English -- Hydraulic machines – Guidelines for dealing with hydro-abrasive erosion in kaplan, francis, and pelton turbines - Edition 2.0

Abstract

Scope: This document gives guidelines for: a) presenting data on hydro-abrasive erosion rates on several combinations of water quality, operating conditions, component materials, and component properties collected from a variety of hydro sites; b) developing guidelines for the methods of minimizing hydro-abrasive erosion by modifications to hydraulic design for clean water. These guidelines do not include details such as hydraulic profile shapes which should be are determined by the hydraulic design experts for a given site; c) developing guidelines based on “experience data” concerning the relative resistance of materials faced with hydro-abrasive erosion problems; d) developing guidelines concerning the maintainability of materials with high resistance to hydro-abrasive erosion and hard coatings; e) developing guidelines on a recommended approach, which owners could and should take to ensure that specifications communicate the need for particular attention to this aspect of hydraulic design at their sites without establishing criteria which cannot be satisfied because the means are beyond the control of the manufacturers; f) developing guidelines concerning operation mode of the hydro turbines in water with particle materials to increase the operation life. It is assumed in this document that the water is not chemically aggressive. Since chemical aggressiveness is dependent upon so many possible chemical compositions, and the materials of the machine, it is beyond the scope of this document to address these issues. It is assumed in this document that cavitation is not present in the turbine. Cavitation and hydro-abrasive erosion can reinforce each other so that the resulting erosion is larger than the sum of cavitation erosion plus hydro-abrasive erosion. The quantitative relationship of the resulting abrasion hydro-abrasive erosion is not known and it is beyond the scope of this document to assess it, except to suggest that special efforts be made in the turbine design phase to minimize cavitation. Large solids (e.g. stones, wood, ice, metal objects, etc.) traveling with the water can impact turbine components and produce damage. This damage can in turn increase the flow turbulence thereby accelerating wear by both cavitation and abrasion hydro-abrasive erosion. Hydro-abrasive erosion resistant coatings can also be damaged locally by impact of large solids. It is beyond the scope of this document to address these issues. This document focuses mainly on hydroelectric powerplant equipment. Certain portions can also be applicable to other hydraulic machines.