Three-dimensional CFD simulation of solid-liquid two-phase flow in the pumping station

forebay with sills

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2012 IOP Conf. Ser.: Earth Environ. Sci. 15 062027
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Three-dimensional CFD simulation of solid-liquid two-phase
flow in the pumping station forebay with sills
Z H Mi
1
, D Q Zhou
1
and Y T Mao
2
1
College of Energy and Electrical, Hohai, Univ. Nanjing, Jiangsu, China
2
Hydroelectric Investigation & Design Institute of SPC, Chengdu, Sichuan,China
E-mail address: nicholas1214m@163.com
Abstract. Sills have been used in the forebay of pumping station in order to eliminate the
circulation and vortex of diffusing flow which impact on pump performance and sediment. In
the paper, three-dimensional method is used to simulate the sill flow in the forebay of pumping
station based on Eulerian solid-liquid two-phase flow model. Research focuses on that sill with
different section, dip and position makes important impact to flow pattern and sediment
movement. The numerical results show that the attempts of adopting discontinuous bottom sills
is the most effective way to eliminate the surface backflow and make the cross-section velocity
distribution tend to uniform. The velocity at the bottom of the forebay and suction bay and near
the pump inlet decrease significantly. Sediment accumulations in the forebay and behind the
bottom sills are avoided or decreased. Compared with the literature and experimental results, it
can be confirmed that CFD simulation results are credible. The further analysis can provide
theoretical basis for improving the flow pattern and avoiding sediment deposition in the
forebay.
1. Introduction
Sediment deposition caused by poor flow of inlet structure in pumping station has a huge negative
impact on unit operation and pump station management[1]. As a modification of flow pattern with the
advantages of simple form and convenient construction, sill has obvious effect on eliminating vortex
and backflow. It comes from the fact that sill can damage plane backflow by creating roll swirl of
elevation. Studies in the past mainly focus on mechanism of flow around sill. Feng Xusong analyzed
main characteristic parameter and flow pattern behind of sill by studying on two-dimension flow
through sill applied for forebay of pumping station[2]. Cheng Li studied on backflow behind of sill
based on RNG k- turbulent model by two-dimension numerical simulation[3]. However, inlet
structure flow in pumping station, especially arrangement with bottom sill, is very complex and show
three-dimensional characteristics. Even so, three-dimensional CFD numerical results of two-phase
flow in pumping station with sill have been rarely reported by now. Therefore, three-dimensional CFD
numerical method is used to simulate flow field and sedimentation in pumping station with sill based
on Eulerian solid-liquid two-phase flow model in the paper.
2. Numerical method
The commercial software, fluent 6.3, has been used to simulate the whole inlet flow field of pump
station. Computational grids consist of almost three billion unstructured tetrahedron elements built by
the Gambit, as a result of tradeoff between grids sensitivity and PC computing capability. Realizable
turbulent model is adopted to close the Reynolds Averaged Navier-Stokes equations. Governing
26th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 15 (2012) 062027 doi:10.1088/1755-1315/15/6/062027
Published under licence by IOP Publishing Ltd
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equations are discreted with finite volume method, and second-order implicit format for time item,
second-order central difference format for diffusion item, second-order upwind format for convection
item, and SIMPLEC method for velocity-pressure coupling solution.
All kinds of boundary condition are set as follows:
1.No-slip boundary condition for the wall, standard wall function for region near the wall.
2.The symmetric boundary hypothesis for the free surface.
3.Velocity inlet is given to the inlet.
4.Outflow is given to the pump inlet passage outlet where flow is fully developed.
In the Euler-Euler approach, different phases are treated mathematically as interpenetrating
continua. Since the volume of a phase cannot be occupied by the other phases, the concept of phase
volume fraction is introduced. These volume fractions are assumed to be continuous functions of
space and time and their sum is equal to one[4]. The Eluerian model is the most complex of the
multiphase models in FLUENT. It solves a set of n momentum and continuity equations for each
phase. Coupling is achieved through the pressure and interphase exchange coefficients. The manner in
which this coupling is handle depends upon the type of phases involved, fluid-solid flows are handled
differently than fluid-fluid flows. For fluid-solid flows, the phase is also dependent upon the type of
mixture being modeled.
The continuity equation of the solid-liquid two-phase flow is described as follow:

