action - · delivery and engineering, neil sequeira agreed. “these abb transformers were way...

action The customer magazineof ABB in Australia

2|2014

Driving industrial productivityAutomated processing helping to sustain Australian manufacturing into the futureABB and RMIT launch Australia-India Research Centre for Automation Software Engineering RMIT has launched a new automation software engineering research centre, connecting the University with industry partner ABBThe evolution from circuit-breaker to power managerThe world’s first low-voltage circuit breaker to be used for energy management and smart grid communications

Features

2 Action 2|2014

The clever country

In Australia, manufacturing remains a cutting-edge and versatile industry and, despite some tough challenges, it has demonstrated a natural ability to adapt and prosper. In this edition of Action we look at some of the smart technologies such as robotics and automated processing, that will help drive our economic growth and reinforce Australia’s position as the ‘clever country’.

We also look at some smart new technol-ogies such as the world’s first low-voltage circuit breaker for energy management and smart grid communications and how Bod-dington Gold Mine is increasing its pro-ductivity with its powerful drive systems for high pressure grinding.

In the research arena, ABB and RMIT launched the Australia-India Research Centre for Automation Software Engineering (AICAUSE). One of the projects AICAUSE is involved in is geared towards “Collabor-ative Engineering” - supporting digital col-laboration between multiple organisations and distributed sites such as production plants for development, operation, main-tenance and services.

And finally, smart technology that has with-stood the test of time is the retirement of three 100-year-old ABB transformers at a SP AusNet zone substation in rural Victoria.

Content

Axel KuhrCountry ManagerABB in Australia

action 2 |2014

Action 2| 2014 • Customer magazine of ABB in Australia • copyright 2014 Tel: +61 1800 222 435 • E-mail: [email protected] • Editor: Leanne Sprlyan • Designer: Lu Nan • To subscribe: [email protected] Produced and published by: ABB in Australia, Corporate Communications • Any use of text or images requires the written consent of the publisher

8 14Local news The evolution from circuit-breaker to power manager

Feature story Driving industrial productivity

3Action 2|2014

Local news5 Girls Experience Industry Days ABB recently played host to girls aged

14-17 at a Girls Experience Industry Day held in Melbourne and Sydney

6 ABB Australia launches online transformer ordering BusinessOnline services has been expanded by ABB to enable its Australian-based customers to purchase distribution transformers online for the first time

7 Ventyx World Asia Pacific 2014 Gold Coast, Australia 23-25 July

11 SVC upgrade to improve grid reliability TransGrid and ABB work together to refurbish Broken Hill SVCs

11 ABB goes solar at Moorebank facility ABB is reducing its environmental impact by installing a 100kW rooftop photovoltaic power system at its Moorebank, New South Wales site

12 ABB and RMIT launch Australia-India Research Centre for Automation Software Engineering RMIT has launched a new automation software engineering research centre, connecting the University with industry partner ABB

Features14 Driving industrial productivity

Automated processing helping to sustain Australian manufacturing into the future

Global news21 World’s largest EV fast charger network in China

ABB announced a strategic collaboration with Shenzhen BYD Daimler New Technology Co.Ltd. (BDNT) to supply direct current fast chargers for DENAZ starting mid-2014

Applications22 Taking mineral productivity to a higher level

ABB variable-speed drive systems are revolutionising the mineral and cement industries

26 ABB robotics at the centre of Australia’s largest palletising solution

Product news28 Best Product of the Year

ABB Freelance wins at 10th Annual Best Product Award ceremonies in Shanghai

Content

2022 Application notes

Taking mineral produc-tivity to a higher level

Global news ABB to equip Sweden’s next-generation high-speed trains

4 Action 2|2014

Local news

They started service before the inven-tion of the toaster, the TV and the in-ternet. Qantas and Canberra weren’t even born yet. And two World Wars, the Beatles, Britney Spears, Monty Python, spaceflight, penicillin and vel-cro also impacted our world for better or worse over those years.So what has withstood the test of time?Three ABB power transformers have been stalwarts in the rural Victorian land-

Now Available in DigitalRead about innovative new technologies, real-world applications, and informative case studies from around the world.Sign up now at http://www.abb.com/review to receive the print or eBook (PDF) of ABB Review and you will receive a beau-tifully produced, comprehensive publica-tion four times a year packed with more than a dozen articles exploring global technology trends impacting industry and infrastructure.

Three workhorses retired after 100 years of active service in Australia!

ABB Review: The corporate technical journal

scape of Australia for the last 100 years, actively doing their business for local utility, SP AusNet. The transformers were part of a zone substation supplying the local area which also included two hydro generation companies.The 9 MVA 22/66 kV GSU transformers were ahead of their time according to Australian transformers market manager, Julian Guild, and required little service over the years.

SP AusNet’s Project Manager for Capital Delivery and Engineering, Neil Sequeira agreed. “These ABB transformers were way over engineered and built to last,” he said. The only loving care they seemed to require was to feed their thirst for oil. Well you wouldn’t deny a 100-year-old a drink every now and then! The three grand old dames (or gents, de-pending on your point of view) are being retired not because they aren’t pulling their weight, but because the SP AusNet substation is being rebuilt.One of the transformers will be shipped to ABB’s Moorebank, Sydney facility where it will live out its twilight years un-der the shade of a gum tree as part of a display of old and new; a testament to the great technology ABB continues to invent and reinvent.Happy 100th birthday transformer 1, 2 and 3. May you enjoy your well-deserved retirement!

ABB tops 2014 global survey for ‘most admired’ ABB has been named by Fortune magazine as the most admired company in its sector in their an-nual global survey.Fortune’s annual rankings are derived from a survey of 15,000 senior execu-tives and industry analysts who rate companies on nine attributes ranging from innovativeness to the ability to attract and retain talent. ABB ranked first within its sector on five (global competiveness, quality of products/services, quality of management, peo-ple management and innovation) of the nine attributes as well as overall. The company moved up from sixth place in last year’s survey in the Industrial Machinery category and are pleased to be recognised as the global leader and the place to work in the industry.

The soon-to-be retired 100-year-old transformers waiting to be decommissioned by SP Ausnet

8 Contact us for more information


W

reviewABB

Innovation highlights 6 Measuring current with light 13 Combined simulations 45 The mains outlet that integrates USB 55

1 |14en

The corporate technical journal

Innovation

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Local news


Girls Experience Industry Days

ABB recently played host to girls aged 14-17 at Girls Experience Industry Day held in Melbourne and Sydney. The aim of the open days was to introduce high school and pre-career girls to exciting fields such as R&D, innovation and technology. The events were held in conjunction with a number of other leading global compa-nies who are members of the National As-sociation of Women in Operations (NAWO). NAWO has been established to encourage and facilitate more women into operational roles and to develop the pipeline of talented women. “We were pleased to welcome a number of girls to ABB on the NAWO Girls Experience Industry Days,” said Rebecca Roberts, Country HR Manager for ABB in Australia. “The girls heard from our female graduates and senior managers on their experience of working at a global engineering company and also had hands-on fun interacting with ABB’s robots and building solar powered toy cars.”

“NAWO is creating a number of develop-ment programs and networking opportuni-ties for women in industry, but it’s also im-portant that we attract and engage young women in their formative years when think-ing about which career path they will take. Understanding how a business runs, that is ‘the engine room’, is critical for women to be strong leaders and we are working with industry to create opportunities for women” said Angela Tatlis, Chair of NAWO.“If you look at engineering, females com-prise approximately 10 percent of the Aus-tralian engineering labour force. This is a very low number when you consider wom-en make up 51 percent of all professionals in Australia,” Angela added.To find out more about how NAWO sup-ports women and industry visit their website www.nawo.org.au

Learning how to optimise the energy efficiency of buildings with ABB’s i-bus KNX automation solution

Girls enjoying the challenge of building an electric motor

ABB’s Rebecca Roberts leading one of the discussion groups at Girls Experience Industry Day

Student, Valeria Bello takes control of an ABB robot

DataCentre Dynamics ConferenceHilton HotelSydney, 24 June 2014The data centre has become the most crucial IT asset for nearly every 21st century organisation. Visit our stand to learn how ABB’s technologies are supporting the organisations who provide the infrastructure behind the digital world.

Queensland Mining and Engineering ExhibitionMackay ShowgroundsMackay, 22-24 July 2014Visit our stand at QME to discover how ABB is helping companies reduce their operating costs and improve their production efficiencies via the implementation of our intelligent automaton and power solutions.

