EFFECTS OF ApPROACH FLOW CONDITIONS ON PUMP SUMP DESIGN

By Gustavo Arboleda, l Member, ASCE, and Mutasem EI·Fade12

ABS~~ACT: An important obstacle to the development of a generalized sump design is the variability of flow
conditions I~ approach are~s. The geometry and alignment of the areas immediately upstream of the sumps are
so closely ~~ to. the requirements of the specific site that it is virtually impossible to standardize their design.
Flow conditions 10 approach areas, therefore, have to be evaluated on a case by case basis to determine their
imp~t on the hydr~ulic performance of the respective pump sumps. This paper presents a case study of one
particular .s~mp design, develo~d through hydraulic model testing, which was highly dependent on approach
flo~ conditions. The ~ase studY.illustrates the ?ffect on hydraulic performance and sump configuration of several
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design features and site constra1Ots prevalent 10 approach areas. The study concludes that significant deviations
from current design practices will be required to attain a generalized sump design.

INTRODUCTION An important obstacle to the development of a generalized

A number of deficiencies and problems with vertical pumps design is the variability of approach flow conditions. Approach
are often related to sump design rather than to mechanical areas can have vastly different configurations depending on
imperfections. Vibration, cavitation, rough running lower than the source of water (ocean, lake, river, channel, cooling tower,
expected efficiency, and reduced pump life can generally be storm drain, sewer, etc.) and on site-specific constraints. Since
traced to flow conditions in the sump and its approach area. the geometry and alignment of the approach area are so closely
These problems and their causes have been researched exten- tied to the requirements of the specific site, it is virtually im-
sively and are widely reported in the literature (Fraser 1953; possible to standardize their design. Flow conditions in ap-
Tullis 1979; Fletcher 1979; EPRI 1980; Sweeney et aI. 1982; proach areas, therefore, have to be evaluated on a case by case
Larsen and Padmanabhan 1986; Dicmas 1978, 1987; Hecker basis to determine their impact on the hydraulic performance
1987; Triplett et al. 1988; Tsou et al. 1994). of the pump sump.
There is agreement among researchers as to the causes of This paper presents a case study of one particular pump
the pump problems and deficiencies. Sweeney et aI. (1982) sump approach that illustrates several design features and site
summarized them as (1) uneven flow distribution in the sump constraints prevalent in approach areas. The rationale used in
causing a net flow circulation around the pump column; (2) arriving at the preliminary design of the pumping facility is
large-scale turbulence generated in the approach to the sump; outlined. The effects of approach flow conditions on the fa-
(3) vorticity generated by flow past pier noses, screen supports, cility's hydraulic performance, which were evaluated through
and other structural members; (4) vorticity generated at fluid physical model tests, are analyzed. The general applicability
shear zones formed at discontinuous flow boundaries in the of design features in the selected sump and approach area con-
vicinity of the pump; (5) vorticity generated in the boundary figuration are discussed.
layer at the sump walls and floor; and (6) vorticity generated
by flow past the pump column. PROJECT DESCRIPTION
While the causes of pump problems and deficiencies caused The Natomas East Main Drain Canal (NEMDC) pump sta-
by flow conditions in the sump have been well established, tion is one of several drainage improvements implemented by
their solutions have not. Different approaches to prevent vor- the Sacramento Area Flood Control Agency in efforts to de-
ticity, provide even flow distributions, and mitigate the effects velop a regional flood control solution for drainage areas in
of large-scale turbulence have been developed primarily Sacramento, Placer, and Sutter counties, in Northern Califor-
through experimental studies using physical models. The var- nia. The pumping facility is located in the NEMDC channel
ious approaches involve the use of sump geometry and flow upstream of its confluence with the American River. A gated
guidance and distribution structures (beams, vanes, screens,
bypass channel conveys drainage flows to the American River.
fillets, ramps, flow splitters) to provide satisfactory flow con- During storm events, when stages on the American River ex-
ditions. To date, however, no definitive design criteria have
ceed those of the NEMDC channel, the bypass channel is
been developed that have general applicability.
closed and the pump station is used to provide the necessary
The most widely used design guidelines are those published
lift to the drainage flows on the NEMDC (Arboleda 1994).
by the British Hydromechanics Research Association (Prosser
1977), the Hydraulic Institute Standards (1975), and the U.S. The NEMDC pumping facility was initially designed to
house three main pumps plus one standby pump, each with a
Army Corps of Engineers (1988). These guidelines provide
recommendations on the size and configuration of pump capacity of 33,666 m 3/h (330 cu ftls). The station was designed
sumps, based on either the suction bell diameter or the antic- with recirculating capabilities that permit pump testing during
ipated flow rates. None guarantees satisfactory flow condi- nonstorm periods. Discharges from the station's pumps are
tions, and all recognize the importance of favorable approach c?nveyed into a rectangular concrete chamber; water from the
flow conditions. discharge chamber flows over a weir into the downstream
channel during storm periods, or through a gated recirculation
'Pres., Water Resources Engrg., Inc., 32704 Gilroy Court, Union City channel back to the pump sump for individual pump testing.
CA 94587. • ' The pump station layout is illustrated in Fig. 1.
'Consulting Assoc. Prof., Dept. of Civ. Engrg., Stanford Univ., Stan-
ford, CA.
Note. Discussion open until February I, 1997. To extend the closing
PRELIMINARY DESIGN
date one month, a written request must be filed with the ASCE Manager Individual pump cells were designed in accordance with
of Journals. The manuscript for this paper was submitted for review and
possible publication on October 2, 1995. This paper is part of the }ourlUll published guidelines. The suction bell diameter was used as
of Hydraulic Engineering, Vol. 122, No.9, September, 1996. ©ASCE, the basic design parameter. Cell width and length, as well as
ISSN 0733-942919610009-0489-0494/$4.00 + $.50 per page. Paper No. the distance from the suction bell to the floor and to the back
11745. wall of the sump were defined in terms of the suction bell
JOURNAL OF HYDRAULIC ENGINEERING / SEPTEMBER 1996/489

