Duan C.G., Karelin V.Y. Abrasive Erosion and Corrosion of Hydraulic machinery
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SERIES ON HYDRAULIC MACHINERY - VOL 2
Abrasive Erosion
(V
Corrosion
of
Hydraulic Machinery
Editors
(. G. Duan
V.
Y.
Karelin
Imperial College Press
Abrasive Erosion
(Vforrosion of
Hydraulic Machinery
HYDRAULIC MACHINERY BOOK SERIES
- Hydraulic Design of Hydraulic Machinery
Editor:
Prof.
H Radha Krishna
- Mechanical Design and Manufacturing of Hydraulic
Machinery
Editor:
Prof Mei Z
Y
- Transient Phenomena of Hydraulic Machinery
Editors:
Prof.
SPejovic, Dr. A P Boldy
- Cavitation of Hydraulic Machinery
Editors:
Prof.
S C Li
- Erosion and Corrosion of Hydraulic Machinery
Editors: Prof Duan C
G,
Prof V Karelin
- Vibration and Oscillation of Hydraulic Machinery
Editor:
Prof H Ohashi
- Control of Hydraulic Machinery
Editor:
Prof.
H Brekke
The International Editorial Committee (IECBSHM):
Chairman:
Prof.
Duan C G
Treasurer: DrRK
Turton
Committee Members:
Prof.
H Brekke (Norway)
Prof.
E Egusquiza (Spain)
Dr. HR Graze (Australia)
Prof.
P Henry (Switzerland)
Prof.
V Karelin (Russia)
Prof.
Li S C (China)
Prof MTde Almeida (Brazil)
Prof MMatsumura (Japan)
Prof.
A Mobarak (Egypt)
Prof.
HNetsch (Canada)
Prof SPejovic (Yugoslavia)
Prof.
H Petermann (Germany)
Prof.
C S Song (USA)
Prof.
HI Weber (Brazil)
Honorary Members:
Prof.
B Chaiz (Switzerland)
Secretary: Prof Li S C
Dr. A P Boldy
Prof VP Chebaevski (Russia)
Prof.
MFanelli (Italy)
Prof.
R Guarga (Uruguay)
Dr. H B Horlacher (Germany)
Prof G Krivchenko (Russia)
Prof.
D K Liu (China)
Prof C S Martin (USA)
Prof.
Mei Z Y (China)
Prof.
HMurai (Japan)
Prof.
H Ohashi (Japan)
Prof.
D Perez-Franco (Cuba)
Prof.
H C Radha Krishna (India)
Prof.
C Thirriot (France)
Prof.
G Ziegler (Austria)
Prof.
JRaabe (Germany)
^§^
SERIES ON HYDRAULIC MACHINERY-VOL 2
Series Editor: S. C. Li
Committee Chairman: C. G. Duan
rasive Erosion
Corrosion
of
hydraulic Machinery
Editors
(.
6.
Duan
International Research Center
on
Hydraulic
Machinery,
Beijing,
China
V.
Y.
Karelin
Moscow Mate University
of
Civil
Enqineerinq,
Russia
Imperial College Press
-(^
Published by
Imperial College Press
57 Shelton Street
Covent Garden
London WC2H9HE
Distributed by
World Scientific Publishing Co. Pte. Ltd.
P O Box 128, Farrer Road, Singapore 912805
USA office: Suite 202,1060 Main Street, River Edge, NJ 07661
UK office: 57 Shelton Street, Covent Garden, London WC2H 9HE
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library.
ABRASIVE EROSION AND CORROSION OF HYDRAULIC MACHINERY
Copyright © 2002 by Imperial College Press
All rights
reserved.
This
book,
or parts
thereof,
may not be reproduced in any form or by any means,
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invented,
without written permission from the Publisher.
For photocopying of material in this volume, please pay a copying fee through the Copyright
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photocopy is not required from the publisher.