ABB’s mining webinar series June - December 2014Improve the effectiveness of your mine’s existing assets and bottom line by attending our automation and power solutions webinar series. - Discover best practice in arc fault

management for improved electrical safety

- How to apply remote asset monitor-ing to maximise equipment utilisation

- Utilising technology to drive improvement across the entire mining value chain

- What is OT/IT technology convergence and how can it help prepare you for the mine operations of tomorrow

For more details and to register for any of the events listed, go to www.abbaustralia.com.au/events

Upcoming events

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Local news

ABB in Australia has launched its new and improved website!

The ABB in Australia website (http://new.abb.com/au) is optimised for mo-bile devices and offers users a different approach, both in terms of look and feel and from a structural point of view, be-ing more visually attractive and easy to use. Moreover, the responsive design of the pages allows the user to browse it using smart phones, tablets or desk-top computers, while having the same high level of quality and content. “Our website is often the initial contact point for many of our customer and busi-ness interactions, and our new agile and interactive website provides an improved and enhanced user experience for all,” said Sally Durrant, Communications Man-ager for ABB in Australia. ABB is also looking at opportunities to in-tegrate information in ways that bring user value, and projects such as “Ask ABB” are helping the company to create informa-tion that is tailored to customers and to the search engines that are an essential part of their lives. Importantly, ABB has plans to make the web more actionable by integrating busi-ness processes such as product availabil-ity, pricing and ordering in ways that make the experience simple and attractive, as technology users expect.

8 Contact us for more information8 Contact us for more information

BusinessOnline services has been expanded by ABB to enable its Aus-tralian-based customers to purchase distribution transformers online for the first time. It now makes designing and buying transformers much easier and faster. The new online service for distribution transformers will improve ordering effi-ciencies for customers and enable ABB to tailor its offering to match specific cus-tomer requirements. The BusinessOnline facility supports ABB customers from the early design stage when specifying and configuring their distribution transformer through to the placing an order and fol-low-up of existing orders. ABB is promoting the online procure-ment platform to customers in Australia by offering a range of stocked distribution transformers at special prices. Other key aspects of BusinessOnline are: - Access to drawings, technical specifica-

tion, protocols, manuals and guides - Product catalogues with technical and

price information - Standardised distribution transformers

in stock making purchasing easier and faster

- Easy and quick access to compare models, features and prices

- Access to the ABB logistic chain

“We want to make it easier for our cus-tomers to do business with us,” said Fulvio Granata, ABB’s general manager for Transformers in Australia. “This now means you can talk to a sales represen-tative who has all the latest information at their fingertips or go online and order stocked transformers directly from us 24/7. “The online platform makes it possible for our customers to get a real-time inte-gration to ABB’s back-end systems. It is easy-to-use and supports the customers’ entire purchasing process, from the initial evaluation phase and product specifica-tion, through to ordering and tracking the delivery of a world-class product,” adds Fulvio.ABB offers a complete range of power and distribution transformers providing the reliability, durability and efficiency re-quired in utility, industrial and commer-cial applications. ABB has more than 55 manufacturing sites globally - including facilities in Perth and a large service unit in Sydney, Australia. BusinessOnline is available via http://on-line.abb.com

ABB Australia launches online transformer ordering

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Local news


Roland Vitelli has rejoined the ABB team as Local Division Manager for Power Systems in Australia and General Man-ager of Ventyx in Australia. Prior to coming back to ABB, Roland was an executive with a State utility, respon-sible for delivering high voltage infrastruc-ture and R&D for the state. His experience on both the vendor and customer side has given Roland a unique perspective on the new technologies that can deliver ad-vanced power needs, and also the regu-latory and business drivers that determine

that technology path.By taking on this dual role, Roland will help bring the ABB and Ventyx organisations even closer together and present to ABB’s customers the true value that the integra-tion of information technology and opera-tional technology can have on the perfor-mance of their infrastructure. “In asset intensive industries like mining, energy and defence, ABB has a unique ability to integrate operational technology such as SCADA, OMS and DMS, with en-terprise software that provides real-time

data on critical assets,” said Roland Vitelli.Roland looks forward to working with ABB’s customers in developing strategies for their asset lifecycle needs.

ABB welcomes backRoland Vitelli

Ventyx World Asia Pacific 2014: Gold Coast, Australia 23-25 July

If you are a public utility or mining or-ganisation, this is the one event you cannot afford to miss this year. Once again Ventyx, an ABB company, is hosting Ventyx World Asia Pacific 2014. Last year we had a global event in San Francisco. This year we are bringing the event to Europe, the US and Asia Pacific. All our markets now have the opportunity to learn more about the value ABB and Ventyx can provide your organisation in optimising operations to enhance financial performance. It is also a great opportunity to network with your peers from across the

region and learn best practices across the full lifecycle of your business.Not only do we have a great agenda with speakers confirmed from industry, our cus-tomers and partners, but there is also a solution showcase which will give you the opportunity to see the depth and breadth of our offerings, as well as speak to the experts directly.Themes that Regional Ventyx World will address include: - Strategic Asset Management- Workforce Enablement and Improvement- Process Improvement and Safety

- Effective Supply Chain ManagementCan your business afford to miss this event? Register now / find out more: http://www.ventyxworld.com/en/region/asiapacific

seeking support on any ABB product, system, service or general enquiry. The centre team is available via telephone, fax, email or the web and provides rapid response including escalation of urgent issues as required.Our contact points:Phone: 1800 222 435 (1800 ABB Help for

24x7 support) +61 2 9738 2277 (International)Fax: +61 3 8544 0001Email: [email protected]: http://new.abb.com/au


ABB Contact CentreThe beginning of a great experience with ABB

The most successful businesses have one thing in common - amazing cus-tomer service! This is the exact same standard of service that the ABB Con-

tact Centre team strives to deliver when providing a single point of contact. The ABB Contact Centre provides a single point of contact for customers

8 Action 2|2014

Local news

With nearly two million Google search results using the search term “circuit breaker + benchmark + Emax 2”, news of ABB’s next generation of air circuit-breakers has been extremely well re-ceived globally.

Now it is Australia’s turn to be impressed, as the new SACE Emax 2 and its Ekip brand of trip units and accessories are now available in our marketplace. De-scribed as efficient and simple to use, the range offers innovative solutions for today’s needs, while anticipating those of

tomorrow. Not only does Emax 2 meet or exceed the standard performances and functions that the market demands from an air circuit-breaker, but it has evolved into a true power manager. For an indi-vidual building installation, a peak power reduction of up to 15 percent can be achieved by using Emax 2 in place of tra-ditional breakers.

It is simply integrated into all projects: from standard systems to the most com-plex and automated networks. Replacing an existing breaker with the new Emax

The evolution from circuit-breaker to power manager

The world’s first low-voltage circuit breaker to be used for energy management and smart grid communications

2 is also technically simple and due to energy savings, the Emax 2 breaker will typically pay for itself within a year. Fea-tures that are either new to the market or superior to existing solutions, make it the best choice for low voltage network needs.

- A patented, Power Controller monitors and controls power usage to reduce management costs.

- Extensive, direct communication abili-ties simplify network integration and eliminate the need for costly and dif-ficult conversion components.

- Optimal frame organisation and accu-rate design provide the ability for high performance switchboards and switch-gear with a reduction of both materials and space required.

- Busbar friendly, modifiable terminals eliminate the need to bend and extend bus bar and provide quick, easy instal-lation.

- Large, colour touch-screen interfaces allow for clear navigation, creating a simple and quick way to find informa-tion or make adjustments.

- A wide variety of accessories have been designed to simplify use or installation and to increase safety.

Control The Power Controller function of Emax 2 uses a patented algorithm to determine the average absorbed power over a pe-riod of time and then controls a load list to maintain the maximum power limit speci-fied by the user. The elimination of instan-taneous based measurements and ability to synchronise with utility measurement devices creates an efficient environment that saves on electricity bills without the need for additional monitoring systems.

The Ekip Link system and Ekip Control Panel enables local monitoring of circuit-breakers and switchgear functions in an

9Action 2|2014

Local news

Emax2 – The first circuit breaker that saves energyTurning a protection device into a smart energy saver

World’s first smart circuit breaker uses complex algorithms and power electronics

Payback in less than a year through energy savings

Avoids blackouts at peak consumption

Protects and controls equipment in industrial and commercial buildings, data centers or ships

…or provide electricity

to the entire house-hold’s of Berlin

Energy savings would power an electric car to the Sun and back

more than 11 times…

Damien Petticrew, Manager of Low Voltage

Products division for ABB in Australia and

Low Voltage Products Manager for South

Asia region discusses the release of Emax

2 and its potential impact on the Australian

marketplace.

