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Substations shrink to fit with GIS

Breathtaking Scope

Focused factories

Renewables- our energy future

New products

Total powertechnology solutions

FAST FORWARD WITH ABB POWER TECHNOLOGIESAutumn 2003

02 FFWD >> Autumn 2003

Published by:ABB LimitedOulton Road, Stone, Staffordshire ST15 0RS

Editor: Karen Strong

Telephone:01785 825050

3 Substations shrink to fitwith GISNew gas insulated switchgear (GIS) technologyis enabling urban transformer substations to bereduced in size dramatically.

4 News A round-up of our latest projects.

6 Breathtaking scopeAn overview of ABB Power Technologies’services and product portfolio.

8 Delivery in weeks ratherthan monthsIntroducing ‘Focused Factories’.

9 Powering upLatest utility automation stories.

10 Our energy futureHelping deliver cleaner, smarter energy anddistributed generation.

11 Product focusWhat’s new in transformers and switchgear.

contents Superpower cut

When the lights went out in the USA recently, it illuminatedthe utter reliance of high-tech nations on electricity.Whatever the precise trigger of the catastrophic poweroutages on the Eastern Interconnected Network, expertsagree that the root of the problem is a transmission systemthat cannot meet the spiralling energy demands of citiesbursting with new technology.

Power supply is a high-profile business. Quite apart from the regulator’s pressure on reliability, there are image-relatedissues to consider as well. Bad press coverage affects autility’s reputation and can damage the share price.

So, what benefits can a utility expect from bringing inexternal specialists for infrastructure asset management andreliability planning in deregulated and competitive markets?

If the specialists are part of a global organisation, there are two particular benefits. One is the ability to draw onbusiness and technical experience working with utilities inmany different countries. The other is that they are morelikely to be fully up to date with the latest technicalpractices.

Global presence is also interesting to utilities that areextending their geographical scale of operations throughmergers and acquisitions in other countries.

ABB’s asset management service is focused on helpingmaximise the return on system infrastructure assets byimproving performance and raising profitability oftransmission and distribution networks. Risk assessment,safety, environmental performance and service quality arekey aspects of the service.

Whatever the scale of the project – network upgrade, newbuild project or long-term network development andoperation contract – our approach is to combine strategicbusiness consultancy with full technical planning andimplementation. This integrated service approach avoids thecost, time and inefficiency problems that can occur whenthere are service handoffs from one supplier to another.

And, through our alliance with Accenture, we are able toundertake large-scale, integrated operations transformationprograms for utilities. Applying ABB’s IndustrialIT platform toachieve automation and information solutions that reachseamlessly across all areas of the utility’s business, fromboardroom to network plant.

Issue 5 Autumn 2003

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Trevor GregoryDivision Head, Power Technologies UKGroup Representative, UK

Autumn 2003 >> FFWD 03

substations

Until the 1970s airinsulated switchgear

(AIS) was the type mostcommonly in use forsubstations. AIS requires largedistances between earth andphase conductors andtherefore a good deal ofspace. This means that forhigher voltages – typicallyabove 36kV – this type ofinstallation is only feasibleoutdoors.

This situation changeddramatically when ABB introducedSF6 (sulphur hexafluoride) as aninsulating medium in switchgearenclosures in order to reduce phaseto earth distances. The advantagesof GIS compared to AIS are:> Less space requirements,

especially in congested cityareas, saving on land costs andcivil works

> Low visibility buildingsdesigned to blend in with localsurroundings

> Less sensitivity to pollution, aswell as salt, sand or even largeamounts of snow

> Increased availability andreduced maintenance costs

> Higher personnel safety due toenclosed high voltageequipment and insignificantelectromagnetic fields.A direct comparison of the

component investment foridentical switchgear configurations

will suggest that the GIS variant ismore costly than the AIS solution.However, this does not show thetrue story. The capability to installa GIS substation within asignificantly smaller site – typicallyup to 80 percent smaller – enablesit to be located close to the loadcentres, providing a far moreefficient network structure at boththe HV (high voltage) and MV(medium voltage) levels. As aresult, both the investment andoperating costs are reduced.

Sites large enough for new AISsubstations are seldom availableand when they are the cost isusually extremely high. But it isnot just the smaller size of the sitethat makes GIS the lower-costoption: GIS is also the moreeconomic alternative whenexpanding or replacing existingsubstations. An inner city site thathas previously been used for an AISinstallation can be sold or rentedout and the income used to financethe new substation. The compactnature of GIS enables an HVtransformer substation to be fullyintegrated in an existing building,which may only have to beincreased in height or have abasement added.

