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User’s Manual

AMG Synchronous Generator

Industrial Application Series

Generator type: AMG 0180-AMG 0500

Serial number:

Document number: 8AMG5854948

Revision: D (09/2011)

Summary of Contents for AMG 0180

Page 1: ...User s Manual AMG Synchronous Generator Industrial Application Series Generator type AMG 0180 AMG 0500 Serial number Document number 8AMG5854948 Revision D 09 2011 ...

Page 2: ...vicing 10 1 8 Disposal and recycling instructions 10 1 8 1 Recycling of material required for transport 11 1 8 2 Recycling of the complete machine 11 Chapter 2 Transport and storage 13 2 1 Transport and unpacking 13 2 1 1 Protective measures prior to transport 13 2 1 2 Lifting the machine 13 2 1 3 Lifting of unpacked machine 13 2 1 4 Checks upon arrival and unpacking 14 2 1 5 Bearing plate 15 2 2 ...

Page 3: ... 3 1 General information 29 4 3 2 Connection of main power cables and neutral cable 29 4 3 3 Earth connection 30 4 3 4 Insulation distances of main power connections 30 4 3 5 Connection of auxiliaries and instruments 30 Chapter 5 Commissioning 31 5 1 General 31 5 2 Check of mechanical installation 31 5 3 Check of electrical installation 31 5 4 Insulation resistance measurements 32 5 5 Automatic Vo...

Page 4: ...nce 53 7 6 3 The correct operating temperature 53 7 6 4 Insulation resistance test 53 7 6 5 Polarization index 57 7 6 6 High voltage test 57 7 6 7 Visual winding inspection 58 7 6 8 Drying 59 7 6 9 Other maintenance operations 59 7 7 Maintenance related to electrical performance excitation control and protection 60 7 7 1 Exciter insulation resistance measurement 60 7 7 2 Protection trips 60 7 7 3 ...

Page 5: ...package 69 9 2 5 Typical recommended spare parts in different sets 69 9 2 6 Order information 70 ANNEX 1 MAIN DIMENSION DRAWING ANNEX 2 ROTOR DRAWING ANNEX 3 MAIN CONNECTION DRAWING ANNEX 4 CONNECTION INSTRUCTION ANNEX 5 COMMISSIONING REPORT ANNEX 6 AUTOMATIC VOLTAGE REGULATOR USER S MANUAL ANNEX 7 TEST REPORT ANNEX 8 TECHNICAL SPECIFICATION ANNEX 9 PERMANENT MAGNET GENERATOR PMG USER S MANUAL ANN...

Page 6: ...s this equipment Ignoring the instruction invalidates the warranty 1 2 European directives Generators sold to European Union must meet the relevant local directives The generator is supplied as a component part of generating set as it has itself no intrinsic function without mechanical power input Every generator is therefore supplied with an EC Declaration of Incorporation according to Machinery ...

Page 7: ...greements made for each work site and safety instructions included in this manual and separate safety instructions delivered with the machine The information in this document is subject to change without notice and should not be construed as a commitment by ABB ABB assumes no responsibility for any errors that may appear in this document This document and parts thereof must not be reproduced or co...

Page 8: ...se or baggy clothing can be lethal when working on or near rotating machinery Clothing should be laundered regularly Clothing which becomes impregnated with oil or other substances can constitute a health hazard due to prolonged contact with the skin even through underclothing As far as it is practicable work on or close to machinery only when they are stopped If this is not possible keep tools te...

Page 9: ...s ESD Precautions must be taken to prevent damage to the electronic control devices of the synchronous machine Ensure that the operating environment is protected against ESD Do not touch electronic circuits while unpacking 1 6 6 Magnetic fields There is a magnetic field presence in the immediate area surrounding rotating machinery Ensure that devices that can be influenced or wiped e g magnetic di...

Page 10: ... g bearing locks vibration dampers before commissioning Store them for further use When storing the machine make sure that the location is dry dust and vibration free danger of bearing damage at rest Measure the insulation resistance before commissioning At values of 1 k per volt of rated voltage dry winding Follow the manufacturer s instructions 1 7 4 Installation Make sure of even support solid ...

