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Annals of Nuclear Energy 97 (2016) 190197

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Annals of Nuclear Energy


journal homepage: www.elsevier.com/locate/anucene

A systematic investigation on flow characteristics of impeller passage


in a nuclear centrifugal pump under cavitation state
Qiang Fu a, Fan Zhang a,, Rongsheng Zhu a, Bo He b
a
National Research Center of Pumps, Jiangsu University, 212013 Zhenjiang, China
b
POWERCHINA SPEM LIMITED COMPANY, Shanghai 201316, China

a r t i c l e i n f o a b s t r a c t

Article history: Cavitation is a greatly harmful flow phenomenon for nuclear centrifugal pumps, and it should be attached
Received 24 May 2016 importance when the pump is designed. Under cavitating conditions the flow patterns in the pump are
Received in revised form 27 June 2016 complex and highly turbulent flow can be induced. In this paper the flow characteristics in the impeller
Accepted 6 July 2016
passage of a nuclear centrifugal pump model were systematically investigated under steady and transient
Available online 27 July 2016
cavitation conditions. At moderate cavitation levels the results show that the fluctuations of the radial
force on the impeller are mainly affected by rotor-stator interaction effects, but are strongly influenced
Keywords:
by cavitation under developed cavitation conditions. At inception vapor is mainly generated near the
Nuclear centrifugal pump
Flow characteristic
leading edge of the blade, and spreads on the suction side of the impeller at higher cavitation levels.
Fluctuation The vapor generation, development and burst under transient cavitation conditions have a strong influ-
Cavitation ence on the flow patterns in the impeller passage. The trends of the simulations are in accordance with
Numerical simulation the measured results, thus confirming the validity of the numerical model used for predicting the char-
acteristics of the flow through the impeller.
2016 Elsevier Ltd. All rights reserved.

1. Introduction two-dimensional curved blades under the cavitating operated con-


dition. Yanxia et al. (2015) used high speed digital movies to study
Centrifugal pumps have been widely used in many areas for a the flow visualization of internal cavitating flow patterns in a cen-
long time, but their operational requirements are now becoming trifugal pump at low flow rates. Xiaojun et al. (2013) analyzed the
stricter and stricter. For example, in centrifugal pumps used in periodically unsteady pressure field and head-drop phenomenon
nuclear reactors not only adequate hydraulic performance but also caused by leading edge cavitation in a single stage centrifugal
stable and reliable operation under some extreme operating condi- pump. They pointed out that the vortex flow generation in the rear
tions must be attained. The centrifugal charging pumps are parts of of the cavitating region is the main reason of the head-drop. Vapor
the Chemical and Volume Control System (CVCS) and designed to usually is generated and bursts for a short time in the cavitating
provide normal charging service to the Reactor Coolant System region of the flow, resulting in the possible onset of flow instabil-
(RCS), which makes them extremely important in nuclear power ities caused by cavitation. Many researchers analyzed the flow
plants. When the pump operates at a sufficiently low pressure, cav- mechanism of cavitation-induced flow instabilities in order to sup-
itation is generated, and its development inevitably affects the ply theoretical information for optimal design of pumps operating
safety operation of the nuclear pumps. This flow phenomenon with better cavitation performance (Tsujimoto, 2001; Yongpeng
takes place in almost all kinds of pumps and has documental et al., 2014; Sloteman et al., 2004; Yamamoto and Tsujimoto,
effects on the performance of the machine, and therefore should 2009; Lee et al., 2009). In addition, a number of other investiga-
be avoided as much as possible. tions on the cavitating two-phase flow in pumps have been docu-
In recent years an increasing amount of information is has been mented in Medvitz et al. (2002), Dular et al. (2005), Zuchao et al.
made available in the open literature on cavitation in centrifugal (2008), Poullikkas (2003) and Long et al. (2009).
pumps. Coutier-Delgosha et al. (2003) numerically and experimen- Transient flow is also a common flow phenomenon occurring in
tally investigated the performances of a centrifugal pump with turbopumps under a wide range of conditions, usually during start-
up, shut-down and variable load operation, and has been the focus
of a number of investigations. Tsukamoto and Ohashi (1982) and Li
Corresponding author. et al. (2010) studied the instantaneous flow characteristics of cen-
E-mail address: zhangfan4060@gmail.com (F. Zhang). trifugal pumps during the start-up period. Wu et al. (2013, 2010)

http://dx.doi.org/10.1016/j.anucene.2016.07.011
0306-4549/ 2016 Elsevier Ltd. All rights reserved.
Q. Fu et al. / Annals of Nuclear Energy 97 (2016) 190197 191

