High Voltage Machines

ABB is the worlds leading supplier of high voltage induction machines

used in a wide range of applications in virtually every industry
including oil, gas & petrochemicals, power generation, marine, pulp &
paper, cement, mining, metals and water treatment. ABBs high voltage
machines have earned an excellent reputation for performance and
reliability.

Cutting-edge technologies backed by

a century of experience
A modular concept
ABB offers a comprehensive range of high
voltage induction motors ranging up to 15 kV
and 18 MW, 50 Hz and 60 Hz and complying
with widely-used standards including European
and NEMA specifications. As part of the Groups
focused factory philosophy, ABB India
manufactures High Voltage (HV) Motors ranging
from 200 kW to 3000 kW at its state-of-the-art
manufacturing facility in Vadodara. These can
be supplied as CACA / CACW / SPDP motors,
based on your application and requirement.
ABBs HV motors are built around a modular
platform. The simplicity of this concept allows
them to be precisely engineered according to
specific customer requirements and
applications. Superior design and manufacture
are important factors in the superlative
performance of ABB products.

The high efficiency of these motors, together

with a range of advanced ventilation
technologies, results in considerable energy
savings throughout the life of the motors.
The built-in advantage
ABB has been developing and manufacturing
electrical equipment for more than 100 years.
This experience and our track record of
building close partnerships with our
customers offer you a genuine competitive
advantage. By continuously developing and
incorporating the most advanced designs and
manufacturing technologies, we optimise
your operating efficiency and maximise
overall reliability.

A motor for all applications

Providing efficient motors for varying applications require design and
manufacturing flexibility and high quality components. The modular
concept ensures that your requirements determine the configuration of
the motor.

Modular design
Using a modular design-and-build principle,
ABBs field-proven motors are manufactured
using a series of building blocks with a
complete range of enclosures and cooling
arrangements. They can be configured for a
wide range of applications including
compressors, pumps, fans, blowers,
conveyors, mills, crushers, refiners and ship
thrusters.

Examples of output at 50 Hz
Output kW

Frames 315-1,120 mm

18,000
15,000

10,000

5,000

ABB High Voltage Machines conform to IEC, BS,

EN, VDE, DIN, IS and other international standards

Poles

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Performance and reliability

The Rotor
The key to long life for the rotor lies in ensuring very low
vibration levels. This is achieved through robust construction
and careful balancing of each completed unit.
Rotor shaft material is selected according to the application.
The spider beam welds and subsequent stress relieving process
is based on rigorous norms and subject to stringent inspection.
Squirrel cages are made from copper, copper alloy or
aluminium, based on the application needs. Swaged rotor
bars provide additional stiffness enabling the motors to
withstand long periods of heavy use.

The Rotor

The Stator
The stator core is welded and machined to form a compact
unit. Radial air ducts ensure uniform and efficient cooling.
The stator core forms a solid block that retains its rigidity
throughout the life of the motor. The complete stator is
vacuum pressure impregnated.
The Frame
The compact, rigid and welded frame construction is
designed to reduce overall weight, provide high lateral and
torsional stability as well as ensure low vibration levels in all
operating conditions and across the speed range.

The Stator

The Bearings
The bearings are designed for reliable and continuous operation
with ease of maintenance. Bearings are selected based on the
power, speed and application of the motor. Anti-friction bearings
with a predicted service life of over 100,000 hours can be
supplied. ABB also offers spherically-seated, self-aligning sleeve
bearings. For greater radial load capacity, cylindrical roller
bearings can be used at the drive end with a deep groove ballbearing at the non-drive end. All bearings feature a sealing
system that prevents penetration of dust. ABB motors use
insulated bearings on the non-drive end side thus preventing
circulation of shaft current due to harmonics.

The Frame

Easy-to-connect terminal boxes

Terminal box

The terminal box is designed to facilitate

cable connection and minimise
installation time. The box can be
mounted on either side of the motor and
is provided with a pressure relief device
as an added safety feature. The motors
can also be provided with Phase
Segregated Terminal Box (PSTB) as per
requirements.

Micadur-Compact Industry
insulation system

Coil locking

ABBs world renowned insulation system provides reliability and long life to
the windings. The windings and connections are insulated with mica-based
tape. When the windings are in place the whole stator is impregnated in the
Vacuum Pressure Impregnation (VPI) process. Class F is standard.

