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Wear-resistant coating for turbine flow passages
Why is it necessary to spray wear-resistant materials onto the flow passages of hydro turbines? The issues of sand erosion and cavitation in hydro turbines have long threatened the normal operation of hydroelectric generating units. The High-Velocity Oxygen-Fuel (HVOF) thermal spraying process has been proven by both domestic and international industries to be a reliable and advanced surface protection method. Hangzhou Liantuo Power Technology Development Co., Ltd., after introducing foreign technology and integrating its own years of practical experience, has developed an advanced repair and anti-erosion technology based on hard-facing welding and thermal spraying. The corresponding process codes are USO26116 and USO26102. This technology fully utilizes imported HVOF spraying equipment and materials, specifically designed to address sand erosion and wear on the flow passages of hydro turbines, providing your generating units with the most reliable anti-erosion protection. Since 1983, the application of wear-resistant coatings on hydro turbine flow passages has been widely promoted and applied domestically. Over 100 hydropower stations across China have used this technology to coat more than 200 units—including Francis turbine runners, turbine guide vanes, and sealing pads—with coatings that exhibit cavitation resistance more than 10 times superior to that of 1Cr18Ni9Ti stainless steel and at least 20 times better than that of ZG30 cast iron. Among the hydro turbine flow passage components, the runner and movable guide vanes suffer the most severe fluid erosion and cavitation damage, especially in hydroelectric units operating under high-sand-content conditions. To ensure the safe operation of hydro turbine generating units, research into surface protection technologies for runners and movable guide vanes is of great importance. Thermal spraying technology provides an effective means of protecting hydro turbine flow passages. A major issue facing hydropower stations is the cavitation damage and sand erosion of turbine flow passage components. Due to differences in water quality, the rate and extent of damage vary significantly. Some hydropower stations must shut down and replace parts after just one water supply season, which not only affects the safe and stable operation of the turbines and increases maintenance costs but also severely impacts power supply. Therefore, extending the service life of hydro turbines and ensuring the safe and economical operation of hydropower stations have been key research topics in China’s hydropower development for many years. Over the years, Chinese scientists and power station workers have jointly conducted extensive research to solve this problem. They have adopted thermal spraying technology to pre-protect relevant turbine components, achieving successful construction practices with remarkable results. This technology was officially approved through on-site technical appraisal in 1985, organized by the Gansu Provincial Science and Technology Commission and the Gansu Provincial Water Resources Department. Specific examples of its effectiveness include: The Xiehu Xia Hydropower Station in Ningxia, located downstream of the Daxia River—a tributary of the Yellow River—suffered severe wear on the turbine bottom ring, top cover, guide vanes, and main shaft due to high sand content in the water, affecting unit operation and power generation. After thermal spraying repair, the worn area on the journal of the No. 1 unit’s main shaft (2.5 mm thick, 310 mm in diameter, weighing about 2 tons) measured 540 mm in length. After repair, the coating remained intact and undamaged even after 25,900 hours of operation. In the Hongya and Hejiabao power stations in the Tianshui region, the high sand content in the water caused severe equipment damage. One new runner had to be scrapped after only 10,000 hours of operation, and all other flow passage components required frequent repairs, driving up maintenance costs to as much as one-quarter of the station’s total revenue. In 1984, five 1,000-kW units nearing scrapping were repaired by thermal spraying of their runners, guide vanes, and front and rear end covers, achieving highly satisfactory results. After the repairs, the Hongya power station operated for over a year with the coating remaining intact, the unit running smoothly and stably, and efficiency improving significantly. Under the same head and flow conditions, power output increased by 85% compared to 1984, and individual unit capacity rose from 700 kW before repair to 860 kW, representing a 22.8% increase. Moreover, the service life of the units was extended by 3 to 5 times, and maintenance costs were reduced by 13,000 yuan. China’s small hydropower stations are scattered throughout the country, and the experience gained in manufacturing equipment and constructing power stations has attracted international attention and received high praise. We believe that thermal spraying