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Cavitation Detection in Power Control of PDF
Cavitation Detection in Power Control of PDF
Abstract: Cavitation is harmful to water turbines and may cause shutdowns for several weeks.
The real-time detection of cavitation risk is increasingly important, and even narrow cavitation-
free power ranges can be utilised in load optimisation. Higher derivative signals calculated from
acceleration signals and their lp norms detect the normal operating conditions, which are free of
cavitation, and also provide an early indication of cavitation risk. On-line cavitation monitoring
is based on cavitation indices calculated from a moving maximum of the lp norms obtained
from samples. Data compression is very efficient, as the detailed analysis only requires feature
values with a short sample time. Power control minimises the cavitation risk by dividing the load
between three turbines, whose conditions are normal, bad and very good. Each turbine has three
operating modes: low, normal and high power. In the normal area, a cavitation free power level
is taken as an operating point. The low and high operating areas are defined by local minima
of the cavitation indices. The control system has a feedforward controller, which allocates the
load to the turbines by means of the cavitation indices, and a linguistic equation (LE) feedback
controller. Each turbine has a P type controller which is adapted to the operating conditions
by the scaling functions. The cumulative time in the strong cavitation provides an indication of
possible damage to be used in selecting the turbine for low power operation.The characteristic
curves are adapted to the recent indices in order to handle the changes in the condition of
the turbines. For power stations with many turbines, alternatives to reduce cavitation risks are
evaluated by simulation to optimise maintenance actions.
Keywords: Cavitation, vibration analysis, higher order derivatives, feature extraction, water
turbine.
0
C
Short periods if a good signal, i.e. a good order α, and a proper order p
−0.5
of weak cavitation are used. The absolute mean can be used if the order α is
−1 proper and the frequency range is sufficient.
−1.5 Cavitation−free Cavitation monitoring is based on the signal analysis of
the signal samples. The analysis is repeated at intervals
−2 defined by the sample time τ :
0 10 20 30 40 50 60
Power [MW] (1) Calculate the value of the norm ||τ Mαp || from the
signal sample.
Figure 2. The cavitation index for a Kaplan water turbine. (2) Calculate the feature max(||τ Mαp ||) from the 10 latest
values of the norm.
(α)
ranges, and the sample times are very short. The mo- (3) Calculate the cavitation index IC by means of the
ment can be analysed first and then combined with the scaling functions.
rms values to obtain the cavitation index if the moment (4) Add the sample time τ to the cumulative time of the
(α)
value exceeds the threshold value. The generalised moment strong cavitation if IC > 1.
(2) indicates possible cavitation but one moment value is (5) Add the sample time τ to the cumulative time of the
not enough for a detailed analysis (Lahdelma and Juuso, (α)
short-term cavitation if 0 < IC < 1.
2008c): the moments should be combined with other fea-
tures, e.g. rms values used in (Juuso et al., 2007). The
180 2
Turbine 1 Turbine 1
160 1.5 Turbine 2 Turbine 2
40 0
140 Turbine 3 Turbine 3
1 Turbine 1
120 Turbine 1
Power ( MW )
Power ( MW )
0.5 30 −0.5
100
IC(4)
I (4)
0
C
80 20 Turbine 2 −1
−0.5
60 Turbine 2
−1
40 10 −1.5
Turbine 3
−1.5
20 Turbine 3
−2 −2
0 0
50 75 100 125 150 175 50 75 100 125 150 175 20 30 40 20 30 40
Power ( MW ) Power ( MW ) Power ( MW ) Power ( MW )
Figure 3. Load allocation based on the cavitation indices Figure 4. Load allocation based on the cavitation indices
of three Kaplan water turbines in the normal and high of three Kaplan water turbines in the low power
power ranges, condition of the turbines are (1) very range, condition of the turbines are (1) very good,
good, (2) normal, and (3) bad. (2) normal, and (3) bad.
30 −0.5 Turbine 3
also provides warnings of a possible risk on short periods
I (4)
Turbine 1
of cavitation if the power is not too low. This is readily
C
−1
suitable for intelligent sensors where a good solution is to 20
use analogue signals x(4) . In the low power range, absolute
averages should be combined with peak value. Because of 10 Turbine 2
−1.5
minor calculation requirements the method is well suitable
for intelligent sensors, where analog differentiation can be Turbine 3 −2
used to obtain the signal x(4) from the acceleration signal. 0 10 20 30
10 20 30
Power ( MW ) Power ( MW )
Data compression is very efficient, as the detailed analysis
only requires the feature values, i.e. the moment and the
rms value, of the appropriate samples. Uncertainty can be Figure 5. Load allocation based on the cavitation indices
handled by presenting the indices as time-varying fuzzy of three Kaplan water turbines in the very low power
numbers analysed from several samples. The classification range, condition of the turbines are (1) very good, (2)
limits and thresholds can also be considered fuzzy. The normal, and (3) bad.
high sensitivity of the analysis methods may allow the
use of lower frequency ranges. A combined analogue and
digital technique can markedly reduce the amount of data. power (Fig. 4). In the very low power range, turbine 3 can
This is important in intelligent sensors, especially if the be kept in a range, where there are only short periods of
rotation speed is very low. weak cavitation (Fig. 5).
Power control minimises the cavitation risk by dividing The load allocation operates as a feedforward control.
the load between three turbines, whose conditions are Feedback control is needed since the cavitation depends
normal, bad and very good. Knowlede-based cavitation on the flow conditions in the turbine. Each turbine has
indices are used for load allocation by minimising the three operating modes: low, normal and high power. In
overall cavitation index (Fig. 3). The solution is easy if the normal area, a cavitation-free power level is taken
all the turbines can operate in power ranges, which are as an operating point. The low and high operating areas
free of cavitation. For higher loads, the system increases are defined by the local minima of the cavitation indices.
production in the turbines in such a way that short-term Turbines can also have more operating areas, e.g. two in
cavitation is minimised (Fig. 3). the low power range as seen in Figure 2.
The optimisation procedure can also use the low power Fuzzy logic control is well suitable for power control since
ranges of the turbines efficiently. However, the low power there is wide operating area where cavitation index is not
ranges in some turbines are selected only when all the needed. In this area, the cavitation index of each turbine is
turbines cannot operate in the cavitation-free area. In this close to -2. Since the cavitation indices are already in the
example, turbine 3 is in a bad condition, but it can be range [−2, 2], the controller can be realised as a linguistic
kept in the cavitation-free area in a wide range of total equation (LE) controller (Juuso, 2004).
The difference of the cavitation index, denoted as (ΔIc )i , turbine has a P type LE controller which is adapted to
is obtained by the operating conditions by the scaling functions. The
(ΔIc )i = (Ic )i − (Ic )av , (8) cumulative time in strong cavitation provides an indication
of possible damage. The characteristic curves are adapted
where (Ic )i is the cavitation index of the turbine i, i = to the recent indices in order to handle changes in the
1, . . . , n, and (Ic )av is the average of the cavitation indices condition of the turbines.
:
n
1
(Ic )av = (Ic )i . (9)
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