1 | 16

ffwd
Focus on Power Grids

New service pulls moisture from transformer oil 26

Joining forces with Microsoft for electric vehicle charging 5
National Grid sees inside switchgear 6
Time to grasp the UK microgrid opportunity 14
Introducing the world’s strongest vacuum tap changer 22
Welcome

Power Grids
ABB’s Power Grids division is the world’s leading supplier of power and automation
products, systems and service solutions across the power value chain of generation,
transmission and distribution serving utility, industry, transportation and infrastructure
customers directly and through channel partners. The division is focused on
addressing key areas such as the integration of renewable energies, growing
network complexity, grid automation, and microgrids. The division also offers
a full range of consulting, service and asset management solutions based on a
lifecycle approach.

6
Radiography

ffwd 1 | 16 Power Grids

David Hughes, Managing Director for
ABB’s Power Grids division
Dear Reader,
Welcome to the latest edition of FFWD,
ABB’s newsletter for customers of our
products, systems and services across the
power value chain. Since the last edition
of the newsletter, ABB has streamlined
its approach and has moved from an
organisation with five divisions to four.
The new Power Grids division focuses
on the changing needs of utility customers.
To do so, it brings together ABB’s complete
power and automation portfolio for power
transmission and distribution. The new
approach became effective on 1st January.
One example of the renewed focus is
the opening of our new power quality facility
in Bromborough. Not only is the facility’s
official opening featured on page 4 but you
can also read about its first new product
launch on page 16, which demonstrates
that the facility is its goal of meeting our
customers’ needs.
We’ve also improved our service offer-
ing, with one example being our new oil
processing rig on page 26. The new rig
will ultimately improve availability and
reduce the lead time for installing new pow-
er transformers.
Another example of service news was the
delivery of the first computed radiography
service in the UK. The service uses x-ray
technology to see inside switchgear without
dismantling it and page 6 has the results
of the first test, which was delivered for
National Grid.
As ever, ABB is looking to the future,
which is why we’ve included a few articles
on future technology. These include how
we are taking new approaches to help our
customers meet Ofgem’s RIIO framework
(page 34), the potential for microgrids to
enhance security of supply in the UK (page
14) and the technology behind our 525 kV
HVDC cables (page 28).
If you find news or views that pique your
interest, then I hope that you’ll get in touch
with me or a member of my team.
All the best,
David Hughes

ffwd issue 1/16 • The customer newsletter of ABB Power Grids • Subscription newsletter available as printed or electronic copy. Subscribe online at abb.com/ffwd
Contact and feedback karen.strong@gb.abb.com • Publisher ABB Limited, Power Grids division, Oulton Road, Stone, Staffordshire ST15 0RS. Phone 01785 825 050

2 abb.co.uk/ffwd Power Grids

 Contents

14 39
Microgrids IET Innovation Awards

26
Pulling moisture from
transformer oil

News Transformers
04 Latest technology news from ABB 22 Introducing the world’s strongest vacuum tap changer
23 Comparing transformer efficiency
Project focus
08 Replacing circuit breakers in Exeter for National Grid
Site work
24 Civils
Rail
10 London Underground’s Package 5B for the Sub Surface
Service
Lines 26 Arrival of new transformer oil vehicle

Digital substations HVDC

12 Bodelwyddan project 30 An upgrade for the Gotland transmission link
31 Completing the Baltic Ring
Microgrids 31 Major upgrade for Great River Energy’s HVDC link

14 Time to grasp the UK microgrid opportunity

GIS technology
Power quality 32 New eco-efficient gas for switchgear
33 Protecting New Jersey’s network from extreme weather
16 New capacitor shelf range

Innovation
Enterprise software 34 Challenging the norm to meet Ofgem’s RIIO model
17 SCADA upgrade for Dubai International Airport

Power consulting
Caithness Moray 36 Enhancing performance with system studies
18 Natural Power delivers as environmental clerk of works

Product news
Cables 38 New VisiVolt for rail safety
20 New cable ship commissioned
28 525 kV cable technology development
Events
Substations 39 Developments in Power System Protection
39 IET Innovation Awards
21 Underground substations

Power Grids abb.co.uk/ffwd 3

News
Official opening for new
UK Power Quality facility
ABB’s UK Power Quality business entered
a new era in October 2015 with the official
opening of its new purpose-built facility
at Bromborough on the Wirral Peninsu-
lar in Merseyside. The ribbon cutting
ceremony was carried out by the Mayor
of Wirral, Councillor Les Rowlands and
Alison McGovern, MP for Wirral South,
which includes Bromborough.
Following the move from Ellesmere Port,
the new facility is already enabling ABB to
provide an even better service to its growing
customer base across the UK, especially
in terms of speed of response. It is also
providing the flexibility and capability for
special project development work.
ABB’s Power Quality Manager Steve Joyce shows a capacitor assembly to Alison McGovern, MP for Wirral South
4 abb.co.uk/ffwd Power Grids
From Bromborough, ABB supports local Mayor and MP to help make this a
industrial customers requiring two main truly special day for every member of the
types of power quality equipment: power team at Bromborough. Power quality is
factor correction (PFC) and harmonic becoming an increasingly important factor
filtering. PFC solutions enable industrial in ensuring business continuity and Brom-
customers to reduce the load on their borough provides the ideal platform for us
electricity supply, saving on electricity bills to address the many new growth oppor-
and freeing up capacity for new loads. tunities that are being created.”
Harmonic filters eliminate the troublesome
harmonics (or noise) that can affect electrical
supplies, causing unexplained shutdowns
as well as premature failure.
David Hughes, Managing Director for
ABB’s Power Grids division said: “The move
to this new facility is taking ABB’s Power
Quality business into a new era and we
were delighted to be joined by both our

Electric vehicle charging points will connect to Microsoft’s Azure platform in the cloud
ABB and Microsoft join
forces to launch next-
generation electric vehicle
charging services platform
ABB and Microsoft Corp have announced
the worldwide availability of a new elec-
tric vehicle (EV) fast-charging services
platform. Combining ABB’s leading EV
charging stations with Microsoft’s Azure
cloud-based services will ensure stability,
global scalability and advanced manage-
ment features for ABB customers. The
collaboration will also take advantage of
machine learning and predictive analytic
capabilities to drive future innovations.
The rapid increase in electric vehicles
around the world goes hand-in-hand with a
mature charging and energy infrastructure.
There are currently just 106,000 publicly
News
New Chief
Technology
Officer
ABB has appointed Bazmi Husain
as Chief Technology Officer (CTO),
starting in January 2016. Husain,
an expert in power and automation
who has been with ABB for more
than 30 years, will report to CEO
Ulrich Spiesshofer.
Husain is currently Managing
Director of ABB India Ltd. In his new
role, he will be based in Bangalore,
India, with an office in Switzerland.
As CTO, Husain will be respon-
sible for overseeing all aspects of
ABB’s global R&D, which serves the
entire company, its scientists and
engineers, and for the R&D activities
within ABB’s divisions.
Reporting to him will be the heads
of R&D at group and division lev-
el as well as ABB’s venture capital
arm, ABB Technology Ventures. With
locations in seven countries, ABB’s
corporate research centres bring
together an international team of
highly skilled scientists across a vari-
ety of disciplines. ABB spends $1.5
billion annually on R&D and employs
some 8,500 technologists.
accessible EV charging stations globally, and
global revenue from electric vehicle charging
services is set to grow from $152.6 million
in 2015 to $2.9 billion by 2023, according
to Navigant Research.
Under the new collaboration, all ABB
chargers will be connected to the Microsoft
Azure cloud and surrounded by value-adding
services, allowing operators and manufac-
turers and partners to take advantage of a
world-class platform.
As CTO, Bazmi Husain is responsible
for overseeing ABB’s R&D
Power Grids abb.co.uk/ffwd 5
News
National Grid catches
some rays
National Grid has become the first oper-
ator in the UK to make use of ABB’s new
computed radiography service. ABB
delivered the x-ray inspection during
condition assessment of two GIS units
at Greystones 275 kV substation near
Middlesbrough.
Greystones was once the feed-in point
for a power station that has since been
decommissioned and dismantled, with
National Grid adopting the site. The firm is
now installing a new fleet of shunt reactors
at several sites and is planning to re-use
the two GIS units at Greystones to control
two of these shunt reactors.
Having adopted the 20-year-old GIS
from another operator, National Grid does
not have a full maintenance history of the
switchgear. It called on ABB to evaluate the
condition of the equipment before returning
it to service or carrying out remedial work.
The condition of Greystones’ switchgear was revealed
6 abb.co.uk/ffwd Power Grids
In addition to a conventional condition
assessment, National Grid accepted
ABB’s recommendation to use the new
technique of computed radiography.
The service uses an x-ray source and
digital capture equipment to see inside
switchgear while keeping it intact. It reveals
an accurate picture of the condition of
equipment, including wear on contacts and
the existence of any defects.
Richard Moore, Manager for ABB’s
High-Voltage Service team in the UK said:
“National Grid is committed to delivering
value for money for its customers under
Ofgem’s RIIO framework, which encourages
innovative approaches to delivering services.
Because our new Computed Radiography
service enabled ABB to give National Grid
an accurate picture of the condition of the
Greystones switchgear, they are able to
proceed with the shunt reactor project with
confidence.”
ABB developed the service in the US to
help its customers achieve significant sav-
ings in the time and expense associated with
the inspection of high voltage switchgear.
Radiographic inspection enables operators
to get an informed picture of switchgear’s
condition, even while it is live.
In comparison, conventional inspection
requires long outages. These are required to
disconnect and earth switchgear before cap-
turing insulating gas and then dismantling,
inspecting and reassembling switchgear. Not
only is this time consuming and expensive
but it also introduces risk.
Computed radiography has several appli-
cations. These include condition assessment
on individual switchgear or across entire
fleets. It also has a role when installing new
switchgear so that subsequent inspection
will reveal the rate of wear on the contacts
and therefore the remaining service life.
 News

Switchgear
for Kilgallioch
Windfarm
ScottishPower Renewables has selected ABB medium voltage
switchgear for Kilgallioch Windfarm. When it enters service in
2017 the site will be the UK’s third largest onshore wind farm. In
total 96 wind turbines will generate up to 239 MW, which will be
enough to power the equivalent of 130,000 households per year.

