Quotation

Date Our reference Page

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1 Introduction

1.1 Background
KSB is tendering to deliver the pumps for the Canoas pumping station, a waste water intake.
Next to the delivery of the pumps a physical scale model test is required to assure that the
feeding of the pumps meets all acceptance criteria. KSB has requested Deltares to provide a
proposal for both CFD and physical model testing. The document at hand presents the proposal
for these studies.

1.2 Objectives
The objective of the CFD modelling is to determine whether large scale flow patterns will occur
in the pumping station which can have a negative influence on the feeding of the pumps.

The objective of the physical model study is to optimize the flow patterns towards the pump
compartments and to verify and optimize the pump feeding against the ANSI/HI 9.8-2018
acceptance criteria under all relevant operating conditions from a hydraulic point of view.
Moreover, the behaviour of sediments will be assessed.

1.3 Capabilities Deltares

Deltares has a long experience of more than 40 years in physical modeling of pumping stations.
Our reference list is attached to this proposal. In addition to this, Deltares has written over 8
scientific publications on modeling of pumping stations over the last 5 years. Next to that, we are
a member of the ANSI/HI 9.8 standard. We work together with other partners on the new revision
of the standard.

Deltares has over fifteen years of experience in performing CFD studies for various hydraulic
applications. The presence of experimental facilities gives a unique position to verify our CFD
against our own experimental measurements. Thanks to this experience Deltares’ CFD experts
have developed a set of best practices for the simulation of a wide range of hydraulic
applications, including approach flows in pumping stations, navigation lock levelling systems,
weir overflows and other multi-phase flows. These best practices involve mesh grading,
appropriate turbulence treatment and other aspects in order to obtain reliable results within a
practical time frame.
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2 System Description

The waste water coming from the main tunnel is flowing via three screening channels into two
wet wells. In each well three suction chambers with pumps are located. Moreover, a weir is
located at a level of about EL. 2517 m to discharge an excess flow into the spillway. A top view
and a side view of the pumping station are given in respectively Figure 2.1 and Figure 2.2.

The discharge per pump depends on the operating condition and varies between 4 m 3/s and
6.4 m3/s per pump. The minimum flow through the pumping station will be 6.2 m 3/s while the
maximum capacity is 38.4 m 3/s.

The exact water levels at which the pumping station will be operated are not yet known. For this
proposal, it is assumed that the minimum water level at which the pumping station will be
continuous operated is about EL. 2514 m. At maximum capacity the water level is assumed to
be about EL. 2518 m.

Figure 2.1 Top view of the pumping station

Figure 2.2 Cross section of the pumping station in the discharge well.
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3 Task 1 CFD modelling

A CFD study will be performed for the pumping station, the wet well including a representative
part of the intake tunnels will be modelled.

3.1 Modelling software Star-CCM+

The simulations will be performed by means of the commercially available software package
Star-CCM+. Star-CCM+ is a Computational Fluid Dynamics (CFD) code for the simulation of
flows in a general sense (https://mdx.plm.automation.siemens.com/star-ccm-plus). The software
can be applied to the numerical simulation of mass, momentum and heat transfer in
incompressible or compressible, laminar or turbulent, steady or unsteady, Newtonian or non-
Newtonian fluid flows. Also, the motion of particles, the mixture of fluids, fluid phases (gas, liquid,
solid), concentrations, chemical and biological reactions, can be simulated if applicable.

A range of techniques are available within Star-CCM+, to simultaneously solve the equations for
mass conservation, momentum conservation (Navier-Stokes equations), heat transfer and
turbulence. Several turbulence models and numerical solvers are available. These models and
solvers, as well as the solution strategy, can be specified by the user. In the experience of
Deltares’ CFD experts, this code is well capable of fulfilling the requirements of this assignment.

Deltares uses Star-CCM+ on a regular basis to asses approach flows in pumping stations as
part of optimisation and verification studies of large pumping stations for power and desalination
plants.

