issue 4 / 2003 the abb india magazine · 2018-05-09 · (ntpc) substation and tarapur (npcil)...

Issue 4 / 2003

The ABB India Magazine

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CONTACTEditorial Team: Harmeet S Bawa, Vikram V Kanth, Namita Asnani,Pavithra Noel.

ABB Limited, GF-Corporate Communications, IndiaKhanija Bhavan, 2nd Floor, East Wing,49, Race Course Road, Bangalore - 560 001.

All trademarks acknowledged.Design: Shilahar Associates, Bangalore. www.abb.com/in

Issue 4 / 2003India Round-up

ABB India books significant MV switchgear4orders from northern state utilities

PGCIL entrusts ABB with another substation project4

Transformer Power5

ABB to partner ONGC for training in high voltage technologies5

Distribution Automation – be part of the6Hyderabad-Secunderabad SCADA experience

Generating Wind Power !8

HV circuit breakers – a big ‘HIT’ !8

Indian Oil goes for ABB analytical products9

Building solutions for Pharma and Biotech9

Peter Smits on how state-of-the-art power technologies10can improve grid reliability

Global Round-up

GIS Substations to boost energy supply in 14Sri Lanka and Saudi Arabia

ABB strengthens reliability of U.S. power supply 15

Technology Digest

DesignIT - Transmission System Configurator 16

Living our commitment to Sustainability 20

Channel Line 21

Q&A 22

Dear Friends,

At the outset, I would like to take this opportunity towish you all a very happy and prosperous new year !

Thanks to the confidence reposed by our valuedcustomers in ABB’s technologies and domaincompetence, we booked several interesting orders,both in the domestic and export markets, building onour strategic focus areas i.e. value-enhancing projects,standard products, service and exports.

On a macro level, the Indian economy picked up growth momentum. Agriculture saw a resurgence.The industrial sector showed signs of revival and is increasingly focusing on productivity andefficiency by leveraging automation technologies as Indian manufacturing strives to achieve worldstandards for global competitiveness.

Power sector reforms, especially in Transmission & Distribution (T&D) are gaining momentum withthe implementation of APDRP (Accelerated Power Development and Reform Programme), thepassing of the Electricity Act, the corporatisation and privatisation of SEBs and increasing focus ondistribution system improvements. This is, of course, only a beginning and we still have a long way togo, in terms of upgrading our T&D network, building a national grid, reducing techno-commerciallosses, rationalising tariff structures and developing our distribution system. Technology will be a vitalfactor in improving the availability and quality of power and ABB as a globally recognised leader inthis sector, shall continue to play a key role in bringing ‘power to the people’ !

In this issue of CONTACT, we focus on Power Technologies where ABB serves electric, gas and waterutilities as well as industrial and commercial customers, with a wide range of product, system andservice solutions for power transmission and distribution. Amongst other features, you will readabout some of the grid challenges faced by the sector, even in the most developed countries of theworld and the technologies on offer to tackle these issues. You will also read about how SCADA(Supervisory Control & Data Acquisition) systems are helping to monitor and control power inHyderabad-Secunderabad.

We, at ABB, remain committed to continue on the path of developing innovative technologies inorder to deliver even greater value to our customers, making them more efficient, productive andcompetitive. In 2004, you shall see many new product ranges from ABB as we expand our portfolioof offerings across the value chain, both in power and automation technologies. We are alsoenhancing capacities, where required, in order to shorten lead times and further speed up thedelivery process. At the same time we shall continue to strengthen our channel partner networkand build on our e-business initiative.

We look forward to your continued support and collaboration in working together, for a ‘better’and ‘brighter’ tomorrow !

Yours sincerely,

Ravi UppalVice Chairman & Managing Director, ABB India

CONTACT – The ABB India Magazine 3

CONTACT – The ABB India Magazine4

ABB India has booked a significant order forindoor switchgear panels with vacuum circuitbreakers from Punjab State Electricity Board(PSEB), Punjab’s leading distribution utility. Thescope of the order includes 420 Unisafe panelswith VD4 circuit breakers.

The VD4 circuit breaker is used in powerdistribution systems for the switching and protectionof cables, overhead lines, distribution andtransformer substations, motors, transformers,generators and capacitor banks. UniSafe is amedium voltage, metal-clad switchgear made ofaligned standard units. Metal sheets segregate eachcompartment and the energised components are airinsulated. These arc-proof units have been tested incompliance with the latest international standards,and also comply with the ABB IndustrialIT

architecture, as part of the PowerIT suite.

ABB India books significantMV switchgear orders fromnorthern state utilities

The UttaranchalPower CorporationLtd (UPCL), anotherlarge state utility inthe north, also placeda similar order withABB for 161 Unisafepanels with VD4 circuit breakers. ABB assisted thecustomer in arriving at the technical solution toinclude a higher basic insulation level (35kV/95kVpinstead of normal 28kV/75kVp) required to suit thehigh altitude application in the hilly state, andswitchgear that is internal arc tested, thus offeringa higher degree of safety and protection to theoperating personnel and surrounding equipment.

Technology, reliability, safety, protection, qualityand competitiveness were the critical factors thatled to ABB’s success.

Power Grid Corporation of India Limited (PGCIL)has entrusted ABB with a turnkey project for a400 kV substation at Boisar in Maharashtra. Thescope of the project includes the design,engineering, manufacture, testing, supply, andcommissioning of the substation. ABB will supplynine 400 kV bays and eight 245 kV bays, 400 kVand 220 kV circuit breakers, instrumenttransformers, control and relay panels, and otherassociated systems for control, illumination, firefighting, air conditioning and ventilation.

The site is located at a coastal area and ABB isamong the few manufacturers in India to havefully type-tested HV equipment to deal with suchclimatic conditions.

One of the highlights is the supply of HVequipment with 31 mm/ kV creepage distance asagainst a normal requirement of 25 mm/ kV forinsulation. The special HV equipment including

PGCIL entrusts ABB withanother substation project

Circuit Breakers,CurrentTransformers andCapacitive VoltageTransformers issuitable for ‘VeryHigh Pollution Severity Levels’. ABB will alsodismantle and reinstall Power Line CarrierCommunication (PLCC) equipment at the Gandhar(NTPC) substation and Tarapur (NPCIL) switchyard.

