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1~exreaez~" 'enla HYDRAULICS BRANCH MRAMINS BRA OFFICIAL FILE COPY
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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 ~
C::t
..•Ly. •.91~•it
(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
IF -qft~. WOU
of
Fig-1. Draft tube of unit 2 and cementing studs used to mount accelerometer
Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 5 September 30, 1986
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)
Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 7 September 30, 1986
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
Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 8 September 30, 1986
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
Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 9 September 30, 1986
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
Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 10 September 30, 1986
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
Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 11 September 30, 1986
Fig-3. Interior views of wicket gates, runner, and snorkel tube.
Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 12 September 30, 1986
Fig-4. 84-inch butterfly valve leaf and seat damage.
Sound & Vibration Measurements at Flatiron Power & Pumping Plant Page 13 September 30, 1986
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.
STORED 21 -3
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