Rail

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Cooking up a power solution for McCain’s Home Fries

Rapid repair gets Corus of approval

A tight fit for Thames Valleysubstations

The Baltic connection

Jubilee Line – more power,more passengers

www.abb.com/ffwd

FAST FORWARD WITH ABB POWER SYSTEMS & PRODUCTSSUMMER/AUTUMN 2008

See page 6

A new approach to asset management

Lifetime decisions

02 FFWD >> SUMMER/AUTUMN 2008

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

Editor: Karen Strong

Telephone:01785 825050

www.abb.com/uk

contents Team work starts at the top

Controlling risk is a key business priority and I would like to takethis opportunity of advocating the role teamworking can play.

I think that within our businesses and business centres we have increasingly embraced teamwork in recent years due to the benefits that can be derived such as reduced risk, better costcontrol and a real "buy-in" and commitment to the promises andtargets that an organisation is expected to deliver.

Teamwork starts at the top of any organisation. Senior managerscannot issue edicts instructing others to teamwork whilstreserving for themselves the privilege of standing aside and notengaging actively themselves.

Teamworking demands ‘leadership’, leading by example,particularly important when the team involves more than oneorganisation. It also requires the development of trust. It calls forthe sharing, willingly, of best practice between ‘team-mates’ butcan also call, on occasion, for constructive criticism between theparties.

In my experience, few companies have the teamworkingexperience that ABB has accumulated over the years. One recentsuccessful example is the work we are doing as a member of theNational Grid Electricity Alliance. Our aim is that no-one should‘see the joins’ in a team that involves ABB, Atkins, Morgan Estand, of course, National Grid. It behaves as a single entity with aclear remit, and overriding focus on delivery.

All this might sound a little idealistic, but in a world of intensecompetition, dynamic decision-making and ever-increasing focus on areas such as health and safety, teamworking providesan excellent framework for removing cost and risk. Of course, the traditional roles of supplier and customer are not lostaltogether, but those priorities have to stand alongside thepriorities of the team.

Each party must have a distinct contribution to make. In our case this is usually our experience and expertise in projectmanagement, engineering and service, coupled with the full range of technologies that ABB can offer.

ABB has a real track record of delivering on every front, a fact that I hope will become apparent as you read on. Certainly, iftimes get tougher there’s a lot to be gained by furtherconsideration of this approach.

Issue 19 Summer 2008

Trevor GregoryABB UK Managing Director

3 Cooking up a power solution for McCain’s Home FriesPower factor correction technology helps the Home Fries company avoid an infrastructure upgrade

4 NewsUK and international news

6 Lifetime decisionsA new approach to asset management helps produce a better return on investment

8 £24 million Thames Valleysubstation dealsNew contract for GIS switchgear requires innovativeapproach to installation

9 The Baltic connectionThe Fenno-Skan link, connecting Finland and Sweden, is being upgraded

10 Jubilee Line – more power formore passengersThe inside story of ABB’s fast track contract to upgrade the DC traction power system

11 Thinking inside the boxContainerized switchgear provides a fast-track solutionfor process industry

12 Feeder protection relay gets ENA approvalThe new REX521 feed protection relay is the latest ABBproduct to win Energy Networks Association approval

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

ABB automatic powerfactor correction technologyhas enabled McCain Foods tomake more efficient use of theexisting power network at itsScarborough site and avoid amajor investment in newpower infrastructure. Thecompany has been able to getits new Home Fries productionline up and running usingexisting supplies.

While McCain Foods was in the process of planning the newHomes Fries production line itbecame clear that the existingpower network, already operatingclose to its maximum 9.5MWload, would not be able to copewith the major additional demand.The company was faced with anestimated cost of around £250,000to install an additional 11kV/400Vsubstation. Worse still, the YEDLpower lines that feed Scarboroughfrom the York Distribution Centrewere already operating up to theirlimit.

McCain called on ABB for help.The first step was a site surveywhich established that a number of

key loads were operating at asignificantly low PF (power factor).PF is essentially a measure of howeffectively electrical power is beingused. The closer to 1 this figure it actually is, the more effective the usage.

ABB’s verdict was that theinstallation of suitable power factorcorrection equipment wouldsignificantly improve networkefficiency and release sufficientuseable power to meet the needs of the new Home Fries line.

