ICCBT2008

Application of Computational Fluid Dynamics (CFD) in Physical

Model of Pump Sump to Predict the Flow Characteristics

Mohd. Remy Rozainy M. A. Z.*, Universiti Sains Malaysia, MALAYSIA

I. Abustan, Universiti Sains Malaysia, MALAYSIA
Abdullah. M. Z., Universiti Sains Malaysia, MALAYSIA
Mohd. Ashraf M. I., Kyoto University, JAPAN

ABSTRACT

This paper presents the application of computational fluid dynamics (CFD) to predict the flow
characteristics in physical model of pump sump. Firstly, the simulation setups for the
computational method processes by generating the computer model using the Gambit pre-
processor. The setup model will be exported to the software; FLUENT code which is a solver
for numerical simulation and accomplished with finite volume method approach. Further,
series of physical experiments and numerical simulations are used to determine the use of
commercially available CFD software as an alternative to the used of physical models. In this
study, physical experiments were set up at Mechanical Services Department, Drainage and
Irrigation Department (DID), Ipoh, Perak. The model configuration and scale were selected
to simulate experimental conditions in the physical pump sump model. This paper discusses
on flow condition at 15L/s and the capability of the simulation technique to predict the flow
characteristics at higher flow rate (30L/s) with minimum water level of 0.18m. In general, the
result shows a similarity between numerical simulation and experimental. Thus, future
research is needed to ensure the capability of the CFD usage in pump sump design.

Keywords: Computational fluid dynamics (CFD), physical model, pump sump, vortex.

*Correspondence Authr: Mohd Remy Rozainy M.A.Z., Universiti Sains Malaysia. Tel: +6045996265, Fax:
+6045941009. E-mail: remyrozainy@yahoo.com

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Application of Computational Fluid Dynamics (CFD) in Physical Model of Pump Sump to Predict
the Flow Characteristics

1. INTRODUCTION

A number of deficiencies and problem with vertical pumps are often related to sump design
rather than mechanical imperfections. When a pump intake bays are not properly designed,
severe swirling flow problems may occur in the pump bay. Particularly, a swirling flow
occurs when pump-approach flow distributions within the intake bay are not uniform
regardless of its origin. Swirling flow, in general, results in uneven impeller loading as well as
formation of free-surface subsurface vortices, all of which are detrimental for proper pump
operations. In the case of pump intake with multiple intake sumps, swirling flow may be
produced by uneven pump capacities even there is no cross flow in front of the intake (Ansar
et al. 2002). Common pump-operating problems, such as impeller cavitations, bearing wear,
noise and vibration problems are often caused by swirling flows (Ansar et al. 2002,
Constantinescu and Patel, 2000, Dicmas 1987, Warring, 1984). There is agreement among
researchers as to the causes of the pump problems and deficiencies. The common of the main
problems are summarized as follows (Larsen and Padmanabhan, 2001; Karassik et al., 2001
and Nakato, 2003):

• Free surface vortices – the air may draw from the surface into the pump. These types
of vortices can cause unbalance loading of impeller, periodic vibration and therefore
reduction in pump capacity.
• Subsurface vortices – which may emanate from floor, site, back walls or combination
among them. These can cause vibration and cavitation that may reduce pump
efficiency.
• Pre-rotation – flow entering the pump which change the angle of the attack of the
impeller blades from the design value and may effect pump efficiency and lead to
cavitation.
• An uneven distribution of flow at the pump throat which may results in unequal
loading of pump impeller. This action will lead to vibration and unbalance loading of
impeller.
• Cavitation that can cause damage on the underside of mixed flow impeller.

These problems encountered in the pump intake will affect the pump performance and
significantly increase the operational and maintenance costs. In order to identify sources of
particular problems and find practical solution for it, the usual approach is to conduct the
laboratory experiments on a scaled physical model. The problems are already there; however
the solutions are still the matter. The main concern and challenge in this study is to understand
the flow characteristics. These results will be compared with the computational result by using
the Computational Fluid Dynamic (CFD), FLUENTTM software. In this paper, computational
fluid dynamics (CFD) model for pump bays had developed and used two-equation turbulence
models. The numerical model predictions with the k-ε turbulence model were compared with
the experimental data from a simple pump sump model.