NEDL’S NORTON SUBSTATION

GIS is proving its worth in acurrent ABB project for NEDL(Northern Electric’s distributionbusiness), which serves the fourth

largest geographic area of the 12 regional electricity distributioncompanies (RECs) in England andWales.

The 132kV substation atNorton, near Middlesbrough,which interconnects the NationalGrid and NEDL’s distributionnetwork, supplies power to Teesideand surrounding areas. It is nowreaching the end of its useful lifeand is being replaced to ensurecontinued reliability of supply.

NEDL’s original plan was toconstruct a new outdoor substationalongside the existing substationusing similar air insulatedswitchgear. This would haverequired the purchase of additionalland. When the project came outto tender ABB suggested analternative based on its state of theart compact ELK- 04 gas insulatedswitchgear housed in an indoorbuilding. This has the advantage of requiring only one quarter of thespace, so it will free up land foralternative usage when the existingsubstation is decommissioned.

Within a £9 million turnkeycontract ABB is providing acomplete design, construction andinstallation service for the newNorton substation, which willfeature 20 bays of switchgear andprovide a 132kV interconnectionfor eight incoming and outgoingcircuits. It is scheduled to enteroperation in early 2005.

Substationsshrink to fit with GIS

Pat Osborne, general manager – power systemsprojects for ABB Power Technologies, explains how new gas insulated switchgear (GIS) technologyis enabling urban transformer substations to bereduced in size dramatically, so that they can fit into the tightest of spaces, be housed indoors, oreven underground

Location of the new 132kV GIS substation

Location of existing 132kV AIS substation whichis to be demolished

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1 Aerial view of NEDL’sNorton Installation

2 The new Norton GISsubstation takes shape.

3 GIS taken to its logicalconclusion – anunderground substation inthe centre of Orenze, Spain.

04 FFWD >> Autumn 2003

news

Britain’s railways madethe headlines recently

with Eurostar breaking the UKtrain speed record on asection of the Channel TunnelRail Link (CTRL).

And there is good news for ABBas well. London Electricity Services(LES), the developer, owner andoperator of the trackside electricalinfrastructure within the ChannelTunnel Rail Link project hasawarded ABB a £16.5 millioncontract for traction powerdistribution systems for section 2 of the CTRL project. This is inaddition to substantial earliercontracts.

In a separate win ABB has beenhas been given an £8 millioncontract as part of Network Rail’sWest Coast Main Line powersupply reinforcement programme.This is the latest in a run ofcontract successes with thecompany having won all the 400kVpower upgrade orders placed to datefor the north-bound section of theWest Coast Main Line.

CHANNEL LINK

The latest Channel Tunnel RailLink win is in addition to earliercontracts including the supply andinstallation of power transformers,Static Var Compensators (SVCs)and Load Balancers.

The ABB feeder substations andauto-transformer stations, tailored

specifically for trackside applica-tions, will be a key element in the25-0-25kV power distributionsystem which is being adopted forthe CTRL. This system, which isalready widely used in mainlandEurope for high speed services,allows for a transmission voltage of50kV, while the voltage seen by thetrain is 25kV. Compared with theconventional 25kV systeminvolving booster transformers, thisarrangement provides: fewer trackfeeding points with an increaseddistance between them; fewerconnections to the distributiongrid; reduced losses and unbalance

on the overhead catenary system;capability to support highertraction loads; reducedelectromagnetic interference oncommunications and signallingcircuits.

WEST COAST LINE

The creation of the new 25-0-25kV supply station at Rugeley,which is one of several planned forthe West Coast Main Lineprogramme, will enable NetworkRail to upgrade its local tracksidepower supplies to the 50kV systemrequired for high-speed railservices.

ABB will provide two 400/25kVconnections to feed the line atRugeley. This involves theinstallation of two new ABBsupergrid transformers at the400kV National Grid substation,one connected into an existingspare bay, the other into a new bay.Also included is the construction ofa joint National Grid/Network Rail25kV compound and associatedswitchgear, and the provision of25kV XLPE cables and associatedfibre optic pilots between the twosites.

A 3am call to an ABB duty engineer wasthe start of a series of rapid response

events that went from shutting a productionline at Walkers Snack Foods, in Leicester, torestoring power and production in very shortorder.

