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Experimental vibration level analysis of a Francis turbine
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2012 IOP Conf. Ser.: Earth Environ. Sci. 15 062056
(http://iopscience.iop.org/1755-1315/15/6/062056)
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26th IAHR Symposium on Hydraulic Machinery and Systems

IOP Conf. Series: Earth and Environmental Science 15 (2012) 062056
IOP Publishing
doi:10.1088/1755-1315/15/6/062056
Experimental vibration level analysis of a Francis turbine

D M Bucur, G Dunca and C Clinoiu
Hydraulics, Hydraulic Machinery and Environment Protection Department,
Politehnica University of Bucharest, 313, Splaiul Independentei, Bucharest,
Romania
E-mail: georgianadunca@yahoo.co.uk
Abstract. In this study the vibration level of a Francis turbine is investigated by experimental
work in site. Measurements are carried out for different power output values, in order to
highlight the influence of the operation regimes on the turbine behavior. The study focuses on
the turbine shaft to identify the mechanical vibration sources and on the draft tube in order to
identify the hydraulic vibration sources. Analyzing the vibration results, recommendations
regarding the operation of the turbine, at partial load close to minimum values, in the middle of
the operating domain or close to maximum values of electric power, can be made in order to
keep relatively low levels of vibration. Finally, conclusions are drawn in order to present the
real sources of the vibrations.
1. Introduction
Francis turbines are commonly used for the power system regulation. As a result, they tend to be
operated over an extended range of regimes, far from best efficiency point. The normal safe operating
range of a Francis turbine is limited by vortices inside the turbine and by cavitation. These phenomena
normally occur in the runner and in the draft tube resulting in significant vibrations. Hydraulic
vibrations, one of the most important factors, are caused by vortex ropes, blade channel vortices, flow
separation, hydraulic pressure fluctuations and cavitation, and can induce vibration of the unit at some
operating conditions [1]. In the same time, during turbine operation mechanical vibration can occur.
The diagnose of the operating systems, machinery and equipment based on limited information in
quantity and quality is one of the current issues not only for operation but also for design and
conception [2].
Machinery vibration measurements are often viewed as quality control or machinery condition
measurements. Although this may be an oversimplification, most people consider low vibration levels
to be indicative of proper machinery behaviour. When vibration amplitudes are high, the general
tendency is to believe that the machinery is experiencing some type of distress or mechanical
malfunction [3]. Therefore since the vibration of machines in operation can be considered a significant
parameter in defining the state of operation, the analysis and interpretation of diagnostic through
vibration involves the use of specific methods and recommendations of probabilistic nature [4].
This paper presents an experimental analyse of a Francis turbine behaviour, from the vibration
point of view. The study is focused on identifying the mechanical vibration sources and the hydraulic
vibration sources.
Published under licence by IOP Publishing Ltd

IOP Publishing
doi:10.1088/1755-1315/15/6/062056
2. Experimental set-up
The analyzed Francis turbine has 27.5 MW power output, 143 m net head and a discharge of 23 m3/s.
It equips a high head hydro power plant in Romania [5]. The measurements are made in site, using
proximity transducers on the turbine shaft and accelerometers on the draft tube cone. At the moment
of in site tests, the available net head was 132 m, which corresponded to a maximum power output of
22 MW.
Shaft sensing proximity probes are used to obtain relative displacement measurements of rotating
or reciprocating shaft surfaces. They are mounted in a traditional manner [3], the vertical probe being
located directly above the shaft at 12 oclock, and the horizontal probe on the right side of the shaft at
the 3 oclock position (Fig. 1). The vibrations signals are acquired using a data acquisition system,
with an acquisition frequency of 500 Hz.
Figure 1. Vibration transducers setting on the turbine shaft.

In order to analyse the draft tube cone vibrations, two piezoelectric accelerometers are used. The
main advantages of these vibration transducers are that they measure casing or structural absolute
motion and can be easily attached to structure. They are mounted on the draft tube cone as shown in
figure 2. The signals are recorded using a special data acquisition system.
Reference level
-2.02 m
-3.72 m
piezoelectric
accelerometers
Figure 2. Vibration transducers setting on the draft tube cone.

