
𝑄: Flow rate (m3
/h)
𝑄des: Rated flow (m3
/h)
𝐻: Head (m)
𝜂: Pump efficiency (%)
𝑛: Rotating speed (r/min)
𝑛𝑠: Specific speed (m3
/h, m, r/min)
Ω𝑠: Nondimensional value
𝑍𝑖: Blade number of impeller
𝛽1: Inlet blade setting angle of impeller (∘
)
𝛽2: Outlet blade angle of impeller (∘
)
𝑏2: Outlet blade width of impeller (mm)
𝜑: Impeller blade wrap angle (∘
)
𝑃𝑠: Shaft power (kW)
𝑃 𝑚: Motor power (kW)
𝐷2: Impeller outlet diameter (mm)
𝐷1: Impeller inlet diameter (mm)
𝑦+
: Nondimensional distance from the wall
𝑘: Average value
𝑅: Range value.
Acknowledgments
This work was supported by the National Natural Science
Foundation of China Grant nos. 51279069 and 51109093
and National Studying Abroad Foundation of China. The
authors would like to express their sincere gratitude to
Professor Weigang Lu for his valuable guidance. Constructive
suggestions from reviewers are also appreciated.
Advances in Mechanical Engineering 7
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[22] N. Pedersen, P. S. Larsen, and C. B. Jacobsen, “Flow in a centrifu-
gal pump impeller at design and off-design conditions—part I:
particle image velocimetry (PIV) and laser Doppler velocimetry
(LDV) measurements,” Journal of Fluids Engineering, vol. 125,
no. 1, pp. 61–72, 2003.
[23] R. K. Byskov, C. B. Jacobsen, and N. Pedersen, “Flow in a cen-
trifugal pump impeller at design and off-design conditions—
part II: large eddy simulations,” Journal of Fluids Engineering,
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[24] Y.-D. Choi, J. Kurokawa, and J. Malsui, “Performance and inter-
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[25] K. Majidi, “Numerical study of unsteady flow in a centrifugal
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[26] W. Shi, L. Zhou, W. Lu, B. Pei, and T. Lang, “Numerical pre-
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pump with different impeller outlet width,” Chinese Journal of
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[27] ISO, “9906 Rotodynamic Pumps-Hydraulic performance
acceptance tests-Grades 1 and 2,” International Standardization
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[28] H. D. Feng, L. Xu, R. P. Xu et al., “Uncertainty analysis
using the thermodynamic method of pump efficiency testing,”
Proceedings of the Institution of Mechanical Engineers C, vol. 218,
pp. 543–555, 2004.
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  • 1. Hindawi Publishing Corporation Advances in Mechanical Engineering Volume 2013, Article ID 385809, 7 pages http://dx.doi.org/10.1155/2013/385809 Research Article Performance Optimization in a Centrifugal Pump Impeller by Orthogonal Experiment and Numerical Simulation Ling Zhou,1,2 Weidong Shi,1 and Suqing Wu1 1 National Research Center of Pumps & Pumping System Engineering & Technology, Jiangsu University, Zhenjiang 212013, China 2 Department of Mechanical Engineering & Materials Science, Washington University in St. Louis, MO 63130, USA Correspondence should be addressed to Ling Zhou; lingzhoo@hotmail.com Received 29 March 2013; Revised 30 June 2013; Accepted 23 July 2013 Academic Editor: Hirosi Noguchi Copyright © 2013 Ling Zhou et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. In order to improve the hydrodynamic performance of the centrifugal pump, an orthogonal experiment was carried out to optimize the impeller design parameters. This study employs the commercial computational fluid dynamics (CFD) code to solve the Navier- Stokes equations for three-dimensional steady flow and predict the pump performance. The prototype experimental test results of the original pump were acquired and compared with the data predicted from the numerical simulation, which presents a good agreement under all operating conditions. Five main impeller geometric parameters were chosen as the research factors. According to the orthogonal table, 16 impellers were designed and modeled. Then, the 16 impellers equipped with the same volute were simulated by the same numerical methods. Through the variance analysis method, the best parameter combination for higher efficiency was captured finally. Compared with the original pump, the pump efficiency and head of optimal pump have a significant improvement. 