Centrifugal pump performance improvement using back cavity filling

Centrifugal pumps consume majority of energy used by the electric motor driven systems among all end users of the industrial sector. Only in European region, a 1% improvement in efficiency (η) of the centrifugal pump is capable enough to reduce CO2 emissions by at least 572 tons per day. The prime motive of this research is to assess the applicability of the novel back cavity filling (BCF) in reducing the disk friction losses of centrifugal pumps without changing the pump's original design. By adding a solid ring to the bearing housing's back-cover plate, the BCF was applied to a medium specific speed pump (Ns = 54 rpm), resulting in a 1 mm back axial clearance from 13 mm. Numerical simulations and experiments were carried out to investigate the effect of BCF on pump performance under two conditions: with and without BCF at best efficient point (BEP) and various partload conditions for 1450 rpm (rated) as well as 1000 rpm. Pump performance characteristics were enhanced by BCF at both rpms for the whole flow rate range. At 1450 rpm, BCF resulted in an average 0.74% increment in total head, 2.08% reduction in input torque, and 2.70% increment in overall efficiency over the flow rate range. While an average 2.04% improvement in total head, 1.33% reduction in input torque, a 3.30% enhancement in overall efficiency were obtained at 1000 rpm. Performance parameter enhancement was higher at lowest part load compared to the BEP on rated rpm.