ABB is also setting up a 400 kV Greenfieldsubstation at Vapi, Gujarat. These two substationswill serve to evacuate power from the TarapurAtomic Power Project in Gujarat.

ABB has previously executed similar projectsfor PGCIL at Jeypore, Vindhyachal (Satna and Binasubstation), Jallandhar and Tivim Ponda substationsand has a long-standing relationship with PGCIL –India’s premier transmission utility.

India Round-up


Transformer PowerABB India’s state-of-the-art power transformermanufacturing facility at Vadodara recently rolledout its 400 kV transformer as part of an order fornine 154 MVA 11/420 kV generator transformers,placed by the Narmada Hydro ElectricDevelopment Corporation Limited. These will beinstalled at the 1000 MW Indira Sagar hydelpower project site in Madhya Pradesh. ABB’sscope includes design, manufacture, supply,erection and commissioning.

The Vadodara facility is also supplying seven200 MVA, 400 kV HVDC Converter Transformersfor PGCIL’s HVDC back to back project atVisakapatnam to facilitate power transfer betweenthe Eastern and Southern regions.

ABB transformers are designed using its patentedTrafoStarTM concept and are built from standardised,high quality components and modules, ensuringhigher reliability and dependability.

Recent export successes from the Vadodarafacility to developed countries as far afield as USA

bear testimony to the quality ofthis unit’s products. These include the export ofthree units of 87.5 MVA 138 kV for a wind farmapplication in USA set up by Florida Light &Power. Other significant export orders in handinclude units for Syria.

ABB is also executing 400 kV transformer ordersfor Gujarat Electricity Board, AP Transco andPower Grid Corporation Limited. The local marketresponse has been extremely encouraging.

ABB to partner ONGC for training inhigh voltage technologies

This programme willbe conducted at ABB’smodern powertechnologies trainingcentre at Vadodara.The training willcomprise sessions onbasic engineeringprinciples, productdesign & functions,troubleshooting, maintenance, erection andcommissioning. The training is aimed at helpingthe engineers minimise downtime, maximise assetproductivity and reduce life-cycle costs.

With over 1,500 mandays of training alreadyconducted since its inauguration in May 2003, thiscentre with state-of-the-art facilities for classroomand hands-on training is proving to be extremelypopular with customers and ABB employees.

Oil and Natural Gas Corporation of India (ONGC)has engaged ABB to conduct a comprehensivetraining programme on high voltage products likecircuit breakers, current and capacitor voltagetransformers, and protection and relay schemesfor its field engineers.

ONGC officials at the training centre


Distribution Automation - be part of theHyderabad-Secunderabad SCADA experience

Some may consider this a tall order - anintegrated Power Distribution Management System,networking 106 stations, spread over 1,500 sq kms –centrally controlled, monitored and operated,serving 1 million consumers across the twin citiesof Hyderabad and Secunderabad in AndhraPradesh, one of India’s most progressive and ITsavvy states !

This was the vision of Andhra Pradesh CentralPower Distribution Company Ltd (APCPDCL), theleading distribution utility in Andhra Pradesh. ABBset out to make this vision a reality by bringingthe latest in power distribution managementtechnology in the form of a state-of-the-art SCADA(Supervisory Control & Data Acquisition) systemto monitor and control the power distributionnetwork for the twin cities of Hyderabad andSecunderabad – a project funded by theDepartment for International Development (DFID)UK, under the Andhra Pradesh Energy Efficiencyproject (APEEP). A similar solution has also beenimplemented by ABB for TNEB to coverelectricity distribution for Chennai city at almostthe same time. ABB has successfully deliveredseveral such systems all over the world giving thecompany an unparalleled domain expertise and

in-depth knowledge with access to the latestsolutions and technologies for Utility Automation.

The APCPDCL project scope encompassed design,supply, erection and commissioning of the SCADAsystem with a control centre at Erragadda,Hyderabad for 132 kV and 33 kV substations inand around Hyderabad and Secunderabad. Thesystem facilitates collection of all relevantinformation from these substations to be sent tothe central computer system installed at the centralcontrol room across a TDM/TDMA backbone overdigital UHF data radios.

In brief, the system provides for effectivedistribution management to improve theavailability and reliability of power, enableeffective load management, reduce restorationtimes in case of outages and to increase theutilisation efficiency of the network equipment.Interruption in any part of the system is reportedinstantaneously through the field devices overmicrowave radio network to the central stationwhere appropriate decisions can be taken quicklyand transformed into action, remotely.

Hon. Chief Minister of Andhra Pradesh, Mr. Chandrababu Naidudelivering the keynote address on the inauguration of the ABB SCADAsystem – an integral part of AP’s distribution system improvement


APCPDCL, Director Operations, Mr G. VinayaKumar shared with us the Hyderabad-Secunderabad SCADA experience so far andsummed up the key benefits of the system in afew succinct points:

– Efficient Distribution and load management ismade possible at a single point as a result ofautomation and substation integration

– Fault detection and analysis is made a lot easierand faster due to availability of real timeinformation

– Prompt and quicker restoration of powersupply in case of outages

– Two years reference data can be stored forfuture analysis

– Stations can be operated as minimal or asunmanned substations

– Load shedding, if required can be programmedin a systematic manner during shortages orexigencies

– System monitoring enables greater grid disciplineand economy in the present regimes of ABT

– Speed of decision-making is significantly increased

On a macro level, this SCADA system facilitatesoptimal allocation of resources, yielding benefits interms of increased availability, higher up-time andquality of power, helping us to serve our consumersmore efficiently. It also helps us to minimisedowntime from outages, by providing real-timeaccess to vital system parameters – closer monitoringand control enables timely, preventive actions andfaster restoration. Load shedding, if required, can alsobe programmed in a systematic manner, reducingthe risks of cascading, grid collapse and blackouts.The system offers operational advantages byintegrating distribution automation functionalities likeautomatic / remote meter reading, load balancing,trouble call management etc. to facilitate effectivedistribution management – this will further help uswhen we move to ABT (Availability Based Tariffs).

Another important feature for us is the remotemetering capability. We are, at present remotelymetering more than 600 locations, across fivedistricts outside Hyderabad.

