IEC 62364:2013

Hydraulic machines - Guide for dealing with hydro-abrasive erosion in Kaplan, Francis and Pelton turbines

IEC 62364:2013 serves to present data on particle abrasion rates on several combinations of water quality, operating conditions, component materials, and component properties collected from a variety of hydro sites; develop guidelines for the methods of minimizing particle abrasion by modifications to hydraulic design for clean water. These guidelines do not include:
- details such as hydraulic profile shapes which should be determined by the hydraulic design experts for a given site;
- develop guidelines based on "experience data" concerning the relative resistance of materials faced with particle abrasion problems;
- develop guidelines concerning the maintainability of abrasion resistant materials and hard facing coatings;
- develop guidelines on a recommended approach, which owners could and should take to ensure that specifications communicate the need for particular attention to this aspect of hydraulic design at their sites without establishing criteria which cannot be satisfied because the means are beyond the control of the manufacturers
- and develop guidelines concerning operation mode of the hydro turbines in water with particle materials to increase the operation life. It is assumed that the water is not chemically aggressive. Since chemical aggressiveness is dependent upon so many possible chemical compositions, and the materials of the machine, it is beyond the scope of this Guide to address these issues. It is assumed that cavitation is not present in the turbine. Cavitation and abrasion may reinforce each other so that the resulting erosion is larger than the sum of cavitation erosion plus abrasion erosion. The quantitative relationship of the resulting abrasion is not known and it is beyond the scope of this guide to assess it, except to recommend that special efforts be made in the turbine design phase to minimize cavitation. Large solids (e.g. stones, wood, ice, metal objects, etc.) traveling with the water may impact turbine components and produce damage. This damage may in turn increase the flow turbulence thereby accelerating wear by both cavitation and abrasion. Abrasion resistant coatings can also be damaged locally by impact of large solids. It is beyond the scope of this Guide to address these issues. Key words: hydraulic, turbines, hydro-abrasive erosion

Machines hydrauliques - Guide relatif au traitement de l'érosion hydro-abrasive des turbines Kaplan, Francis et Pelton

La CEI 62364:2013 est destinée à présenter les données disponibles concernant les taux d'abrasion par particules avec diverses combinaisons de qualité de l'eau, conditions d'exploitation, matériaux et propriétés des composantes; ces données ayant été obtenues sur différents sites hydroélectriques; développer des lignes directrices applicables aux méthodes de réduction au minimum de l'abrasion par particules par des modifications de la conception hydraulique utilisée en l'absence de particules. Ces lignes directrices n'abordent pas les détails tels que
- les profils hydrauliques que les spécialistes en conception hydraulique déterminent pour un site donné;
- développer des lignes directrices établies sur le "retour d'expérience" concernant la résistance relative de matériaux confrontés aux problèmes d'abrasion par les particules;
- développer des lignes directrices concernant la maintenabilité des matériaux résistant à l'abrasion et des revêtements de surface durs;
- développer des lignes directrices relatives à la recommandation d'une méthode, que les propriétaires pourraient appliquer, et dont il convient qu'ils l'appliquent effectivement, afin de s'assurer que leurs spécifications montrent la nécessité d'accorder une attention toute particulière à la conception des formes hydrauliques propres à leur site sans imposer des critères qui ne peuvent être satisfaits dans la mesure où les moyens à mettre en oeuvre ne sont pas maitrisables par les constructeurs;
- développer des lignes directrices concernant le mode de fonctionnement des turbines hydroélectriques en présence de particules afin d'accroître la durée de vie. Ce guide fait l'hypothèse d'une eau chimiquement non agressive; étant donné que cette agressivité dépend des diverses compositions chimiques possibles, ainsi que des matériaux constitutifs de la machine, le domaine d'application de ce Guide ne traite pas de cette question. Ce guide fait également l'hypothèse de l'absence de cavitation au niveau de la turbine. En effet la cavitation et l'abrasion peuvent se renforcer mutuellement de sorte que l'érosion résultante est plus importante que la somme des deux. Comme aucune formulation quantitative de cette abrasion résultante n'est connue, ce guide n'a pas pour objet de l'évaluer, sauf pour recommander, lors de la phase de conception de la turbine, des efforts particuliers visant à minimiser la cavitation. Des solides de grand volume (comme des pierres, du bois, de la glace, des objets métalliques, etc.) véhiculés par l'eau peuvent percuter les composantes de la turbine et les endommager. Ces dommages peuvent pour leur part accroître la turbulence de l'écoulement et accélérer l'usure par cavitation et par abrasion. Les revêtements durs résistant à l'abrasion peuvent également être endommagés localement suite à l'impact de ces solides de grand volume. Ce guide ne traite pas de ces questions. Mots-clés: hydraulique, turbines, érosion hydro-abrasive

