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PAP-508

Progress Report

(Phase - I)

Sound and Vibration fleasurements at Flatiron Power and Pumping Plant

Loveland, Colorado Summer 1986

by

M. N1. Skinner w~

September 30, 1986

1 CL ~

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(Phase - I)

Loveland, Colorado

Summer 1986

by

M. M. Skinner

for

U. S. Bureau of Reclamation

Division of Research and Laboratory Services

Denver, Colorado

September 30, 1986

• 21 • - O• •' • ••

b

M. M. SICENNER

During the period June 22, 1986 - August 22, 1986, accelerometer,

microphone, and hydrophone measurements were made on Units #1 and #2 at

the Flatiron Power and Pumping Plant located near Lcveland, Colorado.

Time and frequency domain records were obtained and analyzed with a

Hewlett-Packard Model 3561A Dynamic Signal Analyzer. Hard copy records

of the analyzer output were made on a Hewlett-Packard model 7470A

Plotter and tape recordings were made on a Nagra type 4.2L, reel-reel

1/4-inch tape recorder. Measurement procedures were developed and some

analyses of results were performed. Copies of original trials of a

variety of analyses are included in the packet at the back of this

report. Unit #2 was dewatered and inspected during an annual scheduled

inspection and maintenance; selected photos are included showing

condition of the suction side of the runner, buckets, wicket gates,

butterfly valve leaf, and valve leaf seat. Recommendations for Phase II

investigations are given.

Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 2 September 30, 1986

INTRODUCTION

For the period from June 22, 1986 - August 22, 1986 an assignment

agreement for Dr. Morris M. Skinner was initiated between the Bureau of

Reclamation, Division of Research and Lab Services and Colorado State

University, Civil Engineering Department. The mobility assignment was

for the purpose of developing data acquisition procedures for evaluating

critical operating conditions at hydropower plants. A three phase

study was planned to extend over approximately three calendar years:

Phase I - Summer 1986, develop procedures.

Phase II - Fall 1986 - Summer 1987, develop base-line spectra and expand measurements to a variety of different units.

Phase III - Fall 1987 - Summer 1988, Training of hydropower personnel.

The detection of damaging flow conditions in a turbine at various

operating points and the use of sound and vibration spectra for

monitoring the condition of a turbine were of prime interest. Efforts

were directed towards the goal of developing practical procedures for

minimizing maintenance costs and downtime.

Four (4) specific tasks were defined

A. Develop and implement a data acquisition plan to collect vibration, pressure, sound, and other data at the Bureau of Reclamation's Flatiron Powerplant in Loveland, Colorado. The Hewlett-Packard 3561A Dynamic Signal Analyzer would be the primary piece of equipment used. The type of analysis would include run-up and coast-down (waterfall display) of sound and vibration spectra, one-third octave analysis and measurement of pressure transients.

B. Work closely with the Bureau of Reclamation engineers to develop appropriate techniques and instrumentation to differentiate between cavitation in the flow versus cavitation against a boundary (such as a turbine blade) and to develop methods to locate the source of a signal. The Bureau of Reclamation would supply supplemental instrumentation to investigate various methods.

Sound & Vibration Measurements at Flatiron Power & Purring Plant Page 3 September 30, 1986

C. Develop a hypothesis based on a background appraisal of cavitation in turbines and other information in the literature that accounts for the observed data within a theoretical framework and can be used as a basis for further investigation.

D. Report on the findings of the first phase of the study.

PLANT DESCRIPITON

The Flatiron Power and Purring Plant, part of the Colorado Big

Thomson project, began initial operation in 1954 and is located

approximately ten (10) miles southwest of Loveland, Colorado. Units #1

and #2 are 35 megawatt Francis type turbines turning at 514 RPM and used

primarily as peaking plants. Difference in elevation between the

Forebay Reservoir (Pinewood Lake) and the Tailrace (Flatiron Reservoir)

is approximately 1100 feet. The two separate penstocks are 84-inch

welded, plate steel, 5790 feet long with 84 inch butterfly valves at the

power house. A flow rate of approximately 550 cubic feet per second can

be delivered to each unit. A snorkel tube mounted in each draft tube

provides outside air to the vortex over a set range on the wicket gates.

