POWERHOUSE
EQUIPMENT
Components and systems for the powerhouse
The powerhouse is the beating heart of the hydropower plant, where the energy of water is transformed into electricity through turbines and generators. Inside it are machines for controlling water flow, cooling, lubrication, lifting, management, and electrical safety. This is where the highest mechanical, thermal, and electrical stresses occur, making the use of reliable, durable, and easily replaceable components indispensable.
TOTOGA supports plant operators and maintenance teams by supplying equipment. We also operate in complex contexts such as historical plants, isolated sites, or those subject to strict regulatory constraints.
GUARD VALVES
AND HEAD VALVES
Hydraulic and electric actuators for gate control
WHAT THEY ARE
Sono dispositivi per l’intercettazione in maniera sicura del flusso d’acqua diretto alle turbine. Le valvole di guardia sono installate subito prima delle turbine ed hanno il compito di mettere in sicurezza l’impianto in caso ci sia un guasto o semplicemente la necessità di una sosta. Sono dotate di azionamento di sicurezza in chiusura tramite contrappeso in modo che anche in caso di blackout dei sistemi di azionamento queste possano svolgere la loro funzione di sicurezza. Le head valves, o valvole di testa condotta, svolgono lo stesso ruolo a protezione delle condotte forzate. Vengono infatti tipicamente installate a monte delle condotte.
PRODUCTS
- Butterfly valves with counterweight and hydraulic actuation;
- Ball valves with movable seal, with counterweight and hydraulic or water actuation
TURBINES
Supply of spare parts and assistance for turbine-generator groups
PRODUCTS
PRODUCTS: TOTOGA provides technical support and spare parts for the main types of turbines used in hydropower plants:
- Francis: suitable for medium heads, ideal for continuous-use plants with variable flow;
- Pelton: for high-head and low-flow plants, using free jets on buckets;
- Kaplan: optimal for low heads and high flows, with adjustable blades.
Custom design or reverse engineering based on new equipment or spare parts:
- Runners
- Guide vanes and distributor components
- Labyrinth seals
- Injectors
- Shafts
- Mechanical centrifuges
SERVICES
On-site dimensional survey and reverse engineering of runners and components;
Custom design or reconstruction of new spare parts for Pelton, Francis, Kaplan and Cross Flow turbines, including: Runners, Labyrinths, Nozzles, Guide Vanes, Wicket Gates, Spiral Cases, Draft Tubes, Shafts;
Supply of bushings, bearings and seals;
Technical consulting for modification, optimization or revamping of hydraulic components;
TOTOGA relies on qualified partners for precision machining and anti-wear coatings, guaranteeing compatibility and performance equal to or superior to the original.
GENERATORS
Maintenance, spare parts supply, and diagnostics for synchronous generators
PRODUCTS
Rolling and sliding bearings, including white metal refurbishing;
Coils;
Heat exchangers;
Poles
Custom-made generators based on client specifications
Replacement voltage regulators
Lifting systems (oil jacking)
Specialist services for electrical insulation measurement
SERVICES
TOTOGA offers a complete service for the management of electric generators coupled with turbines, with specific expertise in vertical and horizontal synchronous and asynchronous machines of medium and large size. Support includes maintenance, diagnostics, spare parts supply, and the possibility of manufacturing new generators on request.
TOTOGA offers:
- Preliminary electrical and mechanical surveys;
- Vibration analysis;
- Dismantling, reassembly and on-site alignment
All activities are carried out in compliance with IEC standards and the technical specifications of the original equipment manufacturer (OEM).
HYDRAULIC POWER UNITS (HPUs)
Hydraulic power units for actuators and operating systems
WHAT THEY ARE
Hydraulic Power Units (HPUs) are the core of hydraulic actuation systems, supplying cylinders and actuators for the operation of gates, trashracks, valves, turbine distributors/injectors and other mechanical equipment. Along with HPUs, associated control panels and complete hydraulic piping can also be supplied, fully customized to the plant’s configuration. A well-designed HPU ensures constant pressure, controlled speed and operational safety even under critical environmental conditions or frequent maneuvers.
PRODUCTS
- Complete hydraulic units with tank, pump group, valves, heat exchangers, instruments and integrated electrical panel
- Customized layouts for installations in confined or outdoor environments
- Certified components sized according to ISO and DIN standards
- Control panels
COOLING WATER SYSTEM (CWS)
Water cooling systems for generators and supports
WHAT THEY ARE
CWS (Cooling Water Systems) are used for cooling generators, bearings, speed regulators and other fundamental components of the powerhouse. Proper operation of the cooling circuit is essential to guarantee operational efficiency and prevent overheating or failures.
PRODUCTS
Shell and tube heat exchangers, plate or immersion radiators for discharge channels;
Self-cleaning or cartridge filters;
Cooling water pumps with mechanical seals and anti-vibration bases;
Flow control and regulation valves;
Temperature probes, pressure gauges and flowmeters;
Electrical panels for system control and automation
CWS systems can be designed for both open-loop operation (with filtered raw water) and closed-loop operation, depending on plant characteristics and available resources. Every configuration is compatible with common SCADA or PLC systems for continuous monitoring of operating parameters and alarms.
On request, complete skid-mounted systems can be supplied, assembled and tested, ready for installation and commissioning.
CRANES
Lifting systems for maintenance in the powerhouse
WHAT THEY ARE
Cranes installed in the powerhouse play a fundamental role in assembly, maintenance and replacement operations of heavy components such as turbines, generators and intercepting valves.
PRODUCTS
TOTOGA supplies different types of cranes and lifting systems, designed to ensure reliability, safety and precision even in confined spaces or in environments subject to heavy-duty conditions.
- Overhead cranes and gantry cranes for large-scale plants;
- Jib cranes or monorail cranes for localized operations;
- Rail-mounted mobile cranes for movement along the intake;
- Electric or hydraulic hoists;
- Certified lifting devices (hooks, spreader beams, chains, etc.)
Every lifting system is designed in compliance with current industrial safety and lifting regulations (e.g. Machinery Directive 2006/42/EC) and can be adapted to the plant’s existing geometry.
POWER CONTROL
Electrical panels, protection systems and auxiliary power supply
WHAT THEY ARE
Electrical management in a hydropower plant is essential to ensure operational continuity, plant safety and equipment protection. TOTOGA supplies components for power distribution, control and supply systems, both in medium and low voltage.
PRODUCTS
Among the equipment supplied:
- Transformers: power and service transformers, oil-filled or resin, for voltage adaptation between generator and distribution grid;
- MV Switchgears: medium-voltage switchboards, air- or gas-insulated (AIS/GIS), with modular compartments and integrated protections;
- MV Circuit Breakers: medium-voltage circuit breakers for the protection of transformers, generators and distribution lines;
- Rectifiers and Battery Banks: auxiliary power systems for essential services, with rectifiers and battery banks ensuring continuity even during grid outages;
- All systems are designed to integrate with SCADA and existing supervision systems, and can be supplied with mimic diagrams, selective protections and customized automation logics;
- Automatic power factor correction units.
TOTOGA can also supply equipment for electrical substations, such as HV/MV transformers, disconnectors, circuit breakers, protection panels and measurement systems, also coordinating engineering and commissioning activities.