2. EXPERIMENTAL SETUP AND METHODOLOGY

In order to asses the applicability of CFD, it is necessary to have some experimental data
which can be used to validate the CFD predictions. Experimental studies on the formation of

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 Mohd Remy Rozainy M.A.Z et. al.

the vortices in a simple pump intake model were conducted at Mechanical Department
Services, Drainage and Irrigation Department (DID), Ipoh, Perak. The experimental setup and
procedures are presented in the next section.

2.1 Experimental Setup and Flow Conditions

The experimental setup, consist of two bay of pump intake model was constructed using
Perspex and steel. Plan and profile views of the model are shows in Figure 1(a) and 1(b). The
model consists of 3.054m long, 0.675m wide flume with 84mm diameter, D1 pump intake
(suction intake). The geometry of the channel was designed based the standards
recommended by the Pumping Manual (Warring, 1984). Water is recirculated from the pump
intake to the inlet through a centrifugal pump and D2 of 80mm PVC piping that provides
steady flow rates of 15L/s.

upstream downstrea upstream downstrea

m

Water D
AA AA
600

s
h

D
s – Submergence (a) (b) c
Floor
h – Water level
c – Clearance

Figure 1. Dimensions of typical pump cell (a) Plan (b) Profile

2.2 Velocity Measurement

Velocities were measured using Valeport Velocity Meter (VVM). This probe is comprised of
an acoustic sensor. The velocity was measured at the center of each velocity node. There are
162 nodes of velocity measurement for a single run of the experiment. Figure 2 show the
location where the velocity data were obtained. Based on the Figure 3, it can be seen that the
positions of the points are fixed at three depth levels (upper, middle and lower). Columns A -
D, E and F - J show the points at the intake, sloping and inlet sections respectively. In all, 72
measurement points are at the intake area, 15 measurement points at the slope and 75
measurement points at the inlet section. The observed measurement points are concentrating
in the intake section. Since, the flow distribution is more significant in this section. The
velocity at the back wall to the bell mouth could not be obtained due to the restriction of
space. The probe was not able to fit into this confined space.

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Application of Computational Fluid Dynamics (CFD) in Physical Model of Pump Sump to Predict
the Flow Characteristics

2.3 Flow Measurement

A Thermo Polysonic Flow Meter (TPFM serial No. 72/3/34811C) was used to obtain the
desired flow rates in the physical pump study. The transducers are suitable for most plastic,
metal and concrete lined pipe. Flow is drawn through the external circulating pump into PVC
pipe that are connected to an Ultrasonic Flow Meter detectors. The water flows through the
control valves that lead to the intake structure. The flow reading was checked before, during
and after velocity measurement were conducted. This is to ensure that the flow was constant
and did not fluctuate more than 5% during the measurement readings. If fluctuation occurs,
the butterfly valve was adjusted so that the flow rate was within the required range.

A B C D E F G H I J

(a)

(b)

Figure 2. (a) Side view, (b) plan view of velocity measurements points

2.4 Flow Observation and Visualization

Final assessment involves an observation and visualization of the flow distribution in the
pump intake. This is done with the aid of water dye tracer, which gives good insight on the
problems that may occur with the flow distribution. Dye was injected in numerous locations to
gain a better understanding of flow distribution approach in the pump intake. The dye was
dosed at the water surface, intake wall, intake floor, intake entrance and under the bell mouth
so that visualization of the flow distribution can be made. The occurrence of surface vortices
and subsurface vortices in the sump intake was noted. Vortices attached to fixed boundaries
below the surface are difficult to detect and may require a careful search with the dye tracer
technique (Carriveau and Baddour, 1988; Larsen and Padmanabhan, 2001). Velocity
measurement, observations and visualization made with dye injections will be discussed in the
result section.