3. Vibration signal processing
Rotating machinery and associated perturbations usually follow shaft rotation, which always moves in
a direction of increasing time. In virtual all cases, careful examination of the time domain behaviour of
a machine is fundamental to the analysis of that equipment [3]. Time domain analysis is representative
for the actual "sequence of events" which occurs on process machinery. Time and orbital domain
analysis depict the fundamental history of the machinery. However, there are situations when the

IOP Publishing
doi:10.1088/1755-1315/15/6/062056
complexities of the dynamic signals exceed the data processing capabilities of an oscilloscope. In
these cases, frequency domain analysis is required for detailed dissection of the signals.
3.1. Time domain and orbit domain, results of the proximity probes
Machinery vibration characteristics processed in time domain and in frequency domain are presented
on several distinct types of plots. The first format consists of vibration signals in the time domain. This
is normally combined with the shaft orbit.
The measurements results are presented for four power output values: 10 MW, 16 MW, 20 MW
and 22 MW.
The time domain and orbit characteristics obtained using the proximity probes mounted on the
turbine shaft are shown in figures 3 to 10. These kinds of plots are useful to identify the shaft preloads.
The presence of various types of unidirectional forces acting upon the rotating mechanical system is a
normal and expected characteristic of machinery [3].
In figures 3, 5, 7 and 9 it can be seen that the amplitude of the displacement on the horizontal and
vertical directions is generally below 0.15 mm, for all the analysed power output values, which means
that the machine has a good behaviour, from the vibration levels point of view.
The shapes of the orbits from the figures 4, 6, 8 and 10 show a slight preload of the shaft that forces
it to have an elliptical motion. The direction of the orbit displacement is coherent with the direction of
the flow entering the turbine impeller.
0.2
0.2
horizontal displacement
vertical displacement
0.15
Measured orbit
0.15
Horizontal Displacement - [mm]
Displacement - [mm]
0.1
0.05
0
-0.05
-0.1
-0.15
-0.2
0.1
0.2
0.3
0.4
0.5
0.6
Time t -[s]
0.7
0.8
0.9
0
-0.05
-0.1
-0.2
-0.2
-0.15
-0.1
-0.05
0
0.05
Vertical Displacement -[mm]
0.1
0.15
0.2
Figure 4. Turbine shaft orbit, for a power output

of 10 MW
0.2
0.2
Measured orbit
0.15
0.15
0.1
Displacement - [mm]
0.05
-0.15
Figure 3. Horizontal and vertical displacement of

the turbine shaft, for a power output of 10 MW
0.05
0
-0.05
-0.1
0.1
0.05
0
-0.05
-0.1
-0.15
-0.15
-0.2
0.1
0.1
0.2
0.3
0.4
0.5
0.6
Time t -[s]
0.7
0.8
0.9
-0.2
-0.2

the turbine shaft, for a power output of 16 MW
-0.15
-0.1
0
0.05
-0.05
0.1
0.15
0.2

of 16 MW

0.2
0.2
0.15
Measured orbit
0.15
Displacement - [mm]
0.1
0.05
0
-0.05
-0.1
-0.15
-0.2
0.1
0.2
0.3
0.4
0.5
0.6
Time t -[s]
0.7
0.8
0.9
0.05
0
-0.05
-0.1
-0.2
-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15
0.2

of 20 MW.
0.2
0.2
Measured orbit
0.15
0.15
0.1
Displacement - [mm]
0.1
-0.15

the turbine shaft, for a power output of 20 MW.
0.05
0
-0.05
-0.1
0.1
0.05
0
-0.05
-0.1
-0.15
-0.15
-0.2
IOP Publishing
doi:10.1088/1755-1315/15/6/062056
0.1
0.2
0.3
0.4
0.5
0.6
Time t -[s]
0.7
0.8
0.9
-0.2
-0.2

