autumn 2006 fast forward withabb power · pdf filea cost-effective way to update outdoor...

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The energy challenge – your response

Model railway project

HV surge arresters providelightning protection

Driving for safety andenvironmental goals

Bridging the North Seaenergy gap with PFS

A new lease of life forpower transformers

www.abb.com/ffwd

Out with the old …

… In with the new

FAST FORWARD WITH ABB POWER SYSTEMS & PRODUCTSAutumn 2006

The new Port Ham switching station nears completion

02 FFWD >> Autumn 2006

Published by:ABB LimitedPower Systems Oulton Road, Stone, Staffordshire ST15 0RS

Editor: Karen Strong

Telephone:01785 825050

www.abb.com/uk

contents Climate Change –Is this an opportunity?

The political parties have finished their conference season withsome very powerful messages about how each of them willresolve the Energy Challenge. Technology will play a large partin each of their visions to combat the effects of climatechange.

ABB is working with many eminent research establishments in conjunction with its own corporate research function tounderstand how we can develop new and improved productsand solutions to help combat the huge energy challenge weall face.

It is also important that government and regulators seize theopportunity to work with industry to reduce the barriers totechnology that’s already in use and is delivering cost-savingselsewhere in the world, but which cannot be deployed here for a variety of reasons. Could this be an opportunity?

In order to capitalise on our huge offshore wind resource theproblem of getting the energy to the demand centres in theSouth need to be resolved. We have teams working with theGovernment and other authorities to demonstrate howmodern technology can assist in resolving the issues ofplanning and environmental effects. Could this be anotheropportunity?

It is important for all parties to allow technology to deliver thebenefits they seek, and this can only be realised by ensuringthat joined-up policy connects with joined-up technology! ABBlooks forward to playing its full part along with its customers in delivering the technology to help address the climatechange challenge.

As you will see in the pages that follow ABB continues todeliver innovative technology. By working with government,regulators, customers and other stakeholders we hope to help the fight against climate change!

Issue 15 Autumn 2006

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Trevor GregoryABB UK Managing Director

3 The Energy Challenge – yourresponseDuncan Botting continues his look at the UK EnergyReview

4 NewsUK and international news

6 Model railway projectThe story behind the success of the Southern RegionPower Supply Upgrade project

8 Driving for safety andenvironmental goalsThe drive for safer working in better environments

9 Bridging the North Sea energygap with PFSHVDC Light technology has been chosen to deliverpower to the Valhall offshore complex from the mainland300km away

10 A new lease of life for powertransformersABB’s transformer remanufacturing service extends thelife of ageing or faulty transformers

11 HV surge arresters providelightning protectionA cost-effective way to update outdoor substations tomodern specifications

12 Integrated electrical networkmonitoring and controlThe new COM 610 is an embedded communicationgateway for industrial and utility applications

Read this issue online:www.abb.com/ffwd

If you are a regular readerof FFWD you will know

that ABB brings you manyexcellent products, solutionsand service offerings. You willalso have noticed that we liketo emphasise HOW we do this:protecting the health & safetyof our customers, employeesand the general public,safeguarding the environment,delivering appropriatetechnology, working withgovernment, regulators andcustomers and all with apassion!

It will come as no surprise thatABB strives to meet the futurechallenges of our changing worldwith a similar approach. In order toachieve this we like to work closelywith our customers to developsolutions that are appropriate fortheir needs. Many of our customershave taken this approach anddiscovered many of the benefits ofdoing so but some have yet torealise the power of this approach.

As discussed in previous issuesthe Government’s fundamentalEnergy Review has led to a deepneed to develop future solutions ina more flexible, reliable, energy-efficient and secure manner.

You will see that ABB has theability to bring huge internationalexperience to these complexquestions. We also combine withmany of the world’s bestuniversities to work with our ownscientists and engineers to produceremarkable research anddevelopment projects that deliveradvanced solutions.

We are involved with many learnedinstitutes and standards bodies, andadvising policy makers and otherstakeholders. So how can thisbenefit you?

In the following pages you willfind examples of individual successstories, business cases andtechnology advances that havebenefited our customers in manyor all of the aims described.

• Why then would you not wantto benefit from such investmentand development?

• How are you going to meetyour Energy Challenge?

• We would like to fast-forwardyour business – we are looking

to work with you and for you.We would like to hear how youare responding to the EnergyChallenge?

