3 |13 Focus on power products and ffwd power systems

Circuit breakers get smart Going underground with substations 8 Boosting power quality for Essex & Suffolk Water 10 Fourth generation of HVDC Light® energised 14 New modular approach to Structure Mounted Outdoor for rail 16 A blast proof packaged substation in a compact container 20 Future proof UniGear Digital medium switchgear 26 From the Editor

ABB Power Products Power Products are the key components for transmitting and distributing electricity. The division incorporates ABB’s manufacturing network for , switchgear, circuit breakers, cables and associated equipment. It also offers all the services needed to ensure products’ performance and extend their lifespan. ABB Power Systems Power Systems offers turnkey systems and services for power transmission and distribution grids and for power plants. Substations and substation automation systems are key areas. Additional highlights include flexible transmission systems (FACTS), high-voltage (HVDC) systems and network management systems. In power generation, Power Systems offers the Underground substations instrumentation, control and electrification of power plants. 8

3 |13 ffwd Power products and power systems Dear Reader, I was also excited to hear the news There’s lots of news coming from ABB’s (on page 5) that two of ABB’s distribution Power Products and Power Systems busi- transformers have passed new testing levels nesses in the UK as the country’s trans- that have been introduced for equipment mission owners and distribution network to be installed at the UK’s airports. operators continue their programmes of Staying at the forefront of substation work to strengthen the electricity grid. technology is never far from my mind and, Work to strengthen the AC transmis- with this in mind, I’m fascinated by ABB’s sion network ready for integrating renew- newly launched approach that makes able energy continues. I am pleased that the most of high value sites by excavat- ABB continues to play a central role as a ing to create underground substations. supplier and has won a number of high Summarised on page 8, the approach profile contracts in this area, including the marries together experience of long-term country's first TCSC (Thyristor Controlled substation operation with knowledge of how Stephen Trotter Series Compensation) equipment, which to deliver complex projects successfully. Division Head of ABB Power is due to be electrified in Cumbria in 2014 Systems UK & Ireland – see page 25 to find out more. Stephen Trotter

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ffwd power products and power systems 3/13 • The customer newsletter of ABB Power Products and Power Systems • Subscription Newsletter available as printed or electronic copy. Subscribe online at www.abb.co.uk/ffwd • Contact and feedback [email protected] • Publisher ABB Limited, Power Systems Division, Oulton Road, Stone, Staffordshire, ST15 0RS. Phone +44 (0)1785 825050

2 abb.co.uk/ffwd Power products and power systems Contents

New disconnecting 12 Packaged substations 20 Data centre 28 developments

News Transformers 4 The latest news and major contract wins from ABB 22 Variable Shunt Reactor technology Substations Energy recovery 8 Making the most of city centre sites with underground 24 The Enviline™ Energy Recuperation System substations FACTS Power quality 25 Great Britain’s first TCSC installation 10 correction and active harmonic filters Medium voltage HV switchgear 26 UniGear Digital 12 New disconnecting circuit breaker with fibre optic sensor Data centres Grid technology 28 The latest DC developments 14 Fourth generation of HVDC Light® energised Protection and control Rail 30 The latest additions to the Relion® family 16 Structure Mounted Outdoor Switchgear Light Corporate social responsibility 17 Reactive power compensation for HS1 32 ABB’s ethical approach to business and leadership Renewables focus Service 18 66 kV inter array systems for offshore wind 34 Condition-based monitoring for GCBs Packaged substations Forthcoming events 20 A reliable package for Total’s Lindsey Oil Refinery 35 Forthcoming IET Innovation Awards

Power products and power systems abb.co.uk/ffwd 3 News

Making the most of natural resources

major framework agreement Aberdeenshire, the consortium will be awarded to a consortium made supported by ABB’s offices in East Kilbride A up of ABB and Balfour Beatty and Stone, Staffordshire and the first proj- Engineering Services will increase the ects will cover substations in Caithness, capacity of the transmission network in Orkney and Shetland. the north of Scotland, paving the way “This framework agreement for SHE to make use of the region’s excellent Transmission is a very important devel- natural resources for renewable electricity opment that continues our drive to both generation. expand and diversify ABB’s customer The five-year deal granted by the base across the UK utility sector,” said Jon licensed Transmission Owner for the north Downs ABB’s Director for Utility Substations of Scotland, Scottish Hydro Electric (SHE) in the UK. Transmission plc, will cover projects at the Scottish Hydro Electric’s framework will region’s 275 kV (kilovolt) and 132 kV GIS integrate renewable power and AIS substations. Working out of a base at Kintore,

Autotransformers to reduce energy consumption

etwork Rail will receive around rail electrification. the West Coast Main Line. ABB has modi- 100 of ABB’s 25-0-25 kV track- The autotransformers comply with fied their design to reduce no load losses N side autotransformers as part of a Network Rail’s guidelines for 12 kiloamp for low traffic areas, which will reduce the three-year UK-wide framework agreement (kA) infrastructure and have already estab- lifetime energy consumption by around 30 signed in December to support the UK’s lished their reliability on Phases 1 and 3A of per cent.

A major autotransformer for Scotland

cottish Power company SP Energy An autotransformer similar to that ordered by SP Energy Networks Networks has ordered one of S ABB’s 400/275 kV autotrans- formers rated at 1,000 MVA to provide the grid connection for the new Wishaw substation in North Lanarkshire. The autotransformer is due for delivery in February 2014 and will play a role in rein- forcing the power transmission and distribu- tion infrastructure in central and southern Scotland, where SP Energy Networks is the network owner and operator. Steven Blanche, General Manager for ABB’s UK business, said “Our success in winning this contract is down to competitive pricing allied to our proven technical capability and a reputation for on-time delivery.”

4 abb.co.uk/ffwd Power products and power systems News

An upgrade at Eggborough

BB has won a project to upgrade Systems, which was a deciding factor in the Automatic Voltage Regulators Eggborough Power Limited’s decision to A (AVRs) at the -fired 2,000 MW select ABB. Based on ABB’s latest excita- (megawatt) Eggborough in tion technology, the UNITROL® 6080 will East Yorkshire. The plant was built in the significantly improve reliability. 1960s and the new contract is the latest Tony Rooney, ABB’s General Manager project to improve environmental perfor- for Power Generation UK said: “This is the mance and replace major components latest in a string of contract wins that con- with more efficient modern designs. firms UNITROL as the excitation solution During the contract, ABB will use its of choice for both new build and retrofit wide expertise of retrofitting Excitation projects.”

A UNITROL 6080 Automatic

Control upgrades at Dungeness ‘B’

DF Energy has selected ABB to tion plant was a major factor in winning the power station’s staff on a simulator system. engineer improvements to the contract, as was the capability to deliver Tony Rooney, ABB’s General Manager E steam turbine control systems at the project to the high quality and safety for Power Generation in the UK, said: “ABB Dungeness ‘B’ station standards that are mandatory in the nuclear has recently secured a series of control by summer 2013. The contract covers industry. system upgrade schemes across the UK the steam turbine governors for Units 1 During the project, ABB’s engineering fleet and this project for Dungeness further and 2 at the 1,040 MW power station in team will work closely with EDF Energy demonstrates ABB's position as a leading Kent and the project forms part of EDF staff to design, supply, install, test and competitive provider of power generation Energy’s ongoing programme of upgrades commission new equipment and interface control systems, implementing advanced at the site. it with the station’s existing ABB Procontrol technology that ensures safe, reliable and ABB’s expertise and extensive experi- P13 distributed control system as well as efficient plant operation.” ence in control systems for power genera- carry out hardware upgrades and train the

Passing new tests with flying colours

s part of a new initiative to ensure Both were subjected to rigorous tests the reliability and continuity of at an independent laboratory, including a A critical airport power networks, 100 percent of their windings, UK Power Networks Services (UKPNS) and both passed all tests, leading ABB to Airports Division has called for all future be the first manufacturer to meet the new transformers to be fully tested to dem- requirements. onstrate that they can withstand extreme “Having passed with flying colours, ABB short circuit conditions. was awarded two contracts to design, build Normally, transformer manufacturers and deliver a total of 16 packaged distribu- need to provide evidence of impulse test- tion substations to serve Heathrow Airport,” ing alongside calculations to establish the said Steve Blanche, General Manager for full short circuit capability but UKPNS' ABB’s transformer business in the UK. new standards call for real-life testing of A mount standard distribution transformers to their limits. transformer With future supply of critical equip- ment at stake, ABB submitted a 2 MVA (megavoltampere) ground mount standard distribution unit and a 1 MVA unit type distribution transformer.

