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    63 views127 pages

    The Hydrulic Design Pump - MJ Prosser

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    Li Zhi Tan

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    © All Rights Reserved
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    THE HYDRAULIC DESIGN OF PUMP SUMPS AND INTAKES M.J.Prosser bhra fluid engineering Contents ae ary GLOSSARY 6 NOTATION 7 summary a 1, INTRODUCTION 8 1.1 General apse 8 1.2. Effect of poor design 8 2. DESCRIPTION OF INTAKE TYPES 12 2.1 Hydraulic features of the approach flow to intakes 12 2.2. Classification of pumping stations and intakes by use 16 3. OPTIMUM SUMP VOLUMES 18 3.1. Mirimum sump volume for one duty pump system {fixed speed pumo) 19 3.2 Minimum sump volume for multipump system {fixed speed pumps) 19 3.3 Derivation of formula for minimum sump volume 19 4 PARTICULAR ASPECTS OF SUMP DESIGN 20 4.1 Good sump design 20 4.2. Unsitisfactory sump design 23 4.3. Mosifications to improve unsatisfactory sumps 26 5. PREFERRED SUMP AND INTAKE DESIGNS 28 5.1. Singe pump sumps 28 - 5.2. Multiple pump sumps a 5.3. Minimum submergence 33 5.4 Spedal designs 34 MODEL TESTING 39 6.1 Whes to undertake model tests 39 6.2. Recommended procedures for sump and intake model tests 40 7. BIBLIOGRAPHY 42 43 APPENDIX 1 HYDRAULIC DESIGN DATA, APPENDIX 2. THEORY OF MODEL “— List of illustrations Figure 1 Figure 2 Figure 3 Figure 4 Figure S Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22, Figure 23 Figure 24 Dizgram to illustrate an intake Diagram to illustrate NPSH Two examples of the subdivision of pump intakes into functional zones Wet and dry well pump installations Bellmouth design Typical pipework for pump not ited directly adjacent to intake The main aspects of a good single cell sump Detail design of sump end wall General layout for inlet (Zone 1} t0 multiple pump sump General layout for multiple pump sump (Zone Iti) Unsatisfactory sump, large sump relative to beilmouth size Unsatisfactory sump, high velocities in jets Unsatisfactory sumps, water falling trom high levels Unsatisfactory sump, side offtake from main channel Unsatisfactory sump, pumps in line with flow Unsatisfactory sump, large divergence angle in approaches to sume Unsatisfactory sump, side inlet with short splitters Modifications to the basic intake design to reduce the tendency for swing flow and submerged vortices Modifications to the basic intake design to reduce the tendency to form air entraining vortices Basie design for single pump, wet well sump with a vertical intake Basic design for single pump, dry well sump Recommended approach channel lengths Basic sump designs for multiple euros, wet well arrangement Examples of multiple pump sumps, including the approach works to the sump Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 List of tables Table 1 Table 2 Table 3 Table 4 Example of a cwo-pump sump for sewage application Sxample showing @ drum screen inlet arrangement Sxample of a small cylindrical sump Example showing multiple intakes from a reservoir Ratating vane or ‘vortometer’ installed in pump suction pipe to observe swirling flow The main flow features of an axisymmetric jet The main features of diffuser design Summary of the flow conditions in a sump which cause undesirable effects on the pump Summary of pump types and their characteristics Typical mean velocities in a basic sump Minimum sump lengths Glossary Figure 1 Diagram to illustrate an intake CAVITATION This is @ phenomenon which occurs in a moving liquid when the local pressure at some position falls to the vapour pressure of the liquid. Bubbles of vapour, known as cavitation bubbles, form at ths position and are carried downstream. When the static pressure rises at a subsequent position in the stream these cavitation bubbles collapse, usually being accom Panied ty a characteristic crackling or singing noise. Very large instantaneous pressures and temperatures occur at the site of the bubbles’ collapse, so that if this ste is adjacent to the pipe wal, or the rotating impeller of a pump, serious mechanical damage to the surface can FOREBAY ‘The area immedia ely upstream of the intake section when the intakes are directly adjacent toa river or reservor. It is also used in some applications instead of the term ‘sump’. INTAKE ‘The short section, or plane, where the water enters a pipe or closed conduit and the flow changes ftom ‘fee surface flow to “internal flow’. Upstream from the intake, the water has 2 fre surface with air above it. Downstream from the intake there is no fee surface and che water completely fis the pipe croseseetion Discharge + Free surface flow ==} pump \ f ot) RR CRRA ner flow Intake ELEVATION MMU PLAN PUMP SUCTION CONDITIONS (NPSH) Caviation must norbe alowed to occu within» pump, so that theresa minimum permisbie absolute pressure atthe pump inlet. In general, this minimum pressure is greater than the vapour presue ofthe fadand normally varies aceording tthe point onthe ow aaingt head curve, at which the pump # operating. Pump manufacturers cormally supply this information in the form of plots of minum head (NPSH required by the pug) against speed and delivery, The designer must then esure that the head atthe suction lenge af the pump (NPSH avast tyeiter than tis mitimum specified head over the operational range ofthe pump. te, NPSH (available) > NPSH itequired), Figure 2 Diagram to illustrate PSH Notation ‘The term NPSH (available), meaning net positive suction head, depends on the relative height between the pump and the sump water level, the head lostes in the suction pipework ‘the vapour preisure and the velocity head in the suction pipe NPSH * 2, + po - Py ht ew ef 's the vertical height of the water surface