What were the key drives behind the de-

velopment of the new Emax 2 Air Circuit-

Breaker?

The development of Emax2 has been based

upon four key pillars

- Control: Power flow optimisation

- Connectivity: Integration within the sys-

tems

- Performance: Meeting all requirements

with the optimum dimensions and sizes

- Ease of use: Efficient operation and user

friendly

Which market / industry segments will

benefit from utilising this new power

manager circuit breaker?

Any company that uses or distributes power

will benefit from such revolutionary technol-

ogy. The Emax 2 has taken the next step

when it comes to research and develop-

ment and transformed the circuit-breaker to

a power manager.

What do you see as the three most sig-

nificant benefits for customers utilising

Emax 2?

We have listened to what the market de-

manded and the needs of our customers

and the Emax 2 address this with the fol-

lowing benefits.

- Increases productivity and reliability

- Reduction in plant management, cost of

installation and the size of the switchboard

- Power management, Emax 2 is not used

for switching but now manages power

thus increasing energy efficiency.

Is Australia the first country to make the

Emax 2 available to customers?

No, the launch of the Emax2 was initially

carried out in Europe and has been used

in the marketplace since June 2013. It was

always planned that Australia would launch

the product in Q1 2014 in line with ABB’s

global launch structure. I am happy to say

that we have product on the shelf and we

have just received our first order for the

product one week after it was launched to

the market.

Will the Emax 2 help ABB grow its market

share in the low voltage products space?

In Australia, our strategy has been based

on factors such as price competitiveness,

stock availability and an attractive techno-

logical offer through cutting edge R&D. We

firmly believe that we now have the best

ACB on the market at a competitive price

and the feedback from the recent launch

of the product in Australia has been very

positive.

How do customers get access to the

Emax 2 to evaluate it for themselves?

There are various electronic tools-online

that allow a digital reality experience for

customers. In addition our sales and prod-

uct teams are happy to demonstrate ap-

plications and conduct product presenta-

tions and demos to our customers.

The perfect blend of control, connectivity, performance, ease of use and safety

individual switchboard. They require no programming and are available for even the most basic Emax 2 trip unit, provid-ing an economical way for a small plant to increase monitoring capabilities or a large plant to simplify local supervision and maintenance.

A Network Analyser feature is able to analyse the quality of power in real time with extreme precision in accordance with EN 50160 and IEC 6100-4 30. As a result, it is possible to identify the causes of increased power loss or a reduction of the working life of cables and capacitors without having to install costly, external instrumentation. With Emax 2’s Network Analyser, malfunctions can be prevented and installation efficiency and the working life of appliances can be increased.

The Ekip Synchrocheck module enables the control of the synchronism condition for placing two lines in parallel before en-abling circuit breaker closing. The abil-ity of the Emax 2 to provide this feature as a module eliminates the need for the

purchase and installation of independent monitoring systems.

Emax 2 offers Generator versions of its Ekip Touch and Ekip Hi-touch trip units. These trip units include all the functions of true generator protection switchgear without the need for external relays or

devices, wiring or inspections. The G ver-sion offers a safe control solution that is immediately ready for use.

Connectivity Every Emax 2 can be equipped with mul-tiple cartridge-type communication mod-ules at any time. The modules allow the

10 Action 2|2014

Local news


The SACE Emax 2 series circuit breakers are equipped with protection trip units containing a large colour touch-screen display for maximum ease of use. Productivity is increased while all stages, from design to daily operations, are simplified.

circuit breakers to be directly integrated into automation and energy management systems through the seven most popu-lar global protocols; including IEC 61850 for the creation of Smart Grid Networks. All functions can be accessed via the in-ternet, in complete safety, using the Ekip Link switchgear monitoring system.

Not only can the rear terminals of Emax 2 be field rotated from horizontal to vertical, but they have been specifically designed to fit the most common bus configura-tions. Each terminal has been created to the standard width of bus bar for that amperage and is equipped with one, two or three terminal stabs for easy connec-tion of one to four bus runs. The terminal technology provides the opportunity for easy connection and installation with less bus bar stock required.

The Ekip Supply Module can be connect-ed to any voltage in AC or DC to internally supply auxiliary power for the trip units and terminal box modules consecutively. The need for any external power sup-ply converter elsewhere in the cabinet is eliminated, saving both space and cost.

The neutral position on Emax 2 can be modified from left to right to provide ul-timate flexibility. In addition, the E6.2 is available with neutral conductor sizes of 50 percent or 100 percent to allow for the correct sizing of bus bar and an op-portunity to reduce construction costs, to

reduce construction costs. Examples of model size variations follow:- E2.2, 2500A with a 440V Icu of 100kA

and Icw 1s of 85kA in a 276mm width. - E4.2, 4000A with a 440V Icu of 150kA

and Icw 1s of 100kA in a 384mm width. - E6.2, 6300A with a 440V Icu of 200kA

and Icw 1s of 120kA in a 762mm width.

Emax 2 contains new generation Rogowski sensors that allow the most precise measurement on the market. The tolerance to 1 percent of the actual value of current, 0.5 percent of voltage and 2 percent of power and energies guarantee precision and enable the circuit-breaker to act as a measurement device in switch-gear. Measurements can be read directly on the wide trip unit display so additional devices can be eliminated.

The Ekip Fan Module continuously moni-tors the internal temperature at the fixed part and activates cooling fans if required. This allows for the ability of increased cur-rent-carrying capacity in switchgear.

Ease of use and safety Emax 2 is the first circuit-breaker to offer large, colour touch-screen displays. They provide clear, easy navigation for quick access to information and adjustment capability that is invaluable in the event of a fault or emergency. In addition, they can be read and used directly, without the need for expensive human machine interface (HMI) units. If desired, they can also be programmed and consulted from a tablet, smart phone or PC via the Ekip Connect application.

Removal of the main Emax 2 cover allows access to the accessory mounting area only, not the operating mechanism or oth-er components. This protects both main-tenance personnel and the breaker itself from unwanted damage. In addition, the key lock accessory is mounted inside the accessory area and allows for the breaker to remain locked, avoiding unwanted op-eration during maintenance.

Dedicated guide rails simplify movement and allow correct, locked and clearly identifiable positioning. The rails extend outside the fixed part so that the mobile part can be easily inserted. In addition, shutters on the fixed part can be locked from the front, without access through the inside of the fixed part. These fea-

tures allow for easy and safe installation and maintenance.

Implementation of breaker settings is sim-plified with the aid of ABB DOC software and Ekip Connect interface. Curves and settings can be determined and saved using the DOC software and the Ekip Connect program can open and read the DOC file, eliminating the need to retype the settings into the breaker or software program and allowing for easy, error free implementation.

Emax 2 contains push-in terminal box technology, making wiring easy and tool-ing-free ensuring immediate, safe wiring. In addition, Emax 2 terminal boxes and wiring set ups are common across the line and its trip units are field interchange-able, creating flexibility and the potential for easy, rapid upgrades without the add-ed cost of a service technician.

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Local news



ABB Australia is working on an upgrade of control systems and extension of the service life of two TransGrid Static var Compensator (SVC) systems in Broken Hill, New South Wales.

The 46-week project will see the team implement products and services from ABB’s Flexible AC Transmission Systems (FACTS) business unit – based in Vast-eras, Sweden – to help maintain the safe-ty, reliability and efficiency of TransGrid’s high-voltage transmission network. Due for completion in the second half of 2014, the contract includes design, engineering, product supply and delivery management services for the Broken Hill No.1 and No.2 SVCs; these systems support TransGrid’s power supply to the Broken Hill area.

The SVCs, which were originally installed in 1986, each consist of a 22 Mvar filter

This is the second ABB site in Austra-lia to introduce solar, reinforcing ABB’s commitment to clean and sustainable energy.

The 400 module photovoltaic (PV) installa-tion was commissioned in November and will contribute six percent of Moorebank’s daily energy usage - a site that covers over 27,000 square metres of office and factory space and accommodates nearly 500 employees.

“Solar is no longer just an alternative but a real energy choice,” said Axel Kuhr, ABB Australia’s country manager. “PV is becoming more competitive with main-stream energy sources as overall system prices decline.”

