Hydro Generator

&
Generator-Motor

Copyright 2014, Toshiba Corporation.

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
2

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
3

 TOSHIBA 2014, All rights reserved.

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Hydro Generator & Generator-Motor Experience

 TOSHIBA 2014, All rights reserved.

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Largest class air-cooled hydro-generator

C.V.G. Electrificacion del Caroni, CA. Venezuela
Guri II : 64P-700/805MVA-113min-1
Stator
Outer diameter16.3m
Height6.1m
Weight740 ton
Frame6 segment

Rotor
Number of Poles:64P
Outer diameter13.6m
Height4m
Weight1200ton
Peripheral velocity80 m/s

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Hydro Generator & Generator-Motor Experience

(100 to 500MVA)

 TOSHIBA 2014, All rights reserved.

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Hydro Generator & Generator-Motor Experience

(100 to 500MVA)

Baram 1
340MVA-150 or 167rpm

Baleh
284MVA-167 or 188rpm

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the information it contains be disclosed to any third party without their written permission

Example of Hydro Generator Experience

(200 to 300MVA class & around 100 to 200 r/min range)

Power Station

Country

No. of
Pole

Unit Capacity
Rated Max.
(MVA) (MVA)

Speed Voltage Freq.

(r/min) (kV)
(Hz)

Year of
Manufacture
<1st Unit>

Type

Sogamoso

Columbia

44

324

324

164

16.5

60

2011

SU

Ghazi Barotha

Pakistan

60

322

322

100

18

50

1999

SU

Alicura

Argentina

40

280

318

150

13.8

50

1982

SU

Ting Zi Kou

China

60

306

306

100

15.75

50

2011

SU

G. M. Shrum

Canada

48

239

290

150

13.8

60

1969

Guri No.1

Venezuela

60

230

265

120

18

60

1972

SU

Macagua No.2

Venezuela

88

250

250

82

13.8

60

1991

Gong Guo Qiao

China

64

250

250

94

15.75

50

2010

SU

Jiang Ping He

China

32

250

250

188

15.75

50

2011

SU

DongQing

China

36

244

244

167

15.75

50

2007

SU

Koldam

India

36

222

244

167

13.8

50

2007

SU

Mosul No.1

Iraq

50

237

237

120

15

50

1984

Nam Ngum 2

Laos

28

228

228

214

15

50

2008

SU

Okutadami #4

Japan

28

223

223

214

15.4

50

2002

SU

Boundary

U.S.A.

56

210

210

129

14.4

60

1984

<Remarks> SU : Semi-Umbrella Type, U : Umbrella Type

 TOSHIBA 2014, All rights reserved.

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
9

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Shaft System Stability

(Bearing Arrangement)

Guide Bearing
Thrust Bearing

Guide Bearing

Rotor

Rotor
Guide Bearing

Guide Bearing

Suspended type

Guide Bearing
Thrust Bearing

Guide Bearing

Semi-Umbrella type

Rotor
Guide Bearing
Thrust Bearing

Guide Bearing

Umbrella type

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Bearings Arrangement Evaluation

Evaluation of shaft stiffness and bearing span

Evaluation of support stiffness of guide bearing
Evaluation of critical speed

Evaluation against unbalanced magnet pull force

<For low & medium speed generators>

Evaluation of critical speed considering unbalanced
magnetic pull force

11

 TOSHIBA 2014, All rights reserved.

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
12

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Thrust and Guide Bearings

Upper guide bearing

Combined type thrust

and lower guide bearing
13

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the information it contains be disclosed to any third party without their written permission

Thrust and Guide Bearing Design

Spring table

Guide bearing
Thrust runner

Thrust spring

Shaft

Thrust pad
Toshiba Spring Support
Thrust Bearing
14

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Thrust Spring
Toshiba Standard Multipoint
Elastic Supporting System
Thrust
bearing
pad

Advantages
equalizing

surface

loading on sliding

compensation

of elastic and
thermal deformation

Thrust spring
15

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the information it contains be disclosed to any third party without their written permission

Optimization of Thrust Bearing Design

Pad form and number of segments

Principal design parameter of thrust

bearing

Thrust pad

- Dimensions of stationary pad

- Mean oil film pressure
- Mean velocity
- Minimum oil film thickness
Deformation of thrust runner
Deformation of bearing bracket
B

OPTIMUM
DESIGN

RELIABLE THRUST BEARING

L
16

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the information it contains be disclosed to any third party without their written permission

