Erosion Wear on Runner of Francis Turbine in Jhimruk Hydroelectric Center

2020 ◽  
Vol 142 (9) ◽  
Author(s):  
Zhongdong Qian ◽  
Zilong Zhao ◽  
Zhiwei Guo ◽  
Biraj Singh Thapa ◽  
Bhola Thapa
Keyword(s):  
Erosion Rate ◽  
Erosive Wear ◽  
Suction Side ◽  
Francis Turbine ◽  
Erosion Wear ◽  
Operation Condition ◽  
Guide Vanes ◽  
Accretion Rates ◽  
Physical Erosion ◽  
Main Action

Abstract Erosion wear is a major problem for hydraulic turbines operating on rivers from the Himalaya Mountains. The runner is the most important energy conversion component but it suffers heavy damage due to direct contact with the sediment-laden water. In this research, the runner's physical erosion wear mechanism is revealed using numerical simulations and the results are compared with damaged runners from Francis turbines in the Jhimruk Hydroelectric Center (JHC). Simulations show that high erosive wear occurs near the blade outlet on the suction side, which is consistent with site observations. Because of the high relative velocity at the runner outlet, the high accretion rate appears to be directly responsible for the heavy erosion rate. The adjustment of the guide vanes is the main action available in real situation to change the operation condition of turbine and flow separation can easily occur under off-design conditions, causing interblade vortex production. The vortex guides particles to one location where they gather, producing high accretion rates and aggravating erosion wear. This implies that the interblade vortex is the main factor that induces severe erosive wear at the blade outlet. When the angle of the guide vanes is adjusted to provide the highest efficiency, the erosion rate can be greatly reduced.

scholarly journals Numerical Study of Sediment Erosion Analysis in Francis Turbine

2019 ◽  
Vol 11 (5) ◽  
pp. 1423 ◽  
Author(s):  
Md Rakibuzzaman ◽  
Hyoung-Ho Kim ◽  
Kyungwuk Kim ◽  
Sang-Ho Suh ◽  
Kyung Kim
Keyword(s):  
Erosion Rate ◽  
Cavitation Erosion ◽  
Numerical Study ◽  
Leading Edge ◽  
Suction Side ◽  
Hydraulic Turbine ◽  
Francis Turbine ◽  
Trailing Edge ◽  
Sand Erosion ◽  
Turbine Design

Effective hydraulic turbine design prevents sediment and cavitation erosion from impacting the performance and reliability of the machine. Using computational fluid dynamics (CFD) techniques, this study investigated the performance characteristics of sediment and cavitation erosion on a hydraulic Francis turbine by ANSYS-CFX software. For the erosion rate calculation, the particle trajectory Tabakoff–Grant erosion model was used. To predict the cavitation characteristics, the study’s source term for interphase mass transfer was the Rayleigh–Plesset cavitation model. The experimental data acquired by this study were used to validate the existing evaluations of the Francis turbine. Hydraulic results revealed that the maximum difference was only 0.958% compared with the CFD data, and 0.547% compared with the experiment (Korea Institute of Machinery and Materials (KIMM)). The turbine blade region was affected by the erosion rate at the trailing edge because of their high velocity. Furthermore, in the cavitation–erosion simulation, it was observed that abrasion propagation began from the pressure side of the leading edge and continued along to the trailing edge of the runner. Additionally, as sediment flow rates grew within the area of the attached cavitation, they increased from the trailing edge at the suction side, and efficiency was reduced. Cavitation–sand erosion results then revealed a higher erosion rate than of those of the sand erosion condition.