Page 11: ...o time open closed condensation drain holes if any Grease the bearings during commissioning before start up in case of re greasable bearings Re grease antifriction bearings while the machine is running Follow instructions on lubrication plate Use right kind of grease Refer to manufacturer s documentation for noise level and information about the use of appropriate noise reducing measures 1 7 7 Mai...

Page 12: ...have to be removed before melting the material Components with electrical insulation The stator and the rotor are the main components which include electrical insulation materials There are however auxiliary components which are constructed of similar materials and which are hence dealt with in the same manner This includes various insulators used in the terminal box excitation machine voltage and...

Page 13: ...order to avoid any risk for fire hazards or explosions Due to various installations used for the purpose it is not possible for ABB to give detailed instructions of the heat treatment process or the maintenance of the heat treatment equipment These aspects must be taken care by the customer Hazardous waste The oil and grease from the lubrication system is a hazardous waste and has to be handled ac...

Page 14: ...d ensure that suitable lifting equipment is available and that personnel are familiar with lifting work The weight of the machine is shown on the rating plate dimension drawing and packing list NOTE Use only the lifting lugs or eyes intended for lifting the complete machine Do not use any small additional lifting lugs or eyes available as they are there only for service purposes NOTE The center of...

Page 15: ...npacking Check upon arrival Inspect the machine and the package immediately upon arrival Any transport damage must be photographed and reported immediately i e within less than one 1 week after arrival if the transport insurance is to be claimed It is therefore important that evidence of careless handling is checked and reported immediately to the transport company and the supplier Use checklists ...

Page 16: ... plate If re lubrication is needed a stainless steel bearing plate is attached to the machine frame The bearing plate indicates the type of the bearings and lubrication to be used see Figure 2 2 Bearing plate for grease lubricated rolling bearings as an example Figure 2 2 Bearing plate for grease lubricated rolling bearings Notation used in Figure 2 2 1 Bearing type of D end 2 Bearing type of ND e...

Page 17: ...hine main terminals Required DC voltage is approx 5 of the rated voltage and current shall not exceed 30 of the nominal current A stable support free from excessive vibrations and shocks If vibrations are suspected to be too high the machine should be isolated by placing suitable rubber blocks under the machine feet Air which is ventilated clean and free from dust and corrosive gases Protection ag...

Page 18: ...rotected surfaces listed in Chapter 2 2 1 Short term storage less than 2 months and Chapter 2 2 2 Long term storage 2 6 months and renew the anti corrosive treatment every 12 months Otherwise follow the instructions for shorter storage periods 2 2 4 Rolling bearings Apply the following measures Rolling bearings should be well lubricated during storage Acceptable grease types are presented in Chapt...

Page 19: ...ine is working Check that the ventilation works Every 3 months Check the insulation resistance see Chapter 7 6 4 Insulation resistance test Check that there is no corrosion on the surfaces If corrosion is observed remove the corrosion and protect the surfaces Check that the anti corrosion agents have not cracked 2 2 6 Storage and care after installation If the machine will not be in operation for ...

Page 20: ...s for screws is given in Chapter 7 4 4 The tightness of fastenings Use these values if no specific tightening torques are given in this manual or in the mechanical and electrical drawings NOTE The values in Table 7 10 General tightening torques are general and do not apply to various items such as diodes support insulators bearings cable terminals or pole fastenings surge arrester capacitors curre...

Page 21: ... NOTE To measure the AH it is better if choose four different positions on the circle top bottom right left i e 90o and select the average value of them 3 1 4 Disassembly of the transport locking device All machines with sleeve or roller bearings have transport locking devices installed For machines with sleeve or cylindrical roller bearings the transport locking device is made of a steel bar atta...

Page 22: ...f the coupling half Never coat mating surfaces with molybdenum disulphide Molykote or similar products The coupling must be covered with a touch guard NOTE In order not to damage the bearings no additional forces should be applied to the bearings when assembling the coupling half Balancing of coupling The rotor is dynamically balanced with half key as standard The way of balancing is stamped to th...

