page 3

page 6

page 7

page 11

page 12

West Coast Main Line powers ahead

Transformer services

Real choice for newconnections

JAS the collaborative wayforward for National Grid

ZX family MV switchgear

www.abb.com/ffwd

The longest way

FAST FORWARD WITH ABB POWER TECHNOLOGIESSummer 2005

ABB HVDC converter technology will play a majorrole in the world’s longest submarine power link –page 9

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02 FFWD >> Summer 2005

Published by:ABB LimitedPower Technologies Oulton Road, Stone, Staffordshire ST15 0RS

Editor: Karen Strong

Telephone:01785 825050

www.abb.com/uk

contents Investment anddelivery in thespotlight

Electricity networks are on the verge of some of the most far-reaching changes for almost half a century. Under the newdistribution price control review (DPR4), electricity DistributionNetwork Operators (DNOs) will be able to spend £5.7 billion overthe next five years in strengthening and developing their networks.This is an increase of around 48 percent over current levels.

This investment, coupled with the introduction of the newregistered power zones which provide financial incentives forDNOs to offer innovative options for generators wanting toconnect to their network, will help remove the barriers to furtherdevelopment of distributed generation and CHP, andaccommodate growth in renewables.

Such significant and rapid investment will require newcollaborative ways of working by DNOs and suppliers. There willbe increased emphasis on contractual transparency, risk sharingand involvement of key suppliers at the initial network designstage.

The key technical problems associated with increasing levels ofdistributed generation are fault-level management, power-flowmanagement and voltage control. As the design, operation andmanagement of networks evolve there will be an increasing needfor more intelligence in power systems, the adoption of newinnovative connections and more actively managed networks.Technologies such as FACTS (Flexible AC Transmission Systems)devices, HVDC transmission, HVDC Light, demand-side and widearea monitoring systems will be fundamental to ensuring securityand quality of supply.

Some insight into how ABB is developing its approach isaddressed by articles in this issue including co-operating withNational Grid’s collaborative practices and working with DNOsand customers to implement new connections quickly, efficientlyand economically.

London’s success in winning the 2012 Olympics will provide afurther boost to UK investment, as the infrastructure to supportthis exciting and ambitious project is created. Along with otherUK-based companies we congratulate the London team on itssuccess and welcome this tremendous opportunity.

Issue 11 Summer 2005

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Trevor GregoryABB UK Managing Director

3 West Coast Main Line powers

ahead

ABB project manager Sarah Hadfield reports on thelatest developments in the power upgrade work on theWest Coast MainLine

4 News

UK and international news

6 Transformer services – the route

to maximum availability

Ian Addison explains how ABB’s UK service team cankeep power transformers running efficiently and reliablyfor a longer working life

7 Real choice for new connections

ABB is one of a handful of companies in the UK to gainfull recognition under the National ElectricityRegistration Scheme as an independent connectionprovider

8 Investing in the way ahead

Duncan Botting outlines how ABB is engaging withgovernment, regulatory bodies, institutions andcustomers to understand and resolve some of the keyissues facing the power industry

9 The longest way

ABB technology will play a major role in creating thenew NorNed link, connecting the national grids ofNorway and the Netherlands

10 Technology

Introducing the new Uvisor MFD flame detection systemand ABB’s global technology magazine

11 JAS the collaborative way

forward

National Grid network design manager Andy Stevensondescribes JAS (Joint Activity Solutions) which iscurrently being trialled with ABB

12 Meet the ZX switchgear family

Whatever the primary switchgear application – ABB’s ZXfamily of gas insulated MV switchgear has it covered

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

>

7941 FFWD July05.qxd 15/7/05 6:05 pm Page 2

A key aim of the programme isto provide 125mph routecapability for tilting trains, such asthe new Virgin Pendolinos. Tomeet this need, Network Rail isupgrading its trackside powersupplies. ABB has been involvedwith the WCML since 1999, whenwe were awarded the contract tobuild a new 400/25kV substationat Patford Bridge, nearNorthampton.

RUGELEY

Most recently, we havesuccessfully completed a two-year,£9 million project to upgrade theexisting substation at RugeleyPower Station in Staffordshire toprovide two new 400/25kVWCML feeder connections. Thisinvolved the installation of twoABB 400/26.25-0-26.25kV40+40MVA SGTs (supergridtransformers) at the 400kVNational Grid substation - oneconnected into an existing sparebay, the other into a new bay. Also included, was theconstruction of a new 25kVcompound and associatedswitchgear, and the provision of25kV XLPE cables and associatedfibre optic pilots between the twosites.

