STAR-CCM+离心泵旋转机械解决方案CentrifugalPumpSolutions_CD-adapco

Discovering Better DesignsFaster for Centrifugal PumpsWhy work with CD-adapco?Pump Companies’Technical ChallengesCD-adapco’s Simulation Solutions•Over-dependence on physical testingàtoo long and expensive•Not enough performance insight across wide operating rangePredicting pump flow performance virtuallyas “a numerical test rig”(flow rates & patterns, pressure changes, NPSH, etc.)•Simulation is only used as a trouble-shooting tool,not to ensure desired performance of new pumpsSimulation-driven design•Not enough time to consider many alternative pump designs;forced to accept “good enough”Automated design space exploration •Preparing to simulate = bottleneck;•Not enough time to optimize designsRobust, streamlined modeling &meshing•Too many simplifying assumptions,approximations; can’t tell howcomplete pump will truly operateSimulating with full-fidelity CAD geometry•Complex flow phenomena (e.g., turbulence, recirculation, cavitation, vibration)Fast, accurate, memory-efficient solvers for complex, unsteady flow phenomena•Can’t afford software licenses needed to do fast design space exploration Fewer products; Affordably scalable licensing;Parallel processing•Motor cooling Flow and Heat Transfer together •Noise & vibration Acoustics•Fluid/gas separation Multiphase Flows§Feed water / Supply pumps(e.g., for boilers, steam generators,reactors)§Make-up pumps§Condensate Extraction pumps§Cooling water pumps(reactors, cooling towers)§Residual Heat Removal pumps§Containment Spray pumps§Circulating water pumps§Booster pumpsEtc.Many Uses for Water Pumps, Hydro TurbinesNeeded: Increased Energy EfficiencyIt has been estimated that 20% of the total energy consumed worldwide is used to run a pump of one sort or another.1In addition, of those pumps, two thirds use 60% more energy than is required.2“Pumps that are not inherently efficient in their peer group across all companies that manufacture the same types of equipment will either be removed from the market or will require redesign in order to meet higher efficiency levels. Someestimates put this at up to 20% of the pumps on the market today.”--Empowering Pumps, 11-Sept-2015“The Newly Proposed Pump Regulation by the Department of Energy”1IEA (2007): Tracking Industrial Energy Efficiency and CO2 Emissions, Paris: International Energy Agency (IEA).“Operating conditions that were not mentioned in the [centrifugal] pump’s order document and were not considered in pump design have been responsible for more than 60% of all unscheduled shutdowns.”Needed: Explore Different Operating Conditions“Operating conditions that were not mentioned in the [centrifugal] pump’sorder document and were not considered in pump design have been responsible for more than 60% of all unscheduled shutdowns .”--Turbomachinery International, July/August 2015, page 14“Alternative operating points and transient operating situations have always been important in this regard.”“The flow rates, required heads, liquid details, and net positive suction head (NPSH)available in different scenarios should be accurately indicated for all possible operating situations.”Gov’t Regulations for Pump Energy EfficiencyWhy Simulate Water Pumps, Hydro Turbines?§Maximum Efficiency §Optimal Performance(at Design Point, BEP)§Robust Performance(Off-Design)§Reliability / Durability §Comply with StandardsDiscover Better Designs FasterPredicting pump flow performance virtually•Faster, cheaper than physical testing•More performance insight across wider operating rangePump Company Technical ChallengesCD-adapco Simulation Solutions•Over-dependence on physical testingàtoo long and expensive•Not enough performance insight across wide operating range Predicting pump flow performance virtually as “a numerical test rig”(flow rates & patterns, pressure changes,NPSH, etc.)Technical Challenges vs. Simulation SolutionsHead vs. Flow Rate Performance Curve for Circulating Water PumpPerformance Curve for Boiler Feedwater PumpB estE fficiency P ointBEPBEPPredicting pump flow performance virtually11H e a dFlow RateExperiment STAR-CCM+Low flow rate High flow rate1212359 GPM1100 GPMQ-H Curve131314InletAtmospheric pressure @ outletBlades rotating at 2900 RPMGoal: Produce pump Performance Curves via simulation(Flow vs. Delta Pressure)15•Flow patterns•Flow rates•Pressures•Vibrations•Head•Torque•Power•Efficiency•Temperature•etc.