One of the major benefits we see from theSCADA system is the ability to closely monitor andtherefore control our feeders’ load and this is ofeven greater significance in case of allocated ruralsupply. This helps prevent wastage, overloadsand overdrawing, thereby improving griddiscipline and preventing cascading problems.Our T&D losses are coming down, as we gaingreater grid control and plug techno-commerciallosses. In turn, our consumers benefit from higheravailability and quality of power and we are ableto charge reasonable tariffs.

Power sector reforms, especially in Transmission& Distribution are gathering pace and AndhraPradesh is at the forefront. The Accelerated PowerDevelopment and Reforms Programme (APDRP) ismusic to our ears and we have identified andplanned several projects, related to distributionsystem improvements. Our priority areas includethe reduction of techno-commercial losses, betterload management and grid discipline,strengthening of transformers - especially in ruralareas and increasing the overall financial viabilitythrough a more balanced rural-urban approach.We must not forget the rural areas, regardless ofthe commercial angle. In any case, experiencetells us that consumers, including farmers, arewilling to pay a reasonable price for availability ofquality power. The villages are also our childrenand agriculture plays a vital role in our economy.In fact, in Andhra Pradesh, it is the dominantsector with nearly 2.4 million pumpsets – thehighest in any state in the country !

As we move ahead, technology will continue toplay a vital role in the delivery of quality power,as the Indian power sector reforms gather paceand we upgrade and modernise our network forhigher system reliability and efficiency.


ABB’s LV motors manufacturingfacility at Faridabad recentlyrolled out its first 250 / 60 kWdual speed wind generator aspart of an order received fromthe Natural Energy ProcessingCompany (NEPC), Chennai.

ABB will design, manufactureand supply custom-madegenerators, made fromstandardised, high qualitycomponents and modulesensuring reliability andflexibility. What’s more, theycome with powerful softwarefor easy operation, and arebased on ABB’s “M2000”concept.

The initial order was followedby an order for another 50generators, reaffirming NEPC’s

Generating Wind Power !

faith in ABB technologies.These generators will bethe first in their range tobe produced from theFaridabad facility.

ABB India has successfullyimplemented a 24x7 e-businessordering and tendering systemfor front-end sales managersanywhere in the world for HVCircuit Breakers (type ED,52-84 kV). This is an integralpart of HITS (High VoltageInformation & TenderingSystem) being implemented ona global scale within ABB.

With the implementation of thissystem, customers stand tobenefit in terms of quickerresponse times and improvedaccuracy in tendering and orderbooking as HITS is integrated tothe Enterprise ResourcePlanning (ERP) system in real-time – for product configurationand order booking. This

HV circuit breakers – a big ‘HIT’ !

translates to improved speed,transparency and efficiency.

Customers can also obtain real-time information like orderstatus, delivery schedules etc.


Indian Oil Company (IOCL) has placed an order onABB for a complete analytical package for itsPanipat refinery expansion project related to theDiesel Hydrotreater (DHDT) and HydrogenGeneration (HGU) Units. The scope of the orderincludes explosion proof analysers, shelters withHVAC for hazardous areas, gas chromatographs andother stack analysers for measuring stack emissionfor monitoring and controlling pollution levels.

ABB is also working on another order for IOCL,Panipat related to their Purified Terapthalic Acid(PTA) plant.

This turnkey PTA analytical package includessupply and integration of analyser, shelters, HVACsystems, various analysers for the measuring ofsulphur dioxide, nitrogen oxides, carbon dioxideand oxygen and include analysers for water, totalorganic carbon, pH, conductivity, dissolved oxygen,dew point, etc.

Indian Oil goes for ABB analytical products

Building solutions for Pharma and Biotech

ISHRAE organised a seminar on ‘Emerging Trendsof HVAC in Pharma & Biotech Industry’ inAhmedabad recently. Eminent industry players fromthe Pharma and Biotech industry attended theseminar including consultants and other HVACrelated industrial experts.

ABB offers a complete range of solutions includingdesign, engineering, supply, erection andcommissioning of Heating, Ventilation, Air-conditioning (HVAC) systems to meet specific

customer requirements for accurate monitoring andcontrol of temperature, relative humidity, pressuredifferential, carbon dioxide, noise levels, etc.

ABB’s project execution capability is in accordancewith GEP / GMP – a benchmark for globalstandards; and also offers all necessary support anddocumentation, to suit customer requirements, forvalidation by global agencies like ISO14644, US-FDA, UK-MCA, SA-MCC.

What, in your opinion were the major causes ofthe recent blackouts and grid failures acrossAmerica and Europe?

The main reason for the mid-August blackout in

eastern U.S. and parts of Canada was the gradually

increasing overload of the transmission grid.

While investment in the U.S. has dropped from

US$ 5 billion in 1975 to US$ 2 billion in 2000, the

load on power grids has grown fourfold in the past

20 years.

In Europe, deregulation and liberalisation have

also led to increased power trading and many

existing power grids were not originally

constructed to cater to huge cross-border power

exchanges. This and integration of other additional

capacities place an excessive burden on the

power grids. National and cross-border power

exchange still faces serious bottlenecks – and

every bottleneck carries the risk of power failures.

To counteract the stress on the grid, we need even

more interconnections, which allow for smoother

and more efficient power trading.

On a macro level, what are the commonproblems being seen by the grids andwhat should be their overall approach tosolve them?

Prior to the liberalisation and deregulation of

power markets, utilities focused on investments

that increased the reliability of their grids and the

availability of power. Liberalisation has, to an

extent, led to additional cost pressures and

hampered new investments. Deregulation in many

countries has led to the creation of an open

market and at times, this underestimates the risk of

voltage instability. If power is transmitted over

long distances, one has to ensure voltage stability

and mitigate reactive power flow. The lack of

efficient interconnections jeopardises this. A

dramatic increase in congestion arises when

transmission line capacities cannot cope with

energy flows.

Quite simply, less focus on reliability, and the

lack of incentives for investments in power

transmission has led to the increasing vulnerability

of the grids.

From a macro point of view, we need a

harmonised regulatory framework that boosts

investment in transmission and distribution to

ensure grid reliability. National regulators should

establish quality standards for power supply.