An explosion in the internal windings of a highvoltage 1500kVA power transformer in the smallhours had brought output to a halt. By 8am theproblem had been inspected and a replacementtransformer located. An ABB engineer was able to by-pass the failedtransformer and restore power to the production

line while the new onewas on its way.The new transformerwas delivered andinstalled within hours. Itwas commissioned and up andrunning by 8pm on the sameday, less than 18 hours afterthe original emergency phone call.Terry Owen, Electrical Engineering Manager forthe Walkers Snack Foods Group, says: “We werevery impressed by the fast positive response to ouremergency. ABB showed the real value of theirmaintenance contracts in the most practical way.”

Rail Trail

Crisp Response For Walkers

Autumn 2003 >> FFWD 05

news

For the next 25 yearsABB will be responsible

for seeing that the streets ofStaffordshire are always well lit.

The company is the CountyCouncil’s private sector partner in a multi-million pound PFI(private finance initiative) projectto maintain, replace and upgraderoad lighting and illuminatedtraffic signs. Apart from raisingthe lighting standard, work withinthe £5 million per year contractshould contribute to feweraccidents and lower crime on the streets.

ABB marked start of thecontract by launching acommunity web site –www.lightingforstaffordshire.net –to provide information, progress

reports and enable residents toreport problems reports.

BIG TASK

According to Councillor JohnWakefield, Leader of StaffordshireCounty Council’s DevelopmentServices, “Initially, the main workwill involve the replacement of25,000 street lights across theCounty in the first five years. Thecontract also covers maintenanceof our entire stock of over 99,000road lighting units and illumi-nated traffic signs and we expectmore than 98 percent of them to be kept lit at any one time.”

ABB is aiming to completenormal lighting repairs within five working days. However foremergencies, where there is a risk to life or property, it will beproviding a two-hour response.

US

Helping Alaska Avoid The BlackoutAlaska could escape the massive powerblackouts which hit the eastern US andCanada recently thanks to the world’slargest battery energy storage systemwhich has begun operation in Alaska.ABB has supplied a power conversionsystem, metering, protection and controldevices and service equipment.

The US$30-million battery energysystem, includes a nickel cadmiumbattery, and is run by Golden ValleyElectric Association (GVEA), a cooperativeserving the Fairbanks area of Alaska.

The battery will provide continuousvoltage support during normal operation,and stabilise GVEA’s system if powersupply problems occur.

Asset management services trackcritical equipmentABB is helping to manage the powertransmission assets of InternationalTransmission Company, a stand alone,independent electric transmissioncompany responsible for operating andmaintaining more than 2,500 miles ofoverhead and underground high-voltagetransmission facilities in southeasternMichigan. Using the specially developedAdviseIT Asset Sentry system, ABB istracking the condition of all InternationalTransmission Company’s criticalsubstation equipment, includingtransformers, circuit breakers, batteriesand relays..

INDIA

Reliable Inter-regional Power TransferPowergrid Corporation of India Limitedhas ordered a Flexible AC TransmissionSystem worth US$17 million from ABB.Under the contract ABB will build a fixedand thyristor-controlled seriescompensation scheme for Powergrid’s4000 kilometre long, 400kV double-circuitinter-regional tie line.

The line, along with the existing1000MW HVDC back-to-back link inChandrapur will ensure reliable powersupply and stable inter-regional transfer of power from the Eastern to theSouthern region in India.

POLAND

Good For GdanskABB has won a 21 month turnkeycontract worth US$18 million to install ahybrid technology substation in Poland.The new plant will replace a substationbuilt in 1959 and upgrade the electricityinfrastructure around the city of Gdansk.The plant will have low operational andmaintenance costs. The existingsubstation will remain in operation whilethe new one is built.

RUSSIA

Largest Power Technology ContractA US$22 million project to supply 500kVhigh-voltage gas insulated switchgear forthe Bureyskaya hydropower station ineastern Russia will be undertaken byABB.

Compact Resiblocdistribution

transformers from ABBprovided the right solution torestricted plant room accessin Mowlem’s £72 millionrefurbishment of the four starCumberland Hotel nearMarble Arch in London.

