Rail
SUMMER/AUTUMN 2008
FAST FORWARD WITH ABB POWER SYSTEMS & PRODUCTS
Cooking up a power solution for McCain’s Home Fries page 3
Rapid repair gets Corus of approval page 5
A tight fit for Thames Valley substations page 8
The Baltic connection page 9
Jubilee Line – more power, more passengers page 10
See page 6
Lifetime decisions A new approach to asset management
www.abb.com/ffwd
Issue 19 Summer 2008
Team work starts at the top
contents 3
Cooking up a power solution for McCain’s Home Fries Power factor correction technology helps the Home Fries company avoid an infrastructure upgrade
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Controlling risk is a key business priority and I would like to take this opportunity of advocating the role teamworking can play.
Lifetime decisions A new approach to asset management helps produce a better return on investment
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£24 million Thames Valley substation deals New contract for GIS switchgear requires innovative approach to installation
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ABB UK Managing Director
News UK and international news
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Trevor Gregory
The Baltic connection The Fenno-Skan link, connecting Finland and Sweden, is being upgraded
10 Jubilee Line – more power for more passengers The inside story of ABB’s fast track contract to upgrade the DC traction power system
11 Thinking inside the box Containerized switchgear provides a fast-track solution for process industry
12 Feeder protection relay gets ENA approval The new REX521 feed protection relay is the latest ABB product to win Energy Networks Association approval
I think that within our businesses and business centres we have increasingly embraced teamwork in recent years due to the benefits that can be derived such as reduced risk, better cost control and a real "buy-in" and commitment to the promises and targets that an organisation is expected to deliver. Teamwork starts at the top of any organisation. Senior managers cannot issue edicts instructing others to teamwork whilst reserving for themselves the privilege of standing aside and not engaging actively themselves. Teamworking demands ‘leadership’, leading by example, particularly important when the team involves more than one organisation. It also requires the development of trust. It calls for the sharing, willingly, of best practice between ‘team-mates’ but can also call, on occasion, for constructive criticism between the parties. In my experience, few companies have the teamworking experience that ABB has accumulated over the years. One recent successful example is the work we are doing as a member of the National Grid Electricity Alliance. Our aim is that no-one should ‘see the joins’ in a team that involves ABB, Atkins, Morgan Est and, of course, National Grid. It behaves as a single entity with a clear remit, and overriding focus on delivery. All this might sound a little idealistic, but in a world of intense competition, dynamic decision-making and ever-increasing focus on areas such as health and safety, teamworking provides an excellent framework for removing cost and risk. Of course, the traditional roles of supplier and customer are not lost altogether, but those priorities have to stand alongside the priorities of the team.
Read this issue online: www.abb.com/ffwd
Each party must have a distinct contribution to make. In our case this is usually our experience and expertise in project management, engineering and service, coupled with the full range of technologies that ABB can offer.
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Published by:
Editor:
ABB Limited Power Systems Division Oulton Road, Stone, Staffordshire ST15 0RS
Karen Strong
FFWD >> SUMMER/AUTUMN 2008
Telephone: 01785 825050 www.abb.com/uk
ABB has a real track record of delivering on every front, a fact that I hope will become apparent as you read on. Certainly, if times get tougher there’s a lot to be gained by further consideration of this approach.
Power factor
Cooking up a power solution for McCain’s Home Fries
ABB automatic power factor correction technology has enabled McCain Foods to make more efficient use of the existing power network at its Scarborough site and avoid a major investment in new power infrastructure. The company has been able to get its new Home Fries production line up and running using existing supplies.
