ABB New Zealand Capability Guide - Motors and Machines ... (HV) and medium-voltage (MV) applications...

ABB New ZealandCapability Guide

1 ABB nationwide | Capability Guide

AUCKLAND

HAMILTON

ROTORUATOKOROA

NEW PLYMOUTH

STRATFORD

WELLINGTON

NAPIER

CHRISTCHURCH

TWIZEL

Contents

02 ABB nationwide

03 ABB’s vision

04 Message from Managing Director

06 Power Products division

07 High Voltage Products

09 Medium Voltage Products

11 Transformers

14 Power Systems division

15 Power Generation

17 Substations

19 Grid Systems

21 Network Management

24 Automation Products division

25 Variable Speed Drives

27 Instrumentation

29 Low Voltage Products

31 Motors and Machines

33 Power Quality

36 Robotics division

37 Robotics

40 Process Automation division

41 Process Automation

43 ABB Performance Services

Capability Guide | ABB nationwide 2

New Zealand locations

Location Address Capabilities

Auckland – Grafton Road 83 Grafton Road, Auckland 1010

Private Bag 92609, Symonds Street, Auckland 1150

Tel: +64 9 356 2160 Fax: +64 9 357 0098

Head office

Motors and Drives

Instrumentation

Power Quality

Process Automation

Power Products and Power Systems sales

RoboticsAuckland – Henderson 133 Central Park Drive, Henderson, Auckland 0610

PO Box 83 203, Edmonton, Auckland 0652

Tel: +64 9 837 1234 Fax: +64 9 837 2950

Medium Voltage Products

Power Products and Power Systems sales

Auckland – Mt Wellington 5 Ponui Place, Mt Wellington, Auckland 6012

PO Box 22 167, Otahuhu, Auckland 1640

Low Voltage

Tel: +64 9 259 5450 Fax: +64 9 259 5499

Power Systems - Service/ABB Performance Services

Tel: +64 9 259 5486 Fax: +64 9 259 5480

Low Voltage Products

Power Systems - Service

ABB Performance Services

Hamilton Pukete Industrial Estate, 117 Maui Street, Hamilton 3200

PO Box 10189, Hamilton 3241

Tel: +64 7 849 3002 Fax: + 64 7 849 3526


Rotorua Forest Research Institute Campus, Sala Street, Rotorua 3010

PO Box 12087, Rotorua South 3045

Tel: +64 7 346 0060

Process Automation


Tokoroa c/o CHH Mill Site, State Highway 1, Tokoroa 3444

PO Box 39, Tokoroa 3444

Tel: +64 7 886 3086 Fax: + 64 7 886 3084

ABB Performance Services customer site

New Plymouth 60 Paraite Road, Bell Block, New Plymouth 4312

PO Box 7050, New Plymouth 4341

Tel: +64 6 755 1120 Fax: +64 6 755 0780

Transformers

Stratford 21 D & E Romeo Street, Stratford 4332

PO Box 369, Stratford 4352

Tel: + 64 6 765 8312 Fax: +64 6 765 8579

Grid Systems

Network Management

Power Generation

SubstationsNapier 21 Carnegie Road, Napier 4110

PO Box 342, Napier 4140

Tel: +64 6 843 1400 Fax: +64 6 843 0398

Power Quality

Wellington Level 7, 138 The Terrace, Wellington 6011

PO Box 3239, Wellington 6140

Tel: +64 4 471 2221 Fax: +64 4 471 2220

Instrumentation

Power Quality

Grid Systems

High Voltage Products

Substation Automation

Power Products and Power Systems salesChristchurch 16 Vulcan Place, Christchurch 8024

PO Box 2120, Christchurch 8140

Tel: +64 3 338-3787 Fax: +64 3 338 0110

Grid Systems

Instrumentation

Motors and Drives

Low Voltage Products

Power Quality

Network Management

Power Generation


Substations

Power Products and Power Systems salesTwizel c/o Meridian Energy State Highway 8 Twizel 7901

Tel: +64 3 435 0904 Fax: +64 3 435 0907

Network Management

Power Generation

3 ABB’s vision | Capability Guide

ABB’s vision

As one of the world’s leading engineering companies, we help our customers to use electrical power efficiently, to increase industrial productivity and to lower environmental impact in a sustainable way. Power and productivity for a better world.

ABB’s mission

Improve performanceABB helps customers improve their operating performance, grid reliability and productivity while saving energy and lowering environmental impact.

Drive innovationInnovation and quality are key characteristics of our product, systems and service offering.

