Gis Abb

Connahs Quay takes shape 14
Moving a mountain for Sloys hydropower substation 6

Blue sky thinking: innovating on substation projects 28
The secrets of successful site delivery 26
How energy storage can help keep the grid in balance 38
ABBs world of substation solutions 4
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Focus on
Substations
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2 FFWD 1|14 Substations special issue
From the Editor
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Dear Reader,
As the UK makes progress towards its
2020 target to meet 15 percent of energy
demand from renewable sources, the coun-
trys transmission and distribution network
operators are looking to make the most of
their substations. The model of how we
distribute power is changing, as a small
number of power stations give way to many
renewable sources spread over a wide
geographical area. Demand patterns are
also changing as smart metering takes off
and consumers become prosumers.
This means that substations will need
to be smarter, more exible and responsive.
Meeting this demand, ABB is leading the
way with innovative approaches to substa-
ti on technol ogy, i ncl udi ng swi tchgear,
transformers, control systems, FACTS
(exible alternating current transmission
systems) and HVDC technologies, plus the
ability to service, refurbish and upgrade
existing substation equipment to enable
operators to make the most of it.
Our projects reect this, with the new
GIS substation at Sloy (page 6) enabling
the hydro electric power station to operate
as a pumped storage site, generating more
power from the existing power station.
Elsewhere, weve delivered a major project
to upgrade Wakeeld substation for North-
ern Powergrid an impressive ten months
ahead of schedule (page 12) and work is
making good progress at Connahs Quay
substation on Deeside (page 14).
With ever more compact switchgear,
were now able to hide substations below
ground level in busy urban centres and
youll nd more about our approach on
page 10.
To explain our portfolio, we have just
launched a new iPad app, which will shortly
be available to download from iTunes. Why
not take a look?
Stephen Trotter
FFWD Substations special issue 1/14 The customer newsletter of ABB Power Products and Power Systems Subscription Newsletter available as printed or
electronic copy. Subscribe online at www.abb.com/ffwd Contact and feedback karen.strong@gb.abb.com Publisher ABB Limited, Power Systems Division,
Oulton Road, Stone, Staffordshire ST15 0RS. Phone 01785 825050
Substations special issue
12
Latest advances in
GIS technology
Stephen Trotter
Division Head of ABB Power Systems
UK & Ireland
ABB Power Products
Power Products are the key components for transmitting and distributing
electricity. The division incorporates ABBs manufacturing network for
transformers, switchgear, circuit breakers, cables and associated equipment. It
also offers all the services needed to ensure products performance and extend
their lifespan.
ABB Power Systems
Power Systems offers turnkey systems and services for power transmission and
distribution grids and for power plants. Substations and substation automation
systems are key areas. Additional highlights include exible alternating current
transmission systems (FACTS), high-voltage direct current (HVDC) systems and
network management systems. In power generation, Power Systems offers the
instrumentation, control and electrication of power plants.
Content
ABBs substations portfolio
4 ABBs world of substation solutions
News
6 Live project news
GIS
10 Latest advances in GIS technology
Project profiles
12 Wakeeld
14 Connahs Quay
Corporate responsibility
16 Safety rst and always
17 Community engagement and involvement
Power system protection
and control
18 IEC 61850
Substation communications
20 Tropos wireless networks
Renewable connections
22 Substation solutions for onshore and offshore
schemes
38
Battery energy
storage systems
18
IEC 61850
24
Packaged substations
Distribution substations
24 Packaged substations
25 Retrotting time served switchgear
Site management
26 ABBs team ready to take on challenges
Innovation
28 Value-added engineering
Project design
30 Working with customers to optimise design
Civils and commissioning
32 Substation commissioning the buck stops here!
Skills
34 Training and development
Service
36 ABBs substations service
Energy storage
38 Battery energy storage systems
An AIS substation installation
Substations are the key element in transmission and distribution
networks. ABB has the specialised knowledge and global
experience to construct and upgrade substations, wherever
they are needed. Our utility customers benefit from both the
most economic application and modern technologies, fulfilling
all their requirements for project execution and system quality
that ensures a long and reliable service life.
ABBs world
of substation
solutions
Air insulated substations
Air insulated switchgear (AIS) is the most
commonly used type of equipment for
substations. It offers exibility in terms of
equipment conguration, as well as com-
paratively low installation costs. Substations
using AIS are found in transmission networks
of all sizes, all over the world. ABB has
been building and supplying AIS equipment
for nearly 100 years.
Gas insulated substations
Gas insulated switchgear (GIS) incorporates
all of the same functional elements as air
insulated switchgear, but condenses them
inside a sealed housing that occupies one
tenth of the space. GIS is ideal for use in
harsh environments, such as corrosive,
sal ty ai r or extreme temperatures. Its
reduced footprint means that GIS can be
located in dense urban areas where space
is limited and aesthetic issues are important.
ABB pioneered the development of GIS
technology, delivering the worlds rst GIS
substations in 1967. Since then, we have
delivered over 10,000 high-voltage GIS bays.
Mobile substations
Substation design has evolved to minimise
the space they occupy and increase exibility.
It is now possible to create mobile substa-
tions on trailers that can be easily trans-
ported and relocated. These mobile units
are used by utilities as a temporary solution
during planned maintenance or restructur-
GIS is compact enough to house indoors
Mobile substations offer
supreme flexibility
ing of existing facilities, for rapid restoration
of supply after a substation failure, and also
to provide fast-track connections for new
generation while planning permission for a
permanent substation is obtained.
Compact secondary substations
Compact secondary substations perform
all the functions of conventional secondary
substations, but all their components are
installed within a very small footprint. These
substations are used typically at the lower
end of the medium-voltage range in urban
areas, where their housings can be adapted
to blend in with the local environment.
Distribution substations are used to step
down the transmission voltage and divide
the ow of electricity between the multiple
outgoing lines of the local distribution
network.
Substation automation,
protection and control
ABBs world-class protection and control
sol uti ons ensure rel i abl e power and
distribution through the smooth operation
of substations. Our IEC 61850-enabled
product portfolio provides open, future-
proof and exible system architectures with
state-of-the-art performance. Combined
with our wealth of practical and the broad
scope of our service and support network,
this makes ABB a leader in substation
automation, protection and control.
News
B
uilding a new GIS substation half
way up a mountain has been no
mean feat for ABBs engineering
team in East Kilbride. The new substation
for Scottish and Southern Energy Power
Di stri buti on wi l l serve the 152.5 MW
hydroelectric power station at Sloy when
i t takes over from i ts ti me-served AIS
predecessor when the last of the circuits
is transferred in mid 2014.
The substation site lies at the heart of
the Loch Lomond & Trossachs National
Park in a mountainside location accessible
only by a single private road. This posed
some unusual challenges to the team in
protecting the environment, and working
in a climate where winter winds regularly
reach 100 miles per hour.
ABBs team started work in creating the
new GIS substation alongside the existing
AIS site in Autumn 2012. Because GIS
takes only around one fth of the space
of AIS, it has been possible to enclose the
new equipment in a streamlined granite-
clad building, which has spotlighting and
clever metal ns that conceal ventilation
and give it a sharp appearance.
Although it normally takes up to 30 weeks
to build a GIS building, ABB fast-tracked
construction for the project, completing the
building (ready for GIS) in only 18 weeks.
Some of the environmental measures
taken have included transferring large
deliveries to atbed trucks for the nal leg
of the journey up the mountain, avoiding
visits from heavy articulated vehicles, and
transporting the staff up the site by bus to
keep vehicle movements to a minimum.
Once the old AIS substation is out of
service, ABB will demolish it, removing
the structures and equipment. In its place,
ABB will then build an access road to the
new building and ll in the old site with
peat, replacing habitat that was lost in the
early 1950s.
Moving a mountain
01 Sloys new GIS substation is housed in a low
profile granite-clad building
02 The site of the AIS substation will be returned
to its natural state
02
01
News
S
cottish Hydro Electric (SHE) Trans-
mission plc has signed a deal with
ABB and Balfour Beatty Engineering
Services to strengthen the transmission
network in the north of Scotland so that
the regions wealth of natural energy can
be exported to consumers further south.
The deal, taking the form of a ve-year
framework agreement, covers a number of
Making the most of natural resources
275 kV and 132 kV gas insulated switchgear
and air insulated switchgear (AIS) substa-
tion projects in the region.
The consorti um, based i n Ki ntore,
Aberdeenshire, will start work on 275 kV
and 132 kV GIS and AIS substations in
Caithness as well as a 132 kV GIS substa-
tion in Orkney and a 132 kV AIS substation
in Shetland. ABB will provide support from
i ts offi ces i n East Ki l bri de and Stone,
Staffordshire.
This framework agreement for SHE
Transmission is a very important develop-
ment that conti nues our dri ve to both
expand and diversify ABBs customer base
across the UK utility sector, said Jon Downs
ABBs General Manager for Utility Substa-
tions in the UK.
E
ngineers at SP Energy Networks (a
subsidiary of Scottish Power) led the
industry in October 2012, when the
operator became the UKs rst customer
for ABBs newest generation of ELK-3 420
kV GIS switchgear.
Launched in April 2012, the ELK-3 is
one third smaller in volume than previous
models, a fact that means the switchgear
can be delivered and installed in self-con-
tained bays, leading to smaller, simpler and
quicker installations and less project risk.
Because models in the ELK-3 range
can be transported as self-contained bays,
they eliminate site assembly and SF
6
gas
handling. Their compact size means that
substation buildings can also reduce in
Scottish Power leads the way with ELK-3
size, pulling down other project costs at
the same time.
When SP Energy Networks 15 bays go
into operation in 2013-15, they will integrate
wind power in the south of Scotland at
brand new substations at Hunterston and
Wishaw and an upgraded substation at
Torness.
Brice Koch, head of ABBs Power Sys-
tems division, said: These substations will
help integrate and deliver clean wind energy
to the people and strengthen the transmis-
sion grid in the region. We are pleased to
support the development of Scotlands
power infrastructure with some of our latest
offerings.
