Experimental study of sediment erosion in Francis runner using a non-recirculating test rig

The problem of sediment erosion in hydraulic turbines has posed challenges in design, operation and maintenance of hydraulic machinery. A study was conducted with a 2 kW model Francis runner for investigating the erosion prone locations. The runner and guide vanes were coated with four different coats of colour (red, yellow, green, and blue). The system was then operated in sediment-laden condition with an average concentration of sediment particles of about 24000 ppm. The runner was operated in sediment-laden conditions for 36 hours and the observations were made after each 4 hours of operation. With increasing hours of operation, the colour coating of the runner was eroded at specific locations and a pattern was revealed showing the areas affected by erosion. The erosion was mostly observed at the trailing edge of the pressure side and the junction of the suction side of the blade and hub. Erosion on the hub was observed towards the leading edge of the runner in the area close to the suction side and the region near the trailing edge of blade. Similarly, the guide vanes were eroded at the pressure side of the leading edge and the trailing edge of the suction side. The causes of erosion were identified as high velocity and acceleration of sediment particles, inter-blade vortex, and vortex due to leakage flow.