Thrust bearing support and wedge effect of oil film

Basic Principle
Thrust Runner

Direction

Oil Film

Conventional
Generator
(Directional)
Direction

Generator-Motor
(Reversible)
Direction

Thrust Pad
Spring

Wedge-shaped Oil Film

between Thrust Runner
and Thrust Pads

Fluid Lubrication

Eccentric Support
of Thrust Pads

Central Support
of Thrust Pads

Tilting of
thrust Pads

Elastic Deformation+
Thermal deformation
Curvature of Thrust Pads

Formation of Wedge
-shaped Oil Film

Formation of Wedge
-shaped Oil Film

17

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Development of Reliable Thrust Bearing

Real transient thrust load test rig

Measured Load fluctuation

Rotating speed(r/min)

Dynamic load

Rotating Speed
Thrust Load
A
C
B
D
E
Direction of rotation

Time (s)

test rig of thrust bearing

Re-created Load Rejection Test

300 ton test rig of thrust bearing

The test rig can be performed transient condition operation.
Dynamic load is applied to test bearing by computer controlled hydraulic actuator.
18

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Cooling System for Bearing

Radial bore for
Self pump
Motor driven
pump
M

Sectional

View

Cooling coil
External oil cooler(s)

External oil cooler(s)

Cooling coil (tube)

Provided in oil reservoir

External oil cooler(s) and oil

circulation by self pump

External oil cooler(s) and oil

circulation by motor driven pump

1.Simple construction

1. All round application

2. Easy maintenance of oil
cooler(s)
3. High reliability

1.All round application

2.Easy maintenance of oil
cooler(s)
3.Small power for oil circulation

Notice

1.Dismantling rotor or oil

reservoir required at
cleaning of coil

1.Large power for circulation

1.Small cooling capacity at failure

of power source condition
2.Stand by pump is required

Application

Generally applied
Except high speed-large
capacity range generator

Applied all range generator

Applied as customer's requirement

System
Advantage

19

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the information it contains be disclosed to any third party without their written permission

Non-Metallic Thrust Bearing

For reversible generator-motor

20

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the information it contains be disclosed to any third party without their written permission

Technical Features of Toshiba Plastic Thrust Bearing

PTFE : Poly Tetra Fluor Ethylene
Long life

Easy maintenance

1/50 of white metal abrasion

Non-burning
Loss reduction

Low running loss

Approx.20% reduction
Low starting friction

1/3 coefficient of starting friction

Elimination of High
Pressure Oil Lift System

of white metal

21

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
22

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Brush Type Oil Mist Seal

(Brush Seal)
Stop
Oil Mist leakage

Lower Bearing

Brush Seal
(Model)
23

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the information it contains be disclosed to any third party without their written permission

Brush Type Oil Mist Seal

Bearing

OIL MIST

Stop oil mist coming out of bearings to

keep your machine clean!
Unique brush type seal reduces
maintenance costs and makes machine life
longer with perfect performance of
stopping oil mist and oil leakage.
Features

Bearing

Brush

Newly developed
brush type seal

- Drastic effect
(leakage 1/20 or less)
- Maintenance free
- Long life
(expected 10 years or more)
- Compact sizes
- Easy installation
- Available for any shaft
diameter and any speed
24

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TOSHIBA Brush Seal

Main Features:
- Drastic effect (leakage 1/20 or less)
- Maintenance free
- Long life (expected 10 years or more)
Oil mist
Oil leakage
Conventional
labyrinth seal

Double plastic brushes

Holder

Bearing cover
< horizontal view >

keep contact

Main
shaft
Bearing
oil basin

<vertical view >

25

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the information it contains be disclosed to any third party without their written permission

Test Result of Air Leakage

600

Test condition
500

Conventional labyrinth seal

Shaft size : OD 300mm

Speed
: 53.4m/s
(3400min-1)
Fluid
: Air

Air leakage [liter/min]

400
300
200

Air leakage in brush seal is 1/20

or less than that in labyrinth
seal.

(Approx. 1/20)
100

Brush seal

0
0

0.5

1.0

1.5

2.0

2.5

3.0

Pressure difference of seal [kPa]

26

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the information it contains be disclosed to any third party without their written permission

Example of Installation
A

Lower Oil Guard

Lower Oil Pan

27

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the information it contains be disclosed to any third party without their written permission

Test Result of Oil Scattering

No oil mist

Brush type seal

oil mist

Labyrinth type seal

Test condition
Shaft size : 1050mm dia
Speed
: 45m/s
Max seal pressure deference : 1 kPa
28

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the information it contains be disclosed to any third party without their written permission

Actual Application Result

BEFORE

AFTER

Oil leakage through labyrinth seal

No oil leakage by brush seal

Pit wall is wet condition with oil mist.

