Brochure Motorformer Very high voltage motors from ABB
We provide motors, generators and mechanical power transmission products, services and expertise to save energy and improve customers processes over the total life cycle of our products, and beyond. 2 ABB Motors and Generators Very high voltage motors from ABB
Motorformer A proven performer in offshore oil and gas platforms and standalone onshore compressor applications ABB Motors and Generators Very high voltage motors from ABB 3
Getting more from less More power, fewer parts, lower total costs Motorformer is the only choice for very high voltage motors in the megawatt power size. Developed by ABB in the late 1990s, this award-winning technology has been successfully delivering operational and cost benefits to industrial compressor applications as well as offshore oil and gas applications for more than 10 years. Drawing on more than 100 years of ABB expertise in AC synchronous motors and generators, Motorformer can operate with input voltages of up to 70 kv and outputs of 50 MW. More power from fewer parts The technology that makes such high voltages possible is the stator design, which is unique to the Motorformer very high voltage motor. Instead of using rectangular copper coils for the stator windings, ABB ingeniously uses standard cross-linked polyethylene (XLPE) single phase power cables that withstand the higher voltages. Standard XLPE cables have a number of properties that enable them to operate with considerably higher voltages than conventional stator windings. the highest power ratings and longest cable distances technically possible. Motorformer is an important addition to these high-efficiency, low-maintenance solutions, where it acts as an electric drive system to power heavy-duty equipment like gas compressors. As a result of this simple but revolutionary design, Motorformer does not require a costly step-down transformer and associated switchgear - thereby reducing the size, weight, power losses, operation and maintenance costs, and environmental impact of the Motorformer solution. Cheaper, cleaner power for offshore applications The ability to operate with such high multi-megawatt input voltages makes Motorformer an ideal complement to powerfrom-shore solutions for offshore applications like oil and gas platforms and floating production, storage and offloading vessels (FPSOs). ABB power-from-shore solutions use an ABB innovation - HVDC Light cable transmission systems to transport large amounts of power (up to 1,200 MW at 500 kv DC) over long distances to offshore platforms, thereby eliminating the need to generate electricity on the platform with gas turbines or diesel generators. ABB can also provide HVAC power-from-shore solutions at Motorformer data Output power Voltages Frequency Protection Cooling Standards Hazardous areas Pole/speed 5 to 50 MW at 50 Hz or 60Hz 15 to 70 kv 50, 60 Hz or VSD IP54, IP55, IP56 Water cooled IEC, NEMA Pressurized 4-pole, 1500/1800 rpm or VSD <2000 rpm 4 ABB Motors and Generators Very high voltage motors from ABB
The benefits of very high voltage motors Fewer components Motorformer takes its power direct from the high voltage supply, thereby eliminating the need for a heavy, spaceconsuming, oil-immersed step-down transformer and associated medium voltage switchgear. Smaller footprint and less weight Footprint and weight are of paramount importance on offshore platforms and FPSOs. An ABB power-from-shore solution eliminates the need for gas turbines, thereby reducing the size and weight of the platform electrification solution (a platform consuming 100 MW of power usually requires several gas turbines to generate the power and meet the platform s redundancy requirements). Increased availability Gas turbines require regular and comparatively long production shutdowns for maintenance. Motorformer and HVDC Light power-from-shore solutions have significantly longer service intervals than gas turbines and, therefore, much better availability Reduced operation and maintenance costs Longer service intervals and fewer components reduce the cost of service, maintenance and spare parts, as well as the need for operation and maintenance staff on the platform. Zero CO 2 and NO x emissions By removing the need for fossil-fuel-burning gas turbines on the platform or FPSO, ABB power-from-shore solutions eliminate emissions of carbon dioxide and nitrogen oxide. This enables Motorformer to power large compressors cleanly and without emitting greenhouse gases. Safe and environmentally friendly Besides zero greenhouse gas emissions, HVDC Light offers other environmental benefits, such as neutral electromagnetic fields, oil-free cables and compact converter stations. Motorformer enhances safety on the platform by not requiring an oil-filled and potentially hazardous power transformer to step down the voltage. ABB Motors and Generators Very high voltage motors from ABB 5
Perfect performance at very high voltage A simple but revolutionary stator and proven ABB components Whereas conventional synchronous motors can operate with an input voltage of only 15 kv, Motorformer can operate at up to 70 kv - almost five times that voltage. This is made possible by a simple yet revolutionary design of the stator that uses standard insulated XLPE cables for the windings instead of rectangular copper strips insulated with epoxy-mica. The technical benefits of this simple, innovative design are threefold: Partial discharge-free cable insulation makes it possible to increase the design voltage Grounded cable end windings provide a corona-free surface and increased design voltage Standard XLPE cables provide a complete insulation system that is factory-tested prior to installation in the motor. 6 ABB Motors and Generators Very high voltage motors from ABB