Numerical Analysis of Erosive Wear on the Guide Vanes of a Francis Turbine

2015 ◽  
Vol 741 ◽  
pp. 531-535
Author(s):  
Hong Ming Zhang ◽  
Li Xiang Zhang
Keyword(s):  
Numerical Analysis ◽  
Volume Fraction ◽  
Three Dimensional ◽  
Erosive Wear ◽  
Francis Turbine ◽  
Two Phase ◽  
Guide Vanes ◽  
Flow Equations ◽  
Sand Erosion ◽  
Volume Method

The paper presents the numerical analysis of erosive wear on the guide vanes of a Francis turbine using CFD code. The 3-D turbulent particulate-liquid two-phase flow equations are employed in this study. The computing domain is discretized with a full three-dimensional mesh system of unstructured tetrahedral shapes. The finite volume method is used to solve the governing equations and the pressure-velocity coupling is handled via a Pressure Implicit with Splitting of Operators (PISO) procedure. Simulation results have shown that the volume fraction of sand at the top of the guide vanes is higher than others and the maximum of volume fraction of sand is at same location with the maximum of sand erosion rate density. The erosive wear is more serious at the top of the guide vanes.

Erosion wear performance of borax filled novel hybrid composites by using the Taguchi experimental design

2016 ◽  
Vol 68 (1) ◽  
pp. 134-140 ◽  
Author(s):  
Mehmet Bagci ◽  
Huseyin Imrek
Keyword(s):  
Erosion Rate ◽  
Hybrid Composites ◽  
Erosive Wear ◽  
Glass Fabric ◽  
Filler Materials ◽  
Erosion Wear ◽  
Reinforced Polymers ◽  
Content Type ◽  
Operational Conditions ◽  
Erosion Rates

Purpose – This study aims to examine solid particle erosion behavior of novel hybrid composite materials where borax (B2O3) particles (∼150 μm) were added to glass fabric and epoxy resin at an amount of 15 and 30 per cent. Design/methodology/approach – The tests that involved slightly rounded and irregular Al2O3 particles having two erodent sizes (200, 400 μm) were conducted at these operational conditions; namely, three impact velocities (23, 34, 53 m/s), two fabric directions (0/90/0, 45/−45/45) and three impingement angles (30°, 60°, 90°). In addition, the design of experiments, which utilizes Taguchi’s robust orthogonal arrays approach, was used and an optimum parameter combination was established, which had a minimum erosion rate. Moreover, scanning electron microscope and X-ray diffraction views show the visual effect of filler material. Findings – All test specimens regardless of their dissimilar characteristics displayed maximum erosion rate at 30° impingement angle. Test specimens with 45/−45/45 fabric direction are more wear-resistant than their counterparts with 0/90/0 fabric direction. The erosion wear of glass fabric reinforced epoxy (GF/EP) composites whose matrix had 15 per cent addition of borax particles was higher than that of neat GF/EP composites. In addition, new composite material formed by including borax particles at a rate of 30 per cent of resin leads to a reduction in erosion rates. Originality/value – While fabric-reinforced polymers take place in most of the studies conducted on erosive wear of composites, studies involving erosion on composites with filler materials can hardly be encountered.

Numerical Investigation of Sediment-Laden Flow in a High-Head Francis Turbine Runner

2013 ◽  
Vol 860-863 ◽  
pp. 1542-1546
Author(s):  
Hong Ming Zhang ◽  
Li Xiang Zhang
Keyword(s):  
Erosion Rate ◽  
Volume Fraction ◽  
Three Dimensional ◽  
Suction Side ◽  
Francis Turbine ◽  
Two Phase ◽  
Flow Equations ◽  
Maximum Value ◽  
Sand Erosion ◽  
Turbine Runner

The 3-D turbulent particulate-liquid two-phase flow equations are employed in this study. The computing domain is discretized with a full three-dimensional mesh system of unstructured tetrahedral shapes. The finite volume method is used to solve the governing equations and the pressure-velocity coupling is handled via a Pressure Implicit with Splitting of Operators (PISO) procedure. Simulation results have shown that the sand erosion rate on pressure side is more than on the suction side of the blade. The maximum value of sand volume fraction and the maximum value of sand erosion rate are at same location.

