Overview of the experimental tests in prototype

Experimental tests in prototype are necessary to understand the dynamic behaviour of the machine during different operating points. Hydraulic phenomena as well as its effect on the structure need to be studied in o rder to avoid instabilities during operation and to extend the life - time of the different components. For this purpose, a complete experimental study of a large Francis turbine prototype has been performed installing several sensors along the machine. Pres sure sensors were installed in the penstock, spiral case, runner and draft tube, strain gauges were installed in the runner, vibration sensors were used in the stationary parts and different electrical and operational parameters were also measured. All the se signals were acquired simultaneously for different operating points of the turbine.Postprint (published version

Detection of hydraulic phenomena in francis turbines with different sensors

Nowadays, hydropower is demanded to provide flexibility and fast response into the electrical grid in order to compensate the non-constant electricity generation of other renewable sources. Hydraulic turbines are therefore demanded to work under o -design conditions more frequently, where di erent complex hydraulic phenomena appear, a ecting the machine stability as well as reducing the useful life of its components. Hence, it is desirable to detect in real-time these hydraulic phenomena to assess the operation of the machine. In this paper, a large medium-head Francis turbine was selected for this purpose. This prototype is instrumented with several sensors such as accelerometers, proximity probes, strain gauges, pressure sensors and a microphone. Results presented in this paper permit knowing which hydraulic phenomenon is detected with every sensor and which signal analysis technique is necessary to use. With this information, monitoring systems can be optimized with the most convenient sensors, locations and signal analysis techniquesPostprint (published version

Experimental measurements of the natural frequencies and mode shapes of rotating disk-blades-disk assemblies from the stationary frame

Determining the natural frequencies and mode shapes of rotating turbomachinery components from both rotating and stationary reference frames is of paramount importance to avoid resonance problems that could affect the normal operation of the machine, or even cause critical damages in these components. Due to their similarity to real engineering cases, this topic has been experimentally analyzed in the past for disk-shaft assemblies and rotor disk-blades assemblies (bladed-disk or blisk). The same topic is less analyzed for disk-blades-disk assemblies, although such configurations are widely used in centrifugal closed impellers of compressors, hydraulic pumps, pump-turbines, and runners of high head Francis turbines. In this paper, experimental measurements, varying the rotating speed of a disk-blade-disk assembly and exciting the first natural frequencies of the rotating frame, have been performed. The rotating structure is excited and measured by means of PZT patches from the rotating frame and with a Laser Doppler Vibrometer (LDV). In order to interpret the experimental results obtained from the stationary frame, a method to decompose the diametrical mode shapes of the structure in simple diametrical components (which define the diametrical mode shapes of a simple disk) has been proposed. It is concluded that the resonant frequencies detected with a stationary sensor correspond to the ones predicted with the decomposition method. Finally, a means to obtain equivalent results with numerical simulation methods is shown.Postprint (published version

Sensor-based optimized control of the full load instability in large hydraulic turbines

Hydropower plants are of paramount importance for the integration of intermittent renewable energy sources in the power grid. In order to match the energy generated and consumed, Large hydraulic turbines have to work under off-design conditions, which may lead to dangerous unstable operating points involving the hydraulic, mechanical and electrical system. Under these conditions, the stability of the grid and the safety of the power plant itself can be compromised. For many Francis Turbines one of these critical points, that usually limits the maximum output power, is the full load instability. Therefore, these machines usually work far away from this unstable point, reducing the effective operating range of the unit. In order to extend the operating range of the machine, working closer to this point with a reasonable safety margin, it is of paramount importance to monitor and to control relevant parameters of the unit, which have to be obtained with an accurate sensor acquisition strategy. Within the framework of a large EU project, field tests in a large Francis Turbine located in Canada (rated power of 444 MW) have been performed. Many different sensors were used to monitor several working parameters of the unit for all its operating range. Particularly for these tests, more than 80 signals, including ten type of different sensors and several operating signals that define the operating point of the unit, were simultaneously acquired. The present study, focuses on the optimization of the acquisition strategy, which includes type, number, location, acquisition frequency of the sensors and corresponding signal analysis to detect the full load instability and to prevent the unit from reaching this point. A systematic approach to determine this strategy has been followed. It has been found that some indicators obtained with different types of sensors are linearly correlated with the oscillating power. The optimized strategy has been determined based on the correlation characteristics (linearity, sensitivity and reactivity), the simplicity of the installation and the acquisition frequency necessary. Finally, an economic and easy implementable protection system based on the resulting optimized acquisition strategy is proposed. This system, which can be used in a generic Francis turbine with a similar full load instability, permits one to extend the operating range of the unit by working close to the instability with a reasonable safety margin.Postprint (published version

