ABB medium voltage products Helping our customers meet evolving energy demands

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1 ABB medium voltage products Helping our customers meet evolving energy demands

2 Preparing for tomorrow s energy needs today Distribution Management System SCADA Instrument transformers Switchgear Protective Relays Distribution Automation Test Switches Asset Monitoring SCADA Wireless Communications Battery storage CapBanks CapControls Protective Relays Distribution Automation Test Switches Switchgear Breaker Protective Relays Distribution Automation Test Switches Cutouts Instrument transformers Breaker Switchgear Reclosers Switchgear Padmount Cutouts Reclosers Instrument Transformers Protective Relays Distribution Automation Test Switches The world s demand for energy is increasing at an alarming rate. Experts expect consumption to rise by 55% over 2008 levels by Utilities and industry must prepare now to meet the challenges of tomorrow. Increasing the reliability of an aging infrastructure The increased demand for energy is happening at a time when much of the existing infrastructure is reaching the end of its expected life span. To ensure the reliability of the grid, utilities and businesses must take a risk-based approach to investments in equipment and system upgrades. Protecting property and personnel Electrical accidents such as arc flash incidents are an all too common occurrence. According to the IEEE, there are an estimated arc flash incidents per year and one death per day in the US alone. In addition to the tragic loss in lives, an arc flash can damage essential equipment at an average replacement cost of over $1 million dollars per incident. Accidents like these reduce the capacity of the grid, put lives at risk, and bring business to a standstill. Getting more done with fewer resources While the infrastructure is aging, so is the workforce. Experts estimate that over half of the energy sector workforce is expected to retire in the next decade. Cost cutting measures are requiring many businesses to delay or forgo the replacement of these skilled technicians. The increased workload is left to the remaining crew as well as less expensive and less experienced new hires. Challenges like these require tough solutions that can increase the reliability, safety, and efficiency of the existing infrastructure while helping businesses do more with less by managing assets and controlling costs. ABB Power Solutions help utilities and businesses address these essential medium voltage solution requirements Preparing for tomorrow s energy needs today ABB medium voltage products

3 Reliability Minimizing downtime Downtime is costly. According to estimates by Berkley National Laboratory, outages cost more than $79 billion dollars in the United States in The majority of that cost, $77 billion, was born by the commercial and industrial sector. Of course, outages are damaging for utilities as well, leading to fines, lost revenues, and potential litigation. While popular perception is that major outages such as those caused by natural events like hurricanes and ice storms are the biggest challenge for industry and utilities, the majority of outages are from momentary disturbances. For a manufacturer, an outage lasting no more than a few seconds may reduce a production run worth millions to mere scrap. These momentary disturbances are often the result of equipment failure caused by heavy use, harsh conditions, or inadequate maintenance. By designing equipment for the toughest conditions and heaviest demands, ABB helps minimize downtime and improve reliability. Designed for heavy use; minimal maintenance ABB produces medium voltage equipment that can withstand even the harshest environments such as the corrosive conditions in a desert or ocean front installation. For example, Grid- Guard, ABB s medium voltage overhead switch for use in smart grid distribution systems, is designed to be maintenance-free and reliably open and close even in corrosive environments after 10 years in the field. In addition to corrosive conditions, factories often have an added challenge of high-vibration environments. Not only does ABB s full suite of switchgear solutions last one third longer in corrosive environments than other switchgear solutions, their rigid construction is designed to withstand high vibration environments as well. Exceeds industry standards One way to be sure your equipment will stand up to environmental and usage demands is to compare it to industry standards. ABB exceeds industry standards in medium voltage solutions wherever possible. For example, ABB Rmag outdoor breakers are rated for 2,000 operations between servicing and 10,000 mechanical or load operations. That s four times the ANSI C requirements. ABB medium voltage reliability application: Fault detection isolation and restoration ABB helps minimize downtime by enabling applications like Fault Detection Isolation and Restoration (FDIR). When an outage occurs, two-way communication allows utilities to identify the fault location quickly. The operator can then isolate it and restore power by rerouting the flow of power on the distribution grid through unaffected areas. For ABB customers, FDIR has improved reliability targets by as much as 33% for utilities and decreased downtime for industry and the consumer. ABB medium voltage products Reliability 3