While McCain Foods was in the process of planning the new Homes Fries production line it became clear that the existing power network, already operating close to its maximum 9.5MW load, would not be able to cope with the major additional demand. The company was faced with an estimated cost of around £250,000 to install an additional 11kV/400V substation. Worse still, the YEDL power lines that feed Scarborough from the York Distribution Centre were already operating up to their limit. McCain called on ABB for help. The first step was a site survey which established that a number of FFWD >> www.abb.com/ffwd
key loads were operating at a significantly low PF (power factor). PF is essentially a measure of how effectively electrical power is being used. The closer to 1 this figure it actually is, the more effective the usage. ABB’s verdict was that the installation of suitable power factor correction equipment would significantly improve network efficiency and release sufficient useable power to meet the needs of the new Home Fries line. ADVANCE AUTOMATIC CAPACITOR BANKS
The solution devised by ABB was to install its sophisticated Advance automatic capacitor banks at eight strategic points in the McCain network – representing a total of 2,900 kVAr. This has restored the PF to acceptable
industry standard levels, ranging from 0.95 to 0.97, and has made an extra 600kVA of power available. This enabled production to start in April 2008 without the need for any new network infrastructure. Bill Bartlett, Corporate Affairs Director of McCain Foods said: “ABB’s power factor correction equipment has played a key role in our energy efficiency programme that enables the line to draw all the power it needs from our existing
power network – without the need for significant capital expenditure on a new substation and power lines.”
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News
MV switchgear in the frame ABB has signed a three-year frame agreement with EDF Energy Networks to supply 33kV ZX1.2 singlebusbar switchgear for substation refurbishment and new-build projects in London, and the East and South-East of England – an area serving around 7.8 million consumers.
As part of the frame agreement, ABB has already been awarded a contract worth around £1 million to supply 68 panels of ZX1.2 switchgear for a number of EDF Energy Networks sites. The agreement makes ABB one of just two potential suppliers for the energy company’s 33kV single-busbar switchgear. It has important
benefits for both parties – EDF Energy Networks can rely on security of pricing and delivery over the next three years, while ABB is guaranteed a volume of orders that enables it to plan factory workload. ABB’s ZX1.2 switchgear features a modular, plug-in approach to meet the specific needs of electricity distribution network owners and operators. It enables compact, flexible substation configurations that offer reliable and costefficient switchgear solutions for single-busbar applications. It has technical acceptance from the Energy Networks Association (ENA) and Network Rail for use at 33kV for ratings up to 31.5kA and 2,000A. Key features of the ZX1.2 switchgear include laser-welded stainless steel enclosures, compact
modular construction and plug-in technology that enables simple, controlled connection of busbar, cable, test bushings and voltage transformer, without the need for ‘on site’ gas handling equipment. All maintenance-free live components – such as switching devices and busbars – are contained under SF6 in gas-tight enclosures, which minimize the effects of ageing and environmental influences to ensure maximum operator availability and a long service life. The ZX1.2 design also offers easy cable access at the rear, with generous provision for conventional control and protection devices, dedicated cable test sockets and full mechanical interlocking between the disconnector/earthing selector and the circuit breaker.
Sustaining innovation The deadline for entries in 2008 IET Innovation in Engineering Awards was late July. Even if you missed your chance this year, it’s worth keeping an eye on the awards’ process with a view to entering next year. ABB sponsors the Sustainability Award and is looking forward to seeing this year’s crop of exciting entries.
ABB’s ZX1.2 switchgear of the sort being supplied to EDF Energy Networks.
Asset performance The 2008 Euro TechCon® conference will take place in Liverpool from 18 to 20 November 2008. ABB will participate in the event, whose central theme is the management of high-voltage assets. This will include a strong focus on core high-voltage assets, principally transformers, switchgear and load tap changers.
According to the IET, the Sustainability Innovation Award is the most all-encompassing of all the categories. It is open to any innovations in the fields of engineering, science and technology that demonstrate a contribution to sustainability. Entries can cover projects, processes, products and initiatives from individuals, small teams or organizations (both engineers and non-engineers). They can cover entirely new concepts or the development of existing processes or products. The winners of this and other categories in the IET Innovation in Engineering Awards will be announced at the annual ceremony at the IET in London on 3 November 2008. Entries for the 2009 awards will be accepted from November this year. Keep watch at http://conferences.theiet.org/innovation_awards/ index.htm.