Numerical Simulation of Cavitating Flow in a Francis Turbine

2008 ◽  
Author(s):  
Lingjiu Zhou ◽  
Zhengwei Wang ◽  
Yongyao Luo ◽  
Guangjie Peng
Keyword(s):  
Numerical Simulation ◽  
Transport Equation ◽  
Flow Rate ◽  
Suction Side ◽  
Cavitating Flow ◽  
Francis Turbine ◽  
Efficiency Change ◽  
Experiment Data ◽  
Calculation Results ◽  
Vapor Fraction

The 3-D unsteady Reynolds averaged Navier-tokes equations based on the pseudo-homogeneous flow theory and a vapor fraction transport-equation that accounts for non-condensable gas are solved to simulate cavitating flow in a Francis turbine. The calculation results agreed with experiment data reasonably. With the decrease of the Thoma number, the cavity first appears near the centre of the hub. At this stage the flow rate and the efficiency change little. Then the cavity near the centre of the hub grows thick and the cavities also appear on the blade suction side near outlet. With further reduce of the Thoma number the cavitation extends to the whole flow path, which causes flow rate and efficiency decrease rapidly.

scholarly journals Micro Hardness and Erosive Wear Behavior of Tungsten Carbide Filled Epoxy Polymer Nano Composites

2020 ◽  
Vol 5 (3) ◽  
pp. 405-415
Author(s):  
M. Kameswara Reddy ◽  
V. Suresh Babu ◽  
K. V. Sai Srinadh
Keyword(s):  
Tungsten Carbide ◽  
Polymer Nanocomposites ◽  
Adhesive Bonding ◽  
Epoxy Polymer ◽  
Wear Behavior ◽  
Erosive Wear ◽  
Nano Composites ◽  
Erosion Wear ◽  
Wear Properties ◽  
The Matrix

The present work studies the tribological performance of Tungsten Carbide (WC) nanoparticles reinforced epoxy polymer nanocomposites. Polymer nanocomposites are prepared by hand lay-up method. Erosive wear and hardness tests were conducted to examine the physical and wear properties of epoxy/WC nanocomposites. Addition of WC nanoparticles led to significant reduction in erosion rate. In addition to that, incorporation of WC nanoparticles enhanced the hardness of epoxy nano composites. At 2% weight of WC nano filler, nanocomposites showed better performance in erosion wear properties and also in hardness. While at 3wt% of WC filler, least performance in hardness was caused by the weak adhesive bonding between the matrix and filler. The nature of erosion wear behavior was observed. Finally worn surfaces of nanocomposites were inspected using a “scanning electron microscope (SEM)”.

Noise Attenuation Potential Using Helmholtz Absorbers Integrated in Low Pressure Turbine Exit Guide Vanes and Turbine Exit Casing End Walls

2020 ◽  
Author(s):  
Manuel Zenz ◽  
Loris Simonassi ◽  
Philipp Bruckner ◽  
Simon Pramstrahler ◽  
Franz Heitmeir ◽  
...  
Keyword(s):  
Suction Side ◽  
Aircraft Engine ◽  
Low Pressure ◽  
Flow Channel ◽  
Operating Conditions ◽  
Noise Attenuation ◽  
Beneficial Result ◽  
Guide Vanes ◽  
Acoustic Liners ◽  
Low Pressure Turbine

Abstract To further reduce the noise emitted from modern aircrafts, every possibility has to be taken into account. Acoustic liners are successfully used in the inlet or the bypass duct of aircraft engines to mitigate the noise emitted by the fan. Due to the rough environment (high temperature, flow velocity, higher order duct modes), the exhaust duct is of limited use concerning the application of acoustic liners. It is well known that the last stage low pressure turbine (LPT) has a dominant influence onto the emitted noise of an aircraft engine especially at low load conditions such as approach. A noise reduction in this area could lead to a beneficial result of decreasing the noise content which is directly emitted in the environment. This paper is about noise attenuation using Helmholtz absorbers in various parts of a turbine exit casing (TEC). These single degree of freedom absorbers have been integrated in turbine exit guide vanes (TEGVs), with the openings on the vanes suction side, as well as in the inner and outer duct end walls. Different absorber neck diameters were investigated and combined with different vane designs. The vane designs studied included a state of the art set-up as well as vanes with a lean. Test runs were performed with altered combinations of vanes and end walls under engine relevant operating conditions in a subsonic test turbine facility for aerodynamic, aeroacoustic and aeroelastic investigations (STTF-AAAI) located at the Institute of Thermal Turbomachinery and Machine Dynamics at Graz University of Technology. Comparisons between all these setups and the respective hard wall reference cases were done. The resulting sound pressure levels as well as sound power levels of all investigated combinations are listed and compared concerning each configurations noise attenuation potential. Additionally, the flow field downstream of every setup is analysed if the aerodynamic behaviour is changing. The investigated operating point is the noise certification point Approach (APP) which is of high importance because of the high acoustical impact onto the environment around airports during the landing procedure of an aircraft. The acoustical data has been obtained by using flush mounted condenser microphones located downstream of the TEC. The whole test section was rotated over 360 deg around the flow channel. To detect if the aerodynamical behaviour changes by including openings into the flow channel end walls as well as into the vanes, aerodynamic measurements have been performed downstream of the TEC. The aerodynamical data was obtained by using an aerodynamic five-hole-probe (5HP) as well as a trailing edge probe.