Influence of the boundary conditions on the natural frequencies of a Francis turbine

Natural frequencies estimation of Francis turbines is of paramount importance in the stage of design in order to avoid vibration and resonance problems especially during transient events. Francis turbine runners are submerged in water and confined with small axial and radial gaps which considerably decrease their natural frequencies in comparison to the same structure in the air. Acoustic-structural FSI simulations have been used to evaluate the influence of these gaps. This model considers an entire prototype of a Francis turbine, including generator, shaft, runner and surrounding water. The radial gap between the runner and the static parts has been changed from the real configuration (about 0.04% the runner diameter) to 1% of the runner diameter to evaluate its influence on the machine natural frequencies. Mode-shapes and natural frequencies of the whole machine are discussed for all the boundary conditions testedPostprint (published version

Condition monitoring of a prototype turbine. Description of the system and main results

The fast change in new renewable energy is affecting directly the required operating range of hydropower plants. According to the present demand of electricity, it is necessary to generate different levels of power. Because of its ease to regulate and its huge storage capacity of energy, hydropower is the unique energy source that can adapt to the demand. Today, the required operating range of turbine units is expected to extend from part load to overload. These extreme operations points can cause several pressure pulsations, cavitation and vibrations in different parts of the machine. To determine the effects on the machine, vibration measurements are necessary in actual machines. Vibrations can be used for machinery protection and to identify problems in the machine (diagnosis). In this paper, some results obtained in a hydropower plant are presented. The variation of global levels and vibratory signatures has been analysed as function as gross head, transducer location and operating points.Postprint (published version

Numerical study on the dynamic behavior of a francis turbine runner model with a crack

Crack appearance in the blade is the most common type of fatigue damage in Francis turbines. However, it is sometimes difficult to detect cracks in time using the current monitoring system, even when they are very large. To better monitor cracks, it is imperative to research the effect of a crack on the dynamic behavior of a Francis turbine. In this paper, the dynamic behavior of a Francis turbine runner model with a crack has been researched numerically. The intact numerical model was first validated by the experimental data available. Then, a crack was created at the intersection line between one blade and the crown. The change in dynamic behavior with increasing crack length has been investigated. Crack-induced vibration localization theory has been used to explain the dynamic behavior changes due to the crack. Modal analysis showed that the adopted theory could basically explain the modal behavior change due to the crack. The FFT results of the modal shapes and the localization factors (LF) has been used to explain the forced response changes due to the crack. Based on the above analysis, the challenge of crack monitoring has been analyzed. This research provides some references for more advanced monitoring technologies.Peer ReviewedPostprint (published version

Power swing generated in Francis turbines by part load and overload instabilities

Hydropower plays a key role in the actual energy market due to its fast response and regulation capacity. In that way, hydraulic turbines are increasingly demanded to work at off-design conditions, where complex flow patterns and cavitation appear, especially in Francis turbines. The draft tube cavitation surge is a hydraulic phenomenon that appears in Francis turbines below and above its Best Efficiency Point (BEP). It is a low frequency phenomenon consisting of a vortex rope in the runner outlet and draft tube, which can become unstable when its frequency coincides with a natural frequency of the hydraulic circuit. At this situation, the output power can significantly swing, endangering the electrical grid stability. This study is focused on the detection of these instabilities in Francis turbines and their relationship with the output power swings. To do so, extensive experimental tests for different operating conditions have been carried out in a large prototype Francis turbine (444 MW of rated power) within the frame of the European Project Hyperbole (FP7-ENERGY-2013-1). Several sensors have been installed in the hydraulic circuit (pressure sensors in the draft tube, spiral casing, and penstock), in the rotating and static structures (vibration sensors, proximity probes, and strain gauges in the runner and in the shaft), as well as in the electrical side (output power, intensity, and voltage). Moreover, a numerical Finite Element Method (FEM) has been also used to relate the hydraulic excitation with the output power swing.Peer ReviewedPostprint (published version