Power products and power systems abb.co.uk/ffwd 5 News

An Oyster 800 wave energy device in Orkney The world is Aquamarine’s Oyster

technology part-funded Aquamarine Power has secured the consent “This is another significant milestone for by ABB Technology Ventures has which will see the deployment of up to 50 Scotland’s wave sector. With 10 per cent A received full consent for a 40 MW Oyster devices in one of the best wave of Europe’s wave power potential and 25 wave energy farm off the north-west coast energy locations in Europe. per cent of its offshore wind and of the Scottish island of Lewis. Announced Scottish Minister for Energy, Enterprise potential, the opportunities for Scotland at the All-Energy event in Aberdeen, and Tourism, Fergus Ewing MSP said: are enormous.” East West goes live

BB has delivered the East West The interconnector establishes an its capacity, it can export Interconnector to EirGrid, the Irish important link between the Irish and UK surplus electricity to the UK, and can A transmission system operator. The grids, enabling cross-border power flows import power when required. 500-megawatt (MW) HVDC Light® con- and enhancing grid reliability and security A 262 km cable system connects nection is the highest capacity link of its of electricity supplies. The new link also Woodland in County Meath, Ireland and kind, based on voltage source converter facilitates power trading between the Deeside in North Wales. The cables are (VSC) technology, to go into commercial two countries and connects Ireland to equipped with extruded polymeric insu- operation. the European grid. As Ireland expands lation that provides strength and flex- ibility to endure the severe conditions of the Irish Sea. HVDC Light’s ‘’ capability can help restore power quickly in the event of an outage, without the aid of external energy sources. “This is yet another example of the growing role of HVDC transmission tech- nology when enabling key emerging trends like integration of renewables and inter- connections” said Brice Koch, head of ABB’s Power Systems business. “ABB remains a market leader in this field and we shall continue to push the boundar- ies of HVDC technology, building on our past legacy.”

An HVDC converter station

6 abb.co.uk/ffwd Power products and power systems News

ABB’s largest indoor 132 kV substation

BB has recently put the final fin- Northern Powergrid decided that a built on stilts to protect from floodwater ishing touches to a turnkey project substation based on compact gas insulated and takes up only around one sixth the A to replace a 132 kilovolt (kV) sub- switchgear (GIS) technology would offer footprint of its predecessor. It houses 22 station at Creyke Beck, to serve Northern an alternative that was both cost-effective bays of ABB’s state-of-the-art ELK-04 GIS, Powergrid customers in and around the and enable minimal disruption to service, comprising four bays of bus couplers and city of Kingston-upon-Hull. The upgraded with the compact GIS substation taking up bus sections, four incoming bays that con- substation will ensure continuity of power around one sixth of the space of the AIS nect to the supergrid transformers at the supply. alternative. adjacent 400 kV National Grid substation Due to the large amount of space occu- The project is ABB’s largest of its type and 14 feeder circuits. pied by air insulated switchgear (AIS), a in the UK and the new GIS station was built While the new substation was energised like-for-like renewal was impractical in terms inside the boundary of the existing site in May 2011, the full turnkey project called of both availability and cost. There was while the old AIS substation remained in for ABB to demolish the old substation and not enough space available on the site to service, which meant an exceptional level flatten and stone-chip the cleared space, build a new AIS substation alongside the of planning and logistics on the compact with final completion in early 2013. existing substation and to allow circuits to site. The 22 bays of ELK-04 at Creyke Beck be transferred bay by bay. The 40 x 25 metre substation was substation ZX switchgear on track for approval

nother piece of equipment that supplying safe and reliable power along has been proving itself is the new the entire length of China’s 968 kilometre A ZX1.5-R medium voltage GIS, which Wuhan-Guangzhou high-speed railway line, has been installed at 11 sites on the WCML it is yet to receive Full Product Approval between Stoke and Warrington as part of from the Network Rail Acceptance Panel. ‘plug and play’ packaged substations. Based on three-phase ZX switchgear, The railway-specific switchgear is based the railway version houses individual gas on ABB’s well-proven three-phase ZX panels in separate compartments for switchgear, which has been reconfigured straightforward installation and opera- for the requirements of two-phase high tion. It is possible to remove a panel and speed lines and single-phase 25 kV rail re-energise the switchboard without han-

ZX1.5-R switchgear is powering China’s high- applications. dling of SF6 gas as the switchgear units are speed railway While the ZX1.5-R is already in operation sealed for life during manufacture.

Power products and power systems abb.co.uk/ffwd 7 Substations

Subterranean substations

Going underground in urban centres.

01

8 abb.co.uk/ffwd Power products and power systems Substations

he biggest challenge of sup- Supported by comprehensive guidelines As equipment ages and ultimately plying efficient and reliable power and sample concepts, ABB’s approach is reaches the end of its working life, access T in a bustling city centre is often in based on the most important aspects of becomes ever more important, not least for finding space for large substations, espe- project execution. Running alongside this, the station’s largest items, the power trans- cially as demand for power grows. 3D simulations will iron out any issues with formers. Envisaging delivery and removal of On one hand, local authorities’ planning the design and layout of the substation bulk items, ABB’s modular approach takes departments are often protective of city long before the start of the construction account of transportation and access to centre sites, particularly those in historic phase. This approach cuts out the margin replace equipment on all levels. settings, and on the other, the value of for error and ensuring that all aspects are Like most substations, underground land in city centre sites for office or retail properly considered, including space for stations are unmanned in normal opera- development often means that there are cable runs, ventilation ducts and safety tion but their design must take account of strong pressures to give land multiple uses. equipment. human safety, which is why safety features One solution to make the most of a Ventilation equipment is an area that such as escape routes, smoke-free zones limited footprint is to dig down, placing is examined particularly carefully, with the and separation of fire loads with bulkheads the substation below ground level, which temperature profile of the surroundings are designed in. frees up the surface for other purposes being balanced against equipment opera- With only two percent of a typical sub- while providing all the functionality of any tion to size ventilation and heat dissipa- station being visible from the surface, conventional substation. tion equipment with ducts sized to keep ABB's underground substation solution ABB’s state of the art underground sub- air velocity and therefore noise emissions keeps potential hazards well away from station concept enables up to 98 percent within permitted levels. the general public. At the same time, it of an installation to be tucked away below Finally, the load-bearing characteristics meets the most stringent requirements for ground, with only cooling ducts and access of the ground and neighbouring structure power supply and delivers compactness, routes visible above ground. are considered as these may inform the economy, reliability and safety. design and layout. Hiding a substation in a city centre 01 A cross section through a typical substation Underground substations are not a new Long-term operation 02 Underground substations have little surface idea, with many already in operation at But the proof of the concept is in the long- impact many sites worldwide. The experience of term operation of a substation, which is constructing such substations, together why ABB’s approach takes account of with knowledge of planning regulations reliability, redundancy, safety, operation has enabled ABB to develop its method- and maintenance. ology. The approach means that ABB can integrate a transformer substation into any urban environment while meeting and 02 future-prooofing customer needs. Using this approach, ABB can hide a substation underneath a building such as a shopping centre, car park or sports stadium. Public spaces like parks, public squares, traffic roundabouts or intersec- tions can seem untouched to the casual observer but below the surface, can be an essential link in a city’s power grid. An underground substation will accom- modate transformers, GIS, automation, protection and control systems, auxiliary equipment, AC and DC distribution boards, batteries, ventilation, air-conditioning and fire protection systems.

Good planning for faster completion When carrying out a construction project in any city centre, time is of the essence, with pressure to keep build times down and deliver projects quickly and to budget. With this in mind, ABB offers a modular approach that can be customised to meet the specific requirements of an individual installation.

