25 August, 2016 – Tech Day , Nairobi , Kenya ABB High

ABB25th August, 2016 – Tech Day , Nairobi , Kenya

High Voltage Product Portfolio

© ABB GroupAugust 26, 2016 | Slide 2

CONTENTS

§ ABB’s Divisions and PGHV

§ Key Facts – BU PGHV

§ High Voltage Products offering – Broadest range in theindustry

§ PGHV in India

§ Technology Innovation and design features – CB / IT andDS.

§ Manufacturing with special facilities & Quality.

ABB - Divisions

August 26, 2016

PGHV – Part of Power Grids Division of ABB

Electrification Products (new)A leading player for LV and MV electrification

Discrete Automation and Motion#1 in industrial motion, a leading robotics player

Process Automation#1 in DCS, leading in process industries, marine

Power Grids (new)

#1 T&D offeringMarket and technology leader

Global reachLargest installed base

Power & Automation

Utilities Transport & InfrastructureIndustry

Power & Automation “for the site”Power & Automation “for the grid”

8/26/2016

Key factsHigh Voltage Products (BU PGHV)

§ Leading global player in high-voltageproducts – applications from 66 kV to 1200kV, AC and DC

§ 35 manufacturing locations worldwide§ About 8000 employees§ Sales support in over 100 countries§ Installations across the world including in

extreme and harsh environments-§ temperature range from -60 °C to +55 °C

§ Product certifications as per a wide rangeof international standards like IEC,ANSI/IEEE, GB or GOST

§ Key facts

8/26/2016

At the forefront of technology leadershipHigh Voltage Products

§ Gas-insulated switchgear - 1967§ Disconnecting circuit-breaker (DCB) in

2000; DCB with Fiber-optic-current-sensor- 2013

§ Generator circuit breakers with highestshort circuit breaking capacity of 300 kA –2012

§ Cryogenic SF6 gas recycling technologySF6 gas purified up to 99.9% -2012

§ Enhancing eco-efficiency with alternativesto SF6 gas, developed in-§ High- voltage circuit breaker on CO2

platform - 2012§ GIS with new eco-efficient gas

mixture - 2014

§ World Firsts

8/26/2016

UHV AC & DC transmission – Technology edgeHigh Voltage Products

§ 1200 kV Hybrid GIS§ India

§ 1100 kV AC GISChina

§ 1100 kV DC§ Bypass breaker

§ 1100 kV DC CouplingCapacitor & Surge Arrester

8/26/2016

Enabling digital gridsHigh Voltage Products

§ Integrated Solutions – digital grid enabled

§ Integrated primaryequipment

§ Advanced Sensors § Integrated control cubiclesand equipment monitoring

Compact, modular withintegrated functionality-breaking, measuring,disconnecting, earthingswitches

Non-conventionaltransducers e.g. forCurrent, Partial Discharge(PD), SF6 with digitalsubstation compatibility

Control and monitoring withseamless integration indigital automation systems

8/26/2016

Life cycle approach to eco-efficiencyHigh Voltage Products

Research and developmentAlternatives to switching andinsulation medium SF6 and oile.g. new gas mixture for GIS,dry capacitors and cableterminations

Product operations anddisposalReduced thermal andresistive lossesEco-efficient disposalprocesses

Product design andmanufacturingReduced space, material,and SF6 gasEnergy efficientmanufacturing

SF6 gas managementOn-line monitoring, reducedleakages, end-of-liferecycling

§ High Voltage Products from ABB – Designed to enhance eco-efficiency over the life cycle

8/26/2016

Solutions for wide range of power quality issuesHigh and low voltage products and solutions

§ Resulting in lower runningcosts and down-time

§ Reduction of systemlosses

§ Enhanced equipment life

§ Compliance with utilityregulations

§ Increased productionefficiency

§ Enhancing eco-efficiency

§ Benefits of having goodPower Quality

8/26/2016

Well positioned across the value chainHigh Voltage Products

§ Enhancing power reliability, efficiency and quality

1. Gas- insulated switchgear2. Air-insulated switchgear3. Hybrid switchgear4. Multifunction modules5. Generator circuit breakers6. Instrument transformers7. Disconnectors8. Surge arresters9. Capacitors and filters10. Power quality solutions11. Water cooling systems12. Cable accessories13. Components e.g. operating mechanisms, insulators14. Service across value chain

§ Range of offerings across value chain

1

2

3

45

678 9

1011


ABB’s high voltage products – global footprintFactories and service centers

Factories - 44Service Centers - 26


BANGALORE

FARIDABAD

VADODARA

MUMBAI

Local Business Unit – High Voltage Product§ Footprint

Source: Internal

Key manufacturing locationsHead office, Bangalore

Zonal sales officesBranch offices

KOLKATA

CHENNAI

§ HV breakers,§ HV Instrument Transformers§ HV Disconnector§ HV Services§ PASS/GIS

§ Capacitor

8/26/2016

ABB in India1.3+ BUSD in revenues, 9000+ employees

Note: the revenue figures are that of 20161USD=64.14 Indian rupees

3,500+employees526 MUSD




ABB in India is the 7th largest contributor to the group business volumesABB in India is the 7th largest contributor to the group business volumes

