Patent Publication Number: US-2020300726-A1

Title: Method for Detecting Fatigue Damage of a Hydraulic Unit, and the Hydraulic Unit Thereof

Description:
TECHNICAL FIELD 
     The present invention concerns a method for detecting the fatigue damage of a hydraulic unit. In particular, the present invention concerns a method for detecting the fatigue damage of the hydraulic unit implementing fatigue indicators arranged for being remotely queried. 
     The present invention also concerns a hydraulic unit provided with fatigue indicators arranged for being remotely queried. 
     PRIOR ART 
     When driven into rotation, for example by a stream of water, the runner of a hydraulic machine has to endure mechanical stress whose magnitude is particularly strong at specific positions, called “hot spot”, notably located at the corners of the runner blades. 
     The cumulative effect of this mechanical stress generates fatigue, which may ultimately trigger the initiation and the propagation of cracks ( FIG. 1 ). 
     The breaking and/or the release of parts of the runner resulting from the appearance of cracks may create major damages of the hydraulic machine and cause its immobilization. 
     This effect is not limited to the runner, and other elements of the hydraulic unit, like the shaft line, the wicket gates or the pipes, are also subject to significant mechanical strain/stress. 
     It is therefore paramount to be able to estimate the fatigue and the associated remaining lifetime of these components of the hydraulic unit. 
     For this purpose, it is generally proceeded to mechanical strain measurement campaigns. 
     For example in the case of the runner, said mechanical strain measurement campaigns generally involve the positioning of gauges, notably strain gauges, in particular in the vicinity of hot spots, and an analysis of data collected by said gauges in order to deduce the mechanical stress undergone at the hot spot location. 
     However, this method is not satisfactory. 
     Indeed, the analysis of the data generally requires the establishment of a hydrodynamical model of the hydraulic unit which is cumbersome to implement. 
     Furthermore, this sequence and the measurement campaign immobilize the hydraulic turbine under test, which is therefore not available for production. In other words, the measurement campaign generates a shortfall for the operator. 
     Besides, the gauges H need to be located in the very close proximity of the specific location, and notably the hot spots, for which access is not convenient. In particular, it requires a wired connection. For example, as depicted in  FIG. 2 , the gauges H are mounted on the suction side, the pressure side, on the leading edge or on the trailing edge of the blades B. 
     In addition, depending on the duration of the mechanical strain measurement campaign, a very limited range of operating conditions can be tested. 
     Finally, the cost for executing such measurement campaign is quite high. 
     It is therefore an object of the invention to propose a method for detecting the fatigue damage of a hydraulic unit which is not as cumbersome as known prior art methods. 
     It is also an object of the invention to propose a method for detecting the fatigue damage of a hydraulic unit for which release of fatigue indicators can be prevented. 
     SUMMARY OF THE INVENTION 
     The aforementioned objects are, at least partly, achieved by a method for detecting a fatigue undergone on at least one specific location of a hydraulic unit, the method being characterized in that the fatigue undergone on the at least on specific location is detected by at least one fatigue indicator, said at least one fatigue indicator arranged for being remotely queried via wirings or via a wireless connection. 
     According to one embodiment, the at least one fatigue indicator is/are calibrated so that they are sensitive to the fatigue undergone on the at least one specific location, optionally, the at least specific location is/are locations, called hot spot, wherein the fatigue undergone corresponds to a local maximum. 
     According to one embodiment, the at least one fatigue indicator is/are positioned away from the at least one specific location. 
     According to one embodiment, the at least one fatigue indicator is/are located on a dry surface of the hydraulic unit. 
     According to one embodiment, the at least one fatigue indicator is/are located on a watered surface of the hydraulic unit. 
     According to one embodiment, the hydraulic unit comprises at least one component chosen among a hydraulic machine, a water or air circuit and valves, or a rotating electrical machine, and wherein the at least one specific location is located on at least one of the at least one component. 
     According to one embodiment, the hydraulic unit comprises a hydraulic machine provided with a runner arranged to rotate around a rotation axis as soon as said unit is in operation, the specific locations being on the runner. 