The Rugeley project proved anexcellent example of the value ofboth advanced planning and a highlevel of co-operation, liaison andteamwork between ABB andNational Grid. These enabled keyelements to be completed on-time,including the phasedcommissioning of the two circuitsand reactor changes. Everythingwas ‘right first time’ within a verytight schedule. And just asimportant, the planning andorganisation helped to establish afantastic health and safety record,with over 90,000 man-hourscompleted on site without a singlelost-time incident.

NICAP

The team forged at Rugeley hastaken this positive experienceforward into two new 400/25kVconnection projects in Cumbria. Inthe drive to deliver increasedefficiency and maximum value formoney we are defining a commoncore scope and engineered solution.So, instead of the traditionalsolution employed at Rugeley, weare adopting a bay solution for thesubstation protection andautomation systems based onNational Grid’s standardisedNICAP (National scheme forIntegrated Control AndProtection) philosophy. This willoffer some important advantages,including the ability to condensethe same functionality into a muchsmaller footprint, and a higher levelof factory assembly and testing toreduce the need for expensive on-site work.

Summer 2005 >> FFWDFFWD >> www.abb.com/ffwd 03

substations

West Coast Main Line powers ahead

ABB has won all the 400kV power upgrade ordersplaced to date for the northbound section of theWest Coast Main Line. ABB project manager SarahHadfield reports on the latest developmentsincluding the successful completion of the Rugeleyupgrade project.

Sarah Hadfield, project manager for Rugeley

The WCML power upgrade project enables trains to run atup to 125mph

The West Coast Main Line (WCML), which runs 641 miles from Euston station in Londonto Glasgow Central and Edinburgh Waverley stations, is the UK's busiest mixed traffic

railway. But over 2,000 passenger and freight train movements each day, and more than 75million rail journeys each year, were taking their toll on an infrastructure that had not seen anysignificant investment since the 1960s. That’s why Network Rail embarked on its West CoastMain Line modernisation programme - Europe's largest wholesale rail renewal scheme.

7941 FFWD July05.qxd 15/7/05 6:05 pm Page 3

The new Broughton Bridge suspension bridge is a new and veryvisible landmark in Milton Keynes. ABB was chosen by main

contractors, GallifordTry to provide and install all the lighting for thebridge and its approaches.

The 40-metre bridge with its 35-metre high mast is fitted with an aircraft warningbeacon. It has been built to provide access to the Broughton area of Milton Keynes.

Since construction work finished ABB has completed the contract to providepower, flood lighting and roadway lighting to the structure.

04 FFWD >> Summer 2005

news

TLC for hospital power supply

Bridge over untroubled waters

As demand for the health servicesprovided by Milton Keynes General

Hospital grows, reflecting thedevelopment of the surrounding area, sodoes the need for the power. For this thehospital looks to ABB specialist expertiseto provide round-the-clock emergencysupport, as well as routine maintenance,necessary upgrades and new installationwork.

After 30 years of growth the hospital now hasover 500 beds in 20 wards, eight operatingtheatres and a total of 1,500 staff. The latestfacility, a new £12 million treatment centre forminor surgery and extended day-care, opened inJanuary 2005.

The continuing expansion of the hospitalkeeps the in-house facilities team and ABB ontheir toes. At times, demands on the availablepower supply can be pushed to the limit. Onone day last year, before the new centre came onstream, total demand reached 1,640kW over sixseparate circuits.

To meet growing demand the incoming cableon the north of the site has recently beenupgraded from 95mm to 185mm diameter. Two11kV feeders bring the power on to the hospitalsite connecting to a ring main with an openpoint so the supply can be switched as needed.

There are six substations around the 60-hectare site. The most recent substation to beinstalled by ABB supplies the new treatmentcentre.

Problems can be identified at any time of theday and night and ABB engineers are on call toprovide immediate assistance and work on site ifneeded.

SAFETY CHECKS

In addition to the main power supply fromthe local DNO (Distribution NetworkOperator), Central Networks, the hospital hassix generators available to kick in and provide

back-up power in emergencies.In practice the generators have had little use.

However, possible problems highlighted by aNHS Safety Bulletin resulted in a thoroughtesting programme being carried out by ABB.

WORKING PARTNERSHIP

ABB’s relationship with Milton KeynesGeneral Hospital goes back more than 12 years.Over that time, the partnership has grown andmutual confidence is very strong. The workload

has expanded too, both in line with theexpansion of the facilities and with the additionof other services.