In particular, we need measurements for power

reliability and security, as well as mechanisms

to enforce compliance.

It is reasonable to believe that the blackouts will

place an added emphasis on the need for

interconnection capacity to enhance the security

of supply. From a technology point of view,

regulators should give special incentives to

solutions that offer fast implementation and

increase the robustness of the transmission grid,

e.g. those that improve voltage stability and

increase grid reliability.

Peter Smits on how state-of-the-art powertechnologies can improve grid reliability

Peter Smits, Head – Power TechnologiesDivision worldwide, Member – ExecutiveCommittee, ABB Group and Chairman –ABB India.

Peter Smits travels the world and meetsvarious utility customers, and understandsthe changing face of power networks to seehow ABB’s Power Technologies offering cancontinue to make a difference !


What technological solutions are available toremedy such blackouts and what role cancompanies like ABB play?

The performance and reliability of the

transmission grid can be enhanced speedily with

the application of proven new technologies,

which also have significantly lower environmental

impact, smaller footprints and are extremely

flexible in their

operation, compared to

conventional ways of

upgrading the grid with

overhead lines.

Today you have

technologies like HVDC

transmission and power

electronic systems that

allow power flow across

regions without

troublesome ‘loop flows’

while providing support

and performance

enhancement for the

surrounding AC

(Alternating Current)

grid. HVDC links also

have built-in overload

control and can be

loaded fully without

increasing the risk for

cascaded line tripping.

Hence, HVDC addresses two issues at the same

time – it increases grid reliability and allows

power trading across grids. You also have HVDC

Light and this latest technology offers enhanced

voltage control and black start capability in

addition to the benefits of traditional HVDC.

Another recent technology offering is FACTS

(Flexible AC Transmission System). FACTS

devices, such as Static Var Compensators (SVC)

and Series Capacitors, enable more power to flow

on existing power lines and also improve voltage

stability. They make the system more resilient to

“system swings” and disturbances. Incidentally,

ABB is implementing the first FACTS solution in

India for Powergrid, between Raipur and

Rourkela, and this is only the second such

installation in Asia. Real-time Wide Area

Monitoring and control of power systems allow

grid-wide monitoring and control of the power

flows, transmission limit calculations and power

plant operation. Advanced control systems, system

protection, communication and automation

applications can significantly improve the capacity

and reliability of the existing system.

ABB offers the above

as part of its Power

Technologies portfolio

and the company is

recognised as a global

leader based on its range

of offering in terms of

products, systems and

services and the

unparalleled domain

expertise and worldwide

experience. ABB’s

investment in R&D and

commitment to innovation

ensures state-of-the-art

technologies to help

utilities in finding

comprehensive solutions

for their transmission and

distribution needs - not

just for the present but

keeping in mind the

future.

What are the lessons, especially for fastdeveloping countries like India?

In my opinion, the emphasis should be on

developing a modern transmission and distribution

network, leveraging the latest technologies, in

order to minimise T&D losses, increase system

efficiency and prevent cascading problems. This

includes replenishment of aging and inefficient

equipment and ensuring quality by strictly

avoiding substandard products. Moreover, it is

important to ensure grid discipline and incorporate

adequate safety measures. Countries like India,

who are in the process of strengthening their

power infrastructure, must learn from recent

experiences around the world and focus on

prevention rather than the cure !


120 years of technoThe history of ABB goes back to the late 19th century and is an illustrious r

technologies during its 120 year heritage, the constant quest for innovatio

1883Ludvig Fredholmestablishes ElektriskaAktiebolaget inStockholm asmanufacturers ofelectrical lighting andgenerators.

1889Jonas Wenströminvents the three-phase system forgenerators,transformers andmotors.

1890Elektriska Aktiebolagetmerges with Wenströms &Granströms ElektriskaKraftbolag to formAllmänna SvenskaElektriska Aktiebolaget,later shortened to Asea.

1988Asea and BBC mergeto form Asea BrownBoveri Ltd (ABB) -one of the largestelectrical engineeringcompanies in theworld

1974Asea invents andlaunches one of thefirst industrial robots.In 2002, ABBbecomes the firstindustrial supplier todeliver 100000robots.

1984Installation of the firstof nine BBCgenerators for theworld’s largesthydroelectric powerstation at Itaipu inSouth America.

1953Asea is the firstcompany in the worldto manufacturesynthetic diamonds.

1954Asea supplies the firstHigh-Voltage DC(HVDC) transmissionsystem in the world,linking the Swedishmainland and theisland of Gotland inthe Baltic.

1960sAsea builds the firstnuclear power plant inSweden and goes onto build nine of thecountry’s 12 reactors.

1901BBC builds the firststeam turbine inEurope.

1932Asea builds theworld’s first self-cooling transformerand expands its fanbusiness by acquiringAB SvenskaFläktfabriken.

1933BBC obtains a patentfor turbine rotorsconstructed ofindividual steel disksthat are weldedtogether.

1998ABB acquires ElsagBailey ProcessAutomation, tobecome the marketleader in the globalautomation market.

1999ABB divests itsnuclear power, powergeneration and railbusinesses.

2001Specific customerdivisions are formed.ABB lists on the NewYork Stock Exchange.Ranks number one inDow Jonessustainability index forthird year in a row.


ological leadership !record of technological leadership. With a legacy of having pioneered manyon continues – reflecting a ‘pioneering spirit’ that gives wings to dreams...

Divisional structure is streamlined tofocus on two core areas of business:Power Technologies and AutomationTechnologies.

2002ABB is one of the firstcompanies to applywireless technology forindustrial applications,enabling data to betransmitted via radiowaves rather than acable.

1891Charles E.L. Brown andWalter Boveri establishBrown Boveri & Cies inBaden, Switzerland.Shortly afterward, BrownBoveri becomes the firstcompany to transmithigh-voltage AC power.

1893Asea builds the firstthree-phasetransmission systemin Sweden.

1990Azipod (AzimuthingPodded Drive) isconceived to giveships moremaneuverability with amotor that is 360-degrees steerable.

1997ABB sets out to createa single IndustrialIT

architecture forseamless real-timeintegration of businessand manufacturingprocesses.