ABB’s role in the project is to supply,
deliver, install and commission the 33 kV
switchgear for each of the 96 turbines
as well as the switchgear at the site
substation. Deliveries will start in March
2016, with final handover planned for the
end of October.
Steve Blanche, ABB’s Account Manager
for ScottishPower said:
“This is a significant project for ABB that
demonstrates that not only does our well
proven switchgear meet ScottishPower
Renewables’ stringent technical require-
ments but it also represents good value
for money in the demanding onshore wind
market.”
The wind farm is located 5 km south of
Barrhill in South Ayrshire and 5 km north
of New Luce, Dumfries and Galloway. It will
cover an area of 32 square kilometres, which
lies across the boundaries of South Ayshire
and Dumfries and Galloway Councils. First
power production is due in November 2016,
followed by full operation of the site in the
first half of 2017.
Turbine switchgear
The turbines will be equipped with SafePlus
secondary switchgear, which is a compact
and reliable type of switchgear manufactured
by ABB in Norway. The philosophy behind
SafePlus switchgear is that it delivers high
performance in a compact unit.
It will be supplied in Compact Secondary
Substations (CSSs) that are engineered,
assembled and tested at ABB’s facility in
the UK. They arrive on site in a secure and
self-contained unit ready to plug and play.
Substation switchgear
The power from the turbines will be received
at a central substation, where ABB’s ZX0.2
primary switchgear will control the incoming
feeds from the 96 turbines. ZX0.2 switchgear
is rated at up to 36 kV and is designed for
secondary substations.
ZX0.2 switchgear is manufactured in
Germany for high levels of safety, reliability
and flexibility. It has a compact footprint
and can be installed against a wall or free-
standing inside a substation, which helps
to minimise the size of the facility.
For Kilgallioch W indfarm, ABB is
supplying ZX0.2 switchgear that integrates
ABB’s Relion protection and control devices.
Both types of ABB switchgear to be
deployed at Kilgallioch are ENA (Energy
Networks Association) assessed.

Indicative photomontage of Kilgallioch Windfarm

Power Grids abb.co.uk/ffwd 7

Project focus

Finding a
better way with
National Grid
The new HPL breaker in place at Exeter

Steve Pickering, Local Product Group Manager for

ABB’s Grid Integration Service team, explains how
a recent substation circuit breaker replacement
exercise has shown that project timescales can be
cut from months to weeks by an innovative and
collaborative approach to design, installation and
commissioning

8 abb.co.uk/ffwd Power Grids


Work was completed during a 26-day outage
National Grid’s RIIO (Revenue= Incen-
tives + Innovation + Outputs) regulatory
framework agreement with Ofgem, the
UK regulator, calls for the replacement
of a large volume of time expired 400
kV substation circuit breakers within a
four-year window. However, it was clear
that the traditional approach to this type
of project would present National Grid
with significant challenges in terms of
both costs and the time required. One
of the most important limiting factors
was the scheduling and availability of
planned outages in which the work could
be carried out.
National Grid decided to explore new
ways of working and in collaboration with
ABB the Exeter substation project was
developed as a trial site to demonstrate
that it was possible to refurbish a 400 kV
bay within a four-week outage period. This
outage period is critical as the impact on the
transmission system can be considerable
if the circuit is not returned to service in
the agreed period. Also the shorter the
outage period then the greater number
of opportunities to refurbish breaker bays
will arise.
Design Philosophy
Working in collaboration with National Grid,
ABB agreed to take a proactive approach
to establishing the scope and design for
Exeter substation. The aim was to establish
a fast track approach to National Grid’s usual
transmission design and project delivery
processes. The team was able to achieve
a clear definition and understanding of the
scope of works and expectations with all
stakeholders, challenging normal practices
to ensure the project delivered in terms of
both efficiency and value. This enabled the
entire project – from order placement to final
commissioning and return to service – to
be completed in approximately 12 weeks.
Project focus
The existing circuit breakers were to be
replaced with ABB’s well-proven HPL 400
kV circuit breakers. So as part of the project
ABB fast tracked their production to allow
delivery to site ahead of the planned outage
period. The scheme design was based on
a like-for-like replacement of the existing
plant. The existing foundations, structures,
protection and control systems to be
retained for re-use with adaptors/interface
components provided where required.
Site Works Philosophy
On site the National Grid and ABB teams
worked in a spirit of collaboration to achieve
a safe site working process to deliver the
following programme within the 26-day
outage period:
Site survey, to ensure agreed site estab-
lishment philosophy and facilities.
–– Stage 1 – Dismantling and removal of
existing air blast breakers = 4 days
–– Stage 2 – Assembling the scaffolding
to create a safe working area = 1 day
–– Stage 3 – Core drilling of the existing
base/structures to accept the new HPL
base structure = 1.5 days
–– Stage 4 – Positioning the new breaker
operating mechanism boxes = 2 days
–– Stage 5 – Assembling the new HPL
circuit breakers = 3 days
–– Stage 6 – Commissioning and return to
service = 14.5 days
The final result was that the project
timescale was cut from months to weeks by
this innovative and collaborative approach
to design, installation and commissioning.
The trial has also shown that reducing
the outage time does indeed open up a
greater number of opportunities to refurbish
breaker bays.
The Exeter trial has demonstrated that
this approach to circuit breaker bay refur-
bishment is: safer, simpler, faster and
cost-effective. Together ABB and National
Grid are ‘Finding a better way’.
Watch a time-lapse
 video of work at Exeter
on YouTube at:
www.bit.ly/abbexeter
Power Grids abb.co.uk/ffwd 9
Rail

MV switchgear to deliver more power for

London Underground trains
ABB’s specialised medium voltage switchgear is being deployed in a turnkey
project to upgrade the 11 kV and 22 kV power network serving London’s new
generation Sub-Surface trains

One of 191 new S-Class trains ABB has won a major turnkey contract
to design, manufacture and supply medi-
um voltage (MV) switchgear to upgrade
the 11 and 22 kilovolt (kV) power net-
works serving London Underground’s
SSR (Sub-Surface Railway) Lines. The
SSR Package 5B contract is part of an
overall power supply upgrade to sup-
port the introduction of 191 brand new
air conditioned trains. The new trains,
which will be in service by the end of
2016, will provide more frequent and
reliable passenger services and great-
ly improved accessibility on the Circle,
District, Hammersmith & City and Met-
ropolitan Lines.

The SSR Package 5B project is the first

to be awarded under London Underground’s
new framework that sets out pre-determined
terms and conditions for suppliers contrib-
uting to its power upgrade programme.
The main focus for ABB over the two
year project is at Mile End substation where
existing time-expired switchgear will be
removed and replaced with 10 panels of
ABB’s UniGear ZS1 primary metal-clad
switchgear, rated at 11 kV together with
35 panels of ZX2 gas insulated switchgear
rated at 22 kV. The project also includes
associated protection, control and moni-
toring schemes utilizing ABB’s IEC 61850
Relion RET 615 and 620 relays to ensure
full compatibility with other switchgear on
the network and ease of integration into the
London Underground SCADA (Superviso-
ry Control and Data Acquisition) system.
ABB is also installing a master MITS
panel at Mile End and slave panel at Green-
Transport for London

wich Generating Station to enable backup

generation to be brought onto the net-
work as required while meeting the G59
regulations for the connection of genera-
tor devices to run in parallel with the main
electrical utility grid.

10 abb.co.uk/ffwd Power Grids


An important element in the project is
for ABB to work in close cooperation with
the contractor responsible for the power
cabling within the tunnels (SSR Package
5A) to ensure efficient connection of the
cables to the switchgear and to commis-
sion them into service.
“The need for programme certain-
ty throughout a very challenging project
schedule was the main reason for London
Underground placing this critical power
upgrade package with ABB,” said David
Hughes, Managing Director for ABB’s Power
Grids division. “Our total focus on deliv-
ery using MV equipment that is tried and
trusted in previous London Underground
projects was the decisive factor.”
UniGear ZS1
The 11 kV panels to be installed are
a special railway version of ABB’s
UniGear ZS1 range of MV primary
metal-clad switchgear. As well as
featuring a compact installation
footprint, the modular design of
the UniGear ZS1 also provides the
ZX2
The 22 kV panels are from ABB’s ZX
family of compact modular metal-
clad gas-insulated switchgear (GIS)
developed to meet the growing
demand from Distribution Network
Operator (DNO) and industrial
customers for cost-effective, flexible
and expandable, primary MV
substation solutions.
The double busbar ZX2 version
features a laser-welded stainless
steel enclosure, compact modular
construction and plug-in technology
that facilitates simple, controlled
connections of busbars, cables, test
Rail
Transport for London
The new rolling stock is air conditioned
flexibility to add additional panels as
operational needs change.
The switchgear, which is
manufactured in ABB’s MV
switchgear centre of excellence in
Brno, in the Czech Republic, is one
of the very few MV panels of its type
that complies with stringent railway
industry requirements.
bushings and voltage transformers.
All maintenance-free live components,
such as switching devices and busbars
are contained under SF6 in gas-tight
enclosures. This eliminates the effects
of ageing processes and environmental
influences to ensure maximum operator
availability and a long service life.
The ZX design also offers easy cable
access (accessible from the rear in the
ZX2 version), generous provision for
conventional control and protection
devices, dedicated cable test sockets
and full mechanical interlocking the circuit breaker gas compartment
between the disconnector/earthing or externally on the HV cables.
selector and the circuit breaker. Current Alternatively, options are available for
transformers can be mounted either in current and voltage sensors.
Power Grids abb.co.uk/ffwd 11
Digital substations

National Grid
Benefits of digital substations
Traditional substations have always relied
on copper cables wiring together primary
equipment like circuit breakers, conventional

trial for digital current and voltage transformers and

protection relays to control of the electricity.
But digital technologies, communications

substations at
and standards that facilitate fibre optic
connections are driving the evolution of
something new – digital substations. This
ground breaking technology is now installed

Bodelwyddan
and under operational trial at National
Grid’s new 400 kV (kilovolt) Bodelwyddan
substation.
Interconnecting substation components
with optical fibre is clearly preferable to
wiring them up with hundreds of individual
copper cables. Not only are digital systems
easier to install, they have proved to be
National Grid is starting its first safer and more reliable, and can reduce

