3 | 16

ffwd
Focus on Power Grids

Future vision for digital substations 18

Dwr Cymru is first UK operator to order SafeRing Air 4

New partnerships central to project delivery 5
MeyGen tidal power scheme to power up this year 8
‘Ultimate’ IEC 61850 deployment for Network Rail’s Great Western programme 14
Welcome
Power Grids
Power Grids offers power and automation products, systems and service solutions
across the generation, transmission and distribution value chain. Its offering
includes transformers, high-voltage products, power transmission systems, and
grid integration and automation solutions – to enable a stronger, smarter and
greener grid.
ffwd 3 |16
Dear Reader,
This October, in line with our Next Level
strategy, ABB announced some changes to
the way we will deliver customer projects.
The goal is to combine ABB’s technical and
engineering knowledge with the engineering,
procurement and construction capabilities
of our partners Fluor for substation projects,
and Aibel for offshore wind connections.
While page 5 includes more detail on this
news, I’ll include updates in future editions
of FFWD.
In terms of technology, one trend that
is particularly notable at the moment is the
David Hughes, Director of Marketing
and Sales at ABB’s Power Grids static compensator (STATCOM). PCS 6000
business in the UK STATCOM units are a major component
in three current projects. They will smooth
voltage and frequency for renewable energy
generation and enable power flows between
previously incompatible distribution grids. In
ffwd issue 3/16 • The customer newsletter of ABB Power Grids • Subscription newsletter available as printed or electronic copy. Subscribe online at abb.co.uk/ffwd
Contact and feedback karen.strong@gb.abb.com • Publisher ABB Limited, Power Grids division, Oulton Road, Stone, Staffordshire ST15 0RS. Phone 01785 825 050
2 abb.co.uk/ffwd Power Grids
6
Caithness Moray
milestone reached
fact, we’ve pulled the stories into a special
section on pages 8 to 12 to highlight the
capabilities of STATCOMs.
It was also exciting to receive ABB’s first
UK order for our new SafeRing Air medium
voltage switchgear from Welsh Water. The
switchgear uses an insulating gas with a
significantly lower global warming poten-
tial than SF6. Read all about it on page 4.
Looking ahead, there’s a lot of buzz
about digital substations now. Claudio
Facchin, President of ABB’s Power Grids
division set the agenda for them at CIGRE
in Paris in August by delivering the keynote
address for the conference. Learn about
our digital substations portfolio on page 16.
So as the nights draw in, I hope this
edition of FFWD gives you plenty food for
thought for future projects.
Best wishes,
David Hughes
 Contents

36
Flexibility is key to
future networks

8
MeyGen power conversion
building complete

30
Fast-track transformer
replacement at Hinkley
Point B

News Power quality

0 4 Latest news from around ABB 22 Automotive plant adopts harmonic filter

Tidal energy Building information modelling

0 8 MeyGen’s initial phase complete 24 Working to the UK’s construction strategy

Innovation Asset management

1 0 Flexible power link to connect distribution grids 26 Asset health intelligence platform

FACTS HV service
1 2 ScottishPower to adopt STATCOMs at Kilgallioch 28 Hinkley Point B transformer refurbishment

Protection and control Switchgear

1 3 New Relion relay 30 Multifunctional switchgear for Blyth grid connection

Rail Energy strategy

1 4 ‘Ultimate’ IEC 61850 for Network Rail 32 Flexibility for a secure energy future

Digital substations Health and safety

1 6 Vision for digital substations presented at CIGRE 34 Safety award from London Underground

Transformers Events
1 8 Line voltage regulation 35 Low Carbon Networks & Innovation
35 IET Innovation Awards
Microgrids
2 0 South African microgrid integrates solar and battery
energy storage

Power Grids abb.co.uk/ffwd 3

News

ABB’s Sue Selwood receiving a Gold Medal award from Don Lloyd, RoSPA Vice Chairman

Another RoSPA gold medal success

The Royal Society for the Prevention
of Accidents (RoSPA) awarded ABB’s
UK service business a 2016 Gold
Medal award in July at an event in
Birmingham. The medals are awarded
to organisations which have achieved
five to nine consecutive Gold Awards –
and ABB’s Power Service team has now
secured nine.
Gold Medal awards are presented only
to the companies that have consistently
demonstrated a very high level of occu-
pational health and safety management
systems and culture, as well as showing
outstanding control of risks and very low
levels of error, harm and loss.
Sue Selwood, Quality, Health, Safety and
Environment Coordinator said “Health and
safety is integral to all of ABB’s activities.
We work hard to live up to our health and
safety principle of ‘Deliver safely, on budget,
on time, in full, and to the right quality.’
Gaining the Gold Medal award from RoSPA
is a real badge of honour.”

Welsh Water orders UK’s

first SafeRing Air
ABB has received the first order for its
recently launched SafeRing Air environmen-
tally friendly medium voltage switchgear
via Welsh Water’s contractor EPS Con-
struction. The switchgear will be deployed
as a secondary distribution ring main unit
(RMU) that will control power for essential
process equipment.
SafeRing Plus was launched in April
2016 as an eco-efficient alternative to SF6
gas insulated switchgear (GIS). It makes
use of a new insulating fluoroketone-based
gas mixture developed by ABB in collab-
oration with 3M that has a global warming
potential (GWP) of less than 1 (almost 100
percent lower than SF6).
Bruno Melles, managing director of
ABB’s Medium Voltage business, said:
“The speed with which we have moved
this technology from development testbed
to commercial application is testament to
our commitment to delivering our ‘Better
World’ promise.”
Following development of the new GIS,
it was tested in high and medium voltage
SafeRing Air is available in ratings up
applications in a pilot project at a Zurich to 24 kV with 16 kA short-circuit and
substation operated by leading Swiss 630 A nominal current
utility ewz.

4 abb.co.uk/ffwd Power Grids


Partnership
working strategy
ABB has announced new partnerships that will
combine its world-leading technology with its
partners’ expertise. The approach is focused on
projects to deliver substations and offshore wind
infrastructure, as well as projects that include high-
voltage cable.
Delivering substations with Fluor
For substations, ABB has formed a strategic
global partnership with Fluor, the global
engineering, procurement, fabrication,
construction and maintenance company.
Commenting on the deal, David Seaton,
Chairman and CEO of Fluor said: “Fluor’s
new global strategic partnership with ABB
targeting the substation market is expected
to bring unique synergies to our power
clients.”
Partnering with Aibel for offshore
wind
In the world of offshore wind, ABB has
partnered with Aibel, the leading service
company within oil and gas and renew-
able energy. The firms will combine their
strengths to deliver state-of-the-art off-
shore wind integration solutions that include
ABB’s power transmission technologies
with Aibel’s experience in delivering infra-
structure in harsh offshore environments.
“Both ABB and Aibel have a proven track
record of providing leading-edge solutions
in their respective areas of expertise. We
have successfully worked together before
Partnerships will combine ABB’s technology with construction and manufacturing expertise
and I am convinced that with our combined
strengths we will be a leading force to reckon
with,” said Jan Skogseth, President and
CEO of Aibel.
Long-term cable partnership
ABB also announced that NKT Cables is
acquiring ABB’s global high-voltage (HV)
cable system business – and that ABB and
NKT cables have signed an agreement for
a long-term strategic partnership.
NKT Cables already has a strong portfolio
in low-, medium- and high-voltage solutions
mainly in the AC (alternating current) area.
By acquiring ABB’s cable business, it is
gaining capabilities in high-voltage cable
technology, manufacturing and service,
as well as a new cutting-edge cable-laying
vessel currently under construction.
“As part of the strategic partnership, ABB
and NKT Cables will work together on future
projects to access market opportunities
in areas like subsea interconnections and
HVDC transmission links”, said Claudio
Facchin, president of ABB’s Power Grids
division.
News
Josh has combined work experience and
academic study during his apprenticeship
Apprentice Josh
Barber shortlisted
for prestigious
award
One of ABB’s latest crop of appren-
tices has been shortlisted in the IET’s
Achievement Awards. Josh was
selected as a finalist in the Apprentice
of the Year category in recognition
of his outstanding engineering and
technical understanding and his work
as a role model.
Josh will join the rest of the short-
listed candidates at an awards event
hosted by engineer and TV present-
er Kate Bellingham on 16 November
in London. He is in with a chance
of walking away with a trophy, cer-
tificate, £1,000 and two years free
membership of the IET.
Incoming IET President Pro-
fessor Jeremy Watson said: “The
standard of this year’s entries was
higher than ever making the judging
extremely difficult. All the IET Appren-
tice and Technician Award finalists
demonstrated skills and knowledge
through their work that went far
beyond their role. They have taken
on challenging tasks and through
innovation and determination to suc-
ceed have brought real benefits to
their companies.
“They have been recognised by
the IET for their achievements and
for being role models to future gen-
erations of engineering apprentices
by having the potential to inspire
others to develop their own engi-
neering career.”
Power Grids abb.co.uk/ffwd 5
News

Milestone reached
on Caithness-Moray link
ABB has made achieved a major mile-
stone on the 1.2 MW Caithness-Moray
HVDC (high-voltage direct current). It
has completed installation of the 28 km
of underground cable in Caithness
between Spittal and Noss Head. ABB
and its contractors will now carry out
reinstatement to return the cable route
to its normal state.

