Table of contents

The authors consider the air entrainment into a suction pipe which is vertically inserted down into a suction sump across a mean free-water surface. This configuration is often referred to as the "vertical wet-pit pump," and has many practical advantages in construction, maintenance and operation. Most of the flows appearing in various industrial and environmental problems like the present suction- sump flow become often complicated owing to both of their unsteadiness with poor periodicity and their fully-three-dimensionality. In order to understand the complicated flow inside a suction sump in the vertical-wet-pit-pump configuration, the authors experimentally observe the flow using the three-dimensional particle tracking velocimetry (3D-PTV) technique, which includes more unknown factors in accuracy and reliability than other established measuring techniques. So, the authors examine the simultaneous measurement by the 3D-PTV with another velocimetry the ultrasonic velocity profiler. As a result, under the suitable condition with high accuracy, the authors have revealed the complicated flow.

The pump sump, which connects forebay and intake of pump station, supplies good flow condition for the intake of the pump. If suction sumps are improperly shaped or sized, air entraining vortices or submerged vortices may develop. This may greatly affect pump operation if vortices grow to an appreciable extent. Moreover, the noise and vibration of the pump can be increased by the remaining of vortices in the pump flow passage. Therefore, the vortices in the pump flow passage have to be reduced for a good performance of pump sump station. In this study, the effect of suction pipe leaning angle on the pump sump internal flow with different water level has been investigated by CFD analysis. Moreover, an elbow type pipe was also investigated. There are 3 leaning angles with 0°, 45° and 90° for the suction pipe. The suction pipe inlet centre is kept same for all the cases. In addition, the three different water levels of H/D=1.85, 1.54, and 1.31, is applied to different suction pipe types. The result shows that the amount of air sucked into the suction pipe increases with increasing the suction pipe leaning angle. Especially for the horizontal suction pipe, there is maximum air sucked into the suction pipe. However, there is certain effect of the elbow type bell mouth installation in the horizontal suction pipe on suppressing the amount of air sucked into the pipe. Moreover, vertical suction pipe plays an effective role on reducing the free surface vortex intake area.

Submerged vortices in a model pump sump and their flow structures were investigated numerically. The model pump sump is composed of a 2,500 mm-long water channel with rectangular cross section of 150 mm (channel width) by 100 mm (water height) and a vertical suction pipe with 100 mm diameter installed at its downstream end. At the upstream end of the channel, a uniform velocity of 0.37 m/s is given. In order to capture appearances and disappearances of submerged vortices in the pump sump, large eddy simulations (LES) are performed. The computational grids for the LES are composed of 2 billion hexahedral elements with 0.255 mm resolution. These grids can resolve the streamwise vortices in the approaching turbulent boundary layers that develops on the channel walls. However, it is not sufficiently fine to capture the vortex cores of the submerged vortices. The LES succeeded to capture appearances of the submerged vortices. By performing LES with several different sets of the wall boundary conditions, we have clearly identified, to the best of our knowledge for the first time, the origin of the submerged vortices. Computations that used a simplified computational model, where the computational domain was localized to the region close to the vortex core, were also performed to predict correctly the vortex core and to investigate dynamics of the vortices. The grid resolution in the simplified computational model was 0.03 mm. We successfully computed the size of vortex core in the simplified computational model. For this model, we also investigated the conditions under which a vortex appears by changing inlet tangential velocity.

Pipes are usually adopted in those conditions for which the pump house is far from water source. As for fore-bay, flow of headrace pipe can be considered as jet-flow. Jet-flow has a high velocity, and creates large pressure gradient between jet-flow and near wall flow, which contributes to large scale circulation. In that circumstance, a single rectification measure cannot effectively improve the flow pattern of intake flow field. For large scale pumping station, there is enough space to arrange complex anti-vortex devices. Thus, a new type of combined diversion piers composed of double-I type pier, three-I type pier and cross anti-vortex baffle was proposed. In order to investigate the influences of combined division piers on flow pattern, four cases with different geometry and location parameters are designed. The results of numerical simulation and site tests show that the combined diversion piers could effectively improve the intake flow field of pumping station with headrace pipe. As for pumping station with headrace pipe, the distance between inlet section of fore-bay and leading edge of double-I type diversion pier should be 0.25L-0.53L (where L is the length of fore-bay). The distance between inlet section of fore-bay and trailing edge of double-I type diversion pier should be 0.5L-0.73L. The total length of double-I type pier should be 0.2L-0.25L.

