Hindawi

Advances in Materials Science and Engineering

Volume 2022, Article ID 2542447, 7 pages
https://doi.org/10.1155/2022/2542447

Research Article
Effect of Cavitation with Vibration on the Powerhouse Structure of
Bulb Turbines Installed in Hydropower Stations

Praveen S,1 Marimuthu S ,1 Manivannan S ,2 Daniel Das A ,1

and Gizachew Assefa Kerga 3
1
Department of Mechanical Engineering, Karpagam Academy of Higher Education, Coimbatore, Tamil Nadu, India
2
Centre for Material Science, Department of Mechanical Engineering, Karpagam Academy of Higher Education, Coimbatore,
Tamil Nadu, India
3
Department of Chemical Engineering, College of Biological and Chemical Engineering,
Addis Ababa Science and Technology University, Addis Ababa, Ethiopia

Correspondence should be addressed to Marimuthu S; [email protected] and Gizachew Assefa Kerga;

[email protected]

Received 8 July 2022; Revised 3 August 2022; Accepted 13 August 2022; Published 3 October 2022

Academic Editor: Samson Jerold Samuel Chelladurai

Copyright © 2022 Praveen S et al. This is an open access article distributed under the Creative Commons Attribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Hydro energy is one of the world’s most abundant and valuable renewable electricity sources. Hydropower is an important source since
it is a clean, sustainable, and cost-effective source of energy. The most perilous characteristic that affects the performance of the hydraulic
turbine and its allied parts is the cavitation phenomenon, which is clear as the increase of vapor bubbles in the liquid through any
hydraulic turbine. Cavitation causes vibration, which is very harmful to turbine guide bearings and their supporting structures.
Sometimes heavy vibration causes cracks in the civil structure of the powerhouse where the bulb turbines are installed. The performance
of the bulb turbine and the stability of the powerhouse structure are studied with the effect of cavitation, vibration, and deformation of
the turbine casing. Experimental measurements are used to determine at what force the shape of cavitation is very destructive and crucial
when the local pressure is less than the vapor pressure of the flowing water, at which static pressure cavities begin to breed and ruin. This
paper focuses on small hydropower stations with bulb turbine installations, which emphasized the performance improvement of these
turbines by avoiding cavitation on the runner blades. Allowing some cavitation on these machines is also recommended, which is within
repairable condition, and the cavitation pitting can be repaired during annual maintenance.

1. Introduction associated with power production under off-design loads [3]

like differences in pressure, vortex fluctuations, and the
Modern years have seen a steady rise in the amount of grid- inception of cavitation and resonance. Hydro turbines may
connected wind, solar, and other electricity generated as a be able to attain a high ramping rate by operating at constant
result of a favorable environment and an on-demand energy speeds [4].
market. Instability in the grid’s functioning has been caused Constant-speed turbines have the runner’s rotational
by the over-penetration of intermittent energy [1]. As a speed constant and operate along with a synchronous speed
result of this expectation, customers are more or less con- line. The guiding vane opening controls the power output.
fident that they will be capable of drawing a bigger or less Two factors may be employed to operate the turbine best in
quantity of grid electricity as needed, and they suppose the variable-speed mode: water passing through guide vanes and
grid to accommodate this. Hydro turbines of the future must the speed of the runner. The synchronizing operation brings
be able to generate a variety of forms of energy [2]. The the input frequency to 50 Hz before joining with the grid to
hydroturbines must function outside the specified area, with achieve speed variation [5]. In order to bind, the effects of
recurrent start-stop and ramping. There are certain issues vortex fluctuation, resonance, live loading, rotational
2 Advances in Materials Science and Engineering