According to David Webb, estates officer inthe hospital’s facilities department: “Wecontinue to find ABB very responsive to ourneeds. Its thorough knowledge of all theequipment and of our site means that it providesus with a reliable, fast and cost-effective service”.

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ABB Power Technologies will be represented on theABB company exhibit at the 2005 Offshore Europe

exhibition which is taking place from 6th to 9th September in the Aberdeen Exhibition and Conference Centre.

The ABB stand is number 663. Visitors can obtain free admissionto the exhibition by registering at www.offshore-europe.co.uk.

ABB has completed theinstallation of a complete

power infrastructure on Maidstone’snew £100 million shopping centredevelopment, Fremlin Walk. Theelectrical contract covered the entirehigh and low-voltage network,including connection to the localelectricity network, installation ofsubstations, cabling and civilengineering work. ABB’s contractwas worth around £350,000, anestimated saving of £50,000 on thealternative new connection solution.

ABB worked fast. The company was onsite in early January and by the end ofFebruary had installed the necessary substation,cabling and equipment to provide power for theopening of the first store.

The new development has been built by MillerConstruction Ltd acting as lead contractor for thesite developers, a consortium including LandSecurities and Maidstone Borough Council.

The rest of the installation, including eightpackage substations and more than 4,000 metres ofcable, was completed by mid May.

The electrical infrastructure includes two high-voltage connections to the local network, one at eachend of the site. The network is designed to supply an

overall load of 5.6MVA.According to Kenny Rogers, Miller Construction’s

project manager, “I don’t think we would havecompleted on time had ABB not been involved.They really pulled out all the stops to get thingsdone.”

Tim Pope, ABB’s project manager says, “Theconstruction timeframe and site constraints wereextremely challenging. We completed our work in aconsiderably shorter time than was provided in theoriginal programme.”

NORTHERN EUROPE

HVDC Light will connect Finland and EstoniaA major power transmission link usingABB’s HVDC Light technology is to bebuilt between Finland and Estonia. Knownas Estlink, the $110 million project issupported by the European Commissionand is to be the first interconnectionbetween the electricity markets of theBaltic and Nordic states. Three-quarters ofthe 100km link will be under water. Theproject will take 20 months and bedelivered by the end of 2006.

BRAZIL

Meeting the growing demand for powerThe Brazilian utility, Electrosul CentraisEléctricas, has ordered a range of high-voltage equipment including seventransformers, eight 550V circuit breakersand 14 (242kV) current transformers worth$22 million from ABB. The equipment willbe used to increase the capacity of anexisting substation and to create a newone in the state of Rio Grande de Sol.

NORTH AMERICA

Alaska energy storage system makes Guinness Book of RecordsThe massive multi-cell battery systemdeveloped by ABB and leading batterymaker, Saft has been officially recognisedas the world’s most powerful battery bythe Guinness Book of World Records.Known as BESS (battery energy storagesystem), it covers an area bigger than afootball pitch and comprises 13,760 nickelcadmium energy cells in four strings.BESS provides emergency power for thearea around Fairbanks, Alaska. It candeliver 27MW of power – enough topower 10,000 households for 15 minutesand even more for shorter periods.

QATAR

Turnkey substation contractKahramaa, the state-owned utility in theGulf state of Qatar, has awarded ABB a$22 million contract to commission threeturnkey substations and equipmentpositioned along a 132km transmissionline across the country. ABB will construct,assemble and commission gas-insulatedswitchgear, transformers, telecoms,protection and DCS equipment.

ALGERIA

Substation upgrade project willincrease power to capital cityA $25 million contract to upgrade eightexisting substations in the region aroundAlgiers, has been won by ABB. A keychallenge is to manage the upgrade withthe minimum of power disruption and injust 15 months. This is the latest in aseries of contracts awarded to ABB byGRTE (Gestionnaire du Reseau TransportÉlectricité, formerly known as Sonelgaz.

Summer 2005 >> FFWD 05

news

INTERNATIONAL NEWS

ABB Power Technologies is well on the way tonotching up an impressive total of 500,000

accident free man-hours on several of its flagship UKprojects. The announcement coincides with ABB beingawarded its third RoSPA Occupational Health and SafetyGold Award in as many years.

In addition to the 2005 Gold Award, ABB has also receivedRoSPA Silver and Merit Awards.

