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1|12 The customer newsletter of ABB Power Products and Power Systems


Delivering a power boost for London Underground EAC wins five-year contract extension from National Grid 04 IEC 61850 project delivered for Teesside offshore wind farm 08 High Speed 1 project enters test phase 11 Hybrid HVDC breakers 12 Introducing Symphony Plus 16 New generation recloser 22 Oil reclamation prolongs active life for transformers 26 Power quality issues put to bed 28 Data centre power 30

Power and productivity for a better world™



Power Products are the key components to transmit and distribute electricity. The division incorporates ABB's manufacturing network for transformers, switchgear, circuit breakers, cables and associated equipment. It also offers all the services needed to ensure products' performance and extend their lifespan.

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 alternating current transmission systems (FACTS), high-voltage direct current (HVDC) systems and network management systems. In power generation, Power Systems offers the instrumentation, control and electrification of power plants.



Stephen Trotter

New indoor high voltage substation


Substation upgrade for the ‘Chapel in the Valley’


Supporting Macmillan Cancer Support


Dear reader, Welcome to the first issue of our customer newsletter for 2012. As you can read in our newspages, the new year got off to a flying start for ABB with the exciting news that our Electricity Alliance Central (EAC) contract with National Grid has been extended for a further five years. You can also find out more about our EAC projects in the article on page 14. Another important development is the opening of our new office in East Kilbride that will provide the ideal platform for supporting power infrastructure projects in Scotland. We are also pleased to welcome our new intake of apprentices who represent our very real commitment to the development and training vital to support not only ABB’s future growth, but also a healthy economy. Simply reading through these pages describing major projects and ground breaking technology, such as the HVDC

hybrid breaker, the true depth and breadth of ABB’s capabilities emerge. They provide a solid foundation for our ambitious growth plans as we look forward to building the advanced ‘smart’ power networks essential for the UK to make the best possible use of its new renewable energy resources. As always, we would be delighted to receive any feedback on the subjects covered in this issue, or suggestions for future issues. Please get in touch – we would love to hear from you. In June, we would also be very pleased to see you at the RenewableUK Global Offshore Wind 2012 Conference & Exhibition in London, where ABB is proud to be the core sponsor.

Stephen Trotter Division Head of ABB Power Systems UK

ffwd 1/12 • the customer newsletter of ABB Power Products and Power Systems • Subscription Newsletter available as printed or electronic copy. Subscribe online at • Contact and feedback [email protected] • Publisher ABB Limited, Power Systems Division, Oulton Road, Stone, Staffordshire ST15 0RS. Phone 01785 825050



Delivering the balance of power

FFWD 1|12 Power Products and Power Systems


News on major contracts and developments in ABB


IEC 61850 project for Teesside offshore wind farm





16 24 24


Jon Downs outlines a new approach to smaller substation projects


Creating a new Bulk Supply Point


New generation GridShield recloser


Reclaiming transformer oil


Power quality issues put to bed for Paragon Print & Packaging


Data centre power




Supporting Macmillan


GBS platform technology for DolWin2


Where to meet ABB this year

High Speed 1 power quality project

Introducing the Hybrid HVDC breaker

Leigh Turley reports on ABB’s experience of working in National Grid’s substation alliance

New Symphony Plus distributed control system Substation upgrade for ‘The Chapel in the Valley’ New connection for SITA

Delivering the balance of power Power Products and Power Systems FFWD 1|12 3



New Head of Regulatory Affairs and Technology for the UK We are delighted to report that Colin Green has joined ABB in the new role of Head of Regulatory Affairs and Technology for the UK.

Electricity Alliance Central wins five-year substation contract extension from National Grid The New Year got off to a flying with the news that National Grid’s Electricity Alliance Central (EAC), a consortium of ABB, Morgan Sindall and Atkins, has been awarded a five-year contract extension to deliver major enhancements to the UK’s electrical transmission infrastructure. These enhancements will primarily involve the design, construction and commissioning of 400 kV, 275 kV and 132 kV transmission substations. During the contract extension, which runs until 2017, individual contracts will continue to be awarded based upon safety performance, cost, on time delivery performance, project scope and geographical considerations. It is therefore not possible to place a total value on the contract extension. The EAC was established in 2006 as one of National Grid’s preferred Alliance partners for substation development and 4

construction projects. It operates in National Grid’s Central region, comprising the Midlands, Greater Manchester and Liverpool. This original award was part of a programme worth up to £2.8 billion to upgrade and develop the electricity transmission network across England and Wales. Stuart Grattage, Head of Engineering for ABB Power Systems in the UK, said: “National Grid’s decision to extend the Alliance contract confirms the success of our innovative approach where all four participants work together as a true partnership. This makes the best use of our

FFWD 1|12 Power Products and Power Systems

individual competencies and shares risk and reward to create an effective team which safely and efficiently delivers complex substation projects, on time and on budget.” Most recently, the EAC has been working on one of the largest ever substation projects undertaken in the UK, creating a replacement 400 kV substation at Deeside. Not only will this new substation play a vital role in the reinforcement of the high voltage transmission infrastructure in northwest England, it will also pave the way for the connection of a new high-voltage direct current (HVDC) power link which is under construction.

Colin has come to ABB after over 15 years experience with the UK energy regulator, where he was most recently Head of Offshore Transmission Policy at the Office of Gas and Electricity Markets (Ofgem). His appointment expands the skills and expertise that ABB can offer in the UK power sector. Colin’s main role is to support ABB in building on its market leading position as a supplier of advanced power transmission and distribution solutions that are missioncritical to the future development of the UK’s energy infrastructure. This will include developing and extending ABB’s high level relationships with key government policy makers, industry bodies and customers to promote the technical and economic advantages of ABB’s world-leading power systems technologies. Thanks to his wealth of experience in the power transmission industry, Colin is especially well placed to promote, for example, the business case for using ABB’s high-voltage direct current (HVDC) technology to create the enhanced infrastructure essential for the effective integration of offshore wind power within the UK grid. Speaking about his new role, Colin said “This is a great opportunity that enables me

to apply my knowledge, skill and experience to support the growth of ABB’s UK business. It is an exciting time to work in the UK power sector with the growth of renewable generation, the development of smarter networks and the drive towards more efficient production and use of energy. ABB is a company with a fantastic culture and tradition and I am looking forward to adding value to ABB and its customers.” “The UK energy market faces some key technical and economic challenges over the next few years” commented Stephen Trotter, Head of ABB's Power Systems Division in the UK. “Colin's appointment will ensure that we can work pro-actively with the various stakeholders – utilities, developers, governmental and non governmental organisations and financial institutions, understanding the business and regulatory environment and ensuring that the market is aware of the value and solutions ABB can provide across a range of technologies – HVDC, energy storage, smartgrids, network protection and control, software, offshore wind, power generation, energy efficiency, rail electrification and tidal/marine.”

Colin Green

‘You’re hired’ - new apprentice class of 2011 In October 2011 we were pleased to say ‘you’re hired’ to the latest class of talented youngsters to join our successful ABB Power Systems apprentice scheme. We received a record number of applications for our 2011 apprentice programme and the applicants faced a tough selection process. The new apprentices are now hard at work, both at our offices in Stone, Staffordshire and studying at NewcastleUnder-Lyme College. At the same time we are already starting the process for this year’s apprentice intake. Power Products and Power Systems FFWD 1|12 5



Power export cable for Humber Gateway offshore wind farm ABB has won a major order from E.ON UK, to supply the power export cables for Humber Gateway offshore wind farm. The contract includes 2 x 14 km circuits of 132 kV 3-core AC submarine cable, with integrated fibre optics and accessories, that will connect Humber Gateway, one of the UK’s largest offshore wind farms, to the mainland grid. When completed, in spring 2015, Humber Gateway will consist of a 73 turbine array that will generate up to 219 MW of electricity, enough energy to power up to 170,000 homes. The wind farm will be located 8 km off the East Yorkshire coast, just north of the mouth of the river Humber. The cable will be manufactured by ABB’s factory in Karlskrona, Sweden, with delivery scheduled during the summer of 2013.