swiftness, and flow rate may be accustomed. It is possible to disintegrate when they enlarge and increase following the
enhance performance in nondesign circumstances [6]. general fluid motion and then unexpectedly disappear [12].
Cavitation is one of the most essential issues since it causes
erosion and lowers the efficiency of hydro turbines. 2. Cavitation in Hydro Turbines
Pressure and temperature distress a liquid’s thermody-
namic phase. The tensile tension that occurs among the Cavitation in hydraulic machinery has objectionable effects,
molecules of water is affected by its peaks and valleys in the for instance flow instabilities, excessive vibrations, material
above parameters. During cavitation, which happens when surface damage, and machine performance loss. Inappro-
the tensile pressure is superior to the leaping force, mole- priately, these problems are fetching added seriousness as
cules breakdown apart and the water converts into a vapor, the intensity of cavitation rises. The first and primary re-
creating a cavity [7]. The cavitation formation may be quirement for increasing the output power of a turbine is
uniform or mixed, liable to the existing environment. For based on shrinking its size to diminish the cost of its
example, in hydro turbines, nuclei progress on the other side components. Hence, the cavitation number is decreased and
of the runner vane or at the borderline between liquid and the speeds are increased.
inner particles, representing mostly heterogeneous nucle- Subsequently, due to the deregulation of the hydropower
ation. Hydro turbine cavitations consist of transit bubble generation sector, there is a good trend to run turbines in
formation and it continues until it bursts at the higher- settings away from the finest competence position, and
pressure region [8]. Many experts have researched turbine cavitation events are most likely brought beneath away from
cavitation during the last two decades. For example, cavi- setting values. As a result, the combined effect of these el-
tation-caused erosion and the creation of nuclei, high-fre- ements increases the likelihood of cavitation issues in hy-
quency vibrations, and noise were all examined in the draulic machinery. Because correction methods are not easy
investigations. Adjustable speed and starting-stopping to implement in operating units, observation and operating
cavitation are significantly unlike cavitation under stable methods that detect cavitation during operation and help to
circumstances of the runner or added simpler situations, overcome dangerous circumstances are the finest option.
such as hydrofoils [9]. As a result of less environmental value The methods for detecting cavitation are based on the
and low operating and maintenance charges for the world’s machine’s caused vibrations and pressures. Because hy-
electricity source, hydroelectric power plants are the utmost dropower generation is unaffected, this strategy is advan-
important renewable energy source. Hydraulic power has a tageous. These detection approaches are created using a basic
lot of promise that has yet to be realized. Hydroelectricity is understanding of the cavitation phenomenon and will be
one of the most environmentally friendly and long-term employed in actual prototypes. As a result, due to cavitation,
clean energy sources available. Because hydroelectric power it can take many forms and ascend in innumerable areas
facilities do not consume fuel and do not contaminate the depending on the machine’s working circumstances, and
air, they do not emit greenhouse gases. They help to avert hence its proper application becomes more complicated
global warming by taking preventative measures. Hydro- [13].
electric power accounts for roughly 16% of global electricity Cavitation happens when vapor bubbles form in a liquid
output. Thermal power facilities harm the environment as a result of a hydraulic turbine. Dynamic pressure fluc-
more than hydroelectric power plants. The quantity of en- tuations can occur in hydro turbines. When the local
ergy produced by a water source in a hydropower plant is pressure drops below a certain level, vapor pressure cavities
determined by the amount of water and the water head. The form as well as grow. Formation and expansion are the two
turbine type to be employed is decided by these two primary phases of such a hollow. When the pressure rises, the
characteristics. The different types of turbines are separated bubble’s growth is reversed, and it suddenly bursts. Refer-
into two classes: impulse turbines and reaction turbines [10]. ence [14].
The turbine type to be employed is decided by these two The succeeding effects on hydraulic machinery are
primary characteristics. The different types of turbines are caused by the cavitating flow: Low-pressure cavities formed
divided into two categories: impulse turbines and reaction amongst the guiding vane blades and the turbine runner
turbines. In comparison to the reaction turbine, the mod- lowered the cross-sectional area. As the discharge and power
ification of the runner blades in the bulb turbine is adjustable shrink, so does the cross section area shrink. The efficiency of
and able to be moved about the pivots fixed to the runner the turbine declines from 5% to 10% when the bubbles break.
boss. Hydraulic machinery Cavitation causes undesirable The inner surface of the turbine casing will be eroded by
outcomes such as water disturbances, severe vibrations, cavitation erosion. Such damaged surfaces grow as a result of
surface quality damage, and machine performance loss [11]. continuous cavitation. When erosion rates increase, material
If the vigor in any region of a hydraulic turbine’s hydraulic particles come out from the inner surface. Cavitation causes
flow, which is in the way of travel amidst the governing unstable radial hydraulic forces on the turbine runner and in
blades or the turbine blades, falls underneath the water’s turbine-generator guide bearings. Vibration and oscillation
evaporation pressure, the water in that region will evaporate, are caused by these instabilities, which are harmful to the
resulting in the development of vacuum volumes occupied above bearings [15]. With partial load, large vortex cavita-
with saturated water vapor inside. High volume impacts tion occurs in the draught tube, which lowers the compe-
induced by the influence of water droplets on the surface at a tence of the draught tube and hence the turbine extends
very great speed degrade the material surface by creating it to from 2% to 5%.
Advances in Materials Science and Engineering 3

