AMS Synchronous Generators

4- and 6-pole, 3-70 MVA, 3-15 kV

Generators that deliver value

Brain Power.

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 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 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

Advantages

ABBs breakthrough as a

of standardisation

supplier of generators came

GE Energy (Norway) is

at the beginning of the

supplying gas turbines

1990s. An essential element

for off-shore installations

was the decision of Alstom

of Norsk Hydro. To fulfil

Power to increase the use

this contract GE Energy

of 4-pole generators in their

has signed an exclusive

industrial turbines. More and

contract with ABB to

more turbine manufacturers

supply the generators.

have followed this trend.

The underlying reasons

So far more than ten

units have been supplied.

are that using a gearbox

The contract requires

means that the turbine can

a high degree of standardi-

operate on its optimum

sation of the product and

speed and that the capital

the logistic procedures.

and running costs of 4-pole

The benefits are already

generators are significantly

apparent. One generator is

lower than for the 2-pole

held on-shore as a standby

alternative. These advan-

for the off-shore units and

tages outweigh the costs

the delivery time has been

of the gearbox.

reduced to 50 % of the
normal time.

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

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.

generator at the ngelholm

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.

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 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 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.

The users requirements determine the generators design

Take a closer look at the possibilities

Our generators are modular, quality-built units with many highly developed components.
Components that together make up the whole. Interesting? Open the page and take a closer look
at your opportunities. After all, it is your requirements that determine just how the generator
will be configured.

Quality in every aspect

The Rotor

Fast control and

Solid pole shoes pro-

electric stability through

vide high damping without

adaptation of the air gap,

damper winding. This also

design of pole shoes and

gives good overload capa-

dimensioning of pole core.

bility 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
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 development 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.

Reliable operation

The stiff rotor and mini-

Over-speed tests are

and long life due to

mum distance between

performed as standard. The

large cooling surfaces and

bearings ensure that the

complete rotor is balanced

effective flow of cooling air.

operating speed is below

at operating speed.

This also gives low uniform

the first critical speed,

rotor temperature. Class H

thus giving low vibrations.

Options

insulation of the coils gives

The shaft extension can

extra thermal margins.

be flanged to match the

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
worlds largest and most modern factories for this
class of work.

The Stator

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

Limitation of the voltage

The Exciter-rectifier

Simple but highly

The compact, brushless

developed design having

exciter unit is mounted

few components and well

on the rotor shaft outboard

adapted protection functions

of the bearings together with

offers high reliability and

a PMG (permanently mag-

easy access for maintenance.

netised auxiliary generator).

No independent support
or alignment is required.

Improved system

Bearing housing design

Independent lubrication

performance due to the

permits easy access for

system gives high reliability.

possibilities of high field

inspection and maintenance.

Oil rings or oil reservoir

forcing. This is important

Bearing housings are

ensures lubrication during

when faults in the supply

insulated from the frame to

emergency rundown.

network arise and to

eliminate circulating currents

Hydrostatic jacking oil

increase the production

in the shaft. The shaft can

systems are available for

of reactive power.

be earthed. Bearings are

applications operating at

sealed against oil leakage

low speed.

with labyrinth seals.

Sleeve bearings are

designed to be insensitive to
misalignment and to permit
large axial play.

10

The Frame

Great stability of the

Shipment of fully tested

Generators smaller than

Small dimensions and

complete generator.

generator. Only the terminal

22 MVA can be installed

low weight simplify prepa-

Dynamic and static stresses

box, and in some cases the

sunk down in the foundations.

ration of foundation and the

are transferred directly to

heat exchanger, need to be

installation. Despite its small

the foundation contributing

removed prior to shipment.

size, the generator is easily

to the great performance.

Cooling form IC8A1W7 for generators below 22 MVA.

accessible for maintenance.

A wide range of cooling

Options for water/air

forms allows an optimum

heat exchangers.

choice for operating and

Systems with double

environmental conditions.

water/air heat exchangers

Irrespective of the cooling

can be designed for full

form, the system provides

load with one of the heat

uniform cooling of the

exchangers out of service.

complete generator.

Heat exchangers with

All water connections are

double tubes.

positioned outside the

Heat exchangers of

frame.

different materials, e.g.

CuNi, stainless steel or
titanium.

11

More than just a generator

We see the generator as a part of the whole

Accurate predictions

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.

Detailed calculations
are made for every proposal to ensure that the
optimum solution has
been identified.

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.

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 oppor-

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.

12

tunities for improving

older generators.

Flexible deliveries
ABBs supply involves

are normally included.

Within our modular system

more than just the gene-

The supply can also include

it is also possible to adapt

rator. The terminal box and

a base-frame for the gear-

new generators to old

generator control panel

box and the generator.

pedestal bearing design.

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

Terminal
box

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.

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Excitation

Generator Control Panel

Synchronous generators require the control of

excitation current in the rotor. ABBs 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 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

Operators control panel

Integration with plant-

A significant advantage of

The regulator in the excita-

A digital multifunction instru-

wide control system

synchronous generators is

tion equipment conforms to

ment is mounted of the front

As an option information

the facility to select the most

the requirements necessary

of the generator control

can be fed into a superior

suitable operating conditions

for accurate control and

panel. Analogue instruments

control system. This allows

constant voltage, constant

offers high stability parallel

can be fitted as an option. In

the operator to monitor

field current, constant reac-

operation with other

certain cases an operators

the generator.

tive power (Mvar) or constant

generators.

panel is provided where

power factor.

alphanumeric signals are

displayed.

14

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.

15

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.

Our generators are found in

Gas, Steam and Combined Cycle plants:
Oil & Gas (Offshore, Onshore and Pipelines)

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 office. A presentation of our marketing facilities
is even closer it can be found at
[Link]. Welcome to ABB.

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.

17

ABB Motors AB
Machines division
SE-721 70 Vsters, Sweden
Tel: +46 21 32 90 00
Fax: +46 21 32 95 10
[Link]

CARE OF. Printed in Sweden by Westers Mediatryck, Vsters.

3BSM 006 540 R001 January 2001

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 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 generators life cycle.