ABB Synchronous Generators
ABB Synchronous Generators
ABB Synchronous Generators
IndustrialIT
As a key element of its business strategy, ABB has committed to a broad program of product development and positioning under the IndustrialIT umbrella. This initiative is geared towards increasing integration of ABB products as the building blocks of larger solutions, while incorporating functionality that will allow multiple products to interact seamlessly as components of real-time automation and information systems. Motors, generators and drives represent fundamental building blocks in the IndustrialIT architecture. ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impacts. The ABB Group of companies operates in around 100 countries and employs about 120,000 people.
Output range at different speeds ....................... 4 Modular construction .......................................... 5 Cooling and protection ........................................ 6 Windings ............................................................... 8 Insulation ............................................................ 10 Stator ................................................................... 12 Rotor ................................................................... 13 Excitation and regulation systems ................... 14 Bearings .............................................................. 16 Accessories ........................................................ 17 Final testing ........................................................ 18
The ABB Group is also working hard in the field of corporate social responsibility which it sees as the commitment by business to contribute to sustainable economic development, working with employees, their families, the local community and society at large to improve the quality of life.
Performance by design
Output range at different speeds
AMG 400 - 630
5
200
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900
3.0
500
60
2500 2000
2.5
50
Output [MVA]
2.0
40
1600
1.5
400
30
1.0
20
355
0.5 10
200
Design standards
The electrical design is based on the relevant IEC or NEMA standards and mechanical design on the relevant ISO standards. In marine or offshore applications the additional design criteria of the applicable classification society are followed. These societies include ABS, BV, CCS, CR, DNV, GL, KR, LR, NK, RINA, and RS.
based on information from engine or generator set builders about the natural frequencies or global vibration modes like base frame horizontal and vertical bending or torsion along the longitudinal axis to help ensure troublefree operation. The generators withstand linear vibration up to the limits specified in the relevant ISO standard (typically 10 - 20 mm/s), which significantly exceeds the vibration originating from the generator itself (max 2.8 mm/s during final testing).
Efficiency
Our generators are designed for high efficiency, with losses minimized through the effective use of materials, state-of-the-art insulation and optimization of rotors, stators and fan designs. This benefits users like power plant operators as high efficiency helps to save money, cuts operating costs and means more electricity for the same investment.
Recommended protections
The generators are built to withstand abnormal situations such as unbalanced load, overcurrent or overload in accordance with the relevant IEC or NEMA standards. However, in order to avoid damage to the generator in situations where the permissible values are exceeded, the following protections are recommended:
Thermal overload in stator winding Network short-circuit Stator interwinding short-circuit Stator earth fault Overvoltage Unbalance load or shorted turns in same phase Underexcitation or loss of synchronism Undervoltage and intermittent loss of voltage Monitoring of temperature detectors
Vibration tolerance
Generators coupled to reciprocating engines are always exposed to engine induced vibration, especially when the generator and engine are built on a common base frame. We use sophisticated design tools to analyze the impacts of external torsional and linear vibrations on the generator. This work is
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Output [MVA]
Output [MVA]
630
Modular construction
ABB's R&D engineers work closely with engine manufacturers, using FEM and dynamic animation techniques to determine various vibration models, test critical parts and verify that hazardous mechanical resonances do not occur in the generator.
Modular design combined with a high degree of standardization means shorter manufacturing times. This benefits customers in terms of faster lead times.
Frame construction
The smaller generators feature a three part modular frame consisting of the stator housing and two end housings. The end housings are precision machined and finally bolted or welded to the stator housing, ensuring perfect alignment and sufficient rigidity to withstand engine induced vibrations. End-shield type bearings are mounted on the end housings. The larger generators are built in a self-supporting full frame and equipped with integral pedestal bearings.