ABB is delivering two land based HVDC

Light converter stations as well as the land
and subsea cable that will connect them.
The project represents a £1.1 billion capital
investment by SHE Transmission and will
ensure the energy security by reinforcing
the transmission network in the north of
Scotland. ABB has engaged the local supply
chain wherever possible, only bringing
in workers from outside the area when
specialist knowledge is needed. Caithness is a great achievement for the planned final work which will be happening
SHE Transmission’s Lead Project Man- whole project team – but particularly for ABB next year, we have reached this point on
ager for the land cable works Michael Blake and all their subcontractors who have led schedule and the focus of onshore cable
said: “The installation of all land cable in the effort on site. Although there is some installation has now turned to Moray.”

The 28 km cable route will be returned to its normal state now that cable installation is complete

6 abb.co.uk/ffwd Power Grids

 News

Power and automation Passengers at Heathrow Terminal 5 are being whisked

between the terminal and the business car park by
ABB-sponsored self-driving pods. The pods raise

in focus at Heathrow awareness of ABB’s work in power and automation

and received ABB livery in March 2016 in a joint

Terminal 5 venture project between ABB, Heathrow, JCDecaux

and Kinetic.

Bringing light to Wick War Memorial

As part of ABB’s commitment to support
the communities where it works, ABB
and its customer Scottish Hydro Electric
Transmission (SHE Transmission) have
lent support to a project in the town of
Wick, Caithness. ABB is working near
Wick to deliver the Caithness-Moray
transmission link and gave its support to
enable Wick Community Council to install
flood lighting at Wick War Memorial,
which commemorates members of the
community who were lost during the
World Wars.
Nicola Sinclair, Secretary of the Royal
Burgh of Wick Community Council said: “We
are deeply grateful to SHE Transmission,
ABB and the Highland Council for their
support in making this idea a reality. We’re
delighted with the results.
“The various projects undertaken by SHE
Transmission in Caithness are a welcome
boost to our economy, and it’s heartening
to find companies who are willing to con-
tribute to community projects in this way.”

Support from ABB and SHE Transmission has enabled flood lighting of Wick War Memorial

Power Grids abb.co.uk/ffwd 7

Tidal energy

The Power Conversion Centre blends into the landscape

Initial phase completed

for innovative MeyGen tidal
power scheme
ABB has completed installation and commissioning of the onshore grid connection
for the initial phase of the world’s first large-scale commercial tidal stream power
generation project, in Scotland’s Pentland Firth. Stuart Grattage, General Manager
T&D Infrastructure & Grid Integration Solutions at ABB, explains how this helps
keep the MeyGen tidal stream project on track to start feeding electricity into the
UK National Grid by the end of 2016.
The MeyGen project, majority owned by The initial demonstration phase of the free electricity for the equivalent of 175,000
Atlantis Resources Limited, will harvest MeyGen tidal array scheme involves the homes.
the tidal resources of one of the most installation of four submerged turbines in the With the completion of the onshore grid
energetic maritime sites in Europe: the Inner Pentland Firth just north of Caithness, connection to the 33 kV Ness of Quoys
strait connecting the Atlantic Ocean each capable of delivering 1.5 megawatts distribution network, the grid is now ready
to the North Sea between the Orkney (MW) of power. Following on from this, the to start accepting power from the subsea
Islands and the Scottish mainland. next phase of development will provide up turbines as soon as they are fully installed
Studies including those by engineers to 86 MW of electricity, enough to power and commissioned.
from the University of Edinburgh and around 42,000 homes – almost 40 percent Scottish First Minister Nicola Sturgeon
University of Oxford indicate this tidal of households in the Scottish Highlands. visited the site on 12th September and
stream has vast energy potential, with Within the next ten years, MeyGen spoke about the benefits of the tidal ener-
ocean currents estimated at five meters intends to deploy up to 398 MW of offshore gy industry, in particular the skilled jobs
per second, among the fastest in the tidal stream turbines in the Pentland Firth to and technology leadership that exists in
British Isles. supply enough predictable and emissions- Scotland.

8 abb.co.uk/ffwd Power Grids


Breaking new ground
The planned levels of generating capacity
mean the MeyGen project is classed as
a Large Power Station connection in this
part of the country, requiring full National
Grid Code compliance. This is the first tidal
generation project to go through the rigorous
diligence process required.
ABB has played a key role in ensuring
compliance, supplying the onshore power
conversion and grid connection systems
needed to feed electricity safely and reli-
ably into the distribution grid. Our project
scope included design, engineering, supply
and commissioning of the power conver-
sion, switchgear and transformer solution
as well as associated civil engineering and
cabling works.
A key element of the ABB solution is the
PCS 6000 Power Converter System, which
ensures that the variable power voltage
and frequency delivered by the tidal stream
turbines will be delivered to the grid within
permitted tolerances. The project also uti-
lises ABB’s ZX0.2 gas insulated primary
medium voltage switchgear.
An important aspect of the project has
been to minimise impact on the environment
and the local population. The Power Con-
version Centre building has been designed
to blend into the surrounding countryside
and features water, waste and cooling
systems that minimise its environmental
impact. Without the use of noise-produc-
ing air conditioning units, ABB has had to
ABB’s scope included design, engineering,
supply and commissioning
develop novel approaches to using natural
convection cooling in what is a challenging
corrosive coastal environment, especially
as this is the first time that we have housed
a large PCS unit in a building.
“Forming partnerships with the lead-
ing players in the energy sector is key to
delivering commercial-scale tidal power pro-
jects that allow us to harness the untapped
potential of global tidal resources,” said Tim
Cornelius, CEO of Atlantis Resources Ltd.
“ABB has clearly demonstrated exceptional
expertise in this area and is delivering the
highest quality results, contributing to the
success of the MeyGen project.”
Tidal energy
Unique wind–tidal combination
In July 2016, the MeyGen project achieved
another world first, when Atlantis agreed
a deal with a nearby wind farm develop-
ment to facilitate access to the distribution
grid for other renewable energy projects.
Lochend Wind Energy Limited is developing
a four-turbine wind farm close to MeyGen’s
onshore site in Caithness. The new agree-
ment will enable these wind turbines to
deliver electricity to the grid whenever the
MeyGen tidal project is not making full use
of the available export capacity. This will
result in improved utilisation and manage-
ment of the existing grid network without
affecting MeyGen’s generation.
“We believe this to be a world first,” said
Tim Cornelius. “It shows how the predict-
ability of tidal generation can also benefit
other forms of renewable energy by allowing
those generators to accurately forecast and
access spare grid capacity. We are delight-
ed to have been able to assist a local wind
farm in getting connected.”
“Sharing transmission assets in this
way and capitalising on the predictability
of tidal power will ensure that, in the long
term, our energy needs are better served
whilst also maximising access to a con-
strained network in the immediate future,”
added Cornelius.
Power Grids abb.co.uk/ffwd 9
Innovation

Western Power Distribution

to trial Flexible Power Link as
part of world-leading ‘smart
network’ programme
ABB is working with the UK DNO (Distribution Network
Operator) Western Power Distribution (WPD) to deploy a
ground-breaking Flexible Power Link that will enable the
connection of previously incompatible distribution networks.
Based on back-to-back power electronic converter technology,
the new solution will enable previously incompatible
distribution networks to be intelligently connected, and help
pave the way for microgrids.

