Simulating Sediment Erosion in a Small Kaplan Turbine

Sediment erosion is a persistent problem that leads to the deterioration of hydro-turbines over time, ultimately causing blade failure. This paper analyzes the dynamics of sediment in water and its effects on a small Kaplan turbine. Flow data is obtained independently and transferred to a separate Lagrangian-based finite element code, which tracks particles throughout the computational domain to determine local impacts and erosion rates. This solver uses a random walk approach, along with statistical descriptions of particle sizes, numbers, and release positions. The turbine runner features significantly twisted blades with rounded corners, and complex three-dimensional (3-d) flow related to leakage and secondary flows. The results indicate that flow quality, particle size, concentration, and the relative position of the blades against the vanes significantly influence the distribution of impacts and erosion intensity, subsequently the local eroded mass is cumulated for each element face and averaged across one pitch of blades. At the highest concentration of 2500 mg/m3, the results show a substantial erosion rate from the rotor blades, quantified at 4.6784 × 10−3 mg/h and 9.4269 × 10−3 mg/h for the nominal and maximum power operating points, respectively. Extreme erosion is observed at the leading edge (LE) of the blades and along the front part of the pressure side (PS), as well as at the trailing edge (TE) near the hub corner. The distributor vanes also experience erosion, particularly at the LE on both sides, although the erosion rates in these areas are less pronounced. These findings provide essential insights into the specific regions where protective coatings should be applied, thereby extending the operational lifespan and enhancing overall resilience against sediment-induced wear.