AMS Synchronous Generators 4- and 6-pole, 370 MVA, 315 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.

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 difcult to dene. They relate to a completely different process. A process where your expectations are fullled. Knowing how to listen, to communicate and to understand. To deliver real benets. 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 users 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 ABBs 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 signicantly lower than for the 2-pole alternative. These advantages outweigh the costs of the gearbox.

Advantages of standardisation GE Energy (Norway) is supplying gas turbines for off-shore installations of Norsk Hydro. To full 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 standardisation of the product and the logistic procedures. The benets 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.

Values that mean more

Performance, availability, productivity and improved operating efciency

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 signicant values is condence. 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. Condence the fundamental value This condence 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 technologys 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 efciency 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.

Life-long responsibility Recently an existing generator at the ngelholm combined cycle plant was upgraded. A new cooler was tted 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.

Quality in every aspect

The Rotor

Fast control and electric stability through adaptation of the air gap, design of pole shoes and dimensioning of pole core.

Solid pole shoes provide high damping without damper winding. This also gives good overload capability and low harmonics.

ABB is one of the worlds 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 exibility 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 benets as soon as possible. We can also introduce changes in ways to ensure that they can be tted to generators supplied earlier so that existing users can also share the benets. 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 rst 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 benet 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 worlds largest and most modern factories for this class of work.

Reliable operation and long life due to large cooling surfaces and effective ow of cooling air. This also gives low uniform rotor temperature. Class H insulation of the coils gives extra thermal margins.

The stiff rotor and minimum distance between bearings ensure that the operating speed is below the rst critical speed, thus giving low vibrations.

Over-speed tests are performed as standard. The complete rotor is balanced at operating speed.

Options The shaft extension can be anged to match the driving machinery. Shaft for double end drive.

The Stator

Limitation of the voltage drop and/or the short circuit current is done by designing the reactances.

High-grade, low-loss electrical steel increases efciency and reduces operating costs.

The stiff frame transmits all forces directly to the foundations.

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 impregnation (VPI) process. The windings are of insulation class F, which gives good thermal margins.

Well developed and proven methods for locking coils into slots and bracing coil ends ensure long term reliability.

The Exciter-rectier

Simple but highly developed design having few components and well adapted protection functions offers high reliability and easy access for maintenance.

The compact, brushless exciter unit is mounted on the rotor shaft outboard of the bearings together with a PMG (permanently magnetised auxiliary generator). No independent support or alignment is required.

Improved system performance due to the possibilities of high eld forcing. This is important when faults in the supply network arise and to increase the production of reactive power.

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.

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.

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

The Frame

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.

Generators smaller than 22 MVA can be installed sunk down in the foundations.

Small dimensions and low weight simplify preparation of foundation and the installation. Despite its small size, the generator is easily accessible for maintenance.

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. Cooling form IC8A1W7 for generators below 22 MVA. All water connections are positioned outside the frame.

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.

More than just a generator

We see the generator as a part of the whole

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 plants control system. Always a part of something bigger The technology in our synchronous generators gives constant high efciency, good excitation characteristics and excellent control of the machine. But generator management is also part of the system. The generator must t smoothly with the turbine and all ancillary equipment. Integration We can offer a wide, exible range of systems for collecting and transmitting information from the generator for protection and for supervision. A concept that can easily be tted 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.
Flexible deliveries ABBs 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 gearbox and the generator.

Accurate predictions Detailed calculations are made for every proposal to ensure that the optimum solution has been identied. Many customers utilise our deep knowledge and our advanced simulation facilities for more advanced studies. ABB offers this extra service for new installations and to identify opportunities for improving older generators.

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 todays world there is a much sharper focus on total concepts and total solutions.

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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.

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

Terminal box

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.

Location The protection system is located in the generator control panel together with logic functions and the excitation equipment.

Advanced options In some cases it is advantageous to t additional protection including telemetrics. For example, direct measurement of rotor earth fault, rotor voltage and rotor current.

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Excitation
Synchronous generators require the control of excitation current in the rotor. ABBs brushless, rectier based excitation system offers control of the rotor current, taking full benet from the advantages of synchronous generators.

Generator Control Panel

The generator control panel is available in several basic formats which are nished 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 A signicant advantage of synchronous generators is the facility to select the most suitable operating conditions constant voltage, constant eld current, constant reactive power (Mvar) or constant power factor. The regulator in the excitation equipment conforms to the requirements necessary for accurate control and offers high stability parallel operation with other generators.

Operators control panel A digital multifunction instrument is mounted of the front of the generator control panel. Analogue instruments can be tted as an option. In certain cases an operators panel is provided where alphanumeric signals are displayed.

Integration with plantwide control system As an option information can be fed into a superior control system. This allows the operator to monitor the generator.

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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. 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 ofce. A presentation of our marketing facilities is even closer it can be found at www.abb.com. Welcome to ABB.

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

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.

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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 Vsters in Sweden. This concentration helps to ensure that the most modern production resources are used to maintain high quality and low costs to reinforce ABBs leading position in this eld. Long-term protable 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 generators life cycle.

3BSM006540 EN, Rev A, February 2008

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

Ellens Byrlda, Vsters.