FFWD >> www.abb.com/ffwd

Maidstone’s mall makes the right connections

Offshore exhibition

Safety record is no accident

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06 FFWD >> Summer 2005

ABB has created a team of highlytrained and experienced transformer

service professionals. This enables us toprovide a fast response, throughout theUK, with a complete portfolio of servicesto keep transformers running at maximumefficiency and reliability. And it’s not justfor ABB, we work happily with powertransformers from any manufacturer.

We appreciate that deregulation of theenergy market and increasing pressure to reducecosts is forcing managers to look continually forways to reduce the life-cycle costs of theirinstalled assets and improve return oninvestment. The situation is especially acute inthe case of power transformers. A substantialproportion of the UK transformer population isnearing the end of its technical lifetime, while atthe same time there is a drive to both optimisetheir performance and increase availability. So wefocus on providing a whole-life service frominstallation, through normal preventivemaintenance and repair and retrofit programmesthat can provide an extra lease of life, rightthrough to end of life management with

minimum environmental impact. This portfolioincludes:

INSTALLATION

We co-ordinate transportation, erection,commissioning and training to bring new ABBtransformers safely on-line as fast as possible andensure a smooth hand-over. And we provide acomplete after-sales service.

CONDITION/RISK ASSESSMENT

In-depth knowledge of the actual status ofequipment based on its recorded history, a reviewof its design and advanced diagnostic techniquescan enable potential faults to be identified beforethey happen. It also provides a sound basis forthe implementation of condition-basedmaintenance or corrective action.

REPAIR SERVICES

Should a major problem arise, the ABB teamprovides a fast response for repairs such as parts

replacement, tap changer rework or moreextensive repairs. The usual starting point insuch cases is a deep diagnosis to assess fully thecondition of the unit, or a failure analysis.Where possible, all work is carried out on-site.However, when more extensive work is requiredwe arrange full factory repair and refurbishmentin one of ABB’s fully equipped transformerfacilities.

UPGRADES FOR A LONGER SERVICE LIFE

In many cases, enhancing a transformer’scurrent condition, or repairing it instead ofreplacing it, can give it a new lease of life,dramatically lowering capital costs as well asproviding a faster turnaround than buying new.Advanced techniques such as on-site oilreclamation and low frequency drying mayreduce ageing and extend lifetime, andrewinding with high temperature insulationmaterials can even boost the transformer to abetter than original specification.

Power transformers are valuable assets, and utilityand industrial companies have every incentive tokeep them running efficiently and reliably for aslong as possible. Ian Addison explains how ABB’sUK transformer service team offers a comprehensivewhole-life service to enable customers to get themost out of their equipment.

Transformer services – the route to maximum availability

transformers

• Trouble free operation• Maximum asset availability and minimum

downtime• Reduced operation and maintenance costs• Reduced capital costs• Improved performance• Upgrading of existing equipment• Planned and optimised investment• Personnel safety and environment protection

Transformerservice benefits

Factory refurbishment is giving thistransformer a new lease of life

ABB s whole-life service keeps transformers operating at maximum performance

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Summer 2005 >> FFWD 07

new connections

FFWD >> www.abb.com/ffwd

Choice is the in-wordthese days. It’s all the

buzz in political circles butmany people feel that, moreoften than not, they end upwith Hobson’s choice ratherthan real alternatives. However,in the UK’s electricity markets,new areas of choice areopening up, bringingopportunities for savingmoney, getting things done on time and better customerservice.

Ofgem, the UK’s regulator ofgas and electricity markets, firstbrought competition to the newconnections market in 1997. Sincethen, things have moved on andnow a handful of companies,including ABB, are proving thatthere are real advantages to lookingbeyond the traditional providers -DNOs (Distribution NetworkOperators) - for a more responsiveand cost-effective service.

The new connections market isestimated to be worth around £400million per year. Contestableconnections (those that are notautomatically placed with localDNOs) account for less than eightpercent of the total, according toOfgem.

Karl Young, ABB’s businessmanager responsible forconnections, believes that manycustomers are not aware of the factthat they can choose an alternativesupplier, and the benefits thismight bring.

The benefits can vary from jobto job. ABB frequently offers itscustomers cost and time savings,but Karl Young would argue thatthe real advantages lie in

commitment, technical expertiseand customer focus. He says,"Many of our customers commentthat, when we are invited to tenderfor a new connections project, westart by visiting the site, so that wecan make relevant technicalsuggestions - often finding betterways of delivering - and we providea comprehensive tenderdocument."