Page 23: ...st be performed with great caution Failure to do so can result in serious vibrations and damage to both generator and prime mover If one bearing design is considered align and couple the coupling discs with the flywheel and couple the flange with the flywheel housing NOTE Alignment must be performed with great caution Failure to do so can result in serious vibrations and damage to both generator a...

Page 24: ...rious vibrations and damage to both driving and driven machine Alignment of the generator with coupling discs In accordance with common practice parallel and angular misalignment should not exceed 0 05 0 10 mm and axial misalignment should not exceed 0 10 mm see Figure 3 3 Checking of misalignment of coupling discs below Figure 3 3 Checking of misalignment of coupling discs NOTE Definite alignment...

Page 25: ...t should not exceed 0 05 0 10 mm and axial misalignment should not exceed 0 10 mm see Figure 3 4 Definition of misalignment The corresponding run out is 0 10 0 20 mm for parallel and angular misalignment and 0 20 for axial misalignment Figure 3 4 Definition of misalignment Notation used in Figure 3 2 Definition of misalignment Parallel misalignment r Angular misalignment b Axial misalignment a Fin...

Page 26: ...4 The tightness of fastenings and check that there is lateral play on the crankshaft 0 1 0 6mm NOTE During this performance use torsional spanner for tightening the screws which connect the flange of the generator and the flywheel housing of the engine and the coupling discs and flywheel For recommended torques see Chapter 7 4 4 The tightness of fastenings More detailed instructions for installati...

Page 27: ...5 0 10 0 15 0 20 0 25 0 30 0 35 0 5 10 15 20 25 30 35 40 45 50 55 Temperature increase K Thermal expansion mm AMG 0180 AMG 0200 AMG 0250 AMG 0280 AMG 0315 AMG 0355 AMG 0400 AMG 0450 AMG 0500 Figure 3 6 The Correlation between thermal expansion and machine temperature rise Permissible misalignment Definite alignment tolerances are impossible to state as too many factors have an influence Too large ...

Page 28: ...4 0 mil Rigid flange 0 02 mm 0 01 mm 0 02 mm 0 8 mil 0 4 mil 0 8 mil 250 500 mm Gear 0 05 mm 0 03 mm 0 05 mm 10 20 2 0 mil 1 0 mil 2 0 mil Flexible 0 10 mm 0 05 mm 0 10 mm 4 0 mil 2 0 mil 4 0 mil 3 3 Final inspection of installation 3 3 1 Covers and enclosures After the machine has been erected and aligned check carefully that no tools or foreign objects have been left inside the enclosures Clean ...

Page 29: ... by the voltage transformer and a current feedback is provided by the current transformer The transformers are installed in the generator Operational limits such as over and under excitation machine voltage and Volts Hz are implemented in the AVR Static reactive power compensation in parallel operation and several other software functions are also available The AVR is equipped with the PC software...

Page 30: ... frequencies indicated on the rating plate of the machine and in Annex 8 Technical Specification are correct Make sure that the sizes of input cables are adequate for the maximum load current and in accordance with local standards Make sure that cable terminations are of appropriate type and of correct size Check the connections of all devices such as temperature probes NOTE Prior to installation ...

Page 31: ...gested that the minimum insulation distances mentioned in Table 4 1 Recommended minimum insulation distances are used These distances apply both for insulation distances between two different phases and for insulation distances between one phase and the earth The air insulation distance is the shortest distance through air between two points with different electrical potential The surface insulati...

Page 32: ...foundation 3 Check for cracks in the foundation and the general condition of the foundation 4 Check the tightness of the fixing bolts 5 Open the machine and check that the air gap is free 6 If possible turn the rotor by hand and make sure that the rotor turns freely and that there are no abnormal sounds 7 Check the assembly of the main terminal box 8 Check that all transport locking devices are re...

Page 33: ... by ABB The AVR has been tested with the specific generator and all the basic settings have been modified and saved so that the AVR will also work at site The correct AVR and the correct generator can be identified by checking the serial numbers on the test report see Test Reports Settings used in testing can be found in Test Reports Checking at site before first run All the settings has to be che...