New indoor high voltage substation completed for Northern Powergrid

East Kilbride office established ABB’s new office in East Kilbride now provides a local hub in Scotland for our Power Systems division. This effective local presence will enable customers in Scotland to access ABB’s state-of-the-art solutions to support the major investments they are making to expand and upgrade Scotland’s electricity transmission, distribution and renewable energy systems. The office, at the Technology Centre on the Scottish Enterprise Technology Park in East Kilbride, will be the base for a number


of new ABB roles working on the full project delivery – from inception, tendering and design through to commissioning and handover – of the many multi-million pound schemes crucial to upgrade and enhance Scotland’s high-voltage power transmission and distribution infrastructure to integrate the country’s fast-increasing level of renewable energy generation. The positions created initially in ABB’s East Kilbride office will require considerable additional labour market resource and

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support, both directly from ABB and within our wider supply chain, to be based on construction sites throughout Scotland. Although this is the first ABB Power Systems office in Scotland, ABB already has an established and thriving business in Aberdeen, serving mainly the oil and gas industries, as well as service personnel located throughout Scotland. ABB is also a major investor in Aquamarine Power, a wave energy technology company with head offices in Edinburgh.

ABB has handed over Northern Powergrid’s new 132 kV indoor GIS (gas insulated switchgear) substation at Tynemouth following the successful on-time completion of a turnkey design and build project. The project has reinforced grid reliability and ensured security of supply for the major population centre served by the Tynemouth substation by replacing outdoor AIS (air

insulated switchgear) equipment that was nearing the end of its service life. The use of ABB’s state-of-the-art compact ELK GIS equipment enabled the new substation to be

built indoors, within a purpose-designed building that occupies around one quarter of the space required by the old substation.

Reinforcing our UK sales operation We are pleased to announce that David Hughes, who was a wealth of experience in ABB’s UK operations, has been appointed as our new Head of Front End Sales (FES) UK. He takes over the role from Richard Oulton who has moved to ABB’s High-Voltage Marketing & Sales function in Zurich.

Power Products and Power Systems FFWD 1|12 7

Network Management

Network Management

delivery. In fact, the whole process from design, engineering, building the panels, carrying out the FAT (factory acceptance test) and shipping them to site was accomplished in just three months.” Flexible open system architecture The adoption by ABB of the IEC 61850 standard offers significant technical advantages through its flexible open system architecture. These include a standardized model of the IEDs and their data and communication services, full interoperability between electrical devices from different vendors, reduced cabling and effective future-proofing of the infrastructure by making it easy to extend and update as needs change. The protection and control system for Warrenby substation is based on IEDs from ABB’s Relion® family of equipment developed specifically to implement the core values of the IEC 61850 standard. They include Relion RET 650, RET 630 and RET 615 transformer protection and control devices. As an example of the ease of integration with third-party equipment, the scheme incorporates an AVC (automatic voltage control) device supplied by another manufacturer.

One of the key technical challenges solved by ABB in designing the system was to ensure that it meet the needs of the engineering recommendation G59, that sets out the standards required for the connection of a generating plant to the distribution systems of a licensed Distribution Network Operator (DNO). Rigorous FAT The rigorous FAT for the Warrenby panels was carried out at ABB’s unique automated System Verification Simulator (SVS) based at Stone, Staffordshire. Rather than carrying out manual switching of equipment to simulate the operation of substation plant, the SVS is able to duplicate the whole substation within the test laboratory. It runs automated, self-monitoring test sequences to provide a high level of rigour and repeatability as well as a full audit trail. “Teesside Offshore Wind Farm is a vital reference project that confirms ABB’s capability to deliver IEC 61850 substation projects” concludes Andy Osiecki. “It is proof positive that this key new development in substation design is now making the transition from the laboratory to practical real-world applications.”

IEC 61850 substation protection and control scheme delivered for Teesside Offshore Wind Farm ABB has delivered a state-of-the-art substation protection and control system, based on the IEC 61850 international standard for substation automation, for EDF Energy Renewables’ Teesside Offshore Wind Farm. The project for Warrenby substation, the wind farm’s onshore connection constructed by Morrison Utility Services, is a significant development as ABB’s first UK implementation of the global IEC 61850 standard that represents a major step forward in simplifying the integration of intelligent electronic devices (IEDs). The offshore wind farm at Redcar, Teesside consists of 27 turbines producing 8

power exported by 33 kV subsea cables to Warrenby, where it will be stepped up by two grid transformers to 66 kV so it can be fed into the regional and national grids via the Northern Powergrid network. Complete protection and control system Morrison Utility Services, the UK’s leading utility service provider, awarded ABB the contract to provide the complete protection

FFWD 1|12 Power Products and Power Systems

and control system for Warrenby substation. According to Andy Osiecki, ABB’s General Manager for Power System Network Management, “the Teesside Offshore Wind Farm project has been a significant challenge, working not only with a new customer, but also a whole new technical approach that effectively required us to start from a blank sheet of paper, and also combined with the need to ensure fast-track

Safety by design features include special feet to improve cabinet stability during assembly. Power Products and Power Systems FFWD 1|12 9



High Speed 1 power quality project enters test phase The start of on-line testing is a critical milestone in ABB’s project to design, manufacture and install state-of-the-art capacitive compensation systems for High Speed 1.

Flexibility is the key for smaller substation projects Jon Downs, General Manager Utility Substations, explains how ABB has replaced the old ‘one size fits all’ approach with a new philosophy tailored to meet the needs of smaller substation projects. ABB is well known for its superb long term track record in delivering major multi-million pound turnkey substation projects, such as Connah’s Quay – one of Europe’s largest substations – which you can read about in the other pages of this newsletter. What is perhaps not so well appreciated is that we are equally adept at working on smaller value projects such as the delivery of individual packages. Listening That is why over the past year or so we have spent a lot of time talking to our customers and importantly listening to exactly what they need in terms of delivery models and processes when we work with them on lower level contracts. A clear picture emerged that a ‘one size fits all’ service simply isn’t appropriate. What is needed is a totally flexible, tailored service that can deliver the ideal response for each project. 10

An important change is reflected in the adoption of multi-functional roles. This means that the project manager might also be the design engineer and then follow on to be the site manager. While making these changes, the over-riding concern is of course to maintain the outstanding levels of health and safety performance, on time delivery and quality demonstrated on our larger projects. In essence, the aim is to deliver ‘big project’ performance for our small project customers in a model that meets their needs. Encouraging results We rolled out this new approach in 2011 and the results have been extremely encouraging, both in terms of winning orders and in the feedback from customers on our tender submissions. The approach to small projects is continuing to evolve as we create a new team with the specific skill sets

FFWD 1|12 Power Products and Power Systems

aligned to the needs of this market, especially in terms of flexibility, adaptability and speed of response. Upgrades and extensions Typical utility substation projects that the team is focusing on include upgrades and extensions, such as circuit breaker replacements, as well as system integration or installation of equipment. In fact, we anticipate that the need for modification and extension of substations is set to increase significantly as they have to adapt to the increasing demands of renewable energy sources in the UK grid. Overall, the message is that ABB now has the flexibility to support any size of substation project from £100k to £100 million. And for what some may describe as a small project we still aim to deliver big project performance and quality.

