Paper No. 142 SILT EROSION IN INDIAN HYDROELECTRIC PROJECTS - LABORATORY STUDIES OF THERMAL SPRAY COATINGS OVFR HYDRO TURBINE. COMPONENTS MK. Sharma , G.S. Grewal, & AK, Singh Electrical Research & Development Association (ERDA), ERDA Road, GIDC, Makarpura, Vidodara-390 010 (India) Ph: 091-268-3048008, Fav 091-268-2638382, E-mail: mtdaerda.org ABSTRACT: Silt erosion damage in under water parts of hydro electric projects and minimisation of these problems (generally termed as ‘Silt Menace’) have been constantly engaging the attention of hydro engineers and manufacturers of hydro power plant equipment world wide. The Indian sub-continent is one of the most vulnerable zones in the world for silt erosion and sedimentation. The rivers of most of the power plants in northern India, China, Bhutan and Nepal originate in the Himalayan region which has relatively weak and fragile geology. During the monsoon days of April-September, the streams carry huge silt load, predominantly comprising of quartz particles, which are very hard in nature and irregular in shape. This heavily si laden water containing up to 15,000 ppm silt of even more during rainy season, find entry into the water conductor system and impinges on the surface of the turbine, underwater components such as runner assembly, guide vanes, labyrinth sealing rings and surface liners of turbine top cover and bottom ring causing severe metal loss due to erosion Hydro turbine components are manufactured from 13%Cr-4%Ni stainless steel. The erosion due to silt is so rapid that within one year of operation for 4000-5000 hours, the worn out components need extensive repairs by way of rebuilding by welding followed by thermal spray metallic coatings or by polymeric coatings. The various generation ullities in the central and state sectors have been incurring huge expenditure in India for the reconstruction of the damaged parts. Investigations made by conducting experimental studies of silt laden water erosion of 13/4 stainless steel, over laid as well as subjected to thermal spray by Plasma, HVOF, D-Gun coatings are presented in this paper. The silt characteristics of Indian rivers are also discussed, The studies presented here were conducted under actual hydraulic conditions simulated in @ unique “Silt-Water Impingement Erosion Test Rig”. In this unique test rig which has been indigenously designed and developed and happens to be the anly one such rig in India, the ennditians encountered in hydro turbines can be simulated by varying and controlling the various operating parameters, Details of extensive experimental investigations carried out in this test rig are reported and discussed in this paper. HydroVision 2008 - Copyright HCI Publications, 18 wn heipub.com iPaper No. 142 1.0 INTRODUCTION: A large number of hydro-turbines installed in Himalayan region have been adversely affected by silt erosion. This problem is more serious during monsoon season when silt laden water enters the turbines with concentration more than 10,000 ppm at some of the power stations This unprecedented damages caused by hard silt particles, have thrown a big challenge to the hydro engineers. The limited counter measures possible are usually resticted to regular replacement of components, application of protective coating on the surface, or repair by welding, The hydro plant engineers have been adopting various surface protective methods to counter this problem like plasma nitriding, ceramic coating by plasma yur, deturiati¥it gun, HVOF gun, flame spray repair welding and polymeric coatings. But due to lack of technical information, technical data and correct testing methods hardly any of these method is successful so far, The obvious reason among the others is that hardly any electricity board is working to counter this damage by their own R&D In this direction, R & D wing of NHPC had been taking lead to reduce these damages by various R & D project on hydro turbine materials and their protecting measures to counter the silt damages. Baira Siul and Salal hydro power plants are most affected power stations by silt damage. Ihe damaged surface of the turbine runner blade and guide vane are shown in Fig. 1 (a-d). The work presented in