Page 34: ...or excess new grease is discharged through the lubrication channel in the bottom of the bearing housing see Figure 5 1 Example of lubrication channel through bearing arrangement of horizontal machine Figure 5 1 Example of lubrication channel through bearing arrangement of horizontal machine NOTE The re lubrication interval will never be longer than 12 months The type of original grease used is fou...

Page 35: ...the values for future reference use 5 8 Shut down The shut down of the machine depends on the application but main guidelines are 1 Reduce the output of the machine to zero 2 Open the main breaker 3 Switch the machine excitation off when applicable 4 Stop the engine 5 Switch the anti condensation heaters on if not automatically done by switchgear ...

Page 36: ...nditions according to the IEC standard technical specifications and internal ABB standards The operation conditions such as maximum ambient temperature and maximum operating height are specified in the performance data sheet The foundation should be free from external vibration and the surrounding air free of dust salt and corrosive gases or substances 6 3 Protection of synchronous generators Prot...

Page 37: ...ection is to thoroughly familiarize personnel with the equipment This is essential in order to detect and fix abnormal occurrences in time Data from the supervision inspection should be kept for future reference and can be of help in maintenance work trouble shooting and repairs It is also recommended that the operational data generator load power factor speed voltage and current as a minimum shal...

Page 38: ...1 Switch the main breaker open 2 Switch excitation off if applicable When the synchronous machine is not in operation anti condensation heaters must be switched on to avoid condensation inside the machine For detailed shut down instructions see Chapter 5 8 Shut down ...

Page 39: ...ability of the machine and the long term availability will increase The data obtained during supervision and maintenance is useful for estimating and planning additional service In case some of this data indicates something out of the ordinary the trouble shooting guides in Chapter 8 Troubleshooting will aid in locating the reason for the trouble ABB recommends the use of experts in the creating m...

Page 40: ...d on basis of this information The maintenance program is based on four levels of maintenance which rotate according to operating hours The amount of work and down time vary so that level 1 includes mainly quick visual inspections and level 4 more demanding measurements and replacements More information about the spare part packages suitable for this type of maintenance can be found in Chapter 9 2...

Page 41: ...el of maintenance are included in the recommended spare parts package The first Level 2 maintenance should be performed after 8 000 equivalent operating hours or one year after commissioning Subsequently the L2 maintenance should be performed yearly or after every 8 000 equivalent operating hours see Table 7 1 Recommended maintenance program Level 3 L3 Level 3 or L3 maintenance consists of perform...

Page 42: ...leaves their rotation unaffected see Table 7 1 Recommended maintenance program 7 3 1 Recommended maintenance program Abbreviation used in maintenance program V visual checking C cleaning D disassembling and assembling R reconditioning or replacement T testing and measurement NOTE Not all options are applicable for all machines Table 7 2 Maintenance intervals Maintenance interval In equivalent oper...

Page 43: ...oltage test Stator coil overhangs V V V V Insulation damages Stator coil supports V V V V Insulation damages tightness Stator slot wedges V V V V Movement tightness Stator terminal bars V V V V Fixing insulation Stator cable terminal fastenings and crimps V V T V T V T Tightness condition Instrumentation V V V V Condition of cables and cable ties Rotor winding insulation V V T V T C V T C Wear cle...

Page 44: ...2 L3 L4 Check Test Bearing assembly V V T V T V T General condition Re lubricated bearing R R R R Re greasing Closed bearing no re lubrication V V V R R Condition change bearing Table 7 8 Maintenance objects for cooling system Maintenance object L1 L2 L3 L4 Check Test Fan V V V V Operation general condition cracks Air intake V V C V C V C Cleanliness operation Air outlet V V C V C V C Cleanliness ...

Page 45: ... below Measurements are usually made when the rotor and the main bearings have reached their normal steady state operating temperatures and the machine running under specified conditions e g at rated speed voltage flow pressure and load If the measured vibration exceeds the acceptance criteria and excessive background vibration is suspected measurements should be made with the machine shut down to...