To raise the efficiency of the system, ABB installed its high performance PVS800 100kW central inverter. This inverter con-verts the direct current (DC) generated by

solar modules into high quality and CO2 free alternating current (AC) that can be fed into the distribution network. The op-timised system control and a maximum

power point tracking (MPPT) algorithm maximises energy and feed in revenues.

bank and a 50 Mvar thyristor-controlled reactor (TCR), to provide an effective operating range of -28 to +22 Mvar. The original installation was built by ABB, which put the company in a strong posi-tion to secure the refurbishment.

According to Andrew Joyce, ABB Austra-lia’s service manager for the east coast, a number of the SVCs’ components – in-cluding the MACH2 control systems, pro-tection systems, thyristor valves and cool-ing systems – had reached the end of their service life and needed replacing.

“These SVCs have been in service for 24 years; the control and protection systems are no longer able to be supported, there are limited existing spares for the control systems, and the reliability of the cooling systems are inadequate,” Andrew ex-plained.

“One of the major challenges with this project is that we are working within an operational substation, and this has re-quired some very careful planning.

“As the original OEM however, we have the right historical knowledge, and are in a prime position to refurbish this site.”

According to Andrew, the new ABB com-ponents scheduled for the Broken Hill SVCs will help provide grid reliability and productivity benefits for the TransGrid system.

“Grid reliability ‘helps keep the lights on’, this is so important now, with critical sys-tems around the world totally reliant on electricity,” Andrew said.

SVC upgrade to improve grid reliability

ABB goes solar at Moorebank facility

TransGrid and ABB work together to refurbish Broken Hill SVCs

ABB is reducing its environmental impact by installing a 100kW rooftop photovoltaic power system at its Moorebank, New South Wales site.

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Local news

RMIT has launched a new automation software engineering research centre, connecting the University with industry partner ABB

The launch of the Australia-India Re-search Centre for Automation Software Engineering (AICAUSE) was hosted by RMIT Vice-Chancellor and Presi-dent, Professor Margaret Gardner AO and was attended by dignitaries from ABB Australia and ABB India, as well as representatives from RMIT’s senior management.

The launch demonstrated the implemen-tation of the centre’s deployment of its core capability of cloud support, robotic testing and visualisation control, with the

facility at the City campus connecting with sites at ABB Australia and India.

Simon de Bell, Business Develop-ment Manager for ABB in Australia and AICAUSE Advisory Board member, high-lighted the critical role of innovation in securing the future of energy supply in Australia by saying, “Practical, results-ori-ented research alliances with universities such as RMIT are a fundamental element for ABB to deliver power and productivity in an energy-intensive world.”

ABB and RMIT launch Australia-India Research Centre for Automation Software Engineering

Mallikarjun Kande (ABB India) Professor Suresh Bhargava, Simon de Bell (ABB Australia), Professor Margaret Gardner AO and Professor Heinz SchmidtImages courtesy of RMIT

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Local news

Professor Heinz Schmidt, Director eRe-search and AICAUSE, said ABB Australia had provided a site in the AICAUSE Virtual Laboratory in Notting Hill, in the south-east of Melbourne, with connectivity be-ing provided to equipment deployed at RMIT’s City campus.

“Through the VITElab, ABB is also provid-ing access to its testing facility in Banga-lore - the largest such facility in the world,” he said.

Prof Schmidt continued, “By virtue of the ABB Bangalore Corporate Research Cen-tre, RMIT is linked into the global research network of ABB headquarters in Zurich, Switzerland. This network includes seven ABB corporate research centres and part-ner universities worldwide.”

AICAUSE was established in 2012 and enables the engagement of relevant research strengths from the Platform Technologies Research Institute and the Design Research Institute within the ABB-RMIT partnership, beyond software engi-neering.

It is designed to encourage partnerships across disciplines, with a number of re-searchers outside the School of Comput-er Science and Information Technology already involved in its activities.

The centre is also moving to establish an ICT focused PhD program with institutes in Bangalore, India, leveraging the ABB partnership in Bangalore.

Following the launch, guests joined a tour of the facilities including the Global Op-erations Visualisation, Advanced Manu-facturing Robot Interoperation Test and Cyber-Physical Simulation Rack labora-tories.

Improving resource sector productivity


The resources sector is moving forward as it

focuses more and more on ‘next generation

mining’, piloting and introducing new tech-

nologies in selected assets. These include

advanced exploration, integrated remote

operating centres, autonomous haulage,

autonomous drilling and different ways of

evaluating and modelling its products and

processes.

It is evident that the importance of automa-

tion in the new resources landscape is be-

coming increasingly clear as organisations

attempt to improve productivity, reduce costs

and increase safety.

RMIT and ABB along with the collaboration

of several resource organisations, are all in-

terested in exploring further development of

technologies in this area.

The challenge with automation is that it re-

quires remote control centres and that aspect

requires transformational change from the

business. This sort of revolutionary change

needs to take place while still maintaining val-

ue from increased production, consistency of

production performance and consistency of

maintenance of very long-lived systems.

AICAUSE aims to support the resources sec-

tor and address the need to invest in remote

operation monitoring and control. The goal

of the centre is to increase productivity by

developing technologies and training to reap

the benefits of automation and high-tech

transformation. We are actively looking for

new partners from the private sector.

One of the projects that AICAUSE is involved

in is geared towards “Collaborative Engineer-

ing”. This project explores means for sup-

porting digital collaboration between multiple

organisations and distributed sites such as

production plants for development, opera-

tion, maintenance, and services. The project

focus is on interoperability and interopera-

tion, both in the narrow technical sense as

well as in the organisational sense such as

dealing with barriers to sharing and exchange

of models, knowledge and technologies. The

benefits of these partnerships are of reduc-

ing costs or accelerating speed to market by

orders of magnitude.

The RMIT portion of the project started in

2013 and were looking for further partners

in this exciting area of engineering collabo-

ration support and knowledge sharing with

divisions of teams over distance, organisa-

tional, jurisdiction and national boundaries.

Scientific challenges addressed in collabora-

tive engineering also comprise security and

confidentiality issues, which are targeted us-

ing semantic interpretation and visualisation

of collaboration data and formal plant models

and exploratory means.

ABB is a partner organisation of AICAUSE

and is a proven performer in the oil and gas

industry and in mine systems automation.

ABB continues to expand its industrial solu-

tions for the hydrocarbon supply chain, en-

compassing production, processing, trans-

portation, storage and distribution.

14 Action 2|2014

Feature story

Driving industrial productivityAutomated processing helping to sustain Australian manufacturing into the future

Practicing what we preach: Robots assembling ABB circuit breakers

15Action 2|2014

Feature story

In Australia, manufacturing remains a cutting-edge and versatile industry and, despite some tough challenges, it has demonstrated a natural ability to adapt and prosper.

This article is intended to remind manu-facturers of the critical role they play in the longevity of Australia’s economy. It will also explain how adopting advanced, knowledge-based power and automation solutions can help companies increase productivity, reduce waste, and squeeze every last ounce of value from our finite resources.

Future-proofing industries

As the global economy’s centre of grav-ity shifts closer to Australia, local manu-facturers will be called upon to deliver innovations in food, housing, medical and consumer products – some of which have not yet been imagined. With the mining boom waning, manufacturers are required, to help drive our economic growth.

More than ever before, Australia requires a smart new breed of manufacturers to lead the charge, as we enter the next era of industrial productivity.

Unique challenges

The next 12 months will prove to be testing times for industry. Rising labour costs, skilled worker shortages, low-cost imports and the high Australian dollar are just some of the challenges companies face.

Importantly, with the recent announce-ments of the imminent closure of all auto-motive assembly lines within the next two to three years, many Australian-based companies will need to adjust their busi-ness models in order to serve non-auto-motive customers, or commence or ex-pand export activity, with a greater focus on global supply chains.

Add to this a dwindling pool of natural resources and a rising population, and it becomes clear just how important it is for

manufacturers and research and devel-opment (R&D) centres to find smart new solutions in order to remain competitive.

But with so much at stake – and a list

of bills and efficiency targets growing by the month – investing in new tech-nology at the plant level, to gear-up for future growth is often considered an insurmountable obstacle. While some companies are forging ahead, develop-ing new manufacturing strategies that will increase their future productivity, some businesses are finding it difficult just to stay afloat.

In the years to come, manufacturers across Australia will need to reinvigorate their growth plans, build their capabilities, lift business innovation, and establish the foundations for a more resilient and di-versified economy, to take the country forward in to a new age.