ADVANCE AUTOMATICCAPACITOR BANKSThe solution devised by ABB was to install itssophisticatedAdvanceautomaticcapacitor banksat eightstrategic pointsin the McCainnetwork –representing atotal of 2,900kVAr. This hasrestored the PFto acceptable

industry standard levels, rangingfrom 0.95 to 0.97, and has madean extra 600kVA of poweravailable. This enabled productionto start in April 2008 without theneed for any new networkinfrastructure.

Bill Bartlett, Corporate AffairsDirector of McCain Foods said:“ABB’s power factor correctionequipment has played a key role inour energy efficiency programmethat enablesthe line todraw all thepower it needsfrom ourexisting

power network – without the need for significant capitalexpenditure on a new substationand power lines.”

FFWD >> www.abb.com/ffwd

Power factor

Cooking up a power solutionfor McCain’s Home Fries

SUMMER/AUTUMN 2008 >> FFWD

04 FFWD >> SUMMER/AUTUMN 2008

News

MV switchgear in the frame

Asset performance

ABB has signed a three-year frameagreement with EDF Energy

Networks to supply 33kV ZX1.2 single-busbar switchgear for substationrefurbishment and new-build projects inLondon, and the East and South-East ofEngland – an area serving around 7.8 million consumers.

As part of the frame agreement, ABB hasalready been awarded a contract worth around£1 million to supply 68 panels of ZX1.2switchgear for a number of EDF EnergyNetworks sites.

The agreement makes ABB one of just twopotential suppliers for the energy company’s33kV single-busbar switchgear. It has important

benefits for both parties – EDF EnergyNetworks can rely on security of pricing anddelivery over the next three years, while ABB isguaranteed a volume of orders that enables it toplan factory workload.

ABB’s ZX1.2 switchgear features a modular,plug-in approach to meet the specific needs ofelectricity distribution network owners andoperators. It enables compact, flexible substationconfigurations that offer reliable and cost-efficient switchgear solutions for single-busbarapplications. It has technical acceptance fromthe Energy Networks Association (ENA) andNetwork Rail for use at 33kV for ratings up to31.5kA and 2,000A.

Key features of the ZX1.2 switchgear includelaser-welded stainless steel enclosures, compact

modular construction and plug-in technologythat enables simple, controlled connection ofbusbar, cable, test bushings and voltagetransformer, without the need for ‘on site’ gashandling equipment.

All maintenance-free live components – suchas switching devices and busbars – are containedunder SF6 in gas-tight enclosures, whichminimize the effects of ageing andenvironmental influences to ensure maximumoperator availability and a long service life.

The ZX1.2 design also offers easy cableaccess at the rear, with generous provision forconventional control and protection devices,dedicated cable test sockets and full mechanicalinterlocking between the disconnector/earthingselector and the circuit breaker.

The 2008 Euro TechCon®

conference will take place in Liverpool from 18 to 20 November 2008. ABB will participate in the event, whosecentral theme is the management of high-voltage assets. This will include a strong focus on core high-voltageassets, principally transformers,switchgear and load tap changers.

Along with conference presentations, workshops and panel sessions, the conferencefeatures an exhibition that provides extensivenetworking opportunities as well as theopportunity to learn about the latest in technology developments.

More information can be found athttp://www.techcon.info/ETC08/.

The deadline for entries in 2008 IETInnovation in Engineering Awards

was late July. Even if you missed yourchance this year, it’s worth keeping aneye on the awards’ process with a view to entering next year. ABB sponsors theSustainability Award and is lookingforward to seeing this year’s crop ofexciting entries.

According to the IET, the SustainabilityInnovation Award is the most all-encompassingof all the categories. It is open to anyinnovations in the fields of engineering, science and technology that demonstrate a contribution to sustainability.

Entries can cover projects, processes,products and initiatives from individuals, small teams or organizations (both engineersand non-engineers). They can cover entirely new concepts or the development of existingprocesses or products.

The winners of this and other categories inthe IET Innovation in Engineering Awards willbe announced at the annual ceremony at theIET in London on 3 November 2008. Entriesfor the 2009 awards will be accepted fromNovember this year. Keep watch athttp://conferences.theiet.org/innovation_awards/index.htm.

ABB’s ZX1.2 switchgear of the sort being supplied to EDF Energy Networks.

Sustaininginnovation

ABB’s Trevor Gregory (left) with Johnny Ball (right) and last year’s winners.