• Why not share your thoughts and respond to:[email protected]

Autumn 2006 >> FFWDFFWD >> www.abb.com/ffwd 03

technology

The Energy Challenge –How are you responding?

Duncan Botting, head of technology and businessdevelopment for ABB in the UK, continues his lookat the Government’s latest Energy Review and thechallenges it poses for everyone.

1 A power transformer on test atABB state-of-the art facilities.

2 Testing silicon wafers for ABBthyristor technology.

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news

Alliance powers up forcentral England

National Grid has chosen thesubstation alliance in which ABB

is a leading participant as its preferredpartner for substation development andconstruction in central England. Thepartnership will be carrying out a share of the £2.8 billion National Grid contracts to upgrade and develop the electricitytransmission system across England andWales.

ABB and its partners, Morgan Est andAtkins, will be working across the Midlands,Greater Manchester and Liverpool. The initialfive-year contract, with potential for a furtherfive-year extension, will be awarded early nextyear.

Individual contracts will be costed andawarded project by project.

ABB will be exhibiting at Railtex 07,the UK’s leading rail show. The

company is on stand M34.The event is taking place at ExCel in East

London and runs from 20 to 22 February.The rail industry is booming with passenger

traffic at it highest level since the 1960s. Freighttraffic is growing too.

ABB will be showing a wide range ofsolutions covering both the power systems

and automation technologies sides of itsbusiness.

More information on the event can be foundat: www.railtex.co.uk

The UK’s top rail event

As ABB prepares Central Networks’new £12 million 132kV indoor GIS

(gas insulated switchgear) station at PortHam, Gloucester for final commissioning,the old outdoor substation is beginning to disappear from view.

ABB is working with a very experiencedcontractor, Masterton Demolition, to carry outthe 10-week project of removing the old AIS(air insulated switchgear) equipment. AsMasterton’s site manager, Chris Mann, says,“There is more to the job than simply knockingdown the old concrete structures and brickbuildings. We need to make sure that the oldtransformers are drained of oil, that obsoletecables are removed and live cables are fullyprotected, that copper earthing strips are cutout, that the small amount of asbestos insulationis handled correctly and culverts and trenchesare back-filled. And, of course, we are adheringto the very high health and safety standards setby ABB. When we have finished, the site will beleft as flat ground, covered by loose chippings.”

Port Hammovesindoors

Lilliker Brothers, the Rotherhambased electrical installation and

power engineering company, has ordereda complete package of MV (MediumVoltage) switchgear and transformersfrom ABB for a distribution substationproject in the oil-rich Niger Delta region of southern Nigeria.

The MV package, comprising ABB’s ZX1.2(33kV) and ZX0 (11kV) ranges of primary gas-insulated switchgear, together with a pair of7.5MVA, 33/11kV, liquid-filled transformers,

will be installed at Ikot Abasi substation as partof a project by the Niger Delta DevelopmentCommission (NDDC) to reinforce the publicdistribution supply between the towns of IkotAbasi and Opobo.

The Ikot Abasi substation is in a very remotearea. The 33kV supply cables linking it toOpobo substation will be supported onoverhead towers in order to negotiate mangroveswamps and then on a bridge to cross the 680m wide Opobo river.

MV package heads for the Niger Delta

Melrosegate site. It includes the establishment of a new 33kV switch house and control room and all associated civil works, protection/auxiliaryequipment and 33kV cable circuit transfers.

CE Electric UK distributes electricity in theNorth East, Yorkshire and Northern Lincolnshirethrough its subsidiary companies NEDL and YEDL.The company’s electricity distribution networksupplies more than 3.7m premises in a 25,000square kilometre area through a network consistingsof more than 31,000 substations, 33,000km ofoverhead line and 66,800km of underground cable.

CHINAExpanding wind power commitmentChina, which is investing more inrenewable energy than any othercountry, is installing a range of ABBequipment in two major schemes: the150MW Jiangsu Rudong wind park nearShanghai and the 100MW Jilin Tongyuproject in north-eastern China. ABB isproviding compact secondarysubstations, distribution transformers,ring main units and pad-mountedtransformers.

ALGERIAPower grid gets $70 million boostSonelgaz, Algeria’s state-owned utility, has placed three orders with ABB,worth $70 million in total. Theequipment to be supplied includes twomobile substations, for use where fixedsubstations are being built, and apackage including gas-insulatedswitchgear, transformers and associatedequipment.