Attract talentABB is committed to attracting and retaining dedicated and skilled people and offering employees an attractive, global work environment.

Act responsiblySustainability, lowering environmental impact and business ethics are at the core of our market offering and our own operations.

Capability Guide | ABB’s vision 4

Welcome to ABB New ZealandFrom Grant Gillard, Managing Director, ABB New Zealand

Power and productivity for a better world – this is the essence of ABB.

ABB is one of the world’s leading suppliers of products and systems for electrical infrastructure, from power generation to installation in houses, and for factory automation and optimisation of industrial processes. Our comprehensive portfolio helps create a reliable and cost-effective energy infrastructure that enables our customers to concentrate on their core competencies and increase their competitiveness.

In addition to power and productivity, we want to create an infrastructure for a better and sustainable world – one that provides a level of comfort for all of us and at the same time does not deplete our resources or harm our environment. Our commitment to sustainability extends to the health, safety and well being of our employees, our customers, and our community.

ABB has a long history of innovation that stems back to the late 1800. Innovation remains a priority for ABB, and each year we invest more than $1B in research and development; discovering ways to enhance our society by new applications of technology.

We are proud to have been supplying our leading-edge technology and services to New Zealand for over 75 years. In addition to providing our local customers with the best products and systems from around the world, we boast our own world class manufacturing capabilities in New Zealand, with our transformer facility in New Plymouth, our switchgear facility in Auckland, who supply to the Australian, Asian and European markets, and our Power Quality operation in Napier, which is responsible for supplying voltage conditioning and converter equipment worldwide for ABB.

5 Power Products division | Capability Guide

Capability Guide | Power Products division 6

Power Products division Key deliverables- Power technology products for ultra-high (UHV), high (HV)

and medium-voltage (MV) applications - Transformers: power, distribution, traction, others - UHV, HV and MV products, including switchgear - Range of power capacitors - Distribution automation products, eg, electronic relays

- Power Products services - Transformer repair, refurbishment, spare parts, maintenance

- Markets served - Utilities, industries, OEMs, EPCs, distributors


High Voltage Products (>36kV)

ABB offers customers a complete range of competitive and innovative high voltage products. Packages of equipment are supplied to power utilities and contractors, either directly or through a channel partner.

ABB is able to provide a strong focus on product and installation as well as installation training and other technical services.

Portfolio

High Voltage (HV) circuit breakers - live tank circuit breakers- dead tank circuit breakers- operating mechanisms- synchronous switching controllers

HV switchgear- integrated switchgear solutions- gas insulated switchgear- gas insulated switchgear modules

Generator circuit breakers

Instrument transformers - current transformers - voltage transformers- capacitor voltage transformers

HV capacitors - HV capacitor units- HV capacitor banks- filter banks

HV surge arrestors

Transmission protection and control

HV cable accessories


High Voltage Products case study

Customer needSuburban development has meant that a high number of high voltage Transpower substation sites around NZ needed to be increased in size. The rural landscape the substations were originally built on has now been developed into residential housing areas. Transpower needed to increase the size of the substations without increasing the sound level emitted from the sites.

ABB’s solutionABB provided Transpower with ‘motor drive’ circuit breakers, which make a significant contribution to reducing thesubstation sound levels.

Traditionally the energy for opening and closing the HV circuit breaker comes from a spring operated mechanism. In comparison, the number of moving parts in ABB’s motor drive breaker has been reduced to one, and the sound level has been measured at 87dB compared with 100dB for the equivalent spring operated breaker.

The benefitsThe motor drive circuit breaker has become the breaker of choice for switching capacitor banks at substations where stringent sound level requirements need to be met. In addition to lower sound levels, ABB’s circuit breaker has also provided Transpower with a significant saving in maintenance costs as a result of the greatly reduced number of moving parts.

The reduction in sound and maintenance disturbance has resulted in a win/win situation for both Transpower and the residents living close to a high voltage substation.


Medium Voltage Products (up to 36kV)

ABB has the capability to develop, manufacture and deliver a full range of medium voltage (MV) products used in utilities, manufacturing and process industries, infrastructure, residential and commercial buildings. ABB’s medium voltage manufacturing facility at Henderson, Auckland, is a global factory with research and development responsibility for the ABB Safelink gas insulated Ringmain switchgear.

This manufacturing operation complements the capabilities of a strong local team, providing customers with the benefits that a manufacturing facility has to offer, such as; research and design, engineering, project management, manufacturing, as well as service support.

In addition to supplying the local market, the Henderson factory also supplies countries such as Australia, United Kingdom and the Netherlands with ABB Safelink products.

