Energy 34 (2009) 14771483

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Effect of size and concentration of silt particles on erosion of

Pelton turbine buckets
M.K. Padhy*, R.P. Saini
Alternate Hydro Energy Centre, Indian Institute of Technology Roorkee, Roorkee, India

a r t i c l e i n f o a b s t r a c t

Article history: Erosive wear of hydro turbine runners depends upon different parameters such as size, hardness and
Received 29 November 2008 concentration of silt particles, velocity of ow, properties of the base material of the turbine components
Received in revised form and operating hours of the turbine. Various researchers have conducted experiments to study the effect
3 June 2009
of these parameters on erosive wear. Most of these experiments were on small-size samples at different
Accepted 5 June 2009
types of test rigs to simulate the ow conditions in turbines, however actual ow conditions and the
Available online 14 July 2009
phenomenon of erosive wear are too complex to simulate. Under the present study, effect of these
parameters on erosion in actual conditions has been investigated experimentally. An extensive experi-
Keywords:
Erosive wear mental study has been carried out on a small scale Pelton turbine. Based on the experimental data
Pelton turbine collected for different parameters, correlations have been developed for wear rate of Pelton turbine
Silt concentration buckets as a function of critical parameters, i.e., size and concentration of silt particles and jet velocity.
Silt size 2009 Elsevier Ltd. All rights reserved.
Correlation

1. Introduction if the silt contains higher percentage of quartz, which is extremely

Many hydro electric project sites in the Himalayan range and in
the northeastern region of India face severe silt erosion problems in
turbines which over a period of time drastically reduces the overall
efciency of power generation system. A study of several existing
hydro electric power stations located in these regions has
conrmed the severity of silt erosion on the critical underwater
parts of turbines and other components of the power station [1].
Himalayan rivers contain very high sediment concentration during
the monsoon season. Major components of this sediment are hard
abrasive sand and silts which severely damage the turbine
components. For efcient operation of hydropower plants in order
to meet the electricity demand the hydro energy is stored either in
reservoirs for dam based schemes or settling basins for run-of-river
schemes. These reservoirs or settling basins are lled with sedi-
ments over a period of time. This problem must be taken care of by
sediment settling systems in power plants. However, lot of unset-
tled sediment pass through the turbines every year and turbine
parts are exposed to severe erosion. The erosion of hydro turbine
components is a major problem for the efcient operation of
hydropower plants. These problems are more prominent in power
stations which are of run-of-river types. The problem is aggravated
* Corresponding author. Tel.: 91 94111 78218.
E-mail address: mamatapadhy@rediffmail.com (M.K. Padhy).
hard (hardness 7 in Mohs scale) [24].
Under a study Naidu [5] reported that about 22 large hydro-
power stations in India are facing silting problem. These power
stations have been classied into three categories based on
quantum of damage as; (i) category A indicates intensive damage
and needs renovation every year, (ii) category B indicates
substantially high damage and needs renovation in every 3 years
and (iii) category C indicates considerable damage and needs
special efforts and resources after 1520 years. In another study
Naidu [5] has stated that Baira Siul project (3  66 MW) in Hima-
chal Pradesh in India, handles nearly 10,000 tons of silt per day, per
machine during critical monsoon days and more than 90% of the silt
passing through these machines is quartz. Nepal is also facing
severe silting problem in hydropower plants with specic sediment
yield of about 4240 tonnes/km2/year. Marshyangdi river is one of
the sediment-laden rivers in Nepal [6]. The sedimentlogical study
performed in 1981 has revealed an average annual load of 26.7
million tonnes and bed load of 2.9 million tonnes. Out of this total
load, 90% of the sediments are transported in the river during the
monsoon season from May to October. Similar conditions also
prevail in rest of the rivers [7].
The turbine parts vulnerable to silt erosion are buckets, nozzle
and needle in case of impulse turbines and guide vanes, faceplates,
runner blades and seal rings in case of reaction turbines.
It is generally considered that erosion damage is the gradual
removal of material caused by repeated deformation and cutting

