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Seat at Government table 7Introducing our new general manager 10New-generation GIS 12FACTS order in Saudi Arabia 16A new lease of life for ageing switchgear 26ABB Tropos: private wireless communication 30

New HVDC circuit breaker hailed as game-changer 8

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power products and power systems

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

From the Editor

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Dear Reader, Welcome to the first edition of ffwd in 2013! 2012 was a good year for ABB Power Products and Power Systems, and we're looking to build on our successes in the coming year. As you will see, this edition of ffwd is packed with our latest news, not least the recent announcement of another world first from our R&D people: the HVDC circuit breaker. The HVDC breaker has excited global media coverage, raised awareness of ABB in the public eye and differentiated us as a technological pioneer to investors and customers. To industry insiders, it’s a product that’s been an aspiration since the earliest days of power transmission. You can read about it on page 8. Looking at the broader picture, ABB Power Products and Power Systems is continuing to perform well as a business. Despite the ongoing economic uncertainty you, our customers, continue to give us your business and it’s my sincere hope that this is down to our focus on satisfying your business needs, striving for excel-lence in serving you, and learning from your feedback.

Stephen Trotter Division Head of ABB Power Systems UK

I was very pleased that Stephanie McGregor was attracted to join the ABB family to help grow our Grid Systems busi-ness in the UK. She brings unique insight into the regulatory side of offshore trans-mission, as well as strong experi ence in managing and delivering infrastructure projects, as detailed on page 10. I’m very excited about our prospects as the market in interconnectors and network reinforce-ment develops. I would also like to extend a warm con-gratulations to Robert Waythe, who we have just appointed as our Head of Sales for Power Products & Systems and also to John Edwards, our new General Manager for High Voltage Products in the UK. My best wishes for a successful 2013!

Stephen Trotter

ffwd power products and power systems 1/13 • The customer newsletter of ABB Power Products and Power Systems • Subscription Newsletter available as printed or electronic copy. Subscribe online at www.abb.co.uk/ffwd • Contact and feedback [email protected] • Publisher ABB Limited, Power Systems Division, Oulton Road, Stone, Staffordshire ST15 0RS. Phone 01785 825050

Power products and power systems

ABB Power ProductsPower Products are the key components for transmitting and distributing elec-tricity. 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.

ABB Power SystemsPower 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. 8 HVDC

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Content

Power products and power systems

18 2012’s intake of apprentices

News4 News on major contracts and developments in ABB

HVDC8 The world’s first HVDC breaker

Grid Systems10 Introducing Stephanie McGregor11 New substation for Sloy

Substations12 New-generation GIS shrinks by one third20 Power security in Docklands

Technology focus14 Environmentally friendly circuit breaker33 Reusing batteries from the Chevy Volt

Protection and control15 Additions to Relion range of controllers 30 ABB Tropos introduces private wireless networks

Rail16 FACTS order in Saudi Arabia17 ZX switchgear range launched for railway applications

28 A world first for UFES

Talent management18 Jon Clarke welcomes new apprentices19 East Kilbride office

Transformers22 Vacuum tap-changers

Energy storage24 Recovering braking energy

Medium voltage26 ENA retrofitting of MV breakers

Project focus28 Retrofitting arc protection on AIS

Corporate social responsibility32 Supporting Special Olympics GB

Cable34 World’s largest cable ship in service for ABB

Forthcoming events35 ABB’s 2013 programme of events

20 Future-proofed power supply for Telehouse


News

Rugeley AVR upgrade completed

ABB recently commissioned an up -grade to the Automatic Voltage Regulators (AVRs) at Rugeley

Power Limited’s 1,000 megawatt (MW) coal-fired power station in Staffordshire. Built in the 1960s, the power station’s original AVRs needed an upgrade, which is why the station’s operator called on ABB

for its technical expertise and extensive experience in retrofitting excitation systems. Working closely with Rugeley Power’s in-house team, ABB fitted two new UNITROL 6080 AVRs with dual auto channels and dual power converters to replace the orig inal units.

I n October 2012, ABB completed the upgrade of the human–machine inter-face (HMI) at the Medway Power Station

in Kent to ABB’s Symphony power gen-eration portal. The project, a full turnkey upgrade, saw ABB UK installing and commissioning the

full system on around 500 screens which control the 668 MW combined-cycle gas turbine power station, including power balance and operation of two gas turbines and a steam turbine. The project included graphics conversion, interfacing to the server and training the station staff.

Kent power station upgrades to Symphony

Key to the upgrade was keeping the same ‘look and feel’ of the old system, a consideration which avoided any operator confusion or additional training. With this in mind, the Symphony system is backward-compatible while adding new functionality.

Rugeley Power Station

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News

Sectos disconnectors to boost rural reliability for UK Power Network

In a drive by UK Power Networks to boost the reliability of its rural distribu-tion networks, ABB has won the first

major UK order for its Sectos switch disconnectors. The pole-mounted equip-ment will help improve UKPN’s record for customer minutes lost throughout north Suffolk and southern Norfolk, the dis-tribution network operator’s most rural networks. UK Power Networks selected the ABB Sectos NXB disconnectors as they meet stringent specifications and are cost-effec-tive and easy to install. The three-phase Gas-Insulated Switchgear (GIS) switches will be rated at 630 amps (A) and 12 kilo-volt (kV) and supplied with integral current transformers and auxiliary voltage trans-formers. They are designed for the most demanding climatic conditions and can be operated manually if required. The units’ role will be to subdivide the network and reroute power when a fault occurs in order to limit power loss to as few homes and businesses as possible. An additional benefit is that they offer a degree of future-proofing, as they are designed to be compatible with anticipated smart grid developments.

Northern Powergrid transformer framework deal

Northern Powergrid has just signed a three-year framework agreement with ABB to supply power trans-

formers for projects to build and upgrade distribution substations in the north of England. ABB has already received 11 firm orders under the deal, which will see transformers

rated at 33 kV, 66 kV and 132 kV installed to distribute electricity safely and reliably to consumers across north-eastern England, Yorkshire and northern Lincolnshire. The move will benefit both the electric-ity distributor and ABB, as recognized by Steven Blanche, General Manager of ABB’s UK transformer business:

“This gives Northern Powergrid complete visibility of costs in advance, while being able to rely on certainty of supply and consistency of design. We have greater flexibility and visibility of orders, which enables us to optimize the workflow through our factories.”


News

A BB has received instructions for 16 shunt reactors from National Grid for substations across the UK.

The orders result from a 2010 framework agreement awarded to supply 400 kV and 275 kV shunt reactors to integrate energy produced by onshore and offshore wind projects. Shunt reactors are a type of transformer designed to overcome the problems posed

National Grid shunt reactor order

by reactive power, which is generated by electric fields acting along lengthy alternat-ing current (AC) transmission lines such as those from wind farms. Left unmanaged, reactive power can lead to the periodic reversal of the flow of energy. The reactors are lightweight and compact and compensate for reactive power with lower losses from noise and vibration.

Funding tidal power innovation

ABB Technology Ventures, ABB’s venture capital arm, is making a £5 million investment in Scot renewables

Tidal Power Ltd (SRTP), a tidal energy technology firm based in Orkney. SRTP has created a floating tidal generator designed for easy and low cost installation and opera-tion. A prototype model has performed well under testing, inputting energy into the

national grid and performing well in a range of tidal speeds. The investment by ABB, along with funds from the Scottish Government, French oil company TOTAL and Norwegian marine firm Fred Olsen, will fund the develop-ment of a 2 MW tidal energy farm off the Orcadian coast, planned to come online by 2015, which would demonstrate com-

mercialisation of the generator. SRTP’s Chief Technical officer, Mark Hamilton, said: “ABBs involvement will allow us to tackle complex cabling and grid connection challenges thereby speeding the technology development process.” Visit www.scotrenewables.com to find out more.


