1

CREATING A NEW ERA OF INTERNATIONAL PARTNERSHIP

The late 1970s saw the introduction of FTK (full turnkey) contracts
involving all civil work, machinery procurement, erection and trial
operation for the international power-plant business.
In the 1980s, much more extensive B00 (build, own and operate)
contracts began gaining popularity. Although both FTK and B00
contracts are quite complicated as well as risky, Toshiba is actively
offering these contracts to meet the needs of its customers.
The illustration above depicts the outline of a full-turnkey contract for
India's Anpara-B power station. In this billion-dollar, five-year contract,
Toshiba headed a consortium of Indian, European, and Japanese
companies to build a highly modern power station in India's remote
interior.
In response to an imminent power crisis within China, Toshiba
spearheaded a full-turnkey contract to build the coal-fired .2 X 350-MW
Shajiao-B power station in a mere two years as a B00 contract.

1
ENGINEERING QUALITY-MANAGEMENT SYSTEM
Toshiba can provide power-station equipment - manufactured at our state-of-the-
art plants - that is fully compliant with ASME requirements and other international
quality-control standards. We can also provide reliable quality-management
systems for the engineering from the start of a project to a plant's completion.

As of January 1994, Toshiba's quality-

management system has been certified
by Lloyd's Register Quality Assurance
Ltd. as being fully compliant with ISO
9001 standards for turbine generators
and their auxiliaries, and since April 1994
for control and substation equipment. As
such, Toshiba is the first company in
Japan to have been awarded ISO 9001
approval for all power-station equipment.

2
Toshiba thermal power plants
Electric energy is a vital commodity for maintaining and improving our present-
day societies and living standards. To ensure adequate, reliable supplies of electric
energy whenever and wherever needed, Toshiba has built a wide variety of thermal
power plants in Japan and around the world.

Toshiba thermal power plants operating around the world

GE
TOSHIBA
Operating reliably under the world's widely varying
environmental conditions, 203 Toshiba thermal generator MITSUBISHI
units [total capacity as of Sept. 1993: 30,081 MW] are
serving the industries and homes of many nations around
the world.
HITACHI

Toshiba’s share of thermal power plants operating in Japan

Toshiba thermal power plants delivered by year

Capacity plants
delivered by year

Export

Domestic

Total Capacity

3
Toshiba offers high-efficiency, large-capacity
power plants to meet a diversity of environmen-
tal and operating conditions.

Electricity has been a vital component of industry and modern-day soci-

eties since their foundation. Because demand for environmentally safe,
affordable electricity continues to expand as we approach the 21st cen-
KAWAGOE #1700MW tury, thermal power plants must play an increasingly important role in
Turbine Generator meeting such demand. With the twin goals of ensuring reliable supplies
Chubu Electric Power Co. of electricity and protecting the environment, Toshiba is incorporating the
latest in power-plant and computer technologies to assure that society's
power requirements will be met-reliably, safely, and economically.

4
Power-generation systems
Today's increasingly diverse societies require that power
plants be highly efficient, economical, easy to operate, and
large capacity. Nuclear-power plants are expected to be the
basic power source for large capacities of power, while conven-
tional plants will continue their high level of operation as a
medium-capacity power source. With its decades of experi-
ence in power-plant technologies - as well as being a leading
integrated manufacturer of electronics, computers and semi-
conductors - Toshiba is uniquely qualified to design and
install power-generation systems to best meet the particular
needs of each installation site

Nuclear power-generation system Geothermal power-generation system

Large-capacity output and high reliability are two key require- This unique system taps the natural supplies of heat energy
ments for nuclear-power plants. that have accumulated inside the earth. Thus, geothermal
power is generally considered to be "earth-friendly."