1. Introduction Pump manufacturing cost and reliability are required by end users, who push industries to concentrate efforts on improving pump efficiency with stricter and stricter manu- facturing constraints [1, 2]. They are involving a large number of variables in the centrifugal pump design process which influences the overall pump performance, such as the blade outlet width, and blade outlet angle blade wrap angle. How to evaluate these factors and set up the correspondingly values are more and more challenging and important [3]. Considerable effort has already been invested in studying the performance optimization in pump [4–7] and turboma- chines [8–10]. There are various methods to optimize the design geometry, including global optimization algorithms based on heuristic algorithms and gradient-based meth- ods. The global optimization algorithms, such as genetic algorithms, artificial neural networks, and response surface method, are prominent in performance improvement quality, but they also cost huge amounts of computational resources and are time consuming to obtain an optimal solution [11, 12]. Orthogonal experiment is an optimization method to research a target which has multiple factors and levels. It is also well known as the name of the Taguchi method, which was developed by Dr. Genichi Taguchi of Japan during the late 1940s [13–15]. His primary aim was to make a powerful and easy-to-use experimental design and apply this to improve the quality of manufactured products. In this optimization method, variables or factors are arranged in an orthogonal table. Orthogonal array properties are such that between each pair of columns each combination of levels (or variables) appears an equal number of times. Due to an orthogonal layout, the effects of the other factors can be balanced and give a relative value representing the effects of a level compared with the other levels of a given factor. In orthogonal table experiments, some representative tests can be chosen from overall tests, and it is helpful to find the optimal scheme and discover the unanticipated important information. The number of test runs is minimized, while keeping the pairwise balancing property [16]. It is very effective for product development and industrial engineering
  • 2. 2 Advances in Mechanical Engineering and has been successfully applied in numerous research areas [17–19]. Generally, the orthogonal experiment uses the original results of the prototype testing. But taking into account the manufacturing process of, large amount of groups requires high accuracy and a longer time period, and the error is also inevitable in the prototype test. If the numerical simulation methods to predict the pump performance are adopted, the error will be lower and saves the manufacture time and cost. With the development of CFD and the great improvement of parallel computing technology over the past decade, the numerical optimization based on CFD simulation is becoming more popular than ever [20–22]. Many relevant researches have demonstrated that the appropriate numerical methods could forecast the pump performance precisely [23– 26]. In this study, in order to improve the performance of the original pump, orthogonal experiment method was used combining with the numerical simulation. The original pump was tested and compared with the numerical results to prove the numerical accuracy. The primary and secondary factors of the design parameters were acquired by way of variance analysis. Meanwhile, the optimal design parameters for better efficiency and head were presented, respectively. 