Portfolio

Switchboards and switchgear panels – primary and secondary switchgear– either gas or air insulated and motor starters– fitted with Vacuum or SF6 circuit breakers

contactors or switches

Indoor apparatus– circuit breakers– contactors– sealed switches– instrument transformers and sensors– fuses and current limiters

Outdoor switchgear – reclosers and circuit breakers– switches and fused cut-outs

Distribution automation– protection relays for various protection applications

Compact substations– transformer and optional secondary switchgear products

and low voltage (LV) switchgear


Medium Voltage Products case study

Customer needProject West Wind is Meridian Energy’s wind farm being constructed at Makara, west of Wellington. The West Wind site is 12km long and 4.5km wide. It will have 62 wind turbine generators, each with a capacity of 2.3MW.

Working to a tight time frame, the wind farm needed a ‘designed to order’ Switchgear capable of disconnecting and connecting electricity from the source to the national grid.

ABB’s solutionAn ABB 33kV Air Insulated Switchgear (AIS) was purchased to be the switching point between the generating wind farm and the national grid. The AIS chosen for this project was a UniGear type ZS2 & was sourced from ABB Turkey. The panels have front and back access for installation, maintenance and routine operations. It came in on budget and with the required delivery time.

The benefitsThe wind farm has an estimated capacity of 142MW, and will generate enough power for the equivalent of 70,000 average homes.


Transformers

ABB design and manufacture high voltage transformers for all generation and distribution applications at some 58 focused factories located in 30 countries worldwide. ABB’s distribution transformer manufacturing facility is located in New Plymouth, where a range of transformers, rated between 10kVA and 5000kVA, for voltages up to 33kV, are manufactured. ABB’s product range in New Zealand comprises; polemount, groundmount and padmount styles. These have been designed utilising ABB’s global technology and are tailored to suit local conditions, with particular regard to corrosion protection for New Zealand and the Pacific Islands’ largely coastal environment.

ABB customers include electricity distribution companies, consultants, contractors and end users. ABB transformers are installed in a variety of applications, which range from rural overhead distribution by electricity distribution networks to heavy industrial installations within the mining, pulp and paper, oil and gas, petrochemical and manufacturing industries.

Portfolio

Distribution transformers – liquid filled and dry type, pole, pad and ground mounted

Power transformers – generator step-up– network couplings– shunt reactors– phase shifting and high voltage direct current (HVDC)

convertor transformers

Industrial and special transformers

Traction transformers

Insulation and components – bushings, tap changers and mechanical components

Service, retrofit and engineering support


Transformers case study

Customer needPowerco Transmission Services (PTS) and NZ Windfarms (the developer of the Te Rere Hau wind farm near Palmerston North) formed an Alliance that has seen PTS design, construct, own and operate the 33kV cable reticulation, transformers, switching station and transmission circuits for a 48.5MW, 97 turbine wind farm.

The large number of transformers required to convert the power from the 97 wind flow 500 turbines were selected from ABB. Due to the harsh conditions of the wind farm, PTS required the transformers to have a high level of corrosion protection.

ABB’s solutionABB were able to provide a large number of transformers from the local factory in New Plymouth. These pad mounted transformers were especially designed with materials to suit the extreme wind farm conditions. They also have front access, making it more convenient for the cabling.

In addition, ABB provided neutral earthing transformers and neutral earthing resistors, which were needed for the substation.

The benefitsThese units are compact in nature, easily installed and reliable, assisting Powerco Transmission Services in its challenge to integrate the power from the wind turbines into the national grid. Each turbine will produce enough energy to power approximately 200 houses a year.

13 Power Systems division | Capability Guide

Capability Guide | Power Systems division 14

Power Systems division Key deliverables- Electrical, automation, control and instrumentation for

power generation- AC and DC power transmission grid systems for traditional

and renewable energy integration (HVDC, HVDC Light, FACTS)- Turnkey substations (incl. substation automation)- Network management and market systems- Power systems services - Consulting and system studies - Repair, retrofit, refurbishment - Software and hardware upgrades - Asset management and diagnostics

Markets served- Utilities, industry, OEMs, EPCs, channel partners


Power Generation

ABB’s power generation service provides power service expertise over the entire life cycle of power equipment and systems from commissioning new plant, operating and maintaining it through to retrofitting or refurbishment. Customers assets are managed from the power plant right through to the transmission equipment, including hydraulic and ancillary equipment, control and instrumentation to HV equipment and communications.