3.2 Scope of work

A detailed analysis of the flow patterns in the pumping station will be performed. A representative
part of the intake tunnel will be taken into account. The main goal of the CFD study is to verify
the design with respect to the approach flow conditions towards the pumps in preparation of the
physical model test. The simulation will not be used to solve for the formation of vortices or air
entrainment at the pumps as this will be part of the physical model test. The CFD study will
provide an indication where vortices and air entrainment might occur. Because of the expected
water level differences (> 20 cm) at low water level and the overflow of the spillway at high water
level (> EL 2517 m), for all simulations a VoF model will be applied to model the interphase
between water and air. In case of overflow over the spillway, a free-flowing weir will be assumed
at all times. The modelling of sediment is not included in the simulations offered. Although zones
where sediments might settle will be indicated based on the simulations.

The flow patterns in the intake structure will be studied for three scenario’s (operating conditions).
A scenario is defined by a water level in the pumping station, the number of pumps in operation
and their discharge and the position of the stop logs (open or closed). The simulations will
assume steady-state conditions. Both dry and rainy weather conditions will be taken into
account. Two of the scenario’s offered will have a water level below the overflow weir crest level
and one of the scenario’s will have a water level above the overflow weir crest level.

The design as provided by KSB will be used for the simulations. The numerical model will include
a representative part of the intake tunnel, the screening channels, the wet wells, suction
chambers and suction pipes until the pump inlet. The screens will be modelled as a resistance
of which the resistance depends on the clogging percentage of the screen. For high water level
conditions, also the spillway wall and a representative part of the emergency tunnel will be
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included. As boundary conditions a discharge boundary will be used at the pomps. At the
remaining boundaries a pressure boundary will be used.

3.3 Scenarios
We offer to simulate three different scenario’s (operating conditions). It is our experience that by
performing those simulations a good overview is obtained of the functioning of the structure.
Additional information obtained by simulating a start-up or stop of the system is limited and is not
covered in the scope of the CFD study. The water levels that can occur should be provided by
KSB.

3.4 Model generation

For each structure, 3D CAD files will be prepared based on 2D drawings to be provided by KSB,
representing the structure to be modelled (at prototype scale, in the baseline configuration). The
drawings will be generated with a detail level appropriate to the CFD simulation and are not
meant as production drawings.

3.5 Design verification

For each scenario the inflow angles to the pump suction, flow patterns and distribution at the
pump inlet and time-averaged flow patterns (in terms of velocity (vectors) and pressure) in the
structure will be reported. These will be obtained by visualizing the flow in an appropriate number
of cross-sections (to be determined) and a representation of the flow field by streamlines.
Moreover, it will be indicated where dead zones occur in the system. This are possible areas
where sediments can be collected.

Deltares experts will analyse the results and when required, measures will be proposed to
improve the flow pattern. It is not expected that major measures to the intake structure are
required. Therefore, in view of time, proposed measures will be tested during the physical model
test. Simulations of these measures in CFD is not included in the scope of work, but offered as
an optional activity. When (preliminary) results of the CFD simulations are available, a video
conference will be held with all parties to discuss whether additional CFD simulations has to be
performed. If the proposed measures have to be assessed in CFD, this will impact the time
schedule for the physical model testing with about 3 weeks.

3.6 Deliverable
The findings of the CFD studies will be presented in a comprehensive report.
– Description of objectives
– Description of the structure subject to CFD modelling, initial model geometry
(including 3D rendering) and mesh
– Overview of initial geometry, scenarios, boundary conditions and simulations
– Overview of the CFD settings used (among others mesh size and turbulence model
used)
– Performance criteria
– Model results
– Expert analysis, evaluations and recommendations

The results of the CFD simulations will be exported to a format which can be imported in
Paraview and delivered to KSB. However, before the simulations start, the Client should inform
Deltares which results should be exported. Deltares will not be responsible for any post-
processing performed in Paraview.
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4 Task 2 Physical model test

A physical model test will be performed in which the approach flow towards the pumps will be
optimised such that proper pump feeding according to the ANSI/HI 9.8-2018 standard will be
obtained. The following work will be performed:
• Construction of the model,
• Submittals of the test procedure (including model drawings),
• Testing of the model and necessary modifications,
• Final testing of the model,
• Witness testing,
• Submittal of the physical model report,
• Video presenting of the physical model test.
A detailed description of these activities is given in the remaining of this Chapter.