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News

INDIADelhi’s T3ABB has won a US$77 million order todesign, supply, install, test and commissionelectrical products and systems for thenew Terminal 3 (T3) building at IndiraGandhi International Airport in Delhi, India.ABB’s solutions are part of a modernizationproject to prepare the airport for the 2010Commonwealth Games. The order coverselectrical infrastructure and control systemsincluding low-voltage panel, cabling, wiring,conduits, light fixtures, bus ducts,Uninterruptible Power Supply (UPS)equipment and a distribution transformer.

QATARCombined-cycle power plantHyundai Engineering and Construction(HDEC) of Korea has awarded ABB aUS$233 million contract to supply powersystems and grid connections for a naturalgas and steam turbine (combined-cycle)power plant, to be built in Qatar. TheUS$3.7 billion Ras Laffan C plant willgenerate 2,730MW, and produce morethan 286,000 cubic meters of potablewater per day. ABB will supply substations,transformers, generator bus ducts andbreakers, medium- and low-voltageswitchgear, the emergency power supplyand the plant’s cable systems. It will alsoprovide engineering services, constructionsupervision, commissioning and training.

CHINAThe HVDC connectionABB has won a US$70 million order forpower equipment from State GridCorporation of China for a new power linkin northeastern China. The new high-voltage, direct current (HVDC) link willtransmit 3,000W over the 920km fromHulunbeir, Inner Mongolia, to Shenyang,Liaoning province. The ABB order is part ofa project with an estimated total value ofUS$400 million. ABB will provide keycomponents for the converter stations ateach end of the link, as well as measuringequipment for the converter stations. Thelink is scheduled to enter commercialoperation in December 2009.

THE NETHERLANDSA magnum orderABB has won a US$150 million contract toprovide power systems and gridconnections for a natural gas and steam-turbine (combined-cycle) power plant in theNetherlands has been won by ABB. Thenew 1,300MW Nuon Magnum power planton the North Sea coast will feed electricityinto the existing Dutch high-voltage gridand could supply power to around twomillion households. ABB’s scope of supplyincludes electrical components for theauxiliary power supply systems, a 380kVhigh-voltage substation and the switchgearbuilding. ABB will also provide 380kVcables, transformers, generator breakers,medium- and low-voltage switchgear,emergency-power diesel sets, batteriesand communication systems, as well asengineering, installation, commissioningand training.

INTERNATIONAL NEWS

A failed furnace transformer at Corus’sintegrated iron and steel plant in

Scunthorpe threatened the company withserious lost production – until ABB’stransformer service team came to the rescue.

Earlier this year, ABB’s on-site transformer diagnosticand repair service enabled one of Corus’s Scunthorpeplants to restore full production less than 10 days afterthe failure of a 132/33kV furnace transformer in theBasic Oxygen Steelmaking (BOS) facility.

Corus Scunthorpe is the UK’s largest integrated steel plant, able to produce 4.5 million tonnes perannum. The steelworks has three furnace transformersin the BOS plant, and an unexpected failure reducedthe plant’s ability to manufacture some of thetechnically challenging grades of steel.

Taking the transformer off-site for a factory repair would have taken at least six weeks, while the current lead-time for a brand new transformer is 18–24 months.

Corus needed a speedy solution and turned to ABB’s UK power systems service team for help.

DIAGNOSTIC TESTSA series of tests using non-invasive diagnostictechniques showed that the fault was in the transformertap-changer in the main tank. This is quite a commonproblem with furnace transformers, as they operateunder severe conditions compared with transformers inpower network applications. They experience frequentcyclic loading, due to the operation of the high-voltagecircuit breaker, as well as over-currents and over-voltagesgenerated by short circuits in the furnace.

The good news for Corus was that ABB’s newlydeveloped on-site repair service enabled thetransformer’s active parts to be removed from the tankso that access could be gained to the faulty tap-changer.All the failed components were replaced on site, in afraction of the time required for a factory repair. Thewhole unit was back in use ten days after the initialfailure.

Rapid repair gets Corus of approval

ABB has won a major contract from E.ONUK to replace the existing VAX-based

operator stations at its 1,420MW Connah’sQuay Combined Cycle Gas Turbine PowerStation at Deeside, North Wales with new MSWindows-based power generation portalconsoles. The contract includes the installationand commissioning of the full system includingancillary services, staff training and a systemfor converting graphics from the existinginstallation to the Windows operating interface.