Power products and power systems abb.co.uk/ffwd 9 Power quality

ABB boosts power quality for Essex & Suffolk Water

ABB’s specialist power quality service has enabled Essex & Suffolk Water (ESW) to solve power factor and harmonic issues affecting the power supply at a pumping station in Essex.

he pumping station is a major clean When PF falls below one, power is not water pumping station built in the being consumed efficiently and more reac- T 1930s, which supplies ESW’s cus- tive power is needed. This happens when tomers in south west Essex and the east the equipment being used on site causes London with water. The site is equipped the voltage and current waveforms to be 01 with three pumps, each of which is out of phase with each other. A low power powered by a 335 kW DC motor and vari- factor leads to energy loss through heat, able speed drive system. which shortens the life of equipment. It The symptoms of flickering lights, a high also reduces the capacity of cables and demand for reactive power and unexpected equipment, preventing them being used tripping of equipment at the pumping sta- to their full capacity. tion led the utility to call in its long-term When PF drops below 0.95, electric- contractor, Mid Kent Electrical (MKE). ity suppliers can impose a charge for the additional power it needs to supply. In the 01 A PQFM active harmonic filter 02 ABB's range of CLMD Improving power factor case of the Pumping Station, the PF had As an ABB Motor Service Partner and dropped to 0.78, leading to a monthly bill member of the ABB Drives Alliance, MKE for reactive power of more than £200 on carried out an investigation of the site’s top of the site’s normal power demand. operation and power consumption. This Capacitors are normally used to help revealed that the existing Power Factor correct a site’s power factor and the three Correction (PFC) capacitors serving the failed units were each replaced site’s three 335 kW pumps had failed and with two of ABB’s CLMD 92 KVAr 480 V that there was an unusually high demand capacitor units, which immediately improved for reactive power. the power factor, bringing it up to 0.95 and Power Factor (PF) is the ratio of ‘real’ reducing the monthly charge for reactive power that is used (in Watts) to the ‘appar- power to only a few pence. ent’ power that needs to be produced (in Russel Kimpton, Drive Systems Engineer Volt-Amps). It is often seen as a measure at MKE said: “Solving the power quality of electrical efficiency and a power factor issues on any site is always the right thing of one demonstrates that power is being to do. The six CLMD capacitors installed

produced and consumed most efficiently. are reducing Essex & Suffolk Water’s CO2

10 abb.co.uk/ffwd Power products and power systems Power quality

emissions by about 80 tonnes per year and match the sinusoidal supply wave shape. of commutation spikes, which are electri- enabled significant savings on the annual Harmonics are found at multiples of the cal spikes that often appear in systems electricity bills”. supply frequency (so, for 50 Hz, 100 Hz equipped with DC drives. These can cause is the second order, 150 Hz is the third problems for active filters, so as an ABB Solving harmonic issues order, etc). They can often lead to serious partner, MKE discussed the design of the As a separate issue, the unexpected trip- problems for electrical and electronic equip- filters directly with ABB’s Power Quality ping of equipment had its root elsewhere ment, including overheating, shortening of Division at Ellesmere Port, leading to and ESW had also experienced failures life and otherwise unexplainable issues. a design that protected against these of instrumentation at the site. When MKE The solution was to install ABB’s PQFM spikes. investigated, it found that the tripping took active harmonic filters, which are designed Installing ABB’s PQFM active filters at place when the pumps’ DC variable speed to smooth out the distortions created on the site solved the site’s harmonic problem drives were in operation. The drives have the supply in medium scale industrial three- and their installation meant that ESW could the role of controlling the voltage fed into phase applications. remove unnecessary equipment, making an the pump’s motor, which in turn controls PQFM filters remove up to 20 harmonics immediate saving in power consumption. the output of the pump. simultaneously in the 2nd to 50th order. A further benefit of the PQFM filter is future- MKE found that with one set of lights They are installed in parallel to the pollut- proofing the power supply in preparation switched on, the current flow through the ing load and monitor the harmonics for for a planned upgrade of the drives. circuit breaker doubled when the DC drives each harmonic frequency. They can then Used together, ABB’s CLMD capaci- were running and this additional current generate a compensation current in perfect tors and PQFM harmonic filters resolved was at a higher frequency. phase opposition to the polluting current, the power quality issues at the pumping Known as harmonics, distortions like therefore eliminating the harmonics. station. these are caused by loads that do not Site investigations found a high level

Waveform with the PQFM active harmonic filter 02

Waveform without the PQFM active harmonic filter

Power products and power systems abb.co.uk/ffwd 11 High-voltage switchgear

A smarter circuit breaker

A new Disconnecting Circuit Breaker (DCB) developed by ABB uses fibre optic technology to simplify substation design and significantly reduce the footprint required for high-voltage switchgear for 362 – 550 kV applications. The Fibre Optic Current Sensor (FOCS) also adds to the intelligence of the device, enabling it to be part of a more flexible, reliable and smarter grid.

This concept was revolutionary at the 01 time, not only reducing the footprint but also paving the way for simpler installa- tion, lower maintenance overheads, lower failure rates and improved levels of safety. Because the primary contacts in a DCB are

enclosed in SF6 gas and protected from pollution, DCBs offer significantly higher reliability than standalone air-insulated disconnectors.

Optical sensor measures current The latest innovation integrates current measurement into the body of the DCB itself. FOCS replaces the multiple current transformers that previously carried out this role, representing a significant saving in space and complexity. FOCS is a type of sensor that measures DC currents by viewing the changes made to a beam of light when it passes through aving been deployed success- switchgear comprises circuit breakers, the magnetic field generated by the current. fully in a 420 kV pilot project in disconnectors and current transformers It can measure currents of up to 600 kA H Sweden, the latest addition to as separate components. Disconnectors (kiloamperes), providing readings that are ABB’s range of switchgear, the DCB- were located on both sides of each circuit accurate to 0.1 percent and it is equipped FOCS, was launched to the world at breaker to isolate it in case of failure or to with a digital interface that is compatible Hannover Messe this April. enable safe maintenance. with the IEC 61850 set of standards. Launching DCB-FOCS is just the latest When ABB pioneered the DCB in 2000, “This latest development is yet another in a long line of high-voltage innovations it extended the functionality of the circuit milestone in our continued commit- in this type of high-voltage circuit breaker. breaker, integrating the disconnecting ment to technology and innovation” said function into the circuit breaker’s break- Giandomenico Rivetti, head of ABB’s High Building on DCB innovation ing chamber and meeting the standards Voltage products business. Conventionally, air-insulated high-voltage of both types of equipment. “Integrating the FOCS with the DCB

12 abb.co.uk/ffwd Power products and power systems High-voltage switchgear

02

reduces footprint while delivering a ‘smart 01 The pilot DCB-FOCS grid’ enabled solution that is virtually ‘plug installation in Sweden 02 A DCB-FOCS unit and play’ and yet flexible enough to accom- modate customer needs. This makes it ideally suited for new and upgrade substa- tion applications with the added benefit of enhanced power availability and reliability.” Because it measures changes to the physical properties of light, it does not require the regular re-calibration that a conventional arrange- ment demands. More compact and low maintenance Combining the space-saving aspects of both DCB and FOCS technologies, the new DCB-FOCS has the potential to reduce the overall physical footprint of a substation by 60 percent compared with a conventional arrangement. It is supplied with standard ethernet cable connections, which make it sim- pler and safer to install and operate while improving efficiency by cutting electro- thermal and electrical losses. Designed for low maintenance, it can be delivered on a standalone basis or as a component part of a complete - gear bay. It is also more environmentally friendly than its predecessor, in terms of the CO2 emissions and material used for production and insulation.

Power products and power systems abb.co.uk/ffwd 13 Grid Technology

Hitting a record high in HVDC Light®

A newly energised converter station in Dörpen West in northern Germany has set a new record voltage record for HVDC Light®. At ±320 kV, the station is a new technology milestone, setting the new record high for a Voltage Sourced Converter (VSC) HVDC application.

14 abb.co.uk/ffwd Power products and power systems Grid Technology

he station is located on the receiving 1,000 – 3,000 MW range and power is end of the DolWin1 transmission link transmitted either using overhead lines, T and was built by ABB on behalf of undersea or underground cables. Using Dutch-German transmission system opera- both HVDC and HVDC Light, it’s possible to tor, TenneT, which will integrate 800 MW transmit power in both directions, an option of generated in the that is not possible for AC transmission. North Sea into the European transmission Applications include connecting wind system. farms to power grids, underground power Its energisation has enabled the capacity links, providing shore power to islands and of power transmission to grow by more offshore oil and gas platforms, connecting than 50 percent while keeping transmission asynchronous AC grids, city centre infeeds losses below 1 percent per converter where space is a major constraint, and station. cross-border interconnections that often Recent developments in converter tech- connect across the seas. nology have made the construction of the HVDC Light is a preferred solution for new station possible, including a new valve long-distance underground and underwa- concept, enhanced semiconductor perfor- ter power links and interconnections, one mance and advanced control systems. of its benefits being that power lines are The development adds further impetus 'invisible', usually being tucked out of site to the evolution of multi-terminal systems below ground or under water. and interconnected HVDC grids, made Compared with AC transmission, HVDC possible when ABB recently removed a Light offers the opportunity to expand the major technology stumbling block with the transmission capacity with a technology announcement of its hybrid HVDC breaker. that takes less footprint, offers neutral “This latest achievement reinforces our electromagnetic fields, oil-free cables and leading position in HVDC transmission and compact converter stations. By using our commitment to the ongoing develop- underground HVDC cables, environmen- ment of this key technology,” said Hanspeter tal impact is kept to a minimum, with no Faessler, Head of ABB’s Grid Systems overhead lines giving local communities business. “ABB is uniquely positioned in cause for objection. this sector with manufacturing capability One of the benefits of HVDC Light is its for converters, cables and semiconductors ability to stabilise AC voltage, a character- - the major HVDC components.” istic which is particularly important for wind parks, where the variation in wind speed HVDC Light can cause severe voltage fluctuations. Designed to transmit power over long ABB has delivered more than 20 such distances, usually underground and under converter stations, including the latest at water, HVDC Light was introduced by ABB Dörpen West, which takes the record of in 1997 as an alternative to conventional HVDC converter station with the highest AC transmission. rated voltage from another station installed Using HVDC Light, it’s economical to by ABB, rated at ±200 kV. transmit power from just a few tens of The new ±320 kV Dörpen West converter station megawatts up to 1,200 MW at a volt- age of ±320 kV. A classical HVDC instal- lation, on the other hand, will typically transmit power in the range of 100 MW and above, with many installations in the

Power products and power systems abb.co.uk/ffwd 15 Rail

Structure Mounted Outdoor Switchgear (SMOS) Light cuts time on-site

ABB’s FSKII+ vacuum outdoor circuit breaker has already established a substantial track record with ABB’s railway customers thanks to its well proven reliable and essentially maintenance-free design.

