ABB Switzerland Ltd, GTSG Birr
Brushless Excitation Systems
Upgrade
UNICITER® for synchronous motors and generators
UNICITER® Brushless Excitation
Overview
Basics:
UNICITER® :
© ABB Group
June 1, 2011 | Slide 2

DC excitation system

Typical installations

Brushless excitation
system

Examples

Advantages

Facts

General characteristics

Standard product range

Example

Beginning a project
UNICITER® Brushless Excitation
DC Excitation System
DC
Carbon dust
Intensive maintenance
Slip-Ring and Brushes
© ABB Group
June 1, 2011 | Slide 3
UNICITER® Brushless Excitation
Typical installations
DC Exciter
© ABB Group
June 1, 2011 | Slide 4
UNICITER® Brushless Excitation
Brushless excitation system – Electrical diagram
Cubicle
+
-
Automatic Voltage Regulator
Stator
(DC)-- stator field winding
Rotor
(AC) -- 3 phase rotor field winding
( AC→DC) rotating rectifier wheel
UNICITER®
Rotor
Stator
© ABB Group
June 1, 2011 | Slide 5
Main rotor pole winding of synchronous
motor (DC)
3 phase winding of synchronous
motor/generator (AC)
UNICITER® Brushless Excitation
Examples
© ABB Group
June 1, 2011 | Slide 6
UNICITER® Brushless Excitation
Advantages




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
© ABB Group
June 1, 2011 | Slide 7
UNICITER® Brushless Excitation
Overview
Basics:
UNICITER® :
© ABB Group
June 1, 2011 | Slide 8

DC excitation system

Typical installations

Brushless excitation
system

Examples

Advantages

Facts

General characteristics

Standard product range

Example

Beginning a project
UNICITER® Brushless Excitation
Facts


Exciter
stator field



Exciter
rotor field
© ABB Group
June 1, 2011 | Slide 9
Made in Switzerland
Over 200 delivered
brushless exciters
Over 45 years of
experience
Operating worldwide
For generators up to 250
MW
UNICITER® Brushless Excitation
General characteristics





© ABB Group
June 1, 2011 | Slide 10
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
UNICITER® Brushless Excitation
Rotor



© ABB Group
June 1, 2011 | Slide 11
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
UNICITER® Brushless Excitation
Stator



© ABB Group
June 1, 2011 | Slide 12
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
UNICITER® Overview current vs. speed
Standard product range
I [A]
1800
WE 112 – 190
1200
WE 68 – 104
900
WE 33 - 58
0
214
© ABB Group
June 1, 2011 | Slide 13
600
1500
Max. speed
speed
1800 Rated
[rpm]
(RPM)
ABB Switzerland Scope - Brushless Excitation
Engineering

Electrical design

Mechanical design

Adaptations / options

Production of
UNICITER® in Birr
Switzerland

AVR preferably via local
excitation group ABB (can
be made by GTSC Birr)
Service offers:
Repair and
upgrade


Replacement of
diode wheel, diodes,
heat sink, ...
Rewinding of
rotor / stator
© ABB Group
June 1, 2011 | Slide 14
Installation and
commissioning
Manufacturing
Inspection

Diagnosis

Overhaul

Installation and
commissioning
preferably by local ABB
with factory supervision
(can be made by GTSC
Birr)
Spare parts
UNICITER® Example
Hydro Power Plant – Horizontal - Switzerland


Old DC commutator exciter
by Brown Boveri
Date of manufacture: 1960
New UNICITER® by ABB
GTSC Birr
© ABB Group
June 1, 2011 | Slide 15
UNICITER® Example
Hydro Power – Vertical – Cameron
Old DC exciter
New UNICITER® exciter
© ABB Group
June 1, 2011 | Slide 16
UNICITER® Example
Exciter Stator Field
© ABB Group
June 1, 2011 | Slide 17
UNICITER® Example
Exciter Rotor Field
Diode wheel
© ABB Group
June 1, 2011 | Slide 18
UNICITER® Example
With included options
Overvoltage
protection (surge
Arrester)
Two separate
diode wheels
© ABB Group
June 1, 2011 | Slide 19
Induction free resistor
(current limiter)
AVR Retrofit Example
Excitation system option
Old AVR
New AVR
© ABB Group
June 1, 2011 | Slide 20
UNICITER® beginning a project
Requested data to start a project





© ABB Group
June 1, 2011 | Slide 21
Mechanical dimensional drawing
Free space available
Electrical main plate data
AVR installation area, electrical system
Photos (complete string and specifically the exciter)
Product Range UNICITER®
References overview
I [A]
1800
> 40 units delivered
WE 112 – 190
> 70 units delivered
1200
> 90 units delivered
WE 68 – 104
900
WE 33 - 58
0
214
600
1500
Special designs on request
© ABB Group
June 1, 2011 | Slide 22
1800
Max.
Rated speed
speed
[rpm]
(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
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
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
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
LG Petrochemie ( Motor )
KW Klamm
New Valley ( Motoren )
© ABB Group
June 1, 2011 | Slide 23
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
© ABB Group
June 1, 2011 | Slide 24
Contact
ABB Switzerland Ltd
GTSC Birr
Global Technical Support Center
5242 Birr, Switzerland
Tel
Fax
Email
I-Net
© ABB Group
June 1, 2011 | Slide 25
+41 58 586 67 41
+41 58 586 69 08
service.motors@ch.abb.com
www.abb.ch/service