Abstract: In this study, failure analysis of pipe system at a micro
hydroelectric power plant is investigated. Failure occurred at the pipe
system in the powerhouse during shut down operation of the water
flow by a valve. This locking had caused a sudden shock wave, also
called “Water-hammer effect”, resulting in noise and inside pressure
increase. After visual investigation of the effect of the shock wave on
the system, a circumference crack was observed at the pipe flange
weld region. To establish the reason for crack formation, calculations
of pressure and stress values at pipe, flange and welding seams were
carried out and concluded that safety factor was high (2.2), indicating
that no faulty design existed. By further analysis, pipe system and
hydroelectric power plant was examined. After observations it is
determined that the plant did not include a ventilation nozzle (air
trap), that prevents the system of sudden pressure increase inside the
pipes which is caused by water-hammer effect. Analyses were carried
out to identify the influence of water-hammer effect on inside
pressure increase and it was concluded that, according Jowkowsky’s
equation, shut down time is effective on inside pressure increase. The
valve closing time was uncertain but by a shut down time of even one
minute, inside pressure would increase by 7.6 bar (working pressure
was 34.6 bar). Detailed investigations were also carried out on the
assembly of the pipe-flange system by considering technical
drawings. It was concluded that the pipe-flange system was not
installed according to the instructions. Two of five weld seams were
not applied and one weld was carried out faulty. This incorrect and
inadequate weld seams resulted in; insufficient connection of the pipe
to the flange constituting a strong notch effect at weld seam regions,
increase in stress values and the decrease of strength and safety
factor.
Abstract: Erosion and abrasion are wear mechanisms reducing
the lifetime of machine elements like valves, pump and pipe systems.
Both wear mechanisms are acting at the same time, causing a
“Synergy” effect, which leads to a rapid damage of the surface.
Different parameters are effective on erosive abrasive wear rate. In
this study effect of particle impact angle on wear rate and wear
mechanism of ductile and brittle materials was investigated. A new
slurry pot was designed for experimental investigation. As abrasive
particle, silica sand was used. Particle size was ranking between 200-
500 μm. All tests were carried out in a sand-water mixture of 20%
concentration for four hours. Impact velocities of the particles were
4.76 m/s. As ductile material steel St 37 with Vickers Hardness
Number (VHN) of 245 and quenched St 37 with 510 VHN was used
as brittle material. After wear tests, morphology of the eroded
surfaces were investigated for better understanding of the wear
mechanisms acting at different impact angles by using Scanning
Electron Microscope. The results indicated that wear rate of ductile
material was higher than brittle material. Maximum wear rate was
observed by ductile material at a particle impact angle of 300 and
decreased further by an increase in attack angle. Maximum wear rate
by brittle materials was by impact angle of 450 and decreased further
up to 900. Ploughing was the dominant wear mechanism by ductile
material. Microcracks on the surface were detected by ductile
materials, which are nucleation centers for crater formation. Number
of craters decreased and depth of craters increased by ductile
materials by attack angle higher than 300. Deformation wear
mechanism was observed by brittle materials. Number and depth of
pits decreased by brittle materials by impact angles higher than 450.
At the end it is concluded that wear rate could not be directly related
to impact angle of particles due to the different reaction of ductile and
brittle materials.