This involves running real trains – a Eurostar and an Hitachi Class 395 – on a representative section of the network to confirm the capability of the ABB equipment to prevent voltage drop issues on the traction power catenary supply. The 68 mile (109 km) High Speed 1 route, from the Central London terminal at St Pancras International to the Channel Tunnel at Dover, is used by Eurostar trains operating the international high speed routes between London, Paris and Brussels as well as high speed domestic trains that provide a commuter service between London and Kent. The High Speed route is supplied with power on the 2 x 25 kV principle using autotransformers. Its nominal line voltage is therefore 25 kV. There are, however, some sections of the line where it can drop as low as 17.5 kV, causing a reduction in overall system performance as well as spurious tripping of the network protection and control systems. Voltage drop The cause of the voltage drop is the inherent design of the isolation transformers (used to isolate between High Speed 1’s AC traction power supply and the adjacent Network Rail DC traction power supply), located in substations along the line. This is because they require large magnetising currents and therefore demand substantial inductive reactive power, which results in a drop in the voltage supply as seen by the train’s catenary. A number of studies commissioned by High Speed 1, including a detailed investigation by ABB’s power quality expert team based in Sweden, confirmed that a reduction in the reactive power demand from the isolation transformers will improve system performance. ABB was then awarded a major contract to design,

develop, manufacture and install a turnkey capacitive compensation solution that will effectively cancel out the inductive power demand of the transformer, and hence reduce the voltage drop. Harmonic filters The ABB solution for High Speed 1 is based on harmonic band pass filters with a rated output of 1512 kVAr, each comprising a 6.4 MVAr capacitor bank and a 303 mH inductor. This equipment installation also includes associated protection and control equipment and a switch-disconnector that enables it to be isolated from the network for maintenance and repair. A total of 17 capacitive compensation filters have been installed at nine AC/DC compounds at strategic positions along the line. “The strength of ABB’s technical solution is of course vital to the success of the High Speed 1 project. However, our overall detailed, consistent and consultative approach to the stakeholder management of all the parties involved during the construction and installation phases while working alongside a live operating railway

network is just as important,” said Seamus O’Neill, ABB Power Systems Operations Manager for Rail. “For example, we worked very closely with the High Speed 1 and Channel Tunnel Rail Link (CTRL) System Review Panel, who are responsible for the introduction of all new assets, to ensure that our project met their stringent technical and operational needs.” “Furthermore, during the equipment delivery and construction phase the ABB team worked very closely with High Speed 1’s own stakeholder management team to support their efforts in liaising with local authorities and residents to minimize any potential disruption.” Live tests The ABB capacitive compensation filters have already passed comprehensive factory acceptance tests (FATs) and pre-commissioning testing with flying colours. Now, in the live test phase, trains are being run between two selected points on the High Speed 1 route to validate the design and prove their capability, ready for all nine sites to be put into full operation later in 2012.

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Hybrid HVDC breakers – a vital breakthrough for Europe’s DC grid Peter Jones, Engineering Manager Grid Systems for ABB UK, explains why the recent announcement of ABB’s Hybrid HVDC breaker concept is a crucial development in plans to create large DC grids. As you can see from the other stories in this newsletter, High-Voltage Direct Current (HVDC) technology is well established in applications such as bringing offshore wind power to shore, supplying oil and gas offshore platforms, interconnecting power grids in different countries and reinforcing existing AC grids. However, as the number of these point-to-point HVDC connections increases, it is becoming apparent that it would be beneficial to connect them the through than rather directly, broader AC grid, as they are currently. This is creating interest in plans for HVDC supergrids. The creation of an HVDC supergrid is a considerable technical advance on single route and multi-terminal HVDC schemes. Multi-terminal HVDC installations have taps along the DC line, however a true DC grid is meshed and provides multiple power flow paths between two points, and might have single or multiple DC voltage levels. The advantages of DC networks are in flexibility and security, in addition to numerous capital

and operating cost incentives. Indeed, many of the reasons for developing meshed AC grids at the beginning of 20th century apply now for enhancing HVDC into DC transmission grids. Hybrid HVDC breaker For smaller regional grids, multi-terminal HVDC technology is available and ready to go now. However, in developing large interregional DC grids we need to achieve the same levels of reliability and performance as AC grids. This has not been possible until now, due to the lack of a suitable DC breaker for isolation of a faulted line or unit. In fact, the relatively low impedance in the DC grid means that, should a short-circuit fault occur, the fault penetration is much faster and deeper than in an AC grid. Fast and reliable HVDC breakers, capable of clearing a fault within a few milliseconds, are therefore required to avoid a collapse of the common DC voltage. The existing mechanical HVDC breakers, capable of interrupting DC currents within

several tens of milliseconds, are too slow to fulfill the requirement of a reliable DC grid. Furthermore, they are complex devices passive additional include which components to create the resonance circuit required to generate current zero crossing for successful breaking of the current once the contacts open. Semiconductor-based DC breakers can easily overcome the limitations in operation speed but generate large transfer losses. ABB has now taken the advantages of mechanical and semiconductor designs and combined them in a prototype hybrid breaker that offers both fast operation and reduced transfer losses. ABB is also addressing a number of other technical issues relating to multiterminal grids including: • Power flow control • Automatic network restoration • DC/DC converters for connecting different regional systems.

Fenno-Skan 2 commissioned ABB has successfully commissioned the Fenno-Skan 2 HVDC power link between Finland and Sweden, a cable-based that system transmission power enables the exchange of an additional 800 MW of power between the two countries, mitigating transmission bottlenecks in the region. The Fenno-Skan link is owned and operated by Fingrid and Svenska Kraftnät. The installation includes two converter stations, one situated in Rauma, on the Finnish side, and the other in Finnböle, in Sweden. The control system of the original link will also be upgraded. The newly commissioned link will run in parallel with Fenno-Skan 1, delivered by ABB in 1989 providing a bipolar link to enhance the capacity for power trading and improve the security of supply in the region.

Valhall offshore platform power link completed ABB has successfully commissioned an HVDC Light link that enables onshore power from Norway’s mainland grid to supply BP’s Valhall multi-platform complex in the North Sea. The new link allows BP to substitute the use of offshore gas turbines to generate electric power thereby eliminating up to 300,000 tons of carbon dioxide (CO2) emissions a year - equivalent to the annual emissions of around 125,000 modern European cars. The installation includes one converter station onshore connected by an HVDC submarine cable to a second converter on the platform, about 294 km offshore. It allows 78 MW of power to be supplied from the mainland to run the field facilities, including a new production and living quarter platform.

Hybrid HVDC breaker

Hybrid DC Breaker

Fast Disconnector

Auxiliary DC Breaker

Current Limiting Reactor Residual DC Current Breaker Main DC Breaker

Fenno-Skan 2 Swedish HVDC station 12

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Design engineering

Design engineering

required to supply backup power for substations by 40%. This saves fuel, reduces CO2 emissions and provides a smaller installation footprint. We have also been able to eliminate the need for a 48 V DC battery system completely, reducing infrastructure and equipment costs as well as commissioning and maintenance costs.

Connecting Carrington Power Station

Design engineering drives Alliance success Leigh Turley, ABB engineering manager, explains how design engineering is making a significant impact on the delivery of high profile substation projects by National Grid’s Electricity Alliance Central (EAC). As well as being ABB engineering manager, I am also the detailed design manager for National Grid’s Electricity Alliance Central (EAC), a consortium of ABB, Morgan Sindall and Atkins, working on high profile substation projects such as Carrington, Cleve Hill and Connah’s Quay. In the nearly two years I have been in this role I have focused on introducing methods that can help improve our engineering performance, including reducing project delivery times, lowering costs and improving quality through increased standardisation and repeatability. Working across the diverse organizations in the Alliance has presented a major logistical challenge. However, we have all pulled together to create a single delivery team, learning from each other and building on our individual strengths. Above everything else, our success is based on effective communication. One example of this is the creation of a design standards handbook that has been made available on National Grid’s Livelink system to share ideas and best practice relating to the design of primary and secondary plant and civil engineering. I believe it is vital to keep building and developing our engineering team to ensure that we have the resource in place as our substation business continues to develop. 14

We are committed to developing people through training, for example we have recently helped one of our layout engineers to make the step up to become an application engineer. Thinking ahead, we have a very active graduate training programme while we have just boosted our intake of apprentices and they will add real value to the business in four years time. To supplement our resources we are also working very closely with the ABB team in Chennai who are now providing excellent electrical engineering support for primary layouts and protection and control system design.