The Flexible Power Link is a key part
of WPD’s Network Equilibrium project,
which is supported through the UK’s
Low Carbon Networks Fund (LCNF)
program. As part of this project, WPD
will trial a 20 MVA Flexible Power Link
for network reinforcement by enabling
the controlled transfer of both real
and reactive power flows between two
incompatible network sections. Such
connections have not been possible until
now because of issues with circulating
currents, protection grading or fault level
constraints.
ABB will provide and install the Flexible
Power Link in WPD’s trial substation loca-
tion in Devon, southwest England, using a
back-to-back power electronic converter
(AC–DC–AC) solution. This will allow power
transfers across two separate 33kV distri-
bution grid groups, which will help balance
generation and demand locally, while also
unlocking additional capacity under both
normal and abnormal network conditions.
This can be achieved quicker and at sig-
nificantly lower financial and environmental
cost than the traditional reinforcement
method of building new connections from
each distribution grid back to the nearest
substation.
WPD and the LCNF estimate that deploy-
ing such Flexible Power Links across Great
Britain would alone release 1.5 GW of
capacity by 2050. When all the methods
proposed for the Network Equilibrium pro-
ject are combined, it is estimated that some
11.3 GW of capacity would be released
across Great Britain by 2050, at a cost
saving of £1.5 billion when compared with
the most efficient traditional network rein-
forcement solutions.
Roger Hey, WPD’s Future Networks
Manager said: “This trial represents a key
component in our development programme
to integrate distributed generation within
electricity networks more efficiently, while
delivering major benefits to distribution
customers. In simple terms, once developed
this flexible link will allow us to move power
around the network where it is needed as
customers adopt greater use of electric
vehicles and heat pumps, for example.”
Network Equilibrium rationale
The key challenge that the Network Equilib-
rium project is designed to address is that
the UK’s electricity infrastructure was orig-
inally designed and developed for passive
power distribution. This is not well-suited to
accommodating high levels of low carbon
technologies such as intermittent distrib-
uted generation sources, electric vehicles
or heat pumps.
Without new solutions for managing
power flows, the integration of significant

10 abb.co.uk/ffwd Power Grids


levels of low carbon technologies causes
voltage management and thermal issues.
DNOs have a particular challenge as a result
of the high volume of customer connection
applications they currently receive. WPD
South West alone typically receives
145 requests for distributed generation
connections (mainly for solar photovoltaic
generation) per month, and this figure
continues to rise. WPD already has 3.5
GW of distributed generation connected
to its networks.
The voltage management and thermal
issues caused by such connections within
electricity distribution networks are made
worse during outage conditions. Doing
nothing or continuing to use conventional
solutions is not an option, as generation
customers will face higher connection costs,
associated with conventional network rein-
forcement across larger areas, and it will
take longer for them to connect.
Innovative solutions are needed to keep
costs down and to encourage the uptake
of low carbon technologies. The Network
Equilibrium project is intended to address
this by demonstrating new design and
operating processes that transform passive
distribution networks into active distribution
systems through the use of new technol-
ogies, including monitoring and control
systems.
Innovation
A static frequency converter will control
power flows between distribution networks
The goal is to enable DNOs to plan network operates at a different voltage
complex networks more effectively for low- and frequency from the local utility power
carbon technologies, optimise voltages and network.
power flows to utilise the existing electricity However, WPD’s Flexible Power Link
network fully, and balance generation and application is the first of its kind in the world.
demand more efficiently – all while increasing By enabling much more controllable con-
the resilience of networks and securing nections between distribution networks
electricity supplies for more distribution at significantly lower cost, it will help pave
customers during outages (maintenance, the way towards the deployment of intelli-
new connections and fault restoration). gent microgrids in the future. This makes it
The focus of WPD’s Network Equilibrium highly significant not only in development of
trial is to balance voltages and power flows smart power networks in the UK, but also
across its 33 kV and 11 kV distribution internationally.
networks, using three methods: Enhanced
Voltage Assessment (EVA), System Voltage
Optimisation (SVO), and Flexible Power
Link (FPL).
ABB has many years’ experience in
delivering back-to-back power converters
of the kind being deployed for WPD’s
Flexible Power Link trial, particularly in rail
applications where the trackside power
Power Grids abb.co.uk/ffwd 11
FACTS
STATCOMS
to help ScottishPower Renewables reach
environmental targets
A typical STATCOM installation
The 239-megawatt, Kilgallioch wind farm
contributes to more than 1.5 gigawatts
(GW) of installed onshore wind capacity
in the UK, with an aim to go up to 2 GW.
ScottishPower Renewables is part of
the major Spanish utility Iberdrola and
the Kilgallioch wind farm in southwest
Scotland is their second largest onshore
wind farm, and the third largest overall
in the UK, covering an area of 32 square
kilometers. The Kilgallioch wind farm
has the capacity to generate enough
electricity to power the equivalent of
130,000 households annually.
ScottishPower Renewables has con-
tracted ABB to supply, deliver, install and
commission three containerized PCS 6000
STATCOM units for a new substation being
12 abb.co.uk/ffwd Power Grids
constructed at the Kilgallioch wind farm, to
which ABB is already supplying switchgear
and associated power equipment.
The STATCOMs will ensure the reliable
grid integration of the wind farm by pro-
viding dynamic reactive power support to
control the voltage and the power factor
at the connection point of the wind farm.
Dynamic shunt compensation contributes
significantly to the power system reliability
and stability. The installation of the STAT-
COM units will also help meet UK grid code
requirements.
Electrical loads both generate and
absorb reactive power. Since the trans-
mitted load often varies considerably from
one hour to the next, the reactive power
balance in a grid varies as well and this
can result in unacceptable variations in
ABB will provide
ScottishPower
Renewables with
three containerized
Static Compensator
(STATCOM) units to
be installed at the
Kilgallioch wind farm
substation.
voltage, including voltage depression or
even voltage collapse. A STATCOM contin-
uously provides variable reactive power in
response to voltage variations, supporting
the stability of the grid. Installing a STAT-
COM at one or more suitable points in a
grid helps increase power transfer capa-
bility by enhancing voltage stability and
maintaining a smooth voltage profile under
different network conditions. Its ability to
perform active filtering is also very useful
for improvements in power quality.
STATCOM devices are part of ABB’s
FACTS (Flexible Alternating Current Trans-
mission Systems) portfolio. ABB pioneered
FACTS technology and is a market and
technology leader in this domain with over
800 installations supplied across the world.
By boosting power capacity and improving
stability in existing grids, FACTS technolo-
gies enable more power to reach consumers
with minimal environmental impact while
also lowering investment costs. More than
20 ABB STATCOMs operate in various UK
wind farms and provide over 600 megavolt-
ampere reactive (MVAr) to help strengthen
the country’s electrical grid.

New Relion relay for generator
and interconnector protection
The new REG615 has joined the Relion 615 series
ABB has introduced a new member to
its Relion 615 series of relays for protec-
tion and control applications in power
distribution. The new REG615 is a dedi-
cated intelligent electronic device (IED)
for interconnector and generator protec-
tion. It introduces generator protection
in the 615 series and is ideally suited to
protecting renewable generation units
distributed around medium voltage grids.
Like all other relays in the 615 series
members, REG615 fully supports the IEC
61850 standard for smart grid communica-
tion, including Edition 2 of the standard that
covers extended interoperability between
devices from different manufacturers.
Choose the right Relion
With a total of 45 individual types of relay across
nine series, ABB has introduced the Relion Inter-
active Selection Guide to help its customers select
the type of IED that best suits their applications.
Find the Relion Interactive Selection Guide
at abb.relionisg.com
Generator and interconnection
protection
Used in generator protection applications,
REG615 offers full protection both during
start-up and normal operation, typically in
small and medium-sized diesel, gas, hydroe-
lectric and combined heat and power plants.
In the role of interconnection protection,
REG615 commits to ensuring a stable and
reliable grid at times when grid-connected
distributed generation units are growing in
both size and number. REG615 continu-
ously monitors distributed generation units
such as solar or wind farms. It can deter-
mine whether and when to disconnect them
from the grid, as well as to detect islanding
from the grid.
Protection and control
Relion family of relays
ABB’s Relion product family includes a total
of nine individual series that are grouped
into four categories, generation, distribu-
tion, transmission and sub-transmission.
These include IEDs for protection and con-
trol for a wide variety of applications at all
voltage levels.
The 615 series includes a range of relays
with standard configurations for applica-
tions in the distribution grid. The series has
dedicated protection and control devices
for feeders, transformers, motors, gener-
ators and other applications. The units are
compact and versatile and integrate pro-
tection, control, monitoring and supervision
in a single device.
The 615 series IEDs share the same HMI
(Human Machine Interface) as other relays
in the Relion family. This gives operators
a consistent experience across the range.
They are characterized by compactness
and have a withdrawable plug-in design
for swift installation and testing.
In common with all of its Relion devic-
es, ABB is committed to lifetime support
for the 615 series protection and control
relays throughout their entire lifecycle. Its
extensive life cycle services include train-
ing, customer support, maintenance and
modernisation.
Power Grids abb.co.uk/ffwd 13
Rail
First ever electric train runs
on Great Western Route
The test run confirmed the successful
operation of ABB’s advanced IEC61850-
based protection and control fault
clearance concepts developed to suit
Network Rail’s own Rationalised Auto
Transformer System (RATS). ABB’s next
step on concluding its current bench test
programme is to implement the automatic
reconfiguration and restoration stages.
The key advantage of the RATS scheme
is that it enables a significant reduction in the
number of circuit breakers required, saving
on capital costs, while maintaining safety and
Factory testing of Network Rail’s protection and control system was carried out at ABB’s System Verification Facility in Stone
14 abb.co.uk/ffwd Power Grids
reliability. The use of ABB Relion protection
and control IEDs (intelligent electronic
devices) and RTUs (remote terminal units)
rather than hard-wired control equipment
also delivers a higher level of operational
information that facilitates remote diagnosis
and faster reconfiguration, while also saving
on copper costs.
RATS scheme will save investment
Network Rail has introduced the RATS
scheme to limit the number of circuit
breakers required along the 235-mile
length of electrified track between London
Paddington and Cardiff. ABB’s approach
replaces a number of high-voltage circuit
breakers with load break switches, which
are less costly to purchase and maintain.
The key difference between circuit break-
ers and load break switches is that circuit
breakers are capable of breaking high fault
currents, whereas load break switches
are not. Instead, ABB’s scheme uses its
advanced substation monitoring and control
technology to open circuit breakers when a
fault is detected, preventing the load break
switches from ever having to tolerate and
break a high level fault current.

