Brushless Excitation Systems

Upgrade
ABB Switzerland Ltd, GTSG Birr
UNICITER

for synchronous motors and generators

ABB Group
J une 1, 2011 | Slide 2
UNICITER

Brushless Excitation
Overview
DC excitation system
Typical installations
Brushless excitation
system
Examples
Advantages
Facts
General characteristics
Standard product range
Example
Beginning a project
Basics:
UNICITER

:
ABB Group
J une 1, 2011 | Slide 3
UNICITER

Brushless Excitation
DC Excitation System
Slip-Ring and Brushes
Carbon dust
Intensive maintenance
DC
ABB Group
J une 1, 2011 | Slide 4
UNICITER

Brushless Excitation
Typical installations
DC Exci ter
ABB Group
J une 1, 2011 | Slide 5
UNICITER

Brushless Excitation
Brushless excitation system Electrical diagram
Cubicle
Stator
Rotor
Rotor
Stator
Automatic Voltage Regulator
(DC)-- stator field winding
(AC) -- 3 phase rotor field winding
( ACDC) rotating rectifier wheel
UNICITER

Main rotor pole winding of synchronous

motor (DC)
3 phase winding of synchronous
motor/generator (AC)
+ -
ABB Group
J une 1, 2011 | Slide 6
UNICITER

Brushless Excitation
Examples
ABB Group
J une 1, 2011 | Slide 7
UNICITER

Brushless Excitation
No carbon dust contamination!
No wear (no electrical no mechanical contacts)
No consumable parts (brushes)
No circuit breaker and no field breaker (in case of static
exciter)
Results in
Reduced maintenance (from each 3/4 months to 5/6 year)
Reduced outage time
Reduced costs for replacement parts
Advantages
ABB Group
J une 1, 2011 | Slide 8
UNICITER

Brushless Excitation
Overview
DC excitation system
Typical installations
Brushless excitation
system
Examples
Advantages
Facts
General characteristics
Standard product range
Example
Beginning a project
Basics:
UNICITER

:
ABB Group
J une 1, 2011 | Slide 9
UNICITER

Brushless Excitation
Made in Switzerland
Over 200 delivered
brushless exciters
Over 45 years of
experience
Operating worldwide
For generators up to 250
MW
Facts
Exciter
stator field
Exciter
rotor field
ABB Group
J une 1, 2011 | Slide 10
UNICITER

Brushless Excitation
WE 33 to WE 190
Rotor external diameter in mm (330 to 1900mm
Mounting
Horizontal or vertical
Speed
1800 - 88 rpm
Retrofits
Modification/ reuse of existing parts
Any brand
Not limited to ABB motors and generators
General characteristics
ABB Group
J une 1, 2011 | Slide 11
UNICITER

Brushless Excitation
Customization
Internal fixation (adjusted diameter,
half-key or shrink, new exciter shaft
with coupling, etc)
Connection to the rotor (through the
shaft, external, rigid, flexible etc.)
Sealed and taped end-winding
(longer operational life)
Insulation
Vacuum impregnated (VPI- Micadur
Compact) winding
Class F
Selected over-tested diodes
Electrical: Forward voltage drop,
endurance, etc.
Mechanical: Acceleration, Storage
Temp, etc
Easy to replace
Rotor
ABB Group
J une 1, 2011 | Slide 12
UNICITER

Brushless Excitation
Customization
External housing:
Re-use or design a
new housing,
Sealing, etc
Splittedstator frame
Insulation
Class F,
Enamelledcopper wire
Vacuum impregnated
Service friendly
Individual poles
Stator
ABB Group
J une 1, 2011 | Slide 13
UNICITER

Overview current vs. speed

Standard product range
0
900
1200
1800
I [A]
600 1500 1800
Max. speed
[rpm]
214
WE 112 190
WE 68 104
WE 33 - 58
Rated speed
(RPM)
ABB Group
J une 1, 2011 | Slide 14
ABB Switzerland Scope - Brushless Excitation
Repair and
upgrade
Engineering
Electrical design
Mechanical design
Adaptations / options
Manufacturing
Installation and
commissioning
Replacement of
diode wheel, diodes,
heat sink, ...
Rewinding of
rotor / stator
Inspection Spare parts
Production of
UNICITER

in Birr
Switzerland
AVR preferably via local
excitation group ABB (can
be made by GTSC Birr)
Installation and
commissioning
preferably by local ABB
with factory supervision
(can be made by GTSC
Birr)
Diagnosis
Overhaul
Service offers:
ABB Group
J une 1, 2011 | Slide 15
UNICITER

Example
Hydro Power Plant Horizontal - Switzerland
Old DC commutator exciter
by Brown Boveri
Date of manufacture: 1960
NewUNICITER

by ABB
GTSC Birr
ABB Group
J une 1, 2011 | Slide 16
UNICITER

Example
Hydro Power Vertical Cameron
Old DC exciter
NewUNICITER

exciter
ABB Group
J une 1, 2011 | Slide 17
UNICITER

Example
Exciter Stator Field
ABB Group
J une 1, 2011 | Slide 18
UNICITER

Example
Exciter Rotor Field
Diode wheel
ABB Group
J une 1, 2011 | Slide 19
UNICITER

