ABB's world of substation solutions 4 - ABB Group

Connah’s Quay takes shape 14 Moving a mountain for Sloy’s hydropower substation 6Blue sky thinking: innovating on substation projects 28The secrets of successful site delivery 26How energy storage can help keep the grid in balance 38

ABB’s world of substation solutions 4

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From the Editor

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Dear Reader, As the UK makes progress towards its 2020 target to meet 15 percent of energy demand from renewable sources, the coun-try’s transmission and distribution network operators are looking to make the most of their substations. The model of how we distribute power is changing, as a small number of power stations give way to many renewable sources spread over a wide geographical area. Demand patterns are also changing as smart metering takes off and consumers become prosumers. This means that substations will need to be smarter, more flexible and responsive. Meeting this demand, ABB is leading the way with innovative approaches to substa-tion technology, including switchgear, transformers, control systems, FACTS (flexible alternating current transmission systems) and HVDC technologies, plus the ability to service, refurbish and upgrade existing substation equipment to enable operators to make the most of it.

Our projects reflect this, with the new GIS substation at Sloy (page 6) enabling the hydro electric power station to operate as a pumped storage site, generating more power from the existing power station. Elsewhere, we’ve delivered a major project to upgrade Wakefield substation for North-ern Powergrid an impressive ten months ahead of schedule (page 12) and work is making good progress at Connah’s Quay substation on Deeside (page 14). With ever more compact switchgear, we’re now able to hide substations below ground level in busy urban centres and you’ll find more about our approach on page 10. To explain our portfolio, we have just launched a new iPad app, which will shortly be available to download from iTunes. Why not take a look?

Stephen Trotter

FFWD Substations special issue 1/14 • The customer newsletter of ABB Power Products and Power Systems • Subscription Newsletter available as printed or electronic copy. Subscribe online at www.abb.com/ffwd • Contact and feedback [email protected] • Publisher ABB Limited, Power Systems Division, Oulton Road, Stone, Staffordshire ST15 0RS. Phone 01785 825050

Substations special issue

12 Latest advances in GIS technology

Stephen Trotter Division Head of ABB Power Systems UK & Ireland

ABB Power ProductsPower Products are the key components for transmitting and distributing electricity. The division incorporates ABB’s manufacturing network for transformers, switchgear, circuit breakers, cables and associated equipment. It also offers all the services needed to ensure products’ performance and extend their lifespan.

ABB Power SystemsPower Systems offers turnkey systems and services for power transmission and distribution grids and for power plants. Substations and substation automation systems are key areas. Additional highlights include flexible alternating current transmission systems (FACTS), high-voltage direct current (HVDC) systems and network management systems. In power generation, Power Systems offers the instrumentation, control and electrification of power plants.

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Content

ABB’s substations portfolio4 ABB’s world of substation solutions

News6 Live project news

GIS10 Latest advances in GIS technology

Project profiles12 Wakefield14 Connah’s Quay

Corporate responsibility16 Safety first and always17 Community engagement and involvement

Power system protection and control18 IEC 61850

Substation communications20 Tropos wireless networks

Renewable connections22 Substation solutions for onshore and offshore

schemes

38 Battery energy storage systems18 IEC 61850 24 Packaged substations

Distribution substations24 Packaged substations25 Retrofitting time served switchgear

Site management26 ABB’s team ready to take on challenges

Innovation28 Value-added engineering

Project design30 Working with customers to optimise design

Civils and commissioning32 Substation commissioning – the buck stops here!

Skills34 Training and development

Service36 ABB’s substations service

Energy storage38 Battery energy storage systems


ABB’s substations portfolio

An AIS substation installation

Substations are the key element in transmission and distribution networks. ABB has the specialised knowledge and global experience to construct and upgrade substations, wherever they are needed. Our utility customers benefit from both the most economic application and modern technologies, fulfilling all their requirements for project execution and system quality that ensures a long and reliable service life.

ABB’s world of substation solutions


ABB’s substations portfolio

Air insulated substations Air insulated switchgear (AIS) is the most commonly used type of equipment for substations. It offers flexibility in terms of equipment configuration, as well as com-paratively low installation costs. Substations using AIS are found in transmission networks of all sizes, all over the world. ABB has been building and supplying AIS equipment for nearly 100 years.

Gas insulated substationsGas insulated switchgear (GIS) incorporates all of the same functional elements as air insulated switchgear, but condenses them inside a sealed housing that occupies one tenth of the space. GIS is ideal for use in harsh environments, such as corrosive, salty air or extreme temperatures. Its reduced footprint means that GIS can be located in dense urban areas where space is limited and aesthetic issues are important. ABB pioneered the development of GIS technology, delivering the world’s first GIS substations in 1967. Since then, we have delivered over 10,000 high-voltage GIS bays.

Mobile substations Substation design has evolved to minimise the space they occupy and increase flexibility. It is now possible to create mobile substa-tions on trailers that can be easily trans-ported and relocated. These mobile units are used by utilities as a temporary solution during planned maintenance or restructur-

GIS is compact enough to house indoors

Mobile substations offer supreme flexibility

ing of existing facilities, for rapid restoration of supply after a substation failure, and also to provide fast-track connections for new generation while planning permission for a permanent substation is obtained.

Compact secondary substationsCompact secondary substations perform all the functions of conventional secondary substations, but all their components are installed within a very small footprint. These substations are used typically at the lower end of the medium-voltage range in urban areas, where their housings can be adapted to blend in with the local environment.

Distribution substationsDistribution substations are used to step down the transmission voltage and divide the flow of electricity between the multiple

outgoing lines of the local distribution network.

Substation automation, protection and controlABB’s world-class protection and control solutions ensure rel iable power and distribution through the smooth operation of substations. Our IEC 61850-enabled product portfolio provides open, future-proof and flexible system architectures with state-of-the-art performance. Combined with our wealth of practical and the broad scope of our service and support network, this makes ABB a leader in substation automation, protection and control.


News

Building a new GIS substation half way up a mountain has been no mean feat for ABB’s engineering

team in East Kilbride. The new substation for Scottish and Southern Energy Power Distribution wil l serve the 152.5 MW hydroelectric power station at Sloy when it takes over from its time-served AIS predecessor when the last of the circuits is transferred in mid 2014. The substation site lies at the heart of the Loch Lomond & Trossachs National Park in a mountainside location accessible only by a single private road. This posed some unusual challenges to the team in protecting the environment, and working in a climate where winter winds regularly reach 100 miles per hour. ABB’s team started work in creating the new GIS substation alongside the existing AIS site in Autumn 2012. Because GIS takes only around one fifth of the space of AIS, it has been possible to enclose the

new equipment in a streamlined granite-clad building, which has spotlighting and clever metal fins that conceal ventilation and give it a sharp appearance. Although it normally takes up to 30 weeks to build a GIS building, ABB fast-tracked construction for the project, completing the building (ready for GIS) in only 18 weeks. Some of the environmental measures taken have included transferring large deliveries to flatbed trucks for the final leg of the journey up the mountain, avoiding visits from heavy articulated vehicles, and transporting the staff up the site by bus to keep vehicle movements to a minimum. Once the old AIS substation is out of service, ABB will demolish it, removing the structures and equipment. In its place, ABB will then build an access road to the new building and fill in the old site with peat, replacing habitat that was lost in the early 1950s.

Moving a mountain

01 Sloy’s new GIS substation is housed in a low profile granite-clad building

02 The site of the AIS substation will be returned to its natural state

02

01


News

Scottish Hydro Electric (SHE) Trans-mission plc has signed a deal with ABB and Balfour Beatty Engineering

Services to strengthen the transmission network in the north of Scotland so that the region’s wealth of natural energy can be exported to consumers further south. The deal, taking the form of a five-year framework agreement, covers a number of

Making the most of natural resources275 kV and 132 kV gas insulated switchgear and air insulated switchgear (AIS) substa-tion projects in the region. The consortium, based in Kintore, Aberdeenshire, will start work on 275 kV and 132 kV GIS and AIS substations in Caithness as well as a 132 kV GIS substa-tion in Orkney and a 132 kV AIS substation in Shetland. ABB will provide support from

its offices in East Kilbride and Stone, Staffordshire. “This framework agreement for SHE Transmission is a very important develop-ment that continues our drive to both expand and diversify ABB’s customer base across the UK utility sector,” said Jon Downs ABB’s General Manager for Utility Substa-tions in the UK.

Engineers at SP Energy Networks (a subsidiary of Scottish Power) led the industry in October 2012, when the

operator became the UK’s first customer for ABB’s newest generation of ELK-3 420 kV GIS switchgear. Launched in April 2012, the ELK-3 is one third smaller in volume than previous models, a fact that means the switchgear can be delivered and installed in self-con-tained bays, leading to smaller, simpler and quicker installations and less project risk. Because models in the ELK-3 range can be transported as self-contained bays, they eliminate site assembly and SF6 gas handling. Their compact size means that substation buildings can also reduce in

Scottish Power leads the way with ELK-3size, pulling down other project costs at the same time. When SP Energy Networks’ 15 bays go into operation in 2013-15, they will integrate wind power in the south of Scotland at brand new substations at Hunterston and Wishaw and an upgraded substation at Torness. Brice Koch, head of ABB’s Power Sys-tems division, said: “These substations will help integrate and deliver clean wind energy to the people and strengthen the transmis-sion grid in the region. We are pleased to support the development of Scotland’s power infrastructure with some of our latest offerings.”