J. Hydraul. Eng., 1996, 122(9): 489-494

 '-------+--..""'""'""''''''',,,,,,''r----,
NEMDC
CHANNEL @J:::::::::::::
FLOW ~
0: ..,....,....
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DISCHARGE
.........................
........................ WEIR

0::::::::::::
0::::::::::::
,t---'-_--1
' " ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' 'hV"•.~••.wMW~ ••

-"'-"-"-"-"-"-"-"-" ""."".".""."." " ,,, ,, !-=-::.--:~-~C~;I~~~CATION

BYPASS
_- - ____
LOW FLOW CHANNEL ------
.. .. .. .. .. .. ..-.-
CHANNEL

FIG. 1. NEMDC Pump Station Layout, Plan View

diameter, as recommended by the British Hydromechanics Re- proach and sump were aligned with the normal direction of
search Association (Prosser 1977). Dimensions of a typical flow in the channel.
pump cell are illustrated in Fig. 2. The approach area included traditional design features, as
The approach area was designed to convey flows from the well as special features mandated by site and operational con-
upstream channel to the sump in the most direct way possible. straints. Some of the features prevalent in approach areas in-
A simple rectangular configuration was selected, and the ap- cluded wing walls at the entrance to the facility, providing a
liv ~4.3""D 1
transition from the channel cross section to the rectangular
approach section; trash racks and their support piers; sloped
floor from channel to sump level; and a common forebay im-
liv-~---" mediately upstream of the pump cells.
Special features included a recirculation channel from the
discharge chamber to the approach area, to allow testing of
individual pumps during nonstorm periods; a sill or closure
o wall at the entrance, needed to maintain minimum levels of
N
pump submergence in the recirculation mode; a gated opening
from the recirculation channel to the approach area; and struc-
o tural members to support a roadway over the approach area.
Sump and approach area configuration and dimensions are il-
lustrated in Fig. 3.
(a)
Hydraulic Performance: Effects of Approach Flow
0.75D Conditions
MIN WSEL
The hydraulic performance of the preliminary design was
evaluated through physical model tests. A Froude Law model
was designed and constructed at an undistorted geometric scale
ratio of 1:18; the selected scale satisfied Reynolds and Weber
number criteria for the minimization of scale effects due to
viscosity and surface tension, and allowed the reproduction
and visualization of relevant flow phenomena. The model in-
o cluded about 61 m (200 ft) of the upstream channel, the sump
III
o and approach areas, the discharge chamber, and the bypass and
recirculation channels. Water passageways were reproduced in
full geometric detail, as were the suction bells and pump col-
FIG. 2. Dimensions of 'TYpical Pump Cell: (a) Plan; (b) Profile umns. Tests were conducted for one, two, three, and four pump
490 I JOURNAL OF HYDRAULIC ENGINEERING I SEPTEMBER 1996

J. Hydraul. Eng., 1996, 122(9): 489-494

 44' 37'
. I" • 1

Ii:'
~ E,
A
STRUCTURAL
SUPPORTS
-1
30" SQUARE ~
COLUMN (TYP

. ~
+-'.'
b"-
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"'.b

.t::E,
~
"-

(a) S;z _ RECIRCULAliON CHANNEL

ELEV. 44'