General Information

• Status: Published
• Publication Date: 26-Jun-2013
• ICS: 23.100.10 - Pumps and motors
• ICS: 27.140 - Hydraulic energy engineering
• Technical Committee: TC 4 - Hydraulic turbines
• Drafting Committee: MT 29 - TC 4/MT 29
• Current Stage: DELPUB - Deleted Publication
• Completion Date: 14-Jan-2019

Relations

• Revised: IEC 62364:2019 - Hydraulic machines - Guidelines for dealing with hydro-abrasive erosion in Kaplan, Francis and Pelton turbines
• Effective Date: 05-Sep-2023

Standards Content (Sample)

IEC 62364


®


Edition 1.0 2013-06



INTERNATIONAL



STANDARD



NORME
INTERNATIONALE
colour
inside


Hydraulic machines – Guide for dealing with hydro-abrasive erosion in Kaplan,
Francis, and Pelton turbines

Machines hydrauliques – Guide relatif au traitement de l'érosion hydro-abrasive
des turbines Kaplan, Francis et Pelton


IEC 62364:2013

---------------------- Page: 1 ----------------------
THIS PUBLICATION IS COPYRIGHT PROTECTED


Copyright © 2013 IEC, Geneva, Switzerland


All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form

or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
either IEC or IEC's member National Committee in the country of the requester.
If you have any questions about IEC copyright or have an enquiry about obtaining additional rights to this publication,

please contact the address below or your local IEC member National Committee for further information.



Droits de reproduction réservés. Sauf indication contraire, aucune partie de cette publication ne peut être reproduite ni
utilisée sous quelque forme que ce soit et par aucun procédé, électronique ou mécanique, y compris la photocopie et les

microfilms, sans l'accord écrit de la CEI ou du Comité national de la CEI du pays du demandeur.

Si vous avez des questions sur le copyright de la CEI ou si vous désirez obtenir des droits supplémentaires sur cette

publication, utilisez les coordonnées ci-après ou contactez le Comité national de la CEI de votre pays de résidence.

IEC Central Office Tel.: [phone]
3, rue de Varembé Fax: [phone]
CH-1211 Geneva 20 [e-mail]
Switzerland www.iec.ch

About the IEC
The International Electrotechnical Commission (IEC) is the leading global organization that prepares and publishes
International Standards for all electrical, electronic and related technologies.

About IEC publications
The technical content of IEC publications is kept under constant review by the IEC. Please make sure that you have the
latest edition, a corrigenda or an amendment might have been published.

Useful links:

IEC publications search - www.iec.ch/searchpub Electropedia - www.electropedia.org
The advanced search enables you to find IEC publications The world's leading online dictionary of electronic and
by a variety of criteria (reference number, text, technical electrical terms containing more than 30 000 terms and
committee,…). definitions in English and French, with equivalent terms in
It also gives information on projects, replaced and additional languages. Also known as the International
withdrawn publications. Electrotechnical Vocabulary (IEV) on-line.