The first ever train to run on a newly-electrified section of the Great Western Line
successfully completed its test runs between Reading and Didcot at speeds up
to 200 kilometres per hour. One key component part of achieving the critical
milestone was the delivery of trackside feeder substations delivered by ABB that
integrate an innovative IEC 61850 protection and control scheme.
ABB’s sophisticated protection and
control scheme integrates approximately
800 IEDs that will control equipment at 31
traction substations using the IEC 61850
smart grid communications standard. Not
only does the system utilize smart grid
communication between the equipment
serving each substation, but also between
individual substations using Network Rail’s
fibre optic Fixed Telecom Network (FTN).
Full factory testing
The vital bench testing and factory accept-
ance testing (FAT) of the protection and
Protection and control equipment is installed in
portable, fully-containerised and factory tested
Auxiliary Equipment Enclosures (AEEs)
control equipment is being carried out at
ABB’s System Verification Facility at Stone
according to the ‘transportable commis-
sioning’ philosophy. This means that the
majority of the work to configure and com-
mission the equipment is carried out under
controlled factory conditions. Not only does
this enable the highest possible level of qual-
ity control, the test engineers are on hand
in the factory to help facilitate planning and
optimization of the onsite installation and
commissioning phase.
Rather than having to take apart a ful-
ly working and tested system, possibly
disturbing wiring and settings and then
reassembling it on site, it is delivered in
portable, containerized Auxiliary Equip-
ment Enclosures (AEEs) that represent a
near plug-and-play solution.
To date, ABB has completed bench test-
ing of the protection and control scheme for
the first section of the line, which will inte-
grate more than 100 IEDs at six substations.
When a fault is identified by the IEDs in
the RATS scheme, they will communicate
and reconfigure the network to isolate the
fault and identify its location to within a
specific section of just a few kilometres.
Not only does this minimize the length of
track affected but also reduces the time
Rail
required for maintenance teams to inspect
and rectify the fault. This will reduce outage
possession times and risk to operating staff.
“The scale and sophistication of the pro-
tection and control scheme on the Great
Western Route Modernisation Programme
is unprecedented, not only in the UK, but
anywhere in the world. It has been designed
to feed into the existing and future SCADA
(supervisory control and data acquisition)
systems, and support Network Rail’s drive
towards smoother and smarter operations
that will help create a digital railway. We are
delighted to be working on this landmark
project to help Network Rail make history
by bringing Brunel’s railway into the 21st
century” said David Hughes, Director of
Marketing and Sales at ABB’s Power Grids
business in the UK.
Modular switchgear
While the RATS protection and control
scheme is the brains of the project, ABB
is also deploying the ‘muscle’ in the form
of its SMOS Light (Structure Mounted
Outdoor Switchgear Light) switchgear.
SMOS Light is delivered to site factory-
assembled and tested, which also reduces
installation time and risk during construction
and maintenance. It features vacuum
insulated FSKII+ circuit breakers that are
the only breaker that meets Network Rail’s
requirement to use non-gas-insulated
switchgear in trackside locations.
The GWRM is the first sizable new electri-
fication project to be undertaken by Network
Rail and the first on a UK main line for 20
years. The expansion and upgrade will result
in more reliable services for passengers and
reduce noise emissions affecting commu-
nities located close to railway lines. It will
also result in increased train frequency and
help boost passenger capacity, to support
economic growth across the region. Elec-
tric passenger services are scheduled to
begin on the route from 2019.
Power Grids abb.co.uk/ffwd 15
Digital substations

Presenting ABB’s
digital grid approach
ABB was at the recent CIGRE conference and of one-way electricity flows is giving way
to multi-directional flows. This is not only
exhibition in Paris to present its vision of digital bringing about changes in the transmis-
substations as key elements in future-oriented power sion infrastructure itself but also the way it
grids to improve efficiency, safety and system visibility. is operated, necessitating more intelligent
management of supply and demand. This
requires sophisticated monitoring, com-
Digital substations will be a key com- The entire electricity system is under- munication and control systems across the
ponent of next generation grids as they going changes on a scale and pace not power value chain of generation, transmis-
enable smarter power systems. This seen since its inception. While there is a sion, distribution, storage and consumption
innovative technology concept supports rapid growth in renewables, which are and calls for a smarter power system that
the digital transformation of the power by nature subject to supply fluctuations, makes greater use of digital technologies.
sector and reinforces ABB’s Internet of generation is now distributed over a myr- Digital substations will play a key role in
Things, Services and People approach. iad of locations and the traditional model the power system of the future. They will

Transformer with
Electronic Control (TEC)
Monitoring and diagnostics

MPLS-TP Network
Remote connectivity via ABB
FOX615 utility hardened multiplexer

Control Room
Including automation, protection and
control, and IEC 61850 station bus

16 abb.co.uk/ffwd Power Grids

 Digital substations

incorporate digital communications via fibre
optic cables, replacing traditional copper
connections using analogue signals. They
will also enable greater flexibility, availa-
bility and safety, while reducing cost, risk
and environmental impact. Digital substa-
tions will also feature Intelligent Electronic
Devices (IEDs) with integrated informa-
tion and communication technology. An
IED is a microprocessor-based protection
and control device for power equipment,
such as circuit breakers, transformers and
capacitor banks. The increasing amounts
of data available in a digital substation will
also enable more sophisticated monitoring,
diagnostics, protection and optimization
of assets.
“Digital substations are a key compo-
nent in shaping the evolving grid and ABB’s
latest technology offering in this area will
enable customers to optimize their oper-
ations” said Claudio Facchin, President of
ABB’s Power Grids division. “Facilitating
grid automation and the convergence of
information and operational technologies
are an integral part of our Next Level strat-
egy and ABB’s Internet of Things, Services
and People approach.”
Claudio Facchin delivered the keynote
address at the opening ceremony of CIGRE
2016 on August 21, presenting the evolution
of the power sector and related technology
trends including the digital substation.
ABB’s digital substation showcase
at CIGRE included disconnecting circuit
breakers (DCB) with Fiber Optic Current
Sensors (FOCS), a hybrid high-voltage
switchgear with a digitally compatible motor
drive, Relion® protection and control IEDs,
the FOX family of communications devices,
a MicroSCADA Pro monitoring system and
an Asset Health Center solution. The exhibit
also demonstrates ABB’s Transformer
Intelligence ® concept, in which sensors,
monitoring platforms and software are
combined to enable the extraction and
analysis of data to optimize performance,
improve safety and optimize costs.

Integrated Non-conventional
Instrument Transformers
Increasing safety and reducing the
substation footprint

Merging Units & Process I/O

Bridging the gap between analogue
and digital world. Compliant to
IEC 61850

IEC 61850 Process Bus

Connecting the switchyard to the
protection and control system

Power Grids abb.co.uk/ffwd 17

Transformers

Line voltage regulation

integrates renewables
At ABB’s recent Transformer Day, Frank Cornelius, a
Senior ABB R&D Engineer, outlined why operators are
now turning to line voltage regulation technology to
help integrate renewable energy into distribution grids.

Line Voltage Regulators can be located anywhere on the MV or LV grid

The transformation to low carbon gen-
eration requires major changes to
electricity distribution and transmis-
sion grids. Instead of large centralised
plants that inject high voltage power into
the transmission system, we now have
decentralised renewable schemes that
feed into the local distribution grid at
many different points. Typically, solar
photovoltaic (PV) plant feeds into the
low voltage (LV) grid and wind turbines
feed into the medium voltage (MV) grid.
Traditional grids are designed on the
basis that there will be a voltage drop along
the distribution line from the transformer to
the consumer. But now they can experi-
ence voltage rises near power producers.
Should the distributed generation be higher
than the load power, the voltage rise can
be very pronounced and exceed the limits
of the grid code. This could result in cur-
tailment as operators limit the amount of
power that can be injected into their grid
to maintain stability.
As an example of this challenge, let’s
consider a situation where plans have
been made to build a 6 MW wind farm
(3 x 2 MW turbines) in a rural area and
the local utility has received a request to
connect to the existing 20 kV grid with
these characteristics:
–– 4 x MV feeder lines
–– 48.4 km total grid length
–– 117 MV/LV substations
–– 10.3 MW maximum load
–– 6.9 MW maximum infeed
After analysis, the utility refused to make
the connection since the maximum infeed
voltage would rise above the permitted volt-
age band, even though the thermal load on
the cables remains uncritical.
There is now a ready answer to this
problem in the form of a line voltage regu-
lator (LVR) that effectively ‘recalibrates’ the
voltage to keep it within the allowed range
across the whole (LV and MV) distribution

