Estimating Wear Rate of Guide Vanes in High-Head Francis Turbines through Flow-Through Testing and DPM Simulation

Abstract

Abstract The development of high-head water resources poses a significant concern due to hydro-abrasive erosion caused by entrained sediment particles. This issue is particularly prevalent in the muddy rivers of the Xinjiang region, China, where Francis turbines are commonly used. With increased soil erosion and rapid sediment transport, the erosion of Francis turbines, especially the guide vanes of high-head turbines, has become increasingly severe. The paper explores key factors that influence the erosion process caused by sediment-laden water. In addition to flow velocity and mud concentration, the properties of the sediment-laden water, such as hardness and size of sand particles, and the concentration ratio of sand particles with different hardness, also play a crucial role in the erosion process. The study is focused on analyzing the erosive effects of sediment-laden water on a high-head Francis turbine’s guide vane. The efficacy of the discrete phase model (DPM) as a simulation method for assessing wear on the guide vane is validated. This model helps analyze critical wear areas on the surface of the vane, enabling the identification of regions most severely affected by erosion due to sediment-laden water. By pinpointing these critical wear areas, the study provides valuable insights into the potential damage caused to the guide vane, thus contributing to better understanding and potential mitigation of erosion in similar turbine systems.