BB is now taking FSKII+ to the next the installation, testing and commissioning The FSK II + vacuum breaker level by offering it as part of the required. The result is a dramatic reduction The latest version of ABB’s railway circuit A unique Structure Mounted Outdoor in installation and commissioning time and breakers is an integral part of the SMOS Switchgear (SMOS) Light modular concept costs. Light concept. The vacuum breaker uses a designed to help network operators cut well proven combination of magnetic actua- around 30 percent of the time required for Building on previous SMOS projects tor and electronic controller and is robust, construction, testing and commissioning While the ABB Railway Modular concept reliable and essentially maintenance-free. of trackside switchgear. is a unique development for the global Building on the 10-year long success SMOS Light integrates all the key market, it has built on the success of a of the previous vacuum breaker, the FSK elements required for isolating the supply number of previous classic SMOS proj- II, the design of the FSK II+ includes exter- to the catenaries, as well as for sectionalis- ects. These include High Speed 1 in the nally bolted HV terminals and polymeric ing of individual parts of track during inspec- UK, Gautrain in South Africa and for SBB, insulators. It has achieved over 10,000 tion and maintenance including: the FSKII+ the Swiss national railway. operations under test conditions, which circuit breaker, disconnector and Voltage Designed for ease of on-site installa- is equivalent to a service life of well over Transformers (VTs) and Current Transform- tion, the environmentally friendly FSKII+ 20 years in typical railway applications. ers (CTs). They are all combined together switchgear meets Network Rail’s standards, While ABB already offers the FSKII+ within a modular steel structure, which is especially the requirement not to use gas- either as loose equipment or integrated fully assembled and tested at ABB’s railway insulated switchgear as it is free of SF gas. into assemblies, the approach with SMOS centre of excellence facility in Geneva and It has been used widely on projects in the Light is designed to be a significant advance delivered to site virtually ready to ‘plug and UK and worldwide so it is ideally suited for for the switchgear, saving time on-site and play’. the SMOS Light concept. stripping the unknowns of risk and cost By eliminating the need to install and ABB is submitting the SMOS Light to from the on-site phase of railway electri- commission discrete components, ABB’s Network Rail’s product approval process fication projects.

SMOS Light concept simplifies the major and is planning to carry out type testing Indicative layout of a substation featuring on-site elements of civil works, especially later this year. SMOS Light

16 abb.co.uk/ffwd Power products and power systems Rail

Maintaining the voltage for HS1

A major 26-month project fter carrying out technical evaluation including having to time visits to rural sites carried out by ABB for the to establish the best solution, ABB to avoid disturbing farmers' harvest A pulled together an international team activities. High Speed 1 (HS1) route including engineers from its centre of As well as the innovative design of has delivered a reactive expertise in Ludvika, Sweden, as well as the units themselves, the project team from its Transmission & Distribution Infra- developed a new design for a terminal power compensation structure business unit in London. The cap for the of each capacitor unit, solution on the 68-mile source of the issue was found to be the which prevents birds being electrocuted line to prevent the line level of inductive reactive power demand when they land on the terminals. This new as a result of the inherent design of the design is now being rolled out worldwide voltage dropping below system’s isolation transformers. on ABB capacitor unit products. 25 kV. The solution put forward was a series During the project, the team overcame of 17 bespoke units to install at nine AC/ some unusual access challenges due to DC compounds which effectively cancel some substations being located far from out the inductive power demand of the the public road on farmland. For these transformers on the line, reducing the sites, the team had to contend with con- voltage drop. ditions due to heavy snow during winter Each unit consists of a capacitor bank months and avoiding disruption to harvest rated at 6.4 MVAr (mega volt amperes activities in late summer. reactive) and a reactor rated at 27.5 kV Commenting on the project, Richard and 303.134 mH (milliHenry). The bespoke Holliday, ABB's General Manager for its design was jointly developed by engineers T&D business in the UK, said: “We were at ABB’s centre of expertise in Sweden very pleased to work together as a single and at its Transmission & Distribution unit with HS1. Their input went a long way (T&D) Infrastructure business unit based to deliver the project in a collaborative in London. and supportive environment.” With sites in both urban and rural

locations, the variety of sites set some ABB’s reactive power solution prevents voltage unusual challenges for the project team, sags on HS1

Power products and power systems abb.co.uk/ffwd 17 Renewables

A higher calling John Edwards, General Manager for High Voltage Products in the UK, explains why there is a growing trend towards higher voltage grids for offshore wind power networks.

he whole sector from the shore. This has led to a greater gas insulated (GIS) switchgear modules. In is under ever increasing pressure emphasis on the need to optimise the the application for offshore wind, all of the T to reduce the cost of energy and offshore collection grid and customers necessary substation switchgear bay func- especially reduce the reliance on gov- are now demanding that arrays operate tions, including circuit breaker, one or more ernment subsidies, such as Renewable at 66 kV rather than the traditional 33 kV combined disconnector/earthing , Obligation Certificates (ROCs). In 2011, seen onshore and for current offshore wind cable connections, current transformers are the UK Government made it clear in its parks. integrated in one compact module. This Renewable Energy Roadmap that the This higher voltage solution has many eliminates the need for discrete items of cost of electricity generated from offshore attractions. Financially, there’s lower CAPEX equipment for each function. wind would have to fall significantly by for inter-array collection infrastructure 2020. DECC’s Cost Reduction taskforce potential to cut costs by increasing the PASS M00 also commented in June 2012 that “the number of generators con- PASS M00 has been introduced to meet the current cost of around £140 per MWh nected to a single array, a reduction in the specific requirements of the fast expand- (megawatt hour) needs to be reduced to overall cable requirement, and the possible ing markets for 66 kV systems. It has an around £100 in order to maximize the size application of single array collection plat- exceptionally compact design based on of the industry.” forms to connect all of the wind turbines a combined disconnector and earthing In response to this drive for cost effi- together. switch system integrated in the same gas ciency, there is a growing trend towards Technically, 66 kV substation trans- chamber as the circuit breaker. maximising the economies of scale that formers are significantly lighter than the The five-position disconnector enables the can be realised from the deployment of a equivalent rated 33 kV units. There are following functions: significant volume of wind generation far lower losses in the array cables and wind –– line disconnection from shore. An example of this is the ever- turbines can be connected in loops to –– disconnection increasing power output ratings being devel- improve operational availability by creating –– earthing of the line through the circuit oped for wind turbine generators; rather a ring network. Also, it’s possible to reduce breaker than the 2 – 3 MW turbines that are com- the number of substation transformers. In –– earthing of the busbar through the monplace today for onshore application, essence, changing to 66 kV offers greater chamber the future will see offshore wind turbines performance headroom, flexibility and growing to 5 MW and above, operating in potentially lower investment costs. The multifunctional PASS M00 module parks producing many hundreds, and in To meet the changing needs of HV off- can also integrate current and voltage some cases, thousands of megawatts. shore networks, ABB has introduced the transformers, surge arresters and protec- Scaling up in the offshore wind sector hybrid PASS M00, 72.5 kV, multi-function tion and control systems. It is available for requires more turbines with higher output SF6 gas insulated switchgear range. This single and double busbar configurations, power ratings, spaced farther apart in wind offers a combination of conventional air has an optional single and triple pole oper- park arrays installed at a greater distance insulated switchgear (AIS) and metal-clad ating mechanism and is ideally suited for

18 abb.co.uk/ffwd Power products and power systems Renewables

132 kV Grid

SE Onshore Less CB Offshore 1 Less cables

33 kV MV TR1 66kV MV TR1

LV 1 MV1 LV 1 MV1

...5 WT 8 WT

5 WT 8 WT 5 Wind Turbines Optimised section: 9/8 Wind Turbines Optimised section: in each Feeder 5 WT 33kV: in each Feeder 8 WT 66kV: 300 mm2 5-9 WTG: 185 mm2 5 WT 9 WT

