ABB AMS Synchronous Generators

AMS Synchronous Generators 4- and 6-pole, 3–70 MVA, 3–15 kV Generators that deliver value

The power from our generators comes from people meeting. From contact with our customers and users. Then new requirements and new opportunities arise. From the joint efforts of our project teams, workshops and test facilities. Then ideas become reality and parts become a whole. It is always together that we create our generators.

2

Generators to serve people Co-operation creates success

We manufacture generators. Develop, design and build. Those are the obvious and visible aspects of our work. But the real reasons for our success in the market are more difficult to define. They relate to a completely different process. A process where your expectations are fulfilled. Knowing how to listen, to communicate and to understand. To deliver real benefits. Knowledge of your world We base our business on experience. Whenever you contact us you are dealing with a partner who has supplied nearly 500 synchronous generators since 1990, both 4-pole and 6-pole, to a wide range of users all over the world. Plants where we have designed and built generators to suit each user’s needs and values. We have listened, understood and delivered. Generators where, in each individual case, we provided the best solution. Experience of the environment for generators Today our generators are operating in very different environments. In normal utilities and industrial environments, but also in violent storms on oil platforms, in “close to city” environments, in icecold northern regions as well as in the searing heat of the tropics. Regardless of where you are we can supply a generator to suit your requirements. It is through just such knowledge that we have become a world-leading supplier. This is not the sort of knowledge you can buy. This knowledge comes only from having been there. In the middle of your reality.

4-pole generators

Advantages

ABB’s breakthrough as a

of standardisation

supplier of generators came

GE Energy (Norway) is

at the beginning of the

supplying gas turbines

1990s. An essential element

for off-shore installations

was the decision of Alstom

of Norsk Hydro. To fulfil

Power to increase the use

this contract GE Energy

of 4-pole generators in their

has signed an exclusive

industrial turbines. More and

contract with ABB to

more turbine manufacturers

supply the generators.

have followed this trend. The underlying reasons

So far more than ten units have been supplied.

are that using a gearbox

The contract requires

means that the turbine can

a high degree of standard-

operate on its optimum

isation of the product and

speed and that the capital

the logistic procedures.

and running costs of 4-pole

The benefits are already

generators are significantly

apparent. One generator is

lower than for the 2-pole

held on-shore as a standby

alternative. These advan-

for the off-shore units and

tages outweigh the costs

the delivery time has been

of the gearbox.

reduced to 50% of the normal time.

3

Values that mean more Performance, availability, productivity and improved operating efficiency

Today it is not just the price and performance of a generator that determine how an investment decision is made. The decision is just as dependent on those other values important to the turbine manufacturer and the end user. In our experience one of the most significant values is confidence. You must feel sure that your new investment is based upon technology that is suitable for your requirements – of today and tomorrow. At the same time your solution should be well proven, supported by many strong references. Confidence – the fundamental value This confidence comes from the basic values of all those working in our organisation. The knowledge and experience of each and every member. The responsibility and quality consciousness of our skilled workforce. Initially this springs from an interest in technical matters. But it comes just as much from pride and from the desire to make every generator the best. Creating value for customers But we never use technology for technology’s sake. We use technology to be able to give you the lowest life cycle cost for each generator and values such as higher productivity, higher operating efficiency and minimised environmental impact, to mention just a few. And the earlier you contact us the greater is the opportunity for us to offer optimum design, a shorter delivery and for us to support you throughout the project. Building generators is like building relationships. Relationships that simplify matters and shorten times. That develop and renew. It is through such relationships that we are always able to create new value for customers and users. Creating values that provide more.

4

Life-long responsibility Recently an existing generator at the Ängelholm combined cycle plant was upgraded. A new cooler was fitted to overcome problems with cooling air quality. The rotor was up-graded to class H insulation. These changes will considerably further extend the life of the generator.

5

Quality in every aspect

The Rotor

Fast control and

Solid pole shoes pro-

electric stability through

vide high damping without

adaptation of the air gap,

damper winding. This also

design of pole shoes and

gives good overload capa-

dimensioning of pole core.

bility and low harmonics.

Reliable operation

The stiff rotor and mini-

Over-speed tests are

and long life due to

mum distance between

performed as standard. The

large cooling surfaces and

bearings ensure that the

complete rotor is balanced

effective flow of cooling air.

operating speed is below

at operating speed.

This also gives low uniform

the first critical speed,

rotor temperature. Class H

thus giving low vibrations.

ABB is one of the world’s leading supplier of synchronous generators to industrial plants, utilities and independent power producers. Evolutionary development means modern products All of our generators have been developed as standard, modular units offering great flexibility to ensure that the right generator can be selected for each installation. We endeavour to introduce each improvement resulting from innovation, from new materials or from new manufacturing methods quickly so that customers can enjoy the benefits as soon as possible. We can also introduce changes in ways to ensure that they can be fitted to generators supplied earlier so that existing users can also share the benefits. After long periods of continuous development it is sometimes necessary to make more radical changes and, in the end of the 1990s we decided to introduce a new range of synchronous generators which would take advantage of all previous development and provide a platform for the future. It was first used for the smaller models but now it is our standard generator for the whole range. The concept facilitates the rapid implementation of change. Also, we apply the same concept to synchronous generators and motors which is of great benefit to both.

