EN 62364-2013 en Hydraulic machines - Guide for dealing with hydro-abrasive erosion in Kaplan Francis and Pelton turbines.pdf

1、BSI Standards PublicationHydraulic machines Guide for dealing with hydro-abrasive erosion in Kaplan, Francis, and Pelton turbinesBS EN 62364:2013National forewordThis British Standard is the UK implementation of EN 62364:2013. It is identical to IEC 62364:2013.The UK participation in its preparation

2、 was entrusted to TechnicalCommittee MCE/15, Hydraulic turbines.A list of organizations represented on this committee can be obtained onrequest to its secretary.This publication does not purport to include all the necessary provisions ofa contract. Users are responsible for its correct application.

3、The British Standards Institution 2013.Published by BSI Standards Limited 2013ISBN 978 0 580 66842 5ICS 23.100.10; 27.140 Compliance with a British Standard cannot confer immunity fromlegal obligations.This British Standard was published under the authority of theStandards Policy and Strategy Commit

4、tee on 30 September 2013.Amendments/corrigenda issued since publicationDate Text affectedBRITISH STANDARDBS EN 62364:2013EUROPEAN STANDARD EN 62364 NORME EUROPENNE EUROPISCHE NORM August 2013 CENELEC European Committee for Electrotechnical Standardization Comit Europen de Normalisation Electrotechni

5、que Europisches Komitee fr Elektrotechnische Normung CEN-CENELEC Management Centre: Avenue Marnix 17, B - 1000 Brussels 2013 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members. Ref. No. EN 62364:2013 E ICS 23.100.10; 27.140 English version Hydrau

6、lic machines - Guide for dealing with hydro-abrasive erosion in Kaplan, Francis, and Pelton turbines (IEC 62364:2013) Machines hydrauliques - Guide relatif au traitement de lrosion hydro-abrasive des turbines Kaplan, Francis et Pelton (CEI 62364:2013) Wasserturbinen - Leitfaden fr den Umgang mit hyd

7、roabrasiver Erosion in Kaplan-, Francis- und Pelton-Turbinen (IEC 62364:2013) This European Standard was approved by CENELEC on 2013-08-01. CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a n

8、ational standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CENELEC member. This European Standard exists in three official versions (English, French, German)

9、. A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions. CENELEC members are the national electrotechnical committees of Austria, Belgium, B

10、ulgaria, Croatia, Cyprus, the Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Swit

11、zerland, Turkey and the United Kingdom. BS EN 62364:2013EN 62364:2013 - 2 - Foreword The text of document 4/279/FDIS, future edition 1 of IEC 62364, prepared by IEC TC 4 “Hydraulic turbines“ was submitted to the IEC-CENELEC parallel vote and approved by CENELEC as EN 62364:2013. The following dates

12、are fixed: latest date by which the document has to be implemented at national level by publication of an identical national standard or by endorsement (dop) 2014-05-01 latest date by which the national standards conflicting with the document have to be withdrawn (dow) 2016-08-01 Attention is drawn

13、to the possibility that some of the elements of this document may be the subject of patent rights. CENELEC and/or CEN shall not be held responsible for identifying any or all such patent rights. Endorsement notice The text of the International Standard IEC 62364:2013 was approved by CENELEC as a Eur

14、opean Standard without any modification. In the official version, for Bibliography, the following note has to be added for the standard indicated : IEC 60193:1999 NOTE Harmonised as EN 60193:1999 (not modified). BS EN 62364:2013 2 62364 IEC:2013 CONTENTS INTRODUCTION . 7 1 Scope . 8 2 Terms, definit

15、ions and symbols 8 Units . 8 2.1Terms, definitions and symbols . 9 2.23 Abrasion rate 11 Theoretical model 11 3.1Introduction to the PL variable . 13 3.2Survey results . 15 3.3Reference model . 16 3.44 Design 17 General . 17 4.1Water conveyance system . 17 4.2Valve . 18 4.3General . 18 4.3.1Selectio

16、n of abrasion resistant materials and coating 18 4.3.2Stainless steel overlays . 19 4.3.3Protection (closing) of the gap between housing and trunnion . 19 4.3.4Stops located outside the valve . 19 4.3.5Proper capacity of inlet valve operator . 19 4.3.6Increase bypass size to allow higher guide vane

