IEC 62364:2019
(Main)Hydraulic machines - Guidelines for dealing with hydro-abrasive erosion in Kaplan, Francis and Pelton turbines
Hydraulic machines - Guidelines for dealing with hydro-abrasive erosion in Kaplan, Francis and Pelton turbines
IEC 62364:2019 gives guidelines for:
a) presenting data on hydro-abrasive erosion rates on several combinations of water quality, operating conditions, component materials, and component properties collected from a variety of hydro sites;
b) developing guidelines for the methods of minimizing hydro-abrasive erosion by modifications to hydraulic design for clean water. These guidelines do not include details such as hydraulic profile shapes which are determined by the hydraulic design experts for a given site;
c) developing guidelines based on “experience data” concerning the relative resistance of materials faced with hydro-abrasive erosion problems;
d) developing guidelines concerning the maintainability of materials with high resistance to hydro-abrasive erosion and hardcoatings;
e) developing 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) developing guidelines concerning operation mode of the hydro turbines in water with particle materials to increase the operation life.
It is assumed in this document 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 document to address these issues. It is assumed in this document that cavitation is not present in the turbine. Cavitation and hydro-abrasive erosion can reinforce each other so that the resulting erosion is larger than the sum of cavitation erosion plus hydro-abrasive erosion. The quantitative relationship of the resulting hydro-abrasive erosion is not known and it is beyond the scope of this document to assess it, except to suggest 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 can impact turbine components and produce damage. This damage can in turn increase the flow turbulence thereby accelerating wear by both cavitation and hydro-abrasive erosion. Hydro-abrasive erosion resistant coatings can also be damaged locally by impact of large solids. It is beyond the scope of this document to address these issues. This document focuses mainly on hydroelectric powerplant equipment. Certain portions can also be applicable to other hydraulic machines. This second edition cancels and replaces the first edition published in 2013. This edition constitutes a technical revision. This edition includes the following significant technical changes with respect to the previous edition:
a) the formula for TBO in Pelton reference model has been modified;
b) the formula for calculating sampling interval has been modified;
c) the chapter in hydro-abrasive erosion resistant coatings has been substantially modified;
d) the annex with test data for hydro-abrasive erosion resistant materials has been removed;
e) a simplified hydro-abrasive erosion evaluation has been added.
Key words: Hydraulic Machines, Hydro-Abrasive Erosion, Kaplan, Francis, Pelton Turbines.
Machines hydrauliques - Lignes directrices relatives au traitement de l'érosion hydro-abrasive des turbines Kaplan, Francis et Pelton
L'IEC 62364:2019 donne des lignes directrices pour:
a) présenter les données disponibles concernant les taux d'érosion hydro-abrasive avec diverses combinaisons de qualité de l'eau, conditions d'exploitation, matériaux et propriétés des composants; ces données ayant été obtenues sur différents sites hydroélectriques;
b) développer des lignes directrices permettant de réduire au minimum l’érosion hydro-abrasive en apportant des modifications à la conception hydraulique normalement 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;
c) développer des lignes directrices établies sur le «retour d’expérience» concernant la résistance relative de matériaux confrontés aux problèmes d’érosion hydro-abrasive;
d) développer des lignes directrices concernant la maintenabilité des matériaux résistant à l'érosion hydro-abrasive et des revêtements de surface durs;
e) 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 les 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 œuvre ne sont pas maitrisables par les constructeurs;
f) développer des lignes directrices concernant le mode de fonctionnement des turbines hydroélectriques en présence de particules afin d’accroître la durée de vie.
