Design and Validation of a Testing Device for Sediment-Induced Erosion Based on Similarity Theory

Sediment-induced erosion is a primary cause of failure in the flow-passage components of Francis turbine units. This study adopted the Realizable k–ε turbulence model to numerically simulate the effects of sediment-induced erosion on the guide components of Francis turbines. Specifically, using flow similarity theory, a testing device suitable for studying the sediment-induced erosion behavior of turbine vanes was designed, and the similarity between the flow fields of actual vanes and testing device vanes was validated. The results revealed a high degree of consistency between the near-wall flow velocities and sediment volume fractions experienced by both vanes at 0.5 vane height. For instance, the midsection of the suction side of the stay and guide vanes exhibited relatively stable velocities of 12.5 m/s and 42 m/s, respectively. Further, sediment volume fractions at the leading edge of the stay and guide vanes reached 0.015, respectively, owing to the impact of sediment-laden flow. Overall, the proposed testing device design methodology can predict the operational lifespan of actual vanes and assess the wear resistance of various coating materials. These findings provide valuable scientific guidance for optimizing the design and operation of hydropower plants.