the turbine shaft, for a power output of 22 MW.
-0.15
-0.1
0.05
0
-0.05
0.1
0.15
0.2

of 22 MW.
3.2. Frequency domain results of the proximity probes

Another type of common steady state data consists in a frequency analysis of the vibration signal. This
is achieved using Fourier analysis techniques to separate a time domain signal into discrete frequency
components. The frequency spectrum of the complex signals generated by machines is characteristic
for each machine, representing a unique pattern, referred to as the "machine signature" [6].
The frequency domain analysis is carried out on 4096 samples. The sampling period is 0.002
seconds, which means a "cutting frequency" of 250 Hz (the Naiquist frequency).
Figures 11 to 14 present the FFT plots of the vibration signals acquired with the proximity probes.
In order to identify the vibration sources, the peaks of the measured frequency spectra are
correlated with the data related to the possible components sources in the machine. This requires
knowledge of the operating and geometrical parameters such as rotational speed, number of impellers
blade etc [7]. There are also taken into account the frequency components generated by the unbalance
or eccentricity of rotating shafts and by the shaft misalignment.
The frequency corresponding to the synchronous rotational speed of the analysed turbine, which
has a value of 428.6 rpm, is
fs =
428.6
= 7.14 Hz
60
.
(1)

IOP Publishing
doi:10.1088/1755-1315/15/6/062056
The fundamental frequency is around 120 Hz, which corresponds to the synchronous rotational speed
multiplied with the number of the turbine impeller blades (17 blades)
f =
n
428.6
N =
17 = 121.44 Hz .
60
60
(2)
1.4
1.4
1.2
1.2
Amplitude - [V]
Amplitude - [V]
Analyzing the plots shown in figures 11 to 14 it can be seen that there is a dominant component of
the signals located at 7 Hz, corresponding to the synchronous rotational speed of this turbine. This can
be due to a rotary unbalance [8]. Also, the fundamental frequency around 120 Hz is present in all the
analysed cases, which means that the shaft is subjected to hydrodynamic forces. Generally, these are
dangerous when causing casing resonance or high-level vibrations at some resonant point of the
structure.
0.8
0.6
0.8
0.6
0.4
0.4
0.2
0.2
100
50
150
50
Frequency - [Hz]
1.4
1.4
1.2
1.2
0.8
0.6
0.8
0.6
0.4
0.4
0.2
0.2
100
50
150
Figure 12. FFT plot for 16 MW power output.
Amplitude - [V]
Amplitude - [V]
Figure 11. FFT plot for 10 MW power output
100
Frequency - [Hz]
150
Frequency - [Hz]
50
100
150
Frequency - [Hz]
Figure 13. FFT plot for 20 MW power output

Figure 14. FFT plot for 22 MW power output.
Furthermore, it can be seen that in all plots the first and the second harmonics of the fundamental
rotational frequency appear. The presence of these two harmonics, in the signals acquired for all
values of output power leads to the conclusion that there can be a matter of mechanical looseness of
the turbine shaft.
The presence of the third armonic at 20 MW and 22 MW power otput (figures 13 and 14) is an
indication on the shaft radial load, which becomes more significant with the increase of the power
output value, because of the hydrodynamic stresses increasing. Actually, the entire frequency
spectrum is richer in harmonics, which is an indication that the hydrodynamic flow behaviour
becomes more unstable for these operating regimes.