2. Geometry and Experiment 2.1. Geometric Model. A typical centrifugal pump was chosen as the research model. The main original parameters of the investigated pump at the design operation condition are summarized in Table 1. Figure 1 gives the general views of the solid model of the impeller and volute. 2.2. Performance Experiment. The original pump was tested in centrifugal pump performance test platform. The schematic arrangement of the test rig facility and test equipment are shown in Figure 2, which have the identification from the technology department of Jiangsu province, China. The test rig precedes the requirement of national grade 1 precision (GB3216-2005) and international grade 1 precision (ISO9906-1999) [27]. Test facilities and measurement methods abide by the relevant measurement requirements. The pump inlet and outlet pressure is measured by a pressure transmitter with 0.1% measurement error. The overall measurement uncer- tainty is calculated from the square root of the sum of the squares of the systematic and random uncertainties [28], and the calculated result of expanded uncertainty of efficiency is 0.5%. The performance of the original pump under multiflow rates was tested by experiments. Detailed experiments results were presented in Table 2. 3. Numerical Simulation Methods 3.1. Meshes. The computational domain was modeled as the real machine, which include the impeller, volute, lateral cavity with seal leakage, balancing hole, inlet section, and outlet Table 1: Specification parameters of the original pump. Description Parameter Value Design flow rate (m3 /h) 𝑄des 40 Head (m) 𝐻 30 Rotating speed (r/min) 𝑛 2850 Specific speed (m3 /h, m, r/min) 𝑛𝑠 23.4 Nondimensional value Ω𝑠 0.444 Impeller diameter (mm) 𝐷𝑖 168 Impeller blades number 𝑍𝑖 6 Impeller blade outlet width (mm) 𝑏2 11 Impeller inlet diameter (mm) 𝐷1 70 Impeller blade warp angle (∘ ) 𝜑 120 Impeller outlet blade angle (∘ ) 𝛽2 12 section. Unstructured grids were used in the volute, and all the other flow passages were meshed with structured girds. Considering that the wall functions were based on the logarithmic law, the maximum of the nondimensional wall distance was targeted to 30 < 𝑦+ < 80 in the mesh process. The total grid elements in the entire flow passages are approximately 1.6 million. Figure 3 gives a general view of the mesh in the impeller and the whole computation domain. 3.2. Methods and Boundary Conditions. The fully 3D incom- pressible Navier-Stokes equations are performed in ANSYS- CFX 13.0 code. The finite volume method has been used for the discretization of the governing equations, and the high resolution algorithm has been employed to solve the equations. Turbulence is simulated with the shear stress transport (SST) 𝑘-𝜔 turbulence model. The space and pres- sure discretization scheme are set as second order accuracy. In the steady state, the simulation is defined by means of the multireference frame technique, in which the impeller is situated in the rotating reference frame, and the volute is in the fixed reference frame, and they are related to each other through the “frozen rotor.” The grids of different domains are connected by using interfaces. At such interfaces, the flow fluxes are calculated based on the linear interpola- tion between the two sides, with fully implicit and fully conservative in flow fluxes. The boundary conditions are considered with the real operation conditions, as summarized in Table 3. Mass flow rate is specified in the pump inlet, and pressure outlet boundary is used at the pump exit. A smooth nonslip wall conditions have been imposed over all the physical surfaces, expect the interfaces between different parts. Maximum residuals are set to 10−5 , and the mass flow value and static pressure value at the pump inlet and outlet are also monitored. When the overall imbalance of the four monitors is less than 0.1% or the maximum residuals are reached, the simulation was considered as steady and convergence. 3.3. Performances Comparison. Through the numerical sim- ulations under different flow rates, the detailed pump per- formance was obtained and compared with the experiments results, as shown in Figure 4. The comparison between test