Along with conference presentations, workshops and panel sessions, the conference features an exhibition that provides extensive networking opportunities as well as the opportunity to learn about the latest in technology developments. More information can be found at http://www.techcon.info/ETC08/. ABB’s Trevor Gregory (left) with Johnny Ball (right) and last year’s winners.
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News
In complete control of Connah’s Quay
INTERNATIONAL NEWS INDIA Delhi’s T3 ABB has won a US$77 million order to design, supply, install, test and commission electrical products and systems for the new Terminal 3 (T3) building at Indira Gandhi International Airport in Delhi, India. ABB’s solutions are part of a modernization project to prepare the airport for the 2010 Commonwealth Games. The order covers electrical infrastructure and control systems including low-voltage panel, cabling, wiring, conduits, light fixtures, bus ducts, Uninterruptible Power Supply (UPS) equipment and a distribution transformer.
A view of Connah’s Quay power station Deeside, North Wales.
ABB has won a major contract from E.ON UK to replace the existing VAX-based operator stations at its 1,420MW Connah’s Quay Combined Cycle Gas Turbine Power Station at Deeside, North Wales with new MS Windows-based power generation portal consoles. The contract includes the installation and commissioning of the full system including ancillary services, staff training and a system for converting graphics from the existing installation to the Windows operating interface.
Key considerations in the new system have included ensuring backward compatibility for existing graphics and retaining the existing ‘look and feel’ of this part of the system. The existing graphics and databases were created in ABB Composer software. The new installation will convert the graphics to run on the new system’s Windows-based platform. The
current control system has more than 1,000 graphics screens on each unit, and a further 150 on common services. The existing installation consists of four generating systems and common services. Each generating unit has four operator screens and there are two servers and two client consoles on the system. There are two servers and one client console for common services. The SODG graphics used on the existing OIS-40 series consoles will be converted to power generation portal (PGP) graphics. The contract includes the supply and installation of a wide range of network interfaces, switches and peripherals as well as cabling, desk and alarms. In addition, ABB will provide installation and commissioning, inspection and testing, training and spares. ABB also recently completed the replacement of the Connah’s Quay steam turbine supervisory system.
Rapid repair gets Corus of approval A failed furnace transformer at Corus’s integrated iron and steel plant in Scunthorpe threatened the company with serious lost production – until ABB’s transformer service team came to the rescue.
Taking the transformer off-site for a factory repair would have taken at least six weeks, while the current lead-time for a brand new transformer is 18–24 months. Corus needed a speedy solution and turned to ABB’s UK power systems service team for help. DIAGNOSTIC TESTS
The Corus plant in Scunthorpe.
Earlier this year, ABB’s on-site transformer diagnostic and repair service enabled one of Corus’s Scunthorpe plants to restore full production less than 10 days after the failure of a 132/33kV furnace transformer in the Basic Oxygen Steelmaking (BOS) facility. Corus Scunthorpe is the UK’s largest integrated steel plant, able to produce 4.5 million tonnes per annum. The steelworks has three furnace transformers in the BOS plant, and an unexpected failure reduced the plant’s ability to manufacture some of the technically challenging grades of steel. FFWD >> www.abb.com/ffwd
A series of tests using non-invasive diagnostic techniques showed that the fault was in the transformer tap-changer in the main tank. This is quite a common problem with furnace transformers, as they operate under severe conditions compared with transformers in power network applications. They experience frequent cyclic loading, due to the operation of the high-voltage circuit breaker, as well as over-currents and over-voltages generated by short circuits in the furnace. The good news for Corus was that ABB’s newly developed on-site repair service enabled the transformer’s active parts to be removed from the tank so that access could be gained to the faulty tap-changer. All the failed components were replaced on site, in a fraction of the time required for a factory repair. The whole unit was back in use ten days after the initial failure.