0360-5442/$ see front matter 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.energy.2009.06.015
1478 M.K. Padhy, R.P. Saini / Energy 34 (2009) 14771483
Nomenclature
C silt concentration (ppm)
D diameter of silt (mm)
D50 mean silt size (mm)
g acceleration due to gravity (m/s2)
H head (m)
P a constant
Q quartz content
S silt particle size (m)
t operating hour (h)
V velocity of ow (m/s)
W normalized wear (g/g) per unit discharge (m3/s)
r density of water (kg/m3)
d erosive wear rate (mm/h)
actions. The process of erosion damage is inuenced by a number of
factors, namely, the average velocity of particles, mass of particles,
concentration of abrasive particles in uid, size distribution of
particles, and their average grain size, angle of impingement, time
interval of the attack and the erosion resistance of structural
material [8]. Most of the earlier studies on erosion were carried out
from material point of view. Finnie [9] and Bitter [10] developed
fundamental erosion models for ductile and brittle materials. Many
other researchers developed different models of erosion [11]. Most
of these models were problem specic and derived from experi-
mental studies addressing some specic problems. Truscott [12]
presented a literature survey on erosive wear tests of materials, for
pumps and turbines. Some of the erosion models, experimental
investigation on erosive wear and case studies of erosion of hydro
turbine components were reviewed by Padhy and Saini [13]. The
erosion models [1419] developed under earlier studies for
hydraulic turbines and pumps were based on certain assumptions
and eld experiences.
Krause and Grein [14] proposed the abrasion rate on conven-
tional steel Pelton runner made of X5CrNi 13/4 which was
expressed by the expression given below;
d PQCV 3:4 f D50 (1)
where d is the erosive wear rate (mm/h), P is a constant, Q is the
quartz content, C is the mean sand concentration, V is the relative
jet velocity and f(D50) is a function dening particle size.
Bajracharya et al. [7] established erosive wear rate of spear and
efciency reduction relationships from the eld survey of Chilmi
Hydro Electric Plant (CHEP), a Pelton turbine based hydro electric
plant in Nepal. They proposed a relationship between the erosion
rate and the particle size at different quartz content levels which is
presented as;
Erosive wear ratefasizeb (2)
where; erosive wear rate is in kg/year, and
a 351.35 and b 1.4976, for quartz content of 38%;
a 1199.8 and b 1.8025, for quartz content of 60%;
a 1482.1 and b 1.8125, for quartz content of 80%;
Relationship between erosion rate and the reduction in ef-
ciency was expressed as;
Efficiency reductionfaerosion rateb (3)
where a 0.1522 and b 1.6946.
Various investigators [2024] conducted experiments to study
the effect of silt parameters on erosive wear. Most of these exper-
iments were conducted on small-size samples at different types of
test rigs. Based on the results obtained on small-size samples the
ow conditions through turbines were simulated. Other investi-
gators [25,26] used jet type test rigs to study the erosion behavior of
different materials. However actual ow conditions and the
phenomenon of erosive wear of turbine components is too complex
to simulate.
In order to take into account the factors like actual ow condi-
tions, variation of impingement angles, curvature of Pelton turbine
bucket, variation of size, concentration of the eroding particles and
jet velocity, the present investigation has been carried out on
a small scale Pelton turbine. The paper presents the effect of the
size and the concentration of the eroding particles and the jet
velocity on erosion of the turbine buckets.
Based on the data generated by conducting an extensive
experimental study for different parameters, correlation has been
developed for wear rate of Pelton turbine buckets. The developed
correlation may be useful for the turbine manufacturing industries.
In order to have prior information about the quantum of erosive
wear by knowing the characteristics of silt. Accordingly precaution
can be taken during the manufacturing process of Pelton turbines.
2. Experimental setup and instrumentation
An experimental setup was designed and fabricated to carry out
the required investigation. Fig. 1 shows a schematic of the test setup
consisting of: (i) Pelton turbine runner; (ii) water tank; (iii) stirrer;
(iv) cooling jacket; (v) service pumpmotor set; (vi) penstock pipe;
(vii) spear valve and nozzle; (viii) control valve; (ix) channel with
weir; (x) generator and (xi) control panel with resistive load .
The Pelton turbine runner having 16 buckets, pitch circle
diameter of 144 mm and nozzle diameter of 10 mm has been
consider for the present investigation. In order to get measurable
amount of erosion in a short period of time, the turbine buckets
were made of brass. The weight of each specimen bucket was
approximately 210 g. A steel tank of 600 mm long, 510 mm wide