ELEV. 25.5' PUMP CELL

ELEV. 20'

(b)
ELEV, 8'

FIG. 3. Sump and Approach Area Configuration: (a) Plan; (b) Sump and Approach Area Configuration

operation at different water levels. Recirculation tests for in- high flow velocity because 50-75% of the flow area was in-
dividual pumps were also performed. effective.
Several hydraulic deficiencies were observed during model In the recirculation mode, flow through the 1.8 m high, 3
testing. The flow distribution within pump cells was uneven, m wide (6 by 10 ft) opening from the recirculation channel
with flow velocities skewed in both the horizontal and vertical spilled partially into the upstream channel, causing a loss of
planes. This was true when pumping from the upstream chan- recirculating volume. Recirculating flows traveled parallel to
nel and in the recirculation mode. Subsurface vortices, iden- the sill to the opposite sidewall, and approached the operating
tified by dye injection, formed under the suction bells for all pump primarily through the trash rack opening on the left side
operating conditions; intermittent subsurface vortices were of the structure, as shown in Fig. 5.
also observed from the back walls and sidewalls under some The preliminary design was modified on the basis of model
test conditions. These deficiencies would translate to vibration, test observations. Structural changes were made to improve
rough running (lower than expected efficiency), and possibly hydraulic performance while staying within the constraints im-
cavitation and reduced pump life in the prototype facility. posed by site and operational requirements.
Flow conditions in the approach area accounted for the ob-
served deficiencies. Flow distribution on the horizontal plane MODIFIED DESIGN
was even up to the forebay, where it was skewed as water Flow guidance and distribution structures were added to the
turned to approach the pump(s) in operation. On the vertical pump cells to provide more uniform flow to the suction bells
plane, flow distribution was affected by the sill at the entrance and eliminate subsurface vorticity. A ramp and a wedge-
to the pumping station and by the floor slope, as illustrated in shaped flow splitter were added under each suction bell. Baffle
Fig. 4. The sill acted as a submerged weir and was effective walls and horizontal beams were incorporated into the sump
in providing an even horizontal flow distribution, but it also design. The configuration and dimensioning of each added fea-
reduced significantly the effective flow area immediately ture were determined experimentally; model tests demon-
downstream. The trash racks, located less than 6 m (20 ft) strated a high degree of interdependence among approach area
downstream of the 1.8-m (6 ft) high sill, experienced relatively configuration, operating conditions, and the shape and posi-
tioning of the added features. The selected sump design is
illustrated in Fig. 6.
In the approach area, the principal change involved moving
the sill or closure wall 12 m (40 ft) upstream. This allowed
incoming flows to occupy the full available cross-sectional
area at the trash racks and beyond. It also prevented spills
during recirculating flows and provided a higher recirculation
volume.
Attempts were made to change the location and size of the
FIG. 4. lYplcal Flow Pattern for One, 1\No, and Three Pump Op- gated opening from the recirculation channel to improve flow
eration conditions in the recirculation mode. Many energy dissipation!
JOURNAL OF HYDRAULIC ENGINEERING / SEPTEMBER 1996/491

J. Hydraul. Eng., 1996, 122(9): 489-494

 STAGNANT AREA
(TYPICAL)
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STANDING
WAVE

FIG. 5. Recirculation Flow Pattern at Floor Level (Plan View)

