Experimental Erosion Flow Pattern Study of Pelton Runner Buckets Using a Non-Recirculating Test Rig

Baig Mirza Umar, Zhengwei Wang (), Sailesh Chitrakar, Bhola Thapa, Xingxing Huang, Ravi Poudel and Aaditya Karna
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Baig Mirza Umar: State Key Laboratory of Hydroscience and Engineering & Department of Energy and Power Engineering, Tsinghua University, Beijing 100084, China
Zhengwei Wang: State Key Laboratory of Hydroscience and Engineering & Department of Energy and Power Engineering, Tsinghua University, Beijing 100084, China
Sailesh Chitrakar: Turbine Testing Lab, Department of Mechanical Engineering, Kathmandu University, Dhulikhel 6250, Nepal
Bhola Thapa: Turbine Testing Lab, Department of Mechanical Engineering, Kathmandu University, Dhulikhel 6250, Nepal
Xingxing Huang: S.C.I. Energy, Future Energy Research Institute, Seidengasse 17, 8706 Zurich, Switzerland
Ravi Poudel: Turbine Testing Lab, Department of Mechanical Engineering, Kathmandu University, Dhulikhel 6250, Nepal
Aaditya Karna: Turbine Testing Lab, Department of Mechanical Engineering, Kathmandu University, Dhulikhel 6250, Nepal

Energies, 2024, vol. 17, issue 16, 1-13

Abstract: Sediment erosion of hydraulic turbines is a significant challenge in hydropower plants in mountainous regions like the European Alps, the Andes, and the Himalayan region. The erosive wear of Pelton runner buckets is influenced by a variety of factors, including the size, hardness, and concentration of silt particles; the velocity of the flow and impingement angle of the jet; the properties of the base material; and the operating hours of the turbine. This research aims to identify the locations most susceptible to erosion and to elucidate the mechanisms of erosion propagation in two distinct designs of Pelton runner buckets. The Pelton runner buckets were subjected to static condition tests with particle sizes of 500 microns and a concentration of 14,000 mg/L. The buckets were coated with four layers of paint, sequentially applied in red, yellow, green, and blue. The two Pelton buckets, D 1 and D 2 , were evaluated for their erosion resistance properties. D 2 demonstrated superior erosion resistance, attributed to its geometrical features and material composition, lower erosion rates, less material loss, and improved surface integrity compared with D1. This difference is primarily attributed to factors such as the splitter’s thickness, the jet’s impact angle, the velocity at which particles strike, and the concentration of sand. D 2 exhibits a great performance in terms of erosion resistance among the two designs. This study reveals that the angle of jet impingement influences erosion progression and material loss, which is important to consider during a Pelton turbine’s design and operating conditions.

Keywords: sediment erosion; pelton bucket; concentration; paint coating; erosion mechanism (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2024
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