QATAR Combined-cycle power plant Hyundai Engineering and Construction (HDEC) of Korea has awarded ABB a US$233 million contract to supply power systems and grid connections for a natural gas and steam turbine (combined-cycle) power plant, to be built in Qatar. The US$3.7 billion Ras Laffan C plant will generate 2,730MW, and produce more than 286,000 cubic meters of potable water per day. ABB will supply substations, transformers, generator bus ducts and breakers, medium- and low-voltage switchgear, the emergency power supply and the plant’s cable systems. It will also provide engineering services, construction supervision, commissioning and training.
CHINA The HVDC connection ABB has won a US$70 million order for power equipment from State Grid Corporation of China for a new power link in northeastern China. The new highvoltage, direct current (HVDC) link will transmit 3,000W over the 920km from Hulunbeir, Inner Mongolia, to Shenyang, Liaoning province. The ABB order is part of a project with an estimated total value of US$400 million. ABB will provide key components for the converter stations at each end of the link, as well as measuring equipment for the converter stations. The link is scheduled to enter commercial operation in December 2009.
THE NETHERLANDS A magnum order ABB has won a US$150 million contract to provide power systems and grid connections for a natural gas and steamturbine (combined-cycle) power plant in the Netherlands has been won by ABB. The new 1,300MW Nuon Magnum power plant on the North Sea coast will feed electricity into the existing Dutch high-voltage grid and could supply power to around two million households. ABB’s scope of supply includes electrical components for the auxiliary power supply systems, a 380kV high-voltage substation and the switchgear building. ABB will also provide 380kV cables, transformers, generator breakers, medium- and low-voltage switchgear, emergency-power diesel sets, batteries and communication systems, as well as engineering, installation, commissioning and training.
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05
Asset Management
Lifetime decisions Liam Warren, ABB’s UK transformer service operations manager, explains how a new approach to asset management can provide greater visibility and predictability for asset managers, enabling them to decide on the appropriate preventive maintenance plans and to target new investment for maximum effect.
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Looking for the maximum return on fixed assets is part of everyday business - whether in the electricity utilities or general industry. Deregulation of the energy market and increasing pressure to reduce costs are forcing managers to look continually for ways to reduce the lifecycle costs of their installed assets and improve return on investment. The situation is especially acute in the case of power transformers. A substantial proportion of the worldwide transformer population is nearing the end of its lifetime, and there is an urgent need to optimize transformer fleet performance through higher availability. Naturally, this has to be achieved at the lowest possible cost and with minimal environmental impact. In the past, it was usual for asset-related decisions to be based primarily on accumulated experience. Capital expenditure was mostly trigged by high growth in energy demand and power assets were replaced by new and more powerful installations long before reaching the end of their useful lifecycle. But in today’s rapidly changing environment, with its severe technical and financial constraints, asset managers need to base their strategic decisions on precise and reliable data in order to convince the ultimate decision makers. However, one of the most frequent challenges faced by transformer owners is the lack of reliable information on asset condition and the difficulty in defining improvements that are justified from both a financial and technical point of view. ABB’s Mature Transformer Management Programme (MTMP) is designed to fill that information gap. This methodology is based on four steps.