Options

insulation of the coils gives

– The shaft extension can

extra thermal margins.

be flanged to match the driving machinery. – Shaft for double end drive.

And modern factories The focus on the development of 4-pole and 6-pole synchronous generators and motors has been highly successful and has enabled us to build one of the world’s largest and most modern factories for this class of work.

6

The Stator

Limitation of the voltage

High-grade, low-loss

The stiff frame

drop and/or the short circuit

electrical steel increases

transmits all forces

current is done by designing

efficiency and reduces

directly to

the reactances.

operating costs.

the foundations.

The insulation system

Well developed and

gives reliability and

proven methods for

long life. The windings are

locking coils into slots and

insulated with Mica based

bracing coil ends ensure

tape. When the windings

long term reliability.

are in place, the complete stator is impregnated in a vacuum pressure impregnation (VPI) process. The windings are of insulation class F, which gives good thermal margins.

7

The Exciter-rectifier

Simple but highly

The compact, brushless

developed design having

exciter unit is mounted

few components and well

on the rotor shaft outboard

adapted protection functions

of the bearings together with

offers high reliability and

a PMG (permanently mag-

easy access for maintenance.

netised auxiliary generator). No independent support or alignment is required.

Improved system

Bearing housing design

Independent lubrication

performance due to the

permits easy access for

system gives high reliability.

possibilities of high field

inspection and maintenance.

Oil rings or oil reservoir

forcing. This is important

Bearing housings are

ensures lubrication during

when faults in the supply

insulated from the frame to

emergency rundown.

network arise and to

eliminate circulating currents

Hydrostatic jacking oil

increase the production

in the shaft. The shaft can

systems are available for

of reactive power.

be earthed. Bearings are

applications operating at

sealed against oil leakage

low speed.

with labyrinth seals.

Sleeve bearings are designed to be insensitive to misalignment and to permit large axial play.

8

The Frame

Great stability of the

Shipment of fully tested

Generators smaller than

Small dimensions and

complete generator.

generator. Only the terminal

22 MVA can be installed

low weight simplify prep-

Dynamic and static stresses

box, and in some cases the

sunk down in the foundations.

aration of foundation and the

are transferred directly to

heat exchanger, need to be

installation. Despite its small

the foundation contributing

removed prior to shipment.

size, the generator is easily

to the great performance.

Cooling form IC8A1W7 for generators below 22 MVA.

accessible for maintenance.

A wide range of cooling

Options for water/air

forms allows an optimum

heat exchangers.

choice for operating and

– Systems with double

environmental conditions.

water/air heat exchangers

Irrespective of the cooling

can be designed for full

form, the system provides

load with one of the heat

uniform cooling of the

exchangers out of service.

complete generator.

– Heat exchangers with

All water connections are

double tubes.

positioned outside the

– Heat exchangers of

frame.

different materials, e.g. CuNi, stainless steel or titanium.

9

More than just a generator We see the generator as a part of the whole

Accurate predictions

In ABB we have a good understanding of building complete systems. We also have solutions that greatly facilitate sending information from the generator system to the plant’s control system.

Detailed calculations are made for every proposal to ensure that the optimum solution has

Always a part of something bigger The technology in our synchronous generators gives constant high efficiency, good excitation characteristics and excellent control of the machine. But generator management is also part of the system. The generator must fit smoothly with the turbine and all ancillary equipment.

been identified. Many customers utilise our deep knowledge and our advanced simulation facilities for more advanced studies. ABB offers this extra service for new instal-

Integration We can offer a wide, flexible range of systems for collecting and transmitting information from the generator for protection and for supervision. A concept that can easily be fitted to your needs and the special requirements of your installation. Tailor-made solutions As complexity increases so does the scope and scale of each order. That places extra demands on the capacity of the supplier. The competence required for your project, regardless of size, is available within ABB. The competence and capacity to tailor solutions that cover every type of installation.

10

lations and to identify opportunities for improving older generators.

Flexible deliveries ABB’s supply involves

are normally included.

Within our modular system

more than just the generator.

The supply can also include

it is also possible to adapt

The terminal box and

a base-frame for the gear-

new generators to old

generator control panel

box and the generator.

pedestal bearing design.

Requirements for all the components in a system to work smoothly together have increased in step with requirements for higher levels of cost-effective production. In today’s world there is a much sharper focus on total concepts and total solutions.

11

Terminal box

Protection

Several terminal box designs are available with generous space for mains connections, measuring transformers, protection against voltage transients and neutral point equipment is positioned on the side of the generator most convenient for the customer.