18 abb.co.uk/ffwd Power Grids


grid. As the graph shows, installation of an
LVR in feeder 4 makes it possible to connect
the 6 MW wind farm with no reinforcement
of the MV distribution grid
An LVR can be installed at any location
on the MV or LV grid. It can regulate the
voltage on a single feeder or a bus with
several feeders. At the HV/MV substation,
the voltage adjustments made by the tap
changer on the transformer influence all
the MV and LV networks on its secondary
side, although voltage drop and rise can
be very different on individual feeders. It is
the same for regulated distribution trans-
formers, where voltage adjustments trickle
down to influence the LV grid.
When one feeder has a large amount of
infeed from generators, an LVR can decou-
ple it from the rest of the network. This
allows the operator to accept the incom-
ing power while staying within the allowed
voltage range.
LVR operation
An LVR works by creating an additional volt-
age that overlays the existing line voltage
to raise or lower it. The additional voltage is
coupled in through a booster transformer.
The variable voltage feeds in from the
line itself via a transformer with an on-load
tap changer (OLTC) in response to readings
from sensors on the primary and second-
Transformers
ary sides of the LVR. The OLTC adjusts the
voltage in steps to achieve +/- 10 percent
of the nominal voltage.
The basic design of the LVR was devel-
oped for long-term low maintenance
operation and high energy efficiency and
it has high short-circuit capability.
The OLTC has a linear configuration,
uses mechanical switches and introduces
resistors in the diverter. The switches allow
up to three million mechanical operations
without the need for maintenance. It is
integrated into an ABB RESIBLOC dry-type
transformer manufactured from cast resin.
Not only does this mean that all components
are free of oil, but it also eliminates any
risk of fire or explosion. ABB’s RESIBLOC
transformers also have the benefits of
high energy efficiency, offer high flexibility
for providing any tap configuration, are
mechanically very stable, are not sensitive
to rapid changes in load or temperature
and are qualified to temperatures as low
as – 60 ˚C.
Other equipment inside the LVR kiosk
or cabinet includes disconnecting and / or
earthing switches on the input and output
for a bypass in case of maintenance, current
and voltage sensors and a bypass switch.
Solving infeed problems
In many cases the main issue for connect-
ing renewables into distribution grids is not
the available capacity, but rather the need
to maintain the voltage within the allowa-
ble range. LVRs can overcome this problem
without the need for investment in expen-
sive grid upgrades. They are also flexible
as they can be relocated to an alternative
location should there be a change in the
needs of the grid operator.
In LV grids, an LVR can normally be
installed in a standard cable distribution
cabinet, usually without requiring the utility
to obtain special permission. This enables
a fast and simple deployment.
MV LVRs are installed in a concrete sub-
station, delivered by ABB fully assembled
and tested. Installation is straightforward as
only the MV cables need to be connected
to the integrated MV switchgear.
Power Grids abb.co.uk/ffwd 19
Microgrids

Innovative microgrid
solution for industrial
facility
Solar-diesel-battery energy solution provides continuity of power
supply for ABB’s premises in South Africa and helps reduce
carbon emissions.

20 abb.co.uk/ffwd Power Grids


ABB has commissioned an integrated
solar-diesel microgrid installation at its
96,000 square meter Longmeadow facility
in Johannesburg, South Africa. This facility
hosts ABB South Africa’s headquarters as
well as manufacturing facilities with around
1,000 employees. This is a world premiere
for the innovative solution with fully grid-
connected and off-grid functionalities
designed to maximize the use of renewable
energy and ensure uninterrupted power
supply. This helps to keep the lights on and
the factories running during any planned or
unplanned power outages on the main grid
supply. By integrating renewable resources
like sun, wind and hydro with energy storage
into the power grid, the potential loss of
power can be avoided.
Providing power shortage solutions
South Africa has the highest electricity
consumption in the sub-Saharan region
and demand continues to outpace sup-
ply. Uninterrupted power supply is critical
for Africa and is vital to maintain continu-
ous operation for the country’s commercial
industries and factories – even when the
local utility has to carry out load shedding.
Power shortages, fossil fuel price volatility,
environmental concerns and the increased
focus on renewable energy sources like
wind and solar, are leading to the search
for sustainable solutions. South Africa is not
alone when it comes to power shortages
and outages and several other emerging
economies in Africa, Asia, South America
and other parts of the world face similar
challenges. There are thousands of facili-
ties that could leverage such a microgrid
solution to address the matter.
“This innovative microgrid solution helps
address a real-world challenge by providing
stable and cost-effective continuity of power
supply while minimising environmental
Microgrids
impact,” said Claudio Facchin, President of
ABB’s Power Grids division. “Penetration of
growth markets like Africa and leveraging
innovative technologies like microgrids to
improve power reliability are key elements
of ABB’s Next Level strategy.”
Stabilising technology
As part of this innovative project, a compact
and versatile PowerStore battery-based grid
stabilizing system to address frequency
and voltage fluctuations has been used.
It also includes a Microgrid Plus energy
management system to manage the supply
of power and balance the fossil-fuel and
renewable energy sources in accordance
with loads, in a coordinated manner,
enabling access to utility grade power.
The 1 MVA/380 kWh PowerStore and
Microgrid Plus, together with a 750 kW
rooftop photovoltaic array have been add-
ed to the existing back-up solution at the
location to boost renewables and provide
continuity of supply during disruptions or
transitions from grid to island operation.
The Microgrid Plus System will ensure
efficient and consistent power flow man-
agement as it is a specially designed
distributed control system. This will reduce
consumption of grid electricity and fuel as
well as optimizing the use of renewable
energy. In addition, the modular Microgrid
Plus System guarantees optimum loading
and spinning reserve in fossil fuel gener-
ators as it is pre-designed for this type of
application.
The main purpose of the PowerStore
(a compact and versatile grid stabilizing
generator) is to protect the power sys-
tem against fluctuations in frequency and
voltage. It does this by rapidly absorbing/
injecting power. State of the art inverters
with virtual generator mode capabilities
have been deployed that make it possible
for the diesel generators to be switched
off for most of the time. The solution can
also ensure a smooth transition from grid
connected to island mode when there are
outages on the grid.
A cloud-based remote service system
will be deployed for the operations and
maintenance of the microgrid in keeping
with ABB’s Internet of Things, Services and
People (IoTSP) approach.
This environmentally friendly solution
contributes to a reduction of carbon emis-
sions as well as substantially reducing the
operational cost of the industrial complex
– CO2 emissions can be reduced by over
1,000 tons/year.
Power Grids abb.co.uk/ffwd 21
Power quality