Portfolio

– After sales service of ABB manufactured equipment and systems

– Preventative and corrective maintenance services– Fault response services– Field operating and switching services– Asset assessment and diagnostics– Plant performance benchmark analysis– Retrofit and refurbishment– Third party power generation services including installation

and maintenance– Electrical protection technician services– Systems control and data acquisition (SCADA)

and distribution control systems (DCS)– System communications– Turnkey plant electrical systems– Plant optimisation– Complete instrumentation, control and electrical integration– HV equipment installation and maintenance– Power station maintenance– High speed data acquisition services– Engineering services– Project management


Power Generation case study

Customer needDue to an unforeseen transformer failure at Mighty River Power’s Waipapa Hydro Generation site, ABB was engaged to assist with the urgent relocation of an 85 tonne three phase transformer from Mighty River Power’s Maraetai site.

ABB’s solutionABB managed the relocation and installation of the transformer including the testing and commissioning. The project plan required ABB to partially disassemble the 220kV/110kV/11kV unit, including bushings, conservator tanks, surge arrestors, and draining the oil to make it a more manageable 56 tonne for transportation. Due to access restrictions at Waipapa power station, the transformer was lifted into position using a 250 tonne capacity crane.

As part of the transformer relocation project a new foundation pad, 220kV supports, 11kV cables, control cabling andmodifications to the transformer cooling water supply was required at Waipapa.

The project was completed in one month from the initial request to final commissioning.

The benefitsInstalling the transformer effectively by ABB, in limited outage windows, ensured reliable power generation availability from Waipapa for Mighty River Power’s customers.


Substations

ABB provides optimised economical and technical turnkey solutions for all substation requirements.With direct access to ABB’s technology and leading range of high- and medium-voltage equipment, ABB are able to provide market leading technological solutions to the conflicting demands of reliability, performance, cost and environmental impact.

In-house technical people are available 24 hours a day, 7 days a week. ABB are equipped with the latest equipment and are familiar with the latest technology including protection and SCADA systems, communications systems, diagnostic test equipment, control and instrumentation, technical design, audit and benchmarking, circuit breaker motion analysis, sulphur hexafluoride (SF6) gas assessment and gas recovery.

Portfolio

– Turnkey transmission and distribution substations– Mobile substations– Upgrade and refurbishment of transmission and

distribution substations– Industrial system and mining project electrification– Railway power supply systems


Substation case study

Customer needThe new gas refining plant at Kupe needed to have its own stand alone power supply. In order to do this, there was a need for Transpower to upgrade their Hawera substation.

ABB’s solutionABB were awarded the responsibility for the projectmanagement, installation of a range of products, and completing all the electrical testing and commissioning for the project.

The products that needed to be installed included an ABB 110/33kV 30MVA transformer, indoor GIS switchgear with a dedicated feeder to Kupe and room for expansion if required, and numerous other products.

The benefitsAfter completion of the project, the Kupe gas refining plant is now non-reliant on the local distribution network. They are able to run independently and can manage their own power supply to match the needs at the plant. This means that they do not have to worry about other users on the network.


Grid Systems

ABB’s patented HVDC technology is used to transmit electricity over long distances by overhead transmission lines or submarine cables. It is also used to interconnect separate power systems, where traditional alternating connections (AC) cannot be used. ABB flexible AC transmission systems (FACTS) enhance the security, capacity and flexibility of power transmission systems. FACTS solutions enable grid owners to increase the capacity of existing transmission networks, while maintaining or improving the operating margins necessary for grid stability.

Portfolio

– Power transmission (HVDC), static VAR compensators and series compensation

– Power quality– Railway (grid connection)– HV cable systems– Wind farm connections


Grid Systems case study

Customer needASEA, now ABB, pioneered commercial High Voltage Direct Current (HVDC) solutions using Mercury Arc technology. This was the technology of choice for the NZ Electricity Department, a forerunner of Transpower, for the original Pole 1 250kV, 600MW HVDC Inter-island link between the South and North Island commissioned in 1965.

To utilise excess generation, and to reduce fossil fuel consumption in the North Island thermal power stations, Transpower required a second pole circuit in 1992.

ABB’s solutionAn ABB HVDC Thyristor Pole was chosen as the most appropriate method of upgrading the existing HVDC transmission scheme for this Hybrid Link Project. The implementation of a control system for the two HVDC technologies was a challenge, successfully achieved.

ABB in consortium with Alcatel STK of Norway supplied the three submarine cables.

The benefitsSince 1992, ABB’s HVDC system has been providing the South Island with access to the North Island’s coal and gas generation, and the North Island with access to the South Island’s hydro generation.

