Industrial Refrigerator Modeling

Refrigerators are an integral part of everyday life to the point where it is almost impossible to image our day without them. As in our everyday life, refrigeration units are also widely used for industrial purposes, not only as stationary units but also for transporting cold goods over long distances. In this blog, we will focus on the simulation and modeling of such an industrial refrigeration unit.

Picture 1 - Industrial Refrigerator
Industrial Refrigerator

Like any stationary refrigeration unit, a unit used for cooled transportation includes an intermediate heat exchanger, a pump, an evaporator, a compressor, a condenser, and a throttle. The most common refrigeration scheme uses three heat fluids in the industrial refrigeration cycle. There is Water, which is used for heat removal from Refrigerant- R134A and Propylene glycol 55%. These other fluids are used as intermediate fluids between the refrigerator chamber and refrigerant loop. The working principle of all fridge systems are based on the phase transition process that occurs during the refrigerator cycle shown in Figure 1. The propylene glycol is pumped into the evaporator from the heat exchanger, in which it cools and transfers heat to the refrigerant. In the evaporator, the refrigerant boils and gasifies during the heat transfer process and takes heat from the refrigerator. The gaseous refrigerant enters the condenser due to the compressor working, where its phase transition occurs to the liquid state and cycle repeats.
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When to Upgrade Your Pump

The typical life cycle cost of an industrial pump depends on its maintenance and energy consumption. Hence, it is necessary to keep track of the pump performance and do periodic maintenance to achieve performance level close to the performance predicted by the manufacturer. There are many instances in which maintenance becomes very costly to achieve the required performance. This is the point when owners must decide about whether to upgrading the system. Figure 1 shows the life cycle cost of typical industrial pumps.

Figure 1 Life Cycle Cost of Typical Industrial Pump
Figure 1 Life Cycle Cost of Typical Industrial Pump

In recent years, there have been many innovations in implementing newer materials as well as improvements in hydraulics. Improving pump designs is an ongoing process with designers looking for increasing performance by a few percentage points. The goal of the present pump manufacturers is to offer higher efficiency and reliability, but replacing an older pumps with newer pumps can mean higher costs. The focus for replacing the internals of the pumps with improved design has gained prominence since many of the components, like the casing and rotor, of the existing pumps can be reused. So instead of replacing the entire pump, it can be upgraded or retrofitted. When it comes to an upgrade, the first thing that should be considered is the return on investment which includes the initial investment, operating costs, and the reduction in energy consumption due to the improved pump performance.

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Introduction to Heat Recovery Steam Generated (HRSG) Technology

The acronym HRSG (Heat Recovery Steam Generated) is in different sources describing the operation of cogeneration and heating plants, but what does it mean? Heat Recovery Steam Generated (HRSG) technology is a recycling steam generator which uses the heat of exhaust from a gas turbine to generate steam for a steam turbine generating electricity.

The simplest scheme of a Combined Cycle Gas Turbine (CCGT) is presented in Figure 1.

The simplest scheme of CCGT
Figure 1: The simplest scheme of CCGT.

In Figure 1, the exhaust flue gases temperature on the outlet of the turbine is equal to 551.709 ℃. This is a too high a temperature to release the gasses into the environment. The excess heat is able to be disposed of while receiving additional electric power which is approximately equivalent to 30% of the capacity of a gas turbine.

To reach the maximum economical and eco-friendly criteria possible for the installation, many pieces of equipment are used including: a waste heat boiler (HRSG); turbines with a selection for a deaerator (Turbine With Extraction, Deaerator); feed and condensate pumps (PUMP2, PUMP); a condenser (Condenser); and a generator (Generator 2). Exhaust gases entering into the HRSG transfer heat to water which is supplied by the condensate pump from the steam turbine condenser to the deaerator and further by the feed pump to the HRSG. Here boiling of water and overheating of the steam occurs. Moving further, the steam enters the turbine where it performs useful work.