LV 1 MV1 5 WT LV 1 MV1 5 WT Optimised section: 66kV: 1-4 WTG: 95 mm2 5 WT 9 WT

1 WT = 5 MW 50 Wind Turbines / 10 Feeder 50 Wind Turbines / 10 Feeder

use as a standard product in the design of new modular substations or for retrofit Case study applications. A design developed by ABB for new –– increase in the power capacity/ PASS transportation generation offshore wind farms equipped current ampacity of a single feeder The PASS modules can be delivered in with 5 MW turbines revealed that the –– reduction in the losses in subsea a standard shipping container without use of PASS M00 modules in 72 kV AC internal grid array cables packaging, so no special arrangements collection grids made it possible to fit a –– decrease in the voltage drop in the are needed for shipping and transportation. complete HV substation within a tower feeder/string PASS M00 is delivered completely ready with the following advantages: –– decrease in the short circuit value to install, with no on site gas treatment or –– reduction in the number of arrays of internal grid apparatus HV testing required. necessary to export the energy –– elimination of the need to produced construct an offshore HV/MV PASS M00 for new generation –– reduction in the number of cables platform substation when offshore wind parks in parallel for each feeder wind parks are close to land PASS M00 is ideally suited to high-voltage

(HV) wind park collection grid applications Rated Power where its advantages are: –– compactness due to full gas insulation –– fast installation time (no HV test is required on site) –– high reliability obtained through lean design –– fast repair in case of faults due to modular assembly –– remote control provided by motor operability

–– easy combination with oil insulated, V39 – 500 kW V80 – 2.0 MW V90 – 3.0 MW V112 – 3.0 MW V164 – 7.0 MW gas insulated and dry power transformers flexible internal configuration and higher reliability 1980 1990 2000 2010

Power products and power systems abb.co.uk/ffwd 19 Packaged substations A fast-track packaged substation for Lindsey Oil Refinery

ABB has delivered a complete modular packaged substation, including 26 panels of UniGear ZS1 medium voltage (MV) switchgear and future-proof protection and control technology for a power network upgrade programme at one of the UK’s most important oil refineries.

The six metre wide container houses two face to face rows of switchgear panels

20 abb.co.uk/ffwd Power products and power systems Packaged substations

BB's fast-track modular packaged substation service has delivered a A new 11 kV substation for the Total Lindsey Oil Refinery (LOR) site in North Lincolnshire. Working within a tightly defined project window, ABB designed, manufactured, delivered and commis- sioned a complete containerised sub­ station, based on its compact UniGear ZS1 MV switchgear. LOR was established in the 1960s on a site five miles from the Humber River estu- ary and was the first UK refinery to process North Sea Oil. It is currently the country’s third largest oil refinery, processing 10 million tons of crude per year, equivalent to 200,000 barrels per day. The refinery’s processes require an extensive power network comprising­ sev­ ABB’s ‘plug and play’ packaged substation, complete with blast-proof walls eral substations from 11 kV down to the sub-distribution level of 415 V. substation within the footprint of one con- RTU 560 remote terminal unit A key element in the upgrade programme tainer was crucial as a second container To complete the substation communications was the replacement of the strategic 1A/2B would have raised challenges in complexity solution, ABB supplied its RTU560 remote 11 kV substation that acts as a main power and blast-proof integrity of the completed terminal unit as the local HMI (Human distribution hub for the site. substation. Machine Interface). The RTU integrated A fast-track solution was required to the new substation within the previously complete the work within the tightly defined REA arc flash protection localised 11 kV site network and enabled 32-week window offered by a planned ‘T&I’ A further vital factor in the compact design remote equipment access at the 1A/2B (Turnaround and Inspection) outage. Both was the use of ABB’s innovative REA arc- substation for the first time. the short timescale and space constraints flash protection system that effectively at the selected location – right in the heart eliminated the need for a conventional New project for Substation 16 of the refinery – made it difficult to build and space consuming, high impedance Following on from the success of Substation a new substation building, especially in bus-zone protection scheme. 1A/2B, ABB is now working on Substation carrying out the substantial civil works to The REA system uses ABB’s class lead- 16 that will provide a new power intake meet blast rating requirements. ing fibre optic light sensing and high speed connection from Northern Powergrid for ABB offered the ideal alternative in the fast switching techniques to continuously the LOR site, as well as the connection form of a containerised substation in a monitor key areas of the switchboard. If for the main 40 MW back-up generator. blast rated enclosure, delivered ready to the light from a developing arc fault is Installed in a conventional substation ‘plug and play’ and installed on deep piled detected, it will trip the incoming breaker building due to its non-critical location, foundations to withstand blast shockwaves. in less than 2.5 ms (milliseconds). Substation 16 has a similar scope to Substation 1A/2B in terms of design, UniGear ZS1 switchgear Relion® future-proof relays delivery, installation and commissioning The substation comprises 26 panels of The innovation in the LOR compact substa- of the complete substation solution. ABB’s UniGear ZS1 switchgear. The com- tion project continued with the use of ABB’s It will feature 3150 A (amp) pact design of this 50 kA fault rated switch- Relion family IEDs (Intelligent Electronic and UniGear ZS1 switchgear, rated at gear, including front cable access, has Devices) to provide a future-proof relay up to 4000 A and 50 kA fault current. enabled it to be configured as two front solution for a variety of demanding func- The switchgear is a withdrawable pattern facing rows made up of one 14-panel tional requirements including generator design that features ABB’s well proven board and one 12-panel board – joined protection, feeder protection, transformer VD4 vacuum circuit breakers. Relion IEDs via a low-level bus-trunking link. protection and line differential protection. will enable Substation 16 to utilise the full The slimline design of the UniGear The Relion units are operating on LOR’s inbuilt capability of the latest IEC 61850 panels meant that two rows of panels, Modbus protocol and they are compatible communications standard for substations. a central walkway, thick blast-proof walls with both fibre optic communications in and 100 mm gaps between the panels and new build substations and retrofit substa- internal walls could be accommodated tions’ existing copper pilot cables using a within a single 6-metre wide standard con- modem link. ABB’s preparatory site tests tainer, along with protection and control confirmed the Relion IEDs’ capability, even equipment and back-up batteries. over the longest cable routes. The ability to fit the entire packaged

Power products and power systems abb.co.uk/ffwd 21 Transformers

01

Variable Shunt Reactors ensure transmission line stability

Steven Blanche, ABB’s General Manager for Transformers, explains why Variable Shunt Reactors (VSRs) are an increasingly popular solution for maintaining voltage stability on transmission lines.