     According to one embodiment, the runner comprises blades, each having two opposite sides, respectively, pressure side and suction side, and extending from an external surface of a hollow hub, the pressure side and the suction side of the blades, the hollow hub further comprises an internal surface opposite to the external surface, the fatigue indicators are located on the internal surface of the hollow hub so that the fatigue indicators are isolated from turbulences likely to occur between the blades while the runner is triggered in rotation. 
     According to one embodiment, the at least one fatigue indicator, when detecting a fatigue above a predetermined threshold of fatigue, translate(s) said fatigue into a variation of a physical parameter, optionally, the physical parameter is an electrical resistance, or a counting of an accumulated strain. 
     According to one embodiment, the at least one fatigue indicator comprises a plate having a top face on which is located a crack gauge. 
     According to one embodiment, the plate comprises a pre-initiated crack that is designed to propagate below the crack gauge as soon as the predetermined threshold of fatigue is reached, optionally, the pre-initiated crack is guided in a groove formed on a bottom face of the plate opposite to the top face, and extending along a first direction. 
     According to one embodiment, the crack gauge comprises an electrical resistance made of conductive wires arranged perpendicularly to the first direction on the top face, and designed to selectively, advantageously successively, break depending on the magnitude of the fatigue causing the propagation of the pre-initiated crack, optionally the conductive wires are arranged along the first direction in order of increasing length. 
     According to one embodiment, the at least one fatigue indicator comprises a central section connecting two lateral sections, the central section being designed to break as soon as the predetermined threshold of fatigue is reached, optionally the two lateral section have a flat shape. 
     According to one embodiment, the method further comprises the collection of the variation of the physical parameter by a data acquisition system via a wireless connection, optionally, the operating conditions of the hydraulic unit are collected by the data acquisition system. 
     The invention also concerns a hydraulic unit which comprises at least one fatigue indicator, the at least one fatigue indicator arranged for being remotely queried via wirings or via a wireless connection, and sensitive to a fatigue undergone on at least one specific location of the hydraulic unit. 
     According to one embodiment, the at least one fatigue indicator is/are calibrated so that they are sensitive to the fatigue undergone on the at least one specific location, optionally, the at least specific location is/are locations, called hot spot, wherein the fatigue undergone corresponds to a local maximum. 
     According to one embodiment, the at least one fatigue indicator is/are positioned away from the at least one specific location. 
     According to one embodiment, the at least one fatigue indicator is/are located on a dry surface of the hydraulic unit. 
     According to one embodiment, the at least one fatigue indicator is/are located on a watered surface of the hydraulic unit. 
     According to one embodiment, the hydraulic unit comprises a hydraulic machine provided with a runner arranged to rotate around a rotation axis as soon as said unit is in operation, the specific locations being on the runner. 
     According to one embodiment, the runner comprises blades, each having two opposite sides, respectively, pressure side and suction side, and extending from an external surface of a hollow hub, the pressure side and the suction side of the blades, the hollow hub further comprises an internal surface opposite to the external surface, the fatigue indicators are located on the internal surface of the hollow hub so that the fatigue indicators are isolated from turbulences likely to occur between the blades while the runner is triggered in rotation. 
     According to one embodiment, the at least one fatigue indicator, when detecting a fatigue above a predetermined threshold of fatigue, translate(s) said fatigue into a variation of a physical parameter, optionally, the physical parameter is an electrical resistance, or a counting of an accumulated strain. 
     According to one embodiment, the at least one fatigue indicator comprises a plate having a top face on which is located a crack gauge. 
     According to one embodiment, the plate comprises a pre-initiated crack that is designed to propagate below the crack gauge as soon as the predetermined threshold of fatigue is reached, optionally, the pre-initiated crack is guided in a groove formed on a bottom face of the plate opposite to the top face, and extending along a first direction. 
     According to one embodiment, the crack gauge comprises an electrical resistance made of conductive wires arranged perpendicularly to the first direction on the top face, and designed to selectively, optionally successively, break depending on the magnitude of the fatigue causing the propagation of the pre-initiated crack, optionally the conductive wires are arranged along the first direction in order of increasing length. 