Nomenclature

b2 outlet width of impeller, mm Re steam generation rate


Cp static pressure coefficient Rc steam condensation rate
Cv absolute velocity coefficient RB bubble radius, m
D1 inlet diameter of impeller, mm R radius of impeller, m
D2 outlet diameter of impeller, mm T time, s
Fx radial force on X axial direction t0 initial time, s
Fy radial force on Y axial direction T temperature, C
Fz axial force u2 impeller outlet circumferential velocity, m/s
Fcond condensation coefficient, 0.01 v absolute velocity, m/s
Fvap correction factor of evaporation, 50 Z number of blades
H head, m U wrap angle, deg
Kp pressure coefficient, 5000 g efficiency
N impeller rotation speed, rpm anuc nucleation volume fraction
P power, kW avap vapor volume fraction
p0 pressure when cavitation starts, pa qvap vapor density, kg/m3
Q flow rate, m3/s ql liquid density, kg/m3
Qd design flow rate, m3/s Dt time step
Qmax maximum flow rate, m3/s NPSHr net positive suction head required, m

investigated the transient flow induced by speed-changes and a suitable number of grid elements is very important for the sim-
rapid openings of the discharge valve in centrifugal pumps. ulation. The predicted head performance of the pump with 4 differ-
Zhang et al. (2014a,b) numerically simulated the transient flow ent numbers of grid elements are compared in Fig. 2 and the detail
patterns of a nuclear centrifugal pump during changes of its oper- of various grid meshes are reported in Table 2. In general, the head
ating conditions at constant rotating speed. of the model pump increases with the number of grid elements
The above investigations only represent a small fraction of the increases. However, the head obtained for grid number 4 only
information available in open literature on transient cavitation in increases by less than 1 m with the respect to the results of grid
centrifugal pumps. However, the adverse effects induced by tran- number 3, while the head discrepancies for the other grids are sig-
sient cavitation in pumps are extremely serious, and cannot be nificantly larger. Therefore grid number 3 was selected in the pre-
ignored in the design process. Therefore, the flow characteristics sent simulations. Fig. 3 shows an overview of partial mesh of the
under both steady and transient cavitation conditions are investi- flow passage, especially the main parts of the geometric structure.
gated in our present study, whose results hopefully represent a The Zwart-Gerber-Belamri model, as expressed by (1) and (2),
useful reference for further research work. proved to yield better precision for cavitation simulation (Zwart
et al., 2004), has and therefore been selected in the present work.
2. Physical model s
3anuc 1  av ap qv ap 2 pv ap  p
Re F v ap ; p < pv ap 1
The pump model is a centrifugal charging pump, which is an RB 3 ql
important component of the reactor coolant system of nuclear
power plants. Cavitation usually occurs in the first stage of the s
multi-stage centrifugal charging pumps. Therefore, in the present
3av ap qv ap 2 p  pv ap
Rc F cond ; p > pv ap 2
study, only the stationary domains including the annual suction RB 3 ql
chamber and the double-channel volute, the rotating domain of
The SST k-x turbulence model is a hybrid model combining
the first impeller stage have been selected as the physical model in
the advantages of the standard k-x and k-e turbulence models.
order to investigate its cavitation characteristics. The main geomet-
The viscous flow near the wall and the turbulence fully developed
ric and hydraulic specifications of the pump are reported in Table 1.
turbulent region can be accurately modeled using the standard k-x
It is required NPSHr 6 7.8 m according to the CVC system in a nuclear
and standard k-e turbulence models, respectively. As a result, the
power plant at the maximum flow rate Qmax = 160 m3/h. The flow
SST k-x turbulence model was applied in this investigation to
domains of the centrifugal charging pump with its first stage
solve the RANS functions.
impeller have been modeled by Pro/E, as shown in Fig. 1.
The average static pressure has been specified at the inlet of the
suction chamber, with uniform normal flow running into the inlet
3. Numerical approach section. The mass flow rate has been assigned at the outlet of the
double-channel volute. The impeller domain rotated with speed
The RANS equations have been performed by using the ANSYS
CFX 14.5 software, which uses a multi-block technique to couple
the separate numerical domains. A high mesh quality is required Table 1
in the numerical simulations for improving the precision of the Specifications of the pump model.