UK trial of ground breaking digital the quantity of copper in a substation by

substation technology at its new
400 kV Bodelwyddan substation
in Denbighshire, northeast Wales.
The project at Bodelwyddan substation will demonstrate how
different technologies can be used at different ends of a feeder
circuit using a mixture of conventional and non-conventional
technology. Proving that old and new technologies can mix is
vital because we are now in a technological transition period,
moving from traditional copper-based installations to modern
fibre-optic based systems.
about 80 percent, a substantial cost saving.
The digital world is moving quickly, how-
ever, in tandem with new developments in
primary equipment. A growing trend is the
use of non-conventional instrument trans-
formers (NCIT), such as voltage dividers or
Rogowski coils combined with optical data
links, and also pure optical sensors.
Smaller than conventional equipment,
their linear measuring capability and high-
er accuracy make sensors very useful for
protection and metering purposes. NCITs
make a substation simpler, cheaper, smaller,
more efficient and safer by replacing sec-
ondary wirings and eliminating the dangers
associated with open CT (Current Trans-
formers) circuits in general.
While ABB has been involved with NCIT
technology since before 2000, a new chap-
ter began for digital substations in 2009
when they first began adopting IEC 61850-

Conventional substation

12 abb.co.uk/ffwd Power Grids

 Digital substations

9-2 process bus standards for transmitting kV Bodelwyddan substation in Denbighshire, the traditional hardwired Standard Bay
sampled analog values, which delivers a northeast Wales in the UK. Solution (SBS) at the Bodelwyddan end on
standardized interface for protection and National Grid is keen to investigate new the Deeside-Pentir feeder. To enable the trial,
control devices. For example, ABB supplied technologies and processes, and ABB ABB has installed a set of GIS (Gas Insulated
more than 300 NCITs for use in Queensland, brings a great deal to the table, including Switchgear) NCITs at the Bodelwyddan
Australia more than 15 years ago, and the exceptional expertise in modern digital sub- end of the Deeside-Pentir feeder, which is
utility has yet to see a single failure in the station systems that safely and efficiently used in conjunction with two merging units
primary sensor. Then in 2011, the first of six bridge the gap between the analog and (MU). At the remote ends of the feeder, a
Australian substations with NCITs installed digital worlds. trial system is connected to conventional
were upgraded to a new secondary system, The NCIT (non-conventional instrument CTs with hardwired connections.
utilizing the IEC 61850-9-2 process bus transformers) and process bus system has
and retaining the existing primary sensors. been installed on one of the three-ended Piggy-back site trial
line feeders at Bodelwyddan substation – The trial has been established on a ‘piggy­-
Bodelwyddan substation the Deeside-Pentir circuit. This circuit is a back’ basis, This means that while the digital
Site trials are an invaluable tool, providing relatively long overhead line – over 80 km equipment will function and respond to
info mation and experience that helps long – crossing an area exposed to fre- operational conditions, the tripping outputs
utilities and manufacturers develop new quent thunderstorms, making it ideal for will not be wired into the circuit breaker
architecture for substation systems. a trial installation with protection devices. tripping system. Instead, the equipment will
The latest of these trials has just been ABB has provided a feeder bay solution be monitored to assess its performance.
commissioned at National Grid’s new 400 using the new architecture in parallel with In addition to the protection system,
two Landis+Gyr revenue meters have been
installed, one connected to the NCIT through
Bodelwyddan process bus trial system architecture overview
the IEC 61850 9 2 process bus and the other
one to conventional metering circuits. This
Bodelwyddan 400kV S/S Pentir 400kV S/S
setup allows direct comparison of metering
ELK-CP3 RED670 Line
Non-Conventional Metering DALEK Trial Relay Panel Differential Protection values from non-conventional and conven-
Instrument
Transformer CP-MUP RED670 Line tional metering systems to demonstrate the
Merging unit 1 Differential Protection
suitability of the non-conventional system
for revenue metering.
AFS The Bodelwyddan pilot is expected to yield
Ethernet
Process Bus
Switch a great many real-world benefits, including:
CP-MUP Conventional CTs
Merging unit 2
–– Building confidence in terms of future
Deeside 400kV S/S technology such as IEC 61850 and NCITs
Conventional Station Bus
RED670 Line –– Gaining long-term experience under real
Current Transformer Differential Protection
life conditions
PDAW Panel
–– Assessing the performance and capabil-
Elec. to FO Converter
L+G ZMQ802 ities of the technologies applied
Conventional Revenue meter
Voltage Transformer –– Reflecting the learning from the trial into
MicroSCADA & IED future customer policies, with respect to
Engineering Workstation
M900 LAN Time architecture, product applications and
Conventional CTs
engineering processes (tools, etc.)

Digital substation

Power Grids abb.co.uk/ffwd 13

Microgrids
Time to grasp the UK
microgrid opportunity
Mention the term microgrid, and most
people tend to think of providing access
to power on remote islands or in poorly
served regions in developing markets.
But recent developments are highlighting
a big potential role for microgrids in
mature power markets, including the UK,
where it’s becoming clear that new ways
of thinking about power supply capacity,
stability and resilience are needed.
A spate of media reports over recent
months have highlighted how it’s not just
in developing markets where generating
capacity, grid stability and resilience are key
areas of concern. Apart from the longer-term
discussions around UK generating capacity,
we’ve seen a growing number of reports
of a variety power grid issues around the
country. Consumers are being asked to
reduce their electricity consumption during
14 abb.co.uk/ffwd Power Grids
Peter Jones,
Technology Strategy Manager,
ABB Power Grids division
periods of high grid load. Local communities
are taking power generation projects into
their own hands. And local grids in major
UK cities are struggling to cope with the
number and scale of construction projects
under way, with one major new building
in London having to bring in power from
a feed two miles away at considerable
additional expense.
We are now seeing profound chang-
es away from the traditional model of
large-scale, centralised generation and
transmission. In particular, synchronous
thermal plant is being replaced by asyn-
chronous embedded renewables, with a
consequent reduction in the system inertia
offered by spinning reserve.
The attraction of microgrids is that they
can play a valuable role in the UK energy
market – in a way that could benefit existing
players, new entrants and consumers alike.
This may require some new ways of working
and disruption to old business models, but
the opportunity beckons.
A recent Navigant Research report
identified over 400 microgrid projects
currently under development globally. While
Ernst & Young have estimated that in the
20 countries analysed by the company,
microgrids could provide anywhere
between USD64 billion and USD171 billion
in electricity cost savings for commercial
companies by 2020. In the UK, the savings
would be equivalent to between 21 and
30 per cent of overall electricity costs.
These savings would arise from the ability
to take advantage of the changing cost
dynamics of newer technology, including
energy storage systems, the falling costs
of solar and wind energy systems, as well
as reduced exposure to increasingly volatile
fossil fuel prices.

Microgrids combine a range of generation sources with energy storage and intelligent load management
The time has come for microgrids
In many respects, microgrids are scaled
down versions of traditional power grids.
A key difference, however, is the closer
proximity of generation sources and user
loads. Microgrids are not just for renewable
energy – they can be based on traditional
diesel gensets for example. However,
typically they integrate multiple sources
such as solar, wind power, biomass, small
hydro, geothermal, waste-to-energy and
combined heat and power (CHP) systems.
Microgrids are also increasingly being
equipped with energy storage systems,
especially as lithium-ion (Li-ion) batteries
become more cost-competitive.
By combining a range of generation
sources with energy storage and intelligent
load management, microgrids provide
reliable, economic and environmentally
friendly power supply. They can also be
used as black start power or to bolster
the grid during periods of heavy demand,
especially in providing vital ancillary services
such as frequency support.
Grid-connected microgrids can be
seamlessly ‘islanded’ from the main grid
when needed, for example during periods
of peak power grid usage, or during a
primary power grid failure. In this mode,
the microgrid isolates its local generation
and loads from a faulty grid and operates
independently for prolonged periods.
The system is controlled through a
microgrid control system, such as ABB’s
Microgrid Plus System, that can incorporate
demand–response so that demand can be
matched to available supply in the safest and
most optimal way. A flywheel- or battery-
based grid stabilizing system like ABB’s
PowerStore may be included to offer real
and reactive power support. The microgrid
control system provides dynamic control
across all the various energy sources,
enabling autonomous and automatic self-
healing operations.
Real-world solutions
ABB has already delivered more than 30
microgrid solutions around the world to help
both utilities and commercial and industrial
customers improve supply stability and
Microgrids
resilience. Ultra-reliable power is attractive
for a variety of businesses and institutions
such as hospitals and microprocessor
manufacturing. But one sector in particular
is growing like no other: data centres.
Today’s state-of-the-art facilities draw tens
of megawatts and energy costs are perhaps
only second to uptime on the data centre’s
list of priorities. Data centres are therefore
uniquely suited to microgrid applications.
Legion House
An excellent example of a microgrid has
been installed by ABB at ‘Legion House’, an
office building in Sydney’s central business
district – Australia’s first carbon-neutral
and autonomous heritage-listed building.
It now generates its own power on site
through biomass gasification –fuelled by
wood chips and waste paper collected
from the 50-storey office block – and can
operate completely independently of the
mains electricity grid.
The gas-fired generators serve as the
building’s base electrical load while the
battery-based energy storage system
dampens the effects of instantaneous load
steps. The system exports spare electrical
power to the adjacent tower building. The
battery power system is also used to serve
the overnight electrical load as well as
minimize the generator operating hours.
The microgrid’s stabilization and battery-
based energy storage systems ensure
the tenants have continuous access to a
reliable electricity supply. They stabilize the
internal (islanded) power network against
fluctuations in frequency and voltage that
can be caused by essential building services
such as elevators and air conditioning
systems. The solution uses advanced
control algorithms to manage real and
reactive power that is rapidly injected or
absorbed to control the power balance,
voltage, frequency and general grid stability.
Microgrids deliver security of supply
In the face of rising energy demands and
the growing favourability of renewable gen-
eration sources, microgrids offer a highly
flexible, modular and scalable solution. Even
in advanced economies like the UK, they
can be used to increase the reliability and
quality of power supply in both grid-con-
nected and isolated operation. They can
also reduce energy costs and enhance their
predictability as well as helping to reduce
carbon footprint and overall environmen-
tal impact. Now is the time for the UK to
embrace microgrids.
Power Grids abb.co.uk/ffwd 15
Power quality
New QCap QS capacitor shelf range
ABB has launched a new range of shelf
capacitors to improve power factor (PF).
PF is the ratio of ‘real’ power that does
the work to the ‘apparent’ power that
needs to be supplied by the electricity
supplier. They made their first public
appearance at the official opening of
ABB’s new Bromborough facility (see
full story on page 4).
Inductive loads such as motors, pumps
and fans cause the power factor to drop,
which takes up ‘head room’ in the power
distribution system, effectively reducing
capacity, reducing equipment life and
potentially leading to financial penalties from
utilities. Installing Power Factor Correction
(PFC) equipment alleviates this.
16 abb.co.uk/ffwd Power Grids
Modular format for panel builders
The new QCap QS shelf range is based
on ABB’s well-proven QCap capacitors
in a modular format for panel builders to
integrate into low voltage distribution panels
and switchboards that will operate under
the conditions specified in the IEC 60831-1
standard.
Three units are available at 50 or 100
kvar, with the larger size being available
with or without a detuning reactor. The units
have been designed for straightforward
installation and to ensure exception reliability
and efficiency during operations.
ABB has opened its new ABB Power
Quality facility in Bromborough to better
serve customers
 Enterprise software