News

The UK Secretary of State for Energy and Climate Change, Edward Davey demonstrated the Government’s

recognition of ABB as a leading player in the wind energy market when he invited Stephen Trotter, the Managing Director of ABB’s Power Systems business in the UK, to sit on its new industry-led board. The Offshore Wind Programme Board pulls together experts from industry, along with representatives from the Government, Crown Estates and conservation advisors. Set up in response to a recent recom-mendation by a Government task force, the Board mirrors a similar approach for the oil and gas sector and aims to bring down the cost of wind power and reduce barriers. Edward Davey said, “I am appointing members to the Offshore Wind Programme Board with the skills and experience to drive down costs, tackle barriers to offshore wind and develop the UK supply chain.”

Seat at Government table demonstrates wind energy leadership

Around 100 of ABB’s 25-0-25 kV trackside autotransformers will be supplied to Network Rail over the

next three years to support the UK’s rail electrification. A major UK-wide framework agreement signed in December 2012 builds on ABB’s record of supplying autotransformers on Phases 1 and 3A of the West Coast Main Line.

Autotransformer deal with Network Rail Rated at 15 megavoltamperes (MVA), the 25-0-25 kV autotransformers comply with Network Rail’s guidelines for 12 kiloamp (kA) infrastructure. ABB revised the design of its autotransformers in the lead up to the framework agreement to reduce the lifetime energy usage by the autotransformer by around 30 per cent – a particular benefit for sites with relatively low rail traffic, where

no load losses become more significant. “Our autotransformers have established a reputation for excellent performance and reliability,” said Bryce Denboer, ABB Sector Manager for Rail.


Tomorrow’s supergrid comes a step closerAnnounced in November, the news that ABB has developed the world’s first HVDC (high voltage direct current) circuit breaker is being hailed as a development which will transform the world’s energy market.

High voltage direct current valve hall

HVDC


The breakthrough removes a 100- year-old barrier to the develop-ment of DC transmission grids,

which will enable the efficient integration and exchange of renewable energy. The new technology breakthrough will enable power utilities to increase the capacity of power lines, reduce footprints and use subsea and underground high-voltage cables, which is not possible with AC. Developing an HVDC breaker is a chal-lenge that is as old as high-voltage trans-mission itself and was central to the ‘war of the currents’ – a debate which raged in the late 19th century which saw DC (pro-moted by Thomas Edison and GE) pitted against AC (supported by Nikola Tesla and Westinghouse). AC won the battle at the time as it was simpler to control and well suited to the applications of the day, but DC still has the advantages of higher capacity, smaller footprint and lower transmission losses, particularly over long distances. It is the lower losses and the suitability for undersea lines which has seen DC grow in importance in recent years, particularly for the UK energy market. Although HVDC lines and interconnectors already exist, they are point-to-point lines and a fault would see the power cut off completely, with the risk of a blackout. The advent of HVDC circuit breakers will allow utilities to build grids with the security of supply brought by having multi-terminal configuration.

Game-changerLegally binding targets to reduce carbon emissions and the challenge of integrating intermittent renewables have prompted the UK Government to conclude that the logical step for ensuring a reliable low-carbon energy supply is through subsea interconnectors and so the next decade will see huge growth in this area. The UK has been working with France, Germany, Norway and Sweden to create an offshore energy grid to link wind farms and other energy sources through the proposed North Sea Offshore Grid. The UK’s energy minister even visited Iceland in May 2012 to investigate the potential for an interconnector to import geothermal energy from Iceland, which would require the world’s longest power cable at a length of up to 1,500 km laid over a mid-ocean ridge. But without an adequate means of control, all of these interconnectors would

be relatively simple point-to-point lines, which is why the recently developed HVDC circuit breakers are being heralded as a game-changer. The vision is to integrate the UK in a reliable Europe-wide super-grid, which pools wind and wave energy from the North Sea, hydro power from Scandinavia and the Alps and solar power from southern Europe as well as the potential geothermal energy from Iceland. Undersea intercon-nectors will provide a back-up to renewable energy so that when the wind dies down or the sun doesn’t shine, energy can be imported without the need for traditional high-carbon fuels. The launch of the new breaker marks the culmination of many years’ effort by ABB’s global R&D team, which has resulted in a breaker capable of blocking and break-ing DC currents at thousands of amperes and several hundred thousand volts while minimizing losses. And the next step? ABB is now planning to deploy the breaker in pilot installations, where it will prove itself by protecting DC transmission systems and prevent power outages. ABB CEO, Joe Hogan said of the new breaker: “ABB has written a new chapter in the history of electrical engineering. This historical breakthrough will make it possible to build the grid of the future. Overlay DC grids will be able to interconnect countries and continents, balance loads and reinforce the existing AC transmission networks.”With these recent advances and ever-mounting political pressure for a sustainable energy supply, the new innovation comes

at the right time to develop the HVDC grids of the future. Find out more at abb.com/hvdcgrid.

So how does it work?Although it has been possible to break HVDC circuits using power electronics, losses were too high for commercial use. ABB's new breakers are capable of con-trolling a power supply for two million Europeans in five milliseconds, which is the same time it takes for a honey bee to flap its wings or one-thirtieth of the time it takes for a human to blink an eye. It sounds deceptively simple. The breaker is a hybrid combination of an ultra fast-acting mechanical actuator and ABB's insulated gate bipolar transistor (IGBT) valve, otherwise known as the power electronic element. Together, these have low losses and are very fast acting. Under normal operation, the current flows through the path of least resistance, in this case a power electronic breaker and mechanical breaker in series. Tripping the breaker is a three-stage process. The first power electronic breaker is tripped, prompting the current to flow through a parallel circuit through a high-resistance main power electronic breaker. It’s this action which overcomes the arcing which would normally occur when the mechanical breaker is fired. The third step is when the main power electronic breaker, having a high resistance which has reduced the current, completes the breaking process.

HVDC

Hybrid DC breaker

Fast disconnector Auxiliary DC breaker

Main DC breaker

Currentlimitingreactor

ResidualDC current

breaker

Schematic diagram of the hybrid HVDC breaker


Grid Systems

Introducing our new General Manager for Grid Systems

Stephanie McGregor General Manager of Grid Systems

H aving joined ABB as General Manager for Grid Systems UK in early September 2012, my role is

to oversee the ambitious growth plans that we have for the UK market. Right now, I am responsible for leading the team that works on the design, engineering, project management and delivery of major proj-ects crucial to upgrading and enhancing the UK’s high-voltage power transmission infrastructure. I’ve spent the past four years oversee-ing the establishment and implementation of a new offshore transmission regime as director for offshore transmission at Ofgem, where I introduced competitive licensing to the emerging market. Prior to Ofgem, I worked for John Laing as Bid Director for projects to build and develop new community infrastructure such as schools and hospitals. At Ofgem, I was aware of ABB as one of the main suppliers into the market. I was attracted to join the company because to me, supply chain and R&D are the most interesting parts of the market and it’s a space where ABB is well and truly established.

Long-term, the role offers many interest-ing new prospects. I already have expe-rience in managing and implementing large-scale infrastructure in a number of sectors. I’ve been a procurer and a client, I've managed contractors and have unique regulatory experience in offshore wind in the UK. I am now able to bring this insight into a new role as a supplier. The big picture is that ABB intends to be a lead player in offshore wind, intercon-nection and HVDC in the UK. I foresee significant growth in the market and we’re also looking for a bigger share. There’s a lot of fantastic innovation at ABB that can be applied intelligently to solving many of the grid challenges that our customers face. Looking to the future, the big trends in grid projects are going to be intercon-nections and network reinforcement. ABB is making key developments in the sup-porting technologies vital to make them happen, including the game-changing hybrid HVDC breaker. With our strong and highly experienced workforce in the UK and the in-depth knowhow that comes from having grown up with the UK market, we are ideally placed to meet the specific needs of our grid systems customers.