technology will play an important role in the development of hydropower stations in China. The working principle of supersonic flame spraying involves mixing and burning oxygen with a combustible gas or kerosene. The resulting flame jet is pressurized and passed through a Laval nozzle, forming a supersonic flame jet. Tungsten carbide-based hard alloy powder is injected into this supersonic flame jet and sprayed onto the surface of hydro turbine components, creating a hard, wear-resistant protective layer. The following diagram illustrates the principle of supersonic flame spraying: As a high-energy spraying method, HVOF spraying produces coatings that are dense and have strong bonding strength. It has been successfully applied to enhance the wear resistance of hydro turbines and has become a widely adopted sand-erosion-resistant process both domestically and internationally. In some power plants, it has achieved excellent results in actual operations, demonstrating high potential for wider adoption. Guangzhou Sanxin Metal Technology Co., Ltd. is one of the earliest companies in China to provide repair services for hydro turbine and pump station components. The company masters several key technologies and employs numerous well-known domestic experts and experienced technical personnel. Fully utilizing advanced machining equipment and quality management methods, the company is committed to delivering first-class quality and providing premium services to its customers. Repair services for hydro turbine components such as upper and lower wear plates, runners, runner chambers, guide vanes, and blades; thermal spraying services for pump-side plates, impellers, and other components; and refurbishment of old pump impellers.
水轮机过流部件喷涂
水轮机上下抗磨板
Product Description
Spraying wear-resistant materials onto the flow passages of turbines. Why spray?
Silt erosion and cavitation in hydro turbines have long posed a threat to the normal operation of hydroelectric generating units. The High-Velocity Oxygen-Fuel (HVOF) thermal spraying process has been proven both domestically and internationally as a reliable and advanced surface protection technique. After introducing foreign technology and integrating it with its own years of practical experience, Hangzhou Liantuo Power Technology Development Co., Ltd. has developed an advanced repair and wear-resistant technology based on hard-facing welding and thermal spraying. The corresponding process codes are USO26116 and USO26102. This technology fully utilizes imported HVOF spraying equipment and materials, specifically designed to address silt erosion and wear in the flow passages of hydro turbines, providing your generating unit with the most dependable wear resistance protection.
The flow passages of the turbine are sprayed with a wear-resistant coating, automatically. Since 1983, this technology has been widely promoted and applied domestically. Over 200 runner units in more than 100 hydropower stations across China have undergone coating treatment on their mixed-flow runners, turbine guide vanes, and sealing gaskets. The cavitation resistance of these coated components is more than 10 times higher than that of 1Cr18Ni9Ti stainless steel and up to 20 times higher than that of ZG30 cast iron.
In the flow passages of the turbine Fluid erosion and cavitation damage to the runner and adjustable guide vanes are the most severe, especially in hydroelectric generator sets operating under conditions with high sediment concentrations. To ensure the safe operation of hydro turbine-generator units, research on surface protection technologies for the runner and adjustable guide vanes is of great importance.
Use thermal spraying technology to effectively protect the flow passages of hydraulic turbines. A serious issue facing hydropower stations is cavitation damage and sand-and-silt erosion on the flow passages of turbine runners. The rate and extent of such damage vary depending on water quality. In some hydropower stations, turbines have to be shut down and replaced with new spare parts after just one water supply season. This not only affects the safe operation and power generation of turbines, increases maintenance intervals, and raises maintenance costs, but also severely impacts the reliability of power supply. Therefore, how to extend the service life of turbines and ensure the safe and economical operation of hydropower stations has been one of the key research topics in China's hydropower development for many years.
For many years, Chinese science and technology workers and power plant employees have jointly undertaken extensive efforts to tackle this challenging problem. They have adopted thermal spraying technology to pre-protect relevant components of hydro turbines, accumulating successful construction experience with remarkably effective results. This technology has now been... In 1985, the on-site technical appraisal was approved under the joint auspices of the Gansu Provincial Science and Technology Commission and the Gansu Provincial Department of Water Resources.