MEXICOStrengthening the power networkCFE, the Mexican state utility has placeda $50 million order with ABB forsubstations and other high-voltageequipment to improve the country’sdistribution and transmission network.The work also includes the installation of 1.8MVA power reactors and a 30kmextension to a 115kV transmission line.

SWEDENSun blockABB has delivered a giant three-limbedtransformer to a nuclear plant that hasbeen frequently affected by black-outscaused by solar flares. The three-phase825MVA, 420/21kV generatortransformer contains one of the largestand heaviest cores ever produced byABB. With three limbs instead of theusual five, the transformer is designed to improve availability and protect theOskarshamn 2 nuclear power plant fromsolar flares or storms.

STEEL INDUSTRYAC system raises steel powerquality Orders totalling $15 million have beenplaced with ABB for flexible ACtransmission systems (FACTS) for steelplants in China, Oman, Spain andTurkey. Orders include static varcompensators, which use FACTStechnology to improve the security,capacity and flexibility of powertransmission and distribution. ABB hassome 200 installations in the steelindustry worldwide.

Autumn 2006 >> FFWD 05

news

INTERNATIONAL NEWSSVA puts Stalybridge substationprotection and automationsystems to the test

FFWD >> www.abb.com/ffwd

ABB has won a £3.3 million turnkeycontract to reinforce CE Electric UK’s

Melrosegate 132/33 kV substation – a major33kV supply point for the city of York. TheMelrosegate project will enable CE Electric to respond to load growth in the area byproviding the necessary reinforcement tomeet the increased demand for power.

The reinforcement work will cover the supply,installation and commissioning of a new ABB132/33kV 90MVA transformer and associated 33kVswitchgear on spare land within the existing

Power supply boost for York

The System Verification Area (SVA) at ABB’s Stone engineering facility is

currently packed with 60 panels of substationprotection and automation equipment as it undertakes out what is probably the largestautomated FAT (Factory Acceptance Test) of its type ever carried out in the UK. Theequipment, all based on National Grid’sstandardised NICAP (National scheme forIntegrated Control And Protection)philosophy, is destined to play a key role atthe new indoor 275kV GIS (gas insulatedswitchgear) substation that ABB isconstructing at Stalybridge, near Manchester.

The Stalybridge NICAP scheme comprises avariety of individual systems that work together toprovide complete protection and control of the new275kV substation and an adjacent 400kV substation,covering feeders, transformers, mesh corners, buscouplers and the overall substation control systems.Over a three-month period, the systems are beinggiven a series of gruelling tests that simulate thebehaviour of substation plant such as circuitbreakers, disconnectors and earthing switches. Theautomated FAT, witnessed by National Grid, willprovide a complete record of all the tests carried outand, on satisfactory completion, the panels willreceive certification for delivery to site.

ABB’s unique SVA facility at Stone.

With 3,196 miles of track, Southern Regionis the UK’s largest private operator of anelectrical distribution system. And we believethat the upgrade was the largest DC project of its type undertaken anywhere in the world.

KENT REGION

ABB in a consortium with Mowlem Railwayswas one of four regional contractors appointedinitially by Network Rail, and was awarded the‘Kent’ region – extending from Ramsgate on thecoast through to Cannon Street substation incentral London. Between 2003 and 2006 theconsortium carried out around £80 million ofproject work, including the construction orupgrading of 27 substations and 17 feeders andinstalling around 100 panels of ABB ZX1.2 gasinsulated MV switchgear and 25km of 33kVcable.

Working on one of the world’s busiest railnetworks presented a whole raft of challengesand constraints as all site deliveries, possessionsand outages had to be planned down to thefinest detail. This was especially importantbecause, while the SRPU project was vital forNetwork Rail’s future plans, its over riding needwas of course to keep the trains running everyday, so potential disruption and delays had to be kept to an absolute minimum.

