Proceedings of the ASME 2009 Fluids Engineering Division Summer Meeting

FEDSM2009
Proceedings of FEDSM2009
August
ASME 2009 Fluids 2-6, 2009,
Engineering Vail,
Division Colorado
Summer USA
Meeting
August 2-6, 2009, Vail, Colorado USA

FEDSM2009-78564
FEDSM2009-78564

SLURRY PUMP CASING WEAR PREDICTION USING NUMERICAL MULTI-PHASE FLOW

SIMULATION

Aleksander S. Roudnev
Ronald J. Bourgeois
Randy J. Kosmicki
Weir Minerals North America
Madison, Wisconsin, USA

ABSTRACT requires using CFD simulations, validated by experimental

Wet end components of centrifugal slurry pumps used in the
hydraulic transport of solids are subject to substantial erosive
wear. Accurate prediction of the casing wear rate and location
for a particular duty is beneficial for correct pump selection
and design, maintenance planning, and elimination of
emergency shutdowns.
CFD multi-phase simulation using the Eulerian-Eulerian
approach is being used successfully to determine the velocity
fields and solids concentration in the centrifugal pump
allowing for accurate predictions of casing wear patterns
resulting from sliding abrasive wear.
Simulation results for various single domain and multi-domain
multiphase simulations are discussed. Emphasis is placed on
results from a 3 dimensional, multi-domain transient,
multiphase simulation and comparison to field data.
INTRODUCTION
A common method for predicting casing wear in a centrifugal
slurry pump is based on a sliding erosion model. An
experimentally determined wear coefficient is used to relate
the local solids velocity and volume fraction to wear. Wear
coefficients, which are a function of the wear material and
solid particle characteristics, are selected using a
representative particle size and available data, such as
presented in the ANSI/HI Standard for Slurry Pumps [1]. The
solid particle velocities and volume fractions are a function of
the particular pump geometry and the operating point.
Specific distribution of internal velocity is directly related to
slurry pump casing wear. Calculation of the flow field
data.
Various levels of analysis are employed by the industry to
predict wear in centrifugal slurry pump casings. These
methods vary in complexity from characteristic formulas
derived from fundamental fluid hydraulic principles, to 2 and
3-dimensional CFD analyses of the hydraulic passages.
Analyses using characteristic equations or 2-dimensional CFD
typically only capture the average velocity gradients of the
primary flow, and thus only indicate trends and relative wear
magnitudes around the volute scroll. A 3-dimensional multi-
domain transient CFD simulation can capture the effect of the
secondary flows and accurately predict local wear rates and
patterns.
Results from different wear prediction approaches, simplified
analytical based on mean velocity and average flow (MVAF),
as well as 3-dimensional single and multi-domain finite-
volume CFD simulations are presented and discussed.
INTERNAL FLOW IN SLURRY PUMP DISCHARGE
CASING
Conventional pump volute (true volute) design methods are
based either on constant angular momentum or constant mean
velocity principles and often rely on experimental coefficients
derived from pumps with similar construction. These methods
do not provide a means to estimate fluid velocity in the casing
for operating points other than the design point. Further these
methods are not directly applicable to the design of slurry
pump discharge collectors with wide internal hydraulic
passages.

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Figure 1. Velocity contour plot for conventional pump
volute
Figure 2. Velocity contour plot for a slurry type discharge
casing.
Typical internal velocity distributions for a conventional
centrifugal pump volute and a slurry pump type discharge
casing, obtained by numerical simulation, are shown in Figure
1 and 2, respectively. Both pumps are designed for the same
specific speed and same impeller diameter, and the plots
reflect operation at best efficiency point rate of flow.
Most common slurry pump discharge casing designs are
volute-type, semi-circular, and circular (constant cross
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section) casing. The geometry of a slurry pump discharge
casing is based on the requirement to ensure free passage of
large solid particles. In many cases the minimum desired free
passage determines the cutwater clearance in a slurry pump
casing. The cutwater section is called T in Figure 3 which
shows a typical profile of a slurry pump discharge casing.
Section G, which is perpendicular to the discharge nozzle axis,
will be called the design section, and the discharge throat is
designated H. Additional volute cross sections A through F,
used in the paper are shown in Figure 3 for reference.
In the text to follow the terms “discharge casing” and “volute”
will be used alternatively to describe a slurry type discharge
casing with wide hydraulic passages.
Figure 3. Schematic of slurry pump discharge casing ,
Reference volute sections
Experimental studies of the discharge casings with wide
hydraulic passages conducted by Bognitskaya [2] and
Gelvanovsky [3] led to the following findings:
• velocity distribution in the design section of discharge
casing while operating at the point of maximum
hydraulic efficiency closely follow the principle of
angular momentum conservation;
• flow through the design section remains fairly constant
within a wide range of pump operating capacities.
 Figure 4. Schematic of internal flow in slurry pump volute at different rates of flow.