  • 3. Advances in Mechanical Engineering 3 (a) Impeller (b) Volute Figure 1: Solid model of the impeller and volute. Pressure transmitter Tank Computer Data acquisition instrument Motor Pump Power distributing cabinet Turbine flowmeter Gate value Figure 2: Test rig. Table 2: Experiment results of the original pump. 𝑄 (m3 /h) 𝐻 (m) 𝑃𝑠 (kW) 𝑃 𝑚 (kW) 𝜂 (%) 51.66 22.01 5.32 6.74 58.15 46.90 24.74 5.17 6.54 61.18 44.58 25.98 5.06 6.40 62.38 40.59 27.63 4.90 6.21 62.27 37.68 28.98 4.78 6.05 62.23 34.10 30.23 4.62 5.85 60.77 30.88 31.18 4.45 5.64 58.88 27.10 32.35 4.26 5.40 55.98 24.05 33.20 4.10 5.19 53.06 20.63 33.77 3.87 4.89 49.09 16.98 34.50 3.66 4.63 43.64 14.39 34.93 3.49 4.42 39.23 0.00 35.18 2.55 3.23 0.00 results and the numerical results has a good agreement, especially for the shaft power. In most cases, both the head and pump efficiency of simulation results are higher than experimental values. At design flow point, the simulation head is 29.21 m and pump efficiency is 64.11%; compared with the experimental head of 28.63 m and efficiency of 62.91%, the error is 2% and 1.9% in percent, respectively. For all the studied flow rates, the numerical results are consistent with the changing trends of the experimental data. It is clearly proven that the numerical methods used in this study could simulate the pump performance accurately. 4. Orthogonal Experiments 4.1. Orthogonal Experiment Design. The effect of many differ- ent parameters on the overall performance characteristic in a condensed set of experiments can be examined by using the orthogonal experimental design. Once the parameters affect- ing a process that can be controlled have been determined, the levels at which these parameters should be varied must be determined. Determining what levels of a variable to test requires an in-depth understanding of the process, including the minimum, maximum, and interval for each level [13, 14]. In this study, according to the manufacturers’ require- ments, the optimization just focuses on the impeller with an identical volute casing. Based on the impeller design experience, five important impeller geometrical factors were selected, namely, impeller outlet width 𝑏2, impeller inlet diameter 𝐷1, impeller blade wrapping angle 𝜑, impeller blade outlet angle 𝛽2, and impeller blade inlet angle 𝛽1. Since the volute is keeping in the same geometry, the impeller param- eters should stay in a reasonable range to match the volute. Therefore, according to the original pump characteristics and impeller design experience, four levels were chosen for each factor, as summarized in Table 4. As long as the number of parameters and the number of levels are decided, the proper orthogonal table could be selected. Many predefined orthogonal tables have been given in the relative reference [13, 14]. These tables were created using an algorithm Taguchi developed and allows for each variable and setting to be tested equally. In the preset study, the orthogonal tables L16 (45 ) are used to arrange the experiments; five factors are evaluated each time and each factor takes four levels, and the detailed experimental programs are presented in Table 5. 4.2. Orthogonal Experiment Results. According to the pre- vious test scheme, the 16 impellers were designed and assembled with the same volute, respectively. Then, the 16 pumps were simulated in the ANSYS-CFX with the same computational methods of the original pump. Table 6 gives
