Cooling Water Sump Model Studies Through CFD Analysis

COOLING WATER SUMP MODEL STUDIES THROUGH CFD ANALYSIS
Dr. N.K.Singh, DGM, COE, BHEL R&D, Hyderabad,

ABSTRACT
Cooling water pumps are widely used in power
plants and in other industries such as steel plants, oil, gas,
cement and coal industries to pump required water for
cooling purpose. Cooling water is drawn through wide
open channels from cooling tower basins through sump.
This Cooling water sump configuration design is based on
power plant unit ratings, discharge of water need to pump
Mr. T. Vijaya Sarathi, Assistant Professor, ME, BVRITN

guide vanes with a cross baffles the flow has become stable
and also intensity of swirl angles reduced to an acceptable
limit for all the combinations of any four pumps working
simultaneously out of five pumps in the cooling water
sump.
Keywords: Sump geometry, Cooling water pump, Swirl
meter, vorticity, Vortimeter, Swirl angle, Vortex breakers,
Spurs, Log gate.
1.0 INTRODUCTION
and hence, the overall design is thus based on site

The Cooling water sump consists of stop-log gate,
specification, no. of pump chambers & pumps capacity

keeping into consideration. While pumping cooling water
from basins, some swirls get generated at the pump intakes.
Due to this swirl action, some mechanical problems arise
which causes severe damage to the pumps and their
forebay, pier walls, and 5-pump intakes. Out of five cooling

water pumps any four pumps are working simultaneously,
and the fifth pump remains as standby. Water enters from
the two inlets which are at right angles (i.e. 90o and 180o)
apart from water basin, and passes through forebay, stop-
supports.
Experimental tests were carried out on a physical
scaled down model to develop sump chambers design that
to prevent vortex formations and in turn reduce the swirls
log gate and then enters in to the five cooling water sump
chambers. From there water is supplied through the pumps
to the required place.
The area immediately up-stream of the pump
around the cooling water pump intakes. This Experimental

studies have been replaced with CFD Analysis to reduce
Time and Cost.
In the present study, two sump configurations have
been included. The first sump geometry has no vortex
breaking device and the second geometry was provided
with vortex breakers, spurs, and guide vanes with a cross
baffle.
Structured multi-block grids were generated in
ANSYS ICEM-CFD and necessary grid refinements were

done around pump intakes. Proper boundary conditions
were set-up at inlet and outlet boundaries in CFX-pre and
converged flow solutions were obtained for various cases
using CFX-11 solver. The objective is to characterize the
flow in the vicinity of pump intakes, compute swirl angles
and study the influence of vortex breakers, spurs in
reducing the swirl in and around pump intakes.
Swirls were computed at each case and influence of
vortex breakers in minimizing the swirl to acceptable value
for maximum and minimum water levels in the sump was
established. Results of CFD analysis have been presented
in the form of various plots, like streamlines, velocity and
vorticity vectors, computed swirl angles at various
locations. After inclusion of vortex breakers, spurs and
chamber is called forebay. The Sump is usually rectangular

and has flat floor. The primary purpose of the sump is to
provide stored volume and to damp out any extremely
disturbed flow pattern arising from up-stream zones. The
sump and intakes should be designed for good flow
conditions at the pump intakes irrespective of the type of
pump.
Stop-log gate is used to reduce the disturbances in
the flow at the top levels and is used to control the flow
distribution, pier walls are used to divide the water channel
in to five pump chambers and to distribute the flow equally
in to the five pump chambers.
The cooling water pumps are designed for rated
and maximum flow capacities of 19000 m 3/hr and 22800
m3/hr respectively. The Channels hail from two different
cooling tower basins with 90 and 180 degree bends
respectively. They join the 960 mm wide common channel
which leads to the forebay. The forebay widens from 960
mm to 2850 mm in a length of 50 meters up to the pump
house. The floor descends from 3.30 meters to 8.50 meters.
These forebay leads further to pump chambers. The forebay
leads to five pump chambers which are situated in the