It was clear that communication andcoordination at all stages, from definition,through design, tender for the individual workpackages to execution, would be key to thesuccess of this project. So we took the unusualstep of co-locating the consortium team alongsidethe client team in Network Rail’s project office in central London. This ensured that, right fromthere start, there was no ‘us and them’, but rather

In 2003, Network Rail embarked on its three-year Southern Region Power

Upgrade (SRPU) programme to support theintroduction of 2,000 new, more comfortable,carriages. Thanks to features such as centraldoor locking, CCTV and air conditioning, theBombardier Class 375/376 Electrostar andSiemens Class 450 Desiros trains drawaround 23 per cent more power than the old rolling stock from the 750V tractionpower supply system – the reason for theupgrade.


rail

Bernard Johnson, programme controller for the ABB Mowlem Southern RegionPower Supply Upgrade (SRPU) team, explains how detailed planning, coordination,collaborative working and an uncompromising approach to health and safety helpedmake the project so successful that in the end nobody noticed it!

Model railway project

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a seamless partnership that enabled issues to besolved before they became problems.

POSSESSIONS

Management of ‘possessions’ – the windowsof opportunity when we could gain access towork on individual sites – was a core elementhandled by specific team members. This wasparticularly challenging, as six months is anormal period of notice for a possession, whileon some of the busiest routes access was onlyavailable at Christmas, so they had to beplanned 12 months ahead. Added to this,Network Rail’s operational requirementssometimes meant that planned possessions hadto be cancelled at the last moment, calling forthe team to think on its feet to reorganise workprogrammes to maintain the overall projectmomentum.

Much of the site work was carried out at night and weekends. We also becameparticularly adept at ‘piggybacking’ on access tosites that had already been granted to NetworkRail’s own team for routine track maintenance.Of course, with two different teams on siteworking with different objectives, carefulplanning was needed to ensure there was no clash of priorities.

DELIVERIES

Hand in hand with the planning ofpossessions, the delivery of equipment to thesites was planned with military precision. A greatdeal of effort went into making this a ‘non-rail’project where possible, using road access ratherthan rail to deliver equipment, although therewere a number of ‘rail-locked’ sites with no roadaccess. On some sites, the limited access calledfor specialised rail-mounted cranes to manoeuvreheavy equipment into position. Again thisrequired long-term planning as there are onlythree such cranes in the country.

ensured that the north Kent ring work packageproceeded without a hitch.

UNDERNEATH THE ARCHES

The innovative side of the consortium reallycame to the fore in constructing a newsubstation in Vauxhall. Space is at a premium in this part of London, and it was difficult to seewhere the substation could be placed. We hit onthe idea of utilising two dilapidated arches of a railway bridge to create a smart new indoorsubstation. As well as special cladding to makethe substation watertight, ventilation and firedetection systems were installed to ensure thecomplete safety of the enclosed transformer.

PEOPLE

The success of the SRPU project was not just down to procedures. A key aspect was theexcellent people we had working as a team acrossthe board - civils, engineering, projectmanagement and installation andcommissioning staff, supported along the way byadmin and specialist safety and possession staff.

At the peak in January 2005, there werearound 140 ABB Mowlem project staff, alongwith many other installation, civils, cable pullingcontractors and site staff.

THE FINAL VERDICT

By November 2005 all the new trains were inservice, with not one train introduction delayeddue to a lack of power, and Network Rail’s viewof the overall Southern Region Power Upgradeproject was: ‘the project was so successful that inthe end nobody noticed it!’

In order to keep on-sitework and costs down, wemade substantial use ofcontainerised substations,housed in robust, long-lastingstainless steel enclosures,which were fitted out off site.

HEALTH AND SAFETY

An uncompromising approach to creating a safe working environment was paramountthroughout the project, with the emphasis onminimising potential risk to site operatives. And this was reflected in a remarkable safetyrecord. All work on the infrastructure wasundertaken with the RIMINI plan system,which is used to make sure the safest system ofwork is used when 'on the line'. In addition wekitted out a safety coach, known affectionately as‘Thunderbird 3’. This was despatched to thevarious sites to show videos and provideinformation and handouts about the specificsafety issues that the working gangs mightencounter on that site.

INNOVATIVE TEAM APPROACH

Mid-way through the project, we started asubstantial work package for the north Kent ringof substations. Because of the way thesubstations in the ring are linked together wecould not take two out of service at the sametime without disrupting the network. So wetook an innovative approach by constituting a separate, dedicated planning team withrepresentatives from all interested parties. Theteam was led by Network Rail, and as well as theconsortium it also included the SCADA team,the network controller, the outage planner andrepresentatives from the team working on theinner London region of the SRPU, since ourwork could also impinge on their area. Bymeeting every week the 12-strong planning team


rail


1 A train passing the newBeckenham substation.

2 The new Vauxhall substationlocated underneath a disusedrailway arch.

3 Craning a containerisedsubstation into position.

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Over the years, ABB hasearned itself an enviable

reputation for safe working on itssites. There is no room forcomplacency, but a continuousdrive over many years is havingits effect: minimising accidentsand strengthening adherence tosafety procedures. Sitting rightalongside this priority is agrowing focus on environmentalissues.