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Design for safety ‘Design for safety’ is a theme that runs through all our engineering activities. One area where some simple thinking ahead has made a tangible impact is in improving access to gas insulated switchgear (GIS) buildings with access ramps that make it easier to move test equipment in and out, as well as reducing manual handling. Lighting has also been brought down to a lower level to eliminate hazardous dark areas, and we are also using reliable low maintenance lighting. Attention to design has enabled us to reduce the size of diesel generators

GIS installation at Carrington

Lean build approach for Carrington Carrington Substation is a very high profile project in which the EAC has built a new 7 bay 400 kV GIS substation that will enable the connection to the transmission system of the new CCGT power station that is being built by Carrington Power Limited in Greater Manchester. This project was used to pioneer a lean building approach that has enabled us to reduce the amount of ‘wet trades’ required on site, such as concreting, brick laying and plastering. An important innovation was the use of prefabricated relay rooms (PRRs). This enabled all the protection and control equipment to be assembled and tested into a series of containers in the controlled environment of our Stone facility. The containers were then transported to site and lowered onto basic concrete foundations, making the installation and commissioning process very fast and simple. Not only does reducing the time we have people

working on site save on project costs, it also reduces risk. All that was then needed for the building itself was a basic weathershield to protect the site equipment. Cleve Hill to connect the world’s largest offshore wind farm The lessons learned at Carrington were applied in the construction of a new 400 kV substation at Cleve Hill, near Faversham, Kent. This will form a key element of the up to 1,000 MW London Array – which will be the world’s largest offshore wind farm when it starts operation in 2012. The Cleve Hill scheme required the construction of a five-bay 400 kV GIS indoor substation and associated infrastructure on a greenfield site. The location of the substation, which is cut into the side of Cleve Hill, means that it is subject to strict planning constraints with regard to its design and size, and the project required careful design and planning in order to gain approval from the local authority. Deeside – ABB’s largest ever substation project The jewel in the crown for the EAC is the construction of a replacement for National Grid’s 400 kV Deeside substation – the largest ever UK substation project that ABB has been involved in. The new substation, scheduled for completion in 2018, will play a

vital role in the reinforcement of the highvoltage transmission infrastructure in northwest England, and pave the way for the connection of new high-voltage direct current (HVDC) power links under construction. The project scope includes the construction of a new 24-bay GIS substation and the supply of key products like switchgear and high voltage cabling, as well as the integration of three 400/132 kV 240 MVA grid transformers and the refurbishment of an existing unit. Not only is the project technically challenging, it also requires effective liaison with multiple stakeholders such as National Grid, International Power, SP Manweb and EON. One team, one goal Within the EAC we have worked extremely hard to integrate all the various different types of engineers into a single delivery team. The hard work clearly paid off, as feedback from the tutors at the IET Power Academy following a recent training exercise was that they couldn’t tell which people belonged to the individual Alliance partners, since they all presented as one team with one clear goal. And this teamwork has brought its own reward with the recent announcement that National Grid has extended the EAC contract for a further five years.

Cleve Hill Substation site (Copyright London Array Limited) Power Products and Power Systems FFWD 1|12 15

Power generation software

Power generation software

integrating data from all plant areas and systems, including turbine control, electrical balance of plant and remote SCADA systems. Through its open architecture, Symphony Plus seamlessly consolidates and rationalizes plant data to improve operator response to changing conditions, so improving plant safety and uptime. Transforms data into actionable business decisions Information is the key to successful business performance. In Symphony Plus Operations, historical, process and business data is collected from across the plant and stored securely. Transforming data into meaningful information, Symphony Plus Operations presents pertinent, easy-to-understand information in intuitive desktop displays to all levels of the organization.

Symphony Plus in tune with current and future power generation needs

Unified engineering workbench Short time to production is the measure of engineering efficiency, Symphony Plus Engineering provides a world-class integrated engineering environment, with the functionality required to engineer, configure, administrate, secure, commission and maintain any Symphony Plus component. Single control and I/O platform Symphony Plus provides total plant automation from a single control and I/O platform that encompasses dedicated

interface modules and devices for all turbine types, OEMs and sizes, as well as an unparalleled selection of combustion instruments. Electrical and device integration Symphony Plus provides process and electrical control from a single platform. Using open standard protocols like IEC 61850 and Modbus TCP, Symphony Plus integrates electrical devices with process control and plant operations. It provides full integration of just about every type of device, and enables the monitoring and management of all plant assets at all levels of the plant. System security ABB understands the need to maintain a secure, reliable control environment while expending minimal time and effort. In addition to the many security features of Symphony Plus, ABB actively participates in several major control system security standards committees. The guidance provided by these committees is designed to increase the integrity and confidentiality of all system functions and help prevent unauthorized control system access. System 800xA ABB will continue to deliver and support 800xA, our mainstream offering for the process industries (and its specific add-ons for power generation) when and where it is required.

The launch of Symphony Plus, the latest generation of our Symphony family of distributed control systems, continues ABB’s tradition of delivering power generation software that helps drive plant productivity and energy-efficiency, as well as enhanced operational security, plant safety and lower total cost of ownership. Commenting on the launch, Franz-Josef Mengede, head of ABB’s power generation business, said, “With the launch of Symphony Plus, we are taking the Symphony success story to the next level, ushering in a new era of total plant automation that is simple, scalable, seamless and secure. “With Symphony Plus, we help balance performance objectives like asset availability, operational reliability and production efficiency with business goals like asset life extension, carbon reduction and regulatory compliance – providing plant owners with an essential tool for achieving sustainable and profitable growth.” 16

Total plant automation Symphony Plus meets a broad spectrum of plant configurations and applications, especially in the power and water industries. It is flexible and scalable; designed to serve the needs of everything from small, serverless applications to large multisystem, multi-server architectures. Symphony Plus supports the seamless integration of field devices, process and turbine automation systems, electrical and Supervisory Control and Data Acquisition (SCADA) solutions, as well as business and maintenance systems. It provides users with a secure, reliable control environment and built-in

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security features that prevent unauthorized system access. Since its introduction over 30 years ago, the Symphony family has gone through several evolutionary changes. Through ABB’s ‘evolution without obsolescence’ lifecycle policy, each generation of the family builds on and enhances its predecessors, while protecting the customer’s previous control system investments. There are now more than 6,000 Symphony systems installed worldwide, making it one of the widest deployed process automation systems in the world. Symphony Plus provides users with a comprehensive view of the plant by Power Products and Power Systems FFWD 1|12 17



ensure the best performance and quality of engineering workmanship and deliveries. Through innovative electrical power applications, we help utilities to build and maintain reliable power systems installations safely and efficiently, providing cost-effective solutions that guarantee results. ABB has supplied turnkey EBoP solutions to a wide variety of projects worldwide, resulting in these benefits: • Integrated solution • Reduced project risk • Optimization of the complete system • Improved plant efficiency • Pre-tested plant configurations • Reduced overall project cost • Reduced number of interfaces • Consistent technology approach and spares strategy • Improved project delivery • Reduced commissioning time and cost • Complete system approach to meet compliance and local regulations • Common platform that minimizes the required investment in hardware spares, reduces training needs and eliminates the need for serial interfaces.

Blackburn Meadows biomass energy project

EBoP – delivering the balance of power Tony Rooney, Head of ABB’s UK Power Generation business, outlines our comprehensive service for electrical balance of plant (EBoP) projects. ABB has the capability, experience and inhouse technologies to deliver turnkey EBoP systems and plant packages tailored to a wide variety of applications (new build and retrofit), especially gas-fired combined-cycle power plants, coal-fired boiler power plants and hydro-electric plants, while our comprehensive portfolio extends to embrace renewable applications particularly 18

energy from waste and biomass, as well as industrial-sized turbine and boiler power schemes." Our EBoP service covers every electrical control and instrumentation system and component in the power plant, apart from the generator and turbine. This includes a broad portfolio of products and solutions that provide a single source of supply for

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both new build and refurbishments projects, from high voltage down to the low voltage level. ABB takes responsibility for the complete engineering, supply, manufacture, delivery to site, installation, commissioning, testing and quality of the EBoP package. Direct control over all engineering and project management functions enables ABB to

HV electrical contract for Blackburn Meadows biomass energy project At the end of 2011, ABB made an important breakthrough within the UK’s biomass sector by securing a major contract with E.ON to supply the HV installation for a biomass-fired renewable energy plant under construction at Blackburn Meadows, near Sheffield. The £120 million renewable energy plant will be set near the site of the old Tinsley Towers, adjacent to Meadowhall, and when operational (in mid-2014) will generate up to 30 MW, enough to power 40,000 homes, by converting recycled waste wood into electricity. As part of the turnkey EBoP solution for the Blackburn Meadows power plant, ABB will be responsible for the design, manufacture, supply, installation and commissioning of a fully complete HV installation associated with the safe and reliable delivery of electrical power generated by the steam into the local grid. Key products to be supplied include an 11/33 kV 40 MVA Generator Step Up (GSU) transformer and Station Auxiliary transformers, 33 kV GIS switchboard and the associated protection and control equipment including the site SCADA system that will interface with DCS systems.

