Efficiency Testing of Pelton Turbines with Artificial Defects—Part 2: Needles and Seat Rings

The erosion of Pelton turbine components in mountainous areas with high sediment input is a major challenge for energy- and cost-efficient operation. Quantitative data on possible efficiency losses associated with local damage are needed. A systematic experimental study was carried out on a model turbine to determine the efficiency losses caused by damaged needles and seat rings. For this purpose, artificial patterns of erosion-like damage were generated on the surfaces of needles and seat rings. These patterns were gradually deepened, and hill charts were measured repeatedly. The combination of needle and seat ring defects was also studied, and the finding is that superimposing the individual efficiency losses of the needle and seat ring resulted in the same efficiency loss measured for both damaged parts. The results of the measurement campaign show that damaged needles should be replaced at an early stage of deterioration, as efficiency losses can quickly add up to several percent and become unacceptable at partial load operations of the turbines.