Pump House. These Five cooling water pump chambers are

ICEM-CFD takes GEOM as Default part name.
same in all dimensions (i.e. 450mm wide and 800mm high)

which are separated by pier walls of 100mm gap between
each chamber.
Fig. 4.6 CW Sump original geometry without vortex breakers
and spurs
2.0
Fig. 4.7 CW Sump original geometry with vortex breakers,

spurs and guide vanes
SCOPE OF WORK
3 D modeling of fluid domain in water channels, fore bay,
pump chambers consisting of stop log, pier walls, pump
intakes, vortex breakers and spurs.Grid generation and
Boundary set-up at inlet, outlets
and free surfaces of
sump.Obtain converged CFD solution without inclusions

and with inclutions of vortex breakersAnalysis and post
processing of results for flow distribution velocity pattern
and estimation of swirls for the maximum.Grid refinements
and obtain solutions with the other turbulent models, like kw and SST models. Arrive the most optimum models and
boundary conditions and grid independent solutions.
Establishment of CFD methodology for doing CW Pump
Sump Model studies. Consolidation of results, finding the
variation of swirl angles along the radial locations of the
pipe
Fig. 4.11 CW Sump Model Surface Mesh

Fig. 4.12 CW Sump Structured Volume (Hexa) Mesh
4.0 BOUNDARY CONDITIONS
The CFD Analysis is carried out using CFX-Pre,
CFX-Solver, and CFX-Post modules. ANSYS CFX-Pre is
the physics definition pre-processor for ANSYS CFX. It is
used to import meshes produced in a variety of mesh
generation software packages and to select physical models
used in the CFD simulation
CFD analysis is carried out to understand the flow
through the sump, predict the pressure distribution and
velocity profiles at various locations of the sump model.
ANSYS CFX-11 software tool is used for analysis purpose.
This interactive process is the second pre-
3.0 MODELING & GRID GENERATION

Flow domain of cooling water sump consists of
processing stage and is used to create input required by the
water channels, fore bay, stop-log gate, pier walls, pump
Solver. The mesh files are loaded into the physics pre-
chambers, and five pump intakes in original geometry. 3-D
processor, ANSYS CFX-Pre. The physical models that are
modeling was made through ICEM-CFD and was
to be included in the simulation are selected. Fluid
discredited and shown the top view in Fig.3
properties and boundary conditions are specified. Physics
The scale down model of CW Sump original geometry
definition involves defining the physical parameters such as
without vortex breakers & spurs and CW Sump original
pressure, temperature, mass flow, etc. and other boundary
geometry with vortex breakers & spurs have been
conditions relevant for the problem.
modeled in ICEM-CFD.
Preprocessing involves the following steps.
The various parts of 3-D modeling were created

through ICEM-CFD which is shown in Fig. 5 i.e.
TOP, BOTTOM, BACK, INLET1, INLET2, PUMPS, OUTLET1,
OUTLET2,
OUTLET3,OUTLET4,
OUTLET5,
WALL,
Importing the mesh assembly and region

definition:
As described earlier the sump model is meshed in
STOP_LOG, CHAM1, CHAM2, CHAM3, CHAM4, CHAM5,
ICEM-CFD. The mesh file with .cfx5 extension
V_BREAKERS,
is imported to CFX-Pre. The boundary conditions
CROSS_BAFFLE
SPURS,
GUIDE_
VANES
AND

file (.bci) specifies the inlet, outlet, top, front,
combinations of four pumps running simultaneously out of
back, and other regions of the model.
available five pumps of Cooling Water Sump model.
Defining boundary conditions in CFX-pre such as

inlets, outlets, wall etc.
In CFX-pre, it takes Default boundary condition
as wall.
Fig. 4.13(a) and Fig.4.13 (b) have been shown defining

boundary conditions in CFX-pre.
Fig.4.13(a) Defining boundary conditions in CFX-pre
Fig. 4.13(b) Defining boundary conditions in CFX-pre

CFX-Solver
ANSYS CFX-Solver solves all the solution
variables for the simulation for the problem specification
generated in ANSYS CFX-Pre. The component that solves
the CFD problem is called the Solver. It produces the
required results in a non-interactive/batch process.
5.1 Swirl calculation