Upgrade for Dubai airport SCADA

ABB is helping Dubai International Airport to increase passenger capacity by According to Dubai Airports’ strategic
upgrading the supervisory control and data acquisition (SCADA) system. During plan for 2020, the operator is planning $7.8
the project, ABB will replace the central computers, deploy the latest version of billion investment that will grow passenger
its Network Manager software and connect these to the existing network of field numbers to 90 million per year, as well
devices. as cargo handling. To achieve this, the
number of stands will increase to 230 and
Dubai International is the world’s busiest sources, including remote terminal units, an additional 675,000 square metres of
airport for international passenger traffic, bay control units and main distribution terminal space will be constructed.
with flights to more than 260 destinations. boards. In the current system, field-based “This upgrade will provide advanced
It is also the world’s third busiest hub in sensors continuously monitor detailed data automation of the power distribution network
terms of international air freight. In 2014, related to the power network in real time, and enable reliable and efficient power
it handled more than 70 million passengers and provide the operator with analytics to supplies to the world’s busiest international
and 2.4 million tons of cargo. support decision making processes and airport, optimizing the use of resources
optimize operations. and minimizing disruption to passengers”
Fast growth said Claudio Facchin, President of ABB’s
Since ABB implemented the airport’s first Reliability and efficiency Power Grids division. “Grid automation and
SCADA system in 2004, the airport has By upgrading the SCADA system, the airport leveraging our software portfolio to deliver
grown five-fold. will benefit from increased operational enhanced customer value are key elements
Today it provides a common power reliability and efficiency. This will provide of our Next Level strategy supporting our
distribution automation system and the basis on which the airport will be able Internet of Things, Services and People
handles data signals from around 100,000 to increase capacity. approach.”

Power Grids abb.co.uk/ffwd 17

Caithness Moray

Meeting our environmental

commitments
ABB is currently working on a £500 million contract to deliver the Caithness Moray
HVDC transmission link. Kelly Wyness, Principal Hydrologist at Natural Power,
explains how the environmental consultancy is helping to ABB keep its programme
on track.

Inspecting the works for the Caithness Moray project

18 abb.co.uk/ffwd Power Grids


Large and complex projects like the
Caithness Moray HVDC power link
present many risks and challenges. In
anticipation of these challenges, ABB
appointed Natural Power in 2014 to
provide an environmental framework and
on-going advice throughout the project.
Natural Power is an independent envi-
ronmental consultancy that was formed
in 1995 to meet the growing demand for
renewable energy projects. We support
all renewable energy sectors, including
onshore wind, offshore renewables, solar,
hydro and renewable heat as well as the
grid and infrastructure that are essential for
transmission of renewable energy.
Pre-construction strategy and surveys
As a major new transmission link with
onshore and offshore elements, the Caith-
ness Moray project was right up our street
and we’ve been heavily involved since the
first phase of ABB’s work.
Our first task was to draft the envi-
ronmental documentation to give ABB’s
customer Scottish and Southern Energy
(SSE), the Scottish Environment Protection
Agency (SEPA), Scottish Natural Heritage
(SNH) and other consultees, the assurance
that environmental considerations were high
on ABB’s list of priorities.
That document formed the basis of all
of our work that followed, including the
project environmental management plan,
which set out the roles and responsibilities
and the legislation.
Below this, we developed site-specific
construction and environmental manage-
ment plans to cover individual sections of
the project: the Spittal to Noss Head land
cable, Port Gordon to Blackhillock land
cable, Blackhillock construction compound,
the Spittal and Blackhillock Convertor Sta-
tions and the Noss Head and Portgordon
HDD Landfalls.
These documents include detailed rec-
ommendations for drainage mitigation and
ecology mitigation for ABB to adhere to,
as well as the results of pre-construction
surveys to identify wildlife such as badg-
ers, otters, reptiles and birds, as well as
the potential impact on water supplies and
drainage networks.
Reasonably practicable
It’s been a comprehensive process and we
see our role as providing ABB with advice
Caithness Moray
to ensure it does what is reasonably prac-
ticable to protect the environment.
Our knowledge of legislation and experi-
ence of working with regulators and principal
contractors like ABB helps to find a balance
between the priorities of the construction
work and environmental protection so that
the project is delivered to programme and
the environment is protected and managed
at reasonable cost.
Inverness-based team
The Caithness Moray project is a substan-
tial piece of work and we’ve had around 15
people working on the project at different
stages so far, with most people being based
in our Inverness office. Because the cable
route runs through land and sea routes and
has landfall points, we’ve called in experts Water quality monitoring
in onshore ecology, ornithology, hydrology
and marine mammals.
At the moment, we’re providing a lot took some peat depth surveys to validate
of day-to-day support as Natural Power previous survey information and we con-
is acting as ABB’s Environmental Repre- firmed that the peat is up to five metres
sentative, with a dedicated environmental deep in places.
manager and senior technical advisors. This presents a major challenge for con-
We also have several consultants acting ventional excavation techniques as the cable
as environmental clerk of works for differ- must be buried underneath the peat. Peat
ent sections of the project. It’s a role that is a priority habitat and is also very wet and
involves getting out and about to support waterlogged. Excavating an open trench
construction teams, provide advice and safely would require a lot of space for both
gather data on the impact of the works. excavation and correct storage of peat,
whereas the narrow working corridor that
Multi-disciplinary team ABB is allowed would not accommodate
I’m in charge of Natural Power’s hydrology this. Our surveys and recommendations
team, which specialises in environmen- have given ABB the insight to consider
tal management, including surface water other options, such as directional drilling.
drainage, groundwater management, water Our findings helped ABB to decide to car-
resources, and pollution control and moni- ry out horizontal directional drilling below
toring programmes. For the Caithness Moray that entire section of peat, which was the
project we work in close collaboration with most practical and cost-effective method
our colleagues in the onshore and offshore of minimising the impact of the cable route.
ecology teams. Our advice also helps ABB to maintain
What’s most important about our role the mitigation in areas where work is draw-
is that our advice keeps ABB’s work in line ing to a close to reduce any impacts on
with environmental requirements, UK and watercourses, water resources and habitats.
European legislation while keeping the pro- The experience shows that we have a
ject on track in line with the programme and good practical and open relationship with
inside the limitations of the site. ABB and that they are able to trust our
That’s the satisfying part of the role, advice and adapt their approach based on
knowing that you’re doing a job well, the evidence we provide.
responding to unexpected challenges and
utilising a pool of talented people.
Acting on survey knowledge
One unusual challenge that arose on the
cable route from Spittal to Noss Head was
a particular area with deep peat. We under-
Power Grids abb.co.uk/ffwd 19
Cables
The new vessel will be a key differentiator for ABB’s high-voltage cable business
Investing in the world’s most
advanced cable-laying vessel
ABB has ordered a new
state-of-the-art cable ship
to boost its capacity and
flexibility to install and
service high-voltage (HV)
subsea cables
ABB has ordered the world’s most
advanced cable-laying vessel to boost
the capacity of its submarine cable
operations while achieving greater
efficiency and precision. The new ship,
custom-built to ABB specifications, will
measure approximately 140 by 30 meters.
It will be constructed at Kleven shipyard
in Norway for delivery in 2017.
20 abb.co.uk/ffwd Power Grids
Thanks to the highest class (DP3)
dynamic positioning technology the ship
will be able to maintain its position with a
high precision.
“This next-generation vessel incorporat-
ing state-of-the-art ABB technologies will
be a key differentiator for our high-voltage
cable business, enhancing flexibility and
execution ability,” said Claudio Facchin,
president of ABB’s Power Systems division.
“It will also improve operational efficiency
and customer focus, supporting profitable
growth in line with our Next Level strategy.”
The new ship will deploy many of ABB’s
own leading marine technologies. The
award-winning Onboard DC Grid and power
distribution solution, for instance, will use
a single DC circuit for ship propulsion to
reduce power consumption. The vessel will
set new standards for reliability and accuracy
and will be equipped with roll-reduction
tanks and the subsea operations will be
executed and monitored by a remotely
operated vehicle using cameras and sonar,
avoiding the need for divers.
The vessel will feature a complete ABB
Integrated Automation System and three
Azipod propulsion units. Together with an
energy storage system for marine appli-
cations it will cut fuel consumption by 27
percent and reduce maintenance compared
to traditional AC systems. Sensors, mon-
itoring hardware and software will enable
data to be sent to shore via a satellite link,
to allow the onshore technical support cen-
tres to work closely with the ship as part
of ABB’s Integrated Marine Operations
solution. Advanced advisory software for
motion monitoring, forecasting and deci-
sion support will also be on board.