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Turbomachinery and Rockets – a Historical/Technical Evolution

Introduction

Quite surprisingly, rockets in their primal form were invented before turbomachinery, even though turbines and pumps are both present in modern launcher engines. However, it is interesting to note that  both can be traced to the same ancestor. In this post we will discuss some of the history and technical evolution of rockets and turbomachinery – and this all starts with an old pigeon.

Figure 1. Steam Turbine and Rocket

Rockets

Circa 400BCE, a Greek philosopher and mathematician named Archytas designed a pigeon-like shape made out of wood that was suspended with wires and propelled along these guides using steam demonstrating the action-reaction principle long before Newton formalized it as a rule in Physics. As we know today, the faster and the more steam escapes the pigeon, the faster it goes. Turn this 90 degrees to have the bird face upward, and you have a very basic rocket concept. However, rockets are a lot more complex than this, and do not typically use steam (except in the case of liquid hydrogen + liquid oxygen propellants) as the propelling fluid.  Read More

Aircraft Fuel Pump Design and Optimization

Introduction to Aircraft Fuel Pumps

Aircraft fuel pumps are one of the most important elements of a fuel system. The operating characteristics and reliability of it are critical for the performance and safety of the aircraft.

Usually, the inlet pressure of the aircraft fuel pump is very low, for example, the aircraft fuel pump of a commercial aircraft needs to operate at altitudes up to 45,000 feet, where the standard atmospheric pressure is about 2.14 psi (about 0.146 atm). What’s more, because fuel is the only consumable fluid carried by the aircraft, it needs to provide all of the cooling necessary for the proper function of the airframe and engine systems. As a result, the temperature of the fuel in the pump increases significantly. The vapor pressure of common fuel used in aircraft gas turbine engines, like Jet A, Jet B, JP-4 etc., gets higher as the temperature increases. Cavitation may occur when the local static pressure in the fluid drops below the vapor pressure of the fuel.

It is very important to avoid the cavitation problem when designing the aircraft fuel pump, because it will cause serious wear, tear, damage of the impeller and performance penalty, which reduces the pumps’ lifetime dramatically. In order to prevent cavitation and have a better suction performance, aircraft fuel pumps use inducers either alone or in conjunction with radial or mixed-flow impeller depending upon the flow and pressure requirements. Figure 1 shows an assortment of fuel pump impellers including radial, mixed flow and inducer types. [1]

Fuel Pump Impeller
Fig.1 Various Fuel Pump Impellers
Designing an Aircraft Fuel Pump with AxSTREAM®

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Computational Fluid Dynamics for Centrifugal Pumps

Pumps are important for many common systems which deal with water, such as heating circulating flows, consumer or industrial water supply, fountains, and fire protection systems.

Pumps are classified into two major categories: Rotodynamic pumps and positive displacement pumps (piston pumps). Rotodynamic pumps can be further classified as axial pumps, centrifugal (radial) pumps, or mixed pumps.

Centrifugal pumps are the devices which impart energy to the fluid (liquid) by means of rotating impeller vanes, and the fluid exits radially from the pump impeller. Such pumps are simple, efficient, reliable, relatively inexpensive, and easily meet the pumping system requirements for filtration. This is a great pump choice for moving liquids from one place to another using pressure.

Types of Rotodynamic Pumps
Figure 1. Types of Rotodynamic Pumps

Centrifugal Pump Design

A centrifugal pump is a very common component in turbomachines, but as with any component, it still needs continual improvement in the design methodology, from conceptual level to the final product development including testing at different levels. The challenge is to design a pump with improved efficiency while minimizing the possibility of cavitation.

Need of Numerical Simulation

Years ago, engineers performed prototype testing at each level of design to check the performance (which was very costly and time consuming). Now with advancements in the computation technology and resources, it is comparatively easier to design high efficiency pumps within a short duration of time. These simulations can be done with a computer, so, the number of physical prototypes required is greatly reduced. The main advantage of numerical simulation is that it allows engineers to virtually test the CAD model early in the design process, and provides flexibility for engineers to iterate the design until getting the required performance.

