COMPANY PROFILE

Transmission and Distribution Substations

Table of Contents
1 INTRODUCTION ........................................................................................................................................ 3

2 PROJECT DEVELOPMENT ...................................................................................................................... 5

3 ANALYTICAL CAPABILITIES ................................................................................................................. 6

4 EXECUTION CAPABILITIES.................................................................................................................... 6

5 T&D SUBSTATION SCOPE ....................................................................................................................... 7

5.1 SUBSYSTEMS ........................................................................................................................................... 8
5.1.1 Gas-Insulated Switchgear (GIS) ....................................................................................................... 8
5.1.2 Transformers ................................................................................................................................... 9
5.1.3 Medium Voltage Switchgear .......................................................................................................... 10
5.1.4 Substation Automation Systems ........................................................... Error! Bookmark not defined.
5.1.5 Cable Systems................................................................................................................................ 12

6 PROJECT MANAGEMENT ..................................................................................................................... 12

6.1 SCHEDULING ......................................................................................................................................... 13

7 DESIGN SERVICES .................................................................................................................................. 14

8 CONSTRUCTION MANAGEMENT AND MAINTENANCE ................................................................. 14

9 SUMMARY................................................................................................................................................. 15

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1 Introduction

ABB is the world market leader for substations. Since the sixties we have delivered around 3500
substations up to 800kV to our utility, industrial, railway and wind power customers. Substations are
the core element for electrical power supply. ABB has the knowledge and experience needed world-
wide to build and upgrade substations without limits due to the site conditions and voltage levels. –
ABB will provide the most economic application to you in a reliable and optimized manner. The
purpose of this document is to introduce interested parties to the turnkey capabilities of ABB with
respect to transmission and distribution projects. Our capabilities include studies, design,
engineering, manufacturing, civil works, installation, commissioning, operation and maintenance as
well as training.

We are committed to providing solutions for efficient and cost effective power supply concepts. As a
member of the global ABB group we share technical expertise, sophisticated analytical tools, and
use proven methodologies and technologies to optimize each case on an individual basis.
As part of an overall EPC (Engineering, Procurement, Construct) contract, we will develop a
proposal in accordance with the Owner’s design requirements, however we will also review possible
alternative designs that maximize the value of the overall project. We are committed to providing
solutions that maximize value delivered in terms of initial cost, total life-cycle cost, reliability, and
start-up time. We want to help our clients be best in class.

Another cornerstone of ABB’s business philosophy is to invest in long-standing relationships based

not only on competitive prices, but even more so on the expertise of our project team and the
excellence of our products and services. Our planners, engineers and technicians are well known for
their extensive experience and innovation.

ABB has one of the largest worldwide installed base of T&D substations and T&D equipment. With
our locally well-established companies, speaking the local language and familiar with all local
requirements and standards, we can bridge over cultural and language barriers as well as avoid
technical acceptance problems. Through our comprehensive product portfolio we are uniquely
prepared to manufacture, assemble, install, service and maintain all equipment from the low voltage
distribution system up to the grid connection.

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Our mission is to develop, market and supply economically attractive, environmentally sound and
high quality products, applications and services for efficient utilization of new and existing
substations. Our vision is to be the natural choice for all kind of substation applications.

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2 Project Development
ABB develops complex projects using a capture team approach. The capture team includes a sales
team, a project manager, project engineer(s), consultants and subcontractors. This approach
addresses all aspects of a potential project prior to submittal of the proposal. This in turn maximizes
the practical “buildability” of a proposed design and reduces the overall risks of quality problems and
delays.

As part of this project our design/build proposal will be in strict accordance with your requirements,
well proven and sound engineering and construction practices and will cover the following scope:

Basic design and detailed engineering of the turnkey substation, including control & protection
and grid connection
Studies and calculations
Permitting and approval procedures
Detailed specifications and procurement of components and material
Manufacturing and factory-testing of the equipment
Shipping including insurance
Project and site management including coordination with customer, and all other parties involved
in the overall project.
Training and documentation
Turnkey installation, testing and commissioning and hand-over to customer

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3 Analytical Capabilities
The design of a turnkey substation requires efficient planning of engineering and management of
services. ABB is the knowledgeable and reliable partner in providing such services.

In order to achieve the optimised technical solution we can perform various studies like design of system
diagrams, short circuit calculations, load flow analysis, cable ampacity calculations, coordination and
selectivity of MCC and LV boards, planning and design of cable routing plus others as listed below.
Backed by these studies, a complete technical solution along with the equipment specifications can be
established, allowing for an overall cost estimation.