National Grid has introduced anew health & safety scoring systembased on the accident triangle.Contractors are given negativescores for accidents and incidentshappening on construction sites,but can regain positive scores forsuccessful SHE visits and contacts.

The focus is not just onavoiding incidents but also stayingon top of the preventativemeasures. Training and regularinspections play important parts inreinforcing the positive safetyculture that ABB and NationalGrid regard as paramount.

The safety triangle is updatedmonthly and shows at a glance howpeople are performing. The scoresof all key suppliers are comparedand the best performers will berewarded.

GROWING AWARENESS

For an organisation the size of ABB, the level of incidents isremarkably low. There were no losttime incidents in one of the latestmonthly reports. However, a total of 48 near misses wererecorded and these reports haveresulted in the removal of thepotential hazards.

Overall, there is clear evidenceof growing safety awareness among

ABB employees, which isreinforced by frequenttraining and effectivemanagement.

SUSTAINABILITY PAYS

ABB pays great attention toenvironmental issues too. Below we look at some of the most recentexamples of how the company istaking a positive approach tosustainability in its processes andon its sites.

CRUSHING VICTORY FOR THEENVIRONMENT AT NORTON

You might expect thedemolition of a large outdoor AISsubstation compound to createlarge amounts of rubble fordisposal by landfill. Not so atNorton, near Stockton on Tees,where ABB has constructed a new indoor GIS substation forCE Electric UK that occupies justone-sixth of the space taken up byits AIS predecessor.

After stripping the oldmechanical and electrical partsfrom the old equipment, ABBremoved and stored the concrete

structures and bases and thenbrought in specialist plant toreduce them to crushed stone. Thismaterial was then utilised for sub-bases, back filling and other civilrequirements across the site.Around 1,100 tonnes of concretehas been crushed and reused.

HONOURABLE DISCHARGE

Excavation work for NationalGrid’s Stalybridge substation, beingconstructed by ABB, required theremoval of contaminated groundwater.

In order to minimise any effecton the environment, as well asmeeting the conditions of the sewerdischarge licence, and ensure thatthe groundwater was contained and treated before disposal, ABBbrought in a specialist company to install a water control system.

In the excavation phase, acontainment bund and rainwaterdrain pump feeding the treatmentsystem oil and water separator was

constructed. Water treatmentequipment was installed to removeother impurities and a strict regularsampling and reporting regime putin place.

This attention to detail is beingmaintained during the constructionphase.

RECYCLING BLOOMS

Environmental matters arealways to the fore at a NationalGrid substation in Leeds, whichalso hosts an environmental centrededicated to sustainabledevelopment. When ABB carriedout a major upgrade, the whole siteteam caught the recycling bug.

A large amount of overgrowngreenery was cut back and turnedinto mulch and then dug into theflower borders; some old concretebases were crushed and used tosupplement the top soil for landlevelling.

Some trees which had to beremoved were used to make flowertubs and decking for theenvironment trail, and even thepacking cases in which equipmentwas delivered was recycled intoshuttering for the new concrete.

environment


In its unrelenting push for safer working in better environments,ABB has been refining its reporting and monitoring procedures.

1 Aerial view of the Stalybridgesite.

2 Old structures turned tocrushed stone at Norton.

Flower tubs made from recycledwood

Driving for safety andenvironmental goals

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The majorredevelopment of BP’s

Valhall production complex,which includes theconstruction of a newproduction and living-quartersplatform, will enable thefacility to maintain outputright through to the middle of the 21st century.

An important feature of theupgrade project is the replacementof existing offshore gas turbines,currently providing power for thefive-bridge linked complex, withpower from the shore (PFS)electricity delivered directly from theNorwegian mainland 300km away.

Oil is supplied from theplatform in the Ekofisk field to

Teesside in the UK, while gas isdelivered into Norpipe throughwhich it is transported to Germany.