1
( ) ( )
l l
l
l l sl l
t l
d
v m
dt

o o o

c | |
+V =
|
c
\ .
(1)
Momentum conservation equation of Liquid-Phase is

.
, ,
( ) ( )
( ) ( )
l
l l l l l l l l l l
l lift l Vm l s l sl
l l sl sl
v v p g
t
F F F K v v m v
o v o o t o
o
c
+V = V +V +
c
+ + + + +
(2)
Momentum conservation equation of Solid-Phase is
, ,
.
( ) ( )
( ) ( )
s s s s
s s s s s s
s lift s Vm s s
s s s s ls l
ls
ls
v v v p p
t
g F F F K v v
m v
o o o t
o o
c
+V = V V +V
c
+ + + + +
+
(3)
For Eulerian model, different phases are not interpenetrating and denoted as volume fraction of the
phase. In each volume unit, sum of all the phase volume fraction is 1[4], volume fraction of sand in the
inlet and outlet is 0.1 and 0.06 respectively. The density of sand is 2500 kg/m
3
and the viscosity
coefficient is 0.001003 kg/ms. Water-liquid is chosen as primary phase and sand as secondary phase
in the process of two-phase simulation.
3. Select characteristic parameters of sill
In order to reference the related research results, select the same model and flow condition provided
by literature[6]. Figure 1 shows the whole experimental model arrangement of hydraulic structure.
26th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 15 (2012) 062027 doi:10.1088/1755-1315/15/6/062027
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Figure 1. The sketch of the whole experimental model arrangement of hydraulic structure
The height, among various characteristic parameters of sill, plays an important role in improving
flow pattern. Height of sill direct effect the length of roller range and flow pattern behind sill. Height
of sill is too low, cannot achieve the expected effect; but too high, increasing head loss of dynamic
water flow. Rajaratnam suggested the height is (0.35~0.6)times of water depth[7]; Liu Chao selected
the height as (0.4~0.55)times of water depth to simulating[8]. In this paper, height of sill is 0.45 times
of water depth.
The common shape of sill is triangle section, trapezoid section and rectangular section. Research
show that trapezoid section and rectangular section have the similar flow pattern, but rectification
effect of triangle section is poor[9]. Therefore, in this paper, choose the best shape of sill from
trapezoid and rectangular section.
Figure 2 to figure 5 are horizontal cross-section velocity field, plotted with streamline. The
numerical simulation results show that both trapezoid and rectangular section could create roll swirl in
the bottom sill rear. However, roller before sill, can induce backflow which affect flow in upstream,
just caused by trapezoid section. Therefore, trapezoid is not suitable for upstream side.










Seen from figure 6 to figure 9, sediment deposits inevitable near the sill because of the low speed
area around sill. The comparison result of numerical simulation shows that sill with rectangular form
has slighter sediment deposition.
Figure 2. Velocity contours and
streamlines in rectangular section of sill
Figure 3. Velocity contours and
streamline in trapezoid section of sill
Figure 4. Velocity contours and
streamlines in combination section of sill
Figure 5. Velocity contours and
streamlines in combination section of sill
26th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 15 (2012) 062027 doi:10.1088/1755-1315/15/6/062027
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According to numerical results of experimental model, sill with rectangular form is the optimal
scheme.
4. Water retaining sill application in forebay of pumping station
In the study, five shaft tubular pump units were installed and design flow of single pump was 34m/s.
The length of the pump station includes approach channel, forebay and intake sump is 690m. Under
the design condition, total flow Q of five pumps is equal to 206.5 m
3
/s and water depth is 1.88 m.
Figure 10 shows the whole preliminary arrangement of hydraulic structure.

Figure 10. The sketch of the whole preliminary arrangement of hydraulic structure
4.1. Eulerian two-phase flow numerical results of preliminary scheme
In order to analyze the numerical results, horizontal cross-sections is intercepted 0.1m from the bottom
floor , in which elevation is -2.5m, and the free water surface. In the paper, time step is set as 0.005s
and Max iteration per time step is 40. The numerical results after 30 seconds are as follows:.
Figure 11 and figure 12 is horizontal cross-sections velocity field, plotted with streamline. Figure
12 indicates that preliminary layout scheme of hydraulic structure makes main flow run near the right
side of approach channel, which causes vortex occurrence on the left side of forebay. Comparing
Figure 6. Contours of sand volume
fraction in rectangular section of sill
Figure 7. Contours of sand volume
fraction in trapezoid section of sill
Figure 8. Contours of sand volume
fraction in combination section of sill
Figure 9. Contours of sand volume
fraction in combination section of sill
26th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 15 (2012) 062027 doi:10.1088/1755-1315/15/6/062027
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figure 11 with figure 12, it is shown that vortex in the left side of forebay is a deep one which extends
from surface to bottom, but vortex occurrence on the left of approach canal is a shallow one which just
appears on the surface.
Figure 13 shows that due to the sluice gate is closed, sill of sediment retaining induces most sand to
deposit in downstream low velocity region of river. However, a few sands still enter approach channel
and deposit in the low velocity region on the left side of forebay.
Seen from figure 11 to figure 13, the vortex area has no significant sediment because its vortex
structure is deep with high velocity of flow at the bottom of pump station. Sediment mainly deposits in
the left side of forebay, which agrees with the distribution characteristics of low velocity region
displayed in the figure 5 and figure 6.