     According to one embodiment, the at least one fatigue indicator comprises a central section connecting two lateral sections, the central section being designed to break as soon as the predetermined threshold of fatigue is reached, optionally the two lateral section have a flat shape. 
     According to one embodiment, the method further comprises the collection of the variation of the physical parameter by a data acquisition system via a wireless connection, optionally, the operating conditions of the hydraulic unit are collected by the data acquisition system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other characteristics and advantages shall appear in the following description of embodiments of a method for detecting the fatigue damage of a hydraulic unit according to the invention, given by way of non-limiting examples, in reference to the annexed drawings wherein: 
         FIG. 1  represents a crack (zone labelled “A”) on a corner of a blade of a runner; 
         FIG. 2  is a photograph representing strain gauges installed on the suction side of a blade of a runner; 
         FIG. 3  represents a hydraulic unit in a perspective view, in particular, the hydraulic unit comprises a hydraulic Francis turbine and a synchronous generator; 
         FIG. 4 a    is a schematic representation of a hydraulic turbine of  FIG. 3  according to a section plan, in particular, the runner is provided with a fatigue indicator located on the internal surface of the hollow hub; 
         FIG. 4 b    is another schematic representation of a hydraulic turbine of  FIG. 3  according to a section plan, in particular, the runner is provided with a fatigue indicator located on the internal surface of the hollow hub; 
         FIG. 4 c    is a schematic representation of a Pelton runner, in particular, the runner is provided with a fatigue indicator; 
         FIG. 5  is a perspective view of a Francis runner blade, the grey levels are associated with the magnitude of the local stresses undergone by the blade while the stream of water is flowing through the runner. 
         FIG. 6  is a perspective view of a plate of a fatigue indicator according to the present invention, presenting a pre-initiated crack in a groove on its bottom face; 
         FIG. 7  is a plan view of a crack gauge from Kyowa implemented in a first embodiment of the present invention; 
         FIG. 8  is a plan view of a fatigue indicator implemented in a second embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS 
     The present invention concerns a method for detecting a fatigue damage of a hydraulic unit. 
     By “fatigue”, it is meant a weakening of a material caused by repeatedly applied loads. It is the progressive and localized structural damage that occurs when a material is subject to cyclic loading. In particular, fatigue occurs when a material is subject to repeated loading and unloading. If the loads are above a predetermined threshold, microscopic cracks will begin to form. 
     In particular, in the present invention, the fatigue is detected with fatigue detectors arranged for being remotely queried, for example via wirings or via a wireless connection. 
     As a very specific example, the fatigue detectors may be implemented for detecting the fatigue undergone on surfaces, called hydraulic surfaces, which delimit a hydraulic channel of the hydraulic unit. 
     In the context of the present invention, the term “hydraulic channel” means a channel that is delimited by hydraulic surfaces, said hydraulic surfaces being the surfaces against which a stream of water exerts the forces when the hydraulic unit is operated in a watered mode. The hydraulic channel also comprises the pipes through which flows the stream of water flows, for example the penstock. 
     It is also understood that the watered surfaces of the hydraulic unit, when operated in a watered mode, are not limited to the hydraulic surfaces. In particular, the hydraulic unit comprises also other surfaces, called protected surfaces. So-called protected surfaces may either be surfaces that get wet by a portion of the stream of water, which flow rate is lower than in the hydraulic channel, for example the internal surface of the hub. Alternatively so-called protected surfaces may be surfaces that remain dry, for example on the external surface of the penstock. 
     According to the present invention, a hydraulic unit comprises a hydraulic machine as well as the water or air circuit (penstock) and valves (spherical or butterfly valves) necessary for its operation. The hydraulic machine can comprise a hydraulic turbine mechanically coupled to a rotating electrical machine. The rotating electrical machine may be a synchronous or an asynchronous generator or a motor-generator. 
     In a particular embodiment, the method may be implemented for detecting fatigue damage of the hydraulic machine of the hydraulic unit, and in particular of the runner of the hydraulic machine. 