Making a new connection is acritical part of most projects. Onmajor developments, the one thingthe main contractor needs isflexibility. Things rarely goaccording to plan, so it is vital thatthe electricity contractor can adaptto meet the changing requirementsof the job and the site.

In its role as connectionsprovider, ABB understands theevolving needs and priorities ofdifferent projects. It also recognisesthat it must work with all theequipment suppliers whoseproducts are approved by the localnetwork operator.

Normally ABB will handle anynew connection from low voltageup to 33kV, although it hashandled at least one in the UK upto 132kV. This was at theUniversity of Birmingham and maywell be the only private connectionof its type in the country.

ABB believes that offeringchoice in new connections willprovide strong financial andoperational benefits to customersacross the country.

ABB is one of a handful of companies in the UK to gain full recognitionas an independent connection provider under the National ElectricityRegistration Scheme. The scheme brings competition, and faster, betterservice to the electricity connections market.

Real choice fornew connections

Ofgem accreditation for new connection servicesABB is one of a select number of companies to be awarded Ofgemaccreditation under the National Electricity Registration Schemeoperated by Lloyd’s Register EMEA. Registration covers design, projectmanagement, cable laying, cable jointing, overhead lines, substationinstallation and associated civil engineering works.

1 ABB has provided new 11kVconnections for the Battersea Reachdevelopment, London

2 The University of Birmingham -probably the UK s only private 132kVconnection

1

2

7941 FFWD July05.qxd 15/7/05 6:05 pm Page 7

As a member of the IEEPower Systems &

Equipment ProfessionalExecutive, I have been leading across industry working group,under the sponsorship of the DTIand Ofgem. This team hascompiled a ‘plan-for-a-plan’,named the Technical Architecture(TA) project, for a new networkinfrastructure vision up to 2050.This plan, published in the ‘WayAhead’ report, presents aframework approach to the manyfundamental technical,commercial, environmental andregulatory challenges faced bythe industry. Consequently, I wasasked to continue as a workprogramme director under thenew Distribution Working Group(DWG) reporting to the jointlychaired DTI/Ofgem ElectricalNetwork Strategy Group (ENSG).This work also resulted in arequest for me to engage in theEU Technical Platform Advisorycouncil, a TA project forEuropean Networks.

In addition, I also representABB, and the electrical engineeringprofession in general, on a numberof highly influentialadvisory/steering groups. I recentlybecame a Visiting Professor atImperial College London, as well asbeing a member of the IEE EnergySector Panel and a member of theUK Energy Research CouncilAdvisory Panel. Further evidence ofthe growing recognition of whatABB’s leading technology can bringto the UK electricity industry isshown in prestigious lectures suchas the IEE Maxwell Lecture givenby Sir John Mogg (Ofgemchairman) earlier this year.

UNIVERSITY COLLABORATION

ABB UK and ABB CorporateResearch collaborates withuniversities and our customer baseto identify and develop the keyenabling technologies for thefuture. Especially important amongthese collaborative projects are the

DTI Innovation funded projects,which are designed to encourageinnovation in an otherwise risk-adverse industry. These work inconjunction with Ofgem’sInnovation Funding Initiative (IFI)and Registered Power Zone (RPZ)incentives. These activities enableABB to demonstrate the power ofour technology to reduce the riskand increase the benefits forDistribution Network Operators(DNOs).

ABB UK has a strategy ofengaging with the best power-accredited universities in the UK.We are now working with thenewly formed University ofManchester (formerly University ofVictoria and UMIST) to become astrategic alliance partner along thesame lines as our successfulrelationships with the University ofCambridge and Imperial CollegeLondon. One of the first steps willbe to sponsor a Phd student to

team up with NGT to investigatethe effect of ageing on DCinsulation at high voltage.

THE POWER ACADEMY

ABB’s own growth plans, incommon with the industry as awhole, call for a new, talentedworkforce to reinforce its alreadystrong and highly-trained UKteam. So to assist in thedevelopment of these newengineers of tomorrow ABB hasjoined the IEE Power Academy tohelp attract more youngsters intothis new era of excitingopportunities. The PowerAcademy’s membership boasts allthe major TNOs, DNOs,manufacturers, consultants anduniversities providing an unrivalledpackage of benefits. As part of aschools awareness programme werecently joined the IEE andSetpoint at Everton FC’s GoodisonPark for a two day exhibition.