results and reducing the computational time. All parts of the pump Geometric specifications Hydraulic specifications
model have been meshed with structured hexahedral grids, and Inlet diameter (mm) D1 140 Nominal speed (r/min) n 4500
the meshes of boundary layers have been thickened. Generally Outlet diameter (mm) D2 236 Design flow rate (m3/h) Qd 110
speaking, the calculated error caused by the mesh are reduced by Outlet width (mm) b2 12 Maximum efficiency g P60%
increasing the number of gird elements, but excessive computer Wrap angle (deg) u 135 Maximum flow rate (m3/h) Qmax 160
Blade number Z 4 Net positive suction head NPSHr 67.8
memory and running time are required in the numerical
required(m)
simulation if the grid number is too large. Hence the selection of
192 Q. Fu et al. / Annals of Nuclear Energy 97 (2016) 190197

Table 3
Test precision standard of grade 2 in China.

Contents Q H P g
Uncertainty 62.0% 61.5% 61.5% 62.8%

In order to resolve the actual temporal variation of the flow, the


time step size of the computation has been adjusted to correspond
to an impeller rotation of 3 degrees. Hence, for a rotation speed of
4500 r/min the time step Dt has been set to be 1.111  104 s. The
Fig. 1. Flow domains of the pump model.
impeller completed 9 revolutions during each computation, so the
total simulation time has been 0.12 s. The results of the last 3 rev-
olutions of the impeller have been used to analyze the periodic
characteristics of the flow.

4. Experimental results

The test has been carried out at Jiangsu University according to


Chinese National Precision Grade No. 2 regulations, whose stan-
dard is reported in Table 3. The original model pump has been
tested in the open test bench, shown in Fig. 4. The flow rate of fluid
has been measured by the turbine flow meter, with 0.5% uncer-
tainty. The pressure in the inlet and outlet has been measured by
pressure sensor, whose uncertainty is 0.1%. An integrated measur-
ing instrument platform has been used to acquire the test data
with 0.5% uncertainty in the test. Both the hydraulic and the cav-
itation performance at the large flow rate have been measured in
Fig. 2. Head comparison under 4 grid numbers. this test, and the affinity laws have been applied to obtain the final
test data.

Table 2
Grid detail of 4 schemes. 4.1. Hydraulic performance
Schemes Scheme 1 Scheme 2 Scheme 3 Scheme 4
The measured head and efficiency are compared in Fig. 5 with
Grid number 954372 1572531 2067148 2611692
their simulated values, and the uncertainty of the measured head,
Heads/m 109.6 118.3 122.1 122.9
efficiency is 0.51%, 0.65% respectively. Both the measured head and
efficiency exceed the designed values at the 1.0Qd operating
n = 4500 r/min, while the other domains were stationary. A med- condition. The measured head is larger than its design head Hd over
ium turbulence intensity of 5% has been set at the inlet section most of the flow rate range, and the measured efficiency is also
and a non-slipping boundary condition has been imposed on all higher than its design value at flow rates from 0.85Qd to 1.6Qd.
solid surfaces. The steady simulated results supplied the suitable The simulated results of the head and efficiency are both higher
initial conditions for transient runs. than their test values and the maximum deviation is about 6% of

Fig. 3. Partial mesh overview of the flow passage.


