Tarlac State University

College of Engineering and Technology

Department of Mechanical Engineering
Romulo Boulevard, San Vicente, Tarlac City, 2300 Tarlac

Comparative Assessment in the Design and Performance of a Centrifugal

Pump by using Autodesk CFD and Traditional Theoretical Design

A Design and Performance Evaluation Submitted to Engr. Marc Arnaldo

In Partial Fulfillment of the Requirements for the Course Subject
MEF343: Fluid Machineries

By

HAMLAG, Justine Angelo Merculio

HIPOLITO, Joshua Quilala
NARDO, Mark Ivan Tumang
OCAMPO, Carlo Raphael Salvador
QUE, Napoleon Dy
RAZON, Ralf Daniel Salazar
RODRIGUEZ, Jayson Rei Libunao
ROSARIO, Ralph Vincent Cao
SEMBRANO, Aaron Pangilinan
TAMAYO, Christian Erzon Vitug

Bachelor of Science in Mechanical Engineering

Tarlac State University

Second Semester
A.Y. 2022 – 2023
 I. Introduction

Pumps were one of the early industrial era’s steppingstones that paved the way for modern

industrial applications that are used in many different industrial sectors of expertise. By means

of converting the motor’s mechanical energy into the energy of fluid flow, pumps are devices

that serves as amplifiers in pipe networks to amplify fluids from low to high pressure areas, or

by raising the liquid from low elevation to higher level. Additionally, pumps can be used in

procedures that call for high hydraulic pressure. Heavy-duty equipment could display this. In

using heavy-duty equipment, it is frequently necessary to have low suction pressure and high

discharge pressure. Fluid rises from a specific depth due to low pressure at the pump's suction

side.; at this point strong pressure at the pump's discharge side causes the fluid to ascend until it

reaches the required height.

Positive displacement pumps and dynamic pumps are the two basic types of a pump. Under

dynamic pumps, a centrifugal pump is classified into three categories Radial flow, axial flow, or

mixed flow. Centrifugal force causes the flow of radial flow pumps to be driven radially to the

outside as it enters the center of the rotating wheel (impeller). The volute case converts the

increased liquid velocity inside the impeller into pressure. It is the usual form of pumpwork for

low viscosity fluids in high flow rate, low pressure devices, making it ideal for uses where the

pump must move huge quantities of fluid. The centrifugal pump type is frequently used to move

water, but it is also an effective way of moving thin fuels and chemicals.

The objective of this paper is to evaluate the significant parameters of the provided problem and

do a comparative analysis of the methods to be used in determining the parameters. First, Manual

calculations will be used to determine the required parameters including the flow rate, head,

pressure, and fluid properties of the pump. It will utilize equations from the principles of fluid

mechanics and fluid machineries. Lastly, Autodesk Computational Fluid Dynamics (CFD) is the

other method used in gathering the data required for the pump analysis. CFD is an application

used by engineers and researchers to create computations and model simulations in fluid

dynamics and to know how the fluid will behave by means of the heat transfer and fluid flow

design simulation of the application.

 II. Pump Design Parameters

The required performance specifications of the pump include flow rate, head, and the

pump efficiency. The pump's performance is influenced by various operating conditions, fluid

properties, and additional factors, which are crucial to consider.

1. Operating Conditions:

The operating conditions play a significant role in pump performance. Factors to be considered

include:

 Flow Rate: The pump in question delivers a flow rate of 20 cubic feet per minute (cfm),

indicating the volume of water being transferred within the system.

 Suction Pressure: The suction gauge reads 5 inches of mercury vacuum (inHg vac),

which should be evaluated to prevent cavitation and ensure sufficient suction conditions.

 Discharge Pressure: The pump generates a discharge pressure of 30 pounds per square

inch (psi) at the outlet, influencing the overall system performance.

 Elevation Difference: The discharge gauge is positioned 5 feet above the suction gauge,

affecting the total head and requiring additional energy to overcome the elevation.