Investing in the way ahead!

collaboration

08 FFWD >> Summer 2005

Duncan Botting, head of technology and business development forABB Power Technologies in the UK, outlines some of the ways thecompany is engaging with the government, regulatory bodies,institutions and customers to understand and help resolve some ofthe key issues facing the power industry.

Available atwww.dti.gov.uk/energy/gas

and electricity /tradingnetworks.index.shtml

The ABB stand at Goodison Park was enthusiastically manned by two of ourengineers from Stone (pictured; Mark Stokes and Stephen Norris).

7941 FFWD July05.qxd 15/7/05 6:05 pm Page 8

ABB HVDC convertertechnology and cables

will play a major role in creatingthe new NorNed link,connecting the national grids ofNorway and the Netherlands.At 580km (360 miles) it will bethe world’s longest submarinehigh voltage cable connection.

The NorNed project, estimatedto cost 550 million Euros and duefor completion by 2008, is the latestand most ambitious in a network ofinter-country power links built upover the past 40 years. It is beingbuilt by the state-owned power gridcompanies, Statnett in Norway andTenneT in the Netherlands, toimprove electric power supplyreliability in the two countries andreduce price fluctuations.

THE CASE FOR A LINK

Norwegian generation is almostentirely based on hydropower. Thismeans that below-normalprecipitation can affect its power

system. By contrast, powerproduction in the Netherlands isbased on fossil-fuel-fired thermalgeneration. The interconnection,which is based on market coupling,will lead to power trading betweenthe two countries and increase thereliability of electricity supply.

In ‘dry’ periods in Norway, thelink will be mainly used to importpower, whereas in ‘wet’ periodssurplus power will be exported tothe Netherlands. Theinterconnection will also reduceCO2 emissions because it will cutthe use of peak-load fossil-fuelledgenerators. Instead it will ease theuse of highly efficient base-loadgenerators by exporting power fromNorway during the daytime andimporting power at night.

It is also expected that the linkcould boost the development ofwind power in the Netherlands byhelping to compensate the effect ofwind fluctuations.

The NorNed link will have amaximum power capacity of

700MW and an operating currentof 824A. In order to reduce cablecosts and losses it will feature twofully insulated 450kV cables. Thisenables the current and the cablelosses to be kept low but requires ahigher converter voltage.

HIGH PERFORMANCE CABLE

ABB has designed the NorNedcable to last for 40 years, althoughit is expected to remain inoperation for even longer. So far,no undamaged submarine cable hasfailed simply because of its age. Inmost cases ageing cables arereplaced because they no longeroffer the required capacity.

Initially, the NorNed link wasintended to provide a transmissioncapability of 600MW,corresponding to a maximumconductor temperature of around40°C. However, studies have shownthat there is sufficient margin toallow for an additional 100MWcapacity even during the warmestsummer periods, making the

effective continuous operationalrating of the NorNed link 700MW.

An unusual challenge for theNorNed cable team is that for theDutch and German section of theproject the customer has specifiedthat both cables be supplied as atwin-core design within a singleouter sheath. The twin-core cablewill run for a distance of 270kmout from the Dutch coast and willthen split into two conventionalsingle-core cables.

More information about HVDCis available at www.abb.com/hvdc

HVDC

Summer 2005 >> FFWD 09

The NorNed link will be the world’s longest submarinehigh voltage cable connection.

The longest way

FFWD >> www.abb.com/ffwd

Part of the NorNed linkwill feature an unusual

twin-core cable

1 NorNed link route

2 Preparing an HVDC cable for delivery

21

7941 FFWD July05.qxd 15/7/05 6:05 pm Page 9

ABB Review, the group’s corporatetechnical magazine, is for people

who are looking for deep insight into thepower and automation technologies,industries and markets with which ABB isinvolved world-wide. Published quarterly,the magazine has more than 72 pages oftechnical content including articlescontributed by ABB and industry expertsfrom around the globe.

The latest issue is focussed on the topic ofcollaboration between industry and education. It includes articles with insights into ABB’sexperience of partnering with leading globalestablishments including Imperial College andCambridge University in the UK, MIT in theUS and other institutions as far apart as Polandand China, and many points in between.

The next issue of ABB Review will focus onthe search for energy efficient solutions forindustrial and utility applications, a search that

is growing in intensity as oil prices rise and thefast developing economies of India and Chinademand their share of the earth’s limitedresources. It will look at energy managementand energy efficient equipment, theirimportance and benefits. Industrial safety isanother aspect of sustainable management andsome of ABB’s contributions in this field will beexamined in some depth.