and 780 mm deep, was used to store water and to prepare silt water
mixture of different concentrations. The depth of water in the tank
was maintained at 450 mm. The upper portion of the tank was
connected to a rectangular channel having a length of 5700 mm,
width 200 mm and depth as 400 mm. During discharge measure-
ment, water after passing through the turbine was allowed to ow
trough this channel. A rectangular weir was xed in the channel for
discharge measurment. The tank was provided with an inlet and an
outlet tap to ll water up to the desired level and a valve to drain
out the silt laden water for different conditions. A stirrer was
attached to operate continuously during the experiments so as to
supply a uniform mixture of silt and water to the turbine. In order
to maintain a constant temperature of the water, a cooling water
jacket was provided at three sides of the tank. A centrifugal pump
having 50 m rated head and discharage capacity of 8 l/s was used to
create hydro potential. A penstock pipe having 60 mm outer
diameter and 4 mm thickness was used for supplying water under
pressure to the turbine. Water from the turbine outlet was allowed
to ow back to the water tank. A spear valve was used at the end of
the penstock pipe with 10 mm nozzle diameter to convert the
potential head of circulating water into velocity head. A control
valve was connected with the penstock pipe at the delivery side of
the service pump to maintain the required head of water. A
generator was directly coupled with the turbine runner shaft. A
resistive load was connected to the generator through a control
panel. The control panel consisted of a wattmeter, a voltmeter and
ballast load in the form of electric bulbs. The electric load was
 M.K. Padhy, R.P. Saini / Energy 34 (2009) 14771483
Fig. 1. Schematic of the test setup.
measured to determine the output. By considering the generator
efciency output of the turbine was determine. However the values
of turbine output was not considered for development of the
correlation. Turbine output was measured to ensure that the
turbine was operating under a given load during experimentation
for different conditions.
A digital pressure transducer with an integrated 4-digit LCD
display ranging from 267 kPa to 8000 kPa and having an accuracy
of 0.075% was used to measure the water head. It was mounted on
the penstock pipe at the inlet to the turbine. A digital analytical
balance having least count of 0.1 mg was used to measure the
weight loss of the buckets. Another digital balance having a least
count of 0.5 g was used to measure the weight of silt. The silt was
graded to different size ranges by sieving through 355 mm, 250 mm,
180 mm and 90 mm sieves.
3. Parameters investigated
Under the present study, effects of three parameters as; silt
concentration, silt size and jet velocity were investigated. Sample of
sand was collected from river Bhagirathi (India) near the head
Table 1
Range of parameters investigated.
Parameters Range
Concentration 10,000 ppm; 7500 ppm; 5000 ppm
Silt size 250355 mm; 180250 mm; 90180 mm;
below 90 mm
Jet velocity 26.61 m/s; 28.23 m/s; 29.75 m/s
Operating time 8h
1479
works of Maneri Bhali Hydro Electric Project, Phase I, which is one
of the most silt affected power houses in India. The quartz content
in the sand sample was more than 90% [27]. Sand was dried in an
oven for 24 h and then sieved to different sizes before mixing with
water. The range of the parameters considered for the present
investigation is given in Table 1.
4. Procedure
In order to investigate the effect of silt parameters on erosive
wear silt laden water was supplied to the turbine operated under
a given head. The procedure to conduct the experiments is discussed
as; before the actual experiments conducted the discharge of the
pump for different heads was calibrated using a rectangular weir.
Initially service pump draw the water from the tank and supplied it
to the turbine. Water from the turbine was allowed to ow through
a channel and then the rectangular weir for discharge calibration.
The height of water over the crest of the weir was recorded by
a pointer gauge and the discharge of the pump corresponding to
each head was computed. After calibration experiments for erosive
wear were conducted. During the experiments for erosive wear, the
channel was closed and water was allowed to ow directly into the
tank from the turbine. In order to prepare the silt water mixture
having various concentrations, required quantity of silt having
desired parameters was added to a known volume of water in the
tank. The stirrer was rotating with a 0.5 h.p. motor at a speed of
60 rpm through a gear box. In order to prevent the settling of silt at
the bottom of the tank silt was mixed with the water in the tank. The
length and diameter of stirrer was kept so that it created turbulence
throughout the volume of water and silt mixture in the tank. Further
1480 M.K. Padhy, R.P. Saini / Energy 34 (2009) 14771483