3. NUMERICAL SIMULATIONS

The numerical simulation has been made after the completion of experimental measurements.
The simulation has been made using CFD code i.e. FLUENTTM 6.2 software. The FLUENTTM

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 Mohd Remy Rozainy M.A.Z et. al.

model serves as a tool that discretizes and solves governing equations for specifics geometrics
using a set of finite volume method. The problem solving steps in CFD analysis are
summarized in Figure 3. The boundary conditions applied once similar condition as in the
experimental setup. The mesh model was divided into three sections. The first section
contains the area started at the entrance of the sump (inlet) with distance 2m. The second
section of mesh model located at the slope area with distance of 0.554m. The last section is
intake section that located 0.5m from end wall of sump. For the first and second sections the
mesh contains 183,854 elements. For the third section the mesh contains 306,750 elements.
Figure 4 shows the surface and the volume mesh of the sump intake.

Figure 3. Problem solving steps in the CFD analysis

Figure 4. The surface and the volume mesh of the sump intake

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Application of Computational Fluid Dynamics (CFD) in Physical Model of Pump Sump to Predict
the Flow Characteristics

4. EXPERIMENTAL RESULTS

4.1 Velocity Distribution

The velocity distribution of water inside of the pump sump with flow rate of 15L/s at water
level 0.18m is shown in Figure 4. The AVS 6.0 software was used to show the contour of
velocity distribution in the sump intake. The velocity value that entered the inlet archived
0.332m/s to 0.390m/s. Results show that the velocity was consistently distributed from
Column A to Column E at each water level. Further, the velocity distribution was found
higher at the upper levels of the measurement points if compared to the velocity distribution at
lower levels. In this section, the frictions effect between water and floor of the sump is
expected to be the major factor. The result in Column F shows that the velocity distribution
was rapidly decreasing. This situation occurs most probably due to the change of flow
distribution that occurred within the area of the sump intake. Similar as before, at Column G,
the velocity distribution (light blue) was higher near the top of the sampling area compared to
the velocity (blue) at the bottom of the sump. Further, a similar phenomenon was not observed
in Column H, I and J. The velocity distribution at the lower level (blue-light blue) was slightly
higher compared to the velocity at the middle (blue) and upper level (blue). This result
indicates the suction effect that is produced during the pump operation.
Upstream Downstream
-3
A B C D E F G H I J m/s (x10 )
I
II

III
IV
-3
UPPER LEVEL m/s (x10 )
I
II
III
IV
MIDDLE LEVEL -3
m/s (x10 )
I
II
III
IV

LOWER LEVEL

Figure 4. Contour of velocity distribution of experimental result in the pump intake

4.2 Visual Observations

The initial location of the vortex is shown by the “o” and the line illustrated the typical path of
the vortex as shown in Figure 5(a). The visual observation of the vortices formed at both sides
of the intake revealed the symmetrical position of the vortices. The vortex Type 5 was
observed consistently with the addition help of dye tracing technique. Further, the vortex Type
5 is pulling air bubbles into the suction intake, for a long period of time. The occurrence ofthis
type of vortex are forming and breaking more than 30s. These could permanently damage the

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impeller of the pump. This problem will lead to the decreasing of pump performance and
efficiency. It also could cause high maintenance and operational costs (Karassik et al. 2001).
The positions of subsurface vortex are directly under the suction intake (bell mouth). This
subsurface vortex formed in 10s to 15s cycles as a fine threadlike line (Dicmas, 1987). This
action will further affect the optimum of pump performance because it reduced pressure in the
vortex core that cans possibility increases the cavitations. The submerged vortex cavitation
when it interacts with the pump impeller will affect the pump’s reliability. Furthermore,
strong vortex causes vibration and noise in the pumps operation (Nagahara et al. 2003).

upstream

Flow
Surface
vortex
Floo
Type 5
Sidewall 1 r Sidewall 2

(b

Suction
intake
downstrea
(a) Subsurface
vortex

(c)
Figure 5. (a) The Formation of vortices exists in physical experiment (b) Surface vortex and
(c) Sub-surface vortex