As well as regular quarterly issues, special

issues of ABB Review are published from timeto time. These report on specific interest areassuch as Power Services or particular regions suchas the latest report on China.

Subscriptions to ABB Review are free. Youare invited to register to receive a printed copysimply by visiting www.abb.com/review. Here,you can also read the latest and past issuesonline or download them as pdfs.

10 FFWD >> Summer 2005

technology

A world of technologyin your hands

Flame detection systems are a crucial part of a power stationor industrial boiler safety system. Their primary responsibility

is to identify potentially dangerous "flame out" conditions whereignition has ceased and continued addition of fuel could cause anexplosion. ABB has drawn on its wealth of experience in thedesign and development of its Uvisor flame scanner systems tocreate its latest MFD flame amplifier – a compact dual channel unitfeaturing advanced microelectronics and a unique algorithm thatoffers unparalleled discrimination in multi-burner applications.

The Uvisor MFD effectively offers two systems in a single package,enabling it to simultaneously process the flame signals from two scanner headsso that a complete flame monitoring system can be created at considerablylower cost, while requiring less cabinet space. It has the flexibility to functionwith a range of different Uvisor scanner heads regardless of spectral range(ultraviolet or infrared) or signal type (flicker or pulse) so it works equally wellwith coal, oil or gas-fired burners. Furthermore, the Uvisor MFD can auto-detect the type of scanner as soon as it is connected, reducing set-up time to aminimum. Straightforward menu-driven configuration is provided by an easy-to-read LCD screen available, in a number of different languages, as standard.

ABB supplies the Uvisor MFD configured with flameproof heads asstandard, and three different types of sensor are available to suit specificapplications. Fixed aiming accessories are provided for wall-fired and oppositewall-fired utility and industrial boilers, while quartz fibre optic flexibleextended probes are available for tilting burner boilers.

New Uvisor MFD flame detection system

Uvisor MFD flame detection system

7941 FFWD July05.qxd 15/7/05 6:06 pm Page 10

Summer 2005 >> FFWD 11

project management

FFWD >> www.abb.com/ffwd

JAS the collaborative way forwardOver the next five years,National Grid is planning a

huge increase in investment innetwork infrastructure. Inevitably,this programme will make evengreater demands on the service,support and technical capabilitiesof key suppliers such as ABB. Sowe are exploring a newcollaborative approach to projectdefinition and delivery – our JointActivity Solutions (JAS) initiative.

Traditionally, National Grid hasissued contracts on the basis ofcompetitive tenders against a pre-defined design concept. Howeverwe felt that this does not alwaysgive us the best value from oursuppliers and a new approach wasneeded – one that enabledsuppliers to become involved inprojects much earlier in theirdevelopment.

The result was the JASinitiative, a framework for acompletely open team-basedrelationship between National Gridand its main substation projectpartners (including ABB, Areva,Siemens and VA Tech) that enablesthem to take a full role in theinitial design work, costing andsolution selection processes.

When we select a supplier for aspecific JAS project, we ensure thatthey are fully briefed to work as anintegral part of our own projectteam. The aim is to create aseamless National Grid - supplierinterface, so that the team canbring all its combined knowledge,experience and technicalinnovation to bear to develop theoptimum lifetime solution. Bytaking more time and spendingmore money at this stage we

believe that we are actuallyremoving risk and cost from thedelivery phase, where the bigmoney is spent (and sometimeslost!). There is even somepossibility that the project timescalemight be shortened, although themajor emphasis is on achieving asafe, efficient, cost-effective andsmooth-running project with apredictable outcome.

During the definition stage thesupplier is contracted for that partof the project on a ‘cost-plus’ basis.Once the appropriate solution hasbeen developed, costed, agreed andsanctioned it then passes into thedelivery stage, during which moredetailed development work will becarried out, the contract for thedelivery phase of the project let andconstruction carried out.

The requirement of the JASinitiative for a new level ofopenness between National Gridand its suppliers poses some majorcultural challenges for both parties.For example, during the optionselection phase we ask the supplierto put budget prices on the table toenable comparison of differentsolutions. This requires a degree oftrust that the prices are not set instone before the chosen option isworked up in more detail.

