AMS Synchronous Generators4- 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.

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Generators to serve people

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 ice-

cold 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

ABB’s breakthrough as a

supplier of generators came

at the beginning of the

1990s. An essential element

was the decision of Alstom

Power to increase the use

of 4-pole generators in their

industrial turbines. More and

more turbine manufacturers

have followed this trend.

The underlying reasons

are that using a gearbox

means that the turbine can

operate on its optimum

speed and that the capital

and running costs of 4-pole

generators are significantly

lower than for the 2-pole

alternative. These advan-

tages outweigh the costs

of the gearbox.

Co-operation creates success

Advantages

of standardisation

GE Energy (Norway) is

supplying gas turbines

for off-shore installations

of Norsk Hydro. To fulfil

this contract GE Energy

has signed an exclusive

contract with ABB to

supply the generators.

So far more than ten

units have been supplied.

The contract requires

a high degree of standard-

isation of the product and

the logistic procedures.

The benefits are already

apparent. One generator is

held on-shore as a standby

for the off-shore units and

the delivery time has been

reduced to 50% of the

normal time.

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Values that mean more

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 throug-

hout 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.

Performance, availability, productivity and improved operating efficiency

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.

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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 develop-

ment 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.

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.

Quality in every aspect The Rotor

Reliable operation

and long life due to

large cooling surfaces and

effective flow of cooling air.

This also gives low uniform

rotor temperature. Class H

insulation of the coils gives

extra thermal margins.

The stiff rotor and mini-

mum distance between

bearings ensure that the

operating speed is below

the first critical speed,

thus giving low vibrations.

Solid pole shoes pro-

vide high damping without

damper winding. This also

gives good overload capa-

bility and low harmonics.

Fast control and

electric stability through

adaptation of the air gap,

design of pole shoes and

dimensioning of pole core.

Over-speed tests are

performed as standard. The

complete rotor is balanced

at operating speed.

Options

– The shaft extension can

be flanged to match the

driving machinery.

– Shaft for double end drive.

Well developed and

proven methods for

locking coils into slots and

bracing coil ends ensure

long term reliability.

The insulation system

gives reliability and

long life. The windings are

insulated with Mica based

tape. When the windings

are in place, the complete

stator is impregnated in a

vacuum pressure impreg-

nation (VPI) process. The

windings are of insulation

class F, which gives good

thermal margins.

Limitation of the voltage

drop and/or the short circuit

current is done by designing

the reactances.

High-grade, low-loss

electrical steel increases

efficiency and reduces

operating costs.

The stiff frame

transmits all forces

directly to

the foundations.

The Stator

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Independent lubrication

system gives high reliability.

Oil rings or oil reservoir

ensures lubrication during

emergency rundown.

Hydrostatic jacking oil

systems are available for

applications operating at

low speed.

The Exciter-rectifier

Bearing housing design

permits easy access for

inspection and maintenance.

Bearing housings are

insulated from the frame to

eliminate circulating currents

in the shaft. The shaft can

be earthed. Bearings are

sealed against oil leakage

with labyrinth seals.

Sleeve bearings are

designed to be insensitive to

misalignment and to permit

large axial play.

The compact, brushless

exciter unit is mounted

on the rotor shaft outboard

of the bearings together with

a PMG (permanently mag-

netised auxiliary generator).

No independent support

or alignment is required.

Improved system

performance due to the

possibilities of high field

forcing. This is important

when faults in the supply

network arise and to

increase the production

of reactive power.

Simple but highly

developed design having

few components and well

adapted protection functions

offers high reliability and

easy access for maintenance.

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The Frame Generators smaller than

22 MVA can be installed

sunk down in the foundations.

A wide range of cooling

forms allows an optimum

choice for operating and

environmental conditions.

Irrespective of the cooling

form, the system provides

uniform cooling of the

complete generator.

All water connections are

positioned outside the

frame.

Small dimensions and

low weight simplify prep-

aration of foundation and the

installation. Despite its small

size, the generator is easily

accessible for maintenance.