Also a pump-turbine unit (Unit #3) operates at two (2) speeds; 300 RPM

for delivering 370 cubic feet per second to Carter Lake against a head

of 240 feet, and 257 RPM when producing 8.5 megawatts at a net effective

head of 250 feet and 100% power factor. Unit #3 was one of the first

pump-turbines installed in the U.S.

MEASUREMENTS

Accelerometer measurements were made on the draft tubes of units #1

and #2 at the general location shown in Fig.-l. Cementing studs were

attached to the steel plate with super glue.* Several other different

* Victor Automotive Products, Inc.

`Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 4 September 30, 1986

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of

Fig-1. Draft tube of unit 2 and cementing studs used to mount accelerometer


adhesive materials, including hot glue, were tried without success.

The cool (60 degrees F), darp steel had to be dried with a heat gun for

several minutes prior to affixing a cementing stud. In the future,

magnetic mountings should be more practical when several points on the

machine are to be sampled and when the mounted resonant frequency does

not interfere with the desired measurement frequency range.

Detailed evaluation of the B & K "Delta Shear Design" type 4370

accelerometer should be accomplished during Phase II; good low frequency

response range (less than 10 hz) and low response to temperature change

is desirable.

Microphone measurements were made approximately one (1) foot in

front of the man-door of the draft tube as shown in Fig.-2. The B & K

hydrophone type 8103 may be used in either water or air. In air the

frequency response range is reduced to about 15 khz. The B & K

hydrophone type 8103 used as a microphone, however, seems to be a very

practical transducer to use for turbine testing work since it is sturdy

and not affected by high humidity conditions. Comparative measurements

between the near field and far field need to be examined in future work.

A demonstration of the B and K sound intensity probe type 3519 would be

useful during phase II.

Hydrophone measurements were made in the tailrace a few feet below

the water surface and in line with the discharge from the draft tube of

each turbine. Both the B & K hydrophone type 8103 and an Interoceans

hydrophone were used. The Interoceans hydrophone has a limited

frequency response of 20 hz to 10 khz. Various tailrace locations

should be carefully evaluated as one of the best places to make sound

measurements for future work. The low frequency signals (less than 400

Sound & Vibration Measurements at Flatiron Power & Piing Plant Page 6 September 30, 1986

Fick-2. Location of B & K Hydrophone Type 8103 (used as a microphone)


hz) are strong, access is no problem, measurement environment is

comfortable, and has minimum interference with the normal flow of plant

operation personnel. Errvironmental conditions, however, such as wind

and various forms of precipitation can alter the sound levels. The B &

K type 8104 hydrephone should be evaluated as the primary sensor for

tailrace measurements.

TTT'T T ITL LPL+

The data may be analyzed in a variety of ways using the HP-3561A

dynamic signal analyzer. Three (3) forms of averaging include RMS, Peak

hold, and time synchronous averaging. The time synchronous averaging

was triggered by a once per revolution pulse off of the turbine shaft.*

A sharp, clean pulse is obtained if a strip of dark tape is used under

the reflective tape. Fluorescent lights should be turned off during the

measurements in order to reduce the 60 hz signal.

Narrow band and one third octave measurement modes were used on the

3561A. Log magnitude, waterfall plots, single, front-back, and upper-

lower format displays were very effective. A closed-circuit, black and

white TV camera with monitor proved to be very useful for correlating

measurements with plant load. Either the wicket gate opening indicator

or the megawatt dial in the control roam can be monitored. There seems

to be a step-function reponse between wicket gate opening and the

megawatt dial. The basic equipment used during Phase I of the study is

listed on the following page.

