Hydropower plays a key role in the actual energy market due to its fast response and regulation capacity. In that way, hydraulic turbines are increasingly demanded to work at off-design conditions, where complex flow patterns and cavitation appear, especially in Francis turbines. The draft tube cavitation surge is a hydraulic phenomenon that appears in Francis turbines below and above its Best Efficiency Point (BEP). It is a low frequency phenomenon consisting of a vortex rope in the runner outlet and draft tube, which can become unstable when its frequency coincides with a natural frequency of the hydraulic circuit. At this situation, the output power can significantly swing, endangering the electrical grid stability. This study is focused on the detection of these instabilities in Francis turbines and their relationship with the output power swings. To do so, extensive experimental tests for different operating conditions have been carried out in a large prototype Francis turbine (444 MW of rated power) within the frame of the European Project Hyperbole (FP7-ENERGY-2013-1). Several sensors have been installed in the hydraulic circuit (pressure sensors in the draft tube, spiral casing, and penstock), in the rotating and static structures (vibration sensors, proximity probes, and strain gauges in the runner and in the shaft), as well as in the electrical side (output power, intensity, and voltage). Moreover, a numerical Finite Element Method (FEM) has been also used to relate the hydraulic excitation with the output power swing.

Due to the increasing share of new renewable energies like wind and solar in the generation of electricity the need for power regulation and energy storage is becoming of paramount importance. One of the systems to store huge amounts of energy is pumped storage using reversible hydropower units. The machines used in these power plants are pump-turbines, which can operate as a pump and as a turbine. The surplus of electrical energy during low consumption hours can be converted into potential hydraulic energy by pumping water to a higher level. The stored energy can be converted into electricity again by operating the runner as a turbine. Due to new regulation requirements machines have to extend the operating range in order to match energy generation with consumption for the grid stability. In this paper the consequences of extending the operating range in existing pump-turbines have been studied. For that purpose, the data obtained after two years of condition monitoring were analyzed. Vibrations and pressure fluctuations of two pump-turbines of 85 MW each have been studied during pump and turbine operation. For turbine operation the effects of extending the operating range from the standard range of 45–85 MW to and increased range of 20–85 MW were analyzed. The change in vibration levels and signatures at very low load are presented with the identification of the phenomena that occur under these conditions. The influence of head in the vibration behavior is also presented. The appearance of fluid instabilities generated at part load that may produce power swing is also presented. Finally, the effect of head on the vibration levels for pump operation is shown and analyzed.

Nowadays, hydropower plays an essential role in the energy market. Due to their fast response and regulation capacity, hydraulic turbines operate at off-design conditions with a high number of starts and stops. In this situation, dynamic loads and stresses over the structure are high, registering some failures over time, especially in the runner. Therefore, it is important to know the dynamic response of the runner while in operation, i.e., the natural frequencies, damping and mode shapes, in order to avoid resonance and fatigue problems. Detecting the natural frequencies of hydraulic turbine runners while in operation is challenging, because they are inaccessible structures strongly affected by their confinement in water. Strain gauges are used to measure the stresses of hydraulic turbine runners in operation during commissioning. However, in this paper, the feasibility of using them to detect the natural frequencies of hydraulic turbines runners while in operation is studied. For this purpose, a large Francis turbine runner (444 MW) was instrumented with several strain gauges at different positions. First, a complete experimental strain modal testing (SMT) of the runner in air was performed using the strain gauges and accelerometers. Then, the natural frequencies of the runner were estimated during operation by means of analyzing accurately transient events or rough operating conditions.

Modal Analysis is an experimental technique widely used to determine the dynamic response of structures. One of the most critical part is the selection of the actuator that will excite the tested structure. In many cases, traditional exciters, such as hammers and shakers, have been used for this purpose. Nevertheless, these exciters may have the disadvantage of modifying the modal parameters (as reported in some cases) and they are difficult to be used when the structure is not accessible (confined and/or submerged). For these cases PZT-patches, that are very light structures (compared to the tested structure), have been recently used as exciters. Although, in the analyzed studies the natural frequencies of the structure have been determined using PZTs, the rest of parameters that determine the FRF (Frequency response Function) have been not obtained. This could be, because the calibration of PZTs as dynamic force transducers is a complicated task and not an information given by the manufacturers, as in other exciters used for the same purpose. This paper analyzes experimentally and analytically the use of PZT-patches as exciters for modal analysis. For this purpose, a tested structure is excited in different ways with a PZT and its response is compared with a reference case, obtained with a classical exciter. Analyses show how to obtain different modal parameters that determine the FRF of the structure, without previous calibration of the PZT. Finally, and in order to show the potential advantages of these exciters for inaccessible structures, the procedure is repeated for the same structure submerged in water, showing that PZT are much more appropriated exciters in these cases.

Nowadays, hydropower plays an essential role in the energy market. Due to its fast response