5. COMPARISON OF NUMERICAL MODELING WITH THE

EXPERIMENTAL RESULTS

Simulations were run utilizing one flow conditions. The flow rate entered to the tank was set
to 15L/s with a uniform velocity distribution of 0.358m2/s at the entrance. These values
provide a Reynolds number of 2.49 × 104 and Froude number of 0.46 (Mohd Remy Rozainy
et al. 2007). For this case, the vortex was consistently present in the tank (near the column
intake). Figures 6 and 7 shown that, the vortex developed directly from FLUENTTM output. In
these figures, the magnitudes of the velocity vectors (in m/s) were indicated by the color scale
and the length. Each vector depends on the direction of the velocity. Velocity vectors inFigure
6 illustrate the circulation patterns near the water surface. Carefully observed of this figure
reveals one set of counter-rotation vortex was developed. The location of the vortex is
symmetrically located at the back of the intake pipe 1 and 2 respectively. Figure 7 shows
subsurface vortex at the bottom level (0m) of the sump intake. This figure shows that the flow
is not symmetrically directed towards the sump intake. From this figure, a subsurface vortex
can be clearly observed under the suction intake. The formation of surface and subsurface
vortex occurred similar vicinity as in experimental observations.
The comparison of the velocity profile between experimental and a simulation result is
presented in this section. The comparison results of velocity magnitude at Row 1 between
observed and calibrated method is shown in the Figures 8. Generally, the profiles from the
observed and calibrated on results showed a similar trend. The velocities observed and

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Application of Computational Fluid Dynamics (CFD) in Physical Model of Pump Sump to Predict
the Flow Characteristics

calibrated are shown a decreasing value trend starting from node A to node J. From the
calibrated results, the values of velocity are slightly smaller than the observed values. The
observed results predicted about 6.8% higher than the calibrated result.
upstream

Sidewall 1 Sidewall 2

m/s

downstream

m/s

Surface vortex

Figure 6. Surface vortex at the upper level of the water

upstream

Sidewall 1 Sidewall 2

m/s

downstream

m/s

Figure 7. Subsurface vortex at the bottom level (0m) of the sump intake

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0.4
0.35
0.3

velocity (m/s)
0.25
0.2
0.15
0.1
0.05
0
A B C D E F G H I J
node position
calibrated observed

Figure 8. Comparison of velocity profile between observed and calibrated results

In general, the simulation results are in the good agreement with the experimental results. A
comparison of the experimental velocity with simulated velocity is shown in Figure 9. It can
be concluded that the calibration processes for velocity magnitude were successful.
Regression coefficient (R2) value shows that 0.99 is obtained from the scattered plot
relationship between observed and calibrated data.

2
0.4 R =0.99
Line of perfect
0.35
agreement
/s)

0.3
calibrated(m

0.25
0.2
0.15
0.1
0.05
0
0 0.1 0.2 0.3 0.4
obse rv e d (m/s)

Figure 9. Scatter plots relationship between observed and calibrated data

6. FLOW CHARACTERISTICS AT HIGHER FLOW RATE (30L/S)

This section discusses the capability of the simulation technique to predict the results of the
flow characteristics in the sump intake. A flow rate of 30L/s was used which is double value
of 15L/s at water level of 0.18m. Figure 5.52 shows the velocity distribution of flow inside of
the pump sump at same flow rate as in Case 10 and Case 11, and operated at minimum water
level of 0.18m. Results show that the velocity is consistently distributed from Column A to
Column E at each water level similar to all other running. Velocity distribution was found
higher at the upper level of the sampling point when compared to the velocity distribution at
lower level. In this section, the frictions effect between water and floor attach of the sump, is
the major component.
The result in Column F shows that the velocity distribution (green-light blue) rapidly
decreased. This situation occurs most probably due to the change of flow distribution that
occurs within the area of the sump intake. Similar as before, at Column G, the velocity

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Application of Computational Fluid Dynamics (CFD) in Physical Model of Pump Sump to Predict
the Flow Characteristics

distribution (blue) was higher near the top of the sampling area compared to the velocity
(blue) at the bottom of the sump. Furthermore, similar phenomena were not observed in
Column H, I and J. The velocity distribution at the lower level (blue) was slightly higher
compared to the velocity at the middle (blue) and upper level (blue). This is the result of
suction effect that is produced from the pump operation.
Upstream Downstream
A B C D E F G H I J -3
m/s (x10 )
I
II
III
IV
UPPER LEVEL -3
m/s (x10 )
I
II
III
IV
-3
MIDDLE LEVEL m/s (x10 )
I
II
III
IV
LOWER LEVEL