According to numerical results of preliminary scheme, some measures should be taken to improve
hydraulic performance and decrease sediment deposition.
4.2. Eulerian two-phase flow numerical results of improved scheme
According to the fact that the length of forebay is relatively short and diffusion angle is too large,
discontinuous bottom sill which have clearance between sill and lateral wall is set in the transition of
forebay in order to eliminate the vortex and decrease sediment on the left side of forebay. Height of
sill is 1.971m which is 0.45 times of water depth, and the sill with rectangular form is introduced into
this paper. The whole arrangement of the improved scheme is shown in the figure 14.
Figure 11. Velocity contours and
streamlines in H=-2.4m horizontal
section for the preliminary scheme
Figure 12. Velocity contours and
streamlines in H=1.88m horizontal
section for the preliminary scheme
Figure 13. Contours of sand volume fraction in H=- 2.4m horizontal section for
thepreliminary scheme
26th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 15 (2012) 062027 doi:10.1088/1755-1315/15/6/062027
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The selected sections for analysis are the same as the preliminary scheme and numerical results are
as follows:
Seen from figure 15 and figure 16, it can be found that under the discontinuous water retaining sill,
vortex region on the left side of forebay has been eliminated, and flow become more uniform than the
preliminary scheme.
Comparing figure 9 with figure 5, it is shown that the flow pattern in the forebay is optimized
significantly and vortex is eliminated. Comparing figure 10 with figure 6, it can be seen that the bias
flow in the approach channel is not so obviously, and low-speed area become smaller than before.






Figure 17 indicates that most sands have been blocked by sediment retaining sill and deposit in the
downstream river. Sedimentation region in the left side of forebay become very small because of
forebay flow pattern improvement. Sediment deposition behind the bottom sill agrees with the
distribution characteristics of low velocity region displayed in the figure 2.
Figure 14. Three dimensional sketch of the whole improved arrangement of
hydraulic structure
Figure 15. Velocity contours and
streamlines in H=-2.4m horizontal
section for the improved scheme
Figure 16. Velocity contours and
streamlines in H=1.88m horizontal
section for the improved scheme
26th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 15 (2012) 062027 doi:10.1088/1755-1315/15/6/062027
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5. Conclusions
In the paper, the flow features and sedimentation of the whole pump station inlet field have been
analyzed by the CFD method. From the numerical results, some conclusions can be drawn as follows:
(1) Eulerian solid-liquid two-phase flow simulation is an effective method to entirely meticulous
analysis the complex flow pattern in forebay of pumping station and revealed the correlativity between
flow field and sediment deposition.
(2) Discontinuous water retaining sill can improve flow pattern by increasing velocity of side wall,
decrease sedimentation in the forebay significantly by eliminating low velocity region.
(3) The results of this study need to be further verified by actual operation of pumping station.
Nomenclature
c'
coefficients of sediment
l
F
an external body force
, lift q F
a lift force
, vm q F
a virtual mass force
g
acceleration due to gravity
H

the horizontal cross-section height
ls sl
K K = Momentum exchange coefficient
between fluid or solid phase l and solid phase s
k
turbulent kinematic energy
sl
m Mass transfer from Solid-Phase to
Liquid-Phase
s
p the solids pressure
Q flow rate (m
3
/s)
l
v Velocity of Liquid-Phase
s
v Velocity of Solid-Phase
Figure 17. Contours of sand volume fraction in H=-2.4m horizontal section for the
improved scheme
26th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 15 (2012) 062027 doi:10.1088/1755-1315/15/6/062027
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c turbulent dissipation rate
l
o Liquid-Phase volume fraction
s
o Solid-Phase volume fraction
l
t Shear stress tensor of Liquid-Phase
s
t Shear stress tensor of Solid-Phase
V Gradient
l
Physical density of liquid
s
physical density of solid
Acknowledgements
The support of College of Energy and Electrical, Hohai University, China is gratefully acknowledged.
This research project is sponsored by Natural Science Foundation of China (No. 51106042)
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IOP Conf. Series: Earth and Environmental Science 15 (2012) 062027 doi:10.1088/1755-1315/15/6/062027
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