energies

Article
Experimental Vortex Flow Patterns in the Primary and
Secondary Pump Intakes of a Model Underground
Pumping Station
Miao Guo 1 , Zhigang Zuo 1, *, Shuhong Liu 1, *, Huijun Zou 2 , Baoyu Chen 2 and Deyou Li 3
1 Department of Energy and Power Engineering, State Key Laboratory of Hydro Science and Engineering,
Tsinghua University, Beijing 100084, China; santaigo10@mail.tsinghua.edu.cn
2 Wuhan Municipal Engineering Design and Research Institute Co. Ltd., Wuhan 430023, China;
zouhj2019@yeah.net (H.Z.); chenby9691@163.com (B.C.)
3 School of Energy Science and Engineering, Harbin Institute of Technology, Harbin 150001, China;
lideyou@hit.edu.cn
* Correspondence: zhigang200@mail.tsinghua.edu.cn (Z.Z.); liushuhong@mail.tsinghua.edu.cn (S.L.)




Received: 11 March 2020; Accepted: 3 April 2020; Published: 8 April 2020


Abstract: In order to provide specific references and suggestions for the design and operation of
underground pumping stations, in this paper, an experimental model of an underground pumping
station, including 4 pumps and 2 pump intakes (primary and secondary), was obtained through
similitude of fluid mechanics. The phase diagrams of various vortices, in terms of different
dimensionless numbers are presented, which can reveal their appearance and evolution process.
Three specific cases with different vortex flows were analyzed. The experiment results may provide a
reference for the current design guidelines for underground pumping stations.

Keywords: vortex flow; primary and secondary pump intakes; experimental study; underground
pumping station

1. Introduction
With the increasing requirements for urban environment and land resources, underground
pumping stations are being widely applied in underground mines, nuclear power plants, sewage
treatment plants, and groundwater diversion projects, etc. [1–4].
Underground pumping stations are named because, in contrast to conventional pumping stations
(Figure 1a), they are located partly or fully below the ground level, usually 10–100 meters or more
underground (Figure 1b), corresponding to the topographic height of the inflow. This leads to a deep
water-collecting well (primary pump intake). It is noted that in underground pumping stations, it
is usually necessary to position a secondary pump intake to facilitate the maintenance and desilting
works on the high content of impurities, silt, and other solid particles in the water. The secondary
pump intake is pressurized rather than open, which is an important factor affecting the formation of
various vortices inside the pump intakes.
It was shown that the vortex flows at the pump intakes may cause performance deteriorations to
the conventional pumping stations, e.g., a decrease in efficiency, mechanical vibrations, and even forced
pump shutdown [5–8]. A number of research studies have focused on the experimental and numerical
capture of the vortex flows, and the flow distribution around the pipe bell in the intake channel.

Energies 2020, 13, 1790; doi:10.3390/en13071790 www.mdpi.com/journal/energies

Standards of American Hydraulic Society for the Pump Intake and definitions of free surface vortices
and subsurface vortices by the ALDEN laboratory [22,23], newly identified free surface vortices and
subsurface vortices are presented through a large number of test results.
The paper is organized as follows: Section 2 mainly includes a detailed description of the model
Energies
test rig2020, 13, 1790
design 2 of 20
and the experimental process. Section 3 is the experiment result analysis. Section 4
draws conclusions from the study.

Figure 1. Pump intake and pump pipeline system of different pumping stations. (a) Conventional
Figure 1. Pump intake and pump pipeline system of different pumping stations. (a) Conventional
pumping station, (b) underground pumping station.
pumping station, (b) underground pumping station.
The literature study of vortices captures, and the evolution of relevant flow patterns mainly
2. Experimental Setup
include the following: Rajendran et al. [9] applied particle image velocimetry (PIV) technique to
measure the vortices on a specific plane in water-pump intake bays. The experimental results showed
2.1. Nondimensional Parameters Influencing Vortex Flows in Pump Intake
that some vortices exhibited intermittent bimodal properties, in terms of their occurring positions.
Anwar In this section,
et al. nondimensional
[10] carried parameters
out experiments affecting
on the the dynamics
free-vortex of the intake
at horizontal vortex when
in pump theintake,
radial
Reynolds number (Re = Q/νh, where Q = is the discharge through intake, ν is the kinematic viscosity of
i.e., Reynolds number Re, Froude number Fr are firstly derived through an analysis of normalized
test fluid, and h is
Navier–Stokes the submergence
equations. depth of
The effects above
theintake axis), and the
dimensionless Weber number
submergence (We = ρQin
depth 2 h/A2 σ,
the
where ρ is the mass density, Q is the discharge
dimensionless velocity solution are also presented. through intake, h is the submergence depth above intake
axis, AA cylindrical
is the cross-section area of intake
polar coordinate pipe,
system was setσ up
and is the surface tension
to analyze of test fluid)
the free-surface were (Figure
vortices larger than
2).
3 × 104 and 104 , respectively. By using different shapes of the bell-mouth, the working efficiency of the
intake was hardly improved. Echavez et al. [11] performed high-speed photographic observations
on the three-dimensional structure of a vertical vortex flow. The results show that the axial flow in
the core zone was important in the vortex formation and development. Andersen et al. [12] studied
the free-surface vortex through the superposition of two explicit visual effects of the flow by adding
fluorescent dyes to the surface and the bottom. It was found that unstable bubbles appeared on the top
Energies 2020, 13, 1790 3 of 20

of the free-surface vortex with a high rotating velocity. Choi et al. [13] found that the submerged vortex
intensity in the vicinity of side walls was higher than both the near rear wall and the upstream region
of the bell-mouth through a pump sump model. Cristofano et al. [14] studied free surface-vortex with
different air content using visualization technology and divided the observed vortex into different
levels. The parameters having significant influences on the vortex state were defined. The theoretical
analyses of the influencing mechanism of these factors were carried out and verified by the model
experiments. Kim et al. [15] investigated the effectiveness of an anti-vortex device (AVD) to suppress
the vortex occurrence in a single intake pump intake model through model experiments. It was found
that the maximum swirl angle was 10.9◦ when there were no AVDs. On the other hand, when the
V
ADVs existed, the maximum swirl angle (θ = tan−1 VZθ , Vz was the axial mean velocity, and Vθ is the
tangential mean velocity at the swirl meter) was reduced to 2.7◦ . According to the analysis of the time
regularity of the PIV experimental results, Duarte [16] found that the flow in the pump intake had a
certain statistical unsteady characteristic and recommended a characteristic frequency of oscillation,
which related to the clearance between the measurement section and the intake pipe.
On the other hand, studies were carried out on the geometric scaling and the flow distribution
around the pipe bell. Padmanabhan et al. [5] compared the distributions of the internal flow field
between one full-sized and two reduced-scale (geometric scales of 1:2 and 1:4, respectively) models
of a pump sump. The scale effects on the swirl flow in the intake pipe and the loss at the inlet of
the intake were shown. Eguchi et al. [17] used three models of different scales and showed that the
critical Froude (Fr) number (Fr = √U , where U = reference velocity, g = gravitational acceleration, and
gL
L = the representative length or span length), above which the gas entrainment appeared, and its size
drastically decreased as the scale factor increased. Mansa et al. [8] found that various vortices appeared
around the bell-mouth, affecting the performance of the intake by PIV technology. Kirst et al. [18,19]
optimized the performance of the vertical pump system by installing a baffle wall after evaluating the
inflow conditions in the structure of the pump intake of a compact sewage pump station model, which
was verified by the experiment.
As for underground pumping stations, research on their complicated internal flow pattern has
not been carried out systematically, and the existing research on the underground pumping station
mainly focuses on the civil structures [20], layout [2], and stability [21], etc. In this context, the present
paper attempts to answer the following questions:

1) How are the vortices distributed in the underground pumping station?

2) What is the mechanism of the complex flow pattern in the underground pumping station?
3) What are the influencing parameters of the vortices in the underground pumping station?

