Scientific Bulletin of the Politehnica University of Timisoara Transactions on Mechanics Special issue

Workshop on Vortex Dominated Flows Achievements and Open Problems Timisoara, Romania, June 10 - 11, 2005

SWIRLING FLOWS IN THE SUCTION SUMPS OF VERTICAL PUMPS. THEORETICAL APPROACH

Eugen Constantin ISBASOIU, Prof* Department of Hydraulic Machinery Politehnica University of Bucharest Carmen Anca SAFTA, Assist. Prof Department of Hydraulic Machinery Politehnica University of Bucharest Tiberiu MUNTEAN, Assist. Department of Hydraulic Machinery Politehnica University of Bucharest Petrisor STANESCU, MEng. S.C. AVERSA S.A. Bucuresti

*Corresponding author: 313 Splaiul Independentei, 060024, Bucuresti, Romania Tel.: (+40) 21 4029 523, Fax: (+40) 21 4029 523, Email: codin@hyd.pub.ro ABSTRACT The paper is the beginning of a study regarding the swirling flows in the intake channel suction sump pump. The goal of the study is to observe the influence of the level upstream the suction pump and the developed of the swirling flow in the sump pump. Vortex types are described. The suction sump dimensions are presented based on the two standards of Hydraulic Institute Standards and British Hydromechanics Research Association. Types of eddy flow prevention devices are described. Some preliminary results of the numerical simulation of the flow in the intake channel suction sump of a large-bore were obtained. The numerical results indicated that the flow inside the suction sump is highly vertical. KEYWORDS Suction sump, large-bore axial pump, k- method, eddy flow prevention devices 1. INTRODUCTION Suction sumps receive water flowing from the intake channel and must direct it smoothly to the pump suction opening. If suction sumps are improperly shaped or sized, air-entraining vortexes or submerged vortexes are developed. This may greatly affect pump operation if vortexes grow to extent. In the design of a conventional sump there are standards [1, 2, 3], each having sufficient information in the aids of the designers. For special applications and particularly for large high-capacity pump installations, sump designs needed a comprehensive model test. 2. VORTEX TYPES Vortexes and water surface turbulence may produce adverse effects on the pump such as: generation of vibration and noise; suction of air, causing pump performance to deteriorate the pump or pump failure; generation of unstable swirling flows at the impeller entrance that to cause a motor overland due to excessive discharge; impeller erosion and submerged bearing wear; vibration, surging and air hammer in water supply pipes because of the entrained air in pumped water Vortexes developing in a pump suction sump with a free water surface are classified into five types; see Figure 1, [3]. A dimple vortex is produced on the water surface, without suction of air. If the dimple on the water surface grows, and its tip intermittently causes suction of air, an intermittent air entraining vortex will appear. When air is continuously entrained a continuous air entraining vortex is developed. A shallow depth of submergence continuously entrains a large amount of air, causing deterioration of pump performance and generates vibration and noise. These three types of vortexes are called surface vortexes, [1]. The fourth type of vortex is the coaxial vortex. It is developed when the water surface is decreased below the level at which the continuous air entraining vortex develops. The center of vortex coincides with the center of the suction bell mouth. A large amount of air is entrained from around the bell mouth. As a result, pump performance deteriorates to an extreme degree and pump failed. The last type of vortex is the submerged vortex. A vortex of this type has no direct relation with the submerged depth of the bell mouth. Such vortex develops in the water, beginning from the side or bottom wall of the sump, with a vapor cone produced in its center. When the vapor crosses the impeller of a vertical shaft type mixed flow or axial flow pump, irregular vibration or noise may be produced. The swirling flow around the suction bell mouth is caused by increased velocity