Intakes of large pump stations are often designed with the aid of hydraulic modeling. The approach flow to pumps is tested for adverse hydraulic phenomena, such as pre-swirl, velocity variations and vortices. Most commonly, the limits for these phenomena are taken from the ANSI/HI 9.8-2012 standard - Rotodynamic Pumps for Pump Intake Design. The standard, however, does not explain how real pumps respond to swirl, uneven velocity distribution or vortices. The present joined study between Deltares and Xylem aims to bridge this gap. At the Deltares pump sump test facility, two identical pump compartments were built according to the ANSI/HI 9.8-2012 standard. In one of the compartments, a submersible, vertical column pump (Flygt PL7020) was installed, while a 1:1 scale model of that pump was installed in the other compartment. This arrangement allowed measurements of both pump performance (pump head and input power as a function of flow rate) and the model parameters (pre-rotation and vortex occurrence) for nearly identical approach flow conditions. By varying the geometry of the approach channels, the asymmetry of the flow was varied to produce various degrees of pre-swirl including values in excess of the commonly accepted limit of 5 degrees. This paper describes the measurement setup, the results of the measurements with the model pump and the measurement plan for the prototype pump.

This paper reports an experimental and theoretical study of rotating stall in a vaneless diffuser which is coupled with a radial impeller. The experiments were conducted at 22 flow rates for two rotating speed: 1200rpm and 1800rpm. The measurements have consisted of: i/ unsteady pressure measurements delivered by two microphones flush mounted on the vaneless diffuser, ii/ 9 steady pressure taps mounted in one radial line on the diffuser to measure the pressure recovery in the vaneless diffuser. The stability of each stall mode was also studied by a 2D linear analysis; and the theoretical prediction was compared to experimental observations. The capabilities and limits of such an approach to predict the development of rotating stall have been evaluated. A non-dimensional analysis of the pressure losses at outlet was conducted to evaluate the effect of the instability development on the performance of the diffuser. It has shown that the arising of rotating stall has a positive effect on the diffuser performance.

Severe radial thrust under off-design operating conditions can be harmful factor for centrifugal pumps. In the present work, effects of geometry of a double volute casing on the hydrodynamic performance of a centrifugal pump have been investigated focusing on off-design conditions. Three-dimensional steady Reynolds-averaged Navier-Stokes analysis was carried out by using shear stress transport turbulence model. Numerical results for the hydrodynamic performance of the centrifugal pump were validated compared with experimental data. The hydraulic efficiency and radial thrust coefficient were used as performance parameters to evaluate the hydrodynamic characteristics of the centrifugal pump. The cross-sectional area ratio of the volute casing, the expansion coefficient of the rib structure, distance between the rib starting point and volute entrance, and radius of the volute entrance, were selected as geometric parameters. The results of parametric study show that performance parameters are significantly affected by both the geometric variables and operating conditions. Some configurations of the double volute casing showed outstanding performance in terms of the efficiency and radial thrust coefficient.

A single-channel pump for wastewater treatment was optimized to reduce unsteady radial force sources caused by impeller-volute interactions. The steady and unsteady Reynolds- averaged Navier-Stokes equations using the shear-stress transport turbulence model were discretized by finite volume approximations and solved on tetrahedral grids to analyze the flow in the single-channel pump. The sweep area of radial force during one revolution and the distance of the sweep-area center of mass from the origin were selected as the objective functions; the two design variables were related to the internal flow cross-sectional area of the volute. These objective functions were integrated into one objective function by applying the weighting factor for optimization. Latin hypercube sampling was employed to generate twelve design points within the design space. A response-surface approximation model was constructed as a surrogate model for the objectives, based on the objective function values at the generated design points. The optimized results showed considerable reduction in the unsteady radial force sources in the optimum design, relative to those of the reference design.

In the present paper, the computer fluid dynamics(CFD) with dynamic mesh model had been applied in scroll hydraulic pump to obtain its flow field at different leakage clearance. The fluid force on the orbiting scroll, the mass flow rate and the hydraulic efficiency at different leakage clearance were calculated based on the flow field data. The results indicated that when the leakage clearance increased from 0.5mm to 1.5mm, the average pressure, maximum of pressure fluctuation, leakage jet flow velocity, shaft power, cavitation degree decreased and the leakage flow rate increased. If the leakage clearance was 2.0mm, the high pressure discharge fluid flowed through the clearance and led to the increase of the average pressure and fluid force. When the leakage clearance is 1.0mm, the average pressure is far lower than that at the 0.5mm clearance, and the hydraulic efficiency is the highest.

