Development of a test rig to evaluate abrasive wear on Pelton turbine nozzles. A case study of Chivor Hydropower

Over 75% of domestic electric power consumption in Colombia is supplied by hydropower. Abrasive wear is degrading turbine components such as Pelton needle valve nozzles. This problem has been studied on the components themselves (in situ). However, it was necessary reproduce the same hydro-abrasive...

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Bibliographic Details
Published in:Wear 2017-02, Vol.372-373, p.208-215
Main Authors: Morales B, Andrés M., Pachón, Ivan F., Loboguerrero U, Jaime, Medina, Jorge A., Escobar G, Jairo A.
Format: Article
Language:English
Subjects:
Abrasive wear
Cemented carbides
Cobalt
Erosion
Flame spraying
HVOF coatings
Hydroelectric plants
Hydroelectric power
Ion nitriding
Needle valve
Nozzles
Pelton turbine
Plasma nitriding
Power consumption
Replication
Sediment
Sediments
Slurry erosion
Test rig
Tungsten carbide
Turbines
Wear
Wear mechanisms
Wear resistance
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Summary:Over 75% of domestic electric power consumption in Colombia is supplied by hydropower. Abrasive wear is degrading turbine components such as Pelton needle valve nozzles. This problem has been studied on the components themselves (in situ). However, it was necessary reproduce the same hydro-abrasive phenomena in a controlled laboratory environment. This study describes the design and construction of a test rig capable of replicating the same wear mechanism present in Pelton needle valve nozzles at Chivor hydroelectric plant. The development of the test rig allowed to conduct empirical testing for the comparison of the plasma nitriding process versus the WC-Co-Cr coat deposited by HVOF to extend the lifetime of the nozzle. Both processes showed significant improvement in hardness and wear resistance compared to the original material specification of the needle valves. •Laboratory test rig to reproduce field erosion conditions of Pelton turbine.•Plasma nitriding as a process to improve erosion resistance on Pelton Turbine nozzles.•Roughness as a qualitative measure of erosion at early stages.
ISSN:0043-1648
1873-2577
DOI:10.1016/j.wear.2016.11.003