.5 0.750
(a) pitch blades, ranged from 0° to 3° for all operating conditions,
compared with values ranging from 7° to 37° for the prelim-
inary design [swirl angles up to 5° are generally considered
,LOW
AF"F"LE WA L SPLITTER acceptable; see Knauss (1987); Nakato (1989)]. There was no
EAM SUPPORT
surface or subsurface vorticity under any operating condition.
In the recirculation mode, however, hydraulic performance
did not meet the same standards. There was lack of uniformity
in the distribution of flow around the suction bells, and al-
though no surface or subsurface vortices were evident, swirl
HORIZONTAL
BEAM RAMP angles as high as 25° were recorded.
The hydraulic deficiencies observed in the recirculation
mode were a product of approach flow conditions. Water ex-
ited the recirculation channel at an average velocity of 1.7 m/s
(5.5 ftIs) and at 90° to the main direction of pump approach
[LEV. 32' (OR HIGHER)
flow. For some of the pump tests, this water had to make as
OR AS REQUIRED) many as three 90° turns in the horizontal plane before reaching
the pump, while undergoing contractions and expansions of
(b) the available flow area and directional changes in the vertical
plane.
ELEV. 23.75'
20'
PRACTICAL APPLICATIONS
Flow distribution and guidance structures improve hydraulic
performance in pumping facilities. A combination of baffles,
horizontal beams, ramps, flow splitters, and corner fillets can
generally be found that will provide satisfactory flow condi-
0.250 tions at the pump suction. The writers based this assertion on
more than 30 physical model studies they performed on struc-
tures similar to the NEMDC pump station. These same studies
indicate that the number of elements, and their correct place-
FIG. 6. Modified Pump Cell Design: (a) Planj (b) Profile ment and dimensioning, is not a function of suction bell di-
ameter or pump flow rate but primarily of the configuration
flow guidance alternatives were tested to control and direct of the approach area. Because of the inherent variability of
recirculation flows. The size and location of the opening used approach flow conditions and the lack of theoretical basis of
in the preliminary design were eventually retained, which im- design, physical modeling has to be used to arrive at satisfac-
plied retaining the common forebay (recirculation flows tory sump designs.
needed the forebay to approach the pump in operation). The A generalized sump or pump intake design may be attain-
selected approach area configuration is illustrated in Fig. 7. able but will require significant deviations from past practices.
The vortex suppression and flow guidance characteristics of
Hydraulic Performance: Effects of Approach Flow baffles, beams, ramps, and flow splitters would have to be
Conditions enhanced by elements of the generalized design to make the
resulting structure independent of approach flow conditions.
The hydraulic performance of the modified sump and ap- One possible alternative still in the developmental and testing
proach design was satisfactory when pumping from the up- stages is the "formed suction intake," also known as a "suc-
stream channel. Flow distribution around the circumference of tion scoop" or "inverted draft tube," which essentially turns
the suction bells was uniformly distributed and steady. The the sump into a conduit that smoothly transitions from a ver-
time-averaged (over 30 s) swirl angle at the base of the pump tical rectangle into a horizontal bell shape (Tullis 1979; Rah-
column, measured with a freewheeling propeller with zero meyer and Tullis 1988; Triplett et al. 1988; Nakato 1989;
492/ JOURNAL OF HYDRAULIC ENGINEERING / SEPTEMBER 1996

J. Hydraul. Eng., 1996, 122(9): 489-494

 30" SQUARE
COLUMN (TYP).......-.[]

SILL
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o
~
• IL

-o-E~f-....::6'--' ~~

TOP OF WALL 1... "'-- -RECIRCULATION CHANNEL -'

ELEV. 32' OR HIGHER

(a)

ELEV. 44'

ELEV. 26'
1 ..
ELEV. 20'

(b)

FIG. 7. Modified Sump and Approach Area: (a) Plan (Pumps not Shown for Clarity); (b) Profile