Computational Fluid Dynamics for Centrifugal Pumps

Computational fluid dynamics (CFD) replaces the huge number of testing requirement. This not only shortens the design cycle time but also significantly reduces development cost.

In a CFD model, the region of interest, a pump impeller flow-path for example, is subdivided into a large number of cells which form the grid or mesh. The PDEs (partial differential equations) can be rewritten as algebraic equations that relate the velocity, pressure, temperature, etc. in a cell to those in all of the cell’s immediate neighbors. The resulting set of equations can then be solved iteratively, yielding a complete description of the flow throughout the domain.

To accomplish CFD simulations, there are several software programs available, but user must select a very well validated software that can provide and easy user interface, automatic mesh generation and flexibility to modify the geometry to perform optimization without needing to move to some other software platform.

In the current trend, automatic mesh generation tools like AxCFD™ are employed in the AxSTREAM® software platforms which reduces the turbomachines meshing complications and generate good quality mesh in considerably short timeframe which can capture the accurate flow features needed. Figure 2 shows the discretized impeller and pressure contour after CFD analysis.

Discretized Impeller and Pressure Contour After CFD Analysis
Figure 2. Discretized Impeller and Pressure Contour After CFD Analysis

AxCFD™, in AxSTREAM® platform, provides user an opportunity to perform CFD analysis by applying standard methods of full three-dimensional CFD, axisymmetric CFD (meridional), and blade-to-blade analysis. User can even perform optimization of the blade profiles and other geometrical parameters within the AxSTREAM® platform and perform CFD simulation without altering any CFD settings.

Applications of Centrifugal Pumps

Centrifugal Pumps are the most popular and commonly used type of pump for the transfer of any type of fluid. The volumetric flow rate range of centrifugal pumps can vary from several tens of ml/hour to  one hundred thousand m3/hour , while the pressure can be normal pressure to nearly 20MPa; and the liquid temperature can be as low as -200℃ or as high as 800℃. The fluid being transferred can be water (clean or sewage), oil, acid or alkali, suspension or liquid metal, etc. Therefore, centrifugal pumps are used across numerous industries:

  1. In the oil and gas or chemical industries, converting crude oil to products requires a complex process. Pumps play an important role in transferring these liquids, providing the required pressure and flow rate for chemical reactions. Sometimes, pumps are used to adjust temperature in certain parts of the system.
  2. In agriculture, centrifugal pumps are used in the majority of irrigation machinery. Agriculture pumps make up half of the total amount of centrifugal pumps being used today.
  3. In mining and metallurgy industries, centrifugal pumps are the most widely used equipment, for draining, and cooling of water supplies, etc.
  4. For power generation, the nuclear power plants need large amounts of primary, and secondary system pumps, while the thermal power plants also need boiler feed pumps, condensate pumps, loop pumps and as well as ash pumps.
  5. In military applications, the adjusting of airplane wings and rudders, turning of turret on ships and tanks, the up and down of submarines, all rely on pumps for hydraulic fluids.
  6. In shipbuilding, there are more than 100 different types of pumps in one typical ocean ship.
  7. Other applications include municipal water supplies and drainage; water supplies of locomotives; lubricating and cooling of machining equipment; bleach and dye transfer of textile industry; and milk and beverage pumping and sugar refining in the food industry.

 

Centrifugal pumps can be classified based on the number of impellers in the pump:

A single-stage pump, with only one impeller, is commonly used for high flow and low to moderate total dynamic head, as in Figure 1.

Single Stage Centrifugal Pump
Figure 1. Single Stage Centrifugal Pump

A multi-stage pump has two or more impellers working in a series to achieve higher total dynamic head.
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Pump Characteristic Curves

Introduction

A pump is a hardware, which feeds energy to a fluid (e.g. Water) to flow through channels. Pumps are used, for example, to direct water out of the ground, to transport drinking or sewerage water over large distances in combined pipe networks or to discard water from polders. In any practical application, the pump needs to work with its best performance. It is also important to check that the flow rate and head of the pump are within the required specifications, which are normally presented as the Pump Characteristic curves. These plots play an important role in understanding the region in which the pump needs to be operated thus ensuring the life of the pump.