IEC Just Published - webstore.iec.ch/justpublished Customer Service Centre - webstore.iec.ch/csc
Stay up to date on all new IEC publications. Just Published If you wish to give us your feedback on this publication
details all new publications released. Available on-line and or need further assistance, please contact the
also once a month by email. Customer Service Centre: [e-mail].


A propos de la CEI
La Commission Electrotechnique Internationale (CEI) est la première organisation mondiale qui élabore et publie des
Normes internationales pour tout ce qui a trait à l'électricité, à l'électronique et aux technologies apparentées.

A propos des publications CEI
Le contenu technique des publications de la CEI est constamment revu. Veuillez vous assurer que vous possédez
l’édition la plus récente, un corrigendum ou amendement peut avoir été publié.


Liens utiles:

Recherche de publications CEI - www.iec.ch/searchpub Electropedia - www.electropedia.org
La recherche avancée vous permet de trouver des Le premier dictionnaire en ligne au monde de termes
publications CEI en utilisant différents critères (numéro de électroniques et électriques. Il contient plus de 30 000
référence, texte, comité d’études,…). termes et définitions en anglais et en français, ainsi que
Elle donne aussi des informations sur les projets et les les termes équivalents dans les langues additionnelles.
publications remplacées ou retirées. Egalement appelé Vocabulaire Electrotechnique
International (VEI) en ligne.
Just Published CEI - webstore.iec.ch/justpublished
Service Clients - webstore.iec.ch/csc
Restez informé sur les nouvelles publications de la CEI.
Just Published détaille les nouvelles publications parues. Si vous désirez nous donner des commentaires sur
Disponible en ligne et aussi une fois par mois par email. cette publication ou si vous avez des questions
contactez-nous: [e-mail].

---------------------- Page: 2 ----------------------
IEC 62364



®



Edition 1.0 2013-06







INTERNATIONAL





STANDARD







NORME



INTERNATIONALE
colour

inside










Hydraulic machines – Guide for dealing with hydro-abrasive erosion in Kaplan,

Francis, and Pelton turbines




Machines hydrauliques – Guide relatif au traitement de l'érosion hydro-abrasive

des turbines Kaplan, Francis et Pelton

















INTERNATIONAL

ELECTROTECHNICAL

COMMISSION


COMMISSION

ELECTROTECHNIQUE

PRICE CODE
INTERNATIONALE

CODE PRIX XC


ICS 23.100.10; 27.140 ISBN 978-2-83220-829-8



Warning! Make sure that you obtained this publication from an authorized distributor.

Attention! Veuillez vous assurer que vous avez obtenu cette publication via un distributeur agréé.

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale

---------------------- Page: 3 ----------------------
– 2 – 62364 © IEC:2013


CONTENTS



FOREWORD . 5

INTRODUCTION . 7

1 Scope . 8


2 Terms, definitions and symbols . 8

2.1 Units . 8

2.2 Terms, definitions and symbols . 9

3 Abrasion rate . 11

3.1 Theoretical model . 11
3.2 Introduction to the PL variable . 13
3.3 Survey results . 15
3.4 Reference model . 16
4 Design . 17
4.1 General . 17
4.2 Water conveyance system . 17
4.3 Valve . 18
4.3.1 General . 18
4.3.2 Selection of abrasion resistant materials and coating . 18
4.3.3 Stainless steel overlays . 19
4.3.4 Protection (closing) of the gap between housing and trunnion . 19
4.3.5 Stops located outside the valve . 19
4.3.6 Proper capacity of inlet valve operator . 19
4.3.7 Increase bypass size to allow higher guide vane leakage . 19
4.3.8 Bypass system design . 20
4.4 Turbine . 20
4.4.1 General . 20
4.4.2 Hydraulic design . 20
4.4.3 Mechanical design . 22
4.4.4 Operation . 28
4.4.5 Spares and regular inspections . 29
4.4.6 Particle sampling and monitoring . 29
5 Abrasion resistant materials . 30
5.1 Guidelines concerning relative abrasion resistance of materials including