dy is known as absolute uncertainty,

dy/y is known as relative uncertainty.

The maximum possible measurement errors in the values of major

parameters of the present investigation were found as given below.

Weight of bucket 0.67%

Size of silt 1.34%
Silt concentration 0.56%
Jet velocity 3.89%

Fig. 2. Surface condition of Pelton bucket after experimentation. 6. Results and discussions

discharge from the outlet of the turbine was allowed to fall directly The patterns of erosion in all the buckets observed were found
into the tank which created more turbulence in the tank and helped to be similar. Photograph of one of the Pelton turbine buckets after
in preventing settling of silt particles. To ensure the prevention of the erosion is shown in Fig. 2. Maximum erosion has been observed at
settling of silt particles it was observed that there was no trace of silt the splitter and some portions at the notch of the buckets. The
particles after releasing the slurry from the tank. splitter is found to be eroded signicantly and the sharp edges have
The net head was measured by the digital pressure transducer become blunt. The marked portion of the splitter was found to be
tted with the penstock before the spear valve and was kept eroded to a considerable depth. The magnied view of erosion
constant during the experimentations. Keeping one parameter as pattern at different location of eroded Pelton turbine bucket is
variable and others as constant, one set of readings was taken at shown Fig. 3(a) and (b). It can be concluded that the erosion has
four values of time interval of 2 h. It is therefore, for considering occurred due to a typical cutting action of silt particles. A number of
different values of concentration, three sets of experiments were channels have been created in the ow path of the continuously
conducted. Similarly, for silt size, four sets and for jet velocity, three owing silt particles.
sets of experiments were conducted. After every 1 h the silt water The effects of individual parameters on erosive wear are dis-
mixture was drained out and fresh silt water was circulated for the cussed in the following sections.
next 1 h run. After every 2 h of experiment, the buckets were
dismantled from the runner, cleaned with detergent, washed in 6.1. Silt concentration
clean water and wiped with tissue paper. Then these were rinsed
with acetone and allowed to dry inside an oven for 2 h at Based on the experimental data, plots have been prepared to
a temperature of 60 C. The loss of weight of the buckets was discuss the effect of silt concentration on the erosive wear rate. Data
measured after every 2 h of run. The quantum of erosion under the
present study was measured in mg with the help of a very high
precision balance having a least count of 0.1 mg. The measurable
erosion has been obtained due to high concentration of the silt over
a short duration of operation. It was found that there was some
erosion of nozzle and pump. However, there was no effect of
erosion in pressure transducer as it was mounted externally. In
order to maintain the jet velocity constant throughout the experi-
ment, the control valve was adjusted to get a constant head reading.
By maintaining the constant head on turbine, it was ensured that
jet velocity through the nozzle remained constant and erosion
effect on nozzle was ignored. However, the impeller of the service
pump got eroded due to circulation of slurry after certain period of
operation. The impeller was replaced with a new impeller to ensure
the required input (head and discharge) to the turbine.

5. Error analyses

An error analysis of experimental measurements has been carried

out on the basis of the method proposed by Kline and McClintock
[28]. Based on the observations of the scatter in the measured values
used in calculating the result, the approach of the analysis is discussed
as; if a parameter is calculated using certain measured quantities as,
y yx1 ; x2 ; x3 .xn
Then uncertainty in measurement of y is given as follows:
" 2  2  2  2 #
dy dy dy dy dy
d dx dx2 dx3 . dxn
y dx1 1 dx2 dx3 d xn

where, dx1 ; dx2 ; dx3 .dxn are the possible errors in measurements Fig. 3. Magnied view of (a) inlet and (b) outlet edge of the Pelton turbine bucket.
x1,x2,x3.xn Arrow shows the approximate ow direction.
 M.K. Padhy, R.P. Saini / Energy 34 (2009) 14771483 1481

a 0.003 b 0.003
10000 ppm 10000 ppm

0.0025 0.0025 7500 ppm

Normalised wear g/g

Normalised wear g/g 7500 ppm
5000 ppm 5000 ppm
0.002 0.002

0.0015 0.0015

0.001 0.001

0.0005 0.0005

0 0
0 2 4 6 8 10 0 2 4 6 8 10
Operating time, h Operating time, h

c 0.0025
10000 ppm
d 0.0025 10000 ppm

7500 ppm 7500 ppm

Normalised wear g/g

Normalised wear g/g

0.002 0.002
5000 ppm 5000 ppm

0.0015 0.0015

0.001 0.001

0.0005 0.0005

0 0
0 2 4 6 8 10 0 2 4 6 8 10
Operating time, h Operating time, h

Fig. 4. (a) Effect of silt concentration on normalized wear for the size range 250355 mm. (b) Effect of silt concentration on normalized wear for silt size 180250 mm. (c) Effect of silt
concentration on normalized wear for silt size 90180 mm. (d) Effect of silt concentration on normalized wear for silt size below 90 mm.