Here are some specific examples of its effects:
The Xiehu Gorge Hydropower Station in Ningxia is located downstream of the Daxia River, a tributary of the Yellow River. Due to the high sediment content in the water, critical components such as the turbine’s lower ring, upper cover, guide vanes, and main shaft have suffered severe wear, affecting the operation and power generation of the unit. After repair using thermal spraying technology, the main shaft of Unit No. 1 (length... The 2.5 mm-diameter, 310 mm-long shaft neck exhibits a wear area extending over 540 mm. After repair, the coating remained intact and undamaged even after 25,900 hours of operation.
In the Tianshui area, the Hongya Power Station and the Hejiabao Power Station have experienced severe equipment damage due to the high sediment content in the water. A new runner is now in operation. The 10,000-hour service life means that these components must be scrapped, and all other flow-path parts require repair, causing the power plant’s maintenance costs to steadily rise—reaching as high as one-quarter of the plant’s total revenue. In 1984, for five 1,000-kilowatt units nearing the end of their service lives, we carried out spray-welding repairs on the runners, guide vanes, and front and rear end covers, achieving highly satisfactory results. After the repairs, the Hongya Power Plant operated with its refurbished equipment for over a year, during which the coating remained intact and undamaged, the unit’s operation remained stable, and its efficiency improved. Under the same head and flow conditions, electricity generation increased by 650,000 kilowatt-hours in 1985 compared to the previous year—a growth rate of 84%. Moreover, the output per unit rose from the pre-repair level of 700 kilowatts to 860 kilowatts, representing an increase of 22.8%. Additionally, the service life of the units was extended by a factor of three to five, and maintenance costs were reduced by 13,000 yuan.
Small hydropower stations are scattered throughout the vast expanse of our country. The expertise China has accumulated in manufacturing equipment for small hydropower stations and in constructing such stations has attracted international attention and received high praise. We believe that thermal spraying technology will play a significant role in China’s hydropower station construction endeavors.
Working Principle of Supersonic Flame Spraying
Supersonic flame spraying works by mixing and burning oxygen with a flammable gas or kerosene. The resulting flame jet, after being pressurized and passed through a Laval nozzle, becomes a supersonic flame jet. Tungsten carbide (base) and other high-hardness, wear-resistant alloy powders are injected into this supersonic flame jet and sprayed onto the surface of turbine components, forming a hard, wear-resistant protective layer. The figure below is a schematic diagram illustrating the principle of supersonic flame spraying:
High-Velocity Oxygen-Fuel (HVOF) thermal spraying, as a high-energy spraying technique, produces coatings that are dense and exhibit strong bonding strength. It has been successfully applied in the field of turbine erosion resistance and has become a widely adopted sand- and silt-abrasion-resistant coating process both domestically and internationally. In actual operations at certain power plants, it has also demonstrated outstanding performance, making it highly valuable for broader application and promotion.
Guangzhou Sanxin Metal Technology Co., Ltd. is one of the earliest companies in China to offer maintenance services for hydro turbine and pump station components. The company masters several key technologies and boasts a team of well-known domestic experts as well as experienced technical leaders. The company fully adopts advanced machining equipment and sophisticated quality management practices, dedicating itself to delivering first-class quality and providing premium services to our valued customers.
-
Maintenance of components such as the upper and lower wear-resistant plates of the turbine, the runner, the runner chamber, guide vanes, and blades.
-
Thermal spraying processing of components such as the upper and lower wear-resistant plates of turbines, runners, runner chambers, guide vanes, and blades.
-
Maintenance of components such as pump side plates and impellers
-
Thermal spraying of components such as pump side plates, impellers, and mixer blades.
