Pressure Pulsations and Vibration Measurements in Francis Turbines with and without Freely Rotating Runner Cone Extension

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1 Proceedings of the International Symposium on Current Research in Hydraulic Turbines CRHT VI March 14, 2016, Turbine Testing Lab, Kathmandu University, Dhulikhel, Nepal Paper no. CRHT Pressure Pulsations and Vibration Measurements in Francis Turbines with and without Freely Rotating Runner Cone Extension Stian Solvik 1*, Magomed Selmurzaev 1* and Ole Gunnar Dahlhaug 1 1 Department of Energy and Process Engineering, Water Power Laboratory, Norwegian University of Science and Technology, Trondheim, Norway *Corresponding author (stiangs@stud.ntnu.no, magomeds@stud.ntnu.no) Abstract Initially turbines were designed to run at best efficiency point over longer period of time without load variation. The energy marked today is different, and the power plants require adjustable units in order to vary the energy production based on demand. As a result, the turbines are under high stresses due to constant load variation. Pressure pulsations and vibrations are a result of this, and are considered to be one of the main sources of fatigue damage in Francis turbines today. NTNU has designed a freely rotating runner cone extension (FRUCE) with the hope of reducing the vibration caused by pressure oscillation. This paper presents the theoretical and experimental correlation between pressure pulsations and vibrations in Francis turbines with and without a FRUCE. Measurements were conducted under steady state operating conditions, with 10 different guide vane openings. The data is filtered and analyzed using Fast Fourier Transform analysis and dominant frequencies are determined for all guide vane openings. All experiments were conducted with and without the FRUCE, in order to determine the change of predominant frequencies. The runner dependent frequencies, as well as the frequencies caused by the elastic fluctuation in the system are observed for both cases. The runner dependent frequencies 5.5 Hz, Hz and Hz as well as the non runner dependent frequencies 15.7 Hz, 42 Hz, 212 Hz and 300 Hz cause the highest peaks in the frequency domain. These frequencies are observed both upstream and downstream of the turbine. Analysis show an increase in pressure pulsations on the measurements with FRUCE. The change in magnitude is most evident at the outlet section of the turbine. However, the vibration measurements are contradicting and rather shows a decrease in frequency amplitudes with FRUCE in place. Keywords: Francis turbine, Pressure oscillation, Vibration, Freely rotating runner cone extension, Francis Introduction Turbines are designed to run at best efficiency point (BEP), this ensures a steady and continuous operation with a high efficiency. Today s energy marked requires the turbines to be under constant load variation, that can cause serious technical operating challenges. Challenges concerning fatigue, cavitation and noise are present, and can be devastating for the operation of the power plant. In recent years, these challenges have resulted in failures on both old and new Francis runners. Researchers at NTNU have taken initiative to design a high head Francis turbine and publish both geometry and model performance data in order to promote the Francis-99 workshops. This is done in an effort to

2 further develop numerical modeling of high head Francis turbines. This project will provide some of the measurement data needed for the Francis-99 workshop. This article presents a study of the correlation between pressure pulsations and vibrations in Francis turbines with and without a freely rotating runner cone extension (FRUCE). The measurements were carried out at the Water Power Laboratory at the Norwegian University of Technology in Trondheim. 2. Theory The efficiency of a turbine is affected by mainly three occurrences; pressure pulsations, sand erosion and cavitation erosion. Pressure pulsations and cavitation in combination with mechanical imbalance of the turbine, is the main source of vibrations in hydropower units. In addition to reducing the efficiency of the unit, the pulsations expose the system to vibrations. A consequence of this are fatigue loads acting on the turbine, eventually leading to damage and fatigue cracks. The frequencies are denoted as runner dependent and non runner dependent frequencies. All frequencies are defined relative to the stationary frame of reference Runner dependent frequencies There are four dominant pressure oscillation frequencies in a hydropower system occurring due to the runner force of the turbine, referred to as the runner dependent frequencies [1]. - Runner frequency This is the frequency caused by rotation of the turbine. The runner blades are exposed to a constant pressure variation, switching from pressure to suction side of the blade. This creates a pressure field around the blade, rotating periodically with the speed of the runner. The runner frequency, Eq. (1), is experienced to have a low amplitude and can be considered constant due to the uniform shape of the runner. f n = n 60 [Hz] (1) - Runner vane frequency A pressure pulse is created every time a point on the impeller vane passes the same guide vane. The amplitude of this frequency is dependent on the distance between guide vanes and runner vanes, and thus, the guide vane opening is of great influence. During steady state conditions, this is the dominating pressure oscillation in the system, Eq. (2). - Guide vane frequency f rv = f n z rv [Hz] (2) Every time an impeller vane passes a guide vane it will undergo a pressure pulsation. This is due to the pressure difference between the two sides of the guide vane. The effect can be reduced by increasing the distance of the vaneless space, as the amplitude is predominant at high guide vane angles. The magnitude of this frequency is dependent on number of guide vanes, Eq. (3). - Rheingans frequency/ Draft tube surge f gv = f n z gv [Hz] (3) Described by Rheingans in 1940 [5], surge is one of the earliest researched pulsation problems in the Francis turbine. It describes the pressure pulsation in the draft tube caused by the flow leaving the runner with a tangential velocity. Direction of the outlet flow depends on operational condition of the turbine, as shown in Fig. 1. At part load, flow (Q) < design flow (Q ), the direction of the flow is the same as the direction of the rotating runner, and opposite of the direction of the runner rotation at full load, Q > Q.