ElectrificationProducts(EP)

ProcessAutomation(PA)

DiscreteAutomationand Motion(DM)

PowerGrid(PG)

Strong local presence across the subcontinent12 manufacturing locations, 22 sales and branch offices

Augu

Key manufacturing locationsHead office, Bangalore

Sales and branch officesMysore

Bangalore

Nashik

Vadodara

HaridwarFaridabad

Mumbai Chennai

Head office

R&D center


ABB’s High Voltage ProductsInnovation is key differentiator

Costoptimization

Smallerproductfootprint

Greenportfolio

Intelligentproducts

Highervoltages

Dry Capacitor technology

1200 kV hybrid GIS

DCB for Smart Grid application

Exam

ples

© ABB High Voltage ProductsAugust 26, 2016 | Slide 16

CIRCUIT BREAKERS

CONTENT OVERVIEW

§ Circuit Breaker Evolution & Portfolio

§ Circuit Breaker Reliability- CIGRE Report

§ Technology Evolution- Interrupter & operating mechanism

§ Design Features, Innovations and advantages


HistoryCircuit breaker development

Air Blast Oil Minimum SF6 GasExample: 420 kV

…around 1960 …around 1980 …today’stechnology


Product PortfolioCircuit breakers for all applications

Standard applications§ Overhead lines§ Transformers§ Capacitor banks§ Harmonic filters§ Shunt reactors§ HVDC Systems

Special applications§ “Tailor made” solutions

ABB Breakers can meet all Customer Needs


Live Tank Breaker Portfolio- ABB

*Ratings valid at -30°C and 50Hz.

ED

LTB

D1

LTB

D1 LT

BE

1

LTB

E2

LTB

E4

(BLG

)

HPL B1 HPL B2

HPL B4

17072

31,5

40

50

145 245 300 420 550

63

80

800

[kA]

[kV]1100

HPL B2 w/o CAP

1200

Test CB


CIGRÉ : Surveys of circuit breaker reliability

§ First survey§ Service data collected 1974—77§ 79000 breaker years of service§ All types of breakers

§ Second survey§ Service data collected 1988—91§ About 75000 breaker years§ Single pressure type of SF6-breakers§ Also GIS surveys took place

§ Third survey§ Service data collected 2004—07§ 281090 SF6-breaker years and around 15000 failures recorded§ Most comprehensive reliability data

Cigre : Reference documents


Cigre : Main sources for major & minor failure rate



Cigre : Reasons for major & minor failure rates


Conclusion of Survey

§ FACTS§ Operating mechanisms are responsible for almost all

major and minor failure§ SF6 gas leakage is the second problem after

operating mechanism.§ Major or minor failure because of interrupter is

negligible.§ Direction of CB development

§ Interrupter chamber should be very energy efficient§ Use of simpler and less mechanically stressed

operating mechanism§ SF6 gas leakage should be minimized by inherent

strong design.


ABB : CB Interrupter & OperatingMechanisms.Technology Evolution


Operating Mech :Energy Level Evolution

BLG for 420kV6000J

STORED ENERGY

FSA for 72.5kV780J

FSA for 145kV800J MSD1 for 245kV

1200J

50%


Technology Evolution- Interrupter ( Self Blast)

• Single Motion Self Blast • Double Motion Self Blast• 50-60% reduction in

operating energy• Simpler, reliable drive

• Full Double Motion Self Blast• 50% reduction in operating

energy• Significant reduction in break

time


InterruptersInterrupter design – LTB and HPL

For all interrupters we use a well provenand simple design

§ Unique patented copper tube design

§ Integrated contact fingers

§ Low resistance in main contacts

§ Extremely few parts

§ Gives high reliability and switchingcapability


InterruptorsWhy we chose it ?

§ Simplicity of design creates robust long term performanceand strong switching capability

§ Supports productivity and fast manufacturing & high qualitycontrol

§ Stronger design remove need for much monitoring ofchamber parts during electrical life of equipment

Old design, 61 parts Optimized design, 3 parts


IN - Interrupters factory


Search foranothersupplier

SupplierSelectionand audit

Comp.Developm

entOK?

N

Regular ProductionComponent Development

FinalInspection

In processQualityCheck

Routinetesting

IncomingInspection

M2 test

Production

Conclude

ProductRevision

Failure

Analyzefailure

Y

Approvalfrom TLC

(OTS)

Globallyapprovedcomp. andsupplier

Inspectionat supplier

end

Y

Quality Process: Flow Chart

Installationof

equipment

CustomerComplaint

throughCCRP

4-Q/8-Danalysis

M2+ testing

ChangeDesign/ImproveQuality

Sustainable Quality


IN - Interrupters factory145kV Cut-out Model

Factory Gallery

View from Mezzaninefloor


IN - Interrupter factoryUltrasonicM/c

CMM

Roller Conveyor


Interrupter Factory


Gas systemOptimized sealing systems

TechnicalDesignDouble O-ringsfor static sealingDouble X-ringsfor dynamicsealingMaterials gooddown to -50°CMinimal amountof sealing joints