The Cooling System

Efficient cooling has to be achieved in all industrial ambient
conditions. Therefore ABB motors offer a range of alternative
cooling systems.

Micadur-Compact Industry (MCI)

Insulation System
AC Machines
Voltages up to 15 kV, Temperature Class F (155C)

Open, ventilated motors can be weather protected. Totally

enclosed motors can be fitted with built-in coolers, air-to-air
or air-to-water cooling.
Uniform, efficient internal cooling is assured on large 2-pole
motors and on all motors having 4 or more poles by rotor air
ducts and radial air ducts in the stator. In smaller 2-pole
motors this is achieved by axial cooling holes in the rotor
together with stator pre-slots and surface cooling of the cores.
External air circuit
Internal air circuit

Ventilation circuit in CACA type enclosure

The Micadur -Compact Industry (MCI) insulation system is

based on the global Vacuum Pressure Impregnation (VPI)
insulation method. The VPI method itself has successfully
demonstrated its reliability for many years with machines
used in all types of applications, and has achieved worldwide
recognition for excellence.
The MCI insulation system is applied to the entire range of
form-wound low and high voltage AC machines produced in
ABBs factories.
Key Features
Excellent Reliability: Years of dependable operational
experience in a wide variety of applications has proved
the excellent reliability of the system.

Ventilation circuit in CACW type enclosure

Proven System: Tens of thousands of machines with

the MCI system have been used successfully by
customers all over the world through the years.
Outstanding Performance: The dedicated mica
insulation combined with the global VPI process applying
special epoxy resin ensures long-life performance.
Properties

Ventilation circuit in SPDP type enclosure

Accurate design and controlled manufacturing processes

ensure that every stator winding with the MCI technique
meets all relevant international standards. Inspections and
tests are conducted during the coil manufacturing and winding
assembly to ensure a high quality for the final product.

Thermal stress

Ambient stress

The thermal endurance capability of the MCI system has

been proved for more than 30 years of operation under
extreme conditions even with machines fully utilising thermal
Class F temperature limits. The thermal performance has
been determined per IEEE Std. 434 and IEC 216-1 to 4 by
evaluating insulation properties over extended periods at
temperatures ranging from 160C to 200C. Based on these
criteria, the MCI system fully meets the requirements of
thermal Class F expressed in IEC 85. MCI insulated stators
have shown outstanding thermomechanical performance
which has been confirmed in severe cycling tests, various
applications and extreme climatic conditions.

Moisture: The penetration of epoxy resin in the coils,

overhang supports and connections during the VPI process
produce a winding which is resistant to very severe ambient
conditions. Further, as a standard option, MCI windings can
be provided sealed according to NEMA Std. 4, Part 20.

Surge withstand level (kV-peak)

70

Chemical resistance: MCI insulation is resistant to acids

and alkalines found in many industrial applications.
Flammability: The MCI system has proven to be virtually
non-flammable according to relevant IEC and ISO standards.
Radiation resistance: All components of the MCI system
exhibit a high resistance to radiation (at least 107 Gy) making
machines with MCI insulation also suitable to nuclear
applications according to IEC 544.

60

Mechanical stress

50

30

The excellent mechanical strength of the MCI coil overhang

bracing enables the system to withstand repetitive dynamic
stresses of fast bus transfer.

20

Structure and manufacturing prior VPI

10

Tight and compact

40

0
2
4
6
Rated voltage Un (kV)

10

12

14

Electrical stress

The coils are made from insulated conductor wires.

Corona resistant polymer/mica combinations are used to
ensure excellent turn-to-turn insulation

The form wound coils are wrapped with porous mica tape
to a thickness determined by the rated voltage to provide
a durable ground wall insulation of high dielectric strength

Conductive corona protection tape is applied on the stator

slot portion of the coils to avoid corona discharges in the
stator slot

At higher rated voltages, a semi-conductive layer is applied

to the coil overhang beginning at the slot exit in order to
achieve uniform stress grading of the voltage to the ground

The unimpregnated soft coils are inserted in the stator slots

Highly resin absorbent fibreglass cords are used for the

coil overhang support. After VPI with epoxy resin, the
support system forms an extremely rigid, winding
overhang structure able to withstand the most severe
service conditions