Compact and skid-mounted,
the ELK-3 delivers savings
ABBs work will enable
Scotland to export more
renewable energy
News
U
K Power Networks is currently
implementing its Regional Devel-
opment Plan for the Central Lon-
don Network to support the anticipated
load growth in the capital. A key element
in this plan is the upgrade of an existing
33/11 kV substation in the Whitechapel
area of East London.
Compact GIS fits the bill for new Whitechapel substation
ABB, working as principal contractor
will be installing 132 kV GIS equipment
wi thi n the confi nes of the new mul ti -
oored building. When the building was
rst designed it was anticipated that the
GIS equipment would need to be installed
within two distinct phases. The exceptionally
small installation footprint offered by ABBs
compact ELK-04 gas insulated switchgear
(GIS) is enabling all of the GIS equipment to
be installed within one phase. This innovative
approach is both saving construction costs
and reducing the time to completion.
The new substation will be supplied
via a new 132 kV cable tunnel, with the
cables coming into the building basement
via a new shaft and adit. The new GIS will
facilitate load transfers between City of
London supply points as well as providing
a 132 kV point of connection for future
reinforcement works.
ABB began its work inside the building in
late summer 2013. The major task now is
to deliver, install and cold-commission the
substation. This calls for detailed logistical
planning since the electricity substation
is located on a very narrow street within
a busy part of Whitechapel. Handover is
scheduled for autumn 2014.
Externally, the substation will have a
striking faade, as mosaic artists have
turned 10 designs painted by local school
children into permanent murals.
A mosaic artist turning school pupil Emad-Ul Hoques design into a colourful mosaic.
D
ave Firth, Senior Project Man-
ager, outlines some of the latest
projects in ABBs DSC (design
supply and construct) framework agree-
ment with Northern Powergrid, the elec-
tricity distribution network operator that
serves 3.9 million domestic and business
customers.
ABB has worked closely with Northern
Powergrid over the past decade to help
upgrade and rei nforce i ts di stri buti on
infrastructure by delivering a diverse range
of major substation projects from 132 kV
down to 11 kV.
Cramlington
One of the most interesting current exam-
ples is at the 66/11 kV substation at Cram-
lington in Northumberland, where we are
putting the nishing touches to a project
to replace two 66 kV bus section circuit
breakers. The previous circuit breakers were
reaching the end of their normal working
life, and they have been replaced by ABB
PASS M00 units with a continuous rating
of 2000 A, and a break rating of 31.5 kA.-
Each PASS hybrid module is a complete
switchgear bay, making this an exception-
ally compact solution.
Sunderland and Cloisters
In Tyne and Wear, we are working on the
Sunderland 66/11/20 kV primary substation
and the Cloisters 20/5.25 kV substation.
There are four primary transformers at Sun-
derland (two at 66/11kV and two at 66/20
kV). The 66/20 kV transformers provide a
supply to Cloisters 20/5.25 kV substation.
This project will replace the existing
66/20kV substation with a new 66/11 kV
substation. The existing 66/11 kV trans-
former and associated 11 kV switchboard
will remain unchanged. The two existing 20
MVA, 66/20 kV transformers will be replaced
with new 15/30 MVA 66/11 kV transformers.
The existing 20 kV switchgear will also be
replaced with 11 kV switchgear compris-
ing two transformer and one busbar circuit
breakers rated at 2000 A continuous, and
eight feeder circuit breakers rated at 630 A
continuous, all with break ratings of 25 kA.
At Cloisters the existing 10 MVA, 20/5.25
kV transformers will be replaced with 5
MVA, 11/5.25kV transformers. Following
the replacement of the 20 kV network with
11 kV, circa 7 MVA of demand will be trans-
ferred from Mount Road primary substation
to the new Sunderland 66/11kV primary
substation. The project will ensure the con-
tinued provision of a safe and secure elec-
tricity supply in this area while also providing
the opportunity to standardise Sunderland
Primary to an 11kV system - bringing addi-
tional capacity to the area while removing
fault-level issues on the 20 kV switchgear.

Fast-track windfarm connections
Renewable energy projects demand fast-
track grid connections to ensure they are
onl i ne and earni ng revenue as fast as
possible.
At the Todmorden Moor and Grange
windfarms in the Northern Powergrid region,
ABB will deliver 33 kV substations in only
around six months from initial order to
commissioning.
The switchroom, to be constructed in
a new blockhouse, will comprise three
panels of ABBs ZX1.2 primary gas insulated
medium-voltage switchgear.
Upgrading Northern Powergrids substation infrastructure
News
All systems go for Pen y Cymoedd Wind Energy Project
grid connection
I
n summer 2013 Vattenfall appointed
ABB to build the grid connection for
the Pen y Cymoedd Wind Energy Proj-
ect, which will be the largest onshore
wind farm in England and Wales when it
enters operation in 2016.
The 76-turbine, 228 MW wind farm, in
South Wales, between Neath and Aberdare,
is a signicant investment for Vattenfall and
for the Welsh economy. ABBs commitment
to sourcing a signicant amount of project
resource locally within Wales was a major
factor in securing the contract. Other factors
were ABBs ability to deliver the project
within Vattenfalls timescale, as well as the
strength of our comprehensive solution that
not only includes the substation equipment
but also the reactive power and associated
control systems.
A very signicant development is that
this is the rst UK project in which ABBs
state-of-the-art substation protection and
control systems, working in combination
with our STATCOM solution, will be used to
control and regulate the output of the wind
turbines to ensure they remain within the
rigorous power quality standards designated
by the National Grids Grid Code.
Work has now started on the project,
which will see ABB construct two new
substations linked by 9.2 km underground
cable connections. To minimize disruption
in this environmentally sensitive location
singular trenching is employed for the route
that has to traverse a high pressure gas
pipeline and pass close to a site of special
scientific interest as well as an ancient
monument.
The substation equipment to be installed
by ABB includes: PCS 6000 STATCOM
units to support the stability of grid volt-
age by providing variable reactive power
in response to voltage transients; compact
PASS switchgear rated at 132 kV; trans-
formers; protection and control equipment
that complies with the IEC 61850 standard.
The turbines on the hillside will feed into
the Pen y Cymoedd substation, which will
step up the voltage from 33 to 132 kV. The
second substation at Rhigos will step up volt-
age from 132 to 400 kV, ready to feed into a
brand new 400 kV National Grid substation.
Interfacing with third parties will be par-
ticularly important for this project, with an
even higher than normal emphasis on com-
munity relations to support Vattenfalls
commitment to inwards investment into
Wales. ABB is sourcing a signicant pro-
portion of the project resource locally within
Wales, including manpower, site manage-
ment, subcontractors and suppliers of all
kinds. Wherever possible, we are involving
the community in the project and making
the most of local skills and resources.
This contract goes to the heart of what
ABB is about as a business: integrating
renewable power while balancing economic
success, environmental stewardship and
social progress, said Stephen Trotter,
Division Head of ABB Power Systems UK
and Ireland. The project is a major milestone
in demonstrating ABBs capability in wind
farm projects and particularly in meeting
the stringent demands of grid codes.
The site of the Pen y Cymoedd wind farm
L
aunched on the UK market in 2013,
ABBs new generation ELK-3 420
kV gas-insulated switchgear (GIS)
has shrunk in size by a third. Its a signifi-
cant innovation which will see custom-
ers make financial savings from smaller
substations and simpler construction,
reduce risk and improve their environ-
mental credentials without compromis-
ing performance.
We can safely say that the size of the
latest ELK-3 GIS is designed to give ABBs
customers several advantages. First among
these is that it allows design engineers to
consider the switchgear for installations
where space is at a premium. In urban
settings where land is expensive, this can
be signicant. New substations will benet
from smaller infrastructure costs and smaller
substation buildings and it may be possible
to free up space at existing substations for
alternative use.
Installation and commissioning costs
are also areas of signicant saving due
to the size reduction. The ELK-3 can be
transported as a single unit on a at rack or
low bed truck. So we can factory assemble,
test and ship the ELK-3 switchgear as a
single bay in a container rather than as
multiple units that need to be assembled
on-site, an exercise which only adds to the
complexity and length of a project.
Weve also found that supplying switch-
gear in single bays can lead to installation
and commissioning times which are up to
40 percent shorter than for traditional GIS
designs. The further advantage of factory
assembly is the knowledge that because
it has been assembled and tested, custom-
ers can be assured of its quality, meaning
that risk can be taken out of the construc-
tion and commissioning process, a factor
which will appeal to those with roles in
operations and engineering, and their col-
leagues in nance.
The ELK-3s environmental credentials
are also an improvement on older models.
Because its smaller, the switchgear uses
up to 40 percent less insulating SF
6
gas
making its environmental impact lower.
Once installed, the products fast single-
interrupter dual motion circuit breaker has
been designed for current ratings of up
to 5,000 A and is capable of providing
protection to power networks with rated
short-circuit currents up to 63 kA.
The ELK-3 bui l ds on ABBs recent
devel opments i n 245 kV and 72.5 kV
swi tchgear and the approach to the
design places drives, position indicators
GIS shrinks in size and
disappears underground
and service platforms at the front of each
unit, enabling easier operation, inspection
and mai ntenance. Bei ng constructed
from standard modular components, the
switchgear is designed around common
substation layouts, and with an eye on
future developments, we also offer the
option to integrate features for smart and
digital substations.
Going underground in urban centres
The biggest challenge in supplying efcient
and reliable power in a bustling city centre is
often in nding space for large substations,
especially as demand for power grows.
On one hand, local authorities planning
departments are often protective of city
centre sites, particularly those in historic
settings, and on the other, the value of
land in city centre sites for ofce or retail
development often means that there are
strong pressures to give land multiple uses.
One solution to make the most of a
limited footprint is to dig down, placing
the substation below ground level, which
frees up the surface for other purposes
while providing all the functionality of any
conventional substation. ABBs state of
the art underground substation concept
enables up to 98 percent of an installation
to be tucked away below ground, with only
cooling ducts and access routes visible
above ground.