The optimized and well provendesign provides

§ Minimized leakage: Less than 0,5 %per year. Suits latest env. regulations

§ Efficient sealing even under extremeconditions: -50 up to +55 °C

Benefits

§ Long Service Life of Many yearsbefore any filling may be required.Depending upon operations normallyno filling needed during the servicelife

§ Environmental friendly


New Reliable Gas Distribution System72.5kV & 145kV Breakers

• 2 joints eliminated• 1 Gas pipe eliminated• Distribution block eliminated


Operational PerformanceABB Circuit breakers – Performance in Varied climate conditions

EDF breakerat s/s inSwitzerlandwithpolymericinsulators

EDF breakerat s/s inAlberta,Canada inextreme lowtemperatureconditions

§ ABB Live tank circuit breakers areoperating in installations with

§ Extreme temperatures (-50 to + 55◦ C)

§ High seismic withstand (≤0.5g)horizontal & vertical accelerations

§ High pollution levels

§ Extended tested for High altitudeOperations – Creating Value

§ Operation in 100% humid environments

§ In High Temperature Desert Areas


Technology InnovationComposite insulators (Silicone rubber)

ABB live tank circuit breakers can be deliveredwith composite insulators§ Flashover resistant§ Hydrophobic insulator surface; water

stays as droplets and suppressesleakage currents

§ Ageing withstand§ Unaffected by natural UV-light§ Reduces the risk for breakdown as com-

pared to EP rubber and epoxy material§ Proven withstand from field

test installations§ Low mass

Benefits§ Increased personnel safety§ Improved insulating properties


Technology Innovation - Controlled switchingSwitchsync™

SwitchsyncTM

Eliminates

transients

§ Reduces switching transients in the sub-station and the systemControlled switching is a method for eliminating harmful transients viatime controlled switching operations. Closing or opening commands tothe circuit breaker are delayed in such a way that making or contactseparation will occur at the optimum time instant related to the phaseangle.

§ All applications§ Capacitor banks, filter banks§ Shunt reactors§ No-load transformers§ No-load transmission lines

Benefits§ Longer life of the equipment§ Improves power quality

Instrument Transformers

8/26/2016

Application

Brain - Relay

Hands & Legs -

Circuit Breakers

Eyes,Ears,Nose & Skin -

CTs, CVTs, VTs

Fault in the Power System

Sensed byInstrumentTransformers &communicatedto Relay

Relay Issues TripCommand To Breaker

Breaker Trips& Clears Fault


8/26/2016

Application


8/26/2016

Application

The main Tasks ofInstrument Transformerare§ To transform current and

voltages from usually highto a value easy to handlefor relays and meters

§ To insulate meteringcircuit from primary highvoltage system

§ To provide possibilities ofstandardizing the metersand relays to few ratedcurrents and voltages

Instrument Transformersare special type of

transformers

Instrument Transformersare special type of

transformers

AV

A/D conversionComputer

Rb

CVT CT


Instrument TransformersReliable Instrument Transformers up to 800 kV

Long experience and reliable productsReliable products reduce the lifetime costs

§ Current Transformers, TypeIMB upto 800 kV

§ Capacitor VoltageTransformers, mixed die-electric type CPB up to 800kV

§ Coupling Capacitors upto245 kV

§ Grading capacitors


Used byCircuit. Breakermanufacturers

ABB IT Manufacturing facilities

ABB Kuhlman, Crystal SpringsUS

Product Range72-170 kV oil CT top core72-123 kV oil IVT34,5-345 kV oil SSVT

ABB EkaterinenburgRussia

Product Range72-145 kV SF6 CT

ABB BarodaIndiaProduct Range72-800 kV oil CT72-800 kV oil CVT

ABB LodiItaly

Product Range72-800 kV SF6 CT72-420 kV SF6 IVT72-245 kV SF6 CT/VT72-420 SF6 SSVT

ABB PrzasnyszPoland

Product Range123 kV oil CT top-core123 kV oil IVT123-145 kV combined CT/VT

ABB LudvikaSweden

Product Range72-800 kV oil CT72-800 kV oil CVT72-170 kV oil IVT

ABBOil-insulated Instrument Transformers:3 CT designs, 72-800 kV2 CVT designs, 72-800 kV3 IVT designs, 72-170 kV1 Combined CT/VT design 123-145 kV1 SSVT design 34,5 kV-345kVSF6 Instrument Transformers1 CT design 72-800 kV1 IVT design 72-245kV1 Combined CT/VT design 72-2451 SSVT design 72-420 kV

JV Jingke CN

Current TransformersProduct Range


66kV/132kV 220kV 400kV

Insulator - Porcelain/Polymer – 31mm/kV creepage max

Up to3000A x 100%

Up to3000A x

100%

Up to 4000Ax 100%

765kV

Up to 4000Ax 100%

40kA/3s

50kA/3s

63kA/1s


Current TransformersIMB – Refined for decades

1930-60’s Present Future


§ The most sold current transformer in theworld, more than 170,000 units areinstalled all over the world, from desertto arctic climates