Electrical contractor, LorneStewart asked panel builder, RidgeEngineering to install two1600kVA dry type distributiontransformers in the new plantroom. The problem was that notonly would they have to fitthrough an overhead access hatchmeasuring just 1.6m x 1.2m, theywere also required to meet a tight

lead time of just seven weeks fromorder placement. Lorne Stewartcalled in ABB Power Technologiesto help explore the possiblesolutions.

The best solution according toABB project manager DaveSwadling was the company’sflexible Resibloc design. “Insteadof the winding coils being cast inmoulds they are manufactured onnumerically controlled windingmachines using glass fibrereinforced epoxy resin forencapsulation and insulation. Thisenabled bespoke winding coils tobe produced to exactly the rightsize so that we could build thetransformers to the correct overalldimensions to pass through theaccess hatch.

“The whole manufacturingand installation process wentwithout a hitch. The transformerswere delivered at 7.00 am on May10 and installation was completeby 1.00 pm.”

Restricted Room Service

The New Staffordshire Lighting Standard

INTERNATIONAL NEWS

06 FFWD >> Autumn 2003

solutions

Breathtaking Scope

Another widely recognised hallmarkof ABB is quality. But it is not quality

just for the sake of it, it is quality focusedtightly on performance and payback.There is no point in building in features orfacilities that no one ever uses but addingvalue through extended life, resilienceand low maintenance – these are veryworthwhile.

ABB as a whole, and its Power Technologiesbusiness, in particular, provides a well balancedrange of products and solutions. The wordsolutions has become somewhat overused. But

ABB really is adept at answering questions or‘finding solutions’ to technical challenges. Thesesolutions are not merely products that meet thespec, they draw on the experience and expertiseof one of the finest teams in the business. Ateam dedicated to finding answers that cut costs,improve output or reduce risk and maintenancerequirements.

HIGH VOLTAGE EQUIPMENT

In the world of high voltage ABB is one ofthe best known companies. And with goodreason because its expertise and knowledge isunequalled. The total global knowledge pool is

vast but this is also reflected locally in the UKand elsewhere, drawing on experience ofworking with some of the world’s mostdemanding companies.

ABB high voltage solutions include:

Circuit Breakers > Instrument Transformers> Gas Insulated Switchgear > High CurrentSystems > Operating Mechanisms -Integrated Switchgear Solutions > PowerCapacitors > Power Cable Systems > SurgeArresters > Service support.

MEDIUM VOLTAGE PRODUCTS

ABB can meet a vast array of needs forreliable medium voltage switchgear and otherapparatus. There is a global product portfoliobacked up by a local focus including service andsupport with a full understanding of localcustomer needs. For individual users or OEMsolutions ABB is fully equipped to supply andsupport its equipment.

The range includes:

Circuit Breakers & Contactors > MV Fuses > Instrument Transformers & Sensors > Surge Arresters > Integrated Protection &Control Panel Kits & Parts MV Switches > Current Limiters > Vacuum Interrupters > Railway Power Supply > PrimaryDistribution Switchgear > MV MotorControl > Secondary Distribution Switchgear> Outdoor Distribution Products > ModularSystems > Special Products > Power Cables > Power Capacitors > Motors, Generators &Drives > Spare Parts, Retrofit & Services.

DISTRIBUTION TRANSFORMERS

ABB offers a full range of transformers forANSI, IEC and other standards. Dry and casttransformers have primary voltages through36kV. Liquid filled transformers have primaryvoltages through 72.5kV.

If there is one word that describes the ABB product range, thatword is probably ‘breadth’. One look at www.abb.com and youbegin to see that the range of products and services, and moreimportantly the expertise behind them, can only be describedas breathtaking.

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Autumn 2003 >> FFWD 07

solutions

Dry type transformers are being increasinglyspecified for applications where environmentalcontamination and fire hazard must be kept to a minimum. They meet strict electrical systemparameters and perform effectively in extremeclimatic conditions.

The core and coil design is a unique featureof ABB’s liquid-filled transformers giving themthe reliability, durability, and space-savingeconomy required in utility, industrial, andcommercial applications.

POWER TRANSFORMERS

As the world’s leading maker of powertransformers ABB offers a very broad range bothof power transformers and reactors for voltagesabove 72.5kV together with full service andsupport across the world.

The range includes:

Power Transformers > TrafoStar > PowerTransformers > Shell-type > Shunt Reactors>Phase-Shifting Transformers > HVDCConverter Transformers > IndustrialTransformers > Traction Transformers > Transformer Components > InsulationMaterials > Fibre Composite Materials.