Figure 4, a, b, and c show internal flow schematic at different
rates of flow through a slurry pump, based on [2]. Part of the
flow inside the pump casing is directed through the discharge
throat and part circulates internally past the cutwater section.
These two flows can be theoretically separated by an
imaginary surface that starts at some distance before the
design section (point a) and ends at the tongue (point b).
At the flow rate corresponding to maximum hydraulic
efficiency of the discharge casing (Fig. 4a), which for the
purpose of this paper is assumed to coincide with the pump
best efficiency point, a division of flow takes place at the
volute tongue such that the velocities in sections T and H are
equal [3]. At partial capacities, as compared to QBEP, less flow
goes through the discharge throat (H) and more flow
accelerates past the cutwater, (T) as represented by the
imaginary separation point shifting from point a to point a2
(Fig. 4b). In both cases the design section flow (G) will exceed
the pump discharge flow rate.
At over capacity the design section (G) passes less flow than
the discharge throat (H), and the cutwater section may see a
back flow of liquid towards the discharge throat, with the
imaginary separation surface shifting to points a1-b1.
A mathematical relationship, applicable to the discharge
casings with wide hydraulic passages, between the flow rate
through section G and flow rates at discharge throat H and
past cutwater T was developed based on conditions of
continuity, as presented in Jivotovsky et al. [4]. This approach,
based on mean velocity and average flow (MVAF) through
casing sections, allows a slurry pump designer to evaluate
liquid velocities and associated relative wear inside the slurry
pump discharge casing for a wide range of flow rates. This is
particularly useful early in the design process when the use of
more complex numerical simulation methods is not justified.
MODEL PUMP AND RESULTS OF MVAF
PREDICTION
The wear studies presented in this paper were obtained for an
end suction centrifugal slurry pump with a specific speed of
33 (1700 US units) with a wide passage volute-type casing
and 5-vane impeller, both made of high chrome iron. The
pump is capable of passing a particle which is 25% of the
discharge diameter. Average pump operating point was at
60% BEP flow rate (0.6 QBEP), relative density of solids SS =
2.8, solids concentration by volume Cv = 33% resulting in
relative density of slurry SM = 1.6. A representative solid size
d85 = 2 mm was used for the purpose of wear rate modeling.
Figure 6 shows an image of the subject pump volute casing
taken in the field. Maximum wear area is located between
sections A and B and shifted towards front (suction) side of