Fletcher 1991, 1994; Tsou et al. 1994). Different configura- Dicmas, 1. L. (1978). "Effect of intake structure modifications on hIe
tions of the formed suction intake have been implemented at hydraulic performance of a mixed flow pump." Proc., IAHR, ASME,
and ASCE Joint Symp. on Des. and Operation of Fluid Machinery,
various installations (Tsou et al. 1994), but further research is Colorado State University, Fort Collins, Colo., 403-412.
still required to arrive at a generalized design. Dicmas, J. L. (1987). "Sump design." Vertical turbine, mixed flow, and
propeller pumps, McGraw-Hill, New York, N.Y.
CONCLUSIONS Electric Power Research Institute. (1980). "Evaluation of basic causes of
repetitive failures of nuclear and fossil feedwater pumps." EPRI Rep.
The NEMDC pump station case study illustrates the limi- NP-157I, Palo Alto, Calif.
tations of available design guidelines. A sump designed in ac- Fletcher, B. P. (1979). "Pumping station, field performance." Tech. Rep.
cordance with best practices, with a simple rectangular ap- HL-79-7, U.S. Army Corps of Enges., Wtrwys. Experiment Station,
Vicksburg, Miss.
proach and appropriate pump submergence still exhibited Fletcher, B. P. (1991). "Hydraulic model investigation: St. Johns bayou
hydraulic deficiencies under all operating scenarios. Hydraulic pumping station, Missouri." Tech. Rep., HL-91-3, U.S. Army Corps of
deficiencies were attributable to approach flow conditions that, Enges., Wtrwys. Experiment Station, Vicksburg, Miss.
because of their variability, are not specifically addressed in Fletcher, B. P. (1994). "Hydraulic model investigation: Cypress Avenue
the most commonly used design guidelines. pumping station." Tech. Rep. HL-94-9, U.S. Army Corps of Engrs.,
The adverse effects of approach flow conditions on hydrau- Wtrwys. Experiment Station, Vicksburg, Miss.
Fraser, W. H. (1953). "Hydraulic problems encountered in intake struc-
lic performance can be mitigated with flow distribution and tures of vertical wet-pit pumps and methods leading to their solution."
guidance structures. A combination of baffles, horizontal Trans. ASME, 643-652.
beams, ramps, and flow splitters will provide satisfactory flow Hattersley, R. T. (1965). "Hydraulic design of pump intakes." J. Hydr.
conditions. The appropriate flow guidance and distribution el- Div., ASCE, 95(2), 223-249.
ements, however, cannot be selected from theoretical formu- Hecker, G. E. (1987). "Chapter 8: Conclusions." Swirling Flow Prob-
lations or published guidelines. Physical modeling is the only lems at Intakes, IAHR hydraulic structures design manual, A. A. Bal-
kema, Rotterdam, The Netherlands.
proven methodology currently available to select and properly Hydraulic Institute Standards. (1983). "Centrifugal, rotary and recipro-
locate and dimension these elements. cating pumps," 14th Ed., HIS, Cleveland, Ohio.
A generalized sump design must be independent of ap- Knauss, J. (1987). "Swirling flow problems at intakes." IAHR hydraulic
proach flow conditions. Since the traditional sump design, structures design manual, A. A. Balkema, Rotterdam, The Netherlands.
even when enhanced by flow guidance and distribution ele- Larsen, J., and Padmanabhan, M. (1986). "Intake modeling." Pump
handbook, 2nd Ed., Section 10.2, McGraw-Hill, New York, N.Y.
ments is highly dependent on approach flow conditions, a gen- Nakato, T. (1989). "A hydraulic model study of the circulating water
eralized design will have to involve nontraditional concepts. pump intake structure: Laguna Verde nuclear power station, unit no.
1," IIHR Rep. No. 330, Iowa Inst. of Hydr. Res., Iowa City, Iowa.
APPENDIX. REFERENCES Padmanabhan, M. (1987). "Chapter 6.2: Design recommendations for
pump sumps." Swirling flow problems at intakes, IAHR hydraulic
Arboleda, G. (1994). "Hydraulic model study of the Natomas east main structures design manual, A. A. Balkema, Rotterdam, The Netherlands.
drain canal pump station." Tech. Rep., Water Resources Engineering, Padmanabhan, M., and Hecker, G. E. (1984). "Scale effects in pump
Inc., Fremont, Calif. sump models." J. Hydr. Engrg., ASCE, 110(11), 1540-1556.

JOURNAL OF HYDRAULIC ENGINEERING / SEPTEMBER 1996/493

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 Prosser, M. J. (1977). "The hydraulic design of pump sumps and in- research study." Tech. Rep. HL-88-2, U.S. Army Corps of Engrs.,
takes. " British Hydromech. Res. Assn., and Constr. Industry Res. and Wtrwys. Experiment Station, Vicksburg, Miss.
Information Assn., Cranfield, Bedford, England. Tsou, J. L., Melville, B. W., Ettema, R., and Nakato, T. (1994). "Review
Rahmeyer, w., and Tullis, J. P. (1988). "A case study on the modeling of flow problems at water intake pump sumps." Proc., Int. Joint Power
of suction scoops to remedy pump intake problems." Proc.• Int. Symp. Generation Con!, Am. Soc. Mech. Engrs., New York, N.Y., 91-102.
Model-Prototype Correlation of Hydr. Struct., ASCE, New York, N.Y., Tullis, J. P. (1979). "Modeling in design of pumping pits." J. Hydr. Div.,
446-455. ASCE, 105(9), 1053-1063.
Sweeney, C. E., Elder, R. A., and Hay, D. (1982). "Pump sump design U.S. Army Corps of Engineers. (1988). "Hydraulic design guidance for
experience: Summary." J. Hydr. Div., ASCE, 108(3), 361-377. rectangular sumps of small pumping stations with vertical pumps and
Triplett, G. R., Fletcher, B. P., Grace, J. L., and Robertson, J. J. (1988). ponded approaches." Engrg. Tech. Letter No. II /0-2-3/3, Washington,
"Pumping station inflow-discharge hydraulics, generalized pump sump D.C., 1-3.
Downloaded from ascelibrary.org by S.V. National Institute Of Technology on 09/07/21. Copyright ASCE. For personal use only; all rights reserved.

494/ JOURNAL OF HYDRAULIC ENGINEERING / SEPTEMBER 1996

J. Hydraul. Eng., 1996, 122(9): 489-494