Meet Stephanie McGregor, recently appointed General Manager for Grid Systems in the UK. She told ffwd about her current role, past experience, why she joined ABB, her unique insight into the UK’s regulatory environment for offshore transmission and how the Grid Systems business will meet the challenges of the future.


Grid Systems

Built in 1950, the plant is the most powerfu l in Scot land, with a capacity of 152.5 MW – enough

power to supply almost 250,000 people in Glasgow and the surrounding area. SSE is building a new pumping station at Sloy, which will enable it to pump water up from Loch Lomond to Loch Sloy during times of low electricity demand and release it to generate an extra 100 gigawatt hours (GWh) of electricity annually to meet peak demands. The new substation will help ensure that Sloy continues to meet Scotland’s energy demands well into the future. To ensure the substation is ready for

hand-over at the end of 2013, ABB engi-neers will manage construction throughout the winter months, which will bring extra challenges in such a remote location. With the latest GIS equipment, Sloy’s new substation will be around one-fifth the size of its predecessor, meaning it can be housed in a building designed to blend in with the setting of the Loch Lomond and Trossachs National Park. Clad in granite tiles and with a low profile, the new struc-ture will be built alongside the existing sub-station, which will then be dismantled and the land returned to its natural condition. Speaking about the office in East Kilbride, which opened in January 2012,

Stephen Trotter, head of ABB’s Power Systems Division in the UK said: “Scotland is a key element in ABB’s long-term strate-gic growth plans, especially as wind farms and other renewable energy sources such as wave and tidal power play an increas-ingly important role in the overall energy mix.” The team at the East Kilbride offers combined expertise in substations, HVDC, FACTS, power cables, onshore and off-shore wind, power generation and railway electrification

New electricity substation for Sloy hydroelectric power station ABB’s engineering team in East Kilbride has been selected to fast-track the construction of a new high-voltage gas-insulated switchgear (GIS) substation and the decommissioning of old air-insulated switchgear (AIS) at the Scottish and Southern Energy (SSE) Sloy hydroelectric power station in the Loch Lomond & Trossachs National Park.

The existing Sloy substation


Substations

New-generation GIS shrinks by one-third


Substations

Launched in April, ABB’s new generation of 420 kV gas-insulated switchgear (GIS) in its ELK-3 range has shrunk in size by a third, an innovation which will see customers make financial savings from smaller substations and simpler construction, reduce risk and improve their environmental credentials without compromising performance.

When ABB introduced the first generation of GIS in the mid 1960s, it represented a leap

forward in switchgear technology, allowing energy firms to reduce the size of sub-stations substantially. We’ve been at the forefront of developing the technology ever since and our latest ELK-3 compact 420 kV equipment delivers high perfor-mance in the control, protection and isola-tion of electrical equipment at a size that is smaller than ever. We can safely say that being one third smaller in volume than its predecessor, the size of the latest ELK-3 GIS is designed to give ABB’s customers several advantages.First among these is that the compact size will allow design engineers to consider the switchgear for installations where space is at a premium. In urban settings where land is expensive, this can be significant. New substations will benefit from smaller infrastructure costs and smaller substa-tion buildings and it may be possible to free up space at existing substations for alternative use. Installation and commissioning costs are also areas of significant saving due to the size of the new generation ELK-3. Because it is that bit smaller than the pre-vious models, it’s possible to transport as a single unit on a flat rack or low bed truck. This means that ABB is now able to factory assemble, test and ship the ELK-3 switchgear as a single bay in a container

rather than as multiple units that need to be assembled on-site, an exercise which only adds to the complexity and length of a project. We’ve found that supplying switch-gear in single bays can lead to installation and commissioning times which are up to 40 percent shorter than for traditional GIS designs, which is no mean feat. The further advantage of factory assembly is the knowl-edge that because it has been assembled and tested, customers can be assured of its quality, meaning that risk can be taken out of the construction and commission-ing process, a factor which will appeal to those with roles in operation, engineering and their colleagues in finance. The ELK-3’s environmental credentials are also an improvement on older models. Because it’s smaller, the switchgear uses up to 40 percent less insulating SF6 gas making its environmental impact lower.Once installed, the product’s fast single-interrupter dual motion circuit breaker has been designed for current ratings of up to 5,000 A and is capable of providing protection to power networks with rated short-circuit currents up to 63 kA. The latest generation 420 kV GIS builds on ABB’s recent developments in 245 kV and 72.5 kV switchgear and the approach to the design places drives, position indi-cators and service platforms at the front of each unit, enabling easier operation, inspection and maintenance.

Being a construction of standard modular components, the switchgear is designed around common substation layouts and with an eye on future developments, we also offer the option to integrate features for smart and digital substations.

Scottish Power first to benefitIn October 2012, the ELK-3 GIS attracted its first UK customer in SP Energy Networks. The Scottish Power subsidiary placed an order for 15 bays of the new unit, which will help the firm integrate the growing levels of wind power production in southern Scotland. Planned to go into operation during 2013–15, the plant represents an invest-ment of around £16 million in integrating renewable energy sources into the Scottish power market, which has traditionally relied mainly on fossil and nuclear fuels. The switchgear will be installed at two brand new substations, at Hunterston and Wishaw, and as an upgrade to an existing substation at Torness. Brice, Koch, head of ABB’s Power Systems division said: “These substations will help integrate and deliver cle an wind energy to the people and streng th en the transmission grid in the region. We are pleased to support the development of Scotland’s power infrastructure with some of our latest offerings.”


Technology focus

SF6 has been the gas of choice for gas insulated switchgear since the 1960s and its introduction saw

switchgear shrink to around one-fifth the size of preceding air insulated switchgear. It’s the strong bonds between the atoms in molecules of SF6 that makes the gas an excellent insulator and these bonds resist the molecular breakdown which causes arcs to form. This comes with an environmental price tag, however, as SF6 is the most potent of all greenhouse gases, a fact which led to a 2006 ban from all applications other than high-voltage switchgear. Its global warming potential adds to the cost and complexity of decommissioning and dismantling old substations.

First viable SF6 alternativeABB has been carrying out extensive research and development for a number of years to minimise the use of SF6. The new LTA platform represents the first viable alternative to SF6 circuit breakers, rep-resenting a potential reduction in CO2 emissions of 10 tonnes through the life of a circuit breaker, or 18 per cent less than its predecessor. The new LTA CO2 live tank high-voltage circuit breaker starts at 72.5 kV and is based on the same principles and compo-nents as the SF6 alternative. It has excellent switching performance and is available as a conventional circuit breaker and as a dis-connecting circuit breaker, which eliminates the need for a separate disconnector. A 145 kV pilot installation of the new switchgear, comprising 132 kV bays and nine 45 kV bays, has been working per-fectly for more than two years at a pilot site in Sweden operated by Vattenfall,

one of Europe’s largest energy generators and its successful operation confirms the technology is now ready for market. “This is yet another ABB innovation mile-stone and reaffirms our ongoing commit-ment to minimizing environmental impact,” said Giandomenico Rivetti, Head of ABB's High Voltage Products business. “This CO2 breaker is part of our strategic thrust to develop eco-efficient high-voltage products with increased reliability.

Switchgear that gives ABB the environmental edgeABB announced another world first at the 2012 Cigré technical exhibition in Paris, when it launched its LTA high-voltage circuit breaker: the first to use carbon dioxide (CO2) instead of sulphur hexafluoride (SF6) as the insulator gas.

LTA CO2 circuit breaker


Protection and control

The new 611 series includes three units for protection and control of busbars, feeders and motors. ABB

has also added to the 630 product line with a new generator management unit, which is designed for controlling small and medium-sized generators fuelled by diesel, gas, hydroelectric, combined heat and power and steam. Because ABB has designed the function-ality of the IEDs to be based on standard configurations, they require less engineering to integrate into clients’ control systems and offer faster commissioning.