Accurate determination of the frequency response function of submerged and confined structures by using PZT-patches

To accurately determine the dynamic response of a structure is of relevant interest in many engineering applications. Particularly, it is of paramount importance to determine the Frequency Response Function (FRF) for structures subjected to dynamic loads in order to avoid resonance and fatigue problems that can drastically reduce their useful life. One challenging case is the experimental determination of the FRF of submerged and confined structures, such as hydraulic turbines, which are greatly affected by dynamic problems as reported in many cases in the past. The utilization of classical and calibrated exciters such as instrumented hammers or shakers to determine the FRF in such structures can be very complex due to the confinement of the structure and because their use can disturb the boundary conditions affecting the experimental results. For such cases, Piezoelectric Patches (PZTs), which are very light, thin and small, could be a very good option. Nevertheless, the main drawback of these exciters is that the calibration as dynamic force transducers (relationship voltage/force) has not been successfully obtained in the past. Therefore, in this paper, a method to accurately determine the FRF of submerged and confined structures by using PZTs is developed and validated. The method consists of experimentally determining some characteristic parameters that define the FRF, with an uncalibrated PZT exciting the structure. These parameters, which have been experimentally determined, are then introduced in a validated numerical model of the tested structure. In this way, the FRF of the structure can be estimated with good accuracy. With respect to previous studies, where only the natural frequencies and mode shapes were considered, this paper discuss and experimentally proves the best excitation characteristic to obtain also the damping ratios and proposes a procedure to fully determine the FRF. The method proposed here has been validated for the structure vibrating in air comparing the FRF experimentally obtained with a calibrated exciter (impact Hammer) and the FRF obtained with the described method. Finally, the same methodology has been applied for the structure submerged and close to a rigid wall, where it is extremely important to not modify the boundary conditions for an accurate determination of the FRF. As experimentally shown in this paper, in such cases, the use of PZTs combined with the proposed methodology gives much more accurate estimations of the FRF than other calibrated exciters typically used for the same purpose. Therefore, the validated methodology proposed in this paper can be used to obtain the FRF of a generic submerged and confined structure, without a previous calibration of the PZT.Peer ReviewedPostprint (published version

On the use of PZT-Patches as exciters in modal analysis: application to submerged structures

Modal Analysis is an experimental technique widely used to determine the dynamic response of structures. One of the most critical part is the selection of the actuator that will excite the tested structure. In many cases, traditional exciters, such as hammers and shakers, have been used for this purpose. Nevertheless, these exciters may have the disadvantage of modifying the modal parameters (as reported in some cases) and they are difficult to be used when the structure is not accessible (confined and/or submerged). For these cases PZT-patches, that are very light structures (compared to the tested structure), have been recently used as exciters. Although, in the analyzed studies the natural frequencies of the structure have been determined using PZTs, the rest of parameters that determine the FRF (Frequency response Function) have been not obtained. This could be, because the calibration of PZTs as dynamic force transducers is a complicated task and not an information given by the manufacturers, as in other exciters used for the same purpose. This paper analyzes experimentally and analytically the use of PZT-patches as exciters for modal analysis. For this purpose, a tested structure is excited in different ways with a PZT and its response is compared with a reference case, obtained with a classical exciter. Analyses show how to obtain different modal parameters that determine the FRF of the structure, without previous calibration of the PZT. Finally, and in order to show the potential advantages of these exciters for inaccessible structures, the procedure is repeated for the same structure submerged in water, showing that PZT are much more appropriated exciters in these cases.Postprint (published version