A desk assessment is not included. That means that the water levels at the pumps for the
different operating conditions should be provided by KSB.

4.1 Introduction
The objective of this study is to optimize the pump sump design and the feeding of the pumps in
a physical model. The pumping station is reproduced to scale and will be tested in order to:
• Check pump working under the given operating conditions (combination of water level and
pumps in operation),
• Design and develop small modifications to achieve acceptable feeding of the pumps.

A scale model will be constructed in Deltares IOS-1 or IOS-2 basin. The designs as provided by
KSB will be tested in order to check proper pump feeding under the different operating conditions.

If the criteria for proper pump feeding are not fulfilled for example due to vortex shedding around
the pump entrance, at most three different (small) modifications at the pump suction chamber to
improve pump working are included in the current scope. Small modifications are limited to
splitters, corner fillings (horizontal or vertical), baffles and surface beams. Modifications and
provisions will be applied after consultation with KSB. The final design will be tested for the
relevant operating conditions. A one day witness test will be held with KSB (and the end-Client)
at Deltares’ office in Delft after completion of the tests.

4.2 Model description

For the physical model test a scale model of the pumping station will be made. The part that
will be modelled is presented in Figure 4.1 (blue box). The physical model will include a
representative part of the main tunnel, the screening channels, the wet wells, suction chambers
and suction pipes until the pump inlet, the spillway wall and a representative part of the
emergency tunnel.

For the model a scale of about 1:10 is proposed, using Froude scaling. This means that the
Froude number in the model is the same as the Froude number in reality. The scale will be such
that the Reynolds and Weber numbers based on the bellmouth are appropriate in order to
represent sufficiently high turbulence intensity and to avoid scale effects.
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Figure 4.1 Top view of the pumping station. The part within the blue box will be modelled.

In the physical model, the suction piping will be reproduced to scale with the pump entrance. The
part until the impeller will be modelled (see Figure 4.2). From the impeller onwards, the pump
will be modelled as a straight pipe (according to the ANSI/HI 9.8-2018 standard). The suction
pipe will be equipped with a roto-meter, while an additional suction line will be constructed and
be equipped with a pitot velocity meter to assess the velocity profile. Pump action will be obtained
by a downstream pump. The flow rate in the suction line is accurately measured with an
electromagnetic flow meter (accuracy about 2 % of measured flow).

Figure 4.2 Drawing provided by KSB of the pumps. The suction piping will be modelled in detail up to the red line.

The physical model tests will be performed for three water levels: minimum and maximum water
level and a third water level to be determined later. Various combinations of pump and screen
operation are tested.
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The screens are reproduced by a perforated plate with the correct flow guiding effects. The model
will be accurately constructed and will be made of plywood and Perspex. It will be assured that
there will be sufficient viewing properties to observe the flow patterns near the suction piping of
the pumps. The model will be located in Deltares’ IOS-1 or IOS-2 basin.

Testing will be performed by using clean water as a medium. This is common practice as the
properties of waste water are often unknown and differ from system to system. Therefore, clean
water will be used to reach proper pump feeding according to the ANSI/HI 9.8-2018 standard.
Thereafter, some tests will be performed to determine the behaviour of solids in the pumping
station. These tests will be performed with particles representing the floating solids and particles
representing the settling solids. The tests with solids will be performed during the final testing.
Note that these tests can only be performed when the characteristics of the waste water (particle
size, particle density, amount of solids) are provided by KSB.

4.3 Testing
In order to maintain the quality of the test, the measurements will not start until a constant flow
rate and a stable water level in the model has been established.

The flow conditions in the pumping station are judged by the following measurements:
· Determination of the flow pattern in the sump by means of dye injection,
· Vortex building and air entrainment into suction pipes of the pumps by means of dye
injection and visual observations,
· Tornado building (bottom and wall) by means of dye injection,
· Swirl in the suction pipe at the impeller inlet with a roto-meter,
· Velocity profile and velocity fluctuations in the suction pipe at the impeller inlet by means
of pitot tubes.

Moreover, some additional tests will be performed for a limit number of test conditions. These
tests are further discussed in Section 4.5. These additional tests are:
• Calibration of the flow over the spillway crest.
• Velocity measurements at certain cross-sections in the intake structure, including
pressure difference measurements to be able to determine the head loss between
different parts of the system.
• Behaviour of solids.

