Reprint from Aluminium World 2009, Volume 2

Emirates Aluminium starts upWorld‘s first fully integrated power distribution system from ABB

Emirates Aluminium (EMAL), a joint venture between Abu Dhabi’s Mubadala Develop-ment Company and Dubai Aluminium Company DUBAL, are building a green field US$5b smelter at the Taweelah industrial zone close to Abu Dhabi. The world’s first fully integrated power distribution system from ABB will set new standards for green field smelter projects.

From the 220kV Gas InsulatedSwitchgear (GIS) to the220/33kV step down trans-

formers, the 33kV and 6.6 kV switchgearall the way to the plant wide 400VACdistribution a fully integrated powerdistribution system nears completion.ABB’s local manufacturing capability,engineering resources and experiencewere fully utilised to make it all possible.

EMAL’s world first smelter fullyintegrated power distribution system willset new standards for green fieldsmelter projects. In line with ABB’senabled IndustrialIT (Industrial Informa-tion Technology), the overall systemintegration, maintenance simplificationand after sales services has beenoptimised throughout the plant. With thefull scale level of integration the mostcost effective operation and mainte-

Emirates Aluminium Starts UpWorld’s First Fully Integrated PowerDistribution System From ABB

nance as well as spare parts manage-ment, has been achieved with EMAL’sadvanced looking forward strategy.

Introduction

Emirates Aluminium (EMAL), a jointventure between Abu Dhabi's MubadalaDevelopment Company, the investmentarm of the Government of Abu Dhabiand Dubai Aluminium Company DUBAL,are building a green field US$5b smelterat the Taweelah industrial zone close toAbu Dhabi. The first phase of the EMALproject will be operational in 2010 witharound 700,000-tons annual capacity.Upon completion of all phases, thesmelter will have a capacity of 1.4million tons, which will make it thelargest single site aluminium smelter inthe world. SNC-Lavalin International, in

joint venture with Worley Parsons, as anEPCM-contractor, leads the completeplant project and is responsible forengineering, procurement, constructionand management.

ABB scope of supply is the totalintegrated power distribution and controlsystem from the 220kV GIS all the way tothe 400VAC plant wide distribution for thepower plant and the smelter. The SCADA(Supervisory, Control And Data Acquisi-tion system) has been integrated from thetop to the bottom. In addition also the400kV feeder protection system andSCADA interface as well as the telecominterface was supplied at the EMAL substation as well as the utility sub-stationside.

ABB’s power quality system Switch-syncTM, which has become industrystandard for switching large loadswithin Aluminium smelter substations,will energise all large loads withminimal power distortion impact to thefeeding generation plant and the powerconversion station.

ABB’s ELK-14, 300KV rated GIS

MIDDLE EAST ALUMINIUM INDUSTRY REPORT

From the 220kV Gas InsulatedSwitchgear (GIS) to the220/33kV step down trans-

formers, the 33kV and 6.6 kV switchgearall the way to the plant wide 400VACdistribution a fully integrated powerdistribution system nears completion.ABB’s local manufacturing capability,engineering resources and experiencewere fully utilised to make it all possible.

EMAL’s world first smelter fullyintegrated power distribution system willset new standards for green fieldsmelter projects. In line with ABB’senabled IndustrialIT (Industrial Informa-tion Technology), the overall systemintegration, maintenance simplificationand after sales services has beenoptimised throughout the plant. With thefull scale level of integration the mostcost effective operation and mainte-

Emirates Aluminium Starts UpWorld’s First Fully Integrated PowerDistribution System From ABB

nance as well as spare parts manage-ment, has been achieved with EMAL’sadvanced looking forward strategy.

Introduction

Emirates Aluminium (EMAL), a jointventure between Abu Dhabi's MubadalaDevelopment Company, the investmentarm of the Government of Abu Dhabiand Dubai Aluminium Company DUBAL,are building a green field US$5b smelterat the Taweelah industrial zone close toAbu Dhabi. The first phase of the EMALproject will be operational in 2010 witharound 700,000-tons annual capacity.Upon completion of all phases, thesmelter will have a capacity of 1.4million tons, which will make it thelargest single site aluminium smelter inthe world. SNC-Lavalin International, in

joint venture with Worley Parsons, as anEPCM-contractor, leads the completeplant project and is responsible forengineering, procurement, constructionand management.

ABB scope of supply is the totalintegrated power distribution and controlsystem from the 220kV GIS all the way tothe 400VAC plant wide distribution for thepower plant and the smelter. The SCADA(Supervisory, Control And Data Acquisi-tion system) has been integrated from thetop to the bottom. In addition also the400kV feeder protection system andSCADA interface as well as the telecominterface was supplied at the EMAL substation as well as the utility sub-stationside.

ABB’s power quality system Switch-syncTM, which has become industrystandard for switching large loadswithin Aluminium smelter substations,will energise all large loads withminimal power distortion impact to thefeeding generation plant and the powerconversion station.