Electrical and mechanical faults can impose unacceptable conditions and protective relays are provided to quickly disconnect the generator from grid.

Recommended protections Other signals Normally connected direct to the common control system of the application.

Terminal box

• Temperature cooling air • Temperature stator windings • Temperature bearings • Vibration; bearings 1) • Temperature/flow cooling water 1) • Temperature/flow lubricating oil 1) 1) Not always included in the generator supply.

Arrangements

Location

Advanced options

The standard arrangement

The protection system is

In some cases it is advan-

is for cable entry from below.

located in the generator

tageous to fit additional

The box normally has the

control panel together with

protection including tele-

same form of protection

logic functions and the

metrics. For example,

as the generator and is

excitation equipment.

direct measurement of

designed to minimise

rotor earth fault, rotor

the risk of damage in the

voltage and rotor current.

event of a short-circuit. Earthing resistors can be placed in a separate box.

12

Excitation

Generator Control Panel

Synchronous generators require the control of excitation current in the rotor. ABB’s brushless, rectifier based excitation system offers control of the rotor current, taking full benefit from the advantages of synchronous generators.

The generator control panel is available in several basic formats which are finished to suit the requirements of each customer. The panel houses the excitation equipment and the protection systems. Conceivable equipment for manual, automatic or manual/automatic synchronisation is also housed here.

Generator Control Panel • Generator differential (87G) • Over frequency (81H) • Stator earth fault (59N) • Over voltage (59) Measuring AVR

• Short circuit (51) • Loss of excitation (40) • Negative sequence current (46)

• Excitation equipment with regulators, low and over exitation limiters. Measuring AVR

• Diode fault protection (58) Note: ANSI codes within brackets.

Advantages of synchronous generators

Operator’s control panel

Integration with plant-

A significant advantage of

The regulator in the excit-

A digital multifunction in-

wide control system

synchronous generators is

ation equipment conforms to

strument is mounted of the

As an option information

the facility to select the most

the requirements necessary

front of the generator control

can be fed into a superior

suitable operating conditions

for accurate control and

panel. Analogue instruments

control system. This allows

– constant voltage, constant

offers high stability parallel

can be fitted as an option. In

the operator to monitor

field current, constant reac-

operation with other

certain cases an operator’s

the generator.

tive power (Mvar) or constant

generators.

panel is provided where

power factor.

alphanumeric signals are displayed.

13

Simplicity throughout A concept full of customer value

An overall objective for us is to make life simpler for our customers. Every stage must be easy, from selection of the generator and how it will be integrated through to installation and commissioning. And, of course, maintenance, servicing and the provision of spare parts. Closer relations reduce costs Frequent contact between the turbine manufacturer, the end user and the generator supplier is clearly an important factor in achieving a good exchange of information and maintaining good communications. Through various forms of partner agreement we can work together to adapt the product interface to simplify logistics and reduce delivery times and, at the same time, support the customer throughout the project phase.

Our generators are found in Gas, Steam and Combined Cycle plants: Oil & Gas (Offshore, Onshore and Pipelines)

Customised designs Within the frame of an agreement the co-operation often grows much deeper. This has, for example, involved our design and development engineers working very closely with the turbine manufacturer and end-user to develop jointly an optimised total solution. A global network An important prerequisite for close co-operation with customers is a local presence. We are present in most countries of the world and you have access to our complete product range and all our expertise by contacting our nearest sales office. A presentation of our marketing facilities is even closer – it can be found at www.abb.com. Welcome to ABB.

Chemicals & Petrochemicals Cement Food, Sugar Mining, Metals Pulp & Paper Independent Power Producers Utilities

Tested to ensure quality We perform a comprehensive test on every generator before it is dispatched to the customer. This test is part of the quality assurance procedure which is followed closely for every delivery. Evidence of the test, in the form of test reports, is handed to the customer on completion of the test.

15

3BSM006540 EN, Rev A, February 2008

ABB AB Machines SE-721 70 Västerås, Sweden Tel: +46 21 32 90 00 Fax: +46 21 32 95 10 www.abb.com

Ellens Byrålåda, Västerås.

ABB 4-pole and 6-pole synchronous generators and motors are sold all over the world by ABB sales companies. They are supported from Sweden. The development, design and production facilities are concentrated at Västerås in Sweden. This concentration helps to ensure that the most modern production resources are used to maintain high quality and low costs – to reinforce ABB’s leading position in this field. Long-term profitable operation of these machines requires reliable performance from every component. To achieve this ABB offers services that extend well beyond the warranty period. These services include preventive and corrective servicing and up-grading to improve performance and extend the life; also the supply of spare parts and support. Servicing is undertaken in conjunction with specialist service companies from within and outside the ABB group, thus providing global cover. ABB can be your partner from the very beginning through to the end of the generator’s life cycle.