•Operatingconditions•Working fluid•Flow solver•Steady orunsteady•Turbulencemodel•y+ walltreatmentSolve &Visualize ImportGeometry MeshSet UpPhysics16Low Flow RateHigh Flow RateStreamlines in an axial pumpCavitation breakdownCavitation inceptionCritical cavitationTypical radial inlet MSI radial inletTypical axial inducer 3700 GPM2700 GPM“STAR-CCM+ gave us confidence that our design of a low-pressure industrial pump would retain the required performance and durability.”–Travis Jonas, MSINo recirculation§Challenge:Improve a low-pressure pump with radial inlet and axial inducer to meet performance specifications §Solution:Used STAR-CCM+ on 132-node cluster for rapid A-to-Bcomparisons: complex 360o geometry;unsteady turbulent flow; and 2 very different design points (2700 vs. 3700 GPM)àre-designed the inlet and inducer §Impact:•Reduced recirculation, avoidedcavitation despite low flow coefficients •Achieved head target (10 ft.)at both design flow ratesSimulation-driven Design•Simulation used proactively to predict performance of new pumps (versus just for troubleshooting),and to make decisions & changes that help optimize the designPump Company Technical ChallengesCD-adapco Simulation Solutions•Simulation is only used as a trouble-shooting tool, not to ensure desired performance of new pumps Simulation-driven designTechnical Challenges vs. Simulation Solutions20A Maturity Model for Engineering Simulations Validate (results)Troubleshoot (design)PredictAutomate(exploration)OptimizeExplore digitally,Confirm physicallyUltimate Goal:Discover Better Designs FasterCritical inversion point(from reactive to proactive engineering)Simulation-driven DesignCAE 1.0CAE 2.0CAE 3.0Discover Better Designs FasterValidateTroubleshoot PredictExplore Optimize= Feasible= InfeasibleObjective 1O b j e c t i v e 2Automated Design Space Exploration •More ability to consider alternative pump designs–to discover better designs faster•Go beyond designs that are just “good enough”Pump Company Technical ChallengesCD-adapco Simulation Solutions•Not enough time to consider many alternative pump designs; forced to accept “good enough”Automated design space explorationTechnical Challenges vs. Simulation SolutionsSolve &VisualizeImport GeometryMeshSet Up Physics Change Design(geometry and physics)# of DesignsTime Design #N+1Design #NSTAR-CCM+CFturbo SHERPA High Power Required Optimal Design Pareto Front Baseline Design ViolatesConstraintBaseline DesignFlow rate = 400 m 3/hPressure head = 30 mPower required = 38.4 kW Optimized DesignFlow rate = 400 m 3/hPressure head = 30 mPower required = 36.0 kWSTAR-CCM+CFturbo SHERPA“I can now obtain better pump designs fasterby spending more time on engineeringdecision-making, and less time on model setup& data transfer.”–Ed Bennett, VP of Fluids Engineering, Mechanical Solutions Inc. (MSI)§Impact:•Power reduced by 6%•Found 33 improved designs;not just 1 that is “good enough”•Scalable platform for optimization and multi-disciplinary simulations§Solution:•Optimization (HEEDS/SHERPA)•Parametric blade design (3rd -party)•Flow simulation (STAR-CCM+)•Process automation (HEEDS)§Challenge:1)Modify impeller to increase pump efficiency; minimize power required2)Obtain set of lowest-power pump designs for set of outlet pressures SHERPARequirementsPerformanceOptimizationSTAR-CCM+CFturboAccurate Simulation of Complex, Unsteady Flows•Improve prediction of actual pump performance•Reduce the risk of recirculation, cavitation, and/or vibrationPump Company Technical ChallengesCD-adapco Simulation Solutions•Complex flow phenomena (e.g., turbulence, recirculation, cavitation, vibration)Fast, accurate, memory-efficient solvers for complex,unsteady flow phenomenaTechnical Challenges vs. Simulation SolutionsPredicting pump flow