     The hydraulic machine can be used in turbine mode for electrical power generation and/or in pump mode for pumping water and/or in condenser mode. 
     Furthermore, the fatigue indicators, depending on their sensitivity, allow to detect, in an early stage, the appearance of cracks in specific locations, for example remote from the areas where said fatigue indicators are located. It is therefore possible, depending on the fatigue damage, to plan inspection or maintenance operation of the hydraulic unit. 
     In particular, the method according to the present invention may be advantageously executed for monitoring the fatigue of the runner, and more particularly of the blades, before occurrence of failure and or cracks. 
     Alternatively, the method according to the present invention may also be advantageously executed for monitoring fatigue damage of components of the generator. As a very specific example, a fatigue indicator according to the present invention is implemented for monitoring the fatigue damage of the rotor spider. In particular, the fatigue indicator is placed on the rotor spider, for example before its commissioning. Therefore, according to the present invention, the monitoring of the fatigue damage of components like the rotor spider for which access is difficult is rendered easier than known prior art technics. The invention provides the benefit that the fatigue damage can be remotely evaluated. 
     It will be appreciated that the invention is not limited to these particular examples and the method may be applied to detect the fatigue damage of any components of the hydraulic unit. 
     The invention will now be described in the context of the turbine mode. However, the skilled person, considering his general knowledge and the following description, can generalize the invention to other modes of operation of the hydraulic machine and in particular the pump and condenser modes. 
       FIG. 3  depicts an overall architecture of a hydraulic unit  10  according to the present invention. 
     The hydraulic unit  10  comprises a generator  20  connected to a grid. The generator may comprise a synchronous generator, an asynchronous generator, a motor generator. 
     It is understood that, without it being necessary to specify, the generator comprises a rotor arranged to rotate inside a stator whose windings are connected to the grid. 
     The hydraulic unit  10  further comprises a hydraulic turbine  30  provided with a runner  40  mechanically coupled to the rotor of the synchronous generator  20  via a shaft line  50  extending along a rotation axis XX′. 
     While in use, the runner is driven into rotation by a stream of water flowing through the runner, and in particular flowing through a hydraulic channel. 
     By “hydraulic channel”, it is meant a flow channel through which the stream of water exerts the forces required to trigger the rotation of the runner. 
     In particular, the hydraulic channel is delimited by hydraulic surfaces, said hydraulic surfaces being the surfaces against which a stream of water exerts the forces when the runner is driven in rotation by said stream of water. The hydraulic channel also comprises the pipes through which flows the stream of water. 
     Within the runner, the hydraulic channel is delimited by surfaces of said runner  40  which are directly exposed to hydraulic perturbations stemming from the flowing of the stream of water. 
     The runner  40  further comprises at least one fatigue indicator F. 
     The at least one fatigue indicator F can be remotely queried via wirings or via a wireless connection. 
     By “fatigue indicator”, it is meant an indicator sensitive to stress cycles (i.e.: fatigue) undergone by the probed device (for example the runner) to which it is coupled. In particular, when the hydraulic unit accumulates repeated loads, on a specific location, above a given threshold, the fatigue indicator modifies its structure irreversibly. Notably and as a non-limiting example, the structural modification of the fatigue indicator involves the breaking of connections which translates into a modification of the electrical resistivity of said indicator. 
     The at least one fatigue indicator may be located on watered or dry surfaces. 
     In particular, the at least one fatigue indicator F is/are calibrated so that they are sensitive to the fatigue undergone on the at least one specific location. 
     By “sensitive”, it is mean that the fatigue indicator can detect damage. 
     For example, the at least specific location is/are locations, called hot spot, wherein the fatigue undergone corresponds to a local maximum. 
     By “local maximum”, it is meant that it exists a region comprising the specific location so that the mechanical stress on said specific location is above the mechanical stress on any other location of said region. 
     Optionally, the at least one fatigue indicator F may be positioned away from the at least one specific location. 
     It is therefore possible to remotely probe the fatigue of specific location for which access is not convenient. 