in the sump above the datum. Thus if the water surface is below the datum, 2, isa negative quantity pS atmospheric pressure ws specific weight of uid a, ‘the fluid vapour pressure ‘hy 8 the head losses in the suction pipe vis the mean velocity in the suction pipe. suMP Usually 2 ied excavation of simple geometric shape adjacent co the pump intakes. Water enters the sump ether irom another chamber containing screens andjor flow contro gates, or direct from un incoming steam or culvert, Wate leaves the sump through short lengths of Pipe (othe pura, which may be suspended above the sump or connected to it through holes in che end wall 9 the sump. eress-sectional area of flow in sump (=W(C+ S)) cross sectional area of flow of restriction in approaches to sump clearance, the vertical distance from intake (9 simp floor bellmeuth diameter pump ine: diameter. or intake pipe diamete flow cate tubmergesce, the vertical distance from the intl tminimim wubmergence, usually detined as the submergence at which entrainment of ai by vortices starts tinear scab factor mean wiotity in sump sump vidih honzostaldistance from bellmouth perimeter to rear wall of ump 19 the water surface in the sump Summary ‘The problems involved in deciding the hydraulic design of a pump sump and intake are outlined Good design practice for a variety of pumping situations is recommended, as ate preferred designs for suitable situations. The circumstances in which hydraulic model tests are desirable ate defined, and gudance is gven on the conduct of such tests 1. Introduction 1.1 GENERAL The design of a pumping station involves many aspects of civil and mechanical engineering, ‘he hydraulic design forming only part of the whole process. The hydsaulic design deals with the channelling of liquids into the pump, the flow through the pump, and the discharge system An unsatisfactory hydraulic design of the intakes and sumps could have far-reaching ‘implications on te overall pertormance of the pumping station. The design of pump intakes and sumps is ametable to solution by hydraulic model analysis, However, without proper apprecistion of the design criteria, an indifferent fra design and layout often results, requir ‘ing extensive alte mons ¢o the model and considerable difficulty in achieving 2 satisfactory design, This publication deals only with the flow and control of water trom its entry into the Pumping station wp to its entry into the pump. The fluids under consideration are water and arr, the water being pumped and the air being above the free surface or, in some cases, being entrained as bubbles within the water However, the resuts wall apply ia principle to other Nuids used in the process industries as long a allowarce is made for effects arising from the difference in the fluid properties. Vis cosity and specific gravity are the most important properties considered. 1.2 EFFECT OF POOR DESIGN Poor hydraulic desgn of @ pump sump and intake could arise because of insufficient attention at the early design stage or because of site constrains. A sumreary ofthe posible consequences ‘iu shown in Tabie |, he fina result being that the operator of the pumping station must accep ~ the operational problems or take remedial measures In ther case, the costs can be substantial 1.2.1 Desirable flow Ideally, the flow approaching the intake section, whete the low enters a closed conduit, should conditions at the pump be uniform, seady and of single phase intake uniform Aow—the velocity, in magnitude and direction, of fluid particles isthe same at all points across the section considered steady Nlow-the velocity, in magnitude and direction, does not change with time single phase—there is no entrained air. vapour or other gases, Some departures from this ieal can be expected even for a well designed system. Boundary layers at walls produce some non-uniformity inthe wlocity profile. Smallscale turbulence and changes with time, for whatever reason, produce some degree of unsteady flow. However, the esign of the chanaels oF culverts leading into the sump, che sump itself with all other necessary structures (eg. perstocks. sereens and guide walls), andthe thape and siting ofthe intake should aim at producing this ideal at che intake cross-section, Particular care should be taken {0 position the stcueture with respect to the directionof approach so that the angular momen: um about the poist of intake is as low at possible (St item 2 of Bibliography). 1.2.2 Undesirable flow conditions at the pump intake 1.2.3 Discussion Any flow pattera which departs significantly from the one of steady uniform flow is undesirable Obviously, in practice, such departures exist It istherefore necessary forthe designer to know what degree of exiemal circulation, unsteadiness, non-uniformity and mixture of phases can be tolerated and what steps should be taken to obviate these poor conditions. The more common forms 0f these undesirable flow conditions are outlined in Table 1. When any ofthe effects listed in Table 3 occur in service ina pumping system, they probably aise from faulty orientation or design of the sump and intake, faults in the design or construction of the pump or from a combination of these. tn practice it can be very difficult to find the real cause of such wrdssirable effects, Pump manufacturers are very conscious of the problem and sive advice to potential customers about sump design. The manufacturers ae often prepared to undertake hydraulic model tests of non-standard sump arrangements remedial When poor flow conditions occur at a pump intake, the effects have to be accepted ‘measures have tobe taken. In ether case, extra costs are involved over and above those niginally estimated for the pumping station. Typically, these extra costs may be caused