Q. Fu et al. / Annals of Nuclear Energy 97 (2016) 190197 193

Fig. 4. Test bench of the centrifugal pump.

rate, but nevertheless, the tendency of the measured and simulated


results in the whole flow range is good. The geometrical structure
of the charging pump is complicated and the pump should operate
at multi flow rates. Thus the internal flow characteristics are extre-
mely intense at the low flow rates. The disk leakages were not
included in the computational domain in order to simplify the geo-
metrical structure, and this is the main reason that the test results
are lower than the simulated results. Although some discrepancies
are manifest in Fig. 12, good overall agreement has been attained
between the simulated and tested results. The hydraulic perfor-
mance comparison illustrated in Fig. 5 verifies the validity of the
adopted model for simulating the flow characteristics of the
impeller.

4.2. Cavitation performance


Fig. 5. Hydraulic performance comparison of simulated and measured results.
Fig. 6 shows the simulated and measured results of the pumps
cavitation performance at maximum flow rate of Q = 160 m3/h, and
the uncertainty of the measured NPSH is 0.58%. Both the simulated
1.08 and measured values of NPSH do not exceed NPSHr, the required
1.04
value for the pump system. The simulated NPSH is 0.782NPSHr
and the measured NPSH is 0.821NPSHr at H = 0.97Hd. Here the
1.00 required experimental NPSH of the pump is defined with a 3% head
Simulated result drop criterion. As a whole, the simulated results are in good accor-
H/Hd

0.96 dance with the measured data with a reasonable value (3.8%) of the
Measured result
0.92

0.88

0.84
0.7 0.8 0.9 1.0 1.1 1.2 1.3
NPSH / NPSHr

Fig. 6. Simulated and measured results of the pump cavitation performance at


Q = 160 m3/h.

the design value. The cavitation requirement at the maximum flow


rate has been the driving design factor of the pump, and therefore
the best efficiency point has been located at higher flow rates than
the design value 1.0Qd. With the increase of flow rate, the tested
results approach the simulated results and almost coincide at the
larger flow rates. The deviation between the measured and
simulated results at the high flow rate is smaller than the low flow Fig. 7. Schematic view of X and Y axis.
194 Q. Fu et al. / Annals of Nuclear Energy 97 (2016) 190197

relative error. The main reason for the deviation is that the leakage, cavitation (3% head drop), serious cavitation (6% head drop) and
frictions and other flow loss were not considered in the simulation. fractured cavitation (head breakdown), respectively corresponding
to the NPSH values equal to 7.2 m, 6.5 m, 6.12 m, 5.9 m and 5.8 m.
5. Results and discussion Fig. 7 shows the schematic view of the X and Y axes in the impeller
axial plane. The radial force along X and Y axes under the different
5.1. Radial forces along the X and Y axes cavitation regimes are discussed in this section, and all the results
were obtained from numerical simulation.
According to the specifications of the nuclear power plant the Fig. 8 shows the radial force fluctuations along the X and Y axial
required NPSHr of the centrifugal charging pump cannot exceed directions under the above five different cavitation regimes. Fig. 8
7.8 m at the maximum flow rate of Q = 160 m3/h. The development (a), (b) and (c) indicate a certain level of periodicity of the radial
of cavitation in the pump at Q = 160 m3/h has been conventionally force fluctuations, with the force along the Y direction larger than
divided into five regimes, indicated here as incipient cavitation in the X direction. The two tongues of the double-channel volute
(0% head drop), developing cavitation (1% head drop), critical are located along the Y axis. Most of the flow unsteadiness occurs

200 Fx Fy 200 Fx Fy
150 150

100 100

50 50
F/N

F/N
0 0

-50 -50

-100 -100

-150 -150

-200 -200
0.00 0.01 0.02 0.03 0.04 0.00 0.01 0.02 0.03 0.04
t/s t/s

(a) Incipient cavitation (0% head drop) (b) Developing cavitation (1% head drop)

200 Fx Fy 200 Fx Fy
150 150

100 100

50 50
F/N

0
F/N

-50 -50

-100 -100

-150 -150

-200 -200
0.00 0.01 0.02 0.03 0.04 0.00 0.01 0.02 0.03 0.04
t/s t/s

(c) Critical cavitation (3% head drop) (d) Serious cavitation (6% head drop)