this paper were carried out under NHPC sponsored project. ‘At both these hydro power plants, martensitic stainless steel! is in use for hydro turbine components which is most widely used steels for hydro power industry through out the world. This steel belongs to the family of martensitic stainless steel grade confirming to the CA-6NM. The commercial and popular name of this steel is 13/4 Cr-Ni steel. The brief description of this steel is described in this chapter. This steel has a very vast applications in power generation parts ie., runner blades, guide vane, impellers, ‘casings, impulse wheels, valves ete. Attempts to reduce erosion by providing ceramic coating on under water parts have proved to be futile since these coating are very difficult to be deposited on the worn out surface at site. Further laboratory tests have shown that the ceramic coating deposition are difficult to be deposited without appreciable porosity, which reduces their adherence as well as erosion resistance. HydroVision 2008 - Copyright ICI Publications, 2008 - www hipub cum 2Paper No. 142 (c) Damaged Guide Vane (d) Damaged Blade Profile Fig. 1. Silt Erosion Damages Of Runner And Gi Vane Of Indian Hydro Power Plant, HydroVieion 2008 Copyright HC! Publications, 2008 - wer-hcipub comPaper No, 142 2.0 DESIGN AND DEVELOPMENT OF EROSION TEST RIG: The erosion due to silt Jaden water is one of the majer problem confronting the designers and manufactures of hydro turbine, pumps, hydro foils, propellers etc. A large number of hydro power projects in India as well as in China are trapped in this silting problem, Attempts to reduce erosion by providing hard surfacing, repair welding and coatings on under water parts have proved to be futile due to lack of simulated crosion testing facilities, Unfortunately most of the testing is being done by irrelevant testing methods, These tests are being carried out generally by dry abrasive testing machine design as per ASTM G.65 whieh hae totally different mechanism of loss of material Juv ly vivsiut Therefore it was necessary to design and fabricate an erosion testing rig which could test the components of turbine under the simulated hydro turbine conditions. The test model for these studies were designed for erosion testing involving an impingement jet of silt laden water on the sample. These testing rigs have been designed to expose surface to erosion in a way which has resemblance to actual condition of water turbine. In this context, it was necessary to fabricate these rigs in the laboratory because the prototype testing facility is extensively costly. Further, prototype testing is @ tine consuming affair. During the present studies, the economic and feasible option was the laboratory test on replicated samples under the simulated hydro turbine Conditions. This can be done on smaller samples and the results can be extrapolated to the similar prototype/ turbine components in actual use. This is less expensive and time saving. {nis impingement erosion testing rig has been fabricated to expose in a way the surface Which has resemblance to impingement on the sample similar to actual condition of hydro turbine. This testing rig is rare of its kind in the country which can be used to Predict the life of the runner blades under the site conditions. This set up has three main Units (i) Silt control unit (i) Erosion chamber (i) Sil-water filtration and water pumping Unit. This machine is designed to expose the sample directly under static mounting at any angle. The function of silt controling unit is to control the flow of dry sand to the water nozzle where it mixed with the water before impingement on the sample. Using the silt control Unit, the feed rate or concentration of sit in water can be closely controlled up to desired pm concentration. In this study, the silt was controlled at 6000 ppm throughout the study. In this set up, the samples can be tested either in static condition at any desired impingement angle. In the erosion chamber sample mounted in a fixture can directly be exposed to silt laden water at a particular impingement angle, The silty water after impinging the sample flows to the silt separating and collecting unit where the silt