Example
With included options
Induction free resistor
(current limiter)
Two separate
diode wheels
Overvoltage
protection (surge
Arrester)
ABB Group
J une 1, 2011 | Slide 20
AVR Retrofit Example
Excitation system option
Old AVR
NewAVR
ABB Group
J une 1, 2011 | Slide 21
UNICITER

beginning a project
Mechanical dimensional drawing
Free space available
Electrical main plate data
AVR installation area, electrical system
Photos (complete string and specifically the exciter)
Requested data to start a project
ABB Group
J une 1, 2011 | Slide 22
Product Range UNICITER

References overview
Special designs on request
0
900
1200
1800
I [A]
600 1500 1800
Max. speed
[rpm]
214
WE 112 190
WE 68 104
WE 33 - 58
> 40 units delivered
> 70 units delivered
> 90 units delivered
Rated speed
(RPM)
ABB Group
J une 1, 2011 | Slide 23
Reference list
Plant Country Year Qty Type P / KW n / nmax rpm
KW Luchsingen CH 1994 1 WE 355 ba 10 / 6 19.5 1000 / 1800
KW Hinterthal CH 1995 1 WE 500 ba 10 / 6 32.3 750 / 1380
KVA Turgi CH 1995 1 WE 500 aa 10 /4 48.5 1500 / 1800
LG Petrochemie ( Motor ) Korea 1996 1 WJ 500 aa 6 27 1185 / 1422
KW Erstfeld CH 1997 1 WE 500 ba 10 / 6 44 750 / 1350
KVA Niederurnen CH 1997 1 WE 500 aa 10 /4 42.7 1500/1800
KW Rchlig I -III CH 1998 3 WE 355 ba 10 / 6 20.4 1000 / 3500
KW Baso-Chu I +II Butan 1998 2 WE 500/40/10 110 428 / 770
AGOCO / Libyen Lybia 1998 1 WE 500 aa 10 /4 58.8 1500 / 1800
KW Klamm A 1999 1 WE 500/10/10 25.7 500 / 925
KW Aue I +II CH 2000 2 WE 355 ba 10 / 6 20.4 1000 / 3500
KW Glattalp CH 2000 1 WE 500 ba 10 / 6 70 1000 / 1800
KW Ladral CH 2000 1 WE 500 ba 10 / 6 44 1000 / 1860
New Valley ( Motoren ) Egypt 2000 24 SE 85 / 40 / 8 165 300 / 450
KW Safien CH 2000 2 WE 630 ea 10 / 8 170 750 / 1300
KW Balm CH 2001 1 WE 500 ba 10 / 8 105 750 / 1350
KW Vissoie II +III CH 2001 2 WE 11310-20-14 99 428,6 / 800
KW RheinauI CH 2001 1 WE 397 /11/36 149 93,75 / 250
KW Nfels CH 2002 1 WE 355 aa 10 / 6 19.2 1000 / 1800
ABB Group
J une 1, 2011 | Slide 24
Reference list
Plant Country Year Qty Type P / KW n / nmax rpm
KW Piottino CH 2005 1 WE 500 fw 10 / 8 150 750 / 1380
KW Chancy-Pougny CH 2005 2 WE 124 / 50 / 20 157 88,2 / 250
KW Bitsch CH 2006 2 WE 112 / 40 / 20 368 375 / 680
KW Waldeck CH 2006 1 SAV 290 / 17 / 16 1100 375 / 680
KW Tiefencastel III +IV CH 2006 2 WE 500 / 10 / 16 112 1000 / 1750
KW Flumenthal I, II, III CH 2006 3 WE 124 / 30 / 20 105 107 / 338
KW Seebach I +II CH 2006 2 WE 112-18-20 200 500 / 920
KW Le Chalet CH 2006 1 WE 500 crw 10 / 16 32 375 / 990
ARAMCO Syn.Motor SA 2006 1 WE 500 aa 10 / 4 75 1800 / 2120
KW Gschenen III +IV CH 2006 2 WE 75 / 35 / 14 208 500 / 925
KW Bargaus CH 2007 1 WE 355 aa 10 / 6 31 750 / 1350
KW Neu-Wernisberg III CH 2007 1 WE355 aa 10 / 6 21 1000 / 1800
KW La Batiaz CH 2007 1 WE 112 / 25 / 20 260 428 / 750
KW Gschenen III +IV CH 2008 2 WE 90 / 22 /12 130 333 / 600
ABB Group
J une 1, 2011 | Slide 25
Contact
ABB Switzerland Ltd
GTSC Birr
Global Technical Support Center
5242 Birr, Switzerland
Tel +41 58 586 67 41
Fax +41 58 586 69 08
Email service.motors@ch.abb.com
I-Net www.abb.ch/service