Since the facility was installed in1981-82, reserves have grown from247 million barrels to 1,050million barrels. It is estimated that529 million barrels remain to beproduced, although the companyhopes that it may be able to extractconsiderably more than this.Output is running at 150,000barrels of oil per day, 200,000barrels of other liquids per day and5 million m3 of gas per day.

The installation has beenexperiencing reservoir compaction,seabed subsidence, which hasincreased water depth by about 5.4 metres over the years. This wasa factor in deciding to replace the

original production andcompression platform with a newproduction-hotel facility designedto meet the site needs until 2050.

COST AND ENVIRONMENTALSAVINGS

Power supply is critical to theperformance of the Valhall facility,and with such a long life ahead ofit, it is essential to meet stricteconomic and environmentalcriteria.

At present power is generated onthe field by gas turbines. These willbe replaced by a 292km powerlinkdirect from the shore – an

unprecedented distance for anoffshore installation.

ABB’s HVDC Light technologywill be used to transmit the powerfrom the mainland. This involvestaking AC power at 300kV fromthe Norwegian grid, converting itto high voltage direct current(HVDC), and transmitting it at150kV through a subsea powercable to the platform, andconverting back to AC at 11kV foruse on the field. The total powerrequirement is 78MW-.

This solution is not only cost-effective but it also offers clearenvironmental benefits - at peak itwill eliminate an annual 300,000tonnes of CO2 and 250 tonnes ofnitrogen oxide, compared with a

combined-cyclepower plant operatingwith low NOx gasturbines.

Grid power inNorway is for themost part clean powergenerated by hydro-electric plants.

Reducing CO2

output will also cutcosts. This is because suchemissions from offshoreinstallations are taxed in Norway.Another benefit is that ABB’sHVDC Light system offers veryhigh availability of 98.5–99 percent – and requires much lowermaintenance than on-platform gasturbines.

An onshore converter station isto be built at Lista near Norway’ssouthern tip, and on the platform,conversion of the HVDC powerwill take place in a dedicatedmodule designed to protectequipment from the effects of salty,humid air.

international


When the Valhall offshore complex is upgraded in 2009, it will no longer begenerating its own power but will be supplied using HVDC Light technology,from the mainland almost 300km away. The result will be safer, more cost-effective energy production and substantially less greenhouse gases.


Bridging the North Sea energy gap with PFS

The UK transformerremanufacturing service has beendeveloped by Mark Turner,operations and quality manager for ABB’s worldwide network oftransformer service centres, whosaid: “The re-manufacturingservice is targeted at medium andlarge power transformers from anymanufacturer, not just ABB. Thecomprehensive service includes on-site assessment of thetransformer’s condition, andarranging for it to be collected and delivered to our factory inDrammen, Norway. At thefactory the transformer is strippeddown to its component parts andrebuilt with the same care andattention to detail as our newtransformers. We then return theunit to site and install andcommission it.

“The cost of remanufacturing a transformer will vary from caseto case. But typically, we would expect to have it back in service ataround 60 to 70 per cent of thecost of a new unit. However, it isdelivery, rather than cost, that willbe crucial for many customers,especially as the current growth in demand world-wide for HVequipment is resulting in everincreasing delivery lead-times.

We can have a remanufacturedlarge power transformer back inservice in around six months.That’s one third of the 18-monthdelivery schedules now beingquoted for new large powertransformers.”

BETTER THAN NEW

The flexibility of ABB’stransformer remanufacturingservice enables customers to opt for an upgrade to ‘better thannew’ specification. This could beas simple as a change in voltagerating or could extend to takingadvantage of ABB’s state-of-the-art computerised design tools to have the transformer completely redesigned to a higher powerrating. Other upgrade possibilitiesinclude enhanced cooling orrewinding the coils with Nomex®

high-temperature insulationmaterial that boosts power, as well as offering significantimprovements in lifetime andreliability.

The remanufacturing servicewill be particularly attractive for the UK’s vast installed base ofpower transformers, many ofwhich were installed in the 1960sand are now near the end of theiruseful working life. However, the

service is also ideal for newertransformers that may havedeveloped a fault or have beendamaged by a network event.Whatever the age of the unit,

once it has been remanufacturedby ABB, the reborn transformerwill be able to look forward toanother full working life ofbetween 25 to 50 years.


transformers

ABB’s new transformer remanufacturing service offers a new leaseof life for ageing or faulty power transformers

A new lease of life for powertransformers

The Drammen transformer re-manufacturing facility in Norway.