Slot wedges retain the coils firmly in the stator slots. For
asynchronous machines, magnetic slot wedges enhance
the power factor and operating efficiency of the machine

Every machine with the MCI insulation system is tested in

various production steps in order to ensure high reliability:
n

Dimensional checks on insulated coils to assure proper fit

in the slots

Turn-to-turn insulation tests on every coil prior to the VPI

process

High potential tests of windings prior to VPI

Final high potential test of windings after VPI at voltages

according to international standards

Dissipation factor test according to CENELEC for

periodical check of VPI and curing process parameters

The MCI system has been extensively type tested in

accordance with IEEE Std 434 and IEC 727-1. The results
indicate a significant dielectric margin of safety according to
IEEE Std. 1043.
Standard designs utilising MCI exceed the international requirements
of impulse voltage capability as expressed in IEC 34-15.

Impregnation Process

Continuous R&D

The VPI and curing of the completely

wound and connected stator winding
with the specially formulated epoxy
resin ensure a sealed and
homogeneous insulation system,
resulting in low dielectric losses, high
dielectric strength, excellent heat
transfer and the elimination of
hazardous internal partial discharges.

ABB has constantly maintained a

leading position in developing insulation
systems for rotating machines. Insulation
R&D work is carried out in our wellequipped insulation laboratories, which in
addition to actual insulation development
are active in international co-operation
and standardisation.
The VPI process

Putting the customer first

Understand Develop Deliver and Support
Quality products
Quality and performance testing of each motor begins during
the manufacturing process and continues to the final
assembly. Documented quality test results, upon completion,
are provided to the customer.
Painting
Painting techniques are varied to suit individual applications
and environments.
Staying ahead
Our R&D programme ensures that our motors incorporate
the latest technology and advanced materials to provide
improved performance and reliability. We endeavour to
quickly introduce each improvement resulting from
innovation, new materials or new manufacturing methods so
that the benefit is passed to our customers as soon as
possible. The close proximity of our research, design and
manufacturing facilities enable us to do this very effectively.
ABB is committed to maintaining this technological edge.
Organised for support
The combination of ABBs experience in supplying high
voltage induction motors, the breadth of the product range
and ABBs advanced information systems allow us to find
the optimal solution every time; and to find it quickly.
ABB supports customers at every stage from a rapid
proposal service, through order tracing to testing, after sales
service and the provision of spare parts.

Service
With its in-depth knowledge of rotating electrical machines,
worldwide experience, in-house R&D and highly skilled
engineers ABB is your ideal partner for all your service needs.
ABB offers you a comprehensive range of service:
n

Dynamic Balancing

Residual Life Analysis

Failure Analysis

Repair

Diagnostic Testing

Site Service

No matter where you are based, ABB will focus on your

requirements from the first contact, through manufacturing to
delivery and whenever you need support. We aim to create
long-term working relationships that are mutually beneficial.
Through these relationships we strive to make our customers
more efficient in an increasingly competitive world.

ABB Limited
HV Machines
Maneja, Vadodara 390 013
Tel: +91 265 2604548-49
Fax: +91 265 2638928
www.abb.com/in

Regional Marketing Offices:

North
NBCC Tower
4th Floor
No. 15, Bhikaji Cama Place
New Delhi 110 066
Tel: +91 11 26186000
Fax: +91 11 26197592/84035

East
No. 9, 3rd Floor
Lala Lajpat Rai Sarani
(Elgin Road)
Kolkata 700 020
Tel: +91 33 22479162/8015
Fax: +91 33 22472427

West
ABB House
Dr. S B Path
Ballard Estate
Mumbai 400 038
Tel: +91 22 56318231 39
Fax: +91 22 56318276/77

Central
Vandana House
1st Floor
G E Road, Ramkund
Raipur 492 001
Tel: +91 771 2660816 18
Fax: +91 771 2653391

South
Sona Towers
4th Floor
71, Millers Road
Bangalore 560 052
Tel: +91 80 2256315/16
Fax: +91 80 2254147
No. 3C, 3D, 3F
Century Plaza, 3rd Floor
561 / 562, Anna Salai
Teynampet
Chennai 600 018
Tel: +91 44 24340201203
Fax: +91 44 24340282