Mounting
All our synchronous generators are designed for horizontal mounting. They are supplied as integral units, even up to the highest sizes and outputs. They therefore require no further assembly on site, which means that installation times are substantially reduced. The most common mounting arrangements are:
IM code Description IM1001 - two end-shield bearings, cylindrical shaft end, feet down IM1101 - two end-shield bearings, cylindrical shaft end, raised feet IM1205 - one end-shield bearing, flanged shaft end, feet down IM1305 - one end-shield bearing, flanged shaft end, raised feet IM2001 - two end-shield bearings, cylindrical shaft, flange at D-end IM7201 - two pedestal bearings, cylindrical shaft end, feet down IM7301 - two pedestal bearings, cylindrical shaft end, raised feet
Corrosion protection
Our generators are designed and built to withstand the applicable environmental conditions. Screws, washers, all surfaces made of steel, aluminum alloy, cast iron and all insulation materials are treated in accordance with the chosen paint system. Selection of a suitable paint system gives reliable anti-corrosion protection even under the most severe environmental conditions. For moderate indoor conditions the standard finish is a two-pack epoxy paint that is moisture-proof in accordance with the relevant standards. Solvent free paints are used wherever possible in order to minimize environmental impacts.
An open air cooled generator (IC0A1) with drip proof protection (IP23).
A totally enclosed generator (IP 54) using an air-to-water heat exchanger (IC8A1W7).
Protection
The enclosures feature protection in classes IP21, IP22, IP23, (drip proof), or IP44, IP54, IP55 and IP56 (totally enclosed), or equivalent NEMA protection classes. Generators are also available for hazardous areas in accordance with IEC/ATEX or NEC definitions.
A totally enclosed generator (IP 54) using an air-to-air heat exchanger (IC6A1A1).
Windings
Form wound coils are used for medium or high voltage stators. High voltage coils include a semiconducting layer to decrease the electrical field at the slot surface.
number of layers of insulating tape can be applied to the copper coil depending on the dielectric barrier defined by the voltage output. All materials used including the vacuum pressure impregnation resin exceed thermal class F (155C) requirements. Class F temperature rise is standard, with Class B rise also available. After insertion into the corresponding slots, the coils are firmly held in place by means of soft wedges and surge ropes at the coil heads prior to vacuum pressure impregnation. The completed process assures long and trouble free service.
The automated manufacturing process uses ABB robots and is located in an environmentally controlled area, ensuring that each medium or high voltage coil is produced with uniform and consistent quality for the highest reliability.
are used to ensure stability up to the rated overspeed. The windings are vacuum pressure impregnated. Exciter windings are made of enamelled copper wire. Proper glass fiber supports are used in the exciter rotor to ensure stability up to the rated overspeed. The windings are also vacuum pressure impregnated.
Insulation
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High vacuum cycle removing air and moisture from the voids and pores of the insulation. Highly stable epoxy resin ensuring superior protection under the most difficult environmental conditions (against lubricants, diesel oil, moisture, common solvents, chemically aggressive gases, abrasive dust, tropical climate etc.). High pressure cycle forcing the resin into even the smallest pores. Oven curing - after the VPI process has been completed, stators and rotors are cured in an oven at high temperature. This produces very strong and stable insulation, exhibiting high mechanical and electrical strength. This is especially important in order to resist inadvertent high stresses from out-of-phase synchronization, transients and short circuits. Even the largest wound stators and rotors are impregnated as complete units. This ensures that both the insulation and the mechanical properties of the windings are excellent which means that they can withstand prime mover induced vibrations and the mechanical stresses caused by transients such as short circuits.
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Stator
The stator frame forms a rigid steel structure that has been designed to withstand vibrations induced by the prime mover.
Frames up to size 1120 are of modular type. The stator core is welded into a cylinder, after which the end-modules with feet are welded or bolted to the stator core. The bearings are flange-mounted on the end-shields. For larger generators, full frames incorporating both the stator core housing and feet, are used. The bearings are mounted on pedestals integrated with the frame, allowing installation of the generator as a fully assembled single unit.
The stator core itself is built of stacked, high-grade, low-loss laminated electric sheet steel, insulated on both sides with a heat-resistant inorganic coating. Radial cooling ducts ensure uniform and effective cooling of the stator.
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Rotor
The characteristics of the rotor play a crucial part in achieving the best possible levels of electrical and mechanical performance. As a result, ABB continues its development work to optimize rotor designs.