IOP Publishing
doi:10.1088/1755-1315/15/6/062056
3.3. Frequency domain results of the piezoelectric accelerometers

To complete the vibration analysis of the turbine behaviour, the signals acquired with the two
piezoelectric accelerometers are processed. The transducers are mounted on the turbine draft tube cone
in order to capture the possible hydrodynamic sources of the vibrations. The recorded signals are
processed using a special data processing system. The frequency power spectrums for four different
power output values (10 MW, 16 MW, 20 MW and 22 MW), for each of the two piezoelectric
accelerometers mounted on the turbine draft tube cone are presented in figures 15 to 22.
-2
-2
10
10
-3
-3
10
Amplitude [mm/s]
Amplitude [mm/s]
10
-4
10
-4
10
-5
-5
10
10
0
200
400
600
800
1000
Frequency [Hz]
1200
1400
1600
Figure 15. Power spectrum plot, for a power

output of 10 MW, lower probe.
400
1000
800
600
Frequency [Hz]
1200
1400
1600

output of 10 MW, upper probe.
-2
-2
10
10
-3
10
-3
10
Amplitude [mm/s]
Amplitude [mm/s]
200
-4
10
-4
10
-5
10
-5
10
0
200
400
1000
800
600
Frequency [Hz]
1200
1400
1600

output of 16 MW, lower probe.
400
1000
800
600
Frequency [Hz]
1200
1400
1600

output of 16 MW, upper probe.
-2
-2
10
10
-3
-3
10
10
Amplitude [mm/s]
Amplitude [mm/s]
200
-4
10
-5
-4
10
-5
10
10
0
200
400
1000
800
600
Frequency [Hz]
1200
1400
1600

output of 20 MW, lower probe
200
400
1000
800
600
Frequency [Hz]
1200
1400
1600

output of 20 MW, upper probe

-2
-2
10
10
-3
-3
10
Amplitude [mm/s]
10
Amplitude [mm/s]
IOP Publishing
doi:10.1088/1755-1315/15/6/062056
-4
10
-4
10
-5
-5
10
10
200
400
1000
800
600
Frequency [Hz]
1200
1400
1600
200
400
600
800
1000
Frequency [Hz]
1200
1400
1600

output of 22 MW, lower probe
output of 22 MW, upper probe
In the power spectrum plots, the frequency of 120 Hz is observed. This value was obtained also in
the FFT plots of the vibration signals acquired on the turbine shaft. It indicates that the two vibrations
are correlated. Also, it can be observed that the higher amplitudes are situated at frequencies between
0 Hz and 200 Hz, which corresponds to mechanical vibrations of the impeller and guide vanes and to
hydrodynamic oscillations and Krmn vortices [9].
The vibration level is higher for the upper probe mounted close to the draft tube cone inlet and
close to runner outlet. This leads to the conclusion that the flow instability is increased when entering
the draft tube cone and it decreases along the draft tube. Also, it can be seen that the vibration level is
proportional with the power output. This means that the flow instabilities increase with the turbine
load, so it can be stated that at partial loads of the turbine the flow is more stable that at higher loads.
However, the power spectrums obtained for lower power outputs show an increased instability,
compared to those obtained for higher values of power. This confirms the hypothesis of vortex rope
presence.
Considering all the above, it can be stated that, from the hydrodynamic point of view, the analysed
turbine has a safe behaviour.
4. Conclusions
In order to analyze the behavior of a Francis turbine, vibration measurements are carried out at the
turbine shaft using proximity sensors, and on the turbine draft tube cone using piezoelectric
accelerometers. The measurements are realized in order to identify the mechanical vibration sources
and the hydraulic vibration sources. The analysis is realized in time and orbit domain plots and in
frequency domain. The results are presented for four values of output power: 10 MW, 16 MW, 20
MW and 22 MW.
Analyzing the proximity probes signals it can be seen that the shaft displacement on the horizontal
and vertical directions is, generally, below 0.15 mm, which does not indicate any dangerous operation
situation.
Analysing the frequency domain results of the proximity probes mounted on the turbine shaft a
rotary unbalance is observed. Also the shaft is subjected to hydrodynamic forces. This conclusion is
coherent with the orbit domain analysis, which underlines a slight preload of the shaft that forces it to
have an elliptical motion. The direction of the orbit displacement is coherent with the direction of the
flow entering the turbine impeller.
The presence of the first and the second harmonics of the frequency corresponding to the
synchronous rotational speed (figures 11 to 14) lead to the conclusion that there can be a matter of
mechanical looseness of the turbine shaft. From the hydraulic behavior point of view, the presence of
the third harmonic shows that the shaft radial load increases togheter with the power output. So it can