Going underground
Finding space for a large substation in a
busy city centre is a major challenge, and
one that is only growing as demand for
power grows. Not only are town planners
protective of city centre sites, but the high
value of the land means that there is great
pressure to give the land a public use.
Digging down can be the logical answer and
the latest generation of compact GIS means
that it is growing more feasible. For example,
ABB’s new generation ELK-3 420 kV GIS is
one third smaller than previous comparable
switchgear. Its reduced size means that it is
possible to squeeze substations into smaller
spaces than ever before, or free up space
at existing substations for other uses. There
are many underground substations already
in operation worldwide. Using experience
of the technology, planning regulations and
construction methods, as well as operation
and maintenance, ventilation and end-of-
life requirements, ABB has developed a
methodology specially for underground
substations. The concept enables up to
98 percent of a substation to be concealed
below ground level, with only cooling ducts
and access routes visible above ground.
This means that substations can deliver a
reliable power supply to consumers while
hiding below buildings, car parks, traffic
roundabouts or public spaces.
Substations
ABB’s HV Substations
app for iPads
A High Voltage Substations
iPad app is available from ABB
through iTunes. Viewers can
click through immersive three-
dimensional views of substations
to learn about the technology
and benefits of GIS and AIS
substations and how ABB can
deliver these on a turnkey basis
from concept to handover.
Power Grids abb.co.uk/ffwd 21
Transformers
Introducing the
world’s strongest
vacuum tap
changer
Innovative design
of transformer
component will
reduce the cost of
power transformers
A new transformer component intro-
duced by ABB in early 2016 will simplify
the design of power transformers and
reduce their cost.
The VUCG 1800 is an on-load tap
changer (OLTC) that regulates voltage by
adjusting the ratio of turns in the windings
in a transformer. Tap changers are essential
to keep network voltage stable under
variable load conditions. They are also
widely used in industrial transformers to
deal with variable network loads in rectifier
and furnace applications.
Until now, power transformers with a
current rating greater than 800 A have had
to split the current, adding complexity and
cost to the design of power transformers.
The VUCG 1800 is designed for rated
currents of up to 1,800 A and removes
The VUCG is designed for rated the need for forced current splitting in the
currents of up to 1,800 A transformer windings.
22 abb.co.uk/ffwd Power Grids
“Achieving a power rating this high
means transformer windings will now be less
expensive to produce, which will help reduce
the total cost of transformer ownership for
customers,” said Petter Nilsson, Global
Product Manager. “ABB’s high current
vacuum tap changer reduces transformer
costs, without compromising end product
reliability. ABB is at the forefront of OLTC
technology development, and this unit is
just the latest example.”
Lower life cycle costs
Vacuum interrupter technology is at the
heart of a new generation of tap changers,
in which electrical arcs are extinguished in
a vacuum rather than oil. The end result is
lower life cycle costs, reduced maintenance,
and longer operation as a result of radical
reduction in contact wear.
The new high-current OLTC was devel-
oped from a design that uses three parallel
vacuum interrupters instead of one, which
was challenging to develop. This has the
additional benefit that because the break-
ing current passes through three vacuum
interrupters instead of just one, wear is
distributed evenly over the contacts, signifi-
cantly reducing the wear on each individual
contact.
The new tap-changer uses the same
proven vacuum interrupters as previous
OLTCs, ensuring the same high quality and
long service life.

Comparing transformer
efficiency
ABB has introduced a new tool to help
operators determine the optimal trans-
former for their applications. It calculates
the total cost of ownership (TCO) of trans-
formers to enable operators to compare
and contrast the cost of owning and
operating a transformer over its lifetime.
The easy-to-use tool compares trans-
formers on a whole life cost basis, with
cost calculations based on the latest draft
of the IEC 60076-20 standard.
The purchase price and loss values of
The TCO tool enables comparison of financial and environmental costs of different transformers
transformers differ widely. The real cost of
a transformer includes both its purchase
price and the cost of running it for its useful
life, which can extend to 40 years.
Looking in more detail, the calculation
takes account of no load losses and
load losses of the transformer and its
cooling equipment, as well as the costs of
commissioning, maintenance and downtime.
Behind the TCO calculator’s simple
interface, the calculation takes account
of the transformer’s anticipated operating
hours per year, average loading, lifetime,
Transformers
changing cost of energy over the lifetime
and interest rates.
The tool gives engineers a resource that
helps to compare alternative transformers,
monetary savings and environmental impact.
This supports decision making and increases
awareness of the financial and environmental
costs of operation.
Using TCO as a basis, ABB can tailor the
design of a transformer to meet the unique
requirements of a particular substation. It
also allows the customer to evaluate multiple
options to find the best fit.
Power Grids abb.co.uk/ffwd 23
Site work

Choosing a
civil partner
Yvonne Passey, Head of Supply Chain for ABB’s Power Grids
division in the UK, explains how ABB evaluates civil engineering
contractors and how it approaches contractor selection for
new HVDC (high-voltage direct current) projects such as
converter stations.

Civil contractors are an essential and
sometimes overlooked aspect of deliv-
ering power infrastructure projects.
Their work plays a vital role in support-
ing and protecting assets throughout
their lifetime.
A good contractor will not just deliver
work packages safely and on time, but will
also provide honest feedback, leading to
more effective design, better ways of work
and faster overall delivery.
That’s why we have a rigorous process
in place to evaluate potential contractors
and select the right civil contractor for each
work package.
Most have a strong local focus, bringing
the benefit of familiarity with local regu-
lations, ground conditions and weather
conditions. They also have logistical advan-
tages in sourcing materials, manpower and
equipment locally. Hiring a local contractor
also reaps the benefit of good communi-
ty relations that outlasts the project itself.
Contractor qualification
ABB’s qualification process ensures we have
a trusted pool of contractors that meet our
standards of project delivery and safety as
well as financial accountability and reporting.
When we’re ready to tender a project,
we choose candidates from this pool based
on their expertise, size and capabilities.
For example, we’d choose a contractor
with cable installation experience for a
cable project and a different contractor to
construct foundations.
Depending on the type of work and the
size of the package, our approach changes.
Work packages in the substation market

Choosing the right contractor for the

work
ABB relies on contractors with many spe-
cialisms. These include civil, structural and
building contractors for substations and
converter stations, plus contractors to
install submarine and underground cables.
As well as other specialists, we also
look for suppliers to deliver services such
as geotechnical and architectural surveys.
This will ensure that we satisfy all of the
requirements of our clients and regulators
such as local authorities.

24 abb.co.uk/ffwd Power Grids


are often small in size and there are many
competent contractors that can deliver on
a design and construct basis.
However, for converter stations, work
packages tend to be larger and more
specialist in nature so we will separate
design and construction work and focus
on a contractor’s technical capabilities.
Whatever the project, our ultimate goal
is to reduce the risk and deliver safely and
to programme for ABB’s customers.
Supplier evaluation
Under ABB’s ‘Suppliers Charter’, we take a
consistent approach to all sub-contractors.
We decide whether to accept a potential
new contractor based on our sub-contractor
qualification process.
We ask potential suppliers to complete
a rigorous self-assessment questionnaire.
This delves into a contractor’s operational
experience, size and capabilities. It covers
codes of conduct, level of liability insurance
cover, plus environment and quality systems
and ISO accreditations.
Because safety is paramount we ask
detailed questions about health and safety
systems and environmental records,
with particular attention paid to lost time
incidents.
We also evaluate the technical com-
petence of the firm and its financial status
to ensure that we consider it for the right
type and size of projects. Because we’re
evaluating them as a partner, it’s important
to gain a full understanding of them as a
company and ensure that they meet ABB’s
high standards.
Lastly, we send a team of experts
including global resource experience to
visit the contractor in person to carry out
an audit to verify the contractor’s approach
is consistent with ABB requirements.
We also call on supply chain specialist
Achilles to assess any potential new
contractor. Achilles draws on its extensive
knowledge of suppliers in the power and
technology community to ensure they meet
our criteria in terms of health and safety as
well as on a legal and financial basis.
Pulling on global experience
Since introducing HVDC technology in
1954, ABB has been awarded more than
110 projects, representing a total installed
capacity of more than 120,000 megawatts
and accounting for around half the global
installed base.
In the case of contractors for specialist
projects such as converter stations, we
Site work
draw on the support of ABB’s global experts
during the final phase of evaluation. For an
HVDC converter station, for example, the
team for our final evaluation will include a
global expert in HVDC technology from
Sweden.
Once accredited, suppliers’ details are
recorded on a central database, meaning
that ABB in the UK can access expert sup-
pliers from overseas if necessary.
Challenges for converter stations
As we introduce HVDC power transmission
into the UK, we are building a network of
suppliers with the right skill set and also
the right approach.
Converter stations are typically larger and
more complex than substations so we are
selecting contractors with strong experience
of building electrical infrastructure. In
addition to the stringent requirements of
our evaluation process, we also need the
contractors to go the extra mile in terms
of collaboration and innovation.
So ABB takes many different aspects into
account when considering which contractors
to invite to tender. New technology calls
for the development of new skills across
the supply chain and for suppliers to take
a proactive approach.
Power Grids abb.co.uk/ffwd 25
Service

Pulling moisture from

transformer oil
Robert Slinger, Operations Manager for ABB’s Transformer
Service Business Unit, introduces a brand new service from
ABB that will be available in 2016 to support the installation and
maintenance of oil-filled transformers for UK customers

ABB has ordered a dedicated rig to
pull moisture from transformer oil. The
service is essential when installing and
commissioning new transformers or to
extend the lifetime of transformers that
are in operation.
By adopting its own rig, ABB will improve
flexibility and availability of oil processing
for customers.
The need for oil processing
Oil-filled power transformers take the form of
a tank that contains the core and windings
of the transformer. They are filled with
insulating mineral oil, which insulates and
cools the windings. In addition, transformer
windings are often insulated with cellulose-
based paper.
Effectiveness of transformer oil as an
insulator is measured by its dielectric
strength. Moisture content in transformer
oil can reduce its dielectric strength and
damage the paper so it is important to
reduce moisture.
Typically, a transformer with less than
one percent moisture content in the paper
could last 40 years, whereas moisture
content of four percent or higher will reduce
the anticipated life to 10 – 15 years. And
because transformers are a major capital
expense with a long lead time, it’s important
to optimise their operation.