Obviously, the solution to these problems is of positive significance for better understanding of
the complex flow pattern in underground pumping stations. The results of this paper give engineering
experience and provide an essential reference for the design and optimization of underground pumping
stations in the future.
In this paper, an experimental model based on the first large-scale underground pumping station
in China was obtained through the similitude of fluid mechanics. In addition to the Design Standards of
American Hydraulic Society for the Pump Intake and definitions of free surface vortices and subsurface
vortices by the ALDEN laboratory [22,23], newly identified free surface vortices and subsurface vortices
are presented through a large number of test results.
The paper is organized as follows: Section 2 mainly includes a detailed description of the model
test rig design and the experimental process. Section 3 is the experiment result analysis. Section 4
draws conclusions from the study.
Energies 2020, 13, 1790 4 of 20

2. Experimental Setup

2.1. Nondimensional Parameters Influencing Vortex Flows in Pump Intake

In this section, nondimensional parameters affecting the dynamics of the vortex in pump intake,
i.e., Reynolds number Re, Froude number Fr are firstly derived through an analysis of normalized
Navier–Stokes equations. The effects of the dimensionless submergence depth HDs in the dimensionless
velocity solution are also presented.
A 2018,
Energies cylindrical polar
11, x FOR PEERcoordinate
REVIEW system was set up to analyze the free-surface vortices (Figure 2).21
4 of

z
Free-surface o r

G
ω
Hs

Inflow Outflow

Figure 2. Bottom horizontal suction of underground pumping

pumping stations.
stations.

Considering
Considering the
thecases
casesofofsteady
steadyaxisymmetric
axisymmetricvortices, thethe
vortices, velocities, pressure,
velocities, andand
pressure, the length can
the length
be scaled as [23,24]:
can be scaled as [23,24]:
U U U r z p
U z*U=∗ =z U, zU *
= ∗ = r U,r U *
=∗ =θ ,Urθ*, = r∗ =
, zr* ,= z∗ =
, pz* =, p∗ = 2 p, ,
θΓ
r U θU
z Q Q , r Q Q , D D H s Hs (1)
Γ  Q  Q 2 (1)
D 2 D2
b ⋅ Hs
b·Hs
D
D ρ  2 ρ D2
D 
where U
where Urr, Uzz, and Uθθ are
are the velocity components
components in the radial, axial, and tangential directions,
respectively. p is
respectively. is the
the pressure,
pressure, bb is
is the
the width
width of
ofthe
thepump
pumpintake,
intake,H Hss is the submergence as shown in
Figure 2, D isis the
the diameter
diameter of the
the main
main intake
intake pipe, Q is the
the flow
flow rate
rate ofof the
the pump station, ΓΓ is the
pump station, the
flow
flow circulation
circulation around
aroundaa vortex
vortexnear
nearthetheintake
intakepipe, andρρisisthe
pipe,and thedensity
densityof ofthe
thefluid.
fluid. Note that U
Note that Uzz is
scaled by the
the average
average axial velocity
velocity in the the intake
intake pipe, and U
pipe, and Urr is scaled by the mean velocity
velocity in the
the
pump intake.
pump intake.
Navier–Stokes
Navier–Stokes equations
equations in
in aa cylindrical
cylindrical coordinate
coordinate system
systemare arethen
thennormalized
normalizedas: as:
∗  ∗ ∂U∗ ⋅  ∗2 ∗2    2 ∗∗  h ∗∗
∂Ur∗ 2 b·Hs Uθ = − b Hs ∂p + 11 ∇∗2 ∗ U∗∗ − Ur
i
: ∗ r : ∗ +Uz∗ D
∂z∗
b ∗ −
U +∗
∗
r ∂r∗
r
− Γ N D ∗ r
2 =
∗ − D D ∂r∗∗ + Re r − ∗2
r ∗
∂Uz∗ ∂p∗
  ∂U∗  
z: ∗ ∗
Uz ∗ + D∗ ∗ ∗ 1
Ur ∂r∗ = − ∂z1∗ − 2 1+ Re∗ ∇∗ Uz
z 1 ∗2 ∗ (2)
: ∗
∗
+ ∂U∂z∗ ∗ b ∗ = ∂U −∗ ∗ U −∗  +Fr  U ∗  (2)
θ: ∗ θ D ∗ θ θ
∗ Uz ∂z∗ + b ∗Ur ∂r∗∗ + r∗ = Re ∇ U∗θ − r∗2
1 ∗2 ∗ θ

∗ ∗
1 ∗ ∗
: ∗
+ ∗
+ ∗ = − ∗
 2 2
where ∇∗2 = ∂r∂∗2 + r1∗ ∂r∂∗ + HDs ∂z∂∗2 . ΓN , Fr, and Re are the normalized flow circulation, Froude
2

∗
where ∇and
number =Reynolds
∗
+ ∗ number
∗ + . ΓN, Fr, and
(the∗definitions Re are
of these the normalized
dimensionless numbers flowarecirculation,
to smooth the Froude
logic
of dimensionless analysis and highlight the influence of flow rate Q and
number and Reynolds number (the definitions of these dimensionless numbers are Sto smooth the submergence H on the vortex
flow
logicpatterns in the underground
of dimensionless analysis and pumping
highlightstation in the present
the influence of flowpaper),
rate Q andrespectively [23,24]:
submergence HS on the
vortex flow patterns in the underground pumping station in the present paper), respectively [23,24]:
Γ·D Q Q
ΓN = · , Fr = , Re = . (3)
=Q , = , s = · v·H . s (3)
p
2
D ·g·H

Here, ΓN is a purely kinematic parameter. In the present experiments, r* and Uz* are both of order
1. Meanwhile, the value of / is 107–109. Thus, the influence of Fr is much greater than Re in
the z-momentum equation. Hence it is assumed that Fr similarity, along with the geometric similarity,
will ensure similarity of circulation. The ratio of the model to prototype Fr is 0.82, 0.86, and 0.90 for
Energies 2020, 13, 1790 5 of 20

Here, ΓN is a purely kinematic

   parameter.
 In the present experiments, r* and Uz * are both of order
1 1
1. Meanwhile, the value of Fr2 / Re is 10 –109 . Thus, the influence of Fr is much greater than Re in
7

the z-momentum equation. Hence it is assumed that Fr similarity, along with the geometric similarity,
will ensure similarity of circulation. The ratio of the model to prototype Fr is 0.82, 0.86, and 0.90 for
three cases respectively, in other words, the proportion of inertial force to gravity in the model is
basically the same as that in the prototype. On the other hand, it should be noted that the geometric
of the test bench is obtained on the basis of Reynolds similarity, that is, the Reynolds number of the
prototype and the model is exactly the same.
For the free-surface vortex, the Weber number similarity should be considered also. In order to
keep the effects of viscosity and surface tension small, the experimental conditions must be maintained
above the critical values of Re and We [25,26]. Here, considering the surface tension of the free surface,
neglecting the atmospheric pressure, the free-surface boundary condition is given as
!
1 1
∆p = σ + , (4)
r1 r2

where ∆p is the Laplace pressure. σ is the surface tension coefficient, and r1 and r2 are the principal
radii of curvature of the surface. According to the relationships in Equation (1), Equation (4) becomes
!
1 1
∗ 1
P = + ∗ , (5)
We r1 ∗ r2
r1 r2
where r1 ∗ = D , r2
∗ = D. Weber number We is defined as [16]

ρQ2
We = . (6)
σD3
The surface tension effects are negligible at the water intakes with a horizontal suction pipe when
We > 370 [5]. The main nondimensional parameters affecting the internal flow in the present study are
listed in Table 1.

Table 1. Pump intake dimensionless parameters.