22 abb.co.uk/ffwd Power Grids


ABB’s power quality
service ensures
smooth production at
UK automotive plant
ABB’s state-of-the-art active filters will eliminate potentially
troublesome harmonics from the site power supply at one
of the UK’s largest car manufacturing plants.
ABB is delivering a complete power
quality service to help maintain a clean
and reliable power supply for BMW’s
MINI Plant Oxford. The service started
with a comprehensive site analysis by
ABB’s Power Quality team to identify
the possible sources of harmful
harmonics and has now progressed to
the design, manufacture and installation
of 12 bespoke PQFM active filters to
eliminate harmonics before they can
cause reliability issues.
Plant Oxford is the birthplace and heart
of MINI production. Hundreds of MINIs
leave the plant’s assembly lines each day
destined for new owners in more than 110
countries around the world.
In common with many modern pro-
duction facilities, Plant Oxford uses a
wide variety of equipment such as electric
motors and variable speed drives (VSDs)
that present a non-linear load on the net-
work. This can result in the introduction of
potentially harmful harmonics that cause
voltage distortion leading to overheating of
cables, motors and transformers, damage
Power quality
each other out so that the feeding trans-
former sees a clean sine wave.
To meet the specific needs of Plant
Oxford, ABB’s UK-based Power Quality
team developed a bespoke 300 A rated
PQFM system housed in a cubicle manu-
to sensitive equipment, tripping of circuit factured by Rittal. The filter is operated by
breakers and blowing of fuses as well as the PQF-Manager, a simple, user-friendly
premature ageing of the installation. That is front panel module that offers direct con-
why APDS, the ABB Drives Alliance partner trol, programming, monitoring and network
that has supplied a large number of VSDs analysis capability.
for the site, called in ABB’s Power Quality The first eight PQFM units were installed
team to carry out the analysis to identify during the Summer 2016 shutdown and a
and eliminate harmonics before they can further four will be installed later in the year.
cause any issues.
ABB identified levels of harmonics, mainly
at the 5th and 7th levels, across the plant,
but especially at the paint shop. To return
the site supply to the level of harmonics
specified in the G5/4 standard ABB then
proposed a solution based on the state-of-
the-art PQFM active filter technology. These
filters continuously monitor the current in
real time to determine what harmonics are
present and then inject harmonic currents
into the network with exactly the opposite
phase. The two harmonics effectively cancel
Power Grids abb.co.uk/ffwd 23
Building information modelling
Substation
construction goes
digital with BIM
Leigh Turley, ABB Power Grids UK Engineering Manager,
explains how ABB is adopting Building Information Modelling
(BIM) for UK substation construction projects.
In May 2011, the UK Government published
the Construction Strategy aimed at ensuring
all its projects use collaborative 3D Building
Information Modelling (BIM) from 2016.
This was an integral part of a four-year
programme of sector modernization with
two key objectives:
–– Reduce the cost and carbon from
construction and operation of the built
environment by 20 percent
–– Unlock more efficient ways of working
at all stages of the project lifecycle
There are many definitions of BIM. It is
essentially about value creation by effec-
tive collaboration throughout the entire
life-cycle of an asset, underpinned by the
creation, collation and exchange of shared
3D models and intelligent, structured data
attached to them.
It’s important to remember that BIM is
about much more than just 3D CAD and
it’s not next generation technology, it is in
operation here and now. Other than pro-
viding a digital-tool set, BIM is not so much
something we use but more a working
24 abb.co.uk/ffwd Power Grids
philosophy based on information modelling
and information management in a team
environment.
There are various levels of BIM, and
to achieve its strategy, the government
requires construction suppliers tendering for
centrally-procured government projects to
be working at BIM Level 2. As a minimum,
they require fully collaborative 3D BIM
(with all project and asset information,
documentation and data being electronic).
This requirement has been introduced
to drive the adoption of BIM processes
throughout the public and private sector
to encourage benefits including:
–– Reduction in CAPEX, delivery and
operational costs
–– Reduced risk
–– Improved carbon performance
–– Predictable planning
While this requirement was introduced
initially for government projects, the benefits
of utilizing BIM Level 2 processes and
information management practices can also
be realised by private sector clients and
projects within the construction industry.
This means that Level 2 is the general
expectation for ABB’s UK substation clients.
It is becoming an important differentiator
on both project award and delivery.
We have adapted ABB’s approach to BIM
to suit the specific needs of substation pro-
jects. For example, not all our projects are
new build and many take place on existing
sites. This has called for the adoption of 3D
scanning technology to capture the details
of the existing structure so that they can
be converted into the site model. We are
also linking into the Primavera package for
effective scheduling as well as using BIM
to work collaboratively with all the project
stakeholders.
BIM offers a number of benefits for
substation projects including:
–– Accurate measurements of the site and
clearances
–– The capability to detect potential
clashes
–– Visualisation
–– Buildability reviews
–– Temporary works evaluation

BIM enables engineers to enhance substation design
–– Production of bills of materials
–– Improved efficiency and client value
–– Less waste and improved OTD (on
time delivery)
–– Support for the development of
RAMS (risk assessments and method
statements)
After reviewing a number of potential
systems, ABB is implementing BIM based
on a combination of the Autodesk Revit,
Navisworks and Primavera packages that
provides an intuitive approach that enables
multiple users to work on a single file
simultaneously.
Our first trial project with BIM was a
Bus Coupler replacement exercise at an
existing indoor 275 kV substation that was
carried out in parallel with a conventional
design scheme. A 3D scan of the structure
was carried out and delivered as a Revit
model available via webshare. Following
this, a Revit model was developed with
the replacement equipment and build
sequencing was applied in line with the
program and an animation produced.
The trial has proved to be a valuable
exercise that clearly demonstrated the pos­
Building information modelling
sibilities of BIM for providing total clarity
for all stakeholders on every aspect of the
project. It has also helped highlight some
of the challenges that BIM can pose – as
an example designers will increasingly be
required to not only draw a substation,
they will also need to develop a deep
understanding of the construction process
to feed the required information into the
model.
From ABB’s perspective, one of the
strengths of BIM is its ease of access and
transportability. The model can easily be
accessed on site using a laptop or tablet Modelling can be accessed on site via a laptop
to provide instant access to critical pro- or tablet
ject information. Furthermore, BIM is not
only about the construction process, it is
an effective approach to the management
of substation assets throughout their life.
We are working collaboratively within
ABB globally to develop the philosophy
further and to share knowledge across our
business units. We see BIM as a journey,
the philosophy will continue to evolve to
match our clients requirements and ABB’s
drive for innovation.
Power Grids abb.co.uk/ffwd 25
Asset management

AssetHealth Center
ABB’s AssetHealth Center (AHC) is a comprehensive intelligence
platform that embeds our unique engineering, equipment
monitoring and systems expertise. This helps establish end-to-
end asset management business processes for reducing costs,
minimising risks, improving reliability and optimising operations
across the enterprise.

Asset management today
The repair-and-replace needs of aging
assets can present significant challenges
for utilities and other asset intensive
organisations due to:
–– Financial pressures that limit
operations and maintenance resources
–– Loss of valuable knowledge as long-
time employees leave or retire
–– Aging fleets
–– An environment of increasing
regulation.
Together, these factors put utilities under
intense pressure to reduce inefficiencies and
eliminate unknowns. Meanwhile, improved
asset monitoring and communications
capabilities hold tremendous promise to
optimise operations; but they deliver such
an overwhelming flow of data that few com-
panies are able to put it to meaningful use.
The idea of the AssetHealth Center
is to utilise all this data for near real-time
performance analysis of assets from one
end of the enterprise to the other. This can
enable utilities to make thoughtful, strategic
and fiscally sound decisions about which
assets should be replaced, and when the
rest should be scheduled for maintenance
and repair.
This vision is difficult to realise. Typical
solutions lack the embedded industry
intelligence needed to turn data into the kind
of actionable knowledge that allows complex
integrated systems to be optimised. Analysis
of data is often done manually, a slow
process that strengthens functional silos
and leaves departments vulnerable when
key engineers retire or leave the company.
Until utilities address the issue of asset
health management systemically – with an
end-to-end solution offering the right combi-
nation of integration, embedded intelligence
and automation – they will struggle under
the demands of aging resources, stringent
regulatory environments and increasing
financial pressure.
The high cost of doing nothing
Most asset health management today is
conducted through a patchwork of routines,
assembled over time in the absence of a
comprehensive solution. These systems
have significant shortcomings for the
management of a vast network of assets:
Incomplete analysis: Fewer than half of
all transformer failures originate with the
insulation system. But asset management
systems typically look only at results from
oil sampling. Maintenance records, loading
history and tests of tap changers and bush-
ings may be overlooked because they are
hard to bring together. Critical repair-and-
replace decisions are based on information
that is most convenient – not necessarily
most meaningful.
Unrealized ROI: Smart grid investments
have created a flow of Big Data that internal
systems don‘t have the capacity to consider.
Reliance on instinct: The simple spread-
sheet is still the most common tool for
making maintenance and lifecycle deci-
sions that can cost millions of pounds
and directly impact reliability. Such manual
processes fail to exploit current technolo-
gy which automates and optimises asset
health decision-making.
Inability to adapt: Home built systems
struggle to evolve as technology and other
factors affect processes and best practices.
The results can be costly: from unplanned
outages to shortened asset lifecycles to
punitive penalties for lapses in regulatory
compliance.
Poor visibility: From the field force to facili-
ties management to engineering to IT to the
executive suite, each part of the organiza-
tion needs the right information presented
in the right way to do its job, and most sys-
tems struggle to meet this need.
Cumulatively, these deficiencies defeat
the impact of what today is often referred
to as asset health management. AHC
changes that.

26 abb.co.uk/ffwd Power Grids

 Asset management

Transformers
AHC

Data sources Extract, transform, Advanced business

Circuit breakers
Databases, historians load (ETL) and intelligence (BI)
SCADA, offline data, performance models solutions
Excel, CSV (comma – Business intelligence
separated value), model (BIM)
paper, etc

Actionable Continuous
AHC
Batteries intelligence feedback

Packaged subject-matter Enterprise Asset

specific expertise (SME) Management
and SME support (EAM) Solutions
– Thermal-winding risk
The AssetHealth Center aggregates data from
a variety of sources and applies advanced
– Short-circuit risk
business intelligence and analytics to power – Dielectric failure risk
a wide range of decision processes on a
single platform.