-
Reconditioning of old pump impellers
Online Quotation
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Spraying equipment SPRAY EQUIPMENT
Wear-resistant coating for turbine flow passages
Why is it necessary to spray wear-resistant materials onto the flow passages of hydro turbines? The issues of sand erosion and cavitation in hydro turbines have long threatened the normal operation of hydroelectric generating units. The High-Velocity Oxygen-Fuel (HVOF) thermal spraying process has been proven by both domestic and international industries to be a reliable and advanced surface protection method. Hangzhou Liantuo Power Technology Development Co., Ltd., after introducing foreign technology and integrating its own years of practical experience, has developed an advanced repair and anti-erosion technology based on hard-facing welding and thermal spraying. The corresponding process codes are USO26116 and USO26102. This technology fully utilizes imported HVOF spraying equipment and materials, specifically designed to address sand erosion and wear on the flow passages of hydro turbines, providing your generating units with the most reliable anti-erosion protection. Since 1983, the application of wear-resistant coatings on hydro turbine flow passages has been widely promoted and applied domestically. Over 100 hydropower stations across China have used this technology to coat more than 200 units—including Francis turbine runners, turbine guide vanes, and sealing pads—with coatings that exhibit cavitation resistance more than 10 times superior to that of 1Cr18Ni9Ti stainless steel and at least 20 times better than that of ZG30 cast iron. Among the hydro turbine flow passage components, the runner and movable guide vanes suffer the most severe fluid erosion and cavitation damage, especially in hydroelectric units operating under high-sand-content conditions. To ensure the safe operation of hydro turbine generating units, research into surface protection technologies for runners and movable guide vanes is of great importance. Thermal spraying technology provides an effective means of protecting hydro turbine flow passages. A major issue facing hydropower stations is the cavitation damage and sand erosion of turbine flow passage components. Due to differences in water quality, the rate and extent of damage vary significantly. Some hydropower stations must shut down and replace parts after just one water supply season, which not only affects the safe and stable operation of the turbines and increases maintenance costs but also severely impacts power supply. Therefore, extending the service life of hydro turbines and ensuring the safe and economical operation of hydropower stations have been key research topics in China’s hydropower development for many years. Over the years, Chinese scientists and power station workers have jointly conducted extensive research to solve this problem. They have adopted thermal spraying technology to pre-protect relevant turbine components, achieving successful construction practices with remarkable results. This technology was officially approved through on-site technical appraisal in 1985, organized by the Gansu Provincial Science and Technology Commission and the Gansu Provincial Water Resources Department. Specific examples of its effectiveness include: The Xiehu Xia Hydropower Station in Ningxia, located downstream of the Daxia River—a tributary of the Yellow River—suffered severe wear on the turbine bottom ring, top cover, guide vanes, and main shaft due to high sand content in the water, affecting unit operation and power generation. After thermal spraying repair, the worn area on the journal of the No. 1 unit’s main shaft (2.5 mm thick, 310 mm in diameter, weighing about 2 tons) measured 540 mm in length. After repair, the coating remained intact and undamaged even after 25,900 hours of operation. In the Hongya and Hejiabao power stations in the Tianshui region, the high sand content in the water caused severe equipment damage. One new runner had to be scrapped after only 10,000 hours of operation, and all other flow passage components required frequent repairs, driving up maintenance costs to as much as one-quarter of the station’s total revenue. In 1984, five 1,000-kW units nearing scrapping were repaired by thermal spraying of their runners, guide vanes, and front and rear end covers, achieving highly satisfactory results. After the repairs, the Hongya power station operated for over a year with the coating remaining intact, the unit running smoothly and stably, and efficiency improving significantly. Under the same head and flow conditions, power output increased by 85% compared to 1984, and individual unit capacity rose from 700 kW before repair to 860 kW, representing a 22.8% increase. Moreover, the service life of the units was extended by 3 to 5 times, and maintenance costs were reduced by 13,000 yuan. China’s small hydropower stations are scattered throughout the country, and the experience gained in manufacturing equipment and constructing power stations has attracted international attention and received