JAS PILOT AT STALYBRIDGESUBSTATION

The ABB pilot for the JASinitiative is the replacement ofStalybridge 275kV substation. This11-bay Air Insulated Switchgear(AIS) substation in GreaterManchester, originally constructedbetween 1957 and 1961, is in needof substantial works as the existingcircuit breakers are almost life-

expired while the concreteinfrastructure is reaching the end of its useful life.

Instead of following thetraditional design, tender andapproval, a core National Grid-ABB team was established at anearly stage of the project to worktogether in carrying out a detailedanalysis of the available options.The team is evaluating two mainoptions for replacement of thesubstation which are:

• Using AIS equipment–demolishing and replacing thesubstation on the existingequipment footprint.

• Using Gas Insulated Switchgear(GIS) – constructing a compactindoor GIS substation adjacent tothe existing equipment.

The JAS team was asked toreview any potential networkreinforcements that could beachieved at Stalybridge. Thisgenerated a number of options forthe adjacent 400kV substation andABB has costed, for sanction, asingle 400kV circuit breakerarrangement involving additionalextensive reconfiguration andrationalisation of overhead linesaround the site.

We have found that ABB isextending a similar approach to itsown key suppliers for theStalybridge project, thusbroadening the expertise andknowledge base available forconsideration when assessing thebest option to be taken forwardwithin the JAS process.

As one of National Grid’s key suppliers in its infrastructure developmentprogramme, ABB is currently helping to trial a more collaborative wayof working – Joint Activity Solutions, or JAS for short. National Gridnetwork design manager Andy Stevenson explains how this newinitiative is helping to deliver the optimum, cost effective solution formajor substation projects.

The National Grid-ABB JAS Team on a site visit to evaluate the GIS installationat Baglan Bay.

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ABB’s ZX family of compactmodular metal-clad gas-insulated

switchgear meets the growing demandfrom DNOs (Distribution NetworkOperators) and industrial customers forcost-effective, flexible and expandable,primary medium voltage (MV) substationsolutions.

The ZX range covers single busbar (ZX0and ZX1.2) and double busbar (ZX2)configurations. With rated voltages from 12kVto 40.5kV, rated short circuit currents up to31.5kA (40kA for the ZX2) and rated currentsup to 2500A, it is ideally suited for a widevariety of utility and industrial applicationswherever electricity is generated or distributed.

The key features of the ZX family includelaser-welded stainless steel enclosures, compactmodular construction and the introduction ofplug-in technology which facilitates simple,controlled connections of busbars, cables, testbushings and voltage transformers.

All maintenance-free live components, suchas switching devices and busbars are containedunder SF6 in gas-tight enclosures. Thiseliminates the effects of ageing processes andenvironmental influences to ensure maximumoperator availability and a long service life,even at high altitudes or in harsh conditionssuch as offshore platforms.

The ZX design also offers easy cable access– accessible from the rear in the ZX1.2 andZX2 versions, generous provision for

conventional control and protection devices,dedicated cable test sockets and full mechanicalinterlocking between the disconnector/earthingselector and the circuit breaker. Currenttransformers can be mounted either in thecircuit breaker gas compartment or externallyon the HV cables. Alternatively, options areavailable for current and voltage sensors.

INSTALLATION TIMES CUT BY AS MUCHAS 75 PERCENT.

While installing a conventional panel oftentakes up to two days, a ZX plug-in panel canbe installed in less than half a day. So in typical

primary distribution substations, comprising10 to 20 panels, customers can expect majorinstallation savings with the ZX. Each ZXpanel is supplied as a complete factory-testedunit, so there is no need to work inside high-voltage compartments or handle gas on site. Infact, the ZX reduces the normal 50-oddinstallation steps to five. And users canupgrade their network gradually, simply byplugging in more units, at minimum cost.Furthermore, maintenance times are very shortcompared to conventional switchgear as thereis no need to disconnect parts, clean thecompartment or refill gas on site.

12 FFWD >> Summer 2005

MV switchgear

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www.abb.com/ffwd

Whatever the primary switchgear application, from utilitynetworks, industry, public buildings, rail infrastructure tooffshore, ABB’s ZX family of gas-insulated MV switchgearhas it covered.

For further information about any of these subjects please visitwww.abb.com/ffwd or contact us as follows:

CONTACTS

Asset Management – 01785 825050Automation – 01785 825050Capacitors – 0151 357 8407HV/MV switchgear – 01925 741469Renewables – 01785 825050

Service – 0845 6011946Substations – 01785 825050Substation Automation – 01785 825050Transformers – 01925 741244General Enquiries – 01785 825050

Meet the ZXswitchgear family

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