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Design of an Advanced Waterjet

William A. Facinelli (AM) Honeywell Tempe, Arizona Alan J. Becnel (M) John G. Purnell CDI Marine Systems Development Division Severna Park, Maryland and Robert F. Blumenthal ANSYS CFX El Dorado Hills, California
ABSTRACT State-of-the-art computer programs have been used to design a waterjet for marine propulsion applications. The design was accomplished in an iterative process between a potential-flow design code and a fully viscous, three-dimensional computational fluid dynamics analysis program. These tools were first directed at the evaluation of three options: a single rotating blade row plus a stator; a rotating blade set consisting of main blades and splitter blades, plus a stator; and two co-rotating blade rows (an inducer and a kicker) plus a stator. In the second step of the design process, the single rotor/stator concept was optimized to maximize the efficiency while matching a given design point. The resulting design is predicted to have much improved cavitation performance compared with a design accomplished with older techniques. Other advantages are reduced weight, shorter length, and lower manufacturing cost.

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BACKGROUND ON THE COMPUTER METHODS

Rotors for waterjets have previously been designed with the assumption of free-vortex radial blade loading. This loading distribution simplifies the design process, because it means equal energy input to the flow at each radius and a uniform axial velocity in the exit jet. However, it results in rather long axial blade lengths for the hub sections. In order to reduce weight and volume, and increase hydraulic efficiency and therefore thrust, it was desirable that a non-uniform radial blade loading

be used for the new design. The use of non-uniform radial blade loading required changes to the basic design and analysis methods and computer programs. The first program used in the design process was the preliminary design code WJOPTIM. This spreadsheet-type program was used to match the pump to the inlet and nozzle. For the purpose of the design of this new waterjet, it was improved to account for nonuniform blade loading. Inputs to the program included desired cavitation margin, fluid vapor pressure, velocity at the pump inlet (assumed uniform for this purpose), inlet hub-to-tip radius ratio, and nozzle loss coefficient.

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Outputs consisted of the pump flowrate and head rise, rotational speed, shaft torque, exit hub-to-tip ratio, and derived quantities such as pump efficiency. The second program was an EXCEL Simplified Streamline Curvature macro SLC that was used in conjunction with WJOPTIM to determine the blade loading pattern. Inputs consisted of the number of streamlines to evaluate, pump efficiency, shaft power, rotational speed, inlet and exit radius ratios, relative amounts of turning at hub, middle, and tip, axial velocity at the inlet, and fluid density. The output was in the form of two tables, the first giving the velocity and pressure distribution at the blade inlet, and the second giving the blade velocity triangles along each streamline through the rotor or stator. The third program used in this design was a streamline curvature code, PLOTSCMD. The code was modified to accommodate non-uniform blade loading, and a diffusion factor subroutine was added to check for flow separation at all radii. The inputs to this program were the upstream inflow information, the flow-turning schedule from macro SLC, and the hub and shroud geometry of the pump. PLOTSCMD then predicted the velocity and pressure fields for the unit. In this manner, the impact of various hub, shroud, and component lengths and geometries can be evaluated.

The designs were checked for problems such as static pressure below vapor pressure at some location. An example output from PLOTSCMD is shown in Figure 1. The blade shapes were generated using TURBOdesign-1, an inverse design code developed by Advanced Design Technology of the U.K. that is based on the potential flow equations. TURBOdesign-1 allows the designer to control the blade surface pressure distributions by specifying the chordwise blade loading at different radii. Secondary flows in the blade passages can also be minimized with the correct blade loading distributions. These features of TURBOdesign-1 allow the designer to develop high efficiency designs with very high suction specific speeds. The hub and shroud contours and radial blade loadings generated by the other programs were input to TURBOdesign-1, along with the assumed blade section profile, thickness distribution, and number of blades. For each type of rotor considered, a computational grid was prepared such as the one shown in Figure 2. The results from this code were the blade shape definitions and surface static pressures, which were checked for possible cavitation regions.

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Pst (ft) 98.14 91.92 85.70 79.49 73.27 67.05 60.83 54.62 48.40 42.18 35.97 29.75 23.53 17.31 11.10 4.88 -1.34 -7.56 -13.77 -19.99 -26.21 -32.42 -38.64 -44.86

15

10

R (inch)

Rotor
5

Stator

-5 0 10

X (inch)

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Figure 1 Example Streamline Curvature Results for Static Pressure