high praise. We believe that thermal spraying technology will play an important role in the development of hydropower stations in China. The working principle of supersonic flame spraying involves mixing and burning oxygen with a combustible gas or kerosene. The resulting flame jet is pressurized and passed through a Laval nozzle, forming a supersonic flame jet. Tungsten carbide-based hard alloy powder is injected into this supersonic flame jet and sprayed onto the surface of hydro turbine components, creating a hard, wear-resistant protective layer. The following diagram illustrates the principle of supersonic flame spraying: As a high-energy spraying method, HVOF spraying produces coatings that are dense and have strong bonding strength. It has been successfully applied to enhance the wear resistance of hydro turbines and has become a widely adopted sand-erosion-resistant process both domestically and internationally. In some power plants, it has achieved excellent results in actual operations, demonstrating high potential for wider adoption. Guangzhou Sanxin Metal Technology Co., Ltd. is one of the earliest companies in China to provide repair services for hydro turbine and pump station components. The company masters several key technologies and employs numerous well-known domestic experts and experienced technical personnel. Fully utilizing advanced machining equipment and quality management methods, the company is committed to delivering first-class quality and providing premium services to its customers. Repair services for hydro turbine components such as upper and lower wear plates, runners, runner chambers, guide vanes, and blades; thermal spraying services for pump-side plates, impellers, and other components; and refurbishment of old pump impellers.
水轮机过流部件喷涂
水轮机上下抗磨板
Product Description
Spraying wear-resistant materials onto the flow passages of turbines. Why spray?
Silt erosion and cavitation in hydro turbines have long posed a threat to the normal operation of hydroelectric generating units. The High-Velocity Oxygen-Fuel (HVOF) thermal spraying process has been proven both domestically and internationally as a reliable and advanced surface protection technique. After introducing foreign technology and integrating it with its own years of practical experience, Hangzhou Liantuo Power Technology Development Co., Ltd. has developed an advanced repair and wear-resistant technology based on hard-facing welding and thermal spraying. The corresponding process codes are USO26116 and USO26102. This technology fully utilizes imported HVOF spraying equipment and materials, specifically designed to address silt erosion and wear in the flow passages of hydro turbines, providing your generating unit with the most dependable wear resistance protection.
The flow passages of the turbine are sprayed with a wear-resistant coating, automatically. Since 1983, this technology has been widely promoted and applied domestically. Over 200 runner units in more than 100 hydropower stations across China have undergone coating treatment on their mixed-flow runners, turbine guide vanes, and sealing gaskets. The cavitation resistance of these coated components is more than 10 times higher than that of 1Cr18Ni9Ti stainless steel and up to 20 times higher than that of ZG30 cast iron.
In the flow passages of the turbine Fluid erosion and cavitation damage to the runner and adjustable guide vanes are the most severe, especially in hydroelectric generator sets operating under conditions with high sediment concentrations. To ensure the safe operation of hydro turbine-generator units, research on surface protection technologies for the runner and adjustable guide vanes is of great importance.
Use thermal spraying technology to effectively protect the flow passages of hydraulic turbines. A serious issue facing hydropower stations is cavitation damage and sand-and-silt erosion on the flow passages of turbine runners. The rate and extent of such damage vary depending on water quality. In some hydropower stations, turbines have to be shut down and replaced with new spare parts after just one water supply season. This not only affects the safe operation and power generation of turbines, increases maintenance intervals, and raises maintenance costs, but also severely impacts the reliability of power supply. Therefore, how to extend the service life of turbines and ensure the safe and economical operation of hydropower stations has been one of the key research topics in China's hydropower development for many years.
For many years, Chinese science and technology workers and power plant employees have jointly undertaken extensive efforts to tackle this challenging problem. They have adopted thermal spraying technology to pre-protect relevant components of hydro turbines, accumulating successful construction experience with remarkably effective results. This technology has now been... In 1985, the on-site technical appraisal was approved under the joint auspices of the Gansu Provincial Science and Technology Commission and the Gansu Provincial Department of Water Resources.