Pump Characteristic Curves

The performance of any type of pump can be shown graphically, which can be based on either the tests conducted by the manufacturer or the simulations done by the designer. These plots are presented as Pump Characteristic Curves. The hydraulic properties of any pump (e.g. Centrifugal Pump) can be described by the following characteristics.

  1. Q-H Curve
  2. Efficiency Curve
  3. Net Positive Suction Head (NPSH) Curve

 

Pump characteristic curves generated from AxSTREAM
Figure 1 Pump characteristic curves generated from AxSTREAM

Q-H Curve

The Q-H curve gives the relation between the volume flow rate and the pressure head, i.e. the lower the pump head, the higher the flow rate. Q-H curves are provided by the manufacturer of the pump and can normally be considered as simple quadratic curves.
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An Introduction to Centrifugal Pumps

In every modern cleaning system there exists at least one pumping unit. With this in mind, understanding how it works and how to use it efficiently is critical to the successful operation and maintenance of that cleaning system. This blog will discuss centrifugal pumps in this context and take a look at important attributes to bear in mind when working with these systems.

In general, pumps are devices which impart energy to a flow of liquid.  Although there are different types of pumps based on the flow direction, blade designs, and so on, centrifugal pumps are in the majority of those used in cleaning systems.  Centrifugal pumps are simple, efficient, reliable, relatively inexpensive, and easily meet the needs of most cleaning system requirements including spraying, overflow sparging, filtration, turbulation and the basic function of moving liquids from one place to another using pressure.

A centrifugal pump uses a combination of angular velocity and centrifugal force to pump liquids.  The below figure illustrates the working principle of the centrifugal pump.

Centrifugal Pump

The pump consists of a circular pump housing which is usually made up of metals, (stain steels etc.) solid plastic, or ceramics.  The outlet extends tangentially from the diameter of the pump housing.  Inside the pump housing there is a rotating component an “impeller” which rotates perpendicular to the central axis and is driven by a shaft secured to its center of rotation.  The shaft, powered by an electric motor, enters the pump housing through a liquid tight seal which prevents leaking.  Liquid entering the pump through the inlet is swirled in a circular motion and displaced from the rotation center of the impeller by centrifugal force.  The combination of the swirling action (angular velocity) and centrifugal force (radial velocity) pushes the liquid out of the pump through the outlet.

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Leveraging AxSLICE for Centrifugal Pump Upgrades and Retrofits

Often, service companies are faced with the challenge of redesigning existing pumps that have failed in the field with extremely quick turnaround times. While there are quick-fix methods to return these pumps into operation, other more complex problems may require taking a step back and analyzing how this particular pump could be redesigned based on its current operation.  These engineering upgrades could solve recurring issues with failure modes of a certain machine, and they could also solve new capacity demands that are imposed by a customer based on their system’s upstream or downstream changes. While efficiency increases could be beneficial to the overall system, many times it is more important to solve capacity requirements and increase the life of the pump by decreasing the Net Positive Suction Head Required (NPSHr).

In this blog post, we will investigate how to move an existing centrifugal pump through the AxSTREAM platform in order to solve engineering challenges seen on common OEM pump upgrades.  With the use of AxSTREAM’s integrated platform and reverse engineering module, many of the CAE tasks that are common in an analysis such as this one can be realized in record speed. The first step of the reverse engineering process occurs in obtaining the necessary geometrical information for the desired pump. Through AxSLICE, the user can take an STL, IGES, CURVE file, or a generated cloud of points and properly transform this 3D profile into a workable geometry inside the AxSTREAM platform. In a matter of minutes, the user can outline the hub and shroud and transform a blank 3D profile into a profile defined by a series of segments.  Seen in Figure 1, the centrifugal pump is now defined by a hub, shroud, and intermediate section.

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