Page 46: ...ble operation In some cases vibration levels can be above value 2 but only if individual special designs of generating set structure and components are applied In all cases the generating set manufacturer remains responsible for the compatibility of the generating set components see ISO 8528 5 1993 15 10 Additional information For more details about vibration measuring see the following Internatio...

Page 47: ...al drawings and Electrical drawings 7 4 5 Rotor construction control Particular attention should be paid to rotor construction because even small damages in the rotor can lead to severe damages in the stator In addition mechanical problems in the moving parts such as the rotor have a tendency to develop faster than in the stationary parts of the machine Therefore rotor construction should be check...

Page 48: ...n of the bearing Re greasable anti friction bearings In order to operate reliably bearings must be satisfactorily lubricated to prevent direct metallic contact between rolling elements bearing and cage races to prevent wear and to protect surfaces from corrosion To ensure reliable operation the bearings should be regularly re greased with high quality rolling bearing grease The choice of grease gr...

Page 49: ...nterval should be halved for every 15 C 30 F increase in bearing temperature and may be once doubled for a 15 C 30 F decrease in bearing temperature Re greasing intervals for frequency converter drives Higher speed operation e g in frequency converter applications or lower speed with heavy load will require shorter lubrication intervals or a special lubricant Consult manufacturing ABB factory Afte...

Page 50: ...few minutes at full speed Stop the machine After the machine has stopped press the specified amount of the correct grease into the bearing Let the machine run 1 2 hours in order to ensure that all excess grease is forced out of the bearing The bearing temperature may temporarily increase during this time If equipped with a handle close it Automatic re greasing A variety of automatic re lubrication...

Page 51: ...ended However a written guarantee should be obtained from the lubricant manufacturer stating that the additives do not damage the bearings or the properties of the grease in the field of the operating temperature This is especially important for EP additives NOTE Lubricants containing EP admixtures are not recommended NOTE Different makes of grease must not be mixed unless the compatibility has be...

Page 52: ...l 1 Support the shaft 2 Remove the grille of NDE shield 3 Remove PMG stator 4 Remove PMG rotor attached with one bolt and a pin For more detailed information about this optional PMG unit see Annex 9 Permanent Magnet Regulator PMG User s Manual 5 Remove the NDE shield 6 Extract the ball bearing with a puller see Figure 7 1 The bearing puller 7 Check the O ring seal and the preloading wavy washer an...

Page 53: ...d 432 1992 IEEE Guide for Insulation Maintenance for Rotating Electrical Machinery 5 hp to Less Than 10 000 hp 7 6 1 Particular safety instructions for winding maintenance Some of the hazardous works of the winding maintenance include Handling of hazardous solvents varnishes and resins Hazardous substances are required for cleaning and re varnishing windings These substances can be dangerous if in...

Page 54: ...apted to the customer s particular circumstances i e servicing of other machines and operating conditions as long as recommended servicing intervals are not exceeded 7 6 3 The correct operating temperature The correct temperature of the windings is ensured by keeping the exterior surfaces of the machine clean by seeing to the correct operation of the cooling system and by monitoring the temperatur...

Page 55: ...nsulation resistance and the temperature R Insulation resistance value at a specific temperature R40 Equivalent insulation resistance at 40 C R40 k x R Example R 30 M measured at 20 C k 0 25 R40 0 25 x 30 7 5 M Table 7 10 Temperature values in degrees Celsius C and degrees Fahrenheit F C 0 10 20 30 40 50 60 70 80 90 100 110 F 32 50 68 86 104 122 140 158 176 194 212 230 General considerations The f...

Page 56: ...eter The test voltage is 1000 VDC The test time is 1 minute after which the insulation resistance value is recorded Before the insulation resistance test is conducted check that The secondary connections of the current transformers CT s including spare cores are not open see Figure 7 3 Connection of the stator windings for insulation resistance measurements part a All power supply cables are disco...

Page 57: ...nce measurement the winding phases must be earthed to discharge them Insulation resistance measurements of the rotor field winding and excitation machine The test voltage for the rotor windings and excitation machine is 500 VDC When testing the windings of the rotors Short circuit the rectifier before measuring Measure the rotor winding temperature if possible or estimate otherwise measurement tem...