Pit wall is dry condition without oil mist.

(at 8 months after application of brush seal)
29

 TOSHIBA 2014, All rights reserved.

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
30

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Stator Core Buckling Problem

Stator core buckling problem is caused by
thermal stress due to thermal expansion of the
core.
Core buckling problem is one of major cause of
stator coil insulation damage.

50

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Prevention of Stator Core Buckling

Increasing Clamping Strength of Stator Core
Independent clamping plates at top and bottom of stator core
Sufficient number of key bars

Stator Frame and Base Fixing Structure to allow thermal

expansion of stator
Adequate soft tightening of stator frame and stator base
Radial pin or key
Lubricant coat

Decreasing Thermal Stress of Stator Core

Low magnetic flux density at stator core back
High grade silicon steel material
Suitable number of air ducts
Clamping finger of nonmagnetic material

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the information it contains be disclosed to any third party without their written permission

Stator Core Clamping System

In order to prevent stator core from buckling, the stator core
laminations have to be securely held in place by clamping plates at
top and bottom ends.
Integral structure of
bottom clamping
plate with the stator
frame

Inadequate
clamping force for
stator core

Independent
clamping plates
at top and
bottom ends

Core buckling

Past design

Current design
33

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the information it contains be disclosed to any third party without their written permission

Structure of stator and core clamping system

Core clamping method

F1
F2
F1
F2
F3

The compression force is applied to the center of gravity of the

stator core laminations, compression force is generated from the
tightening force of rib studs. In order that stator frame have to
support the reaction force, it has reinforcement of the same
number as rib stud.

F3

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Stator Core Clamping System

(Example of Analysis Result)
Loose

Tight
Minimum principal stress

Past Design

Current Design

Deformed shape is completely different at the bottom portion.

35

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Stator Frame and Base Fixing Structure

Provision to allow thermal expansion of stator in radial direction
S.frame

S.base

Thermal
expansion

S.core

Sliding portion

Radial pin or key

between frame and base
Sliding portion
36

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
37

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the information it contains be disclosed to any third party without their written permission

Stator Coil Insulation System

Mica taping
Resin Rich Mica Tape

Dry Mica Tape

Vacuum and Pressing

by shrinking
Heat press
Straight portion

in
Vacuum
Vessel

Hardening by the
heating furnace

Hardening under final

pressurization by liquid

Hot Press System

V.P.R. System

Vacuum, Pressurized Impregnation

in Vacuum Vessel
Heat press
Straight portion

Hardening by the heating furnace

V.P.I.System

V.P.I.System

TOSHIBAs VPR
Heat Press System

Vacuum & Pressurized System

38

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VPR System v.s. VPI System

1.

Difference : Mica tape material

- Dry Mica for VPI system
- Resin Rich Mica for VPR (Toshiba insulation system)

2.

Same approach : Removing Voids

Removing voids in the mica tape is the most important process for
manufacturing of stator coil insulation.
Both VPR and VPI system includes vacuuming
process in the pressure vessel to remove voids.

Stator coil by VPR system has the same

characteristic as the one by VPI system.
39

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Process of VPR Insulation System

- Stator bars taped with resin-rich mica tape are vacuumed to remove
voids and moisture from mica tape during tank treatment.
- The mica tape layers are molded and cured under pressure by heatmelted pressure-heat medium in the vacuum pressure tank.
HIGH QUALITY (VOID - FREE)
GOOD PERFORMANCE

VACUUM & HEAT PRESS TYPE

(TOSHIBAS System)
PRESS BY N2
HEAT PRESS BY LIQUID

WINDING RESINRICH MICA TAPE

FORMING
BY STEEL PLATE

VACUUM DRYING
& HEAT PRESS IN VESSEL

40

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Experience of VPR Insulation System

Toshiba has extensive
experience in hydro
generator coils
GURI-: 805MVA-18kV

CHAIRA: G/M-235MVA-19kV

41

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Corona Shielding of Stator Bar

Semi-conducting Silicon
Carbide Glass Taping
End Portion

End Portion

Slot Portion
Conducting Glass Taping

42

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Corona Shielding Method of Stator Bar

