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A New Approach For The Study of Silt Erosion of Hydro Turbine
A New Approach For The Study of Silt Erosion of Hydro Turbine
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
599
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
However, often parts per million (ppm) by weight is III. MATHEMATICAL EROSION M ODEL
used, which is equivalent to mg/l, with the approximation A new theoretical model is proposed for the erosion of
of 1,000 ppm equal to 1 kg/ m3 of water being normal metals by particles at normal incidence. The model
usage (1,000 ppm is equivalent to 0. 1%). Erosive wear employs a criterion of critical plastic strain to determine
rate is proportional to the concentration up to a certain when the material will be removed. This critical plastic
limiting value of the wear [5]. strain is defined as the strain at which the deformation in
B. Characteristics of Fluids the target localize sand hence results in the lip formation
[1]. This model is used for mechanical application and
The main characteristics of fluids include velocity and
acceleration of water carrying sediment, impingement not used for hydro turbines. It can be used for hydro
angle, media of the flow, temperature, and turbulence. turbines which are operating under silty water. This
model have been for the hydro turbine for calculation of
The effect of each characterizes on erosive wear is
mass loss and obtained results have been verified with
important.
mass loss obtained by the experiment carried out on the
(a) Velocity of Water Carrying Sediment Pelton turbine of brass material.
In actual practice, material damage due to plastic The erosion rate depends strongly on the magnitude of
deformation and cutting occur simultaneously and the the deforming volume. The plastic deformation spreads
ratio of these damage mechanisms depends on the on the target surface is related to the impact crater area,
velocity of particle and the impingement angle together i.e. proportional to crater radius (W), while the depth to
with other parameters [14]. Up to certain velocity, also which the deformation spreads depends on the crater
referred as critical velocity or threshold velocity, the depth (d). Thus the plastic volume V, should be
particle cannot skid on the surface due to friction and proportional to W2d, i.e. to the crater volume Vc, [1]
cutting action does not take place. As the velocity Thus
increases higher than critical velocity, both cutting and V = α Vc
plastic deformation component increases, which amplify
the erosion rate drastically. = (1)
(b) Impingement Angle
Where, α is a constant of the order of unity. „N‟ is
The impingement angle is defined as the angle number of particle strike on the surface of target material.
between the eroded surface and the trajectory of the „r‟ is the radius of the particle which strike on the surface
particle just before impacting a solid surface [15]. If the in meter. „ρb‟ is the density of particle in Kg/m3. „ʋ‟ is
particles are moving parallel to the surface, impingement velocity of particle through which it strikes over the
angle is almost 0 ° and minor erosion may take place. surface. „C‟ is the temperature dependence of the shear
When particles are moving normal to the surface, than modulus.
the impingement angle is 90 °. The relation of the C with melting point
(c) Effect of Temperature on Erosive Wear temperature(Tm) of the metal is given below.
The primary effect of temperature in wear is to soften
the eroded material and increase wear rates [5]. C= (2)
600
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
Typical values of A are as follows: pure metals, A= 1.2 Table 2.
Required parameters
- 2.0; substitution solid solution alloys, A = 0.9 - 2.0;
steel (quenched and tempered), A = 0.6 - 0.7; Parameters Values Remark
precipitation hardened, A = 0.3 -0.5. For the brass Type of silt Quartz In experiment 90.37% silt
material A is taken as 1. is quartz.
„Єc‟ is the magnitude of the critical strain at which Density of 2540 Kg/m3 If density is increase than
localization of deformation and hence lip formation quartz hardness of material is
occurs, and its magnitude can be find out by the equation increase so it is related to
hardness of silt.
given below.
Average Silt size 302μm
Concentration 10000ppm
Єc = (3)
Material of Brass For the experiment
turbine buckets material for brass is taken
Where nc, is the instantaneous strain-hardening so verified erosion weight
coefficient at a strain of Єc .The value of the exponent p with it property of brass is
as a function of S and ni (the initial strain- hardening taken into account.
exponent). Where S is a constant in the range of 0 - 0.5. Density of brass 8490 Kg/m3 If density is increase than
And ni is the initial apparent strain-hardening exponent. hardness of material is
For b.c.c. metals, S should lie in the range 0 - 0.1. increase so it is related to
hardness of material.
ɑ= (4) Specific heat of 310 J/Kg.K
brass(Cp)
The value of the exponent t determines the steepness
Melting point 1163K
of the strain gradient associated with each impact. Under temperature (Tm)
steady state erosion conditions, the strain increments strength 310MPa
caused by successive impacts super-impose on each coefficient of
other. Nevertheless, since the accumulated strain is the brass (K)
sum of all the individual strain increments, as a first Temperature 3.92 × 10-4 Shear modulus is depends
approximation, it can be assumed that it will vary with dependence on melting point
depth in the same fashion as the individual strain shear modulus temperature of material.
increments, thus the variation in strain with depth for (C)
eroded samples can be used to determine the value of t. Strain-hardening 0.49
Such strain-depth data are not readily available in the exponent (n)
Critical Strain- 0.3
literature. The data of Ives and Ruff [2] for a copper
hardening
target indicate that t should lie in the range 4 - 6. exponent (nc)
IV. ANALYTICAL RESULTS The results obtained by using the equations (1)-(4) and
The equations (1), (2), (3) and (4) have been used for experimental result comply each other. Parameters taken
calculation of eroded material of turbine. The operating for the calculation of eroded material are same as the
parameters used for the calculation of weight loss of parameters has been used in experimental study.