Ce document 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 document ne traite pas de cette question. Ce document fait également l'hypothèse de l'absence de cavitation au niveau de la turbine. En effet la cavitation et l'érosion hydro-abrasive peuvent se renforcer mutuellement de sorte que l'érosion résultante est plus importante que la somme des deux. Comme aucune formulation quantitative de cette érosion résultante n’est connue, ce document n'a pas pour objet de l'évaluer, sauf pour suggérer, lors de la phase de conception de la turbine, des efforts particuliers visant à minimiser la cavitation. Des objets solides de grandes dimensions (comme des pierres, du bois, de la glace, des objets métalliques, etc.) véhiculés par l'eau peuvent percuter les composants 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 érosion hydro-abrasive. Les revêtements durs résistant à l’érosion hydro-abrasive peuvent également être endommagés localement suite à l'impact de ces particules de grandes dimensions. Ce document ne traite pas de ces questions. Ce document se concentre principalement sur les équipements des centrales hydroélectriques. Certaines parties de ce document peuvent également s'appliquer à d'autres machines hydrauliques. Cette deuxième édition annule et remplace la première édition publiée en 2013. Cette édition constitue une révision technique. Cette édition inclut les modifications techniques majeures suivantes par rapport à l’édition précédente:
a) La formule pour le TBO du modèle de référence des turbines Pelton a été modifiée;
b) la formule pour le calcul de l’intervalle d’échantillonnage a été modifiée;
c) le chapitre sur les revêtements résistant à l'érosion hydro-abrasive a été substantiellement modifié;
d) l’annexe sur les données test pour les matériaux résistant à l’érosion hydro-abrasive a été supprimée;
e) une évaluation simplifiée de l’érosion hydro-abrasive a été ajoutée.
Mots-clés: machines hydrauliques, l’érosion hydro-abrasive, Kaplan, Francis, turbines Pelton
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IEC 62364 ®
Edition 2.0 2019-01
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Hydraulic machines – Guidelines for dealing with hydro-abrasive erosion
in kaplan, francis, and pelton turbines
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IEC 62364 ®
Edition 2.0 2019-01
REDLINE VERSION
INTERNATIONAL
STANDARD
colour
inside
Hydraulic machines – Guidelines for dealing with hydro-abrasive erosion
in kaplan, francis, and pelton turbines
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 23.100.10; 27.140 ISBN 978-2-8322-6431-7
– 2 – IEC 62364:2019 RLV IEC 2019
CONTENTS
FOREWORD . 6
INTRODUCTION . 8
1 Scope . 9
2 Terms, definitions and symbols. 9
3 Abrasion rate Prediction of hydro-abrasive erosion rate . 13
3.1 Model for hydro-abrasive erosion depth . 13
3.2 Reference model . 15
3.3 Simplified hydro-abrasive erosion evaluation . 15
4 Design . 16
4.1 General . 16
4.2 Selection of abrasion resistant materials with high resistance to hydro-
abrasive erosion and coating . 17
4.3 Stainless steel overlays . 18
4.4 Water conveyance system . 18
4.5 Valve . 18
4.5.1 General . 18
4.5.2 Protection (closing) of the gap between housing and trunnion. 19
4.5.3 Stops located outside the valve . 19
4.5.4 Proper capacity of inlet valve operator . 19
4.5.5 Increase bypass size to allow higher guide vane leakage . 20
4.5.6 Bypass system design . 20
4.6 Turbine . 20
4.6.1 General . 20
4.6.2 Hydraulic design . 20
4.6.3 Mechanical design . 22
5 Operation and maintenance . 29
5.1 Operation . 29
5.2 Spares and regular inspections . 30
5.3 Particle sampling and monitoring . 30
6 Abrasion resistant materials Materials with high resistance to hydro-abrasive
erosion . 32
6.1 Guidelines concerning relative abrasion hydro-abrasive erosion resistance of
materials including abrasion hydro-abrasive erosion resistant coatings . 32
6.1.1 General . 32
6.1.2 Discussion and conclusions . 33
6.2 Guidelines concerning maintainability of abrasion hydro-abrasive erosion
resistant coating materials . 34
6.2.1 Definition of terms used in this subclause . 34
6.2.2 Time between overhaul for protective coatings . 34
6.2.3 Maintenance Repair of protective coatings. 36
7 Guidelines on insertions into specifications. 37
7.1 General . 37
7.2 Properties of particles going through the turbine . 38
7.3 Size distribution of particles . 39
Mineral composition of particles for each of the above mentioned periods.