200
Fx Fy
150

100

50
F/N

-50

-100

-150

-200
0.00 0.01 0.02 0.03 0.04
t/s
(e) Fractured cavitation (head breakdown)
Fig. 8. Radial forces on the X and Y axes under different cavitation conditions.
Q. Fu et al. / Annals of Nuclear Energy 97 (2016) 190197 195

in the proximity of each tongue, and as a result the fluctuation 0.6 A B C D


of the radial force is more intense along the Y axial than in the
X-direction. Before the intensity of cavitation increases to the crit- 0.5
ical regime, the interaction between the rotor and stator is the
0.4
main source of the flow unsteadiness, as can be inferred from the
periodicity of the radial force. When cavitation reaches to the seri- 0.3

Cp
ous cavitation regime, large amounts of vapor are generated in the
flow passage and their motion and development greatly influence 0.2
the radial forces along the X and Y axes, which become disorderly
0.1
and aperiodic. Beyond the critical cavitation regime the effects on
the flow pattern become dominant, and finally in the fractured cav- 0.0
itation regime the flow unsteadiness is mainly caused by cavitation
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
rather than rotor-stator interaction phenomenon.
t/s

5.2. Flow characteristics in the transient cavitation regime Fig. 10. Transient static pressure in the impeller.

In order to further investigate the flow patterns in the impeller


of the centrifugal pump under transient cavitation conditions, the The pressure increases from the inlet to the outlet of the impeller
evolution of the flow characteristics from inception to the and the fluctuations in the outer part of the impeller are stronger
fractured cavitation regime are discussed in the following. All of than in the inner part. This is because the fluid gets energy from
the numerical setups are the same as for the analysis of steady cav- the rotating impeller and the outer part of the impeller is more
itation except for the inlet pressure, which has been defined by the affected by rotor-stator interaction effects. When cavitation starts,
CEL program of CFX. The variation of the inlet static pressure under the pressure in the inlet part remains nearly constant up to
cavitating conditions has been defined by means of function (3). t = 0.12 s and then nearly decreases to 0 for a very short time, as

p0 t < 0:04s can be seen from the pressure characteristics at points A and B.
pt 3 The pressures at points C and D decrease slightly at t = 0.15 s, then
p0  kp t  t0 t P 0:04s
remain almost constant up to t = 0.5 s, and finally drop to 0 after-
where t0 is initial time, t0 = 0.04 s; p0 is the pressure when cavita- wards. The main reason of this behavior is that vapor is generated
tion starts, Pa; kp is pressure coefficient, kp = 50000, Pa/s. in the inner part of the impeller at incipient cavitation conditions,
The steady flow field obtained from previously calculations has and then is convected to the outer part when cavitation becomes
been used to initialize the transient simulation. Also in this case more intense. The pressure of the impeller is strongly influenced
the time step Dt has been taken equal to 1.111  104 s and the by the generation and burst of the vapor phase.
total simulation time is 0.68 s. The transient velocity fluctuations at the four monitoring points
Four typical monitoring points A, B, C and D have been defined in the impeller during the development of cavitation are shown in
inside the impeller in order to analyze the characteristics of the Fig. 11. Consistently with previous trends illustrated in Fig. 10, the
flow in the centrifugal pump under transient cavitation operation. amplitudes of the pressure and velocity fluctuations in the impeller
All monitoring points have been located along the mean streamline are larger at points C and D than at points A and B. The velocity
of the impeller and their relative positions are shown in Fig. 9. fluctuation in the outer part of impeller is prone to be affected
The pressure coefficient Cp and the velocity coefficient Cv by the rotor-stator interaction effects. It remains almost constant
defined as: at all monitoring points before t = 0.12 s, then increases rapidly
at points A and B and decreases slightly at points C and D. In this
C p p=0:5qu22 4
time range cavitation occurs in the inlet part of the impeller and
does not reach the outer part. The velocities at points A and B
C v 2v =u2 5
are larger than at C and D up to t = 0.56 s. At this time cavitation
These two equations have been used to describe the flow reaches the outer part of the impeller and the velocities rise up
pressure and velocity under the transient cavitation conditions. suddenly at points C and D, indicating that the cavitation extend
Fig. 10 presents the transient static pressure fluctuations at the through the whole flow passage of the impeller at the end of the
four monitoring points in the impeller under cavitation conditions. transient cavitation run.