Key to this evolution is investing in a new breed of smart technology, such as ro-botics and automated processing sys-tems.

Now and in the future, it is of the utmost importance that manufacturers – small and large – are given the tools to help them understand how cost-effective, safe, reliable and easy-to-use, good au-tomation and robotics systems are. The Asian Century

Asia is the world’s most populated area and, within a few years, will be both the largest producer of goods and services, and the largest consumer of them.

In the not-too-distant future, Asia will also be home to the majority of the world’s middle class. This, according to a gov-ernment whitepaper published in 2013 called ‘Australia in the Asian Century’, poses a unique opportunity for the wealth of Australia, which will be boosted in the next decade through increased engage-ment with its neighbours.

Finding imaginative new ways to use robotics to increase production output and manufac-turing flexibility, and reduce material waste, can help local manufacturers mitigate the increasing pressures of the high dollar, wage growth and skilled worker shortages.

ABB robots packs up to 900 pieces of frozen

fish per minute

When family owned food processor Simplot

looked to improve its manual frozen fish pack-

ing operations in Australia, they turned to ABB

robots for the solution.

16 Action 2|2014

Feature story

Economic growth in Asia will continue to drive demand for Australia’s manu-factured goods, energy and mineral re-sources.

Local industry will endeavour to increase ties with Asia through manufacturing and R&D, and sharing knowledge within the two regions.

Though the Australian economy is cur-rently one of the strongest in the world – with a highly-skilled, creative and pro-ductive population, along with world-class educational institutions – the ex-tent to which our manufacturing industry taps in to this ‘Asia boom’ will be based on choice, not chance, the whitepaper warns.

Australian businesses are becoming in-creasingly outward looking, innovative and capable of acclimatising and re-sponding to change, and some manufac-turing businesses are already adapting to the opportunities presented by the Asian Century. ”Australia has a wonderful his-tory of innovation and inventiveness. It is very encouraging to see many of our local customers adapting their business models and increasing their uptake in

technology, in order to capitalise on the exciting opportunities presented by the Asian Century.” said Jussi Rautee, ABB in Australia’s Discrete Automation and Motion division manager.

According to the International Federation of Robotics (IFR)*, the automotive, met-als and electronics sectors are leading the charge in robotics uptake, with these industries driving the majority of global demand for the technology. (*Based on 2011 IFR statistics)

Technology for productivity

Technology is a well-recognised enabler of productivity improvement. From the in-vention of the first water pump in Egypt in 200 BC to the advanced, computer-based optimisation processes of recent times, technology harnessed to produc-tivity has improved living standards and transformed the lives of ordinary people all over the world. Industrial robots are often called ‘the extended arm of man’, in that they continuously advance pro-ductivity by meeting or exceeding strin-gent industrial requirements of precision and efficiency. Finding imaginative new ways to use robotics to increase produc-tion output and manufacturing flexibility, and reduce material waste, can help lo-cal manufacturers mitigate the increasing pressures of the high dollar, wage growth and skilled worker shortages.

Robots are usually associated with han-dling repetitive tasks in a process – either in high volume production roles or where flexible handling systems are needed for frequent changes. New technologies are proven to transform productivity and ef-ficiency for the better; integrating them into existing facilities results in much fast-er output, higher quality and greater flexi-bility, in virtually all production processes. Robot automation systems deliver a host of benefits in a wide variety of manufac-turing applications, including:- food and beverage- pharmaceuticals - foundry and forging - metal fabrication - plastics - automotive - packaging and palletising - electrical and electronics- solar and wood sectors

Technology is a well-recognised enabler of productivity improvement.

ABB robot helps keep trailer maker competitive with 60 percent productivity increase

An industrial robot installed on a linear track system has increased productivity and turnover for

Brisbane-based Drake Trailers, one of Australia’s largest manufacturers of low-loader and specialist

large scale trailers.

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Feature story

The latest statistics from the IFR indicate a record-breaking number of industrial robots are being installed worldwide. And it’s no wonder: with a growing number of case studies showing why it’s worth in-vesting in robotic automation, the global robotic ranks are expected to swell to 1.3 million machines in 2014.

Manufacturers around the globe have been touting the importance of opera-tions analysis for years, with the old ad-age “You can’t manage what you don’t measure” now a part of the industry ver-nacular. More recently, companies are realising that gaining control of their key process variables – quality, safety and waste – is not just beneficial, but para-mount in order to remain competitive.

It is well-known that if quality, safety and waste are managed correctly, produc-tion costs will fall. In the future howev-er, successful manufacturers will focus their efforts not only on reducing cost, but identifying efficiencies. Streamlining workflows, and improving the visibility of enterprise information, will help manufac-turers make important decisions as they start building a more responsive and ag-ile organisation, through improvement in productivity and efficiency.

While the possibility of reducing day-to-day manufacturing costs alone is a com-pelling reason to invest in new technolo-gy, the industry’s crucial role in the future wealth of our nation makes a critical case for embracing new and proven automat-ed processing techniques.

Don’t get left behind

Manufacturers, who make the choice to invest in the future wealth of their busi-nesses, building their capabilities and lift-ing business innovation, will be in a much better position to take advantage of fu-ture opportunities like the Asian Century.

Sitting still will allow the competition to get further ahead, and ‘band aid solu-tions’ will often cost more in the long run. With technology suppliers constantly im-proving their robotics and automation of-ferings – especially in the areas of speed, power consumption and safety – ‘invest-ing to save’ is the mantra many smart manufacturers are adopting.

“Robotics technology is becoming in-creasingly versatile, with many robots

being deployed into a variety of new ap-plications,” said Olivier Coquerel, ABB’s business unit manager for Robotics in Australia. “Beyond the production envi-ronment, robots are also driving down cost and increasing productivity in areas such as warehousing and distribution.”

For example, technology suppliers have been working hard to minimise the foot-

print and increase the flexibility of indus-trial robots, making it easier for units to be incorporated in to existing operations. These robots offer increased dexterity, with more axes of movement than ever before, thereby greatly improving the speed and flexibility of traditional pro-cesses.

In the packaging world, robot-based au-tomation ensures the kind of flexibility needed to handle ever-shorter product lifecycles, new packaging designs, prod-uct variants and batch manufacturing. Compared to dedicated hard automation, robot lines are shorter, and allow far bet-ter utilisation of floor space.

In the pharmaceuticals industry, the ab-solute accuracy, repeatability and high up-time of robots suit perfectly the de-mands on quality validation and trace-ability in the sector, offering massive improvements over manual operation or

dedicated production equipment.

In the metal fabrication and welding mar-ket, advances in robotics programming simplicity are allowing smaller shops to accurately and quickly weld limited vol-umes of highly diverse parts. Pre-engi-neered, standard solutions can be up-and-running in a day or less, providing companies with a significant advantage

“Beyond the production environment, robots are also driving down cost and increasing productivity in areas such as warehousing and distribution.”

ABB robot solves skills shortage for Australian coatings specialist

ABB robots have helped custom joinery coating specialist, Hilustre of Australia solve their skills shortage.

They now produce consistently high quality products with increased flexibility and improved efficiency -

and with no specialist painting skills required.

18 Action 2|2014

Robot revitalises pharmaceutical packaging line in Melbourne

An ABB FlexPicker robot plays a role in an expanded packaging line that has increased production and

throughput at a pharmaceutical plant in Melbourne, Australia. The system packs sterile nebules into

blister packs.

Feature story

over their competitors. Highly sophisti-cated robots can also be incorporated into existing metalworking operations to tend CNC machines, without the need for extra floor-space and without block-ing operator access.

Why robotic automation

Robotic automation presents an increas-ingly attractive option for today’s compa-nies looking for ways to balance enhanced competitiveness against tightening costs and spiraling overheads. Robots have been proven to reduce operating costs, material waste and capital costs, while improving product quality, and increas-ing production output and manufacturing

flexibility. They can also improve the qual-ity of work for employees, improve health and safety, reduce labour turnover, and save floor space.

Take energy for example. With no re-quirement for minimum lighting or heating levels, robots offer a great opportunity to cut your energy bills. Current estimates point to a potential saving of eight per-cent for every 1°C reduction in heating levels, while savings of up to 20 percent can be achieved by turning off unneces-sary lighting.

The inherent accuracy and repeatabil-ity of robots means you can achieve a consistently high-quality finish for every product produced. Robots eliminate the problems associated with tiredness, dis-traction and the effects of repetitive and tedious tasks. Robots can be left running overnight and during weekends with little supervision, helping companies increase output levels and meet customer order deadlines.