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 the casing. Also a distinctive wear gouge can be seen adjacent
to the cutwater section T. Average linear wear rate calculated
from the lost thickness of the casing wall divided by operating
time was 0.036 mm/hour at the highest wear point and 0.011
mm/hour for design section. Figure 7 shows the solid size
distribution in slurry for the researched application.
Figure 6. Actual casing wear pattern, 60% BEP flow (front
side top, sections ref. Figure 3).
Cyclone Feed Particle Size Distribution
100
90
80
Cumulative % passing
70
60
50
40
30
20
10
0
0.01 0.1 1 10
Particle size (d) mm
Figure 7. Particle size distribution, d85 selected.
When a slurry pump operates at or near its hydraulic BEP flow
rate, the highest internal velocities in the discharge casing take
place at the design section G and this area will exhibit the
highest relative wear. When the pump operates at partial
capacity, the pump flow rate decreases, however the flow
through the design section remains fairly constant. At the
same time, decreasing the pump flow rate will cause velocities
in all other sections A through F (except the discharge throat)
to increase. As a general guideline, the value of the average
velocity past the cutwater approaches that in the design section
when pump operates at Q = (0.65…0.7) QBEPh flow rate. If the
flow rate is further reduced the cutwater area (or transitional
section in case of semi-circular design) becomes the
determining factor of casing wear life. As the pump operates
beyond BEP and the pump flow rate increases, flow passing
through the design section again remains relatively constant,
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however flow through the remaining sections A through F
(except the discharge throat) decreases.
These trends are reflected in Figure 8 which plots the MVAF
results for the subject pump at the operating point which this
paper focuses on (60%), as well as QBEP and 130% of QBEP
flow rate.
The results of MVAF analysis for 60% of the QBEP flow rate
operation predicts a ratio of maximum wear rate to that at
design section as approximately 3.6 to 1, which is close to the
global actual measured of 0.036/0.011 = 3.27, and wear trend
correctly points towards cutwater section. However the peak
wear is placed directly at the cutwater T versus actual A-B
area, and there is no means to pick up the three dimensional
wear pattern details as the MVAF approach is based on
average values.
Figure 8. MVAF predicted relative wear rates at various
flow rates
BOUNDARY CONDITIONS FOR CFD WEAR
MODELING
To improve the accuracy of the predicted absolute wear rates a
CFD analysis is required. It is common to use a simplified
100
model of the pump to save computational expense. For
predicting casing wear, this simplification is usually to model
a 2D or quasi-3D casing only. The finite element 2D
probabilistic model approach is described in, for example,
Shook et al. [5], and finite element quasi-3D modeling
presented by Addie et al. [6].
When modeling these simplified casings it is necessary to
convert the actual casing cross sections to a representative
section of constant depth. This requires that the profile of the
casing scroll is modified to maintain the same relative areas as
the actual casing. This simplification adds another level of
uncertainty to the analysis if the original cross section of the
casing is not substantially rectangular. In order to obtain a
higher accuracy of wear rate and distribution prediction, it is
common to run a 3D single domain analysis using a mesh that
represents the actual casing geometry.
Whether conducting a 2D, quasi-3D, or 3D single domain
CFD analysis of the casing the boundary conditions at the
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 casing inlet, which is the impeller outlet, are typically today’s computing power and commercial software packages
specified as components of an absolute velocity. Since the it is possible to run the multistage transient case in a few days.
flow at the impeller outlet does not exactly follow the blade, A transient rotor-stator allows for simulating the effects of
velocities at the impeller outlet (casing inlet) are obtained with impeller pump out vanes, as well as internal leakage.
theoretical performance calculations. These calculations may Accurate predictions of wear rate and location are possible as
use a variety of estimates for slip factors to predict the pump the analysis captures the secondary flows resulting from the
theoretical head. For the purposes of this exercise the slip interaction between the domains.
factor proposed by Stodola [8] is used with modifications to
better reflect the effects of low number of relatively thick
vanes typical for a slurry pump impeller [4]. On the basis of
theoretical head the average tangential velocity at the impeller
outlet is estimated (assuming no pre-rotation at the impeller
inlet). Radial exit velocity is assumed uniform and calculated
through a basic conservation of mass.

D2 × ω g × H th Q
UT = Vt = Vr =
2 UT π × D 2 × b2

U T - Peripheral velocity of impeller OD, D2 - Impeller

diameter, Vt - Fluid tangential velocity, Vr -Fluid radial
velocity, H th - Pump theoretical head, g - Gravitational
constant, b2 - Impeller width

It is also necessary to estimate the velocities of the solid

particles. A slip coefficient can be employed or the particle
and the carrier fluid velocity can be set equal. The end result Figure 9. Single domain casing mesh
of this estimate is a radial and tangential velocity specification
for the carrier fluid and the solid particles; this in combination
with an assumed even distribution of the particles specifies the
boundary conditions for the inlet of the volute.

For comparison another approach to developing the single

domain boundary conditions at the casing inlet was used. The
flow parameters obtained from a single domain impeller
simulation were used to provide the velocity and volume
fractions for the boundary conditions at the volute inlet. This
process is computationally less expensive than a multi-domain
analysis; however it does not capture the interaction between
the volute and the impeller domains. Volute mesh for this case
is shown in Figure 9.

While it is possible to predict the general wear rate and

location with a single domain approach, the volute inlet
boundary conditions are close to the areas of interest and the
solution is sensitive to their specification.

The final simulation method employed was a transient rotor-

stator analysis. This is a 3-dimensional multi-domain
simulation containing a mesh of the impeller (rotor), inlet, and
volute, as shown in Figure 10.

A transient rotor-stator simulation moves the impeller mesh in
small increments, solving the flow field at each step and
applying an upwind transient averaging to the intermediate
solutions. This approach is computationally more expensive
compared to the single domain simulations; however with
Figure 10. Multi-domain meshes
For the CFD simulation results described in this paper, wall
boundary conditions are specified as free slip for the solid
particles and no slip for the liquid phase. K-epsilon turbulence
model is used for the liquid phase, and a dispersed phase zero

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 equation model for the solid particles. While it is understood
that the K-epsilon turbulence model can not capture all the
effects due to the rotating flow it is widely used in successful
simulations of turbomachinery, for example, Gonzalez et al.
[7].
Subscripts, Calc - Values calculated from theoretical pump
performance, t - Tangential, r - Radial, CV - Volumetric
Concentration.

