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Measurements for Condition Monitoring of Hydropower plants: A Review

Article in IOP Conference Series Earth and Environmental Science · June 2022
DOI: 10.1088/1755-1315/1037/1/012019

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3rd IAHR-Asia Symposium on Hydraulic Machinery and Systems (IAHR-Asia 2021) IOP Publishing
IOP Conf. Series: Earth and Environmental Science 1037 (2022) 012019 doi:10.1088/1755-1315/1037/1/012019

Measurements for Condition Monitoring of Hydropower

plants: A Review
P Sapkota1, S Chitrakar1, H P Neopane1*, and B Thapa1*
1
Turbine Testing Lab, Department of Mechanical Engineering, Kathmandu University;
Email: [email protected], [email protected]

Abstract: Condition monitoring is an extension of the predictive maintenance or proactive mainte-

nance process for detecting faults in a machine component with the help of pre identified measuring
parameters to identify a significant change which is indicative of a developing fault. The fault de-
veloped due to various factors in the hydropower plants can damage or halt the operation of power
plants. The literatures on the measurement process for condition monitoring of power plants has been
reviewed and discussed. Since condition monitoring is a newer and a broader topic, few literatures
were available and they were review on the basis of measurement and faults detection processes.

Keywords: Condition Monitoring, Measurement, Hydropower plants, Sensors

1. Introduction
Hydropower is a renewable energy source which operates on natural water cycle. With the use of hydro
mechanical devices, the kinetic energy of flowing water gets transformed to mechanical energy. Glob-
ally, hydro source is one of the dominant sources of renewable energy. In the year 2019, all over the
world, 37.6 exajoules of energy has been consumed from hydro as a fuel source which is about 6.4%
shares among the total global fuel sources [1].

Hydropower plants have different mechanical components. These mechanical components are prone to
failure. The components suffer different types of mechanical failures like excess deformation, brittle
fractures, ductile fractures, fatigue and creep. Mostly, the causes of these failures are the physical
phenomenon like erosion, corrosion, vibration, temperature and other environmental factors [2].

1.1. Condition monitoring

Condition monitoring is an extension of the predictive maintenance or proactive maintenance method
for identifying problems in a machine component using pre-defined measuring parameters to identify a
substantial change that indicates the onset of a failure. [3]. Condition monitoring enables maintenance to
be planned or other steps to be taken to avoid consequential damages and their repercussions. Condition
monitoring offers the distinct advantage of allowing problems that would shorten normal lifespan can be
addressed before they develop into a serious failure [4].

The authors in [5] have discussed about the methods of condition monitoring i.e. online monitoring and
offline monitoring. According to authors, online monitoring is the process of continuous and rapid data
collection, processing its analysis, diagnosis and prediction at real time. Similarly, offline monitoring
has been discussed as the process of monitoring and inspecting using hand-held sensors, portable data
collectors and computer software for detecting any faults in the components.

2. Measuring Parameters in Power Plants

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
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Published under licence by IOP Publishing Ltd 1
3rd IAHR-Asia Symposium on Hydraulic Machinery and Systems (IAHR-Asia 2021) IOP Publishing
IOP Conf. Series: Earth and Environmental Science 1037 (2022) 012019 doi:10.1088/1755-1315/1037/1/012019

Each and every hydropower are unique due to its hydrological and geological natures and their entire
design varies due to their natures. Thus, measuring parameter in hydropower plants can differ due to
head, discharge, no of units, types of turbines, alignment of turbines, submergence, sediments and other
factors. Also, the hydropower plants can have their own unique nature of problems because of these
different factors. The Figure 1 shows elaborative measurement model of different parameters in a hy-
dropower plant.

Figure 1. Different measuring parameters of water turbine system[6].

2.1. Temperature
Temperature is an important parameter that need to be monitored in hydropower plants. The authors in
[6] have shown the different places for the measurement and monitoring of temperatures in hydropower
plants. They have extensively measured the temperature of upper guide bearing babbit, lower guide
bearing babbit, thrust bearing babbit and temperatures of heat exchangers as shown in Figure 1.
The author in [7], has discussed about the bearing oil temperature of hydropower plant which has im-
portant role during the operation of hydro power plants. The author has mentioned the acceptable
bearing temperatures of vertical shaft turbines (refer Table 1). According to the author, continuous op-
eration of old hydropower plants has been hampered by bearing overheating failures, and bearing
temperature is influenced by a number of factors including ambient air temperature, cooling water

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3rd IAHR-Asia Symposium on Hydraulic Machinery and Systems (IAHR-Asia 2021) IOP Publishing
IOP Conf. Series: Earth and Environmental Science 1037 (2022) 012019 doi:10.1088/1755-1315/1037/1/012019

temperature, cooling water flow rate, initial bearing temperatures, duration of operation, and generating
unit electrical load.

