An experimental investigation has been carried out in order to evaluate the detection of cavitation in actual hydraulic turbines. The methodology is based on the analysis of structural vibrations, acoustic emissions and hydrodynamic pressures measured in the machine. The proposed techniques have been checked in real prototypes suffering from different types of cavitation. In particular, one Kaplan, two Francis and one Pump-Turbine have been investigated in the field. Additionally, one Francis located in a laboratory has also been tested.First, a brief description of the general features of cavitation phenomenon is given as well as of the main types of cavitation occurring in hydraulic turbines. The work presented here is focused on the most important ones which are the leading edge cavitation due to its erosive power, the bubble cavitation because it affects the machine performance and the draft tube swirl that limits the operation stability.Cavitation detection is based on the previous understanding of the cavity dynamics and its location inside the machine. This knowledge has been gained from flow visualisations and measurements in laboratory devices such as a high-speed cavitation tunnel and a reduced scale turbine test rig. The main techniques are the study of the high frequency spectral content of the signals and of their amplitude demodulation for a given frequency band. Moreover, low frequency spectral content can also be used in certain cases. The results obtained for the various types of cavitation found in the selected machines are presented and discussed in detail in the paper. Conclusions are drawn about the best sensor, measuring location, signal processing and analysis for each type of cavitation, which serve to validate and to improve the detection techniques. r

The mechanical design of hydraulic turbines is conditioned by the dynamic response of the runner that is usually estimated by a computational model. Nevertheless, the runner has complex boundary conditions that are difficult to include in the computational model. One of these boundary conditions is the water in which the runner is submerged. The effect of the added mass and damping of water can modify considerably the natural frequencies of the runner. An experimental investigation in a reduced scale model of a turbine runner, using modal analysis, was carried out. Several impact tests with the runner freely suspended in air and in water were done. The response was measured with accelerometers located in different positions of the runner. From the modal analysis, the natural frequencies, damping ratios, and mode-shapes were determined. The same mode-shapes obtained in air were obtained in water but with lower natural frequencies and higher damping ratios in water. The difference in the natural frequencies is shown to be dependant basically on the added mass effect of the water and not on its added damping. This difference also depends on the geometry of the mode, presenting different values for different mode-shapes. Using nondimensional values, the reduction in the natural frequencies can be extrapolated to other Francis runners presenting similar geometrical characteristics. r

The highest vibration levels in large pump turbines are, in general, originated in the rotor stator interaction (RSI). This vibration has specific characteristics that can be clearly observed in the frequency domain: harmonics of the moving blade passing frequency and a particular relationship among their amplitudes. It is valuable for the design and condition monitoring to count on these characteristics. A CFD model is an appropriate tool to determine the force and its characteristics. However, it is time consuming and needs highly qualified human resources while usually these results are needed immediately and in situ. Then, it is useful to determine these characteristics in a simple, quick, and accurate method. At present, the most suitable method indicates a large amount of possible harmonics to appear, without indicating the relative importance of them. This paper carries out a theoretical analysis to predict and explain in a qualitative way these frequencies and amplitudes. The theoretical analysis incorporates the number of blades, the number of guide vanes, the RSI nonuniform fluid force, and the sequence of interaction. This analysis is compared with the method currently in use, and both methods are applied to a practical case. The theoretical analysis gives a resulting force over the pump turbine, which corresponds well to the measured behavior of a pump turbine in terms of its frequencies and the relationship between their amplitudes. A corrective action is proposed as a result of the analysis and after it is carried out in one of the units, the vibration levels are reduced. The vibration induced by the RSI is predicted considering the sequence of interaction and different amplitudes in the interactions between the same moving blade and different stationary blades, giving a different and original interpretation about the source of the vibration characteristics. A successful corrective action is proposed as a consequence of this new interpretation.

a b s t r a c tA failure investigation was conducted on a high-pressure machine with a large pump-turbine runner that was 2.9 m in diameter and had a maximum discharge rate of 32 m 3 /s.A part of the runner broke off during operation. This released a piece of the crown, which went through the machine, causing further damage. An analysis of the broken runner revealed a fatigue problem, so the dynamic/vibratory behavior of the runner during machine operation was investigated to determine the cause.First, the excitation forces acting on the runner during operation were studied. The main excitation in pump-turbines is generated by the interference between the rotating blades and the stationary vanes, known as a rotor-stator interaction (RSI), which produces large pressure pulsations. The amplitude of the pressure pulsations was measured in the prototype using pressure transducers.Second, the modal response of the runner structure was analyzed. A finite element (FEM) model of the runner was developed and the main natural frequencies and associated mode shapes were identified.A dynamic analysis was then performed to determine the runner response. A harmonic excitation simulating the pressure pulsation of the RSI was applied to the numerical model of the runner. The results showed a large stress concentration in the T-joint between the blade and crown where the crack originated. Finally, the possible causes of the damage are discussed.

In this paper, a numerical simulation to analyze the influence of the surrounding water in a turbine runner has been carried out using finite element method (FEM). First, the sensitivity of the FEM model on the element shape and mesh density has been analysed. Secondly, with the optimized FEM model, the modal behaviour with the runner vibrating in air and in water has been calculated. The added mass effect by comparing the natural frequencies and mode shapes in both cases has been determined.The numerical results obtained have been compared with experimental results available. The comparison shows a good agreement in the natural frequency values and in the mode shapes. The added mass effect due to the fluid structure interaction has been discussed in detail.Finally, the added mass effect on the submerged runner is quantified using a non-dimensional parameter so that the results can be extrapolated to runners with geometrical similarity.

No abstract

The present study deals with the shedding process of the von Kármán vortices at the trailing edge of a 2D hydrofoil at high Reynolds number Reh=25×103–65×103. This research focuses mainly on the effects of cavitation and fluid-structure interaction on the mechanism of the vortex generation. The vortex shedding frequency, derived from the flow-induced vibration measurement, is found to follow the Strouhal law provided that no hydrofoil resonance frequencies are excited, i.e., lock-off. For such a regime, the von Kármán vortices exhibit strong spanwise 3D instabilities and the cavitation inception index is linearly dependent on the square root of the Reynolds number. In the case of resonance, the vortex shedding frequency is locked onto the hydrofoil eigenfrequency and the spatial coherence is enhanced with a quasi-2D shape. The measurements of the hydrofoil wall velocity amplitude and phase reveal the first torsion eigenmotion. In this case, the cavitation inception index is found to be significantly increased compared to lock-off conditions. It makes clear that the vortex roll-up is amplified by the phase locked vibrations of the trailing edge. For the cavitation inception index, a new correlation relationship that encompasses the entire range of Reynolds numbers, including both the lock-off and the lock-in cases, is proposed and validated. In contrast to the earlier models, the new correlation takes into account the trailing edge displacement velocity. In addition, it is found that the transverse velocity of the trailing edge increases the vortex strength linearly. This effect is important in the context of the fluid-structure interaction, since it implies that the velocity of the hydrofoil trailing edge increases the fluctuating forces on the body. It is also demonstrated that cavitation developing in the vortex street cannot be considered as a passive agent for the turbulent wake flow. In fact, for fully developed cavitation, the vortex shedding frequency increases up to 15%, which is accompanied by the increase of the vortex advection velocity and reduction of the streamwise vortex spacing. In addition, a significant increase of the vortex-induced vibration level is found at cavitation onset. These effects are addressed and thought to be a result of the increase of the vorticity by cavitation.

No abstract