Post-diving tubular pump is always used in large-discharge & low-head irrigation or storm drainage pumping station, its impeller and motor share the same shaft. Considering diving tubular pump system's excellent hydraulic performance, compact structure, good noise resistance and low operating cost, it is used in Chinese pump stations. To study the hydraulic performance and pressure fluctuation of inlet and outlet passage in diving tubular pump system, both of steady and unsteady full flow fields are numerically simulated at three flow rate conditions by using CFD commercial software. The asymmetry of the longitudinal structure of inlet passage affects the flow pattern on outlet. Especially at small flow rate condition, structural asymmetry will result in the uneven velocity distribution on the outlet of passage inlet. The axial velocity distribution uniformity increases as the flow rate increases on the inlet of passage inlet, and there is a positive correlation between hydraulic loss in the passage inlet and flow rate's quadratic. The axial velocity distribution uniformity on the outlet of passage inlet is 90% at design flow rate condition. The predicted result shows the same trend with test result, and the range of high efficiency area between predicted result and test result is almost identical. The dominant frequency of pressure pulsation is low frequency in inlet passage at design condition. The dominant frequency is high frequency in inlet passage at small and large flow rate condition. At large flow rate condition, the flow pattern is significantly affected by the rotation of impeller in inlet passage. At off-design condition, the pressure pulsation is strong at outlet passage. At design condition, the dominant frequency is 35.57Hz, which is double rotation frequency.

In this paper, CFD approach was employed to analyse the inlet and outlet pressure pulsation characteristics of reactor coolant pumps with different inflows. The Reynolds- averaged Naiver-Stokes equations with the k- turbulence model were solved by the computational fluid dynamics software CFX to conduct the steady and unsteady numerical simulation. The numerical results of the straight pipe and channel head were validated with experimental data for the heads at different flow coefficients. In the nominal flow rate, the head of the pump with the channel head decreases by 1.19% when compared to the straight pipe. The channel head induces the inlet flow non-uniform, and the non-uniformity of the inflow induces the outlet flow of the pump with channel head different from that of the straight pipe. Meanwhile, the pressure pulsation signals are analysed using RMS, Standard Deviation and Peak-to-Peak Value method. At the points of the inlet and outlet, the pressure pulsation characteristics between the channel head and straight pipe are compared, and the difference is obviously. It is evident that the two different inflows of channel head and straight pipe have significant effect on the pump unsteady pressure pulsation. Finally, it is expected that the effects of non-uniform inflow on the pump performance and unsteady pressure pulsation are absolutely different from the uniform inflow. It is very important to provide accurate input conditions for the design and safety of the reactor.

Pressure fluctuation near the tongue is one of the primary sources of pump vibration and noise. In order to investigate the effect of pressure fluctuation near the tongue, the RANS equations and the RNG k-epsilon turbulence model are employed to simulate the flow in the pump. The SIMPLE algorithm is applied to couple the solutions of the system of equations. Flow field within the centrifugal pump under different flow rates are obtained by simulation. The simulation results are compared with the experimental data to verify the reliability of the calculation model. It is found that the pressure fluctuation at each monitor point is a periodic wave but non-uniform under small flow rate. When the flow rate is larger than the design flow rate, average pressure and standard deviation at monitor points is relative uniform. The dominate frequency of pressure fluctuation is the blade passing frequency and the amplitude of pressure fluctuation is regular. At small flow rate, complex unstable flow makes average pressure and standard deviation at monitor points increasing obviously. Amplitude of pressure fluctuation is larger than that of design flow rate conditions and the maximum amplitude of pressure fluctuation in frequency domain exists at the monitor point just behind the tongue along the impeller rotation direction.

Relevant industrial standards or customer's specifications could strictly forbid any device adjusting the axial rotor/stator position, so that tip clearance between semi-open impeller and casing might become a result of the pump machining tolerances and assembling process, leading to big tip clearance variations compared to its nominal value. Consequently, large disparities of global performances (head, power, efficiency) and axial loads are observed with high risk of both specifications noncompliance and bearing damages. This work aims at quantifying these variations by taking into account tip clearance value and pump specific speed. Computational Fluid Dynamics is used to investigate this phenomenon by means of steady simulations led on a semi-open centrifugal pump numerical model including secondary flows, based on a k-omega SST turbulence model. Four different specific speed pump sizes are simulated (from 8 to 50, SI units), with three tip clearances for each size on a wide flow range (from 40% to 120% of the best efficiency point). The numerical results clearly show that head, power and efficiency increase as the tip clearance decreases for the whole flow range. This effect is more significant when the specific speed is low. Meanwhile, the resulting axial thrust on the impeller is very sensitive to the tip clearance and can even lead to direction inversion.

The paper investigates the hydrodynamic field generated by the symmetrical suction elbow at the pump impeller inlet. The full three-dimensional turbulent numerical investigation of the flow in the symmetrical suction elbow is performed using FLUENT then the flow non-uniformity generated by it is numerically computed. The numerical results on the annular cross section are qualitatively and quantitatively validated against LDV data. A good agreement between numerical results and experimental data is obtained on this cross section located downstream to the suction elbow and upstream to the pump impeller. The hydrodynamic flow structure with four vortices is identified plotting the vorticity field. The largest values of the vorticity magnitude are identified in the center of both vortices located behind the shaft. The vortex core location is plotted on four annular cross sections located along to the cylindrical part between the suction elbow and the pump inlet. Also, the three-dimensional distribution of the vortex core filaments is visualized and extracted. The shapes of vortex core filaments located behind the pump shaft agree well with its visualization performed on the test rig. As a result, the three-dimensional complex geometry of the suction elbow and the pump shaft are identified as the main sources of the flow non-uniformity at the pump inlet.