Figure 2. Temperature measuring points in shaft and bearings [7].

Table 1. Typical Bearing Temperature of Oil and metal in hydropower turbine [7]

Bearing Type Temperature/deg C (Alarm)

Metal Oil
Upper Guide Bearing 85 70
Lower Guide Bearing 85 70
Thrust Bearing 85 70
Turbine Guide Bearing 75 70

The hydro-generator design manual [8] has also mentioned the similar position of sensors for measuring
the temperatures. The manual suggests to use resistance temperature detectors (RTD) and thermometers
for measuring temperatures in following different locations.
 Thrust bearing metal temperature: As many as four Resistance Thermometers (RTDs).
 Upper-and lower-guide bearing metal temperature: Resistance Thermometers (RTD).
 Thrust bearing oil temperature: Thermometer on thrust bearing oil reservoir.
 Upper-guide bearing oil temperature: Thermometer on upper-guide bearing reservoir.
 Lower-guide bearing oil temperature: Thermometer on lower-guide bearing reservoir.
 Thrust bearing, upper-guide bearing, and lower guide bearing cooling water return tem-
perature: Thermometer in each bearing water outlet piping.
 Bearing cooling water supply temperature: Thermometer located in bearing water supply
piping.

2.2. Pressure
Pressure is an important indicator in the field of condition monitoring. Pressure measurement in dif-
ferent places have different applications. It can be helpful to identify developing or predicting faults in
machine or components. The authors in [6] has measured pressure of water in heat exchanger, water

3
3rd IAHR-Asia Symposium on Hydraulic Machinery and Systems (IAHR-Asia 2021) IOP Publishing
IOP Conf. Series: Earth and Environmental Science 1037 (2022) 012019 doi:10.1088/1755-1315/1037/1/012019

pressure in seal ring, oil pressure of different hydraulic system and pressure as net static head of the
power plant.

The water pressure monitoring in the heat exchanger ensures the functionality of cooling system of
power plant. The flow obstruction can be identified if there is differential pressure in shell & tube of
exchanger. Similarly, the sudden drop in pressure can be the indication of developing faults in heat
exchanger that affects the cooling system of power plants. Similarly, the water pressure in the seal ring
& head covers helps to know about the stress developed in the respective components and leakage
identification is possible.

The operation of hoists, valves & actuators and their operation is carried out using pressurized hydraulic
oils. The pressurized lube oil is also used at suitable pressure for the lubrication of bearing, gears and
couplings [9]. The purpose of lube oil is to continuously provide cool, clean oil to the bearings and gear
at proper pressure, temperature and flow rate [10]. Thus, the oil pressure monitoring system is an added
benefit for the safe operation of power plants.

The static pressure measurement in the inlet (P1) of turbine & outlet of draft tube (P2) in case of Francis
turbines determines the net head of power plants [11]. Net head is calculate using equation 1. In case of
thermodynamic efficiency testing (refer Figure 3), IEC 60041 has defined the process of expressing the
absolute pressure values are as water levels (middle point of measuring vessels) [12].

(1)

Figure 3. General Specific diagram of measuring vessels in thermodynamic efficiency testing [12].

The authors of [13] investigated the failure of a huge pump-turbine runner. They detected pressure
pulsations in prototype turbines, which are the cause of rotor-stator interaction, or interference between
revolving blades and stationary vanes. They have determined the cause of failure is due to the vibration
and deformation in the runner due to the pressure pulsations generated by rotor stator interaction. The
authors in [14] have also studied the pressure fluctuation in turbines flow passages and concluded that it
has coupled influence on other factors like cavitation, vibrations and turbines efficiency.

2.3. Flow (Discharge)

Flow measurement has also various applications. The authors in [6] has measured the flow of water in
the heat exchanger and labyrinth seal rings. The flow measurement is very useful to determine the rate of

4
3rd IAHR-Asia Symposium on Hydraulic Machinery and Systems (IAHR-Asia 2021) IOP Publishing
IOP Conf. Series: Earth and Environmental Science 1037 (2022) 012019 doi:10.1088/1755-1315/1037/1/012019

heat transfer from heat exchanger and labyrinth seal rings. Any obstruction in flow can be directly
identified while constantly monitoring the flow of the system and developing faults in the machine
components can be easily identified.