Compact and skid-mounted, the ELK-3 delivers savings

ABB’s work will enable Scotland to export more renewable energy


News

UK Power Networks is currently implementing its Regional Devel-opment Plan for the Central Lon-

don Network to support the anticipated load growth in the capital. A key element in this plan is the upgrade of an existing 33/11 kV substation in the Whitechapel area of East London.

Compact GIS fits the bill for new Whitechapel substation ABB, working as principal contractor will be installing 132 kV GIS equipment within the confines of the new multi-floored building. When the building was first designed it was anticipated that the GIS equipment would need to be installed within two distinct phases. The exceptionally small installation footprint offered by ABB’s

compact ELK-04 gas insulated switchgear (GIS) is enabling all of the GIS equipment to be installed within one phase. This innovative approach is both saving construction costs and reducing the time to completion. The new substation will be supplied via a new 132 kV cable tunnel, with the cables coming into the building basement via a new shaft and adit. The new GIS will facilitate load transfers between City of London supply points as well as providing a 132 kV point of connection for future reinforcement works.ABB began its work inside the building in late summer 2013. The major task now is to deliver, install and cold-commission the substation. This calls for detailed logistical planning since the electricity substation is located on a very narrow street within a busy part of Whitechapel. Handover is scheduled for autumn 2014. Externally, the substation will have a striking façade, as mosaic artists have turned 10 designs painted by local school children into permanent murals.

A mosaic artist turning school pupil Emad-Ul Hoque’s design into a colourful mosaic.

Dave Firth, Senior Project Man-ager, outlines some of the latest projects in ABB’s DSC (design

supply and construct) framework agree-ment with Northern Powergrid, the elec-tricity distribution network operator that serves 3.9 million domestic and business customers. ABB has worked closely with Northern Powergrid over the past decade to help upgrade and reinforce its distribution infrastructure by delivering a diverse range of major substation projects from 132 kV down to 11 kV.

CramlingtonOne of the most interesting current exam-ples is at the 66/11 kV substation at Cram-lington in Northumberland, where we are putting the finishing touches to a project to replace two 66 kV bus section circuit breakers. The previous circuit breakers were reaching the end of their normal working life, and they have been replaced by ABB PASS M00 units with a continuous rating of 2000 A, and a break rating of 31.5 kA.- Each PASS hybrid module is a complete

switchgear bay, making this an exception-ally compact solution.

Sunderland and CloistersIn Tyne and Wear, we are working on the Sunderland 66/11/20 kV primary substation and the Cloisters 20/5.25 kV substation. There are four primary transformers at Sun-derland (two at 66/11kV and two at 66/20 kV). The 66/20 kV transformers provide a supply to Cloisters 20/5.25 kV substation. This project will replace the existing 66/20kV substation with a new 66/11 kV substation. The existing 66/11 kV trans-former and associated 11 kV switchboard will remain unchanged. The two existing 20 MVA, 66/20 kV transformers will be replaced with new 15/30 MVA 66/11 kV transformers. The existing 20 kV switchgear will also be replaced with 11 kV switchgear compris-ing two transformer and one busbar circuit breakers rated at 2000 A continuous, and eight feeder circuit breakers rated at 630 A continuous, all with break ratings of 25 kA. At Cloisters the existing 10 MVA, 20/5.25 kV transformers will be replaced with 5 MVA, 11/5.25kV transformers. Following

the replacement of the 20 kV network with 11 kV, circa 7 MVA of demand will be trans-ferred from Mount Road primary substation to the new Sunderland 66/11kV primary substation. The project will ensure the con-tinued provision of a safe and secure elec-tricity supply in this area while also providing the opportunity to standardise Sunderland Primary to an 11kV system - bringing addi-tional capacity to the area while removing fault-level issues on the 20 kV switchgear. Fast-track windfarm connectionsRenewable energy projects demand fast-track grid connections to ensure they are online and earning revenue as fast as possible. At the Todmorden Moor and Grange windfarms in the Northern Powergrid region, ABB will deliver 33 kV substations in only around six months from initial order to commissioning. The switchroom, to be constructed in a new blockhouse, will comprise three panels of ABB’s ZX1.2 primary gas insulated medium-voltage switchgear.

Upgrading Northern Powergrid’s substation infrastructure


News

All systems go for Pen y Cymoedd Wind Energy Project grid connection

I n summer 2013 Vattenfall appointed ABB to build the grid connection for the Pen y Cymoedd Wind Energy Proj-

ect, which will be the largest onshore wind farm in England and Wales when it enters operation in 2016. The 76-turbine, 228 MW wind farm, in South Wales, between Neath and Aberdare, is a significant investment for Vattenfall and for the Welsh economy. ABB’s commitment to sourcing a significant amount of project resource locally within Wales was a major factor in securing the contract. Other factors were ABB’s ability to deliver the project within Vattenfall’s timescale, as well as the strength of our comprehensive solution that not only includes the substation equipment but also the reactive power and associated control systems. A very significant development is that this is the first UK project in which ABB’s state-of-the-art substation protection and control systems, working in combination with our STATCOM solution, will be used to control and regulate the output of the wind turbines to ensure they remain within the rigorous power quality standards designated

by the National Grid’s Grid Code. Work has now started on the project, which will see ABB construct two new substations linked by 9.2 km underground cable connections. To minimize disruption in this environmentally sensitive location singular trenching is employed for the route that has to traverse a high pressure gas pipeline and pass close to a site of special scientific interest as well as an ancient monument. The substation equipment to be installed by ABB includes: PCS 6000 STATCOM units to support the stability of grid volt-age by providing variable reactive power in response to voltage transients; compact PASS switchgear rated at 132 kV; trans-formers; protection and control equipment that complies with the IEC 61850 standard. The turbines on the hillside will feed into the Pen y Cymoedd substation, which will step up the voltage from 33 to 132 kV. The second substation at Rhigos will step up volt-age from 132 to 400 kV, ready to feed into a brand new 400 kV National Grid substation. Interfacing with third parties will be par-ticularly important for this project, with an

even higher than normal emphasis on com-munity relations to support Vattenfall’s commitment to inwards investment into Wales. ABB is sourcing a significant pro-portion of the project resource locally within Wales, including manpower, site manage-ment, subcontractors and suppliers of all kinds. Wherever possible, we are involving the community in the project and making the most of local skills and resources. “This contract goes to the heart of what ABB is about as a business: integrating renewable power while balancing economic success, environmental stewardship and social progress,” said Stephen Trotter, Division Head of ABB Power Systems UK and Ireland. “The project is a major milestone in demonstrating ABB’s capability in wind farm projects and particularly in meeting the stringent demands of grid codes.”

The site of the Pen y Cymoedd wind farm


Launched on the UK market in 2013, ABB’s new generation ELK-3 420 kV gas-insulated switchgear (GIS)

has shrunk in size by a third. It’s a signifi-cant innovation which will see custom-ers make financial savings from smaller substations and simpler construction, reduce risk and improve their environ-mental credentials without compromis-ing performance. We can safely say that the size of the latest ELK-3 GIS is designed to give ABB’s customers several advantages. First among these is that it allows design engineers to consider the switchgear for installations where space is at a premium. In urban settings where land is expensive, this can

be significant. New substations will benefit from smaller infrastructure costs and smaller substation buildings and it may be possible to free up space at existing substations for alternative use. Installation and commissioning costs are also areas of significant saving due to the size reduction. The ELK-3 can be transported as a single unit on a flat rack or low bed truck. So we can factory assemble, test and ship the ELK-3 switchgear as a single bay in a container rather than as multiple units that need to be assembled on-site, an exercise which only adds to the complexity and length of a project. We’ve also found that supplying switch-gear in single bays can lead to installation and commissioning times which are up to 40 percent shorter than for traditional GIS designs. The further advantage of factory assembly is the knowledge that because it has been assembled and tested, custom-ers can be assured of its quality, meaning that risk can be taken out of the construc-tion and commissioning process, a factor which will appeal to those with roles in operations and engineering, and their col-leagues in finance. The ELK-3’s environmental credentials are also an improvement on older models. Because it’s smaller, the switchgear uses up to 40 percent less insulating SF6 gas making its environmental impact lower. Once installed, the product’s fast single-interrupter dual motion circuit breaker has been designed for current ratings of up to 5,000 A and is capable of providing protection to power networks with rated short-circuit currents up to 63 kA. The ELK-3 builds on ABB’s recent developments in 245 kV and 72.5 kV switchgear and the approach to the design places drives, position indicators

GIS shrinks in size and disappears underground

and service platforms at the front of each unit, enabling easier operation, inspection and maintenance. Being constructed from standard modular components, the switchgear is designed around common substation layouts, and with an eye on future developments, we also offer the option to integrate features for smart and digital substations.

Going underground in urban centresThe biggest challenge in supplying efficient and reliable power in a bustling city centre is often in finding space for large substations, especially as demand for power grows. On one hand, local authorities’ planning departments are often protective of city centre sites, particularly those in historic settings, and on the other, the value of land in city centre sites for office or retail development often means that there are strong pressures to give land multiple uses. One solution to make the most of a limited footprint is to dig down, placing the substation below ground level, which frees up the surface for other purposes while providing all the functionality of any conventional substation. ABB’s state of the art underground substation concept enables up to 98 percent of an installation to be tucked away below ground, with only cooling ducts and access routes visible above ground. Underground substations are not a new idea, with many already in operation at many sites worldwide. The experience of constructing such substations, together with knowledge of planning regulations has enabled ABB to develop its methodology. The approach means that ABB can integrate a transformer substation into any urban environment while meeting and future-proofing customer needs.