Annex A (informative) PL calculation example . 41
Annex B (informative) Measuring and recording abrasion hydro-abrasive erosion
damages . 43
B.1 Recording abrasion hydro-abrasive erosion damage . 43
B.2 Pelton runner without coating . 44
B.3 Needle tip and mouth piece without coating . 44
B.4 Pelton runner with hardcoating . 44
B.5 Needle tip, seat ring and nozzle housing with coating . 44
B.6 Francis runner and stationary labyrinth without coating . 45
B.7 Francis runner with coating and stationary labyrinth . 45
B.8 Guide vanes and facing plates without coating . 46
B.9 Guide vanes and facing plates with coating . 46
B.10 Stay vanes . 46
B.11 Francis labyrinth seals uncoated . 47
B.12 Kaplan uncoated . 47
B.13 Kaplan coated . 47
B.14 Sample data sheets . 47
B.15 Inspection record, runner blade inlet . 49
B.16 Inspection record, runner blade outlet . 50
B.17 Inspection record, runner band . 51
B.18 Inspection record, guide vanes . 52
B.19 Inspection record, facing plates and covers . 53
B.20 Inspection record, upper stationary seal . 54
B.21 Inspection record, upper rotating seal . 55
B.22 Inspection record, lower stationary seal . 56
B.23 Inspection record, lower rotating seal . 57
B.24 Inspection record, runner bucket . 58
B.25 Inspection record, Pelton runner splitter . 59
Annex C (informative) Monitoring of particle concentration and properties and water
sampling procedure . 60
C.1 General . 60
C.2 Sampling before building a power station . 60
C.3 Sampling in existing power stations . 61
C.4 Logging of samples . 61
Annex D (informative) Procedures for analysis of particle concentration, size,
hardness and shape . 62
D.1 General . 62
D.2 Particle concentration . 62
D.3 Particle size distribution . 62
D.4 Mineralogical composition of the particles . 62
D.5 Particle geometry . 63
Annex E (informative) Tests of abrasion resistant materials .
Annex E (informative) Frequency of sediment sampling . 76
Annex F (informative) Typical criteria to determine overhaul time due to abrasion
hydro-abrasive erosion . 77
F.1 General . 77
F.2 Parameters which are observable while the unit is in operation . 77
F.3 Criteria that require internal inspection of the unit . 78
Annex G (informative) Example to calculate the amount of erosion in the full model the
hydro-abrasive erosion depth . 79
– 4 – IEC 62364:2019 RLV IEC 2019
Annex H (informative) Examples to calculate the TBO in the reference model . 81
Annex I (informative) Background for hydro-abrasive erosion depth model . 84
I.1 Theorical model Model background and derivation . 84
I.2 Introduction to the PL variable.
...
IEC 62364 ®
Edition 2.0 2019-01
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Hydraulic machines – Guidelines for dealing with hydro-abrasive erosion
in kaplan, francis, and pelton turbines
Machines hydrauliques – Lignes directrices relatives
au traitement de l'érosion hydro-abrasive des turbines kaplan, francis et pelton
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
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About the IEC
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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 corrigendum or an amendment might have been published.
IEC publications search - webstore.iec.ch/advsearchform Electropedia - www.electropedia.org
The advanced search enables to find IEC publications by a The world's leading online dictionary on electrotechnology,
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committee,…). It also gives information on projects, replaced and French, with equivalent terms in 16 additional languages.
and withdrawn publications. Also known as the International Electrotechnical Vocabulary
(IEV) online.
