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

4-pole generators Advantages
We base our business on experience. Whenever you
ABB’s breakthrough as a of standardisation
contact us you are dealing with a partner who has
supplier of generators came GE Energy (Norway) is
supplied nearly 500 synchronous generators since
at the beginning of the supplying gas turbines
1990, both 4-pole and 6-pole, to a wide range of
1990s. An essential element for off-shore installations
users all over the world. Plants where we have designed
was the decision of Alstom of Norsk Hydro. To fulfil
and built generators to suit each user’s needs and
Power to increase the use this contract GE Energy
values. We have listened, understood and delivered.
of 4-pole generators in their has signed an exclusive
Generators where, in each individual case, we provided
industrial turbines. More and contract with ABB to
the best solution.
more turbine manufacturers supply the generators.

have followed this trend. So far more than ten

Experience of the environment
The underlying reasons units have been supplied.
for generators
are that using a gearbox The contract requires
Today our generators are operating in very different
means that the turbine can a high degree of standard-
environments. In normal utilities and industrial
operate on its optimum isation of the product and
environments, but also in violent storms on oil
speed and that the capital the logistic procedures.
platforms, in “close to city” environments, in ice-
and running costs of 4-pole The benefits are already
cold northern regions as well as in the searing heat
generators are significantly apparent. One generator is
of the tropics. Regardless of where you are we can
lower than for the 2-pole held on-shore as a standby
supply a generator to suit your requirements.
alternative. These advan- for the off-shore units and
It is through just such knowledge that we have
tages outweigh the costs the delivery time has been
become a world-leading supplier. This is not the
of the gearbox. reduced to 50% of the
sort of knowledge you can buy. This knowledge
normal time.
comes only from having been there.
In the middle of your reality.

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.
Life-long responsibility
Recently an existing
Confidence – the fundamental value
generator at the Ängelholm
This confidence comes from the basic values of all
combined cycle plant was
those working in our organisation. The knowledge
upgraded. A new cooler was
and experience of each and every member. The
fitted to overcome problems
responsibility and quality consciousness of our skilled
with cooling air quality.
workforce. Initially this springs from an interest in
The rotor was up-graded
technical matters. But it comes just as much from
to class H insulation.
pride and from the desire to make every generator
These changes will
the best.
considerably further extend
the life of the generator.
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.

4
5
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 pro-
vide high damping without
damper winding. This also
gives good overload capa-
bility and low harmonics.

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 Reliable operation The stiff rotor and mini- Over-speed tests are
which would take advantage of all previous develop- and long life due to mum distance between performed as standard. The
ment and provide a platform for the future. It was large cooling surfaces and bearings ensure that the complete rotor is balanced
first used for the smaller models but now it is our effective flow of cooling air. operating speed is below at operating speed.
standard generator for the whole range. This also gives low uniform the first critical speed,
The concept facilitates the rapid implementation rotor temperature. Class H thus giving low vibrations. Options
of change. Also, we apply the same concept to insulation of the coils gives – The shaft extension can
synchronous generators and motors which is of extra thermal margins. be flanged to match the
great benefit to both. 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 impreg-
nation (VPI) process. The
windings are of insulation
class F, which gives good
thermal margins.

7
The Exciter-rectifier Simple but highly
developed design having
few components and well
adapted protection functions
offers high reliability and
easy access for maintenance.
Improved system Bearing housing design
performance due to the permits easy access for
possibilities of high field inspection and maintenance.
forcing. This is important Bearing housings are
when faults in the supply insulated from the frame to
network arise and to eliminate circulating currents
increase the production in the shaft. The shaft can
of reactive power. 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.
8
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.
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 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 prep-
aration of foundation and the
installation. Despite its small
size, the generator is easily
accessible for maintenance.

A wide range of cooling Options for water/air

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.
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.

9
More than just a generator

We see the generator as a part of the whole

In ABB we have a good understanding of building Accurate predictions

complete systems. We also have solutions that greatly Detailed calculations

facilitate sending information from the generator are made for every pro-

system to the plant’s control system. posal to ensure that the

optimum solution has

Always a part of something bigger been identified.

The technology in our synchronous generators Many customers utilise

gives constant high efficiency, good excitation our deep knowledge

characteristics and excellent control of the machine. and our advanced

But generator management is also part of simulation facilities for

the system. The generator must fit smoothly with more advanced studies.

the turbine and all ancillary equipment. ABB offers this extra
service for new instal-

Integration lations and to identify

We can offer a wide, flexible range of systems opportunities for improving

for collecting and transmitting information from older generators.

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 Flexible deliveries

As complexity increases so does the scope and scale ABB’s supply involves are normally included. Within our modular system
of each order. That places extra demands on the more than just the generator. The supply can also include it is also possible to adapt
capacity of the supplier. The competence required The terminal box and a base-frame for the gear- new generators to old
for your project, regardless of size, is available within generator control panel box and the generator. pedestal bearing design.
ABB. The competence and capacity to tailor solutions
that cover every type of installation.

10
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 Terminal
box
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.

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 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.

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.

• Diode fault protection (58)

Measuring AVR

Note: ANSI codes within brackets.

Advantages of synchronous generators Operator’s control panel Integration with plant-

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.
The regulator in the excit-
ation equipment conforms to
the requirements necessary
for accurate control and
offers high stability parallel
operation with other
generators.
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.
wide control system
As an option information
can be fed into a superior
control system. This allows
the operator to monitor
the generator.

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 Our generators are found in
time, support the customer throughout the project phase. Gas, Steam and Combined Cycle plants:
Oil & Gas (Offshore, Onshore and Pipelines)
Customised designs Chemicals & Petrochemicals
Within the frame of an agreement the co-operation Cement
often grows much deeper. This has, for example, Food, Sugar
involved our design and development engineers Mining, Metals
working very closely with the turbine manu- Pulp & Paper
facturer and end-user to develop jointly Independent Power Producers
an optimised total solution. Utilities

A global network
An important prerequisite Tested to ensure quality
for close co-operation We perform a comprehen-
with customers is a local sive test on every generator
presence. We are present before it is dispatched to the
in most countries of the customer. This test is part
world and you have of the quality assurance
access to our complete procedure which is followed
product range and all our closely for every delivery.
expertise by contacting our Evidence of the test,
nearest sales office. A presen- in the form of test reports,
tation of our marketing facilities is handed to the customer
is even closer – it can be found at on completion of the test.
www.abb.com. Welcome to ABB.

15
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.

3BSM006540 EN, Rev A, February 2008

Ellens Byrålåda, Västerås.

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