3 Figure 1. Velocity profile of the outlet triangle at design point, part load and high load [4] Biggest contribution of pressure pulsation in the draft tube is the vortex rope, at part load, and a pulsating cavitated vortex core at high load. At certain conditions, the corresponding frequencies can reach amplitudes strong enough to cause radial force fluctuation propagating upstream through the runner. Worstcase scenario the fluctuation frequency coincides with the resonance frequencies of the system, further amplifying the fluctuations. The frequency is described by Eq. (4) Non runner dependent frequency f R f n [Hz] (4) 3.6 In a hydro power plant, these pulsations are categorized as mass oscillation or water hammer pulsations caused by of the moving masses of water oscillating in the waterway. The phenomena is always present in rotating hydro-machinery, and amplifies significantly if the water masses are exposed to sudden changes in flow. The most common source is the change of guide vane opening, which produces a small change in internal pressure. These fluctuations in pressure propagate trough the water at the speed of sound. This will either accelerate or decelerate the flow both downstream and upstream of the runner, causing pressure pulsations in the system. The period and frequency of elastic fluctuations are given by Eq. (5) and Eq. (6): T = 4L a (5) f = 1 t = a 4L (6) When dealing with water hammer pulsations, another definition has to be taken into consideration: u-tube fluctuation. The phenomena is a consequence of water hammer pulsations travelling through the system to upper and lower reservoir levels. The motion will decrease due to friction, but the frequency might still reach a considerable magnitude. Table 1 shows the calculated expected frequencies. The calculations are based on the geometrical data of the test turbine, (see Table 2). The runner speed of the turbine, n, is set to 333 rpm.

4 Table 1. Expected frequencies - Notation Frequency [Hz] Runner frequency f n 5.55 Runner vane frequency f rv Guide vane frequency f gv Rheingans frequency f R Elastic fluctuations Turbine to Pressure tank f TP Elastic fluctuations Turbine to Surge tank f TS Elastic fluctuations Pump to Pressure tank f PP Experimental Configuration 3.1. Turbine Investigated The turbine investigated is a model Francis turbine, the runner is scaled 1:5.1 from its 430 MW prototype Francis runner located in Tokke Power Plant in Norway. Table 2. Francis turbine model at Water Power Laboratory, NTNU Dimension Model Inlet diameter Outlet Diameter Runner inlet height D 1 = 0.63 m D 2 = m B 1 = 0.06 m Speed number Ω = 0.27 Max efficiency [+/- 0.16%] h h = 93.4 % Runner blades Z rv = 30 Operating Head H = 12 m The laboratory structure enables turbine operation with both open and closed loops, with their own advantages and disadvantages. The current experiments are executed with closed loop, due to the ability to maintain constant conditions during the logging sequence. This also provides a higher accuracy when repeating the measurements. LabVIEW together with data acquisition hardware from National Instrument was utilized to record the data. Data from ten different guide vane angles (4 to 14), has been sampled for 60 seconds under steady state operating condition. The runner speed of the pump was adjusted in order to maintain a constant head of 12 meters. Both experiments are run in collaboration with PhD Candidate Peter Joachim Gogstad Experimental Apparatus The IEC [2] and IEC60994 [3] standards have been used for the placement of both pressure and vibration sensors.