According to IEC 60193 (model acceptance test), discharge can be measured using primary methods
like weighing method, volumetric method moving screen method. Similarly, the secondary methods
includes velocity-area method, pitot tubes, tracer methods, thin-plate weirs, differential pressure de-
vices, electromagnetic flowmeters, acoustic or vortex flowmeters [11].

In the hydropower system, large scale discharge measurement is the most complicated parameter to be
measured and discharge is very important to determine the performance of the turbines [15] [16]. Since
power plants operates in different loading conditions, it also helps to optimize the operation of the tur-
bines. The authors in [16] have studied about the winter-Kennedy method in hydraulic discharge
measurement. It concludes, the Winter-Kennedy as a relative method of discharge measurement at low
cost & time for low head power plants based on the process of measuring differential pressure in the
radial section of spiral casing.

The author in [15] has also studied the different techniques for measuring the discharge of hydro power
plants. The author suggests, velocity-area method and pressure time method to be attractive for low and
very low head power plants, tracer method to be less popular and ultrasonic method to not have reached
the acceptance among specialist.

2.4. Oil level

As previously mentioned in 2.2 lube oils are used for the lubrication of bearings and pressurized oils are
used for operation of actuators, valves and hoists. The oil level can be another parameter in condition
monitoring for detecting the faults in the machine components. If the oil level decreases the critical level
can be the indication for development of fault in the system. The authors in [6] has measured the oil
levels in upper guide bearing, lower guide bearing and thrust bearing.

2.5. Displacement
The authors in [6] have measured the displacement of guide vane servo motor and displacement of
runner regulating oil distributor. The displacement of guide vane servo motor can be helpful to deter-
mine and regulate the angle of attack and flow control in the turbine system. Similarly, the displacement
of runner regulating oil distributor is used to change the turbine blade angle in case of Kaplan turbines.

2.6. Rotational Speed

The rotational speed is one of the important parameters in the field of condition monitoring. Power
plants operates in synchronous to variable speed, its monitoring can be helpful to determine the load
rejection of generators. According to IEC 60193 (model acceptance test), maximum runaway speed has
to be determined during the model testing of turbines in different operating conditions [11].

The authors in [17] has performed experimental and numerical investigation on the influence of rota-
tional speed and particle size on wear of hydro turbine steel. They have used slurry pot tester for their
experiments. As per their conclusion, erosion mass loss of stainless-steel increases with the increase in
the rotational velocity and particle size of slurry.

2.7. Cavitation
Cavitation in hydraulic machinery causes undesirable outcomes such as flow instabilities, excessive
vibrations, material surface damage, and machine performance loss. [18]. According to the author,
cavitation can manifest itself in hydraulic turbines in a variety of ways, depending on the machine design
and operating conditions, resulting in excessive vibration levels, instabilities, and erosion, all of which
invalidate equipment functioning and cause damage. In hydraulic turbines, they have identified three
types of cavitation: inlet leading edge cavitation, outlet bubble cavitation, and draft tube swirl. The

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3rd IAHR-Asia Symposium on Hydraulic Machinery and Systems (IAHR-Asia 2021) IOP Publishing
IOP Conf. Series: Earth and Environmental Science 1037 (2022) 012019 doi:10.1088/1755-1315/1037/1/012019

induction of cavitation also causes structural vibrations, acoustic emissions, and hydrodynamic pressure,
according to the authors. Also, authors add, the unstable leading-edge capitation causes vibration on the
runner blades which propagate through mechanical system and their detection is carried out using vi-
bration measurement in turbine guide bearing pedestal. Similarly, for outlet bubble cavitation on runner
blades, authors had suggested for radial vibration measurement in turbine guide bearing and pressures in
the draft tube wall. In case of draft tube swirl, the authors describe the adequate technique to measure the
draft tube wall pressure to identify the pulsation directly from the low frequency spectrum.

The authors in [19] have discussed on the detection of erosive cavitation on hydraulic turbines that uses
demodulation technique of the envelope of the high frequency signals. They have used a bandpass filter
for envelope of signal followed by Hilbert transform and finally Fast Fourier Transform (FFT). In the
resulting spectrum, the presence of hydraulic frequencies such as RSI indicates the erosive cavitation.
For the measurement, they had used accelerometers, acoustic emission sensors and microphone as
shown in Figure 4.

Figure 4. Experiment setup for erosive cavitation detection [19].

The authors of [20] looked into using a psychoacoustic technique to identify cavitation in centrifugal
pumps. They used a microphone to demonstrate a new method of monitoring cavitation in a centrifugal
pump. Multiple sound signal measurements and descriptors could be tremendously valuable in charac-
terizing all stages of cavitation. They retain all of the advantages of traditional acoustic emission de-
tection, such as low cost, ease of implementation, and operation, while also making it more resilient to
background noise and hence ideal for an industrial environment.