Doubling the transmission capacity of the original link also deferred the need for new generating plant in the North Island.


ABB provides centralised market and asset management systems for electrical networks, district heating networks, gas networks and energy markets.ABB is also a system integrator, offering turnkey telecommunications solutions for the operational needs of utilities and supporting them to grow on WAN applications.

Portfolio

– SCADA systems– Utility communications services– Teleprotection solutions– Power line carrier systems– Radio systems– Network management– Combined power line carrier, fibre optic and radio systems– Security device manager (SDM) systems for SCADA and

digital communication systems (DCS) tele-protection– Telemetry systems.

Network Management


Customer needMeridian Energy, one of New Zealand’s leading power generation companies, required support for its network systems.

ABB’s solutionAfter winning the contract in 1999, ABB offers Meridian Energy a custom made package to meet their needs including telecommunications and telemetry, infrastructure management, voice and data responsibility and power communications.

The benefitsMeridian Energy benefits from having a single point of responsibility for the services provided, a clearly defined service level agreement and is also able to draw upon ABB’s international expertise.

Network Management case study

23 Automation Products division | Capability Guide

Capability Guide | Automation Products division 24

Key deliverables– Low-voltage circuit protection and control products – Instrumentation– Low- and medium-voltage drives– Low- and high- voltage motors and generators– Power electronics systems– Product services

Markets served– OEMs, distributors, installers, system integrators

and panel builders– End-users within building automation, factory automation,

marine, transportation, power utility, water, irrigation and manufacturing industries

Automation Products division


ABB is the number one supplier of variable speed drives in New Zealand and with the widest product range available you can be sure of getting the right solution for your business needs. The range includes application specific solutions ranging from pump, fan, conveyor and compressor applications through to demanding crane and marine solutions. ABB Drives are committed to providing the highest level of applications, technical support and service to their customers. Drives Sales, Applications and Service Offer

Machinery Drives – AC drives from component drives up to high

performance machinery drives. Provide speed control for diverse applications designed for ease of installation and commissioning.

Standard Drives – AC Drives for standard industry applications with common

user and process interfaces. Common software tools for sizing these drives and inbuilt assistants for commissioning and maintenance.

Industrial Drives – AC Drives utilising direct torque control for applications

requiring high overloadability or precise torque control. These highly flexible AC drives can be tailored to meet the precise needs of industrial applications.

– Low harmonic, regenerative and liquid cooler drives.

Medium Voltage AC Drives – with the highest reliability using patented IGCT

semiconductors and exceptional performance levels with direct torque control.

DC Drives – with the highest power to size ratio designed for new

or retro fit applications.

Drive PC tools – for commissioning and analysis of drive performance.

Drive services – technical and applications support, 24 hour service

response, service contracts, spare parts and training.

Drives alliance partners – certified partners providing sales, support and system

integration of ABB drives.

Variable Speed Drives


Customer need A consultant requested a drive solution for a Tauranga City Council waste water treatment plant. Of particular importance in the selection of the drive solution was the size of the distribution transformer, the existing drive load, the physical size of the drive and the duty of the load.

ABB’s solution ABB provided an ACS800-37 cabinet built low harmonic drive for this application. These drives utilise an active front end inverter to mitigate the harmonic current at the source – providing the lowest harmonic current of all drives without the need for additional filtering equipment or complicated multi-pulse transformer arrangements. The drive is contained in a single package.

The benefits The ABB drive met the requirements of the ultra low harmonic current and provided genuine unity power factor allowing optimised sizing of the distribution transformer. The physical size of the drive was the lowest of all alternatives due to the ‘everything inside’ nature of the drive.

Variable Speed Drive case study


ABB is a global leader in instrumentation with solutions certified to international standards, and a worldwide network of manufacturing plants sales offices, after sales service centres and calibration facilities, strategically located around the world.The instrumentation group has a strong history and is built upon leading names and brands in the automation world; Alfa Laval Automation, Bailey Controls, BushBeach Engineering, Fischer & Porter, Hartmann & Braun, Kent, Schoppe & Faeser, Sensycon, Taylor, TBI-Bailey and the most recent acquisition of the Torbar Flowmeters business of FloMax.

IndustrialIT enabled instruments from ABB with Foundation Fieldbus, Profibus or Hart Communications deliver the option to choose the best fieldbus solution as well as open engineering (stand alone or system integrated), special solutions for intrinsic safety and increased availability. The device type management allows asset monitoring for enhanced asset optimisation, by delivering more reliable status data and accurate measuring values. The remote diagnosis capability and device status data allow maintenance management systems to provide plant efficiency, plant security, plant availability, plant reliability, and process optimisation.