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Figure 2 - Example TURBOdesign-1 Grid A linear stress analysis was performed for each blade design. Boundary conditions restricting translations were applied at the nodes corresponding to points on the hub. Loads applied included the pressure distribution on the blade, obtained from TURBOdesign-1, and centrifugal loads at the given rotational speed. The material properties for 15-5 stainless steel were also used. The predicted radial deflection of the blade tip was compared with the assumed tip gap of about 0.050 inch. Also, the maximum and minimum principal stresses on the pressure and suction sides of the blade, respectively, were compared with the allowable values for the material. Viscous effects in the pump section were predicted using CFX-TASCflow, a Computational Fluid Dynamics (CFD) program widely used in pump applications. CFX-TASCflow employs a conservative, finite-element based control volume method and a pressure-based coupled solver for solution of the discretized NavierStokes equations. This code has been successfully used to predict turbomachinery performance for nearly two decades. In particular, it has been shown to accurately model cavitation effects. In this application, the program was used to analyze a single blade row, or several blade rows in combination usually via a Stage Interface approach. The Stage Interface is a means of coupling blade rows together that are in different rotational frames of reference (e.g., a rotor-stator) by circumferentially averaging pressure and velocity but maintaining spanwise gradients. This interface is especially useful for allowing multiple blade rows to be modeled by using just a single blade in each blade row. Mass, momentum and energy are fully conserved across the interface, even for blade rows with significantly different pitch ratios. 1.1 Preliminary Rotor Design The programs just described were first used to produce a preliminary design of each of three rotor types: 1. A single rotor with seven equally sized blades 2. A single rotor with four main and four splitter blades 3. An inducer with four blades followed by a kicker with eight blades. The numbers of blades were chosen based on the experience of the authors with similar pump designs. The preliminary design process is shown in Figure 3. First, program WJOPTIM was used to define the diameter and operating conditions. The results of this analysis are listed in Table 1. Then the design programs (SLC, PLOTSCMD, and TURBOdesign-1) and the stress analysis code were used in an iterative manner with CFX-TASCflow for each type of rotor. The resulting rotor designs are shown in Figure 4, and the predicted characteristics are given in Table 2. Table 1 Diameter and Operating Conditions Pump diameter (in) Rotational speed (rpm) Torque (ft-lbf) Flow rate (ft /s) Water density (slugs/ft )
3 3

23.0 1113.9 6181.6 101.98 1.9905

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3 times Run SLC, PLTSCMD, and TURBOdesign for the Type 1 rotor Perform linear stress analysis Run CFXTASCflow for the Type 1 rotor

2 times Determine operating conditions using WJOPTIM Run SLC, PLTSCMD, and TURBOdesign for the Type 2 rotor Perform linear stress analysis Run CFXTASCflow for the Type 2 rotor Compare rotor results

2 times Run SLC, PLTSCMD, and TURBOdesign for the Type 3 rotor Perform linear stress analysis Run CFXTASCflow for the Type 3 rotor

Figure 3 Rotor Preliminary Design Process

Type 1 (Single rotor with seven blades)

Type 2 (Single rotor with four main and four splitter blades) Figure 4 Preliminary Rotor Designs

Type 3 (Inducer + kicker)

Table 2 Rotor Trade Study Type 1 2 3 Description Single rotor Main + splitters Inducer + kicker Rotor efficiency 0.937 0.932 0.937 Head rise (ft of water) 101.3 97.9 102.3 Relative weight (lbs) 0 -6.5 -12.5 Blade stress at root (ksi) 13.0 14.0 24.4/15.7

The cavitation predictions from CFX-TASCflow are shown in Figure 5. For each Type, the CFD code was run with decreasing values of inlet total pressure, and therefore decreasing amounts of net positive suction head (NPSH) at the inlet to the model. At each of these points, the predicted head rise across the rotor was noted. The head rise at each point was divided by the head rise at a high inlet pressure to arrive at the non-

dimensional value for the vertical axis in Figure 5. As one looks from right to left in the Figure, the bump in head rise and subsequent roll-off are characteristics of cavitation onset. Consideration of the Table 2 results suggested no clear winner among the three Types studied. All of the options offered high efficiency, good cavitation performance, and acceptable stress levels.

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1.005 Head rise with cavitation/Head rise at high NPSH (without cavitation)

1.000

0.995 Type 1 0.990 Type 2 Type 3 0.985 Inlet condition: NPSH=40 ft 0.980 20 30 40 50 60 70 80 90 100 Net positive suction head (ft)
Figure 5 Cavitation Predictions From CFX-TASCflow for the Three Types

1.2 Preliminary Stator Design A stator was designed via a process similar to what was used for each of the rotors. For this purpose, the exit velocity distribution as a function of radius from the preliminary Type 1 rotor was used at the stator inlet boundary in the CFX-TASCflow runs. A picture of this eight-bladed design is shown in Figure 6. The head loss across the stator was estimated to be two feet of water. A compact pump design was achieved in part by making the stator integral with the nozzle of the waterjet. This feature is illustrated in Figure 7 for the preliminary stator concept.

Figure 6 Preliminary Stator Design

Figure 7 Integral Stator/Nozzle (With Straight Exit Section for the CFD Model)

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1.3 Final Rotor Design In an effort to reduce the rotor weight, decrease the manufacturing cost, and improve the efficiency, the Type 1 rotor was chosen for optimization. In particular, the number of blades was reduced from seven to five. Iterations between the design programs and CFXTASCflow were done with these goals in mind. match the design point increase the efficiency maintain a margin above vapor pressure throughout the blade keep the blade stresses low.

and roughness values in the CFD model was straightforward. Assessment of manufacturing tolerance effects was done by defining a profile parameter as shown in Figure 12. Variation of the blades in this manner was essentially a check for the effect of small changes in incidence angle.