by 1, delays in commissioning the pumping station incveased maintenance during the life of the pumping station changes in pecformance or restrictions in the operating range of the pumps structural alterations in the sump to improve flow conditions retrospective model tests to determine the necessary alterations. (eon08a and ot acne 64 panen ry (Gatiooe ogo) sea tow ns ey a saat ny oy. nes por novsineg ad ays uo s1995}8 aygensapun asnea yorym du ur svornpuo moy jo Aseununs | ages 0 n ru pue pence Avid i sow i aye sos nd ; . os oo H {9 FS leona | TaN ah ie ox eH oe —_____i» ee no puE vaadu ayy ovUT dee s3tem (wou uaty ‘peau mon) ‘aus spin on sous open oq denen ete sy, mou vey stieyosip oso os peau wooteg | oor doom sqpadur ogy ‘soot }- ost wed put | (oy wupous “peat Lene) ou nou AN re ou “ nee ue ousuonsrew saumduns wpa Buie> 0) Jovepysa wis sea om ur apt aq uayjo eo Sues durnd My ‘soot - ‘001 (ou oy E04 WAH) smoly oda dung sopsyieraeiey: yi pe sadihi Guund jo AreUnunS 4 2.1.2 Pump types 21.3. Number of pumps Zone lit ‘The sump is vsualy rectangular and, except for sewage applications, has a flat floor. A sump ‘may serve mare than one pump. The intake may be a Suspended belmouth 2s shown in Figure 3(), oF it nay be built, wholly or partly, into a wal. The primary purpose of the sump i to provide stored volume and to damp out any exiremely distorted flow patterns arising from Zone Zone IV As shown in Figure 3, this is a short section of pipe between the intake and the pump impeller. In some casts, ths section can be faisly long and perhaps contain several bends and changes in scrosssection, The ‘low should always fill this pipe section to ensure that there is no free surface. ‘With a [ong inlet pipe, the flow patterns at the pump ate influenced by the design of the bends and the changes inthe pipe cross-section and are not influenced much by poor conditions at the Jntake. Long suction pipes are unusual since they introduce a large pressure drop with the con- sequent possibilty of cavitation at the pump. ‘The sump and insake should be designed for good fow conditions atthe intake irrespective of the type of pump. The selection of a pump, or pumps, fora particular situation involves 2 wide variety of incercelted parameters besides the obvious requirement of equeting the pump out- put flow to the design head conditions. As many of these factors have some beating on the sump and intake design, some of the more important aspects are considered here: 1 Rotodynamic pumps fall into three main categories—centrifugal, mixed Aow and axial (see Table2) ‘The pums would normally be matched (o ihe system so that it operates at its maxi mum efficiency point on the Q-H curve 3. Some pumps have an unstable region where the head increases with increasing flow. This region is not usable in a pumping system. 4, Some centrifugal pumps have an ‘overloading’ power characterstic where the power required continues esing as its low ineveases beyond the maximum efficiency goint Such 2 ceadition could overload the motor ané/or increase the flow to potentially ddangecous conditions for some systems. ‘The flowsuts off completely at some limiting value af Q before zero H xs reached in centrifuga pumps. This happens when complete cavitation occurs within the pump. (On the omer hand, axial flow pumps may continue delivery with fully developed cavitation. 6, In genera, mixed flow pumps have a steep Q-H cueve, maximum efficiency occurring at high lscharge 7. axial pumps can cause probiemts i tis necessary to run at zer0 or low flow as the pover requirements may be double the valu a itsbest efficiency point. 8. In ene move care is needed in sump design for an axis! pump than for 2 centcfugal ‘one, a5 th anil tvpe is more sensitive (0 inlet ow conditions. The double suction emltfags pump is the teast susceptible to poor iniake conditions. In practice tis adisable to nstall more chan one pump so that maintenance can be under. ‘aiken without mieruping the supply Often she mest suitable way of obcsining a vacuble supply of water irom a pumping station iso instal evera! pumps of differing capacities and to switch complete pump units (on 0 off as demand dictates. [Fa very fine control of ouput is needed then the pumps must be driven by a variale speed motor, which increases costs ad 2. Description of intake types 2.1 HYDRAULIC FEATURES OF THE APPROACH FLOW TO INTAKES. 2.1.1 General A typical pump intake and sump arrangement may be subdivided into four sections of zones layout Figure 3 shows sucha subdivision, together with ather typical features that are necessary for the operation ofan intake, Taking them in order these ave: Motor Mex tend Min waterlee 1 { O r a Discharge valves High level inlet ELEVATION Low level inlet Band screens Bellmoath 4 = 6 Discharge manifold Tyts || Wet wet! sump ! i | ez z ans i J +E t J Pe peastocke 1 i im a ~~ Taietd |“ TApproaeah Samp) ia) typical sump arrangement Gate shat Screens and raking equipment ——/ | =e ELEVATION Figure 3 ‘Sut trap: L Two examples of the sub division of pump intakes toh idoteehacbat Into functional zones #voU ini Zune £ ‘The warer is charnelled into the pumping station as free surface Flow or as internal flow hrough an inlet culvert, There may be several inlet channels, or the water may be taken from a aatural stream or iver. The final entry into Zone [1 i often through a conteal structure such as 4 penstock or we Zone if This contains «ers such as sereens, for removing solié matter ftom the water and pensiocks the flow into the approgriate sump (Zone II). and division wa lg:0 cont 2.1.4 Pump priming 2.1.5 Wet weil and dry well pumping stations 2.1.6 Bellmouth design Figure 4 Wet and dry well pump installations ‘Most pumping stations have between two and six pumps installed, with