Analysis of uncertainties in fatigue load assessment : a study on one Kaplan hydro turbine during start operation

Abstract: In the future, hydropower plants are expected to operate more flexibly. This will lead to a more varied operation of the turbine and the generator, such as more start and stop in order to stabilise the frequency in the grid. Studies show that these transient operations are more costly in terms of fatigue degradation, i.e. consumption of fatigue life. Vattenfall has developed a methodology with the aim to analyse fatigue loads, acting on the runner and the rotor in hydropower units during operation. With a numerical model, the loads are assessed with input data gathered from measurements together with given data on several parameters. Some of the input data are bearing structure stiffness, bearing oil properties, and point of action of forces, etc. Several of these input parameters are subject to a degree of uncertainty, which affect the assessed fatigue load, determined with the methodology. This study will focus on analysing one fatigue force component acting on the runner. The aim with this study is to answer the following research questions: (i) Which input parameters, that are subject to a degree of uncertainty, contribute the most to the combined standard uncertainty in the assessed fatigue force? (ii) How much does the combined standard uncertainty in the assessed fatigue force amount to? (iii) How does the uncertainty in the assessed fatigue force affect the fatigue damage?. The combined standard uncertainty in the fatigue force is determined with methods in uncertainty propagation. In order to evaluate the effect from the uncertainty in the fatigue load on the fatigue damage, a statistical analysis of the ratio between the fatigue damage associated with a probability of exceedance and the expected fatigue damage is conducted. From the results it can be observed that the governing uncertainty parameter is the offset of the shaft displacement signal, which amount to 40 % of the combined standard uncertainty in the fatigue force. Of the nine analysed uncertainty parameters, three parameters are bearing properties parameters, i.e. the bearing clearance, the oil film temperature and the point of action of bearing forces, which amount to 47.5 % of the combined standard uncertainty in the fatigue force. Therefore, in order to decrease the uncertainties, focus should be kept on the bearing properties. Given each parameters uncertainty, the ratio between the combined standard uncertainty in the fatigue force and the expected fatigue force amount to 7 %. This corresponds to a ratio between the standard uncertainty in the fatigue damage and the expected fatigue damage of 35 %, due to the value of the index of S-N curve of five. Given the standard uncertainty in the fatigue force together with the index of S-N-curve, the ratio between the fatigue force associated with a probability of exceedance and the expected fatigue force can be assessed, i.e. the fatigue force ratio. Consequently, the fatigue force ratio amount to 1.32 for a probability of 0.0032 %, 1.09 for a probability of 10 % and 1.04 for a probability of 30 %. These probabilities correspond to the fatigue damage ratios, i.e. the ratios between the fatigue damage associated with a probability of exceedance and the expected fatigue damage of 4, 1.56 and 1.20. Thereby, the uncertainty in the fatigue force can greatly affect the uncertainty in the fatigue damage, dependent on the value of the index of S-N-curve. The results from this study imply the importance of considering the uncertainties in fatigue load assessments. These results provide support for assessing load levels for runner dimensioning to finally, be able to derive a correct margin of safety. This in order to not underestimate fatigue damage and thereby decrease the risk for unexpected fatigue failure.