Conventional power plant

This is a common type that burns coal, oil or natural gas to
generate steam, which drives a steam turbine. It is generally
called a thermal power plant.
Medium-load power supply
The type of power supply that regulates power generation
according to power demand that varies from season to season or
from time to time each day is called a medium-load power supply,
in contrast to a basic power source that keeps supplying a
constant amount of electric energy throughout the year.

5
Conventional power-generation system

"Conventional" plants are those that burn coal, oil or natural

gas to generate power, hence they are called "thermal" power
plants. Two key areas where these types of plants must be
improved are increased capacities and higher rates of effi-
ciency.

Conventional power-generation system

This is a new type of power-generation system that uses a gas

turbine to drive a generator. It also has facilities to recover waste
heat from the gas turbine to generate steam and drive a steam
turbine. Combined-cycle technology operates at high thermal
efficiency, generates large-capacity output, and has excellent
operability. Another advantage is that NOx emissions from a gas
turbine's exhaust have been reduced to very low levels.

6
Electric systems
A thermal power plant's electric system plays a key role: con-
verting turbine-rotation energy into reliable electric energy.
Key components of a plant's electric system include: high-effi-
ciency generators; excitation system for steady control of
generator voltage; electrical auxiliary system; transformers
and gas circuit breakers that link the plant to its power-trans-
mission lines. High reliability of the overall system is assured
by careful design and coordination of all its key components.

Digital AVR (automatic

voltage regulator)
A power plant's digital AVR plays
an important role in keeping the
generator's output voltage con-
stant. Digitization has become
increasingly important for assur-
ing a plant's reliability.
Generator
The generator is the plant's key
component for converting rota-
tion energy into electricity. Key
factors are increasing generator
capacity and developing new
cooling technologies.

Gas circuit breaker Main transformer

To meet the requirements of the Output voltage from a power
trend toward higher-voltage, plant's generator is "stepped up"
larger-capacity power plants, gas before supplying it to the plant's
circuit breakers were developed transmission lines. Key factors
to efficiently and reliably break are insulation and materials tech-
high voltages and large currents. nologies to achieve high levels of
reliability.

Emergency Diesel Generator Set

Medium Voltage Motor Control Center

Switchgear

AVR The automatic voltage regulator composes the excitation system that regulates the generator's field current in order to
keep output voltage constant.

7
Information and control systems
Achieving a high degree of power-plant reliability is crucial for
assuring a steady supply of electricity to the communities and
industries a plant serves. The plant's information and control
systems provide an integrated interface that is responsible not
only for monitoring and controlling its boiler and turbine-gen-
erator, but for all other tasks as well, such as data management
and technical-service support.

An intensive-information-
integrated system for thermal
power plants

The plant's information system is designed

and programmed to manage an extensive
range of operations, including power gener-
ation, thermal efficiency, starts and stops,
energy and heat losses, operation history,
and technical support as necessary.

Operation Data Management

Display

An advanced digital control

system for thermal power plants

Toshiba's digital control system for ther-

mal power plants is designed to efficiently
control and operate the boiler and turbine-
generator, involving automation and opera-
tional-support systems.

Central Operator Console

Plant Operation Monitoring Display

Computer System

8
Thermal Power Plant Engineering
Engineering
It is a challenging task to integrate the many highly
sophisticated technologies used in thermal power plants so
that the plant operates efficiently, economically, and reliably
under various operating environments. In addition, a
manufacturer must be constantly researching, developing, and
testing new technologies for the power plants of tomorrow.
Such intricate responsibilities cannot be successfully met
without the precise, reliable coordination of various fields of
engineering.
As one of the world's leading manufacturers of power
plants, Toshiba is uniquely qualified to serve
the power-generation needs of today

9
 Toshiba Thermal Power Plant Engineering

System engineering enables management of an assembly of

multiple units so that they function as a single unit of equip-
ment. Toshiba's Thermal Power Plant Division provides a
comprehensive range of plant system-engineering services
for thermal power plants that function as a large-scale
system. The Thermal Power Plant Engineering Division takes
part in the construction of thermal power plants, cooperates
with Toshiba's Sales, Design, and Research Departments in
developing markets and new power-generation systems, and
actively participates in the research projects of various
international engineering societies and associations.