In terms of flexibility, once programmed, robot systems can easily switch between processes, helping businesses meet changes in product design or customer demand, with the minimum of effort. Fur-ther, the quality of these products will be vastly increased; manufacturers will have more products finished on the first run to the standard required by their custom-ers, reducing the amount of breakages and waste produced as a result of poor-quality or inconsistent finishing.

Workers will benefit from an automated process line, too; robots can readily take over unpleasant, arduous or health threatening tasks that may be currently undertaken by manual workers. They can also decrease the likelihood of accidents caused by contact with machine tools or other potentially hazardous produc-tion machinery or processes. Robots can help to eliminate ailments associated with repetitive or intensive processes, such as repetitive strain injuries (RSI) and vibra-tion white finger (VWF).

New technology also allows operators to enter the working area of the robot, with-out risk of injury.

In the packaging world, robot-based automation ensures the kind of flexibility needed to handle ever-shorter product life-cycles, new packaging designs, product variants and batch manufacturing.

19Action 2|2014

Electrolux automated their manufacturing facility in Adelaide

Electrolux in Adelaide have gained improved quality, increased productivity and safety, flexibility and

reliability by choosing robot-based automation for their door bonding facility.

Robot made a big difference to hot, dusty and previously hazardous environment

Perth based manufacturer or fastenings, Donhad found the benefit of installing the robotic system is

two-fold; First was the risk of injury is greatly reduced as the robot now performs the grinding tasks and

secondly was the quality of the final product is improved due to the repeatability that the robot delivers.

Feature story


Robots can be mounted in multiple con-figurations to help save highly valuable space in manufacturing areas. They can also be programmed to work in confined spaces, and can be mounted on shelf systems, walls, or even ceilings.

Robots are now available with all these features and benefits and, when teamed with advanced, knowledge-based power and automation solutions – such as in-tegrated control systems allowing pro-gramming, simulation and production monitoring – serve the twin goals of en-hanced productivity and eco-efficiency.

No doubt, there has never been a better time to invest in the future productivity of both your business, and Australia.

Of course, every manufacturer is differ-ent, and companies should take the time to seek expert advice about how they can plan for their future.

Robots have been proven to reduce operating costs, material waste and capital costs, while improving product quality, and increas-ing production output and manufacturing flexibility.

20 Action 2|2014

Global news

ABB to equip Sweden’s next-generation high-speed trains

Swedish state-owned rail firm, SJ has issued ABB with a $200 million order to supply the electrical systems for all of its 36 ‘SJ 2000’ next genera-tion high-speed trains.

This order follows an earlier roll-out of 50 ABB DC fast chargers at the beginning of 2013 and brings CLEVER’s total nation-wide network of DC fast chargers to 100 locations. CLEVER’s network comprises both AC and DC chargers, supporting all electric vehicles on the Danish market. ABB’s Terra 51 is specially designed for free-way driving and is capable of charging an electric vehicle in 30 minutes or less. Expansion of nationwide infrastructure network with 50 smart DC fast chargers is expected to take 6 weeks.

The CLEVER network of DC fast char-gers and AC chargers builds on Den-mark’s commitment towards becoming independent of fossil fuels by 2050.

Map of CLEVER’s charging network in Denmark

Click to play the videoABB Chief Executive Officer, Ulrich Spiesshofer receives the award for ‘large corporation’ from His Highness General Sheikh Mohammed bin Za-yed Al Nahyan, Crown Prince of Abu Dhabi

Photo credit: Ryan Carter / Crown Prince Court – Abu Dhabi

ABB EV chargers the CLEVER choice

Leading Danish electric-mobil-ity operator CLEVER selected ABB to supply 50 Terra 51 DC fast chargers for CLEVER’s country-wide network.

The SJ 2000’s upgraded electrical sys-tems will ensure more reliable power sup-ply while reducing energy consumption in a significant way. Punctuality, reliability and higher comfort are key factors to fur-ther improve customer satisfaction.

ABB will supply the entire power con-version and control systems on the trains, delivering modern technology for the coming decade. The trains, which were launched in the late 1980s, will also be equipped with a new, fresh-looking inte-rior design.

The first retrofitted train will be deliv-ered in 2015. After successful testing and evaluation, the remainder of the trains will be built incrementally through 2019.

ABB wins Zayed Future Energy Prize 2014

“It is a great honour to have won the Za-yed Future Energy Prize 2014,” said ABB Chief Executive Officer, Ulrich Spiesshofer. “ABB stands for power and productivity for a better world. This prize underlines our re-lentless drive for innovation to create new offerings and value propositions for our cli-ents in the renewable energy and energy efficiency fields.”

The Zayed Future Energy Prize was launched in 2008 to recognise and reward the very best solutions in renewable energy and sustainability.

Gaining the prestigious accolade against big international rivals highlights ABB’s driving concerns with energy ef-ficiency, sustainability and advanced technology, whether via breakthroughs in high-voltage direct current, electric vehicle charging or renewables and solar power.

8 Contact us for more information 8 Contact us for more information 8 Contact us for more information

ABB has been awarded the Za-yed Future Energy Prize 2014 in recognition of its efforts to drive innovation, renewable energy and energy efficiency.

21Action 2|2014

Global news

World’s largest EV fast charger network in China

ABB announced a strategic collaboration with Shenzhen BYD Daimler New Technolo-gy Co. Ltd. (BDNT) to supply direct current fast chargers for DENZA starting mid- 2014.

ABB has successfully com-missioned four low-speed dual pinion drive systems at the De-tour Lake gold mine in Ontario, Canada.

These systems include the largest low-speed dual pinion mill drives in the world. The low-speed concept operates with-out a gearbox, with motors driving the pinions directly, thus increasing overall system efficiency. ABB’s state-of-the-art dual pinion mill drive systems are the most operation and mechanically-friendly solutions available on the market today. Features include variable-speed opera-tion, real time frozen charge protection, the frozen charge remover function, con-trolled roll-back and positioning without additional drive.

These features and drive characteris-tics enable smooth mill operation, reduce maintenance requirement, increase ener-gy efficiency and availability of the com-plete production line.

The wall-mounted chargers will have in-novations designed for user convenience and safety such as a mobile app for re-mote monitoring and control of charging sessions with the option of charging sta-tus change notifications.

The fully electric DENZA car is de-signed for journeys of more than 200 kilo-metres and is among the first long-range EVs to go on sale in China. DENZA will of-fer its customers the convenience of fast charging at home, at work or at public charging stations and will have its world premiere at the 2014 Beijing Auto Show.

World’s largest ring-geared mill drives commissioned by ABB

The Grand Egyptian Museum (GEM), the largest archaeolog-ical museum in the world, will soon be equipped with ABB’s reliable power and automation technologies.

Managing power at King Tut’s new home

Envisioned as an architectural master-piece, the GEM is spread over 48.6 hect-ares (120 acres) of land and borders the timeless Giza pyramids. In fact, the over-all framework for the design is a set of visual axis that emerge from the pyramids to the site of the museum.

The museum will pay homage to over 100,000 pieces of ancient Egyptian art and artifacts including the famous golden mask of King Tutankhamun. The museum opens in 2015.

ABB was awarded the GEM project by the Orascom Construction/BESIX joint venture to furnish the complete electrical package. The scope includes an Extend-ed Automation System 800xA to manage the power, transformers, medium-voltage switchgear, ring-main units, low-voltage panels, a Supervisory Control and Data Acquisition (SCADA) system, and retract-able supply post panels. ABB heating, ventilation and air conditioning (HVAC) drives will also be installed in pump and fan applications including commissioning and start up.

8 Contact us for more information8 Contact us for more information 8 Contact us for more information

Grand Egyptian Museum key plan

22 Action 2|2014

Applications

ABB variable-speed drive systems are revolutionising the mineral and ce-ment industries. Having recently set new power rating records for SAG mills, ball mills and ring-geared mills, ABB delivered and commissioned one of the world’s most powerful drive systems for high pressure grinding rolls at the Boddington Gold Mine in Australia.

The solution is part of a remarkable cat-alogue of achievements that has taken cement and mineral productivity onto a new and higher level. ABB continues extending the frontiers of grinding opera-tions by delivering or winning orders for some of the most powerful drive systems in all main grinding applications - semi-autogenous (SAG) mills, ball mills and HPGRs.