Key considerations in the new system haveincluded ensuring backward compatibility for existinggraphics and retaining the existing ‘look and feel’ ofthis part of the system. The existing graphics anddatabases were created in ABB Composer software.The new installation will convert the graphics to runon the new system’s Windows-based platform. The

current control system has more than 1,000 graphicsscreens on each unit, and a further 150 on commonservices.

The existing installation consists of four generatingsystems and common services. Each generating unithas four operator screens and there are two servers and two client consoles on the system. There are twoservers and one client console for common services.

The SODG graphics used on the existing OIS-40 series consoles will be converted to powergeneration portal (PGP) graphics.

The contract includes the supply and installation of a wide range of network interfaces, switches andperipherals as well as cabling, desk and alarms. In addition, ABB will provide installation andcommissioning, inspection and testing, training and spares.

ABB also recently completed the replacement ofthe Connah’s Quay steam turbine supervisory system.

In complete control ofConnah’s Quay

A view of Connah’s Quay power station Deeside, North Wales.

The Corus plant in Scunthorpe.

06 FFWD >> SUMMER/AUTUMN 2008

Looking for the maximum return on fixedassets is part of everyday business - whether inthe electricity utilities or general industry.Deregulation of the energy market andincreasing pressure to reduce costs are forcingmanagers to look continually for ways toreduce the lifecycle costs of their installedassets and improve return on investment.

The situation is especially acute in the case ofpower transformers. A substantial proportion ofthe worldwide transformer population is nearingthe end of its lifetime, and there is an urgentneed to optimize transformer fleet performancethrough higher availability. Naturally, this has tobe achieved at the lowest possible cost and withminimal environmental impact.

In the past, it was usual for asset-relateddecisions to be based primarily on accumulatedexperience. Capital expenditure was mostlytrigged by high growth in energy demand andpower assets were replaced by new and morepowerful installations long before reaching theend of their useful lifecycle. But in today’srapidly changing environment, with its severetechnical and financial constraints, assetmanagers need to base their strategic decisionson precise and reliable data in order to convincethe ultimate decision makers.

However, one of the most frequent challengesfaced by transformer owners is the lack ofreliable information on asset condition and thedifficulty in defining improvements that arejustified from both a financial and technicalpoint of view. ABB’s Mature TransformerManagement Programme (MTMP) is designedto fill that information gap. This methodology isbased on four steps.

STEP 1: TRANSFORMER FLEETSCREENINGLarge transformer fleets (from 20 to over 100units) are evaluated using readily available datasuch as type of application, time in operation,gas in oil, power factor, maintenance history and major events or experience with sister units.

The aim is to obtain a general ranking for the population, based on technical andeconomic criteria, and to identify clusters ofunits requiring further investigation or somebasic maintenance.

This first-step screening also provides keyinformation for estimating an outline budget for future maintenance or unit replacement, andidentifies the units that should be given priority.

STEP 2: TRANSFORMER DESIGN ANDCONDITION ASSESSMENT A smaller number of units (typically 10 to 20)are selected from Step 1 and modern design,testing and quality assurance tools are used toevaluate their design and construction. Inaddition, advanced diagnostic tests areperformed to assess each of the principalproperties of the transformer, including:mechanical condition, thermal condition (ageingof the insulation), electrical condition of theactive parts and the condition of the accessoriessuch as tap-changer(s), bushings, over-pressurevalves, air-dryer system, pumps and relays.

This process provides important informationabout the condition and suitability of the unitsand enables the identification of the appropriatemaintenance, repair or retrofit activity requiredto ensure their reliability.

Actions could include: listing of spare parts to

Asset Management

Liam Warren, ABB’s UKtransformer service operations manager,explains how a new approach to assetmanagement can provide greater visibilityand predictability for asset managers,enabling them to decide on theappropriate preventive maintenance plansand to target new investment formaximum effect.

Lifetime decisions

be kept in stock, a prioritized list of on-sitemaintenance measures, and proposals to relocateunits, decrease their load or replace them. Costsare reduced, as action is restricted to certaincomponents and is only taken when it is reallyneeded.

For example, if the actual condition of anageing transformer is suitable for overloadingbut not for short-circuit operation, action couldbe focused on just improving the rigidity andclamping of the winding blocks.