The Relion range is designed to offer simple and powerful protection and control solutions for utilities and industrial applica-tions. With a patented mechanical design, any member of the Relion range can be easily and securely inserted and plugged in. The range is designed with interoperability in mind and meets the IEC 61850 compat-ibility standard for substation devices. The easy-to-use Web-based Human–Machine Interface (WHMI) enables operators to set parameters and signal configurations for the new devices, as well as the existing members of the Relion range.

The new members of the Relion family have been designed with similar functional-ity and look and feel as existing members, meaning that they’ll be a good fit for sub-stations where Relion devices are already fitted.

New additions to Relion range of IEDs

ABB recently added to its cost-effective range of Relion intelligent electronic devices (IEDs), which play a role in energy supply by providing control and protection for medium-voltage substations and power systems.


Rail

As part of the turnkey solution, ABB will design, supply, install and commission two identical static var

compensators (SVCs) at the Haramain High Speed Railway’s (HHR) 380 kilovolt (kV) substations. These installations will support the large scale railway intercon-nection between the cities of Mecca and Medina. The project is scheduled to be completed by 2015. This is the biggest FACTS order received so far by ABB and Brice Koch, head of ABB’s Power Systems division said of the deal: “This solution will help strengthen the transmission grid and enhance reliability of power supply to important rail links being developed in Saudi Arabia. SVCs are part of ABB’s family of FACTS technologies, which help enhance the capacity and flexibility of power transmission systems and also

contribute to the development of smarter grids.” The project builds on ABB’s experience of delivering railway projects for SEC, including a 2001 order for $85 million to supply 380 kV indoor gas-insulated switchgear (GIS), a key component of the new substations to power the 444 km long high-speed Haramain rail line. These substations will supply electric-ity to high-speed (360 kph) electric trains that are expected to help transport about three million passengers annually. The railway will link the pilgrimage cities of Mecca and Medina via the King Abdullah Economic City, Rabigh, Jeddah and King Abdulaziz International Airport. The new rail line is expected to reduce traffic con-gestion on the roads, and will cut travel time between Medina and Mecca from six hours to two.

About FACTSFACTS (Flexible Alternating Current Trans-mission Systems) techno l ogies allow more power to reach consu mers with minimal environmental impact, lower investment costs and shorter implementation times than the traditional alternative of building new power plants and transmission lines. They also help address voltage and frequency stability issues and enable the transmission system to run more efficiently. Along with smartphones and digital photography, the IEEE (Institute of Electri-cal and Electronics Engineers) publication, Spectrum named FACTS among its Top 11 technologies of the decade. ABB is a pioneer and global leader in the growing field of FACTS, and has delivered more than 800 such installations across the world.

Record order for FACTSIn October, ABB won its largest order to date for FACTS. Worth around $115 million, the deal will see Saudi Arabia’s national power transmission and distribution operator, Saudi Electricity Company (SEC), implementing a FACTS (flexible alternating current transmission system) solution to enhance the reliability of the transmission grid that feeds the country’s major railway interconnections.


Rail

As a ‘plug and play’ option, ABB can also supply the ZX1.5-R as part of its compact substation portfolio, in

which comes with all the medium- and low-voltage switchgear, protection equipment and battery backup systems in a robust steel container. Being based on ABB's three-phase GIS ZX technology, the new switchgear takes up to 70% less space than conventional options and is based on a modular and flexible design. Inside the panels, the switchgear uses single busbar, two-phase (or single-phase) technology. It provides excellent maint-enance performance thanks to its internal layout, which houses individual gas compartments in their own panel. Operationally, this leads to low mainte-nance requirements and lower total invest-ment and operating costs, with a higher mean time between failures (MTBF) and lower mean time to recovery (MTTR), as a panel can be removed from a switchboard and the switchboard re-energized without any SF6 gas handling. As with all members of the ZX range, installation and commissioning risks to personnel and the environment are kept

to a minimum because the arc quenching SF6 gas used for insulation is sealed for life into switchgear units at ABB’s factory, meaning there is no need for gas handling on site. The new switchgear is already in use in major global infrastructure projects, such as China’s high-speed railway network, where it is helping provide safe and reli-able power along the entire rail line. Back in the UK, ABB has won its first order outside China from Network Rail, which is trialling the ‘plug and play’ option at several sites on the West Coast Main Line (WCML) between Stoke and Warrington,

after ABB was awarded Network Rail’s Trial Approval Status. Bryce Deboer, ABB's Sector Manager for Rail, said: “The technical capability of the switchgear is of course important. But for Network Rail it is delivery on time and on budget that is critical. Our UK team played a crucial role in demonstrating that we have the in-depth engineering support to deliver the project successfully.” ABB anticipates that ZX1.5R will receive Full Product Approval from the Network Rail Acceptance Panel (NRAP) once it has proven itself on the WCML.

ZX switchgear now available for railwaysABB has introduced a new version of its ZX switchgear specifically aimed at railway applications. The ZX1.5-R models extend the proven range, widely used in industrial and utility sites, to meet the specific requirements of two-phase supplies for high-speed lines and single-phase 25 kV applications.

01 The ZX1.5R powers China’s high speed railway | 02 ZX1.5R panels

02

01


Talent management

All ABB power systems projects are underpinned by a strong team of more than 150 design engineers,

working in groups focused on the key areas of substations, rail, network man-agement, service, power generation and HVDC. This significant resource is now being further reinforced by a major recruit-ment drive to ensure that we have the capacity to meet our ambitious plans for future growth. While we have opportunities at just about every level, with fewer people now studying engineering at university we face significant challenges in finding and keeping the best people. That’s why we are invest-ing in our own apprentice scheme, focused on growing our own design engineers.

"You're hired"We were very pleased to say "you’re hired" to the 2012 intake of recruits to our highly successful design engineering apprentice scheme based at Stone. They are now on the road to an exciting and rewarding career in electrical engineering that com-bines real-world experience with rigorous tuition and guided study in association with Newcastle-under-Lyme college in

Staffordshire. This is the second year that we have been running this specialised two-year scheme, which is designed to take appren-tices up to BTEC Level 3, although we expect that at least half of these will go on study at degree level. Applicants go through a rigorous assessment process, which aims to uncover their practical apti-tude and abilities, rather than simply focus on academic achievements. The success of this selection process is reflected by the results from our first intake in 2011, with a 100 per cent pass rate and the majority at distinction level.

Making a real contribution from day oneThe scheme is structured to combine study, training and practical work in a way that enables young people to make a real con-tribution to our business, virtually from day one – to the extent that nearly half of the time worked by our 2011 apprentices was directly attributable to customer projects. The scheme has also created a fantastic level of engagement across our engineer-ing teams, with established staff providing a great deal of input and encouragement.

Our senior management are particularly involved and with many of them having come through apprentice schemes them-selves they are keen to encourage this new generation to follow in their footsteps. The apprentices themselves are also encouraged to become involved in attract-ing more young people into engineering. For example, they are helping to drive our schools' support programme which offers a route for pupils to become actively involved with ABB, from taking part in our school support day to joining us on work experience. Perhaps the finest illustration of the quality of our scheme is that Gareth Hall, who recently completed his apprenticeship, was the National Skills Academy for Power Apprentice of the Year for 2012. Gareth is now taking the next step in his studies by starting a foundation degree course sponsored by ABB. We were also excited to have Gareth as one of our representa-tives at a recent House of Commons event hosted by ABB and attended by over 200 parliamentarians and customers.

Developing talent in houseJon Clarke, ABB Engineering Support Manager, explains how ABB is building its engineering design resources at all levels.

Engineering Support Manager Jon Clarke with the 2011 and 2012 apprentices


Talent management

Powering up in ScotlandAt the start of 2012, ABB established a new office in East Kilbride to provide a Scottish hub for our Power Systems division. This effective local presence now enables customers such as Scottish Power and SSE to access ABB’s state-of-the-art solutions to support the major investments they are making to expand and upgrade Scotland’s transmission and distribution systems.

