Turbine Aeration System of Tehri HPP

R R Semwal Karan Bargali

Addl Gen Manager(O&M) Manager(O&M)

Synopsis

The vertical shaft Francis-runner of Tehri Power plant has been designed to operate under
a head variation of 90mtr. The rated speed of turbine is 214.8 RPM with Turbine setting at
(-) 6.5 mtr below TRC. As the reservoir level recedes or sometime to meet Grid schedules;
turbines operate at part loads. Francis turbine when working at partial loads, present
pulsations that are due to the Von carman Vortex in the vanes and Vortex rope in the draft
tube. These phenomenons generate strong vibrations and noise that may lead to failures
on the mechanical elements of machines. To mitigate the effect of turbine operating at
partial loads, away from best efficiency point (BEP), closer to cavitation zone and to ensure
smooth and quite operation with low vibrations, pressure pulsations, and noise etc, Tehri
Power Plant has an efficient turbine aspiration system.

1.0 Francis Turbine & cavitation:

The Francis turbine is a reaction turbine, in which the fluid changes pressure as it moves
through the turbine, giving up its energy. The turbine is located between the high pressure water
source and the low pressure water exit.

The liquid enters hydraulic turbines at high pressure; this pressure is a combination of static and
dynamic components. Dynamic pressure of the liquid is by the virtue of flow velocity and the
other component, static pressure, is the actual fluid pressure which the fluid applies and which
is acted upon it. Static pressure governs the process of vapor bubble formation or boiling.

Cavitations occur when the static pressure of liquid falls below its vapor pressure; the liquid
boils and bubbles of vapor are formed. When these bubbles are carried to high pressure zone,
its vapor condenses and bubble suddenly collapse as vapors are condensed to liquid again.
This results in formation of cavity and surrounding liquid rushes to fill it. The stream of liquid
coming from all the direction collides at center of cavity giving rise to local pressure.
Cavitations can occur near the fast moving blades of the turbine where local dynamic head
increases due to action of blades which causes static pressure to fall. Cavitations also occurs at
the exit of the turbine as the liquid has lost major part of its pressure heads and any increase in
dynamic head will lead to fall in static pressure causing Cavitations.

1.1 Detrimental Effects of Cavitations

The formation of vapor bubbles in cavitations is not a major problem in itself but the collapse of
these bubbles generates pressure waves, which can be of very high frequencies. The bubbles
collapsing near the machine surface cause erosion on the surfaces called as cavitations
erosion. The streams of liquid coming from all directions collide at the center of cavity giving rise
to a very high local pressure whose magnitude may be as high as 7000 atm. Formation of cavity
and high pressure are repeated many thousand times a second. This causes pitting on the
metallic surface of runner blades or draft tube. The material then fails by fatigue, added by
corrosion. The collapses of smaller bubbles create higher frequency waves than larger bubbles.
So, smaller bubbles are more detrimental to the hydraulic machines however they do not cause
any significant reduction in the efficiency of the machine. With further decrease in static
pressure more number of bubbles is formed and their size also increases. These bubbles
coalesce with each other to form larger bubbles and eventually pockets of vapor. This disturbs
the liquid flow and causes flow separation which reduces the machine performance sharply.
The detrimental effects of cavitations are summarized as below:

a) Erosion of material ( blade surface)

b) Distortion of blade angle
c) Loss of efficiency to above erosion/distortion
d) Flow instabilities
e) Acoustic Noise
f) Excessive vibrations

2.0 Effect of introducing Air

The effect of Air introduced into the runner has three dimensions: forming cavities, resisting
compression and dissolving in water. Utilizing these three effects of air-water interaction, air is
introduced into the flow in water turbines during steady state as well as during transient regimes
of operation to address following issues basically attributable to cavitation phenomenon:

a) Absorption of noise.
b) Attenuation of fluid oscillations
c) Avoidance of unsteady (helical) draft tube flow patters
d) Cushioning of shocks produced by collapsing vortex cavities.
e) Reduction of cavitations impact on the runner
f) Increasing the dissolved oxygen content/improving water quality

According to the different purposes, the most effective way and the location of introducing the
air are also different. An inappropriate method may not only be in effective, but may worsen
things. Moreover, the cost effectiveness of a solution depends on the realization. The effect of
making cavities more permanent by filling them with air (rather than vapor) is utilized where
problems are linked with collapsing regions of cavitations flow. Cavitations at runner blades
may, in addition to erosion, results in a strong fluid borne noise in the audible range of
frequencies. That noise is caused by collapse of large number of small bubble-type cavities
within the runner flow passage. By injecting air up stream of runner or directly at runner blade
surface, it is possible to mitigate erosive action as well as noise, because the increased air
content in the small cavities prevents there instantaneous collapse.