10
Engineering work

Engineering work for thermal plants encompasses six separate

areas of the various machines that constitute a thermal power
plant: Mechanical engineering; Electrical engineering; Infor- Plant layout planning
mation and control engineering; Civil engineering; Construction
and field engineering; and Project engineering for overall Mechanical engineering
project management. Extensive efforts and coordination in Mechanical engineering covers design of
these six fields of engineering are combined to build safe, the plant's steam-cycle and machine sys-
tems. The project's mechanical engineers
reliable, efficient thermal power plants. make decisions regarding the specific-
ations of steam turbines, condensers,
and other system auxiliaries.

Basic plant planning start

Civil engineering
Civil engineering considerations encom-
pass the basis of plant construction,
including structural design and building
design.

Structure analysis diagram

11

Single-line diagram
Electrical engineering
Specifications for the thermal plant's gen-
erators, transformers, switchgears, protec-
tion, control & monitoring systems, etc. are
all determined on the basis of electric-
system engineering.
I & C system configuration
Information and control
engineering
Information and control engineering en-
compass the planning and basic designing
of the instrumentation, control and plant-
operation monitoring system, as well as
the information-management system for
the overall thermal power plant.

Installation start Commissioning Plant completion

start

Construction and field engineering

Project engineering Construction and field engineering are respon-

Project engineering includes devising and man-
aging the overall project's scheduling, as well as
managing all engineering to ensure efficient
coordination.
sible for the erection and commissioning of the
individual components of the thermal power
plant under construction. The efforts of these
engineers play a key role in preparing the
installed systems for commercial operation.

Project schedule Equipment handling plan

12
 Project Project engineering involves planning the plant's
various construction stages, schedule management,
engineering
and overall project management to ensure efficient
integration and coordination of the various fields of
engineering required to design, manufacture, com-
mission, acid bring the new plait in-service.

Negotiating with customers;

monitoring proper execution of
contracts; setting project target
dates; setting up the administration
office for project management;
overall coordination
Equipment-transportation plans;
shipping plans; customs clearances;
heavy-object handling plans
Contract services; taxation issues;
applying for required approvals from
local authorities; insurance and
indemnity matters; plant delivery;
plans for training customer's staff

Selection of subcontractors;
technical negotiations
Overall schedule monitoring;
selection of subcontractors

Technical coordination;
Coordination of quality-assurance programs; plant general plan;
dealing with inspection authorities: engineering schedule
managing inspection scheduling management; drawing
control; complete manuals

Preparing progress reports

Project management
Project management concerns a wide rang, of
work involving general plant planning; technical
Project schedule coordination; schedule management; shipping
plans; negotiations with the customer; and
inspections, all which are essential to bringing
the plant service safely, efficiently, and on
schedule.

13
 Civil engineering Civil engineering paves the way for the actual con-
struction of a safe, efficient thermal power plant
through the preparation of comprehensive archi-
tectural and engineering plans.

Hydrologic Design Structural Design

Structure Analysis

Architectural Design

Civil engineering
The scope of civil engineering includes
designing individual buildings for the
thermal power plant equipment and related
struc-ures; preparing an overall plan for
building layout; planning the intake and
discharge of the plant's cooling water;
designing the plant's concrete stacks of
300 meters in height; designing piers for
vessels carrying tens of thousands of tons
of coal; designing obstruction lights;
providing for various types of fire-fighting
equipment and other building ancillaries.