scholarly journals CFD Investigation of a High Head Francis Turbine at Speed No-Load Using Advanced URANS Models

2018 ◽  
Vol 8 (12) ◽  
pp. 2505 ◽  
Author(s):  
Jean Decaix ◽  
Vlad Hasmatuchi ◽  
Maximilian Titzschkau ◽  
Cécile Münch-Alligné
Keyword(s):  
Power Plants ◽  
Turbulence Modeling ◽  
Suction Side ◽  
Hydraulic Turbine ◽  
Operating Conditions ◽  
Francis Turbine ◽  
Hydroelectric Power ◽  
Electrical Grid ◽  
Runner Blade ◽  
Pumped Storage

Due to the integration of new renewable energies, the electrical grid undergoes instabilities. Hydroelectric power plants are key players for grid control thanks to pumped storage power plants. However, this objective requires extending the operating range of the machines and increasing the number of start-up, stand-by, and shut-down procedures, which reduces the lifespan of the machines. CFD based on standard URANS turbulence modeling is currently able to predict accurately the performances of the hydraulic turbines for operating points close to the Best Efficiency Point (BEP). However, far from the BEP, the standard URANS approach is less efficient to capture the dynamics of 3D flows. The current study focuses on a hydraulic turbine, which has been investigated at the BEP and at the Speed-No-Load (SNL) operating conditions. Several “advanced” URANS models such as the Scale-Adaptive Simulation (SAS) SST k - ω and the BSL- EARSM have been considered and compared with the SST k - ω model. The main conclusion of this study is that, at the SNL operating condition, the prediction of the topology and the dynamics of the flow on the suction side of the runner blade channels close to the trailing edge are influenced by the turbulence model.

Erosion Wear Behavior of Coatings with Growth Defects Produced by Ion Beam Enhanced Pulsed Filtered Vacuum Arc Deposition

2010 ◽  
Vol 97-101 ◽  
pp. 1527-1531 ◽  
Author(s):  
Feng Fang Wu ◽  
Jian Xin Deng ◽  
Pei Yan ◽  
Wen Long Song
Keyword(s):  
Erosion Rate ◽  
Wear Behavior ◽  
Ion Beam ◽  
Hard Metal ◽  
Solid Particles ◽  
Wear Loss ◽  
Erosion Wear ◽  
Growth Defects ◽  
Tin Coatings ◽  
Arc Deposition

The erosion wear behavior of TiN coatings with growth defects was studied. The TiN coatings were produced on a hard metal by ion beam enhanced pulsed filtered vacuum cathode arc deposition. The erosion wear was tested with a gas blast apparatus. In the test, TiN coatings were impacted at an impingement angle of 90° by angular SiC solid particles with an average diameter of 124um. The maximum depth of the erosion scar measured by the optical profiler was used to evaluate the erosion wear loss of the coatings. The coatings proved to have much lower erosion rate than that of the substrate material and consequently, the erosion rate increased significantly to the high level of the hard metal substrate after the coatings were penetrated. The failure mechanism was revealed by examining the surface morphologies of the coatings before and after the erosion test. The erosive wear of the TiN coatings with growth defects behaved as typical brittle materials. The damage mechanism of the coatings with growth defects was described.

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