The new office, at the Technology Centre on the Scottish Enterprise Technology Park in East Kilbride,

provides the base for more than 30 new posts working on the full project delivery – from inception, tendering and design through to commissioning and hando-ver – of the many multi-million pound schemes crucial to upgrading and enhanc-ing Scotland’s high-voltage power trans-mission and distribution infrastructure to integrate the country’s fast-increasing level of renewable energy generation. Although this is the first ABB Power Systems office in Scotland, ABB already has an established and thriving business in Aberdeen, which mainly serves 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. The new office in East Kilbride will bring ABB closer to its Scottish customers and to a local supply chain to help us deliver construction projects. In addition, ABB has strong links with many universities in Scotland as well as trade bodies such as Scottish Renewables. The initial roles at East Kilbride are focused around sales and tendering, elec-trical and civil engineering and project management, as well as various profes-sional support services. These will be

supplemented with a variety of construction skills, such as site management and super-vision, installation teams, commissioning engineers and technicians. In addition, ABB is working with a range of local civil and electrical construction companies to carry out activities such as cable installa-tion, civil works and erection of electrical equipment. Many of the energy projects in Scotland are in the early stages of development, with some not due to start for several years. However, ABB recognizes the role we can play in helping to shape and develop these projects, ensuring that the right technolo-gies and solutions are used to deliver a robust and cost-efficient energy strategy.

East Kilbride engineers are working on a new substation for Sloy


Substations

Future-proofed power security for TelehouseTelehouse, a leading provider of global data centres and managed ICT solutions, has successfully future-proofed the power supply for its London Docklands campus with the creation of its own primary 132 kilovolt (kV) substation. ABB was responsible for the turnkey project to design, supply, install and commission all the electrical plant from the high voltage gas insulated switchgear (GIS) and transformers to the low voltage switchboards.

01


Substations

Telehouse’s London Docklands campus houses the IT infrastruc-ture of around 500 major interna-

tional organizations as well as offering connectivity to internet service providers, carriers, operators and internet exchanges. Continuity and security of power supply for the server banks is absolutely crucial, so the site is supplied by four redundant 11 kV power systems on separate grids to ensure maximum redundancy and reli-ability levels of 99.999%. The decision to create the new primary substation was driven by the desire to meet the increased demand for power from the latest addition to the Docklands campus – the state-of-the-art Telehouse West Building. At the same time, there was a desire to provide even greater levels of reliability and protection for the electricity supply.

Increasing demand to 40 MVAPreviously, the campus had a peak demand in the order of 13.5 to 15.6 megavoltam-pere (MVA), while the new West Building was estimated to require 14 MVA, result-ing in a total peak of 29.6 MVA. This figure excluded future load growth within the existing buildings. There was also a need to allow for future expansion in the order of an additional 10 MVA. This resulted in a projected maximum demand of 40 MVA. After carrying out detailed cost studies, it was decided by Bob Harris, Telehouse’s Technical Services Director, that the most cost-effective route to providing more power for the site would be to replace its existing metered feed from the UK Power Networks 11 kV distribution network with a direct connection at 132 kV. This would also enable Telehouse to take full advan-tage of the reduction in DUoS (distribution use of system) charges payable to the distribution network operator (DNO). Telehouse brought together a consortium of consultants to carry out a turnkey project for the new primary substation including: Arcadis – the lead consultants, Mace – building and civil works; WSP – M&E; YRM – Architects. Telehouse/Arcadis issued ABB with an invitation to tender for the design, supply, installation and commission-ing of the electrical network in the summer of 2010.

Tapping into a 132 kV circuitTo create the new connection, ABB has tapped into the existing UK Power Networks 132 kV circuits. These have been linked by

two diverse 500 metre underground cable circuits feeding through the new indoor substation within the Telehouse campus. The use of ABB’s state-of-the-art compact ELK-04-735 gas insulated switch-gear (GIS) technology enabled the substa-tion to be constructed within a very small footprint. As part of the GIS specifica-tion process it had to undergo a rigor-ous approval procedure with UK Power Networks, this was achieved successfully with the full support of Telehouse. Dual redundancyThe network has been designed for dual redundancy (on a 2N basis), so if the normal live feed should be interrupted it will switch seamlessly to the alternative feeder route. This has required the doubling up of key equipment, such as two banks of 132 kV GIS together with two ABB 33/50 MVA 132/11 kV grid transformers. ABB also designed, supplied and installed the sub-station protection and control equipment. On the secondary distribution side, ABB has installed UniGear 2500 A, 11 kV switchgear as well as all the ancillary equip-ment including 350 kilovoltampere (kVA) auxi l iary transformers, earthing resistors, substation earthing, batteries and battery chargers, SCADA interface and 415 V switchgear.

Contestable and non-contestable elementsA significant element in the project was the high level of liaison between ABB and

UK Power Networks on all aspects of the contestable and non-contestable elements of the work. A particular advantage offered by ABB is that it is one of a select group of companies accredited under the National Electricity Registration Scheme (NERS) operated by the Lloyd’s Register Group on behalf of the UK DNOs. This scheme provides technical assessment of service providers who elect to be assessed for accreditation for contestable works asso-ciated with the installation of electrical connections. This close liaison enabled UK Power Networks to focus on the non-contestable element – the provision of the connection point with sufficient capacity, while ABB delivered a project-focused single interface to design and construct the connection to UK Power Networks’ own standards. Due to its central London location and close proximity to a busy business district, a particularly important aspect of the project was to ensure that noise and disruption was kept to a minimum, especially while working in the Telehouse campus and the external areas for the high voltage cable routes. This required careful planning and execution, especially in the scheduling of deliveries and civil works. The entire Telehouse substation project was executed on a fast-track basis, from contract award in November 2010, suc-cessfully energizing in May 2012 with 11 kV connections available to support Telehouse’s business prior to the 2012 London Olympics.

01 ELK-04-735 gas insulated switchgear | 02 Unigear 11 kV switchgear panels

02


A tap changer is used to change the turn ratio between windings in a power transformer. This ratio

determines the voltage ratio between the windings and is essential for the stabi-lization of network voltage under vari-able load conditions. An on-load tap changer (OLTC) normally has a regula-tion range of ±20 per cent of the total l ine voltage. Regulation is performed in around 9 to 35 steps and is oper-ated between 10 to 20 times a day in normal grid applications. There is also a large demand for tap changers used in industrial transform-ers in rectifier and furnace applications. In some applications these may perform several hundred thousand switching opera-tions per year. Phase-shifting transform-ers (for management of power flow in AC networks) and HVDC transformers (for long-distance transmission and cou-pling of unsynchronised networks) are two other areas where there is an emphasis on voltage regulation.

Traditional diverter switch tap-changersThe majority of on-load tap changers in use today are based on the traditional diverter switch design, such as that used in ABB’s UCG type. The switching mecha-nism is mounted inside a sealed cylindri-cal, glass fibre-reinforced epoxy enclosure which permits separation of the oil inside the diverter switch unit from the oil in the transformer. This ensures that oil affected by arcing cannot contaminate the trans-former oil. Wear of contact surfaces due to arcing, as well as by-products from the oil, cause pollution in the form of particles. Smaller

particles will be suspended in the oil while larger particles will form sludge at the bottom of the diverter housing. UCG tap-changers are tried and tested and provide an extremely reliable and pre-dictable technology. The simple and rugged design ensures a service life equal to that of the transformer. Under normal grid con-ditions even the diverter switch contacts will last as long as the transformer but, in extremely demanding applications where there are an exceptional number of switch-ing operations per day, these may have to be replaced at some point. An overhaul is scheduled every seven years and includes cleaning of the mechanism, checking for contact wear, filtering the oil and checking the oil's dielectric strength.

