Industrial mixed flow pump impellers have been developed in the course of R&D programs in which their performance was optimized by extensive model (physical prototype) testing. The paper reports on investigations aimed at further improvement of both the current performance levels of these impellers as well as the design procedures that are now available for this task. A multilayer (1D-Q3D-3DCFD) modeling and simulation approach has been thoroughly analysed and applied to provide data to select initial design parameters (1D), support blading optimization at BEP (Q3D), and verify performance at the off-design operation (3DCFD). Application of 3DCFD in a dual-role (design and research) computational environment is discussed as an approach which enables efficient and low-cost operation of the CFD-based design cycle, taking into account capabilities and limitations of current 3DCFD technology. CFD-based multilayer/dual role concept of a design system has been found to generate design solutions of the enhanced design quality at a substantially reduced design time and cost in comparison with previously applied design-test-and-modify approach. Design analyses were performed on an existing public domian (NEL Mk1) impeller. Consistent application of the above multilayer approach resulted in impeller redesign which remains within baseline impeller size envelope and exhibits design signatures which have been identified in previous research works as contributing to impeller loss reduction and stable performance characteristics at part-load operation.
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