The unit contains an oil processing rig and an accommodation trailer

26 abb.co.uk/ffwd Power Grids


Specialist equipment removes trace moisture from transformer oil
That’s where oil processing comes in.
It is required when preparing to fill a new
transformer with insulating oil for the first
time. While the mineral oil delivered to site
is high quality, it must be processed to
remove trace moisture contents.
The service may also be required during
the lifetime of the transformer in the case
of moisture ingress into the transformer.
Dedicated rig
To deliver the service, ABB has purchased
a dedicated oil processing rig. The rig is
housed in a truck with a staff welfare facility
in a separate trailer. Together the total length
from nose to tail is equivalent to a large 40
foot heavy goods vehicle.
On board the truck is specialist equip-
ment supplied by Micafluid of Switzerland
for moisture removal and oil heating.
New transformer installation
For brand new transformers, high quality
mineral oil is delivered to site in a tanker
but before it fills the transformer, trace
moisture must be removed. The oil will
arrive on site around 80 percent of the way
through the build.
The first step is to attach a vacuum pump
to the transformer to remove water vapour
along with the air inside it.
Oil is then pulled from the oil tanker and
through the processing rig, which heats
the oil then passes it through a degassing
chamber and into the transformer, which
fills slowly.
Once filled, the vacuum is released and
the oil is pulled from the transformer, through
the plant and returned to the transformer
in what is called a pass. Typically, several
passes are required until the rig has met
the exact specification of moisture content
and dielectric strength.
Life extension for existing assets
The other aspect of the service is to extend
the service life of existing transformers.
During this service, ABB’s rig will arrive on
site and carry out several passes, where oil
is drawn from the transformer and pulled
through the rig for heating and degassing.
ABB’s life extension service is available
for transformers from any manufacturer and
is likely to be most popular with utilities
and other applications where reliability and
availability are paramount.
Service
If there is sufficient demand, ABB will
consider extending its service capability to
include removal of acidic compounds and
sludges from transformer oil.
There are two major benefits to oil rec-
lamation, the first being environmental as
it reduces waste. Second, oil reclamation
is more effective than oil replacement as it
draws impurities out of the paper insulation
inside the transformer, therefore regener-
ating the paper as well as the oil.
Practicalities
A typical transformer will contain between
10,000 and 120,000 litres of oil and the
time required to remove moisture will range
from 12 hours to around five full days, with
the rig operating 24/7.
To support the process on site, two
technicians will man the rig, which requires
sampling the oil at regular intervals. They
will be housed in the staff welfare facility in
the trailer, which also includes a state-of-
the-art laboratory for analysis and testing
of samples.
Additional 24-hour support from Micafluid
experts is in place through a support
contract so that any issues can be resolved
without delay.
Power Grids abb.co.uk/ffwd 27
Cables

World’s most
powerful extruded
cable system
Anders Gustafsson, R&D Manager at ABB’s high
voltage cable factory in Karlskrona in Sweden, takes
a closer look at the technology behind ABB’s new
525 kV extruded HVDC cable system.

28 abb.co.uk/ffwd Power Grids


ABB launched a new extruded HVDC
cable system rated at 525 kV DC that is
capable of transmitting up to 2.6 GW of
high-voltage direct current (HVDC) power
on underground or subsea routes. Since
their introduction in the 1990s there has
been rapid development in extruded
HVDC cable technology, driven by the
need to connect remote energy sources.
Key components of the new cable sys-
tem include a cross-linked polyethylene
(XLPE) DC insulation material, an oil- and
porcelain-free termination that uses ABB
bushing technology, as well as a land joint
and a flexible sea joint.
The cable
ABB developed a new insulating materi-
al for the cable in close collaboration with
Borealis, the major polyethylene and poly-
propylene manufacturer. Having studied
several options, the team ultimately select-
ed a new grade of non-filled XLPE material
As well as good mechanical, chemical
and electrical properties, the insulation
material meets additional requirements
for DC voltage. Low DC conductivity is
particularly important because conductivity
of insulation material increases with electric
field and temperature, therefore increasing
the risk of failure due to thermal runaway.
DC also presents extra requirements
during cable manufacture. While AC cable
must be free from faults such as voids,
cracks and contamination, the environment
for DC cable manufacture must also be
free from particular chemical compounds.
A single pair of ABB’s latest 525kV HVDC extruded
cable will be able to transmit up to 2.6 GW of power
from renewable energy resources
2.6 GW
capacity
Joints
Joints are essential as they form the con-
nection between cable ends. Land cables
are delivered in many short lengths, which
are connected on-site using prefabricated
joints, whereas cable ships can carry many
kilometres of subsea cable, which can be
jointed together under factory conditions.
Factory joints on the new 525 kV cable
resemble the actual cable. Conductors are
welded and semiconducting and insulating
layers are completed with moulding or
extrusion. The process requires clean factory
conditions and takes up to two weeks.
On the other hand, a prefabricated joint
can be installed within a couple of days
inside a controlled container to protect the
jointing environment. It includes all of the
same elements as the body of the cable
as well as extra protection to ensure the
mechanical and electrical stability of the
joint.
Terminations
Terminations for the 525 kV extruded cable
are based on ABB’s 800 kV HVDC bushing
technology. The terminations are designed
to connect to overhead bus bars, either
indoors or outdoors.
The terminations are made up of a pol-
ymeric composite insulator that will not
shatter, and a corona ring that is designed
for varying environmental conditions. They
Cables
… enough to serve
the electricity needs of
Paris , City of Lights
are filled with insulating SF6 gas and have
been designed for electrical stability using
similar principles to prefabricated joints.
Testing
The final stage in development of the new
system was testing of cable and acces-
sories. ABB followed the electrical testing
requirements in CIGRE Technical Brochure
No. 496, as well as mechanical testing
as established in the IEC standards. The
cable successfully passed testing as a
prototype, and through testing of individ-
ual components and as a complete cable
system including terminations and land
and sea joints.
Ultimately, the new cable has opened
up the potential to transmit at least 50 per-
cent more power over extreme distances
than ever before. By stepping up to the
higher voltages, transmission will be more
reliable and experience lower losses than
ever before.
Power Grids abb.co.uk/ffwd 29
HVDC
Upgrading the first ever
HVDC link
ABB has been called in by Vattenfall Eld-
istribution AB to the island of Gotland
in the Baltic Sea to deliver a £15 million
upgrade to the world’s first commercial
HVDC power transmission link. ABB first
installed the link in 1954 and has progres-
sively upgraded it in the decades since,
so the project takes ABB back to the
roots of the game-changing technology.
The 150 kV link has the capacity to trans-
mit 320 MW of power over a distance of 100
km from Västervik on Sweden’s mainland
to Ygne substation on the island of Got-
land. The link provides power for 58,000
residents of Gotland and enables the island-
ers to export wind power to the mainland.
ABB’s work to upgrade the link will
enhance capacity and security of supply,
and enable the growth of wind power
generation on the island.
During the project ABB will install its
MACH (Modular Advanced Control for
HVDC) control and protection system,
which will act as the brain of the HVDC link.
30 abb.co.uk/ffwd Power Grids
After several decades of round-the-clock
operation, the link’s existing analogue control
system was still in working order but was
in need of modernisation to maintain high
availability and avoid unforeseen outages.
The most important part of the control
system is the converter firing control and in
the MACH control and protection system it
is built around high performance computer
components that give unequalled calculation
capacity. In turn, this ensures the highest
possible performance. The new system
is designed to run permanently for a life
greater than 30 years. It also incorporates
advanced fault registration and remote
control functions.
ABB’s scope of work for the project also
includes upgrades to the cooling system
and a modern operator interface that will
help to extend the lifetime of the link as
well as providing improved availability and
functionality.
Revisiting Gotland
When it was energised in 1954 the Gotland
HVDC transmission system was the first
commercial example of HVDC technology in
the world. Since then, ABB has progressively
upgraded the transmission link, with the
latest upgrade being another step in this
journey.
The island was the setting for another
‘world first’ in 1999 when ABB introduced
the world’s first interconnection using
HVDC Voltage Sourced Converter (VSC)
technology, also known as HVDC Light.
 HVDC

LitPol interconnector
completes the Baltic Ring
ABB has handed over a 500 MW inter- grid reliability while paving the way for power focus on efficient project execution as well
connector that links the grids of Lithuania trading” said Patrick Fragman, Managing as on our leading technologies to deliver
and Poland. The LitPol interconnector Director of ABB’s Grid Systems business, enhanced customer value, in line with our
is the final link in the European Union’s part of the company’s Power Grids division. Next Level strategy.”
Baltic Ring initiative, which has the objec- “The completion of this link reinforces our
tive of interconnecting the grids of nine
countries around the Baltic Sea: Lithua-
nia, Poland, Germany, Denmark, Norway, The LitPol back-to-back station interconnects Lithuania and Poland
Sweden, Finland, Estonia and Latvia.

LitPol is ABB’s 15th interconnection in

the Baltic region to date and ABB handed
it over to Lithuanian transmission system
operator Litgrid in late 2015. The link takes
the form of a classic voltage source con-
version-based HVDC back-to-back station.
A conventional alternating current con-
nection was not possible as the Lithuanian
and Polish grids are not synchronised. ABB
was responsible for the design, engineering,
supply, installation and commissioning of
the converter station, including high-voltage
equipment, power transformers, thyristor
valves and MACH control system.
“The LitPol Link helps interconnect the
Baltic region, improving power security and

Great River Energy’s HVDC upgrade

An HVDC power transmission link in
the US is also benefiting from upgrade
and lifetime extension from ABB. The
Great River Energy has appointed ABB
to deliver a $130 million upgrade to
its +/- 400 kV transmission system.
control and protection systems and other
related equipment at the converter stations.
“Maintaining Great River Energy’s high
reliability standards for this vital system
is not only critical for delivering power
in the short term, but also because it
will continue to provide a corridor for
delivering energy from North Dakota in
the future,” said Greg Schutte, Great
River Energy’s Project Leader.