perhaps two or three pump sets being the most common arrangement. Suinps with seven or eight pumps are cecasionally found, but a more common practice is to subdivide a pumping station into two similar units Rotogynamic pumps do not start pumping unless the casing and the suction pipe are full of water before the pump starts, The level of the pump impelles must therefore be set below the Fowest pump stat water level in the sump, or separate provision must be made for priming, such a5 a rubsidity filling device or @ vacuum pump. A pump car be installed in 2 wet or a dry well. Figure 4 illustrates a vertical suspended pump Jina wet well anda similar pump in a dry well. In a dry well, the bellmouth may be direct in the wall or urmed down through an angle of up to 90° as shown. ‘The wet wal configuration has the great advantage of simplicity and reduced civil ‘enginecring costs, and is widely used, However, maintenance can be a problem as it involves 4de-vatering the sump of lifting the pump unit out of the well The wet well arrangement i very suitable fr intermittent duty such as for pumping storm water where the wel will be dry fa ‘The dry well configuration i usually used when reliability isa prime requirement, since the pump can be reached and maintained at all simes. The ‘torned-down' tellmouth of Figure 4(€) 2 popular arangement in sewage applications since it lows + lower water cover in the sump than a horizontal incake (Figure 4(2)), and in general is less prone (0 vortex action at soma water level The main purpose af a bellmouth entry to a circular pipe 5 10 abviace the flow separation which occurs with sharp edged inlet (see Figure 5), This ensures that te Now is uniform throughout the intake cross section (assuring that the approach flow in the sump is reasonably uniform) and thatthe Read losses associated with the Intake are minimal For animale ina vertical wall, replacing the sharp edge by a radius equal to about one tenth ofthe pipe diameter i che minimum required. a freely suspended betimouth would need a lager radius to cater for the flow coming from behind the bellmouth, In practice, most pump manufacturers specify belimouth shapes which are usually based on a querter of an elipse. The bellmouth diameter D is usually inthe range | Sd to 1 Bd, where dis the inet pipe diameter eeeeeet - Motor a 5 g a) Wet well {b} Dry weli ~ horizontal (©) Dry welt - flow intake tumed-down inceke Flow separates from sharp corner Ieaving recirculation zone / i Turbulence downstieam as Jet formed at vena eontracta expands to fill pipe A Ve TT Ti Yena contracta Sharp edged intike Normal range of Did is Sto 1.8 Figure 5 No separation HRD>O1 i Radius at intake ‘Typical bellmouth design based on quarter ellipse (major axis = minor axis = 2) Bellmouth diameter Belimouth design Ded+2a+2) AA designer must understand effects which the commonly used component parts of « sump have 2.1.7 Hydraulic aspects of other on the flow patterns. The head loss is often of mina: importance compared with the distr- sump components ‘bances caused by these components. For example, the head loss through a penstock opening resent only a few centimetres difference in water level, but the resulting jet in the may Sump could introduce severe swirl unless suitable devices are used to break up the jet. Appendix 2 deals with low patterns and losses of sereens, diffusers and jets At the intake section, a8 defined in Figure 1, che flow no longer has a Free surface, and some of the poorer flow conditions originating from the approaches to the sump may be improved bY the confinement of the internal flow section to the purmp inlet lange. Large-scale turbulence may be damped and distorted velocity profiles made more uniform, but problems arising (rom air entrainment and swirling flow remain unaltered unless the internal flow section is very long, 21.8 The devetop- ment of the flow patterns from the intake section to the pump inlet fange— fone ly Itis important that the design ofthis internal flow section should not introduce new preb: lems. I there ae srupt changes in pipe crossecon area and very sharp bends, the wlodi profile deteriorates ang turbulence and unsteady flow oscu,lem 12 of the Bibliography Should be consulted fr the more detaled aspects bt the general principles canbe summarised = |. The crossection ares should reduce unifomiyin the diction of flow 2, Bends should have as large a radius of curvature eletive tothe pipe diameter a8 space allows. 3. Straight hngths of pipe, atleast one half of one pipe diameter ia length, should bein serted between any two pipe sections which involve changes in flow direction or velocity (e.g. EF in Figure 6). 2.2 CLASSIFICATION OF PUMPING STATIONS AND INTAKES BY USE ‘The following list ves typical applications of intakes. It is obviously impossible to comment On all the different features but some of the more commen aspects are mentioned. Pump inlet fangs x Plan on XX Figure 6 A Rectangular section intake DE Constant area bend AB Radiuson corners EF Straight length Typical pipework for BC Converging section FG Conical converging section pump not sited directly —C_ Square cross section G Ramp inlet Mange adjacent to intake CD Squweto-circular section 2.2.1. Water supply, The pumping tation may be fed from a reservoir with an almost constant level supply, or from Untreated water (from a ver witk a large range of water levels. The latter case gives rise tothe very common problem river, canal or reservoir of trying to withdraw water from 2 sedimentladen river without getting the sediment into the to treatment works, or sump and intake. Sereens are always used, and are either fixed bars inclined to the vertical and to another reservoir or cleaned by kand or mechanical raking or band screens