STEP 1: TRANSFORMER FLEET SCREENING
Large transformer fleets (from 20 to over 100 units) are evaluated using readily available data such as type of application, time in operation, gas in oil, power factor, maintenance history and major events or experience with sister units. The aim is to obtain a general ranking for the population, based on technical and economic criteria, and to identify clusters of units requiring further investigation or some basic maintenance. This first-step screening also provides key information for estimating an outline budget for future maintenance or unit replacement, and identifies the units that should be given priority. STEP 2: TRANSFORMER DESIGN AND CONDITION ASSESSMENT
A smaller number of units (typically 10 to 20) are selected from Step 1 and modern design, testing and quality assurance tools are used to evaluate their design and construction. In addition, advanced diagnostic tests are performed to assess each of the principal properties of the transformer, including: mechanical condition, thermal condition (ageing of the insulation), electrical condition of the active parts and the condition of the accessories such as tap-changer(s), bushings, over-pressure valves, air-dryer system, pumps and relays. This process provides important information about the condition and suitability of the units and enables the identification of the appropriate maintenance, repair or retrofit activity required to ensure their reliability. Actions could include: listing of spare parts to
Asset Management
be kept in stock, a prioritized list of on-site maintenance measures, and proposals to relocate units, decrease their load or replace them. Costs are reduced, as action is restricted to certain components and is only taken when it is really needed. For example, if the actual condition of an ageing transformer is suitable for overloading but not for short-circuit operation, action could be focused on just improving the rigidity and clamping of the winding blocks. STEP 3: LIFE ASSESSMENT/PROFILING
Life assessment/profiling ranks the transformer population according to the evaluated reliability of each unit. Priority can then be given to taking corrective or preventive action on the most critical units to improve the overall reliability of the fleet and reduce the costs associated with the risk of unplanned outage. Maintenance priorities are driven both by technical considerations related to the condition of the units and also the overall strategy of the company that owns the assets. Several asset management scenarios are therefore possible. An important criterion directly linked to the strategy of the asset owner is to minimize the lifecycle cost of the assets or the total cost of ownership. ABB has taken the life assessment approach a stage further by working in conjunction with utility companies to develop a financial model that evaluates the lifecycle cost of a transformer fleet or individual unit over a given period. The model enables the end-user to derive the maximum value from the exercise and helps decision makers and asset owners identify the most financially efficient maintenance scenario. STEP 4: IMPLEMENTATION OF ENGINEERING SOLUTIONS
Based on the results of this rigorous analysis programme, engineering solutions are identified
to achieve risk reduction, life extension and the general health improvement of the fleet. These solutions include: • preventive and corrective maintenance • field repair and retrofit • relocation and transportation • testing and advanced diagnostics • factory repair • planned transformer replacement. In addition to the traditional transformer maintenance and repair techniques, some new technologies are now being adopted, including on-line oil regeneration, on-site repair, lowfrequency heating and ‘better than new’. On-line oil regeneration has demonstrated technical and economical advantages when applied to old transformers with aged acidic oil. It is more environmentally friendly than oil replacement and shows a much better efficiency over a long time. ABB has developed an extremely efficient and cost-effective on-site repair service that effectively takes the factory to the transformer. It is ideal for remote locations where transportation is difficult and costly. However, on-site repair is also increasingly popular as a way of getting missioncritical transformers back on line quickly, at a fraction of the cost and lead-time required to install a new replacement unit. A low-frequency heating (LFH) system can dry transformer active parts much faster, without compromising quality. The remaining moisture content of the solid insulation is typically below one per cent. The drying time can be less than half that for a traditional hot oil and vacuum process. This reduction in lead-time when drying a wet transformer or repairing a failed unit on site could be vital. For operators who need to boost the power of their existing units, ABB offers a ‘better than new’ service under which coils are rewound with Nomex® high-temperature insulation material. This results in significant improvements in
lifetime and reliability. As well as the cost advantages for the unit, side benefits include: lower environmental impact than scrapping, no construction needed to prepare the site (the footprint remains identical), and lower weight than conventional units. CONCLUSION
The MTMP approach to asset management provides vital evidence to support transformer owners deciding whether to maintain or replace their fleet. On a long-term strategic level, a significant benefit of such a study is that it provides a clear picture of the maintenance and renewal investments required over the next 20–30 years to deliver the required asset reliability and availability. It provides solid information to compare different asset management strategies and to select the approach that best supports the organization’s overall technical and financial strategy. A programme to extend the lifetime of aged units will, for example, postpone investments in new units and so improve the cash flow of the company. In the medium term, asset managers can identify how best to use maintenance and replacement budgets. Funds can be allocated to units that show the best return on investment, while reducing technical and operational risks. In the short term, the method enables the maintenance manager to quantify the costs and benefits of each planned maintenance action.
Life management process: The 3 + 1 steps ABB approach
Transformer fleet
Step 1 Transformer fleet screening
Step 2 Transformer design & condition assessment
Regular diagnostics History
Step 3 Life assessment & profiling
Advanced diagnostics Design review Replacement
Refurbishment
Upgrade
Engineered solutions
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Step 4 Engineered solutions
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07
Substations
£24 million Thames Valley substation deals
A view of the Reading Earley site at the start of the project.
