Scientific Bulletin of the Politehnica University of Timisoara Transactions on Mechanics Special issue

The 6th International Conference on Hydraulic Machinery and Hydrodynamics Timisoara, Romania, October 21 - 22, 2004

DEVELOPMENT OF AN EMPIRICAL EQUATION TO PREDICT THE DISC FRICTION LOSSES OF A CENTRIFUGALLP PUMP
Ali NEMDILI, Dr * Dpartement de Gnie Maritime, Facult de Gnie Mcanique Universit des Sciences et de la Technologie dOran Dieter-Heinz HELLMANN, Prof. Dr.-Ing. University of Kaiserslautern, Department of Mechanical Engineering, Institute of Fluid Flow and Displacement Machinery, P.O. Box 3049, 67663 Kaiserslautern, Germany

*Corresponding author: B.P. 1505, El-MNaouer, Oran 31000, Algrie, Algeria Tel.: (+213) 41421771, Fax: (+213) 41421771, Email: alnemdili@yahoo.com ABSTRACT This paper deals with experimental investigations on fluid friction of rotational discs in real centrifugal pump casings. The results show that the disc friction loss depends on the side gap geometry, on the Reynolds number, on the width of the volute, and on the surface roughness. As a result of these investigations, an improved empirical equation to predict the disc friction losses is developed. This proposed empirical equation can predict the experimental results with a very good accuracy. KEYWORDS Centrifugal pump, disc friction loss, empirical equation NOMENCLATURE b D g k kS M R Re s t n [m] [m] [m/s2] [-] [m] [N.m] [m] [-] [m] [m] [RPM] [s-1] [kg/m3] [m2/s] width diameter of disc gravity angular velocity ratio hydraulic roughness friction torque - moment radius of disc Reynolds number axial gap (disc and housing) radial gap (disc tip and housing) rotational speed angular velocity mass density kinematic viscosity ABBREVIATIONS RPM Revolution per minute 1. INTRODUCTION Despite the extraordinary high level in the design of centrifugal pumps, it is necessary to improve the overall efficiency. This can only be achieved through more in depth experimental and theoretical research. Friction losses, which occur during the rotation of discs and cylinders in closed casings filled with fluid play in many cases a decisive role. Their possible exact knowledge constitutes an important step in the calculation of pumps. Disc friction losses caused by the fluid flow in the clearance between the impeller and the housing are expressed as a power loss. Disc friction losses in impeller side rooms of turbomachines have been treated in numerous publications. A number of empirical equations to predict the disc friction losses [1 - 7] were suggested by many researchers, but generally there is not an exact mathematical model to predict these losses. Most of the published work on disc friction is concerned with plain thin discs rotating in closefitting cylindrical casings and has been generally presented in terms of the non-dimensional torque coefficient cM. The purpose of the investigations reported here is to develop an improved empirical equation by examining discs with different geometrical parameters running in a real centrifugal pump volute casing of different width. The results show that the disc friction loss depends strongly on the axial gap, on the Reynolds number, on the surface roughness and on the width of the volute. 235

Subscripts and Superscripts 2 outlet

2. EXPERIMENTAL SETUP AND PROCEDURE A general layout of the test stand for the identification of the power demand of disc friction in water tests is indicated in Figure 1 and Figure 2. The torque is measured by means of a torque meter mounted on (8) and the rotational speed by means of a stroboscope lamp (9). The mechanical seal is cooled with water, which is regulated by the valve (11). The ball valve (14) is used to the air escape of the trial equipment. The pump (10) is filled with water by means of the shut-off slide (12). The inlet and the outlet of the pump are direct connected with socket (15 and 18), which at the same time support the resistance thermometers (16 and 17). The temperature difference between (16) and (17) is measured by means of a precision temperature measurement device (21).
14 6

To evaluate the disc friction experiments are conducted without the assembly of the disc and without filling the pump with water for various values of the rotational speed in order to obtain the mechanical power due to bearing- and mechanical seal frictions. The influence of the diffuser device will be investigated through the inset of three different volutes. The rotational speed will be varied by means of an electronic hand-adjustable speed control integrated in the motor.

x=2

b2 s

20 15 16 13
t

D2

21

12 4

R
11

22 17 19 18 10

b4
9 8 3

t = 1mm

Cover
2 7 1

Figure 2. Detail drawing of disc assembly 1 Fixation plate 2 Motor attachment 3 Electric motor with speed control 4 Attachment 5 Volumetric flow meter indicator 6 Filter 7 Multiple disc coupling 8 Extended piece for the torque meter 9 Mark for the rotational speed measurement (stroboscope lamp) 10 Test pump 11 Flow cooling regulating valve of the pump mechanical seal 12 Shut-off slide 13 Volumetric flow meter 14 Ball valve for the ventilation 15-18 Socket at the pump inlet/outlet 16-17 Resistance thermometer 19 Ball valve for the pump injection with water 20-22 Pressure gauge inlet/outlet 21 Precision differencetemperature measurement Table 1 gives width of tested discs with the corresponding axial gap and surface roughness. Table 1. Geometrical arameters of the tested discs Width B2 (mm) 18 23 29 36 Axial gap s (mm) 13.5 11 8 4.5 Roughness kS (m) 5.45 6.46 5.26 8.62

Figure 1. General layout of test stand A more complete description of the test stand and accessories is included in [5]. 236

Experiments are conducted for the following parameters: Axial clearance between the disc and the end walls of the casing in term of s / R ratios of 0.040, 0.071, 0.098 and 0.12. Tip clearance was constant t / R ratio of 0.009. Outlet width of the volute b4 (b4 = 38; 48 and 54 mm). Rotational speed n varies from 900 to 1800RPM.