STEP 3: LIFE ASSESSMENT/PROFILINGLife assessment/profiling ranks the transformerpopulation according to the evaluated reliabilityof each unit. Priority can then be given to takingcorrective or preventive action on the mostcritical units to improve the overall reliability ofthe fleet and reduce the costs associated with therisk of unplanned outage.

Maintenance priorities are driven both bytechnical considerations related to the conditionof the units and also the overall strategy of thecompany that owns the assets. Several assetmanagement scenarios are therefore possible. An important criterion directly linked to thestrategy of the asset owner is to minimize thelifecycle cost of the assets or the total cost ofownership.

ABB has taken the life assessment approach a stage further by working in conjunction withutility companies to develop a financial modelthat evaluates the lifecycle cost of a transformerfleet or individual unit over a given period. The model enables the end-user to derive themaximum value from the exercise and helpsdecision makers and asset owners identify themost financially efficient maintenance scenario.

STEP 4: IMPLEMENTATION OFENGINEERING SOLUTIONSBased on the results of this rigorous analysisprogramme, engineering solutions are identified

to achieve risk reduction, life extension and thegeneral health improvement of the fleet. Thesesolutions include:

• preventive and corrective maintenance• field repair and retrofit • relocation and transportation• testing and advanced diagnostics• factory repair • planned transformer replacement.In addition to the traditional transformer

maintenance and repair techniques, some newtechnologies are now being adopted, includingon-line oil regeneration, on-site repair, low-frequency heating and ‘better than new’.

On-line oil regeneration has demonstratedtechnical and economical advantages whenapplied to old transformers with aged acidic oil.It is more environmentally friendly than oilreplacement and shows a much better efficiencyover a long time.

ABB has developed an extremely efficient andcost-effective on-site repair service that effectivelytakes the factory to the transformer. It is ideal forremote locations where transportation is difficultand costly. However, on-site repair is alsoincreasingly popular as a way of getting mission-critical transformers back on line quickly, at afraction of the cost and lead-time required toinstall a new replacement unit.

A low-frequency heating (LFH) system candry transformer active parts much faster, withoutcompromising quality. The remaining moisturecontent of the solid insulation is typically belowone per cent. The drying time can be less thanhalf that for a traditional hot oil and vacuumprocess. This reduction in lead-time whendrying a wet transformer or repairing a failedunit on site could be vital.

For operators who need to boost the power of their existing units, ABB offers a ‘better thannew’ service under which coils are rewound withNomex® high-temperature insulation material.This results in significant improvements in

lifetime and reliability. As well as the costadvantages for the unit, side benefits include:lower environmental impact than scrapping, no construction needed to prepare the site (thefootprint remains identical), and lower weightthan conventional units.

CONCLUSIONThe MTMP approach to asset managementprovides vital evidence to support transformerowners deciding whether to maintain or replacetheir fleet.

On a long-term strategic level, a significantbenefit of such a study is that it provides a clearpicture of the maintenance and renewalinvestments required over the next 20–30 yearsto deliver the required asset reliability andavailability. It provides solid information tocompare different asset management strategiesand to select the approach that best supports the organization’s overall technical and financialstrategy. A programme to extend the lifetime of aged units will, for example, postponeinvestments in new units and so improve thecash flow of the company.

In the medium term, asset managers canidentify how best to use maintenance andreplacement budgets. Funds can be allocated to units that show the best return oninvestment, while reducing technical andoperational risks.

In the short term, the method enables themaintenance manager to quantify the costs andbenefits of each planned maintenance action.

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Asset Management

Transformer fleet Step 1 -Transformer fleet screening

Step 2 -Transformer design &condition assessment

Step 3 -Life assessment & profiling

Step 4 -Engineered solutionsEngineered solutions

Regular diagnosticsHistory

Advanced diagnosticsDesign review

Replacement Refurbishment Upgrade

Life management process: The 3 + 1 steps ABB approach

08 FFWD >> SUMMER/AUTUMN 2008

Substations

Scottish and Southern Energy (SSE)has awarded two Thames Valleysubstation contracts worth a total of £24million to an ABB and Balfour Beattyconsortium. The consortium will designand construct two new indoor state-of-the-art gas-insulated switchgear (GIS)distribution substations at Reading,Berkshire and Iver Heath,Buckinghamshire to replace existingoutdoor air-insulated switchgear (AIS)substations that are approaching the endof their service life.