1963The first datatransmission at carrierfrequency is performedby BBC over a 735-kilovolt high-voltageline to a power stationcontrol unit.

1969BBC develops thefirst gearless cementdrive in the world.

1971BBC builds the mostpowerful transformerin the world at1300MVA.

1939BBC builds the firstcombustion gasturbine for generatingelectricity.

1944BBC develops the firsthigh-speed locomotivewith driving shaftsfitted exclusively inbogies.

1952The first 400 kVtransmission line isbuilt by Asea.

Brown Boveri supplies Europe’s firstlarge-scale combined heat and powerplant producing alternating current.

2003ABB further simplifiesits divisional structure.AutomationTechnologies to havethree and PowerTechnologies fiveBusiness Areas.


1989ABB acquires 40companies in its firstyear, including thepower transmissionand power distributionbusinesses ofWestinghouse ElectricCorporation.


Global Round-up

ABB has won a turnkey contract to strengthenenergy supplies in the Sri Lankan capital,Colombo, and its industrial outskirts.

ABB will install four substations based on GasInsulated technology (GIS) over the next twoyears for Ceylon Electricity Board (CEB). CEBopted for the compact GIS technology becausespace in Colombo is at a premium.

The project involves the design, manufacture,testing, erection and commissioning of theswitchgear, new transformers and associatedequipment. ABB will supply 132kV GIS units,33kV and 11kV GIS units, power transformers,and control and protection panels, includingsubstation automation systems.

In another turnkey order received from SaudiElectricity Company (SEC), ABB will extend thelargest gas insulated substation in Saudi Arabia andthe project scope includes the supply, installationand commissioning of a 380kV gas insulatedsubstation extension as well as the related controland protection system in the eastern area of SaudiArabia, close to Jubail.

The substation is an important node in the SaudiArabian high voltage network and servesresidential and industrial loads at the Persian Gulfcoast. The extension is needed to meet the

GIS Substations to boost energy supplyin Sri Lanka and Saudi Arabia

Gas Insulated Substations

ABB is a pioneer in developing Gas InsulatedSubstations. In the year 1967, ABB delivered thefirst Gas Insulated Substation in the world andsince then, ABB has supplied more than 10,000High Voltage Gas Insulated Switchgear bays.The use of SF6 gas as an insulating medium inswitchgear reduces the clearance distancebetween active and non-active parts of theswitchgear, resulting in the following keyadvantages of gas insulated applicationscompared to air insulated applications:

Less space requirements – especially incongested city areas

Less sensitivity to pollution, as well as salt,sand or even large amounts of snow

Less operation and maintenance costs

increased power demand in this area and tostrengthen the high voltage transmission system inthe Gulf region.

ABB has previously commissioned a GISsubstation comprising 5 cross bays on 380kV and6 cross bays on 230kV including 4 large 750MVApower transformers.


ABB is executing a project to help International

Transmission Company (ITC), Southeast

Michigan, US manage its power transmission

assets aimed at improving reliability and

increasing up-time.

ABB’s wide range of asset management services

will help International Transmission Company

track the condition of all its critical substation

equipment, including transformers, circuit

breakers, batteries and relays. ABB will also

help the customer schedule and track the status

of maintenance activities.

ABB’s solution will assist data collection,

integration and analysis, decision-making and

work execution, enhancing efficiency and

reliability of the transmission system and

resulting in lower overall energy costs.

To help asset-intensive companies manage their

installed assets more effectively, ABB has

developed AdviseIT Asset Sentry, an Internet

based data analysis and decision support system

that enables an asset manager to assess

equipment condition, improve operational and

maintenance effectiveness, and optimise asset

performance.

Offered as an Application Service Provider

service (ASP), Asset Sentry collects, analyses

trends, and manages equipment health data from

data collection processes such as routine

inspections, predictive maintenance diagnostics,

and online monitoring systems.

Using Asset Sentry, ABB can help utilities make

more efficient use of their operating and capital

expenditure, while allowing them to improve

the reliability of their systems.

In another recent US project, ABB has

successfully commissioned a High Voltage Direct

Current (HVDC) transmission system link

called the ‘Rapid City Tie’ interconnecting the

eastern and western power grids. This 200 MW

back-to-back system is expected to boost grid

reliability and lower risk of blackouts as it

ABB strengthens reliability ofU.S. power supply

allows controlled power flow between the

independent power grids. It will also help

counter disturbances in voltage and frequency in

either of the grids.

The two high-voltage alternating current (AC)

grids in the eastern and western U.S. do not

operate synchronously and require a technology

interface to connect them. ABB’s pioneering

HVDC technology to interconnect power grids

takes the AC power from one grid, converts it

into DC power, and then reconverts it back to AC

for the other grid.

International Transmission Company’s assetsthat ABB is helping to manage:

28 substations

43 transformers

700 breakers

More than 8,000 relays

50 battery systems

200 buses

12 reactors

More than 50 RTU SCADA Systems and

4,000 Kms overhead and underground HighVoltage transmission facilities


Technology Digest

DesignIT

TransmissionSystem Configurator

1. Major investments are being made in power transmission systemsto eliminate bottlenecks and congestion as well as to provide merchanttransmission lines.

However, assessing the value of such newinfrastructure can be difficult, as it depends to alarge extent on the network situation in a givenmarket environment. This situation is, in fact, theprincipal factor driving business development andthe identification of business opportunities. As theproject chain in [2] shows, any tool forstreamlining such an evaluation has to address awhole host of other issues, too. For example,certain basic specifications can be defined for eachproject, such as: ‘Which points have to beconnected?’ and ‘What is the expected power flowto be handled?’

The next step is to translate these basicspecifications into feasible alternative solutions at amore detailed, but still conceptual design level.This involves defining the different solutionstechnically such that the cost to the customer canbe determined and used as input for a subsequent

Transmission capacity is a key profit factor intoday’s largely deregulated utility business, andnetwork operators are continually investing ininfrastructure to maximise it. Investmentdecisions of this order need to be based on athorough technical and economic evaluation ofthe network’s condition as well as an analysisof all the alternatives. Besides the sheercomplexity of this, there is the problem ofmarket volatility, which makes everything frominvestment planning to commissioning andoperation very time-critical.