17、leakage 19 4.3.7Bypass system design . 20 4.3.8Turbine 20 4.4General . 20 4.4.1Hydraulic design 20 4.4.2Mechanical design . 22 4.4.3Operation 28 4.4.4Spares and regular inspections . 29 4.4.5Particle sampling and monitoring . 29 4.4.65 Abrasion resistant materials . 30 Guidelines concerning relative

18、 abrasion resistance of materials including 5.1abrasion resistant coatings 30 General . 30 5.1.1Discussion and conclusions . 31 5.1.2Guidelines concerning maintainability of abrasion resistant coating materials 32 5.2Definition of terms used in this sublcause 32 5.2.1Time between overhaul for protec

19、tive coatings 32 5.2.2Maintenance of protective coatings 33 5.2.36 Guidelines on insertions into specifications 34 General . 34 6.1Properties of particles going through the turbine 35 6.2Size distribution of particles 35 6.3Mineral composition of particles for each of the above mentioned periods . 3

20、6 6.4Annex A (informative) PL calculation example 37 Annex B (informative) Measuring and recording abrasion damages . 39 BS EN 62364:201362364 IEC:2013 3 Annex C (informative) Water sampling procedure 52 Annex D (informative) Procedures for analysis of particle concentration, size, hardness and shap

21、e . 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

22、 TBO in the reference model 70 Bibliography 73 Figure 1 Estimation of the characteristic velocities in guide vanes, Wgv, and runner, Wrun, as a function of turbine specific speed 13 Figure 2 Example of flow pattern in a Pelton injector at different load 14 Figure 3 Example of protection of transitio

23、n 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 ben

24、ds 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.

25、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

26、 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 pr

27、operties 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

28、 Table B.1 Inspection record, runner blade inlet form 44 BS EN 62364:2013 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 cover

29、s 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 tes

30、t 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 i

31、n 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 BS EN 62364:201362364 IEC:2013 7 INTRODUCTION Many owners of hydroel

32、ectric 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 p

33、hase, 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

34、 severe particle abrasion service. This has led some owners to write into their specifications, conditions which cannot be met with known methods and materials. BS EN 62364:2013 8 62364 IEC:2013 HYDRAULIC MACHINES GUIDE FOR DEALING WITH HYDRO-ABRASIVE EROSION IN KAPLAN, FRANCIS, AND PELTON TURBINES

35、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 mod

36、ifications 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

37、 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 atten

38、tion 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 operati

39、on 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 c

40、avitation 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

41、 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

42、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 ap

43、plicable to other hydraulic machines. 2 Terms, definitions and symbols Units 2.1The International System of Units (S.I.) is adopted throughout this guide but other systems are allowed. BS EN 62364:201362364 IEC:2013 9 Terms, definitions and symbols 2.2For the purposes of this document, the following

44、 terms, definitions and symbols apply. NOTE They are also based, where relevant, on IEC/TR 61364. Sub-clause Term Definition Symbol Unit 2.2.1 specific hydraulic energy of a machine specific energy of water available between the high and low pressure reference sections 1 and 2 of the machine Note 1

45、to entry: For full information, see IEC 60193. E J/kg 2.2.2 acceleration due to gravity local value of gravitational acceleration at the place of testing Note 1 to entry: For full information, see IEC 60193. g m/s22.2.3 turbine head pump head available head at hydraulic machine terminal H = E/g H m

46、2.2.4 reference diameter reference diameter of the hydraulic machine 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 Not

47、e 2 to entry: See IEC 60193 for further information. D m 2.2.5 abrasion depth depth of metal layer that has been removed from a component due to particle abrasion S mm 2.2.6 characteristic velocity characteristic velocity defined for each machine component and used to quantify particle abrasion dama

48、ge Note 1 to entry: See also 2.2.20 to 2.2.24. W m/s 2.2.7 particle concentration the mass of all solid particles per m3of water solution 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 approx

49、imately corresponds to 1 kg/m3. C kg/m32.2.8 particle load the particle concentration integrated over the time, T, that is under consideration =TdttKtKtKtCPL0hardnessshapesize)()()()( =NnnsnnnnTKKKC1hardnessshapesize ,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 cal