Jon Downs, ABB’s UK General Manager, Utility Substations, outlines the latest developments in GIS technology – the new ELK-3 range, and a new concept in underground substations.

GIS

Jon Downs – ABB’s General Manager for Utility Substations in the UK


It’s possible to tuck away 98% of a substation below ground level

Using this approach, ABB can hide a substation underneath a building such as a shopping centre, car park or sports stadium. Public spaces like parks, public squares, traffic roundabouts or intersections can seem untouched to the casual observer but below the surface, can be an essential link in a city’s power grid. An underground substation will accommodate transformers, gas insulated switchgear (GIS), automation, protection and control systems, auxiliary equipment, AC and DC distribution boards, batteries, ventilation, air-conditioning and fire protection systems. Like most substations, underground stations are unmanned in normal operation but their design must take account of human safety, which is why safety features such as escape routes, smoke-free zones and separation of fire loads with bulkheads are designed in. With only two percent of a typical substation being visible from the surface, ABB’s underground substation concept keeps potential hazards well away from the general public. At the same time, it meets the most stringent requirements for power supply and delivers compactness, economy, reliability and safety.

Compact ELK-3 switchgear can be transported on a single truck

GIS


Project profiles

The major turnkey contract, placed in 2009, continued ABB’s long-standing relationship with Northern Powergrid

on strategic substation projects that goes back to 2003, when we built the Norton 132 kV substation near Stockton-on-Tees. Together with Creyke Beck and Tynemouth, Wakefield B substation is one of three high-profile substation contracts that ABB has recently delivered for Northern Powergrid.

GIS replaces AISThe previous Wakefield B substation was based on air insulated switchgear and, after around 50 years in service, it was reaching its replacement age. AIS equipment requires a great deal of site space. This meant that a like-for-like renewal project was impracti-cal in terms of both availability and cost. This was mainly because it would have required either an outage of many months

Wakefield B GIS substation – delivered ahead of schedule

– as the old substation was demolished and the new one constructed on the same site – or the purchase of additional land so that a new substation could be built adja-cent to the old one. The proven space-saving capability of ABB’s GIS technology provided an alterna-tive that blends in with the surrounding area. It has enabled a new indoor substa-tion to be constructed within the limited

Innovative approaches to design and outage management enabled the ABB project team to deliver Northern Powergrid’s new Wakefield B gas insulated switchgear (GIS) 132 kV substation in Yorkshire 10 months ahead of schedule.


Project profiles

free space available on the existing site – while the old AIS substation remained in operation. The project has effectively con-densed the new Wakefield B GIS substation into around 25 percent of the AIS substa-tion’s footprint. ABB was awarded the turnkey contract to provide a complete design, construction and installation service for the new substa-tion, featuring 14 bays of ABB ELK-04 132 kV GIS equipment. The project also required the installation of 132 kV cross-linked poly-ethylene (XLPE) cables to transfer existing Northern Powergrid connections into the new substation. In addition, it required modification of the terminal towers for the overhead lines to provide new sealing end platforms, with modification of existing sealing end platforms to accept the new XLPE cables.

Project management philosophyThe project was scheduled over three years, with hand-over due in January 2012. How-

ever, ABB’s project management philosophy is to seek every possible opportunity for adopting innovative approaches that can help improve quality, drive down costs and ensure on-time delivery or even improve scheduled delivery. A key element of suc-cessfully delivering substation projects is optimising the planned outage windows. In close consultation with our customer and cable contractor, ABB modified the content of outage work and sequence, which significantly reduced the time to final hand-over.

Outage planningRather than planning individual outages sequentially for each of the 10 circuits to be transferred, ABB arranged to transfer three circuits with three individual outages in parallel. This was accomplished twice – accounting for six circuits – while the remaining four circuits were transferred sequentially. The parallel transfer of the cable circuits called for precisely coordinated planning and execution, as taking three circuits out of service together transferred a significantly increased load on to the rest of the substation. It was therefore imperative to complete the work on time to minimise the duration of increased load. To make maximum use of the outages, a high level of preparatory work was completed in advance. This focused on the coupling of the cables to the tower sealing end platforms. During the outage,

all that was then required was to install the downleads from the towers to the cable sealing ends, which had previously been connected to the GIS equipment.

Transition joints and PASS M0 switchgearTwo of the 10 cable circuits required the creation of transition joints to connect the new XLPE cabling to oil-filled cables. During the cable transfer process, ABB also made use of the new PASS M0 hybrid temporary switchgear solution pioneered in its Reading substation project for Scottish & Southern Energy (SSE). The PASS M0 switchgear was connected to an existing redundant circuit, and then used to power up the GIS switchgear. Once all the circuits had been transferred, the PASS M0 was removed. The indoor substation constructed for the new Wakefield B is a two-storey building with the GIS equipment installed on the first floor. This allowed for the creation of a substantial cable basement to accommodate the large bending radius required by the XLPE cables which results from their large conductor cross-section of 1,000 mm2.

Wakefield delivered 10 months earlyThe net result of ABB’s innovative approach to managing the project, backed by a high level of communication and cooperation with the customer and subcontractors, was that Wakefield B was handed over in March 2011, functioning exactly as required but 10 months ahead of schedule.

PASS MO switchgear

ELK-4 switchgear at Wakefield substation


Project profiles

T he new Connah’s Quay substa-tion, scheduled for completion in 2018, will play a vital role in the

reinforcement of the high-voltage trans-mission infrastructure in northwest Eng-land, and facilitate the connection of new high-voltage direct current (HVDC) power links, such as EirGrid’s East West Inter-connector between the UK and Ireland that came online in 2012. The contract falls within the scope of the Electricity Alliance Central (EAC), in which ABB is working as part of a consortium with At-kins and Morgan Sindall to deliver major enhancements to National Grid’s 400 kV substation infrastructure. The existing Deeside air insulated switch-gear (AIS) substation, constructed by the CEGB in the 1960s, is near the end of its asset life. It currently serves as an in-feed for two major power stations: Connah’s Quay (1,380 MW) and Deeside Power (505 MW) and it is nominated as the optimum con-nection point for a number of new HVDC projects. A number of possible upgrading and replacement options were considered, eventually it was decided to construct a new gas insulated switchgear (GIS) sub-station offline and transfer circuits over on a staged basis. Once the new GIS substa-tion is commissioned, the old AIS substa-tion will be migrated over and demolished to make way for the remaining connections into the new substation. The project scope includes the construc-tion of a new 24-bay GIS substation, with 20 bays licensed for National Grid and four for customer connections. ABB is supply-ing the GIS, a 5000 A rated version of its well proven ELK-4 range to cater for high power flows, together with standard bay

protection and control solutions and high voltage cabling. The project also calls for the integration of three new 400/132 kV 240 MVA grid transformers together with an existing refurbished unit. “Not only is the project technically chal-

Connah’s Quay – ABB’s largest ever UK substation project

lenging, it has also required effective liaison with multiple stakeholders such as National Grid, International Power, SP Energy Net-works, EirGrid, EON and Local Authori-ties,” says Paul Turnbull, ABB Lead Project Manager. Don Ruddick, ABB Design Team

Connah’s Quay substation – the facts – GIS building over 135 metres in length – 400 tonnes of steel used for catwalks and support

steel work – 24 fully equipped GIS bays – 10 feeders, 4 bus sections, 2 bus couplers, 4 customer

connections, 4 SGTs (Supergrid transformers) and capacity for 4 future circuits

– 4.6 km of gas insulated busbar (GIB)

The replacement for National Grid’s 400 kV Deeside substation is ABB’s largest ever UK substation project.

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Project profiles

01 The new substation building is longer than an international football pitch

02 A view inside the GIS building

Leader added “we have also paid special attention to logistics, as the building itself is enormous – longer than an international football pitch – with catwalks and support steel alone weighing in at over 400 tonnes. Additional challenges have been presented due to the proximity of both an SSSI (site of special scientific interest) and badger sets.” In contrast to some substation projects that need to blend into the local back ground, the local authorities stipulated that Con-nah’s Quay should make an architectural statement with its striking striped cladding. The building itself is complete with all the GIS installed and the majority of the 4.6 km GIB (gas insulated bus) also installed. The site team is now pre-commissioning all of the equipment putting the project well on target for the first circuits to be transferred in 2014.

