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Hydro-abrasive erosion in Pelton turbine injectors: A numerical study

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  • Messa, Gianandrea Vittorio
  • Mandelli, Simone
  • Malavasi, Stefano

Abstract

Numerical simulations were performed to investigate how the design and the operation conditions of a Pelton turbine injector affect its vulnerability to hydro-abrasive erosion, alongside with its flow control capacity. Use was made of a Volume Of Fluid (VOF) model for simulating the free nozzle jet, a Lagrangian particle tracking model for reproducing the trajectories of the solid particles, and two erosion models for estimating the mass removal. The comparison against earlier studies and the experimental evidence, integrated with a careful sensitivity analysis, gave strength to the reliability of the numerical model. Nozzle seat and needle were the injector components most vulnerable to erosion. As the valve was closing, the erosion of the needle strongly increased, whilst that of the nozzle seat remained broadly constant. The influence of the injector design was also explored, suggesting that a reduction of the needle vertex angle is likely to enhance the risk of erosive wear. Finally, it was found that the possibility to condense the effects of the needle stroke and the needle vertex angle in a single parameter (i.e. the effective opening area) is no more allowed when hydro-abrasive erosion is considered, thereby assessing the need for case-specific wear prediction analyses.

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  • Messa, Gianandrea Vittorio & Mandelli, Simone & Malavasi, Stefano, 2019. "Hydro-abrasive erosion in Pelton turbine injectors: A numerical study," Renewable Energy, Elsevier, vol. 130(C), pages 474-488.
    • Handle: RePEc:eee:renene:v:130:y:2019:i:c:p:474-488
    DOI: 10.1016/j.renene.2018.06.064
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    References listed on IDEAS

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    1. Padhy, M.K. & Saini, R.P., 2012. "Study of silt erosion mechanism in Pelton turbine buckets," Energy, Elsevier, vol. 39(1), pages 286-293.
    2. Padhy, Mamata Kumari & Saini, R.P., 2008. "A review on silt erosion in hydro turbines," Renewable and Sustainable Energy Reviews, Elsevier, vol. 12(7), pages 1974-1987, September.
    3. Padhy, M.K. & Saini, R.P., 2011. "Study of silt erosion on performance of a Pelton turbine," Energy, Elsevier, vol. 36(1), pages 141-147.
    4. Padhy, M.K. & Saini, R.P., 2009. "Effect of size and concentration of silt particles on erosion of Pelton turbine buckets," Energy, Elsevier, vol. 34(10), pages 1477-1483.
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    2. Xiao, Yexiang & Guo, Bao & Rai, Anant Kumar & Liu, Jie & Liang, Quanwei & Zhang, Jin, 2022. "Analysis of hydro-abrasive erosion in Pelton buckets using a Eulerian-Lagrangian approach," Renewable Energy, Elsevier, vol. 197(C), pages 472-485.
    3. Khan, Rehan & Ullah, Sati & Qahtani, Faez & Pao, William & Talha, Tariq, 2024. "Experimental and numerical investigation of hydro-abrasive erosion in the Pelton turbine buckets for multiphase flow," Renewable Energy, Elsevier, vol. 222(C).
    4. Li, Lihao & Lu, Jiaxing & Gong, Yong & Zhao, Haoyu & Liu, Xiaobing & Zhu, Baoshan, 2024. "Sediment erosion characteristics of Pelton turbine runner: Effects of sediment concentration and diameter," Renewable Energy, Elsevier, vol. 220(C).
    5. Guo, Bao & Xiao, Yexiang & Rai, Anant Kumar & Liang, Quanwei & Liu, Jie, 2021. "Analysis of the air-water-sediment flow behavior in Pelton buckets using a Eulerian-Lagrangian approach," Energy, Elsevier, vol. 218(C).
    6. Guo, Bao & Xiao, Yexiang & Rai, Anant Kumar & Zhang, Jin & Liang, Quanwei, 2020. "Sediment-laden flow and erosion modeling in a Pelton turbine injector," Renewable Energy, Elsevier, vol. 162(C), pages 30-42.
    7. Yexiang Xiao & Bao Guo & Soo-Hwang Ahn & Yongyao Luo & Zhengwei Wang & Guangtai Shi & Yanhao Li, 2019. "Slurry Flow and Erosion Prediction in a Centrifugal Pump after Long-Term Operation," Energies, MDPI, vol. 12(8), pages 1-17, April.
    8. Jie Liu & Yilin Zhu & Quanwei Liang & Yexiang Xiao & Zhengshu Liu & Haijun Li & Jian Ye & Nianhao Yang & Haifeng Deng & Qingpin Du, 2024. "Analysis of Sediment Erosion in Pelton Nozzles and Needles Affected by Particle Size," Energies, MDPI, vol. 17(7), pages 1-16, March.
    9. Jean Decaix & Cécile Münch-Alligné, 2022. "Geometry, Mesh and Numerical Scheme Influencing the Simulation of a Pelton Jet with the OpenFOAM Toolbox," Energies, MDPI, vol. 15(19), pages 1-13, October.
    10. Hong, Sheng & Wu, Yuping & Wu, Jianhua & Zhang, Yuquan & Zheng, Yuan & Li, Jiahui & Lin, Jinran, 2021. "Microstructure and cavitation erosion behavior of HVOF sprayed ceramic-metal composite coatings for application in hydro-turbines," Renewable Energy, Elsevier, vol. 164(C), pages 1089-1099.
    11. Leguizamón, Sebastián & Alimirzazadeh, Siamak & Jahanbakhsh, Ebrahim & Avellan, François, 2020. "Multiscale simulation of erosive wear in a prototype-scale Pelton runner," Renewable Energy, Elsevier, vol. 151(C), pages 204-215.

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