Topic Services Provided

Planning Studies Network and reliability impact studies

Short-circuit calculations
Load flow analysis
Estimation of auxiliary system loads

Design Studies Short-circuit calculations

Voltage drop calculations
Load flow analysis
MV & LV cable ampacity calculations
Design of AC and DC auxiliary system single line diagrams
Station auxiliary transformer sizing calculations
Battery sizing calculations
Planning & design of cable and bus duct routing
Design of cable laddering and trench system
Reliability analysis
Preparation of equipment specification and bill of material for
procurement

Figure 1: ABB’s studies and engineering service capabilities

4 Execution Capabilities
Figure 2 below shows the execution capabilities, which we can offer to our utility, industrial, railway
power and wind power customers. As the unique manufacturer of all electrical equipment used in a

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 substation, ABB provides a fully engineered turnkey package including coordination of interfaces
and installation & commissioning.

Figure 2: Execution Capabilities

5 T&D Substation Scope

ABB covers the complete supply of all material and services starting from the simple disconnector up
to turnkey substations and retrofit of existing systems. ABB offers a vast experience in design and
execution of turnkey substation projects, combining the needs from the customer’s side with
innovative design and equipment from ABB’s side. This secures that the budget, quality and time
schedules all are within the given frames. Figure 3 below shows an overview about the T&D
substation portfolio.

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 Figure 3: T&D Substation Scope

5.1 Subsystems

5.1.1 Gas-Insulated Switchgear (GIS)

For 40 years ABB has been actively engaged in the technology and development of gas insulated
switchgear for high voltage transmission. A global business approach puts us in the position to
fulfil the most demanding requirements from customers all over the world.

We manufacture GIS up to ratings of 800 kV, which benefit our customers with
Minimum space requirement
World-class in availability
Minimum operating costs (maintenance free)
Extreme environmental conditions capability
Safety for personnel
High seismic withstand capability
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 You will find ABB GIS in places like New York City, Tokyo, Beijing, Riyadh, and London; you will
find it in Alaska and Hawaii; you will find it in refineries along the Gulf coast and in the Caribbean
islands. Possible GIS applications are just as diverse as the locations of our substations –
whether it is high real estate prices, aesthetic requirements, protection from corrosive
atmospheres, or maximum reliability with minimal maintenance – GIS deserves the substation
planner’s consideration.

Figure 4: GIS Substation

5.1.2 Transformers
ABB is a world leader in the development of power transformers. It continuously seeks innovative
solutions that are reliable, high performance, low cost and aligned with the market. For example,
the TRAFOSTAR transformer solution – a show case of technological uniformity and
standardisation – is designed and manufactured by all ABB transformer plants. This technology is
continuously updated by incorporating the latest advancements and then rigorously tested by R&D
experts at ABB’s global transmission and distribution research facilities. Each transformer design is
customised to meet or exceed requirements and international standards, providing an overall low
life cycle cost to the customer.

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 Each manufacturing step is rigorously monitored and controlled using an elaborate 6-sigma control
system. The end result is a superior quality transformer, partial discharge free, providing long-term
reliability and low maintenance.

Figure 5: Power Transformer Figure 6: Unit Auxiliary and Step-up Transformer

5.1.3 Medium Voltage Switchgear

ABB offers a complete range of medium voltage switchgear for primary and secondary distribution
developed from customer requirements.

Our portfolio includes air insulated and gas insulated panels with a choice of gas or vacuum circuit
breakers. The voltage range is 1 - 40 kV and current ratings cover all possible technical
combinations meeting ANSI and IEC requirements.

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 Figure 7: ZX Metal-clad GIS MV Switchgear

Figure 8: UniGear metal-clad AIS MV-Switchgear

5.1.4 Substation Automation and SCADA

ABB delivers all the systems required to successfully automate a substation: from the protection
relay to SCADA systems, from system design to life-long operation. Throughout the life of your
substation, you enjoy the benefits of a single, reliable partner. Design, engineering,
commissioning and service – all from one, experienced hand.
Our product development continuously follows state-of-the-art technology and requirements.
Close cooperation with customers allows ABB to always fulfill the most recent developments on
the market. ABB has a long tradition and experience in producing numerical control and
protection for substations. The modular hardware and software design allows an extremely
flexible installation. Simplicity of adaptation to the size of the primary system and the desired
protection schemes are achieved through the combination of the software library and hardware
modules. Economic applications can thus be achieved in the full range of applications for which it
is intended.