4.4 Acceptance criteria

The tolerances to be applied on the test results will be based on the ANSI/HI 9.8-2018 standard
and Deltares’ experience. The ANSI/HI 9.8-2018 standard acceptance criteria are widely
accepted and used for the hydraulic evaluation of pump sumps scaled in a physical model. On
request additional acceptance criteria of KSB can be applied.

4.5 Test procedure

A test procedure report will be made prior to the model testing including details of the tests to be
performed. This test procedure has to be approved by KSB before execution of the test program.
The currently anticipated number of tests that will be performed in each phase are summarized
in Table 4.1. Note that the exaggerated velocity test and the clogging test will be performed
during the final and supplementary testing.
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Table 4.1: Number of tests to be performed for the physical model test.
Final test Supplementary tests
Initial Optimization test
tests Ex. Velocity
(per modification) Velocity profiles Clogging Air Entrainment
150%

20 5 2 2 2 1

The physical model study will be performed in the following steps:

Phase I (initial testing)

The initial testing will start with the calibration of the spillway crest. As our model set-up is based
on regulating the flow based on the water level and the flow through the suction pipes,
adjustments to the main set-up have to be made to be able to calibrate the flow over the crest.
Additional pumping capacity and flowmeters will be installed to be able to calibrate the flow over
the spillway crest. The calibration will be performed by measuring the water depth above the
spillway crest for three different discharges.

Testing of the design (provided by KSB) without any flow guiding structures like splitters and
fillings in the pump compartments. Assessment of the hydraulic behaviour of the pumping station
is based on criteria for proper pump operation regarding vortex building, air entrainment, pre-
rotation, and flow patterns (flow separation, instabilities, dead zone building).

For each of these tests, the screen will be assumed cleaned at 100%. A dedicated clogging test
will be performed during Phase III (final testing).

The test results will be compared with the acceptance criteria given in the ANSI/HI 9.8-2018
standard. If they do not fulfil the requirements, optimization tests will be performed (Phase II). If
the test results of Phase I are acceptable (which is not in line with the expectations), Deltares
will skip Phase II and proceed with Phase III.

Phase II (optimisation testing)

If the present design leads to unacceptable conditions according to ANSI/HI 9.8-2018 standard,
Deltares will test configurations of small modifications for a limited set of operating conditions
selected from the initial testing (based on worst behaviour). Deltares has the free choice to
propose appropriate measures. KSB will be informed which modifications are planned to be
tested. KSB can reject a certain modification only if it is not feasible from a construction point of
view. KSB should react within 1 day on the proposed modification. If more time is required, the
standby rate of the facility will be charged. At most three different sets of configurations are
included in the scope. The optimisation test is concluded once all measured criteria are
acceptable. Our experience is that in most cases three modifications are sufficient to reach
acceptable flow patterns towards the pumps. If acceptance criteria are not met after three
modifications, Deltares will advise KSB on how to proceed.

Assessment of the hydraulic behaviour of the pumping station (including the screening channels)
is based on criteria for proper pump operation: vortex building, air entrainment, pre-rotation and
flow patterns (flow separation, instabilities, dead zone building.
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Phase III (final testing)

Final testing consists of the measurement of the velocity profile and an exaggerated velocity test.

1. Velocity profiles of the pumps: This test is performed in order to determine whether these
pumps are functioning within the acceptance criteria related to the velocity profile.
2. Exaggerated velocity tests: The exaggerated velocity test (Fr ex = 1.5 x Frprototype) is
performed in order to check on any significant scale effects for free surface vortices (not
expected with the proposed scale). The occurrence of free-surface vortices will be checked.

Phase IV (Supplementary testing)

The supplementary testing will be performed to determine the robustness of the design.