Figure 10. Contour of velocity distribution of simulation result in the pump intake
at water level 0.18m with flow rate of 30L/s

This section revealed the results of velocity vector or visualization at water level 0.18m with
flow rate of 30L/s. Figure 11 to Figure 12 shows the flow characteristics at certain locations in
the sump intake. The velocity vectors in Figure 11 illustrate the circulation patterns near the
water surface. Two sets of counter rotating vortices have appeared and these two vortices are
shown by the orange circles that were located directly behind the pump intake. This situation
is in contrast with previous case (water level 0.18m, flow rate 15L/s). By doubling the flow
rate, the results show two counter rotating surface vortexes occurred.

There was no dead flow region at the corner back of the sump intake. This situation occurred
because of the high velocity flow at the back area of the column intake. Figure 12 shows a
plan view of the velocity vectors for the flow elevation below the pump intake at an elevation
(0m) this figure shows that the flow is not symmetrically directed towards the pump intake. A
subsurface vortex which is directly under the suction intake can be observed clearly .In this
case, subsurface vortex is the largest size compared to previous case of study. If this situation
occurred in the study, the operations of the pump have to be stopped because it can damage of
the pump.

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 Mohd Remy Rozainy M.A.Z et. al.

upstream

m/s

downstream

m/s

Figure 11. Two surface vortices at the water surface

upstream

m/s

downstream

m/s

Figure 12. Subsurface vortex directly below the pump intake

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Application of Computational Fluid Dynamics (CFD) in Physical Model of Pump Sump to Predict
the Flow Characteristics

7. CONCLUSIONS

The present study was undertaken to access the capability of numerical model to simulate the
complex flow in a sump intake. The different types of vortices are clearly observed. The
location, number and general structure of the surface and the subsurface vortices predicted by
the numerical model were found to be in good agreement with those observed in the
experiment. The average velocity difference between experimental and simulated results was
6.8% meanwhile regression coefficient, R2 value was 0.99. Together, the results of this
validation study suggest that the numerical model is a useful engineering tool and could be
employed in preliminary design to identify the geometric configurations and flow parameter
that may lead to strong vortices developed in the intake and swirl of the suction intake
column.

REFERENCES

[1]. Alboleda, G. & El-Fadel, M. Effects of Approach Flow Conditions on Pump Sump
Design, Journal of Hydraulic Engineering. 1996. 122(9).
[2]. Ansar, M., Nakato, T., & Constantinescue, G. S. Numerical Simulations of inviscid
Three-Dimensional Flows at Single and Dual Pump Intakes, Journal of Hydraulic
Research. 2002. 40(4).
[3]. Constatinescue, G.S. & Patel, V.C. Role of Turbulence Model in Predicted of- Pump
Bay Vortices, Journal of Hydraulic Engineering. 2000. 126(5).
[4]. Dicmas, J.L.Vertical Turbine, Mixed flow and Propeller Pumps, McGraw-Hill. 1987,
New York.
[5]. Karassik, I.J., Messina, J.P., Cooper, P. & Heald, C.C. Pump Handbook, McGraw-Hill.
2001. New York.
[6]. Mohd. Remy Rozainy, M.A.Z, Abustan. I, Abdullah, M.Z., Muhad. R.M. Nawi, & M.A.
Ismail, Flow Characteristics in Physical Model of Pump Sump using Computational
Fluid Dynamics (CFD), National Seminar on Civil Engineering Research (SEPKA),
Johor Bahru, 2007.
[7]. Warring, R.H., Pumping Manual, Gulf Publishing Company, 1984, Texas.
[8]. Nagahara, T., Sato, & T. and Okamura, T., Measurement of the Flow Around the
Submerged Vortex Cavitation in a Pump Intake by Means of PIV. Fifth International
Symposium on Cavitation, Osaka, 2003.

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