§ Improved in several generations duringmore than 65 years

§ A reliable product with no need forregular maintenance

Long experience, rich inheritance and reliable products

Reliable products reduce the lifetime costs

Experience

QualityReliability

1960 2015

Current TransformersCurrent TransformersConstructional features

12345678

9

10

1. Expansion Tank2. Nitrogen gas cushion3. Oil4. Primary Terminal5. Primary Flange6. Insulator7. Insulated primary conductor8. Secondary cores with winding9. Secondary terminal box10.Bottom Tank

Hair pin type Dead Tank CTRobust and proven designHair pin type Dead Tank CTRobust and proven design


Current TransformersDesign Advantages

Quartz FillingüEmbedding active parts in quartz gives advantageto CT for withstanding strong vibrations duringtransportation and earthquake and provide excellentdynamic strength during short circuit faultüBeing a bad conductor of heat, rapid heating andcooling is avoided , hence eliminates possibility ofgas bubble formation.üQuartz being hygroscopic in nature absorbs theremenant moisture from oil thus improves the qualityof oil.

üDry N2 gas without movingparts, No maintenanceüMinimum 15% gas comparedto oilüAll O rings and gaskets underoil which ensures better gasketlife and leak detectionüSS Bellows with top sealing forhigher currents

Reliable Expansion system

Optimized primary designüPrimary conductor is hollow Aluminium tubeand facilitates heat dissipation by oilcirculation through tube by thermocyphiceffect.üAbove design avoids thermal ageing ofmain insulation and thus CT has very goodthermal stability.üGraded and automised insulation improvesquality and minimises variations

Seismic AspectsüLow Centre of gravityüHeavy cores in bottom tank and will notstress insulatorsüQuartz embedded active partüBottom tank acts as a part of support

We have flexible solutions and offer custom made products byoptimizing best technology and economy


Current TransformersComparison between Dead Tank and Live tank CT

CENTRE of GRAVITY

PRIMARY

ACTIVE INSULATION

SECONDARY CORES

SECONDARY LEADS

Dea

dTa

nkTy

peC

T

Live

Tank

Type

CT

Center ofgravity

Reduce thecosts forsupports

Current TransformersComparison between Dead Tank and Live tank CTSeismic aspects-IMB

Excellent seismic performance due to lower CG

Ease ofhandling

Current TransformersComparison between Dead Tank and Live tank CTInsulation

Stress distribution

Steep waveHigh Voltage

Earth

Capacitive grading(semiconductor)

• Simple and controlled wrapping of primarywinding

• Automated insulation technique• Improves quality and minimizes variations

• Manual or semi-automated insulation• Complex and demanding wrapping• Manual works----May cause variations in insulation

Implies quality risks

Dea

dTa

nkTy

peC

T

Live

Tank

Type

CT


Current TransformersComparison between Dead Tank and Live tank CT


Dea

dTa

nkTy

peC

T

Live

Tank

Type

CT

Heat from secondary isdissipated in surrounding

oil.Heavy weight cores arefree resting on suppprt

Heat from secondarywindings is dissipated

through main insulationcausing faster thermal

ageing.Heavy core weight is

borne by main insulation


• Pressurized air system has been established that leads to a dust free environment in the shopfloor.

• The insulation is dried in ovens at high temperature and vacuum to remove moisture. ASCADA system has been set up for precise control and monitoring of the oven.Efficient drying ensures reduced tan delta and enhances life of product

• After drying CTs are connected to Oil Filling system, where the CTs go through evacuation byapplying vacuum to ensure that there is no moisture or trapped gases in CT. The vacuum levelof 0.15 pascal is checked on individual CTs.

• After oil filling (at 65oC and vacuum ) the CTs are subjected pressurized impregnation at 1.6-1.8 kg/cm2 . Thus ABB CTs experience high vacuum and positive pressure during processwhich proves leak free CTs and suitability of components and robust sealing design.

SCADA control for OvensA typical oven graph of 400kV CT

Air pressurized system to ensureDust free environment

Current TransformersHigh quality production process


§ Unique automated insulation technique improves quality and minimizes variations,reduces dimensions and increases voltage withstand.

§ Primary insulation room is dust free ( to ensure PD free insulation) and hastemperature controlled environment ( to get required quality of winding)

§ The supplier for critical raw material such as crepe paper and aluminium foil aresingle source for all ABB factories globally

§ Proven insulation design over years through out all ABB factories with skilled andcertified workmen and stringent quality norms.

Other manufacturersuse manual insulation

ABB automated insulationprocess

Current TransformersAutomated Winding Machines


Current TransformersSuccess stories

ü Recently ABB has supplied 400kV_4000A CTs to KETRACO,Kenya in 2015.

ü ABB has supplied 400kV_4000A CTs with TPY core for HVDCproject NE Agra.

ü ABB has supplied > 200 nos of 800kV_4000A CTs various sites ofPower grid and others.

ü IMB type transformers are most sold and more that 170000 unitsare delivered all over world.

ü ABB Sweden is certified supplier to Russia with ambient of – 60oCü ABB Sweden have supplied huge number of 800kV_4000A CTs

with TPY cores to Hydro cuebec Canada.ü ABB Sweden have supplied and installed huge number of IMB CTs

in South America with very high altitude.