ABB’s ELK-14, 300KV rated GIS

MIDDLE EAST ALUMINIUM INDUSTRY REPORT

external influences. The system is of amodular architecture and permitsindividual solutions that can be adaptedto changing needs at any time. Themodular design has the advantage of areduction in space requirement of up to40% compared to previous GIS systems.

The use of Aluminium enclosuresreduces the weight of the switchgear aswell as reducing cost for civil foundationsand load-bearing components.

The substation automation systemSAS690 is designed for controlling and

is a very demanding task for the EPCMengineers, normally ending up in a longlasting painful exercise. At EMAL allpower distribution levels 220kV, 33kV,6.6kV and 400VAC have beenintegrated on the same control andprotection architecture platform simpli-fying this task tremendously. The GISdesign is as such that the circuitbreakers can be controlled for switchingthree phase or single phase with aphase switching accuracy of less than1ms in difference.

This switching accuracy of the 220kVGIS circuit breakers is required to allowthe installation and make use of ABB’spower quality system SwitchsyncTM, forswitching large loads within Aluminiumsmelter substations with minimal powerdistortion impact to the feeding genera-tion plant and the power conversionstation.

The ELK-14 single-phase, earthedmetal enclosure, guarantees maximumoperational safety and reliability as allparts are enclosed and effectivelyprotected and insulated against negative

The 400/220kV step down transformer350MVA has also been fitted with thissystem to minimise inrush currents andprolong the equipments life time. The400kV feeding GIS switchgear for thestep-down transformer is also equippedwith ABB’s REC670 bay control unit tomake it possible to enable a plant wideinterface with the SCADA system.

One 220kV GIS Substation forpower plant and Smelter

With the location of the power plantand the smelter within a close area itwas possible to have a single GIS forthe power plant and smelter. The GIS onthe one side is directly connected to thegenerator step up transformers and onthe other side to the rectiformers andauxiliary power transformers. The inter-facing of the GIS controls and protection

SwitchsyncTM for highest powerquality performance

EMAL Control and protection architecture

Cooling design for 55° C PowerTransformers

MIDDLE EAST ALUMINIUM INDUSTRY REPORT

EMAL's advancedlooking forwardstrategy made the fullintegration possibleand will result in mostcost effective operation

the GIS and the 33kV switchgear toavoid long cable runs. Also at the EMALsite this was made possible due to acompact substation arrangement.

33kV Switchgear ZX2 with latestcontrol and protection relays

ABB’s ZX2 metal glad GIS insulatedmedium switchgear has been selectedby EMAL and is installed within the220kV GIS building allowing shortestcable connection from the GIS to thestep down transformers and to the 33kVswitchgear. The 40 breaker cubicleswith gas-tight busbar system in ahermetical sealed compartment as wellas the circuit breakers within their ownSF6 gas compartment guarantees forhighest safety operation standards andare in normal operation maintenancefree. Other features like stainless steelenclosure, modular design and plug inpanels make this type of switchgearsimple to install and operate. Thecontrol and protection relays areconnected via a serial bus to the mainsubstation control system reducing

220/33kV Power Transformers

ABB’s trafostar design is constantlyupdated and is used as a standarddesign within all ABB transformer facto-ries around the world. The standarddesign allows for a wide variation onambient temperatures which makes itsimple to apply. In particular for highambient temperature the coolingconcept and design is very important.As the ambient temperature at the EMAL

site can easy reach 55°C close attentionthe cooling of the transformers had tobe taken. The location of the smelterspower transformers is normally close

monitoring the primary and secondaryequipment of a substation. Typical appli-cations are substation for power utilities,industry and power plants. At EMAL allthree applications had to be integrated onthe SAS690 substation automationsystem. The SAS690 is part of ABB’sSAS600 series solutions for substationsautomation based on IEC61850. Itprovides the communication and integra-tion of ABB’s bay control and bay protec-tion solutions (REC670 and RED 670), allthe station level functions and as anoption the remote link to e.g. a networkcontrol centre.

The use of industrial Ethernet and thecompatibility of the station equipmentallow solution independent selection ofdifferent communication topologies toensure maximum performance andavailability to optimal cost. The use ofstandard hardware and Windows-basedapplications for the station computer /HMI (Human Machine Interface), allowsa system to be designed that is open forother Windows and MS Office-basedbusiness applications. It also makes iteasier to source spare parts locally andreduces the training costs for thesystem administrators.

UniGear Type XS1 rated up to 24kV ZX2 33kV Double busbar Metal glad GIS insulated switch gear

MIDDLE EAST ALUMINIUM INDUSTRY REPORT

Modular mechanicaland electrical principlereduces space andallows for flexible andcompact design

the GIS and the 33kV switchgear toavoid long cable runs. Also at the EMALsite this was made possible due to acompact substation arrangement.