02


Corporate responsibility

ABB is fully committed to a healthy, safe, secure and responsible work-place for its employees, subcon-

tractors, partners and customers. This includes making sure that we have the right procedures and competencies in place, alongside the necessary personal protec-tive equipment (PPE) in full and correct use. But we also believe that the most significant factor in health and safety is in the thought processes that must be adopted to achieve safe working and the open and mature culture needed to allow reporting. Every injury is an injury too many, every hazard spotted and removed is a step towards reducing risk and every near miss reported is a learning opportunity. We’re currently leading on a number of initiatives with the goal of keeping people

safe. The first of these is called ‘Stop take five’ and is an important consideration for our employees in construction roles. By stopping and taking five minutes to think about risks of construction and whether a team needs to adapt to a change of circumstances (for example, sudden wet weather might have a significant impact on site conditions), ‘Stop take five’ is designed to make sure construction work takes place in a controlled manner. Another initiative is ABB’s regular sup-plier forum, in which we proactively engage our supply chain by gathering our staff together with suppliers and subcontractors to share information about risks and safe working methods. The third initiative is on hazard reporting, with activities focused on maintaining an

Safety first and always

open reporting culture. Alongside these, we have been upgrading our PPE, particularly flame resistant PPE, which protects the wearer from electrical arc type injuries. This comes on top of our universal standard for gloves and glasses, which protect against hand and eye injuries. Al l this proactive work has been successful in delivering a safe working culture. ABB has been able to report long periods of zero non-reportable injuries: four years in the substations service sector, three years in the electricity alliance and two years in other areas of substations work. This is quite an achievement, given that 12 months without a reportable injury is remarkable but because every injury is one too many, ABB will keep working hard to raise safety standards.

Trevor Farrington, ABB’s Health and Safety manager, explains how safe working is embedded in the company’s culture.


Corporate responsibility

Community relations

A key part of our site managers’ remit is to integrate with local communities, listen to (and address)

any concerns and support local initiatives in an approach that is tailored to meet local circumstances. Typical actions are adopting special approaches to traffic, communicating regularly with communities and collaborating with our customers’ own community relations teams. We’ve even set up dedicated call centres.

Local involvementBeing mindful of the potential disruption around construction, we aim to minimise our impact by building relationships with affected communities. In partnership with local stakeholders, we often leave project areas in better shape than when we arrived by landscaping rough terrain or re-planting trees and shrubs. In addition, ABB is committed to achiev-ing 90 percent local involvement for every

UK power project, including labour, services and where possible materials, only bringing in specialised commissioning and installa-tion engineering skills from outside. We believe that this ensures smooth and effi-cient project delivery and makes good business sense by avoiding the costs involved in bringing in outside labour and materials.

ABB works hard to create close links with the local community around its projects because being perceived as a good corporate citizen is essential to being ‘at home’ everywhere we operate.

ABB is mindful of the potential impact of its project on the environment


Power system protection and control

The introduction of IEC 61850 in 2004 represented a huge step forward in simplifying the integration of protec-

tion and control IEDs (intelligent electronic devices), and it is now acknowledged as the global communications standard for substation automation and power distribu-tion systems. With its standardised model of the IED and its data and communication services, IEC 61850 ensures interoperability between electrical devices from different vendors and is able to replace all the typical protocols found in the substation automation domain. Based on Ethernet technology and provid-ing a flexible and open system architecture, IEC 61850 makes the application future-proof over the entire system lifecycle.

ABB has played a significant role in the development and implementation of the IEC 61850 standard and it is essentially the default choice for the majority of our substation projects. A key enabler in the deployment of the IEC 61850 standard has been the launch of our innovative Relion® family of IEDs developed specifically to implement its core values through full native compliance. So far, we have concentrated on the IEC61850-8.1 station bus. However, we are now focusing on the IEC 61850-9-2 process bus that enables current and voltage measurements to be transmitted to protection and control devices via a fibre-optic communication network, resulting in reduced copper cabling and increased safety.

New horizons in substation protection and control

The process bus also supports the standardised integration of non-conventional instrument transformers (NCITs), bringing performance improvements and further reductions in cost and space requirements. NCITs also improve safety because they eliminate the risk of voltage hazards, which can arise in conventional transformer circuits. In 2012, we saw the first fully compliant commercial installation of IEC 61850-9-2 process bus technology. This was installed for the Australian utility, Powerlink, to pro-vide advanced automation functions to enhance availability and grid reliability at Loganlea, a key substation serving south-east Queensland, a-fast growing region of Australia.

Ibrahim Cobaniglu, ABB UK Sales and Marketing manager for Substation Automation, outlines some of the latest developments in protection and control technology.

01


Power system protection and control

Communications – AFS Family Solutions Driven by IEC61850 and other Ethernet based communication protocols, switches are now finding their way into uti l ity networks. Green field developments in particular are an ideal opportunity to con-sider this type of solution in substation and distribution communication networks. ABB’s AFS650 and AFS670 family offers many features which are required in the utility environment, including fast protec-tion schemes as well as redundant pow-er supply and alarm contacts. They also enable the stepwise introduction of Smart Grid applications, such as integration of renewable energy sources, advanced dis-tribution automation solutions and similar.

Extension for Stone’s System Verification SimulatorThe outstanding success of our unique automated factory acceptance test (FAT) system at Stone has recently seen it fur-ther extended and upgraded. The traditional method of conducting a FAT on bay control and protection equipment is to hook up the IEDs (Intelligent Electronic Devices) and relays to a network of switches, relays and lamps selected to simulate the substation plant. Our view is that this approach, which relies heavily on manual switching and recording of results, does not offer the levels of rigour, repeatability or the full audit trail appropriate for state-of-the-art protection and control schemes. That is why we offer our own dedicated, fully automated, computer-controlled test installation, or System Verification Simulator (SVS). The computer-controlled SVS is linked to ABB’s own engineered modules that simulate the behaviour of substation plant such as circuit breakers, disconnectors and earthing switches. In effect, we can dupli-cate the whole substation within the labo-ratory, and run automated, self-monitoring

test sequences to establish that the sub-station interacts correctly with the protec-tion and control panels. Over a period of time we have established a library of test routines to cover all potential situations. The real advantage of this unique facility is its repeatability. It responds just like the real plant, without human intervention to flick test switches and so on. And because the tests are automated, we have been able to uncover some aspects of the equipment’s behaviour, such as timing issues, that could not be picked up by manual testing.

Portable relay roomsFor a number of utility projects in the UK we are now delivering portable, fully-con-

tainerised relay rooms. They provide all the vital protection and control cubicles and accessories in a fully tested factory-assembled package that creates what is virtually a plug and play solution. Not only are the systems easy to install and com-mission, they are fully portable so can be relocated as needs change, while offering a 40-year service life.

Total serviceWhile delivering state-of-the-art protection and control systems is crucial, it is vital that they are fully supported throughout their operational life-cycle. So we have devel-oped a range of service packages including 24/7 support for critical systems.

01 Australia’s Loganlea Substation has been fitted with the IEC 61850 process bus

02 AFS switches are modular and IEC 61850 compliant

03 Factory acceptance testing at Stone

02

03


Substation communications

Take control: Tropos brings a new dimension to utility communicationsAndy Osiecki, General Manager of ABB’s UK power system network management business, explains how the recent acquisition of Tropos Networks adds to ABB’s ability to meet the needs of its UK power generation and transmission customers through private wireless networks that deliver secure control over grids whatever the weather.

Data Centre

Fibre/PTP

2.4/5/8/3.65 GHz

900 MHz

HAN (ZigBee)

HAN

Energy Storage Device

Substation

Feeders


Substation communications

I n a world where wireless communica-tion is becoming the norm and where Smart Grids are becoming reality, ABB

is now able to offer a new service to power utilities in the UK following its ac-quisition of Silicon Valley-based Tropos Networks. Now part of ABB’s Utility Communications product group, Tropos provides private wireless networks which free operators from the need to lease costly bandwidth from third parties. The wireless networks also ensure network availability when and where it’s needed, the ability to run multiple applications with high bandwidth and low latency and a high level of security. Tropos has been developing its wireless network technology for nearly a decade and has experience of installing end-to-end solutions, with over 70,000 routers in operation at more than 1,000 customers in 50 countries. It has established itself as the industry leader in the field and is an excellent fit with ABB, bringing a new dimension to our offerings. With a client list that includes blue-chip organizations in sectors ranging from utilities, through mining and oil & gas, to Smart Cities and ports, the Tropos business offers huge potential for ABB, especially in the UK power utility market.

Networks and applications So what exactly is the offering? Tropos describes its two main areas of expertise as being Smart Grids and Smart Cities. Its solutions include networks of routers and directional radio systems, arranged in a mesh or grid structure, along with the architecture and network management to support them. These networks can handle an assortment of applications. In the energy sector, these include Advanced Metering Infrastructure (AMI), demand management and response, distribution automation and control, outage management, mobile

workforce appl icat ions, distr ibuted generation and video security. A key feature is that there is no restriction to a single application vendor, giving customers the freedom to choose the applications that suit them. It’s possible to run any application that operates over an enterprise IT network or the internet.

Performance and flexibility Because every router in an ABB Tropos network is intell igent, data is routed efficiently to where there is capacity. This minimizes delays and gives Tropos’ customers real-time visibility and control of their assets. Networks are also scalable, meaning that customers can choose to start small and grow when needed. As the network grows, each smart router will automatically reconfigure itself, making expansion relatively simple. The mesh network design offers inherent reliability, as the network can handle any outage by redirecting data intelligently and seamlessly.