ü ABB is homologated supplier to Power grid, NTPC, GETCO in Indiaand ABB Sweden to many big utilities like Russian national grid ,National grid in UK, ENEL , TRENA in Italy and TENNET inGermany.


Capacitor Voltage TransformerLong experience

§ Produced in different generations sincethe early 50´s

§ Mixed dielectric, since more than 25years. Possible to use our CVTs for highaccuracy metering

1955 2005

Long experience andreliable products

2014


Capacitor Voltage Transformer - Construction

Primaryterminal

CVD withSynthetic oil

EMU

Terminal Box

H F Bushing


Capacitor Voltage TransformerDesign features

Voltage Range: 72 - 800 kVHigh voltage capacitor§ High or extra high capacitance§ Metal Bellow used for oil volume compensation§ ABB type mixed dielectric:

§ 1 paper & 2 poly-propylene-film§ Synthetic oil in CVD and mineral oil in EMU

Advantages§ Better PLCC performance

§ Wider bandwidth§ Insensitive to temperature variations

§ High accuracy stability§ Accuracy maintained for all

service conditions§ Solder free design

High accuracy at all service conditions

Reduce the risk to lose money at revenue metering


Capacitor Voltage TransformerAdvantages of synthetic oil over mineral oil

SyntheticOil in

capacitorLow loss angle

Very lowviscosity for

betterimpregnation

Very highbreakdown

voltagesustained for

life time Very low pourpoint, hence

suitable for lowtemperature

High volumeresitivity


Capacitor Voltage TransformerEMU

Electro Magnetic Unit (EMU)

§ High intermediate voltage -20/√3 kV or 24/ √3 kV§ Better transient

response

§ Active Ferro-resonancedamping circuit§ L-C-R circuit

§ Accuracy§ Quality winding and

proper tuning facilitatesmaintaining accuracy



Capacitor Voltage TransformersAutomated Winding Machine

§ We know that, to be able to produceworld class products, personnel andmachinery of production have to beworld class.

§ Our workshop has the most modernmachinery and process equipment.These are often tailor made in order tosatisfy the high demands of ourcustomers

§ Coil winding room is class 10000 withautomatic dry coil testing facility

Modern factory

High quality


Capacitor Voltage TransformersComparison between EMVT and CVT

1. Modular constructionEasy to transport, handle anderect

2. Can be used as couplingcapacitor for PLCC

3.All CVTs are provided withFR damping circuit

4.Uniform electrical stressdistribution thus more reliabledesign

1.Single & bulky unit

2.Communication applicationis not available

3.EMVTs experienceresonance with gradingcapacitors provided with CBwhich create permanentresonance and this can lead tofailure.

4.Non uniform electrical stressdistribution due to inter turn &interlayer capacitance

CVTEM

VT


Non conventional Instrument TransformerSSVT- Oil Filled Station Service Voltage Transformer

• Combines oil-filled dielectric structure of HV Inductive VT withdistribution transformer power ratings

• Can supply 600 volt class output with up to 333kVA power ratingfor electrical panel within control room

• Conveniently sited within substation to provide substation controlpower directly from the HV transmission bus

• Used in North America since late 1980s with ratings up to 245kV• Confirming to IEC & IEEE


Non conventional Instrument TransformerSSVT- Oil Filled Station Service Voltage Transformer

SSVT

§ Auxiliary power for substation - Used inlieu of main transformer MV tertiary- lowerenergy losses and power quality control

§ In switching stations where MV notavailable

§ Eliminates need to buy control power fromoutside

§ Cost effective, reliable source of power§ Community Electrification - areas with no

distribution infrastructure§ Remote Sites - cell towers, pumping

stations, mining & Construction

Reasons to use SSVT


Non conventional Instrument TransformerFOCS- Fiber Optic Current sensor


Fiber-optic currentsensor

Disconnecting circuit breaker with FOCS § Optical fiber replaces tons ofconventional equipment

§ Zero footprint capability§ True image of primary current (no

magnetic saturation, large bandwidth)§ Inherent galvanic isolation of

electronics from high-voltage§ Intrinsically safe§ Digital communication§ ABB’s FOCS achieves 0.2% accuracy

in outdoor temperature range(appropriate sensing fiber packaging,intrinsic temperature compensation ofFaraday effect)

§ Field data over 3 years show stableperformance within metering accuracy

§ Superior behavior at faults with DCcomponents


Instrument TransformersFocus on Environmental Aspects

§ All metal parts recyclable and re-usable

§ Biodegradable mineral oil andminimized oil content

§ Strict adherence to non use ofrestricted/banned material fromenvironment, health and safety concern

§ Certified according to§ ISO 9001§ ISO 14001§ OHSAS 18001


Disconnectors – Critical Component of S/SAvailability


Disconnectors in a Substation

-+0.00

TUBO AL Ø40

4.50 3.50 3.50 2.50 2.50 4.00 4.20 4.20 4.00 2.50 3.00 3.80

CB

DS

SA1

2

4

104 5 6

TUBO AL Ø100

7 3 65

8

9

9

8

7

6

POWER TR.