Case Re Fr We
1 4.01 × 105 1.46 × 10−2 1.44 × 104
2 4.44 × 105 0.16 × 10−2 1.79 × 104
3 1.43 × 105 0.75 × 10−2 3.16 × 103

Besides, the cavitation numbers in the main pipe for case 1, 2, and 3 is 12, 10, and 33, respectively,
i.e., the cavitation did not occur in there for all cases presented in this experiment.
Meanwhile, referencing the velocity components of the steady axisymmetric vortices [27–30], it
can be normalized by Equation (1) as

8r∗
Ur ∗ = −v   [1 + ln(1 + a·Hs ·z∗ )] (7)
D rm ∗ 2 + 2r∗2

Γ 2r∗ 1 Hs
 
Uθ = 2
+ a· ·z∗ (8)
2π rm + 2r∗2
∗ D D
16vrm ∗ 2 1 Hs ∗
  
∗
Uz =  2 a + z ln(1 + a·Hs ·z ) (9)
D
D rm ∗ 2 + 2r∗2
where rm is the radius of the vortex core, a is an independent variable. In Equations (7)–(9), it can be
found that the relative submergence HDs and the relative water level z∗ = Hzs influence the axial and
Energies 2020, 13, 1790 6 of 20

tangential velocities. The submergence (critical water level) plays a significant role in the formation
and evolution of the vortices in the underground pumping station.

2.2. Normalized Geometric Parameters of the Experimental Facility

The research object of this paper is the first large-scale underground pumping station in China
(Wuhan Beihu Sewage Underground Pumping Station, which collects sewage by urban underground
pipelines and discharges it to the next level after industrial purification treatment). In the underground
pumping station of this paper, two pump intakes are utilized. Namely, a primary pump intake is
mainly used to store water, and the secondary pump intake is mainly used to remove impurities
from the water, including sand sediments, sludge, and other solid pollutants, especially in the sewage
pumping station.
The operation of each pump set is determined by the upstream flow rate and other factors (such
as water level in the primary pump intake and regular maintenance of pump set). The pumps can
be used in a group or individually. The experimental model is obtained referring to the related
regulations [31–34]. The geometric scale between the pump station and the model was finally decided
as 10:1. The depth of the prototype primary pump intake of the underground pumping station was
HP = 45.8 m, and the maximum flow rate of each pump set in the main pipeline was Qmax = 3.87 m3 /s,
thus giving the corresponding dimensionless as HP * = 32.25 and Qmax * = 774, respectively. The volume
and height of the model primary pump intake of the test rig were 2.38 m3 and 1.8 m, respectively.
Combining the analysis of Section 2.1, the dimensionless geometric parameters of the experimental
facility of the underground pumping station are shown in Table 2, normalized by the main pipe diameter.

Table 2. Dimensionless geometric parameters of the experiment facility.

Dimensionless Parameters Value

Length of test bench L* 21.89
Width of test bench W * 12.72
Height of test bench H* 12.68
Main pipe diameter D* 1.00
Branch diameter d* 0.59
Height of test bench HP * 32.25
Maximum flowrate Qmax * 774

2.3. Experimental Facility

According to the design standards above, the experimental facility was designed and manufactured,
as shown in Figure 3. To observe and record the various complex flow patterns inside the intake,
4 Polymethyl Methacrylate (PMMA) were sealed and fixed on the predesigned and retained stainless
steel frame on the side wall 1 of the primary pump intake with flat head socket hexagon screws.
In order to observe the flow patterns at the inlet and outlet of each pump, the inlet and outlet sections of
pumps 1–3 (as shown in Figure 3a), and the outlet section of pump 4 were specially made of transparent
pipes. To observe the complex flow pattern inside the secondary pump intake at the entrance of pump
4, the side wall 2 wes composed of PMMA, as shown in Figure 3c,d. An ultrasonic water level meter
with accuracy to within 1.0% full scale (FS) was installed at the primary pump intake. The magnetic
flow meter (1.0% FS) and the ultrasonic flow meters (1.5% FS) were installed at the outlet pipe of each
pump to measure the flow rate from 0 to 90 m3 /h. Considering the uncertainty of the experiment, the
repeatability of each case was verified, i.e., duplicating each test to eliminate statistical errors due to
instabilities of the test rig as much as possible.
 specially made of transparent pipes. To observe the complex flow pattern inside the secondary pump
intake at the entrance of pump 4, the side wall 2 wes composed of PMMA, as shown in Figure 3c,d.
An ultrasonic water level meter with accuracy to within 1.0% full scale (FS) was installed at the
primary pump intake. The magnetic flow meter (1.0% FS) and the ultrasonic flow meters (1.5% FS)
were
Energies installed
2020, 13, 1790at the outlet pipe of each pump to measure the flow rate from 0 to 90 m /h. Considering
3
7 of 20
the uncertainty of the experiment, the repeatability of each case was verified, i.e., duplicating each
test to eliminate statistical errors due to instabilities of the test rig as much as possible.

Energies 2018, 11, x FOR PEER REVIEW (a) 7 of 21

(b)

(c) (d)
Figure 3. The experimental facility. (a) 3D model (the asterisk indicates the secondary pump intake),
Figure 3. The experimental facility. (a) 3D model (the asterisk indicates the secondary pump intake),
(b) circulation loop, (c) connection between the branch and main pipes of pump 1–3, (d) secondary
(b) circulation loop, (c) connection between the branch and main pipes of pump 1–3, (d) secondary
pump intake.
pump intake.
2.4. Experimental Process
More than ten cases were designed for convenience of comparison, and three cases were chosen
to show the diversity of vortex types, referencing the operational conditions in practice. Therefore, at
the high-water level, different Re cases (case 1 and 2) and low water level (case 3) were selected for
comparison and comprehensive analysis, as shown in Table 3 (‘×3’ means the first, second, and third
pumps are running, and ‘+1’ means the fourth pump is in operation). The experimental procedure is
Energies 2020, 13, 1790 8 of 20

2.4. Experimental Process

More than ten cases were designed for convenience of comparison, and three cases were chosen
to show the diversity of vortex types, referencing the operational conditions in practice. Therefore, at
the high-water level, different Re cases (case 1 and 2) and low water level (case 3) were selected for
comparison and comprehensive analysis, as shown in Table 3 (‘×3’ means the first, second, and third
pumps are running, and ‘+1’ means the fourth pump is in operation). The experimental procedure is
described as follows.

Table 3. Operating conditions.

Case Q* (Q/Q4 ) Hs /D
1 2.98 × 3 = 8.94 3.51
2 2.98 × 3 + 1.0 = 9.94 3.51
3 1.06 × 3 + 1.0 = 4.18 2.43

To initiate the experiments, water needed to be filled to the highest level of the working conditions,
i.e., HDs = 3.51. Then the pumps were turned on in sequence with rotating speeds increasing slowly
to reach the target water level. Then, g the rotating speed of the pump was regulated to obtain the
interested flowrate. The flow patterns were recorded by a high-speed camera. The observations and
measurements were performed when the flow rate and water level were stable for 20 minutes. The
repeatability and frequency of related test phenomena were evaluated to minimize systematic errors.
The water level was measured by both an infrared water level meter and a water level scale in the
primary pump intake. The valve at the bottom of the secondary pump intake was then open to lower
the water level to the case 3 ( HDs = 2.43).

