This document is intended to assist application engineers, designers, planners and users of sewage and storm water systems incorporating Flygt axial- and mixed ow pumps installed in a column. A proper design of the pump sump is crucial in order to achieve an optimal inow to the pumps. Important design requirements to be met are: uniform ow approach to the pumps, preventing pre-rotation under the pumps, preventing signicant quantities of air from reaching the impeller and transport of settled and oating solids. The Xylem standard pump station design can be used as is, or with appropriate variations according to company guidelines. Pump and sump are integral to an overall system that includes a variety of structures and other elements such as ventilation systems and solids handling equipment. Operating costs can be reduced with the help of effec- tive planning and suitable operation schedules. Xylem personnel and publications are available to offer gui- dance in these areas. Transient analysis of pump system behavior, such as air chamber dimensioning, valve selection, etc., should also be considered in wastewater pump station design. These matters are not addres- sed in this brochure, but Xylem can offer guidance. Please consult a Xylem engineer to achieve optimum pump performance, maximum pump life, and a guaran- tee that product warranties are met. The design recommendations are only valid for Xylem equipment. Xylem assumes no liability for non-Xylem equipment. Contents 4 Flygt PL and LL pump introduction Xylem submersible and verti cally installed axial ow pumps (PL) and mixed ow pumps (LL) have been used in a wide variety of applications all over the world. Applications include storm water sta- tions and sewage treatment plants, land draina- ge and irrigation systems, sh farms and power plants, shipyards, amusement parks and many other applications wherever large volumes of water have to be pumped. Flygt submersible PL and LL pumps offer important advantages such as: Compact motor and pump unit No separate lubrication system No external cooling system Low operating sound level Quick connection and disconnection for installation and inspection Minimal station superstructure Simple pipe work Flygt PL and LL pumps are usually installed in a vertical discharge tube on a support ange incor- porated in the lower end of the tube. No ancho- ring is required because the weight of the pump is sufcient to keep it in place. The pumps are equip- ped with an anti-rotation gusset. This arrangement provides the simplest possible installation - the pump is just lowered into the discharge tube by hoist or crane. Retrieval of the pump is equally simple. General considerations for pumping station design The proper design of the pump sump is crucial in order to achieve an optimal inow to the pumps. Ideally, the ow at the pump inlet should be uni- form and steady, without swirl, vortices or entrai- ned air. Non-uniform fow at the pump intake can reduce efciency and cause pulsating loads on the pro- peller blades, resulting in noise and vibrations. Unsteady fow can also cause fuctuating loads, noise and vibrations. Swirl in the intake can change the head, fow, efciency and power in undesirable ways. It can also augment vortices. Vortices with a coherent core cause discontinu- ities in the ow and can lead to noise, vibration and local cavitation. Vortices emanating from the free surface can become sufciently powerful to draw air and oating debris into the pump. Entrained air can reduce the fow and effciency, causing noise, vibration, uctuations of load and consequent physical damage. Experience with designs already in use provides valuable guidelines for the design of multiple pump stations. Adaptations of existing and well- proven designs can often provide solutions to complex problems even without model tests. Xylem has extensive experience based on many successful projects, and the services of our quali- ed engineers are always available. For special applications beyond the scope of this brochure, please contact your local Xylem system engineer for assistance. Flygt mixed ow pumps (LL) Flygt axial ow pumps (PL) 5 Pumping station with multiple pumps Multiple pump systems provide greater capacity, operational exibility and increased reliability, which is why pumping stations are usually equip- ped with two or more pumps. Transition to the sump, whether diverging, con- verging or turning, should result in