5 Pressure Transducers The placement of the sensors is in accordance to IEC The suggested placements are given in Fig. 2. The standard strongly recommends placement of (p1), (p2) and (p3) when performing pressure measurements. Figure 2. The recommended placement of pressure transducers [2] Pressure measurements were conducted for three main areas of the turbine; inlet pipe, vaneless space and draft tube cone. The inlet pipe section of the turbine is equipped with three pressure sensors in order to determine the speed of sound in this area. The placement of the static pressure transducer are illustrated Fig. 3. The distance between I1 and I2 is measured to approximately 8.5 m, and 4 m between I2 and I3. In order to analyze the vortex propagation in the draft tube, three additional transducers are located in the lower section of the turbine, O1, O2 and O3.. Figure 3. Placement of inlet and lower draft tube static pressure transducers For placement of transducers in the upper draft tube cone, IEC recommends following: p1 and p2 should be placed 0,3 1 diameters from the low pressure side of the impeller. Additional transducers in the draft tube cone in the same plane as p1 and p2, preferably 90 apart [2]. The piezoelectric pressure sensors in this section were already installed, and after consultation with PhD candidate Peter Joachim Gogstad, it was decided to keep them in place. The sensors are located slightly above 1 diameter from the impeller.

6 Vibration sensors For the measurement of vibration three uniaxial accelerometers have been used. As sown in Fig. 4, the three vibration sensors have respectively been placed on the upper head cover (v1), lower head cover (v2) and on the lower part of the draft tube (v3). Their placement has been determined in order to observe the vibrations present throughout the unit. 4. Results and Discussion Figure 4. Location of vibration sensors The experiments were conducted during November and December of The following chapter presents the resulting data. A comparison study is conducted based on the analysis from steady state operation of the turbine before and after installation of the FRUCE. Due to the large amount of data obtained during the analysis of pressure measurement, the discussion is concentrated around outlet transducers O1 and O2 at part load, as this was considered the most informative part of data. For vibration measurements, sensors v1 and v2 are chosen for presentation of results Pressure Fluctuation All the predominant frequencies calculated beforehand were observed throughout the different turbine sections. Runner vane frequency was most dominant in the vanless space, but could be traced decreasing both upstream and downstream of the turbine. For upper and lower sections of the draft tube, frequencies due to elastic fluctuation between the turbine and surge tank were highly evident throughout the analysis. Rheingans frequency was also observed for lower guide vane openings. Frequencies due to mass fluctuation between the turbine and pressure tank were also present for all transducers, with a decreasing trend towards the lower section of the turbine. Fig. 5 and 6 illustrates the measured frequencies before and after the FRUCE for lower draft tube transducers, O1 and O2. The figures represent steady state operation at PL, with the colors indicating the frequency intensity.

7 The effects of FRUCE on the dominant frequencies are not evident and the same frequencies are observed for both measurements. The runner vane frequency at 166 Hz is nearly unaffected by the FRUCE. The change of pulsations becomes apparent only for lower frequencies. Analyzing transducer O1, below 100 Hz, the FRUCE seems to amplify the elastic fluctuations f TP = 15.7 Hz and f TS = 42 Hz, corresponding to fluctuations between turbine and pressure tank and turbine and surge tank respectively. Contradicting behavior is observed lower in the draft tube, for O2 transducers. The largest change is in f TS, with a major decrease in amplitude with FRUCE. The FRUCE does slightly amplify the f TP frequencies due to mass oscillation upstream of the turbine. The Rheingans frequency is observed to decrease with FRUCE at upper section of the draft tube. The change in amplitude is small, but still evident. Pressure transducer O2, does not show signs of the Rheingans frequency without the FRUCE. However, it is possible to observe the Rheingans frequency, with an obvious peak at approximately 1.8 Hz, with the FRUCE installed. This indicates an increase in the pressure pulsations in the lower part of the draft tube. Figure 5. O1- Steady state PL -Upper with FRUCE lower without FRUCE