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Proceedings of the Workshop on VORTEX DOMINATED FLOWS. ACHIEVEMENTS AND OPEN PROBLEMS, Timisoara, Romania, June 10-11, 2005

of pump-approach flow, non-uniform flow and drift flow in the suction sump, Figure 2. In [2] the coaxial vortex and the submerged one are called subsurface vortexes and are described as Type C, Type B and Type A. Type C and type A are

the same as the coaxial vortex and the submerged vortex, see [1]. Type B is similar in formation and movement to the Type C vortex but of grater magnitude or intensity. Type B vortexes may be either periodic or continuous.

a) Dimple vortex

b) Intermittent air entraining vortex

c) Continuous air entraining vortex

d) Coaxial vortex

e) Submerged vortexes Figure 1. Vortexes types, a, b, c, d, e

Figure 2. Submerged vortex at the entrance of the impeller from sump bottom 3. STANDARD CONFIGURATION FOR A SUCTION SUMP A good sump design must be capable of delivering the pumped liquid from a channel or pipeline to the pump intake with an acceptable efficiency, without any detrimental effect on the pump hydraulic or mechanical performance. Is considered the submergence, Zi, minimum vortex submergence only, see Figure 3. Sump design parameters are given in ratios of suction bell diameter D or as a function of a basicvelocity, for example the approach velocity, Vch, [4]. It is assumed this in the limiting value of the net positive suction head available (NPSHA), defined as:

Figure 3. Standard sump configuration, [4]

NPSHA = ha hvpa + Z s

(1)

where: ha is atmospheric pressure, (m), absolute; hvpa is vapor pressure of pumped liquid, (m), absolute at pumping temperature; Zs is water depth over impeller eye, (m).

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The Hydraulic Institute Standards, [1] and the British Hydromechanics Research Association, [2] recommended sump dimensions versus flow and in ratios of pump suction bell diameter, see Table 1. Japan Association of Agricultural Engineering Enterprises, [3] shows recommended sump dimensions for different types of sumps according with pump bore size. JAAEE considered the sump dimensions not only for sump with free water surface but also for intake channel to the suction sump. In this case the following considerations should be taken into account: the intake channel to the suction sump should be straight; flow velocity should be about 0.5 to 0.7 m/s in the intake channel upstream of the sump; distribution of flow velocity into each sump should be as uniform as possible; for a pumping station with many pumps, suction pipe arrangement for each pump should be studied; drift flow and swirling flow due to accumulations of earth and sand must be prevented.

Standard dimensions of large-bore pumps with intake channels to the suction sump are presented in Figure 4 and Table 2.

Figure 4. Standard dimensions of large-bore axial flow pumps, [3]

Table 1. Basic sump dimensions Standard Hydraulic Institute BHRA Pump capacity, (m3/h) 2,270 22,700 All flows Bottom clearance Back wall clearance ZC/D* lB/D* 0.62-0.73 0.45-0.53 0.5 0.84-1.00 0.88-1.04 0.75 Minimum vortex submergence, Zi/D* 1.52-1.80 1.33-1.57 1.5

* First number is for an assumed suction bell velocity of 1.3 m/s; second number is for an assumed bell velocity of 1.8 m/s. Table 2. Standard dimensions of large-bore axial flow pumps, JAAEE Bore size (mm) 2200 2400 2600 2800 C 3000 3200 3400 3600 D 3000 3300 3500 3800 Principal dimensions (mm) F G H I 3200 6000 4200 1800 3500 6600 4600 2000 3900 7000 5000 2200 4200 7600 500 2400 J 4200 4600 5000 5600 K 4000 4300 4600 5000

4. EDDY FLOW PREVENTION DEVICES Various effective types of eddy flow prevention devices have been used to prevent vortexes and swirling flows generated by installation conditions. For large-bore pumps, such devices are often installed to decrease the depth of submergence of the suction bellmouth and to reduce the required excavation for the suction sump. Suction cone, the cruciform guide or vertical splitter are such devices. The suction cone, Figure 5, is installed in the sump under the pump suction bell. The dimensions are in according with suction bell diameter, D. The cruciform

or X-shaped, guide is installed under the pump suction, Figure 6. It improves the flow path into the suction when a sump is too short or is subject to upstream disturbers. 5. PRELIMINARY NUMERICAL RESULTS OF THE FLOW IN THE SUCTION SUMP A theoretical approach of the flow in the suction sump was beginning. It was considered the practical dimensions of the suction sump of a large-bore axial pump. The goal of this approach is to find the influence of the level upstream the intake channel to the suction sump in the swirling flow development.

