CAVlTATlON MONITORING OF HYDRAULIC MACHINES BY VIBRATION ANALYSIS

POUR L'OBTENTION DU GRADE DE DOCTEUR S SCIENCES TECHNIQUES

PAR

Michael KAYE
M. Sc. in Sound ard Vibration Studis. University of Southampton. Royaume-Uni de nationalil6 britannique

acceptb sur proposniondu jury:

Prof. F. Avelian, directeur de thse Dr P.Dupont. rapporteur Prof. E. Egusquiza. rapporteur Dr M. Farhat, rapporieur Dr D. Gillet, rapporteur

Lausanne. EPFL
2000

Summary
This work verifies the suitability of vibration analysis for the use of cavitation monitoring of hydraulic machines. A number of analysis methods have been developed and used together to investigate the cavitation behaviour in model and prototype Francis turbines. Cavitation is identified and characterised, and the relative cavitation aggressiveness quantified. Characterisation includes the identification of; cavitation modulatcd by the passage of the blades or output swirl, individual blades experiencing the most aggressive Cavitation and sporadic cavitation. Distinction between cavitation and sand or particle impacts can be made. Attached cavitation on the rotating parts of hydraulic machines can be modulated by pressure fluctuations caused by the passage of the blades by the guide vanes and volute tongue or the outlet swirl. A demodulation technique is used to detect this. The technique looks for a repetition in the high frequency envelope of the vibration signal at a frequency characteristic to the machine. Joint time-frequency analysis (JTFA) and auto-correlation are used to reduce background noise and so help identify the characteristic frequencies. JTFA is also used to characterise non-uniform and intermittent cavitation, as well as to quantify relative cavitation aggressiveness. Other techniques such as phase averaging. double enveloping and coherence have been used to complement the main technique, and verify interpretation of results. A technique that detects spikes in the time series identifies and quantifies sporadic cavitation. Preliminary tests made on the cavitation tunnel show that the frequency content of cavitation induced vibration is largely broadband above 20kHz. The demodulation technique can detect the shedding frequency of transient cavities generated during unstable leading edge cavitation. Results from Francis turbines demonstrate the usefulness of vibration monitoring to complernent standard model cavitation tests and investigate the cause of erosion on prototype turbines. Furthermore it can be used as a research tool in order to gain a better understanding of the fluid phenomenon. Vibration measurernent was made using high frequency accelerometers mounted close to the guide vanes and guide bearings. Analogue enveloping was found to be more useful than digital enveloping as it allow longer tirne lengths to be acquired. This improves the frequency resolution of spectra and gives a more statistically average sample. Dynamic calibration is necessary in order to compare measurements from different machines and obtain an estimate of erosive force. The principle is to estimate the transfer function between the area of cavitation and the measurement location. Sources of error have been addressed and reduced. The calibration technique consists of two stages. Firstly, the ratio of acceleration between the region of erosion and the measurement location is estimated using a spark plug to create a high frequency pressure pulse. Secondly, a high frequency instmrnented hammer obtains the Point Inertance at the measurement location. The Transfer lnertance can then be estimated from results of the two stages, and hence an estimate of erosive forces on the blade can be inferred.

Keywords :

Cavitation Vibration Monitoring Francis Turbine

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Rsum
ia prsente tude concerne la caractrisation de I'agressivit de la cavitation dans les
machines hydrauliques travers la dtection vibratoire. Pour atteindre cc but, des mthodes originales d'analyse des signaux de vibration sont dveloppes et permettent d'analyser le comportement de la cavitation dans les modles et les prototypes de machines hydrauliques. Une technique de dmodulation des signaux de vibration est utilise pour la dtection de la cavitation dveloppe sur I'aubage. Elle consiste examiner les composantes hautes frquences modules aux frquences caractristiques de la machine. Des outils mathmatiques de traitement des signaux sont dvelopps pour rduire le bruit et dtecter la cavitation intermittente ainsi que la quantification de I'agressivit de la cavitation. D'autres outils complmentaires tels que le moyennage de phase et la cohrence ont t gaiement dvelopps pour mieux interprter les rsultats. Plusieurs techniques de traitement sont utilises ensemble pour extraire I'information sur la cavitation. Elles consistent identifier la cavitation non-uniforme due une diffrence de I'agressivit de la cavitation entre les aubes, l'aube o la cavitation est la plus agressive, la cavitation module par la torche. En outre, l'agressivit relative de la cavitation est ainsi estime. II a t dmontr que des acclromtres hautes frquences ayant une frquence naturelle au-dessus de 100 kHz sont suffisants pour la dtection vibratoire de la cavitation. Des acclrorntres plus robustes ayant une frquence de rsonance infrieure (-50 kHz) peuvent aussi tre utiliss si l'on accepte d'exploiter l'information dans la zone de rsonance du capteur. II a t6 galement dmontr que la dmodulation analogique est meilleure que la dmodulation numrique puisqu'elle permet des enregistrements de longues dures. Ceci apporte une amlioration notable des estimateurs statistiques. Des essais prliminaires sont raliss dans le tunnel hydrodynamique du LMH dans le but d'tudier le contenu spectral des vibrations induites par la cavitation sur un profil bidimensionnel et de tester la technique de dmodulation. Les rsultats des essais raliss des turbines Francis montrent clairement que l'utilit de la dtection vibratoire de la cavitation. En effet, elle constitue un outil complmentaire prcieux lors des essais standard de modles de turbines et permet d'analyse les causes d'rosion dans les prototypes. L'talonnage dynamique est ncessaire dans les prototypes de turbines pour estimer les forces subies par I'aubage suite aux implosions rptes des cavits rosives. La fonction de transfert est estime entre le lieu de ces implosions et les points de mesure. L'talonnage dynamique est effectu en deux tapes. Dans la premire, la fonction de transfert des acclrations entre I'aubage et les points de mesure est dduite au moyen d'explosions dans l'eau. Ensuite, un marteau instrument est utilis pour rhaliser des impacts sur les lieux de mesure et dduire la relation entre les forces sur I'aubage et I'accleration aux points de mesure.