performance virtually8506506757007257507758008250.200.100.050.15A m p l i t u d e (R S 796, 0.132Overall level P UX Overall level P UY Overall level P UZVibration Limit (0.2)9006757007257507758008258508750.500.000.100.200.300.400.050.150.250.350.45M )i n /s776, 0.384Vibration LimitOverall level P UXOverall level P UY Overall level P UZVibrationLimit (0.2)Extracted Flow RegionOriginal ~14m/sModified ~9m/s§Solution:CFD simulation to predict flow velocities,vibrations in Original design versus Modified design (withvolute changed to increase B-gap)§Challenge:In newly installed centrifugal pump,reduce vibration below acceptance limits Reduced velocityat cutwaterOriginal2.9% B-gapModified 7.0% B-gap §Impact:•Velocity at cutwater reduced 36%•Vibrations reduced 66%,to far below acceptance limits•B-gap width kept in 6-10% range to avoid excessive vane pass vibrationpresented atbySimulation of Complex, Unsteady FlowsCavitation inside a double-suction pumpSuctionInlet VoluteImpellerInlet Total Pressure –175 kPa Inlet Total Pressure –80 kPaInlet Total Pressure –40 kPa Inlet Total Pressure –27 kPaInlet Plane of symmetry§Impact:•Clear understanding of pump performance across wide operating range•Confidence in pump design through simulation •Unsteady solution with cavitation•Poly meshed (~5M cells)•CAD geometry; half-model with splitter; 1 blade passage cyclically patterned §Solution:§Challenge:Accurately predict pump performance at BEP (+/-)as well cavitation occurrence Simulation of Complex, Unsteady FlowsEnergy & Power“STAR-CCM+ has all of the featuresrequired to solve extremely complex problems in hydraulic turbomachinery”–Edward Bennett, Ph.D., VP of Fluids EngineeringRobust, streamlined modeling & meshing•Fewer modules = fewer data transfers, less error, less training •Tight geometry connection to 3rd-party CAD software •Less manual, tedious model cleanup required•Modeling-and-simulation process can truly be automated •Enables faster design space explorationPump Company Technical ChallengesCD-adapco Simulation Solutions•Preparing to simulate = bottleneck;•Not enough time to optimize designs Robust, streamlined modeling &meshingTechnical Challenges vs. Simulation SolutionsRobust, streamlined modeling & meshinggeometrysolids meshfluids meshphysicssetupflow visualizationheat visualizationAll-in-one Simulation EnvironmentBring geometry from CAD into STAR-CCM+NXSTAR-CCM+Options:1)neutral files(.igs, .stp,.x_t, .x_b)2)native CADpart files (.prt)3)STAR CAD Client[Good][Better][Best]NXSTAR-CCM+3) using STAR-NX CAD ClientDrive Design changes in CAD and STAR-CCM+ will updateSTAR-CCM+NX3) using STAR-NX CAD ClientDrive design changes in STAR-CCM+ and the CAD will updateRobust, streamlined modeling & meshing700,000 polyhedral cells including2 prism layers for better flow accuracyRobust, streamlined modeling & meshing2 prism layersRobust, streamlined modeling & meshingenables rapid Design Space ExplorationSolve &VisualizeImport Geometry Mesh Set Up PhysicsGeometry ChangeRobust, streamlined modeling & meshingBaselineImprovedSTAR-CCM+CFturboSHERPARobust, streamlined modeling & meshingenables automated Design Space ExplorationSimulating with full-fidelity CAD geometry •Remove simplifying assumptions and approximationsthat reduce accuracy•Understand how the entire pump machinery will operatePump Company Technical ChallengesCD-adapco Simulation Solutions•Too many simplifying assumptions,approximations; can’t tell how machine will truly operate Simulating with full-fidelity CAD geometryTechnical Challenges vs. Simulation SolutionsSimulating with full-fidelity CAD geometry§ A large axial pump designed to provide durable performance under severe conditions§Flow Physics•Complex, transient flow through 360 degrees•Stationary and rotating domains•Unsteady forced response§Relevant STAR-CCM+ features to facilitate a solution•Unsteady flow solver•Unsteady cavitation model•Unsteady stationary/rotating interfaces•Advanced unstructured CFD meshing from CAD geometry•Parallel capability for large size and economical time to solutionVertical Pump Flow Domain。