Hydraulic Power Plant Machine Dynamic Diagnosis

Abstract

A method how to perform an entire structural and hydraulic diagnosis of prototype Francis power machines is presented and discussed in this report. Machine diagnosis of Francis units consists on a proper evaluation of acquired mechanical, thermal and hydraulic data obtained in different operating conditions of several rotary and non rotary machine components. Many different physical quantities of a Francis machine such as pressure, strains, vibration related data, water flow, air flow, position of regulating devices and displacements are measured in a synchronized way so that a relation of cause an effect can be developed for each operating condition and help one to understand all phenomena that are involved with such kind of machine. This amount of data needs to be adequately post processed in order to allow correct interpretation of the machine dynamics and finally these data must be compared with the expected calculated data not only to fine tuning the calculation methods but also to accomplish fully understanding of the influence of the water passages on such machines. The way how the power plant owner has to operate its Francis machines, many times also determined by a central dispatcher, has a high influence on the fatigue life time of the machine components. The diagnostic method presented in this report helps one to understand the importance of adequate operation to allow a low maintenance cost for the entire power plant. The method how to acquire these quantities is discussed in details together with the importance of correct sensor balancing, calibration and adequate correlation with the physical quantities. Typical results of the dynamic machine behavior, with adequate interpretation, obtained in recent measurement campaigns of some important hydraulic turbines were presented. The paper highlights the investigation focus of the hydraulic machine behavior and how to tailor the measurement strategy to accomplish all goals. Finally some typical recommendations based on the experience obtained on previous diagnostic reports of Francis turbines are performed in order to allow a better and safe operation of these power plant units.