were generated for different concentration under a xed value of jet
velocity of 28.23 m/s. Since all the 16 buckets were more or less
identical, the average value of weight loss was considered for
analysis. For silt particles of different size ranges, the variation of
normalized wear (loss of weight/original weight) of buckets with
operating time has been presented in Fig. 4(ad). It can be seen in
these gures that the erosive wear increases almost linearly with
time, This shows that erosive wear rate is constant for a given
concentration and particle size. The slopes of these lines, signifying
the time rate of erosive wear, are different for different concentra-
tions and different size ranges. The slopes are seen to be increasing
with increase in silt concentration, which show that, for a given
range of sizes, the erosive wear rate increases as the silt concen-
tration increases. The variation of wear rate with concentration is
reported by the plots in Fig. 5. It can be observed from this gure
that with the increase in concentration the wear rate increases,
although the rate of increase is not same for different range of sizes.
6.3. Jet velocity
In order to determine the effect of jet velocity on erosive wear,
experiments were conducted at different heads with silt particles
in the range of 90180 mm and a concentration of 5000 ppm.
Based on the experimental results, the normalized erosive wear
has been analyzed for unit discharge. Fig. 7 shows the normalized
erosive wear per unit discharge for different values of jet velocity.
Four readings were taken for each velocity and average of all data
was considered for plotting the graph. It can be observed from
Fig. 7 that the erosive wear rate follows the power law with
respect to the jet velocity (i.e. W f Vn). The value of n has been
evaluated in the present study as 3.79. The obtained value of n has
been found in good agreement with other investigations for Pelton
turbine [4,34].

6.2. Silt size 0.003

0.0025
Normalised wear, g/g

In order to investigate the effect of silt size on the bucket wear,

different silt sizes were considered while other parameters i.e., silt
0.002
concentration, jet velocity and operating hour were kept constant.
Under the present investigation, natural silt was collected from the 0.0015
site of the existing power house. The range of sizes considered is
given in Table 1. Fig. 6 shows the variation of the normalized erosive 250-355 micron
0.001
wear with the mean particle size (D50) for various concentrations. It 180-250 micron
0.0005 180-250 micron
is seen that within the range of particle size investigated, the
below 90 micron
erosive wear increases with the increase in the particle size for all
0
the concentrations considered. The increase in the erosive wear 8000
4000 5000 6000 7000 9000 10000 11000
rate has been found to be more prominent for higher values of
Concentration,ppm
concentration (10,000 ppm). These ndings are found in good
agreement with the ndings of other investigators [2933]. Fig. 5. Effect of silt concentrations on normalized wear for different silt size ranges.
1482 M.K. Padhy, R.P. Saini / Energy 34 (2009) 14771483

0.003 0.6

0.0025
0.5
Normalised wear, g/g

0.002
0.4

Predicted wear
0.0015 + 6.7%

0.001 0.3
10000 ppm
0.0005 7500 ppm 0.2
5000 ppm
0 - 6.7%
0 100 200 300 400 0.1
Mean particle size, micron

Fig. 6. Effect of silt size on normalized wear for different concentrations. 0

0 0.1 0.2 0.3 0.4 0.5 0.6
6.4. Development of correlation for wear rate Observed wear

The effect of silt parameters i.e., particle size, concentration,
operating parameter i.e., jet velocity and operating hours on the
erosive wear of buckets have been discussed earlier. It has been
observed that these parameters play critical roles in the erosion of
turbine buckets. A system designer may require the correlations for
erosive wear rate in order to predict the efciency drop of Pelton
turbine under the actual conditions having silt laden water ow.
Correlation for wear rate as a function of the system and the
operating parameters is required to be developed from the exper-
imental data. As discussed earlier, the erosive wear rate is strongly
dependent on the silt parameters, silt size (S), silt concentration (C),
water jet velocity (V) and operating hours of the turbine (t).
Thus the equation for normalized erosive wear rate can be
written as:
W f S; C; V; t
It has been found that regression of data deals with the rst
order. From the rst order regression of the data on loglog scale,
the value of the constant and the exponents for S, C, V and t are
found to be as 4.02E  12, 0.0567, 1.2267, 3.794 and 1 respectively.
The nal form of the correlation for normalized erosive wear
rate is obtained as follows:
W 4:02  1012 S0:0567 C1:2267 V3:79 t
Fig. 8 shows the comparison of the experimental data of erosive
wear rate and those obtained from the above correlation. A good
agreement has been observed. The average absolute percentage
deviation between the experimental data and calculated values of
erosive wear rate has been found to be within 6.7%.
0.06
Normalised wear per unit
Fig. 8. Comparison of actual wear and predicted wear of Pelton turbine bucket.
7. Conclusion
On the basis of experimental investigation, it has been
concluded that the erosive wear rate increases with an increase in
the silt concentration irrespective of the silt size. However, for
a given value of silt concentration, the erosion rate has been found
to be higher for larger size particles as larger particles have higher
impact energy.
Using experimental data a correlation for erosive wear rate was
developed as a function of particle size, silt concentration, jet
velocity and the time of operation which has been found to have
a good agreement with experimental data.
The developed correlation may be useful for turbine
(4) manufacturing industry in order to predict the quantum of erosion
in Pelton turbine bucket at manufacturing stage.
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