3. Results and Analysis

3.1. Classification of Free- and Sub-Surface Vortex

Based on the experimental results of this research, the following classification of free- and
sub-surface vortex is proposed, as shown in Figure 4. In the evolution process of the free-surface
vortex, with the increase of the turbulence of the free surface flow, the surface swirl becomes the surface
dimple. Further, a dyeing vortex and vortex pulling floating trash without air occurs gradually in the
intake with increasing intensity of swirl and intake pipe suction. Finally, the vortex pulling air bubble
group forms when the free surface fluctuates violently, and the bubble group is rotating with a certain
vertical circumference. On the other hand, when the free surface motion is not violent, vortex pulling
serial air bubbles appear, and eventually, the full air core is pumped into the intake pipe, as shown
in Figure 4a. For the sub-surface vortex, with the coupling of the swirl flow near the walls and the
suction of the intake pipe, the sub-surface swirl flow develops into the dye vortex (define). Then, if the
water contains air, the air bubbles group, and serial air bubbles are formed and sucked into the intake
pipe gradually. Finally, due to the great suction, the air core is formed and pumped into the intake
pipe, as shown in Figure 4b. It should be pointed out that the V-level free-surface vortex, the III- and
IV-level submerged vortices are presented by a large number of experimental processes in this paper,
which may be caused by the violent fluctuation of the water surface or the high air content of the fluid
in the test.
the water contains air, the air bubbles group, and serial air bubbles are formed and sucked into the
intake pipe gradually. Finally, due to the great suction, the air core is formed and pumped into the
intake pipe, as shown in Figure 4b. It should be pointed out that the V-level free-surface vortex, the
III- and IV-level submerged vortices are presented by a large number of experimental processes in
this paper, which may be caused by the violent fluctuation of the water surface or the high air content
Energies 2020, 13, 1790 9 of 20
of the fluid in the test.

Outflow Outflow Outflow

Free-surface Free-surface Free-surface

Inflow Inflow Inflow

(I) (II) (III)

Outflow Outflow Outflow Outflow

Free-surface Free-surface Free-surface Free-surface

Inflow Inflow Inflow Inflow

(IV) (V) (VI) (VII)

I. surface swirl, II. surface dimple, III. dye core to intake, coherent swirl throughout the water column,
IV. vortex pulling floating trash but not air, V. vortex pulling air bubble group (screw) to intake, VI.
vortex pulling serial air bubbles to intake, VII. full air core to intake.
Energies 2018, 11, x FOR PEER REVIEW 9 of 21
(a)

Outflow Outflow

Inflow Inflow

(I) (II)

Outflow Outflow Outflow

Inflow Inflow Inflow

(III) (IV) (V)

I. swirl, II. dye core, III. air bubble group (screw), IV. serial air bubbles, V. air core.

(b)
Vortex classification. (a) Free-surface vortex. (b)
Figure 4. Vortex (b) sub-surface
sub-surface vortex.
vortex.

3.2. Vortex
3.2. Vortex Distribution
Distribution Phase
Phase Diagram
Diagram
According to
According to the
the analysis
analysis inin Section
Section 2.1,
2.1, the
the dimensionless
dimensionless parameters
parameters reflecting
reflecting the
the water
water level,
level,
Hs
vortices formation, and flow in the pump intake of underground pumping stations are and Re,
vortices formation, and flow in the pump intake of underground pumping stations are D and Re,
respectively. Therefore, in order to understand the appearance and evolution of the various vortices
respectively. Therefore, in order to understand the appearance and evolution of the various vortices
in the primary and secondary pump intakes of the underground pumping station under different
in the primary and secondary pump intakes of the underground pumping station under different
cases, all vortices are presented in HDs ~Re diagram (Figure 5). They are classified into free-surface
cases, all vortices are presented in
vortices (7 levels) and sub-surface vortices ~Re diagram
(5 levels).(Figure 5). They are classified
The corresponding into free-surface
vortex patterns occurring
vortices (7 levels) and sub-surface vortices (5 levels). The corresponding vortex
in the primary and the secondary pump intake are drawn in Figure 5a,b, respectively. Note that patterns occurring in
the primary
high-level and the secondary
free-surface pump
vortices and intake arevortices
sub-surface drawn in Figure
appear in 5a,b, respectively.
the primary Note that pump
and secondary high-
level free-surface vortices and sub-surface vortices appear in the primary Hand secondary pump intake
intake at low Reynolds number (Re = 1.43 × 10 ) and low water level ( D = 2.43). As the Reynolds
5 s

at
number (Re = 4.01
low Reynolds × 105 ) (Re
number and=water ( HDs low
105) and
1.43 ×level water
= 3.51) level ( the
increase, = 2.43). As the
high-level Reynolds number
free-surface vortices
(Re = 4.01 × 10 ) and water level ( = 3.51) increase, the high-level free-surface vortices decreases,
decreases, and the
5 high-level sub-surface vortices still exist. When the water level remains unchanged,
and the
and the high-level
Reynolds number continues
sub-surface to increase
vortices still exist.(Re = 4.45
When 105 ), high-level
the× water free-surface
level remains vortices
unchanged, and and
the
sub-surface vortices appear in the primary and secondary pump intakes. Such
Reynolds number continues to increase (Re = 4.45 × 10 ), high-level free-surface vortices and sub-
5 operating conditions
surface vortices appear in the primary and secondary pump intakes. Such operating conditions
should be avoided to reduce adverse consequences, e.g., pump efficiency decreases, cavitation and
cavitation erosion, and accidental pump shutdown. The above three representative cases will be
analyzed in detail below, and are marked in Figure 5. In addition, it should be highlighted that the
research on the vortex distribution phase diagram has mainly been about the free-surface vortex to
 Energies 2018, 11, x FOR PEER REVIEW 10 of 21
Energies 2020, 13, 1790 10 of 20

248 and the high-level sub-surface vortices still exist. When the water level remains unchanged, and the
249 should
Reynolds number
be avoided tocontinues to increase
reduce adverse (Re = 4.45 ×e.g.,
consequences, 105),pump
high-level free-surface
efficiency vortices
decreases, and sub-
cavitation and
250 cavitation
surface erosion,
vortices appear in the primary and secondary pump intakes.
and accidental pump shutdown. The above three representative cases will beSuch operating conditions
251 analyzed
shouldin bedetail
avoided to reduce
below, and are adverse
marked consequences,
in Figure 5.e.g., pump efficiency
In addition, it shoulddecreases, cavitationthat
be highlighted andthe
252 research
cavitation erosion, and accidental pump shutdown. The above three representative cases will be
on the vortex distribution phase diagram has mainly been about the free-surface vortex to
253 analyzed in detail below, and are marked in Figure 5. In addition, it should be highlighted that the
date, such as Anwar et al.’s [10] study, based on pipe intake experimental results; without a bellmouth,
254 research on the vortex distribution phase diagram has mainly been about the free-surface vortex to
a variation of coefficient of discharge with circulation parameter was obtained, which can be used to
255 date, such as Anwar et al.’s [10] study, based on pipe intake experimental results; without a
256 predict the appearance of a free-vortex when the values of the nondimensional parameters, besides,
bellmouth, a variation of coefficient of discharge with circulation parameter was obtained, which can
257 the be
vortex
usedregion divided
to predict the strongofvortex
the appearance regionwhen
a free-vortex and dimple
the valuesregion
of thetonondimensional
estimate the free-vortex
parameters, type
258 roughly. Echavez and McCann [11] found that when the free-surface vortex
besides, the vortex region divided the strong vortex region and dimple region to estimate the free- or axial discharge is less
259 thanvortex type roughly. Echavez and McCann [11] found that when the free-surface vortex or axial
a certain value, the free-surface vortex discharge does not go entirely through the central pipe,
260 anddischarge
based onisthe less than a certain
experimental value, the
results, the limit
free-surface
values vortex
at which discharge
the flows does not go entirely
separated through It
was obtained.
261 can the centralthat
be found pipe, andthe
once based onisthe
limit experimental
reached, results,
an increase in the
axiallimit values at
discharge which thesuch
originates flows separated
that the depth
262 of the
wasairobtained. It can berapidly
core augments found that once
until the limitthe
it reaches is reached,
bottom of anthe
increase
tank.inCristofano
axial discharge
et al. originates
[14] carried
263 out such that the depth
an experiment and of determined
the air core augments rapidly until
the free-surface vortexit reaches the bottom
occurrence map.ofThethe tank. Cristofano
results indicated
264 thatetthe
al. No
[14]vortices
carried out an experiment
(Stage 1 and Stageand determined
1) Stage the free-surface
2 transition zones were vortex occurrence
quite map. The
well defined, while
265 the results indicated that the No vortices (Stage 1 and Stage 1) Stage 2 transition
Stage 2 (gas entrainment transition zone) was characterized by some mismatches; this probably zones were quite well
266 means
defined, while dimensionless
that other the Stage 2 (gas groups
entrainment
(Fr andtransition zone)were
We), which was characterized
not considered by in
somethemismatches;
map, affected
267 in athis probably means that other dimensionless groups (Fr and We),
non-negligible way the physical dynamics of the gas entrainment phenomenon. Furthermore, which were not considered in the
268 in some
map, affected in a non-negligible way the physical dynamics of the gas entrainment phenomenon.
cases, the high flow rate at inlets disturbed the water free surface, introducing oscillations
269 Furthermore, in some cases, the high flow rate at inlets disturbed the water free surface, introducing
and tiny waves that seem to have an inhibitory effect on the free-surface vortex intensification and
270 oscillations and tiny waves that seem to have an inhibitory effect on the free-surface vortex
the gas entrainment occurrence. But similar methods are seldom used in the research on the various
271 intensification and the gas entrainment occurrence. But similar methods are seldom used in the
272 vortices of the conventional pump station. Furthermore, there is no related reference in the research on
research on the various vortices of the conventional pump station. Furthermore, there is no related
273 the sub-surface
reference in the vortex.
research Besides,
on the similar investigation
sub-surface on the
vortex. Besides, underground
similar pumping
investigation station has not
on the underground
274 appeared.
pumping Therefore,
station has compared withTherefore,
not appeared. the study compared
on the vortex withflow patterns
the study in vortex
on the a conventional pump
flow patterns
275 station, based on the summary of relevant research and significant
in a conventional pump station, based on the summary of relevant research and significant experimental experience, we have
276 experimental experience, we have summarized the vortex distribution phase diagram and obtained
summarized the vortex distribution phase diagram and obtained Figure 5, in order to help the readers
277 better
Figure 5, in order
understand thetoevolution
help the readers bettervortex
of complex understand the evolution
flow patterns of complex
for different vortex
water levelflow
andpatterns
Reynolds
278 number
for different water level and
in the underground Reynolds
pumping number
station, in the
from underground
a macro pumping station, from a macro
perspective.
279 perspective.
4.00 Free-surface vortices
I
3.50 II
Case 1 Case 2 III
3.00 IV
V
2.50 VI
VII
Hs Case 3
2.00
D
Sub-surface vortices
1.50 I
II
1.00 III
IV
0.50
V
0
0 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50
Re (105)