4 Efficiency Reducing distribution losses For utilities, the challenge is to increase the efficiency of the grid and improve its capacity to meet new levels of demand. ABB medium voltage solutions help utilities implement a number of applications that can dramatically increase the capacity of the existing grid. Volt/VAr control By adding two-way communications and Volt/VAr software, the operator is able to coordinate and control capacitors, voltage regulators, and load tap changers downstream to the customers and upstream to the feeder/substation in real time. Integrating Volt/VAr control with network management software takes it one step further, allowing the utility to optimize the power factor downstream to customers, upstream to feeders/substations and across the network between substations. Volt/VAr control can reduce distribution losses by as much as 5% or an estimated 32.5 billion kwh globally. Conservation voltage reduction Utilities must regulate the voltage delivered to within ± 5% of the required nominal voltage for each consumer to ensure customer satisfaction, minimize waste and associated costs, and meet public utility commission expectations. Conservation voltage reduction frees up grid capacity by lowering voltage in order to reduce demand and losses while staying within an acceptable range. Feeder metering Feeder metering measures the distribution of energy to commercial and residential sectors and compares those readings with revenue to ensure that the utility is properly billing for energy consumption. Studies indicate that feeder metering allows utilities to identify and correct losses equivalent to 6.5% of annual revenues, helping them return millions of dollars to their bottom line. Volt/VAr control and conservation voltage reduction can reduce distribution losses by as much as 5%. 4 Efficiency ABB medium voltage products

5 Safety Protecting property and personnel According to the IEEE, there are over 2000 arc flash incidents every year and one death per day in the US alone. Even if a technician survives the incident, they face years of painful treatment at an average cost of $1.5 million. 3 In addition to the human toll, arc flash incidents can easily cause upwards of a million dollars in property damage per incident. For industry, this means lost revenues and damaged reputations. For utilities, it can mean lost revenues and expensive litigation at an average of $5 10 million per incident. Keys to protecting property and personnel There are a number of ways utilities and industry can protect property and personnel. ABB offers medium voltage solutions that support these initiatives. Replace older equipment with systems with higher safety ratings. ABB has levels of switchgear that are compliant with IEEE C37/ ratings: Type 2, 2B, 2C, and 2BC. This allows switchgear customers to choose the safety ratings appropriate for their application. ABB adds additional features for type 2BC, including extra gasketing between low voltage compartments and one-way gaskets designed to collapse around wires extending between compartments. These extra features help prevent gas seepage into the low voltage compartment during the pressure build-up that happens during an arc fault. Keep personnel at a safe distance. The majority of arc flash incidents occur during maintenance, especially during the replacement of circuit breakers and switchgear. ABB s remote racking solution is a portable device that allows technicians to remotely rack an ADVAC or AMVAC circuit breaker at distances of 10 to 20 feet. The system includes a number of other safety features, including a touch screen interface with true closeddoor racking capability and redundant digital drives with battery backup to provide fail-safe racking in the event of a power failure. Real-time breaker travel indication and user controls include an emergency stop, manual start/stop, and automatic retrieval and recovery of a circuit breaker. IEEE C37/ standard ratings Type 2 Switchgear with arc-resistant design features at the exterior (front, rear and sides) of the equipment. Type 2B Meets type 2 criteria, plus arc protection to the low voltage compartment. Arcing does not cause holes in the walls isolating the low voltage control or instrument compartments. Type 2C Meets type 2 criteria, plus arc protection between all compartments in a lineup, isolating arcing faults from adjacent compartments. Type 2BC The most stringent safety designation available. Equipment meets type 2, type 2B and type 2C criteria. ABB is one of very few vendors to offer switchgear that meets the Type 2BC designation. Isolate the arc flash to minimize property damage. One key to maximizing personnel safety and minimizing damage to property is to immediately detect and isolate the arc flash. The REA arc protection system enables fail-safe and instantaneous arc detection anywhere within the switchgear enclosure. This allows the system s fast Insulated Gate Bipolar Transistor (IGBT) to react instantly (<2.5 ms) to isolate the arc and minimize damage to the switchgear lineup. Remove personnel from the greatest dangers. An arc flash incident can produce temperatures up to 20,000 Celsius, and inhalation of hot gasses is the leading cause of death. ABB SafeGear offers an optional plenum designed to channel these hot gasses out of the building and away from personnel, providing an extra level of protection. 3 Source: Flacon Engineering Consultants ABB medium voltage products Safety 5