nearly uniform ow at the sump entrance. Obstacles that genera- te wakes should not be allowed to interfere with the approaching ow. High velocity gradients, ow separation from the walls and entrainment of air should be avoided. Hydraulically, three zones of the pumping station are signicant: inlet, forebay and pump bay. Inlet: An inlet conveys water to the pumping station from a supply source such as a culvert, canal or river. Usually, the inlet has a control structure such as a weir or a gate. Forebay: The role of the forebay is to guide the ow to the pump bays in such a way that it is uni- form and steady. Because the inow to each module should be steady and uniform, the design of the forebay feeding the individual modules is critical and should follow guidelines in this brochure. Design of the forebay depends on water approach to the pumping station commonly encountered as parallel with the sump centerline, the preferred layout, or perpendicular to the sump centerline. Front inow to the station If water approaches the station parallel to the sump centerline, the inlet should be placed sym- metrically with respect to the pumps. If the width of the inlet is less than the total width of the pump bays, the forebay should diverge symme- trically. The total angle of divergence should not exceed 20 for Open Sump Intake Design or 40 for Formed Intake Design. The bottom slope in the forebay should not be larger than 10. If these parameters cannot be met, ow direction devices should be used to improve the ow distribution. Such arrangements and more complex layouts should be investigated, using model tests, in order to arrive at suitable designs. Pump bay Forebay Inlet area 6 Side inow to the station When the inow is perpendicular to the axis of the pump bays, an overow-underow weir can help redistribute the ow, as shown to the right. A substantial head loss at the weir is required to dissipate much of the kinetic energy from the incoming ow. Alternatively, bafe systems can be used to redirect the ow, but model tests are then required to determine their correct shape, position and orientation. The distance between the weir or bafes and the pump bays must be sufcient to allow eddies to dissipate, and entrained air to escape, before the water reaches the pump inlet. Pump bay: In practice, only the design of the pump bay can be standardized for a given pump type. A properly designed bay is a prerequisite for correct presentation of ow to the pumps, but it does not guarantee correct ow conditions. A bad approach to the pump bay can disturb the ow in the pump intake. As a rule of thumb, the approach velocity to the individual pump bays should not exceed 0,5m/s. The dimensions of the bays indivi- dual modules are a function of pump size and the ow rate (see page 12). 7 Pump bay design variations Open sump intake design is the most sensitive to non-uniform approaches, because it requires a longer forebay and longer dividing walls between the individual pump bays than the formed intake design installations. If an open sump intake design is used for more than three pumps, the length of the dividing walls should be at least 2/3 of the total width of the sump. If ow contraction occurs near the sump entrance because of screens or gates, the sump length should be increased, to 6D or more, depending on the degree of contraction. Draft tube intakes are the least sensitive to distur- bances of the approaching ow that can result from diverging or turning ow in the forebay, or from single pump operation at partial load. Therefore, draft tube intakes, C-confguration, are nearly always the preferred choice. Open sump intake design Open sump intake design includes devices such as splitters and divider plates that alleviate the effects of minor asymmetries in the approaching ow. Open sump intake design for Flygt PL pumps Open sump intake design for Flygt LL pumps Submergence diagram for open sump intake design The minimum required submergence of the pump inlet with open sump intake design is a function of the ow rate, the pump inlet diameter and the distribution of the ow at the approach to the pump. Each diagram has three curves for various conditions of the approaching ow. Because vor- tices develop more readily in a swirling ow, more submergence is required to avoid vortices if the inlet arrangement leads to disturbed ow in the sump. Hence, the upper curve in the submergence diagrams is for a perpendicular approach, the middle one is for the symmetrical approach and the lowest curve for duty-limited operation time (about 500 hours/year). The curve appropriate to the inlet situation should be used to determine the minimum water level in the sump to preserve reliable operation of the pumps. 