SECT. A-A

10 DS

IEV 441-14-05: A mechanical switching devicewhich provides, in the open position, anisolating distance in accordance with specifiedrequirements


nThe above assumptionsare no longer validnModern circuit breakers

require less maintenancethan disconnectors withopen contacts

§ Historically, bays were designed to make it possible to isolate thecircuit breaker for maintenance§ The basis was that circuit breakers demanded more

maintenance than disconnectors§ Typical maintenance intervals for old circuit breakers 1-2

years and for disconnectors 4-5 years§ To avoid total outage of the busbar during disconnector

maintenance a second busbar was used

Why are disconnectors required?

DS – User’s Expectation : Reliability with Min.Maintenance

§ Operates smoothly & consistently whencommand is given

§ Consistent Main Circuit Resistance (mVdrop) over life. Less losses.

§ Short time current withstand capacity withsome min. current carrying capability

§ Minimum maintenance during Lifetime§ Good lubricating system§ Synthetic and dry lubrication

§ Retains isolating properties§ Links do not get disturbed§ Permanent adjustments

§ Good seismic withstand capability§ Constructional flexibility to suit various

layouts & spaces in the s/s

Reality & Consequences§ Unable to carry rated

current due to deteriorationof current carrying path

§ Unable to close or open(correctly) due todeterioration of linkagesetc.

§ Failure of interlocks due toauxiliary switch malfunction

§ Failure of electrical circuitsdue to poor enclosure.

§ Failure to withstandseismic forces.

§ Mechanical failures wheninstalled in special layouts

Grid collapse

Unable to (close)energize circuit.

More downtime formaintenance

Spare inventory

Unsafe operation

Unable to isolate(open) the circuit.

Severethreat tosafety

Loss ofrevenue

WHY DOES IT HAPPEN ?

§ Jamming of rotary pedestal/linkages

§ Change/shift in the setting of disconnector.

§ Mechanical breakage/damage of contacts and mating parts

§ Hot spots are formed on contact and terminal pads

§ Rusting of cabinets. Jamming of door hinges.

§ Malfunctioning of Aux. Switches

§ All linkages/ bearing assembly require frequent/periodic greasing

§ Setting of limit switches change after some operation and require re-adjustment to have proper operation of disconnector.

SDF eDB GW54 GW57 DSSP72-550kV 72-420kV 123-550kV 245-550kV 123-245kV

4000A, 50kA 3150A, 50kA 5000A, 63kA 4000A, 63kA 4000A, 50kA

Center Break * ** Double Break* ** Pantograph Horizontal Knee Semi-Pantograph

Remarks: Higher ratings on request

DISC with / without earthing switch

Motor or manual drive mechanism

Stand-alone earthing switch

(*) CN local portfolio, center break (GW55) and double break (GW56)(**) BG Local portfolio – centre break (NSA) and Double Break (NRB)

INABB

CNTHB

PGHV B&M – DisconnectorsProduct Portfolio

ABB ChinaBeijing

Product Range123-550kV PA-DISC245-550kV HK-DISC123-245kV SP-DISC

Type Description

CB Center Break

DB Double Break

PA Pantograph

HK Horizontal Knee

SP Semi-Pantograph

VB Vertical Break

ABB EgyptCairo

Product Range72-245kV CB-DISC

ABB BulgariaSevlievo

Product Range72-550kV CB-DISC< 52 kV DB- DISC **

ABB Russia,Ekaterinberg

Product Range123-245kV CB-DISC

ABB IndiaVadodara

Product Range72-550kV CB-DISC72-420kV DB-DISC

PGHV B&M – DisconnectorsFootprint

ABB DS : Excellence in Design – Special FeaturesSmooth and Easy Contact Alignments - Flexibility with Simplicity

Absolute RotationalAlignment

§ Contact alignment isessential to avoid Unduemechanical & thermal stress& create long term reliability§ Only Cylindrical form can

give

Special FeaturesSpring Less Main Contacts - High contact reliability

OR

§ No Separate springs§ No rusting/ corrosion§ No loose positions. Min.

components & maint.§ Consistent Contact

resistance over longperiods.

Special FeaturesTerminal Head – Weather proof & Robust

TulipContacts

§ Tulip contacts protected from outdoorconditions

§ Graphite and synthetic materialbearings used for life longperformance

§ Synthetic contact grease used forenduring lubrication

Special FeaturesTurn Tables – Maintenance Free Design

§ Turn table bearings protectedfrom environment

§ Two stainless steel bearingsfor reliable rotary movementand reduced friction

§ High temperature stablegrease used for lubrication.Lifetime lubrication. Virtuallyno maintenance

Special FeaturesLinks & End Fittings

§ Several Conventional designs use bushes or no bushes atall. This leads to metal to metal contacts that need regularmaintenance

§ During the operation, three dimensional freedom notachieved and could lead to additional friction anddeformation of parts.