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Contents
List of Figures and Tables Nomenclature Abbreviations

Page viii xii

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Part 1
1

Introduction

Cavitation and Erosion 1.1 The Cavitation Phenornenon 1.2 Types of Cavitation 1.3 Erosion The Need for Cavitation Erosion Monitoring 1.4 1.4.1 Turbine Acceptance Tests - Model and Prototype 1.4.2 Optimisation of Prototype Operation 1.4.3 Upgrades and Modifications 1.4.4 Prototype with a Specific Cavitation Problem 1.4.5 Cavitation Rcsearch 1.5 Vibration as a Measurement Parameter for Cavitation Monitoring Thesis Postulate and Layout Thesis Postulate 2.1 Thesis Layout 2.2

Part II
1

State of the Art

17

Literature Survey 1.1 Generation of Erosive Cavitation

1.2 1.3 1.4 1.5 1.6 1.7 Vibratory Approach to Cavitation Monitoring Dynamic Calibration Time Frequency Analysis Neural Networks Sand Erosion Machine Condition Monitoring Systems

Cavitation Analysis Techniques 2.1 Demodulation Technique 2.1.1 Principle of the Technique 2.1.2 Description of the Demodulation Technique 2.2 Phase Averaging 2.3 Coherence

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Part iil
1

Experimental Program

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31 31 31 33 34 34 36 37 37 38 38

Selection and Testing of Transducers and Enveloping Method 1.1 High Frequency Accelerometers 1.1.1 Accelerometers Operation and Frequency Response 1.1.2 Effect of Mounting Method on Accelerometer Natural Frequency 1.1.3 Deteclion Test for Accelerometer Natural Frequency 1.1.4 Natural Frequency Detection Test Results and Conclusions 1.2 Acoustic Emissions Sensor 1.3 Analogue and Digital Enveioping Techniques 1.3.1 Digital Enveloping 1.3.2 Analogue Enveloping 1.3.3 Discussion of Analogue Verses Digital Filtering and Enveloping Techniques Test Instrumentation Preliminary lnvestigation - Caviation Tunnel Tests 3.1 Test Description 3.2 Frequency Content Investigation 3.3 Unstable Leading Edge Cavitation Shedding Frequency Investigation 3.4 Conclusions to Cavitation Tunnel Tests Model Francis Turbine Tests 4.1 Model Test Overview Test 1 - Short Time Data Acquisition 4.2 4.2.1 Test Description 4.2.2 Visual Observations 4.2.3 Visual Observations of Vibration Time Series 4.2.4 Overall RMS Vibration Levels 4.2.5 Auto-Power Spectra of the Envelope Test 2 - Long Envelope Data Acquisition 4.3 4.3.1 Test Description 4.3.2 Visual Observations 4.3.3 Visual Observations of Vibration Envelope Series 4.3.4 Overall RMS Vibration Levels 4.3.5 Auto-Power Spectra of the Envelope Test 3 - Short Time Data Acquisition 4.4 4.4.1 Test Description 4.4.2 Demodulation Analysis Results 4.5 Preliminary Analysis Conclusions Prototype Francis Turbine Tests 5.1 General Description of the Turbine 5.2 Test description 5.3 Preliminary Results 5.3.1 Visual Observations of the Vibration Time Senes 5.3.2 Auto-Power Spectra of the Envelopes 5.3.3 Different Types of Accelerometers

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Part IV
1
1.1 1.2 1.3

Calibration
The Need for Calibration Description of Calibration Techniques Problematic Errors Associated with Calibration 1.3.1 Location of Cavitation 1.3.2 Frequency Content of Applied Force 1.3.3 Frequency Response of Transducers 1.3.4 Effect of Water on the Transfer Path 1.3.5 Effect of Rotation on the Transfer Path 1.3.6 Electronic Parasites due to the Operation of the Spark Generator Spark Plug Technique Hammer Technique Laboratory Tests 3.2.1 Test Arrangement 2.3.2 Test Results 2.3.3 Discussion of Results Prototype Tests 2.4.1 Test Arrangement 2.4.2 Test Results 2.4.3 Discussion of Results