Portfolio

– Analytical instruments– Actuators and positioners– Temperature measurement– Flow measurement– Pressure measurement– Level measurement– Recorders, indicators and process controllers– Instrumentation service

Instrumentation


Customer needPost-Harvest Solutions Limited, an OEM involved in the export fruit packing industry wanted a system that could accurately control the chlorine content of the water for transportation of the fruit by a chemical addition to the water. This is a very important process to ensure no bugs are left either on the surface, or within the stem area of the fruit, causing rot to form while in storage or when being transported to markets.

ABB’s solutionHaving studied their requirements, ABB offered AX460 series pH and ORP analysers, ABB AP200 electrode systems for incorporation in an export fruit packing and transport system.This system closely controls the chlorine content of the water and fully met the customer’s requirements.

The benefitsABB’s products give Post-Harvest Solutions Limited the ability to ‘plug and produce’ with virtually no on-site tuning of control functions required. The most recent order of analyser and control products brings the total order for Post-Harvest Solutions Limited up to 120 systems for their fruit packing system. Currently Post-Harvest Solutions Limited is targeting the overseas market, taking into account the addition of ABB SM500 videographic recorders/data loggers with in-built web page which allows access to the packing conditions via the internet, as well as collecting the data remotely. This means any early warnings of process malfunctions can be seen and preventive action taken.

Instrumentation case study


ABB manufactures and supplies a range of power distribution and motor control equipment to OEMs and switchboard builders for commercial and industrial applications. ABB’s low voltage products are also distributed through a network of electrical wholesalers throughout New Zealand aimed principally at both the domestic and commercial markets.Breakers & Switches– ACB (Air Current Breakers)/MCCB (Moulded Case

Circuit Breakers)– Switches and fusegear

Control Products– Motor control equipment including contactors/overloads,

plug-in relays and electronic relays– Control products including pilot indicators, limit switches

and wireless proximity– PLC (Programmable Logic Controller)

and HMI (Human Machine Interface)– UMC22 intelligent motor control protection– Softstarters– Terminal blocks– Automation products– Power factor correction

Enclosures & Din Rail Products– MCB (Miniature Circuit Breakers)– Installation products– Enclosures– Intelligent building automation– Distribution boards– Form 1 MCC (Motor Control Centre) cabling systems– High current distribution boards

Wiring Accessories– Trunking

After sales service

Spare parts

Low Voltage Products (up to 1000V and 6300 amps)


Customer needBallance Agri-Nutrients, New Zealand’s leading fertiliser manufacturer and distributor, required an upgrading of their existing chemical process control equipment.

ABB’s solutionABB worked with the Ballance Agri-Nutrients’ project design team and switchboard builder, Switchboard Services, to incorporate communication technology from softstarters, moulded case circuit breakers, motor protection and power factor controllers.

The benefitsThe integration of the communication technology enabled monitoring, and therefore greater energy efficiency, and ultimately increased reliability of Ballance Agri-Nutrients’ plant.

Low Voltage Products case study


ABB continues to set the benchmark for LV motors, MV motors and machines. By utilising its technical knowledge and experience of global markets, ABB strives to create total solutions which run flawlessly for years and even decades aimed at long term energy efficiency improvement in a sustainable way. ABB has improved the design and functionality of its motors and machines in several ways to ensure longer lifetime and uninterrupted operations. For example, new motors run even cooler than before, thus helping windings and bearings to last longer.

Motors and machines offer

Process performance LV motors – Best in class solutions with highest levels of reliability and

performance, particularly suited to demanding continuous process operations where end users cannot afford loss of production through breakdowns.

– Premium efficiency levels (exceeding EFF1 requirements) ensure lowest running costs and hence lowest life cycle costs.

Industrial performance LV motors – Motors renowned for efficiency, performance and reliability

with the widest range of frame sizes and materials available.– High modularity allows all variants generally required

in industry, therefore providing flexibility and individual solutions matched to customer requirements.

Hazardous area motorsThe ABB range includes – flameroof motors – increased safety motors – non-sparking motors

Motors for additional applications – including marine motors– permanent magnet motors– brake motors– high ambient motors

Synchronous motors and generators

High Voltage induction motors

DC motors

Motors and Machines


Customer needAn 11kV generator was required for turnkey installation at Fonterra’s Waitoa site. The generator is being used in a co-generation capacity to create sustainable power for part of Fonterra’s site by connecting to the steam turbine which uses the existing steam produced for drying milk powder on site.