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Proceedings of the Workshop on VORTEX DOMINATED FLOWS. ACHIEVEMENTS AND OPEN PROBLEMS, Timisoara, Romania, June 10-11, 2005

Boundary conditions for the entrance boundary were the velocity inlet calculated for a flow rate of 1 m3/s and then for 10 m3/s, and for the exit, the flow rate was constantly maintained. A no-slip condition is applied to the stationary suction sump walls. The boundary conditions for the turbulence quantities, turbulence kinetic energy and turbulent dissipation rate are considered to be predefine, at the beginning, [6]. Some numerical results are given below.

Figure 5. Suction cone, [4] It was considered an intake channel to the suction sump for a large-bore axial and vertical pump. The suction sump was with out suction cone and vertical splitter. A computational grid for pump sump was of 141,754 tetrahedral elements of TGrid type. A fine mesh was generated around the suction pipe. Calculations of the flow were made with k- model, using FLUENT, CFD code. The solution domain is bounded by the entrance boundary, the annular exit and the sump wall.

Figure 6. Cruciform used for inlet flow improvement

Figure 7. Pathlines for 10 m3/s flow range.

Proceedings of the Workshop on VORTEX DOMINATED FLOWS. ACHIEVEMENTS AND OPEN PROBLEMS, Timisoara, Romania, June 10-11, 2005

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Figure 8. Pathlines for 1 m3/s flow range.

Figure 9. Velocity vectors in horizontal sections for 1 m3/s flow range.

Figure 10. Velocity vectors in vertical section for 1 m3/s flow range

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Proceedings of the Workshop on VORTEX DOMINATED FLOWS. ACHIEVEMENTS AND OPEN PROBLEMS, Timisoara, Romania, June 10-11, 2005

Figure 11. Velocity vectors and the swirl at the entrance of the pump, for 10 m3/s flow range 6. CONCLUSIONS In the theoretical and experimental approach of the swirling flow in the suction sump of the pump some practical problems were described. The suction sump dimensions were presented based on the two standards of Hydraulic Institute Standards, [1] and British Hydromechanics Research Association, [2]. Also the vortex types were described. Some preliminary results of the numerical simulation of the flow in the intake channel suction sump of a large-bore were obtained. The numerical results indicated that the flow inside the suction sump is highly vertical. The future step in this study is to improve the numerical model and even the geometry and the mesh of the suction sump. The goal of this study is to see the influence of the level of upstream intake of the suction pump concerning the pump efficiency. BIBLIOGRAPHY
1.***, Hydraulic Institute Standards, 14th ed., Hydraulic Institute, 14600 Detroit Ave., Cleveland, Ohio 44107, 1983 2.M.J. Prosser, The Hydraulic Design of Pump Sumps and Intakes, British Hydromechanics Research Association, Cranfield, Bedford, England, 1977 3.***, Pumping Station Engineering Handbook, Japan Association of Agricultural Engineering Enterprises, 1990 4.J.L. Dicmas, Vertical Turbine, Mixed Flow and Propeller Pumps, McGraw-Hill Book Co., 1989 5.R. Iwano, T. Shibata, Numerical prediction of the submerged vortex and its application to the flow in pump sumps with and without a baffle plate, 9th International Symposium on Transport Phenomena and dynamics of Rotating Machinery, Honolulu, Hawaii, 2002 6.*** FLUENT 5 Users Guide, FLUENT Inc., 1998