     For example, the at least one fatigue indicator F may be located on at least one area, called protected area, positioned away from the hydraulic channel ( FIGS. 4 a  and 4 b   ). 
     By “positioned away from the hydraulic channel”, it is meant a fatigue indicator not exposed to and not perturbing the stream of water flowing through the hydraulic channel when the hydraulic machine is in operation. In other words, the fatigue indicator is in an area, called protected area, remote from the hydraulic surfaces. 
     The inventors have noted that the cumulative effect of repeated loads affects the runner as a whole. In particular, the loading effect on the runner, whatever the considered location, depends on the operating conditions and the mechanical characteristics of the runner. More precisely, considering said operating conditions and mechanical characteristics, the accumulated strain or stress on a particular location of the runner can be deduced from the knowledge of the accumulated strain or stress on any other location. 
     Therefore, a fatigue indicator located on an area provides indications of the accumulated strain or stress on other locations of the runner, and for example on specific locations of the hydraulic surfaces of the runner. 
     Notably, the specific locations are locations, called hot spots, wherein the mechanical stress undergone, while the runner is rotating, corresponds to a local maximum. 
     To this regard, the  FIG. 5  is a perspective view of a Francis runner blade. The grey levels are associated with the local stress undergone by the blade while the stream of water is flowing through the runner. It can be noted in this  FIG. 5  that the stress undergone by the blade (location A) in the corner at the intercept of the trailing edge  43   a  and the hollow hub  44  are quite high with respect to the rest of the blade. 
     The fatigue indicator may be calibrated to detect a damage on a specific location of the runner when fatigue of said specific location is above a given fatigue damage threshold. 
     The method can comprise the implementation of a plurality of fatigue indicators F calibrated to detect different damage magnitudes. 
     According to this configuration, it is possible to evaluate the magnitude of the damage undergone by the runner. 
     The implementation of the aforementioned concepts are not limited to the runner, and can be generalized to other elements of the hydraulic unit, and notably, for example, to the shaft line, the valves, the wicket gates, the pipes, the generator. 
     The calibration of the fatigue indicators can be based on numerical simulations. In particular, the numerical simulations can involve computational fluid dynamics for calculating pressure loading on the runner, and finite element analysis of the stress stemming from said pressure loading. 
     To this regard, the skill in the art can consult the document [1] cited at the end of the description. 
     Alternatively, the calibration of the fatigue indicators may be executed during a learning period or in a reduced scaled model of the runner. 
     By “reduced scale model”, it is meant a laboratory hydraulic machine and whose size or footprint is advantageously reduced with respect to the hydraulic machine. 
     A complementary calibration, based on the material and the geometry of the fatigue indicator, may be executed to determine propagation velocity within said fatigue indicator. 
     For example, the runner is a Francis runner that comprises blades  43 , each having two opposite sides called, respectively, pressure side and suction side, and extending from an external surface  44   a  of a hollow hub  44 , having for example a conical shape ( FIGS. 4 a  and 4 b   ). 
     The blades  43  may be further secured on the periphery of the runner by a peripheral shroud  47  ( FIGS. 4 a  and 4 b   ). 
     The hub further comprises an internal surface  44   b  opposite to the external surface  44   a.    
     The hydraulic channel of a Francis runner is delimited by the pressure sides and the suction sides of the blades, and by the external surface of the hollow hub  44 . 
     According to this configuration, the fatigue indicators may be located on an internal surface  44   b  of the hollow hub  44 , opposite to the external surface, so that said indicators are isolated from the stream of water circulating through the hydraulic channel when the hydraulic machine is in operation. For example, the fatigue indicators may be glued, welded or mechanically secured to the internal surface ( FIGS. 4 a  and 4 b   ). 
     In another example illustrated in  FIG. 4 c   , the runner is a Pelton runner. 
     The fatigue indicators, when detecting a damage above a predetermined threshold of damage, translate said damage into a variation of a physical parameter. According to one example, the physical parameter is an electrical resistance. 
     Alternatively, the physical parameter is a counting of an accumulated strain or stress or loading. To this regard, the fatigue indicator may be provided with a processor configured to execute the counting of the strain or the loading. 
