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Computational analysis of Pelton bucket tip erosion using digital image processing

Erosion of hydro turbine components through sand laden river is one of the biggest problems in Himalayas. Even with sediment trapping systems, complete removal of fine sediment from water is impossible and uneconomical; hence most of the turbine components in Himalayan Rivers are exposed to sand laden water and subject to erode. Pelton bucket which are being wildly used in different hydropower generation plant undergoes erosion on the continuous presence of sand particles in water. The subsequent erosion causes increase in splitter thickness, which is supposed to be theoretically zero. This increase in splitter thickness gives rise to back hitting of water followed by decrease in turbine efficiency. This paper describes the process of measurement of sharp edges like bucket tip using digital image processing. Image of each bucket is captured and allowed to run for 72 hours; sand concentration in water hitting the bucket is closely controlled and monitored. Later, the image of the test bucket is taken in the same condition. The process is repeated for 10 times. In this paper digital image processing which encompasses processes that performs image enhancement in both spatial and frequency domain. In addition, the processes that extract attributes from images, up to and including the measurement of splitter's tip. Processing of image has been done in MATLAB 6.5 platform. The result shows that quantitative measurement of edge erosion of sharp edges could accurately be detected and the erosion profile could be generated using image processing technique.