Modular design, standardized components Each ABB very high voltage motor is built to meet customer and application requirements. Quality in every detail Assembled from a modular platform of proven standardized ABB synchronous motor components, each very high voltage motor is designed to operate at the peak of reliability and efficiency over a long and productive operating life, thereby minimizing operation, maintenance and energy costs over the life cycle of the motor. Rotor Like all conventional ABB large synchronous 4- and 6-pole motors, Motorformer has a solid rotor with integrated solid salient poles made from single-piece steel forging. A solid pole plate is attached to the pole to provide excellent overload capability, low harmonics, and superb starting characteristics with high starting torque and low starting current. The large cooling surfaces and effective flow of cooling air keep the rotor temperature low and uniform to ensure reliability and a long operating life. The rotor windings are class H insulated for extra thermal margins. And, the rigid rotor construction and minimal distance between bearings ensure that the motor operates below the first critical speed, keeping vibration levels low. Stator core The stator core is - as on all ABB large synchronous motors - made of high grade, low-loss laminated electrical steel, insulated on both sides with a high-quality insulating coating. Radial cooling ducts ensure uniform and effective cooling. The rigid stator construction minimizes vibrations by transmitting all forces via the frame to the foundation. Frame Motorformer is designed for horizontal mounting. The robust frame transfers dynamic and static stresses directly to the foundation, reducing vibration and contributing to the overall excellent performance of the motor. Each ABB motor is designed and built to withstand the relevant environmental conditions of the application in question, including the harsh operating conditions of offshore platforms. Cooling system For power ratings up to 10 MW, Motorformer uses conventional air-to-air and air-to-water coolers. For ratings above 10 MW, Motorformer uses air-to-water coolers only. Separate fans force the inner cooling air flow independently of rotor speed. Exciter Motorformer uses a compact conventional brushless exciter unit mounted on the rotor shaft outboard of the non-drive bearing. This simple well-proven design has few components. No independent support or alignment is required. The high level of field forcing delivers excellent system performance, which increases the production of reactive power and is beneficial if faults arise in the supply network. Excitation control The motor excitation control panel is available in a variety of basic formats. It houses the excitation equipment, protection system and logic functions for starting. A wide range of instrumentation and control equipment is available to protect the motor and ensure reliability and availability and extended product lifetime. The motor excitation control panel can be adapted for integration with a management and supervisory system. Communication via the Internet can also be supplied to facilitate remote support. ABB Motors and Generators Very high voltage motors from ABB 7
Complete power-from-shore solutions Cheaper, cleaner power for offshore oil and gas platforms Power-from-shore is the most economical and environmentally friendly way to provide power for offshore oil and gas platforms and floating production, storage and offloading vessels (FPSOs). ABB delivered the world s first power-to-platform solution in 2003 and has subsequently delivered or is delivering - high voltage DC and high voltage AC power-from-shore solutions for several oil and gas platforms. Motorformer is playing a key role in several of those solutions Turnkey solutions using proven ABB ABB pioneered power-from-shore solutions, delivering the world s first HVAC power-from-shore connection in Saudi Arabia in 2003, and the world s first HVDC power-from-shore solution in Norway in 2005. Since then ABB has delivered HVDC and HVAC power-from-shore solutions for several major oil and gas companies, even in demanding Arctic waters. ABB offers turnkey power-from-shore solutions using compact, lightweight HVDC Light converter stations and robust, oil-free HVDC Light cables. ABB is the only company that can offer complete power-from-shore solutions using its own widely proven products and technologies. ABB HVDC Light solutions can transport up to 1,200 MW of power at 500 kv over a distance of several hundred kilo- meters. For shorter distances, ABB can also offer HVAC alternatives The clean, cost-effective alternative to gas turbines HVDC Light makes it possible to transport electric power to, from and between offshore installations where distances and/ or power range prohibit AC transmissions. This voltage source converter technology is more efficient, more environmentally friendly and safer than conventional offshore power generation. Emissions of greenhouse gases from low efficiency gas turbines are eliminated along with the health and safety hazards associated with gas-fired rotating equipment. HVDC Light requires considerably less operation and maintenance resources than gas turbines. 8 ABB Motors and Generators Very high voltage motors from ABB