22 abb.co.uk/ffwd Power products and power systems Transformers

he voltage along an overhead trans- and/or rotating phase compensators it is possible to switch the unit in or mission line or underground cable a VSR can be coordinated with them out at a minimum-power tap position T depends on both its capacitive to maximise the dynamic capacity of –– Better fine tuning of the voltage to charging characteristics – which generate the network during a network failure. cope with seasonal and daily load reactive power – and its loading. –– For wind power plant applications, variations is available. If the transmission system is working a VSR may be the optimal device –– Flexibility for future load conditions in at its natural load, also called the Surge for controlling reactive power. the network Impedance Load (SIL), there is a balance A switched reactor or capacitor –– The ratings of these VSR units are between the reactive power generated and requires far too many switching 80-150 MVar at 300 kV, 120-200 consumed. The voltage profile along the operations, while the advanced MVar (three-phase) at 420 kV and, line is ideal and no reactive power com- control offered by an SVC may not recently, 90-200 MVar at 420 kV pensation is needed. If the line is loaded be needed. above its natural load the consumption –– Seasonal load variations. To maintain A transmission company in the US of reactive power will be higher than that a stable voltage at low loading has implemented ABB’s VSRs connected generated and the voltage will decrease condition the full Mvar rating is directly to the high voltage line. By utiliz- along the line. needed. As the load increases in the ing ABB’s oil-immersed shunt reactors When the system is not loaded, or only intermediate season the VSR acts to design, they were also able to eliminate slightly loaded, it consumes little reactive fine tune the voltage to the required environmental concerns surrounding elec- power. This results in a voltage increase level tromagnetic flux spread around open air along the line that can reach damaging –– Daily load variations. The requirement core reactors. levels. To avoid this, we use a device - for more flexible compensation of The rating of these VSR units is 50-100 known as a shunt reactor - to consume the reactive power can be achieved by MVAR (three-phase) at 242 kV. reactive power, thus stabilizing the voltage regulating the VSR A final example is found in some African along the line. A shunt reactor is similar in –– High voltage AC cables generate countries where relatively long transmis- appearance to a transformer, but with the much more reactive power per unit sion lines feed small load centres. The difference that it has just a single voltage of length than overhead lines and loads have a daily variation and there are system (one set of main bushings). due to thermal constraints in the also future plans to increase the load. That Traditionally, shunt reactors have had cable it can normally not be operated makes the ABB VSR a good solution for fixed ratings, with no means of regula- at its natural load. There is a need the owner of the transmission lines since tion. If regulation is needed, then they for reactive power compensation it is essential to accommodate variability are switched in and out to follow the load to stabilise the voltage. At variable in the inductive reactive power compensa- variations. This can result in step changes stationary loads, better fine-tuning of tion requirements. For these applications in the system voltage level and more stress the voltage, which leads to enhanced the size of the units has been up to 30 on breakers. network control, can be achieved MVar (three-phase) and voltage ratings of There is now growing interest in the use using a VSR between 110 and 225 kV. of a new design of variable shunt reactor –– Network changes. As network (VSR) developed by ABB. This uses a tap topology changes, then the demand 01 A VSR rated at 250 MVA changer, of the same type used in power for reactive power compensation transformers, to vary the inductance by may change. The new demand can changing the number of electrical turns be met by regulating the VSR. in the reactor windings. It is now possible –– Flexible replacement of reactors. to fine tune the system voltage to provide During maintenance or a reactor regulation capability. Overall, the transmis- failure, the VSR can be adjusted to sion system benefits from improved power act as a replacement quality, optimized grid operation and the –– VSR field references possibility of interaction with other regu- lation devices, such as SVCs (Static Var The main transmission line system in Compensators). Norway has been upgraded from 300 kV to 420 kV. In the new 420 kV grid, the VSR application scenarios system operator has decided to use only –– Reduction of network voltage spikes VSRs instead of shunt reactor units with when switching in and out fixed fixed power ratings. This offers several power rated reactors. Instead of two advantages: or more fixed rating reactors a single –– If the MVar size of the reactor is low VSR will reduce both the number compared to the short-circuit power of circuit breakers required and the of the network, the voltage will jump installation footprint when the reactor is switched in or –– In substations with SVC equipment out. To minimize this phenomenon,

Power products and power systems abb.co.uk/ffwd 23 Energy recovery

ENVILINE™ ERS scoops major rail award

02

01

he ENVILINE Energy Recuperation braking energy and reducing the operator’s

System (ERS) made a particularly CO2 emissions. The new approach to man- T strong impression when it won the aging surplus braking energy can reduce a electrification category of the inaugural rail operator’s overall energy consumption Railtex Awards. by as much as 10 to 30 percent without the need to invest in new rolling stock or Meeting demand for energy efficiency network control systems. ABB developed the ERS as part of the An additional benefit of the ERS is that ABB showcased its suite ENVILINE range to meet the growing it can mitigate reactive power when not of products for railway demand for energy recovery, storage and pushing energy back to the AC network energy efficiency at dissipation in traction infrastructure. and provide active filtering, thus improving Currently, rail vehicles regenerate their power quality. London’s Railtex 2013 braking energy into electrical energy. Most The ERS has been designed to be exhibition and conference. of the time, a small portion of this kinetic compatible with new and existing systems The event brings together energy is used to power on-board loads, and has a small footprint, low capital cost while the remaining energy is sent back and low maintenance requirements. railway policy makers, to the network and reused if a nearby Reacting to receiving the award, David opinion formers and vehicle is accelerating. If this is not pos- Hughes, Head of ABB Power Products senior figures. sible, the network voltage increases due UK, said: “We are delighted to be one of to the excess energy and the surplus must the first winners of a Railtex award. Our be dissipated into wayside or on-board success in the Electrification category is resistors, which can contribute significantly an important recognition of the very sig- to tunnel heating. nificant contribution that we believe the 01 An ENVILINE ERS unit 02 ENVILINE DC wayside The ERS was developed to allow the Energy Recuperation System can make infrastructure energy flow from the DC traction grid back to boosting the energy efficiency of DC to the AC grid, avoiding the waste of surplus traction systems.”

24 abb.co.uk/ffwd Power products and power systems Facts

A GB first for FACTS technology

National Grid has selected ABB’s TCSC (Thyristor Controlled Series Compensation) equipment in the country’s first installation of this type of equipment, which will boost the power transfer capacity from Scotland to England. The project is part of National Grid’s preparations for Great Britain’s electricity transmission network to meet the target for 15 percent of the UK’s energy to be produced from renewable energy sources by 2020.

ational Grid has selected ABB’s AC by enhancing the security, capacity and “We are delighted that National Grid has TCSC (Thyristor Controlled Series flexibility of power transmission and distri- selected ABB’s TCSC equipment for its first N Compensation) equipment in the bution systems. GB installation in this critical infrastructure country’s first installation of this type of The series compensation equipment to project. It’s an important recognition of equipment, which will boost the power be installed at Hutton substation will use ABB’s position as a cost effective global transfer capacity from Scotland to thyristor control to increase the power flow, market leader in FACTS, with a complete England. The project is part of National mitigate SSR (subsynchronous resonance) portfolio of solutions and key components Grid’s preparations for Great Britain’s and ensure that the power supply system manufactured in-house,” said Jon Downs, electricity transmission network to meet remains stable. It is the first time that TCSC ABB’s Director for Utility Substations in the target for 15 percent of the UK’s equipment will be installed in GB and so the UK. energy to be produced from renewable is a landmark contract. energy sources by 2020. The TCSC equipment, which is sched- A typical TCSC installation uled to go live in 2014, is one of a number of infrastructure enhancements on the existing AC power system which together will increase the power transfer capacity between the Scotland and England network boundary by around 1 gigawatt (GW). The project will be delivered through National Grid’s Electricity Alliance Central. Its scope includes design, supply, installa- tion and commissioning of TCSC equipment at the Hutton 400 kV (kilovolt) substa- tion in Kendal, Cumbria, with associated works being carried out at the nearby Harker, Heysham, Penwortham and Stanah substations. TCSC is a type of equipment that uses thyristor control to regulate the power flow and ensure that the power supply system remains stable. It uses the technique of series compensation, which improves power system stability and allows more power to be transferred through existing circuits. It is part of ABB’s FACTS (Flexible Alter- nating Current Transmission Systems) portfolio, which allows more power to be transferred over long distances when using

Power products and power systems abb.co.uk/ffwd 25 Medium voltage

UniGear digital is ready for the age

A new generation of switchgear was born in June at Stockholm’s CIRED conference and exhibition when ABB launched the latest in the UniGear line of medium voltage switchgear. UniGear Digital takes ABB’s popular switchgear to the next level, ready for the coming smart grid era.

01

26 abb.co.uk/ffwd Power products and power systems Medium voltage

n innovative solution combining Furthermore, because UniGear Digital’s an IED or carry out monitoring remotely, protection, control, measurement interface is based on the Relion range, avoiding the need for a site visit. A and digital communication, the switchgear operators will be able to adapt switchgear panels are designed to enable readily to the user-friendly human machine Future proofing a safe, flexible, eco-efficient and smart interface (HMI). As demand grows, the new digital panels electrical network that can deliver power can be plugged in to extend and upgrade reliable and efficiently. Better operational performance substations ready to be part of a smart The IEC 61850 communication protocol From an operational perspective, the digital grid, using the concept of interoperability is central to the new approach to UniGear switchgear represents increased substation under the IEC 61850 standard to ensure Digital and the switchgear’s advanced availability and equipment safety. that devices are compatible irrespective design and components help to reduce The new UniGear Digital panels meet of manufacturer. This means that UniGear resources and minimise environmental the highest requirements for peer-to-peer Digital is built for flexibility, scalability, modi- impact. GOOSE (Generic Object Oriented Substa- fication and expansion without the need The difference to earlier models is that tion Event) communication, which is faster for complex additional wiring. state-of-the-art digital current and voltage than systems that use the traditional hard- sensors are integrated into each panel, wired approach. Constant supervision of Availability alongside ABB’s multifunctional Relion peer-to-peer communication links between While the UniGear range includes switchgear IEDs (Intelligent Electronic Devices), which panels will ensure that switchgear trips for single level, double level and double ensure compatibility with the IEC 61850 quickly and reliably following an event. Busbar solutions, UniGear Digital is currently digital communication protocol. New, high performance applications available exclusively as an option for the A combination of well-proven technolo- such as high-speed busbar transfer and popular UniGear ZS1 up to 17.5 kV, which gies, the new digital switchgear panels fast load shedding are also enabled under has applications in utilities, industry, marine, are based on ABB’s well established and the digital approach, meaning that UniGear transport and infrastructure settings. reliable UniGear design. The digital ele- Digital is ushering in a level of performance ABB plans to extend the digital concept ments are provide by ABB’s state-of-the-art that is better than ever before. to the entire UniGear portfolio as demand Relion IEDs and digital current and voltage Remote connection via an ethernet inter- for smart grid-ready technology grows. sensors. face means that it is possible to reconfigure The combination is designed to perform a central role in medium voltage smart 02 grids, with the Relion 615 range providing the backbone of the UniGear Digital com- munication concept.