Centrifugal pump performance curve instability, characterized by a local dent at part load, can be the consequence of flow instabilities in rotating or stationary parts. Such flow instabilities often result in abnormal operating conditions which can damage both the pump and the system. In order for the pump to have reliable operation over a wide flow rate range, it is necessary to achieve a design free of instability. The present paper focuses on performance curve instability of a centrifugal pump of mid specific speed (ω_s = 0.65) for which instability was observed at part load during tests. The geometry used for this research consist of the first stage of a multi-stage centrifugal pump and is composed of a suction bend, a closed-type impeller, a vaned diffuser and return guide vanes. In order to analyse the instability phenomenon, PIV and CFD analysis were performed. Both methods qualitatively agree relatively well. It appears that the main difference before and after head drop is an increase of reverse flow rate at the diffuser passage inlet on the hub side. This reverse flow decreases the flow passing area at the diffuser passage inlet, disallowing effective flow deceleration and impairing static pressure recovery.

In hydropower systems among hydropower plants there are integrated pumping stations (PS). In order to ensure higher flow rate, the pumps have constructive differences besides regular. Consequently, the complex shape of the suction-elbow with symmetric inlet generates an unsteady flow which is ingested by impeller. These phenomena's also generate stronger unsteady flow conditions, such as stall, wakes, turbulence and pressure fluctuations, which affect the overall mechanical behaviour of the pump with vibration, noise and radial and axial forces on the rotor. Alternatively, an axial rotor can be installed in front of the impeller. In this case, the flow non-uniformity will be decreased and the static pressure will be increased at the impeller inlet. Consequently, the efficiency behaviour practically remains unchanged while the cavitational behaviour is improved. From the assembly between axial rotor and centrifugal impeller, the axial rotor usually works in cavitation and is often replaced. The paper investigates experimentally and numerically the comparison between pump impeller without and with axial rotor hydrodynamics taking into account the flow given by the symmetrical suction elbow. Full three-dimensional turbulent numerical investigation of the symmetrical suction elbow, with axial rotor and without, pump impeller and volute are performed. The hydrodynamic analysis confirms that once the axial rotor is mounted in front of the pump impeller increase the static pressure and the incidence angle is improved at the inlet of the pump impeller.

This paper focuses on the unsteady flow behaviour inside the vaned diffuser of a radial flow pump model, operating at partial flowrates (0.387Q_i, 0.584Q_i and 0.766Q_i where Q_i is the impeller design flowrate).The effects of the leakage flows are taken into account in the analysis. PIV measurements have been performed at different hub to shroud planes inside one diffuser channel passage for a given speed of rotation, for several flowrates and different angular impeller positions. The performances and the static pressure rise of the diffuser were also measured using a three-holes probe in the same experimental conditions. The unsteady numerical simulations were carried out with Star CCM+ 10.02 code with and without leakage flow. The PIV measurements showed a high unsteadiness at very low flowrate which was confirmed by the numerical calculations. In previous studies it has been shown that the global performances, as the efficiencies are in good agreement between calculations and measurements. In this paper, a joint analysis of measurements and numerical calculations is proposed to improve the understanding of the flow behaviour in a vaned diffuser.

The complete pump characteristics including its 4-quadrant behaviour are of essential interest for off-design operations such as a pump trip. At this exceptional load case the pump enters the dissipation mode and moves further into the turbine mode while the direction of rotation and the flow direction will change. The time-consuming and expensive experimental investigation of the 4-quadrant behaviour requires a specific test rig, allowing the flow direction as well as the rotational direction of the investigated pump to be reverted. By measuring the pump performance (head and efficiency) at variable positive and negative discharge and rotation the complete pump characteristics are evaluated. Nowadays CFD- analysis allows for the reliable prediction of the hydraulic performance of a pump near the design point. However, abnormal operating conditions lead to complex and unsteady flow phenomena inside the pump. Besides steady-state calculations in the normal operating conditions quite comprehensive transient CFD-investigations are required to simulate the whole pump characteristics accurately. The present study focuses on the comparison of the results obtained on the test rig and by numerical methods and shows a remarkably good agreement between them. It can be shown that it is possible to reliably simulate the 4-quadrant behaviour of a mixed flow diffuser pump based on CFD-methods. Furthermore an exemplary waterhammer calculation shows the successful application of the numerically calculated 4- quadrant behaviour.