Data storage for future spectra comparisons and evaluations is of

prime concern. The HP-3561A DSA can provide hard copy via an HP-IB

*Monarch Optical Trigger, Model SPS-5


Item Manufacturer Serial No. Owner

1.) 3561A Dynamic Signal Hewlett Packard 2338A01027 CSU Analyzer w/bubble memory

2.) Acoustic Listening Interocean Systems, Inc. 3955015 CSU and Calibration System Model 902

3.) Hydrephone Type 8103 Brdel and Kjaer

4.) Change Amplifier BrUel and Kjaer Type 2635

5.) Accelerometer Model Columbia 3030

6.) Charge Amplifier Model Columbia 4102

7.) 7470A Plotter Hewlett Packard

8.) 1/4-inch, reel-reel Nagra 4.2 tape recorder

9.) Optical Trigger Model Monarch SPS-5

10.) TV Camera Model Pansonic WV-1500

11.) Video Monitor Model Panasonic TR-930

812703 USER

795728 USER

203 USER

574 USBR

2308A36635 M.M.Skinner

L102194 CSU

189055 CSU

3YA09419 CSU

KD6220381 CSU

12.) SLR AutoFocus Camera Polaroid 7G976373237 M.M.Skinner


interface to the 7470A plotter and/or records can be stored in the

internal bubble memory of the ASA. Future data collection systems need

to incorporate a desk top computer (Hewlett Packard Model 310) to access

disk drives for spectra storage and retrieval.

nMIC~rn

(TASK A) A vibration and sound (in air and water) data acquisition

plan was developed. Pressure transient measurements in the penstock

were not accomplished, but need to be started in the next phase. Run-up

tests were tried, but didn't appear to be useful. Waterfall plots,

however,are valuable for checking consistency of a given frequency.

One-third octave displays will be very useful for long-term monitoring

of machine condition and for detecting the occurrence of general

cavitating flow. Acoustic emission (AE) measurements need to be

initiated for detecting cavitation on the wicket gates and impeller.

(TASK B) Acoustic emissions instrumentation selection and use need

to be implemented in Phase II of this study. The shafts from individual

wicket gates are easily accessible at the head cover and should provide

an ideal location to position the sensor for AE detection. A pickup

from the shaft of the impeller will need to be installed to monitor AE's

originating on the impeller. Locating the spatial position of

cavitation implosions has not been considered in this phase.

(TASK C) Fundamental frequencies related to the rotation speed

(8.57 hz), the bucket passing frequency (13 x 8.57 = 111.4 hz), the

wicket gate passing frequency (20 x 8.57 = 171.3 hz), and the first and

second sidebands of the wicket gate passing frequency; 171.3 hz + 1 and

2 x 8.57 = 180 hz,188.5 hz, 163 hz and 154 hz have been observed. The

first and second harmonics of the bucket passing frequency (223 hz and


334 hz) are also apparent. For narrow band analyses, a frequency range

from 0-400 hz seems to be wide enough to include the fundamentals plus

harmonics and sidebands of interest. Monitoring the magnitude of the

fundamentals, harmonics, and sidebands may be the parameters of interest

to use in "condition based monitoring". Copies of all the original

trials made during Phase I after the first week in July are included in

the packet at the end of this report. Many of the trials were made

under changing loads, but the plots are included for possible reference

in future work.

INSPECTION OF UNIT 2: The opportunity to inspect the inside of Unit #2

during a scheduled maintenance shutdown was of great interest. Some

cavitation damage was evident, but the runner and wicket gates appeared

to be in fair condition considering the age of the unit. General

roughening on the suction side of all the wicket gates and localized

damage on the pressure side of some of the buckets were observed. The

four-inch ventilation pipe for the snorkel in the draft tube caused some

cavitation damage on the walls of the draft tube. Epoxy repair on the

suction side of the runner was extensive; see Fig.-3. Apparently, the

butterfly valve leaf and seat were eroded while the valve was in a

closed position. Considerable noise was noted at times during the

summer when the valve was in the shut-off position and the high pressure

flaw leaked past the seal. Fig.-4 shows some of the damage.