3.0 AIR ENTAILING AT TEHRI HEP

At Tehri HEP, following air aspiration/injection technique are utilized to meet different ends:
 i) Air Injection during steady state
ii) Air Injection during transient state
iii) Air Injection for water Depression (Synchronous condenser mode of operation)

3.1 Air Injection during Steady state

Francis turbines working at optimal conditions have a purely axial exit water flow, however,
when working at partial or above full load, i.e. not optimal conditions, the fluid exiting the
spiral casing starts to have a tangential velocity component creating a tendency in the fluid
to swirl. This flow pattern is called as Vortex and is most severe cause of efficiency
reduction and pressure fluctuations (surging phenomenon) experienced by Francis turbines
at part load.

Draft tube vortex rope at part load

Flow regions with concentrated vortices can develop cavitations in their central cores due
to the low pressure generated. If the tip of the vapor filled vortices are in contact with a solid
surface they become potentially erosive since final collapse of whole cavity take place on
them.

This vortex rotates in same direction as the runner at the part load and in opposite direction
at overload with the frequency usually ½ to ¼ of runner rotating speed. In such low
frequencies, circumferential pressure pulsations are generated. When surging (pressure
pulsation) is strong, vibration of the draft tube or the penstock will be caused with resulting
power swing and a possible rupture of the draft tube liner. If vortex precession frequency
matches the draft tube natural frequency, the system will resonate and strong surges may
occur.

Inserting air into the draft tube flow, under the runner, is the most common measure to
reduce pressure pulsations and cavitations. When air is supplied into the draft tube, air
foam gathers in low pressure interior of center cone, breaking the vortex core and causing it
to become larger thus becoming stable. Because it is not necessary to inject the air using
pumps or compressors, turbines which operate this way are said to be auto-venting.

Auto-venting turbine aeration generally consists of three different aeration options, which
are distributed, central and peripheral aeration.

a) PERIPHERAL AERATION METHODS

In this method, air injection is made radially through a transversal pipe, tripod etc
inserted through draft tube wall. However, this peripheral air injection method is not
so efficient and effective. This is attributable to the fact that the distance to the
center cone for air to travel is too far when air is fed from draft tube wall and that
more air get wasted as it escapes with the water flow (ie dissolve). This
methodology contributes to efficiency drop of turbine

b) DISTRIBUTED AERATION METHODS (as in case of Koteshwar HEP):

Vacuum breaking valves are apparatus for realizing distributed aeration systems. In
this method air injection is made through turbine head cover near to runner hub.
Vacuum breaking valves are spring loaded valves provided over turbine head cover.
When there is excessive vacuum below the runner due to sudden closing of guide
apparatus or part load operation of the unit, the valve opens and supplies atmospheric
air to break the vacuum. The valve automatically closes by the spring force when there is
no vacuum. The feasibility of external air admission in case of vacuum breaking
valves strongly depends on a correct design of air-path. If air is fed to point other
than the very center of runner hub, the intake pressure may be so high that air
admission is impossible in some critical load range. Even if sufficient vacuum is
available at the inner flow contour, natural suction may be obstructed by an
unfavourable design of aeration path because there are other important functions to
be fulfilled in the same area viz compensation of axial thrust, shaft sealing and
runner coupling. The vacuum-breaker systems were not designed to transport large
volumes of air. Usually, the piping system that provides air to the turbine is long, with
bends, elbows, and valves which cause a significant loss of energy as air flows
through the venting network. This results in limitations on the flow rate of air that can
be vented into the release flow

c) Central Aeration system (as in case of Tehri HEP):

This method entrains air through hollow turbine-generator-extension shaft using

aeration valve. This aeration valve is very similar to vacuum breaking valves but
highly effective in performance since it allows air aspiration directly under runner
hub. Since the pressure at the opening of air tube is negative (suction pressure), the
 necessary air flow rate is supplied by natural intake of air. The aeration valve
(installed on top of the generator shaft at EL. 605.00), is again a spring loaded
device that allows or interrupts air supply to the spiral casing. At the bottom, a
stainless steel sealing ring is fixed which affects the tight sealing of valve by
pressing against the rubber sheet fixed on the valve. To prevent efficiency loss, the
air flow through the valve is limited to a maximum of 2% (at atmospheric pressure)
of the water flow in the turbine. But, in some conditions of downstream level and
guide vane opening, water from the turbine can rise until the valve’s level and even
go thought it. If the valve sealing is compromised or the valve fails letting water go
through it, there is a high chance of occurring leakage to the generator’s
components (e.g. slip ring). As a protection measure, sensors were installed in the
aeration chamber and also drainage pipes are provided. Sensors are also provided
to detect water level which after a certain value, send a signal to a relay that shuts
down the generator (trip).