A key element in the Reading project willbe the use of ABB’s innovative PASS MOswitchgear modules to provide a temporaryspace-saving solution that will free up vitalbuilding space. This will enable the new GISsubstation to be built in the very restrictedspace available at the existing site.

The new 132kV substation at Reading andthe 66kV substation at Iver Heath are ABB’sfirst major substation projects for SSE. Theyplay a vital role in SSE’s plans to reinforce itsdistribution network in the south of England to ensure security of supply and provide

additional capacity. SSE regards both sites asflagship projects and asked the consortium todeploy innovative, cost-effective solutions thatwill enable the new GIS substations to beconstructed within the confines of the existingAIS sites.

VITAL CONSTRUCTION SPACE AT READINGThe Reading site is already completely fullwith AIS switchgear which has to remain inservice until the circuits can be transferred tothe new substation. The option of expandinginto nearby heavily wooded green space tomake room for the construction of the newindoor GIS building was rejected because ofthe planning time, expense and project delaysinvolved.

ABB’s solution uses its proven modularPASS MO switchgear as an interim measurewhile the new GIS building is built within theexisting site. By dismantling old generatorcircuit-breakers that once served thedemolished North Earley power station, justenough space will be freed up for ABB toinstall its PASS MO modules that will takeover the operation of the existing AIS circuits.

When complete, the new 132kV substationwill comprise 13 bays with space for fourfuture circuits. After all the circuits have been transferred to the new substation, the temporary PASS MO modules will be removed.

FAST TRACK FOR IVER HEATHThe construction of the new 66kV substationat Iver Heath is more straightforward, as thereis already sufficient space on the existing site.The challenge here is to get the new GISsubstation on line as quickly as possible. Theconsortium is placing a major emphasis onplanning and logistics.

The Iver Heath site is on the floodplain ofthe River Colne, so the building is beingconstructed on stilts to protect it against thepredicted level of a once in 100 years flood.This approach has already proved a successfulmethod of flood protection in UKinstallations. When complete, the newsubstation will provide six extra bays, takingthe total number of bays to 24.

£24 million Thames Valleysubstation deals

A view of the Reading Earley site at the start of the project.

The announcement of theFenno-Skan 2 link, due for completion in2011, has given renewed impetus tointernational co-operation in the sharingof power resources. The new 800MWhigh-voltage direct current (HVDC)connection between Sweden and Finlandbuilds on the success of the existing572MW link, which came into service in1989 and was upgraded in 1998.

ABB delivered the original link and will besupplying two HVDC converter stations for the new connection. HVDC is a technologythat enables power to be transmitted over long distances with minimal transmission loss.

ABB pioneered HVDC more than 50 yearsago, with the first link connecting the Swedishisland of Gotland with the mainland. Sincethen, HVDC systems have been installedaround the world, with the vast majority beingbuilt by ABB. The company has participated ina total of 60 HVDC projects worldwide with atotal capacity of more than 48,000MW.

In recent years, there have been a growingnumber of cross-border and undersea HVDCprojects, including the NorNed and the BritNedlinks in Europe.

THE NORTH-SOUTH DIVIDEThe Finnish and Swedish power transmissionare part of the Nordic Nordel joint grid.

Both countries have similar challenges withpower generation and distribution. While power

consumption is largely focused in the south,hydro power generation is centered in the north.The existing AC connections are also in thenorth, resulting in long transmission distancesbetween the two nations. By using HVDCinterconnections in the south, overall powercapacity is greatly increased with easyredistribution of load flows between thenetworks, which in turn reduces the losses inthe Nordel grid as a whole.

FIRST STEPSFenno-Skan 1, a monopolar 500MW HVDCinterconnection across the Gulf of Bothnia,came into service in November 1989. It was theworld’s first 400kV HVDC interconnection,and at the time was also the world’s longestsubmarine interconnection.

Special control modes have meant that thelink has had a beneficial effect on the northernAC connections between the two countries. Thishas been achieved by increased damping ofelectromechanical oscillations, a higher transientstability limit and increased capacity on sectionsof the Swedish grid.

The link was upgraded in 1998 to provide a maximum continuous capacity of 572MWwith a short (one-hour) overload capability of600MW. On-line temperature measurements are fed into the cable load prediction system tocalculate the current transmission capability.