2. Fluid Properties:

Understanding the properties of the fluid being pumped is essential for pump selection and

performance assessment. In this case:

3
 Density: The water being pumped has a density of 62 pounds per cubic foot ( lb m /ft ),

influencing the weight and mass flow rate of the fluid.

 Viscosity: Although the problem does not provide information about the water's viscosity,

it is generally assumed to be relatively low for water applications.

3. Pump Efficiency:

The pump efficiency, specified as 70%, measures its ability to convert input power into useful

output power. A higher efficiency indicates better energy utilization and cost-effectiveness.
4. Other Important Factors:

Several additional factors impact the pump's performance and should be considered:

 Cavitation: The suction pressure must be carefully evaluated to prevent cavitation, which

can lead to reduced pump efficiency and potential damage.

 Net Positive Suction Head (NPSH): The availability of NPSH is critical to prevent

cavitation and ensure stable pump operation, although information about it is not

provided in the problem.

Considering these operating conditions, fluid properties, and other important factors is essential

in selecting an appropriate pump, ensuring optimal performance, and avoiding issues such as

cavitation, inefficiency, or potential damage to the system.

Figure 1. Isometric View

Figure 2. Front View.

 Figure 3. Back View.

Figure 4. Geometry Design of the Impeller.

III. Manual Calculations

This section presents the calculations performed to determine the parameters needed for

the pump design.

Figure 5. Schematic Diagram of the Pump.

The given parameters are:

Centrifugal Pump

ft ρ =62 lbm P =5 inHg vac P =30 psiz =5 fte =70 %

3
Q=30 w 3 1 2 2 p
min ft
Required:

a) Size of the Motor, Pw

b) Brake Power, Pb

Solution: (Assumption: Constant velocity head)

(Therefore Inlet and Outlet diameter are constant)

First step is to solve the fluid power, using the formula of:
Pw =γ Qh

Unfortunately, dynamic head is unknown. But we can solve using Bernoulli’s equation:

∆ P ∆V2
H= + + ∆ z+ hf 2+ hf 1
γ 2g

where:

lbm
P1=5 inHg vac P2=30 psiz 2=5 ft ΔV =is not solvable ρw =62
ft 3

Substituting from the equation:

[ ( )]
lb
14.7
lb ¿2
H= 30 2 −(−5 inHg ) ¿¿¿
¿ 29.92∈Hg

H = 80.38 ft

Therefore, we can now solve the hydraulic power, Pw

( )
3
lbm ft
62 30 (80.38 ft)
ft 3
min
Pw =
ft −lb
33000
HP−min

Pw =4.53 HP
Solving for the size of pump motor or brake power, PB

Using the formula of:

Pw P
e p= ; Pb= w
PB ep

4.53 HP
Pb=
0.7

Pb=6.47 HP ≈ 6.5 HP

Retrieved from the shop inverter.com centrifugal pump of Using Similar Pump with the same

efficiency of 70% (10 HP Vertical Centrifugal Pump)

m3
Q2=65 ≈ 286 gpm
hr

H 2=28 m ≈ 92 ft

N 2=2900 rpm

D 2=160 mm ≈ 6.3∈¿

Solving For Impeller Speed, N 1

Assumption: Geometrically similar pump.

N 1 √ Q1 N 2 √ Q2
3
= 3
4 4
H1 H2

1 1
N 1 (Q 1) 2 N 2 (Q 2 )2
3
= 3
4
H1 H24

( )( )
1 3
Q2 2 H1 4
N 1=N 2
Q1 H2

Substituting:
 ( )(
0.1337 ft 3 1
286 gal/min x 2

)
3
1 gal 80.38 ft
¿ 2900 rpm 4
3
30 ft /min 92 ft

N 1=2958.74 rpm

Solving for Impeller Diameter, D 1

Q1 Q2
3
=
N 1 D1 N 2 D 23

Q 1 N 2 D 23
D 13=
Q2 N 1

√
3
Q1 N 2 D2
3
D 1=
Q2 N 1

Substituting:

D 1= √ 30 ft 3 /min (2900 rpm)¿ ¿ ¿

3

D 1=5.77∈¿

Solving for Specific Speed, N s

N √Q
NS= 3
H4

Substituting:

¿
√
2958.74 rpm 30 ft /min
3

3
( 0.1337
1 gal
ft )
3

4
(80.38 ft )

N S =1650.98 rpm

Solving for the velocity of fluid inside the pump,

V =πDN
Substituting:

¿π¿

V =4469.42 ft /min ≈ 4469.42 fpm

Manual calculations were used to evaluate the operating conditions of the pump. Parameters such

as flow rate, head, pressure, and fluid properties are considered in the calculations. These

calculations help determine the system requirements and ensure that the pump is capable of

meeting the desired performance criteria. Manual calculations were performed using equations

derived from fundamental principles of fluid mechanics, such as the Bernoulli equation, pump

laws, and conservation equations.

IV. CFD Simulation

Input Materials:
1. Casing: Solid Type – Iron
2. Impeller: Rotating Region Type
3. Fluid Type: Water
Boundary Conditions:
1. Volume Flow Rate at the inlet and outlet: 30 ft3/min
2. Inlet Pressure: -5 inHg
3. Outlet Pressure: 30 psi
4. Speed: 3623.7 rpm
Geometry tools- build surface was used to fill the void of the inlet and outlet ports of the pump,

resulting in the CFD generated volume, which was set to fluid water. Automatic mesh sizing was

selected.
 Figure 6. Automatic meshing of the centrifugal pump

Figure 7. Solver tab settings

The solver was set to have 10 iterations before entering solve

 Explain how the CFD simulation was used to predict the pump performance and optimize

the design

 Present the CFD simulation results, including pressure and velocity distributions, and

compare them to the manual calculation results

 Figure 8. Velocity magnitude

Shown in the figure is the velocity magnitude of the fluid, and how the fluid passes through the

entrance and exit, also it was shown the fluid passing through the rotating region, which is the

impeller.

Figure 9. Static pressure

The distribution of pressure in the above figure, is shown. The dark blue arrows entering the

volute, it signifies that the entrance is at suction pressure and green arrows above signifies that

the exit is at discharge pressure.

In order to forecast and improve the performance of pumps, including their design,

computational fluid dynamics (CFD) simulation is a potent technique. Solving mathematical

equations that represent fluid flow in a pump using computer software is what CFD simulations

do. The behavior of the fluid inside the pump may thus be accurately predicted, enabling design

engineers to enhance pump efficiency. The performance of pumps can be improved in a number

of ways using CFD models, such as:

1. Optimizing the design- Different pump designs can be tested using CFD simulations.

Engineers can undertake studies in iterations utilizing various design geometries to optimize a

design for greater efficacy and performance.

2. System performance prediction- By inputting the operating conditions of a system, such as

flow rate and pressure, CFD simulations can predict the overall performance of the pump.

3. Evaluation of flow properties- CFD simulations can be used to ascertain a pump's flow

properties, such as flow velocity, turbulence intensity, and recirculation zones. Areas for design

optimization and enhancement can be found using this information.

4. Validate physical testing- CFD simulation can be used to provide confidence in the physical

testing results and validate specific configurations.

Engineers can use CFD simulations to identify potential areas of failure in a pump, often before

any physical testing is conducted, allowing engineers to optimize the design to prevent failure.

Design engineers can cut expenses associated with physical testing and development time while

producing more dependable and effective pumps by using CFD models to forecast pump

performance and optimize designs. CFD simulation is a valuable tool for many applications,

such as aerospace, automotive, industrial and offshore applications.

V. Data Analysis/ Comparison of Results

Iteration Vx Velocity (cm/s)

1 5.72369

2 3.90513

3 3.63737

4 1.6901

5 1.86585

6 3.68696

7 2.34651

8 2.32791
 9 2.30583

10 2.16344

After performing 10 iterations, the Computational Fluid Dynamics (CFD) analysis gave an outlet

velocity value of V2 = 2.16344 cm/s = 0.0216344 m/s. The results also show a volume flow rate

of 30 cfm that match the volume flow rate parameter given in the problem. This value deviates

significantly from the calculated value of V2 = 22.6989132 m/s. The dependency of CFD results

is due to the lack of parameters related to the velocity head, making it impossible to accurately

determine the velocity.