The AssetHealth Center addresses these
issues through a true convergence of OT
and IT. It integrates existing monitoring
infrastructure and systems with business
intelligence that transforms operational data
into actionable information. It offers a unique
and powerful combination of:
–– ABB’s equipment-based operational
technology (OT)
–– Enterprise information technology
(IT) from ABB’s Enterprise Software
product group
–– Embedded intelligence developed
over years by ABB in its role as an
automation leader in the world’s
electrical markets
–– ABB’s partnership with Microsoft,
which builds on analytics and cloud
capabilities.
From strategic repair-replace decisions
to such tasks as managing parts inventory
and scheduling maintenance activities,
AHC centralises and automates the jobs of
assembling relevant data, putting it into full
context to provide actionable knowledge,
and prioritising response.
Central to AHC is its ability to bring a
wide range of disparate asset information,
subject-matter expertise, and software
solutions into a unified cohesive system.
This unlocks the true value of smart grid
investments, captures and institutionalises
years of employee wisdom, and delivers
actionable intelligence to key stakeholders
across the business.
AssetHealth Center is fully scalable; it
can be implemented incrementally – begin-
ning with the utility’s own systems and best
practices.
Because it accepts data using emer-
gent communication standards designed
for advanced smart grid networks, AHC
avoids stranding assets – whether it’s SCA-
DA, an oil sampling system, or a monitoring
communications network – by allowing an
implementation strategy built around exist-
ing systems that function well, regardless
of their brand or manufacturer. And it can
be used to make even the most difficult
data accessible for the first time, such as
unified battery inspection records for com-
pliance reporting.
AssetHealth Center can transform
today’s utility from the inside out – providing
end-to-end visibility, understanding and
decision-support so every asset can be
managed at or near real time – and in the
context of what’s best for the entire network.
Benefits include:
–– Increased T&D system efficiency
–– Reduction in incidence and duration of
unplanned outages
–– Improved regulatory compliance
–– Optimised decision-making for repair-
replace activities
–– Improved return on smart grid
investments
–– Improved capital planning
–– Transition to a cost-saving predictive
maintenance strategy
–– Optimization of repair and maintenance
scheduling
–– Increased utilisation of data
–– Scalability to avoid stranding
assets and to enable incremental
implementation
–– Future-proofing to assure new assets
are managed from the beginning of
their lifecycle

Power Grids abb.co.uk/ffwd 27

HV service
Fast track transformer
replacement at Hinkley
Point B
ABB successfully completed a fix priced
contract to supply and install a new
transformer at Hinkley Point B nuclear
power station within the tight timescale
of a planned outage. During the project,
ABB’s round the clock working allowed
a challenging timeframe of 30-day
outage to be met.
During routine testing and oil sampling,
EDF Energy found that an existing 275/
11 kV station transformer at Hinkley Point
B nuclear power station would need to be
replaced.
However, the challenge was to carry
out the replacement in no more than 30
days during the power station’s planned
outage in January 2016. The outage for
the entire power station was set to be over
45 days but the transformer in question is
crucial for power generation, so EDF Energy
challenged ABB to completely replace the
transformer during a reduced outage of
only 30 days. The alternative approach
was a three-year wait until the next major
outage – but EDF was not willing to delay.
This meant that ABB had a major chal-
lenge ahead to compress its programme of
works. This would begin with dismantling
and removing the old transformer, followed
by replacing the Earthing Resistor and then
replacing fire detection pipework and 11 kV
cabling and of course installing and com-
missioning a new transformer that ABB
designed specifically for the application.
28 abb.co.uk/ffwd Power Grids
Critical asset
The transformer in question was Station
Transformer 3, which supplies the power
station, including the vital control and instru-
mentation systems that are required for
nuclear power generation. Its role meant that
it was essential to bring the power station
back online at the end of the major outage.
Transformer technology has developed
significantly since the original unit was first
manufactured by AEI. Because of this, ABB
designed the replacement transformer to
incorporate developments such as higher
efficiency, more monitoring capabilities, more
advanced cooling and greater reliability.
The new transformer is also different in
size – it is more compact. As a result, ABB
took extra care to perfectly line up the new
transformer’s terminations with EDF Energy’s
existing oil-filled cable sealing ends.
This was critical because any damage
to the cable sealing ends would not only
impact the outage programme for the trans-
former itself but also for the power station’s
major outage, potentially leading to loss of
availability for Hinkley Point B. Due to this,
ABB’s team took immense care to protect
the cable sealing ends.
Another challenge was the restricted
access that required a significant amount
of scaffolding.
Compressed working
ABB took several measures to replace
station transformer 3 within the 30 day
timescale, working with the EDF Energy
Investment Delivery organisation, site teams
and National Grid. Measures included
round-the-clock working as well as stringent
preparations, including partially building the
transformer in late 2015, long before the
outage. However, some operations were
delayed due to the emergence of further
challenges that arose during the outage
itself. These included restrictions on crane
work in windy, winter weather.
Robert Slinger, Operations Manager for
ABB’s Power Grids business said: “Every
day of lost generation costs EDF Energy one
million pounds. Due to our flexible working
approach and completion of pre-outage
preparatory work, we successfully replaced
the transformer at Hinkley Point B on pro-
gramme in 30 days. This allowed EDF
Energy to bring the power station’s gen-
erating equipment online.”
Planning crucial to success
The overall planning for EDF Energy’s out-
age dates back years. This is due to various
reasons – long lead times required for the
order, manufacture, factory acceptance
testing (FAT) and delivery of major plant
such as transformers, as well as detailed
programme planning and resourcing. EDF
Energy submitted its order to ABB for the
replacement Station Transformer 3 around
18 months before the planned outage.
 HV service

Station Transformer 3 supplies the power station’s control and instrumentation systems

Power Grids abb.co.uk/ffwd 29

Switchgear
PASS Multifunctional module to
provide 66 kV grid connection for
Blyth offshore wind farm
EDF Energy Renewables is pioneering
66 kV cable technology for the Blyth offshore
wind farm, with ABB’s innovative switchgear
module playing a key role in the onshore
substation. John Edwards, General Manager
HV Products for ABB in the UK, outlines the
background to the project.
30 abb.co.uk/ffwd Power Grids
EDF Energy Renewables has started
construction work on its new 41.5 MW
offshore wind farm off the coast of Blyth
in Northumberland. Onshore work on the
project is already underway, with offshore
construction work set to begin in 2017 to
install five turbines boasting a combined
41.5MW in capacity, although the pro-
ject has permission for a maximum total
generating capacity of almost 100 MW.
The power generated by the wind farm
will be exported to an electricity substation
at Blyth for connection to the National Grid.
The turbines will provide enough elec-
tricity to power the equivalent of 33,000
homes, and the project will feature a host
of new technologies designed to help bring
down the LCOE (Levelised Cost of Electric-
ity) for cost of clean power. For example,
new giant 8 MW turbines will be used.

Blyth Offshore could have an installed capacity of up to 99.9 MW
Switch to 66 kV
The most significant development is that
Blyth will be the first offshore wind project
to use 66 kV cable technology. Until now
the standard has been 33 kV, but the higher
voltage offers many attractions. Financially,
there’s lower CAPEX for inter-array collec-
tion infrastructure, potential to cut costs
by increasing the number of wind turbines
connected to a single array, less cable is
needed, and it’s possible to construct a
single platform to collect power from all of
the wind turbines in an array.
PASS MFM
The onshore substation will include the
first UK unit of an ABB 72.5 V PASS MFM
(Multifunctional Module). This is the latest
development in the well proven PASS (Plug
and Switch System) hybrid switchgear
concept. MFMs are compact multifunctional
modules that combine all these traditional
substations functions in a single compact
product:
–– High-voltage switchgear
–– Power transformer
–– Medium-voltage switchgear
–– Control and protection
The MFM concept offers major savings
in space to reduce the overall substation
footprint. It is also a very cost-effective
solution that enables significant reduction
in construction and engineering time as
the majority of the assembly and testing
is carried out at the factory. The module
is easy to transport using conventional
commercial vehicles and will be delivered
essentially ready to use, so that typically
site installation and commissioning can be
completed in around two weeks. As well
as saving costs, the reduction in on site
work also contributes to the safety of the
overall project.
High-voltage element
The high-voltage part of the MFM is based
on the PASS family of hybrid modules. The
term ‘hybrid’ indicates the combination of
a traditional air-insulated switchgear (AIS)
and SF6 gas-insulated module (GIS) to
take advantage of both of these different
technologies.
This hybrid solution utilizes a conven-
tional and very reliable AIS busbar.
Switchgear
All functions (with the exception of ring-
core current transformers) are integrated
into a single SF6gas-insulated enclosure:
–– circuit breaker
–– disconnector
–– earthing switch
–– cable terminals
–– voltage transformer
This compact design can save up to
70 percent of the space necessary for an
equivalent AIS bay. The flexibility of the PASS
is unmatched in the field of high-voltage
switchgear and this important characteris-
tic has enabled modular integration of the
PASS with the power transformer which
led to the MFM concept.
Shunt reactor
In addition to the PASS MFM, ABB will
supply, install and commission a 1000 KVAr,
66 KV shunt reactor to act as an absorber of
reactive power, thus increasing the energy
efficiency of the Blyth system.
Power Grids abb.co.uk/ffwd 31
Energy strategy
Flexibility for a secure
energy future
Peter Jones, ABB Technology Strategy
Manager.
The UK’s power industry is entering a period
of dramatic change. Around two-thirds of
our existing power stations are expected to
close down by 2030 as older coal, nuclear
and gas fired plant reaches its end of life.
At the same time, the quest to decarbon-
ise generation and embrace renewables is
Energy storage is an integral element of the microgrid deployed for AusNet in Australia
32 abb.co.uk/ffwd Power Grids
driving a shift from the traditional ‘top-down’
model of power generation, transmission
and distribution to one where generation
resources are diverse in both nature and
capacity, widely distributed, increasingly
intermittent and counted in the thousands
rather than the hundreds. We will also see
significant increases in the demand for
electricity as new sectors such as heat and
transport switch to electrification.
Achieving these profound changes
demands previously unheard-of levels of
system flexibility to allow both demand
and supply to react to changes in power
generation and consumption. The ability to
ensure continuity of supply at the correct
voltage and frequency in this increasingly
complex and unpredictable environment
will be a key challenge for power network
operators.