ABB’s solutionABB supplied a 4.4MVA, 11kV brushless synchronous generator manufactured in Sweden for this application. After many months of preparation and project management, the generator arrived in NZ in an oversized container and was subsequently lifted into the powerhouse at Waitoa where the roof was removed. Installation work consisted of mechanical mounting and alignment, power connections, control and protection wiring, cooling connections and testing. Commissioning was completed after detailed planning and involved fitting around the production levels on site to achieve full power testing.

The benefitsCo-generation plants are highly efficient, which helps companies to remain competitive in their industries through efficient use of resources. As an indicator of capability, the generator has the capacity to generate enough power for over 2000 households.

Maintenance contracts and spares packages have been offered by ABB to Fonterra to ensure the flawless operation of the generator over its entire lifecycle.

Motors and Machines case study


Power Quality

ABB has developed and successfully introduced systems to provide solutions in power protection, static frequency converters and grid connection.Power Protection solutions– Voltages sags, surges and short outages are common

in the world’s electricity supplies resulting in considerable product loss and downtime.

– The AVC2 Active Voltage Conditioner protects sensitive loads from these common disturbances in utilities. Correcting sags, surges, unbalance and poor regulation within a few milliseconds.

– Where short power outages are present in the utility supply the AVCRTS provides the additional protection required.

Static Frequency Converters– Connecting anything from a yacht to a super tanker to

the dockside electrical supply, the SFC2, VSP4 and VSP5 features match the most demanding marine (ship and shore based) and industrial applications.

Grid Connection Inverter solutions– The growing use of clean renewable electricity sources

is creating demand for electricity grid connected inverter solutions. Based around ABB’s modular intelligent inverter platform semi-customised systems can be configured from standard modules to produce very high reliability systems.

Typical applications – Fast reactive power control (STATCOM)– Battery Energy Storage Systems (BESS)– Grid connect flywheel energy storage interfaces– Alternative energy interfaces (fuels cells, photovoltaic,

variable speed mico-hydro)


Customer needAmcor Flexibles in Auckland produce flexible packaging for food products on multiple blown film lines with some wrappings consisting of up to nine layers of various plastics components. Any voltage disturbance in the surrounding network would halt the production line creating wastage and down time.

After a power quality disturbance careful flushing of the extruder screws, barrel and dies is required otherwise gel marks and burn spots would degrade the next production lot of wrapping.

ABB’s solutionABB installed the first AVC 1000kVA unit back in 1998 and followed up with a second 1000kVA unit in 2005. These units take all the incoming power and actively compensate for any power disturbance ensuring the extruders and film lines have perfectly conditioned electricity. This flows through to the product quality and ultimately the plants “bottom line”.

The benefits“Before we installed the AVC, the slightest flicker of the lights and we’d be in trouble.” says Darryn Shepherd, Production Manager for the Albany site. “but installing the AVC on our production line power feed was one of the best moves we ever made”.

Power Quality case study

35 Robotics division | Capability Guide

Capability Guide | Robotics division 36

Key deliverables– Robots, application equipment and software– Standardized manufacturing cells for material handling,

machine tending, welding, cutting, painting, finishing, etc.– Engineering for systems in press automation, body-in-white,

paint processes, power train assembly– Product and systems service

Markets served– Automotive and their Tier 1 suppliers– General industries including foundry, metal fabrication,

plastics, electronics, food and beverage, machine tools, solar, wood, pharmaceuticals and chemicals

Robotics division

37 Robotics division | Capability Guide

ABB is a leading supplier of industrial robots, modular manufacturing systems and service. A strong solutions focus helps manufacturers improve productivity, product quality and worker safety. ABB has installed more than 160,000 robots worldwide. ABB is New Zealand’s only robot company in its own right.

Robots, Systems & Service Offer

Industrial Robots– small, large, paint & special robots

Robot Controllers & Software – including "Next Generation" safety

Industrial Software Products – programming– simulation– production monitoring

Application equipment & accessories – including standard global cells and solutions

Applications by industry – Automotive, foundry & forging– metal fabrication– plastics– packaging– picking and palletising– solar – wood– gluing and sealing– material handling and machine tending

Service and support – service contracts– parts – training– used robots and productivity programs

Robotics division

Capability Guide | Robotics division 38

Customer needABB was approached by Seeka, New Zealand‘s largest kiwifruit supply company, who wanted a more automated and streamlined picking and packing process, to achieve efficiency and greater output.