(a)
 Energies 2020, 13, 1790 11 of 20
Energies 2018, 11, x FOR PEER REVIEW 11 of 21

4.00 Free-surface vortices

I
3.50 II
Case 1 Case 2 III
3.00 IV
V
2.50 VI
VII
Hs Case 3
2.00
D
Sub-surface vortices
1.50 I
0.29
II
1.00 III
0.21
IV
0.50
0.25 V
0
0 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50
Re (105)

(b)
280 Figure
Figure 5. 5. Distributionsofofvortices
Distributions vorticesin
in the
the pump
pump intake
intakeofofthe
theunderground
undergroundpumping
pumpingstation. (a) Vortex
station. (a) Vortex
281 patterns in the primary pump intake. (b) Vortex patterns in the secondary pump
patterns in the primary pump intake. (b) Vortex patterns in the secondary pump intake. intake.

282 3.3.3.3. Case

Case Study
Study

3.3.1. Case 1: Re = 4.01 × 1055 and HD

Hs s = 3.51
283 3.3.1.2018,
Energies Case11,1:xRe
FOR= 4.01
PEER×REVIEW
10 and = 3.51 11 of 21
D
In case 1, there was no free-surface vortex above level III in the primary pump intake, as shown
284 In In
in Figure case
case 1,1,there
6. A thereIV
level was
was nofree-surface
no free-surface
sub-surface vortex
was above
vortex
vortex above
formed level
levelIII
underIIIininthe
the theprimary
top wall pump
primary the intake,
ofpump as shown
intake,
main pipe asand
shown
the
285 in Figure 6.
in Figure 6.pump
secondary A
A levellevel IV sub-surface
IV sub-surface
intake. These gasesvortex
vortex was formed
wascame
mainly formed under
under
from the
the the top wall
top wall
dissolved of the
of the
gases main pipe
in main and
pipe and
the water the the
and the
286 secondary
secondary
sub-surface pumpintake.
pump
vortex intake.
attachedThese
These gases
to gases
the topmainly
wall, came
mainly came
caused from
bythe
from thedissolved
dissolved
suction gases
gases
effect in the
at in
the water
the and
water
branch the the
and
inlet sub- sub-
of each
287 surface
surface
pump.
vortex attachedtotothe
vortex
Due toattached
thetop
the suction effect
topwall,
wall, caused
caused by
of pump bythe
3, the the suction
suctioneffect
intermittent effectatatthe
suction thebranch
branch
vortex
inlet of each
oninlet
the of
top
pump.
each
wallpump.
was
288 Due to
Due to the the suction
suction in effect
effect of pump
of pump 3, the
3, the intermittent
intermittent suction
suction vortex on the top wall was formed, as as
formed, as shown Figure 6b. This vortex was sucked intovortex
the inleton of
thepump
top wall was formed,
3, which may lead
289 shown in Figure 6b. This vortex was sucked into the inlet of pump 3, which may lead to the
shown in Figure 6b.
to the deterioration of This
pumpvortex was sucked
3 performance, e.g.,into the inlet
affecting of pump 3,
the operation whichand
stability mayevenleadcausing
to the
290 deterioration of pump 3 performance, e.g., affecting the operation stability and even causing pump
deterioration
pump shutdown. of pump 3 performance, e.g., affecting the operation stability and even causing pump
291 shutdown.
shutdown.

292
293 Figure 6. The flow patterns in primary and secondary pump intakes for case 1. (a) No obvious vortices
294 in the6.primary
Figure pump
The flow intake,
patterns (b) level and
in primary IV sub-surface
secondary vortex
pump in the vicinity
intakes of1.the
for case (a)inlet
No of pump vortices
obvious 3 on
295 Figure 6. The
the primary
in the
flow
top wall of patterns in
the secondary
pump
primary
intake, (b)pump
and secondary
level intake.
pump intakes for case 1. (a) No obvious vortices
IV sub-surface vortex in the vicinity of the inlet of pump 3 on the
in the primary pump intake, (b) level IV sub-surface vortex in the vicinity of the inlet of pump 3 on
top wall of the secondary pump intake.
the top wall of the secondary pump intake.

Figure 7 shows the evolution process of the sub-surface vortex generated in the primary pump
intake for case 1. The vortex was sucked into the inlet of the branch pipe of pump 3. Due to the main
pipe flow, the sub-surface vortex presented a ‘U’ shape along the flow direction. In Figure 7b,c, the
‘U’ shaped flow presented an up-and-down swing pattern parallel to the mainstream flow direction,
Energies 2020, 13, 1790 12 of 20

Figure 7 shows the evolution process of the sub-surface vortex generated in the primary pump
intake for case 1. The vortex was sucked into the inlet of the branch pipe of pump 3. Due to the main
pipe flow, the sub-surface vortex presented a ‘U’ shape along the flow direction. In Figure 7b,c, the ‘U’
shaped flow presented an up-and-down swing pattern parallel to the mainstream flow direction, which
was mainly caused by the turbulent flow in the main pipe. After a period of time, due to the cascade
effect of turbulence and viscous dissipation of fluid, the sub-surface vortex fractures and decomposed
into a certain amount of interrupted vortex zones, as shown in Figure 7d.
Energies 2018, 11, x FOR PEER REVIEW 12 of 21

(c)

(a) (d)