(a) (b)

Figure 1: 2D hydrofoil cavitation: (a) travelling bubbles; (b) unstable attached sheet.

2.1. Travelling Bubbles. Bubbles are formed that cover the

body with very small and tiny nuclei in the vacuum regions
of the flow shown in Figure 1. The breakdown is when they
come into an unfavorable pressure gradient while traveling
with the flow. The amount of air in the liquid has a big
impact on these bubbles. Their erosive power, however, is
supposed to be relatively feeble. The premise that a lonely
bubble will continue spherical in an infinite liquid can be
used to represent it [16]. The Universal Rayleigh–Plesset
equation is a lawful estimation growth of the bubble in this
situation, and it is resolved to obtain the bubble dimensions.

2
PB (t) − P∞ (t) d2 R 3 dR 4v dRB 2c
� RB 2B + 􏼠 B 􏼡 + + .
ρ dt 2 dt RB dt ρRB
Figure 2: Travelling bubble cavitation.
(1)
In the form of separated bubbles, these bubbles are damage in the case of a natural frequency coupling
related to the vacuum side of the blade in the middle of the phenomenon.
runner vane adjacent to the trailing edge. Due to the low To progress in the channels between the blades, which in
Thomas number, these traveling bubbles begin to progress, turn produces the vortex, the flow separation is caused by the
and they expand in size when the machine is overloaded and occurrence of dissimilarities from the hub to the band, which
operating at its greatest flow rate [17]. According to Figure 2, causes secondary vortices. It is possible to fix them at the
(a) kind of cavitation causes substantial machine downtime junction of the runner’s top edge or midway between blades
and even leads to blade erosion. near the suction side of the crown [18]. When the tips of the
runner vane are in contact with the blade area, they are
capable of damaging the track. At low loads, these vortices
2.2. Vortex Cavitation. Vortices advances in water-flowing emerge and provide a high amount of wideband noise. It is
areas with cavitation formation due to the vacuum. The promising for them to look and cavitate at exceptionally high
vortices make a potentially erosive atmosphere since the head operation ranges. This causes them to become un-
cavity’s bursting of bubbles occurs on them when the tips of balanced, resulting in a significant quantity of shaking.
these vortices with vapor content come into touch with a Compared to Francis turbines, Kaplan turbines have a
solid face. This sort of cavitation can form if Von Karman lower risk of leading-edge cavitation. When running in on-
vortex-shedding happens at the end of the hydrofoil where cam mode, the machine’s runner vanes have a changeable
the pressure becomes a vacuum, as shown in Figure 3. This dimension. As a result, the draught tube swirl is more than in
results in lift fluctuations in lockstep with the frequency of Francis turbines as well. Due to the greater blade loading,
shedding. When hydraulic equipment is functioning at part traveling bubble cavitation may also occur on the vacuum
load, cavitation due to vortex can happen in the water path. side of the runner vane. Tip vortex cavitation is a kind of
Vortices advance in water-flowing areas with cavitation Kaplan turbine cavitation that is all its own. The gap between
formation due to the vacuum. This can cause exhaustion the tip of the blade and the case is where the cavitation
4 Advances in Materials Science and Engineering

occurs [19]. This cavitation destroys a region along the

middle portion of the blade at the suction side, due to the tip
of the vortex meeting the runner vane area, as a result of
which the tip of the vortex meets the runner vane area. The
tip of the blade might also be eroded.

