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Article history: Sediment particles passing through the turbine components erode the surface in contact. Gradual
Received 31 July 2011 removal of base material changes the runner prole and also weakens its structure. One of the major
Received in revised form consequences of this is gradual loss of turbine efciency. Attempts have been made from past researches
25 February 2012
to develop empirical relations to estimate the effects of sediment erosion in hydraulic turbines.
Accepted 27 February 2012
Available online 29 March 2012
Present study is conducted to identify an appropriate erosion model for Francis turbine. Two standard
erosion models have been selected to estimate erosion rates and consecutive reduction in efciency of
the runner. Improved empirical relation to estimate the sediment erosion in Francis runner has been
Keywords:
Turbine
proposed. Comparison of results from the improved empirical relation has been done with the results of
Sediment experimental measurements at the site.
Erosion It has been found that sediment data from the site can be analysed to predict the damage in Francis
Modelling runner due to erosion. The results from the improved erosion model are found to be consistent with the
Efciency earlier studies and experimental measurements. A simple erosion model as the proposed one can help to
formulate appropriate design, operation and maintenance strategy for Francis runner at a specic site
conditions.
2012 Elsevier Ltd. All rights reserved.
0360-5442/$ e see front matter 2012 Elsevier Ltd. All rights reserved.
doi:10.1016/j.energy.2012.02.066
B.S. Thapa et al. / Energy 41 (2012) 386e391 387
eld measurements. However, limited numbers of erosion models in Thapa [1] has conducted laboratory tests of various turbine
hydraulic machineries have been validated for their reliability [8]. materials to estimate the erosion rates under different test condi-
tions. For 16Cr5Ni, which is most widely used turbine material, his
2.1. General models of erosion ndings give following empirical relation to predict the erosion rate.
100 2 500
80 2 000
70
Percent finer
60 1 500
50
40 1 000
30
1. p.
6.
11 .
1 6 k t.
2 1 k t.
2 6 k t.
3 1 k t.
22
2 7 u g.
1 . u g.
6. .
1 1 p.
16 p.
21 p.
26 .
5 . k t.
1 0 v.
1 5 o v.
Diameter in microns
ok
ok
.o
.o
.o
.o
.o
.a
.a
se
se
.s
.s
.s
.s
no
.n
.n
t.
t
p
ep
e
e
ov
.
Fig. 1. Particle size distribution of sand sample for JHE [19].
Fig. 2. Sediment concentration through one turbine unit at JHC [14].
4.2. Trial 2
Erosion model used by Bajracharya [9] as given in Eq. (6) and Eq.
(7) have been used for computation of erosion rate. The size needed
for this model is taken same as size factor (ksize) for trial 1. Fig. 5
shows the results given by the second trial of erosion model. As
per the given equations the results of modelling are in terms of
proportionality function. For JHC, with 80% of hard particles, the
results can be expressed as follows:
Er f 1.84 (mm/year of operation)
This model includes size of eroding particles only as the
parameter to estimate the erosion rate. It lags inclusion of several
other important factors as concentration, shape and hardness of
particles, property of base materials etc., which play decisive role in
determining erosion rate. Furthermore, this model predicts erosion
in terms of proportionality only and may mislead the evaluator.
However, inclusion of appropriate factors as proportionality
Fig. 3. Erosion of JHC runner during the operation period of 4000 (Courtesy, BPC). constant could make this model more accurate and reliable. This
has been attempted in next trial of erosion modelling.
Table 2
IEC-62364 erosion model and associated parameters [11].
is equal to the value predicted by this trial of erosion modelling for of sediment concentration by compromising drop in efciency up
yearly average sediment concentration of 400 ppm. Result of to certain level of cut-off concentration. Determining the material
thermodynamic efciency measurements [14] shows 4% loss in removed due to sediment erosion, by cumulating operational time
total efciency at JHC due to erosion, in which the runner and corresponding sediment concentration, the proper mainte-
contributes about 25%. This shows the consistency of this trial of nance schedule can be projected.
erosion modelling with ndings from earlier research studies. Results of this trial show its utility for predicting erosion
Results from Fig. 7 could be used to formulate operational and damage in hydropower plant in a simple way. Inclusion of reduc-
maintenance policy. The runner can be operated at the higher level tion in efciency due to leakage from labyrinth seals in this model
could be a step ahead for further study. Mette [23] has found by CFD
analysis that Tabakoffs erosion model can be applicable for
Table 3
Relevant data from JHC for erosion modelling.
Table 4
Determination of Kf from IEC erosion model for JHC.
Fig. 5. Erosion rate predicted from Trial 2. Fig. 7. Trial 3 modelling results for JHC for Kf 4.
B.S. Thapa et al. / Energy 41 (2012) 386e391 391
numerical modelling of sediment erosion of Francis turbines. [12] Truscott GF. Literature survey of abrasive wear in hydraulic machinery. Wear
1972;20:29e50.
Validation of the proposed model by similar numerical methods
[13] Padhy MK, Saini RP. Study of silt erosion on performance of a Pelton turbine.
would be valuable for it technical applications. Energy 2011;36(1):141e7.