ABB’s new transformer remanufacturing serviceenables ageing or faulty power transformers to be

completely rebuilt and returned to as-new condition, or even upgraded to a higher specification. A remanufacturedtransformer provides the same performance as a newtransformer at a much lower cost. However, the mainadvantage is ABB’s fast turnaround that can have acustomer’s transformer back in operation in around one-third of the normal delivery time for a new unit.

HV surge arresters providelightning protection

ABB’s surge arresterretrofit service enables

the transformer circuits inoutdoor high voltagesubstations, typically up to400kV, to be upgraded to ahigh level of protection againstthe damaging over-voltagescreated by lightning strikes.This provides an efficient andcost-effective method forincreasing the security andreliability of the substationoperation and minimisinginterruptions to the powersupply delivered to consumers.


retrofit

ABB has developed a specialist retrofitting service for HV surgearresters that provide a cost-effective route to update outdoorsubstations to modern specifications.


The retrofit service utilisesABB’s well-proven Pexlim surgearresters. These use zinc oxide(ZnO) blocks in a compositesilicone rubber housing that isextremely resistant toenvironmental pollution andvandalism. The material offers thevery highest safety levels since it isself-extinguishing and will failsafely rather than exploding whenover-stressed.

In new substation projects, theadditional cost and complicationof installing surge arresters isrelatively small. However,retrofitting surge arresters toexisting installations is muchmore challenging, as suitableoverhead mounting gantries,typically of a ‘goalpost’ design 20m high and 21m in span, haveto be transported on site anderected by crane. There may alsobe a need for additionalfoundation works and possiblypiling.

Tom Smith, ABB projectmanager responsible for the surgearrester installation service, says:“Our surge arrester retrofit hasrefined its skills in 39 installationsalready completed successfully forUK customers. Having experienceof just about every possiblepermutation enables us to providevery fast turnaround, withinstallation usually completedwithin a week.

“A key aspect of the service isthe careful advance planning andcoordination we provide to ensurethat the installation work ties inwith planned outages, so that wecan minimise potential disruptionto the substation operation. Andwe have developed safe workingmethods that enable us to carryout a significant proportion of thecivil works, even piling forfoundations, without having totake an outage.”


communications

www.abb.com/ffwd

ABB’s new COM 610 meets thechallenge of providing plant

managers and users with a trulyintegrated electrical network monitoringand control system that does not rely on specifying a single manufacturer forall equipment. It acts as a reliable, cost-effective hub for connectingprotection relays and terminals withdiffering protocols to the networkcontrol centre.

The COM 610’s communicationarchitecture is based upon proven protocolimplementations, utilising OPC frameworks(that provide open connectivity via openstandards) that guarantee the flexible andextensive use of information. There are notheoretical limits on the number of master/slaveprotocols, lines or devices, providing fullyflexible configuration. It is delivered with pre-installed software, so all the installer needsto do is to connect it and download the crossconnection configuration.

INDUSTRIAL DESIGN

The COM 610 features a compact androbust design that makes it ideal for harshenvironments. Its enclosure offers protection toIP50 and it has no moving or other vulnerableparts, while its modular software architectureguarantees easy expandability and ease of use.

SAVINGS IN COMMISSIONING

Information modelling within the COM 610gateway is based on the IEC 61850 standardthat ensures open and flexible informationmanagement. The intuitive configuration toolutilises pre-defined data templates for easy drag-and-drop operation. When the configuration iscomplete, it is downloaded to the gateway over a TCP/IP connection, and the COM 610 isready to use.

HIGH LEVEL OF INTEGRATION

The COM 610 gateway is open to anymaster system using de facto master protocols. It is also fully compatible with ABB’sMicroSCADA technology – for the creation of complete automation solutions.

OPTIMISED SUPERVISION

Monitoring the COM 610 is made simple byusing either the CET configuration tool, basedon the IEC 618570-7 model with drag-and-

drop signal mapping, or astandard webbrowser.

ABB’s COM 610 is an embedded communication gatewaydesigned for both industrial and electrical utility applications.

For further information about any of these subjects please visitwww.abb.com/ffwd or contact us as follows:

CONTACTS

Substations – 01785 825050HV Switchgear – 01925 741457MV Switchgear – 01925 741433Automation – 01785 825050Service – 0845 6011946

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