Analysis of hydro-abrasive erosion in a high-head Pelton turbine injector using a Eulerian-Lagrangian approach

Abstract

High-head hydropower plants deploy Pelton turbines to harness energy; however, turbine components face severe abrasive erosion due to suspended sediments. The erosion of the Pelton injector leads to the degradation of the jet quality, reducing the turbine efficiency considerably. Recently, the erosion of an internal servomotor design of the injector has been studied numerically; however, the cavitation-erosion synergy was not explored. This study serves as the extension of the literature with an analysis of the hydro-abrasive erosion and inception of cavitation in an injector with an external servomotor of a high-head hydropower plant (HPP). A Eulerian-Lagrangian approach is used to study the effects of sediment properties and flow parameters on hydro-abrasive erosion; whereas, the Schnerr-Sauer model is used to analyze the inception of cavitation. Interestingly, an increase in particle size from 40 microns to 200 microns resulted in a 95.7% reduction in needle erosion; but, led to a two-fold increase in nozzle erosion. For an increase in the plant head from 200 m to 820 m, the increase in erosion rate of the nozzle and the needle is 4.36 and 1.4 times, respectively. Moreover, the possibility of cavitation in the Pelton injector also increases with an increase in the head of the HPP leading the injector to higher susceptibility to the synergic effect of cavitation and hydro-abrasive erosion. This study attempts to assist the hydropower development in high-head regions with a risk of high sediment flow and manage the existing plants efficiently.