[14] Pradhan PMS, Joshi PN, Biswakarma MB, Stole Sediment H,
5. Conclusions Efciency Thermodynamic. Measurement at Jhimruk hydropower plant,
Nepal in monsoon 2003. In: proceedings of ninth international symposium on
river sedimentation, China; 2004.
Sediment erosion in hydro turbines is a complex phenomenon [15] Bardal E. Korrosjon og Korrosjonsvern. Trondheim: Tapir, 1985 [in
and there is a need of further research to develop methods for more Norwegian].
[16] Tsuguo N. Estimation of repair cycle of turbine due to abrasion caused by
accurate computation of its effects. Inclusion of leakage losses, suspended sand and determination of desilting basin capacity. In: Proceedings
induced by erosion, in the empirical models is still a challenge. Flow of international seminar on sediment handling technique, NHA, Kathmandu;
factor dened by IEC-62364 erosion model needs further clari- 1999.
[17] Finnie I. Erosion of surfaces by solid particle. Wear 1960;3:87e103.
cation for its easy computation. [18] Ruud J. Sediment handling problems Jhimruk Hydroelectric Centre. Masters
Analysing the results from existing erosion models and Thesis at Norwegian University of Science and Technology, Norway, 2004.
comparing them with the experimental data, an improved empir- [19] Butwal Power Company (BPC)/Hydro Lab. Additional settling basins at Jhim-
ruk headworks, hydraulic design and model study. Nepal. 2004.
ical erosion model to estimate erosion rate and loss in runner [20] Thapa B, Dhalhaug OG, Shrestha R, Kaphl KP. Sediments of Nepalese rivers
efciency of Francis turbine, has been developed. For JHC the with respect to sand erosion of hydraulic turbine. In: Proceedings of ninth
improved erosion model estimates drop in efciency of the runner international symposium on river sedimentation, Yichang, China; 2004.
[21] Meland HA, new design of a Francis turbine in order to reduce sediment
alone to be 1% per year, which is consistent to the results of eld
erosion. Masters Thesis at Norwegian University of Science and Technology,
measurements. The new erosion model can be used as an effective Norway, 2010.
tool to formulate appropriate design and maintenance strategy for [22] Neopane HP, Dhalhaug OG, Thapa B. Alternative design of a Francis turbine for
the Francis runner at the specic site. sand laden water. In: Proceedings of international conference on hydro-
powerehydro Sri Lanka; 2007.
[23] Eltvik M, Neopane HP, Dhalhaug OG. Prediction of sediment erosion in Francis
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dynamic problems in hydraulic machinery and Systems, Serbia; 2011.
[1] Thapa B. Sand Erosion in Hydraulic Machinery. Ph.D. Thesis at Norwegian
University of Science and Technology (NTNU), 2004.
[2] Thapa B, Shrestha R, Dhakal P, Thapa BS. Problems of Nepalese hydropower Biraj Singh Thapa is a MS by Research graduate from Mechanical Engineering
projects due to suspended sediments. Journal of Aquatic Ecosystem Health Department at Kathmandu University with the topic Hydraulic design of Francis
and Management; 2005:251e8. turbine exposed to sediment erosion. He is also a researcher for RenewableNepal
[3] Eltvik M. Sediment erosion in Francis turbines. Masters thesis at NTNU, 2009. Project with Kathmandu Universtiy, Norwegian University of Science and Technology,
[4] Darling K. Erasing erosion. International Water Power and Dam Construction; Nepal Hydro & Electric and DynaVec as partners to develop new turbine
2005. manufacturing facility in Nepal.
[5] Padhy MK, Saini RP. Effect of size and concentration of silt particles on erosion
of Pelton turbine buckets. Energy 2009;34(10):1477e83.
[6] Duan CG, Karelin VY. Abrasive erosion and corrosion of hydraulic machinery. Bhola Thapa obtained his PhD in Mechanical Engineering at The Norwegian University
London: Imperial College Press; 2002. of Science and Technology in 2004. Currently he is a Professor at Department of
[7] Bitter JGA. A study of erosion phenomena. Part I and II. Wear 1963;6:5e21. Mechanical Engineering and Dean of School of Engineering at the University. His
and 169e190. research area is Sand Erosion of Hydraulic Machinery.
[8] Padhy MK, Saini RP. A review on silt erosion in hydro turbines. Renewable and
Sustainable Energy Reviews 2008;12:1974e87.
[9] Bajracharya TR, Acharya B, Joshi CB, Saini RP, Dahlhaug OG. Sand erosion of Ole G. Dahlhaug obtained his PhD in Mechanical Engineering at The Norwegian
Pelton turbine nozzles and buckets: a case study of Chilime hydropower plant. University of Science and Technology in 1997. He worked at SINTEF as Research
Wear 2008;264:177e84. Scientist, with Research and testing of pumps and turbines. Currently he is a Professor
[10] Neopane H. Sediment erosion in hydro turbines. Ph.D. Thesis at NTNU, 2010. at Waterpower Laboratory at NTNU. He is also a member of IEC. He has been actively
[11] IEC. Hydraulic machines e guide for dealing with abrasive erosion in water. working in Nepalese hydropower plants in research of sand erosion of turbine
62364 Ed. 1.0, 2009. components and efciency measurements.