turbine due to silt erosion are shown in table 1. The Experiment is carried out for the Pelton turbine of brass
parameters required for calculation of weight of silt material. The turbine has 16 number of bucket. Erosion
eroded material of Pelton turbine are given in Table 2. of the turbine has been determined by striking the water
Table1
with silt of average size 302μm and 10000ppm silt
Operating parameters concentration. Operating head of the turbine is 45m and
discharge 0.00378cumec. Erosion results are taken at
Parameters every 2 hour. Mass losses of the buckets are given below
Head (H) 45.2m in Table 3.
Discharge (Q) 2.09 × 10-3 cumec
Flow Velocity (v) 26.62 m/s
Pitch circle diameter 245mm
Nozzle diameter 10mm
Number of buckets 16
601
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
Table 3: The model employs a criterion of critical plastic strain
experimental mass loss from the turbine buckets [4]
to determine when the material will be removed. This
critical plastic strain is defined as the strain at which the
deformation in the target localize sand hence results in
the lip formation.
This model used for mechanical application. Now it
has been used for hydro turbines. It has been found that it
can be used for hydro turbines operating under silty
water. In this study, mass loss due to erosion has been
determined analytically by using the model as well as
experimentally.
It has been seen that the theoretical model can be
satisfactorily use for erosion assessment of turbine. It has
also been found that the silt erosion is directly
proportional to concentration level.
REFERENCES
[1 ] G. Sundararajan and P. G. Shewmon, “A new model for the
erosion of metals at normal incidence”, Wear, 84 (1983) 237 –
The amount of analytically determined eroded material 258.
weight is 0.138gm and the weight loss found from the [2 ] L. K. Ives and A. W. Ruff, ASTM Spec. Tech. PubJ. 664, 1979,
experiment is 0.1369gm. p. 5.
The mass loss has been calculated by using equations [3 ] M. A. Moore, R. C. D. Richardson and D. G. Attwood, Metall,
(1)-(4) at varying concentration 1000 ppm to 10000 ppm Trans., 3 (1972) 2435.
by keeping other parameters constant. The variation of [4 ] M.K. Padhy and R.P. Saini, “Study of silt erosion on performance
mass loss with different concentration level is shown in of a Pelton turbine”, PhD thesis. AHEC, IIT Roorkee (2011).
Figure 1. [5 ] Hari Prasad Neopane, “Sediment erosion in Hydro Turbines”,
PhD thesis, Waterpower Laboratory,Department of Energy and
Process Engineering, Norwegian University of Science and
Technology (NTNU), Norway, February 2007 to March 2010.
[6 ] H. Brekke, Hydraulic design of turbines, in: C.G. Duan, V.Y.
Karelin (Eds.), “Abrasive Erosion and Corrosion of Hydraulic
Machinery”, ICP, London, 2003.
[7 ] J. Sato, K. Usami, T. Okamura, S. Tanaba, “Basic studies of
coupled damage caused by silt abrasion and cavitation erosion”,
ASME FED 136 (1992).
[8 ] Zu, J. B., Hutchings, I. M., and Burstcin, G. T., “Design of slurry
erosion test rig”, Wear, 1990, 140, 331–344.
[9 ] Feng, Z. and Ball A., “The erosion of four materials using seven
erodents – towards an understanding”, Wear, 1999, 233–235,
674–684.
[10 ] Tsai W., Humphrey J. A. C., and Cornet I. “Experimental
measurement of accelerated erosion in a slurry pot tester”, Wear,
1981, 68, 289–303.
[11 ] Levy A. V. and Cliik P. “The effects of erodent composition and
shape on the erosion of steel”, Wear, 1983, 89, 151–162.
Figure 1.Mass loss (gm) vs concentration (ppm) [12 ] Liebhard M. and Levy A. “The effect of erodent particle
characteristics on the erosion of metals”, Wear, 1991, 151, 381–
Figure 1 indicates that if concentration of silt 390.
increases, mass loss from the turbine also increases.
[13 ] Hutchings I. M. Tribology-friction and wear of engineering
From the model it is seen that mass loss from the turbine materials, 1992 (Arnold, Pans).
surface is directly proportional to the silt size, density of [14 ] Mack, R., Drtina, P., and Lang, E. “Numerical prediction of
silt (hardness of silt), velocity of flow, silt concentration erosion on guide vanes and in labyrinth seals in hydraulic
and inversely proportional to the density of turbine turbines”, wear, 1999, 233–235, 685–691.
material (hardness of turbine material). [15 ] G.P. Tilly, Treatise on Material Science and Technology, vol. 13,
Academic Press Inc., 1977, pp. 287–319.
[16 ] Akhilesh K. Chauhan, D.B. Goel, S. Prakash. “Solid particle
V. CONCLUSIONS
erosion behaviour of 13Cr–4Ni and 21Cr–4Ni–N steels”, Journal
A new theoretical model was used for the assessment of Alloys and Compounds 467 (2009) 459–464.
of erosion of metals by silt particles at normal incidence.
602