settie down in different Partition of the tank before going to re-circulating water tank. After final filtration of Hydro\ision 2008 - Copyright HCI Publications, 2008 www heipub.com 4Paper No, 142 sand, this water can be reused to erosion chamber through pumping system. This machine has facilities to control the following parameters, (a) Pressure of Water (b) Impingement Angle (o) Silt Concentration (d) Silt Particles Size (e) Sample Size (f) Velocity of Water Stream 3.0 SILT CHARACTERISTICS AND ANALYSIS: The sand collected from Salal Hydro power station, Jammu & Kashmir was used in erosion studies. The shape, size and their qualitative and quantitative study were made on this sand, Sieve Analysi The sieve analysis of the silt was carried out by standard methods. The laryest particles Used in this study were up to size 700 jim. The distribution of the parlicles size are shown in Fig. 2a. Sand particles range from very fine to fine sand in size. The shape of the particles range fron) semni-round to sub-angular and is only moderately sorted. Petrographic Analysis: The sand particles were also studied for their constituents and quantitative analysis (petrogaphic) by XRD method. These particles were characterized by a set of line Positions 26 and a set of relative line intensities |. The angular position 2 © is dependent on the wavelength, however the lattice spacing is the fundamental quantity. Because many substances are available in this sand. so there is a collection of diffraction pattern for these substances. Therefore it is easy to identity an unknown substance by obtaining its diffraction pattern and matching it with the known pattern from a standard known Powder Diffracton File (PDF). This data reveals that this sand contains ~89% quartz particles, The constituents percentage of this sand are shown in the Pi chart given in Fig. 2b. Shape Analysis: SEM was used to study the shape of the particles. The shape of particles was well defined from sub-angular to angular. The particles of large size (500-700 ym) were rounded in shape whereas particles up to 360 jum were polyhedral in shape. The tips of the particles wore observed to be sharper the smaller the size. The shape of the Particles of the size ~300 jum were semi-rounded and tips of the particles of size 250 him were conical. Sub-angular to semi angular shapes were observed in the size of 100- 150 jm and particies of the size ot 100 ym had well defined sub-angular to sharp angular tips. The micrographs of the particles shape before erosion are shown in Fig. 2 (c-) HydroVieion 2008 - Copyright HC! Publication, 2008 - wwnw.heipub.comPaper No, 142 (a) Distribution of Silt Particle Size [oy Constituents of Sitt Particle Size | yy ft a (©) Shape of Silt Parti le of 100) Size (d) Shape of Silt Particle of 75 Size Fig. 2. Silt Characteristics and Constituents Of Salal Hydro Power Plant. HydroVision 2008 - Copyright IC! Publications, 2008 - wow hipub cant 6Paper No, 142 4.0 EXPERIMENTAL STUDIES: Stainless Steel: The 13/4 SS was cast in the plate form. The nominal composition of this steel is C-0.04, Cr-11.5, Ni-d.12, Mo-0.69 and Si-0.38 %. The cast metal of this grade solidifies as o-ferrite followed by an almost complete transformation to austenite in the high temperature region. During cooling down, the austenitic start transforming almost completely to martensite At room temperature, the microstructure consists of low carbon martensite, 1-2 % é-ferrite and 1-4 % retained austenite. The micro structure of as cast steel shows un-tempered martensitic structure. The microstructure also shows pools of delta ferrite in the matrix. The carbide is also presant at the grain boundaries. In heat treated condition, the structure shows the homogeneous microstructure. The martensitic needles got tempered as observed in the microstructure. The retained austenite is also observed at few places in very lttle quantity. Very fine carbide is observed in the structure. The microstructure of heat treated 19/4 SS is shown in Fig.