Great stability of the

complete generator.

Dynamic and static stresses

are transferred directly to

the foundation contributing

to the great performance.

Shipment of fully tested

generator. Only the terminal

box, and in some cases the

heat exchanger, need to be

removed prior to shipment.

Cooling form IC8A1W7 for generators below 22 MVA.

Options for water/air

heat exchangers.

– Systems with double

water/air heat exchangers

can be designed for full

load with one of the heat

exchangers out of service.

– Heat exchangers with

double tubes.

– Heat exchangers of

different materials, e.g.

CuNi, stainless steel

or titanium.

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More than just a generator

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.

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.

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.

We see the generator as a part of the whole

Accurate predictions

Detailed calculations

are made for every pro-

posal to ensure that the

optimum solution has

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-

lations and to identify

opportunities for improving

older generators.

Flexible deliveries

ABB’s supply involves

more than just the generator.

The terminal box and

generator control panel

are normally included.

The supply can also include

a base-frame for the gear-

box and the generator.

Within our modular system

it is also possible to adapt

new generators to old

pedestal bearing design.

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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.

Terminal box

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.

Advanced options

In some cases it is advan-

tageous to fit additional

protection including tele-

metrics. For example,

direct measurement of

rotor earth fault, rotor

voltage and rotor current.

Location

The protection system is

located in the generator

control panel together with

logic functions and the

excitation equipment.

Arrangements

The standard arrangement

is for cable entry from below.

The box normally has the

same form of protection

as the generator and is

designed to minimise

the risk of damage in the

event of a short-circuit.

Earthing resistors can be

placed in a separate box.

Protection

Electrical and mechanical faults can impose

unacceptable conditions and protective relays are

provided to quickly disconnect the generator

from grid.

Terminal box

Recommended protections

Other signals

Normally connected direct to the common control system of the application.

• 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.

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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 regulator in the excit-

ation equipment conforms to

the requirements necessary

for accurate control and

offers high stability parallel

operation with other

generators.

Operator’s control panel

A digital multifunction in-

strument is mounted of the

front of the generator control

panel. Analogue instruments

can be fitted as an option. In

certain cases an operator’s

panel is provided where

alphanumeric signals are

displayed.

A significant advantage of

synchronous generators is

the facility to select the most

suitable operating conditions

– constant voltage, constant

field current, constant reac-

tive power (Mvar) or constant

power factor.

Integration with plant-

wide control system

As an option information

can be fed into a superior

control system. This allows

the operator to monitor

the generator.

The generator control panel is available in several

basic formats which are finished to suit the require-

ments of each customer. The panel houses the excitation

equipment and the protection systems. Conceivable

equipment for manual, automatic or manual/auto-

matic synchronisation is also housed here.

Measuring AVR

Measuring AVR

Generator Control Panel

• Generator differential (87G)

• Over frequency (81H)

• Stator earth fault (59N)

• Over voltage (59)

• Short circuit (51)

• Loss of excitation (40)

• Negative sequence current (46)

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

• Diode fault protection (58)

Note: ANSI codes within brackets.

Advantages of synchronous generators

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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.

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 manu-

facturer 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 presen-

tation of our marketing facilities

is even closer – it can be found at

www.abb.com. Welcome to ABB.

Tested to ensure quality

We perform a comprehen-

sive 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.

Our generators are found in

Gas, Steam and Combined Cycle plants:

Oil & Gas (Offshore, Onshore and Pipelines)

Chemicals & Petrochemicals

Cement

Food, Sugar

Mining, Metals

Pulp & Paper

Independent Power Producers

Utilities

Simplicity throughout

A concept full of customer value

ABB ABMachines SE-721 70 Västerås, SwedenTel: +46 21 32 90 00Fax: +46 21 32 95 10www.abb.com

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.

3BS

M00

6540

EN

, Rev

A, F

ebru

ary

2008

Elle

ns B

yrål

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