Experiments are conducted with water. The state of zero delivery of the pump is simulated, the impeller is replaced by a disc, that means that the complete blade passages are filled up with material. Power due to the disc friction PDF is thus determined as follows:

coefficient for the mode of turbulent flow with merged boundary layers is:

cM

PDF = PS PM

s 0.0102 R = 0.2 Re

0.1

(5)

(1)

where PS and PM are respectively the shaft and the mechanical power. Shaft power PS is calculated means the measured torque MS and speed n:

Nixon and Cairney [6] suggested the following empirical equations for the disc friction coefficient cM , one for hydraulically smooth disc, the other for a rough disc: for hydraulically smooth regime, kSkS,crit:

PS = M S

2 n 60

(2)

s t c M = 0.075 Re 0.2 1 + 0.75 + (6) R R

and for rough regime, kSkS,crit:

To obtain a non-dimensional presentation of the results, the non-dimensional torque coefficient cM according to the following equation will be used:

cM =

PDF

2 n 5 R 60
3

(3)

cM =

1 + 0.75 R 3.8 log 10 k S

t R
0.25

s 2.4 R

(7)

Finally it is to note, that the temperature was measured when a stationary temperature level for each speed and each disc width appears. It takes approximately 5 to 10 minutes. The density and the kinematic viscosity of test fluid are evaluated according to [4].

The critical value for kS is:

k S ,crit =

150 R

(8)

(t ) = C n t n
n =0

(t ) = e

110 3.152 110 + t

(4)

10 6

Experiments realized by Poullikkas [7] are based on the regime of turbulent flow with merged boundary layers, which is the more likely to occur in centrifugal machinery. The proposed equation based on theoretical and experimental results takes into account the effect of the surface roughness, this appears to be convenient:

with : C0=999.84; C1=6.7983 x 10-2; C2=-9.106 x 10-3; C3=1.005273 x 10-4; C4=-1.12676 x 10-6; C5=6.5918 x 10-9. A main value of the temperature t between the inlet and the outlet of the pump is used. 3. PREVIOUS WORK ON DISC FRICTION IN CENTRIFUGAL PUMPS A lot of empirical equations to predict disc friction losses were suggested by many researchers: Daily and Nece [1] showed four possible modes of flow for a disc running in an enclosed casing. The best empirical expression of the disc friction

cM

k = S R

0.25

s R Re 0.2

0.1

(9)

Theses equations are used for the comparison of the test results with the theory. 4. EXPERIMENTAL RESULTS AND DISCUSSIONS Figure 3, Figure 4 and Figure 5 show the experimental results obtained for the various clearances and the three different volutes. It can be seen from the curves cM = f(Re) that: In all cases the disc friction loss cM declines with increased Reynolds-number (Figures 3 and 4). The disc friction coefficient cM declines approximately steady in the same form with increased values of axial clearance s. 237

 By increasing of the s / R ratio the disc friction coefficient cM decreases. The influence of the geometry of the volute is obtained in Figure 5. The analysis of the curves shows that small differences between the three curves for disc friction coefficient versus Reynoldsnumber appear. Therefore the inset of the volute has only small influence on disc friction coefficient.
8 7

In order to examine the quality of the introduced approximate equations by the different authors and to reveal the effects of a real centrifugal pump geometry on the qualitative and quantitative development of the disc friction losses, a comparison of the established experimental results with these approximate equations was to be carry out. The results are shown in the Figure 6 for the various values of the width and the three volutes.
: Measured : Correction of the measured results : Equation (5), (1960) : Equations (6) and (7), (1972) : Equation (9), (1995)

Disc friction coefficient cM x 10

6 5 4 3 2 1 0 1.2 1.4 1.6 1.8 2.0

-6

Experimental results (Volute with b4 = 54mm) s = 13.5mm; s = 11 s = 8; s = 4.5

Reynolds number Re x 10

Disc friction coefficient cM x 10

2.2

2.4

2.6

Figure 3. Influence of the axial clearance on the disc friction coefficient

4.5
3

Disc friction coefficient cM x 10

4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 1.2
Corrected experimental results using (1 + 5 x b2 / D2) Volute with b4 = 54mm : s = 13.5mm; : s = 11 : s = 8; : s = 4.5