Vacuum interrupter technologyIn the quest for greater efficiency and to meet key performance and financial targets like improved availability and cost reduc-tion, many transformer users worldwide are now embracing vacuum interrupter technology as an alternative that offers some distinct advantages. In these new-generation tap-changers, electrical arc quenching takes place in a vacuum and not in oil. This substantially reduces contact wear and residues from arcing do not pollute the insulating oil. The benefits of using a vacuum tap-changer include: – Lower lifecycle costs, less

maintenance and increased time in operation because of a radical reduction in contact wear

– A cleaner environment for routine inspection, which reduces downtime

– Reduced sensitivity to moisture in the insulating oil due to the absence of

polluting by-products such as carbon – Independence of switching

characteristics from the condition of the insulating oil

– Reliability due to the redundant contact system

– Full interchangeability with existing installations

– Possibility of using alternative insulating fluids

VUCGVUCG is the first in ABB’s series of vacuum tap-changers. They can be used in trans-formers up to approximately 500 MVA, which covers the majority of all transformers manufactured today. Both the UCG and VUCG models have identical housings and tap selectors. Only the diverter switch mechanism varies, so that the units are completely interchangeable, with no need to redesign the transformer itself. All conventional UCGs, even units dating back to when they were first intro-duced in the late 1970s, can be upgraded with vacuum technology as quickly and easily as performing a normal overhaul. In many cases this enables the tap-changer’s nominal load to be increased, while deliv-ering all the advantages associated with vacuum technology. Key VUCG technical data: – Maximum step voltage: 500 V – Maximum load current: 700 A for

three phase and 1600 A for single phase, without the need for enforced current splitting

– Lifetime: 1,000,000 operations, which is several times the lifespan of a typical transformer

Vacuum tap-changers – a logical progression for transformersSteven Blanche, General Manager Transformers for ABB UK, explains the advantages of the new generation tap-changers that utilize vacuum technology, so that arc-quenching takes place in a vacuum and not the transformer oil.

Transformers


VUCG vacuum tap changer

Transformers


SEPTA recovers energy from train braking

Energy storage

Pennsylvania gets on board the power train


Energy storage

For train operators like the Southeast-ern Pennsylvania Transit Authority (SEPTA), energy represents a huge

outgoing. SEPTA is the sixth-largest rapid transit system in the USA, serving the four million residents of Philadelphia and the surrounding area. SEPTA handles more than 300 million journeys by commuter rail, light rail, subway, elevated railway, bus and electric trolley bus and its annual energy consumption is in the region of 500 million kilowatt-hours (kWh). Almost half of SEPTA’s power is used to propel trains and, traditionally, significant amounts of energy is wasted every time trains brake. It was the desire to recover this wasted energy that drove SEPTA to ask ABB to provide a solution to capture, store and reuse it. Recovery and reuse of braking energy is well proven and is now widely used in hybrid electric vehicles and, more recently, by bus operators the world over. The solu-tion installed by SEPTA is based on ABB’s EnvistoreTM Regenerative Energy Storage System, which usually uses capacitors to store braking energy and release it again shortly afterwards to boost train acceleration. But for SEPTA’s application, the system has been taken a step further. The capaci-tors were replaced with high performance lithium-ion (Li-ion) batteries supplied by Saft, a world leader in the design and manufacture of advanced technology bat-teries for industry. Li-ion batteries are often used in railway applications because of their long life and high output voltage. The energy recovery and storage system is complemented with software that enables SEPTA to monitor energy prices and sell the stored energy back to the grid when energy prices are high, usually during peak hours and in hot weather, so helping reduce operational costs and creating a new revenue stream.

This ground-breaking application of energy recovery is not only proving finan-cially sound for SEPTA but is also helping the grid operator to keep the grid in equi-librium with an energy source which can be called upon at a moment’s notice – a service for which SEPTA can charge a premium. The heart of the operation is a substa-tion on one of SEPTA’s busiest routes, the Market–Frankford line. The substation serves five train stations and the Li-ion batteries are installed here, rather than on board the trains themselves. On the average working day, these five stations each handle 400 stopping trains; enough to generate a total of more than 1,200 MWh of energy a year, equivalent to around US$440,000 in energy savings (or revenue). Until now, wayside energy storage for mass transit systems has not been com-mercially viable, but with the ability to sell

energy back to the grid at peak times, companies like SEPTA can realize financial benefits. SEPTA is now experiencing a drop in energy consumption (and energy bills) of 10 per cent, equal to around US$190,000 a year, plus revenue of between US$75,000 and US$250,000 per year, along with the assurance of having power in the event of an emergency outage. Together, these form a compelling case for further investment for any transport firm. SEPTA itself has the potential to scale the pilot up to the 30 substations on its rail and trolley bus network and it has already received a grant to install an energy storage facility at a second substation. What's next for ABB’s EnvistoreTM solu-tion? It was recently selected by Warsaw’s AGP Metro Polska as part of a package of ABB rail solutions for the new metro line 2, where it will recycle the braking energy from trains and gravitational energy from passing under the Vistula river.

August 2012 saw the launch of a pilot system installed by ABB to capture the excess energy produced during train braking in the city of Philadelphia. Although energy recovered from braking in hybrid vehicles is usually used to boost acceleration, ABB’s solution also allows the train operating company to store the energy and sell the energy back to the grid at times of high demand, turning trains into power generators and saving 10 per cent on the overall energy bill.

Power control and energy storage system


Old MV switchgear gets a new lease of lifeABB is the first and only switchgear supplier in the UK to offer an Energy Network Association (ENA) assessed retrofit service for out-dated and ageing medium voltage switchgear. It's an offer that has attracted a major distribution network operator (DNO) to be the first to benefit from the service.

Retrofitting old medium voltage switchgear

Medium voltage


Signed in December 2012, the agree-ment with Scottish & Southern Energy (SSE) is the operator's

largest-single contract for equipment on its distribution network in 2012. It will address the increasing obsolescence, maintenance, reliability and safety issues associated with SSE’s existing oil-filled circuit breakers, which date back as far as the 1950s.

Equipment safety ratingWhen Ofgem introduced a new health and safety index in 2010, it had the objective of rating network equipment and ensuring safe operation. The move prompted DNOs to review the condition of their plant and rate its condition from 5 (the lowest) to 1 (the highest). While much of the original fixed switch-board equipment, such as housings and busbars, was found to be in good condi-tion, the circuit breakers moving parts were showing their age, meaning the condition of many switchboards was ranked as 'low'. The knock-on effect is that DNOs are keen to take action to raise safety standards.

ENA-assessed solutionABB's retrofitting service brings existing switchboard equipment up to modern safety and reliability standards. ABB is offering the service in collaboration with OEM partner P&B Switchgear and it has successfully undergone assessment by the ENA as well as field trials with UK utility customers. In most cases, retrofitting an ABB circuit breaker will boost a switchboard initially rated at 4 up to a level of 2 and will extend

its life by 20 years or more. Essentially, the field trials gave vital experience of the variations presented by existing switchboard equipment and helped create a ‘plug and play’ solution to meet the challenges of the hundreds of possible permutations in substations across the country.

Cost and installation considerationsRetrofitting new circuit breakers costs around 30 per cent less than completely replacing the switchboard and there are significant reductions in outage time and project complexity. Typically, it takes as little as four hours to upgrade an individual panel. The work can be carried out in incremental stages and a complete switchboard could be completed in less than five working days. It’s an approach that involves minimal disruption to normal substation operation and cabling can remain in situ, so there is no need for a total outage. Another benefit is that the upgrade can be treated as operational expenditure (OPEX) rather than capital expenditure (CAPEX). The solution has been designed to fit the characteristics of the vast majority of equipment produced by UK manufactur-ers, including GEC, Reyrolle, South Wales Switchgear, Brush and many others. Hundreds of retrofit and circuit protec-tion permutations are available and they’re based on two central options, which replace vacuum oil with either a spring-operated mechanism or with a magnetic actuator. The two main options for retrofitting circuit breakers are: – VOR-S (vacuum oil replacement with

a spring operated mechanism), which is built around ABB’s well-proven Vmax vacuum circuit breaker.