8 Lateral approach Symmetrical approach Limited operation 1,4 1,2 1 0,8 0,6 0,4 0,2 0 0 20 40 60 80 Flygt LL 3085, LL 3102 Q (l/s) S (m) 2,4 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 0 50 100 150 200 250 Q (l/s) S (m) Flygt LL 3152 2,8 2,6 2,4 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 0 100 200 300 400 Q (l/s) S (m) Flygt LL 3201 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 0 10 20 30 40 50 60 70 80 90 100 110 Q (l/s) S (m) Flygt LL/NL 3127 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,6 0 500 1000 1500 Q (l/s) S (m) Flygt LL 3400 2 1,8 1,6 1,4 1,2 1 0,8 0,6 0,4 0 100 200 300 400 500 600 700 Flygt LL 3356 Q (l/s) S (m) 3 2,8 2,6 2,4 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 0 100 200 300 400 500 600 Q (l/s) S (m) Flygt LL/NL 3300 Submergence diagram for open sump intake design Note that NPSH has to be fulflled according to the performance curve for the designed duty point. 9 3 2,5 2 1,5 1 0,5 0 0 0,2 0,4 0,6 0,8 1 1,2 Flygt PL 7050, PL 7045 Q (m 3 /s) S (m) 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 0 100 200 300 400 Flygt PL 3127 Q (l/s) S (m) 4 3,5 3 2,5 2 1,5 1 0,5 0 0,25 0,50 0,75 1,00 1,25 1,50 1,75 2,00 Flygt PL 7055, PL 7061, PL 7065 Q (m 3 /s) S (m) 2,2 2 1,8 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 0 100 200 300 400 Flygt PL 3140, PL 3152 Q (l/s) S (m) 6 5 4 3 2 1 0 0 1 2 3 4 5 6 7 8 Flygt PL 7115, PL 7121, PL 7125 Q (m 3 /s) S (m) 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 Flygt PL 7101, PL 7105 Q (m 3 /s) S (m) 3 2,5 2 1,5 1 0,5 0 0,25 0,50 0,75 1 1,25 1,50 1,75 2 2,25 Flygt PL 7076, PL 7081 Q (m 3 /s) S (m) 3 2,5 2 1,5 1 0,5 0 500 1000 1500 2000 2500 Q (l/s) S (m) Flygt LL 3531, LL 3602 10 Formed intake design Formed intake design can be constructed in either concrete or steel. The intake reduces disturban- ces and swirl in the approaching ow. The incli- ned front wall is designed to prevent stagnation of the surface ow. The geometrical features of this intake provide for smooth acceleration and tur- ning as the ow enters the pump. The minimum inlet submergence should not be less than nomi- nal diameter (D). This design is recommended for stations with multiple pumps with various opera- ting conditions. Formed intake design in concrete Formed intake design in steel Installation components The objective in the design and development of installation components is to devise simple sys- tems, which offer a wide variety of options to deal with most situations. These components have been developed to facilitate design work and esti- mation of costs. Normally, the installation com- ponents will be manufactured locally, based on Xylem drawings. The drawings can also serve as a basis for the development of new or modied components which better match the local require- ments and/or manufacturing facilities. Drawings are available for the following installa- tion components: Cover (C) for discharge elbows (E1 and E2) B C Column bracket (B) for anchoring the tube 11 Vertical discharge column (D) in which the pump is set. Depending upon the depth of the station, the installation may consist of one part (D1) or several parts joined together by anges (D2), or it may consist of a short tube prepared for grouting in concrete (D3). Discharge elbows (E) with rectangular exit fange (E1) and discharge elbows with circular exit fanges (E2, E3, E4). Supporting frame (F) for suspending the tube from the ceiling. Intake device is preferable for very adverse inow conditions or when pump bay dimensions are less than recommended. The main function of the intake device is to preserve an optimal inow to the pump by gra- dual acceleration and redirection of the ow toward the pump inlet. D1 D2 D3 E1 E2 E3 E4 F 12 Recommended dimensions All dimensions are in meters [m] Open sump intake design for Flygt PL pumps Open sump design for Flygt LL pumps