abrasion resistant coatings . 30
5.1.1 General . 30
5.1.2 Discussion and conclusions . 31
5.2 Guidelines concerning maintainability of abrasion resistant coating materials . 32
5.2.1 Definition of terms used in this sublcause . 32
5.2.2 Time between overhaul for protective coatings . 32
5.2.3 Maintenance of protective coatings . 33
6 Guidelines on insertions into specifications . 34
6.1 General . 34
6.2 Properties of particles going through the turbine. 35
6.3 Size distribution of particles . 35
6.4 Mineral composition of particles for each of the above mentioned periods . 36
Annex A (informative) PL calculation example . 37
Annex B (informative) Measuring and recording abrasion damages . 39

---------------------- Page: 4 ----------------------
62364 © IEC:2013 – 3 –


Annex C (informative) Water sampling procedure . 52

Annex D (informative) Procedures for analysis of particle concentration, size,

hardness and shape . 53


Annex E (informative) Tests of abrasion resistant materials . 56

Annex F (informative) Typical criteria to determine overhaul time due to abrasion

erosion . 67

Annex G (informative) Example to calculate the amount of erosion in the full model . 68

Annex H (informative) Examples to calculate the TBO in the reference model . 70


Bibliography . 73


Figure 1 – Estimation of the characteristic velocities in guide vanes, W , and runner,
gv
W , as a function of turbine specific speed . 13
run
Figure 2 – Example of flow pattern in a Pelton injector at different load . 14
Figure 3 – Example of protection of transition area . 19
Figure 4 – Runner blade overhang in refurbishment project . 21
Figure 5 – Example of “mouse-ear” cavitation on runner band . 22
Figure 6 – Detailed design of guide vane trunnion seals . 23
Figure 7 – Example of fixing of facing plates from the dry side . 25
Figure 8 – Head cover balancing pipes with bends . 26
Figure 9 – Step labyrinth with optimized shape for hard coating . 28
Figure 10 – Development of spiral pressure over time . 33
Figure D.1 – Typical examples of particle geometry . 55
Figure E.1 – Schematic of test rig used for test 1 . 56
Figure E.2 – ASTM test apparatus . 58
Figure E.3 – Test coupon . 59
Figure E.4 – Slurry pot test facility . 60
Figure E.5 – High velocity test rig . 61
Figure E.6 – Samples are located on the rotating disk . 62
Figure E.7 – Comparison of two samples after testing . 62
Figure E.8 – Whole test system of rotating disk . 62
Figure E.9 – Schematic of test rig used for test 8 . 64
Figure E.10 – Testing of samples on hydro abrasive stand . 65

Figure E.11 – Cover of disc . 65
Figure E.12 – Curve of unit abrasion rate with circumference velocity for 3 kinds of
materials . 66

Table 1 – Data analysis of the supplied questionnaire . 16
Table 2 – Overview over the feasibility for repair C . 33
Table 3 – Form for properties of particles going through the turbine . 35
Table 4 – Form for size distribution of particles . 36
Table 5 – Form for mineral composition of particles for each of the above mentioned
periods . 36
Table A.1 – Example of documenting sample tests . 37
Table A.2 – Example of documenting sample results . 38
Table B.1 – Inspection record, runner blade inlet form . 44