-3. ‘The samples were cut in fiat and rectangular size of (75x25x6)mm from the cast plates for the erosion test. The cast steel was heat treated before coating and testing. The heat- treated 13/4 steel gives the best optimised mechanical properties. In heat treated condition, these steel shows the hardness 300VHN/ toughness 30J as compare to hardness 450VHN/ toughness 80J in as cast condition. Total six number of samples were well prepared for the studies, Thermal Spray Coatings: The base material of 13/4 SS was over layer by thermal sprayed coatings. The various coating materials such as Al,Os, NiCr-BSi and TiC-CiC-Co were used in the study. The coatings were sprayed thermally by processes such as HVOF, Thermal Plasma and D-gun methods, The properties of deposited material, thickness and hardness of surface etc after deposition are shown in Table-1 TABLE-1 Properties Of MetalliciCeramic Coated Samples, Coating Powders And Processes. Sr] Sample | Sample | Treatment? Coating | Hardness | Coating Identification | Code Coatings Process (VHN) | Thickness T_[sTass AAT Tempered =u 2. BNC- A99 B_ [ALO; Plasma Spra 694 3._| Met Coat-t C|NiCr-BSi HVOF 750 4. [ARCI-2 D__[AL0;-131O D-Gun 1000 5._[BHELA E | TiC-Cr-82C0 HVOF 1100 HydreVision 2000 - Copyright 11C1 Publications, 2008 - werm:hjpubs. conn 1Paper No. 142 The hardness of all the samples were measured and are plotted in bar diagram as shown in Fig, 4. This bar diagram shows that maximum hardness value was observed in sample-E which is HVOF coated TiC-CrC-Co overlay. Test Procedure and Test Parameters: A uniform test procedure was employed for all the samples through out the study. The erosion test was conducted on heat teated and coated samples. The samples were cleaned and polished first and then weighted in an electronic balance to an accuracy of 0,0001gm, eroded for duration of various hours and again weighed to determine the weight loss. Five consecutive tests of one hour each were conducted for each sample The erosion data of 5 hrs duration tests are shown in Table-2, The following parameters were used in this study. Silt particle concentration 5000 ppm Duration of test : Shes. -let Impingement Velocity 40 m/sec Particle size used up to 700 um Condition of testing static Angle of impingement 20° Total Silt Used 25.5 kgs Sample Mounting Position Static TABLE2 EROSION DATA OF H.1 AND COATED SAMPLES Sample Sample Erosion Coating Matorial | Weight Identification _| Time-hrs Loss (mg) 43/488 5 HT 172.0 BNG- A99 5 ALO: a9 Met Coat-1 5 _Nicr-BSi 284 ‘ARCI-2 5 AL0+13T10 6250 | __BHEL-+T S___ TiC-CrC-82C0 350 5.0 FROSION BEHAVIOUR OF COATIN The erosion behavior of 13/4 SS and coated material by silt has been studied. The results of these studies are presented in Table-2, The weight loss of these coatings tested in static condition are shown in bar diagram fig. 5. The tested samples were examined on surface for damage anpearance The detailer observations are illistrated elenrly with the halp of bar chart as shown in Fig. 485. In these charts the erosion of the material has been plotted in terms of weight loss of the material coatings. All the samples were tested for § hrs of erosion. In most of the samples, concave profile is observed on the surfaces. The rate of this profile or thickness of erosion is different in all the materials. IydroVision 2008 - Copyright HC! Publications, 2008 - ww hipub.com 8Paper No, 142 It can be clearly seen from Fig. 5 that coating material sample no. B (plasma spray coated) has got totally washed out in 5 hrs of erosion. The sample no. D (D-Gun coated) hardly shows any sign of concavity on the surface or erosion marks. The surface topography of the eroded 13/4 stainless steel! sample has been carried out by the examination under scanning electron microcopy (SEM). The mechanism of material loss could be determined by micrography as shown in Fig. 6. The SEM analysis shows that the erosion causes gradual removal of material form the surface by the ploughing mechanism. Cutting marks at the center can also be seen in this figure. The morphology of eroded surface indicates that the erosion is due to sand impact where pleuighing and lip fracture are dominant. Coatings Hardness Samples Code Fig, 4. Hardness of Various Thermal Spray ‘ing Materials. a -e- 0 Sample Code Witte flog ¢ 520s Fig. 6. Damage Mode of Ploughing Mechanisin in Heat Treated 13/4 Base Material Fig. 5. Silt Erosion