Turnkey EBoP solution for Didcot OCGT ABB’s momentum in UK EBoP projects continued in early 2012 with the award of a major contract by RWE npower to supply a turnkey electrical balance of plant (EBoP) solution for the repowering of the Open Cycle Gas Turbine (OCGT) plant at Didcot Power Station in Oxfordshire. The Didcot OCGT plant, comprising four diesel fired turbines with a total capacity of 100 MW, is designed specifically for peaking operation. During periods of high demand, it offers a flexible, reliable and fast-responding source of additional capacity to provide support for the National Grid. In the repowering project the OCGT plant’s electrical control and protection systems are being upgraded to the very latest operational standards. ABB’s turnkey EBoP solution for the Didcot OCGT power plant includes the design, engineering, supply, installation and commissioning of all the equipment and civil engineering required to control the electrical power generated by the gas turbines and to deliver it safely and reliability into the local grid. Key systems to be supplied include an 11 kV substation based on ABB’s UniGear ZS1 switchgear fitted with VD4-G Generator Circuit Breakers, auxiliary transformers, and the protection and control equipment including the control system that will interface with the DCS at Didcot B CCGT station.

UniGear ZS1 switchgear Power Products and Power Systems FFWD 1|12 19

Project delivery

Project delivery

Two grid transformers have now been installed at the BSP

New BSP substation will provide essential power boost for London Underground The current major project to create a new Bulk Supply Point (BSP) for London Underground (LU) provides a perfect example of ABB’s capability to deliver a complete design, project management and construction service for rail substation projects. This capability that not only includes all the electrical equipment, but also cabling and the very substantial civil works required to create a new substation building within an extremely restricted footprint. 20

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Transport for London (TfL) has a number of existing 132 kV BSPs that supply power for LU. This additional BSP is now needed to increase the available power to support the full operation of new air-conditioned rolling stock that, since 2010, is being phased in on the sub-surface (SSL) lines – the Circle, District, Hammersmith & City and Metropolitan. The BSP’s desired 120 MW capacity dictated that it should be located relatively close to a grid supply point. It also had to be located close to the LU infrastructure in order for the necessary cable connections to be made between it and the existing distribution system. The most appropriate site for the new BSP substation was identified adjacent to an underground station. Restricted site The new BSP is designed to take electricity from a nearby National Grid 400/132 kV substation (constructed by ABB in 2004) and step it down through transformation (132/22/11kV) to feed into the LU power supply system. In the past there were houses and shops on the site, but they have been long since demolished and most recently, the site was used as a car park. The major challenge for ABB has been in working within this restricted site, hemmed in on all sides with an operating railway close by, to create a large, modern substation building.

The project commenced in 2009, and ABB has focused on the excavation and civil works to create a new cable and switchgear basements and multi-level reinforced concrete building. The scale of this exercise is illustrated by the need to remove 11,000 cubic metres of spoil materials – some 2,300 lorry loads. Extensive deep piling has also been carried out to create the foundations. This level of civils work in a busy area of London has called for a very detailed approach to logistics and communications, not only with contractors and travel authorities but also in ensuring minimal disruption for the local community. Electrical equipment Following completion of the civil works, ABB moved on to install the electrical equipment. This includes: three 22/11 kV 25 MVA coupling transformers; two 132/22 kV 120 MVA grid transformers; a 35 panel 22 kV switchboard featuring ZX2 GIS (gas insulated switchgear); a 27 panel 11 kV switchboard featuring UniGear AIS (air insulated switchgear); LV switchgear; two 11 kV earthing / auxiliary transformers; ventilation system and associated mechanical systems; 110 V batteries and charger. A major project milestone was the successful delivery and installation of the two grid transformers, each weighing 97 tonnes, completed over two weekends at the end of 2011. Transporting the transformers into the

centre of London and manoeuvring them into position was a highly complex logistical exercise requiring months of planning with ABB’s transportation partner ALE (Abnormal Load Engineering) to develop the optimum installation methodology. Stakeholder management Equally important was detailed attention to stakeholder management. This involved working in close liaison with the local council, police and residents to identify the best route, arrange the necessary road closures, traffic diversions, suspension of parking spaces, removal of traffic lights and signs to enable the two massive loads to reach the site with minimum disruption. The substation is also being provided with new SCADA RTU (remote terminal units) for the 11 kV and 22 kV switchgear. Extensive fibre optic cabling will be installed to provide the communication path between the BSP, other substations and the LU control centres. In its first large scale cabling exercise for LU, ABB is also carrying out cabling works associated with the BSP including around 55 km of 22 k and 11 kV XLPE cable installed in tunnels and ducts.

The new BSP project is scheduled for completion in the summer of 2012.

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Medium voltage

Medium voltage

provides advanced time synchronization capabilities that eliminate the inaccuracy issues related to the time stamping of disturbances and other events.

RER620 relay – part of ABB’s new Relion® family of IEDs The GridShield recloser is controlled by the RER620 relay, which is part of ABB’s new generation Relion® family of intelligent electronic devices (IEDs). The RER620 provides extensive protection and automation capabilities based on full native implementation of the core values of the IEC 61850 standard. In addition to IEC 61850, the relay also supports the industry standard DNP3.0, IEC 60870-5-101, IEC 60870-5-104 and Modbus® protocols ensuring easy incorporation within existing systems with the flexibility to migrate easily to IEC 61850.

New generation recloser is ready for current and future grid challenges ABB’s new GridShield® outdoor vacuum recloser for 15 kV and 27 kV feeder and substation applications has been developed to meet the growing need for increased automation in electricity distribution networks, higher service reliability and lower network maintenance and management costs. The GridShield recloser enhances grid reliability and efficiency by providing an automatic response to system disturbances. Reclosers combine a circuit-breaking function with the ability to restore the power automatically and quickly, so that temporary faults are less likely to result in prolonged power outages for utility customers.


The GridShield recloser is intended for use on distribution feeders or in substations, and incorporates a number of design features aimed at maximising long-term reliability and minimising routine maintenance needs. The GridShield recloser has also been designed to meet the challenges of

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enhanced grid automation. It offers the capability to perform as recloser, breaker, automated switch or sectionalizer, or even to connect distributed generation to the grid or to communicate GOOSE (Generic Object Oriented Substation Event) messaging utilizing the IEC 61850 data model.

When integrated with ABB’s COM600 station automation device, the RER620 can be used to perform network-level control and system management functions. In applications using smart peer-to-peer GOOSE communications, the RER620 delivers enhanced fault detection, isolation and restoration schemes, re-routing loads while maintaining protection coordination to provide power for the healthy portion of the feeder swiftly and effectively. High impedance fault detection – sensing a downed conductor – is one of the advanced integral protection features of the GridShield recloser and RER620 combination. The GridShield recloser also

New generation insulation material and other important features The use of hydrophobic cycloaliphatic epoxy (HCEP) as insulation material reduces the likelihood of flashovers and insulator erosion. The creepage performance of these HCEP insulators is the best in the industry, and far exceeds the requirements of ANSI standards. In addition, it exceeds IEC Level IV requirements for equipment operating in polluted environments. The magnetic actuators and vacuum interrupters are rated at 10,000 full-load operations. The actuators require no routine lubrication, maintenance or adjustments; and the bi-stable technology means no power is required to maintain an open or closed position. No electronics are housed in the interruption compartment, reducing unit down time and eliminating the costs of line switching when servicing the unit controls. Single or triple-phase applications Because there are three independent actuators fitted in the cabinet, the GridShield recloser can be used in single or triple-phase tripping applications. The single phase tripping capability reduces the number of momentary interruptions caused by one phase to ground temporary faults.