0 1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

2.1

2.2

2.3

2.4

2.5

a)
6

Disc friction coefficient cM x 10

1.4

1.6

1.8

2.0

2.2
-6

2.4

2.6

Reynolds number Re x 10

Figure 4. Correction of the curves taking into account the factor (1 + 5 x (b2/D2))
8 7 6 5 4 3 2 1 0 1.2
Experimental results (b2 = 36mm, s = 4.5mm) : Volute with b4 = 38mm : Volute with b4 = 48 : Volute with b4 = 54

Disc friction coefficient cM x 10

0 1.4

1.6

1.8

2.0

2.2
-6

2.4

2.6

2.8

Reynolds number Re x 10

b) Figure 6 Comparison of experimental results with those using the different equations a) for s = 8 mm and volute with b4 = 38 mm b) for s = 13.5 mm and volute with b4 = 54 mm
2.0 2.2
-6

1.4

1.6

1.8

2.4

2.6

Reynolds number Re x 10

Figure 5. Influence of the width of the volute on the disc friction coefficient 238

From the Figure 6 the following conclusions can be explained: For all values of clearance and every volute, the curves corresponding to the experimental results

lie over other curves obtained using the approximate equations. The comparison of the results shows that the best approximate equation, which can predict with minimum error the corrected experimental results by taking into account the factor indicated in the Figure 4 above, seems to be the equation (9) given by [7]. However still certain deviations are found because the experiments are done using a real centrifugal pump casing.
: Measured s = 4.5mm : Calculated using Equation (11) : Measured s = 13.5mm : Calculated using Equation (11)

Using the principles of the dimensional analysis the following relationship can be written:

cM

c d b a s k S b4 = f (Re ) , , , R R s

(10)

In the case of turbulent regime, the exponent a is equal to 0.2 and according to the approximate analysis of [6] and [7], the following equation is suggested:

cM

k = S R

0.25

s R

0.1

b 4 s

0.2

Re 0.2 (11)

The proposed empirical equation (11) can predict the experimental results as shown in the following Figure 7. 5. CONCLUSIONS

8 7 6 5 4 3 2 1 0 1.2

1.4

1.6

1.8

2.0

2.2
-6

2.4

2.6

Reynolds number Re x 10

a)
8 7

0 1.2

1.4

1.6

1.8

2.0
-6

2.2

2.4

2.6

Reynolds number Re x 10

b) Figure 7. Prediction of the experimental results using the proposed equation a) for volute with b4=38mm b) for volute with b4=54mm

The paper presents investigations of discs with different geometrical parameters running in a real centrifugal pump volute casing of different width. The power absorbed by discs rotating in a volute pump casing is measured. The obtained results show that the disc friction loss depends strongly on the axial gap, on the Reynolds number, on the surface roughness and on the width of the volute. From the analysis of experiments and computations the following conclusions can be drawn: The disc friction coefficient declines approximately steady in the same form with decreased values of the disc width b2 and increased values of Reynoldsnumber. By increasing s / R ratio the disc friction coefficient decreases. The inset of the volute has only small influence on the disc friction coefficient. The best approximate equation, which can predict the experimental results with a minimum error seem to be the equation given by [6]. However still certain deviations are found out because the experiments are done using a real centrifugal pump casing. The proposed empirical equation can predict experimental results well with an error to 10 percent. This equation allows the calculation of disc friction loss taking into account the effects of roughness, of axial gap, of the geometry of the volute and of the Reynolds number. The procedure agrees reasonably well with the data obtained using the last one equation presented in the literature. Comparison of calculated and measured disc friction loss confirms the validity of this procedure. 239

Disc friction coefficient cM x 103

Disc firction coefficient cM x 103

REFERENCES 1. Daily J.W. and Nece, R.E. (1960) Chamber Dimension Effects on Induced Flow and Frictional Resistance of Enclosed Rotating Discs. ASME Journal of Basic Engineering, Vol. 82, No.1, pp.217-232. 2. Glich J.F. (2003) Disk friction losses of closed turbomachine impellers. Forschung im Ingenieurwesen 68, Springer Verlag, pp. 87-95, DOI 10.1007/s10010-003-0111-x. 3. Glich J.F. (2003) Effect of Reynolds-number and surface roughness on the efficiency of centrifugal pumps. ASME Journal of Fluids Engineering 125 4, 670-679. 4. Lnzmann, H. (1995) Einflu des Spaltstroms bei Spiralgehusepumpen mit glattem Kegelspalt und mit Bauch-schaufeln. Mitteilungen des PfleidererInstituts fr Strmungsmaschinen, Heft 2, Verlag und Bildarchiv W.H. Faragallah. 5. Nemdili, A. (2000) Einzelverluste von Kreiselpumpen mit spezifischen Drehzahlen nq = 15 ... 35 min-1. Kaiserslautern, Univ., Diss., Verlag Universitt Kaiserslautern, Germany, ISBN: 3-92517845-7, ISSN: 1615-6587. 6. Nixon, R.A. and Cairney, W.D. (1972) Scale effects in centrifugal cooling water pumps for thermal power stations. NEL Report N505. 7. Poullikkas, A. (1995) Surface Roughness Effects on Induced Flow and Frictional Resistance of Enclosed Rotating Discs. Transactions of the ASME, Journal of Fluids Engineering, Vol. 117, pp.526-528.

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