Rugged and reliable With an IP67 rating and tamper-evident casings, ABB Tropos routers are designed to cope with almost any physical challenge, a necessity when routers are routinely installed in outdoor locations in the field. Equipment is designed to withstand temperatures from -40 ˚C to +85 ˚C, wind speeds of up to 165 miles per hour and sandy or dusty environments as well as the damp, salt-laden climate found in coastal locations. The option of adding mobile routers enables the network to be extended whatever the location of field staff – one mobile router even gave uninterrupted network access throughout the launch of the rocket on which it was installed. This build quality contributes to network accessibility figures of better than 99.99 per cent. Recognising customers’ demands for

networks that are both reliable and secure, Tropos has integrated a high level of security into its products, which have been deployed in military and law enforcement applications. Each device is equipped with multi-layered security, including VPN, WPA2 encryption, AES encryption and support for multiple VLANs. Networks also feature software alarms and authentication and security measures to restrict unauthorized access.

Unique positionWhile there are other providers of wireless mesh networks in the market, only ABB Tropos has a track record in delivering end-to-end solutions for utility applications and distribution networks. The company has worked on networks for power generation, substations and utilities longer than in any other sector. As the number of applications managed over a wireless mesh network grows, so does the financial benefit. Some customers have achieved return on investment in as little as one year when integrating several applications on to their networks.

Network router


Renewable connections

Substations form an essential el-ement in the grid connection of renewable energy schemes from

onshore and offshore windfarms to wave, tidal, solar and biomass power projects. To meet the specific needs of this sector, ABB has developed a broad portfolio of substation solutions. This includes the design, installation and commissioning of gas insulated switchgear (GIS) and air insulated switchgear (AIS) substations up to 400 kV and beyond, including civil engineering works as required. Our scope covers both high-voltage (HV) and medium-voltage (MV) substations

for transmission and distribution network connections. All of these substations utilise ABB’s extensive portfolio of modular and compact switchgear solutions as well as transformers, reactors, filters, control and protection systems, alongside dynamic reactive compensation solutions to ensure grid code compliance. For HVAC connected offshore wind farms, the ABB Grid Systems business can supply the turnkey solution for the complete electrical transmission system, incorporating both onshore and offshore HV substations, plus design and supply of the offshore platform.

Substations – the vital link for renewable energy projects

Offshore substation for Thornton Bank wind farmSeptember 2013 saw ABB complete the delivery of the subsea transmission link for one of Europe’s largest offshore wind farms with the commissioning of the 325 MW grid connection for the Thornton Bank wind farm. The project, carried out for Belgian company C-Power NV, was delivered on schedule. The transmission link was constructed as part of an expansion of the Thornton Bank wind farm. In the first phase of its development, six wind turbines with a total capacity of 30 MW were built and

Kevin Mills, ABB’s Sector Manager for renewable energy connections, outlines ABB’s range of substation solutions for onshore and offshore renewable energy projects.

01


Renewable connections

a temporary connection to the mainland was built by ABB. The second and third phases of the project involved adding 48 wind turbines, which takes the wind farm’s capacity to 325 MW, which is transmitted 30 km ashore via the transformer station platform. ABB was responsible for delivering the grid connection as a turnkey project, which included the system engineering, design, supply and commissioning of the AC sub-sea cables, land-based cable systems and the offshore substation and platform that houses it.

Hadyard Hill wind farm ABB power transformers and associated high-voltage switchgear and control equipment play a vital role in connecting SSE’s 120 MW Hadyard Hill wind farm development to Scotland’s main power transmission grid. For the Hadyard Hill project, ABB supplied two 90 MVA 132/33 kV power transformers, an 11-panel 33 kV switchboard, two 5 MVar capacitors, a 145 kV dead tank circuit breaker, six CVTs, six surge arrestors and line traps.

PASS M0 saves space for distribution substationsABB’s innovative PASS M0 space-saving hybrid AIS and GIS switchgear module can save up to 70 per cent of the space normally required for a conventional AIS substation. This enables renewable energy operators to make optimum use of the restricted installation footprint often available for the construction of a suitable distribution substation. It also reduces the need for civil works such as foundations, steelwork and cable trenching operations. The pass M0 design, which has full Energy Networks Association (ENA) and Scottish Power approvals, is based on a hybrid of ABB’s traditional AIS and metal-clad GIS switchgear units. Rated at up to 145 kV, it integrates all the necessary substation switchgear bay functions, including a circuit breaker, one or more combined disconnector/earthing switches, bushings for connection to single or double busbar systems and a current transformer in one compact module, eliminating the need for separate pieces of equipment for each function. ABB supplies the PASS M0 module as a completely pre-fabricated, pre-wired and pre-tested unit. It fits into a standard truck

01 Hadyard Hill wind farm substation 02 Cleve Hill substation serves the London

Array (Photograph courtesy of London Array Limited)

03 Thornton Banks’ offshore grid connection

container for delivery without any special packaging. No special arrangements are needed for shipping and transportation, and once on site just a simple 30° rotation of the outer poles completes the final layout. A key feature of the PASS M0 is its virtually maintenance-free design. The line and busbar disconnectors, as well as the earthing switches, are integrated within the breaking chamber. These components are completely immune from all environmental conditions, ensuring lifelong reliability, and eliminating routine maintenance of high-voltage parts to overcome a major weakness of AIS substations.

02

03


Distribution substations

Fitting into a tight spot ABB has delivered an 11 kV packaged substation to act as the main power distri-bution hub for the UK’s second largest oil refinery, Total Lindsey Oil Refinery (LOR). Both the short project timescale and the space constraints at the selected location at the heart of the refinery gave the project team challenges, particularly in carrying out the substantial deep piled foundations to withstand blast shockwaves to ensure continuity of service in case of an explosive event at the site. Housed in a single thick blast-proof container, the substation contains 26 panels of UniGear ZS1 medium voltage switchgear, together with protection and control equip-ment, and back-up batteries. It was the slimline design of ABB’s Uni-Gear ZS1 that enabled the substation to fit within the confines of a single six metre

standard container. The 50 kA fault rated ZS1 features front cable access, which allowed for two front facing rows joined via a low-level bus-trunking link and a central walkway. Not only is the six metre standard container the largest size permitted on UK roads, any larger and it would not have fitted within the confines of the site – a crucial factor in ABB winning the contract. The other critical factor was the ability to deliver the substation within a tightly defined 32-week project window to meet LOR’s planned Turnaround and Inspection outage.

Raising airport standards ABB has won two important contracts from UK Power Network Services airports divi-sion to supply a total of 16 packaged sub-station transformers for Heathrow Airport. A key factor in winning the contract was

that our medium voltage (MV) transformers installed in the substations have recently been fully type tested, including rigorous short circuit tests carried out at an inde-pendent European test laboratory. ABB is a well established supplier to UK Power Networks Services for distribution transformers that step down the supply from the airport’s MV power network to the low voltage supply required for general use. Generally, transformer manufacturers are only required to provide documented proof of their ability to withstand short circuits by means of calculations. However, as part of a new initiative to ensure the reliability and continuity of critical airport power net-works, UK Power Networks Services has called for all its future transformers to be fully type tested to demonstrate that they can withstand short circuit conditions. As the first transformer manufacturer to

Distribution SubstationsABB has more than 100 years of experience in building and upgrading air and gas insulated distribution substations around the world. This has provided ABB with the expertise necessary to deal with all kinds of challenges in the construction of indoor and outdoor substations.

The refinery’s main power distribution substation is housed in a single blast-proof container


meet the new UK Power Network Services requirements, ABB was therefore in the perfect position to be awarded the order to design, build and deliver 16, 1 MVA packaged substations for Heathrow Airport, each comprising a distribution transformer, close coupled ring main unit (RMU) and LV cabinet.

Future-proofing older MV switchgearA fast track project saw the completion of a major contract to improve the safety and reliability of 60 circuit breakers at eight Scottish and Southern Energy Power Dis-tribution (SSEPD) substations on Scotland’s east coast. With the goal of boosting the safety of the substations, ABB and its OEM partner P&B Switchgear carried out a retrofit of the existing oil filled circuit breakers, some of which date back to the 1950s. ABB and P&B launched the retrofit service in response to Ofgem’s 2010 introduction of a health and safety index rating of equipment, which rates the condition of plant from a low score of 5 to a high score of 1. After surveying their equipment, many DNOs (Distribution Network Operators) have found that much original switchboard equipment, such as housings and busbars, remains in good condition but that the moving parts of the switchgear are showing their age, leading to low safety scores. The service, assessed by the ENA (Energy Networks Association), can boost the safety rating from a level 4 to 2, at the same time as extending the life of the equipment by 20 years or more and it costs around 30 per cent less than completely replacing a switchboard. It can be extended to equipment manufactured by GEC, Reyrolle, South Wales Switchgear, Brush and many others. Hundreds of retrofit and circuit protection permutations are available. The project for SSEPD included the replacement of 60 South Wales Electric C4X and C8X circuit breakers with retrofit units based on ABB’s well-proven Vmax vacuum circuit breaker. At the same time, the ratings of the circuit breakers were upgraded to double the current they can handle. A further benefit of the retrofit project was that it took as little as four hours to work on each individual panel. This meant that the project for SSEPD could be delivered

Distribution substations

with minimal disruption to the substations’ operation and the switchboards were upgraded and operating to higher safety levels within three months. James Pierce, ABB’s Power Products Medium Voltage Service Manager for the UK, said: “Thanks to the successful completion of the ENA assessment process by P&B Switchgear, our OEM partner, we are

currently the UK’s first and only switchgear supplier to offer an ENA assessed retrofit service for MV switchgear.”