– VOR-M (vacuum oil replacement with magnetic actuator mechanism), incorporating P&B Switchgear and ABB components

Sixty circuit breakers for SSEABB's major new contract with SSE will see eight substations on Scotland’s east coast retrofitted with 60 new circuit break-ers, commencing in January 2013. During the project, 60 South Wales Electric C4X and C8X circuit breakers will be replaced with retrofit units based on ABB’s well-proven Vmax vacuum circuit breaker. The circuit breakers will also be upgra-ded from 400 A and 800 A to 630 A and 1,240 A respectively. As a fast-track contract, there will be minimal disruption to the substations’ normal operation and all work will be com-plete – with the switchboards’ upgraded and operating to higher safety levels – within three months.

Medium voltage


Project focus

A world first for UFES: arc protection on old open switchgear When aluminium supplier Hydro wanted to upgrade a medium voltage substation to improve safety for operating staff at its Norsk Hydro Produkjon ASA power station, it called on ABB to supply its recently developed Ultra Fast Earthing Switch (UFES) arc eliminating technology. The project represented the world’s first retrofit project for UFES technology at an old open switchgear installation.

01


Project focus

Based in Norway, Hydro operates throughout the worldwide alumin-ium market, from bauxite extrac-

tion in Brazil to smelting in Australia and supplies formed aluminium products in every continent. Hydro’s domestic operations combine smelting, remelting, production of rolled product, precision tubing and extrusions. To meet its energy needs, Hydro par-tially owns and operates 17 hydroelectric power stations, which together produce an impressive nine terawatt hours (TWh) of electricity per year. Of these, it was the plant at Norsk Hydro Produkjon ASA that came into focus when it recognized the need to upgrade its AIS switchgear to protect staff against the risk of arc formation. With the ability to detect and extinguish an arc in less than four milliseconds, ABB's UFES offered a fitting solution. This rapid operation is achieved by channelling the uncontrolled release of energy of the arc through a solid metal three-phase earth connection. It’s the low impedance of this earth connection that encourages the arc current to flow through the UFES unit, triggering the switch to open and stop the current.

Why ABB developed UFES As an expert in medium-voltage electri-cal equipment, ABB knew its customers wanted to improve the safety of switch-gear without resorting to the cost of full replacement and so developed UFES in 2011 with the three principles of speed, safety and savings in mind. Although arcs form only rarely in switch-gear, when they do, they are enormously hazardous. The sudden rise in temperature to almost 20,000˚C twinned with an explo-sive blast resulting from the sudden thermal expansion of the air can have devastating effects, both on man and machine. The ultra-fast operation of the switch is essential. An uncontrolled arc can reach the intense heat to start a cable fire in 0.1 seconds, a copper fire in 0.15 seconds and a steel fire in 0.2 seconds. With this in mind, it’s essential to detect and earth the arc in as quickly as possible. ABB's UFES does this in only 0.004 seconds. In Hydro’s case, the main objective was to protect its operational staff from potential injury but the control of arc for-mation also helps prevent severe damage to switchgear and the surrounding area. In this way, UFES helps ensure greater system availability in the aftermath of an

arc forming, along with a drastic reduction in downtime and service costs. UFES is available as a withdrawable assembly to insert into a panel or as a box mounted on top or on the end cover of a panel. Once fitted, UFES will spring into operation when the flash of an arc forming triggers one of several optical sensors. Arc detection takes only around 2.5 mil-liseconds and together with three-phase current detection will lead UFES’s primary switching elements to channel the current to earth and break the circuit, quenching the arc before it forms. While ABB originally designed UFES to be compatible with ABB switchgear, it can be retrofitted to non-ABB switch-gear, including old-fashioned open-style switchgear, as was the case at Hydro’s installation. The system is now gaining a foothold in the market as a form of insurance against the risk of injury and damage, as well as the resulting production losses and asso-ciated costs.

01 UFES arc protection unit | 02 Working on UFES

02



Data Centre

Fibre/PTP

2.4/5/8/3.65 GHz

900 MHz

HAN (ZigBee)

HAN

Energy Storage Device

Substation

Feeders

Take control: Tropos brings a new dimension to utility communicationsAndy Osiecki, General Manager of ABB’s UK power system network management business, explains how the recent acquisition of Tropos Networks adds to ABB’s ability to meet the needs of its UK power generation and transmission customers through private wireless networks that deliver secure control over grids whatever the weather.

ABB Tropos network architecture



Networks and applicationsSo what exactly is the offering? Tropos describes its two main areas of expertise as being smart grids and smart cities. Its solutions include networks of routers and directional radio systems, arranged in a mesh or grid structure, along with the architecture and network management to support them. These networks can handle an assort-ment of applications. In the energy sector, these include Advanced Metering Infrastructure (AMI), demand management and response, distribution automation and control, outage management, mobile work-force applications, distributed generation and video security. A key feature is that there is no restric-tion to a single application vendor, giving customers the freedom to choose the applications that suit them. It’s possible to run any application that operates over an enterprise IT network or the internet.

Performance and flexibilityBecause every router in an ABB Tropos network is intelligent, data is routed effi-ciently to where there is capacity. This minimizes delays and gives Tropos’s cus-tomers real-time visibility and control of their assets. Networks are also scalable, meaning that customers can choose to start small and grow when needed. As the network grows, each smart router will automati-cally reconfigure itself, making expansion relatively simple. The mesh network design offers inherent reliability, as the network can handle any outage by redirecting data intelligently and seamlessly.

Rugged and reliableWith an IP67 rating and tamper-evident casings, ABB Tropos routers are designed to cope with almost any physical challenge, a necessity when routers are routinely

installed in outdoor locations in the field. Equipment is designed to withstand temperatures from -40 ˚C to +85 ˚C, wind speeds of up to 165 miles per hour and sandy or dusty environments as well as the damp, salt-laden climate found in coastal locations. The option of adding mobile routers enables the network to be extended whatever the location of field staff – one mobile router even gave uninterrupted network access throughout the launch of the rocket on which it was installed. This build quality contributes to network accessibility figures of better than 99.99 per cent. Recognizing customers’ demands for networks that are both reliable and secure, Tropos has integrated a high level of secu-rity into its products, which have been deployed in military and law enforcement applications. Each device is equipped with multi-layered security, including VPN, WPA2 encryption, AES encryption and support for multiple VLANs. Networks also feature software alarms and authentication and security measures to restrict unauthorized access.

Unique positionWhile there are other providers of wireless mesh networks in the market, only ABB Tropos has a track record in delivering end-to-end solutions for utility applications and distribution networks. The company has worked on networks for power generation, substations and utilities longer than in any other sector. As the number of applications managed over a wireless mesh network grows, so does the financial benefit. Some customers have achieved return on investment in as little as one year when integrating several applications on to their networks.

I n a world where wireless communica-tion is becoming the norm and where smart grids are becoming reality, ABB is

now able to offer a new service to power utilities in the UK following its acquisition of Silicon Valley-based Tropos Networks. Now part of ABB’s Utility Commun-ications product group, Tropos provides private wireless networks which free operators from the need to lease costly bandwidth from third parties. The wireless networks also ensure network availability when and where it’s needed, the ability to run multiple applications with high band-width and low latency and a high level of security. Tropos has been developing its wireless network technology for nearly a decade and has experience of installing end-to-end solutions, with over 70,000 routers in operation at more than 1,000 customers in 50 countries. It has established itself as the industry leader in the field and is an excellent fit with ABB, bringing a new dimension to our offerings. With a client list that includes blue-chip organizations in sectors ranging from utili-ties, through mining and oil & gas, to smart cities and ports, the Tropos business offers huge potential for ABB, especially in the UK power utility market.