§ This could also lead to galvanic corrosion

Special Features - SolutionLinks – Frictionless joints , Maintenance free

§ Use of insulated rod endspherical stainless steelbearings give§ Protection to galvanic

corrosion§ Three dimensional flexibility

in movement§ Giving reduced friction

through the life

Bearing after 10 years in field

Special FeaturesDrive Type MD80 – Common to SDF & eDB

Ø All mounting nuts & bolts are of noncorrosive material

Ø Aux. Switches are suitable for SCADAapplications and can be changed from NOto NC and vice-versa even at site.

Ø AL. cabinet and powder coated withPolyurethane paints -gives lastingprotection to corrosion.

Ø Stainless steel door hinges does not allowdoor jamming even after many years.

Ø In built safety mech. safety release asstandard feature – main arms cannot rotatemore than 90 degrees in manual ormotorized mode

Special FeaturesDead Center Locking – High Seismic withstand

Disconnector -- CloseDead center position -- 1

Disconnector -- OpenDead center position -- 2

Special FeaturesConstructional Flexibility - Any side mounting of drives and ES

Special FeaturesConstructional Flexibility – Tandem Arrangements for Center Break to 245kV

Disconnectors in

a substation

User’s

Expectation

Reality &

Consequences

A probable

SOLUTION

ABB’s offering

Few installations

and accolades

Special FeaturesConstructional Flexibility – Vertical Mounting arrangements


Special FeaturesConstructional Flexibility - Integrated or Stand Alone Earth switches


Special FeaturesConstructional Flexibility – Modular Transport Assemblies


Special InstallationsProven quality & flexibility in Worldwide Installations

Isolator

Drive

Gantrymountedatelevationof upto 15mtrs. Op.Mech. Atworkingheight

145KV - Bangladesh

245kV - Colombia

Special InstallationsProven quality & flexibility in Worldwide Installations – Guatemala

SGF123n100+2E (TANDEM)AT AL-ARCHA, Kyrghystan

Disconnector with 3drives on one phase –Reliable operation inminimum ambienttemperatures upto – 40 C

Special InstallationsProven quality & flexibility in Extreme Environments

ABB’s DS – Robust and Reliable OfferingsStrong solution to system availability

§ Operates correctlyconsistently when commandis given

§ Gives consistent & less MainCircuit Resistance (mV drop)over lifetime

§ Has good short time currentwithstand capacity

§ Needs no Lubrication withpermanent adjustments

§ Strong seismic capability§ Provides adequate isolation

during maintenance

ABB DSRELIABLEsolution

Saves EnergyTime & Money !


Functional Integration

Valu

eThe ABB Breakers & Module Evolution

DCBn Circuit Breakern Disconnectorn Earthing Switch

LTBn Circuit Breaker

DTBn Circuit Breakern Current Transformer

PASSn Circuit Breakern Current Transformern Disconnectorn Earthing Switchn Voltage Transformer

Compact/CompassnCircuit BreakernCurrent TransformernVoltage TransformernDisconnectornEarthing SwitchnBusbar / Bus ducts

LTB39 000

DTB8 000

PASS2 500

DCB500

GLOBAL 201450 000 breakers

GISnCircuit BreakernCurrent TransformernVoltage TransformernDisconnectornEarthing SwitchnBusbar / Bus ducts

LTB1 500

DTB850

PASS550

DCB100

GLOBAL 20143000 MUSD


PASS M0SPASS M00 PASS M0

Hybrid Switchgear PASS – ABB India Portfolio

72.5 kV 145 kV 245 KV

50 / 60 Hz 50 / 60 Hz 50 / 60 Hz2500 A 3150 A 4000 A31,5 KA 40 kA 50 kA


GIS - ABB India Portfolio

ELK-04 /145S

ELK-14 /245S

ELK-3 /420C

145 kV 245 kV 420 kV

3150 A 3150 A 5000 A

40 kA 50 kA 63 kA


Surge Arresters

Available up to 800 kV for surge protection inLV, MV and HV networksAll voltage classes and surge ratings

Applications§ Indoor and outdoor substations and

transmission lines§ High energy applications

Special features§ Polymeric housing for improved performance


High voltage capacitors and filters

Capacitor and harmonic filtering solutions up to 800 kVto improve the efficiency and reliability of utility andindustrial networks.

Applications§ Reactive power compensation§ Improvement of asset utilization§ Reduction of network losses§ Compliance with grid regulations§ FACTS/HVDC

Special features§ Quality and technology leadership§ Products supported by application know-how§ Extensive portfolio coverage


Low voltage capacitors and filters

Capacitor units, banks and harmonic filters up to1000 V to improve the efficiency and reliability ofindustrial and commercial networks.

Applications§ Automatic Power factor correction§ Harmonic filtering§ Load balancing§ Reactive power compensation§ Dynamic voltage support

Special features§ ‘Best in class’ functionality§ High level of reliability and safety§ Compliance with Power Quality regulations

Our Service Centers Network26 Service Centers,1000 Service Experts

Moorebank, AustraliaGuarulhos, BrazilMontreal, CanadaSantiago, ChileBeijing, ChinaBogota, ColombiaHelsinki, FinlandParis, FranceMannheim, GermanyVadodara, IndiaLodi, ItalyKuala Lumpar, MalaysiaSan Luis Potosi, Mexico

Bergen, NorwayLima, Peru

Cheboksary, RussiaAl-Khobar, Saudi ArabiaGauteng, South. Africa.