Viewing the internal geometry of the turbine helped in developing

some hypothesis about the characteristic frequencies that were observed.

For example, vortex shedding off of the stay vanes and wicket gates,

particularly when they are at some angle of attack, can certainly induce

mechanical vibrations (to be sensed by accelerometers) and acoustic

At


Fig-3. Interior views of wicket gates, runner, and snorkel tube.


Fig-4. 84-inch butterfly valve leaf and seat damage.


signals (for detection by hydrophone or microphone). Typically two (2)

cycles of pressure oscillation parallel to the free stream would be

caused by every one (1) cycle perpendicular to the free stream.*

Hydrophone measurement should be continued in the tailrace. The

appropriate location for accelerometer and microphone measurements in

the draft tube area, the head cover area, and on the scrollcase need to

be investigated further. Measurements should be made under steady flow

conditions and confirmed by a pressure transducer in the penstock just

upstream of the 84-inch butterfly valve. A computer aided testing

system for managing data acquisition, analyses, and display should be

considered for implementation during the latter part of Phase II.

A B & K hydrophone type 8104 with about 400 feet of cable

connected to a B & K charge amplifier type 2635 should be the primary

device for tailrace measurements. The B & K hydrophone type 8103 with

about 400 feet of cable connected to a B & K charge amplifier type 2635

should be the primary device for measuring airborne sound near the draft

tube and the head cover. B & K accelerometer type 4370 with about 400

feet of cable connected to a B & K charge amplifier type 2635 is also

recommended as a standard device for Phase II. One (1) B & K type 2635

charge amplifier can service all three (3) sensors. With this

configuration, data acquisition can be accomplished from a convenient

location in the control room. The closed-circuit TV camera can monitor

*Unit #2 has ten (10) stay vanes, but only nine (9) actively divide the flaw for producing vortex shedding. The Strouhal number—Cs) for the at y vanes on unit #2 should be about 0.2; since fs = a, then fsz; 0.2 Jvlhz

Sound & Vibration Measurements at Flatiron Power & Piing Plant Page 14 September 30, 1986

the wicket gate opening on the appropriate unit. The pressure

transducer output on the penstock also needs to be cabled to the control

room.

Efforts during Phase II need to concentrate on collecting

calibrated baseline spectra for units #1 and #2 and other units. Output

should be calculated directly in Pascals vs frequency for sound

measurements and in meters per second squared vs frequency for the

accelerometers. Both narrow-band (0-400 hz) and 1/3 octave (3.15hz-

5khz, band #s 5-37) measurement modes should be used. Time-synchronous

averaging should be triggered from the turbine shaft. Field calibration

needs to be accomplished with a B & K type 4294 calibration exciter

(for accelerometer) and B & K type 4223 calibrator (for hydrophone). A

B & K acoustic emissions system should be evaluated during Phase II. A

demonstration of the B & K sound intensity probe type 3519 should be

scheduled. Other turbines should be analyzed to obtain a wider

experience base on different types and sizes of units: Estes, Marys

Lake, Pole Hill, Alcova, Fremont Canyon, Seminole, Kortes, Blue Mesa,

Morrow Point, Crystal, and Mount Elbert are being considered.

Controlled tests on the Grand Coulee #3 model (presently at Estes) would

be very helpful.

ACKTOWLEDGEMENTS

The generous cooperation of the personnel at Flatiron during the

summer of 1986 made Phase I of this study a very enjoyable and

enlightening experience. The plant operators and management provided

many helpful suggestions and turbine operation details directly related

to the successful data collection development program.

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1~exreaez~ 'enla mramins hydraulics branch · during the period june 22, 1986 ... a snorkel...

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