with automatic cleaning. The space be- river) tween the sreen bars usually ranges from 5 to 50 mm with the object of preventing debris from enceringthe sump. Screens alone will not prevent sediment entry Tne pumping station will probably be faiey Large, with multiple pumps including at least ‘one stand-by pump, and may have to cater for changes in inlet water level 2.2.2 Water supply, Screens are normally unnecessary in this type of intake. treated water {from treatment works to a istribution network, or to another reservoir ‘of water tower) 22.3 Stormwater Coarse screens re needed to keep debris from the pump intake. Pump duty is intermittent a {froma culvert or a wet well suepis practicable and relaively cheap sump into a river, the sea, a reservoir or hold ing tanks) Factors to consider are 1. requted discharge capacity an retention time 2. numer of pumps required 3. dischaige capacity ofeach pump ‘operating evel for each pump. desirability of fixed or variable speed pumps minimum cycle time for each pump. Lf variable speed pumps are used, the number of starts per hous ceases to be of signifi. cance and imum sump volume is governed by the control system for varying the pump speed, The wate; level can normally be held to wrhin $00 mer: ofa set point for this type of conta, 3.1. MINIMUM SUMP VOLUME FOR ONE DUTY PUMP SYSTEM (FIXED SPEED PUMP) may be shov (ze Set sump is exactly half the pumping rate (Qp) and thatthe cycle time (7) is determined as follows: ret 2% Hence for a frequency of 10 starts/h (le. T= 6 min) = $x pump discharge/min, 3.2. MINIMUM SUMP VOLUME FOR MULTI-PUMP SYSTEM (FIXED SPEED PUMPS) 4s fora single pump unit, the volume between siop and start is related to the capacity of the pump started by av Q ‘Additiond capacity is required to allow a vertical distance of 1$0 mm between the start cor stop levels ofconsecutive pumps. T For some applications such as sewage, which may become septie, there are restraints on the maximum volume of the sump. 3.3 DERIVATION OF FORMULA FOR MINIMUM SUMP VOLUME Suppose purpieg rate inflow rate Volume Time between sarts Then net flow vien not pumping Then net flow vhen pumping ¥v Time taken tof] = = = v Qp - Qr Time taken toenply = ¥ Time forcomplete cycle = T= — % %- 2 O10, - O09 1, QelQp ~ 20) | OpQr - OF 7 Op YO, Now Q, and V are constant and f (frequency of starting) Differentiace both des wet to Qr af _ Op = 20 4” VO, A ©. ovten g, = 22 4, 2 By inspection thief 1 maximum value for /and by substitution ae o when Tis minimum, 4. Particular aspects of sump design ‘The examples of good and bad design details given in this Section represent the accumulated experience of designeis and operators of pumping statisis over many years and are based on ‘model test5 and observations at full scale. In most instances, there isa reasonable explanation o| why particular arrangements aze hydraulically good or bad, and the explanation does point to general design rules hat should be followed. One aspect of sump design is that, in practice, the designer may be forced by external circumstances, sich a land availability, ca use hydraulically poor layouts. These conditions can be improved by the we of such devices as baffles or sereens, but their effectiveness would have to be studied in model tests. Unfortunately, arrangements similar to the examples given in Section 4.2 have to be used sometimes, and the designer may aeed to incorporate these special devices and to use model tests to derive catisfactory flow conditions. 4.1 GOOD SUMP DESIGN Examples of good sump design practice are illustrated in Figuves ? to 10. The preferred designs ~ given in Section 5 define the basic geometric parameters of good sump design, but the main poiis to remember vhen considering the design of the whole sump system, Zones I, Il and UI (see Section 2.1), are 1. The flow aporoaching the pump inteke, whether a horkzontd or a vertical bellmouth, should be uniform across the widih of the channel 2. The kinetic energy associated with changes in level, whether down a slope, steps or a wei. should be dissipated well away from the final approach to the pump(} Obstructions, suchas supporting pillars, should be steamtined to obviate flow separation rear the intake section, 4. Areas where stagnant water could oecur should be filled in Average velocities must be Kept low about 0.6 ms maximum for flow into the pumping station and 6.3 m¢ maximum for the approach flow to the belimouth if there are no solids ‘a the water, For stwage, meen velocity should be greater than 0.7 mis at all sections, teashracks 6. Screens used for ssh exclusion also have 2 use as flow straightening sceens. Si and band screens so that they sesve this dual function where possibe X = Horizontal distance from bellmouth to rear wall C = Height of beLimouth above sump floor, for vertical intake = Height of water surface above belimouth D~= Belimouth outer diameter = Sump length, with uniform cross-section, measured from rear wall to fist major upstream change Of cross-section Wy Lateral width of samp Yq = Mean velocity in sump Q= Flow rate Good features Bellmouth near to sump floor, C=4D Intake close to rear wall; X°4D Flat sump fioor Width about 2D; up to 3D acceptable Deep water, S large and at least greater than 1D Long approach from upstream obstructions; L large and at least greater than 4D 7. Mean approach velocity should be low; Beet ey 2 shoutd be less than 0.3 m's cseerereene WSO) LLL THE. Figure 7 The main aspects af a good single cell sump ‘The clearance ofthe bellmouth from the floor should be in the range 40 to¥D. If C is less than 4D, the flow arei under the lip of the bell is less than the flow azea into the bell and the result ing deceleration ‘auses unsteady flow in the bellmouth. If C s greater than D there