Modernization services for motors and generators

Capital spares

Rotors, stators, and other capital spares are typically custom made, resulting in longer delivery times compared to standard spare parts. To minimize unexpected downtime and maximize operational availability, having capital spares on hand is essential. To reduce unexpected downtimeand maximize operational availability, having capital spares on hand is essential. ABB helps you identify the optimal capital spare through site surveys and motor/generator diagnostics.

Key benefits:

• Minimized downtime and production loss in case of failure
• Ability to use a single component across multiple motors and generators
• Strengthened risk management strategy

Refurbishment

ABB’s refurbishment service restores your high-voltage motor or generator to its original performance and reliability—or even beyond in some cases. It offers a cost-effective and sustainable alternative to purchasing a new unit, especially when existing capital spares can be reused. Refurbishment with existing capital spares can be completed within weeks, compared to 6-12 months lead time for replacement unit.

Key benefits:

• Restored performance and reliability
• Extended equipment lifetime—up to 20 years
• Faster turnaround using available spares

Control panel upgrades and replacements for synchronous motors and generators

Control panels play a vital role in synchronous motor and generator applications, but their electronic components typically degrade faster than mechanical parts. Over time, this can lead to reduced performance. To maintain reliability and efficiency, it is important to plan for an upgrade or replacement at least once during a motor’s and generator’s life. The optimal decision depends on your specific setup, and ABB helps you choose the most suitable solution for your application.

Key benefits:

• Improved reliability and increased operational uptime
• Enhanced functionality
• Full factory support and access to a complete range of spare parts
• Thorough evaluation of existing equipment with adaptation to new systems

Automatic Voltage Regulator upgrades for synchronous generators

The Automatic Voltage Regulator (AVR) upgrade service helps prevent unplanned generator downtime caused by malfunctioning of the AVR, while also ensuring ongoing technical support. Instead of replacing the old AVR with an identical unit, ABB offers an upgrade to the latest UNITROL® AVR, delivering enhanced reliability.

Retrofit kits

ABB’s retrofit kits enable the integration of new features that enhance maintenance and extend the lifetime of motors and generators. 

Key benefits:

• Improved condition monitoring
• Longer equipment lifetime
• Kits are easy to install and maintain
• Full manufacturer support

For high-voltage generators used with diesel and gas engines, retrofit solutions include:

• Air-flow sensors
• Earth fault detection systems
• Hydrostatic jacking
• Vibration sensors

Each solution contributes to greater reliability, efficiency, and long-term performance.

Brush-lifting system

Upgrading your ABB slip-ring motors with a brush-lifting system significantly reduces brushes and slip-ring wear, lowering service costs and boosting reliability. This system can be installed on new ABB slip-ring motors or retrofitted to existing units, following a prior engineering evaluation.

Key benefits:

• Increased production uptime
• Reduced maintenance and spare part costs
• Extended motor lifetime
• Flexible brush arrangement regardless of load conditions

This makes it a smart investment for long-term performance and operational efficiency.

Rotor upgrades for GBA motors and generators

Upgrading a motor or generator rotor during an L4 maintenance program is a time- and cost-efficient way to enhance performance. The latest rotor technology improves thermal and mechanical strength, resulting in greater reliability. Depending on the setup, this upgrade can extend rotor lifespan by up to 15% and increase power output by over 5%.

Key benefits:

• Increased reliability and extended lifetime through improved thermal resistance and mechanical design
• Higher power output
• Reduced cost of ownership thanks to longer service life and better return on investment
• Optimized use of scheduled maintenance time by integrating the upgrade into planned service activities

Exciter rotor upgrade

ABB introduces new replacement exciter rotors for AMS 1000–1250 and GBA 800–1250 motors and generators to enhance reliability and availability. The upgraded design features improved winding configurations for superior electrical performance, while mechanical enhancements—based on FMEA analysis—boost durability and operational efficiency. An optimized cooling system ensures better thermal management, and simplified replacement of rotating rectifier components minimizes downtime in case of failure, resulting in a more robust and maintainable solution.