ISBN
1-86094-335-7
Printed in Singapore by Mainland Press
CONTENTS
Foreword of the Editor xi
Contributing Authors xiii
1 Fundamentals of Hydroabrasive Erosion Theory 1
V. Ya
Karelin,
A.I. Denisov and
Y.L.
Wu
1.1 Introduction 1
1.2 Mechanism of Hydroabrasive Effect Produced by Particles 4
1.3 Abrasive Erosion of Hydraulic Turbine 21
1.3.1 Illustrative Examples of Hydraulic Abrasive in
Hydraulic Turbines 21
1.3.2 Silt Erosion of Hydro-turbines 25
1.4 Abrasive Erosion of Pump 34
1.4.1 Examples of Hydraulic Abrasion Taking Place in
Pumps 34
1.4.2 Silt Erosion in Pumps 36
1.5 Technical and Economic Effect Caused by The Erosion Arising
in Hydraulic Turbines and Pumps 42
1.6 Approach to Anti Abrasive from Hydraulic Machinery 48
1.6.1 Approach Avenues on Anti-silt Erosion of Hydraulic
Machinery 48
1.6.2 Anti-abrasion Hydraulic Design of Pumps 49
1.6.3 Prediction of Silt-Erosion Damage in Pump Design by
Test 49
References 51
2 Calculation of Hydraulic Abrasion 53
V.
Ya
Karelin,
A.I. Denisov and
Y.L.
Wu
2.1 Calculation of Hydraulic Abrasion Proposed by
V.
Ya Karelin,
and
A.I.
Denisov 53
2.2 Prediction Model of Hydraulic Abrasion 74
2.2.1 Prediction Erosion Model Proposed by Finnie and Bitter 74
V
VI
Contents
2.2.2 Mechanistic Model Developed by The Erosion/Corrosion
Research Center 84
2.2.3 Prediction Erosion Model Proposed by McLaury et
al.
88
References 93
3 Analysis and Numerical Simulation of Liquid-Solid Two-Phase
Flow 95
Y.L. Wu
3.1 Basic Equations of Liquid-Solid Two-Phase Flow through
Hydraulic Machinery 95
3.1.1 Introduction 95
3.1.2 General Concepts of Multiphase Flow 97
3.1.3 Basic Equations of Multiphase Flow 101
3.2 Closed Turbulent Equations for Liquid-Solid Two-Phase Flow
through Hydraulic Machinery 110
3.2.1 Closed Turbulence Model Using the Modeled Second
Correlation 110
3.2.2 The Algebraic Turbulence Stresses Model of
Two-Phase Flow 117
3.2.3 The k-s-kp Turbulence Model of Two-Phase Flow 120
3.2.4 Lagrangian-Eulerian Model for Liquid-Particle
Two-Phase Flow 125
3.3 Numerical Simulation of Liquid-Particle Two-Phase Flow
through Hydraulic Machinery by Two-Fluid Model 132
3.3.1 Numerical Method for Simulating Liquid-Particle
Two-Phase Flow 132
3.3.2 Calculated Examples of Two-Turbulent Flow by
Using Two-Fluid Model 141
References 152
4 Design of Hydraulic Machinery Working in Sand Laden Water 155
H. Brekke, Y.L. Wu and
B.Y.
Cai
4.1 Hydraulic Design of Turbines 155
4.1.1 Introduction 155
4.1.2 Impulse Turbines 156
4.1.3 Reaction Turbines 172
4.2 Effects of Silt-Laden Flow on Cavitation Performances and
Geometric Parameters of Hydraulic Turbines 181
4.2.1 Effects of Silt-Laden Flow on Cavitation
Performances of Hydrauliv Turbines 181
4.2.2 Model Experiments on Cavitation of Turbines in
Silt-Laden Flow 186
4.2.3 Selection of Geometric Parameters of Turbines
Operating in Silt-Laden Flow 187
4.3 Hydraulic Design of Slurry Pump 196
4.3.1 Internal Flow Characters through Slurry Pumps 196
4.3.2 Effects of Impeller Geometry on Performances of
Slurry Pumps and Its Determination 202
4.3.3 Vane Pattern 208
4.3.4 Hydraulic Design of Centrifugal Slurry
Pumps
212
4.3.5 Hydraulic Design of Slurry Pump Casing 216
4.3.6 Hydraulic Design for Large-Scale Centrifugal
Pumps in Silt-Laden Rivers 219
4.4 Hydraulic Design of Solid-Liquid Flow Pumps 220
4.4.1 Working Condition of Solid-Liquid Flow Pumps 220
4.4.2 Hydraulic Design of Solid-Liquid Flow Pumps 223
4.4.3 Examples of the Design 230
References 232
5 Erosion-Resistant Materials 235
M. Matsumura and
B.E.