A final run with the rotor blade alone was done using the complete inlet velocity profile shown in Figure 8, which had been obtained previously for a specific waterjet inlet. In this case a 360 model of the rotor blade was set up and run in CFX-TASCflow. The resulting rotor is shown in Figure 9. The final rotor design was also analyzed for cavitation performance to obtain results like those shown in Figure 5. The predictions were compared with those for another rotating group designed with older techniques. This comparison is shown in Figure 10. Clearly, the new design should be much more resistant to cavitation. 1.4 Final Stator Design In order to be further away from a multiple of the number of rotor blades, and to decrease the weight and cost, the stator blade count was reduced from an initial ten to eight. The final stator design was verified by a run of CFX-TASCflow using a rotor-plus-stator stage model. Some results from this run are shown in Figure 11. 2. PARAMETRIC STUDY/DESIGN OF EXPERIMENTS

Figure 8 Inlet Velocity Profile

Certain simplifying assumptions were made in the process of designing the rotor. First, the tip clearance was held at 0.050 inch. Second, the surface was assumed to be hydrodynamically smooth. Also, no analysis was done of the effect of blade deviations caused by manufacturing inaccuracies. In order to have a robust blade design, a parametric study which included a design of experiments (DOE) was accomplished. Implementation of different clearance

Figure 9 Final Rotor Design

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Head rise with cavitation/Head rise at high NPSH (without cavitation)

1.01 1.00 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 20 30 40 50 60 70 80 90 100 Net positive suction head (ft) Inlet condition: NPSH=40 ft Type 1 - 5 blades Baseline

Figure 10 Cavitation Predictions from CFX-TASCflow for an Older Design and for the New Rotor

Figure 11 Results From Stage Analysis

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.030" .030"
Stacking line at trailing edge

The results of this analysis imply that the rotor efficiency is highly sensitive to tip clearance and surface finish, but insensitive to the profile parameter, at least over the range of 0.030 inch. This information suggests that the clearance be held as tight as possible (without encouraging tip rub) and that the finish be as smooth as economically feasible. 2.1 Off-design Performance An analysis of the advanced waterjet was done to predict off-design performance. Three runs of CFXTASCflow were done with the stage model of the final pump design, in which the flow rate was 10% below, 5% above, and 10% above the design value. The results in terms of overall pump efficiency are shown in Figure 13. As indicated in the figure, the calculated efficiency depends upon where the exit plane is positioned. When the exit plane is at the model exit, the efficiency includes the nozzle losses as well as stator losses. One additional source of losses, when using the exit plane to calculate the overall efficiency, is related to the boundary conditions applied along the jet boundary in the nozzle computation. To model the jet downstream of the nozzle, the location of the free surface must be determined. CFX-5 has the capability to perform free surface calculations, and was used to model the flowfield downstream of the nozzle exit. As

Figure 12 Profile parameter definition The matrix of parameter variations and the predicted rotor efficiency values from the CFXTASCflow runs (for the rotor alone) are given in Table 3. Table 3 Parametric Study Table
Run (Design) 1 2 3 4 5 6 7 Radial Clearance (in) 0.05 0.05 0.15 0.05 0.15 0.1 0.05 0.05 Profile (in) 0.00 -0.03 -0.03 0.03 0.03 0.00 -0.03 0.03 Surface Finish (Micro-in) 0.0 20.8 13.3 13.3 20.8 17.1 125.0 125.0 Rotor Efficiency 0.940 0.937 0.920 0.938 0.918 0.928 0.924 0.923

0.93 0.92 0.91 Pump Efficiency 0.90 0.89 0.88 0.87 0.86 90 95 100 105 Flowrate (ft3/s) 110 115

102

Design flow rate

TASCflow, 1 inch past stator TASCFLOW, model exit

Figure 13 Predicted Off-Design Performance

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shown in Figure 14, the jet boundary was then specified in CFX-TASCflow using a slip wall boundary condition with the location of the free surface based on the CFX-5 solution. Because of slight differences

between the CFX-5 and CFX-TASCflow models, pressure and velocity gradients were observed in the CFX-TASCflow solution on the jet boundary that would not be present on a constant-pressure free surface.

Slip Wall Boundary Condition

Streamlines colored by meridional velocity

Figure 14 Meridional View From Stage Model Including Exit Jet

3.

CONCLUSIONS analysis implied that the pump efficiency will drop only about 1 point over the useful speed range of a typical marine vehicle. This rotor/stator/nozzle design is compact, lightweight, and easy to manufacture, and its predicted cavitation performance is much better than that of an older design.

This project demonstrated how a combination of fluid dynamics-based design programs, a stress analysis code, and a flexible CFD analysis tool can be used to optimize a waterjet pump. CFX-TASCflow was also used in a parametric study on clearance, incidence angle, and surface finish for the rotor. An off-design

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