The Stage of Corona Shielding
Before
Tank Treatment
Method

After
Tank Treatment

By Taping

By Taping

By Painting

Equality of Coil Surface Resistance

Good

Good

Not Good

Mechanical Strength

Good

Good

Weak

Adhesion between Main Insulation

and Corona Shielding

Good

Weak

Good

Corona Shielding is Carried Out by Taping Before

Tank Treatment
43

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the information it contains be disclosed to any third party without their written permission

Toshibas Stator Coil Manufacturing Process

(Single Turn Coil)
Purchase of
Strand Wire
Drum

Wire Cutting and

Removal of Insulation

Roebel Transposition

Molding
Bar

Transposition

Covering strip

Wire

Press molding

Layer Short Test

of Strand

Forming

Insulation

Taping of Corona
Protection Tape

Taping Machine

Taping Machine

Measurement
of Tand

High Potential Test

End Portion
End portion

Straight portion
Lead Portion (brazed)

Applying of Molding
Plate

Tank Treatment
Bath

Vacuum tank

Bar
Visual Inspection

Liquid storage

Packing and Shipping

Site

44

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Stator Coil Wedging System

Tank-Treated Semiconducting Corona
Shielding (Glass)

Semi-conducting
Corona Shielding

Advantages

Higher

Bottom Bar

Reliability of Coil
Bar Fixing
Improved Workability of
Wedge System
Short Installation Time

Bottom Bar

Top Bar

Slot Side Fillers

Top Bar

Slot Side Fillers

Top Ripple Spring

Top Fillers
Previous Design
(One Piece Type)

Wedge

Top Fillers

Taper Slide
Toshiba Standard Design
(Two Pieces Type & Top
Ripple Spring)

Wedge

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Stator Bar Wedge System

Top Ripple Spring
0.3mm thickness
Top Fillers

Master Slide Gauge

0.8mm thickness
Top Fillers

Wedge
Taper Slide

1.6mm thickness
Top Fillers

46

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
47

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Ventilation Cooling System of Generator

Simple construction
- No motor driven fan nor fan blade

Uniform cooling air flow

- Cooling air flows into stator core
directly

Easy to control cooling air volume

- By adjusting the air inlet area

Applicable also for reversible

generator-motor

High efficiency
- Small windage loss

Toshiba Typical Radial Air Flow Cooling System

48

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Ventilation Cooling System

Rotor fan

External fan

Radial duct

Sectional
view

System
Application for
generatormotor
Generator

Fans of the rotor

External fans

Radial flow

1972
Medium speed

Present

Large capacity and/or

high speed
1978

All range

Conventional generator
49

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Air Flow Passage for Ring Type Rim

For high speed machine

Rim block

Rim block
stacking

Air duct space between

rim block stacking

Complete ring rim

and cooling air flow passage
50

 TOSHIBA 2014, All rights reserved.

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TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Air Flow Passage for Segment Type Rim

For large and low speed machine
Rim punching

Rim stacking

Complete segment rim

and cooling air flow passage

Air duct space

between segments

51

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Cooling Air Passage of Stator

Stator coil
Stator core
Heat exchanger

Uniform air flow

52

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Verification and Optimization of

Ventilation Performance by CFD

Example of static pressure

distribution around rotor and stator

Example of cooling air velocity

distribution around rotor and stator
53

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Radial Ventilation Cooling System

ROTOR

Test Rig of Radial Ventilation

STATOR

Ventilation Circuit Model

Verification of theoretical analysis by test rig

Reliability on radial ventilation system for
475MVA-500min-1 G/M is already verified
54

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Contents
1. Experience of Hydro Generator & Generator-Motor
2. Reliable and Trouble-Free Solution for Hydro Generator
- Shaft System Stability
- Thrust Bearing Reliability
- Oil Vapor Prevention
- Stator Core Buckling Prevention
- Stator Coil Reliability
- Air Ventilation Cooling System
- Cooling Water System Option
55

 TOSHIBA 2014, All rights reserved.

This document is CONFIDENTIAL and is the INTELLECTUAL PROPERTY of
TOSHIBA CORPORATION. It must not be copied, loaned or transferred, nor must
the information it contains be disclosed to any third party without their written permission

Cooling System Option <Closed Circuit System>

(In case of no good external cooling water quality)

Upper Guide Bearing

Oil Cooler

P
P
Generator Air Cooler

Thrust & Guide

Bearing Oil Cooler

Water to Water
Heat Exchanger

P
P

External Cooling Water

Turbine Guide
Bearing Oil Cooler