Shaft
The rotor comprises a shaft, a hub for larger machines, and salient poles. The shaft is manufactured of forged or rolled steel and machined to exact specifications. Rotors for frame sizes 1250 and greater are normally equipped with a separate hub which is shrink-fitted onto the shaft. The shaft ends are normally cylindrical or flanged.
are secured to the shaft or hub by bolts from above or below, or by means of dovetails. The poles are fitted with a copper or brass damper winding. All rotor assemblies are vacuum pressure impregnated (VPI) as complete units for excellent insulation and mechanical strength. After impregnation, the complete rotor assembly is dynamically balanced on two planes.
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Poles
The poles are normally manufactured from 2 mm laminated steel sheet. The sheets are pressed together with inserted steel bars which are welded to the end plates. The pole structure is integrated or the poles
ABB / Synchronous Generators GB 02-2004
Terminal Boxes
The integrated terminal box is located on top as standard and can be designed to allow cable entry from either the right or left side. For models up to AMG1120 the standard method of cable entry is from below, for AMG1250 or larger, from the side. Optionally, separate terminal boxes mounted on the side of the generator are available, featuring busbars outside the generator frame and allowing connections from any specified direction. For auxiliary and instrument cables separate auxiliary terminal boxes may be supplied as required.
Rotor with three phase armature winding and rotating full-wave diode bridge rectifier feeding main rotor field windings with DC current Stator with DC winding. The current to the stator is supplied by AVR Complete exciter is mounted inside generator frame with easy access through removable inspection covers.
Both analog and digital AVRs are available, type used depending on level of performance and variety of functions required. AVR is either mounted directly inside generator terminal box (small generators) or supplied on a mounting plate designed for installation inside generating set control panel (large generators). Typical features of AVRs (depending on type of AVR selected): Voltage regulation in island mode with droop-type reactive load sharing
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Analog and digital AVRs are available for a perfect match with the application requirements. Installation on mounting plates or inside generator terminal box.
Power factor control in parallel operation with grid Excitation for sustained short circuit Soft start Over-voltage protection Underfrequency protection Under/over-excitation protection Voltage matching Rotating diode condition monitoring Field winding thermal overload protection Back-up arrangements with either manual control or redundant double AVRs with automatic or manual change-over
Voltage transformer, and current transformers for excitation in short-circuit conditions, or Auxiliary winding in stator, or PMG (permanent magnet generator) mounted outboard of the NDE bearing
4. Current transformer for actual value measurement
Used for reactive load control in either droop or power factor control modes
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Bearings
The choice of bearing arrangement and type is based on factors such as load carrying capacity, speed of rotation, type of prime mover coupling, and client choice. Operating conditions such as ambient temperature, air cleanliness, vibrations, shock and inclination (marine and offshore platforms) affecting the bearing are also taken into account.
Antifriction bearings
(standard for AMG 400-630) The bearing assembly is of the deep-groove ball type. The DE bearing is blocked while the NDE bearing is directly prestressed on the shaft. Under normal operating conditions (lubrication, alignment, vibration, temperature and environment) and without undue external load, the bearings are designed for a life expectancy in excess of 50 000 hours. A grease nipple is provided to ease periodical changing of the grease in the bearing assembly. Excess grease is ejected into a container that is easily accessible for cleaning. NDE bearings are insulated to prevent shaft current circulation.
Provided that the operating conditions are carefully followed, their life expectancy is practically infinite. To prevent bearing damage from circulating currents, all NDE bearing housings are electrically insulated by means of non conducting PTFE film. The bearings are typically self-lubricated by oil ring. The lubricating oil is picked up by the oil ring and transferred directly to the shaft. In the case of high ambient temperature or
Accessories
We offer a large selection of accessories to meet our customers requirements. Certain accessories are included as standard, depending on the size and type of generator. For nonlisted accessories, please contact us.
Protection
Air filters at air inlet, standard or SOLAS Anti-condensation heaters Differential protection current transformers Earth fault voltage transformers Surge arrestors Surge capacitors Slip rings for rotor earth fault protection Diode failure monitoring unit Ex accessories for hazardous areas Bearing insulation
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inclined operating position (marine applications) an external cooling circuit for the oil may be necessary, unless the oil comes direct from the engine cooled lube oil system.