In brief, some of these are:- Two 28 MW GMDs for the 40-foot

Taking mineral productivity to a higher level

SAG mills and four 22 MW GMDs for the 28-foot ball mills at the Toromocho and Bozshakol copper mines in Peru and Kazakhstan. When both mines are commissioned, they will have the most powerful SAG mill GMDs and largest ball mill GMDs in operation.

- The world’s most powerful ring-geared mill drives currently in operation at the Detour Lake Gold Mine in Canada. Each of the four dual pinion RMDs has a rating of 15 MW and is designed for low-speed operation in two ball mills and two SAG mills. All four mills have been commissioned. In addition, ABB will deliver 18 MW dual pinion low-speed mill drive systems for two 36-foot SAG and three 26-foot ball mills and one 11 MW dual pinion low-speed drive system for a regrind mill for the Hycroft mine in Canada.

- And, for the Boddington Gold Mine, the four 2 x 2.8 MW drive systems for the HPGRs are among the most powerful

One of the world’s most powerful HPGR drive systems installed at Boddington Gold Mine – photo courtesy of Newmont

23Action 2|2014

Applications

and largest in the world. ABB has also delivered similarly powerful HPGR drive systems to the Karara iron ore mine and Cadia East gold and copper mine, both of which are also in Australia.

In fact, ABB drive systems have played a pivotal role in helping HPGR technology become a high-throughput and energy-efficient grinding process and a competi-tive alternative to SAG mills throughout the past decade. During this period ABB has raised the power rating record for HPGR drive systems on three separate occasions – from 2 x 1 MW for the São Luís iron ore pelletising plant in Brazil in 2002 to 2 x 2.5 MW for the Cerro Verde copper mine in Peru in 2006, and now 2 x 2.8 MW for Boddington and the Karara and Cadia East mines in Australia. ABB also has the designs in place to meet HPGR power requirements of around double the present record. By currently having the largest installed base for HP-GRs worldwide, ABB can draw from vast experience to continue optimising the HPGR drive system to bring more value to the solution.

Maximum process controlABB variable-speed drive systems for HPGRs are complete solutions. They encompass the medium voltage circuit breaker, converter transformer, motors and frequency converters. Such is the efficiency and accuracy of ABB drive systems that they enable the HPGRs to always operate optimally whatever

the grinding conditions. For a mine like Boddington with four HPGRs running 24 hours a day, 360 days a year, this can significantly improve the operating mar-gins of the mine.

HPGRs consist of two counter-rotating rolls, one fixed and the other floating. The ore is fed from a hopper into the gap between the rolls for crushing at high pressure. ABB variable-speed drive sys-tems enable the grinding rolls to operate at optimal speed. They provide accurate load sharing between the two rolls, and are network friendly.

The drive systems allow the speed of the rolls to be varied. This makes it pos-sible to adjust the HPGR to the actual grinding conditions and the properties of the ore, which can change considerably throughout the life time of the mine. They also enable throughput to be maintained at nominal values by compensating, through the increase of the motor speed (rpm), the reduction of the circumferen-tial speed caused by the roll wear.

Thanks to ABB’s Direct Torque Control technology, the drives have the fastest torque/speed response on the market. This enables them to respond quickly and accurately to the frequent load tran-sients typical of HPGR applications. The power factor is greater than 0.95 throughout the entire speed range, which eliminates the need for power factor cor-rection equipment. The overall result is maximum process control and continu-

ity, and minimum wear and tear of the mechanical equipment.

Australia’s largest gold mineOwned by Newmont Mining, one of the world’s largest gold producers, Bod-dington Gold Mine lies about 130 km southeast of Perth in Western Austra-lia. Production at the mine began in September 2009 following the complete modernisation and expansion of an ex-isting mine, which was closed in 2001. The new state-of-the-art Boddington mine produced 724,000 ounces of gold and 67 million pounds of copper in 2012. Its current outlook for 2013 is between 700,000 – 750,000 ounces of gold. As at December 31, 2012 Newmont reported 18.6 million ounces of gold reserves and 2180 million pounds of copper reserves at Boddington.

The four HPGRs at Boddington were provided by Polysius, the world’s lead-ing supplier of HPGRs. Polysius has a market share of 60 percent in the mineral industry and an installed base of more than 260 high pressure grinding rolls in various industries.

In fact, ABB drive systems have played a pivotal role in helping HPGR tech-nology become a high-throughput and energy-efficient grinding process and a competitive alterna-tive to SAG mills through-out the past decade.

ABB variable-speed drive systems enable the grind-ing rolls to operate at op-timal speed.

ABB’s ability to deliver a complete drives system is of huge significance for both Polysius and New-mont Mining.

24 Action 2|2014

Applications

Located upstream of four ball mills, the HPGRs have a roll diameter of 2.4 m, a width of 1.7 m and a design throughput of 2,313 tons per hour. They are driven by two ABB variable- speed drive sys-tems, each of which comprises two con-verter transformers, two medium voltage frequency converters and two squir-rel cage induction motors. Each drive system has a power rating of 2.8 MW. ABB adapted the drives to meet Austra-lian electrical and safety standards, and provided transformers manufactured at an ABB Australia transformer factory to meet a request from the mine’s owners for locally produced equipment.

ABB’s ability to deliver a complete drives system is of huge significance for both Polysius and Newmont Mining. The key components – circuit breakers, trans-formers, drives and motors – are all products in which ABB is the market and technology leader. ABB is also the mar-ket and technology leader in drive sys-tems for grinding mills and is a key pro-vider of complete power and automation solutions for mines, cement plants and mineral processing facilities. The com-pany’s comprehensive portfolio includes

industry-leading collaboration produc-tion management solutions.

This extensive application and process expertise means that ABB has a unique ability to provide a complete grinding roll solution that matches the exact require-ments of the plant and the customer. For Polysius, this translates into low risk, supplier reliability and proven technol-ogy; for Newmont Mining it means all of those things and – most importantly – a lower cost of ownership over the entire life cycle of the drive system.

Sharing the loadOne of the key factors determining HPGR performance is load sharing be-tween the two rolls. The circumferential speed of the two rolls has to be as close as possible to minimise wear, and the torque has to be equal to avoid perma-

nent overloading of one of the rolls and the drive train. The ABB drive system has inbuilt fiber optically connected master-follower control modes, which perform uniquely accurately and with coordinated load sharing.

Figure 1 shows the torque and speed measurements of both motors for HPGR 02 at nominal throughput over a 10-min-ute period on 19 Nov 2010, 15 months after commissioning. The chart shows the accuracy with which the load shar-ing between the master and follower drives are performed by the frequency converter. It is clearly visible that the mo-tor torque (green and light green scale) and the motor speed (blue and red scale) from master and follower drives are virtu-ally overlapping. This means that the dif-ference between the speed and torque (violet scale and turquoise scale) of the master and follower motor is kept close to zero during operation. What is also noteworthy is how quickly the torque and speed difference converges at near-zero conditions. This is due to the fast dynamic response of ABB’s renowned Direct Torque Control technology.

Measurements like these are part of the feedback that ABB provides to the me-chanical supplier in order to help opti-mise the installation and improve over time the design of the HPGRs and the drive system.

Mining Industry -- The Future is Automation

Figure 1

One of the key factors de-termining HPGR perfor-mance is load sharing be-tween the two rolls.

The package uses a re-mote access platform to provide secure, real-time monitoring and control of the HPGRs.

25Action 2|2014

Applications

Remote monitoring and diagnosticsTo ensure that the HPGRs continue to operate at peak efficiency and with maximum protection, Newmont Mining has opted for ABB’s remote diagnostics services. This package of vital tools and services combines remote connectivity, communications security, and advanced monitoring and analysis with global tech-nical support.

The package uses a remote access plat-form to provide secure, real-time moni-toring and control of the HPGRs. The platform consists of a virtual support en-gineer located at the mine that monitors the supported products and systems; a service centre that acts as a knowledge repository, control centre and communi-cations hub; and a communication serv-er that provides secure, encrypted and authenticated communications over the Internet between the service centre and the virtual support engineer. (The mea-surements in figure 1 were extracted by means of this remote access platform).

The benefits for Newmont Mining are considerable. Remote monitoring mi-nimises unplanned interruptions and im-proves the overall equipment effective-ness (OEE) of the system components over their life cycle. It provides Newmont with round-the-clock access to ABB en-gineering expertise and support, as well as a structured range of tools and servic-es that support maintenance programs and schedules.