isa tendency for the upward component of flow into the bellmouth to become unstable and promote swirling flow. The proxisity of the end and side walls to the bellmouth inhibits the production of swirl ing Mlow and rar=x formation. Good features 1, Filinsome of the dead space behind bellmouth, either with simple fillets or more complex Formwork Keep distance of rear wall and other fillets from Up of bell- mouth (ie. X,Y and 2) within the range 4D to4D. Line of pumps Line of symmetry Zone Ill ‘otuttiple pump, i ‘open sump) } | Good features Figure 9 1, Inlet to samp should be normal to the line of pumps, 2, Inlet to sump should be along the General layout for inlet line of symmetry “one 1) to multipie 3. Hg should be less than 1.2 ms pump sump B= Pump spacing W= Width betwees spitters T= thickness of splizuss = Length of splitten Good features Figure 10 4, B should be 2 co 24D, although satisfactory conditions can be obtained up to 4D if the inereased spacing iS:equired for access to the motors. General layout for ‘multiple pump of pumpeare opering, st sump (Zone 11!) rma ne 2 2. Open sump with sone in-filling behind the pumps, 3. Ifthe flow distnbution is skewed or from the side, and when lest than the maximum number may be necessary’ Ii splitters are to be used, £ should be not 4.2 UNSATISFACTORY SUMP DESIGN 4.2.1 Main geometric Some aspects geometric design which can Tead to poor sumps ate summarised below and features leading to unsatisfactory flow conditions 42.2 Undesirable hydraulic conditions in a sump Alustrated in Fgures 11 t0 17 1. underszed penstocks and contol gates or valves 2 abnuo\ changes in flow direction (eg. sharp sores) 3. eapily diverging passages (cg, diffuser wit too large an angle of divergence) 4 steep dope \weies with no provision for dissipating the energy of the falling nappe 6, dlun: pias, piers and guide vanes any ésign, or mode of operation, which leads (0 asymmetric distribution of the flow inte ihe sump inlet te the sump above the water level. ltems 1,2, 3,6and 7 may cause swirl at the bellmouth, and in extreme cases may result in the formation of airenttaining vertices and submerged Vartives. Items 4, 5 and 8 can prod eration, while ems 3, 4 and 5 can cause surging within the sump. The object ofa sump and its approaches isto provide storage and good Now conditions to the pump. Ifthe deugn incorporates some poor geometric features, undesirable hydraulic condi ‘ions may oecurin the sump, such as these listed telow 1. jets (hgh velocity flows discharging into. stagnant or slowly moving body of simtlar fluid) ae particularly undesirable when they impinge on support columns because large, unsteady eddies form as downstream wakes 2. cegionsof separated low 3. high velocity flows (greater than 2 mis) 4 unsteaty flow 5. large su 6, free fling Muid (e.g the nappe of a weir) L 1 + Positioning the intake in the middle of a large sump is nor recommended, (However, the number of starts per hour may limit the ‘minimum sump size so that a single pump may need a large sump.) ‘Asuinp which is lage in relation to the bellmouth diameter is susceptible to large: scale circulation within the sump with a high degree of switl at the pump inlet and probabiy recult in air entrainment due to vortex action, Figure 11 Unsatistertory sump, large sumo relative to bellmouth size ae O — ce (SO Penstock \ Penstock See a) (ey ‘Thejets produced by the pipe inlet or penstock will cause very uneven flow distribution at the bellmouth even though the mean velocity is below the recommended 0.3 m/s ‘The bellmouth is comecty sited near the d wall of the sump, b ih is far 00 short to ensure the highly distorted velocity profile produced by the penstock Unsatisfactory sump, high “= —— will not affect the flow into the pump and velocities in jets cause excessive swirl Figure 12 1 @ (e) IPGGLOTY SUMS, Inert isfacto ales tothe sump in the form of falling jets, ether overs weir a) ar over the ead of e culvert water feline fromm high (o), wit enan au ava the sump. If the intake is unde: the fallag oto coe wo at levels & ‘enter the pump. cat Figure 14 Unsatisfactory sump, side offtake from ‘main channel Figure 15 Unsatisfactory sump, pumps in tine with flow Figure 16 Unsatisfactory sump, large divergence angle in approaches to sump Le WML j; o— eo + ‘The short chu nber in the side of a channel will cause violent swirl around the intake bellmouth Unies L is greater than 8D. oe | ; * : Ce = 6226 || Nor recommended (unless L > 8D and W > 3D and Yq < 0.3 mis ‘The wakes from upstream intakes will have serious effects on the performance of succeeding intakes No! recommended Foré > 20° (@ = 60° as shown) This shows an attempt to feed Mow normally to the line of the pumps. Uniform approsch low cannot be achieved with the very wide angle of divergence from the inlet culvert to the sump. Figure 17 Unsatisfactory sump, side inlet with short splitters Side inlets are notiecommended. The short splitters between each pump are not recommended 4.3 MODIFICATIONS TO IMPROVE UNSATISFACTORY SUMPS There are thrte couses of action which can be taken to improve an unsatisfactory sump design | Increase the submergence. This is the simplest action in principle, but in practi it can be vary eapensive beeause id usually means a tage increase in excavauion and civil ‘engines costs to deopen the sump. In the ease of very poor flaw conditions to the intake, the submergence ratio, $/D may have to be increased many times abave the base minimum, Reshape the approach flow passages. It is possible o make significant improvements {oan otherwise poor arrangement arising from a limited site for the pumping station However, is almost impossibie co affect this reshaping without the aid of an hydeau lie model Use anti-vortex devices. Since the