1. Clogging of the screening channels: The clogging will be simulated by blocking

approximately 50% of the screens for the operating conditions selected from these
investigated in the optimization phase.
2. Air entrainment test: starting at the low water level, the water level will be dropped until air
entrains from the free surface into the Pumps. This test shows the operational margin of the
system with respect to the water level.
3. Tests with solids: Different solids, representing the particles in waste water, will be used to
perform 2 tests. The test conditions will be selected from the optimisation testing. It will be
reported where deposit of solids occurs. It is not within the scope of Deltares to judge
whether this is acceptable or not. Optimisation of the pumping station based on the outcome
of these tests, are not included within the scope of work as the implication of the outcome
of these tests cannot be foreseen.
4. Head loss and velocities: The following measurements will be performed for three operating
conditions:
– Measuring the pressure difference between 4 different locations in the intake
structure to determine the head loss.
– Water depth.
– Performing at four cross sections, at least 6 velocity measurements per cross-section.

4.6 Witness testing

A witness test will be held at the end of Phase IV. It consists of a dedicated testing program for
one day aimed at showing the owner and KSB the results of the investigation. The witness test
will be documented in minutes, which are submitted to KSB at the end of the testing day.
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5 Deliverables

5.1 Task 1 CFD modelling

The findings of the CFD studies will be presented in a comprehensive report.
– Description of objectives
– Description of the structure subject to CFD modelling, initial model geometry
(including 3D rendering) and polyhedral mesh
– Overview of initial geometry, scenarios, boundary conditions and simulations
– Performance criteria
– Calibration of CFD model
– Model results
– Expert analysis, evaluations and recommendations

5.2 Task 2 physical model test

In addition to the below deliverables, progress reports will be provided on a weekly basis by
email.

5.2.1 Drawings
Prototype drawings will be submitted for review. After approval of the prototype drawings, model
drawings will be submitted in the Test procedure report.

5.2.2 Test procedure

The test procedures including acceptance criteria and model drawings shall be established and
submitted for approval. The test procedures shall be approved by KSB before the start of the
testing.

5.2.3 Final report

One electronic copy (PDF) of the draft report in the English language shall be submitted to KSB
for review. The final report shall be submitted to KSB within two weeks upon receipt of comments
on the final draft report. The report shall include the following description of items:
· Similarity criteria and deviation of model-prototype-flow relationships,
· Experimental facilities and instrumentation,
· Model test procedure
· Drawings and photographs showing model details,
· Photographs documenting the operation of the model at various test conditions including the
original and final design,
· Velocity profiles at the impeller inlet,
· Performance of the original design,
· Performance of the modified design,
· Results and discussion.

5.2.4 Video
A movie will be made, in the English language, showing all stages of each physical model
investigation from testing of the original design up to the final design.
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6 Required data

KSB shall provide the following data:

· Concept drawings with foreseen dimensions and levels of the intake structure in AutoCAD
format,
· Detailed drawings with dimensions of the pumps in AutoCAD format,
· Screen drawings including the details such as mesh size,
· Operational water levels at the pumps for all operational conditions to be tested in the
physical scale model tests (on request Deltares can perform a head loss calculation to
determine the operational water levels at the pumps),
· Possible operating conditions,
· Relevant discharges of all pumps,
· Dimensions that cannot be changed.
· Characteristics of the solids in the waste water (particle size, particle density, amount of
solids).
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7 Tentative time schedules

The start of the work depends on available capacity of manpower and facilities at the time of
settlement of all contractual issues, but will normally be within two weeks after the order of
commence. Commencement of the work can start after receipt of all input data. A definite
reservation of the facilities will be made based upon settlement of all contractual issues.

The tentative time schedule is valid provided that the Client reacts within:
• one week for reports
• one day for drawings
• one day for proposed modifications during the optimisation phase (discussion will be
performed via video conference)

Table 7.1: Time schedule for physical model testing

Project
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
week no.
Contract /
collection of
data x
Task 1 CFD modelling1
Model set-up x x
Simulations x x x
Analysis x x
Reporting x D R F
Task 2 Physical model testing
Prototype
D F
drawings
Model
x D F
drawings
Test
x D R F
procedures
Model
x x x x x
construction
Initial testing x x
Optimization
x x
testing
Final testing
x x
(incl. solids)
Witness test x
Reporting x x D
D= submission of draft report;
R= Review by the Client;
F= Submission of final report

1
If an additional CFD simulation has to be performed for a proposed measure, three additional
weeks are required for the CFD modelling and thus the physical model testing will be delayed by
three weeks.