(b) (e)
Figure 7. The evolution process of the sub-surface vortex in the primary pump intake. (a) Pump 3 inlet,
Figure 7. The evolution process of the sub-surface vortex in the primary pump intake. (a) Pump 3
(b–e) sub-surface vortex sucked downstream to the inlet of pump 3.
inlet, (b–e) sub-surface vortex sucked downstream to the inlet of pump 3.
3.3.2. Case 2: Re = 4.45 × 105 and HDs = 3.51
3.3.2. Case 2: Re = 4.45 × 105 and = 3.51.
The evolution of a free-surface vortex for case 2 in the primary pump intake is shown in Figure 8.
Due The evolution
to the of aforce,
centrifugal free-surface vortex
part of the forthe
air in case 2 in the primary
free-surface vortex pump intake
rope was is shown
separated informed
and Figure
8. Due to the centrifugal force, part of the air in the free-surface vortex rope was separated and formed
into an air cluster independently. The preliminary process of the air cluster is illustrated in Figure 8a.
The larger air clusters were then thrown out of the main vortex rope and disintegrated (as shown in
Figure 8b,c). Finally, the separated air fragments were all sucked into the next installations along with
the free-surface vortex rope (as shown in Figure 8d).
Energies 2020, 13, 1790 13 of 20

into an air cluster independently. The preliminary process of the air cluster is illustrated in Figure 8a.
The larger air clusters were then thrown out of the main vortex rope and disintegrated (as shown in
Figure 8b,c). Finally, the separated air fragments were all sucked into the next installations along with
the free-surface
Energies vortex
2018, 11, x FOR rope
PEER (as shown in Figure 8d).
REVIEW 13 of 21

Figure 8. The
Figure 8. processinofthe
is applied free-surface vortex shedding
original experimental air cores
results; under centrifugal
the identified forceresults
experimental in the primary
(Figures
pump intake.
9b,d, and 11b)(a)were
The obtained
preliminary in process
MATLAB. of the air cluster;
First, (b,c) the
the real-time larger air clusters
experimental resultswere
were then thrown
compared
out of the main vortex rope and disintegrated; (d) the separated air fragments were
with the background data (the water in the pump intake without pump running), and then the vortexall sucked into the
next installations along with the free-surface vortex rope.
area was extracted. Then, the threshold method (each pixel is given a gray value of 0–255 degrees for
recognition) was used to further identify the vortex area and its contour.
Based on the in-house code, the image recognition technology [33] is applied in the original
experimental results;
The operating the identified
conditional experimental
difference between results
the cases(Figures
1 and 29b,d
wasand
that 10b) were
in case obtained
2, pump in
4 was
MATLAB.
open, and First, the real-time
the water experimental
in the primary pump results weresubjected
intake was comparedtowith the background
a more intense suction data (the
effect.
water in the pump intake without pump running), and then the vortex area
Therefore, the sub-surface vortex and free-surface vortex (screw) (Figure 9a,b) appeared in the was extracted. Then,
the threshold
primary pumpmethod
intake.(each
Due topixel
the is given fluctuation
violent a gray value ofof 0–255
the free degrees
surface, for recognition)
these air bubbleswas used
on the to
free
further
surface identify
began tothe vortex
rotate area and
around its contour.
a certain axis and gathered (as shown in Figure 9a,b), some of them
The operating conditional
were sucked into the main pipe or the nextdifference between
pump theinlet
casesand1 and 2 was
may that
have in casethe
affected 2, pump 4 was
operational
open, andofthe
efficiency thewater
pump.inSome the primary pump intake
of these bubbles was subjected
were trapped into the to a more intense
secondary suction
pump intake, effect.
coupled
Therefore, the sub-surface vortex and free-surface vortex (screw) (Figure 9a,b)
with the complex flow pattern, and then formed a variety of sub-surface vortices in the secondaryappeared in the primary
pump
pump intake. Due to9a,b
intake. Figure the (there
violentwere
fluctuation
both theofsub-surface
the free surface,
vortexthese air bubbles vortex
and free-surface on the and
freethe
surface
sub-
began to rotate around a certain axis and gathered (as shown in Figure 9a,b), some
surface vortex attached to the side wall 2 of the primary pump intake) shows the sub-surface vortex of them were sucked
into the main
formation pipe or
process in the
the next pump
primary inlet intake
pump and mayand have affected
Figure the operational
7 describes one of theefficiency
evolutionof the pump.
processes
Some
after the sub-surface vortex was pumped downstream. Besides, level VII free-surface vortex flow
of these bubbles were trapped into the secondary pump intake, coupled with the complex was
pattern, and then formed a variety of sub-surface vortices in the secondary pump
formed in the primary pump intake (Figure 11a,b), which was continuously suctioned into the main intake. Figure 9a,b
(there were
pipe and theboth
nextthe sub-surface vortex and free-surface vortex and the sub-surface vortex attached to
installations.
the side wall 2 of the primary pump intake) shows the sub-surface vortex formation process in the
primary pump intake and Figure 7 describes one of the evolution processes after the sub-surface vortex
was pumped downstream. Besides, level VII free-surface vortex was formed in the primary pump
intake (Figure 10a,b), which was continuously suctioned into the main pipe and the next installations.
Energies 2020, 13, 1790 14 of 20
Energies 2018, 11, x FOR PEER REVIEW 14 of 21

Figure 9. (a,b) level V free-surface and level V sub-surface vortices original results and the related
Figure
gray 9. (a) and
recognition (b) level
results, V original
(c,d) free-surface
leveland
VIIlevel V sub-surface
free-surface vortices
and related original
gray results results
recognition and thein the
Energies 2018, 11, gray
related x FORrecognition
PEER REVIEW results, (c) and (d) original level VII free-surface and related gray 16 of 21
primary pump intake.
recognition results in the primary pump intake.

In case 2, since pump 4 was working, flow patterns were more complex in the secondary pump
intake. The suction of pump 4 had influence, on top of the complex flow patterns in the primary
pump intake that were carried by the main flow to the secondary pump intake. A large number of
bubbles that coalesced near the top wall of the secondary pump intake were partly caused by the
free-surface vortex in the primary pump intake. The sub-surface vortex in the primary pump intake
was pumped to the secondary pump intake, and the vortex rope formed by its dissipative fracture.
Some air bubbles may have occupied near the top wall of the secondary pump intake, and then been
sucked into the pump 4. As shown in Figure 10a, the back wall attached vortex formed by the intake
pipe due to the strong suction effect located in the middle and lower part of the back wall of the
secondary pump intake. Figure 10b shows the intermittent suction vortex near the top wall of the
secondary pump intake. As mentioned above, the formation of the cavity region on the top wall was
mainly due to the gas in the water, various vortices carrying gas in the primary pump intake,
cavitation (some cases), and the suction effect of the intake pipe. Figure 10c shows the phenomenon
of spiral air bubbles being pumped into the intake pipe on the top wall of the secondary pump intake.
These bubbles were mainly caused by the bubbles in the water and the free-surface vortex in the
primary pump intake.