Numerical simulations were conducted using ANSYS CFX-5

analysis system from ANSYS, Inc. of Canonsburg, PA. All
simulations used a tetrahedron mesh with an inflated prism
layer at the walls. Total number of elements in the single
volute domain simulation was 1 million. Multidomain
transient simulations used a somewhat coarser mesh for the
volute, due to the multiple domains, and had a total element
count of 1.6 million. Single domain simulations were
considered converged when iteration error rms was less than
1e-3. Multidomain transient simulations were considered
converged when mass conservation of each phase was within
2% and coefficient loop iteration error was 1e-3. Further
indication of convergence for transient rotor-stator simulations
was periodic values of key parameters: torque and pressure.
Figure 12. Transient rotor-stator results at vane OD.
Once the solution has been obtained for the local velocity
The first approach for the single domain CFD simulations was
fields and volume concentrations, wear on the casing walls
to set the inlet parameters based on the theoretical velocity
can be estimated using a wear coefficient corresponding to the
calculations. The velocity of the solid particles was assumed
d85 particle size and the equation for linear wear rate in the
equal to the velocity of the carrier fluid, and both assumed to
following form
be equal to Vt Calc and Vr Calc plotted as straight lines in
Figure 10. This resulted in a volume fraction of 0.33 for the
Wr = VS3 × ρ S × CV × WC sand at the volute inlet.

A second approach for the single domain CFD simulation was

Wr = Wear rate (linear), VS = Local solids velocity, ρ S =
Solids density, CV = Local solids concentration by volume,
WC = Experimental wear coefficient, single value [1].
Shown in Figure 11 are the velocities and volume fractions at
the outer diameter of the impeller used as inlet boundary
conditions for the single domain casing analyses which
corresponds to 60% BEP flow rate.
to derive casing inlet parameters based on the outlet flow field
from a CFD solution of a single domain steady-state impeller
simulation with assumed uniform solid particles distribution at
impeller inlet. Equations were derived from this output and
used for the inlet boundary specifications; these are also
shown in Figure 11.
Finally a multi-domain (multi-stage) transient simulation was
conducted. Impeller outlet flow field parameters, internal for
this type of simulation, are plotted in Figure 12 for comparison
with the ones obtained from steady-state impeller modeling
(Figure 11).

Both the transient and steady-state simulations correctly

predict the radial velocity of the solid particles as higher than
the carrier fluid as a result of the redistribution of these
particles. However the steady-state solution predicts a more
symmetrical distribution of solid particles and velocity
gradients across the impeller outlet than expected for low flow
rates. Simulation results from the transient analysis (Figure
12) predict a distribution of solid particles at the impeller
outlet which is more representative of the low flow condition
point.

It is worth noting that the predicted effects of redistribution of

solid particles on solids velocity and volume fraction correlate
with impeller outlet blockage and inertial effects. Volume
Figure 11. Single-domain results at impeller vane OD.
fractions and velocities presented in the graphs are also
affected by the circumferential area based averaging used to
The meaning of symbols in Figures 11 and 12 are as follows:
interpret the results. Mass flow of both liquid and solid
V – Velocity, S - Solids, W - Carrier fluid (water);
phases is kept constant for the various simulations. Mass flow

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 rates scale directly with velocity and volume fraction. As the
velocity of the solid phase relative to the carrier phase
changes, the volume fractions change such that mass is
conserved.
RESULTS OF CFD WEAR PREDICTIONS
The results of CFD wear modeling at 60% of pump BEP flow
rate are presented in Figures 13, 14, and 15 for single domain
with calculated uniform input, single domain steady state and
multi-domain transient simulations respectively. In all these
figures the back (drive) side of the casing is to the left for left
part of figure and bottom for right part of figure.
Single domain wear prediction conducted with calculated
constant boundary conditions (Figure 13) correctly placed the
location of maximum wear on the volute scroll within sections
A-B (see Figure 5) with the wear rate of 0.040 mm/hour (12%
above actual), but shifted the peak wear area to the back of the
casing, contrary to field observation. Apparently the three-
dimensional flow field inside the volute casing translates
uniform velocity and volume fraction input in a way that puts
heavier load towards the casing drive side.