Retrofitting can boost the safety rating of switchgear


Site management

It’s all about project deliveryElectrical Installations Manager Chris Hensby explains how ABB’s approach to site management means that his team is ready to take on any technological and programme delivery challenge.

01


Site management

We have a team of around 50 site managers, site supervisors and commissioning engineers who

deliver construction and installation con-tracts across the UK. Projects range in size from £1 million to £100 million and up, covering all sorts of transmission and dis-tribution technologies, including substations, generation, small power generation, trans-mission, distribution, cabling, HVDC and FACTS, to name but a few. Site management is about driving the programme forward while looking after the site, our client and subcontractors, plus reporting progress effectively. It’s important to keep a close eye on the work to make sure the scope and time frames are deliv-ered as expected. Our site managers protect the interests of everyone by maintaining effective control of exactly what happens on site. On site, it can be easy to focus on just the practical aspects of project delivery but it’s equally important to make sure that the contractual side is also well understood, so our site managers play a vital role in ensuring that we comply fully with the con-tract requirements. A very substantial proportion of the day-to-day work is focused on health and safety, including making sure that contractors are working to the daily briefs, appropriate risk assessments and method statements and managing the site induction process. With such a broad portfolio of projects, site teams can vary from just a handful of operatives for a small job to 100 operatives covering a variety of skills. For example,

for the new 400 kV substation at Connah’s Quay, we have a lead site manager over-seeing a team of specialists who look after key aspects such as the mechanical or electrical build and the commissioning work. While responsibilities can vary widely, all of our site managers receive the same training to ensure the work is delivered to the required procedures and safety stan-dards expected within ABB. When projects interface with third parties coordination and interface meetings are held with all stake-holders to ensure all safety and design issues are addressed. There’s often a community relations or an environmental aspect to the work and we’ll take on that too. One recent example was where we had waste palisade fencing at one site, and our site manager arranged to deliver it and install it at a nearby school. We also often work with ecologists to survey for wildlife, such as bats or newts, and take the appropriate course of action, whether that’s to stop work to avoid nesting bats or moving wildlife to a place of safety. Over the years since I joined the team, it has grown and now includes specialist site managers, site supervisors and com-missioning engineers that together offer unrivalled site management capability for customers. The team is also well structured to offer exceptional career opportunities to support the development of young professionals. It is very important that we have both expe-rienced hands and apprentices coming up through the ranks. We support apprentices through a programme of academic quali-

fications and on-the-job training to get the right electrical and mechanical training and commissioning experience to develop into a fully fledged site manager in the fullness of time. This strong team means that ABB’s site managers are willing to take on jobs the length and breadth of the country and deliver new technologies, with recent proj-ects including substations from 11 kV to 400 kV across the country, solar, protection and control and even a wave power project in Orkney. Much of our work is driven by the out-ages planned by our clients, which are fixed and immovable. These hard deadlines mean that ABB’s team is focused directly on the on-time delivery of key project milestones. And when the project is delivered, we know that our site delivery team will be standing alongside the customer, helping to energise the equipment and bring it online. This total visibility and responsibility at every stage, from site preparation to final handover, is central to our commitment to a comprehensive, high quality service that makes ABB's site delivery team best in class.

01 ABB has a site management team of around 50

02 An ABB site with time served AIS and a new GIS building

02


Innovation

T raditional substations have been substantially over-engineered –the logical approach for installations

where the safety and reliability demanded by clients are paramount. However, the world has changed and new commercial imperatives call for a demonstrable return on investment (ROI). It is now critical to adopt value-added engineering principles to achieve a ‘fit for purpose’ design, one that removes unnecessary costs while maintaining the essential elements of qual-ity, reliability and sustainability that ABB’s clients expect. To implement these value-added engi-neering principles we keep our substation design processes under constant review. This means challenging the norm and ask-ing searching questions, especially when it comes to elements that have ‘always been done this way.’ ABB’s global 145,000 strong workforce gives us the advantage that we can tap into what the rest of the world is doing and apply it in the UK context. The strength of our team is vital to value-added engineering and it includes senior engineers with a wealth of experience and newly qualified engineers, who offer fresh new ideas. It’s a combination that helps guide our customers to the ultimate value-added solution – a substation project based on efficient, high quality and sustainable design. This ensures competitive costs, shortened delivery schedules, managed capital investment and improved operational performance. A key element in value-added engineering is to support operational management. For example, improving system access and reducing maintenance requirements can help ensure security of supply. This is a crucial consideration as an outage that interrupts customer power supplies could result in daily losses of around £300k, so a focus on continuity delivers significant, measurable value for our substation clients. Value-added engineering also reduces

Value-added engineering

the time and red-tape involved in planning consents by creating designs that need less infrastructure, smaller wayleave require-ments and possibly less land to be pur-chased. Innovative design can also reduce vehicle movements – a traditional AIS substation might require 40 deliveries to site, whereas a hybrid PASS switchgear design can reduce that to three or four deliveries. Naturally, we pride ourselves on being able to deliver ideal customised solutions for every application. But that is not always necessary, or desirable. Standardisation of designs can reduce programme and instal-lation complexity and significantly reduce

re-engineering times with a direct positive impact on health and safety both during and after construction. Essentially, ABB is keen to ensure deep commercial understanding across the board, and how design directly influences total operating costs. This includes not just capital investment in equipment, but hidden costs, such as infrastructure and full life-cycle costs. For example, a conventional GIS sub-station design surrounds the equipment with expensive access gantries and walk-ways. But now we question if this is really needed, when temporary equipment could easily be hired in as and when required,

Leigh Turley, ABB T&D Engineering Manager, explains how ABB’s value added engineering initiative is focused on driving out unnecessary costs while maintaining quality – helping to deliver the optimum cost-effective substation project.


Innovation

which we know from experience works well in other countries. Another example is that substation fencing and cable trenches are relatively expensive. We can usually reduce the amount of fencing and trenching with no compromise of safety and functionality of the final design, helping to take out sig-nificant project costs. Value added engineering is definitely not about penny-pinching and we never lose sight of our quality goals. However, through the rigorous application of this approach, ABB is now delivering optimised substation designs that exceed performance and safety requirements, while driving down costs (TOTEX) throughout their entire life-cycle.

Mobile substations move aheadABB’s new mobile substations are an excel-lent example of value-added engineering taken to its logical conclusion. Combining primary equipment, protection and control and transformers in an easily transportable format, they are ideally suited for three key application areas: – Emergency replacement – to ensure

security of supply in cases such as a transformer failure.

– Planned outage management – to keep outages to a minimum when carrying out essential maintenance and repair work.

– Customer connections – for example to bring a new wind farm or solar power installation online as soon as possible so that customers receive an early return on their investment.

Innovative engineering and intelligent design enable the mobile substation to be built and tested off-site, then quickly deployed to provide reliable and safe connection to the power grid. This reduces civil works, installation, testing and commissioning on site. It also cuts delivery times from months to weeks and reduces the infrastructure significantly compared to a conventional air insulated switchgear (AIS) substation bay. Mounted on a trailer for easy transpor-tation and deployment with no need for special licences, the mobile substation is a hybrid version of an outdoor AIS and a GIS substation. It is based on ABB’s pioneering PASS (Plug and Switch System) modular concept, rated at 132 kV or 400 kV, that

combines all the functions of a complete AIS or GIS switchgear bay – circuit break-er, current transformer, disconnectors and earthing switch – in a single gas-insulated module. This significant reduction in the number of components and moving parts makes PASS exceptionally compact and virtually maintenance-free. ABB mobile substations are fast becom-ing an important tool for utilities worldwide. They can be transported by road, rail or air and quickly deployed whenever and wher-ever they are needed for periods typically ranging from six to 10 months, a period that could allow a wind farm operator time to obtain planning permission for a perma-nent grid connection substation. But with emphasis on a solution that is mobile rather than temporary, they are fully engineered for a long service life of over 20 years using the same technology used in fast-track permanent substation solutions.

Mobile substations offer the reliability of a fully engineered solution


Project design

A ll ABB’s customers are unique and have different drivers for substation development, when reviewing tender

documentation we aim never to go into a project with pre-conceived ideas. Our philosophy is to look at every site on its own merits. While we often put forward a solution that follows the initial indicative layout, our customers are usually very happy for us to sit down with them to discuss alternative designs that might offer considerable technical and commercial advantages.

Innovative substation design makes the difference

GIS versus AISOne example is the choice of switchgear. When replacing an AIS (air insulated switchgear) substation a ‘like for like’ AIS solution could seem the obvious approach. We often surprise customers when we show them that a GIS (gas insulated switchgear) alternative can be only slightly more expensive in terms of initial outlay (CAPEX), and when considering the total cost (OPEX) of a substation over its 40 year lifespan, GIS can work out significantly cheaper, due

to the reduced maintenance requirements and system reliability. The classic reason to use GIS over AIS is when there’s a limited installation footprint available. But GIS can be ideal for many other reasons. For example, when a substation needs a significant amount of piling. We only need to pile just the small footprint of the GIS building, as opposed to a large outdoor AIS site, saving both money and reducing the programme delivery time. It’s not always possible to use GIS. Sometimes a customer doesn’t want a building or can’t get planning permission for a building. But we now have innovative AIS alternatives, such as the compact hybrid PASS concept. There are some schemes where we’ve installed a single bay of PASS switchgear in place of a conventional ‘H’ AIS configuration that would take the space of a car park.