Scottish
and Southern Energy (SSE) has awarded two Thames Valley substation contracts worth a total of £24 million to an ABB and Balfour Beatty consortium. The consortium will design and construct two new indoor state-ofthe-art gas-insulated switchgear (GIS) distribution substations at Reading, Berkshire and Iver Heath, Buckinghamshire to replace existing outdoor air-insulated switchgear (AIS) substations that are approaching the end of their service life.
A key element in the Reading project will be the use of ABB’s innovative PASS MO switchgear modules to provide a temporary space-saving solution that will free up vital building space. This will enable the new GIS substation to be built in the very restricted space available at the existing site. The new 132kV substation at Reading and the 66kV substation at Iver Heath are ABB’s first major substation projects for SSE. They play a vital role in SSE’s plans to reinforce its distribution network in the south of England to ensure security of supply and provide
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additional capacity. SSE regards both sites as flagship projects and asked the consortium to deploy innovative, cost-effective solutions that will enable the new GIS substations to be constructed within the confines of the existing AIS sites.
When complete, the new 132kV substation will comprise 13 bays with space for four future circuits. After all the circuits have been transferred to the new substation, the temporary PASS MO modules will be removed.
VITAL CONSTRUCTION SPACE AT READING
FAST TRACK FOR IVER HEATH
The Reading site is already completely full with AIS switchgear which has to remain in service until the circuits can be transferred to the new substation. The option of expanding into nearby heavily wooded green space to make room for the construction of the new indoor GIS building was rejected because of the planning time, expense and project delays involved. ABB’s solution uses its proven modular PASS MO switchgear as an interim measure while the new GIS building is built within the existing site. By dismantling old generator circuit-breakers that once served the demolished North Earley power station, just enough space will be freed up for ABB to install its PASS MO modules that will take over the operation of the existing AIS circuits.
The construction of the new 66kV substation at Iver Heath is more straightforward, as there is already sufficient space on the existing site. The challenge here is to get the new GIS substation on line as quickly as possible. The consortium is placing a major emphasis on planning and logistics. The Iver Heath site is on the floodplain of the River Colne, so the building is being constructed on stilts to protect it against the predicted level of a once in 100 years flood. This approach has already proved a successful method of flood protection in UK installations. When complete, the new substation will provide six extra bays, taking the total number of bays to 24.
HVDC
The Baltic connection FINLAND Rauma Finnböle
SWEDEN
Dannebo
The announcement of the Fenno-Skan 2 link, due for completion in 2011, has given renewed impetus to international co-operation in the sharing of power resources. The new 800MW high-voltage direct current (HVDC) connection between Sweden and Finland builds on the success of the existing 572MW link, which came into service in 1989 and was upgraded in 1998.