In the experimental set-up (carried out by
external agency), five vortimeters are placed in the five
pipe-intakes at height of 265 mm from the floor-level to
measure the rotation of the vanes of vortimeter. The
swirl angle is calculated experimentally using the
formula
1
Model discharge= (22800/3600)*(1/316)=
0.0200 m3/s
2
Area of pipe= 0.7854*0.142 =0.015394 m2
3
Axial velocity in pipe = 0.0200/0.015394 =
1.30 m/s
4
Peripheral velocity of vortimeter =
3.1416*0.130*N/60 = 0.0068068*N
D= Diameter of Vortimeter = 0.130 m
N= Rotations of Vortimeter = rpm
5
Vortex angle = (Peripheral velocity of
Vortimeter) / (Axial velocity of water in the
pipe)
Vortex/Swirl angle, Tan = (0.0068068*N) /
1.30=0.005236*N
= tan-1( Vr / Vy)
In
CFD
analysis, the swirl angle is calculated as follows:
1
Net directional Vorticity ( y) along flow in
pumps intakes i.e. y-axis,

2
Angular velocity, y = y /2
3
Fig.4.14 (a) Required convergence is obtained

for original sump model mesh
Rotation Velocity, Vr = y *r = y *0.07
4 Axial Velocity Vy along flow in pumps
Fig.4.14 (b) Required convergence is obtained
Where y and Vy are computed in CFX-post
for modified sump model mesh
Results using function calculator
Post Processing
5 Vortex/Swirl angle ()
CFX-Post is a flexible state-of-the-art postprocessor. It is designed to allow easy visualization,

qualitative and quantitative post-processing of the results of
5.2
Post Processing Results And Discussions
CFD simulations.
CFD converged solutions have been obtained for
5.0 RESULTS AND DISCUSSIONS
20 cases, with maximum and minimum water levels for the
5. Post-processing results of CFD simulations

CFD converged solutions have been obtained for
two geometrical configurations of sump model without
20 cases, with maximum and minimum water levels for the
inclusion of vortex breakers and spurs, and sump model
two
with inclusion of vortex breakers and spurs, and for various
geometrical
configurations
and
for
various

combinations of four pumps running simultaneously out of
available five pumps.
Various plots like streamline, vorticity and velocity profiles
at various locations have been shown. Swirl angles have
been computed using the net directional vorticity as
available in the result file of CFX-post
Fig.5.9 CW sump with inclusion of vortex breakers and spurs vector plot-500mm
Typical velocity vector plots for both sump

models at bell-mouth (i.e.110mm from floor level) are
shown in Fig.5.10 (a), Fig.5.10 (b), Fig.5.11 (a) and
Fig.5.11 (b). Similarly Fig.5.12 (a) and Fig.5.12 (b) shows
The stream-line plots for maximum water levels for the

both geometries of sump model have been shown in Fig.
5.1 (a) and Fig.5.1 (b). Similarly the stream-line plots for
minimum water levels for the both geometries of sump
model without inclusion, and sump model with inclusion of
the typical view of velocity components for both sump

models at height of 500mm from floor level. These Figures
show the variation of magnitude of velocity in vicinity of
pump intakes as colors indicate the magnitude of velocity
vectors accordingly have been shown in figures.
vortex breakers and spurs are shown in Fig.5.2 (a) and