Disconnecting Circuit Breakers Another recent innovation is a Disconnecting Circuit Breaker with Fibre Optic Current Sensor (DCB-FOCS). The new switchgear has enabled a combined disconnector, circuit breaker and current measurement into a single compact device, which requires less maintenance than conventional technology, as it integrates the two switching functions into a single piece of switchgear and uses a

David Dewitt, Bid Manager – Power Systems, explains how innovation is ABB’s way of staying ahead of the competition.


current measurement technology that does not require regular recalibration. Integrating the FOCS with the DCB reduces footprint while delivering a ‘smart grid’ enabled solution that is virtually ‘plug and play’ and yet flexible enough to accommodate customer needs. This makes it ideally suited to new and upgrade substation applications with the added benefit of enhanced power availability and reliability. Because the DCB-FOCS combines the space-saving aspects of both DCB and FOCS technologies, the new module has the potential to reduce the overall physical footprint of a substation by 60 percent compared with a conventional arrangement. It is supplied with standard ethernet cable connections, which make it simple and safe to install and operate, while improving efficiency by cutting electro-thermal and electrical losses. It can be delivered on a standalone basis or as a component part of a complete switchgear bay. Developments in GISNew developments in more compact GIS units offer considerable opportunities, as

Project design

at a project in London. The initial scheme involved a two stage building construction allowing a phased circuit transfer. We have been able to devise an alternative arrange-ment, with all switchgear set out in a dog-leg configuration fitting in just half of the proposed building. Now the second building extension is no longer required, saving the customer both time and money. Site securitySite security is another important consid-eration. Copper theft is prevalent on AIS substations, where it’s easy for thieves to target and remove the easily visible copper. Housing a GIS substation inside a building with high security doors can eliminate theft and its associated costs (which of course include the cost of operational outages, the price of replacement copper and the resource to replace it).

Local resourcing We’ve also started with a fresh sheet of paper with a new wind farm connection project. Not only are we going the extra mile in sourcing a high percentage of the project resource and equipment locally, we also put

forward an alternative technical solution to the client, which they have adopted. Although the original scheme was sized for the wind farm to be operating at 100% capacity, we put forward the case that wind farms rarely operate at that level. Instead, we suggested an alternative design based on a more realistic wind farm model. This not only removed one high voltage transformer from the scheme altogether, but also the associated switchgear, cables and civil engineering works. It also enabled the optimisation of the 10 km underground cable link, the overall impact on pricing was a saving in the region of £1 million for the customer. It’s this willingness to question the norm that sets ABB apart. We’ll always look at a scheme and apply our knowledge of the latest technology, constraints and environment. The aim is always to find the best overall through-life solution for the customer in terms of programme, cost and technology.


Civils and commissioning

Substation commissioning – the buck stops here! ABB’s philosophy has taken commissioning from being the last link in the chain to place it at the heart of the overall design and construction process.

Site experience is fed back to the design office


Civils and commissioning

Commissioning is the critical stage of any substation design and build project. It is the first time that all

the various equipment is tested as a com-plete entity. The pressure is on to prove that the project works safely, that it will feed power at the right levels and the protection and control systems function correctly. So it really is a case of ‘the buck stops here’ especially when working within a fixed out-age period to get the project signed-off and handed over to the customer. Traditionally the industry has regarded commissioning as the last link in the project chain – from winning the order, developing the design, carrying out civil works, install-ing the equipment and then calling on the commissioning team to prepare it for hand-over. It was not unusual for the commis-sioning engineers to arrive on site ‘cold’ with little prior project knowledge. They would then be bombarded for requests for test schedules, risk assessments, working documents and so on. Resulting in a great deal of work being done ‘on the hoof’, with little forward planning.

Documented programmeClearly, there is a better way to do things. So our commissioning management team is set up to deliver a more structured and fully documented commissioning pro-gramme – with the aim of ensuring that the commissioning engineers are fully prepared when they arrived on site. An important stage in this process is the development of a commissioning file for each project. With some 20-plus sections, the folder includes accurate documentation of: – Inspection and test plans – Switching programmes – Thermal rating schedules – Stage-by-stage documentation – Protection settings – Emergency return to service – Method statements and risk

assessments.

ABB’s commissioning engineers are also fully integrated within the project design and installation team. So rather than arriv-ing on site and trying to make someone else’s design work, they can provide direct input to the design as it happens, right from the very start. Not only does this provide another pair of eyes to review the design, the feedback of practical site experience proves invaluable in ensuring that the sys-tems will function as designed, and can

actually help to shorten the commissioning process as well. We find this approach really helpful in developing the best value-added solution.

A people businessNaturally, the success of the commission-ing process comes down to finding the right people. And we have worked very hard to build a team with the right qualifications, and authorisations, such as TP141, com-bined with experience in design, protection and control and site management. Crucially, we look for people who do rather more than just follow a set of rules, who can check what other people have done, and think round problems. We also aim to develop a close working relationship to support the customer throughout the project and to understand fully how they like to work.

Planning aheadThe ability to plan ahead is especially impor-tant when dealing with events such as an emergency return to service. Sometimes, for reasons completely out of our own control, we may lose the outage window we have taken – for example when a fault occurs at a neighbouring substation. So whatever stage we are at, the commission-ing engineers must have a contingency plan to restore the circuit as quickly as possible.

Expanded scopeABB’s particular approach expands our scope to offer extra added-value services that can relieve some of the burden on the customer. For example, it was usual for the

customer to develop the switching pro-gramme to ensure that the new HV equip-ment was energised safely and correctly. This can now be performed by the com-missioning team. Furthermore, we can ensure safe energisation of LV systems through the development of our own authori-sation process, where commissioning engineers become ABB nominated persons to carry out the LV switching design pro-cess, helping to develop the optimum added-value solution. It greatly reduces the potential of unexpected design issues aris-ing on site, so that the commissioning process runs as smoothly as possible. Most importantly, it enables customers to be assured that the commissioning will provide complete proof that when the substation enters service, it will function safely and correctly, exactly as it has been designed.

Complete proofIn summary, ABB’s approach to commis-sioning provides a formalised structure at every stage, with all the work to be carried out fully documented and presented for customer approval before we arrive on site. It enables site experience to be fed back into the design process, helping to develop the optimum added-value solution. It greatly reduces the potential of unexpected design issues arising on site, so that the commis-sioning process runs as smoothly as pos-sible. Most importantly, it enables customers to be assured that the commissioning will provide complete proof that when the sub-station enters service, it will function safely and correctly, exactly as it has been designed.

A commissioning programme provides structure


Skills

Building ABB’s substation team of the futureJon Clarke, Engineering Support Manager for Power Systems, explains how ABB is building its substation engineering resources at all levels.

Jon Clarke with some of ABB’s recent apprentices


Skills

P lanning for the future is one of the great challenges for any business, and although it’s impossible to

make exact predictions, one thing is for certain: as a society, we’re demanding more of our electricity generation, trans-mission and distribution systems. Renewable energy and Smart Grids are definitely part of the future and we’ll need smart engineers to deliver them, which is why we are planning now with a structured path for attracting and developing talent. This includes a commitment to encouraging young people into engineering careers, through a school outreach programme that has been running for more than 10 years, along with our apprenticeship and graduate schemes. The rapid pace of technological devel-opment in recent decades means that having people with the ability to learn, adapt and apply new skills is a must-have for ABB. The business world has never been more volatile but it is also full of untapped potential. We are looking for people who are agile and curious, as well as bright and willing to move with the company. This both helps the business succeed and helps our people develop their own careers. At all levels of the organisation, we look to hire and develop talented people. Through the performance and development appraisal process, we work with our high performing employees and provide oppor-

tunities to develop and gain experience in the UK and overseas, opening up a world of possibilities. In 2011, ABB Power Systems fully restructured its apprentice scheme, work-ing with Newcastle-under-Lyme college in Staffordshire to create a tailor-made pro-gramme, which combines real-world expe-rience with rigorous tuition and guided study. Those who have joined us on the programme are now on the road to an exciting and rewarding career in electrical engineering. The emphasis is on both classroom learning and providing practical experience, and right from the start our apprentices are involved in working in spe-cific teams to help deliver projects for ABB’s customers. Our approach to attracting apprentices is by building on the school industry days we hold for 14-year olds and subsequent work experience for 15-16 year olds. Schools that focus on STEM (science, technology, engineering and maths) subjects are especially fertile ground for ABB. Around 16 pupils visit from each of the schools involved in our industry day pro-gramme. During these industry days we challenge them by setting a small project that gives them experience of considering technology, plus safety, the environment and teamwork. At the end of the day, they give a short presentation on the findings of their project together with the lessons learnt.

During the course of these days we are able to invite those people that have shown keen interest in the company back the next year for meaningful work experience and maintain a link with them to ensure they are contacted personally the following year to consider applying to join the apprenticeship scheme. This has developed into a channel to attract the most enthusiastic and bright young talent to join the company. The apprentice scheme in particular has created a fantastic level of engagement across our engineering teams, with estab-lished staff providing a great deal of input and encouragement to those undertaking their studies. Our management team is actively involved and with many of them having come through apprentice schemes themselves, often going on to study at degree level and beyond, they are keen to encourage this new generation to follow in their footsteps.