8 Figure 6. O2- Steady state PL -Upper with FRUCE lower without FRUCE 4.2. Vibration As with the analysis of the pressure measurements, a large amount data is available for the vibration sensors. The analysis of vibration measurement show the same frequencies as the pressure pulsation measurements. The predominant frequencies calculated beforehand are clearly visible in all vibration measurements, showing a strong correlation between the pressure- and vibration- frequencies measured. The goal of the FRUCE is to reduce the magnitudes of the frequencies in the system, thereby reducing the vibrations in the system. However, by comparing the results of each sensor with and without the FRUCE, some contradicting behavior is observed. It is observed that vibration sensor 1 and 3 follow the same pattern. Both sensors show an increase in almost all frequency magnitudes with the FRUCE. By comparing the relative intensity measured with sensor 1 and sensor 3 during different operational points with the FRUCE, it is noticed that the intensity of the full range of frequencies increases compared to the measurements without FRUCE. The measurements between part load (PL) and the best efficiency point (BEP) show a steady increase from being five times greater to being ten times greater with the FRUCE. Between BEP and high load (HL) the higher frequency slightly decreases, going back to the same levels as observed during Pl operation. Contrary to the observation made from sensor 1 and 3, sensor 2 shows that the frequency magnitudes decrease significantly with the FRUCE. The analysis of the measurements from sensor 2 show that the lowest frequency range remains at the same level both with and without the FRUCE. However, the higher frequency range show a clear reduction in the frequency amplitudes when using the FRUCE. The plots shown in Fig. 7 and Fig. 8 show the differences between the frequency magnitudes in sensor 2 and sensor 3. Blue line is without FRUCE, red line is with FRUCE.

9 Figure 7. FFT Sensor V2 Steady state PL -Upper with FRUCE lower without FRUCE Figure 8. V3 Steady state PL -Upper with FRUCE lower without FRUCE 5. Conclusion Pressure oscillation and vibration measurements have successfully been carried out on a model Francis turbine both with and without freely rotating runner cone extension (FRUCE) at the Water Power Laboratory at NTNU. The measurements were performed for 10 different steady state operating conditions. The collected data of both vibration and pressure pulsations are analyzed and correlated to each other.

10 The predominant frequencies observed throughout the analysis are shown to be consistent with the calculated values. The runner vane frequency, Rheingans frequency and frequencies caused by elastic fluctuations are present under all steady state conditions. Runner vane frequency is identified as the dominant frequency in the vaneless space, and can be observed in both upstream and downstream sections of the turbine. At PL operation, the Rheingans frequency is observed as far upstream as the inlet section of the spiral casing. The results of the study clearly indicate that there are strong correlation between the observed vibration frequencies and pressure oscillation frequencies under all steady state operating conditions. Frequencies caused by elastic fluctuations are observed to be the main source of vibrations. The frequency magnitudes are highly dependent on the operational point, with an increase in magnitude for higher loads i.e. higher outlet velocity. The high frequencies of 120, 180 and 212 Hz is considered to be load dependent and can be attributed to elastic fluctuations and vortex shedding in the system. Among external frequencies, the grid frequency at 50 Hz and the AC- DC tension based 300 Hz frequency are present in the analysis. When comparing the measurements with and without the FRUCE, one is unable to clearly conclude on the effects of the FRUCE on the system. At the inlet section of the turbine, the FRUCE contributes to a large increase the amplitudes for lower frequencies while showing a decrease in the higher amplitudes. Throughout the vanless space, runner, draft tube and outlet the pressure frequencies tend to show a slight increase in amplitudes in the lower frequencies with FRUCE and next to no change in the higher frequency ranges. The vibration measurements are somewhat contradicting that increase in all frequency amplitudes. The sensors at the draft tube and upper head cover supports an increase in the lower frequency range with the FRUCE. However, the analysis also shows that the magnitude increases on some of the higher frequency. It should be noted that the sensor at the lower head cover displays no change in the lower frequency range with and without the FRUCE while at the same time showing a significant decrease in magnitudes for the higher frequency range. This suggests a contradicting behavior throughout the system and not a straightforward answer when it comes to the use of FRUCE and its effect on vibrations and pressure pulsations in a Francis turbine system. Acknowledgement We would like to thank our supervisor Professor Ole Gunnar Dahlhaug, PhD. -Candidate Peter Joachim Gogstad and Carl Werdelin Bergan, and the technical staff in the lab, especially Joar Grillstad for being available for questions and technical guidance. References [1] Haugen, J. O., "Laboratoriet Typiske frekvenser i strømningsmaskiner", [2] International Electrotechnical Commission (IEC); International standard IEC Hydraulic turbines, storage pumps and pump-turbines Model acceptance Tests. Second Edition, [3] International Electrotechnical Commission (IEC); International standard IEC Guide for field measurement of vibrations and pulsations in hydraulic machines (turbines, storage pumps and pumpturbines). First Edition, [4] Dahlhaug, O.G., Turbomachinery, 2015 [5] Rheingans, W. J., Power swings in hydroelectric power plants, 1940.

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