What is needed, once an opportunity toimprove the profitability of a transmissionsystem has been identified, is a tool forstreamlining the evaluation. The DesignIT

Transmission System Configurator (TSC) wasdeveloped to do just that. Built upon ABB’sIndustrialIT software framework, it shortens thetime to create and evaluate different systemsolutions from months to just hours.

Before committing to a major investment inelectrical power transmission, network operatorscollect volumes of data and facts for evaluation.Many different scenarios are possible – so manyin fact that the success of the evaluation oftendepends on how effectively an operator’sknowledge of the electricity markets can belinked with the functional capability and supportprovided by the advanced technical solutions athis disposal.

Transmission capacity translates into profit

New electrical power transmission lines,constructed to eliminate bottlenecks andcongestion or as merchant transmission lines, cangenerate profit for all the market participants.


economic evaluation. The specification resultingfrom this is used as input for the detailed designduring the EPC1) phase.

Speeding up the process

Mapping the basic specification to technicallyfeasible, but different solutions, and theirsubsequent economic evaluation, is a time-consuming process. Product and marketknowledge has to be combined in extensivestudies case-by-case. Even experienced powersystem engineers may need a month or longer todesign an alternative solution – selecting,configuring, and harmonising the necessarysubsystems, then calculating the cost and the priceto quote to the customer. What the DesignIT

Transmission System Configurator does is combineall this knowledge and data in a way that allowsfaster processing. Alternative solutions can begenerated and evaluated in a much shorter time.

Modelling with black boxes

As implied, the function of the DesignIT

Transmission System Configurator is to generateconceptual solutions for transmission systemconfigurations. Unlike a sales configurator, whichsimply handles (well-defined) variations ofexisting products, the design configuratorcalculates complex dependencies at the beginningof the design process. In the case of a powertransmission line, for example, there aredependencies to consider – and balance –between the voltage level, the wire and the towertype as well as the reactive power (var)compensation.

The individual components of the transmissionline are modelled using a completely newapproach, patented by ABB [1], that makes fulluse of our technical, product and human expertknowledge and experience base. It breaks thetransmission system down into parts, each ofwhich is modelled as a black box. A black boxcan, for example, represent a substation, lineelement, var compensator, transformer or controldevice. Using the black boxes as building blocks,customers and sales engineer can progressivelytest the specification and solutions. The high levelof detail enables the price and technical feasibilityof a solution to be determined with high accuracyalready at this early stage of a project. Byoptimising the technical and economic parametersin this way, ABB can assure customers of anoptimal result.

2. The DesignIT Transmission System Configurator supports the entireproject chain for power transmission lines.

Economic evaluation

To be really beneficial, an economicevaluation has to consider allpossible uncertainties over the totalinvestment period. These uncertaintiesare mainly the result of the volatilebehaviour of today’s energy markets, but technicalrisks, such as maintenance and outages, also haveto be included.

The basis for the economic evaluation is theinvestor’s own business model for the energymarket situation considered. ‘Uncertain’ parameterscan be modelled using probability distributionfunctions, combined with a Monte-Carlosimulation. A number of variations are thencalculated to determine the distribution and theuncertainty of standard investment parameters,such as return on investment or net present value.These values are decisive in the selection of anappropriate technical solution.

ABB’s entire solutions portfolio can beaccessed

The DesignIT tool provides key support at allstages of a project, from early discussions withpotential investors right through to the offerphase. This has special benefits during the initialproject discussions, as possible solutions – andalternatives – can be generated and evaluatedquickly, allowing the value of potentialinvestments to be estimated without any need forextensive network studies.

As mentioned, the main benefit of DesignIT lies inthe speed with which several different solutionscan be generated. This accelerates the decision-making process considerably and avoidsunnecessary delays. Results are obtained in days,even hours – a dramatic reduction from themonths that are often needed with conventionalmethods. Being able to generate severalalternative solutions makes the entire portfolioof ABB solutions accessible for any givenapplication. The flexibility and simplicity withwhich different solutions can be generated evenallows very advanced or uncommon solutions tobe evaluated and discussed with ease. The black


box approach ensures a quick and detailedresponse. And it has the additional advantage thatthe design and technical teams are not neededuntil the final stages of a quotation. All parties,and the customer in particular, can vary theparameters and then quickly see their technicaland economic impact.

Although it may be less specific than conventionalsystems, the black box technique has the keyadvantage that it overcomes the need forpremature, costly detailed design. Use of theDesignIT Transmission System Configurator startswith the customer’s idea and ends when thecustomer is convinced that the best solution hasbeen found.

Validation of the configuration process

Transmission projects in Brazil were chosen fortrial application of the black box modellingapproach. The solutions that were developed forthese projects have been validated by comparingthem with solutions designed in the conventionalway. The comparisons showed the precision to liewithin ±5%.

A thorough economic evaluation based on thebusiness model for the Brazilian market showedthat, for this country’s particular regulationframework, the optimal solution is stronglydependent on the reliability of alternativesolutions [3]. In order to obtain sound economicresults, it is therefore essential to model thereliability as a probability distribution.

ABB Brazil has already started using the DesignIT

Transmission System Configurator algorithms as atool in its AC systems solution development. As aresult, far less effort is required to develop feasiblesolutions than before. The main advantage hasproved to be the responsiveness achieved in thebusiness development and solution engineeringphases of a project. The configurator is now beingused to optimise transmission system solutions forthe newly planned 11,000 MVA Belo Montehydropower plant. By using and optimisingleading-edge information technology in the field ofpower system configuration, such projects areproving the ability of the ABB IndustrialIT approach

to leverage important benefits in business areasbeyond industrial automation technology.

The DesignIT solution

What requirements have to be met? HV transmissionsystems are complex entities, both with regardto their configuration and their operation. Acomputerised tool designed to help sales engineersdraw up detailed offers for such systems,specifying both the electrical behaviour and theexpected cost/price of the solution, therefore hasto fulfill a number of special requirements.

For example, it must have access to the (stored)cost-related data of the system components – inthis case, transformers, substations, HV lines andvar compensation equipment. What is more, asmost of the subsystems are not off-the-shelfproducts, but engineered to order, the tool mustbe able to derive a relatively accurate costestimate from general specifications. The toolmust also incorporate knowledge concerning theelectrical behaviour of the system components,and it must be able to derive from this knowledgeinformation about the more complex electricalbehaviour of the combined system. At the sametime the ‘configuration’ process – the creation andevaluation of different options and alternatives –should be as user-friendly as possible, i.e. mostlyusing ‘point & click’ or ‘copy & paste’.