ABB delivered the original link and will be supplying two HVDC converter stations for the new connection. HVDC is a technology that enables power to be transmitted over long distances with minimal transmission loss. ABB pioneered HVDC more than 50 years ago, with the first link connecting the Swedish island of Gotland with the mainland. Since then, HVDC systems have been installed around the world, with the vast majority being built by ABB. The company has participated in a total of 60 HVDC projects worldwide with a total capacity of more than 48,000MW. In recent years, there have been a growing number of cross-border and undersea HVDC projects, including the NorNed and the BritNed links in Europe. THE NORTH-SOUTH DIVIDE
The Finnish and Swedish power transmission are part of the Nordic Nordel joint grid. Both countries have similar challenges with power generation and distribution. While power
FFWD >> www.abb.com/ffwd
consumption is largely focused in the south, hydro power generation is centered in the north. The existing AC connections are also in the north, resulting in long transmission distances between the two nations. By using HVDC interconnections in the south, overall power capacity is greatly increased with easy redistribution of load flows between the networks, which in turn reduces the losses in the Nordel grid as a whole. FIRST STEPS
Fenno-Skan 1, a monopolar 500MW HVDC interconnection across the Gulf of Bothnia, came into service in November 1989. It was the world’s first 400kV HVDC interconnection, and at the time was also the world’s longest submarine interconnection. Special control modes have meant that the link has had a beneficial effect on the northern AC connections between the two countries. This has been achieved by increased damping of electromechanical oscillations, a higher transient stability limit and increased capacity on sections of the Swedish grid. The link was upgraded in 1998 to provide a maximum continuous capacity of 572MW with a short (one-hour) overload capability of 600MW. On-line temperature measurements are fed into the cable load prediction system to calculate the current transmission capability. The total length of the cable connection is 200km, with 198km undersea and 2km on
land. The maximum depth is 117m, with an average depth of 80m. The seven-section cable was laid in two parts and jointed at sea. FENNO-SKAN 2
For Fenno-Skan 2, ABB will supply two HVDC converter stations as part of an 800MW power link. The contract is part of a larger scheme that includes a 400kV AC substation in Finnböle, a 70km DC overhead line in Sweden, and a 200km submarine cable. The new Swedish converter station will be considerably further inland than the existing one. For the Fenno-Skan 2 project, ABB will be responsible for system engineering, including design, supply and installation of the two HVDC converter stations. The system is scheduled to be in operation by the end of 2011.
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09
Rail
Jubilee Line – more power for more passengers
ABB has been awarded a fast-track, two-year contract to upgrade the DC traction power systems on the Jubilee Line, in readiness for more frequent services, as part of London Underground’s programme of improvements across the capital’s transport infrastructure.
people per hour at peak times. In the second phase, due for completion in 2009, the Jubilee Line signalling systems will be renewed completely to enable Automatic Train Operation (ATO). This will permit a major increase in train frequency and increase passenger capacity by a further 33 per cent.
MORE TRAINS, MORE OFTEN
TRANSFORMER RECTIFIER UNITS
The Jubilee Line will carry a large proportion of the traffic generated by the 2012 Olympics to the main site at Stratford, East London. The first phase of the planned improvement in passenger capacity was completed in early 2006, when a seventh car was added to the 59 existing six-car trainsets and four complete new trains were introduced. This increased capacity by some 17 per cent – equivalent to an extra 3,000
ABB’s role is to provide an extra 8MW of power for the Jubilee Line’s 630V DC traction supply to support the additional demand created by the extra traffic. The project includes the design, supply, installation and commissioning of nine Transformers Rectifier Units (TRUs) (sometimes called Traction Converters) at four existing substations. The TRUs, each rated at 2.5MW, will convert the 11kV and 22kV AC supplies
from the London Underground network to the +420V/-210V DC power required by the trains. ABB is also carrying out civil engineering works at most of the sites. The Jubilee Line contract was awarded in May 2008, following a competitive tender that placed a major emphasis on supply chain performance and demonstration of excellent relationships with sub-suppliers. It is going well, with the main delivery team established and all major equipment orders such as for the TRUs, HV and DC cables and civil engineering design placed within 30 days of contract signature – a key milestone set at the outset by London Underground. FACTORIES IN POLAND, SPAIN AND FINLAND
The ABB Power Systems Rail team, based in London, worked with the main manufacturing plants in Poland, Spain and Finland to develop a complete understanding of the contract requirements. This called for detailed workshop meetings in Spain and Poland, prior to the contract award, to establish acceptance in principle of the terms and conditions that would apply to the project. Then, when the contract was awarded, the success of these workshops enabled orders to be placed very quickly. Other important factors in ABB’s favour included: system knowledge gained over many years working on the London Underground network; London office base; ability to meet the programme; and demonstration of the competencies of the rail project delivery team. ABB is proud to be working with London Underground to help it realize its vision and that of Transport for London to have a ‘world class metro system for a world class city’.