d i a g r a m Pump type 13 Formed intake design in steel Formed intake design in concrete Small duplex sump only Flygt pumps up to 3152 14 Head loss calculations Head losses are comparatively small for systems using propeller pumps. Even so, an accurate pre- diction of losses, and hence the total required head, is crucial when selecting the best pump. Propeller pumps have relatively steep head and power characteristics, and an error in predicting the total head can result in a signicant change in the power required. A potentially vulnera- ble situation can arise if head loss is signicant- ly under estimated, which can mean that a pump operates against a higher head, delivers less ow and uses more power. Conservative assumptions should thus be made in determining head loss cal- culations. For all installations described herein, the head losses that must be accounted for occur in the components of the discharge arrangement (fric- tion losses in short pipes are usually negligible). The loss coefcients and the head loss as a fun- ction of the ow rate for the system components designed by Xylem are shown in the diagrams. For system components not covered by this docu- ment, loss coefcients can be obtained from their manufacturers or from appropriate literature. H H [m] Q [m 3 /s] H=( ) Q 2 3 H W HS HS E1 E5 Side 700 850 E5 Top HS=Static head E1 W=700 K=0.45 E5 W=1050 K=0.37 E5 W=1400 K=0.35 E5 W=1750 K=0.34 E5 W=2100 K=0.33 H=Head loss HS=Static head 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 H=Head loss Inlet dia Inlet dia K . W . 2g Flygt P7045, P7050 E1, E5 r E2 Do=500 K1=2.5 Do=600 K1=1.3 Do=700 K1=1.13 Do=500 K2=2.0 Do=600 K2=0.86 Do=700 K2=0.77 K1: Sharp bend K2: Smooth bend = 0 > 0,1 Inlet dia O u t l e t
d i a H [m] 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Q [m 3 /s] 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 Flygt P7045, P7050 E2 r Do r Do H [m] 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Q [m 3 /s] 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 Flygt P7045, P7050 E3, E4 E3 E4 Do=500 E3 K=1.23 Do=600 E3 K=0.60 Do=700 E3 K=0.32 Do=500 E4 K=1.34 Do=600 E4 K=0.65 Do=700 E4 K=0.35 Inlet dia Inlet dia O u t l e t
d i a O u t l e t
d i a 15 H [m] Q [m 3 /s] 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Flygt P7076, P7081 E1, E5 H H=( ) Q 2 3 H W HS HS E1 E5 Side 1000 1200 E5 Top HS=Static head E1 W=1000 K=0.45 E5 W=1500 K=0.37 E5 W=2000 K=0.35 E5 W=2500 K=0.34 E5 W=3000 K=0.33 H=Head loss HS=Static head H=Head loss Inlet dia Inlet dia K . W . 2g r E2 Do=800 K1=1.75 Do=900 K1=1.23 Do=1000 K1=1.13 Do=800 K2=1.2 Do=900 K2=0.83 Do=1000 K2=0.77 K1: Sharp bend K2: Smooth bend = 0 > 0,1 Inlet dia O u t l e t
d i a H [m] 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Q [m 3 /s] 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 Flygt P7076, P7081 E2 r Do r Do Q [m 3 /s] 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 H [m] 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0 Flygt P7076, P7081 E3, E4 E3 E4 Do=800 E3 K=0.78 Do=900 E3 K=0.49 Do=1000 E3 K=0.32 Do=800 E4 K=0.85 Do=900 E4 K=0.53 Do=1000 E4 K=0.35 Inlet dia Inlet dia O u t l e t
d i a O u t l e t
d i a H [m] Q [m 3 /s] 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 1,2 1,0 0,8 0,6 0,4 0,2 0 Flygt P7055, P7061, P7065 E1, E5 H H=( ) Q 2 3 H W HS HS E1 E5 Side 800 950 E5 Top HS=Static head E1 W=800 K=0,45 E5 W=1200 K=0,37 E5 W=1600 K=0,35 E5 W=2000 K=0,34 E5 W=2400 K=0,33 H=Head loss HS=Static head H=Head loss Inlet dia Inlet dia K . W . 2g r E2 Do=600 K1=2,1 Do=700 K1=1,27 Do=800 K1=1,13 Do=600 K2=1,5 Do=700 K2=0,85 Do=800 K2=0,77 K1: Sharp bend K2: Smooth bend r Do r Do = 0 > 0,1 Inlet dia O u t l e t
16 H [m] Q [m 3 /s] 0 0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0 3,3 3,6 3,9 4,2 4,5 1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0 Flygt P7101, P7105 E1, E5 H H=( ) Q 2 3 H W HS HS E1 E5 Side 800 950 E5 Top HS=Static head E1 W=1200 K=0,45 E5 W=1800 K=0,37 E5 W=2400 K=0,35 E5 W=3000 K=0,34 E5 W=3600 K=0,33 H=Head loss HS=Static head H=Head loss Inlet dia Inlet dia K . W . 2g H [m] 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 Q [m 3 /s] 0 0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0 3,3 3,6 3,9 4,2 4,5 Flygt P7101, P7105 E2 r E2 Do=1000 K1=1,51 Do=1200 K1=1,13 Do=1000 K2=0,99 Do=1200 K2=0,77 K1: Sharp bend K2: Smooth bend = 0 > 0,1 Inlet dia O u t l e t
d i a r Do r Do Q [m 3 /s] 0 0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0 3,3 3,6 3,9 4,2 4,5 H [m] 0,60 0,55 0,50 0,45 0,40 0,35 0,30 0,25 0,20 0,15 0,10 0,05 0 Flygt P7101, P7105 E3, E4 E3 E4 Do=1000 E3 K=0,66 Do=1200 E3 K=0,32 Do=1000 E4 K=0,73 Do=1200 E4 K=0,35 Inlet dia Inlet dia O u t l e t
d i a
O u t l e t
d i a