Figure 10. (a) Original level VI free-surface vortices, and (b) the related gray recognition results in the
Figure 11.
primary (a) Original
pump intake. level VI free-surface vortices, and (b) the related gray recognition results in the
primary pump intake.
In case 2, since pump 4 was working, flow patterns were more complex in the secondary pump
In The
intake. this suction
case, theofflow
pumprates of pumps
4 had 1–3on
influence, were
topincreased significantly,
of the complex and the
flow patterns flowprimary
in the rate of pump
pump
4 connected
intake to the
that were secondary
carried pump
by the mainintake was
flow to thestable. The flow
secondary pump pattern in the
intake. secondary
A large number pump intake
of bubbles
was coalesced
that relatively near
stable
thecompared
top wall of with
the case 2, as can
secondary pumpbe intake
seen fromwerethe evolution
partly causedprocess of the flow
by the free-surface
pattern inside the secondary pump intake (Figure 12). A small bubble
vortex in the primary pump intake. The sub-surface vortex in the primary pump intake was was formed on the top wall of
pumped
thethe
to secondary
secondarypump pumpintake,
intake, shown
and thein Figure
vortex 12a.
rope With by
formed theitsinternal flowfracture.
dissipative of the secondary pump
Some air bubbles
may have occupied near the top wall of the secondary pump intake, and then been sucked intonew
intake, the bubbles moved randomly near the top wall. These bubbles converged to form a the
bubble4.with
pump a larger
As shown geometric
in Figure radius.
11a, the backDue
wallto surfacevortex
attached tension and the
formed internal
by the intakepressure
pipe due of the
to the
secondary
strong pump
suction intake,
effect theinsub-surface
located the middlevortex
and lowershowed
part an ellipsoidal
of the back wall shape
of thewith the long
secondary axis
pump
parallel to the top wall. Two large bubbles with the same geometric scale appeared,
intake. Figure 11b shows the intermittent suction vortex near the top wall of the secondary pump which were far
away from each other, as shown in Figure 12. With further progress of internal
intake. As mentioned above, the formation of the cavity region on the top wall was mainly due to theflow in the secondary
pump
gas intake
in the above,
water, two vortices
various large bubbles
carryingwith
gasa relatively long-distance
in the primary pump intake, moved in a spiral
cavitation around
(some an
cases),
unfixed circle, and the distance between them became increasingly smaller (as shown in Figure 12c).
Finally, the above two bubbles fused into a larger one, and this moved to a position near the
secondary pump intake. At this time, due to its large volume and the suction effect of the intake pipe
in the secondary pump intake, the bubble presented as a cone pattern, and the top of the cone
gradually fell off andwas sucked into the intake pipe, as shown in Figure 12d.
Energies 2020, 13, 1790 15 of 20

and the suction effect of the intake pipe. Figure 11c shows the phenomenon of spiral air bubbles being
pumped into the intake pipe on the top wall of the secondary pump intake. These bubbles were mainly
caused by the bubbles in the water and the free-surface vortex in the primary pump intake. 15 of 21
Energies 2018, 11, x FOR PEER REVIEW

Figure 11. Vortices in the secondary pump intake. (a) Vortex location, (b) back wall attached-vortex,
Figure 10. Vortices in the secondary pump intake. (a) Vortex location, (b) back wall attached-vortex,
(c) vortex pulling serial air bubbles from top wall to the secondary pump intake, (d) vortex pulling air
(c) vortex pulling serial air bubbles from top wall to the secondary pump intake, (d) vortex pulling
bubble group (screw) from top wall to the secondary pump intake.
air bubble group (screw) from top wall to the secondary pump intake.
3.3.3. Case 3: Re = 1.43 × 105 and HDs = 2.43
3.3.3. Case 3: Re = 1.43 × 105 and = 2.43.
Compared with case 2, in case 3 the water level was decreased and the flow rate was increased.
Compared
Intermittent with casevortex
free-surface 2, in case 3 thefrequently
occured water levelinwas decreased
the primary and the
pump flowThe
intake. ratevortex
was increased.
appeared
Intermittent
parallel to thefree-surface
side wall ofvortex occured
the primary frequently
pump intake, in
as the primary
shown pump
in Figure intake.
10a,b, Thewas
which vortex appeared
intermittently
parallel
suctioned tointo
the the
side wallpipe
main of and
the the
primary pump intake,Along
next installations. as shown
with thein strong
Figuresuction
11a,b, effect
whichofwasthe
intermittently
main pipe, in this suctioned into
case, the airthe
wasmain pipe and
pumped the nextinto
continually installations.
the bottomAlong
of thewith the strong suction
vortex.
effectInofthis
the case,
mainthe pipe, in rates
flow this case, the air1–3
of pumps waswere
pumped continually
increased into the
significantly, andbottom of the
the flow ratevortex.
of pump
4 connected to the secondary pump intake was stable. The flow pattern in the secondary pump intake
was relatively stable compared with case 2, as can be seen from the evolution process of the flow
pattern inside the secondary pump intake (Figure 12). A small bubble was formed on the top wall of
the secondary pump intake, shown in Figure 12a. With the internal flow of the secondary pump intake,
the bubbles moved randomly near the top wall. These bubbles converged to form a new bubble with
a larger geometric radius. Due to surface tension and the internal pressure of the secondary pump
Energies 2020, 13, 1790 16 of 20

intake, the sub-surface vortex showed an ellipsoidal shape with the long axis parallel to the top wall.
Two large bubbles with the same geometric scale appeared, which were far away from each other,
as shown in Figure 12. With further progress of internal flow in the secondary pump intake above,
two large bubbles with a relatively long-distance moved in a spiral around an unfixed circle, and the
distance between them became increasingly smaller (as shown in Figure 12c). Finally, the above two
bubbles fused into a larger one, and this moved to a position near the secondary pump intake. At this
time, due to its large volume and the suction effect of the intake pipe in the secondary pump intake,
the bubble presented as a cone pattern, and the top of the cone gradually fell off andwas sucked into
the intake
Energies 2018,pipe, as shown
11, x FOR in Figure 12d.
PEER REVIEW 17 of 21

Figure 12. Vortex in the secondary pump intake. (a) The observation area of the top wall of the
Figure 12. Vortex
secondary in the (b–e)
pump intake, secondary pumpofintake.
evolution vortex (a) The observation
pulling area of
serial air bubbles onthe
thetop
top wall
wall of
of the
the
secondary
secondary pump intake, (b–e) evolution of vortex pulling serial air bubbles on the top wall of the
pump intake.
secondary pump intake.
3.4. Vortex Area Evolution Diagram
3.4. Vortex Area Evolution Diagram
It is well known that the vortex volume (air volume) has a direct effect on the suction capacity on
the inlet
It is of theknown
well pump,that
i.e.,the
it plays
vortexanvolume
important(airrole in thehas
volume) performance of the
a direct effect on pump [11,14].
the suction Based
capacity
on the
on thisinlet
consideration,
of the pump, thei.e.,
vortex volume
it plays is an important
an important parameter,
role in the and itofisthe
performance of pump
great significance
[11,14]. Based to
reveal
on thisthe vortex volume
consideration, theof various
vortex vortices
volume in important
is an the primary pump intake
parameter, andbased
it is ofongreat
the variation of the
significance to
projected
reveal the area
vortexof the vortex,
volume of in the two-dimensional
various frame with
vortices in the primary pumptime. Figure
intake 13 shows
based on thethe projected
variation of
the
areaprojected
of the vortexareaevolution
of the vortex, in the two-dimensional
in the primary pump intake of the frame with time.
underground Figure 13
pumping shows
station, the
which
projected area ofarea
is the projected theratio
vortex evolution
of the in thevortex
free-surface primary
andpump intakevortex
sub-surface of thein underground
the background pumping
of the
station,
primarywhichpump is the projected
intake in the fieldarea ratiobased
of view, of theonfree-surface vortex andtechnology
the image recognition sub-surface[35];vortex in the
where, the
background of the primary pump intake in the field of view, based on the image recognition
technology [35]; where, the projected area ratio of vortex rope is the ratio of the captured area of the
vortex rope to the area of the background, represented by A (%). The abscissa is the number of
shooting frames, represented by N; here, the processed results are based on the results of continuous
30 s shooting (photographic speed 60 fps). From the perspective of the projected area of the vortex,
Energies 2018, 11, x FOR PEER REVIEW 18 of 21

which
Energies indicated
2020, 13, 1790that the free-surface vortex and subsurface vortex were captured at the same17
time.
of 20
Compared with the above two cases, the A value for case 3 was lower, which was mainly due to the
lower occurrence of the sub-surface vortex. Besides, between the N = 900 and N = 1200, the free-
projected area ratio of vortex rope is the ratio of the captured area of the vortex rope to the area of
surface vortex gradually transformed into serial air bubbles, or a very thin vortex rope, which led to
the background, represented by A (%). The abscissa is the number of shooting frames, represented
the lower value of A. In Figure 13, the averaged value of the projected area ratio is the sum of the
by N; here, the processed results are based on the results of continuous 30 s shooting (photographic
projected area of the vortex in each time and divides it by the number of shooting frames. The
speed 60 fps). From the perspective of the projected area of the vortex, the evolution of the ratio of the
evolution vortex in each case can be reflected thoroughly, based on this point of view. All of the
projected area of the free-surface vortex and the subsurface vortex in the primary pump intake under
presented phenomena were consistent with the experimental results, which shows the validity and
three different conditions can be quantitatively observed.
reliability of the analysis method.