Why use reclosers? A recloser is a protection device for electrical distribution networks. It combines a circuit breaker that trips if an overcurrent is detected (indicating a short circuit somewhere in a section of the network), with an electronicallycontrolled reclosing function that automatically restores power to the affected line if the fault clears itself quickly – which usually happens around 80 percent of the time. There is a double incentive for electricity distribution companies to deploy reclosers in their networks. The first is that reclosers prevent transient short circuits from triggering prolonged

power outages. This results in better supply continuity to customers. The second benefit is that reclosers restore power automatically, without requiring an engineering site visit. A transient short circuit is the type of event that can be caused, for example, when a branch of a tree momentarily touches overhead cables as it falls to the ground. Reclosers handle this type of event much better than circuit breakers. Typically, power would be restored to customers in a matter of a few seconds or less. Only if the cause of the short circuit has not cleared itself would the recloser keep

the breaker open until the cause is manually cleared. Reclosers like the new ABB Gridshield also have electronic control equipment with multiple network interfaces, so the reclosers can be integrated into a wider network automation strategy. However, even with a fast-acting recloser installed in a feeder network, a transient short circuit will still cause a momentary interruption to customer supplies. But this is much preferable to a power outage that lasts until a maintenance team can get to the breaker site to restore power.

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Circuit breaker replacement

Grid connection

Substation upgrade for the ‘Chapel in the Valley’ ABB has been awarded a contract by RWE npower renewables to upgrade the substation serving Cym Dyli, within the Snowdonia National Park, one of Britain’s oldest hydroelectric power stations which started generation in 1906. attention to detail to obtain the requisite planning permission for the work to be carried out. Second, the valley location makes access difficult. When it was built, three traction engines were needed to help mule and horse teams haul heavy machinery and other supplies the eight miles over the Llanberis pass from the

Reliability, safety and security The substation equipment from the 1989 rebuild is now nearing the end of its service life. ABB is therefore upgrading the substation with the latest switchgear and circuit breaker technology to ensure the optimum reliability, safety and security of supply. The existing site circuit breaker will be modified to meet the latest standards while a new second circuit breaker will installed in the form of ABB’s well proven VD4 vacuum circuit breaker fitted in a UniGear air insulated switchgear (AIS) panel. Other work will include the installation of earthing transformers and the modification of the protection and control circuits with new current and voltage transformers with metering capability. Listed building The Cwm Dyli project represents two specific challenges relating to its age and location. First, the Listed building (which is known locally as the ‘Chapel in the Valley’ due to its design) has required significant 24

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railway station. This time ABB is relying on four-wheel-drive vehicles. In order to avoid working through the winter, the ABB site team carried out the preparatory civil works in Autumn 2011. They will return in Spring 2012 to carry out the installation and commissioning of the electrical equipment.

SITA UK is the latest in ABB’s global series of waste to energy projects shown here

Fast-track grid connection for extension to SITA UK’s Teesside Energy from Waste plant ABB has been awarded a major contract by SITA UK, part of the SUEZ ENVIRONNEMENT group, to provide a fast-track grid connection for the extension of its Energy from Waste plant currently under construction at Billingham, Teesside.

Courtesy of Norman Childs Photography

The project, featuring ABB’s state-of-the-art UniGear primary MV switchgear, includes the modification of the site’s single existing 33 kV circuit breaker and the installation of an additional second circuit breaker to ensure fail-safe operation. Construction of Cwm Dyli commenced in 1906 to supply power for Wales’ then prosperous slate industry. It also produced electricity for the first ever transatlantic transmission station set up by Marconi in 1912, near the village of Waenfawr, Caernarfon. Water for the site comes predominantly from the Llydaw lake some 320 metres above the site high on the slopes of Mount Snowdon and travels to the powerhouse through a two kilometre long pipeline. The site was rebuilt in 1989 , when the original Pelton wheel turbines were replaced by a single Francis turbine capable of producing 9.8 MW of green energy.

The new connection, comprising a 66 kV site substation together with a 1.5 km underground cable, will enable SITA UK to feed an additional 21 MW of power into the local grid via Northern Powergrid’s Tees North substation. SITA UK specialises in the controlled incineration of residual waste, which cannot be recycled or composted, to recover renewable energy in the form of electricity. The site at Haverton Hill Road, Billingham currently has three Energy from Waste lines that process around 390,000 tons of household and commercial waste a year to generate just over 29 MW. The site is now being extended with the construction of the North East

Energy Recovery Centre (NEERC), which will add two further processing lines capable of handling an additional 256,000 tons of waste a year to generate a further 21 MW. ABB is providing a complete grid connection solution for SITA UK’s two new processing lines covering the design, manufacture, installation and commissioning of a new 66 kV substation, including switchgear and protection and control systems, and the underground cable link to the local Northern Powergrid substation. The project is being carried out on a fast-track basis to ensure that the grid connection is in place ready for the plant’s planned start-up in 2013.

“This latest contract for SITA follows the success of the similar grid connection project we carried out for the site’s third processing line that came on-line in 2009”, said Richard Holliday, ABB UK General Manager – T&D Infrastructure & Grid Integrated Solutions. “It is a perfect example of ABB’s proven capability as an Independent Connection Provider (ICP), as an ever increasing number of developers are now coming to us to help solve their utility connection issues by providing a project-focused single interface to drive down costs, improve cash flow, speed up the programme and reduce the overall project risk.”

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Acids form as a result of oil degradation due to oxidation, indicating that the transformer oil is ageing. Corrosive sulphur is also well known as a significant cause of premature transformer failure as it reacts with copper components to form highly conductive copper sulphide that deposits on windings and the paper insulation, causing a breakdown of insulating properties and resulting in shorting, arcing and even fires. Deeside Power Station, which opened in 1994, is a 515 MW CCGT (combined cycle gas turbine) power station owned by International Power GDF Suez and sited by the river Dee in Flintshire, North Wales. It has three GSU transformers (two for each of the gas turbines and one for the steam turbine) that step-up the voltage produced by the generator units to the 400 kV required by the UK transmission system. Oil tests carried out as part of a general maintenance programme had indicated increasing levels of acidity and the presence of corrosive sulphur. The oil in each of the three transformers had previously been passivated using 7 litres (100 ppm) of Irgamet 39. Subsequent tests showed an unexpectedly high consumption of the

passivator so Deeside Power asked ABB’s specialist UK transformer repair and maintenance team to take further samples and recommend remedial measures. These new tests confirmed that the oil was in a condition where it needed reconditioning or replacement. The main aim was to remove the acidity and sulphur that were reducing the DP (Degree of Polymerization) value of the paper insulation, which is an important indicator of its remaining service life. It was decided to use ABB’s unique online oil reclamation service to reclaim the oil rather than replacing it with new. This process enabled the acidity and sulphur to be removed over a period of time with the transformers remaining energized, so the power station could continue to operate at full capacity without the need for an outage. Mobile oil reclamation rig The reclamation process, in which the oil is circulated continuously through ABB’s mobile oil reclamation rig, housed in a 40 foot trailer, took around 10 weeks for each transformer due to the large volume of oil to be processed – a 190 MVA GSU transformer, such as the units at Deeside

Power, holds 70,000 litres. The progress of the reclamation process was monitored by checking the colour of the oil as it changed from a dark brown to a light straw colour. At this point the oil was sampled for laboratory testing to confirm the successful removal of acids and corrosive sulphur. Reclamation is superior to an oil change Initially, it might appear that carrying out a complete change of the transformer oil would be a faster and more efficient method of eliminating the by-products of oil degradation. However, extensive laboratory and field tests carried out by ABB have shown this offers only a short term benefit as the new oil soon becomes contaminated by the residual oil in the tank and the insulation. So, while the reclamation process is longer and slower, it provides a permanent long-term solution that restores the properties of the oil to very near those of new oil by removing acids, sludge and other degrading products like corrosive sulphur. This also has a beneficial effect on the ageing of the paper insulation.