Tropos’s impressive customer list includes: EDF, EON, RWE, JEC, TATA, Scottish Power, SSE, London Underground, Network Rail, UK Power Networks, INEOS, BIS, HS1, RIA, Bombardier Transportation Systems, Bechtel, ENW Telecomms, SSE Telecomms, Metropolitan, Cable and Wireless, National Grid, Mott MacDonald, Northern Power Grid.

Network router


Corporate social responsibility

Throughout 2012, ABB continued to support charities on both a local and national basis...

Special Olympics Great Britain 10k London Run

Special Olympics Great Britain was the Official Charity of the British 10k London Run, held on Sunday

8 July 2012 in the build-up to the Olympic Games. A number of ABB staff were among the 1,650 runners pounding London’s streets and they raised a remarkable total of over £7,500.

I n June, our Stone site held a garden fete to raise funds for Special Olympics Great Britain. The day of fundraising

activit ies, which included stal ls and games and a visit from some Special Olympics athletes, was officially opened by the mayor and mayoress of Stone, Mike and Sue Shaw. Stephen Trotter, division head of ABB Power Systems, said, "Supporting the Special Olympics is a key element of ABB’s local community work in the UK. While events like this are all about raising money, our engagement with Special Olympics Great Britain is much broader. Specifically we encourage our staff to become involved

Macmillan Coffee Morning

ABB is a long standing supporter of Macmillan Cancer Support. At the end of September 2012, ABB sites

across the UK took part once again in the World's Biggest Coffee Morning, helping Macmillan in its aim to raise more than £10.8 million to help fund the Macmillan therapists, nurses and support line workers who make sure people living with cancer have the best team in their corner, every step of the way.

Some of ABB’s runners in London

Stone Garden feteby volunteering to help with the running of their sporting events throughout the year." ABB has sponsored the Special Olympics in various countries since 2001. It is a key element of ABB’s community work and supports the company’s commitment to work with disadvantaged people in areas where the company has operations. Established in 1968, Special Olympics is the world’s largest sporting movement for people with learning disabilities. The organization is recognized by the International Olympic Committee and enjoys the membership of 3.25 million participat-ing athletes in over 180 countries.


Technology focus

After eight years or 100,000 miles, the Volt’s battery will have lost only 30 per cent of its life – not enough

to continue as a hybrid car battery but leaving plenty of scope for another application. It's a project that has ABB's commit-ment to environmental stewardship at its core, as it has the potential for recycling automotive batteries, which might otherwise go to landfill and also for supporting the integration of renewable energy sources into the grid. In November 2012 ABB announced a grid-ready prototype capable of provid-ing back-up power for up to five homes. Combining the Volt batteries with an ABB inverter and test software, the prototype was demonstrated at GM’s Electrification

Experience event in San Francisco, where it provided 25 kW of power and 50 kWh of energy to support lighting and audiovisual equipment. Building on this success, Duke Energy, the USA’s largest power utility, announced that it will test the prototype on its grid, a move which will show how the concept works on a real-life grid with real-life cus-tomers and ABB expects to learn a lot from the experience. By 2014, it will know how the prototype has performed on Duke Energy’s grid and the feasibility of recyc ling the batteries to benefit energy utilities and consumers alike. Until then, the project is still in the R&D phase and so it’s too early to know whether the applications for the Volt cells are tech-nically or financially feasible but several

applications are in mind: – Providing power back-up to

supply three to five homes or small commercial buildings

– Peak shaving, where energy is stored at times of low demand and released at peak demand, when it’s at its most expensive. This will benefit consumers with low-cost energy and benefit utilities by relieving the pressure and cost of meeting peak demand

– Integration of solar, wind or other renewable power, the main drawback of which is its dependence on environmental factors which rarely coincide with consumer demand

Driving home energy storageAs the markets for hybrid vehicles and renewable energy have matured, they have thrown up an opportunity: recycling hybrid vehicle batteries to store on-grid energy. Grasping this opportunity, ABB has entered into a partnership with General Motors (GM) to test the technical and economic feasibility of using the battery pack from GM’s award winning Chevrolet Volt.

The prototype energy storage system


Cable

World’s largest cable-laying vessel joins ABB

As you would expect from the world’s largest cable-laying ship, the Lewek Connector’s stats are impressive.

The top line figure is the record-breaking 9,000 tonne cable capacity over two turn-tables. Together these can carry more than 100 km of typical dual-core cable, similar to that laid by ABB for the NorNed interconnector between Norway and the Netherlands in 2008. This 9,000 tonne payload is a sig-nificant advance on similar vessels. For ABB’s clients, this means that the Lewek Connector will be at work laying their cable for longer stretches, leading to less time travelling back to port, fewer connectors and faster laying of the lines.

ABB recently signed a charter agreement for the Lewek Connector, a world-class subsea cable-laying vessel worth over US$300 million which was launched last year and is capable of operating in waters as deep as 3,000 metres. Since then, the ship has already been put to good use in laying HVDC subsea cables in the waters around the UK and is ideally suited to help ABB’s clients lay cables and umbilicals which will become the subsea backbone of the European supergrid.

At 157 metres long and with a beam of 32 metres, the ship’s robust construction allows it to operate in sea conditions with wave heights of 4 to 5 metres. It has a transit speed of 16 knots, making it suit-able to travel anywhere in the world where its services are needed or return to port to restock. The ship was purpose-built for laying power connections to oil and gas platforms or from wind farms or other renewable energy sources. Cables are laid over the port side of the vessel, leaving the stern free for the ship’s propellers and rudder. On-board facilities include: – 400 tonne and 50 tonne cranes with

active heave compensation

– Two tensioners rated at 35 tonnes each, alongside a chute and work platform to feed cable into the water

– A spooling tower to control the cable feed when loading in dock

– Two cable turntables, allowing 6,000 tonne capacity on-deck and a further 3,000 tonnes below decks

– A helipad for crew change-over at sea

Recently renamed the Lewek Connector, the ship was originally called the AMC Connector and can be seen in action on our YouTube channel – just search YouTube.com for ABB Power and Lewek Connector.


Forthcoming events

IET Sustainability AwardOn 22 November last year, the 2012 Institution of Engineering’s (IET’s) Innovation awards ceremony was hosted by world record-breaking swimmer Mark Foster at The Brewery in London’s Chiswell Street. Head of Engineering for UK Power Systems, Stuart Grattage, presented the ABB-sponsored Sustainability award to Highview Power Storage for its pilot cryogenic energy storage.

Following the awards, ABB confirmed that it will continue its long-term sponsorship of the Sustainability

award, which has the objective of promot-ing sustainable innovation in the fields of engineering, science and technology.

Highview’s pilot plant uses waste heat from a Slough power station exhaust to cool and clean air, which is stored as liquid nitrogen. Releasing the nitrogen will see it expand as a gas and drive a turbine, with the potential to produce 10 MW. With

energy storage high on the agenda and a pilot plant that’s been proving it’s worth, the IET’s judges were unanimous in giving the award to Highview Power Storage. Nominations for the 2013 awards will open in the Spring.

Stuart Grattage and Mark Foster present the Sustainability award to Robert Sinclair

Forthcoming eventsABB has a full and stimulating schedule of events for 2013 and we would be delighted to see you at one of the major exhibitions and conferences we are attending.

Event Location Date Website

Wave & Tidal London 27-28th February renewableuk.com

Scottish Renewables Edinburgh 18-19th March scottishrenewables.com

Railtex London 30th April – 2nd May railtex.co.uk

All Energy Aberdeen 22-23rd May all-energy.co.uk

Offshore Europe – Oil & Gas Aberdeen 3-6th September Offshore-europe.co.uk

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

Harnessing the power of wind?

Naturally.

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

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