The link transmits 1,000 MW over a

distance of 700 km between the Coal
Creek power station in North Dakota
and the city of Dickinson in Minnesota.
Since the system was commissioned
by ABB in 1978 it has provided more
than 99 percent availability and ABB
upgraded the link to use the MACH
control system in 2002.
During the current upgrade project,
ABB’s scope includes upgrades of the
converter valves, valve cooling systems,

Power Grids abb.co.uk/ffwd 31

GIS technology
World’s first switchgear
installation with new
eco-efficient gas
For decades, sulpur hexafluoride (SF6)
has been the predominant insulation
medium for switchgear due to its technical
properties. ABB has been developing and
deploying alternatives to this greenhouse
gas on the path towards greater eco-
efficiency and lower environmental
impact and is now commissioning the
world’s first pilot with a new eco-efficient
gas mixture.
With global warming and climate change
becoming worldwide concerns, products
are increasingly being developed that have
the lowest possible environmental impact.
Research is ongoing to find alternatives to
even well-established technologies. And
this is the case with SF6, a man-made gas
developed in the early 20th century which,
Switchgear ready for delivery
32 abb.co.uk/ffwd Power Grids
due to its excellent properties for electric
insulation and arc interruption is used
extensively as the dielectric medium in high
and medium-voltage switchgear. In addition
to enabling safe and reliable operation, it
has also made it possible to significantly
reduce the size of switchgear installations,
and SF6 will remain as the main insulation
medium for years to come.
SF6 is a greenhouse gas and its lifecycle
management requires careful handling and
can entail substantial costs, particularly
when decommissioning ageing substations.
As the demand for electricity rises world­
wide, especially in emerging countries,
demand for high-voltage switchgear is
also rising. This is driving the search for
alternatives to SF6.
ABB has achieved a recent breakthrough
by commissioning the world’s first high- and
medium voltage pilot gas-insulated switch-
gear (GIS) bays with a new eco-efficient
gas mixture. This fluoroketone-based gas
mixture is a chemical compound developed
for switchgear applications in collabora-
tion with 3M.
The GIS bays for 24 kV and 170 kV volt-
age ratings are installed in a pilot substation
in Zurich operated by leading Swiss utility
ewz, which was inaugurated in August 2015.
The fluorinated molecule has a chem-
ical composition that decomposes under
ultraviolet light in the lower atmosphere.
Therefore, the molecule’s atmospheric
lifetime is extremely short (less than 15
days versus 3,200 years with SF6) and it
decomposes into negligible quantities of
CO2 that are not harmful for the environ-
 GIS technology

ment. Because of this, its Global Warming

Potential (GWP) is less than 1, even lower
than CO2 (GWP=1). In addition, the fluor-
inated molecule is practically non-toxic,
non-flammable and neither the substance
itself nor the effects of decomposition would
deplete the ozone layer.
This GWP is almost 100 percent lower
than that of SF6, without any compromise
on equipment quality and reliability. The new
gas mixture is the only one available so far
that meets performance criteria after being
type tested according to IEC standards and The innovative Oerlikon substation in Zurich
has a GWP <=1. In addition, the lifecycle
analysis (LCA) of the product shows that depletion potential (ODP), is non-toxic and ruption medium.
deployment of high-voltage GIS with this non-flammable. An acceptable interruption performance
new gas mixture can lower CO2 equivalent In the insulation regime, testing per- has been established using a standard
emissions by up to 50 percent through the formed at ABB laboratories has shown that high-voltage circuit breaker. For lower rat-
lifecycle of the equipment, the other half transmission and distribution ratings can ings and low temperature applications, CO2
being attributable to raw materials, manu- be addressed with a fluoroketone-based may be used as an alternative.
facturing and thermal losses. admixture, where the lower ratings (sub As well as contributing to the efforts of
Despite the known challenges, in the transmission) are also feasible with con- reducing global warming, the new tech-
search for alternatives, gas mixtures com- stituent gases of the atmosphere such as nology also brings end-users the possible
posed of fluoroketones with technical air or N 2 and CO 2. Power testing performanc- benefits of simplified operations, as the use
CO2 as a carrier gas have shown acceptable es have also shown the high potential of of SF6 entails significant regulatory work
insulation and switching capabilities where fluoroketone-based admixtures for indoor such as inventory management and other
this mixture has only a GWP <=1, no ozone applications as a switching and arc inter- logistic requirements.

Building resilience
In the USA, New Jersey’s oldest and
largest utility, Public Service Electric
& Gas (PSE&G) has turned to ABB
to supply gas-insulated switchgear
(GIS) in a major upgrade to two sub-
stations that will protect the network
from severe weather and enhance
power reliability.

PSE&G is upgrading 50-year-old AIS

(air insulated switchgear) Hillsdale sub-
station to prevent power outages for
residents in severe weather. It is con-
verting Jackson Road AIS substation
to allow for increased capacity without
expanding the footprint of the site.
The utility selected ABB’s 420 kV
ELK-3 GIS because of its robustness,
reliability and small footprint com-
pared with AIS. ABB’s scope includes
design, supply and commissioning of
the switchgear. ABB’s ELK-3 GIS

Power Grids abb.co.uk/ffwd 33

Innovation

Finding a
better way
Leigh Turley, Engineering Manager for Grid Integration
division, explains how ABB is working with its
customers to challenge the norm and to deliver
projects more quickly, and reduce risks and costs.

Driven by Ofgem’s RIIO (Revenue = Incentives + Innovation + Outputs) model,

operators are under growing pressure to deliver improvements and upgrades to
their power transmission and distribution networks at lower cost and risk. To help
them achieve this, we are drawing on its experience of delivering projects around
the world as well as its culture of challenging accepted norms.

When looking for opportunities to drive
down cost and risk, it’s important to con-
sider new and different ways to approach
engineering problems at every stage from
inception through design, construction,
commissioning and handover.
Understanding the customer’s priorities,
objectives and long-term operations are
vital. It’s important to focus on potential
savings that are viable and that will add
value at every stage of a project from scope
to commissioning.
The approach encourages us to ques-
tion systems, processes, planning consents,
land take, team roles and responsibilities,
installation, outage management, con-
structability, modular design, testing, and
operation and maintenance.
Not only are safety, health, environment
and quality central to finding new ways
of working but they can also benefit the
programme, with off-site manufacturing
being particularly helpful in improving on
quality and reducing risk.
A process for innovation
The approach can be simplified as a pro-
cess. After receiving a project scope
document from the customer, we take the
first step of reviewing it with the objective
of adding value and finding efficiencies.
Our engineering team compares its ide-
as to see which ones add value, creating
a hierarchy to evaluate the impact, cost,
value and efficiency of potential savings
or efficiencies. This is an essential tool in
bringing focus onto the ideas that are sim-
ple to apply and add value, as well as the
most important factor, which is whether it
is likely to be acceptable to the customer.
At this point, we present the new approach
to the client, how it differs to the original
specification and its potential benefits.
Questioning the scope
One recent example was challenging the
stop required for a turnkey project to deliver
a 132 kV substation, which included access
gantries around switchgear for maintenance,
as well as a lighting scheme, welfare facilities
and a mess room.
As an unmanned site that is going to
require infrequent visits by a service engi-
neer, there was major potential for savings.
Eliminating permanent gantries and
specifying ladder access to substation
equipment only when it is required cuts
out the cost of the gantries, reduces the
building size, footprint and can simplify the
planning process.

34 abb.co.uk/ffwd Power Grids


In addition welfare facilities, mess rooms
and formal parking are not necessary for
every unmanned site, particularly when
there is another site with such facilities
nearby. Cutting such items from the scope
will save the capital cost as well as clean-
ing and maintenance.
Alternative lighting
Lighting is another area with potential for
savings. Conventionally, lights are installed
around the fence line of sites, calling for
excavation to install ducts, structures and
connection to a lighting circuit.
An alternative is to install spot lighting
onto a substation building, which reduces
cable runs and eliminates ducting and
structures altogether. This approach
impacts on health and safety, programme,
raw materials and eliminates the cost of
maintaining lighting structures.
Saving site work
Re-thinking the approach to site work is
another area with potential for major savings
as anything that saves time on site has
major potential for cost savings.
One technique is to raise substation
structures above the ground, which removes
the need to excavate, as well as risks of
contaminated land or service strikes and
their potential to delay the programme.
Modular construction can also help,
as demonstrated by ABB’s Portable Relay
Rooms (PRRs). These contain all the
required protection and control equipment
and arrive on site pre-tested and ready to
plug and play. Another example is to reduce
risk and save time by replacing on-site
assembly of re-bar with pre-fabricated
assemblies that can be rolled out like a
carpet.
The approach even extends to the roles
Innovation
played by individuals in a team. Using
individuals with multiple skills who can fulfil
multiple tasks across more than one role
means that project team can be smaller
and more flexible.
Smarter approach to outages
Rethinking the approach to outages can
reduce the length of an outage, consolidate
more work into a single outage or lead to
more flexibility.
The objective is to optimise outages for
the customer and reduce the overall risk
to the network. For example by completing
multiple work packages during a single
longer outage, the customer can reduce
the overall scope, eliminate further outages
and improve system security.
Overall, the one aspect that is truly
essential to the process is honest and open
communication.
Power Grids abb.co.uk/ffwd 35
Power consulting

Model answers
Fahd Hashiesh, Head of Power Consulting for ABB Power Systems in the UK,
presents two case studies that demonstrate how offline system studies can
enhance power system performance

The effective planning, design and operation of industrial and commercial power response with the existing load shedding
systems requires engineering studies to evaluate existing and proposed system scheme. It can be seen that the 22 kV bus
performance, reliability, safety, and economics. Studies, properly conceived and frequency falls below the under frequency
conducted, are a cost-effective way to prevent surprises and to optimize equip- setting of the GTG (47.5 Hz) and it persists
ment section. In the design stage, these studies can identify and avoid potential for approximately 1 second – which is very
deficiencies in the system before it goes into operation. In existing systems, studies close to the generator under frequency
can help to locate the cause of equipment failure and misoperation and determine settings. This caused the tripping of
corrective measures for improving system performance. generators in the plant. It was evident that
the existing load shedding scheme was not
To show how system studies are applied load shedding scheme should shed the properly coordinated and new settings were
in practice it is useful to review two case loads based on the critical need to avoid recommended.
studies in detail. generator tripping at high load demand The proposed under frequency load
i.e. under frequency (UF). In this case the shedding scheme operates when the system
Blackout analysis for an oil and generator tripped on UF even after the loads frequency reaches 47.5 Hz, 0.25sec or a
gas plant had been shed. rate of change of frequency > 0.9 Hz/sec
An oil refinery was powered by a single GTG To investigate the root cause of generator with 49 Hz and a GTG under frequency
(gas turbine generator) generating 18 MW tripping, a dynamic analysis was carried out setting of was 47.5Hz, 1 sec.
in addition to 22 MW of power imported by modelling the generators with dynamic Fig 2 shows the 22 kV bus frequency
from the grid to meet a load demand of 40 parameters, automatic voltage regulator response with the new load shedding
MW. A three phase fault on the grid side (AVR) and governor models. scheme. In the frequency plot, the 22
had resulted in a heavy voltage dip in the The existing under frequency load kV bus frequency falls below the under
plant, and the grid incomers had tripped on shedding scheme operated when the system frequency setting of the GTG (47.5Hz for
directional overcurrent protection, isolating frequency reaches 47.5 Hz for 0.25 sec or 1sec), but it only persists for 0.2 seconds.
the plant from the grid. After islanding, a rate of change of frequency > 0.9 Hz/sec This leaves a sufficient margin with the
the GTG was tripped on under frequency with 48.5 Hz and the GTG under frequency generator under frequency settings. There
protection resulting in a total plant blackout. setting was 47.5 Hz, 1 sec. is therefore no generator tripping and hence
In the islanded plant condition, the Fig 1 shows the 22 kV bus frequency no plant blackouts.