Rate of Various Therm: l Coating Materials. HydroVision 2008 - Copyright! Publications, 2008 - worn hjpub eum 9 aPaper No. 142 CONCLUSIONS: In the present work, silt erosion studies have been carried out on base material and on thermal spray coatings. Total five nos of samples were studied for erosion. Silt impingement erosion testing rig was specially designed and fabricated to test for erosion under simulated hydro power conditions. The rig has provision to subject test sample in static conditions at any angle of impingement varing from 0-90°. Resiries this, provision has been made in the rig to regulate silt concentration (ppm), jet velocity and water Pressure. All necessary tests on the silt such as sieve, shape and petrographic analysis were also conducted Various fests an differant samples were conducted for five hre duration ranging from one hr to five hrs to assess their performance under silt-water impingement. The finding of these studies have been discussed in this paper and these findings are summarized as follows, 1) Samples coated with AlsOs-13TiO by Detonation Gun process have shown best results which show that the bond strength by D-Gun process is excellent among the various processes employed under the parameters employed in these studies respectively. 2) Samples coated with WC-CrC-Co by HVOF process have also demonstrated appreciable resistance to erosion but not as_good:as by D-Gun process, Therefore, bond strength provided by HVOF process is also substantial 3) Samples coated with NiCr-BSi by HVOF process haye also shown poor results. 4) Samples coated with Al,Q3 with plasinia spray process have shown poorest resuits. 5) Erosion suffered by base material 13/4 stainless steel has shown moderate loss of material REFERENCES: |. M.&.Sharma, “Wear Damage Mechanism In Hydro Electric Under Water Parts-A brasion Or Erosion” CBIP Ist Int. Cont. On Silting Problems In Hydropower Plants, New Delhi 9-11 Feb, 1999. 2. Ch, Schneider, M. Engelhardt * Industrial Scale Application Of Erosion Protection Coatings For Water Turbine,” Munich, Germany, Conf. Procd., Material Week 2000, M.K.Shatma, Alphonsa Joseph, Project Repon On “Laboratory Evaluation Of Plasma Nitriding Components OF 13/4 Cr Ni Stainless Steel And Rehabilitated Components OF Hydro Turbine” Submitted To National Hyd Power Corporation, India, Dec, 2001 4. M.Ramamoorty, G.N.Mathur and M.K.Sharma. “Design And Development Of Model Test Facility For Predicting Silt Demace”. Proceedings Of 2* Int. Canf On Sitting Prablome tn Hydropower Plants, Bangkok, Thailand, Organised By CBIP, New Delhi, 26-28 Sept., 2001 5. MK -Sharma “Development Of Welding Technology For Eroded Components Of Hydro “Turbines”. Project Report Submitted To Department OF Science & Technology, India, 2000. 6. M. Engelhardt, Ch. Schneider And D. Oechsle “Real Seale Performance Of Adv Erosion Protection ‘Technique On Water Turbines" Proceedings OF 2" Int, Conf. On HydroVision 2008 - Copyright HCI Publications, 2008 - wer. ncipub.com wPaper No 142 Problems In Hydropower Plants, 26-28 Sept, 2001, Bangkok, Thailand, Organised By CBIP, New Delhi 7. MAK Sharma and A.K.Singh, “GTA and SMA welding of hydro turbine stainless steel and their effect on mechanical properties” IIW Int. Congress2005 on “Frontiers of welding science and technology” organized by IIW India, Feb., 16-19, 2005 at Mumbai 8. MK Sham, * Suucture-Properties co-elution in welded CA-6NM stainless steel”, Ime, Welding Conf-IWC 2001 on * Advances in welding and cutting technology", Organized by IIW & CI, New Delhi, India, Feb.15-17,2001 9. M.K.Sharma, * Renovation and Modernization of aged hydro power plants” Seminar on Renovation & modernization and life extension of hydro power plants” Organized by CBI &-P, Ministry of Power, Cochin, Feb.12-14, 2001. 10, MAK. Das & Mukesh K. Sharma, “Combating high silt erosion rate problems of runner blade fof hydro turbines of Himalayan Terrain - A three pronged strategy", Ind International conference on Accelerated development of power resourees in the 2ist century, China, 25- 27 Oct, 1999, 11, MX, Sharma and U.N.Puntambekar, “Refurbishment of damaged components of hydeo- power plants by welding & coating technology and their erosion behavior” hydro centenary celebration Seminar on “Up rating and refurbishment of hydro power plants” (Chand garh,Inida, 7-1 9Noy.1997. 