Underground substations are not a
new idea, with many already in operation
at many sites worldwide. The experience
of constructing such substations, together
with knowledge of planning regulations has
enabled ABB to develop its methodology.
The approach means that ABB can integrate
a transformer substation into any urban
environment while meeting and future-
proong customer needs.
Jon Downs, ABBs UK General Manager, Utility Substations, outlines the
latest developments in GIS technology the new ELK-3 range, and a new
concept in underground substations.
GIS
Jon Downs ABBs General Manager for Utility
Substations in the UK
Its possible to tuck away 98% of a substation below ground level
Using this approach, ABB can hide a
substation underneath a building such as a
shopping centre, car park or sports stadium.
Public spaces like parks, public squares,
trafc roundabouts or intersections can
seem untouched to the casual observer
but below the surface, can be an essential
link in a citys power grid. An underground
substation will accommodate transformers,
gas insulated switchgear (GIS), automation,
protection and control systems, auxiliary
equipment, AC and DC distribution boards,
batteries, ventilation, air-conditioning and
re protection systems.
Like most substations, underground
stations are unmanned in normal operation
but their design must take account of human
safety, which is why safety features such
as escape routes, smoke-free zones and
separation of re loads with bulkheads are
designed in.
Wi th onl y two percent of a typi cal
substation being visible from the surface,
ABBs underground substation concept
keeps potential hazards well away from the
general public. At the same time, it meets
the most stringent requirements for power
supply and delivers compactness, economy,
reliability and safety.
Compact ELK-3 switchgear can be
transported on a single truck
GIS
Project profiles
T
he major turnkey contract, placed in
2009, continued ABBs long-standing
relationship with Northern Powergrid
on strategic substation projects that goes
back to 2003, when we built the Norton
132 kV substation near Stockton-on-Tees.
Together with Creyke Beck and Tynemouth,
Wakeeld B substation is one of three high-
prole substation contracts that ABB has
recently delivered for Northern Powergrid.
GIS replaces AIS
The previous Wakeeld B substation was
based on air insulated switchgear and, after
around 50 years in service, it was reaching
its replacement age. AIS equipment requires
a great deal of site space. This meant that
a like-for-like renewal project was impracti-
cal in terms of both availability and cost.
This was mainly because it would have
required either an outage of many months
Wakefield B GIS substation
delivered ahead of schedule
as the old substation was demolished
and the new one constructed on the same
site or the purchase of additional land so
that a new substation could be built adja-
cent to the old one.
The proven space-saving capability of
ABBs GIS technology provided an alterna-
tive that blends in with the surrounding
area. It has enabled a new indoor substa-
tion to be constructed within the limited
Innovative approaches to design and outage management enabled the ABB
project team to deliver Northern Powergrids new Wakefield B gas insulated
switchgear (GIS) 132 kV substation in Yorkshire 10 months ahead of schedule.
Project profiles
free space available on the existing site
while the old AIS substation remained in
operation. The project has effectively con-
densed the new Wakeeld B GIS substation
into around 25 percent of the AIS substa-
tions footprint.
ABB was awarded the turnkey contract
to provide a complete design, construction
and installation service for the new substa-
tion, featuring 14 bays of ABB ELK-04 132
kV GIS equipment. The project also required
the installation of 132 kV cross-linked poly-
ethylene (XLPE) cables to transfer existing
Northern Powergrid connections into the
new substation. In addition, it required
modication of the terminal towers for the
overhead lines to provide new sealing end
platforms, with modification of existing
sealing end platforms to accept the new
XLPE cables.
Project management philosophy
The project was scheduled over three years,
with hand-over due in January 2012. How-
ever, ABBs project management philosophy
is to seek every possible opportunity for
adopting innovative approaches that can
help improve quality, drive down costs and
ensure on-time delivery or even improve
scheduled delivery. A key element of suc-
cessfully delivering substation projects is
optimising the planned outage windows.
In close consultation with our customer
and cable contractor, ABB modied the
content of outage work and sequence,
which signicantly reduced the time to nal
hand-over.
Outage planning
Rather than planning individual outages
sequentially for each of the 10 circuits to
be transferred, ABB arranged to transfer
three circuits with three individual outages
in parallel. This was accomplished twice
accounting for six circuits while the
remaining four circuits were transferred
sequentially.
The parallel transfer of the cable circuits
called for precisely coordinated planning
and execution, as taking three circuits
out of servi ce together transferred a
signicantly increased load on to the rest of
the substation. It was therefore imperative
to complete the work on time to minimise
the duration of increased load.
To make maximum use of the outages,
a hi gh l evel of preparatory work was
completed in advance. This focused on
the coupling of the cables to the tower
sealing end platforms. During the outage,
all that was then required was to install the
downleads from the towers to the cable
sealing ends, which had previously been
connected to the GIS equipment.
Transition joints and
PASS M0 switchgear
Two of the 10 cable circuits required the
creation of transition joints to connect the
new XLPE cabling to oil-lled cables. During
the cable transfer process, ABB also made
use of the new PASS M0 hybrid temporary
switchgear solution pioneered in its Reading
substation project for Scottish & Southern
Energy (SSE). The PASS M0 switchgear
was connected to an existing redundant
circuit, and then used to power up the GIS
switchgear. Once all the circuits had been
transferred, the PASS M0 was removed.
The indoor substation constructed for the
new Wakeeld B is a two-storey building with
the GIS equipment installed on the rst oor.
This allowed for the creation of a substantial
cable basement to accommodate the large
bending radius required by the XLPE cables
which results from their large conductor
cross-section of 1,000 mm
2
.
Wakeeld delivered 10 months early
The net result of ABBs innovative approach
to managing the project, backed by a high
level of communication and cooperation
with the customer and subcontractors, was
that Wakeeld B was handed over in March
2011, functioning exactly as required but
10 months ahead of schedule.
PASS MO switchgear
ELK-4 switchgear at
Wakefield substation
Project profiles
T
he new Connahs Quay substa-
tion, scheduled for completion in
2018, will play a vital role in the
reinforcement of the high-voltage trans-
mission infrastructure in northwest Eng-
land, and facilitate the connection of new
high-voltage direct current (HVDC) power
links, such as EirGrids East West Inter-
connector between the UK and Ireland
that came online in 2012. The contract
falls within the scope of the Electricity
Alliance Central (EAC), in which ABB is
working as part of a consortium with At-
kins and Morgan Sindall to deliver major
enhancements to National Grids 400 kV
substation infrastructure.
The existing Deeside air insulated switch-
gear (AIS) substation, constructed by the
CEGB in the 1960s, is near the end of its
asset life. It currently serves as an in-feed for
two major power stations: Connahs Quay
(1,380 MW) and Deeside Power (505 MW)
and it is nominated as the optimum con-
nection point for a number of new HVDC
projects. A number of possible upgrading
and replacement options were considered,
eventually it was decided to construct a
new gas insulated switchgear (GIS) sub-
station ofine and transfer circuits over on
a staged basis. Once the new GIS substa-
tion is commissioned, the old AIS substa-
tion will be migrated over and demolished
to make way for the remaining connections
into the new substation.
The project scope includes the construc-
tion of a new 24-bay GIS substation, with
20 bays licensed for National Grid and four
for customer connections. ABB is supply-
ing the GIS, a 5000 A rated version of its
well proven ELK-4 range to cater for high
power ows, together with standard bay
protection and control solutions and high
voltage cabling. The project also calls for
the integration of three new 400/132 kV
240 MVA grid transformers together with
an existing refurbished unit.
Not only is the project technically chal-
Connahs Quay
ABBs largest ever
UK substation project
lenging, it has also required effective liaison
with multiple stakeholders such as National
Grid, International Power, SP Energy Net-
works, EirGrid, EON and Local Authori-
ties, says Paul Turnbull, ABB Lead Project
Manager. Don Ruddick, ABB Design Team
Connahs Quay substation the facts
GIS building over 135 metres in length
400 tonnes of steel used for catwalks and support
steel work
24 fully equipped GIS bays
10 feeders, 4 bus sections, 2 bus couplers, 4 customer
connections, 4 SGTs (Supergrid transformers) and
capacity for 4 future circuits
4.6 km of gas insulated busbar (GIB)
The replacement for National Grids 400 kV Deeside
substation is ABBs largest ever UK substation project.
01
Project profiles
01 The new substation building is longer
than an international football pitch
02 A view inside the GIS building
Leader added we have also paid special
attention to logistics, as the building itself
is enormous longer than an international
football pitch with catwalks and support
steel alone weighing in at over 400 tonnes.
Additional challenges have been presented
due to the proximity of both an SSSI (site
of special scientic interest) and badger
sets.
In contrast to some substation projects
that need to blend into the local back ground,
the local authorities stipulated that Con-
nahs Quay should make an architectural
statement with its striking striped cladding.
The building itself is complete with all the
GIS installed and the majority of the 4.6 km
GIB (gas insulated bus) also installed. The
site team is now pre-commissioning all of
the equipment putting the project well on
target for the rst circuits to be transferred
in 2014.
02
A
BB is fully committed to a healthy,
safe, secure and responsible work-
place for its employees, subcon-
tractors, partners and customers. This
includes making sure that we have the right
procedures and competencies in place,
alongside the necessary personal protec-
tive equipment (PPE) in full and correct use.
But we al so bel i eve that the most
signicant factor in health and safety is
in the thought processes that must be
adopted to achieve safe working and the
open and mature culture needed to allow
reporting. Every injury is an injury too many,
every hazard spotted and removed is a step
towards reducing risk and every near miss
reported is a learning opportunity.
Were currently leading on a number of
initiatives with the goal of keeping people
safe. The rst of these is called Stop take
ve and is an important consideration for
our employees in construction roles. By
stopping and taking ve minutes to think
about risks of construction and whether
a team needs to adapt to a change of
circumstances (for example, sudden wet
weather might have a signicant impact on
site conditions), Stop take ve is designed
to make sure construction work takes place
in a controlled manner.