6 Cost and asset management Making the best use of limited resources Now, more than ever, utilities need to maintain tight control over costs. Operating budgets are being reduced in order to reach target margins, and there are limited funds available for maintenance and training. While many companies have an urgent need to replace or upgrade older systems due to safety or reliability concerns, smaller capital expense budgets demand a pragmatic approach. Five cost management strategies ABB works with utilities and industry to implement five cost management strategies that help control costs while maximizing safety, reliability, and efficiency. Optimize design. When new systems are required, ABB can design and specify solutions that meet the needs of the application. For example, utilities can buy switchgear with lower interrupting capacity (often less than ½) with the use of the IS Limiter. Upgrade instead of replace. ABB offers several solutions that allow existing equipment to be upgraded to meet new requirements. ABB s IS Limiter can also be implemented to protect existing, underrated equipment against the effects of short circuit current, eliminating the need to replace the switchgear. REA arc flash protection system can be added to existing systems to minimize damage from potential incidents. Replacing legacy recloser relays with Relion relays instead of replacing the entire recloser has saved ABB utility customers as much as $10,000 per recloser. thousands of dollars in instrumentation transformer inventory carrying costs due to ABB s unique ability to ship units in four weeks or less often 8-10 weeks faster than the competition. Choosing the right path For businesses looking to achieve objectives such as increasing reliability, decreasing costs, or improving safety, asset management is of vital importance. Do systems need to be replaced? Can they be upgraded? Or can capital investments be postponed through proper monitoring and maintenance? ABB works with utilities and industry to create an Asset Lifecycle Plan that helps them choose the best option: Refurbish and retrofit: ABB refurbishment services can extend the life of essential equipment. Repair: When repairs are called for, ABB helps customers minimize downtime with easy access to service centers and technicians around the globe. Upgrade: Older systems can often be upgraded to meet new standards for safety and reliability. Monitor & Maintain: Predictive, condition-based maintenance can help businesses focus on the areas of greatest risk and minimize operating expenses. Replace: When systems need to be replaced, ABB innovations help businesses implement solutions that meet their objectives. Reduce required training time. Systems that require little to no training can help businesses adapt to a less experienced workforce. ABB s Relion family of protective relays can be preconfigured in the factory at no additional cost, saving technicians the time and expense of configuring systems in the field. Reduce maintenance. Businesses are able to maintain a tighter control over their operating budgets and make do with fewer resources when they select medium voltage solutions with reduced maintenance requirements. For example, AM- VAC breakers have only one moving part compared to the 157 found in traditional spring breakers. Not only does this make the breaker easier to maintain, it can save as much as $2775 over the first ten years of life. Reduce spare parts inventory. Smart businesses recognize the cost of carrying excess inventory and will do their best to minimize the number of repair parts necessary. Utilities can save 6 Cost and asset management ABB medium voltage products

7 Pulling it all together Meeting the needs of the medium voltage OEM Original Equipment Manufacturers (OEMs) deliver systems for customers with a variety of requirements. ABB offers medium voltage components and services that allow OEMs to design and build systems that are reliable, easy to install and maintain, and improve personnel and equipment safety. ABB offers a wide range of solutions that complement the OEM s own manufacturing capabilities, core competencies, and capacity. ABB OEM solutions offers a number of benefits to OEM switchgear suppliers including: A consistent supply of components Improved margins Reduced staffing requirements Improved customer satisfaction with advanced technology components Greater ability to meet customer requirements for medium voltage solutions with unique design specifications ABB Packaging: a single point of contact ABB Packaging, also known as Non Systems Product Packaging (NSPP), provides a single point of contact throughout the life cycle of our customers projects, packaging solutions from different factories, business units, and even vendors worldwide into one solution. All ABB project managers are highly trained professionals certified by the ABB internal project management accreditation program as well as the Project Management Institute. Having a single point of contact helps our customers improve project coordination and control and reduce risk through a number of means: Reduced process complexity Clear accountability Improved vendor negotiation and lower product costs Lowered engineering and project administration costs Greater access to industry expertise Harmonized terms and conditions OEM solutions Full fabrication Limited Fabrication Systems manufacturers Breaker manufacturers Relay panel OEMs Control specialists Integrator/ packagers ABB solutions Abbreviated switchgear Test switches Medium voltage switchgear Breakers Control handles Vacuum bottles L-frames Indoor air-insulated load break switches Enclosures Protective relays Instrument transformers Auxiliary relays Breaker modules Address specific applications Extend core competencies Design or licensing assistance Mazimize value add ABB offers a complete range of medium voltage solutions for OEMs of every type. ABB medium voltage products Pulling it all together 7

8 Contact us ABB Inc. Medium Voltage Switchgear, Outdoor Products, & OEM Apparatus 655 Century Point Lake Mary, FL Phone: Customer service: ext ext customer.service.group@us.abb.com 1VAL0001-DB Rev A January 2013 ABB Inc. Medium Voltage Distribution Components 3022 NC 43 North Pinetops, NC Phone: Fax: ABB Inc. Distibution Automation 4300 Coral Ridge Drive Coral Springs, FL Phone: Fax: ABB Inc. Medium Voltage Service 2300 Mechanicsville Road Florence, SC Phone: HELP-365 (option 7)