12. M. K. Sharma, D.B.Goel and P.S.Misra, “Silting problems in hydro power — stations” ‘Sesqutcentenniat celebration, university of Koorkee and C1stéet hydro centenary’ celebration seminar, WRDTC, University of Roorkee,14.May, 1997, Hyaroviston 2008 - Copyright HCI Publications, 2008 - wv heipub.com uPaper No. 142 Brief biodata- Dr.M.K.Sharma gy DeM.K-Sharma is Manager & Head of the proup Working inthe fleld of Materials, NDT & RLA, Elecical Materials, Vibration & Seismie, Condition Monitoring and RLA & LE of Hyd. He ‘obtained his Maser of Philosophy in Materials Science in 1986 and obtained his Ph.D in Materials Engineering from University of Roonkee (IIT, Roorkee) in 1946, He worked at Metallurgical Engineering Depariment, Roorkee University as research Fellow, research scientist an fell scientist from 1986-1997. His area of specialization is hydro turbine steels, welding and wear & erosion problems. He joined Ectrical Research & Development Association (ERDA) Vadodara in 1987 as St. Scientist where he is working on development of new materials, magnetic & electrical materials, wear and erosion and Vibration. He has more than 20years of experience in these areas, Currently he i working’ on development of new materials & technologies, condition assessment, Remaining Life Studies & Life extension of aged powerplants. He isthe recipient of various awards including Young Scientist & Young Engineer Award. He is a member of various professional societies including Intemational Association on Flociciyy Generation, Transmission & Distribution (Afro-Asian Region) He is conferred by American Biographical Insitate (ABI), USA with an Honorary appointment to the Research Board of Advisors. Brief biodata- Dr.G.Grewal 1e. G. S. Grewal is Senior Manager & Head (Materials Teohnology Division) atthe Electica! Research & Development Association (ERDA), Vadodara. He obtained his Ph. D. (specialization in Thermodynamics, Transpor! Phenomenon & Chemical Phissics) in the year 1989 trom the University of Maryland, College Park, USA. His areas of expertise include Meallurgy, Welding, Thermodynamies, Mechanics, Modeling & Process Analysis, Random Variable Calculus & Statisical Analysis, Fracture Mechanies, Conditional assessment & Conosion Engineering. ie has mare thas 22 years of experience in thauw ureae, Hie io @ Life Member of Pi Kappa Honor Society (USA) for which a distinguished comitee nominated him for his aeademie performance at the Departmen of Chemical & Nuclear Engineering, University of Muryland-College Park, He is an ¢-Member of the American Society fr Materials (ASM — International) and a Life Member of « number of Professional Societies, which Include the Indian Society of Heat - & Mass Transfer, & The Indian Institute of Welding Brief biodata- A.K.Singh A.XKSingh is working as Director with Flectical Research & Development. Association, Vadodara, He received his M. Tech. degre in Turbo Machines ftom IIT, Delhi in the year 1979 He has three decades of experience as a power sector professional and twa years of academic experience as a Professor of Mechanical Engineering. His field of expertise includes Turbo- Machines, Fluid Mechanics & Fluid Power, RLA & LE, Condition Monitoring, Quality Management, Energy Management, ete. He provides technology tetining on Power Pant Engineering. He 18a Fellow of Institution of ingincers (India), Fellow of Society of Power Engineers (India), Member of Indian Institute of Welding, Member of Intemational Association on Electricity Generation, Transmission & Distribution (Alio-Asian Region), Member ofthe Research Advisory Commitee of National Innovation Foundation, india, Member fof the Advisory Board for Aesal Repevay's constituted by Goveriment of Gujarat and Member af the Refigertion and Air Conditioning Sectional Commitee ofthe Bureau oF Indian Standards. He has contributed ten technical papers to Jourals, Conferences and Seminars in the field of RLA, R&M, Condition Monitoring of Power Plant Equipment and Eneray Management. HyutuVision 2008 - Copyright HI Pubiations, 2008 - waw.eipub.com 2