Another initiative is ABBs regular sup-
plier forum, in which we proactively engage
our supply chain by gathering our staff
together with suppliers and subcontractors
to share information about risks and safe
working methods.
The third initiative is on hazard reporting,
with activities focused on maintaining an
Safety first and always
open reporting culture.
Alongside these, we have been upgrading
our PPE, particularly ame resistant PPE,
which protects the wearer from electrical
arc type injuries. This comes on top of our
universal standard for gloves and glasses,
which protect against hand and eye injuries.
Al l thi s proacti ve work has been
successful in delivering a safe working
culture. ABB has been able to report long
periods of zero non-reportable injuries: four
years in the substations service sector, three
years in the electricity alliance and two years
in other areas of substations work.
This is quite an achievement, given that
12 months without a reportable injury is
remarkable but because every injury is one
too many, ABB will keep working hard to
raise safety standards.
Trevor Farrington, ABBs Health and Safety manager, explains
how safe working is embedded in the companys culture.
Community relations
A
key part of our si te managers
remi t i s to i ntegrate wi th l ocal
communities, listen to (and address)
any concerns and support local initiatives
in an approach that is tailored to meet
local circumstances. Typical actions are
adopting special approaches to traffic,
communicating regularly with communities
and collaborating with our customers own
community relations teams. Weve even set
up dedicated call centres.
Local involvement
Being mindful of the potential disruption
around construction, we aim to minimise
our impact by building relationships with
affected communities. In partnership with
local stakeholders, we often leave project
areas in better shape than when we arrived
by landscaping rough terrain or re-planting
trees and shrubs.
In addition, ABB is committed to achiev-
ing 90 percent local involvement for every
UK power project, including labour, services
and where possible materials, only bringing
in specialised commissioning and installa-
tion engineering skills from outside. We
believe that this ensures smooth and ef-
cient project delivery and makes good
busi ness sense by avoi di ng the costs
involved in bringing in outside labour and
materials.
ABB works hard to create close links with the local community
around its projects because being perceived as a good
corporate citizen is essential to being at home everywhere
we operate.
ABB is mindful of the potential impact of its project on the environment
Power system protection and control
T
he introduction of IEC 61850 in 2004
represented a huge step forward in
simplifying the integration of protec-
tion and control IEDs (intelligent electronic
devices), and it is now acknowledged as
the global communications standard for
substation automation and power distribu-
tion systems.
With its standardised model of the IED
and its data and communication services,
IEC 61850 ensures interoperability between
electrical devices from different vendors and
is able to replace all the typical protocols
found in the substation automation domain.
Based on Ethernet technology and provid-
ing a exible and open system architecture,
IEC 61850 makes the application future-
proof over the entire system lifecycle.
ABB has played a signicant role in the
development and implementation of the
IEC 61850 standard and it is essentially
the default choice for the majority of our
substation projects. A key enabler in the
deployment of the IEC 61850 standard has
been the launch of our innovative Relion

family of IEDs developed specically to
implement its core values through full native
compliance.
So far, we have concentrated on the
IEC61850-8.1 station bus. However, we
are now focusing on the IEC 61850-9-2
process bus that enables current and
voltage measurements to be transmitted to
protection and control devices via a bre-
optic communication network, resulting in
reduced copper cabling and increased safety.
New horizons in substation
protection and control
The process bus also supports the
standardised integration of non-conventional
instrument transformers (NCITs), bringing
performance improvements and further
reductions in cost and space requirements.
NCITs also improve safety because they
eliminate the risk of voltage hazards, which
can ari se i n conventi onal transformer
circuits.
In 2012, we saw the rst fully compliant
commercial installation of IEC 61850-9-2
process bus technology. This was installed
for the Australian utility, Powerlink, to pro-
vide advanced automation functions to
enhance availability and grid reliability at
Loganlea, a key substation serving south-
east Queensland, a-fast growing region of
Australia.
Ibrahim Cobaniglu, ABB UK Sales and Marketing manager for Substation
Automation, outlines some of the latest developments in protection and
control technology.
01
Power system protection and control
Communications
AFS Family Solutions
Driven by IEC61850 and other Ethernet
based communication protocols, switches
are now fi ndi ng thei r way i nto uti l i ty
networks. Green field developments in
particular are an ideal opportunity to con-
sider this type of solution in substation and
distribution communication networks.
ABBs AFS650 and AFS670 family offers
many features which are required in the
utility environment, including fast protec-
tion schemes as well as redundant pow-
er supply and alarm contacts. They also
enable the stepwise introduction of Smart
Grid applications, such as integration of
renewable energy sources, advanced dis-
tribution automation solutions and similar.
Extension for Stones System
Verication Simulator
The outstanding success of our unique
automated factory acceptance test (FAT)
system at Stone has recently seen it fur-
ther extended and upgraded.
The traditional method of conducting
a FAT on bay control and protecti on
equipment is to hook up the IEDs (Intelligent
Electronic Devices) and relays to a network
of switches, relays and lamps selected to
simulate the substation plant. Our view
is that this approach, which relies heavily
on manual switching and recording of
results, does not offer the levels of rigour,
repeatability or the full audit trail appropriate
for state-of-the-art protection and control
schemes. That is why we offer our own
dedicated, fully automated, computer-
control l ed test i nstal l ati on, or System
Verication Simulator (SVS).
The computer-controlled SVS is linked
to ABBs own engineered modules that
simulate the behaviour of substation plant
such as circuit breakers, disconnectors and
earthing switches. In effect, we can dupli-
cate the whole substation within the labo-
ratory, and run automated, self-monitoring
test sequences to establish that the sub-
station interacts correctly with the protec-
tion and control panels. Over a period of
time we have established a library of test
routines to cover all potential situations.
The real advantage of this unique facility
is its repeatability. It responds just like the
real plant, without human intervention to ick
test switches and so on. And because the
tests are automated, we have been able to
uncover some aspects of the equipments
behaviour, such as timing issues, that
could not be picked up by manual testing.
Portable relay rooms
For a number of utility projects in the UK
we are now delivering portable, fully-con-
tainerised relay rooms. They provide all
the vital protection and control cubicles
and accessories in a fully tested factory-
assembled package that creates what is
virtually a plug and play solution. Not only
are the systems easy to install and com-
mission, they are fully portable so can be
relocated as needs change, while offering
a 40-year service life.
Total service
While delivering state-of-the-art protection
and control systems is crucial, it is vital that
they are fully supported throughout their
operational life-cycle. So we have devel-
oped a range of service packages including
24/7 support for critical systems.
01 Australias Loganlea Substation has been
fitted with the IEC 61850 process bus
02 AFS switches are modular and IEC 61850
compliant
03 Factory acceptance testing at Stone
02
03
Take control: Tropos
brings a new dimension
to utility communications
Andy Osiecki, General Manager of ABBs UK power
system network management business, explains how
the recent acquisition of Tropos Networks adds to ABBs
ability to meet the needs of its UK power generation and
transmission customers through private wireless networks
that deliver secure control over grids whatever the weather.
Data Centre
Fibre/PTP
2.4/5/8/3.65 GHz
900 MHz
HAN (ZigBee)
HAN
Energy Storage Device
Substation
Feeders
I
n a world where wireless communica-
tion is becoming the norm and where
Smart Grids are becoming reality, ABB
is now able to offer a new service to
power utilities in the UK following its ac-
quisition of Silicon Valley-based Tropos
Networks.
Now part of ABBs Utility Communications
product group, Tropos provides private
wireless networks which free operators
from the need to lease costly bandwidth
from third parties. The wireless networks
also ensure network availability when and
where its needed, the ability to run multiple
applications with high bandwidth and low
latency and a high level of security.
Tropos has been developing its wireless
network technology for nearly a decade
and has experience of installing end-to-
end solutions, with over 70,000 routers in
operation at more than 1,000 customers in
50 countries. It has established itself as the
industry leader in the eld and is an excellent
t with ABB, bringing a new dimension to
our offerings.
With a client list that includes blue-
chip organizations in sectors ranging from
utilities, through mining and oil & gas, to
Smart Cities and ports, the Tropos business
offers huge potential for ABB, especially in
the UK power utility market.
Networks and applications
So what exactly is the offering? Tropos
describes its two main areas of expertise
as being Smart Grids and Smart Cities.
Its solutions include networks of routers
and directional radio systems, arranged
in a mesh or grid structure, along with the
architecture and network management to
support them. These networks can handle
an assortment of applications. In the energy
sector, these include Advanced Metering
Infrastructure (AMI), demand management
and response, distribution automation
and control, outage management, mobile
workf orce appl i cati ons, di stri buted
generation and video security.
A key feature i s that there i s no
restriction to a single application vendor,
giving customers the freedom to choose
the applications that suit them. Its possible
to run any application that operates over
an enterprise IT network or the internet.
Performance and exibility
Because every router in an ABB Tropos
network i s i ntel l i gent, data i s routed
effi ci entl y to where there i s capaci ty.
This minimizes delays and gives Tropos
customers real-time visibility and control
of their assets.
Networks are also scalable, meaning
that customers can choose to start small
and grow when needed. As the network
grows, each smart router will automatically
reconfi gure i tsel f, maki ng expansi on
relatively simple. The mesh network design
offers inherent reliability, as the network
can handle any outage by redirecting data
intelligently and seamlessly.
Rugged and reliable
With an IP67 rating and tamper-evident
casings, ABB Tropos routers are designed
to cope with almost any physical challenge,
a necessity when routers are routinely
installed in outdoor locations in the eld.
Equipment is designed to withstand
temperatures from -40 C to +85 C, wind
speeds of up to 165 miles per hour and
sandy or dusty environments as well as the
damp, salt-laden climate found in coastal
locations. The option of adding mobile
routers enables the network to be extended
whatever the location of eld staff one
mobile router even gave uninterrupted
network access throughout the launch of the
rocket on which it was installed. This build
quality contributes to network accessibility
gures of better than 99.99 per cent.
Recognising customers demands for
networks that are both reliable and secure,
Tropos has integrated a high level of security
into its products, which have been deployed
in military and law enforcement applications.