Fig.5.2 (b).
In all these Figures, Pump 3 is off and Pumps 1, 2, 4, 5 are
working and the flow path colored with velocity magnitude
accordingly are being shown. The flow starting from inlet
and approaching through various sections of the sump
model and finally entering into various pump intakes can
be seen in Figures 5.1(a), 5.1(b), 5.2(a) and 5.2(b).
The
stream-line
plots
for
the
two
Fig.5.10 (b) velocity component sump without

vortex breakers and spurs vector plots- vector
plot at 110mm
geometrical
configurations show some improvements in terms of

location and type of recirculation. It is observed that flow
pattern and the recirculation intensity has got reduced to a
large extent after providing vortex breakers and spurs for
both maximum and minimum levels.
Fig.5.11 (a) CW sump without vortex breakers and

spurs vector plots (Swirl present)
Fig. 5.6(a) Sump without inclusion of

vortex breakers and spurs vector plot
Fig.5.11 (b) CW sump with vortex breakers and spurs vector

plots (Reduced Swirls)
Fig. 5.6(b) Sump with inclusion of

vortex breakers and spurs vector plot
Fig.5.7 CW sump with inclusion of vortex breakers and spurs -
.3 Computed Swirl Angles Without and With Inclusions of
vector plot-110 mm
Vortex Breakers, Spurs and Guide Vanes with cross baffle
Fig.5.8 CW sump with inclusion of vortex breakers and spurs vector plot-265mm


CFD study was carried out for analyzing the flow
behavior of a cooling water sump Module.
From the study the following conclusion were made:
Converged solutions obtained for both the cases
Graph 5.1 (a): Swirl angles without and with inclusions min.
with
level 1234 as working pumps
simultaneously for various combinations.
Graph 5.1 (b): Swirl angles without and with inclusions max.
four
out
of
five
pumps
running
Post-processing done to extract various flow

parameters.
CFD analysis shows the effect of Vortex breakers

in reducing swirl around the pump intake and
overall improvement in flow behavior with
Vortex breakers, Spurs and Guide Vanes with a
cross baffle.
Graph 5.2 (b): Swirl angles without and with inclusions min.
Results shown in various plots like streamline,

velocity vectors and swirl plots around
regions
of bell-mouth, pump intakes and at locations

where vortimeters were installed in experimental
studies.
Results available from experimental model tests
have been compared with CFD results for various
cases and presented in various Tables.
For varying nature of swirls in intake pipes, the

swirl angle vs working pumps plots for all modes
of operations show considerable reduction of
swirl with vortex breakers compared to original
geometry.
7.0 FUTURE SCOPE OF WORK

The CFD analysis will be carried out to improve the flow
behavior at the pump intakes by reducing the swirl
component with different cases.
It is proposed to modify the dimensions of Vortex breakers
and spurs, such that the swirl present at the bell-mouth is
negligible.
To increase the effective use of CW sump the grids will be
further refined, and various turbulent models are to be used
in the CFD analysis.
6.0 CONCLUSIONS

8.0 REFERENCES
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Petrescu, V. and Constantinescu, S.G. (1993). The study
Tokyay, T. and Constantinescu, S.G. (2005), Large Eddy
of turbulent flows using a modified k- model, Scientific
Simulation
Bulletin of the Civil Engineering Institute, Bucharest,
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Reynolds
Averaged
Navier
Stokes
Simulations of flow in a realistic pump intake: A validation
Romania, Vol. 36, No. 2, 43-60.
study, World Water and Environmental Resources
Kirkil, G., Constantinescu, S.G., and Ettema, R. (2005),
Congress, Alaska, May 2005.
The horseshoe vortex system around a circular bridge pier
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on
Simulation
Environmental Resources Congress, Alaska, May 2005.
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Averaged
Navier
Stokes
equilibrium
scoured
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Simulations of flow in a realistic pump intake: A validation
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Conference: Hydroinformatics 98, Editors Babovic, V and
Validation of a computational model to predict suspended
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Estuarine Morphology Conference, University of Illinois,
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COOLING WATER SUMP MODEL STUDIES THROUGH CFD ANALYSIS

Dr. N.K.Singh, DGM, COE, BHEL R&D, Hyderabad,

Mr. T. Vijaya Sarathi, Assistant Professor, ME, BVRITN

and hence, the overall design is thus based on site

specification, no. of pump chambers & pumps capacity

forebay, pier walls, and 5-pump intakes. Out of five cooling

around the cooling water pump intakes. This Experimental

Structured multi-block grids were generated in

ANSYS ICEM-CFD and necessary grid refinements were

chamber is called forebay. The Sump is usually rectangular