Sediment erosion damage is one of the main causes of structural failure in reaction turbine units. To study the mechanism through which sediment erosion affects the water-guiding mechanism of a reaction turbine unit, this study obtained the average concentration and particle size of sediment during the flood season based on the statistics of the measured sediment data from the power station. Additionally, the characteristics of the solid–liquid two-phase flow of the diversion components of the reaction hydraulic turbine were numerically calculated. Based on the velocity triangle change in the guide apparatus and the flow similarity principle, a flow-around wear test device for the guide apparatus of the reaction turbine was designed. Furthermore, the similarity of the sand–water flow field between the guide apparatus of the prototype unit and the test device was compared and analyzed. The results demonstrated that the sand–water flow field of the diversion components of the prototype unit was axisymmetric and exhibited a potential flow distribution. Additionally, uniform sand–water flow occurred within the guide apparatus, with a small sand–water velocity gradient near the wall of the stay vanes (SV) and the guide vanes (GV). The maximum volume fraction of sediment particles was observed in the tailing area of the spiral casing, indicating an enrichment phenomenon of sediment particles. The velocity of the sediment particles on the surface of the guide vane in the single-channel sediment wear test device and prototype unit ranged from 6.2 to 7.8 m/s, and the velocity of the sediment particles on the surface of the stay vane ranged from 5.1 to 14.6 m/s, and the difference of the sediment particles’ velocity near the wall was 1 to 3 m/s. The trailing vorticity of the guide vane reached a maximum of 120 s⁻¹. Consequently, the single-channel sediment erosion test device can unveil the sediment erosion mechanism of the guide apparatus of a reaction turbine.

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.

Pelton turbines frequently encounter significant sediment wear when operating in sandy river environments. The runner bucket of these turbines is particularly prone to wear, which results in considerable reductions in turbine efficiency and operational stability. This research focused on a large-scale Pelton turbine with a 500 MW standalone capacity in a sandy river setting. Numerical simulations of sand–water flow within the runner bucket were conducted using the volume of fluid (VOF) model, shear stress transport (SST) k-ω model, and the discrete phase model (DPM). Additionally, a sediment wear prediction model, based on wear tests conducted on a model turbine, was utilized to estimate sediment wear within the Pelton turbine bucket. The results indicated a maximum bucket wear rate of 2.61 × 10⁻⁷ mm/s. Specifically, the 04Cr13Ni5Mo runner bucket, typically made from stainless-steel wear-resistant material, is expected to experience over 5.62 mm of wear after one year of operation under rated conditions, emphasizing the severity of sediment wear. To prolong the operational life of the unit, further investigations into surface wear resistance treatments for the runner water buckets are recommended.

During partial-load operation, hydroelectric units are frequently subjected to hydraulic vibrations caused by pressure fluctuations within the turbine. These vibrations can result in deformation of the runner blades and, in severe instances, lead to crack formation. Over the years, research efforts have primarily focused on specific operating conditions, with relatively insufficient attention paid to the study of operational stability under broad-load operation. This study investigates the recurrent occurrence of crack damage in the runner blades of a Francis turbine installed at a major hydropower station. The issue emerges in response to the operational requirements of a modern power system, which mandates wide-load operation across varying heads (154.6 m, 197 m, 229.4 m) and guide vane openings (10%, 25%, 50%, 70%, 100%). To inform the development of optimized operational control strategies, this work examines the deformation and von Mises stress distribution patterns on the runner blades under these wide-load conditions. The findings reveal that the maximum blade deformation predominantly occurs in the mid-section of the trailing edge under most operating scenarios, while the peak von Mises stress consistently appears near the band at the trailing edge. Both peak deformation (1.99 mm) and peak von Mises stress (170.92 MPa) were observed at the maximum head (229.4 m) under 100% guide vane opening. Notably, significant deformation and stress levels were also encountered at openings below 25% under low-head conditions. On the basis of the research results, suggestions for ensuring the safe and stable operation of power station units under wide-load conditions were proposed.