Each device is equipped with multi-
layered security, including VPN, WPA2
encryption, AES encryption and support
for multiple VLANs. Networks also feature
software alarms and authentication and
security measures to restrict unauthorized
access.
Unique position
While there are other providers of wireless
mesh networks in the market, only ABB
Tropos has a track record in delivering end-
to-end solutions for utility applications and
distribution networks. The company has
worked on networks for power generation,
substations and utilities longer than in any
other sector.
As the number of applications managed
over a wireless mesh network grows, so
does the nancial benet. Some customers
have achieved return on investment in as
little as one year when integrating several
applications on to their networks.
Network router
S
ubstations form an essential el-
ement in the grid connection of
renewable energy schemes from
onshore and offshore windfarms to wave,
tidal, solar and biomass power projects.
To meet the specific needs of this sector,
ABB has developed a broad portfolio of
substation solutions.
This includes the design, installation and
commissioning of gas insulated switchgear
(GIS) and air insulated switchgear (AIS)
substations up to 400 kV and beyond,
including civil engineering works as required.
Our scope covers both high-voltage
(HV) and medium-voltage (MV) substations
for transmission and distribution network
connections. All of these substations utilise
ABBs extensive portfolio of modular and
compact switchgear solutions as well as
transformers, reactors, lters, control and
protection systems, alongside dynamic
reactive compensation solutions to ensure
grid code compliance.
For HVAC connected offshore wind
farms, the ABB Grid Systems business
can supply the turnkey solution for the
complete electrical transmission system,
incorporating both onshore and offshore
HV substations, plus design and supply
of the offshore platform.
Substations the vital link
for renewable energy projects
Offshore substation for Thornton Bank
wind farm
September 2013 saw ABB complete the
delivery of the subsea transmission link for
one of Europes largest offshore wind farms
with the commissioning of the 325 MW grid
connection for the Thornton Bank wind
farm. The project, carried out for Belgian
company C-Power NV, was delivered on
schedule.
The transmission link was constructed
as part of an expansion of the Thornton
Bank wind farm. In the rst phase of its
development, six wind turbines with a
total capacity of 30 MW were built and
Kevin Mills, ABBs Sector Manager for renewable energy connections,
outlines ABBs range of substation solutions for onshore and offshore
renewable energy projects.
01
a temporary connection to the mainland
was built by ABB. The second and third
phases of the project involved adding 48
wind turbines, which takes the wind farms
capacity to 325 MW, which is transmitted
30 km ashore via the transformer station
platform.
ABB was responsible for delivering the
grid connection as a turnkey project, which
included the system engineering, design,
supply and commissioning of the AC sub-
sea cables, land-based cable systems and
the offshore substation and platform that
houses it.
Hadyard Hill wind farm
ABB power transformers and associated
hi gh-vol tage swi tchgear and control
equipment play a vital role in connecting
SSEs 120 MW Hadyard Hill wind farm
development to Scotlands main power
transmission grid.
For the Hadyard Hill project, ABB supplied
two 90 MVA 132/33 kV power transformers,
an 11-panel 33 kV switchboard, two 5 MVar
capacitors, a 145 kV dead tank circuit
breaker, six CVTs, six surge arrestors and
line traps.
PASS M0 saves space for distribution
substations
ABBs innovative PASS M0 space-saving
hybrid AIS and GIS switchgear module can
save up to 70 per cent of the space normally
required for a conventional AIS substation.
This enables renewable energy operators
to make optimum use of the restricted
installation footprint often available for
the construction of a suitable distribution
substation. It also reduces the need for civil
works such as foundations, steelwork and
cable trenching operations.
The pass M0 design, which has full
Energy Networks Association (ENA) and
Scottish Power approvals, is based on a
hybrid of ABBs traditional AIS and metal-
clad GIS switchgear units. Rated at up
to 145 kV, it integrates all the necessary
substati on swi tchgear bay functi ons,
including a circuit breaker, one or more
combined disconnector/earthing switches,
bushings for connection to single or double
busbar systems and a current transformer
in one compact module, eliminating the
need for separate pieces of equipment for
each function.
ABB supplies the PASS M0 module as
a completely pre-fabricated, pre-wired and
pre-tested unit. It ts into a standard truck
01 Hadyard Hill wind farm substation
02 Cleve Hill substation serves the London
Array (Photograph courtesy of London
Array Limited)
03 Thornton Banks offshore grid connection
container for delivery without any special
packaging. No special arrangements are
needed for shipping and transportation, and
once on site just a simple 30 rotation of
the outer poles completes the nal layout.
A key feature of the PASS M0 is its
virtually maintenance-free design. The line
and busbar disconnectors, as well as the
earthing switches, are integrated within the
breaking chamber. These components are
completely immune from all environmental
conditions, ensuring lifelong reliability, and
eliminating routine maintenance of high-
voltage parts to overcome a major weakness
of AIS substations.
02
03
Fitting into a tight spot
ABB has delivered an 11 kV packaged
substation to act as the main power distri-
bution hub for the UKs second largest oil
renery, Total Lindsey Oil Renery (LOR).
Both the short project timescale and the
space constraints at the selected location
at the heart of the renery gave the project
team challenges, particularly in carrying out
the substantial deep piled foundations to
withstand blast shockwaves to ensure
continuity of service in case of an explosive
event at the site.
Housed in a single thick blast-proof
container, the substation contains 26 panels
of UniGear ZS1 medium voltage switchgear,
together with protection and control equip-
ment, and back-up batteries.
It was the slimline design of ABBs Uni-
Gear ZS1 that enabled the substation to
t within the connes of a single six metre
standard container. The 50 kA fault rated
ZS1 features front cable access, which
allowed for two front facing rows joined via
a low-level bus-trunking link and a central
walkway. Not only is the six metre standard
container the largest size permitted on UK
roads, any larger and it would not have
fi tted wi thi n the confi nes of the si te
a crucial factor in ABB winning the contract.
The other critical factor was the ability
to deliver the substation within a tightly
dened 32-week project window to meet
LORs planned Turnaround and Inspection
outage.
Raising airport standards
ABB has won two important contracts from
UK Power Network Services airports divi-
sion to supply a total of 16 packaged sub-
station transformers for Heathrow Airport.
A key factor in winning the contract was
that our medium voltage (MV) transformers
installed in the substations have recently
been fully type tested, including rigorous
short circuit tests carried out at an inde-
pendent European test laboratory.
ABB is a well established supplier to UK
Power Networks Services for distribution
transformers that step down the supply
from the airports MV power network to the
low voltage supply required for general use.
Generally, transformer manufacturers are
only required to provide documented proof
of their ability to withstand short circuits
by means of calculations. However, as part
of a new initiative to ensure the reliability
and continuity of critical airport power net-
works, UK Power Networks Services has
called for all its future transformers to be
fully type tested to demonstrate that they
can withstand short circuit conditions.
As the rst transformer manufacturer to
Distribution Substations
ABB has more than 100 years of experience in building and upgrading air and
gas insulated distribution substations around the world. This has provided
ABB with the expertise necessary to deal with all kinds of challenges in the
construction of indoor and outdoor substations.
The refinerys main power distribution substation is housed in a single blast-proof container
meet the new UK Power Network Services
requirements, ABB was therefore in the
perfect position to be awarded the order
to design, build and deliver 16, 1 MVA
packaged substations for Heathrow Airport,
each comprising a distribution transformer,
close coupled ring main unit (RMU) and LV
cabinet.
Future-proong older MV switchgear
A fast track project saw the completion of
a major contract to improve the safety and
reliability of 60 circuit breakers at eight
Scottish and Southern Energy Power Dis-
tribution (SSEPD) substations on Scotlands
east coast.
With the goal of boosting the safety of
the substations, ABB and its OEM partner
P&B Switchgear carried out a retrot of the
existing oil lled circuit breakers, some of
which date back to the 1950s.
ABB and P&B launched the retrofit
servi ce i n response to Ofgems 2010
introduction of a health and safety index
rati ng of equi pment, whi ch rates the
condition of plant from a low score of 5 to
a high score of 1.
After surveying their equipment, many
DNOs (Distribution Network Operators)
have found that much original switchboard
equipment, such as housings and busbars,
remains in good condition but that the
moving parts of the switchgear are showing
their age, leading to low safety scores.
The servi ce, assessed by the ENA
(Energy Networks Association), can boost
the safety rating from a level 4 to 2, at
the same time as extending the life of the
equipment by 20 years or more and it costs
around 30 per cent less than completely
replacing a switchboard. It can be extended
to equi pment manufactured by GEC,
Reyrolle, South Wales Switchgear, Brush
and many others. Hundreds of retrot and
circuit protection permutations are available.
The project for SSEPD included the
replacement of 60 South Wales Electric
C4X and C8X circuit breakers with retrot
units based on ABBs well-proven Vmax
vacuum circuit breaker. At the same time,
the ratings of the circuit breakers were
upgraded to double the current they can
handle.
A further benet of the retrot project was
that it took as little as four hours to work
on each individual panel. This meant that
the project for SSEPD could be delivered
with minimal disruption to the substations
operati on and the swi tchboards were
upgraded and operating to higher safety
levels within three months.
James Pierce, ABBs Power Products
Medium Voltage Service Manager for the UK,
said: Thanks to the successful completion
of the ENA assessment process by P&B
Swi tchgear, our OEM partner, we are
currently the UKs rst and only switchgear
supplier to offer an ENA assessed retrot
service for MV switchgear.
Retrofitting can boost the safety rating of switchgear
Site management
Its all about
project delivery
Electrical Installations Manager Chris Hensby explains how
ABBs approach to site management means that his team is
ready to take on any technological and programme delivery
challenge.
01
Site management
W
e have a team of around 50 site
managers, site supervisors and
commissioning engineers who
deliver construction and installation con-
tracts across the UK. Projects range in size
from 1 million to 100 million and up,
covering all sorts of transmission and dis-
tribution technologies, including substations,
generation, small power generation, trans-
mission, distribution, cabling, HVDC and
FACTS, to name but a few.