H [m] Q [m 3 /s] 0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0 6,5 7,0 2,0 1,8 1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0 Flygt P7115, 7121, 7125 E1, E5 H H=( ) Q 2 3 H W HS HS E1 E5 Side 800 950 E5 Top HS=Static head E1 W=1400 K=0,45 E5 W=2100 K=0,37 E5 W=2800 K=0,35 E5 W=3500 K=0,34 E5 W=4200 K=0,33 H=Head loss HS=Static head H=Head loss Inlet dia Inlet dia K . W . 2g r E2 Do=1200 K1=1,45 Do=1400 K1=1,13 Do=1200 K2=0,95 Do=1400 K2=0,77 K1: Sharp bend K2: Smooth bend = 0 > 0,1 Inlet dia O u t l e t
d i a
H [m] 1,5 1,4 1,3 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 Q [m 3 /s] 0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0 6,5 7,0 Flygt P7115, P7121, P7125 E2 r Do r Do Q [m 3 /s] 0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0 6,5 7,0 H [m] 0,70 0,65 0,60 0,55 0,50 0,45 0,40 0,35 0,30 0,25 0,20 0,15 0,10 0,05 0 Flygt P7115, P7121, P7125 E3, E4 E3 E4 Do=1200 E3 K=0,59 Do=1400 E3 K=0,32 Do=1200 E4 K=0,65 Do=1400 E4 K=0,35 Inlet dia Inlet dia O u t l e t
d i a
O u t l e t
d i a
17 Installation type 1 Suitable for pumping liquid to a recipient with small level variations or where a short running time can be expected, so shut-off devices are not requi- red. This arrangement is simple. It involves the least possible number of steel components. The pump is set in a circular concrete shaft with a relative- ly short tube grouted in place, installation compo- nent D3, which is used as the base for the pump. Alternatively, the shaft can have a rectangular cross-section above the discharge column. The shaft extends above the maximum water level in the outlet channel to prevent water from running back to the sump when the pump is shut off. Installation type 2 An alternative to the concrete shaft is to place the pump in a steel column with a collar that rests on a supporting frame (installation component D1). The top of the pipe must extend sufciently above the maximum water level to prevent back-ow from the outlet channel. Installation types The following examples show possible alternatives using Xylem designed installation components. 18 Installation type 3 This arrangement may be used with either a free discharge, when liquid is pumped to a reci- pient with small water level variations, or with a ap valve, when the water level on the outlet side varies considerably so that the outlet is occasion- ally submerged. The ow is discharging into a closed culvert through the component E1. Installation type 4 This arrangement is suitable wherever the liquid is pumped to a recipient with a varying water level. The outlet is equipped with a ap valve to prevent back-ow. When the pump is not in operation, the valve closes automatically, preventing water from running back into the sump. The static head is the difference between water level in the sump and water level at the outlet, and it will be kept to a minimum in this type of installation. Elbow type E2E4 can be used for discharging. 19 Installation type 5 This easy-to-install elbow construction allows pumps to work in combination with a siphon or discharge line. When outlet is submerged a siphon breaking valve is required to prevent back-ow and allow venting at start. This installation keeps the static head to a minimum, since the static head will be the difference between the water level in the sump and the water level at the outlet. Two types of elbows can be used with this station E2E4. As in previous cases, the steel tube rests on a support frame (installation component D1). Note: Support bracket (B1) should be used if the free unsupported length of the column pipe exceeds 5 times pipe diameter. Installation of pumps Pump installation can be facilitated with the aid of the Dock-Lock device for easy and safe retrieval of pumps in a wet well. The Dock-Lock consists of a spring-loaded hooking device, a guide line and a tension drum. Because the line guides the hook, theres no time wasted trying to nd the pump shackle. The device ensures that the hook actually locks into the shackle. Pumps are retrieved safely, easily and quickly, with minimal maintenance costs. Cable protection and suspension for tube installed pumps For tube-installed submersible pumps, proper cable protection and suspension is essential for trouble free operation. Cable suspension and pro- tection requirements become more stringent with longer cable lengths and higher discharge veloci- ties. 20 A few basic principles govern good cable protec- tion and suspension practices: 1. Cables must be suspended in such a way that if they should move, they will not come in contact with any surfaces which could abrade the jacket these include pump and tube components, as well as other cables. 