The total length of the cable connection is200km, with 198km undersea and 2km on

land. The maximum depth is 117m, with anaverage depth of 80m.

The seven-section cable was laid in two partsand jointed at sea.

FENNO-SKAN 2For Fenno-Skan 2, ABB will supply two HVDC converter stations as part of an 800MW power link.

The contract is part of a larger scheme that includes a 400kV ACsubstation in Finnböle, a70km DC overhead line inSweden, and a 200kmsubmarine cable. Thenew Swedish converterstation will beconsiderably furtherinland than the existingone.

For the Fenno-Skan2 project, ABB will beresponsible for systemengineering, includingdesign, supply andinstallation of thetwo HVDCconverter stations.The system isscheduled to be inoperation by the endof 2011.

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HVDC

Finnböle

SWEDEN

FINLAND

Dannebo

Rauma

The Baltic connection

010 FFWD >> SUMMER/AUTUMN 2008

Rail

ABB has been awardeda fast-track, two-year contract to upgradethe DC traction power systems on theJubilee Line, in readiness for morefrequent services, as part of LondonUnderground’s programme ofimprovements across the capital’stransport infrastructure.

MORE TRAINS, MORE OFTENThe Jubilee Line will carry a large proportion ofthe traffic generated by the 2012 Olympics tothe main site at Stratford, East London. The firstphase of the planned improvement in passengercapacity was completed in early 2006, when aseventh car was added to the 59 existing six-cartrainsets and four complete new trains wereintroduced. This increased capacity by some 17 per cent – equivalent to an extra 3,000

people per hour at peak times.In the second phase, due for completion in

2009, the Jubilee Line signalling systems will berenewed completely to enable Automatic TrainOperation (ATO). This will permit a majorincrease in train frequency and increasepassenger capacity by a further 33 per cent.

TRANSFORMER RECTIFIER UNITSABB’s role is to provide an extra 8MW of powerfor the Jubilee Line’s 630V DC traction supplyto support the additional demand created by theextra traffic. The project includes the design,supply, installation and commissioning of nineTransformers Rectifier Units (TRUs) (sometimescalled Traction Converters) at four existingsubstations. The TRUs, each rated at 2.5MW,will convert the 11kV and 22kV AC supplies

from the London Underground network to the+420V/-210V DC power required by the trains.ABB is also carrying out civil engineering worksat most of the sites.

The Jubilee Line contract was awarded inMay 2008, following a competitive tender thatplaced a major emphasis on supply chainperformance and demonstration of excellentrelationships with sub-suppliers. It is going well,with the main delivery team established and allmajor equipment orders such as for the TRUs,HV and DC cables and civil engineering designplaced within 30 days of contract signature – a key milestone set at the outset by LondonUnderground.

FACTORIES IN POLAND, SPAIN AND FINLANDThe ABB Power Systems Rail team, based inLondon, worked with the main manufacturingplants in Poland, Spain and Finland to develop acomplete understanding of the contractrequirements. This called for detailed workshopmeetings in Spain and Poland, prior to thecontract award, to establish acceptance inprinciple of the terms and conditions that wouldapply to the project. Then, when the contractwas awarded, the success of these workshopsenabled orders to be placed very quickly. Otherimportant factors in ABB’s favour included:system knowledge gained over many yearsworking on the London Underground network;London office base; ability to meet theprogramme; and demonstration of thecompetencies of the rail project delivery team.

ABB is proud to be working with LondonUnderground to help it realize its vision andthat of Transport for London to have a ‘worldclass metro system for a world class city’.

Jubilee Line – more power for more passengers

011FFWD >> www.abb.com/ffwd

MV Switchgear

ABB’s containerized switchgearis providing the ideal fast-track solution fora growing number of process industrycustomers who need to upgrade theirmedium-voltage (MV) distributionnetworks. The fully pre-engineered unitsare delivered to site ready to ‘plug andplay’. This approach not only results in amore cost-effective overall project that isaround 20 per cent faster to completethan the conventional ‘build on site’ route,it also provides a smooth change-overwith minimal disruption.