Types of Turbine aeration system during steady state of operation

3.2 AIR INJECTION DURING TRANSIENT STATE

During loading and unloading of Units, turbine passes through transient a regime which
falls under unstable zone of operation (corresponding to given head, Unit MW falls in
proximity to cavitation line in HILL Chart). Since the tail race level of Tehri power station is
higher than distributor center line, the static pressure in the draft tube becomes higher;
hence, natural air admission to the draft tube becomes difficult. In such an instance, forced
air supply from compressor is injected into runner via 02 nos 65NB pipe inserted at head
cover. A pneumatic valve is operated in the region of 30-50% of Guide Vane opening which
introduces the compressed air at 0.8MPa.In the absence of this air injection, there are
considerable vibration and sound emanating from turbine-generator.
The effect of entraining this compressed air into water has multiple effects described as
below:

a) It makes cavities more permanent by filling them with air (rather than vapor).
Injecting air upstream of the runner or directly at the runner blade surface mitigates
the erosive action because increased air content in small cavities prevent their
instantaneous collapse.
b) It reduces noise since the presence of non-condensable gas ( ie air) in vapor
bubbles cushions the collapse.
c) It inhibit occurrence of cavitations as the air bubbles aid in relieving the sub-
atmospheric pressure.
d) It attenuates shock waves and deflects micro-jets. The dampening effects of air
entrainment on shock wave are usually associated with change water properties,
especially the compressibility of air-water mixture, and with forced oscillation of air
bubbles that dissipates the energy of shock waves.

3.3 Air Injection for water Depression (During Synchronous condenser

mode of operation)

The Tehri hydro generators are not used only for generating electric power but are
sometimes driven as rotary phase modifiers (synchronous condenser) mode of operation
so as to improve the power factor of the power transmission system. When the generators
are driven as phase modifiers in parallel with the transmission system, the resistance of the
water turbine runner may be reduced by placing it in the compressed air in order to
minimize the input as much as possible . Not only in synchronous condenser mode but also
in operations such as turning reserve operation and starting pump-turbine as a pump, the
runner of the hydraulic machine is rotated within compressed air filling the runner chamber.

The sequence of operation in case of Tehri HEP hydro-generator is described below:

i ) Water depression in draft tube:

When the generator is so used as a synchronous condenser, only wattless power should
be drawn from the line. The work to be done by the generator should therefore be
minimized and should be limited to overcome friction and windage in the generator and the
turbine. The work required to motor the generator can be decreased substantially by
dewatering the turbine and rotating the runner in air. Since the hydraulic turbines are
located below tail-water levels, this is accomplished by depressing the water level below
the level of the runner by admitting pressurized air into the turbine runner casing. More
particularly, the water in runner casing is forced down into the draft tube by air under
pressure into the casing so that the runner may be placed in the compressed air, thereby
decreasing the runner rotation resistance and reducing the input to the generator.

The initial injection of air to depress water level must be very rapid to avoid undesirable
vibration and uplift of rotating components. Air at 4.0 MPa is injected into the draft tube via
pneumatic valve connected onto a Φ150NB pipe. This pipe, before entering turbine head
cover splits into 02 pipes of Φ100NB each. The pneumatic valve remains open for nearly
15 sec and admits air into runner chamber which ultimately depresses the water. During the
water depression process, the line pressure of Φ150NB pipe drops upto 2MPa. The total
water depression is recorded/observed through a level gauge.

ii) Opening runner seal cooling:

When the turbine is rotating in air the water normally passing through the turbine is not
available for cooling the runner seals. If the seals are not properly cooled the temperature
of the adjacent surfaces of the seals increases causing expansion, and in some instances
the seals actually contact and seize. When seizure does occur excessive damage usually
results. Furthermore, seizure of the runner seals usually requires an expensive and time
consuming major dismantling of the turbine including removal of the runner to free the
seized seal elements. In order to prevent heat elevation due to idling of the runner
(windage losses), a large quantity of cooling water must be fed between the rotating portion
and the stationary portion of the hydraulic machine during such operation. This cooling
water is taken from the normal cooling water supply via a solenoid valve. For monitoring the
flow an electromagnetic flow meter is also installed in runner seal CW pipeline. A Φ50NB
pipe is extended through head cover for sprinkling water onto runner near to runner cone.

Runner seal have been provided into runner crown and shroud (both rotating seals) and on
head cover and bottom ring (both complementary fixed seals). The gap between runner
seal of crown and head cover is 1.5mm, while gap between runner seals of shroud and
bottom ring is 2.5 mm. Since the gap at bottom runner seal is wider as compared to gap at
upper runner seals, therefore cooling arrangement is provided near to upper runner seal.
However, the water helps to cool runner in toto, and hence restricts runner expansion.