2. Cables should be bundled together, using com- ponents which will not cut or abrade the cables. 3. Proper strain relief and support at prescribed intervals (depending on length) should be provi- ded. Spring-controlled tensioning and an integra- ted guide wire are recommended for long cable lengths. Xylem offers a variety of cable protection and sus- pension accessories with recommendations to suit all types of installations and running condi- tions. Contact your local Xylem Application eng- ineer for information on the best system to meet your needs. Flygt cable suspension system Corrective measures The designs described in this brochure have been proven to work well in practice. However, in some applicationsperhaps due to limitations of space, installation of new pumps in old stations, or dif- cult approach conditionsnot all the requirements for a good, simple design can be met. Sometimes, for example, it may be impossible to provide ade- quate submergence so that some vortexing or swirl may occur. Corrective measures must then be undertaken to eliminate the undesirable fea- tures of the ow, particularly those associated with excessive swirl around the pump tube, with air-entraining surface vortices and with submer- ged vortices. Swirl around the pump tube is usually caused by an asymmetrical velocity distribution in the approach ow. Ways should be sought to improve its symmetry. Subdivision of the inlet ow with divi- ding walls, and the introduction of training walls, bafes or varied ow resistance are some options that may achieve this result. Alternatively, a reduc- tion of the ow velocity, for example, by increasing the water depth in the sump, can help to minimize the negative effects of an asymmetrical approach. Relatively small asymmetries of ow can be cor- rected by the insertion of splitter plates between the pump tube and the back wall of the sump and underneath the pump on the oor; these plates block the swirl around the tube and prevent for- mation of wall vortices. These measures are integral features in most of our standard congu- rations. Submerged vortices can form almost anywhere on the solid boundary of the sump, and they are often difcult to detect from above the free sur- face. Their existence may be revealed only by the rough running of the pump or from erosion of the propeller blades. They can be detected much more readily in model tests. They can be elimi- nated by disturbing the formation of stagnation points in the ow. The ow pattern can be altered, for example, by the addition of a center cone or a prismatic splitter under the pump, or by insertion of llets and benching between adjoining walls, as in some of our standard congurations. Air-entraining vortices may form either in the wake Back wall and oor splitter plates Back wall vortex caused by oor splitter only 21 of the pump tube or upstream from it. They form in the wake if the inlet velocity is too high or the depth of ow is too small, and they form upstream if the velocity is too low. In either case, these vorti- ces can be eliminated by introducing extra turbu- lence into the surface ow, for example, by placing a transverse beam or bafe at the water surface. Such a beam should enter the water at a depth equal to about one quarter of the tube diameter and be placed at a point about 1.52.0 diameters upstream of the tube. If the water level varies con- siderably, a oating beam can be more effective. In some cases, a oating raft upstream of the tube will eliminate air-entraining vortices. This raft may be a plate or a grid. Both forms impede the forma- tion of surface vortices. An alternative is the use of an inclined plate similar to that shown in the draft tube installation. Pump station model testing Hydraulic models are often essential in the design of structures that are used to convey or control the ow distribution. They can provide effective solu- tions to complex hydraulic problems with unmat- ched reliability. Their costs are often recovered through improvements in design that are techni- cally better and yet less costly. Model testing is recommended for pumping sta- tions in which the geometry differs from recom- mended standards, particularly if no prior experience with the application exists. Good