2.8. Vibration
Vibration of equipment has been a serious concern in hydropower stations, according to the authors'
review in [21], causing catastrophic equipment failure and power plant shutdown. The shaft vibration,
bearing absolute vibrations, turbine cover vibrations, thrust bearing axial vibration, stator core vibra-
tions, stator bar vibrations, and stator end winding vibrations are all included in vibration monitoring.
Low frequency accelerometers have been recommended for monitoring the absolute vibration of the
bearings and turbine cover.

Vibration on the spinning machinery of the turbine runner might be caused by any of the following
factors. Mechanical imbalance, misalignment, cavitation, turbine bearing instability, rough zone oper-
ation, incorrect lubrication of mechanical parts, faulty bearing, wicket gate linkage failure, cracked or
chipped blades and shaft are some of them. [21].

6
3rd IAHR-Asia Symposium on Hydraulic Machinery and Systems (IAHR-Asia 2021) IOP Publishing
IOP Conf. Series: Earth and Environmental Science 1037 (2022) 012019 doi:10.1088/1755-1315/1037/1/012019

The authors in [22] have presented the vibrational analysis to diagnosis the problems in the machines.
The study has focused on the change of vibration level due to different operation condition of turbines
due to increasing and decreasing water reservoir level at different seasons. They have used two accel-
erometers for measuring the vibration, pressure transducers for measuring pressure and OneProd MVX
for monitoring system.

In the other study, authors of both paper [6] [14] have used sensors for measuring vibration in the fol-
lowing position as shown in Table 2. In their hydropower system, they have measured radial vibration of
the upper guide bearing, axis flange and turbine guide bearing. Similarly, they have measured horizontal
vibration of upper pedestal and stator base. They have also used key phase signal for determining the
vibration of shafts.

Table 2. Vibration measurement position and sensors used [14]

Measurand Location Sensor adopted Number

Radial vibration in +X/+Y directions of the upper guide bearing electro-vortex sensor 2
Radial vibration in +X/+Y directions of the axis flange electro-vortex sensor 2
Radial vibration in +X/+Y directions of the turbine guide bearing electro-vortex sensor 2
Horizontal vibration in +X/+Y directions of the upper pedestal low-frequency vibration 2
sensor
Horizontal vibration in +X/+Y directions of the stator base low-frequency vibration 2
sensor
Horizontal and vertical vibrations in +X/+Y directions of the upper low-frequency vibration 4
pedestal sensor
Key phase signal Electro-vortex sensor 1

3. Conclusion
Condition monitoring or predictive maintenance is being developed as a reliable tool with the recent
advancement in technologies along with the computational power of computers. Condition monitoring
can effectively predict the developing faults on machine of components in real time with the help of
measurements from different sensors installed in the power plants. The common problems in the power
plants are erosion in different components, noise, cavitation, leakage, vibration, heating etc. Monitoring
of different parameters like power output, reservoir level, temperatures, pressure, flow, oil level, dis-
placement, rotational speed, vibration and cavitation can be useful to pre determine the possible problem
that can halt the operation of power plant.

In this paper, the process of monitoring parameters has been reviewed from different authors and has
been discussed. Also, different locations for the temperature measurement have been identified and
discussed. The application of pressure measurement has been reviewed and identified for different se-
vere problems. The location & equipment for cavitation & vibration measurement has been extensively
reviewed and discussed.

Acknowledgments: This work is a part of Ph.D. study at Turbine Testing Lab, Department of Me-
chanical Engineering at Kathmandu University. The work is being facilitated by EnergizeNepal pro-
ject, FranSed project and CMHydro project (Nepal Electricity Authority) at Turbine Testing Lab.
The authors would like to express their gratitude to all of the colleagues at the turbine testing lab for their
unwavering assistance during this research.

Conflicts of Interest: The authors state that they have no competing interests in the publication of this
research.

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 3rd IAHR-Asia Symposium on Hydraulic Machinery and Systems (IAHR-Asia 2021) IOP Publishing
IOP Conf. Series: Earth and Environmental Science 1037 (2022) 012019 doi:10.1088/1755-1315/1037/1/012019

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[8] Anon 1992 Hydrogenerator - Design Manual
[9] Stewart M 2001 Centrifugal pumps vol 55
[10] Forsthoffer M 2019 Forsthoffer’s Component Condition Monitoring 77–91
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