Classroom learning


Service

Lifetime service for substation assets ABB offers a comprehensive service that supports critical transmission and distribution substation assets throughout their life. The aim is to maintain substations in optimum performance and avoid costly failures so that our customers continue to enjoy safe, reliable, efficient and profitable performance from their assets, large or small, during their lifetime.

Transformer fault analysis


Service

We have the people, skills and in-depth knowledge to cover the full spectrum of substation asset

service requirements, from routine inspec-tion of an 11 kV network, right through to the construction management, installation and commissioning of a new 400 kV GIS substation. Our service is not restricted to equip-ment supplied by ABB equipment – we can support equipment from just about any manufacturer across all the major business sectors including: – power generation – utilities – industrial processes – transport – construction – public sector – renewable energy – data centres.

Supporting distribution networksABB specia l ises in the inspect ion, maintenance and repair of electrical power distribution equipment and networks up to 33 kV for utility, industrial and public sector customers. Round-the-clock emergency support provides an immediate response to network problems – isolating the fault, restoring supplies and making a permanent repair quickly and safely. Qualified personnel, high-voltage fitters and cable jointers are all ESI trained to the highest nationally recognised standards and operate under a set of distribution safety rules to ensure the reliable and safe operation of distribution systems. Using dedicated HV test vehicles, ABB engineers can identify disruptive and costly system faults. Permanent faults are precisely located using a combination of pulse echo, impulse current and capacitor discharge devices. Excavation and jointing can then be carried out to restore the network. To track intermittent faults, the engineers use fault burning, equipment with high current, but low voltage, to accelerate degradation and make the fault permanent and so easier to locate.

Getting more from HV assetsABB can take complete responsibility for the inspection, maintenance and repair of high-voltage (HV) transmission assets, as well as associated control and protection systems.

Specialist engineers ensure that critical high-value network assets are maintained in optimum condition to guarantee maximum reliability, safety and availability. System support contracts are offered for generation, utility and industrial trans-mission customers. These can range from simple hotline support through to life cycle agreements.

24/7 system supportABB offers cost-effective long-term support for the overall substation. Based on profes-sional life cycle predictions for products and systems, including component reliability calculation analysis, a 24/7 hotline guar-antees a fast response when needed.

Maximum Transformer Availability

ABB has a complete portfolio of services to keep generation, system and grid power transformers running at maximum efficiency and distribution reliability. We can also co-ordinate the transport, erection, commis-sioning and training needed to bring new ABB transformers safely online as fast as possible and ensure a smooth hand-over and a complete after-sales service. The emphasis is on providing a whole-life service from installation, through normal preventive maintenance and repair, and retrofit programmes that can provide an extra lease of life, to end-of-life manage-ment with minimum environmental impact. This portfolio includes:

Understanding your assetsIn-depth knowledge of the actual status of equipment, based on its recorded history, a review of its design and advanced diagnostic techniques, enables potential faults to be identified before they happen. This also provides a sound basis for the implementation of condition-based maintenance or corrective action.

Fast repairsShould a major problem arise, ABB provides a fast response for repairs such as parts replacement, tap changer refurbishment or more extensive work. The usual starting point in such cases is an in-depth diagnosis to assess the condition of the unit. Where possible, all work is carried out on site.

Cable fault location

However, when more extensive work is required, full factory repair and refurbishment can be arranged in one of ABB’s transformer repair facilities.

A new lease of lifeABB also offers a transformer remanufac-turing service that can extend the life of ageing or faulty power transformers, enabling them to be fully refurbished then recommissioned. Upgrades in specification can also be incorporated as part of this service. As well as being cheaper than a new transformer, a fast turnaround can have a transformer back in operation in around one third of the normal delivery time for a new unit.


Energy storage

The UK power landscape is in a period of dramatic change. There is a shift from centralised fossil-fuelled gen-

eration to more distributed and inherently variable renewable energy sources such as wind, solar, wave and tidal. At the same time, loads are changing, including large-scale data centres, widespread use of air-conditioning and the deployment of electric vehicle (EV) charging infrastructure. These fundamental changes in the architecture and controllability of the grid call for smart, efficient power transmission and distribution networks. And they require the storage of energy at appropriate times

The BESS way forward

and locations – both to balance the rapid change in 'ebb and flow' between genera-tion and consumption and also to maintain grid stability. ABB offers complete battery energy storage system (BESS) solutions that inte-grate seamlessly into the power network. We employ a variety of battery technologies from world-class manufacturers to ensure that we deliver the perfect combination of energy storage and power technologies to match a customer’s specific application needs. BESS can perform a number of important grid functions:

Frequency regulationThe energy storage system can be charged or discharged very quickly in response to fast increases or decreases in load, maintaining the balance between supply and demand. This approach to frequency regulation is a particularly attractive option due to its rapid response time, the accuracy of the regulation and the emission-free operation.

Base load levelling and peak shavingBase load levelling and peak shaving involves storing power during periods where perhaps renewable energy may be being produced in excess of demand or when costs are low and delivering it during periods of high demand, when costs are high. This approach can enable the deferral of investments in grid upgrades or in new generating capacity and avoids incurring high power costs for short term peaks.

Power QualityABB technology is already used extensively for the management of reactive power, the addition of this technology into the Battery Energy Storage Systems provides a further dimension – the management of active power. Our power converter systems have the capability to meet both reactive and active power needs, providing the grid with the flexibility to manage any situation, at any time in the daily demand cycle and for prolonged periods of time. ABB is building on the success of the initial project by implementing a new a

Stuart Grattage, Head of Engineering for ABB Power Systems in the UK, explains how battery energy storage systems (BESS) can help keep the grid in balance.

Dynamic energy storage solution


Power Station Load Leveling (Generation Utilization)/Frequency Regulation Spinning Reserve

Large Residential/Commercial/Industrial Loads

Peak Shaving

Capacity Firming

Load Leveling(Postponement of grid upgrade)

Renewables Voltage Support/Power Quality

110 kV

20 kV 380 kV

20 kV ring

33 kV 110 kV

380 kV transmission line

Load

Energy storage

software algorithm that adds predictive charge and discharge control capability. Ongoing trials will then demonstrate the operation of the site as an autonomous peak shaving asset.

Comprehensive system approachBatteries are based on direct current (DC). To connect them to the alternating current (AC) grids mainly used for power transmission and distribution requires a conversion step, using power electronics. ABB has an outstanding track record in delivering power electronics systems, such as our PCS range, that combine excellent performance with instantaneous response to create the essential stable interface. As part of our total system philosophy, we are also working very closely with our Power System Network Management (PSNM) team to take BESS control systems to the next level to ensure that energy storage is fully integrated within the overall grid management system. Furthermore, through Ventyx, the leading enterprise software specialist that joined the ABB Group in 2010, we are adding a new dimension to energy storage as part of an overall smart grid solution. By gathering information from the wider network, we are evolving energy storage beyond the simple ‘on’ or ‘off’ approach to enable intelligent management of power flows. Overall, building an efficient, reliable and durable BESS calls for a range of key technologies and competencies – from circuit breakers and transformers through

batteries and power electronic conversion, on through system- and grid-level control, to smart forecasting. ABB can provide all of these from a single source as demonstrated in these current projects:

The Alaska BESSThe Golden Valley Electric Association (GVEA) operates and maintains around 5,000 kilometers (km) of transmission and distribution lines and 35 substations in the Alaska region. In 2003, ABB applied implemented battery storage technology, combined nickel-cadmium batteries with power converters to create a spinning reserve solution that provides back-up electricity for GVEA when necessary. Recognised by Guinness World Records as ‘the world’s most powerful battery system’, it can supply power at 27 MW for 15 minutes or 46 MW for 5 minutes, which allows ample time for local generation to come online.

Switzerland’s largest battery energy storage projectABB recently commissioned the largest battery energy storage project of its kind in Switzerland with EKZ, a leading distribu-tion utility and one of the largest energy companies in Switzerland. To enable additional power to be provided to the grid on demand, ABB supplied and installed a battery energy storage solution using Lithium-ion (Li-ion) batteries that can provide 1 MW of power for 15 minutes. The storage facility is integrated into

EKZ’s power distribution network and is being used to evaluate performance in key areas such as balancing peak loads and intermittent power supply, and the viability of the solution for grid optimisation.

Dynamic energy storage installation in the UKABB worked with UK Power Networks, which supplies power to over eight million homes and businesses in the UK, to develop a dynamic energy storage solution for a substation site in Norfolk. The installation, commissioned in 2011, enables renewable energy generated by local wind power plant to be fed into the power network when needed. It also ensures that some of the energy is kept in reserve to regulate power flow to compensate for the intermittence of wind power and to support power quality in the event of a fault. To meet these needs, ABB implemented a turnkey DynaPeaQ® solution incorporating SVC Light®, which included eight stacks of 13 Li-ion battery modules located in an 11 kV grid. Together, these high power density modules can store up to 200 kilowatt-hour (kWh) of electrical energy. The installation provides dynamic voltage control in the distribution system and, at the same time, enables dynamic storage of surplus energy from the wind power plant. This surplus energy is used to level out peaks in grid loading to provide grid stability.

Typical grid energy storage applications

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 will be available soon via iTunes. www.abb.com

Our substation portfolio at your fingertips?

Definitely.

ABB LtdTel. +44 (0)1785 825 050Fax. +44 (0)1785 819 019 E-mail. [email protected]

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