---------------------- Page: 5 ----------------------
– 4 – 62364 © IEC:2013


Table B.2 – Inspection record, runner blade outlet form . 45

Table B.3 – Inspection record, runner band form. 46


Table B.4 – Inspection record, guide vanes form. 47

Table B.5 – Inspection record, facing plates and covers form . 48

Table B.6 – Inspection record, upper stationary seal form . 49


Table B.7 – Inspection record, upper rotating seal form . 49

Table B.8 – Inspection record, lower stationary seal form . 50

Table B.9 – Inspection record, lower rotating seal form . 51


Table E.1 – Relative wear resistance in laboratory test 1 . 57
Table E.2 – Relative wear resistance in laboratory test 2 . 57
Table E.3 – Relative wear resistance in laboratory test 3 . 58
Table E.4 – Relative wear resistance in test 4 . 59
Table E.5 – Results of test . 60
Table E.6 – Results of test . 61
Table E.7 – Results from test . 63
Table E.8 – Relative wear resistance in laboratory test 8 . 64
Table E.9 – Results of relative wear resistance for some materials (U = 40m/s) . 66
Table G.1 – Calculations . 69
Table H.1 – Pelton turbine calculation example . 70
Table H.2 – Francis turbine calculation example . 71

---------------------- Page: 6 ----------------------
62364 © IEC:2013 – 5 –


INTERNATIONAL ELECTROTECHNICAL COMMISSION

____________



HYDRAULIC MACHINES –

GUIDE FOR DEALING WITH HYDRO-ABRASIVE EROSION

IN KAPLAN, FRANCIS, AND PELTON TURBINES





FOREWORD


1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC
Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
in the subject dealt with may participate in this preparatory work. International, governmental and non-
governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely
with the International Organization for Standardization (ISO) in accordance with conditions determined by
agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity
assessment services and, in some areas, access to IEC marks of conformity. IEC is not responsible for any
services carried out by independent certification bodies.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62364 has been prepared by IEC technical committee 4: Hydraulic

turbines.
The text of this standard is based on the following documents:
FDIS Report on voting
4/279/FDIS 4/283/RVD

Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.

---------------------- Page: 7 ----------------------
– 6 – 62364 © IEC:2013


The committee has decided that the contents of this publication will remain unchanged until

the stability date indicated on the IEC web site under "http://webstore.iec.ch" in the data

related to the specific publication. At this date, the publication will be


• reconfirmed,

• withdrawn,

• replaced by a revised edition, or

• amended.





IMPORTANT – The 'colour inside' logo on the cover page of this publication indicates
that it contains colours which are considered to be useful for the correct
understanding of its contents. Users should therefore print this document using a
colour printer.

---------------------- Page: 8 ----------------------
62364 © IEC:2013 – 7 –


INTRODUCTION


Many owners of hydroelectric plants contend with the sometimes very aggressive

deterioration of their machines due to particle abrasion. Such owners must find the means to

communicate to potential suppliers of machines for their sites, their desire to have the

particular attention of the designers at the turbine design phase, directed to the minimization

of the severity and effects of particle abrasion.


Limited consensus and very little quantitative data exists on the steps which the designer

could and should take to extend the useful life before major overhaul of the turbine

components when they are operated under severe particle abrasion service. This has led

some owners to write into their specifications, conditions which cannot be met with known
methods and materials.

---------------------- Page: 9 ----------------------
– 8 – 62364 © IEC:2013


HYDRAULIC MACHINES –

GUIDE FOR DEALING WITH HYDRO-ABRASIVE EROSION

IN KAPLAN, FRANCIS, AND PELTON TURBINES







1 Scope


This Guide serves to:

a) present data on particle abrasion rates on several combinations of water quality, operating
conditions, component materials, and component properties collected from a variety of
hydro sites;
b) develop guidelines for the methods of minimizing particle abrasion by modifications to
hydraulic design for clean water. These guidelines do not include details such as hydraulic
profile shapes which should be determined by the hydraulic design experts for a given
site;
c) develop guidelines based on “experience data” concerning the relative resistance of
materials faced with particle abrasion problems;
d) develop guidelines concerning the maintainability of abrasion resistant materials and hard
facing coatings;
e) develop guidelines on a recommended approach, which owners could and should take to
ensure that specifications communicate the need for particular attention to this aspect of
hydraulic design at their sites without establishing criteria which cannot be satisfied
because the means are beyond the control of the manufacturers;
f) develop guidelines concerning operation mode of the hydro turbines in water with particle
materials to increase the operation life;
It is assumed in this Guide that the water is not chemically aggressive. Since chemical
aggressiveness is dependent upon so many possible chemical compositions, and the
materials of the machine, it is beyond the scope of this Guide to address these issues.
It is assumed in this Guide that cavitation is not present in the turbine. Cavitation and
abrasion may reinforce each other so that the resulting erosion is larger than the sum of
cavitation erosion plus abrasion erosion. The quantitative relationship of the resulting
abrasion is not known and it is beyond the scope of this guide to assess it, except to
recommend that special efforts be made in the turbine design phase to minimize cavitation.
Large solids (e.g. stones, wood, ice, metal objects, etc.) traveling with the water may impact

turbine components and produce damage. This damage may in turn increase the flow
turbulence thereby accelerating wear by both cavitation and abrasion. Abrasion resistant
coatings can also be damaged locally by impact of large solids. It is beyond the scope of this
Guide to address these issues.
This guide focuses mainly on hydroelectric powerplant equipment. Certain portions may also
be applicable to other hydraulic machines.
2 Terms, definitions and symbols
2.1 Units
The International System of Units (S.I.) is adopted throughout this guide but other systems
are allowed.

---------------------- Page: 10 ----------------------
62364 © IEC:2013 – 9 –


2.2 Terms, definitions and symbols


For the purposes of this document, the following terms, definitions and symbols apply.


NOTE They are also based, where relevant, on IEC/TR 61364.

Sub- Term Definition Symbol Unit

clause

2.2.1 specific E J/kg
specific energy of water available between the high and

hydraulic
low pressure reference sections 1 and 2 of the machine

energy of a
machine

Note 1 to entry: For full information, see IEC 60193.

2
2.2.2 acceleration local value of gravitational acceleration at the place of g m/s
due to gravity testing
Note 1 to entry: For full information, see IEC 60193.
H
2.2.3 turbine head available head at hydraulic machine terminal m
        H = E/g
pump head
2.2.4 reference reference diameter of the hydraulic machine D m
diameter
Note 1 to entry: For Pelton turbines this is the pitch
diameter, for Kaplan turbines this is the runner chamber
diameter and for Francis and Francis type pump turbines
this is the blade low pressure section diameter at the
band
Note 2 to entry: See IEC 60193 for further information.
2.2.5 abrasion depth depth of metal layer that has been removed from a S mm
component due to particle abrasion
2.2.6 characteristic characteristic velocity defined for each machine W m/s
velocity component and used to quantify particle abrasion
damage
Note 1 to entry: See also 2.2.20 to 2.2.24.

3 3
2.2.7 particle the mass of all solid particles per m of water solution C kg/m
concentration
Note 1 to entry: In case the particle concentration is
expressed in ppm it is recommended to use the mass of
particles per mass of water, so that 1 000 ppm
3
approximately corresponds to 1 kg/m .
3
the particle concentration integrated over the time, T, that PL
2.2.8 particle load kg × h/m
is under consideration
T
PL = C(t )× K (t )× K (t )× K (t )dt

size shape hardness
∫
0
N
 
 
≈ C × K × K × K ×T
n size,n shape,n hardness,n s,n
∑
 
 n=1 
C(t) = 0 if no water is flowing through the turbine.
If the unit is at standstill with pressurized spiral case then
C(t)=0 when calculating PL for runner and labyrinth seals,
but C(t)≠0 when calculating PL for guide vanes and facing
plates.
2.2.9 size factor factor that characterizes how the abrasion relates to the K
size
size of the abrasive particles
2.2.10 shape factor factor that characterizes how the abrasion relates to the K

shape
shape of the abrasive particles
2.2.11 hardness factor factor that characterizes how the abrasion relates to the K
hardness
hardness of the abrasive particles

---
...