Taking an oil sample from a transformer

Oil reclamation service prolongs active life for transformers ABB’s state-of-the-art on-line oil reclamation service has helped Deeside Power Station to ensure the reliability and long service life of its three vital GSU (generator step-up) transformers by removing high levels of acidity and harmful corrosive sulphur from their insulating oil. 26

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The oil is circulated through the mobile rig

Laboratory testing Power Products and Power Systems FFWD 1|12 27

Power quality

Power quality issues put to bed for Paragon Print & Packaging ABB’s specialist power quality service has enabled Paragon Print & Packaging, the UK market leaders in food packaging for the fresh and chilled food sector, to solve potential plant reliability and efficiency issues at three of its key printing facilities in the east of England. ABB’s Advance power factor correction (PFC) systems have been installed at the Paragon sites in Spalding and Wisbech, while a PQFI active harmonic filter has been installed at Boston.


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Power quality

Spalding – detuned PFC equipment addresses harmonic current issues The project commenced when CV Electrical, the contractor responsible for maintaining Paragon’s electrical infrastructure, called in ABB to investigate an issue with frequent nuisance tripping of the main incoming supply protective device at the Spalding site. Paragon had already taken an important step in maintaining the site’s power quality by installing a series of capacitor banks to ensure that the power factor on the 415 V network was held at the acceptable industry standard level of 0.95 lag. However, it was found that the harmonic currents present on the network were causing the five capacitor banks (5 x 50 kVAr) to degrade prematurely. Not only was this reducing the operating efficiency of the capacitors, during peak load periods it was causing the main incoming breaker to trip – a major concern for a site where the reliability and availability of the production lines are core to its business. It was actually Paragon’s investment in the state-of-the-art printing technology required to maintain its position as the UK’s largest manufacturer of self-adhesive food labels that was contributing to the problem. This is because advanced printing equipment utilises variable speed drives (VSDs) that are a notorious source of network harmonics. ABB’s detailed investigation established that the total harmonic distortion (THD) on the network was above the recommended levels stipulated in Energy Networks Association Engineering Recommendation G5/4-1 – Stage 2 Table 12 ‘Planning levels for harmonic current distortion and connection of non-linear equipment to transmission systems and distribution networks in the UK’. If this issue, together with possible system resonance, was not addressed then the output of the existing capacitors would continue to degrade over a period of time, reducing the power factor and allowing the site’s peak demand to increase, with the possibility of further main incomer tripping occurring. The recommendation was to remove the existing capacitors completely and replace them with a 250 kVAr Advance automatic capacitor assembly fitted with detuning reactors to mitigate the damaging effects of the harmonics. A year on from the installation, the Spalding site is operating efficiently with no reported tripping incidents.

Boston – harmonic filtration solution Following the success of the Spalding project, ABB was asked to investigate Paragon’s Boston site. It was found that again the harmonic distortion on the network was outside the G5/4-1 recommendation. ABB was able to offer the ideal solution in the form of its new generation PQF (power quality filter) family of active filters. They operate by continuously monitoring the current in real time to determine what harmonics are present and then injecting harmonic currents into the network with exactly the opposite phase to the components that are to be filtered. The two harmonics effectively cancel each other out so that the feeding transformer sees a clean sine wave. A 450 A PQFI unit designed specifically for heavy industrial loads was installed and harmonic distortion assessments carried out following its commissioning confirmed that the harmonics are now limited to well below the G5/4-1 requirement.

Wisbech – PFC solution At Wisbech, ABB was asked to help improve the site’s power factor (PF). PF is essentially a measure of how effectively electrical power is being used. Ideally it would be 1 (unity), and the closer to this figure it actually is then the more effectively electrical power is being used and vice versa. The investigations found that the PF of 0.845 lag was well below acceptable industry standard levels, which usually call for a PF of 0.95 or better. In fact, a site PF lower than 0.95 can now result in penalty charges being imposed by the local electricity supply company. To rectify the situation, ABB installed sophisticated power factor correction (PFC) equipment in the form of its Advance 400 automatic capacitor equipment comprising a total bank of 300 kVAr, complete with a detuning reactor to eliminate any issues with network harmonics.

PQFI filters

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Data centres

Data centres

– – – – – – –

Low voltage switchboards MNS system iPDUs (Power Distribution Units) Active filters Power factor correction Network communication Air-insulated medium voltage switchboards Dry-type transformers

The ABB strategy for Data Centres is to provide the technology and services required to build reliable and efficient solutions that meet the client’s requirements.

– – – –

i-bis EIB/KNX Network communication

Delivering energy efficient data centre power from incomer to server The developers and operators of today’s new-generation data centres make major demands on their power network infrastructure. Downtime due to loss of power simply cannot be contemplated, so operators insist on total reliability and availability. ABB has responded by developing a unique comprehensive approach that covers every need from the incoming supply through to the server racks. This includes all the AC and DC systems, automation and services required to deliver reliable and efficient solutions for a diverse range of data centre installations. 30

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iPDUs (Power Distribution Units) Rack power panel Power measurement Network communication

– EFF1 high efficiency motors – Inverter – Network communication

Rather than dealing with separate suppliers for individual project elements, a data centre developer can work with ABB to meet all its power requirements from a single source. This saves both time and money. It also has the advantage that all ABB equipment is guaranteed to work together seamlessly, ensuring fast-track installation and commissioning. ABB’s scope of supply goes well beyond grid connection, medium-voltage (MV) and low-voltage (LV) switchboards, power distribution units, protection relays and transformers. It also offers variable speed drives (VSDs), motors and power quality equipment. This all comes with the installation, maintenance and 24/7 service support of a major global organization.

Grid Connection: As an Independent Connection Provider (ICP) registered under the Lloyds NERS scheme, ABB can offer a turnkey solution for contestable utility connections at all voltages to include the integration of Air Insulated Switchgear (AIS), Gas Insulated Switchgear (GIS) and Hybrid solutions. ABB offers a complete one-stop shop package for the electrical distribution in data centres. ABB can also provide ‘Rapid Build Substations’ that enable customers to have a grid connection in the minimum time. Medium voltage switchgear ABB offers the full spectrum of both AIS and GIS switchgear. With the growth in size of data centres the full load current and fault levels can increase dramatically. ABB has the product range to cater for these and all data centre applications. An important element in ABB’s range is the UniGear 500 R Fixed Circuit Breaker panel, which is currently the most compact air-insulated MV switchboard on the market. A further advantage of the UniGear 500 R is that it coordinates perfectly with the well-proven UniGear ZS1 portfolio. So, for example, it is possible to specify on the same busbar: a UniGear with withdrawable incomer; fixed circuit breaker outgoing; and additional starter switchgear. Relion range of relays ABB has developed its Relion family of IEDs (intelligent electronic devices) to unleash the full potential of the IEC 61850 standard for communication, Power monitoring and interoperability of substation automation equipment. This new family includes the Relion 615 relay that provides absolutely selective protection, making it ideally suited to data centre protection and control applications. DC power leads the way for data centre energy efficiency Data centres consume around 1.5% of the entire world’s electric power. Given the tremendous growth that the industry continues to experience, energy efficiency has become a top priority.

DC (direct current) powered data centres are now being adopted across the industry largely due to their cost advantage in terms of both initial investment (less equipment) and operating costs (greater efficiency). But significant energy efficiency gains can also be made in a variety of areas such as: • HVAC efficiency – variable speed drives and high efficiency motors can cut HVAC costs by as much as 50% • Facility efficiency – Electrical power distribution design can reduce energy wasted in the facility by up to 30% compared to conventional designs • Personnel efficiencies – instrumentation can be configured from a central control area, eliminating the need for engineers to physically adjust the device • Utility rates and billing – with the right monitoring and control capability, data centre operators can take advantage of time-of-use rates and demand response programs to lower electricity costs.