first signs ef poor sump performance are usually the occurrence of vortices at the intakes, itis sometimes satisfactory to add devices similae ‘o those stown in Figures 18 and 19. Cones and splitters placed 2t the bellmouth can, reduce switl and submerged vortices (Figure 18). Giids and extension plates over the intake can reduce the tendency to form air entraining vortices (Figure 19). However, sreat care » needed in the design and specification of these devices if they are to be effective. Consultation with the pump manufacturer is essential and model tests are probably required. Figure 18 Modifications to the basic intake design to reduce the tendency for swirling flow and submerged vortices Figure 19 Modifications to the basic intake design co reduce the tendency to form air entraining vortices cood fen ones orion contons (np manatnen ston sie [,G toresises —n seen Grid above intakes reduces vortex development ELEVATION | PLAN (a) Grid thove torizontal intake Mean veloatty at int section co be torizontal fess thas0.6 mis._ jorizontal plate over original vertical intake reduces vortex development. Also reduces “quantity of fish entering intake, (b) Plate over wertical intak 2.2.8 Sewage (un- treated from a cul vert or sump to sewage works} 2.2.5. Irrigation 2.2.6 Cooling water (from sea, river or lake to sea, river or take} 2.2.7 Dock impound- ing or dewatering 2.2.8 General industrial use (cooling water and process water) 22.9 Land de 2.2.10 Gravity intakes nage A typical raw sewerage pump sump is a minimum size to keep the approach flow velocities high ‘enough for the solid matter to remain in suspension, ut compacible with required stored volume. Stagnant ateas must be avoided to prevent settling of the solid matter, and quite ela: borate benching and corner filets are often used. Dry well with tumed-cown bellmouth: through the wall are common features. Submersible pump and motor units are becoming ‘common for sizes up to 200 mm in diameter. ‘The designs are similar to those for water supply. Uses include power stations (oll, gas, coal and nucle), chemical plant, and liquid natural gas plants. Pump sizes re up to the largest manufactured. Installations very from vertically sus pended bowl pumps in wet wells, 0 vertical or horizntal pumps in siver and reservoir embankments with the pumps installed in dry wells. Travelling screens with no cross connec dons between pumnps are commonly used. The sump is formed either in the dock floor or at thesid of the dock with culvert or pipe connections. The design of gravity drainage channels in the dock floor is an important factor for dewate Many varieties of sump arrangement are used. Self-contained unit: with automatic control are often sited in remote places. The design of soreening arrangements needs careful atiention because of problems caused by the accumulation of weeds, No pumps are needed but problems of air entrainment and swirl have to be solved. Typical ages are 1, Hydroeleexic power plant intakes Pumped storage hydroelectiie power 3. Lock fling and emptying 4, Culvert envances 5. River intales—for isigation, water supply 6, Intakes to tipply pump forebays or sumps --in many eases water flows from a river or theses, by gravity, thiough a culvert into the main sump. The intake at the seawari (or river) end of te system needs simple design only and in many cases the eects of any aie entrainment or swat are not transmitted zeros the sump to tte pump. 3. Optimum sump volumes 8 During startup of at electric motor, higher curcents then is normal renning are drawn from the eleciric supply. Thiscauses an instantaneous disturbance in the supply, cesulting in a voltage ip, an generates considerable heat energy inthe motor. These effets put a constraint on the ‘maximum number of starts ina given tne and hence 09 the minimum sump volume, This must be remembered whex deciding the optimum sumnp dimensions fos goad flow conditions 5. Preferred sump and intake designs 5.1.1 Wet well arrangements Figure 20 Basic design for single pump, wet well sump with a vertical intake tis relatively easy to determine a standard design for single sump, but 1 becomes much more difficult for multiple pump arrangements because of the many ways of arranging pumps in a ven sump. The multiple pump cases shown are either of unitised design (i. placing several single pump cells sce by side) or all the purnps are together in an open sump, The best layout fora given pumpingstation may be different from the standard designs shown, but the peine ples involved provide che right basis for the design. For pumpi stations which use radical departures fcom the standard designs, there is usually a need to finalise the details of the sump geomeliy by experiments in a reduced scale hydreulic model, Section 6 gives dexails of the principles and praciice of modelling pump sumps. 5.1. SINGLE PUNP SUMPS A basic design fora simple rectangular surnp suitable for vertical spindle axial or bow! type ‘pumps is shown in Figure 20. The dimensions are given in terms of the bellmouth diameter D, since most manufaciwers use similar ratios of bellmouth diameter to pump inlet diameter, 'ypicaly this atio Did is between 1.5 and 1.8. Tolerances on these recommended dimensions sannot be defined, but they are not critical 10 about 20% The distance X = 3D, between the bellmouth and tke back wall, may have to be increased for medium size pumps (say 3 m*s f0 7 m?