Save time Because it packages switching and com- munication functions together, the new generation of switchgear offers a 30 percent shorter delivery time together with easier purchasing, engineering, installation and commissioning. In one move, the digital offer has removed a whole raft of complexity, with associated lead time, risk and cost. Using IED connec- tivity packages, it’s quick and easy to connect the digital switchgear to a custom- er’s SCADA system.

01 Unigear Digital is based on the ABB’s well proven ZS1 switchgear 02 Unigear Digital delivers IEC 61850 control and protection by integrating Relion relays

Power products and power systems abb.co.uk/ffwd 27 Data centres

01

Data centres power ahead with ‘grid to chip’ solutions

David Hughes, Head of ABB Power Products UK, outlines how ABB covers every data centre need, from creating a new 132 kV grid connection to distributing power down to 240 V.

01 ABB offers a comprehensive data centre service 02 ABB offers the ultimate in safety and energy efficiency

28 abb.co.uk/ffwd Power products and power systems Data centres

he essence of ABB’s philosophy for there is no need for rear access for mainte- and terminals on the low-voltage side. data centre projects is our compre- nance and service operations. The panel T hensive ‘grid to chip’ power solution. incorporates ABB’s proven Vmax vacuum Enhanced safety This was exemplified in the project we circuit breaker in a special fixed version – if To ensure the enhanced safety of data carried out recently for Telehouse, the a problem should arise it can be replaced centre power supplies ABB offers state-of- leading provider of global data centres and in less than 90 minutes. the-art technologies, including two major managed ICT solutions. Starting with the For IEC 61850-based protection and developments: creation of a dedicated primary 132 kV control, the UniGear 500R panels can be –– The REA arc flash mitigation relay substation for the London Docklands fitted with ABB Relion® intelligent electronic that uses patented fiber-optic sensor campus, we delivered a turnkey service to devices (IEDs). technology to instantaneously detect design, supply, install and commission all In addition to the high level of safety light from an arc to signal a ‘trip’ to the electrical plant from the high voltage and reliability required to ensure continu- the designated circuit breaker in less gas insulated switchgear (GIS) and trans- ity of supply for the data centre, this ABB than 2.5 ms, minimizing an arc flash formers to the low voltage switchboards. equipment is also exceptionally energy incident efficient as it can operate under free cool- –– UFES, an ultra fast earthing switch, Grid connection ing conditions, with no requirement for air provides detection and grounding of A key aspect of ABB’s data centre service conditioning. faults in times significantly faster than is that we can operate as an Independent breaker clearing times, leading to Connection Provider (ICP), up to the Increased energy efficiency the avoidance of injury and damage 132 kV level that is beyond the scope of Data centres use very significant levels and the reduction of production most ICPs, to carry out new connection of power, so there is an ever increasing outages. The UFES arc protection projects ranging from the regulated pro- emphasis on enhanced energy efficiency. system channels the uncontrolled vision of service alterations to the turn- ABB’s new EcoDry™ range of ultra-efficient, release of energy by the arc into a key management of multi-million pound dry-type distribution transformers can play solid metal, 3-phase connection to contestable connections for commercial a vital role in improving energy efficiency in earth potential. The internal arc is customers. Using our knowledge and power distribution networks. At the heart extinguished within an operation time experience of working with Distribution of the EcoDry design is AMDT (Amorphous of < 4ms after detection of the fault Network Operators (DNO), developed over Metal Distribution Transformers) core tech- many years, we work closely with the host nology. This, combined with optimized coil To round off the portfolio, ABB also utility and provide a project-focused single designs, can provide significant reduction offers low-voltage (LV) switchboards, power interface to drive down costs, speed up in no-load losses by up to 70 percent, and distribution units, protection relays and the programme and reduce the overall more than 30 percent under full load. transformers as well as variable speed project risk. Dry-type distribution transformers also drives (VSDs), motors and power quality offer major practical advantages. These equipment. Naturally, this all comes with the Medium voltage services include no fire risk, no risk of escape of installation, maintenance and 24/7 service Typically, power for a data centre will be pollutants or fire-hazardous substances, support of a major global organi­sation. supplied by ABB medium-voltage trans- long lifetime; high mechanical strength, Overall, with ABB, data centre cus- formers. Our Midel oil range is especially ability to cope with load changes, over- tomers can meet all their power supply popular for locations where fire resistance loads, short-circuits and over- and requirements from a single source, secure and safety are essential and it also enables reduced installation footprint. This means in the knowledge that their comprehensive the transformers to be installed inside the they can be installed near their place of solution will offer the ultimate in safety and buildings, rather than externally. use – reducing cabling and losses in cables energy efficiency. To distribute power throughout the site we recommend our 11 kV UniGear 500R 02 primary metal-clad Air Insulated Switchgear (AIS) that has been developed specifically to meet the needs of customers requiring the simplicity, lower cost and smaller installation footprint offered by a fixed circuit breaker panel. At just 500 mm wide, the UniGear 500R represents a significant space sav- ing compared with standard switchgear panels, especially in applications such as data centres where banks of 10 or more panels are installed. The UniGear 500R panel ensures maximum safety and reliability, with mechanical interlocks between the circuit- breaker, three-position line disconnector and cable testing device. All components can be accessed directly from the front, so

Power products and power systems abb.co.uk/ffwd 29 Protection and control

New Relion® 620 range extends control capability

ABB’s recently launched 620 series of its highly successful Relion® family of protection and control IEDs has extended the product line’s ability to meet the demands of utility and industrial power distribution systems.

30 abb.co.uk/ffwd Power products and power systems Protection and control

01 Another advantage is that the casings electrical equipment with an additional level have a patented plug-in design to speed of customisation, making it ideal for both up installation, testing and commissioning, new build and retrofit projects. allowing controllers to be installed and wired It is also possible to wire additional before delivery of the plug-in units. This inputs and outputs into the 620 series, also reaps benefits during the operational compared with the 615 series. The wider life of the equipment because an operator casing of the 620 models can accommo- can always be confident that a spare will date additional wiring, which makes the fit, a fact that shortens the mean time to series more suited to applications where repair. new control and automation needs to be compatible with a legacy system. Feeders, motors, transformers and Better communication The new 620 series is intended as the ‘big The GOOSE communication protocol is the brother’ of the 615 series, with current approach that meets the IEC 61850 stan- products being suited to perform protec- dard. GOOSE enables IEDs to exchange tion and control for feeders, motors and information over an ethernet-based network transformers. and so saves the need to hard wiring a The feeder protection IED, the REF620, conventional root and branch communi- protects cable and overhead line feeders, cations layout, saving time and bringing whereas protection for transformers is inherent security. available from the RET620, which supports When faults inevitably take place on power, unit and step-up transformers in a distribution grid, it is vital that control s a whole, the Relion® family includes distribution systems. Finally, the REM620 is systems maintain communication. Fast a wide range of products for the an IED dedicated to protection and control and secure peer-to-peer communication A protection, control, measurement of medium and large asynchronous motors is built into all models across the entire and supervision of power systems. Products in medium-voltage applications. Relion® family. range from protection of secondary distri- Like models in the 615 series, models In common with the entire product family bution systems with the 605 series to the in the 620 series are housed in compact and as devices that support IEC 61850, fully customisable 670 series for intercon- and withdrawable units that can be wall or the new 620 devices offer options for nected transmission networks. panel mounted and which feature a large redundant communication, ensuring that What unifies all members of the family display screen and navigation buttons. the breakdown of a single component in is that they are built for interoperability The difference is that the 620 series a communication network will not impact to the IEC 61850 standard for design of offers more scalability and flexibility than the system as a whole. automation equipment, while at the same the 615 series, which is more standardised. High Availability Seamless Redundancy time being compatible with Modbus and Members of the 620 series feature 16 (HSR) sends messages through both direc- other protocols, when specified. programmable push buttons which can be tions in a network. When this detects a The new 620 series shares the same used as additional alarm LEDs or control broken communication link, it raises an Human Machine Interface look and feel as buttons for tasks such as blocking, setting alarm. the other Relion IEDs. In fact, throughout groups or triggering the disturbance Alternatively, Parallel Redundancy the product family, the location of a push recorder, an option which can be set up to Protocol (PRP) sends messages from an button with a certain function is always the log faults. IED over two identical networks that are same, and the menu structure identical, Configurable at the unit itself or remotely independent of one another. This removes whatever the model. Consequently, once from a control room, the Relion® 620 series the risk of communication breakdown in you are familiar with one Relion IED, you fills a gap in substation control and automa- the case of a fault in one of the networks. can use them all. tion, with the IEDs in the series protecting 01 Members of the Relion® 620 series