LOOSE PRODUCTS

Loose products include a wide variety ofprotection relays from 440V up to 575kV.

UTILITY SERVICES – FROM PLANNING TO PERFORMANCE

ABB’s Utility Services business specialises inthe analysis of medium to large networks. Itconducts traditional system studies (load flow,fault level, voltage regulation, protection, co-ordination etc) putting particular emphasis onperformance optimisation using specialistsoftware, Performance Advantage™ .

The Power System Contracting businessundertakes the construction of new substationsas well modifying and extending existingsystems. The in-house team can tackle projectsfrom planned transformer changes andswitchboard extensions to the constructionmanagement, installation and commissioning of400kV GIS substations.

In the industrial market ABB engineers willundertake operationally sensitive work,integrating with production requirements toavoid disruption to production.

ABB’s Distribution Services unit is expert inthe operation, inspection, maintenance and

repair of electrical power distribution equipmentand systems up to 33kV for both utilities andindustrial organisations.

The Transmission Services business team isresponsible for commissioning, gas handling,intrusive overhaul, condition assessment,planned maintenance and fault response. Theirfocus is on obtaining optimum performanceand long life.

RAIL – STAYING ON TRACK WITH TECHNOLOGY

Recent contracts for the Channel Tunnel RailLink and the West Coast Main Line (see pages 4and 5) highlight ABB’s capability in supportingthe urgent upgrading of Britain’s rail network.

ABB not only has the technology andequipment necessary for fast and cost effectivedeployment on the rail network it can supportthe application of cost-effective and minimalmaintenance solutions.

Using powerful modelling tools the companycan provide vital data on possible failure rates,meantimes between failures and associateddowntime – all with a view to implementing theright technology and achieving minimal risk.

1 LTB Compact switchgearhas enabled BirminghamUniversity’s 132kVsubstation to fit a very tight space.

2 Installing a 400/275kVsubstation transformer.

3 Dismantling of overheadlines for NEDL.

4 Damping system for theWest Coast Main Line.

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focused factories

Delivery in Weeks RatherThan Months

ABB’s focused factory in Lodz,Poland, specialises in the

manufacture of medium-sized distributiontransformers from 250 to 2000kVA forindustrial, commercial and utilitycustomers throughout Europe. It is ABB’sfirst fully Industrial IT-drivenmanufacturing plant and it is deliveringreal customer benefits.

At an international press conference held atthe plant in May, Brice Koch, ABB head ofDistribution Transformers business area, toldjournalists: “The dream of radically improvedspeed has become a reality in Lodz. We have cutcycle time for all products from 16 weeks to twoweeks, production is being doubled and qualityis consistently high.”

HOW IS IT POSSIBLE?Industrial IT is ABB’s patented technology

for providing users of power and automationproducts with fast access to all the informationneeded to install, operate and maintain them. InLodz, Industrial IT links the transformerconfigurator, all the different systems andmachinery in the plant, and provides real-timeinformation.

As Trevor Gregory, head of ABB PTP (UK)explains: “The usual delivery time for adistribution transformer in the industry is fiveweeks. However, the actual production time isonly five days. By making sure that all orderinterfaces and factory production systems arelinked in real-time we have been able to cut thattime drastically.”

ORDERS AND DELIVERY DATES ONLINE

“Customer benefits begin at the start of theprocess,” continues Gregory. “Ordering adistribution transformer is carried out by“CollaborateIT Quotation and Pricing System –Trafonet”, an online configurator rather than

the traditional, slower approach in whichquotations and offers were produced from “hardcopy” catalogues and price lists quoting standardlead times for delivery.

“With the latest technology, a salespersonmeeting a customer can immediately configure

the technical data for a transformer on a laptop, quote a price, verify the factory’sproduction capacity and schedule, place theorder in the Enterprise Resource Planning(ERP) system at the factory, and confirm thedelivery date.”

ABB’s focused factory in Lodz, Poland, specialises in the manufacture of medium-sized distribution transformers from 250 to 2000kVA for industrial, commercialand utility customers throughout Europe. It is ABB’s first fully Industrial IT-drivenmanufacturing plant and it is delivering real customer benefits.

08 FFWD ISSUE 5 >> Summer 2003

1 50 journalists from 16countries participated at thefirst media viewing of ABB'sIndustrial IT factory in Lodz,Poland

2 No paper work anymore atthe ABB distributiontransformer factory in Lodz:the Industrial IT systemprovides the operators witheverything they need toproduce uniquetransformers.