2.3. Draft Tube Swirl. Directly below the runner cone, is

created the draught tube’s cavitation vortex-core flow. On
the left, the circumferential velocity of the flowing water is
cleared from the blade, its volume is dependent on the plant
cavitation factor and it occurs between a partial load to an
overload condition. Vortices travel counterclockwise
whereas under half load and clockwise when overloaded. The
accurate speed of 0.25–0.35 times turbine rotational swift- Figure 3: Von Karman vortex-shedding 2D hydrofoil.
ness is seen in the vortex core from 50% to 80% of the finest
proficiency flow rate. In this occurrence, the low frequency is
powerhouse structure. Figure 5 shows the Kaplan Turbine
used to produce pulsations of circumferential pressure. If the
schematic diagram.
occurring frequency coincides with the draught tube’s
The appearance of cavitation has a noteworthy impact on
natural frequency oscillation if any, large variations result.
the system’s power generation. In general, as ambient
The turbine and even the powerhouse are subjected to severe
pressure drops, the lift and drag numbers of a hydrofoil do
vibrations as a result of the pressure variation due to the
not change; pressures are caused on the lower surfaces as
bubble burst inside the draught tube [20]. The draught tube
well as by a decrease in lockstep. The pressure on the top
cone is axially centered once the vortex has passed the point
surface is constrained by the vapour pressure and cannot be
of greatest efficiency. Large changes are caused because the
reduced, nevertheless, as cavitation happens along the upper
occurring frequency and the draught tube’s natural fre-
surface of the foil. On the other hand, the pressure on the
quency oscillation are in the same phase. The vibrations are
lowest surface is not limited and continues to fall, pro-
really strong around the turbine and even the powerhouse.
gressively approaching that on the top of the foil. When the
The bubble inside the draught tube ruptured as a result of the
pressure differential across the foil reduces, the lift coeffi-
pressure change.
cient drops as well. Furthermore, the resulting shift in the
geometry of the pressure scattering causes drags to rise. As a
3. Turbine Setting Level result, cavitation reduces lift and upturns drag, limiting
The position Hs in Figure 4 that regulates the pressure with power generation and worsening system loads.
respect to the vapor pressure beginning is the machine’s setting To categorize cavitation in real-world machinery,
level. Highly depending on this level, bubble cavitation occurs measurement and analysis of brought-out signals are used.
even at the machine’s highest efficiency point. The cavitation It’s not a simple process to detect since the location, be-
factor of a hydraulic turbine is influenced by the value [21]. The havior, and method of formation of cavitation bubbles are
International Electrotechnical Commission (ICE) suggests different on the turbine specification and working envi-
using the Thoma number, often known as the plant cavitation ronment. Due to the kind of excitation and the transmission
numberσ p, which is described as channel to the sensor is affected by this. In addition, noise
from additional excitation causes, such as hydrodynamic,
NPSE mechanical, or electromagnetic, might simultaneously oc-
σp � , cur. When it comes to improving detection, selecting the
E
(2) right sensor and measurement location on the machine is
P 1 P very critical. Reference [23]. It is typical to practice con-
NPSE � I + g􏼐ZI − Zref 􏼑 + C2I − v ,
ρ 2 ρ ducting pressure measurements on a draught tube wall or on
the pedestal of the turbine’s guide bearing while doing vi-
Pa 1 P bration measurements on the guide vane arm. Measure-
NPSE � − gHs + C2I − v . (3)
ρ 2 ρ ments must also be taken under various operating
circumstances to ensure that the machine’s whole working
range is monitored. It is also important that the observed
4. Effects of Cavitation signals are captured at the appropriate locations.
Hydraulic noise is measured and analyzed to learn more
Cavitation vulnerability is a chief limit state in the present about cavitation’s characteristics. Pioneer’s work shows how
hydro turbine design. Cavitation enhances the opposing, this connection might be utilized in manufacturing appli-
corrosion, vibration, and fatigue of marine structures, cations like hydro turbines to monitor erosive cavitation in
according to research [22]. Furthermore, cavitation-in- actual machinery [24]. When it comes to turbines, structure-
duced vibration greatly increases noise generation, which is borne noise is quite easy to quantify. Using fluid-borne noise
especially problematic for turbines positioned in the is another option, although it is not always viable to place a
Advances in Materials Science and Engineering 5