Moreover, the tool has to be fully functional instand-alone mode, as the sales engineer might notalways have convenient and secure access toABB’s corporate network. For this reason, andbecause the knowledge contained in the systemevolves over time (costs and prices change, newproducts become available, etc), the tool also hasto be capable of being updated in the field, andby a user who may not be a software expert.

Just having the latest version of the information forevery available system component, however, isnot enough; what is also needed is a ‘versioning’mechanism that helps the user understand why acertain configuration for a previous project waschosen in the first place. After all, the productsand costs at the time might have led to a designthat is less than optimal for the current project.Also, as the subsystem configuration algorithmsmight be specific to certain boundary constraints,such as country regulations, there are, in reality,always a number of equally valid current versions,and the tool has to select the right one at run-time.

With these requirements in mind, and driven by adesire to create a re-usable, generic solution to the

3. Internal representation of transmission system elements as black boxesfor the conceptual design(S/S = Substation, T = Transformer, RPC = Reactive Power Compensation)


problem, the decision was made to base the toolon ABB’s IndustrialIT architecture.

Advantages of the IndustrialIT architecture

Designing and configuring HV transmission lines,which are engineered to order and are often one-of-a-kind, is a highly complex process requiringspecial expertise in many areas.

Standard configurator software is well suited fordesigning systems where the options are limitedand the interdependencies are known. However,it soon shows its limitations when it comes tosolving the complex numerical calculations usedto configure more sophisticated systems. This, andthe fact that several different analytical tools couldbe needed to evaluate alternative solutions,pointed to the need for a special kind ofconfiguration tool. ABB’s response was to developthe DesignIT configuration framework, which hasboth generic and domain-specific parts.

The early evaluations showed that the Industrial ITarchitecture is very well suited for implementing thesubsystem (object) centred configuration approachdescribed in [1]. The Aspect Integrator Platform (AIP)supports this with its tree browser based front-endand the underlying Aspect Object paradigm2), whichallows all kinds of data and applications, evenexternal ones, to be linked to a conceptual object.

Mapping the problem to the Aspect Objectparadigm

In the resulting software architecture, eachsubsystem of the HV transmission system isrepresented by two types of Aspect Object. Thefirst type represents the subsystem – for example,a transformer – as a domain object in the userinterface used to assemble and evaluate alternativesolutions. One instance of this Aspect Object typeis stored in the system (eg, for the transformer) ineach alternative solution and in each project.

4 DesignIT configurator framework for system solutions

The second type represents the configurationalgorithm and data for the transmission systemcomponent in question. Again, the system storesone instance of this Aspect Object for eachversion of the configuration algorithm. However,the existence of this second type of AspectObject, and the complex version managementmechanism used to dynamically link the two typesat run-time, is completely hidden from the user.

Both types of Aspect Object carry one set ofAspects which are specific to the HV transmissionsystem domain and another set which, like theuser interface, is completely generic for this kindof configurator application, providing functionssuch as parameter entry, versioning, cost andprice calculation, automatic tender documentgeneration, etc.

Framework for the future

Basing the configurator architecture on the AspectObject paradigm makes it easy to exchange,redesign or add new black box components.Among other things, this allows more detail,realism and accuracy to be added, for example bybreaking down the substation subsystem intoprimary and secondary equipment subsystems.

The separation of generic and application specificparts of the software tool also facilitates quickadaptation of the framework to completelydifferent domains. This is important, as systemsolutions in different areas can have similarconfiguration problems. The potential of theDesignIT configuration framework is underscoredby the interest being shown within the ABBGroup in applying it in areas as varied as windparks, subsea oil fields and oil drilling rigs.

Source: ABB Review

5 Screenshot showing details of a line subsystem configured with theDesignIT TSC


Living our commitment to SustainabilityABB acknowledged for promotingsustainable developmentABB has won the Platts 2003 Global EnergyAward for helping develop the world’s mostpowerful storage battery system. The EnergyEngineering Project of the Year accolade wasawarded for the Battery Energy Storage System(BESS) in Fairbanks, Alaska, owned by the GoldenValley Electric Association (GVEA).

The BESS will stabilise the local grid and reducethe number of outages for Golden Valley’scustomers by 65%. It can produce up to 27 MW ofpower for 15 minutes. For a shorter time, theBESS can even produce up to 46 MW.

There were nearly 200 nominations from everycontinent and every field of energy in this year’scompetition. The Award, one of the most prestigiousin the industry, recognises innovation, practicalityand commitment to safety and the environment.

ABB has also won an environmental excellenceaward in Colombia for its environmental policiesand contribution to society. The initiative is part ofABB’s Environmental Management System (EMS),introduced four years ago to improve the qualityof life for people in Bogota. Reduction in the useof natural resources and a waste disposalprogramme formed an integral part the overallsustainable development programme.

Helping little dreams come true...

After the success of itssustainability initiative at theGovernment Primary School atPeenya, Bangalore, ABB Indiahas taken on a similar project atHaliyal – a little district in NorthKarnataka, by adopting a school

in the district. The project isaimed at improving theinfrastructure of the school. Theinitiative will also focus onpromoting sports and other co-curricular activities, encouragingmeritorious students andimproving the environment inand around the school.

A two-year MoU has beensigned with the government andwork towards infrastructuralimprovement has already begun.

Fostering links with academia…As part of an ongoing programme with ABB, MSUniversity, Vadodara has deemed the CorporateR&D Centre at Maneja as a doctoral researchcentre and recognised ABB’s JJ Patel, VR Kanetkarand GR Patel as guides for the University’sresearch programmes. Anupam Arya, GR Patel andVK Shah will also be completing their doctoral

The existing building is over100 years old and has beendemolished to make way for thenew school building. Theconstruction work has begun andthe school is expected to beoperational by June.

This project marks anothermilestone along ABB’s journeyof living its commitment tosustainability and making adifference to the communities itoperates in.