Onshore applications Boosting efficiency at air separation units ABB delivered the world s first Motorformer very high voltage motor in 2001. Installed at an air separation plant in Sweden, the motor has been operating at maximum reliability and availability in a round-the-clock application ever since. Motorformer is ideal for onshore applications like air separation units, where its ability to improve the reliability, availability and energy efficiency of compressors is well proven. The world s first Motorformer has been driving a recycle compressor at an air separation plant in Sweden since 2001. The plant supplies gaseous oxygen and nitrogen by pipeline to several petrochemical plants located on the same industrial estate. The process is energy-intensive and very demanding and operates non-stop. Reliability and availability of the very high voltage motor is vital. Network stability is an important benefit for the customer and the network operator. Due to the large number of electric motors in nearby petrochemical plants, the local power network is required to meet high demands for reactive power and starting current. Because Motorformer is a synchronous motor operating at a very high voltage level, it can boost and support the power network with reactive power whenever required. By selecting Motorformer to drive the recycling compressor at the plant, the plant owner has obtained a number of significant benefits: Reduced and simplified system layout due to the elimination of the transformer and related medium voltage switchgear. Substantial reduction in system losses Improved reliability and availability of the compressor drive system Reduced expenditure on service, maintenance and spares Network stability ABB Motors and Generators Very high voltage motors from ABB 9
Powering gas compressors in offshore applications Motorformer in conjunction with an ABB HVDC Light or HVAC power-from-shore solution is the most beneficial way to power large offshore loads such as gas compressors. In one gas compressor application Very high voltage motors, rated at 44 and 50 MW, were installed to compensate for falling pressure in the gas reservoir and to enable production rates to be maintained. ABB was selected to deliver the world s first DC power-fromshore solution to power the two compressor units with electricity from the mainland grid. The solution was centered on two groundbreaking ABB technologies - HVDC Light and the Motorformer very high voltage motor. The HVDC Light solution converts AC power from the 132 kv mainland power grid to DC at an onshore HVDC Light converter station. Two HVDC Light power cables, with a combined capacity of more than 80 MW, transport the power at 60 kv DC to the platform, a distance of 70 kilometers. There, the power is reconverted to AC in a compact lightweight converter station module and fed to the two ABB very high voltage synchronous motors, which drive the two gas compressors. The installation started operating in 2008. Customer benefits Economical and environmentally friendly turnkey solution using proven ABB technologies Compliance with Statoil s stringent requirements for project execution, which include zero harm to people and the environment and no production losses at Troll A and Kollsnes Significantly lower installation, operating and maintenance costs compared to conventional gas turbine alternatives Zero carbon dioxide and nitrogen oxide emissions 10 ABB Motors and Generators Very high voltage motors from ABB
Life cycle services and support From pre-purchase to migration and upgrades ABB offers a complete portfolio of services to ensure trouble-free operation and long product lifetimes. These services cover the entire life cycle. Local support is provided through a global network of ABB service centers and certified partners. Pre-purchase ABB s front-end sales organization can help customers to quickly and efficiently select, configure and optimize the right motor or generator for their application. Installation and commissioning Professional installation and commissioning by ABB s certified engineers represent an investment in availability and reliability over the entire life cycle. Engineering and consulting ABB s experts provide energy efficiency and reliability appraisals, advanced condition and performance assessments and technical studies. Condition monitoring and diagnosis Unique services collect and analyze data to provide early warnings of problems before failures can occur. All critical areas of the equipment are covered. Maintenance and field services ABB offers life cycle management plans and preventive maintenance products. The recommended four-level maintenance program covers the entire product lifetime. Repair and refurbishment Support for all ABB motors and generators and other brands is provided by ABB s global service organization. Specialist teams can also deliver emergency support. Migration and upgrades Life cycle audits determine the optimum upgrades and migration paths. Upgrades range from individual components to direct replacement motors and generators. Training Product and service training courses take a practical approach. The training ranges from standard courses to specially tailored programs to suit customer requirements. Specialized support Specialized support is offered through ABB s global service organization. Local units provide major and minor repairs as well as overhauls and reconditioning. Service contracts Service contracts are tailored to the customer s needs. The contracts combine ABB s entire service portfolio and 120 years of experience to deploy the optimal service practices. Spare parts Spare parts and support are offered throughout the life cycle of ABB products. In addition to individual spares, tailored spare part packages are also available. ABB Motors and Generators Very high voltage motors from ABB 11
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