Blackout analysis for an oil and gas plant

60.5
50.7

49.7 50.1
GTG UF
Relay Pickup
48.9 47.5Hz/1sec 49.5

48.9
48.1 ~1sec
Bus Frequency 48.3 GTG UF 0.2sec Bus Frequency
47.3 Relay Pickup
47.7 47.5Hz/1sec

45.5 47.1
0 1 2 3 4 5 6 7 8 9 10 0 0.4 0.8 1.2 1.6 2 2.4 2.8 3.2 3.6 4
Time Time

Fig 1: Frequency plot with existing load shed scheme Fig 2: Frequency plot with proposed load shed scheme

36 abb.co.uk/ffwd Power Grids


Power Consulting
Driven by continued evolution in the
UK’s power infrastructure market, it
is more important than ever to have a
thorough understanding of the complex
regulatory landscape and a strategy for
dealing with it.
ABB’s Power Consulting team has
been established to provide support. It
provides the expertise, tools and detailed
models to ensure that new grid con-
nections are fully grid code compliant,
eliminating the risk of heavy penalties
or missed opportunities.
As a strategic product group with-
in ABB’s Power Grids division, Power
Consulting is made up of 125 technical
experts located globally (USA, Brazil,
India, Germany, UK and Spain). It pro-
vides deep know-how to customers on
extensive matters related to electrical
power systems (operation, planning,
Substation equipment failure analysis
The objective of this analysis was to
investigate the root cause for the failure of a
400 kV substation CT (current transformer)
during shunt reactor switching – the
CT is located before the shunt reactor).
The entire substation was modelled in
PSCAD (a software tool for simulating
electromagnetic transients) and all the
elements were modelled as a frequency
dependence model.
The substation was modelled with seven
bays – four bays for incoming lines, one
Substation equipment failure analysis
Voltage (KV)
1.0
0.8 Re-ignition Voltage
0.6
0.4
0.2
0.0
-0.2
-0.4
-0.6
0.0850 0.0900 0.0950 0.1000
Fig 3: Voltage across breaker for current chopping 20A
A FACTS (Flexible Alternating Current Transmission Systems) installation
design, expansion and asset management).
This expert team offers new approach-
es and solutions in areas like transmission
systems, HVDC, FACTS, system controls,
energy efficiency, power market analysis,
asset evaluation, industrial systems, sys-
tem and equipment design and selection,
bay for the shunt reactor and two bays for
400/220 kV transformers.
The following scenarios were applied to
investigate the root cause for the CT failure:
(i) 400 kV shunt reactor breaker switching
with different chopping currents
(ii) R e-ignition phenomena after breaker
contacts have been separated
The shunt reactor breaker switching
analysis was carried out for a range of
chopping currents. Fig 3 shows that the
transient recovery voltage across the breaker
(the TRV) at a 20 A chopping current is 690
Voltage (KV)
800
600
400
200
0
-200
-400
-600
0.1050 0.1100 0.1150 0.1200 0.090 0.100
Fig 4: Re-ignition voltage in the 400kV breaker
Power consulting
integrated T&D planning, renewable
integration, power quality and grid code
compliance.
Most importantly, the team is able to
offer a unique combination of technical
and economic perspectives.
kV, which exceeds the TRV limits of the 400
kV breaker i.e.624 kV. There was therefore
a strong possibility that re-ignition was
taking place across the breaker contacts.
The occurrence of re-ignition was con-
firmed by monitoring the breaker re-ignition
voltages. Fig 4 shows the 400 kV breaker
re-ignition voltage of 800 kV exceeds the
TRV limits of the breaker i.e. 624 kV.
To limit the TRV across the breaker, the
following mitigation methods were proposed
(a) Pre-insertion resistor (b) Controlled
switching.
0.110 0.120 0.130 0.140 0.150 0.160
Power Grids abb.co.uk/ffwd 37
Product news
VisiVolt enhances
rail safety
Safety is at a premium for the rail indus-
try. In its annual report on safety on UK
railways, the Rail Safety Standards Board
(RSSB) identifies unguarded electricity
supplies as presenting a hazard to rail
infrastructure workers.
Exposure to live conductors is avoidable
– for example, there is potential for poor
communication between workers to lead to
someone approaching a distribution panel
that is live. With this in mind, the industry
has been calling for products that improve
safety in such circumstances by providing
an additional and independent source of
information about voltage status.
In response, ABB has developed a
new version of its VisiVolt passive voltage
indicator especially for high voltage rail
conductors. The VisiVolt is attached to a
conductor and shows at a glance whether
it is live.
It offer operations personnel a degree
of visual certainty if the overhead line is live
before isolation and earthing is carried out.
Because it provides safety assurance, our
customer Network Rail is putting the VisiVolt
through its Product Approval process.
38 abb.co.uk/ffwd Power Grids
Passive voltage indicator
The VisiVolt exploits the fact that live
conductors generate an electric field close
to their surface. At its centre it has an LCD
(liquid crystal display) that is activated by the
conductor’s electric field. The electric field
creates a capacitive current and polarises
the LCD panel, which shows a large lightning
arrow symbol when the conductor is live.
Its presence means that workers can
see at a glance whether equipment is live,
even from outside a substation enclosure.
Workers don’t need any extra tooling or
electronics to check for voltage.
One alternative method is to adopt
capacitive discharge testing kits. But these
require the installation of intelligent post
insulators with neon lamps to indicate volt-
age, and also an external power supply.
New version optimised for rail
ABB first introduced two models of the
VisiVolt in 2006, with the LCD optimised for
voltages common in medium voltage power
distribution systems operating from three to
36 kV. Since then it has proven successful
in operation on medium voltage networks
in Europe and beyond.
Following calls from the rail industry, it
has now launched the VisiVolt type C, which
is optimised for voltages in the tightly defined
range of 25 to 27.5 kV, the international
standard range for electrified railways.
Indoor and outdoor applications
The VisiVolt is around the size of a smart-
phone and has a silicone elastomer housing
that is bright orange for good visibility. It
was developed to withstand wide fluctua-
tions in temperature and humidity as well
as rain and UV exposure.
It can be permanently attached with tie
wraps for indoor and outdoor substations.
Because it uses a passive LCD to monitor
for electric field and has no moving parts, it
doesn’t need a power supply or batteries,
making it a low maintenance and low cost
way to enhance safety.
Once installed, it can remain opera-
tional for many years without the need for
maintenance.
Potential for UK applications
The VisiVolt is well suited to rail applications
anywhere in the world such as on switchgear
and transformers in trackside substations.
Major rail electrification infrastructure
projects in the UK mean that electrical
safety is becoming more important and
simple products like the VisiVolt can play an
important role in preventing access to and
raising visibility of live conductors.
It can be attached direct to insulated or
bare conductors and can be installed on
systems where indicators are not typically
installed, including open switchgear and
overhead systems. Flexible mounting means
that it can be installed simply on any cross
section or diameter of conductor.
Not only does it give visual indication
of the presence of voltage, but the VisiVolt
can also make localisation of faults easier.
Overall, it contributes to a higher level of
safety for operating and servicing trackside
substations and overhead lines. By actively
warning personnel, the VisiVolt has potential
to protect lives and prevent accidents and
their consequences.
Jay Mehta, ABB’s Sector Manager for
rail said: “With VisiVolt there is no need to
access the electrical compound you can just
walk up to the fence line and use a visual
check to establish whether conductors are
live. There is no need for extra electronics
or tooling.”
 Events

Developments in Power
System Protection
ABB was a headline sponsor of the
DPSP (Developments in Power System
Protection) conference on 7 to 10 March
in Edinburgh. The conference brought
together more than 250 experts in pow-
er system control and protection from
more than 30 countries.
Delegates from industry, academia and
business attended to learn about the latest
thinking in application, ownership, manage-
ment, design and development of system
protection and control systems.
ABB experts made presentations during opportunity to share knowledge, network
15 conference sessions on a wide range of and learn about experience of control and
topics that focused on the latest technolo- protection in an informal setting as well as
gies, business practices, applications and through the conference programme.”
techniques in control and protection. ABB
also contributed two poster presentations
and ABB’s Dr Murari Saha chaired a session
on Thursday 10 March on new algorithms
and software solutions.
David Hughes, Managing Director for ABB’s
Power Grids division, said: “ABB signed up
as a headline sponsor of DPSP because
the conference gave us an unrivalled

Desolenator takes ABB

Sustainability Prize

ABB’s David Hughes with Desolenator’s Jiajun Cen and Gal Moore, and celebrity host Ortis Deley from Channel 5’s The Gadget Show

In November ABB senior management
attended a glittering awards ceremony
in London for the IET Innovation Awards,
where ABB was once again sponsor of
the Sustainability category.
The winner, from a very strong field, was
Desolator, which developed an innovative
clean technology device that uses solar
energy to purify water for people in devel-
oping countries. It is the most affordable
and sustainable residential water purifica-
tion and desalination system on the market
(removing 99 percent of all contaminants).
It produces 15 litres of drinking water per
day, runs on solar energy alone, lasts 20
years and requires little to no maintenance.

Power Grids abb.co.uk/ffwd 39

 Our substation portfolio at your fingertips?

Definitely.

ABB has created a new app for the Apple iPad to help its customers fully understand its
substations portfolio. The app contains details on all of ABB’s substations products and
how they fit within a substation layout. The ABB Substations APP includes details about
GIS and AIS switchgear, transformers, protection and control equipment, as well as
a myriad of other equipment. It lets users explore our substations solutions within an
interactive 360˚ virtual landscape, with the ability to zoom in on particular products or
installations to learn about technical details. Acting as a dedicated product catalogue,
the app is now available via iTunes. www.abb.com

ABB Ltd
Tel. +44 (0)1785 825 050
Fax. +44 (0)1785 819 019
E-mail. info@gb.abb.com