VI. Results and Discussion

Discuss the overall design process and the advantages and disadvantages of using both

CFD and manual calculation methods.

The design of a centrifugal compressor is limited by non-aerodynamic factors such as the price,

size of the overall frame, inertia of the rotating parts, and durability. To achieve high pressure

ratios, titanium metal is used instead of aluminum, which results in an increase in cost. However,

current requirements are for pressure ratios that can be achieved at rotational speeds suitable for

aluminum impellers. To increase the pressure ratio, the magnitude of the impeller blade back-

sweep must be lessened. This will result in a decrease in operating range, but it can be regained

by applying a positive swirl at the impeller inlet. The advantages and disadvantages of using

Computational fluid dynamics (CFD) software for fluid analysis forecasts how a working fluid

will interact with its geometric surroundings and operational environment. Understanding the

energy loss models incorporated into the design code is essential for accurately predicting these

interactions. Skin friction, excessive pressure recovery, airfoil incidence, flow recirculation, and

blade tip leakage are just a few examples of these energy losses. CFD analysis can be used to

find a solution to compressor off-design operation by looking at plots of the pressure ratio versus

exit corrected mass flow rate. This graph is helpful because the compressor in jet engines is

designed to provide a constant flow of air into the combustion section. The advantages and
disadvantages of using manual calculation methods. The splitter blades should be shortened and

the slope of the leading edge should be increased, according to the results of using the

optimization method to determine this. Further research led to the creation of new blades that

begin in the center of the hub, whereas the base design fixed their location along a 30% length of

the hub. While the leading edge in the base design is quite radial with a zero angle, it has a 40-

degree upward angle in the optimal design.

Evaluate the pump design and suggest any improvements or areas for future work.

Pumping conditions, pump sealing, and impeller shape are examples of mechanical factors.

When it comes to geometry, you will generally have to choose between practicality, efficiency,

and affordability. Duty point, flow rate, fluid properties, and system resistance are all hydraulic

factors. With increased environmental concerns and a constant desire to cut costs, energy

efficiency is an essential subject for industry. Pumping systems account for the world's electrical

energy consumption. And according to US Department of Energy studies, pumping systems are

typical industrial facilities' power expenses. This alone demonstrates how critical it is to improve

the energy efficiency of your pumping systems. Furthermore, the following are the primary

strategies to increase pump efficiency: prevent oversizing the pump; perform impeller trimming;

use variable frequency drives; use parallel pumping systems; limit pipework pressure loss;

eliminate wasteful use; and perform maintenance.

VII. Conclusion

This study aims to gather information and learn how to design a centrifugal pump

efficiently and effectively. In today’s competitive and sophisticated technology, centrifugal pump

is a more widely used type of pump mainly because of its characteristics that made it more

efficient than any other type of pump. There are many factors to consider before buying a

centrifugal pump. Factors such as application, size, power, performance, efficiency etc.

Traditional theoretical calculation and CFD simulation regarding the design and performance of

centrifugal pump is done in this study. The results obtained shown in the paper represent the

design of the centrifugal pump and how the fluid reacts to the pump components. In a traditional

theoretical approach, the researchers calculated the important parameters of the pump such as
power, bore and stroke, pump head and pump speed by using the values given. On the other

hand, CFD simulation creates a visual representation on how the fluid in a pump reacts on its

components. By using this method, we can design a pump specifically based on how and where

it will be deployed efficiently. Simulations, especially CFD, is life changing because you can

simulate a pump with different kinds of physical conditions.

VIII. References

HW Blue. (2021, March 15). Autodesk Fusion 360: Centrifugal Pump [Video file]. Retrieved

from https://www.youtube.com/watch?v=9BcJOqpUrzk

10 hp Vertical Centrifugal Pump. (n.d.). Retrieved from https://www.inverter.com/10hp-vertical-

centrifugal-pump

Arnaldo, Marc Florenz (2023) Lecture 2 Pumps, Fluid Machineries

IX. Documentation