Site management is about driving the
programme forward while looking after the
site, our client and subcontractors, plus
reporting progress effectively. Its important
to keep a close eye on the work to make
sure the scope and time frames are deliv-
ered as expected. Our site managers protect
the interests of everyone by maintaining
effective control of exactly what happens
on site.
On site, it can be easy to focus on just
the practical aspects of project delivery but
its equally important to make sure that the
contractual side is also well understood,
so our site managers play a vital role in
ensuring that we comply fully with the con-
tract requirements.
A very substantial proportion of the day-
to-day work is focused on health and safety,
including making sure that contractors are
working to the daily briefs, appropriate risk
assessments and method statements and
managing the site induction process.
With such a broad portfolio of projects,
site teams can vary from just a handful of
operatives for a small job to 100 operatives
covering a variety of skills. For example,
for the new 400 kV substation at Connahs
Quay, we have a lead site manager over-
seeing a team of specialists who look after
key aspects such as the mechanical or
electrical build and the commissioning work.
While responsibilities can vary widely,
all of our site managers receive the same
training to ensure the work is delivered to
the required procedures and safety stan-
dards expected within ABB. When projects
interface with third parties coordination and
interface meetings are held with all stake-
holders to ensure all safety and design
issues are addressed.
Theres often a community relations or
an environmental aspect to the work and
well take on that too. One recent example
was where we had waste palisade fencing
at one site, and our site manager arranged
to deliver it and install it at a nearby school.
We also often work with ecologists to survey
for wildlife, such as bats or newts, and take
the appropriate course of action, whether
thats to stop work to avoid nesting bats
or moving wildlife to a place of safety.
Over the years since I joined the team,
it has grown and now includes specialist
site managers, site supervisors and com-
missioning engineers that together offer
unrivalled site management capability for
customers.
The team is also well structured to offer
exceptional career opportunities to support
the development of young professionals.
It is very important that we have both expe-
rienced hands and apprentices coming up
through the ranks. We support apprentices
through a programme of academic quali-
cations and on-the-job training to get the
right electrical and mechanical training and
commissioning experience to develop into
a fully edged site manager in the fullness
of time.
This strong team means that ABBs site
managers are willing to take on jobs the
length and breadth of the country and
deliver new technologies, with recent proj-
ects including substations from 11 kV to
400 kV across the country, solar, protection
and control and even a wave power project
in Orkney.
Much of our work is driven by the out-
ages planned by our clients, which are xed
and immovable. These hard deadlines mean
that ABBs team is focused directly on the
on-time delivery of key project milestones.
And when the project is delivered, we
know that our site delivery team will be
standing alongside the customer, helping
to energise the equipment and bring it
online. This total visibility and responsibility
at every stage, from site preparation to nal
handover, is central to our commitment to
a comprehensive, high quality service that
makes ABB's site delivery team best in
class.
01 ABB has a site management team of
around 50
02 An ABB site with time served AIS and
a new GIS building
02
Innovation
T
raditional substations have been
substantially over-engineered the
logical approach for installations
where the safety and reliability demanded
by clients are paramount. However, the
world has changed and new commercial
imperatives call for a demonstrable return
on investment (ROI). It is now critical to
adopt value-added engineering principles
to achieve a t for purpose design, one
that removes unnecessary costs while
maintaining the essential elements of qual-
ity, reliability and sustainability that ABBs
clients expect.
To implement these value-added engi-
neering principles we keep our substation
design processes under constant review.
This means challenging the norm and ask-
ing searching questions, especially when
it comes to elements that have always
been done this way. ABBs global 145,000
strong workforce gives us the advantage
that we can tap into what the rest of the
worl d i s doi ng and appl y i t i n the UK
context.
The strength of our team is vital to value-
added engineering and it includes senior
engineers with a wealth of experience and
newly qualied engineers, who offer fresh
new ideas. Its a combination that helps
guide our customers to the ultimate value-
added solution a substation project based
on efcient, high quality and sustainable
design. This ensures competitive costs,
shortened delivery schedules, managed
capital investment and improved operational
performance.
A key element in value-added engineering
is to support operational management.
For example, improving system access
and reducing maintenance requirements
can help ensure security of supply. This is
a crucial consideration as an outage that
interrupts customer power supplies could
result in daily losses of around 300k, so
a focus on continuity delivers signicant,
measurable value for our substation clients.
Value-added engineering also reduces
Value-added engineering
the time and red-tape involved in planning
consents by creating designs that need
less infrastructure, smaller wayleave require-
ments and possibly less land to be pur-
chased. Innovative design can also reduce
vehicle movements a traditional AIS
substation might require 40 deliveries to
site, whereas a hybrid PASS switchgear
design can reduce that to three or four
deliveries.
Naturally, we pride ourselves on being
able to deliver ideal customised solutions
for every application. But that is not always
necessary, or desirable. Standardisation of
designs can reduce programme and instal-
lation complexity and signicantly reduce
re-engineering times with a direct positive
impact on health and safety both during
and after construction.
Essentially, ABB is keen to ensure deep
commercial understanding across the board,
and how design directly inuences total
operating costs. This includes not just
capital investment in equipment, but hidden
costs, such as infrastructure and full life-
cycle costs.
For example, a conventional GIS sub-
station design surrounds the equipment
with expensive access gantries and walk-
ways. But now we question if this is really
needed, when temporary equipment could
easily be hired in as and when required,
Leigh Turley, ABB T&D Engineering Manager, explains how ABBs value
added engineering initiative is focused on driving out unnecessary costs
while maintaining quality helping to deliver the optimum cost-effective
substation project.
Innovation
which we know from experience works well
in other countries. Another example is that
substation fencing and cable trenches are
relatively expensive. We can usually reduce
the amount of fencing and trenching with
no compromise of safety and functionality
of the nal design, helping to take out sig-
nicant project costs.
Value added engineering is denitely not
about penny-pinching and we never lose
sight of our quality goals. However, through
the rigorous application of this approach,
ABB is now delivering optimised substation
designs that exceed performance and safety
requirements, while driving down costs
(TOTEX) throughout their entire life-cycle.
Mobile substations move ahead
ABBs new mobile substations are an excel-
lent example of value-added engineering
taken to its logical conclusion. Combining
primary equipment, protection and control
and transformers in an easily transportable
format, they are ideally suited for three key
application areas:
Emergency replacement to ensure
security of supply in cases such as a
transformer failure.
Planned outage management to
keep outages to a minimum when
carrying out essential maintenance
and repair work.
Customer connections for example
to bring a new wind farm or solar
power installation online as soon as
possible so that customers receive
an early return on their investment.
Innovative engineering and intelligent design
enable the mobile substation to be built
and tested off-site, then quickly deployed
to provide reliable and safe connection to
the power grid. This reduces civil works,
installation, testing and commissioning on
site. It also cuts delivery times from months
to weeks and reduces the infrastructure
signicantly compared to a conventional
air insulated switchgear (AIS) substation
bay.
Mounted on a trailer for easy transpor-
tation and deployment with no need for
special licences, the mobile substation is a
hybrid version of an outdoor AIS and a GIS
substation. It is based on ABBs pioneering
PASS (Plug and Switch System) modular
concept, rated at 132 kV or 400 kV, that
combines all the functions of a complete
AIS or GIS switchgear bay circuit break-
er, current transformer, disconnectors and
earthing switch in a single gas-insulated
module. This signicant reduction in the
number of components and moving parts
makes PASS exceptionally compact and
virtually maintenance-free.
ABB mobile substations are fast becom-
ing an important tool for utilities worldwide.
They can be transported by road, rail or air
and quickly deployed whenever and wher-
ever they are needed for periods typically
ranging from six to 10 months, a period
that could allow a wind farm operator time
to obtain planning permission for a perma-
nent grid connection substation. But with
emphasis on a solution that is mobile rather
than temporary, they are fully engineered
for a long service life of over 20 years using
the same technology used in fast-track
permanent substation solutions.
Mobile substations offer the reliability of a fully
engineered solution
Project design
A
ll ABBs customers are unique and
have different drivers for substation
development, when reviewing tender
documentation we aim never to go into
a project with pre-conceived ideas. Our
philosophy is to look at every site on its own
merits. While we often put forward a solution
that follows the initial indicative layout, our
customers are usually very happy for us to
sit down with them to discuss alternative
desi gns that mi ght offer consi derabl e
technical and commercial advantages.
Innovative
substation
design makes
the difference
GIS versus AIS
One example is the choice of switchgear.
When repl aci ng an AI S (ai r i nsul ated
switchgear) substation a like for like AIS
solution could seem the obvious approach.
We often surprise customers when we show
them that a GIS (gas insulated switchgear)
al ternati ve can be onl y sl i ghtl y more
expensive in terms of initial outlay (CAPEX),
and when considering the total cost (OPEX)
of a substation over its 40 year lifespan,
GIS can work out signicantly cheaper, due
to the reduced maintenance requirements
and system reliability.
The classic reason to use GIS over
AIS is when theres a limited installation
footprint available. But GIS can be ideal for
many other reasons. For example, when a
substation needs a signicant amount of
piling. We only need to pile just the small
footprint of the GIS building, as opposed to
a large outdoor AIS site, saving both money
and reducing the programme delivery time.
Its not always possible to use GIS.
Sometimes a customer doesnt want a
building or cant get planning permission for
a building. But we now have innovative AIS
alternatives, such as the compact hybrid
PASS concept. There are some schemes
where weve installed a single bay of PASS
switchgear in place of a conventional H
AIS conguration that would take the space
of a car park.
Disconnecting Circuit Breakers
Another recent innovation is a Disconnecting
Circuit Breaker with Fibre Optic Current
Sensor (DCB-FOCS). The new switchgear
has enabled a combined disconnector,
circuit breaker and current measurement into
a single compact device, which requires less
maintenance than conventional technology,
as it integrates the two switching functions
into a single piece of switchgear and uses a
David Dewitt, Bid Manager Power Systems, explains how
innovation is ABBs way of staying ahead of the competition.
current measurement technology that does
not require regular recalibration.