33kV Switchgear ZX2 with latestcontrol and protection relays

ABB’s ZX2 metal glad GIS insulatedmedium switchgear has been selectedby EMAL and is installed within the220kV GIS building allowing shortestcable connection from the GIS to thestep down transformers and to the 33kVswitchgear. The 40 breaker cubicleswith gas-tight busbar system in ahermetical sealed compartment as wellas the circuit breakers within their ownSF6 gas compartment guarantees forhighest safety operation standards andare in normal operation maintenancefree. Other features like stainless steelenclosure, modular design and plug inpanels make this type of switchgearsimple to install and operate. Thecontrol and protection relays areconnected via a serial bus to the mainsubstation control system reducing

220/33kV Power Transformers

ABB’s trafostar design is constantlyupdated and is used as a standarddesign within all ABB transformer facto-ries around the world. The standarddesign allows for a wide variation onambient temperatures which makes itsimple to apply. In particular for highambient temperature the coolingconcept and design is very important.As the ambient temperature at the EMAL

site can easy reach 55°C close attentionthe cooling of the transformers had tobe taken. The location of the smelterspower transformers is normally close

monitoring the primary and secondaryequipment of a substation. Typical appli-cations are substation for power utilities,industry and power plants. At EMAL allthree applications had to be integrated onthe SAS690 substation automationsystem. The SAS690 is part of ABB’sSAS600 series solutions for substationsautomation based on IEC61850. Itprovides the communication and integra-tion of ABB’s bay control and bay protec-tion solutions (REC670 and RED 670), allthe station level functions and as anoption the remote link to e.g. a networkcontrol centre.

The use of industrial Ethernet and thecompatibility of the station equipmentallow solution independent selection ofdifferent communication topologies toensure maximum performance andavailability to optimal cost. The use ofstandard hardware and Windows-basedapplications for the station computer /HMI (Human Machine Interface), allowsa system to be designed that is open forother Windows and MS Office-basedbusiness applications. It also makes iteasier to source spare parts locally andreduces the training costs for thesystem administrators.

UniGear Type XS1 rated up to 24kV ZX2 33kV Double busbar Metal glad GIS insulated switch gear

MIDDLE EAST ALUMINIUM INDUSTRY REPORT

Modular mechanicaland electrical principlereduces space andallows for flexible andcompact design

use of standardised components allowsits flexible and compact design.Depending on customer requirement,operating and environmental conditionsdifferent designs levels are available.EMAL’s MNS low voltage switchgearwas manufactured at ABB’s Dubaiproduction facilities which alsoproduced EMAL’s control and protec-tion system for the 33 and 6.6kVswitchgear as well as the SCADAsystem for the MV and LV distributionsystem.

The consistent application of themodular principle both in electrical andmechanical design as well as the use ofstandardisation components allows itsflexible and compact design.

Summary

EMAL’s world first smelter fullyintegrated power distribution system willset new standards for green fieldsmelter. In line with ABB’s enabledIndustrialIT (Industrial InformationTechnology), the overall system integra-tion, maintenance simplification andafter sales services has been optimisedthroughout the plant. With the full scalelevel of integration the most cost effec-tive operation and maintenance as wellas spare parts management, has beenarchived with EMAL’s advanced lookingforward strategy. ■

Contact Information:Max Wiestner, Industry ManagerPrimary Aluminium, COEAluminium, ABB Switzerland,max.wiestner@ch.abb.com

switchgear is the most complete avail-able on the market, being able to counton vacuum and gas circuit breaker andvacuum contactors with fuses. All thisapparatus is interchangeable inside thesame switchgear unit. This makes useof a single switchgear-user interfacepossible, with the same service andmaintenance procedure and operations.Apart from the traditional functionalunits, the solutions, compact unitsequipped with contractors with fusesand double busbar systems. The use ofthese units allows extremely efficientuse of space.

Low Voltage Switchgear type MNS

The MNS low voltage switchgearsystem is designed and built to be theheart of any modern, highly automatedmotor control or power distributionsystem. The consistent application ofthe modular principle both in electricaland mechanical design as well as the

cabling requirements by some 50 tonsof copper cables for such a large installation.

6.6kV Switchgear UniGear XS1

ABB’s UniGear XS1 is an arc-proof,air-insulated metal-clad type switchgearwhich is used in many different indus-tries on shore and off shore like oilplatforms and ships. The switchgear ismodular and built up by placingstandardised units side by side in acoordinated way. The switchgear issimple and apparatus and instrumentscan freely be configured. The functionalunits of the switchgear are guaranteedarc proof in accordance with ICE 62271-200 standards. All start up and serviceoperations can be carried from the front.The switchgear and the earthingswitches are operated from the frontwith the door closed. The switchgearcan be installed close to the wall. Therange of apparatuses for UniGear

MIDDLE EAST ALUMINIUM INDUSTRY REPORT

Typical MNS Low Voltage Switchgear

Reprinted from Aluminium World 2009 Volume2Published by Sovereign Publications

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Contact us

ABB Switzerland LtdSegelhofstrasse 9PCH-5405 Baden 5 DaettwilSwitzerlandPhone: +41 58 586 84 44Fax: +41 58 586 73 33E-mail: process.industries@ch.abb.com

www.abb.com/aluminium