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5.1.5 Cable Systems
ABB manufactures XLPE (solid dielectric) cables for high voltage applications up to 500 kV.
However, the strength of ABB with regard to cables is the ability to provide a complete cable
system. A cable system includes manufacture of cables, terminations and splices, laying of cables,
installation of accessories, supervision and commissioning. A cable project from ABB can also
include site surveys, duct bank design, cable pulling, and all civil work.
Solid dielectric cables are a highly reliable means of underground transmission. Monitoring can be
provided with the use of an external or integrated optical fiber. In addition, XLPE technology offers
a major benefit in terms of reduced environmental impact when compared to oil filled alternatives.

In 1984, ABB was the first company to deliver and successfully commission XLPE cable for 245 kV
underground transmission to the utility serving the city of Stockholm. ABB also delivered the first
400 kV XLPE cable system in 1998 to the utility serving the city of Berlin.

In addition, ABB has a wealth of experience with submarine transmission cable projects. This
includes some of the longest HVDC submarine cables in the world. ABB has provided turnkey
submarine AC and DC cable systems in Asia, Australia, Europe, the United States and Caribbean.

Figure 9: Installation 400 kV XLPE Cable Figure 10: Submarine cable laying

6 Project Management
ABB provides Project Management expertise to meet the needs of your project so that it is
completed on time, on budget and within the determine requirement for quality and performance.

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We will coordinate and manage the whole project, based on your detailed specification, or working
with you to develop functional requirements that maximize value. We adhere to the policy of Project
Management being the key integrator that brings all the components of the project together.

The ABB Project Managers have been trained in accordance with Project Management Institute
(PMI) standards and apply this international methodology, integrated with vast experience into all
the practical aspects that bring success towards the project. The key ABB Project Managers are
Project Management Professionals (PMP) certified and will lead a team of trained professionals
including the site execution team and engineering team. He will be the single point of contact for
our customer in all project-related matters. The Project Engineer is responsible for all in-house
engineering and subcontracted engineering work, coordinating deliverables with the overall project
schedule. Depending on the contract scope the project manager will appoint a site manager
responsible for all site activities including day-to-day contact with customer, coordinating and
supervising subcontractors, job-site safety and quality control. One key responsibility of the Project
Manager is working with the customer to establish approvals on potential subcontractors and
identify that all key requirements of the project are met.

ABB can coordinate all aspects of the project including:

Engineering
Risk Management
Supply management
Manufacturing of ABB and non-ABB equipment
Time schedules and milestones
Logistics
Coordinating and supervising commissioning activities, including outage schedules.
Project Communications

6.1 Scheduling
ABB utilizes the latest technology in software for Schedule Development and uses the Critical Path
Method (CPM) to plan and schedule all activities. ABB also uses many other reporting tools such
as Gantt Charts, Milestone Charts, S-Curve and Earned Value Analysis to control and monitor the
schedule, track the works and monitor all aspects of the project including costs and schedule
performance indices. ABB will incorporate each sub-contractor’s schedule into the master schedule
and track the project on one schedule. Schedule change control or re-scheduling shall be

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 accomplished via critical path methodology, adjusting non-critical work to achieve overall success
with the target for no milestone slippage.

7 Design Services
The ABB team has extensive experience in designing and building substations, utilizing an array of
modern tools and techniques. We are prepared to tailor designs to meet client requirements, while
offering proven standards as appropriate.

The final engineering product consists of detailed engineering drawings for construction. Material
lists including detailed information and performance specifications for purchase of apparatus,
structures and all other components of the equipment will be included.

As part of a project ABB is prepared to perform relay coordination studies, insulation coordination
studies, structural analysis, lightning shielding, grounding, and electromagnetic field (EMF) studies
and consulting.

As far as work performed by subcontractors is concerned, ABB will approve and issue all
submittals to the client through our Project Manager. This will ensure a coordinated submittal of
drawings and documents and provide client with the convenience of a single point of contact. ABB
will work closely with customer and any subcontractor to assure the success of the overall project.

8 Construction Management and Maintenance

Besides the design and manufacturing of electrical equipment, ABB has extensive experience in all
aspects regarding material logistics, installation services and commissioning of the delivered
equipment.
Logistics, including shipment, tracking and on time deliveries will be managed by ABB’s project
manager office team in co-ordination with the substation overall time schedule. Special works, such
as supervising of component site assembly will be performed by factory-trained equipment experts.
In addition ABB can maintain your substation equipment, over its entire life-cycle in order to
increase the availability of your substation.

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9 Summary
Summarizing the above, ABB is your professional and reliable partner for turnkey substations
starting from the planning process over designing, manufacturing, transportation, installation and
commissioning as well as during operation of your substation.

Our mission is to develop, market and supply economically attractive, environmentally sound and
high quality products and systems, applications and services for new and existing substations. Our
vision is to be the natural choice for all kind of substation applications.

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