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Introduction and Problematic

Cornparison and Testing of Calibration Techniques

2.1 2.2 2.3

2.4

Final Calibration Procedure

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Part V
1
1.1 1.2

Development of Analysis Techniques

Analysis Strategy Use of an Artificial Generated Signal 1.2.1 Synthesis of an Artificial Signal Effect of Vibration from Other Sources Auto-Correlation Auto-Power Spectrum Noise Reduction Using Joint Time-Frequency Analysis (JTFA) 2.4.1 JTFA Algorithm Selection 2.4.2 Noise Reduction Technique Description Irnprovernents Achieved by Noise Reduction Techniques Noise reduction Techniques Applied to Example Model Test Data Noise reduction Summary

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Introduction

Noise Reduction
2.1 2.2 2.3 2.4 2.5 2.6 2.7

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Detection of Non-Uniform and Intermittent Cavitation

3.1 3.2 3.3 3.4 3.5 Introduction Joint Time Frequency Analysis (JTFA) Technique Description Cavitation Intensity Distribution 3.3.1 STFA Spectrogram Coefficients at the Characteristic Frequency 3.3.2 De-Noised Signai Identification of Blades with Particular Cavitation Problems Testing Time-Frequency Anaiysis 3.5.1 Half of the Blades Experiencing Cavitation 3.5.2 Most of the Blades Experiencing Cavitation 3.5.3 Few Blades Experiencing Cavitation 3.5.4 Different Levels of Cavitation Intensity 3.5.5 One Blade with Very Strong Cavitation Example Experimental Results Cavitation Intensity 4.1.1 Auto-Power Spectrum Amplitude 4.1.2 Spectrogram Coefficients Average Value 4.1.3 Spectrogram Coefficients Maximum Value 4.1.4 Cavitation lntensity Units Artificial Signal Reconstnicted Using Experimental Spectrogram Coefficients Statistical Analysis 4.3.1 Example Results from Model Turbine Tests 4.3.2 Discussion of Results Double Envelope Demodulation The need for Spike Detection Spike Amplitude and Rate of Occurrence Parameters used for Spike Detection 5.3.1 Crest Factor 5.3.2 Kurtosis 5.3.3 Peak Value

3.6
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Other Improvements to the Demodulation Technique

4.1

4.2 4.3 4.4

Spike Detection
5.1 5.2 5.3

Part VI
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Application of Analysis Techniques

Cavitation Analysis Using Short Time Data - Model Francis Turbine Test 1
1.1 1.2 1.2 1.3 Demodulation Technique Phase Averaging Spike Detection Model Test 1 Conclusions Characteristic Frequency and Non-Uniform Cavitation 2.1.1 Double Envelope Demodulation

Cavitation Analysis Using Long Envelope Data -Test 2

2.1

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2.1.2 Interpretation of the Auto-Power Spectnim of Envelope 2.1.3 Average STFT Spectrogram 121 2.1.4 Phase Averaging Cavitation Modulated by Output Swirl 5.2.1 Closer inspection of the envelope time series 2.2.2 Interpretation of the Auto-Power Spectrum of Envelope 2.2.3 Double Envelope Demodulation 2.2.4 Phase Averaging The Influence on Cavitation Modulated by Adjacent Guide Vanes Change of Angle of Cavitation on the Blades Shape of the Modulation Quantification of Relative Cavitation Aggressiveness Spike Detection Discussion 2.7.1 Turbine Cavitation Characteristics 2.7.2 Long Envelope Verses Short Time Data Acquisition 2.7.3 Transducer Measurement Locations Model Test 2 Summary and Conclusions 3.8.1 Summary of Cavitation Test Findings 3.8.2 Measurement and Analysis Techniques Conclusions

Cavitation Analysis Using Short Time & Long Envelope Data - Prototype 177 Francis Turbine - Test 3 3.1 Spike Detection 177 3.2 Phase Averaging, Spectrogram Coefficients and Double Enveloping 179 3.3 Coherence 182 3.4 Prototype Test Conclusions 183

Part VI1
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Conclusions and Perspectives

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Conclusions 1.1 Cavitation Monitoring 1.2 Analysis Techniques 1.3 Instrumentation 1.4 Dynamic Calibration Recommendationsfor Further Work 2.1 Further Development and Testing 2.2 Relation to Erosion Rate 2.3 Study of Scaling Laws for Cavitation from Model Tests to Prototype References Appendix A Commercial and Practical Implications A. I Machine Condition Monitoring Systems A.2 Mechanical Seal Condition Monitoring A.3 Development of Instrumentation A.4 Remote Analysis 189 189 189 189 191

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A.5 A.6

Industrial Accelerometers Cavitation Monitoring Proccdure

Curriculum Vitae of Author

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