The recently published ‘Smart Power’
report from the Infrastructure Commission,
together with Ofgem’s 2015 position paper
‘Making the electricity system more flexible
and delivering the benefits for consumers’
sets out the challenges – and opportunities
– facing the UK power industry very well.
They highlight the three key areas in which
the UK needs to innovate over the coming
decades in order to take full advantage of
what it calls the smart power revolution:
interconnection, storage and demand
flexibility.
Interconnection
As an island nation, the UK does not
currently have the number of power inter-
connections enjoyed by our continental
neighbours – with a total capacity of just
4 GW, around 5 percent of total generation
capacity. However, by the early 2020s this
should reach over 11 GW with new connec-
tions to France, Norway, Denmark, Ireland
and Belgium helping to balance supply and
demand and manage consumer costs.
Energy storage
Energy storage is highlighted as a key area
for attention. As the UK’s rotating power
reserve is lost with the decommissioning
of large, centralised power stations, energy
storage solutions will be vital to maintaining
grid frequency and voltage levels within man-
dated tolerances. Here, regulation will play
a vital role in ensuring a level playing field
between generation and storage.
In addition to helping reduce the impact
of peak demand, storage has the potential to
ease constraints on grids, possibly enabling
the deferment of major investments in
network reinforcement projects. Storage can
also provide demand for generation sources
Energy strategy
during periods of low demand, putting an
end to the curtailment of wind farm output
that currently costs £90 million a year.
Flexibility for local balancing
When it comes to demand flexibility, a whole
raft of sophisticated energy management
solutions are coming on stream that will
help enterprise and residential consumers
optimise their electricity usage in ways that
both reduce overall costs as well as enabling
the local balancing of supply and demand.
Traditionally, power network operators
have had the flexibility to balance supply
and demand mostly through controlling
the output of large, centralised generation
resources in real time. As we make the shift
towards a far greater number of smaller,
distributed generation resources, with a
far greater proportion of renewable energy
sources, balancing supply and demand
becomes a much more complex challenge.
Demand flexibility covers a broad range
of activities that can help reduce or shift
demand for electricity during peak periods.
They include adjusting the consumption of
electrical appliances or other facilities or
deploying off-grid sources of power. There
is major potential to allow residential and
business consumers to change the way
they use electricity. Steps have been taken
with the rollout of smart meters. But there
is still a long way to go. As an example of
what can be achieved, demand flexibility is
already enabling countries such as Australia
and the US to meet up to 15 percent of
their peak demand for electricity.
Third party aggregation
Flexible distribution networks will enable
consumers, generators and storage
providers to provide flexibility through an
intermediary, combining their outputs to
meet the requirements of anyone who
needs to purchase flexibility anywhere on
the system. Taken to its logical conclusion,
the future power network may well be
a collection of many semi-autonomous
micro- and nano-grids with the capability
to connect to the national grid or to make
a seamless transition to islanded operation
as required.
What is clear from the reports is that
there is a significant opportunity for the
UK to embrace flexibility, especially as we
are a world leader in the data analytics and
software development vital for the seamless
management of energy supply and demand.
Power Grids abb.co.uk/ffwd 33
Health and safety

Site team shines

like a beacon
A site team with members from
ABB and project partners London
Underground (LU) and Industrial
Switchgear Services (ISS) was given a
Beacon award on 11 August.

The Beacon awards are LU’s scheme Beacon site and team awards have a
for recognising good practice in site stringent assessment process. The team
management and they recognise five award involves a five-step assessment
elements of construction that make the process including an initial self-assessment
work of individual contractors or projects by the construction team, two assessments
shine like a beacon. The elements are at different site locations, a joint construction
consideration, environment, cleanliness, and HS&E assessment and a formal
safety and health, and management independent HS&E Beacon assessment.
and values.
Mark Logue (ISS Site Manager), Mike Gambe
ABB’s site team was working along- (ABB Project Manager), Chris Tong
(LU Head of Power and Cooling), Keith Parker
side LU’s Power and Cooling team to
(ABB Operations Manager), Vanessa White
install high voltage and fibre optic cabling, (ABB HSE Manager) and Mark North
switchboards, remote terminal units (LU Project Manager)
(RTU), batteries and chargers at Mile End
Substation.
The work formed part of LU’s Sub-
Surface Railway Package 5B, which is part
of an overall power supply upgrade. It will
support the introduction of 192 brand new
air conditioned trains on the Circle, District,
Hammersmith & City and Metropolitan lines
by the end of 2016.
LU’s Power Project Manager Mark North
said: This award win for the team is a great
example of demonstrating our collaborative
commitment to health and safety. There are
many benefits to achieving a Beacon award
and improved site morale and working rela-
tionships is just one of them.”
ABB’s Operations Manager Keith Park-
er said: “We’re delighted to achieve this
award alongside the Power and Cooling
team. It really emphasises our close work-
ing relationship with everyone involved and
demonstrates what we can achieve when
we work together as one team.” The power upgrade will support new air-conditioned rolling stock on the sub-surface lines

34 abb.co.uk/ffwd Power Grids


Low Carbon Networks & Innovation
11 - 13 October 2016
Manchester Central
Exhibition Opportunities
ABB experts will be on hand at the Low
Carbon Networks & Innovation (LCNI)
Conference in Manchester on 11 – 13
October. The event is organised by
the Energy Networks Association as a
forum where leaders and experts from
the power industry can explore the lat-
est developments in transmission and
distribution.
ABB is delivering three partnerships
under Ofgem’s Network Innovation initia-
tive. The first of these is Electricity North
West Limited’s Respond project, which is
IET Innovation Awards
As a sponsor of the IET Innovation
Awards, ABB is looking forward to the
12th annual awards event, to be held on
16th November at The Brewery, London.
ABB sponsors the Sustainability cate-
gory because it is closely aligned with
ABB’s vision of ‘power and productivity
for a better world’.
The evening awards event follows imme-
diately after the IET Achievement Awards, a
daytime event that celebrates the achieve-
the first UK adoption of the Is-Limiter, the
world’s fastest fault current limiting and
switching device.
The second project is the FITNESS
(Future Intelligent Transmission Network
Substation) project with SP Energy Net-
works, which will be the first substation
to be equipped with fully integrated digital
protection and control systems.
Lastly, Western Power Distribution’s
Network Equilibrium project will see ABB
deploy a back-to-back power link that will
balance power flows between distribution
networks.
ments of young engineering apprentices and
technicians. ABB’s apprentice Josh Barber
will be a finalist at the Achievement Awards.
David Hughes, Managing Director for
ABB’s Power Grids division will be present-
ing the sustainability award on the night and
said: “I am very much looking forward to
hearing the winner announced on the night
and being inspired by them. Past winners
Events
Peter Jones, Technology Strategy Man-
ager for ABB’s Power Grids Division said:
“We’re attending LCNI because it’s a great
opportunity to talk about how we can apply
the latest ABB technologies to help devel-
op flexible power networks that support
the UK’s low carbon future. We are one of
the few exhibitors at the event to be able
to demonstrate three Innovation Technol-
ogy Partnership projects.”
range from the solar desalination system
for producing drinking water that won in
2015 to a pilot system for energy storage
using liquid air.”
Award winners at the 2015 IET Innovation Awards
Power Grids abb.co.uk/ffwd 35
 Active Filters. Improved power quality combined
with efficiency and cost savings.

ABB’s PQF (Power Quality Filter) range of microprocessor controlled active filters is
designed to address the growing challenges of harmonics in low voltage electrical
networks. They help improve power quality, enhance efficiency, provide transient free
reactive power compensation and facilitate load balancing. Direct benefits include
increased capacity, minimal down-time, reduced running costs, equipment protection
and mitigation of emissions. ABB is a technology leader with a wide range of
products, systems and services that improve power quality including capacitors and
filters, power electronics-based compensators and software solutions, across the
power value chain for low, medium and high-voltage applications, helping to shape a
stronger, smarter and greener grid. www.abb.co.uk

ABB Power Quality

Tel. +44 (0)151 357 8400
E-mail: abbep@gb.abb.com