14
 Mechanical
engineering
Heat Cycle Design
Heat Balance Diagram
Steam-cycle design and
system engineering
A larger-capacity, higher-efficiency ther-
mal power plant must meet the require-
ments of higher steam temperatures
and pressures. The goal of a steam-
cycle design is to use the steam's
thermal energy to the maximum extent
of efficiency. Teams of mechanical
engineers prepare the final spe-
cifications for a thermal plant's high-and
Mechanical engineering encompasses heat-cycle
design, the main aspect of a thermal power plant's
operating efficiency; design of the plant's machine
systems; as well as the general design of the plant
to assure safe, efficient operation.
System Design
Layout Planning by CAD
low-pressure turbines and condensers,
etc. They also design a general unit
interlock that serves as the basis of
efficient plant operation and safety.
Such engineers do much of the
necessary design work using CAD
workstations, and verify their designs
using extensive simulation models to
assure maximum efficiency.
Piping Diagram
Unit Interlock Diagram
15
 Electrical Electrical engineers plan and design the plant's
electrical systems to assure safe, efficient operation,
engineering
and they establish equipment specifications best
suited to the required electrical systems.

System design
A thermal power plant consists of generators, transformers,
auxiliary switchgears, switchyard and diesel generators, plus
other various kinds of sophisticated equipment. Electrical engi-
neering offers the most suitable system that integrates the var-
ious equipment and subsystems into an overall power-plant
system so that the system is highly efficient, safe, reliable, and
economical. Plant single line diagrams are created, a protection
relay system is selected and set to suit the individual plant's
requirements, and detailed plant-operation procedures are pre-
pared. Toshiba engineers use computers for system design; to
study system stability and failure analysis; to calculate fault cur-
rent and voltage-drop; and to simulate all possible system-oper-
ation conditions so as to ensure maximum plant reliability.

Single Line
Diagram

Fault Analysis

Equipment specifications
Basic specifications are determined for the
electrical equipment, with the goal of sys-
tem integration and performance at opti-
mum levels. To meet the various operation
patterns and requirements for efficient
plant operation, digital AVR, digital pro-
tection relays, and other digital devices are
incorporated for maximum controllability
and precision.

Protection Coordination Curve

Digital Type AVR

16
 Information and Information and control engineering develops a
control engineering system with a man-machine interface that best
meets the customer's requirements for advanced-
yet-easy operation of systems.

I & C system configuration

Basic design of information and control
systems
The plant's information and control systems are deter-
mined based on requirements of mechanical and elec-
trical engineering. The system also represents the
needs of the customer, that is, the electric power com-
pany. To ensure maximum operational surveillance and
ease of operation, a basic system plan is created; the
system's configuration is drawn up; the system's input-
output information is collected; control logic diagrams
are prepared; and the logic of the plant's automation
systems is examined carefully. Such integrated engi-
neering efforts lead to the development of information
and control systems that are human-friendly.

System Inputs/Outputs Engineering

Logic Diagram

Central control room design

To achieve the highest levels of surveillance, operability, and
operator comfort, the design of a thermal power plant's cen-
tral control room is carefully examined in coordination with
the design staff of Toshiba's head office.

17
 Construction and Construction and field engineering is responsible for
safe, efficient plant erection and commissioning.
field engineering Toshiba's state-of-the-art testing modules are
designed using the integrated manufacturer's latest
computer technologies, enabling maximum testing
analysis before the plant goes in-service.

Schedule Control
Equipment Handling Plan

Turbine Installation
Module-Component Construction (HRSG)

Installation, commissioning, commercial operation Commissioning

A detailed construction schedule allows sufficient time for commissioning
runs to minutely analyze all major plant components, to assure that the sys-
tem can deliver maximum performance and stability as designed. Toshiba's
installation engineering teams manage these extensive quality-assurance
activities. Installation engineering is also involved in the application of Tosh-
iba's module-component construction process, which increases the ratio of
factory-based prefabrication and reduces field work. This field of engineer-
ing also is responsible for incorporating new, labor-saving technologies and
processes into Toshiba's overall plant-construction process.

