Brushless+Excitation+Systems

Brushless Excitation Systems Upgrade

ABB Switzerland Ltd, GTSG Birr

UNICITER® for synchronous motors and generators

© ABB GroupJune 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® :


UNICITER® Brushless ExcitationDC Excitation System

Slip-Ring and Brushes

Carbon dust

Intensive maintenance

DC


UNICITER® Brushless ExcitationTypical installations

DC Exciter


UNICITER® Brushless ExcitationBrushless excitation system – Electrical diagram

Cubicle

Stator

Rotor

Rotor

Stator

Automatic Voltage Regulator

(DC)-- stator field winding

(AC) -- 3 phase rotor field winding ( AC�DC) rotating rectifier wheel

UNICITER®

Main rotor pole winding of synchronous motor (DC)

3 phase winding of synchronous motor/generator (AC)

+ -

Stator

Rotor

(DC)-- stator field winding

(AC) -- 3 phase rotor field winding( AC�DC) rotating rectifier wheel

UNICITER®


UNICITER® Brushless ExcitationExamples


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


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® :



� 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



� 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



� 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



� Customization� External housing:

� Re-use or design a new housing,

� Sealing, etc� Splitted stator frame

� Insulation� Class F, � Enamelled copper wire � Vacuum impregnated

� Service friendly� Individual poles

Stator


UNICITER® Overview current vs. speedStandard 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 Switzerland Scope - Brushless Excitation

Repair andupgrade

Engineering

� Electrical design

� Mechanical design

� Adaptations / options

Manufacturing Installation andcommissioning

� Replacement ofdiode wheel, diodes, heat sink, ...

� Rewinding ofrotor / stator

Inspection Spare parts

� Production of UNICITER® in Birr Switzerland

� AVR preferably via localexcitation 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:


UNICITER® ExampleHydro Power Plant – Horizontal - Switzerland

� Old DC commutator exciterby Brown Boveri

� Date of manufacture: 1960

New UNICITER® by ABBGTSC Birr

�


UNICITER® ExampleHydro Power – Vertical – Cameron

Old DC exciter

New UNICITER® exciter


UNICITER® ExampleExciter Stator Field


UNICITER® ExampleExciter Rotor Field

Diode wheel


UNICITER® Example With included options

Induction free resistor (current limiter)

Two separate diode wheels

Overvoltage protection (surge

Arrester)


AVR Retrofit ExampleExcitation system option

Old AVR

New AVR


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


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



Rated speed (RPM)


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 Rüchlig 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 Rheinau I CH 2001 1 WE 397 /11/36 149 93,75 / 250

KW Näfels CH 2002 1 WE 355 aa 10 / 6 19.2 1000 / 1800


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 Göschenen 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 Göschenen III +IV CH 2008 2 WE 90 / 22 /12 130 333 / 600


Contact

ABB Switzerland LtdGTSC BirrGlobal Technical Support Center 5242 Birr, Switzerland

Tel +41 58 586 67 41Fax +41 58 586 69 08Email [email protected] www.abb.ch/service

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