Improving the Modeling of Pressure Pulsation and Cavitation Prediction in a Double-Volute Double-Suction Pump Using Mosaic Meshing Technology

Abstract

Over the years, Computational Fluid Dynamics (CFD) has been an integral part of most pump design processes. Unfortunately, as calculation schemes and flow investigations become more complicated, the cost of conducting numerical simulations also becomes more expensive in terms of computational time. To remedy this, cutting-edge technology, together with novel calculation techniques, are continuously introduced with the end target of producing more accurate results and faster computing time. In this paper, CFD simulations are run on a numerical model of a double-volute double-suction pump prepared using ANSYS Fluent Mosaic meshing technology. Poly-Hexcore, the first application of Mosaic technology, fills the bulk region with octree hexes, keeps a high-quality layered poly-prism mesh in the boundary layer, and conformally connects these two meshes with general polyhedral elements. This technology promises to provide a lower number of cells along with a significant increase in computing speed. In this paper, steady state results of the model with Mosaic Poly-Hexcore mesh with ~37% fewer cells produced comparable results with a similarly sized model prepared with multi-block structured hexagonal mesh. The predicted pump head, efficiency and shaft power under the design conditions were within 1% for both models, while calculation time was reduced by ~25%. Additional simulations using the Poly-Hexcore mesh showed that the model was able to closely predict the pump’s NPSH3 for 0.8QD, 1.0QD, and 1.2QD compared with the manufacturer’s data. Under cavitating flow conditions, the formation of vapor bubbles was observed on the suction side, starting at the leading edge of the blade and slowly forming as thin sheets towards the trailing edge as the suction pressure is reduced. Lastly, pressure fluctuations were observed from pressure coefficient data collected at several monitoring points in the volute and the impeller. It was seen that due to the interaction between the stationary casing and the rotating impeller, pulsations were equivalent to the blade passing frequency and its harmonics.