18
Plant maintenance and update services
At present, a large number of thermal power plants are in
operation around the world in support of the planet's diverse
societies. However, another key aspect of thermal-power
engineering is maintaining and upgrading existing plants at a
level of operation whereby they continue providing safe, reli-
able, efficient power. To that end, Toshiba provides compre-
hensive maintenance and upgrade programs designed to apple
the latest technologies and techniques that are constantly
being developed by Toshiba's industry-leading R&D efforts.

Renovative maintenance
To date. Toshiba has supplied over 300 thermal
power plants around the world. In addition, it
continues to provide preventive-maintenance and
technology-update services to ensure steady
supplies of safe, efficient power from the plants it has
built.
A preventive and renovative maintenance plan is
designed based on the plant's operating history, its
particular operational conditions, the customers
needs, and environmental-protection considerations.
New technologies and techniques are automatically
incorporated into Toshiba's plant' maintenance plans.

19
20
Technological development for conventional
conventional power plants

To make a conventional thermal power plant more economical,

it must be larger in capacity and higher in efficiency than previ-
ous models. To meet these two requirements, Toshiba's design
engineers are continually producing and testing new structural
designs and heat-resistant materials.

Larger capacities
The aerodynamic design of and materials used for the long
blades in the final stage of the plant's steam turbine are instru-
mental factors for increasing a power plant's capacity.
Toshiba's decades of power-plant experience has enabled its
Turbine 40” Bucket
design engineers to develop final-stage turbine blades of 42
and 52 inches in length as a means of achieving the twin goals
of larger plant capacities and higher efficiency rates.

33.5”/40” Titanium Blade

Higashi Ougishima #1
1,000MW Turbine Generator
Tokyo Electric Power Co.

21
 Research and development

High efficiency
Increasing a thermal power plant's rate of operational effi-
ciency is achieved by higher pressure and temperature of the
plant's steam. Toshiba is able to manufacture turbines that
operate reliably at ultra-super-critical pressures as a result of Trend of Steam Condition
its extensive background in developing high temperature
materials that safely withstand such pressures and tempera-
tures. This process has been greatly aided by Toshiba's long
experience as an integrated manufacturer of state-of-the-art
electronics, such as the sophisticated equipment used to
analyze and verify these new materials' mechanical strength
and stress-tolerance levels. Turbine-efficiency ratings have
been further improved by Toshiba's use of three-dimensional
analysis of materials in its quest to develop more efficient tur-
bine nozzles.

High Efficiency Compound Lean Nozzle

USC Turbine
(Kawagoe #1)
Ultra-super-critical pressures
A steam turbine whose steam pressure exceeds the standard level of 246atg
for a large-capacity thermal power plant is called an Ultra-Super-Critical
Pressure turbine (USC turbine).

22
R&D for combined
combined--cycle plants
The thermal efficiency of a combined-cycle power plant depends on the temperature of the
gas turbine's inlet combustion gas. A combined-cycle plant using a 1,300 ｰ C class gas
turbine can achieve a thermal-efficiency exceeding 54% at generator terminal. Toshiba
development engineers are currently working on a ceramic-based turbine that promises to
achieve even higher operational temperatures. Toshiba has also developed a dry, low-NOx
combustor that minimizes a plant's ill effects on the surrounding environment.

23
 Research and development

Dry Low-NOx Combustor

Low-
Low-NOx technology
The efficiency of a gas turbine can be increased by raising the
temperature of its inlet gas. On the other hand, NOx emission
increases due to higher combustion temperature. However,
Toshiba designed and developed a low-NOx combustor that
ensures uniform, stable combustion. The combustor minimizes
NOx at the source of its generation. In addition, the combined-
cycle plant's waste-heat recovery boiler, which recovers steam
energy-from waste gas, is now provided with a catalyst that
decomposes NOx. Such advances have enabled development
of combined-cycle plants that are both high in thermal efficiency
and friendly to the environment.