Integrating the FOCS with the DCB
reduces footprint while delivering a smart
gri d enabl ed sol uti on that i s vi rtual l y
plug and play and yet flexible enough
to accommodate customer needs. This
makes it ideally suited to new and upgrade
substation applications with the added
benet of enhanced power availability and
reliability.
Because the DCB-FOCS combines the
space-saving aspects of both DCB and
FOCS technologies, the new module has
the potential to reduce the overall physical
footprint of a substation by 60 percent
compared with a conventional arrangement.
It is supplied with standard ethernet cable
connections, which make it simple and
safe to install and operate, while improving
efciency by cutting electro-thermal and
electrical losses. It can be delivered on a
standalone basis or as a component part
of a complete switchgear bay.

Developments in GIS
New developments in more compact GIS
units offer considerable opportunities, as
Project design
at a project in London. The initial scheme
involved a two stage building construction
allowing a phased circuit transfer. We have
been able to devise an alternative arrange-
ment, with all switchgear set out in a dog-
leg conguration tting in just half of the
proposed building. Now the second building
extension is no longer required, saving the
customer both time and money.

Site security
Site security is another important consid-
eration. Copper theft is prevalent on AIS
substations, where its easy for thieves to
target and remove the easily visible copper.
Housing a GIS substation inside a building
with high security doors can eliminate theft
and its associated costs (which of course
include the cost of operational outages,
the price of replacement copper and the
resource to replace it).
Local resourcing
Weve also started with a fresh sheet of
paper with a new wind farm connection
project. Not only are we going the extra mile
in sourcing a high percentage of the project
resource and equipment locally, we also put
forward an alternative technical solution to
the client, which they have adopted.
Although the original scheme was sized
for the wind farm to be operating at 100%
capacity, we put forward the case that wind
farms rarely operate at that level. Instead, we
suggested an alternative design based on
a more realistic wind farm model. This not
only removed one high voltage transformer
from the scheme altogether, but also the
associated switchgear, cables and civil
engineering works. It also enabled the
optimisation of the 10 km underground
cable link, the overall impact on pricing
was a saving in the region of 1 million for
the customer.
Its this willingness to question the norm
that sets ABB apart. Well always look
at a scheme and apply our knowledge
of the latest technology, constraints and
environment. The aim is always to nd the
best overall through-life solution for the
customer in terms of programme, cost and
technology.
Substation
commissioning
the buck stops
here!
ABBs philosophy has taken commissioning from being the
last link in the chain to place it at the heart of the overall
design and construction process.
Site experience is fed back to the design office
C
ommissioning is the critical stage
of any substation design and build
project. It is the rst time that all
the various equipment is tested as a com-
plete entity. The pressure is on to prove
that the project works safely, that it will feed
power at the right levels and the protection
and control systems function correctly. So
it really is a case of the buck stops here
especially when working within a xed out-
age period to get the project signed-off and
handed over to the customer.
Traditionally the industry has regarded
commissioning as the last link in the project
chain from winning the order, developing
the design, carrying out civil works, install-
ing the equipment and then calling on the
commissioning team to prepare it for hand-
over. It was not unusual for the commis-
sioning engineers to arrive on site cold
with little prior project knowledge. They
would then be bombarded for requests for
test schedules, risk assessments, working
documents and so on. Resulting in a great
deal of work being done on the hoof, with
little forward planning.
Documented programme
Clearly, there is a better way to do things.
So our commissioning management team
is set up to deliver a more structured and
ful l y documented commi ssi oni ng pro-
gramme with the aim of ensuring that the
commissioning engineers are fully prepared
when they arrived on site. An important
stage in this process is the development
of a commissioning le for each project.
With some 20-plus sections, the folder
includes accurate documentation of:
Inspection and test plans
Switching programmes
Thermal rating schedules
Stage-by-stage documentation
Protection settings
Emergency return to service
Method statements and risk
assessments.
ABBs commissioning engineers are also
fully integrated within the project design
and installation team. So rather than arriv-
ing on site and trying to make someone
elses design work, they can provide direct
input to the design as it happens, right from
the very start. Not only does this provide
another pair of eyes to review the design,
the feedback of practical site experience
proves invaluable in ensuring that the sys-
tems will function as designed, and can
actually help to shorten the commissioning
process as well. We nd this approach really
helpful in developing the best value-added
solution.
A people business
Naturally, the success of the commission-
ing process comes down to nding the right
people. And we have worked very hard to
build a team with the right qualications,
and authorisations, such as TP141, com-
bined with experience in design, protection
and control and site management. Crucially,
we look for people who do rather more than
just follow a set of rules, who can check
what other people have done, and think
round problems. We also aim to develop a
close working relationship to support the
customer throughout the project and to
understand fully how they like to work.
Planning ahead
The ability to plan ahead is especially impor-
tant when dealing with events such as an
emergency return to service. Sometimes,
for reasons completely out of our own
control, we may lose the outage window
we have taken for example when a fault
occurs at a neighbouring substation. So
whatever stage we are at, the commission-
ing engineers must have a contingency
plan to restore the circuit as quickly as
possible.
Expanded scope
ABBs particular approach expands our
scope to offer extra added-value services
that can relieve some of the burden on the
customer. For example, it was usual for the
customer to develop the switching pro-
gramme to ensure that the new HV equip-
ment was energised safely and correctly.
This can now be performed by the com-
missioning team. Furthermore, we can
ensure safe energisation of LV systems
through the development of our own authori-
sati on process, where commi ssi oni ng
engineers become ABB nominated persons
to carry out the LV switching design pro-
cess, helping to develop the optimum
added-value solution. It greatly reduces the
potential of unexpected design issues aris-
ing on site, so that the commissioning
process runs as smoothly as possible. Most
importantly, it enables customers to be
assured that the commissioning will provide
complete proof that when the substation
enters service, it will function safely and
correctly, exactly as it has been designed.
Complete proof
In summary, ABBs approach to commis-
sioning provides a formalised structure at
every stage, with all the work to be carried
out fully documented and presented for
customer approval before we arrive on site.
It enables site experience to be fed back
into the design process, helping to develop
the optimum added-value solution. It greatly
reduces the potential of unexpected design
issues arising on site, so that the commis-
sioning process runs as smoothly as pos-
sible. Most importantly, it enables customers
to be assured that the commissioning will
provide complete proof that when the sub-
station enters service, it will function safely
and correctl y, exactl y as i t has been
designed.
A commissioning programme provides structure
Skills
Building ABBs
substation team
of the future
Jon Clarke, Engineering Support Manager for Power
Systems, explains how ABB is building its substation
engineering resources at all levels.
Jon Clarke with some of ABBs recent apprentices
Skills
P
lanning for the future is one of the
great challenges for any business,
and although its impossible to
make exact predictions, one thing is for
certain: as a society, were demanding
more of our electricity generation, trans-
mission and distribution systems.
Renewable energy and Smart Grids are
denitely part of the future and well need
smart engineers to deliver them, which is
why we are planning now with a structured
path for attracting and developing talent.
This includes a commitment to encouraging
young people into engineering careers,
through a school outreach programme that
has been running for more than 10 years,
along with our apprenticeship and graduate
schemes.
The rapid pace of technological devel-
opment in recent decades means that
having people with the ability to learn, adapt
and apply new skills is a must-have for
ABB. The business world has never been
more volatile but it is also full of untapped
potential. We are looking for people who
are agile and curious, as well as bright and
willing to move with the company. This both
helps the business succeed and helps our
people develop their own careers.
At all levels of the organisation, we
look to hire and develop talented people.
Through the performance and development
appraisal process, we work with our high
performing employees and provide oppor-
tunities to develop and gain experience in
the UK and overseas, opening up a world
of possibilities.
In 2011, ABB Power Systems ful l y
restructured its apprentice scheme, work-
ing with Newcastle-under-Lyme college in
Staffordshire to create a tailor-made pro-
gramme, which combines real-world expe-
rience with rigorous tuition and guided
study. Those who have joined us on the
programme are now on the road to an
exciting and rewarding career in electrical
engineering. The emphasis is on both
classroom learning and providing practical
experience, and right from the start our
apprentices are involved in working in spe-
cic teams to help deliver projects for ABBs
customers.
Our approach to attracting apprentices
is by building on the school industry days
we hold for 14-year olds and subsequent
work experi ence for 15-16 year ol ds.
Schools that focus on STEM (science,
technology, engineering and maths) subjects
are especially fertile ground for ABB.
Around 16 pupils visit from each of the
schools involved in our industry day pro-
gramme. During these industry days we
challenge them by setting a small project
that gives them experience of considering
technology, plus safety, the environment
and teamwork. At the end of the day, they
give a short presentation on the ndings of
their project together with the lessons learnt.
During the course of these days we are
able to invite those people that have shown
keen interest in the company back the next
year for meaningful work experience and
maintain a link with them to ensure they are
contacted personally the following year to
consider applying to join the apprenticeship
scheme. This has developed into a channel
to attract the most enthusiastic and bright
young talent to join the company.
The apprentice scheme in particular has
created a fantastic level of engagement
across our engineering teams, with estab-
lished staff providing a great deal of input
and encouragement to those undertaking
their studies. Our management team is
actively involved and with many of them
having come through apprentice schemes
themselves, often going on to study at
degree level and beyond, they are keen to
encourage this new generation to follow in
their footsteps.
Classroom learning
Service
Lifetime service for
substation assets
ABB offers a comprehensive service that supports critical transmission and
distribution substation assets throughout their life. The aim is to maintain
substations in optimum performance and avoid costly failures so that our
customers continue to enjoy safe, reliable, efficient and profitable performance
from their assets, large or small, during their lifetime.
Transformer fault analysis
Service
W
e have the people, skills and in-
depth knowledge to cover the
full spectrum of substation asset
service requirements, from routine inspec-
tion of an 11 kV network, right through to
the construction management, installation
and commissioning of a new 400 kV GIS
substation.