The HPGR drive systems are not the only instance of ABB’s involvement at Boddington. In a separate contract not connected to the HPGR solution, ABB provided a turnkey 132 kV substation comprising 132 kV air insulated switch-gear, three 132/33 kV 110 MVA trans-formers, control and protection panels, substation automation equipment, and capacitor banks and detuning reactors. The capacitor banks improve the power factor of the entire mine and reduce line harmonics. They are activated automati-

cally and typically control power factor between 0.98 lagging and unity. Har-monic filtering is not required at the mine and total harmonic distortion figures are very low.

The significance of BoddingtonThe success of the Boddington HPGRs has provided the market with the confi-dence it needs to accept HPGR technol-ogy as proven, reliable and beneficial. The Polysius-ABB solution for Cerro Verde in Peru in 2006 was the turning point in this process of acceptance in that it was large (four units), powerful (2 x 2.500 MW) and fast (1,200 rpm). Although sub-sequent solutions for mines in Canada, Australia and Peru helped cement con-fidence, the sheer size, throughput and power rating of Boddington has brought final proof that HPGRs are a proven, pro-ductive and highly efficient alternative to SAG mills.


The success of the Boddington HPGRs has provided the market with the confi-dence it needs to accept HPGR technology as proven, reliable and beneficial.

26 Action 2|2014

Applications

At GWF’s Castlemaine production site, there are 16 ABB robots working to serve 32 packaging lines, making it the biggest robotic palletising system in the country.

The palletising line collects over 450 different products at the rate of about 9,000 cartons per hour, coming from four different packing areas. Some 27 lines and more than a kilometre of con-veyor bring products into the palletising cell, which has 16 ABB robots serving 32 pallet stations, and another robot at the front of the station preparing the pallets. Finally, two rail systems with four shuttles deposit the finished pallets at two stretch wrapper stations, which wrap more than 100 loaded pallets an hour and feed them to the automated guided vehicles (AGV’s).

Four key production areasThe GWF Castlemaine operation pro-duces a wide range of smallgoods which are supplied to consumers through the retail food service and small distribu-tor network. The factory is divided into four key plants: ham, bacon, salami and continental small goods. Each of these production areas is serviced by a shared palletiser and distribution service.

GWF packaging team leader, Troy Thom-as, said: “The problems we were expe-riencing before the robots were from

Click to watch the video

Watch how 16 ABB robots serve 32 packaging lines, collecting over 450 different products at the rate

of about 9000 cartons per hour, coming from four different packing areas

ABB robotics at the centre of Australia’s largest palletising solution George Weston Foods (GWF) is one of Australia and New Zealand’s largest food manufacturers, employing around 8,000 people at nearly 60 sites. The new GWF production facility in Castlemaine, Victoria is now home to Australia’s largest robotic palletising system, featuring 16 ABB palletising robots.

27Action 2|2014

Applications

manual handling, including occupational, health and safety (OHS) issues, down-time and not getting product out fast enough, and the labour cost.”

Kim Martin, GWF’s supply chain manag-er, said: “We had challenges with retailers in terms of making sure the consistency and quality of the pallets was as required for their automated networks. And like everyone else, we also had increasing la-bour costs and concerns about our abil-ity to make the productivity targets we needed in order to remain competitive.”

“The market trend is towards smaller, more shelf-ready pack sizes,” Kim add-ed. “Obviously that increases the repeti-tiveness of the tasks, therefore increasing our OHS risk as well, which is probably the main issues that we have on site.”

Troy added, “I think the defining factor was knowing that we could eliminate a lot of manual handling and remove a fair bit of the associated labour costs.”

Kim said the ability to manage produc-tion speed and volume in four facilities that empty product into a central dis-tribution space is definitely improved, and was accomplished in the available footprint. “And we have obviously seen a huge reduction in OHS injuries associ-ated with palletising, because we have largely eliminated that task,” she added.

“Other improvements are significantly re-duced levels of pallet rejections from cus-tomers, and the ability to deal smoothly with the production volume now being processed out of this site as each of the facilities have come online.”

Melbourne-based Andrew Donald De-sign Engineering (ADDE) designed and installed the system for GWF. ADDE Gen-eral Manager, Barry Hendy, said: “We chose the IRB 4600 robot because the orientation and positioning of the cartons meant we needed the extra dexterity of a six-axis robot. This ensures the stations will be able to handle all of the palletising tasks coming in from the conveyors.”

Line configuration was chosen based on the speed of the individual lines. Each automated row is able to look after two lines and maintain the rates on those two lines, which dictates the line configura-tion of 16 robots, serving the 32 pallet stations.

“We’re very happy with the way the proj-ect is working to specifications,” said Barry. “The customer is very happy, and it is a great-looking facility. Building greenfield allowed us to make a world-class facility.

GWF’s new palletising system can process up to 9000 cartons of smallgoods in an hour


“We have obviously seen a huge reduction in OHS in-juries associated with pal-letising, because we have largely eliminated that task.”

“Other improvements are significantly reduced lev-els of pallet rejections from customers, and the ability to deal smoothly with the production volume now being processed out of this site as each of the facilities has come online.”

28 Action 2|2014

Product news

Process Automation

Advantages − Freelance has been around

for approximately 20 years − Engineers continually lever-

age research and new tech-nologies

− More power, more speed and more functionality

ABB’s Freelance Version 2013 distribut-ed control system has been named “Best Product of the Year 2013” (Process and Advanced Control) by Control Engineer-ing China, one of the Asian regions lead-ing trade publications.

With more than 18,000 installations spanning more than 100 countries, ABB continues to introduce innovations in its Freelance distributed control system

ABB Freelance wins at 10th Annual Best Product Award ceremonies in Shanghai.

(DCS), a full-fledged distributed control system that combines the advantages of both worlds by having the small footprint of a PLC with the full functionality of a DCS.

Freelance Version 2013 is the latest re-lease and our answer to the ever-increas-ing demands of our customers for more power, more speed and more functional-ity from their DCS.

Best Product of the Year


29Action 2|2014

Product news

Discrete Automation and Motion Discrete Automation and Motion Power Products

Advantages − Increased public and opera-

tor safety − Increased system and pro-

cess availability − Minimised repair costs after a

fault event − Limit system down time

Advantages − Real-time tactile feedback − Reduced risk of assembly

failures − Fully integrated into ABB’s

hardware and software − Suitable for high precision

robotic applications

Advantages − Increased accuracy, payload

and speed − Power consumption lowered

by 15 percent − Four variants ranging in pay-

load from 150 to 235 kg − 2.65 to 3.20 metres reaches

Integrated Force Control makes robots more intelligent.

ABB’s new technology, Integrated Force Control, makes robots more intelligent and able to handle variations to a pro-cess with real-time external inputs and the sensitivity of the human hand while shortening programming time up to 70 percent.

Integrated Force Control allows the robot to react to its surroundings and can deviate from a programmed path or speed, based on feedback from the force sensor. A force-controlled robot can be programmed to mimic the movements of a human arm, applying search patterns to find the correct position to assemble a given part.

Multitude of new generation im-provements delivering a lifetime of affordability and reliability.

ABB has released the IRB6700 which is the newest flagship model in the largest heavy duty modular family of robots.

Every robot in the 6700 family has been designed to accommodate Lean ID—a new Integrated Dressing (ID) solution to achieve a balance between cost and du-rability by integrating the most exposed parts of the dress pack into the robot.

Equipping an IRB 6700 with Lean ID makes it easier to program and simu-late with predictable cable movements, creates a more compact footprint, and lengthens service intervals due to less-ened wear and tear.

ABB’s ABBACUS Metal Enclosed Capacitor Bank (MECB) introduces Q-ACT, the latest innovation in arc fault containment technology.

The type tested protection system utilis-es ABB’s advanced sensing and tripping relays in conjunction with a sophisticated fibre optic network to detect the onset of an arc.

Using ABB’s Ultra-Fast Earthing Switch (UFES) device, the arc is extinguished in less than four milliseconds leaving the metal enclosed capacitor bank and its components completely undamaged and operational after an arc fault.

8 Contact us for more information 8 Contact us for more information8 Contact us for more information

Q-ACT Arc Containment Technology Metal Enclosed Capacitor Banks

Seventh generation of large industrial robots

ABB robots get smarter

Register for Ventyx World Asia Pacific 2014July 23-25, 2014 Gold Coast, AustraliaRegister now: www.ventyxworld.com/en/region/asiapacific

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