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MV Switchgear
Thinking inside the box
ABB’s containerized switchgear
PLUG AND PLAY
ADDED SAFETY
is providing the ideal fast-track solution for a growing number of process industry customers who need to upgrade their medium-voltage (MV) distribution networks. The fully pre-engineered units are delivered to site ready to ‘plug and play’. This approach not only results in a more cost-effective overall project that is around 20 per cent faster to complete than the conventional ‘build on site’ route, it also provides a smooth change-over with minimal disruption.
A key advantage of the pre-engineered containerized switchgear is that the majority of the assembly is carried out in a controlled factory environment – there is very little site work needed. Civil works are minimal since all that is required is basic foundations for the container to rest on – this results in a significant reduction in project costs . Once the unit is in place it is simply a question of connecting it up to the appropriate HV cables, so the need for outages is also minimized.
Since the majority of the construction work is carried out offsite, the containerized switchgear helps to reduced health and safety concerns, especially in the limited space found in the typical industrial process environment.
MINIMAL DISRUPTION TOTALLY INTEGRATED SOLUTION
ABB supplies the containerized switchgear as a fully equipped, totally integrated solution, comprising: • 33kV ZX1.2 gas insulated switchgear or 11kV Unigear vacuum switchgear • IS limiters, the world’s fastest switching devices, for short-circuit protection • control equipment • batteries and chargers to provide back-up power • heating and lighting
One of the most popular applications for ABB’s containerized switchgear is at process sites where customers need to replace or upgrade an existing switchgear installation that is nearing the end of its working life. Because all the main construction work is carried out off line there is minimal disruption to the normal site operation. Furthermore, the transfer of circuits from old to new switchgear can be scheduled for the most convenient time that has least impact on production. FASTTRACK
The equipment is housed in a robust container constructed in either GRP or steel according to site requirements. The actual size varies depending on the switchgear application, but typically the container will be around ten metres long, five metres wide and four metres high. This compact size enables the container to be easily transported on a standard low-loader.
FFWD >> www.abb.com/ffwd
The combination of a pre-engineered solution and minimal civil works makes containerized switchgear the ideal approach when a fast-track solution is required. In most cases, ABB would expect to show a 20 per cent reduction in the time from order to energization compared with the more traditional route.
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Substation Automation
Feeder protection relay for G59/1 applications now ENA-assessed
ABB has continued its string of assessments for feeder terminals used in the protection, control and measurement of medium-voltage (MV) networks by gaining acceptance for its new REX521 feed protection relay which is ideally suited for G59/1 embedded generator applications. This type assessment, managed by the Energy Networks Association (ENA), is an important step in obtaining product acceptance by National Grid and other leading customers in the UK electricity supply industry.
The REX521 uses the same protection functions as ABB’s REF541/3/5 feeder terminals that have already gained ENA acceptance, but is housed in a more compact, cost-effective design. It is primarily intended for use in distribution substations to provide short-circuit, over-current
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and earth-fault protection, as well as autoreclosing of substation feeders. In its H50 version, the REX521 is suitable for installation where embedded generators connect to a public supply network. While voltage and frequency protection are normally used to disconnect generators in the event of a loss of mains condition, the REX521 provides a special Loss of Mains function based on the rate of change of frequency (ROCOF). This function provides a faster response than under/over-frequency protection.
public electricity suppliers. In the event of a power system fault, the incoming circuit breaker must be opened. This is to prevent the generator from exporting power an islanded public electricity supply network. There is a risk that an embedded generator may not recognize a fault condition with traditional over-current and fault protection. Other methods, such as the ROCOF function on the REX521, are required to ensure network security. COMPLETE SOLUTION
ENGINEERING RECOMMENDATION G59/1
In the UK, when any kind of generator producing in excess of 16A per phase (3.7kW) is connected in parallel to the public electricity supply, it must comply with ENA’s Engineering Recommendation G59/1 – which provides guidance for the connection of embedded generating plant to the distribution systems of
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The REX521 complements ABB’s complete range of solutions for power system protection, control, measurement and supervision. This now includes everything from basic protection relays to advanced feeder protection and bay control terminals, with support for a wide range of communication protocols and standards, including IEC 61850.
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