However, when cooling water is sprayed on the seals it collects in the runner casing adding
additional drag and therefore requiring more work to rotate the runner.

iii) Opening of makeup air:

Once the water is at desired level, make up air must be introduced to compensate for water
leaking past the closed wicket gates, cooling water from runner seal and water drained from
bottom ring collected into draft tube. Almost after 6 min of water depression, water begin to
rise in draft tube. The water column in level gauge rise and trigger a level switch which
opens a pneumatic valve. This pneumatic valve is connected on a Φ65NB pipe and
resupply air at 0.8MPa.

iv) Opening of drainage leakage valve:

The turbine head cover is a structural member covering the turbine runner chamber that
functions as a water barrier to seal the turbine. It also serves as a carrier for the upper
wicket gate bushings, upper seal surface for the wicket gate vanes, support for the gate
operating ring, carrier for the runner stationary seal rings (shaft seal), and support for the
turbine guide bearing. The bottom ring serves as a carrier for the bottom wicket gate
bushings, bottom seal surface for the wicket gate vanes, and a carrier for the bottom runner
stationary seal ring. The drainage leakage valve is connected to bottom ring and drains
leakage water.

v) Opening of bypass valve of MIV :

This valve is opened to makeup water in the volute (spiral casing) that leaked past the
closed wicket gates. This water leakage arises from draining of water from bedding gap or
from top and bottom clearances of guide vanes. Secondly, when turbine is switched from
TM mode to CM mode, the wicket gate and MIV closes. The time difference in guide vane
closing and MIV closing may also result in water seepage past the guide vane.

vi) Opening of air release valve:

After stop command is issued to unit running in synchronous condenser mode, another
pneumatic valve is opened to release air trapped inside runner casing and draft tube.
Complete air release is made followed by water replenishment.

A typical plot of Active power, reactive power, Guide opening during unit operation in SC
Mode is depicted below

Gen Voltage

Line Voltage

Active Power

Reactive Power

Guide Vane opening

4.0 COMPRESSED AIR SYSTEM AT TEHRI POWER HOUSE

Architecture of Compressed air system in power house is depicted below. The system
comprises of 4X4.0 MPa receiver tanks for water depression during synchronous
condenser mode of operation. There are also 0.8MPa tanks for air replenishment during SC
mode and to inject compressed air during turbine unstable mode of operation. The O&M
manual mentions that all units are designed to operate on condenser mode with work
duration in this mode up to 8 hrs a day, one or two unit can work in this mode
simultaneously.

To Receiver Tank:
Turbine & MIV OPU

Make up air in SC Mode, air

for unstable mode
To Gen Brakes

SC Mode water depression

SLD of Compressed Air System at Tehri HEP

5.0 CONCLUSION

Tehri Francis turbine is outstanding since single turbine caters a head variation of
90 mtr round the year. The turbine passes through different operating regimes
corresponding to head and as dictated by HILL chart. Aeration of turbine becomes
mandatory for smooth and safe operation of Units. Selecting proper Aeration
methodology becomes vital and it should fundamentally address three criteria:
adverse operating conditions, reasonable amount of air flow needed to decrease
this surging and determination of position of air pipe installation. Francis turbine
installed at Tehri HEP present classic case of turbine aeration systems. Air
admission not only helps in mitigate adverse effect of cavitation but also results in
small gains at partial load. This increase in efficiency is due to the fact that air helps
in breaking the eddy losses and preventing surging. Further air admission in low
pressure zones of a Francis turbine also help to increase the amount of dissolved
oxygen (DO) in water passing through the turbine.
.

6.0 REFERENCES:

i. Introduction to Synch-Condense mode: Tyler Braun

ii. Methods for Air Admission In Hydroturbines: Benoît PAPILLON, Michel
SABOURIN, Michel COUSTON, Claire DESCHÊNES
iii. HAP – Best Practice Catalog – Francis Turbine Aeration
 iv. Performance Analysis Of An Aeration Valve And Its Protections Of A
Generating Unit In Itaipu Hydroelectric Power Plant
v. Design criteria for air admission systems in Francis turbines, Peter K.Doerfler
vi. Investigation of the Use of Air Injection to Mitigate· Cavitation Erosion,
UNIVERSITY OF MINNESOTA, st. Anthony falls hydraulic laboratory.
vii. O&M Manual of Turbine-BHEL
viii. Using Dissolved Oxygen Prediction Methodologies in the Selection of
Turbine Aeration Equipment-Jason Foust,Stuart Coulson
ix. Evaluation of Francis turbine aeration as a measure to attenuate pressure
pulsations- João Marra, Luan Malikoski Vieira
x. Special Thanks to Sh J S V Sharma, Ex-AGM(BHEL) and Mr Tyler Braun
(Tacoma Power).