/s) to provdeaccess for maintenance, =a) oR & on It may be conmenient to make the end wall in the form ofa circular are rather than 40 Use comer fillet. As ongas the principle of about 4D minimum space between the bellmouth and she wall is maintained, the design proves satisfaerory. Thus, in Figure 20, (b) and (c) ate alterna "ves co the standard shape shown in (a). These designs re applicable if these is uniform steady tingle phate (low though the channel cross-section upstream of the belimouth as described in Section 1.2.1, The ditance of this plane of uniform flow from she bellmouth cents line i bout 3D. Radius =D fe} aide 4 Plane of uniform flow S= HD (min) 5.1.2 Dry well arrangements 5.1.3 Mean velocities Figure 21 Basic design for single pump, dry well sumo When siguficane variations occur in the velosity and turbutence distribution at this section, all the problems discussed in Section 3 begin to oscur. For mildly non-uniform conditions (which, inprciee, occur in many sumps), remedial measures include increasing the submergence (depth of liqui over the bellmouth) and by the use of further structures such as cones, splitters or eroses underneath the bellmouth ‘The basic acrangement should be used ifthe intake isin the end wall ofthe sump. For a horizor ‘al intake (Figure 21(a)), the corner fillets are omitted. The bellmouth may be omitted over pert of is crcurference thot allowing the intake tobe set with its cente line $d above the rump flor. ‘The tained down bellmouth shown in Figuee 21(b)is the more common arrangement ‘Assuming 2 typical belimouth diameter to pumnp inlet diameter of Did = 1.75 and a pump inlet ‘mean velocity of 4 mys (which is typical for a modern axial flow pump), we have Table 3 Typical mean velocities in @ basic sump {Section [Mean velocity mis Pump init) 40 | Bellmouth (D) 13 | Approach channe! 03 @Dx HD) Asa rough guide, the mean velacity of the flow approaching a bellmouth intake should be 0.3 ms or less. Minimum water lve! janis water evel 1 y YZ s=i00 + y rinimam ot =D i 3 Perea ose tenmuy i ft ae | TET z h 7 beet a D x EE, ALL ore . 7 wal To wap! ae wero! sah wero 1 Y DTT TT 7 Te 4a) Horizontal intake (b) Turned-down bellmouth 2 5.1.4 Length of approach channel Figure 22 Recommended spproach channel fengths In Figute 22(). an almost full-width, band sereen is shown which helps to smooth out any up- ‘stream flow disturbance and so L may be relatively short. The more usual (UK practice) example shown ir Figure 22(b) with a lager aree contraction needs a longer approach length. If the area ratio, a/4 is less than about 0.5, or the flow enters the channel from the side, some form of baffling is needed and the length £ depends ery mach on the effectiveness ofthe butfles or flow sceses, Model tests are advisable to determine optimum approach length and ball arangement, Table 4 Minimum sump lengths { ai LD Comments 1 4 |Full width band sereen ao | | | obstructions i : 08 i 6 Asabove, some obstruction — | | i | Gee Figure 22(a)) 1 i os 10 Typical UK band screen (see : | Bigure 2206) {less than os - Baifles needed aA = 08 (a3 shown) | LE 6D asstown) | pe ee (Sump floor ¢0 be level for this length) @ aT | tions ¥ te la A. = a | } ! L(= 100 as showa) I ‘(Sump floor to be level for this length) i oy 5.2 MULTIPLE PUMP SUMPS : 52.1 Wet well ‘The basic desges shown in Figure 23 provide twoalternatve ways of installing three pumps in arrangements a sump where uniform steady flow occurs just upstream of the intakes. Where the approach flow i less uniform than the ideal case, Figure 23b)is preferable to Figure 23(a). These designs give the prefecred way of defining the final part of the sump, Zone Ill However. in most cases this information wil be insufficient to produce @ complete design since it ignores the approach to the sump, “Zone I’, other than tostate that the flow must be uniform and steady. The sump designs given in Figure 23, show three pursps, but are suitable {or other numbers af pumps By incceasing ot reduring the width and Keeping similar inter-pump Spacing Great cae is needed in applying he opensump to complete system. This point is discussed zguin on Section 5.2.3 f uniform flow (2) Open sump {h) Unitsed sump Top of dividing = 1 walls above max satet level Figure 23 Basic sump designs for multiple pumps, wet well arrangement 6.2.2 Dry welt arrangements 5.2.3 Approaches to the sump Figure 24 Examples of multiple pump sumps, including the appraach works ta the surmp (plen views) ‘The wet well standard designs shown in Figuce 23 can be easily adapted for dry well installation of the pumps. The plan dimensions should be the same whether the intake is a turned down bellmouth (Figure 4(c)) or a horizontal intake through the end wall (Figure 4(b)), The corner fillets or radi need not be used if the intakes are horizontal. For a given depth of water above the highest point of the intake bellmouth, 2 honzontal intake in the end wal gives slightly better low concitiont than a vertical intake, However, a vertical intake gives «Tower minimum operating water depth than s honzontal incake, and this sascounts for the common use of a tumed-down bellmouth for éry well installations More varationis possible in the positionig ofthe pumps, and the type of pumps, in 8 dry well than in 2 wet well, but the main advantage ofa dry well isthe ease of undertaking pump maintenance Examples of muttipk sump design which include the approach to the sump, are shown in Figure 24. These arenot basic designs, but they indicite ways of incoxporeting the open sump Gesign and the unitied design into an overall system. The problem of providing steady, uniforms low to 4 multiple simp is made more difficult because, in the majority of applications, the intakes must function satisfactorily with all possible combinations of pumps in operation. mf 20° max Downsione not | wo ‘more than 10” Level floor (0 Beample of ope ump Sven. {4 L( 10 as shown) > De oases emcee go 7 Penscacks (b) Example of un csed somp design The flow atterns in an open sump vary appreciably as they depend oh the number and

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