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

DiscoveringBetterDesignsFasterforCentrifugalPumps2WhyworkwithCD-adapco?PumpCompanies’TechnicalChallengesCD-adapco’sSimulationSolutionsOver-dependenceonphysicaltestingàtoolongandexpensiveNotenoughperformanceinsightacrosswideoperatingrangePredictingpumpflowperformancevirtuallyas“anumericaltestrig”(flowrates&patterns,pressurechanges,NPSH,etc.)Simulationisonlyusedasatrouble-shootingtool,nottoensuredesiredperformanceofnewpumpsSimulation-drivendesignNotenoughtimetoconsidermanyalternativepumpdesigns;forcedtoaccept“goodenough”AutomateddesignspaceexplorationPreparingtosimulate=bottleneck;NotenoughtimetooptimizedesignsRobust,streamlinedmodeling&meshingToomanysimplifyingassumptions,approximations;can’ttellhowcompletepumpwilltrulyoperateSimulatingwithfull-fidelityCADgeometryComplexflowphenomena(e.g.,turbulence,recirculation,cavitation,vibration)Fast,accurate,memory-efficientsolversforcomplex,unsteadyflowphenomenaCan’taffordsoftwarelicensesneededtodofastdesignspaceexplorationFewerproducts;Affordablyscalablelicensing;ParallelprocessingMotorcoolingFlowandHeatTransfertogetherNoise&vibrationAcousticsFluid/gasseparationMultiphaseFlows3§Feedwater/Supplypumps(e.g.,forboilers,steamgenerators,reactors)§Make-uppumps§CondensateExtractionpumps§Coolingwaterpumps(reactors,coolingtowers)§ResidualHeatRemovalpumps§ContainmentSpraypumps§Circulatingwaterpumps§BoosterpumpsEtc.ManyUsesforWaterPumps,HydroTurbines4Ithasbeenestimatedthat20%ofthetotalenergyconsumedworldwideisusedtorunapumpofonesortoranother.1Inaddition,ofthosepumps,twothirdsuse60%moreenergythanisrequired.2--EmpoweringPumps,11-Sept-2015“TheNewlyProposedPumpRegulationbytheDepartmentofEnergy”Needed:IncreasedEnergyEfficiency1IEA(2007):TrackingIndustrialEnergyEfficiencyandCO2Emissions,Paris:InternationalEnergyAgency(IEA).2Almeida,AnibalT.etal;EuPLot11MotorsFinalReport,UniversityofCoimbra,December2007,p:68“Pumpsthatarenotinherentlyefficientintheirpeergroupacrossallcompaniesthatmanufacturethesametypesofequipmentwilleitherberemovedfromthemarketorwillrequireredesigninordertomeethigherefficiencylevels.Someestimatesputthisatupto20%ofthepumpsonthemarkettoday.”5“Operatingconditionsthatwerenotmentionedinthe[centrifugal]pump’sorderdocumentandwerenotconsideredinpumpdesignhavebeenresponsibleformorethan60%ofallunscheduledshutdowns.”--TurbomachineryInternational,July/August2015,page14Needed:ExploreDifferentOperatingConditions“Operatingconditionsthatwerenotmentionedinthe[centrifugal]pump’sorderdocumentandwerenotconsideredinpumpdesignhavebeenresponsibleformorethan60%ofallunscheduledshutdowns.”--TurbomachineryInternational,July/August2015,page14“Alternativeoperatingpointsandtransientoperatingsituationshavealwaysbeenimportantinthisregard.”“Theflowrates,requiredheads,liquiddetails,andnetpositivesuctionhead(NPSH)availableindifferentscenariosshouldbeaccuratelyindicatedforallpossibleoperatingsituations.”6Gov’tRegulationsforPumpEnergyEfficiency7WhySimulateWaterPumps,HydroTurbines?§MaximumEfficiency§OptimalPerformance(atDesignPoint,BEP)§RobustPerformance(Off-Design)§Reliability/Durability§ComplywithStandardsDiscoverBetterDesignsFasterPredictingpumpflowperformancevirtuallyFaster,cheaperthanphysicaltestingMoreperformanceinsightacrosswideroperatingrange9PumpCompanyTechnicalChallengesCD-adapcoSimulationSolutionsOver-dependenceonphysicaltestingàtoolongandexpensiveNotenoughperformanceinsightacrosswideoperatingrangePredictingpumpflowperformancevirtuallyas“anumericaltestrig”(flowrates&patterns,pressurechanges,NPSH,etc.)TechnicalChallengesvs.SimulationSolutions10Headvs.FlowRatePerformanceCurveforCirculatingWaterPumpPerformanceCurveforBoilerFeedwaterPumpBestEfficiencyPointBEPBEPPredictingpumpflowperformancevirtually11PredictingpumpflowperformancevirtuallyHeadFlowRateExperimentSTAR-CCM+LowflowrateHighflowrate12Predictingpumpflowperformancevirtually12359GPM359GPM359GPM1100GPM1100GPM1100GPMQ-HCurve1313Predictingpumpflowperformancevirtually14PredictingpumpflowperformancevirtuallyInletAtmosphericpressure@outletBladesrotatingat2900RPMGoal:ProducepumpPerformanceCurvesviasimulation(Flowvs.DeltaPressure)15PredictingpumpflowperformancevirtuallyFlowpatternsFlowratesPressuresVibrationsHeadTorquePowerEfficiencyTemperatureetc.OperatingconditionsWorkingfluidFlowsolverSteadyorunsteadyTurbulencemodely+walltreatmentSolve&VisualizeImportGeometryMeshSetUpPhysics16PredictingpumpflowperformancevirtuallyLowFlowRateHighFlowRatePredictingpumpflowperformancevirtuallyStreamlinesinanaxialpumpPredictingpumpflowperformancevirtuallyCavitationbreakdownCavitationinceptionCriticalcavitationTypicalradialinletMSIradialinletTypicalaxialinducer3700GPM2700GPM“STAR-CCM+gaveusconfidencethatourdesignofalow-pressureindustrialpumpwouldretaintherequiredperformanceanddurability.”–TravisJonas,MSINorecirculation§Challenge:Improvealow-pressurepumpwithradialinletandaxialinducertomeetperformancespecifications§Solution:UsedSTAR-CCM+on132-nodeclusterforrapidA-to-Bcomparisons:complex360ogeometry;unsteadyturbulentflow;and2verydifferentdes