Research on Sediment Erosion and Anti-Wear Coating Materials for Water-Intake Components of Hydraulic Turbines in Sandy Rivers

Abstract: The operational efficiency, stability, and lifespan of hydroelectric power plants operating on sediment-laden rivers are affected by sediment erosion. A numerical simulation of the sand–water flow in the water-intake components of a turbine at a specific power station was conducted using the Euler–Lagrange method. Additionally, sediment erosion tests were carried out on the water-intake components coated with epoxy mortar material. The results indicate that sediment erosion on the stay vane surface mainly occurs on the front face, with the most severe erosion at the head, while sediment erosion on the stay ring surface primarily occurs near the stay vane head. The extent of erosion is mainly influenced by the distribution characteristics of sediment particles. The wear of epoxy mortar coating material is minimally affected by the spraying thickness. Adding 30% hardener to the epoxy mortar material can significantly improve the erosion resistance of the stay vane surface by about 30%. The erosion rate on the frontside of the stay vane is approximately 2.6 times that of the backside. Based on the sediment erosion tests and numerical simulation results of the sand–water flow, an estimation formula for the sediment erosion rate of the epoxy mortar erosion-resistant coating was established. This formula can be used to predict the anti-sediment erosion performance of epoxy mortar materials applied to the water-intake components of this turbine and similar river turbines.