Using a vibratory technique, cavitation monitoring is

done in hydraulic turbines. As a means of testing, a small
change of the turbine’s distributor is designed to lessen
cavitation aggressiveness and hence the associated erosion,
this approach was utilized in a big Francis turbine. Fixed
components of the turbine prototype were tested for cavi-
tation-induced vibrations and compared to identical and
unrehabilitated turbines [26].
A novel cavitation erosion device that produces vortex
cavitation has been developed. The capacity of this forma-
tion of vortex cavitation to create real cavitation damage is
compared to the same found in fluid equipment tested in a
comparative study. In testing subjected to cavitation in water
flow areas, hardened surface layers are identified to be denser
compared to cavitation in vibratory conditions, leading to a
Figure 4: Interblade vortex cavitation. greater amount of erosion [27].
The analysis of the variation, level of noise, and regularity
bonding of the signals was done. The calculation findings
were entered into a database and connected to the opera-
tional conditions provided by the head of water and the
opening of the guide vane. Sound induced in flowing water
and mechanical noise cannot be mistaken for the sound
produced by cavitation because of its unique frequency
characteristics. The head on the machine due to water flow
and hydraulic power generated is used to determine the
cavitation intensity. Due to the intensity of cavitation for a
particular condition of operation, the actual power gener-
ated and planned with the water head is used to calculate the
degree of cavitation erosion [27].
Hydroelectric power plants with different capacities are
used to meet fluctuations in demand in electrical power
networks. Hydraulic machinery was put through off-design
operation in order to keep up with the rapidly changing
market demands. There is a stimulating cause for the entire
turbine setup in that whirling flow exiting the runner of a
Francis turbine. Self-excitation occurred when a vortex rope
was used under high-load operating settings because of its
inherent energy source [28].
Figure 5: Kaplan turbine.
The deformation of the external provider cone in the bulb
turbine is because of cavitation. At the time of the erection of
the turbine, the top and bottom sides of the outer distributor
pressure sensor near the runner. As a result of signal at- cone inflate in size from the original dimensions. The left- and
tenuation during transmission, it is impossible to detect right-hand side dimensions were condensed from the erec-
cavitation noise directly. tion data. The pressure waves and impact mechanisms are
accountable for the impairment of the cavitation erosion
5. Theoretical Investigations phenomenon. Throughout his study, the author has found a
correlation between the lie of the outer distributor cone and
Hydraulic turbine damage is shown which is to be caused by the number of hours worked in the equations.
cavitation difficulties, sand erosion, material faults, and fa-
tigue in water turbines. Kaplan turbines’ draught tube cones 6. Conclusion
and runners are most vulnerable to cavitation. Improvements
in hydraulic design and fabrication of mechanisms, the use of According to the machine design and operating conditions,
erosion-resistant materials, and the configuration of turbines cavitation can appear in a variety of ways. Vibration levels
to operate inside acceptable cavitation conditions were found rise, which leads to unstable machinery, deterioration of
to minimize cavitation erosion [25]. components, and downtime. Hydraulic turbines are par-
Detailed information on the source of pitting in the ticularly interested in the intake leading-edge cavitation, the
runner, cavitation repair techniques, cavitation pitting sites, bubble cavitation at the exit, and the swirling draught tube
repair procedures, and places of great stress in the runner. cavitation. These cavitation problems affect a wide range of
Areas of typical cavitation pitting have been discovered. hydro equipment. Cavitation has a noteworthy impact on
6 Advances in Materials Science and Engineering

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