Figure 13. Wear rate prediction: Single-domain, boundary conditions based on theoretical calculations

Figure 14. Wear rate prediction: Single-domain, boundary conditions derived from impeller simulation

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 Figure 15. Wear rate prediction: Multi-domain: Transient rotor stator simulation

Single domain wear prediction using boundary conditions
derived from impeller simulation (Figure 14) gave the same
wear rate magnitude as the first method and also correctly
pinpointed the location of peak wear on the suction side of
the volute at sections A-B. However this analysis gave no
indication of the characteristic gouge behind the cutwater
tongue at T. This can be explained, as mentioned earlier, by
the fact that the details of impeller-volute domains
interaction are not being captured in this type of analysis,
and some secondary flow effects are not accounted for.
Actual measured wear is obtained from a test pump
operating in a minerals processing application. Changing
demand of the plant causes variations in pump operating
point and slurry composition throughout the test.
All CFD simulations are run on geometry which represents
the new pump components. During the field operation
period pump geometry changes as a result of wear. Actual
measured wear is based on the final geometry and represent
an average throughout the life of the part.

Multi-domain transient wear analysis with averaging
resulted in predicted maximum wear rate of 0.034 mm/hour
(6% below actual), correct location of the peak wear area,
and also showed the characteristic asymmetrical wear
behind the cutwater.
DISCUSSION
MVAF average wear profile, as mentioned previously, quite
satisfactorily indicates relative magnitude of wear variation
around the scroll, as well as overall increase in material loss
towards the cutwater area. However location of maximum
wear area is shifted and placed directly at the cutwater area
of the casing scroll.

Actual material loss measurements were taken from the test

volute of a slurry pump installed in the field. Results of
material loss measurements along the discharge casing
centerline in comparison with predictions from numerical
simulation and MVAF average trend are illustrated in Figure
16. Wear profile from the multi-domain CFD simulation
shows broader peak wear, but the magnitude and location of
maximum wear are in good agreement.

Differences between CFD predictions and actual wear are

attributed to error introduced by modeling assumptions as
well as process variations during service life of the test
casing. Modeling assumptions which contribute to error are
the relatively simple sliding erosion model used and also the
fact that actual slurry with broad distribution of solid
particles is approximated with a mixture of water with single Figure 16. Comparison of actual wear profile at
sized solids. centerline of slurry pump discharge casing with trend
predicted by CFD analysis and MVAF average.

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 CONCLUSIONS
Basic analytical slurry pump casing wear evaluation
approach using mean velocity and flow values is very
simple, and requires minimum input. The analysis can be
performed as soon as the characteristic areas are calculated,
before the part layout is available. Generally this approach
provides for a wear trend and magnitude evaluation, but not
the exact location of maximum wear.
In order to obtain higher accuracy level of wear rate and
distribution prediction, a finite volume CFD code was used
to model wear in a slurry pump casing by different
simulations with multiphase medium. Existing wear models
and wear coefficients where employed to calculate the wear
rate and distribution based on local velocity and volume
fractions.
Three different CFD approaches were used to model wear in
a centrifugal slurry pump casing, two with a 3D single
domain with differently set inlet boundary conditions, and
one with a 3D multi-domain transient simulation.
All 3D simulations predicted similar wear rate magnitudes.
Where the simulations differed was in the predicted location
of maximum wear. Only the transient multi-domain
simulation was able to accurately predict the wear locations,
including the secondary wear zone just past the volute
tongue.
Predicting the general wear location relative to the cutwater
and the wear rates in slurry pump casings can be
accomplished using a variety of simulation techniques.
Accurate prediction of wear due to primary and secondary
flows requires a transient simulation which captures the
interaction between the impeller and casing.
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REFERENCES
1. ANSI/HI 12.1-12.6-2005, American National Standard
for Rotodynamic (Centrifugal) Slurry Pumps, Section
12.3.4.1, Hydraulic Institute, Parsippany, NJ,
www.Pumps.org
2. Bognitskaya, F.A., 1959, Study on wet ends of pumps for
suspended solids, Proceedings/VIGM, Issue XXIV, pp. 38-
77, Moscow, Mashgiz (in Russian)
3. Gelvanovsky, V.P., Suprun, V.K.,1974, To the question of
influence of a slurry pump discharge casing design on its
optimum regime, Proceedings/VNIINerud, Issue 38, pp. 54-
59, Tolyatti (in Russian)
4. Jivotovsky, L.S., and Smoilovskaya, 1986, L.A.,
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5. Shook, C.A., and Roco, M.C., 1991, Slurry flow
principles and practice, pp. 174-182, Boston, Butterworth-
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6. Addie, G.R., Pagalthivarthi, K.V., Kadambi, J.R., 2004,
PIV and finite element comparisons of particles inside a
slurry pump casing, BHR Group, Hydrotransport 16, pp.
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structure and global variables in a centrifugal pump, ASME
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8. Stodola, 1927, A., Steam and Gas Turbines, McGraw-Hill
Book Company, New York, N.Y.