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automation

Malaysia’s newest coal-fired powerstation at Manjung is fully controlled

by one of the largest control systems evermade by ABB.

Control of the station, which is fuelled by sub-bituminous and other low-sulphur grade goal for minimum pollution,involves some 25,000 I/O, plus 24 serial linksfor soft I/O. The £640 million plant has beenconstructed by a consortium consisting ofAlstom Power and Peremba Construction, a local company.

The ABB automation system was specifiedby the end user following successful use at manyof its other power stations. Thesystem controls all areas of thepower plant including boilers andburners on the three 700MWgensets, coal mills, flue gasdesulphurisation and commonservices such as feed pumps.

As a starting point for futureasset optimisation strategies,much of the instrumentation hasbeen delivered with HARTcapability – ABB’s Contrans 1interface system allowing digitalinformation to be accessed and

used for non-control purposes.Another interesting feature is the human

interface technology. Initially an operatorinterface for plant control, it can be used as a later stage for web-based plant management.This ties in with the trend towards ever-largersystems controlled from a central point,including initiate sequences and the gathering of maintenance and management information.

The Manjung plant is located 200 kilometresnorth of Kuala Lumpur on the west ofMalaysian peninsular. It has been built forJanamanjung Sdn Bhd, a subsidiary of thecountry’s electricity utility, in response to a fast-growing demand for power.

ABB Contrac actuators are helpingScottish Power’s 300MW Cockenzie

coal-fired power station on the Firth of Forthprepare for the advent of BETTA (the BritishTrading and Transmission Arrangements).

The original control system for the steamgenerators at the 35-year old station would nothave been sufficient to cope with the new tradingregime. However, when Andy Geddes, whomanages the station’s control system, discussedthe fine points of actuators with Dave Pridgeon ofABB Power Technologies it became clear that thenew Contrac actuators could provide the idealcost-effective solution.The Contrac actuator has the fineness of controlnecessary to modulate the output of a steamturbine to the precise levels required. As AndyGeddes says: “Embedding this new piece ofequipment into the heart of the old system haspreserved the original operating characteristics andprotection functions. The flyweight governor stillprovides the crucially important first level of overspeed function. But the Contrac actuator hasremoved the reliance on gearing that was the mainsource of inaccuracy and problems with backlash.”

Cockenzie Power Stationnow BETTA prepared

Fire power under control

AUTOMATIC ASSET INFORMATION

All asset information for finishedtransformers at Lodz is automatically organisedin an “Aspect-Object” format enabling ABB toprovide customers with a detailed electronicrecord of drawings, technical data, test resultsand other necessary data for managing theirinvestment. .

“ONE GLOBAL FACTORY”

The Lodz Industrial IT model is scheduledto be copied at other ABB focused distributiontransformer factories around the globe, makingit possible to check capacities and provide anonline answer about which factory can carry outan order quickest.

“We are in the process of implementing the‘virtual’ global factory concept. Oncecompleted, it will be an importantbreakthrough for ABB in the drive for increasedspeed and the full utilisation of capitalresources,” says Brice Koch. “With our focusedfactory approach and Industrial IT platform, itdoesn’t matter whether the transformer ismanufactured in Poland, Germany, China orthe United States. It will always be a top quality‘made by ABB’ product. And you can be sure ofa fast delivery.”

Focused to meetUK needsCustomers requiring a particular UKspecification should look no further than theABB Waterford transformer facility in SouthernIreland.

Denis Casey, Marketing Manager at Waterford,explains. “Pole-mounted transformers arewidely used by utilities in the UK and Irelandfor overhead distribution networks. Followingmajor investment in new technology, Waterfordis now the ABB focused factory for singlephase pole mounts in Europe.

“We are also the European centre ofexcellence for EATS (Electricity AssociationTechnical Specification) ground mounttransformers following the transfer ofmanufacturing from Dundee. And, we havebeen designated as the European focusedfactory for the development of single phaseand three phase padmount transformers in therange 50kVA to 2MVA.”