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Stay up to date on all new IEC publications. Just Published IEC Glossary - std.iec.ch/glossary
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once a month by email. French extracted from the Terms and Definitions clause of
IEC publications issued since 2002. Some entries have been
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IEC 62364 ®
Edition 2.0 2019-01
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Hydraulic machines – Guidelines for dealing with hydro-abrasive erosion
in kaplan, francis, and pelton turbines
Machines hydrauliques – Lignes directrices relatives
au traitement de l'érosion hydro-abrasive des turbines kaplan, francis et pelton
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 23.100.10; 27.140 ISBN 978-2-8322-6286-3
– 2 – IEC 62364:2019 IEC 2019
CONTENTS
FOREWORD . 5
INTRODUCTION . 7
1 Scope . 8
2 Terms, definitions and symbols. 8
3 Prediction of hydro-abrasive erosion rate . 12
3.1 Model for hydro-abrasive erosion depth . 12
3.2 Reference model . 13
3.3 Simplified hydro-abrasive erosion evaluation . 14
4 Design . 15
4.1 General . 15
4.2 Selection of materials with high resistance to hydro-abrasive erosion and
coating . 16
4.3 Stainless steel overlays . 16
4.4 Water conveyance system . 16
4.5 Valve . 17
4.5.1 General . 17
4.5.2 Protection (closing) of the gap between housing and trunnion. 17
4.5.3 Stops located outside the valve . 17
4.5.4 Proper capacity of inlet valve operator . 18
4.5.5 Increase bypass size to allow higher guide vane leakage . 18
4.5.6 Bypass system design . 18
4.6 Turbine . 18
4.6.1 General . 18
4.6.2 Hydraulic design . 18
4.6.3 Mechanical design . 20
5 Operation and maintenance . 26
5.1 Operation . 26
5.2 Spares and regular inspections . 28
5.3 Particle sampling and monitoring . 28
6 Materials with high resistance to hydro-abrasive erosion . 29
6.1 Guidelines concerning relative hydro-abrasive erosion resistance of
materials including hydro-abrasive erosion resistant coatings . 29
6.1.1 General . 29
6.1.2 Discussion and conclusions . 30
6.2 Guidelines concerning maintainability of hydro-abrasive erosion resistant
coating materials . 30
6.2.1 Definition of terms used in this subclause . 30
6.2.2 Time between overhaul for protective coatings . 30
6.2.3 Repair of protective coatings . 31
7 Guidelines on insertions into specifications. 32
7.1 General . 32
7.2 Properties of particles going through the turbine . 33
7.3 Size distribution of particles . 34
Annex A (informative) PL calculation example . 35
Annex B (informative) Measuring and recording hydro-abrasive erosion damages . 37
B.1 Recording hydro-abrasive erosion damage . 37
B.2 Pelton runner without coating . 37
B.3 Needle tip and mouth piece without coating . 38
B.4 Pelton runner with hardcoating . 38
B.5 Needle tip, seat ring and nozzle housing with coating . 38
B.6 Francis runner and stationary labyrinth without coating . 39
B.7 Francis runner with coating and stationary labyrinth . 39
B.8 Guide vanes and facing plates without coating . 39
B.9 Guide vanes and facing plates with coating . 40
B.10 Stay vanes . 40
B.11 Francis labyrinth seals uncoated . 40
B.12 Kaplan uncoated . 40
B.13 Kaplan coated . 41
B.14 Sample data sheets . 41
B.15 Inspection record, runner blade inlet . 42
B.16 Inspection record, runner blade outlet . 43
B.17 Inspection record, runner band . 44
B.18 Inspection record, guide vanes . 45
B.19 Inspection record, facing plates and covers . 46
B.20 Inspection record, upper stationary seal . 47
B.21 Inspection record, upper rotating seal . 48
B.22 Inspection record, lower stationary seal . 49
B.23 Inspection record, lower rotating seal . 50
B.24 Inspection record, runner bucket . 51
B.25 Inspection record, Pelton runner splitter . 52
Annex C (informative) Monitoring of particle concentration and properties and water
sampling procedure . 53
C.1 General . 53
C.2 Sampling before building a power station .
...
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