IOP Publishing
doi:10.1088/1755-1315/15/6/062056
be stated that the hydrodynamics of the flow does not lead to an abnormal behaviour of the machine,
from of vibrations point of view.
Acknowledgment
To the Hidroelectrica Company for important contribution in completing the in site measurements.
Appendix A. Nomenclature
fs
Frequency corresponding to the synchronous rotational speed [Hz].
f
Fundamental frequency [Hz].
n
Synchronous rotational speed [rpm].
N
Number of the turbine impeller blades.
References
[1] Swain M 2008 Vibrations in a Francis turbine a case study Electrical India 48(5)
[2] Gafianu M, Creu S and Drgan B 1989 Diagnosticarea Vibroacustic a Mainilor i Utilajelor
(Bucharest: Tehnic)
[3] Eisenmann R C and Eisenmann R C 1997 Machinery Malfunction Diagnosis and Correction
(New Jersey: Prentice Hall PTR)
[4] Wang F, Zhu Y, Li X, Ma J, Wang L and Tang X 2007 Experimental Investigation of Pressure
Fluctuation and Vibration in a Large Francis Turbine ASME/JSME 2007 5th Joint Fluids
Engineering Conf. (San Diego, USA, 2007) 879-884
[5] Research contract 2011 entitled Determination of real operation parameters of Francis turbines
with power output higher than 20 MW
[6] Bannister R and Donato V 1971 Sound and Vibration 5(9) 14-21
[7] Bucur D M, Dunca G and Clinoiu C 2012 U.P.B. Sci. Bull., Series D 74(1) 59-66
[8] Buzdugan G, Mihailescu E and Rades M 1986 Vibration Measurements (Bucharest: Academiei)
[9] Barglazan M 1999 Turbine Hidraulice Si Transmisii Hidrodinamice (Timisoara: Politehnica)

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Experimental vibration level analysis of a Francis turbine

Please note that terms and conditions apply.

26th IAHR Symposium on Hydraulic Machinery and Systems

Experimental vibration level analysis of a Francis turbine

Published under licence by IOP Publishing Ltd

26th IAHR Symposium on Hydraulic Machinery and Systems

Figure 1. Vibration transducers setting on the turbine shaft.

Figure 2. Vibration transducers setting on the draft tube cone.

26th IAHR Symposium on Hydraulic Machinery and Systems

Horizontal Displacement - [mm]

Figure 4. Turbine shaft orbit, for a power output

Horizontal Displacement - [mm]

Figure 3. Horizontal and vertical displacement of

Figure 5. Horizontal and vertical displacement of

Figure 6. Turbine shaft orbit, for a power output

26th IAHR Symposium on Hydraulic Machinery and Systems

Horizontal Displacement - [mm]

Figure 8. Turbine shaft orbit, for a power output

Horizontal Displacement - [mm]

Figure 7. Horizontal and vertical displacement of

Figure 9. Horizontal and vertical displacement of

Figure 10. Turbine shaft orbit, for a power output

3.2. Frequency domain results of the proximity probes

26th IAHR Symposium on Hydraulic Machinery and Systems

Figure 12. FFT plot for 16 MW power output.

Figure 11. FFT plot for 10 MW power output

Figure 13. FFT plot for 20 MW power output

26th IAHR Symposium on Hydraulic Machinery and Systems

3.3. Frequency domain results of the piezoelectric accelerometers

Figure 15. Power spectrum plot, for a power

Figure 16. Power spectrum plot, for a power

Figure 17. Power spectrum plot, for a power

Figure 18. Power spectrum plot, for a power

Figure 19. Power spectrum plot, for a power

Figure 20. Power spectrum plot, for a power

26th IAHR Symposium on Hydraulic Machinery and Systems

Figure 21. Power spectrum plot, for a power

26th IAHR Symposium on Hydraulic Machinery and Systems

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