Numerical simulation of multiphase flow and prediction of sediment wear in a large Pelton turbine

The problem of sediment wear presents a significant challenge for hydraulic turbines operating in sediment-rich rivers, particularly for high-head Pelton turbines. In this study, the VOF model, SST k–ω model, and DPM model were employed to simulate the gas–liquid–solid three-phase flow within a large Pelton turbine, which operates under a rated water head of 671 m and has a single capacity of 500 MW, at a hydropower station situated on a sediment-laden river. The sediment wear prediction model, derived from the sediment wear test of the model turbine, was utilized to forecast the sediment wear on the flow components of the Pelton turbine at the hydropower station. The results show that there are obvious pressure and velocity gradients near the nozzle outlet of the Pelton turbine in the power station, and the wear of the nozzle surface is gradually increasing, and the wear in the downstream area of the nozzle is more serious. The wear rate at the needle tip surface reached 1.372 μm/h, while the socket ring surface exhibited a wear rate of 3.175 μm/h. he highest wear rate recorded for the water bucket is 0.940 μm/h. After a year of continuous operation, the maximum erosion observed was 5.62 mm on the runner bucket made of stainless steel and wear-resistant metal, 8.23 mm on the spray needle, and 19.05 mm on the nozzle mouth ring, highlighting the severity of sediment wear on the Pelton turbine. It is recommended that surface treatment technology be applied to the flow-through components of the Pelton turbine at this hydropower station to enhance the wear resistance of the turbine and extend the operational life of the unit.