  • 4. 4 Advances in Mechanical Engineering (a) Overall view (b) Impeller Figure 3: Mesh sketch. Table 3: Boundary conditions. Position Boundary condition Inlet Mass flow inlet Outlet Pressure outlet boundary Walls Nonslip wall Impeller Rotating reference frame Volute Stationary reference frame Interface General connection Wall function Automatic near-wall treatment Simulation results Experiment results 0 10 20 30 40 50 60 70 16 20 24 28 32 36 40 Q (m3 /h) 0 10 20 30 40 50 60 Ps(kW)𝜂(%) 2 3 4 5 H(m) Figure 4: Experiment and simulation results comparisons of the original pump. the predicted pump head and efficiency of the 16 programs at the design flow rate. Due to the orthogonal features, the importance order of each factor could be found through the analysis. These 16 test sets have tested all of the pairwise combinations of the independent variables. This demonstrates significant savings in testing effort over the all combinations approach. Variance analysis method (i.e., range analysis method) was used to clarify the significance levels of different influencing factors Table 4: Orthogonal experimental factors. Factors Name A B C D E Notation 𝑏2/mm 𝐷1/mm 𝜑/∘ 𝛽2/∘ 𝛽1/∘ Levels 1 8 64 100 10 0 2 9.5 66 115 15 6 3 11 68 130 20 12 4 12.5 70 145 25 18 Table 5: Orthogonal experiment scheme. No. A B C D E 1 8 64 100 10 0 2 8 66 115 15 6 3 8 68 130 20 12 4 8 70 145 25 18 5 9.5 64 115 20 18 6 9.5 66 100 25 12 7 9.5 68 145 10 6 8 9.5 70 130 15 0 9 11 64 130 25 6 10 11 66 145 20 0 11 11 68 100 15 18 12 11 70 115 10 12 13 12.5 64 145 15 12 14 12.5 66 130 10 18 15 12.5 68 115 25 0 16 12.5 70 100 20 6 on the diameter and morphology of obtained fibers [13, 14], and those most significant factors could be disclosed basing the result of range analysis. The average values of each level for each factor were named as 𝑘𝑖, which is calculated as follows 𝑘𝑖 = 1 𝑁𝑖 𝑁𝑖 ∑ 𝑗=1 𝑦𝑖,𝑗. (1)
  • 5. Advances in Mechanical Engineering 5 Table 6: Numerical simulation results of the 16 programs under design point. No. 𝐻/𝑚 𝜂/% 1 27.89 64.57 2 28.19 65.93 3 28.04 66.40 4 27.24 63.23 5 30.14 66.38 6 30.00 67.13 7 30.07 66.94 8 30.05 66.81 9 32.05 66.94 10 31.36 66.93 11 31.30 66.38 12 30.67 66.82 13 31.87 67.42 14 30.74 67.49 15 32.98 65.84 16 32.54 64.42 Table 7: Range analysis of pump efficiency. A B C D E 𝑘1 65.032 66.328 65.625 66.455 66.037 𝑘2 66.815 66.870 66.243 66.635 66.058 𝑘3 66.767 66.390 66.910 66.032 66.942 𝑘4 66.293 65.320 66.130 65.785 65.870 𝑅 1.783 1.550 1.285 0.850 1.072 Table 8: Range analysis of pump head. A B C D E 𝑘1 27.840 30.488 30.433 29.843 30.570 𝑘2 30.065 30.073 30.495 30.353 30.713 𝑘3 31.345 30.597 30.220 30.520 30.145 𝑘4 32.033 30.125 30.135 30.567 29.855 R 4.193 0.524 0.360 0.724 0.858 The variances between each factor were defined as 𝑅 to analyze the difference between the maximal and minimal value of the four levels for each factor: 𝑅 = max (𝑘1, 𝑘2, . . . , 𝑘𝑖) − min (𝑘1, 𝑘2, . . . , 𝑘𝑖) , (2) where 𝑖 is number of levels, 𝑗 is number of factors, 𝑦𝑖,𝑗 is the performance value for factor 𝑗 in level 𝑖, and 𝑁𝑖 is the total number of levels, that is, 𝑁𝑖 = 4 in this study. The analysis results for pump efficiency were shown in Table 7 and Figure 5. As seen from Table 7, we find that the factor influence of the pump efficiency decreases in the order: A > B > C > E > D according to the 𝑅 values. The impeller blade outlet width was found to be the most important determinant of efficiency. When the factor A employs the 64.0 64.5 65.0 65.5 66.0 66.5 67.0 67.5 8 9.5 11 12.5 64 66 68 70 100 115 130 145 10 15 20 25 0 6 12 18 Efficiency(%) A B C D E Figure 5: Level influence of each factor for pump efficiency. 26 27 28 29 30 31 32 33 Head(m) 8 9.5 11 12.5 64 66 68 70 100 115 130 145 10 15 20 25 0 6 12 18 A B C D E Figure 6: Level influence of each factor for pump head. value of 11 mm, the pump has the highest efficiency. Factor D has the lower significant influence on the pump efficiency compared with the other factors. The reason maybe is that the volute in this paper is changeless. For all the five factors, their changing trends all have an obvious peak value; it means that each factors has a best value or levels for the better efficiency. Accordingly, the best program of optimized pump efficiency is A3, B2, C3, D2, and E3, namely, 𝑏2 = 11 mm, 𝐷1 = 66 mm, 𝜑 = 130∘ , 𝛽2 = 15∘ , and 𝛽1 = 12∘ . Table 8 is the range analysis of the head; the levels of influence are indicated in Figure 6. According to the 𝑅 values, factor influence rank is A > E > D > B > C for the head. The primary factor that impacts the pump head is impeller outlet width. The best parameters combination for higher head is A4, B3, C2, D4, and E2, namely, 𝑏2 = 12.5 mm, 𝐷1 = 68 mm, 𝜑 = 115∘ , 𝛽2 = 25∘ , and 𝛽1 = 6∘ . 