As per the state of the art, the hydraulic design of the various types of impellers, diffusers, volutes and inlet casing is based on empirical methods such as described in this chapter. The first design created that way is then subject to analysis and optimization by CFD. Even then the accuracy of performance prediction is not always satisfactory. This, because the 3D-flow through the pump depends on the complex shapes of the flow paths given by the inlet casing, impeller and collector. To compound the issue, the interaction of the main flow with the flow in the impeller side rooms can have an unexpectedly large influence on the Q-H-curve and efficiency (an example can be found in chap. 9.1). Always remember that it is the combination of all parameters and shapes of the hydraulic channels which determines the flow patterns -hence performance. In order to reduce the uncertainties of performance prediction, a systematic approach to hydraulic design is advocated. To this end, chapter 7.14 introduces a novel concept for a fully analytical description of the impeller geometry. Prior to starting the hydraulic design all requirements the pump has to fulfill and the boundary conditions imposed should be thoroughly reviewed and documented (see "hydraulic specification" in Chap. 17).
Methods and Boundary Conditions
Methods for the Development of Hydraulic ComponentsThis chapter deals with one-dimensional calculation procedures and design methods for impellers, volute casings, diffusers and inlet casings. For developing these components, the main dimensions and blade angles are calculated in a first step. Subsequently, the hydraulic contours are designed based on certain rules and methods. Many pump manufacturers employ computer programs for this work, and the drawings are generated on 2D-CAD systems. However, these methods are also increasingly replaced by 3D-CAD systems with which fully three-dimensional ge- Fig. 7.45. The complex hydraulic channels can be evaluated better with such models than with the conventional two-dimensional representations in various sections and views. Even more importantly, 3D-CAD systems provide the capability to directly manufacture the hydraulic components (or the casting patterns) by NC milling, stereo lithography or other fast-prototyping processes, [16]. The advantages of such processes are evident in terms of geometrical accuracy and lead times (not in the least also for model tests with milled or stereo-lithographed components). Since manual designs on the drawing board are rather the exception, the subsequent discussion of the design methods emphasizes the fundamental aspects of the design processes rather than a very detailed description of geometrical operations. The development of hydraulic components often comprises the following steps:1. Calculation of the main dimensions and blade angles by one-dimensional methods based on empirical correlations for slip factors and hydraulic efficiencies (based on databases and experience), Chap. 3. 2. Generating an initial design. 3. Optionally...