ABB’s solutionABB’s Flexpicker IRB 340 robot was the perfect solution. The Flexpicker is an extremely versatile parallel-arm robot with a potential speed of more than 150 picks per minute (a cycle time of just 0.4 seconds). The moving arms of the robot are lightweight and can achieve accelerations in excess of 10g. The Flexipicker is equipped with a suction gripper, coupled with a vision system that continuously photographs the fruit and feeds this to ABB’s Pickmaster software. This enables the Flexipicker to correctly orientate the product in the tray, regardless of how the fruit is lying on the conveyer.

The benefitsThe customer was so impressed with the robots immediate performance during a short trial that they left the machine running through the rest of the season alongside the human packers. Once permanently installed, the robot has increased it’s productivity as it is able to pack 90 to 100 fruit per minute, completing a pallet in one hour – equivalent to the work of two people.

Robotics case study

39 Process Automation division | Capability Guide

Capability Guide | Process Automation division 40

Key deliverables– Integrated process control and information

management systems– Automation products, solutions and systems– Industry-specific application know-how and services

Markets served– Full range of process industries, including pulp and paper,

metals and minerals, chemicals and pharmaceuticals, oil and gas

– Marine and Turbocharging

Process Automation division


Process Automation

ABB’s Process Automation division provides industrial and power customers with essential information on the performance of manufacturing operations using ABB’s world leading Industrial IT technology, manufacturing execution systems, process analytical systems, paper quality control systems, force measurement and drive systems.

Integrated information and process control solutions

Power generation

Minerals and mining

Oil and gas

Pulp and paper

Consumer manufacturing

Cement

Refining and petrochemicals

Process functional safety

ABB supports customers over the product life cycle with a comprehensive service, spares and after sales support network to ensure that customers gain the maximum benefit after the initial system investment.


Customer needAs part of Genesis Energy’s ongoing investment in key renewable energy plant, they needed to upgrade their hydro power station control systems at five stations:Tokaanu, Rangipo, Tuai, Piripaua and Kaitawa.

ABB’s solutionABB are now well underway in the two-year project, utilising ABB’s extended operator workplace Industrial IT Control System 800xA. This is the first use of the extended operator workplace in the South Asia Region.

The benefitsThe new system monitors each of the stations water turbines as well as the frequency and voltage of the energy output remotely.

The features of the new system include ergonomic flexibility to adjust to Genesis’ specifications and increased screen and projector adaptability.

Process Automation case study


ABB is one of the world leaders in performance services and has been servicing New Zealand for over 25 years.Portfolio

Maintenance and field services

Automation and optimization services

Driving servicing and repair specialists

Coil forming and manufacturing

Precision balancing and alignment services

Condition monitoring

Turbine and generator servicing

Marine services– including turbochargers– Control valve servicing and repair specialist– Spare parts and repair services

Maintenance consulting and benchmarking

Training

Project Management

Shutdown management and planning

ABB Full Service– performance based outsourcing

In addition to the Full Service contract for Carter Holt Harvey at their Kinleith pulp and paper mill, ABB also has motor service specialist workshops in Auckland, Hamilton and Christchurch.

ABB supports customers over the product life cycle with a comprehensive service, spares and after sales support network to ensure that customers gain the benefit of initial information system investment.



Customer needTo compete more efficiently in global pulp and paper markets Carter Holt Harvey, Australasia’s leading forest products company, needed to achieve efficiency improvements.

ABB’s solutionABB took over the complete maintenance organisation of the mill in 2003 under a five-year Full Service maintenance services contract. This was extended for a further five years in 2009.With approximately 190 employees onsite, ABB has been implementing world-class processes and procedures developed in its other 150 Full Service contracts around the world.

The benefitsSince ABB took over the provision of maintenance services, plant availability and reliability have improved, while maintenance costs have been reduced. The mill has achieved record performance levels, with a substantial increase in output and decrease in total energy usage per ton of dried product.

Performance Services case study

Connect emission-free power to the grid?

Naturally.

ABB is helping construct the world’s largest offshore wind farm. Using our eco-friendly transmission technology, this 400-megawatt plant is expected to avoid 1.5 million tons of CO2 emissions per year and improve the reliability of the power grid. It’s just one of the ways that we, as the biggest supplier of electrical products and services for the wind industry, can use renewable power sources to help combat climate change. www.abb.com/energyefficiency

Contact Us

ABB LimitedNew ZealandPrivate Bag 92 609, Symonds Street, Auckland 1150Phone: +64 9 356 2160Fax: +64 9 357 0098www.abb.co.nz

© June 2009 A

BB

Limited, N

ew Zealand

ABB New Zealand Capability Guide - Motors and Machines ... (HV) and medium-voltage (MV) applications...

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