ABB’s data centre portfolio: • Grid connection solutions at all utility voltage levels • AC and DC power solutions • HV, MV and LV switchgear • Transformers • Motor control centres (including variable speed drives) • Power distribution units (PDUs) • Rack power panels • Protection relays • Power quality solutions • SCADA systems • Electrical power monitoring and remote supervision • UPS systems • Data centre information management (DCIM) • 24/7 service support

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Corporate Social Responsibility

PASS M00 is perfect for wind farm HV internal collection grids ABB’s PASS series of hybrid switchgear modules combines the advantages of traditional air-insulated switchgear (AIS) and advanced SF6 gas-insulated switchgear (GIS) technologies. The newest addition to the family is the PASS M00 range of multifunctional modules that cover voltages between 72.5 kV and 100 kV and breaking currents up to 40 kA. PASS M00 is a combination of well proven standard components including: circuit breaker, a spring operating mechanism, current transformer and an innovative new concept for the combined disconnecting and earthing function. This five-position disconnector, which is integrated in the main chamber, enables the following functions: • Line disconnection • Busbar disconnection • Earthing of the line through the circuit breaker • Earthing of the busbar through the chamber The multifunctional PASS M00 module can also integrate current and voltage transformers, surge arresters and protection and control systems. It is available for single and double busbar configurations, has a single and triple pole operating mechanism option and is ideally suited 32

for use as a standard product in the design of new modular substations or for retrofit applications. Wind farm applications PASS M00 is ideally suited to high-voltage (HV) wind farm collection grid applications where it offers these advantages: • 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, gas insulated and dry power transformers. A case study of new generation offshore wind farms equipped with 5 MW turbines

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revealed that the use of PASS M00 modules in 72 kV collection grids made it possible to fit a complete HV substation within a tower with the following advantages: • Reduction in the number of arrays necessary to export the energy produced • Reduction in the number of cables in parallel for each feeder; • Increase in the power capacity/current ampacity of a single feeder; • Reduction in the losses in subsea AC internal grid array cables; • Decrease in the voltage drop in the feeder/string; • Decrease in the short circuit value of internal grid apparatus; • Eliminate the need to construct an offshore HV/MV platform substation when offshore wind farms are close to land • Flexible internal configuration and higher reliability

Supporting Macmillan Cancer Support ABB recently celebrated its 12th year as a supporter of Macmillan Cancer Support, during which time our UK employees have raised over £700,000 to help change the lives of people affected by cancer. Cancer is the toughest fight most of us will ever have to face. But there is a team of people who are there to support every step of the way and that’s the Macmillan team. They simply couldn't provide their vital services without the people who support them – people like you. There are many ways that ABB staff has got involved in the past year – some more energetic than others! Among the more energetic activities were two separate climbing expeditions to conquer Kilimanjaro, the highest mountain in Africa; a team participated in the Great North Swim, the

UK’s biggest outdoor swimming event; and others pounded 13 miles of Newcastle’s streets to complete the Great North Run, the world’s largest half marathon. Other more gentle fund-raising activities included the whole company participating in Macmillan’s annual ‘Wear your Macmillan t-shirt to work’ day. Sharon Cottam from Macmillan Cancer Support said of ABB’s fund-raising efforts: “This is testament to the support from ABB staff, raising yet another superb total in 2011 of over £28,000. I cannot thank ABB enough. One in three of us will get cancer

and it’s the toughest fight most of us will ever face. By joining Team Macmillan in a fundraising event you're helping support people and their families living with cancer.” Trevor Gregory, Managing Director of ABB in the UK, said: “Our staff are passionate about supporting such a worthwhile cause as Macmillan Cancer Support. Thanks to the efforts of our staff, we are helping Macmillan to support cancer sufferers, their friends and families. It’s both humbling and rewarding but something ABB is proud to be involved in.”

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International Project


Forthcoming events ABB has arranged an exciting schedule of events for 2012. So please come and see us at one of these major exhibitions and conferences.

GBS platform technology to play vital role in DolWin2 project The German company TenneT Offshore GmbH, has awarded a $1 billion contract to ABB to supply an 900 MW transmission link that will connect offshore wind farms located in the cluster DolWin (Gode Wind II wind farm, 400 MW, and other wind farms) in the North Sea to the German grid.


electromagnetic fields, and compact converter stations. It is ideal for connecting remote wind farms to mainland networks without distance limitations or constraints on the grid. ABB is responsible for system engineering including design, supply and installation of the offshore converter (including the platform), sea and land cable systems and the onshore converter station. The land cables will be laid underground, thus minimizing environmental impact. This is the third offshore wind connection order for ABB in Germany, following the 800 MW Dolwin1 link awarded in 2010 and previously the BorWin1 project.

FFWD 1|12 Power Products and Power Systems

Location Date


DPSP (Developments in Power System Protection)


April 23-26

Offshore Wind Conference & Exhibition


June 13-14 events/global-offshorewind-2012

RWM (Resource & Waste Management)


September 13-16

Sponsorship sustained for IET Innovation in Engineering Awards

Dolwin2 follows the success of the Borwin1 HVDC light project shown here

The wind farms will be connected with AC cables to the HVDC converter station based on an offshore platform situated in the North Sea and further through 45 km of DC sea cable and 90 km of land cable to the HVDC onshore station at the grid connection point at Dörpen-West. The transmission system will have a total capacity of 900 MW at ±320 kV, which today is the world's largest offshore HVDC system. The completed link will be capable of supplying more than 1.5 million households with clean wind-generated electricity. The HVDC Light system that will be used offers numerous environmental benefits, such as electrical losses of less than 1 percent per converter station, neutral


A vital element in the DolWin2 project will be ABB’s innovative, robust and scalable GBS (Gravity based self-installing) platform concept, developed in cooperation with a leading player in the offshore sector to meet the challenge of locating HVDC converter stations in demanding offshore locations. The new GBS design addresses key issues such as efficient production and ease of installation, as it requires only a minimal level of offshore works, without the need for a heavy-lift vessel or jack-up operations. The design also offers complete flexibility within challenging installation programmes, as it can be installed in the waters of the North Sea, and elsewhere, at any time of the year.

In 2012, ABB is proud to be continuing its long-term sponsorship of the IET Innovation Awards, which celebrate the products, technologies and processes that lead the way in engineering innovation. The ABB-sponsored Sustainability category is the most all-encompassing of all of the Innovation Awards. It is open to any and all innovations in fields of engineering, science and technology that demonstrate a contribution to sustainability. Entries for projects, processes, products and initiatives are welcomed either from individuals, small teams or organisations (both engineers and non engineers) that are both innovative in nature and sustainable from a resource perspective. The entry can cover an entirely new concept or the development of an existing process or product to provide a sustainable approach. In 2011, the award was won by Ashwoods Automotive for its Hybrid Drive System that works by taking wasted energy from braking and decelerating and storing it to be used to assist commercial vehicles when required. It offers an interesting alternative to low range, high cost electrical vehicles. For more information:

Robert Llewellyn (left) and Stuart Grattage (right) of ABB present the 2011 award to Martin Kadhim of Ashwoods Automotive Power Products and Power Systems FFWD 1|12 35

Harnessing the power of wind? Naturally.

Transforming the power of wind into electricity, integrating it efficiently into the grid and maintaining network reliability are key challenges. They drive the evolution of more flexible and intelligent power systems, aiming to balance unpredictable and intermittent supply with demand. ABB’s HVDC Light® technology plays a central role in enabling long-distance transmission and cross-border grid connections, under-ground and underwater, to deliver reliable, high-quality power supplies with minimal losses.

Sponsors of RenewableUK 2012, Global Offshore Wind Excel, London, 13-14 June

Power and productivity for a better world™

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