MS University,Vadodara

research programmes at theCentre. Their topics for researchare ‘optimisation of distributionsystems’, ‘power quality’ withspecial reference to reactive power compensationand ‘longitudinal insulation in circuit breakers anddisconnectors’.

Channel Line


Born in Ambala, 44 year old Ashok Gupta,is the proprietor of Selz Business House,one of ABB’s leading channel partners forLV products in Chandigarh. Ashok has livedin Chandigarh, the “city beautiful”, since1964. He went into business in 1985 afterbeing a dealer for Indian Oxygen and in2000 was a distributor for leading electricalcompanies.

“I like to deal with world-class companies –only the best ! My impressions of ABB were

Selz Business House on the growth trackvery good and their technology strength wasthe main attraction.” During his three yearassociation with ABB, he has grown thebusiness volume more than five times from amere rupees nine lakh and has no hesitationin saying: “I want to grow with ABB anddouble the present business within a year ortwo. I also want to expand the product rangeand look forward to adding other standardproducts and mass electricals to my portfolio.”Ashok Gupta is proud of his partnership withABB, especially satisfied with the technology,product quality and on-time delivery. Whilehe recognises that efforts have been made, hewould like to see after sales supportimprove further.

Selz has a business mix of institutional,domestic as well as industrial customers andis also one of India’s leading dealers for BajajElectricals Limited. On the personal front,Ashok is a “family man”, who likes trekkingand leisure drives. He would like to see histwo sons aged 16 and 11 become engineers,as technology is dear to his heart !

Weigh feeders have been employed forcontrolling flow of raw material in processinglines. Their widespread application howeverhas been hampered by lack of accuracy,reliability and cost. Traditionally, individualPID controllers for each of the weigh feederswere being used resulting in a higher cost.

JK Automation, ABB’s channel partner inKolkata now offers you a more reliable,accurate and cost-effective solution byblending the powerful PID controller of theABB AC800F/AC800M controller, takinginputs from drives (PID macro) over aMODBUS and customisable software. Thisnew solution offers quicker response andhigher precision.

JK Automation offers an innovative solution

You Ask – We Answer

Q. Do you offer solutions in the area ofelectrical control systems for powergeneration and distribution?

K K Verma, Indian Oil Corporation, Begusarai

ABB has a long standing experience in offeringElectrical Control Systems (ECS) for captivePower Plants/ Electric Distribution systems andsolutions for...

– Load shedding schemes

– Generator control/ Active reactive power control

– Synchronisation

– Basic SCADA functionality for the electricalnetwork for industrial plants

ABB has delivered one of the largest and mostcomplex ECS systems with the above functionalitiesfor Reliance (Jamnagar and Hazira Complex), HPL,CPCL, BPCL and also at IOCL (Barauni).

Q. I need more details on the ACS 800 driveand the user benefits.

S Mukherjee, Satyajit Ltd, Kolkata.

The ACS 800 drive belongs to ABB’s DriveIT suite,part of its IndustrialIT offering and is based on DirectTorque Control (DTC) technology.

ACS 800-01 and ACS 800-02 Single Drives areavailable in IP 21, IP 54 or IP 55 degree ofprotection. The drives, up to 110 kW, are compact,wall-mounted ACS 800-01 drives and from 90 kWup to 500 kW are bookshelf-style ACS 800-02drives with a new innovative free-standingenclosure.


One of the main benefits of the ACS 800 series is awide range of drive products with commontechnologies like Start-up Assistant, AdaptiveProgramming and DTC, common features, commonuser and process interface with fieldbuses, commonsoftware tools for sizing, commissioning,maintenance and common spare parts.

The ACS 800 goes one step further compared tonormal parameter programming with the addition ofAdaptive Programming. It is like having a small PLCinside your drive. Moreover, Adaptive Programmingneeds no additional hardware or software.

Standard features include a choke for harmonicfiltering and drive protection, extensive and flexibleI/O, user-friendly control panel with a start-upassistant and a silent cooling fan.

Main advantages and benefitsinclude:

– Improved production

– No external PLC required

– User-friendly and easy-to-use

– High energy savings

– Smooth power-loss ridethrough

– Reduced costs

– Adaptiveprogramming tomeet specificapplications

Q. Does ABB offer technology for AutomaticFlatness Control (AFC) for aluminium sheets?

S K Jhahjaria, HINDALCO Industries, Renukoot

ABB offers thestressometerwhich is anAutomaticFlatnessControl systemfor rolling millapplications.This product consists of a measuring roll filled withpressductor loadcells and software for measuringand control.

Communicating...

As the world progresses, more and more technology enters our living rooms and the importanceof ‘quality power’ increases by the day. In this issue, we have focused on power technologiesthat play a vital role in bringing this power to our homes, offices and factories. We hope tocontinue bringing you the latest developments and technologies on offer and look forwardto your ongoing support in maintaining this regular CONTACT. I take this opportunity towish you a happy and prosperous 2004!

Harmeet S. Bawa, Head GF-Corporate Communications, ABB India


Power Technologies

Posters

Safety Precautions

Brochures

High Voltage Machines Building solutions LV Motors - Technical

Mailers

Robotics range

www.abb.com/in

ABB is a global leader in power and automation technologies that enable utility andindustry customers to improve performance while lowering environmental impact. ABBPower Technologies cover a wide range of products, systems and services for powertransmission and distribution, including turnkey solutions for substations, utility automationand bulk power transmission.

The offering encompasses a wide spectrum of products across the entire voltage range,including outdoor and indoor circuit breakers, air and gas insulated switchgear, disconnectors,capacitor banks, reactive power compensators, power and distribution transformers as well asinstrument transformers.

ABB provides cutting-edge solutions like High Voltage Direct Current (HVDC) and FlexibleAC Transmission System (FACTS) that facilitate higher capacity utilisation and efficienttransmission of power, while minimising the risk of cascaded line tripping. ABB also offersdistribution automation and network management solutions like Supervisory Control & DataAcquisition (SCADA), Wide Area Protection (WAP) and a host of technologies that help reduceT&D losses, increase uptime and improve the overall reliability of the grid.

issue 4 / 2003 the abb india magazine · 2018-05-09 · (ntpc) substation and tarapur (npcil)...

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