Figure 13. Vortex area evolution in the pump intake of the underground pumping station.
Figure 13. Vortex area evolution in the pump intake of the underground pumping station.

For case 1, the vortex projected area was relatively low when N < 450, which means that the
4. Discussion
vortex was not fully formed, only an occasional number of bubbles were sucked into the main pipe,
A number
and then of recommendations
the free-surface vortex was can be given
gradually to theadesign
formed, and operation
large number of andespite
of bubbles, underground
the full
pumping station,
air core, were based
sucked on the
into the main
resultspipe.
of this
A research. Although
similar situation for a lower
occured Re (Re
for case < 1.5
2, but the× 10 5), a lower
time moved
back about 450–900 frames. In cases 1 and 2, especially when N = 1300, the peak value of A appeared,
level free-surface vortex occurs, it is recommended to run at a higher water level if possible to
eliminate the related
which indicated thatvortices. It is also vortex
the free-surface strongly suggested
and subsurface thatvortex
underground pumping
were captured at station
the same should
time.
operate
Compared at awith
high-water leveltwo
the above > 3.0) when
( cases, the A 1.5 × 10for
value 5 < case
Re <3.0 × 10lower,
3 was 5. For high
whichRe was
(Re >mainly
4.0 × 10due5), the
to
the lower occurrence
application of the sub-surface
of vortex elimination vortex.beBesides,
devices should considered between
when the N = 900
the water and
level N = be
cannot 1200, the
raised
free-surface vortex gradually transformed into serial air bubbles, or a very thin
infinitely. Moreover, it is recommended to refer to the relevant operation in the primary pump intake vortex rope, which
led the
for to the lowerpipe
sewage value of A. In Figure
maintenance in the13,secondary
the averaged
pump value of the
intake (forprojected
example,area
shutratio
down is the
thesum
pump of
the projected
and use a lower area of the
flow ratevortex
pumpin foreach time and
relevant workdivides it by the
to eliminate numberthe
or reduce of vortices
shootingwithinframes.pumpThe
evolution vortex in each case can be reflected thoroughly, based on this point of view. All of the
intake).
presented
On the phenomena
other hand, were
for consistent with thepumping
the underground experimental results,
station which shows
engineering design,thebased
validity
on and
the
reliability of the analysis method.
experimental results of the present paper and our experimental experience, it is suggested that the
sharp corner in the pump intake and the sharp edge of the supply pipe should be rounded of as much
4. Discussion
as possible, which mainly result in the undesirable flow patterns such as vibration, and stagnation in
the actual operation
A number of the underground
of recommendations canpumping
be givenstation, which may
to the design and even lead itoftoan
operation beunderground
out of order.
pumping station, based on the results of this research. Although for a lower Re (Re < 1.5 × 105 ), a lower
5. Conclusions
level free-surface vortex occurs, it is recommended to run at a higher water level if possible to eliminate
the related vortices.theory
The similarity It is also
ofstrongly suggested
fluid mechanics that
was underground
utilized pumping
to obtain station
the physical should operate
experimental at a
model
Hs
high-water level (
with the model ratio > 3.0) when 1.5 × 10 5 < Re <3.0 × 105 . For high Re (Re > 4.0 × 105 ), the application
D of 10:1. According to the different pipe structures of the pumping station, the
of vortex elimination devices
quantitative and qualitative shouldof
analysis berelated
considered
flow when
patternsthewas
water levelout
carried cannot
based beonraised infinitely.
the Reynolds
Moreover, it is recommended to refer to the relevant operation in the primary pump intake for the
number Re and the relative submergence . The evolution process of various vortices in the primary
sewage pipe maintenance in the secondary pump intake (for example, shut down the pump and use a
and secondary pump intake of a typical underground pumping station were obtained. The various
lower flow rate pump for relevant work to eliminate or reduce the vortices within pump intake).
Energies 2020, 13, 1790 18 of 20

On the other hand, for the underground pumping station engineering design, based on the
experimental results of the present paper and our experimental experience, it is suggested that the
sharp corner in the pump intake and the sharp edge of the supply pipe should be rounded of as much
as possible, which mainly result in the undesirable flow patterns such as vibration, and stagnation in
the actual operation of the underground pumping station, which may even lead it to be out of order.

5. Conclusions
The similarity theory of fluid mechanics was utilized to obtain the physical experimental model
with the model ratio of 10:1. According to the different pipe structures of the pumping station, the
quantitative and qualitative analysis of related flow patterns was carried out based on the Reynolds
number Re and the relative submergence HDs . The evolution process of various vortices in the primary
and secondary pump intake of a typical underground pumping station were obtained. The various
vortex patterns were classified into free-surface vortices (VII levels) and sub-surface vortices (V levels),
through a large number of test results.
It was found by the experiments that: in case 1, there was no obvious free-surface vortex and
sub-surface vortex in the primary pump intake. Due to the suction effect in the inlet of pump 3, the
intermittent suction sub-surface vortex was formed near the top wall of the main pipe. In addition,
the sub-surface vortex in the primary pump intake was pumped to the branch inlet. The sub-surface
vortex presented a ‘U’ shape along the flow direction and finally fractures. For a larger flow rate, there
was a free-surface intermittent suction vortex in the primary pump intake, and there were back wall
vortex and air bubble group vortex in the secondary pump intake in case 2. These bad suction flow
patterns directly caused the inflow conditions of related pump groups to get worse. In case 3 with the
lower water level, multiple free-surface vortices appeared in the primary pump intake frequently, and
the maximum tip depth reached 0.69d. At the same time, a large amount of air with strong rotation at
the top of the tip was pumped into the main pipe in the form of bubbles. Due to the strong suction
effect of the intake pipe in the secondary pump intake, the volume of the bubble began to increase. The
bubble presented as a cone pattern and was pumped into the intake pipe intermittently. Furthermore,
all kinds of vortex phenomena were marked in different dimensionless water level and Reynolds
number maps, to connect and reveal the emergence and development evolution process of various
vortices in the primary and secondary pump intake of the underground pumping station.
The experiment results show that the related design and operation criteria and dimensionless
analysis of underground pumping stations proposed in this paper are effective and feasible. The
free-surface and sub-surface vortices were observed, which had an important reference meaning for the
analysis and suppression of vortex in future research. The next research will focus on the quantitative
pump group performance and the evolution process of pump group performance along with the bad
flow patterns. In addition, this model might have great potential to be implemented in the current
design guidelines for the underground pumping station.

Author Contributions: Conceptualization, M.G., B.C., and H.Z.; methodology, M.G., S.L., and Z.Z.; validation,
M.G., S.L., and Z.Z.; formal analysis, M.G., Z.Z., and D.L.; investigation, Z.Z. and S.L.; data curation, M.G., Z.Z.,
and S.L.; writing-original draft preparation, M.G., Z.Z., and S.L.; writing-review and editing, M.G. and Z.Z.;
supervision, S.L. and Z.Z.; project administration, M.G., Z.Z., and S.L.; funding acquisition, M.G., Z.Z., S.L., and
D.L. All authors have read and agreed to the published version of the manuscript.
Funding: This research was funded by the National Key R&D Program of China (2018YFB0606103), the National
Natural Science Foundation of China (No.51876100, 51909132), and the Open Research Fund Program of State Key
Laboratory of Hydroscience and Engineering (sklhse-2018-E-02).
Conflicts of Interest: The authors declare that they have no conflict of interest.
Energies 2020, 13, 1790 19 of 20

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