Chen
5.1 Selection of Erosion-Resistant Materials 235
5.1.1 Multiposion Test in a Real Water Turbine 235
5.1.2 Laboratory Erosion Tests 241
5.1.3 Selection of Materials for Hydraulic Machines 246
5.2 Metallic Materials 250
5.2.1 Testing Apparatus and Procedure 251
5.2.2 Test Results 255
5.2.3 Damage on Pump Components 257
5.2.4 Requisites for Laboratory Tests 258
5.3 Organic Polymer Linings 262
5.3.1 Conventional Polyurethane Lined Pipe 263
Contents vii
Vlll
Contents
5.3.2 Room-Temperature Curing Polyurethane (RTV) 265
5.3.3 Durability of RTV Lined Pipe 269
5.3.4 Cost Estimation 272
5.4 Ceramics 273
5.4.1 Bulk Ceramics 275
5.4.2 Cemented Carbides 279
5.4.3 Coatings 282
5.5 Metal Protective Coating 285
5.5.1 Bead Welding 285
5.5.2 Paving Welding 291
5.5.3 Alloy Powder Spray Coating 292
5.6 Non-Metallic Protection Coating 298
5.6.1 Epoxy Emery Coating 299
5.6.2 Composite Nylon Coating 303
5.6.3 Rubber Coating of polyurethane 305
5.6.4 Composite Enamel Coating 307
5.7 Surface Treatment against Erosion Damage 308
5.7.1 Quenching and Tempering 309
5.7.2 Diffusion Permeating Plating 309
References 312
6 Interaction between Cavitation and Abrasive Erosion Processes 315
V. Ya
Karelin,
A.I. Denisov and
Y.L.
Wu
6.1 Effect of Suspended Particles on Incipient and Developed of
Cavitation 315
6.2 Effect of Cavitation on Hydroabrasive Erosion 330
6.3 Relationship between Hydroabrasive Erosion and Cavitational
Erosion 338
References 348
7 Corrosion on Hydraulic Machinery 349
M. Matsumura
7.1 Fundamentals of Corrosion 349
7.1.1 Corrosion Cell 349
7.1.2 Electrode Potentials 351
7.1.3 Polarization 356
7.1.4 Polarization Diagram 359
7.2 Application of Corrosion Theories 361
7.2.1 Pourbaix Diagram 361
7.2.2 Influences of pH and Fluid Velocity upon Corrosion
Rate 363
7.2.3 Cathodic Protection 366
7.2.4 Passivity 368
7.2.5 Stainless Steel 369
7.2.6 Polarization-Resistance Method 371
7.3 Corrosion of Pump Parts 373
7.3.1 Corrosion Caused by Velocity Difference 373
7.3.2 Corrosion Promoted by Mixed
Use
of Different
Materials (Galvanic Corrosion) 377
7.3.3 Crevice Corrosion and Other Localized Corrosion 381
7.4 Interaction of Corrosion with Erosion 387
7.4.1 Experiment on Slurry Erosion-Corrosion 387
7.4.2 Basic Equations Describing the Combined Effect
of Erosion and Corrosion 394
7.4.3 Analysis on a Single Crater 397
7.4.4 Parameters Affecting the Mutual Interaction
Mechanism 404
References 406
Contents ix