Our service is not restricted to equip-
ment supplied by ABB equipment we can
support equipment from just about any
manufacturer across all the major business
sectors including:
power generation
utilities
industrial processes
transport
construction
public sector
renewable energy
data centres.
Supporting distribution networks
ABB speci al i ses i n t he i nspect i on,
maintenance and repair of electrical power
distribution equipment and networks up
to 33 kV for utility, industrial and public
sector customers. Round-the-cl ock
emergency support provides an immediate
response to network problems isolating
the fault, restoring supplies and making a
permanent repair quickly and safely.
Qualied personnel, high-voltage tters
and cable jointers are all ESI trained to the
highest nationally recognised standards
and operate under a set of distribution
safety rules to ensure the reliable and safe
operation of distribution systems.
Using dedicated HV test vehicles, ABB
engineers can identify disruptive and costly
system faults. Permanent faults are precisely
located using a combination of pulse echo,
impulse current and capacitor discharge
devices. Excavation and jointing can then
be carried out to restore the network. To
track intermittent faults, the engineers use
fault burning, equipment with high current,
but low voltage, to accelerate degradation
and make the fault permanent and so easier
to locate.
Getting more from HV assets
ABB can take complete responsibility for the
inspection, maintenance and repair of high-
voltage (HV) transmission assets, as well as
associated control and protection systems.
Specialist engineers ensure that critical
high-value network assets are maintained in
optimum condition to guarantee maximum
reliability, safety and availability.
System support contracts are offered
for generation, utility and industrial trans-
mission customers. These can range from
simple hotline support through to life cycle
agreements.
24/7 system support
ABB offers cost-effective long-term support
for the overall substation. Based on profes-
sional life cycle predictions for products
and systems, including component reliability
calculation analysis, a 24/7 hotline guar-
antees a fast response when needed.
Maximum Transformer
Availability
ABB has a complete portfolio of services
to keep generation, system and grid power
transformers running at maximum efciency
and distribution reliability. We can also co-
ordinate the transport, erection, commis-
sioning and training needed to bring new
ABB transformers safely online as fast as
possible and ensure a smooth hand-over
and a complete after-sales service.
The emphasis is on providing a whole-
life service from installation, through normal
preventive maintenance and repair, and
retrot programmes that can provide an
extra lease of life, to end-of-life manage-
ment with minimum environmental impact.
This portfolio includes:
Understanding your assets
In-depth knowledge of the actual status of
equipment, based on its recorded history,
a revi ew of i ts desi gn and advanced
diagnostic techniques, enables potential
faults to be identied before they happen.
Thi s al so provi des a sound basi s for
the implementation of condition-based
maintenance or corrective action.
Fast repairs
Should a major problem arise, ABB provides
a fast response for repairs such as parts
replacement, tap changer refurbishment
or more extensive work. The usual starting
point in such cases is an in-depth diagnosis
to assess the condition of the unit. Where
possible, all work is carried out on site.
Cable fault location
However, when more extensive work is
required, full factory repair and refurbishment
can be arranged in one of ABBs transformer
repair facilities.
A new lease of life
ABB also offers a transformer remanufac-
turing service that can extend the life of
agei ng or faul ty power transformers,
enabling them to be fully refurbished then
recommissioned. Upgrades in specication
can also be incorporated as part of this
service. As well as being cheaper than a
new transformer, a fast turnaround can
have a transformer back in operation in
around one third of the normal delivery time
for a new unit.
Energy storage
T
he UK power landscape is in a period
of dramatic change. There is a shift
from centralised fossil-fuelled gen-
eration to more distributed and inherently
variable renewable energy sources such
as wind, solar, wave and tidal. At the same
time, loads are changing, including large-
scale data centres, widespread use of air-
conditioning and the deployment of electric
vehicle (EV) charging infrastructure.
These fundamental changes i n the
architecture and controllability of the grid
call for smart, efcient power transmission
and distribution networks. And they require
the storage of energy at appropriate times
The BESS
way forward
and locations both to balance the rapid
change in 'ebb and ow' between genera-
tion and consumption and also to maintain
grid stability.
ABB offers complete battery energy
storage system (BESS) solutions that inte-
grate seamlessly into the power network.
We employ a variety of battery technologies
from world-class manufacturers to ensure
that we deliver the perfect combination of
energy storage and power technologies to
match a customers specic application
needs. BESS can perform a number of
important grid functions:
Frequency regulation
The energy storage system can be charged
or discharged very quickly in response
to fast increases or decreases in load,
maintaining the balance between supply
and demand. This approach to frequency
regulation is a particularly attractive option
due to its rapid response time, the accuracy
of the regulation and the emission-free
operation.
Base load levelling and peak shaving
Base l oad l evel l i ng and peak shavi ng
i nvol ves stori ng power duri ng peri ods
where perhaps renewable energy may be
being produced in excess of demand or
when costs are low and delivering it during
periods of high demand, when costs are
high. This approach can enable the deferral
of investments in grid upgrades or in new
generating capacity and avoids incurring
high power costs for short term peaks.
Power Quality
ABB technology is already used extensively
for the management of reactive power,
the addition of this technology into the
Battery Energy Storage Systems provides
a further dimension the management of
active power. Our power converter systems
have the capability to meet both reactive
and active power needs, providing the grid
with the exibility to manage any situation,
at any time in the daily demand cycle and
for prolonged periods of time.
ABB is building on the success of the
initial project by implementing a new a
Stuart Grattage, Head of Engineering for ABB
Power Systems in the UK, explains how battery
energy storage systems (BESS) can help keep the
grid in balance.
Dynamic energy storage solution
Power Station Load Leveling (Generation Utilization)/Frequency Regulation
Spinning Reserve
Large Residential/
Commercial/
Industrial Loads
Peak Shaving
Capacity Firming
Load Leveling
(Postponement of grid upgrade)
Renewables Voltage Support/Power Quality
110 kV
20 kV 380 kV
20 kV ring
33 kV 110 kV
380 kV transmission line
Load
Energy storage
software algorithm that adds predictive
charge and discharge control capability.
Ongoing trials will then demonstrate the
operation of the site as an autonomous
peak shaving asset.
Comprehensive system approach
Batteri es are based on di rect current
(DC). To connect them to the alternating
current (AC) grids mainly used for power
transmission and distribution requires a
conversion step, using power electronics.
ABB has an outstanding track record in
delivering power electronics systems, such
as our PCS range, that combine excellent
performance with instantaneous response
to create the essential stable interface.
As part of our total system philosophy, we
are also working very closely with our Power
System Network Management (PSNM)
team to take BESS control systems to the
next level to ensure that energy storage
is fully integrated within the overall grid
management system.
Furthermore, through Ventyx, the leading
enterprise software specialist that joined the
ABB Group in 2010, we are adding a new
dimension to energy storage as part of an
overall smart grid solution. By gathering
information from the wider network, we are
evolving energy storage beyond the simple
on or off approach to enable intelligent
management of power ows.
Overall, building an efcient, reliable
and durable BESS calls for a range of key
technologies and competencies from
circuit breakers and transformers through
batteries and power electronic conversion,
on through system- and grid-level control,
to smart forecasting. ABB can provide all of
these from a single source as demonstrated
in these current projects:
The Alaska BESS
The Golden Valley Electric Association
(GVEA) operates and maintains around
5,000 kilometers (km) of transmission and
distribution lines and 35 substations in the
Alaska region.
In 2003, ABB applied implemented
battery storage technology, combined
ni ckel -cadmi um batteri es wi th power
converters to create a spinning reserve
solution that provides back-up electricity
for GVEA when necessary. Recognised by
Guinness World Records as the worlds
most powerful battery system, it can supply
power at 27 MW for 15 minutes or 46 MW
for 5 minutes, which allows ample time for
local generation to come online.
Switzerlands largest battery energy
storage project
ABB recently commissioned the largest
battery energy storage project of its kind
in Switzerland with EKZ, a leading distribu-
tion utility and one of the largest energy
companies in Switzerland.
To enable additional power to be provided
to the grid on demand, ABB supplied and
installed a battery energy storage solution
using Lithium-ion (Li-ion) batteries that can
provide 1 MW of power for 15 minutes.
The storage facility is integrated into
EKZs power distribution network and is
being used to evaluate performance in key
areas such as balancing peak loads and
intermittent power supply, and the viability
of the solution for grid optimisation.
Dynamic energy storage
installation in the UK
ABB worked with UK Power Networks,
which supplies power to over eight million
homes and businesses in the UK, to develop
a dynamic energy storage solution for a
substation site in Norfolk. The installation,
commissioned in 2011, enables renewable
energy generated by local wind power plant
to be fed into the power network when
needed. It also ensures that some of the
energy is kept in reserve to regulate power
ow to compensate for the intermittence
of wind power and to support power quality
in the event of a fault.
To meet these needs, ABB implemented
a turnkey DynaPeaQ
solution incorporating
SVC Light
, which included eight stacks of

13 Li-ion battery modules located in an 11
kV grid. Together, these high power density
modules can store up to 200 kilowatt-hour
(kWh) of electrical energy.
The installation provides dynamic voltage
control in the distribution system and, at
the same time, enables dynamic storage
of surplus energy from the wind power
plant. This surplus energy is used to level
out peaks in grid loading to provide grid
stability.
Typical grid energy storage applications
ABB has created a new app for the Apple iPad to help its customers fully understand its
substations portfolio. The app contains details on all of ABBs substations products and
how they t within a substation layout. The ABB Substations APP includes details about
GIS and AIS switchgear, transformers, protection and control equipment, as well as
a myriad of other equipment. It lets users explore our substations solutions within an
interactive 360 virtual landscape, with the ability to zoom in on particular products or
installations to learn about technical details. Acting as a dedicated product catalogue,
the app will be available soon via iTunes. www.abb.com
Our substation portfolio at your fingertips?
Definitely.
ABB Ltd
Tel. +44 ( 0)1785 825 050
Fax. +44 ( 0)1785 819 019
E-mail. info@gb.abb.com

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Connahs Quay takes shape 14

Moving a mountain for Sloys hydropower substation 6

, which included eight stacks of

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