Terminals
Integrated air insulated connection box Separate air insulated terminal box Separate phase insulated terminal boxes Separate phase segregated terminal boxes Termination kits for phase segregated terminal boxes Cable glands MCT Cable Auxiliary terminal boxes
Cooling
CuCu, CuNi or stainless steel, single or double tube, fresh or sea water heat exchangers for air-towater closed circuit cooling Aluminum or stainless steel airto-air heat exchangers with shaft mounted secondary fans or electric fans for air-to-air closed circuit cooling
Mounting
Hold down bolts Locking pins Jacking screws Shims Sole plates Anchor bolts Separate steel frames SAE flange
Lifting beams Shaft extensions for rotor removal Seaworthy packing Impregnated seaworthy packing Tarpaulin packing
Lubrication systems
External lube oil cooling and circulation units Jack-up pumps
Documentation
Local language documentation CD ROMs or printed
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Final testing
Numerous tests are performed on the generator components as they progress from one manufacturing stage to the next. These tests include quality monitoring, inspections and insulation reliability evaluations. A set of final tests is performed once all the parts and components have been integrated, in order to verify that the generator meets or exceeds the customers requirements. All tests are performed according to IEC-34 unless otherwise specified. Testing to NEMA MG 1, IEEE-115 or marine classification society requirements is available upon request.
Routine tests
The routine test program is performed on every generator and is included in the price of the generator.
Visual inspection Air gap measurement and sleeve bearing clearance check (larger generators) Insulation resistance measurement before dielectric test Winding resistance measurement Checking of temperature detectors and space heaters Terminal markings and direction of rotation Axial play for unlocked bearings Bearing run Vibration measurement No load point Short circuit point Testing of the automatic voltage regulator Overspeed test Auxiliary check Insulation resistance measurement Dielectric tests Insulation resistance measurement after dielectric test
Special tests
Special tests may be performed to verify the performance in special conditions. They may, for example, be based on customer specifications or classification society requirements. Such tests may include:
Determination of reactances and time constants Measurement of shaft voltage Voltage wave form measurement Sound level measurement.
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A reliable partner
Customer focus is an integral part of ABBs internal processes. It starts from the very first contact, extends through manufacturing and delivery and continues with after sales service available around the world.
Application Engineering
In addition to its standard product range, ABB is also a leading supplier of customized generators. Our engineering department can design generators that meet the customers requirements in every respect. This flexibility has made us a recognized leader in supplying tailored solutions.
facilities to download documentation relating to their generator, monitor the progress of their unit through manufacturing, and even witness tests on-line.
Documentation
Every generator is supplied complete with all necessary operating and maintenance manuals. This documentation should be studied prior to installation and operation. The machine should be inspected and maintained on a regular basis in order to ensure continuous and reliable operation.
Online tools
ABB uses the Internet to provide information and communicate with its customers. Extensive information about the entire range of synchronous generators is available at www.abb.com/motors&drives An advanced online Project Management Tool eSolutions presently available for larger generators, provides customers with a number of functions, including
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From 0.055 kW to 60 MW a comprehensive range of motors and generators for all industrial applications.
Our range runs from a 0.055 kW standard motor to a 70 MW generator, encompassing low and high voltage, induction and synchronous, and AC and DC motors and generators. ABB motors and generators are designed for all industrial applications, and a complete range of options and auxiliary equipment is available.
Our products meet all widely used standards and are approved for use in hazardous areas. Protection classes include flameproof, nonsparking, increased safety, dust ignition protection and pressurized. ABB is at the forefront of innovation, development and new applications.
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ABB Oy Electrical Machines P.O.Box 186 FI-00381 Helsinki Finland Tel. +358 (0)10 2211 Fax +358 (0)10 22 22675
ABB Automation SAS Rue du Gnral de Gaulle Champagne sur Seine FR-77811 Moret-sur-Loing France Tel. +33 (0)1 6074 6500 Fax +33 (0)1 6074 6565
http://www.abb.com/motors&drives