Madrid, SpainLudvika, Sweden

Zurich, SwitzerlandKaohsiung, TaiwanBangkok, Thailand

Abu Dhabi, UAEStone, UK

Mount Pleasant, USA


HV Service facilityVadodara

• Installation and commissioningCertified staff and on-site testing

• Spare PartsCurrent and legacy products

• Maintenance and field servicesAsset updates and remote service

• Extension, Upgrades & RetrofitExtension of legacy assets with state-of-the-art components,Upgrade of switchgear components with cutting-edge technology

• Repair and refurbishmentOn-site or factory repair

• Power quality services

• Training and certificationIn factories, on-site, on-line



Manufacturing with Special Facilities& Quality


World Class ProductionABB’s production facilities

§ We know that to be able to produceworld class products, the personneland machinery of production haveto be the same

§ Our workshop has the most modernprocesses and machinery. Theseare often tailor made in order tosatisfy the high demands of ourcustomers


Local Business Unit – High Voltage ProductsManufacturing facilities in India

Maneja, Vadodara100 acres

HV Circuit BreakersHV Inst. Transformers

HV DisconnectorsHV Services

Technology CentreTraining Centre

Savli, Vadodara30 acres

Gas Insulated Switchgear(GIS)

Plug and switch system(PASS)

Peenya, Banglore18 acres

HV & LV Capacitors



Special Facilities :Mech. Test Lab.:Sustainable Quality

Testing for Reliability§ Mechanical Type Tests on the circuit breakers are performed

§ As a requirement of the standards for certification.§ They are to be regularly performed on the equipments to improve the

reliability.§ Such testing helps in improving quality of the product by identifying the

deficiencies in the materials or the manufacturing processes

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Special Test Faclities - EHV Test laboratoryState-of-the-art equipment

© ABB India March 9, 2010

Accredited by NABL

Laboratory equipped with

§ Series Resonant Test System§ Impulse Voltage Test Set-up§ Facilities for wet tests

Tests that can be performed

§ Power Frequency Voltage tests up to 700 kV§ Lightening Impulse Voltage tests up to 1600 kvp§ Switching Impulse voltage test§ Partial Discharge measurement§ Radio interference voltage (RIV) test§ Visible Corona test§ Capacitance measurement§ Di-electric dissipation factor (tan δ)


§ Established in Dec’2010§ No of Resources – approx. 40§ R&D Spend ~ 4 MUSD§ 3~4 patents / year

§ Vision§ To be recognized as the model products

development center which will help local andglobal business units in terms of creatingvalue through technology and in full alignmentwith ABB Global culture

§ Strategy§ Development related to local mkt needs. Act

as Technical lead center for such product/s.§ Increase contribution in international/global

R&D projects§ Serve other global PPHV TCs with key

area (Simulation and design)§ Develop new Mechanical Lab

§ Enhance R&D activity§ Product quality improvement

Technology Center, IndiaFor High Voltage Products

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IN TC – Workingacross almostcomplete PPHVPortfolio


Training CentreManeja, Vadodara

Classroom Outdoor switchyard Demo room

§ Hands on training for a wide range of Power products

§ Customer training

§ Internal / Employee training.

§ Equipped with a live demo room and outdoor switchyard withequipment in operating condition


Quality and operational excellenceWe share our global experience with you

We prove our reliability§ With successful product installations in all kind of harsh

environments from -55 °C to +55 °C§ With product certifications according to a wide range of

international standards like IEC, ANSI/IEEE, GOST, DL or GB§ With experience showing that many of our installations exceed

the designed service life of 30 years§ For any issues claim through Customer Complaint Resolution

Process (CCRP) available on www.abb.com


Local Business Unit – High Voltage Products§ Certifications – ISO 9001, 14001, OHSAS 18001

8/26/2016

Well positioned across the value chainHigh Voltage Products

§ Enhancing power reliability, efficiency and quality

1. Gas- insulated switchgear2. Air-insulated switchgear3. Hybrid switchgear4. Multifunction modules5. Generator circuit breakers6. Instrument transformers7. Disconnectors8. Surge arresters9. Capacitors and filters10. Power quality solutions11. Water cooling systems12. Cable accessories13. Components e.g. operating mechanisms, insulators14. Service across value chain

§ Range of offerings across value chain

1

2

3

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1011

High Voltage ProductsWhy ABBü ABB cares and strives to satisfy customer requirements.

ü Long experience > 50 years , ABB HV equipment are installed in all climates allover world

ü Safe and reliable products with complete range from 66kV to 765kV/1200kV class

ü Optimum and well engineered Product customized to requirement

ü Strong technical support from Global Technology Lead Centre (TLC) and localTechnology Centre (TC) . ABB can offer custom made solutions.

ü Stringent quality control and NABL accredited laboratory for type and routine tests

ü Modern manufacturing facility with trained, experience and skilled work force.

ü Prompt after sales service

Documents

25 August, 2016 – Tech Day , Nairobi , Kenya ABB High