TOTALLY INTEGRATED SOLUTIONABB supplies the containerized switchgear as afully equipped, totally integrated solution,comprising:

• 33kV ZX1.2 gas insulated switchgear or11kV Unigear vacuum switchgear

• IS limiters, the world’s fastest switchingdevices, for short-circuit protection

• control equipment• batteries and chargers to provide

back-up power• heating and lighting

The equipment is housed in a robustcontainer constructed in either GRP or steelaccording to site requirements. The actual sizevaries depending on the switchgear application,but typically the container will be around tenmetres long, five metres wide and four metreshigh. This compact size enables the container tobe easily transported on a standard low-loader.

PLUG AND PLAYA key advantage of the pre-engineeredcontainerized switchgear is that the majority ofthe assembly is carried out in a controlledfactory environment – there is very little sitework needed. Civil works are minimal since allthat is required is basic foundations for thecontainer to rest on – this results in a significantreduction in project costs . Once the unit is inplace it is simply a question of connecting it upto the appropriate HV cables, so the need foroutages is also minimized.

MINIMAL DISRUPTIONOne of the most popular applications for ABB’scontainerized switchgear is at process sites wherecustomers need to replace or upgrade an existingswitchgear installation that is nearing the end ofits working life. Because all the mainconstruction work is carried out off line there isminimal disruption to the normal site operation.Furthermore, the transfer of circuits from old tonew switchgear can be scheduled for the mostconvenient time that has least impact onproduction.

FASTTRACKThe combination of a pre-engineered solutionand minimal civil works makes containerizedswitchgear the ideal approach when a fast-tracksolution is required. In most cases, ABB wouldexpect to show a 20 per cent reduction in thetime from order to energization compared withthe more traditional route.

ADDED SAFETYSince the majority of the construction work iscarried out offsite, the containerized switchgearhelps to reduced health and safety concerns,especially in the limited space found in thetypical industrial process environment.

Thinking inside the box

SUMMER/AUTUMN 2008 >> FFWD

012 FFWD >> SUMMER/AUTUMN 2008

Substation Automation

ABB has continued its string ofassessments for feeder terminals used inthe protection, control and measurementof medium-voltage (MV) networks bygaining acceptance for its new REX521feed protection relay which is ideallysuited for G59/1 embedded generatorapplications. This type assessment,managed by the Energy NetworksAssociation (ENA), is an important step in obtaining product acceptance by National Grid and other leadingcustomers in the UK electricity supplyindustry.

The REX521 uses the same protectionfunctions as ABB’s REF541/3/5 feeder terminalsthat have already gained ENA acceptance, but ishoused in a more compact, cost-effective design.It is primarily intended for use in distributionsubstations to provide short-circuit, over-current

and earth-fault protection, as well as auto-reclosing of substation feeders.

In its H50 version, the REX521 is suitablefor installation where embedded generatorsconnect to a public supply network. Whilevoltage and frequency protection are normallyused to disconnect generators in the event of aloss of mains condition, the REX521 provides aspecial Loss of Mains function based on the rateof change of frequency (ROCOF). Thisfunction provides a faster response thanunder/over-frequency protection.

ENGINEERING RECOMMENDATION G59/1In the UK, when any kind of generatorproducing in excess of 16A per phase (3.7kW) isconnected in parallel to the public electricitysupply, it must comply with ENA’s EngineeringRecommendation G59/1 – which providesguidance for the connection of embeddedgenerating plant to the distribution systems of

public electricity suppliers.In the event of a power system fault, the

incoming circuit breaker must be opened. Thisis to prevent the generator from exporting poweran islanded public electricity supply network.

There is a risk that an embedded generatormay not recognize a fault condition withtraditional over-current and fault protection.Other methods, such as the ROCOF functionon the REX521, are required to ensure networksecurity.

COMPLETE SOLUTIONThe REX521 complements ABB’s completerange of solutions for power system protection,control, measurement and supervision. This nowincludes everything from basic protection relaysto advanced feeder protection and bay controlterminals, with support for a wide range ofcommunication protocols and standards,including IEC 61850.

Feeder protection relay for G59/1applications now ENA-assessed

CONTACTSYou can find more informationon the stories in this issue at:www.abb.com/ffwd or call usas follows

Rail – 01785 825050Power Generation – 01785 825050Substations – 01785 825050HV Switchgear – 01925 741457MV Switchgear – 01925 741433Automation – 01785 825050Protection & Control – 01785 825050

Service – 0845 6011946Power Quality – 0151 3578400Transformers – 01925 741469Asset Management – 01785 825050Wind Power – 01785 825050General Enquires – 01785 825050