     Advantageously, each fatigue indicator comprises a plate  50  having a top face  51  on which is located a crack gauge G 1  ( FIG. 6 ). 
     In particular, the plate  50  may comprise a pre-initiated crack  53  that is designed to propagate below the crack gauge G 1  as soon as the predetermined threshold of fatigue is reached. 
     The formation of the pre-initiated crack enhances the sensitivity to stress accumulation (or fatigue) of the fatigue indicator and therefore makes it possible to anticipate at a very early stage the appearance of cracks on the specific locations. 
     The sensitivity of the fatigue indicator may be further enhanced by suspending the plate of said fatigue indicator on two pedestals. 
     It is thus possible to plan inspections and maintenance before the occurrence of major failure of the component of the hydraulic unit, and thus extend its lifetime. 
     By “lifetime”, it is meant a time before a failure occurs on the runner under specific operating conditions. 
     Advantageously, the pre-initiated crack is guided in a groove formed on a bottom face of the plate opposite to the top face, and extending along a first direction Z. 
     According to a first embodiment of the present invention illustrated in  FIG. 7 , the crack gauge G 1  may comprise an electrical resistance made of conductive wires CW 1  arranged perpendicularly to the first direction Z on the top face, and designed to selectively break depending on the magnitude of fatigue damages causing the propagation of the pre-initiated crack. In other words, the number of broken conductive wires depends on the magnitude of damage detected in the specific locations. 
     Advantageously, conductive wires CW 1  are arranged along the first direction in order of increasing length. 
     According to a second embodiment of the present invention illustrated in  FIG. 8 , each fatigue indicator F can comprise a central section CS connecting two lateral sections LS 1  and LS 2 , for example, having a flat shape. The central section is a zone of weakness wherein the stress undergone by the fatigue indicator accumulates. In particular, the central section is designed to break as soon as the predetermined threshold of fatigue is reached as described in document [2] cited at the end of the description. 
     Whatever the embodiment considered, the method may comprise the collection of the variation of the physical parameter by a data acquisition system connected, via wirings or a wireless connection, to the at least one fatigue indicator. 
     In particular, the wirings may pass along the shaft line of the hydraulic unit. Optionally the wirings are housed in a groove formed along the shaft line. 
     In particular, the wirings may pass along the shaft line  50  of the hydraulic unit ( FIG. 4 ). 
     Optionally the wirings are housed in a groove formed along the shaft line. 
     Alternatively, the shaft line  50  is a hollow shaft inside which the wiring passes. 
     A coupling flange (having for example a disk shape) at one end of the shaft line  50  can ensure the securing of said shaft line to the runner. In particular, the wirings can pass along a groove formed on the coupling flange for connecting the at least one fatigue indicator. 
     The hydraulic unit can also comprise measurement means for measuring parameters like torque fluctuations experienced by the shaft line, bearing vibration and shaft line displacement or hydraulic pressure pulsations. 
     These parameters define operating conditions which directly affect the lifetime of the runner, and can therefore be transferred via wirings or via a wireless connection to the data acquisition system. 
     The fatigue indicators installed, when located on protected areas, do not interfere with the stream of water driving into rotation the runner, so that their release is prevented. 
     Consequently, the fatigue indicators can be permanently installed on the runner. 
     Dewatering/rewatering sequence are not anymore necessary so that the cost associated with a fatigue detection of the hydraulic turbine according to the present invention is limited compared to the method known from prior art. 
     The invention also concerns a hydraulic unit which comprises at least one fatigue indicator, the at least one fatigue indicator arranged for being remotely queried via wirings or via a wireless connection, and sensitive to a fatigue undergone on at least one specific location of the hydraulic unit. 
     The at least one fatigue indicator F is/are, optionally, positioned away from the at least one specific location. 
     REFERENCES 
     
         
         [1] Pierre-Yves LOWYS et. al., “hydro plant operating range extension transverse approach for increasing turbine flexibility”, hydrovision International 2014, Track H: Technical paper; 
         [2] EP 0 032 101.