> Single and three phase pole mountedtransformers from 10kVA to 315kVA

> EATS ground mount transformers from200kVA to 2,500kVA

> Single and three phase padmounttransformers from 50kVA to 2MVA

Autumn 2003 >> FFWD 09

010 FFWD >> Autumn 2003

renewables

Our Energy FutureIn July, Trade Secretary PatriciaHewitt gave the green light for the

next generation of offshore wind farms toprovide up to 6GW (gigawatts) of newenergy generation by 2010, enough topower one in six UK households. This,coupled with further plans to increasecapacity from medium sized CHP(combined heat and power) and improveenergy efficiency, means that significantsteps are now in place to achieve thegovernment’s ambitious targets.

“Growing political pressure to reducegreenhouse emissions is driving a trend towards‘distributed’ electricity production and supply,”comments Peter Jones, Business DevelopmentManager ABB PT (UK). “While large powerstations will continue to be vitally importantsources of electricity, the aim is to havedistributed power generation from combinedheat and power plants, wind turbines, fuel cells,biomass and other small generating units closerto the point of demand. This power will be

actively managed to meet local needs and tofeed surplus power into the national gridsystem.”

Described by industry experts and the UKgovernment as the ‘Rewiring of Britain’, aconsiderable degree of new engineering effortwill be required to achieve this as Jones pointout.

“Putting energy generation and storage onthe users’ doorstep requires an economic andenvironmentally sound way to adapt the currenttransmission and distribution network if we areto minimise investment, improve reliability andlower costs of generation connection and energysupply.

“Technological innovation has a key part toplay in underpinning these goals and indelivering a low carbon economy cost-effectively,” he continues. “As the world’snumber one supplier of innovative powersystem technologies, ABB is ideally placed toadvise on and provide the technology to connectwind and other distributed sources to the gridand distribution networks, economically andefficiently.“

THE TECHNICAL CHALLENGE

The UK transmission and distribution powernetworks have been designed to carry powerfrom centralised power stations via transmissionlines to the distribution companies and then onto customers via the distribution network. Thecost-effective accommodation of large offshorewind farms and embedded CHP units inmature distribution systems, whilst maintainingsecurity of supply standards, demandsinnovative connection solutions.

“ABB is actively working with DistributionNetwork Operators, wind farm developers,government and regulatory bodies to bringexisting global ABB technology and innovativesolutions to address many of the embeddedgeneration connection issues,” explains Jones.

“Our experience inn installing powernetworks all over the world – many involving

small-scale generation in developing economieswhere large-scale transmission and generationinfrastructure does not exist – is particularlyrelevant. It allows us to develop and deployinnovative solutions based on tried and testedinstallations.”

ABB INNOVATION

The operation of large-scale offshore windfarms presents a number of technical challengesparticularly in the areas of subsea transmissionand power system stability and security. ABB’sDC power transmission technology (HVDCLight) for the supply of large-scale electricalenergy to offshore oilrigs, is the first of its kind.The adaptation and application of thistechnology will allow secure connection of thehundreds of UK wind farm turbines nowplanned to be positioned many miles out to sea.

Connecting small scale embedded generationinto existing utility networks can increase localfault levels beyond the rating of existingswitchgear, requiring expensive switchgearreplacements which would make the cost of thegenerator connection too high for the project toremain feasible.

To address this problem, ABB has developeda technology that enables direct connection ofgenerators to be made without the need toupgrade existing switchgear. “Its application willenable many new generator connections whichotherwise would have not been economicallyviable,” comments Jones.

SUSTAINABILITY

ABB’s commitment to sustainabledevelopment is underscored by the developmentof eco-efficient state-of-the-art products andsystems for distributed power.

Technologies which help reduce the cost of connection and of operating embeddedgeneration whilst maintaining network securityand reliability. Technologies that will helpalternative and renewable forms of energy takecentre stage.

The Energy White Paper committed Britain to providing10% of energy from renewable sources by the year 2010,and an aspiration to double that by the year 2020.Peter Jones comments.

Autumn 2003 >> FFWD 011

product roundup

The ABB SafePlus range ofSF6 gas-insulated compactsecondary switchgearprovides a flexible, user-friendly, modular and fullyextendable solution for a widerange of distributionapplications up to 24kVincluding single panels, ringmain units and switchboards.

Typical SafePlus installationswill include building services, lightindustry, secondary substations,light mining, tunnels, undergroundrailways and wind turbines.

SafePlus panel types availableinclude fault make, load break

disconnectors at 630A, fault make,fault break circuit breakers at 630Aand 200A. Air insulated meteringpanels can also be supplied.

