Hydro Generators Workshop
CLEAN CURRENTS 2026
Time: 1:30 PM - 5:45 PM
Day: 9/22/2026
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This workshop focuses on all things hydro generators! Attend this 4-hour course to learn about:
-- Generators 101 - how hydro generators operate, their anatomy, and the interaction of the primary components
-- Keys to Extending the Life of Existing Generators
-- Stator Core Resonance and Vibration
Direct participant questions and comments will be encouraged throughout the workshop.
Specific Content for the Workshop
Extending the Life of Existing Generators
Successfully accomplishing hydro generator life extensions can be a very daunting task with a broad array of considerations, challenges, and options. The oldest active hydro generators have been in operation for well over a hundred years and have likely had at least one life extension, if not multiple life extensions performed.
Younger vintage hydro generators are well into their expected design life and are candidates for a life extension. There are many similarities between old and new vintage machines; however, there are also unique differences that must not be ignored. Both will be explored in this all-inclusive workshop studying hydro generator life extension.
Topics in this portion of the workshop include:
-- Initial planning aspects of Asset Management, including condition assessment, foundational documentation and data collection, and how these aspects relate to the development of the life extension scope of work
-- importance of a comprehensive uprate study, as well as the primary key elements from the study and how they relate to the life extension scope
-- a hydro generator's insulated components including the rotor poles, stator core laminations, and stator windings
-- necessity of prequalification elements, key specification requirements, and need for QA/QC checks both during execution and as a final check
-- importance of qualifying components intended for reuse, including tests and checks to ensure reliability (specific attention will be drawn to components that can appear satisfactory for reuse but really are not)
-- rotor pole to pole leads (these can see significant mechanical stress during normal operation and the case will be made for their replacement and possible analysis for improvement)
-- Recommendations for effective planning and project management
-- How to work effectively with project vendors, including setting realistic milestones and clear expectations
-- Domestic and global supply chains, from the perspective of managing risk to support project goals
-- Review of CTQ (Critical To Quality) elements as well as CTS (Critical To Success) factors
Insights into Core Resonance during Rated-Flux Loop Testing of a Stubborn, Uncooperative Salient-Pole Generator
Rated-flux loop tests are often used to validate the condition of existing or new stator cores. A recent experience at a Bureau of Reclamation hydro facility revealed several uncommon issues during loop testing, including difficulty meeting the hot-spot temperature rise of a new stator core due to a power-frequency resonance and strong vibration.
This portion of the workshop explores topics from proper engine-generator sizing to core resonance.
It will also cover flux paths under loop test excitation compared to normal operation, and the underlying physics of core vibration in these scenarios. In this case, extreme core vibration and high levels of noise necessitated testing near-50Hz to avoid a 60Hz resonance point. Configuring the loop power source for this was challenging but feasible.
And, finally, comparisons of core vibration, sound levels, temperatures, and loop current for 60Hz and near-50Hz test conditions will be presented.
