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Implementation of a monitoring strategy on a Pelton turbine

Authors: Vitkovskaya, Elizaveta;

Implementation of a monitoring strategy on a Pelton turbine

Abstract

Esta tesis presenta una estrategia de monitorización de estado para una turbina Pelton de eje horizontal, con el objetivo de caracterizar su huella vibracional mediante datos operativos a largo plazo y modelado numérico. La monitorización convencional se basa en umbrales estáticos que no reflejan la compleja naturaleza hidráulica de las turbinas de impulso. Para superarlo, se desarrolló un enfoque basado en datos utilizando un conjunto de dos años para construir diagramas vibracionales multidimensionales, correlacionando aceleraciones con condiciones variables de potencia y altura. La metodología integra simulaciones mediante el método de elementos finitos para realizar un análisis modal del rodete, identificando frecuencias naturales y modos de diámetro nodal. Los resultados se comparan con datos espectrales obtenidos de siete sensores en los cojinetes de la turbina y del generador. El análisis identifica una zona de equilibrio hidráulico entre 3 MW y 8 MW, donde se minimiza la tensión mecánica. Por encima de 9 MW se observa una transición a un régimen de vibración estocástica. Comparaciones espectrales en condiciones idénticas (482 m, 10 MW) registradas en distintos momentos muestran incrementos de energía en las bandas tangencial (550–650 Hz) y radial (700–900 Hz), atribuidos a excitaciones hidráulicas forzadas y no a resonancias estructurales. Finalmente, se definen superficies de referencia de operación normal ajustando datos dentro de un rango estable de 4–9 MW. Estas actúan como referencia dinámica, permitiendo indicadores adaptativos basados en parámetros SCADA y facilitando la detección temprana de fallas y el mantenimiento basado en la condición.

Aquesta tesi presenta una estratègia de monitorització de condicions per a una turbina Pelton d’eix horitzontal, amb l’objectiu de caracteritzar la seva empremta vibratòria mitjançant dades operatives a llarg termini i modelització numèrica. La monitorització convencional es basa sovint en llindars estàtics que no reflecteixen la complexitat hidràulica de les turbines d’impuls. Per superar-ho, s’ha desenvolupat un enfocament basat en dades amb un conjunt de dos anys per construir diagrames vibracionals multidimensionals, correlacionant acceleracions amb condicions variables de potència i alçada. La metodologia integra simulacions del mètode d’elements finits per realitzar una anàlisi modal del rodet, identificant freqüències naturals i modes de diàmetre nodal. Els resultats es comparen amb dades espectrals de set sensors situats als coixinets de la turbina i del generador. L’anàlisi identifica una zona d’equilibri hidràulic entre 3 MW i 8 MW, on es minimitza l’estrès mecànic. Per sobre de 9 MW s’observa una transició cap a un règim de vibració estocàstica. Comparacions espectrals en condicions idèntiques (482 m, 10 MW) mostren increments d’energia a les bandes tangencial (550–650 Hz) i radial (700–900 Hz), atribuïts a excitacions hidràuliques forçades i no a ressonàncies estructurals. Finalment, es defineixen superfícies de referència de funcionament normal ajustant estadísticament dades dins d’un rang estable de 4–9 MW. Aquestes actuen com a referència dinàmica, permetent indicadors adaptatius basats en paràmetres SCADA i facilitant la detecció precoç de fallades i el manteniment basat en la condició.

This thesis presents a condition monitoring strategy for a horizontal-shaft Pelton turbine, aiming to define its vibrational fingerprint using long-term operational data and numerical modeling. Conventional vibration monitoring relies on static thresholds that often fail to capture the complex hydraulic behavior of impulse turbines. To address this, a data-driven approach was developed using a two-year dataset to build multidimensional vibrational hill charts, correlating acceleration levels with varying power and head conditions. The methodology integrates Finite Element Method simulations to perform modal analysis of the runner, identifying natural frequencies and nodal diameter modes. These results are compared with experimental spectral data from seven sensors on turbine and generator bearings. The analysis identifies a hydraulic equilibrium zone between 3 MW and 8 MW, where mechanical stress is minimized. Above 9 MW, a transition to a stochastic vibration regime is observed. Spectral comparisons at identical operating conditions (482 m head, 10 MW) recorded at different times show increased energy in tangential (550–650 Hz) and radial (700–900 Hz) bands. These variations are attributed to forced hydraulic excitations rather than structural resonances, as they do not align with modal frequencies. Finally, normal operation reference surfaces are defined by statistically fitting data within a stable 4–9 MW range. These act as adaptive diagnostic benchmarks, enabling condition indicators that respond to real-time SCADA parameters and support early fault detection and condition-based maintenance.

Country
Spain
Related Organizations
Keywords

Hydraulic turbines, Finite element method, Automated plant protection, Vibrational hill chart, Elements finits, Mètode dels, Data acquisition, Nodal diameter, Àrees temàtiques de la UPC::Enginyeria mecànica::Motors::Turbines, Condition indicators, Condition monitoring, Finite Element Method, Turbine signature (Fingerprint), Turbines hidràuliques, Condition-Based maintenance, Spectral band

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selected citations
These citations are derived from selected sources.
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
0
Average
Average
Average