Here are some specific examples of its effects:
The Xiehu Gorge Hydropower Station in Ningxia is located downstream of the Daxia River, a tributary of the Yellow River. Due to the high sediment content in the water, critical components such as the turbine’s lower ring, upper cover, guide vanes, and main shaft have suffered severe wear, affecting the operation and power generation of the unit. After repair using thermal spraying technology, the main shaft of Unit No. 1 (length... The 2.5 mm-diameter, 310 mm-long shaft neck exhibits a wear area extending over 540 mm. After repair, the coating remained intact and undamaged even after 25,900 hours of operation.
In the Tianshui area, the Hongya Power Station and the Hejiabao Power Station have experienced severe equipment damage due to the high sediment content in the water. A new runner is now in operation. The 10,000-hour service life means that these components must be scrapped, and all other flow-path parts require repair, causing the power plant’s maintenance costs to steadily rise—reaching as high as one-quarter of the plant’s total revenue. In 1984, for five 1,000-kilowatt units nearing the end of their service lives, we carried out spray-welding repairs on the runners, guide vanes, and front and rear end covers, achieving highly satisfactory results. After the repairs, the Hongya Power Plant operated with its refurbished equipment for over a year, during which the coating remained intact and undamaged, the unit’s operation remained stable, and its efficiency improved. Under the same head and flow conditions, electricity generation increased by 650,000 kilowatt-hours in 1985 compared to the previous year—a growth rate of 84%. Moreover, the output per unit rose from the pre-repair level of 700 kilowatts to 860 kilowatts, representing an increase of 22.8%. Additionally, the service life of the units was extended by a factor of three to five, and maintenance costs were reduced by 13,000 yuan.
Small hydropower stations are scattered throughout the vast expanse of our country. The expertise China has accumulated in manufacturing equipment for small hydropower stations and in constructing such stations has attracted international attention and received high praise. We believe that thermal spraying technology will play a significant role in China’s hydropower station construction endeavors.
Working Principle of Supersonic Flame Spraying
Supersonic flame spraying works by mixing and burning oxygen with a flammable gas or kerosene. The resulting flame jet, after being pressurized and passed through a Laval nozzle, becomes a supersonic flame jet. Tungsten carbide (base) and other high-hardness, wear-resistant alloy powders are injected into this supersonic flame jet and sprayed onto the surface of turbine components, forming a hard, wear-resistant protective layer. The figure below is a schematic diagram illustrating the principle of supersonic flame spraying:
High-Velocity Oxygen-Fuel (HVOF) thermal spraying, as a high-energy spraying technique, produces coatings that are dense and exhibit strong bonding strength. It has been successfully applied in the field of turbine erosion resistance and has become a widely adopted sand- and silt-abrasion-resistant coating process both domestically and internationally. In actual operations at certain power plants, it has also demonstrated outstanding performance, making it highly valuable for broader application and promotion.
Guangzhou Sanxin Metal Technology Co., Ltd. is one of the earliest companies in China to offer maintenance services for hydro turbine and pump station components. The company masters several key technologies and boasts a team of well-known domestic experts as well as experienced technical leaders. The company fully adopts advanced machining equipment and sophisticated quality management practices, dedicating itself to delivering first-class quality and providing premium services to our valued customers.
-
Maintenance of components such as the upper and lower wear-resistant plates of the turbine, the runner, the runner chamber, guide vanes, and blades.
-
Thermal spraying processing of components such as the upper and lower wear-resistant plates of turbines, runners, runner chambers, guide vanes, and blades.
-
Maintenance of components such as pump side plates and impellers
-
Thermal spraying of components such as pump side plates, impellers, and mixer blades.
-
Reconditioning of old pump impellers
Online Quotation
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