Power products and power systems abb.co.uk/ffwd 31 Corporate Social Responsibility

Continued support to Special Olympics GB

ABB has continued its support for Special Olympics GB, the country’s largest provider of year-round sports training and competition programmes for children and adults with intellectual and learning disabilities.

he city of Bath hosed this year’s Summer Games from 28th August T to 1st September, bringing together 1,700 athletes over 12 sports in five days. ABB’s staff where on hand to help run the ten-pin bowling event, as well as attending the Games’ opening ceremony at Bath’s famous Royal Crescent. Eighty-one athletes competed in the ten-pin bowling event, which was held at Bowlplex in nearby Bristol. ABB has lent its support to the char- ity since 2000 and more than 100 ABB employees signed up to volunteer at the Special Olympics ten-pin bowling event. Through the contribution of its employees, ABB is contributing to Special Olympics GB's goal of increasing its volunteering network to 6,000 by the end of the year.

ABB staff members supported Special Olympics GB's ten-pin bowling event

32 abb.co.uk/ffwd Power products and power systems Corporate Social Responsibility

Reaching out with ABB’s Leadership Challenge

ABB's Head of Human Resources, Gary Steel explains the success of the firm's Leadership Challenge programme and why ABB offers to run it for customers, suppliers and the community.

hen it was launched in 2003, the alry had the best horses, the best riders, 01 Leadership Challenge was only and the best fighters in 1939 but they were Wmeant to last a short time but just one war too late.” after 10 years and more than 50,000 To open up a channel into the commu- delegates, it's still going strong. nity and raise its profile, ABB has extended “We have more than 300 people all over the programme to reach out to suppliers, the world as trainers and we tend to run customers and young people in educa- it with intact teams, which means people tion, with Gary’s philosophy being that the have a common background. It’s 20 per- earlier someone encounters the principles, cent teaching tools and processes then the longer they will have to perfect their the other 80 percent is people discussing practice. using the tools and how to apply them in “It’s around getting rid of these advocacy their own workplace.” wars where he who shouts loudest wins. The leadership challenge is based on People rarely step back from the normal psychology developed at MIT, which finds practice of thinking that they should be that when people are thrown a challenge, best as an individual. The whole design they naturally think about the best outcome of the programme is to get people think- for themselves and overlook the big pic- ing ‘us’ and how much better we can be ture but Gary wanted to encourage ABB if there’s an ‘us’.” employees to think about what’s best for 01 Gary Steel the company and it’s this that embodies 02 ABB has extended its leadership programme leadership. to its customers “It’s not a deeply psychological pro- gramme but it gives people three days out 02 to think on a number of concepts and is premised around the notion that people have too much vested in an issue to be truly objective about how to resolve it and so they allow that vesting to get in the way of the best result. So far we’ve had about 50,000 people go through the programme worldwide and it’s run in 16 languages in 70 countries.” “We’re predominantly a company of engineers, who love certainty and stick- ing to the plan but the business world has never been more volatile and uncertain. And if you don’t have your radar tuned to what’s changing, which it could be by the minute, the risk of all those qualities that used to be relevant to our industry is that something maybe missed and you’ve got the Polish cavalry system. The Polish cav-

Power products and power systems abb.co.uk/ffwd 33 Service

Condition-based monitoring for GCBs ABB’s reliability feedback system (RFS) project is developing tools for Generator Circuit Breakers (GCBs) to facilitate a shift from traditional time-based monitoring to condition-based maintenance strategies.

CBs play a vital safety role in power Electrical residual life the three residual life indications reaches plants, where they are used to Every time a circuit breaker operates, its zero. When half of the time-based residual Ginterrupt very high fault currents contacts are ablated and eventually are life is used up, an inspection should be (up to 250 kA) in the busbar between the no longer functional. performed. generator and main transformer. In addition, With RFS, ABB’s service teams are able routine operational procedures, such as Mechanical residual life to periodically review the condition of the synchronization of the generator with the The mechanical residual life is reduced GCB to proactively determine and recom- grid, are simplified compared with block by one every time the circuit breaker is mend service activities like inspection and layouts without a GCB. triggered. This represents the mechanical electrical overhaul. It offers great potential This vital role demands 100 percent wear on the system. for power plant operators to reduce their availability and reliability. So ABB is devel- maintenance downtime while still ensuring oping increasingly sophisticated tools to Time-based residual life that GCBs are kept in the ideal safe and provide customers with increased visibility If neither the mechanical nor the electrical reliable operating condition. of the condition and remaining life of their residual life is used up within a certain time GCBs. This has resulted in the creation of limit, an overhaul is still required to account the reliability feedback system (RFS) pilot for additional concerns not modelled in the project. Its goal was to obtain residual life other residual life concepts. data from the field to help ABB’s service Using residual life in maintenance ABB teams to recommend the optimum over- service teams use a myriad of information haul intervals for GCBs. to determine the right time for a GCB over- A typical life span for a GCB is 20 to haul, including experience, measurements 40 years. Their safety critical application and service reports. The new RFS-GCB requires regular inspections and overhauls. software aids the process by using residual The residual life of a GCB is the amount life information to suggest possible overhaul of ablation the breaker can take before dates as the basis for long-term overhaul an overhaul is required. The breaker has planning. three types of residual life (the overhaul is For a GCB there are two different main- indicated when the first of these reaches tenance jobs – overhauls and inspection. zero): An overhaul occurs when either one of

34 abb.co.uk/ffwd Power products and power systems Forthcoming events Forthcoming events ABB has a full and stimulating schedule of events for 2013 and we would be delighted to see you at one of the major exhibitions and conferences we are attending.

Event Location Date Website Scottish Renewables Marine Conference Inverness 18-19th September scottishrenewables.com

IET Innovation Awards London 20th November theiet.org/innovation

RenewableUK Conference and Exhibition Birmingham 5-7th November renewableuk.com

Scottish Renewables Green Energy Awards Edinburgh 5th December scottishrenewables.com

Help Joyce Rock reach her pinnacle One ABB employee is going the extra mile this November when she will be trekking to Everest Base Camp to raise funds for Macmillan, one of ABB’s chosen charities.

01 02

01 Joyce on one of her trekking challenges 02 Joyce will face many challenges during her trek to Everest Base Camp

oyce Rock is no stranger to chal- king for up to 8 hours per day across chosen charities. I’ve had great support lenge events, having already crossed varied terrain, facing extreme weather from my family and from my colleagues J the Sahara, trekked across Iceland conditions and taking precautions against at ABB, who have been amazing with and climbed Kilimanjaro alongside ABB altitude sickness. Climbing almost 3,000 fundraising.” team-mates. Joyce’s major contribution metres, Joyce will reach a high point at Joyce will be one of the many ABB during these challenges was recognised the lookout of Kalapatar, which at 5,545 employees helping to raise funds for when she was chosen as a Torchbearer metres above sea level is at ‘extreme Macmillan on 27 September, when ABB in last year’s Olympic Torch Relay. altitude’ – truly on top of the world. offices across the UK will host their indi- But her trip to Everest Base Camp Explaining why she has been driven to vidual coffee mornings in support of the will be the most strenuous challenge so take on her latest challenge for Macmillan, charity’s World’s Biggest Coffee Morning. far. During her 19-day adventure, the Joyce said: “I started fundraising for Help Joyce reach her target at justgiv- 60 year-old PA in the Power Products Macmillan having lost friends and family to ing.com/JOYCE-ROCK3. division will face tough conditions, trek- cancer and because it was one of ABB’s

Power products and power systems abb.co.uk/ffwd 35 Substations that can hide in a city?

Certainly.

Bustling urban centers need efficient and reliable electricity, but have little room to accommodate large electrical installations. ABB’s Gas Insulated Switchgear (GIS) technology can shrink the size of an electrical substation by as much as 70 percent, so it can be located in the midst of cities and in other space-restricted areas, sometimes even indoors or underground, minimizing environmental impact. We offer a range of products, systems and services for power generation, transmission and distribution to help increase power capacity, enhance grid reliability, improve energy efficiency and lower environmental impact. With a 125 year heritage of technology innovation ABB continues to shape the grid of the future. For more information please visit us at www.abb.com

ABB Ltd Tel. +44 (0)1785 825 050 Fax. +44 (0)1785 819 019 E-mail. [email protected]