1.6
A B C D
1.5

1.4

1.3
Cv

1.2

1.1

1.0

0.9

0.8
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
t/s

Fig. 9. Monitoring points on the impeller. Fig. 11. Transient relative velocity in the impeller.
196 Q. Fu et al. / Annals of Nuclear Energy 97 (2016) 190197

The generation, development and burst of the vapor in the 6. Conclusions


impeller flow passage are typical features of cavitation, and
Fig. 12 shows the variation of the vapor volume fraction variation The flow characteristics on the impeller of a nuclear centrifugal
at the four monitoring points in the impeller during the transient pump model operating under cavitating conditions at high flow
run. It can be seen clearly that the vapor fraction starts to increase rates have been systematically investigated. Both the results under
after t = 0.13 s at points A and B and after t = 0.58 s at points C and the steady and transient cavitation have been discussed.
D. Although the vapor variation trends at points A and B are nearly Although some deviation has been observed between the simu-
the same, the vapor fraction at point A is much larger than at point lated and measured results, both trends are consistent and the rel-
B. In addition, the vapor moves rapidly towards the outer part of ative error remains with acceptable limits. The overall good
the impeller, and therefore the falling speed at A is more pro- agreement between the simulations and experimental measure-
nounced than at B after the vapor volume fraction has reached ments confirms the validity of the model adopted for predicting
its maximum value. The vapor fraction at points C and D increases the flow characteristics of the impeller.
significantly and even exceeds the vapor fraction in inlet part of the At slight cavitation development conditions the fluctuations of
impeller at the end of transient cavitation run. When cavitation radial force are mainly affected by the rotor-stator interaction phe-
reaches the fractured cavitation regime, the flow in the impeller nomenon, but become more and more dominated by cavitation
passage becomes disorderly and highly turbulent, generating the when its intensity increases towards the fractured cavitation
second rise of the vapor fractions at the four monitoring points regime, and finally the flow unsteadiness is mainly caused by cav-
in the impeller. itation rather than rotor-stator interaction.
Since vibrations and other unsteady flow phenomena occur in Under transient cavitation conditions the vapor generation,
conjunction with cavitation, especially under the transient condi- development and burst have a strong influence on the flow pat-
tions, the operation stability of the centrifugal pump system can- terns in the impeller passage. At cavitation inception vapor is
not be ignored. The axial force on the centrifugal pump impeller mainly generated near the leading edge of the blades, and progres-
under the transient cavitation run is shown in Fig. 13. At the begin- sively extends on the suction side of the impeller at increasing
ning of the transient run, cavitation is light and has almost no levels of cavitation. At the end of transient cavitation regime, vapor
influence on the axial force, which fluctuates in the 330365 N nearly blocks the whole flow passage of the impeller and leads to
range with no sudden changes. The axial force on the impeller the development of a highly turbulent flow in the trailing regions
starts to increase from t = 0.12 s and nearly reaches to 475 N at of the blade passages. The generation and motion of the vapor
t = 0.22 s. Then, it falls down to 370 N, rises up again to a high phase and its bursting in the fractured cavitation regime lead to
value, and finally decreases at the end of the transient cavitation a change of flow patterns in the blade passages, which is a main
run. The generation and motion of the vapor phase and its bursting reason for rising and falling of the axial force on the impeller.
in the fractured cavitation regime lead to a change of flow patterns
in the blade passages, which is a main reason for rising and falling
of the axial force on the impeller. Conflict of interest

0.5
The authors declare that there is no conflict of interest regard-
A B C D ing the publication of this paper.
0.4

Acknowledgement
0.3
fv

0.2
This study is financially supported by the National Natural
Science Foundation of China (Grant No. 51379091, No. 51239005
0.1 and No. 51509108), Natural Science Foundation of Jiangsu Province
of China (Grant No. BK20140554, No. SBK2015042921), Postdoc-
0.0 toral Science Foundation of China (Grant No. 156993) and Priority
Academic Program Development of Jiangsu Higher Education Insti-
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
tutions (PAPD). The supports are gratefully acknowledged.
t/s

Fig. 12. Transient vapor volume fraction in the impeller.


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