Page 58: ...ce on temperature Thus the line in Figure 7 2 Correlation between the insulation resistance and the temperature becomes less steep Windings with open creepage distances are very sensitive to the effects of dirt and humidity There are several rules for determining the lowest acceptable value with which the machine can be safely started For the polarization index PI the values usually range between ...

Page 59: ...orting bolts and squirrel cage windings are also signs of deterioration but they take longer to develop into a failure Humidity in the winding often causes e g rust on iron drop marks dripping and wetting marks on dirt layers Bush shaped patterns often charred and left behind by the tracking currents warn of an approaching failure In rare cases the conductors are corroded Marks of the electrical e...

Page 60: ...ing in an oven the temperature rise and the maximum temperature should be monitored carefully The oven temperature should be around 90 C or 194 F for 12 to 16 hours and then 105 C 220 F for six to eight hours These times can vary and the correct time should be monitored with and insulation resistance test Effective drying is achieved with the right balance of heat and ventilation The air circulati...

Page 61: ... be protected with alarms and trips in case of abnormal running conditions both electrical and mechanical Some of these protections can be reset and the machine restarted directly as the fault is located 7 7 3 Automatic voltage regulator AVR The automatic voltage regulator AVR is important in controlling and protecting the machine and problems in connections or settings of the AVR might lead to di...

Page 62: ... responsible for the increase in the temperature Excessive heat production might be caused e g by a winding problem or by network unbalance and in these cases corrective actions on the cooling system would be ineffective or harmful 7 8 1 Cooling System The machine is cooled with a shaft mounted fan The cooling air is taken in from the surroundings air at the non drive end and it is blown out from ...

Page 63: ...Page 62 When abnormal temperature rise has been detected it should be also checked that temperature measurement system is operating correctly ...

Page 64: ...mechanical electrical and thermal problems and problems associated with the lubrication system The checks and corrective actions mentioned should always be conducted by qualified personnel If in any doubt the After Sales of ABB should be contacted for more information or technical assistance regarding troubleshooting and maintenance For optional PMG unit see Annex 9 Permanent Magnet Regulator PMG ...

Page 65: ...Page 64 8 1 Mechanical performance Table 8 1 Trouble shooting for mechanical performance Troubleshooting Mechanical performance x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x ...

Page 66: ...Page 65 8 2 Lubrication system and rolling bearings Table 8 2 Trouble shooting for lubrication and rolling bearings ...

Page 67: ... 8 3 Thermal performance open air cooling system Table 8 3 Troubleshooting for thermal performance Troubleshooting Thermal performance open air cooling system x x x x x x x x x x x x x x x x x x x x x x x x x ...

Page 68: ... 8 3 Trouble shooting for electrical performance x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Troubleshooting Electrical performance and excitation system of generators with transformer excitation ...

Page 69: ...ction as well as in electromagnetic and insulation technology issues 9 1 5 After sales contact information Contact the Service department by Phone 8 30 am 5 30 pm 86 791 835 0869 GMT 8 Fax 86 791 835 0814 e mail aftersales generator cn abb com 9 2 Spare parts 9 2 1 General spare part considerations The machines manufactured by ABB are designed and manufactured to provide reliable and trouble free ...

Page 70: ...es and system disturbances The electrical windings of the ABB machines have good protection against wear but only if correct maintenance and operating conditions are followed The correct operating temperature must not be exceeded and the windings must be cleaned from dirt regularly The winding can also be subjected to accelerated wear due to a number of electrical disturbances 9 2 4 Selection of t...

Page 71: ... 1 set 9 2 5 3 Capital spare parts package Spare part Amount Exciter rotor 1 pc Exciter stator 1 pc Rectifier bridge 1 set Rotor complete 1 pc Stator with frame 1 pc 9 2 6 Order information To ensure fast and correct spare part order and delivery our After sales personnel should be provided with the serial number of the machine in question The serial number can be found either on the rating plate ...

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