engineering practice calls for model tests for all major pumping stations if the ow rate per pump exceeds 2.5m 3 /s (40000USgpm) or if multiple pump combinations are used. Tests are particularly important if: Sumps have water levels below the recommen- ded minimum Sumps have obstructions close to the pumps Sumps are signifcantly smaller or larger than recommended (+/- 10%) Multiple pump sumps require baffes to control the ow distribution Existing sumps are to be upgraded with signif- cantly greater discharges A model of a pumping station usually encompas- ses a representative portion of the headrace, the inlet structure, the forebay and the pump bays. The discharge portion of the ow is seldom inclu- ded. Testing may encompass the following ow features and design characteristics: Inlet structure: fow distribution, vortex forma- tion, air entrainment, intrusion of sediment and debris. Forebay and pump bays: ow distribu- tion, mass swirl, surface and bottom vortices, sedi- ment transport. Operating conditions: pump duty modes, start and stop levels, pump down proce- dures. Model testing can also be employed to seek solu- tions to problems in existing installations. If the cause of a problem is unknown, it can be less expensive to diagnose and remedy with model studies rather than by trial and error at full scale. The pump manufacturers involvement is often required in the evaluation of the results of model tests. Experience is required to determine whether the achieved results are satisfactory and will lead to proper overall operation. Xylem can offer guidance regarding the need for model tests and assist in their planning, arrange- ment and evaluation. Floating raft or vortex breaker grid Surface bafe for vortex suppression 22 Computational modeling Computational fuid dynamics (CFD) analysis has the potential of providing far more detailed infor- mation of the ow eld at a fraction of cost/ time needed for the model tests and it has been more and more accepted as a tool in station design. In combination with Computed aided design (CAD) tools it is possible to obtain a more effcient method for numerical simulation of station design. CFD offers increased qualitative and quantitati- ve understanding of pumping station hydraulics. It can provide good comparisons between vari- ous design alternatives.However, the possibili- ties of CFD should not be overestimated. Diffcult cases are encountered where free surface effects are importantfor instance. Also, a phenomenon like air entrainment is diffcult to capture with CFD analysis. Both model tests and CFD have advantages and disadvantages that need to be evaluated in each individual case. Xylem can advise on a good com- bination between model tests and CFD. Systems Engineering Xylem Systems Engineering offers in-depth exper- tise in the design and execution of comprehensive solutions for water and wastewater transport and treatment. Our know-how and experience are combined with a broad range of suitable products for delivering customized solutions that ensure trouble-free operations for customers. To do this our engineers utilize our own specially developed computer programs, as well as commercial, for design and development projects. Scope of assistance includes a thoroughgoing analysis of the situation and proposed solutions together with selection of products and accesso- ries. We also provide hydraulic guidance and assis- tance for ow-related or rheological issues. Customers turn to us, as well, for analysis of com- plex systems for network pumping, including cal- culations for hydraulic transients, pump starts and ow variations. Additional services: Optimization of pump sump design for our products and specic sites Assistance with mixing and aeration specifca- tions and design of appropriate systems System simulation utilizing computational fuid dynamics (CFD) Guidance for model testing and organizing it Guidance for achieving the lowest costs in operations, service and installation Specially developed engineering software to facilitate designing The range of services is comprehensive, but our philosophy is very simple: There is no substitute for excellence. Flygt is a brand of Xylem. For the latest version of this document and more information about Flygt products visit www.ygt.com 1) The tissue in plants that brings water upward from the roots 2) A leading global water technology company
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