4.3. Optimal Pump Performance. In this study, we focus on the pump efficiency improvement, so the optimal impeller design was adopted as A3, B2, C3, D2, and E3 (i.e., 𝑏2 = 11 mm, 𝐷1 = 66 mm, 𝜑 = 130∘ , 𝛽2 = 15∘ , and 𝛽1 = 12∘ ) based on the results of the orthogonal experiment. Then, the final optimized impeller was designed and assembled with the same volute and simulated by the same numerical methods. Figure 7 compares the pump efficiency and head between the optimal pump and original pump, which are both predicted by the numerical methods. At the design flow rate, the optimal pump has 67.55% efficiency and 30.93 m head. Compared with the original
  • 6. 6 Advances in Mechanical Engineering 15 20 25 30 35 40 Original pump Optimal pump 0 10 20 30 40 50 60 Q (m3 /h) H(m) (a) Head 30 40 50 60 70 Original pump Optimal pump 0 10 20 30 40 50 60 Q (m3 /h) 𝜂(%) (b) Efficiency Figure 7: Predicted performance comparison between the original and optimal pumps. pump with 64.11% efficiency and 29.21 m, the increase is 5.4% and 5.9% in percent separately. In the pump operating flow range (0.8∼1.2 times design flow rate), the optimal pump has an obvious performance promotion. However, due to the influence of the volute, the optimal pump did not present a similar improvement in the smaller or larger flow area. It is indicated that the best way to optimize the pump drastically should be considering the design of the impeller and volute at the same time. 5. Conclusions How to improve the impellers performance by changing their geometric characteristics is always challenging. In the present study, a centrifugal impeller was optimized by the orthog- onal experiment method. The geometric parameters of the original pump were distributed clearly. Detailed numerical methods for pump performance prediction were presented, such as meshes, boundary conditions, and turbulence model. The original pump was manufactured and tested in a cen- trifugal pump test rig. Then, the numerical results of the original pump were compared with the experimental ones, and the comparisons between the two methods have a good agreement. Five main impeller geometric characteristics were chosen as the research target to carry out the orthogonal exper- iment. The best programs for pump efficiency and head were obtained through the variance analysis method. The performance comparisons between the original pump and optimal pump show a remarkable improvement. The results also demonstrated that the impeller outlet width has the largest effect on both pump efficiency and head. But the optimal pump did not present an obvious improvement in the smaller or larger flow area. Therefore, the best way to optimize the pump performance should consider the impeller and volute together in the design process. Notation 𝑄: Flow rate (m3 /h) 𝑄des: Rated flow (m3 /h) 𝐻: Head (m) 𝜂: Pump efficiency (%) 𝑛: Rotating speed (r/min) 𝑛𝑠: Specific speed (m3 /h, m, r/min) Ω𝑠: Nondimensional value 𝑍𝑖: Blade number of impeller 𝛽1: Inlet blade setting angle of impeller (∘ ) 𝛽2: Outlet blade angle of impeller (∘ ) 𝑏2: Outlet blade width of impeller (mm) 𝜑: Impeller blade wrap angle (∘ ) 𝑃𝑠: Shaft power (kW) 𝑃 𝑚: Motor power (kW) 𝐷2: Impeller outlet diameter (mm) 𝐷1: Impeller inlet diameter (mm) 𝑦+ : Nondimensional distance from the wall 𝑘: Average value 𝑅: Range value. Acknowledgments This work was supported by the National Natural Science Foundation of China Grant nos. 51279069 and 51109093 and National Studying Abroad Foundation of China. The authors would like to express their sincere gratitude to Professor Weigang Lu for his valuable guidance. Constructive suggestions from reviewers are also appreciated.
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