Application note

Synchronous motors for the air separation industry

Another typical characteristic of air separation plants is that
they are classified as safe areas, meaning so non-hazardous
motors are used.
ABB has supplied the worlds largest and second largest
4-pole synchronous motors to air separation plants, rated at
59.1 MW (79.3 kHP) and 55 MW (73.8 kHP), respectively.
Technical specifications
Data below covers ABBs full range of 4- and 6-pole
synchronous motors, which are used in various applications.
Motor type: AMS
Output power: 0-65 MW (0-87 kHP)
Frame size: 710 to 1250
Number of poles: 4- and 6-pole
Voltages: 3-15 kV
Frequency: 50 or 60 Hz
Protection: IP23, IP54, IP55, IP56, IPW24
Cooling: IC01, IC31, IC611, IC616, IC81W,
IC86W
Standards: All main standards available,
including IEC, NEMA, and CSA
Hazardous areas Ex n (non-sparking), Ex p (pressurized)
Air separation plants use the cryogenic
distillation process to split atmospheric
air into its components mainly nitrogen
and oxygen, but also argon and other
rare gases. The purity levels achieved
are typically of the order of 99.999%.
The air is first compressed and then allowed to expand, which
causes it to cool to low temperatures. All the energy required
for cooling is therefore delivered by the compressors. The
gases in the air are separated on the basis of their different
boiling temperatures.
Boiling temperatures:
Nitrogen 80 K (-193C / -316F)
Oxygen 90 K (-183C / -297F)
Argon 87 K (-186C / -303F)
Electrical energy represents around 70% of overall production
costs, which makes the efficiency of the compressor motors
an important issue. Reliability is also crucial, as a short
disturbance in the electrical supply may lead to an imbalance
in the process, meaning the plant has to stop. When the
process is restarted, it can take 15 - 24 hours of full operation
before the correct process balance is restored and acceptable
purity levels are reached again.
Tailor made high speed synchronous motors
ABB is a major supplier of 4- and 6-pole synchronous motors
to drive compressors in air separation plants. The motors are
typically coupled to the compressor via a separate gearbox
or bullgear. Depending on the plant size, the motors are
generally rated 5 60 MW (6 81 kHP), and the current trend
is towards even larger motors.
The motors and associated excitation panels are tailor made
to customer specifications on the basis of a standardized
design. In many cases special requirements have to be met
with regard to issues like shaft fatigue, oscillating torque,
bonding and special accessories.
In the vast majority of cases, fixed speed motors are used
to drive air separation compressors. When required, a VSD
(variable speed drive) can be used for soft starting.
9
A
K
K
1
0
5
8
0
7

E
N

1
2
-
2
0
1
2
Main benefits
With more than one hundred years of motor manufacturing
experience, ABB has unrivalled engineering competence
and know-how in motors, their starting issues and
influence on the supply network.
Solid support is available to customers at every stage of
the project. This includes expert consultation on selecting
the optimum starting method especially important where
large motors are started on relatively weak networks.
Shaft fatigue, oscillating torque, and other application
specific issues are given very careful attention.
As a global player, ABB can design its products to meet
local and regional regulations in all parts of the world.
When spare parts are needed, ABBs global logistics
network ensures fast delivery.
Site supervision and assistance by qualified personnel are
available on request.
ABB has a unique and broad product offering, and all main
application and market needs can be fulfilled.
Copyright 2012 ABB. All Rights Reserved
We reserve the right to make technical changes or modify the contents of this
document without prior notice. No part of this publication may be reproduced
or transmitted in any form or by means, electronic, mechanical, photocopying,
recording or otherwise without prior written permission of ABB.
For more information please contact:
www.abb.com/motors&generators
150 motors since 2000
The following list highlights the largest and smallest 4- and
6-pole synchronous motors supplied to air separation plants
in recent years. Around 150 of the motors were supplied
between January 2000 and June 2012.
Pcs. Power [kW] Power factor Speed [rpm] Starting method Country Year
2 59 100 0.95 1500 LCI Abu Dhabi 2011
1 55 000 1.0 1500 LCI South-Africa 2010
1 40 000 0.8 1000 LCI Italy 2008
2 34 500 0.95 1200 LCI Saudi-Arabia 2007
1 55 000 1.0 1500 LCI South-Africa 2003
1 34 500 0.95 1200 Capacitor+reactor Saudi-Arabia 2003
1 4 400 0.90 1500 DOL Sweden 2001
1 4 400 0.90 1500 Capacitor Finland 1998