24
Information and control systems
Today's thermal plants must respond to the diverse needs of power
demand. In addition to improved operation panels and central CRT
displays to aid safety and efficiency in plant operation, Toshiba
researchers are also developing AI-based (artificial intelligence)
information and control systems based on new control theories.

Scale Model of Central Control Room

Next-
Next-generation monitoring and control systems
The use of a large wall-mounted screen, and central CRT display
screens facilitates maximum operator alertness and responsiveness
to the plant's operating conditions. To realize a human-friendly
operational environment, a scale model of the central control room is
used to simulate an operator's visibility by CCD camera provided in
the model.

25
 Research and development

AI-
AI-computer support system
The growing diversity of energy demands requires
that thermal power plants be increasingly flexible
in their ability to adapt to the need for frequent
plant starts and stops. Toshiba has developed an
artificial-intelligence operation-support system that
significantly assures rapid, accurate recovery of
plant operation in the event that unplanned opera-
tional changes or faults occur. The highly flexible
yet automatic responses of the AI-based system
identify individual problems before they become
system faults, thereby enhancing reliability and
efficiency of the operation.

Operation Support System Display Equipment Diagnosis System Display

Application of advanced control theories

A range of modern-day control theories such as fuzzy logic, neural
networks, and GPC can be applied to nonlinear and multiple input-
output systems according to the specific characteristics of a plant's
control objectives. Toshiba is constantly conducting research on
these and other advanced control systems.

Prototype Application of Advanced Controls

26
Information and control systems

Toshiba's extensive R&D efforts include the development of

a geothermal binary cycle power plant; a superconducting
generator; advanced heat-pump technologies; an ice storage
system; and other heat-utilizing systems related to power-
generation technology.

Geothermal binary cycle power

plant
Toshiba's geothermal power-generation sys-
tem uses a low-boiling-point working fluid.
Gas that has been heated to high tempera-
tures and pressures within the earth is used to
drive a turbine/generator. Toshiba's research
in this field indicates that increased plant
capacities and a wider range of applications
are feasible.

27
 Research and development

Superconducting
generator
This unique generator uses the
strong fields generated by the
superconductivity phenomenon.
This source has enabled higher
rates of efficiency, reduced plant
dimensions, and increased sys-
tem stability. The key requirement
of cryogenic technology lies in the
use of liquid helium to achieve the
low temperatures required to pro-
duce the superconductivity phen-
omenon.

Heat Pump With Magnetic Bearings

Direct Contact Ice Storage System

28
 Engineering network
Toshiba thermal power plants are built by the concerted efforts
of its Thermal Power Plant Division and other divisions of
Toshiba Corporation, as well as member companies of the
Toshiba group. An extensive range of R&D efforts in thermal
power engineering is a certain step toward realizing significant
technological developments that will constitute the thermal
power-generation plants of tomorrow.

29
 Head Office (Tsurumi)

Head Office (Hibiya)

Keihin Product Operations

Fuchu Works

Hamakawasaki Works
30
 Overseas Office: Toshiba International Corporation:

TOSHIBA London, Moscow, Vienna,

Beijing Shanghai, Guangzhou,
Hong Kong, New Delhi,
San Francisco, Houston,
Vancouver
Toshiba International Corporation
TOSHIBA CORPORATION Bangkok, Taipei, Manila, Pty. Ltd.: Sydney, Melbourne
Jakarta, Colombia, Toshiba International Company
1-6, UCHISAIWAICHO 1-CHOME, CHIYODA-KU TOKYO, 100-0011, JAPAN
Rio de Janeiro, Buenos Aires Limited: London
PHONE: -81-3 3597 2345 FACSIMILE: +81-3-5512-8115
TELEX: J22587 TOSHIBA

● For further information, please contact your nearest Toshiba Liaison Representational or International Operations-Producer Goods.
● The data given in this catalog are subject to change without notice.

3052-3 98-2 R2