An ideal application for SafePlussingle panels is to isolate and earthdown a single transformer formaintenance. Typically thetransformer will be fed via a longradial cable, possibly from aswitchboard owned by a utilitycompany. Having a local 11kVisolator means that the transformercan be isolated and earthedwithout having to pay for theinvolvement and services of thelocal Regional Electricity Company(REC).

SafePlus – the ideal compactsecondary switchgear solution

Stockanswer fordistributiontransformers For customers who need atransformer ‘right now’, then ABB’sstock range of ONAN distributiontransformers – available for deliverywithin one week – could be theanswer. Stock is available in the following ratings:

> 315kVA> 500kVA, > 800kVA, > 1000kVA, > 1250kVA, > 1500kVA> 2000kVA> 2500kVA

email distrans.sales@gb.abb.com

TEC monitors transformers’ vital signsPower transformers are critical, high-valuelinks in any power system. If they fail or

have to be removed from service formaintenance, major parts of the grid may shutdown.

Utilities need their transformers to work at optimumperformance for as long as possible. This requires detailedknowledge of the transformers ‘state of health’, so ABBhas developed the TEC (Trafostar Electronic Control)system to maintain complete, real-time control oftransformers.

The TEC system is a significant advance overconventional transformer data displays, which are usuallyprovided by monitoring instruments on a component-by-component basis wired into a control room. Instead,TEC collects all the information it needs from just a fewmulti-purpose sensors and transmits a constant stream ofinformation over a single fibre-optic link back to thecontrol room. And unlike other monitoring systems,TEC can intervene operationally and make decisions andrecommendations based on available real-time data. Forexample, TEC can direct the cooling system to ensuredifferent fans are used in rotation, switching coolers tomanage usage, wear and efficiency. And it can control andoperate the tap-changer. Discrepancies and potentialmalfunctions can be flagged, avoiding breakdowns andoutages.

All new ABB power transformers are being deliveredwith TEC as standard.

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www.abb.com

ZX1.2 switchgear now UKnetwork approved

ABB’s new ZX1.2 range of metal-clad gas-insulated medium voltage

switchgear has successfully completedthe rigorous testing demanded by the

Electricity Association (EA) and NetworkRail in order to gain technical acceptancefor use at 33kV for ratings up to 31.5kAand 2000A. As well as receiving the vitalEA Notice of Conformity Certificate theZX1.2 range has already been acceptedfor use on the prestigious Network RailSouthern Region Power Supply Upgradeproject.

ABB has designed the ZX1.2 range with amodular, plug-in approach which meets

the specific needs of ElectricityDistribution Network owners and

operators by providing compact,flexible substation configurations

to offer reliable and costefficient switchgear solutions

for single busbar applications. ZX1.2 is also ideally suitedto a wide variety of utilityand industrial applicationswherever electricity isgenerated or distributed.

The key features of theZX1.2 design include laserwelded stainless steelenclosures, compactmodular construction andthe introduction of plug-intechnology which

facilitates simple, controlled connections ofbusbar, cable, test bushings and voltagetransformer without the need for ‘on site’ gashandling equipment.

All maintenance-free live components, suchas switching devices and busbars, are containedunder SF6 in gas-tight enclosures, whicheliminate the effects of ageing processes andenvironmental influences to ensure maximumoperator availability and a long service life.

The ZX1.2 design also offers easy cableaccess at the rear with termination fixing at aconvenient height of 1250mm, generousprovision for conventional control andprotection devices, dedicated cable test socketsand full mechanical interlocking between thedisconnector/earthing selector and the circuitbreaker.

Current transformers can be mounted eitherin the circuit breaker gas compartment orexternally on the HV cables. Alternatively,options are available for current and voltagesensors.

ZX1.2 switchgear was assessed againstElectricity Association Technical Standard

(EATS) 41-36 “Distribution switchgear forservice up to 36kV (cable and overheadconductor connected)” and has been issued witha Notice of Conformity (NOC) certificatenumber 1027.

ABB’s new range of gas-insulated MV switchgearhas gained technical acceptance from the EA andNetwork Rail

CONTACTS

Substations – 01783 825050

HV/MV Switchgear – 01923 741469

Automation – 01783 825050

Service – 0845 6011946

Transformers – 01923 741469

Asset Management – 01783 825050

Wind Power – 01783 825050

General Enquires – 01783 825050

For further information about any of these subjects please contact: