ABB has been in the energy business for 120 years. Using energy more efficiently will not only contribute the lion's share of emissions reductions needed, it is arguably the most sustainable and cheapest way to reduce emissions and address global energy security. Energy- efficient systems can pay for themselves in energy saving, sometimes within months, and further reduce operation and maintenance costs in the long term. Plug in to this issue to understand how we help customers squeeze the most value from each unit of energy they use.
1. 3 | 12
contact
The customer magazine
of ABB in India,
Middle East & Africa
Energy efficiency – doing more
with less
Why energy efficiency? 06
Using energy more efficiently is critical to business and national competitiveness
ABB solves 100-year-old electrical engineering puzzle 16
New technology to enable future DC grid
2. 06 Why energy efficiency?
Using energy more efficiently is critical to
business and national competitiveness
10 Keeping India on the go
State-of-the-art power electronics technologies
transform one of the longest rail networks in
the world
contact 3|12 Dear friends, voltage DC transmission and flexible AC
India is growing and so are our energy transmission are some examples.
needs. Unfortunately, the gap between
the electrical energy we produce and Our high-efficiency motors, drives, control
our requirements has been steadily systems, energy management systems,
increasing, affecting growth and the lighting solutions, turbochargers and
stability of our power network. Our charging solutions all make energy
attempt to add more generation capacity go further in industry, residential and
is at a cost to the environment. And, commercial buildings and transportation.
reducing demand at the cost of growth
is not a real option. Here we feature glimpses of some
solutions we provide as well as global
Energy efficiency has the promise of successes through innovations and
reducing the gap in the most economical expertise that ABB has pioneered in the
Bazmi Husain and environmentally friendly manner in field of energy efficiency.
Country Manager and the near term. In the longer term, efficient
Managing Director use of energy will allow our economic Welcome to the world of energy efficiency
ABB Limited, India growth to be sustainable. – the alternative fuel!
ABB has invested in technologies to Best regards,
improve the efficiency of electricity
generation, transmission and distribution,
to make more energy available at the
point of use. Our optimization solutions, Bazmi Husain
network management solutions, high
Contact 3| 1 2 • Customer news magazine from ABB • copyright 2012 • web: www.abb.com • email: contactmagazine@in.abb.com • Publisher: ABB Group
• Layout: Shilahar Associates, Bangalore, India
2 contact 3 | 12
3. Contents
19
Another European port
goes green
Shore-to-ship solution
for Ystad port in
Sweden
16 ABB solves 100-year-old electrical engineering puzzle
New technology to enable future DC grid
News For a better world
04 Expanding the Saudi power grid 18 Chevrolet Volt battery reuse
Center for learning, Faridabad Electric vehicle batteries to power homes for
05 Boiler fingerprinting for captive power plant the first time in the world
India service tie-up with SAIL
Product news
Energy efficiency 20 Just launched
11 Taking the motor world by storm What’s in the basket of new product offerings?
ABB’s synchronous reluctance motor and
drive voted Europe’s automation product of
the year
In focus
12 University lighting solution wins 22 Innovative marine propulsion
international award Breaking the ice
Energy-efficient lighting and heat protection for
an eight-square-kilometer campus
13 Cutting the cost of wastewater treatment
MV drives reduce energy consumption by
more than 1 million kilowatt-hours a year
14 Towards a sustainable cement industry
Significant order to enhance energy efficiency
for Holcim in India
15 Energy efficiency tops ACC priorities
Interview with K N Rao, Director, Energy and
Environment, ACC Limited
contact 3 | 12 3
4. News
Expanding the Saudi
power grid
Orders, worth around $170 million, were faithful every year. The substation deploys urban areas. Saudi Arabia has among the
booked to execute substation projects for our compact and robust gas-insulated highest residential electricity consumption
the Saudi Electricity Company (SEC), the switchgear (GIS) technology, and will be in the world. The country is executing
country’s national power transmission and accommodated in a multi-storied building. an ambitious Ninth Development Plan
distribution operator. Its considerably smaller footprint is ideally (2010-2014) aimed at raising its installed
The design, supply, installation and suited to tight spaces. power generation capacity by more than
commissioning of a substation will help International Monetary Fund (IMF) 20 gigawatts (GW) to reach around 72
meet the increased demand for electricity estimates population increase from 28 GW by 2014.
in and around the central pilgrimage area million to approximately 37 million by For more information: www.abb.com/substations
of Makkah, which hosts millions of the 2020, with nearly 85 percent living in
Center for learning, Faridabad
On the 18 th anniversary of Low Voltage
Products (LP) operations in India, a
training and demo center, the first of its
kind in Northern India, was inaugurated.
It will display the full range of products
from LP and Discrete Automation and
Motion (DM) divisions and be open to and
benefit both customers, as well as internal
sales engineers. The training center can
accommodate classroom training for 12
participants at a time. It features a live
Robot Demo facility and KNX training for
system integrators kicked off in November
2012. The new center will ideally be used in
different ways to showcase latest offerings training to engineers, authorized service For more information: www.abb.com/lowvoltage
to prospective customers and to offer dealers, customers and end users. www.abb.com/robotics
4 contact 3 | 12
5. News
In brief Boiler fingerprinting for
Making a mark captive power plant
The Golden Peacock Global
Sustainability Award 2012 was
presented to ABB in India on 11
October 2012 at Nursery Pavilion
Hall of Lord’s Ground, Marylebone
Cricket Club (MCC) in London.
In Nashik, the vacuum interrupter
(VI) team won the 13th Annual Rising fuel costs and tightening emission and dynamic performance analysis was
Greentech Environment Excellence norms are forcing captive and utility power carried out. Both, control loop designs
Award 2012 in the Silver category plants to be more energy-efficient and and tuning were investigated and the
for outstanding contributions to reliable. Recently, we were invited by a reasons for under-performance of some
energy conservation. captive power plant customer to conduct an of the key control loops were identified.
energy audit of an under-performing boiler All the key findings were presented, along
and recommend the means to improve with recommendations for improving the
Riding the metro performance in terms of efficiency and performance of the boiler, and are to be
reduced fuel bills. This included the issue implemented shortly. The typical investment
of steam balance mismatch between steam towards implementing the solution is in the
generation and steam utilization. range of 60-70 lakhs INR, while typical
The ABB team visited the plant, benefits range from 30-70 lakhs INR per
interacted with plant management, annum.
engineers and operators to understand For more information: www.abb.com/
the key concerns. Based on the plant energyefficiency
data collected, a detailed, steady state
On his visit to India, our Group
CEO, Joe Hogan caught a ride in
the pride of Bangalore, the newly India service tie-up with SAIL
started metro service from MG
Road to Byapanahalli. Earlier this SAIL, one of India’s largest steel
year, the Bangalore Metro project manufacturers, operates 10 steel plants,
team from ABB received an award five of which are Integrated Steel Producers.
from BMRCL for successfully It is currently in the process of modernizing
completing one million safe and expanding its plants, extensively
man-hours. adopting state-of-the-art technologies,
and requiring re-deployment of a large
part of its workforce.
Investing in India Over a period of two years, we will train
about 4,000 employees across the various critical applications.
To help customers access plants of SAIL. The training will be conducted mostly at
technology at more competitive This will facilitate SAIL in developing SAIL plants, as well as ABB locations, and
prices, ABB is investing in local and enhancing technical competency, to will cover a wide portfolio. For improved
production of gas-insulated (GIS) adapt and maximize returns on deployed training effectiveness, the modules are
and hybrid switchgear (PASS), and technologies. ABB has a huge installed developed to include theoretical and hands-
distribution transformers in Gujarat. base of products, systems and solutions on exercises using specially designed
The facility will be operational in across all SAIL plants, measuring, training kits/simulators.
2013. controlling and optimizing many process- For more information: www.abb.com/service
contact 3 | 12 5
6. Energy efficiency
Why energy
efficiency?
Using energy more efficiently is critical to
business and national competitiveness.
It’s also the fastest, most effective way to
protect our environment by breaking the
link between economic development and
climate change.
W
e have been in the energy Nine percent of all the electricity
business for over 120 years generated worldwide is lost in transmission
and ABB technologies are and distribution. Flexible AC transmission
used along the entire energy systems (FACTS) enable more power to
value chain, from the extraction of resources travel over existing networks, which is
and their transformation into electricity, critical in dense urban areas.
liquefied natural gas or refined petroleum And, ABB high voltage direct current
products, to their efficient end use in (HVDC) electrical transmission and Mechanical hoist drum at Totten mine, Sudbury,
industry, transportation and buildings. high-efficiency power and distribution Ontario, Canada – equipped with energy-
efficient drives from ABB
transformers reduce power losses over
Utilities great distances. This can help integrate
Power generation is by far the largest renewable energy from remote locations
energy consuming industry. The efficiency into the grid, or to bring reliable electricity
varies widely with the fuel and technology to remote mines or offshore platforms.
used: in traditional coal-fired plants, only
about 35 percent of fuel consumed is Industry
converted into electricity. Just six process industries account
In addition to high conversion losses, for two-thirds of the global final energy
power plants consume on average, 5 consumption: iron and steel, oil and gas,
percent of the electricity they generate. chemical and petrochemicals, non-metallic
Using sophisticated control systems and minerals, pulp and paper, and non-ferrous
energy-efficient equipment can reduce metals. Despite significant improvements
energy consumption by 10 to 30 percent. through energy efficiency, there is still room
We also address thermal energy for ways, which complement rather than
efficiency of boilers – by automating their change production processes in energy-
future efficiency, one chemical plant was intensive industries.
able to realize $300,000 in energy savings We help customers improve efficiency
across four boilers, as well as improved in two ways:
performance, from a $75,000 investment. 1) Through leading technologies: In
6 contact 3 | 12
7. Energy efficiency
Improving energy efficiency has the we have learned that energy savings of 5
to 35 percent can often be created.
clearest impact on saving money,
improving business results, and Transportation
delivering more services for consumers. Innovations for shipping
Around 90 percent of world trade is
The UN global initiative on Sustainable carried by some 70,000 vessels that make
Energy for All up the international shipping industry. Fuel
accounts for 30-40 percent of the cost of
running a cruise ship and between 50-60
2011, the global installed base of ABB percent for most merchant vessels. ABB’s
variable speed drives saved some 310 Azipod®, the world’s first rotating propulsion
million megawatt-hours of electricity, the device, fitted to the outside of a ship’s hull,
equivalent of the annual power consumption is now installed on half of all cruise liners
of 75 million EU households. built over the past two decades, reducing
2) Through our experts, who help energy consumption of open-water vessels
customers understand where and how they by 5 to 15 percent.
use energy, and then identify and implement ABB’s experts have worked on some
opportunities for improvement. Over ten 3,000 marine automation and control
years of experience in many industries, systems around the world, which are
contact 3 | 12 7
8. Energy efficiency
operated by Deutsche Bahn, Germany’s
national rail operator, cutting energy by at
least 12 percent. This is the first project
worldwide involving the exchange of high-
speed train converters while leaving all
other components of the traction chain
and all interfaces unchanged.
Buildings
By 2050 there will be 4.5 billion people
in cities around the world, creating an
urgent need for infrastructure. Old buildings
offer room for improvement, while modern
buildings house energy-intensive data
centers and sophisticated air conditioning
systems.
ABB’s intelligent building control system,
based on the KNX global open standard, is
increasing efficiency in thousands of new
and existing buildings in more than 60
countries, enabling customers to reduce
energy consumption by about 50 percent,
with a payback period of between one
and five years. Three ABB i-bus® KNX-
equipped buildings in Singapore, including
the region headquarters of Xilinx, Applied
Dual hoist ship-to-shore cranes – Busan, South Materials Inc, and the Singapore National
Korea Library, have won prestigious BCA Green
supported and maintained by experts at Mark Platinum awards from the Building
22 marine service centers. and Construction Authority for their energy
We are also developing a complete suite efficiency.
of software products, known as Smart Annual consumption for heating and
Marine Integration (SMI), to monitor, control ventilation can be cut by as much as 45
and optimize every energy consumption percent using very simple methods, such
process during vessel operation. Some as individual room temperature control,
components of it are already available and combined with moderately reducing the
Finland-based Viking Line, has selected room temperature, or heating control based
ABB’s energy management system for a on the outdoor temperature.
new ultra-energy-efficient passenger vessel High-efficiency motors and the
that will have almost zero GHG emissions. alternating current (AC) drives used to
control them offer further efficiencies as
Keeping rail energy usage on track motors consume about 40 percent of a
Rail is seeing renewed interest as a building’s electricity, and AC drives can
sustainable and energy-efficient form of reduce energy consumption in these
transport, capable of reducing congestion, applications by as much as 80 percent.
emissions and noise.
We supply components for both rail Putting it all together
infrastructure and rolling stock, and are Many technologies that improve
one of very few independent suppliers to energy efficiency are readily available.
offer a complete traction package to rolling However, often, the greatest potential for
stock manufacturers. We have solutions savings often lies in the gaps between
to transfer power efficiently from grids production processes and functional silos
to railways. Our regenerative braking – manufacturing, facilities management,
systems capture and store energy that maintenance and support processes such
would otherwise be lost, and high-efficiency as electrification, compressed air, steam
turbochargers boost the performance of and water.
diesel engines. For this reason, ABB advocates
In just 13 months we developed a new a holistic approach – understanding
traction converter to refurbish the first where and how energy is used so you
fleet of high-speed InterCityExpress trains can prioritize projects which will bring
8 contact 3 | 12
9. Energy efficiency
Interview
Energy efficiency as a
sustainable, competitive
advantage
Why is energy efficiency such a hot operational benefits. For example, Jim Kelly, head of ABB's global
topic today? improperly tuned boilers not only waste energy efficiency initiative, discusses the
potential and the challenges of energy
It’s high on the radar of countries energy, but they are often unable to
efficiency.
and industries alike because energy respond quickly to changes in steam
is increasingly one of our greatest demand – this can hurt product quality
challenges. Security of energy supply and reduce plant throughput. investment, and for management to
is a very real problem, from generation have confidence that they will reap the
shortfalls to unreliable power So are a lot of companies intended savings.
quality. Businesses in locations with embracing these technologies?
comparatively high energy prices are We see a big disconnect between How can companies overcome
finding it more and more difficult to recognition and action. In an ABB- these obstacles?
compete in a global marketplace. commissioned global survey of top More and more we see operating
At the same time, the world has industrial executives, while about 90 companies turning to partners
become intensely aware that we percent acknowledged that energy like ABB who are equally fluent in
can’t continue meeting the challenge efficiency will be a critical success technology on the plant floor and cash
of secure, affordable energy only by factor for their business in the flows in the board room. For example,
adding new carbon-based thermal coming decades, only 40 percent financing is often a critical hurdle and
generation capacity. Industrial energy had invested in energy efficiency in requires new approaches such as
efficiency doesn’t command the the past three years and only a performance-based contracts that will
media attention of solar power or third had undertaken a plant-wide pay for improvements out of operating
electric cars, but it is a workhorse for energy audit. expenses instead of CAPEX.
tackling climate change. These contracts can include
How do you account for this gap? guaranteed savings metrics to
Are the technologies to create this It really comes down to a lack reduce performance risk. In today’s
savings already available? of facts and resources. Many lean operating environment, many
Yes. There are a slew of manufacturers simply don’t have manufacturers of course know their
automation and power solutions transparency as to where and how processes well, but in many cases
that are well proven. It’s not just the their energy is used, preventing don't have the experts to identify
technical features – there is ample optimization. In addition, other and implement energy efficiency
evidence of the business benefits. priorities such as quality, productivity improvements themselves. Therefore,
Naturally there are cost savings, but and safety improvements also place to have a partner who can take you
in addition, companies who learn to demands on both human and capital through the full cycle of identification,
do more while using less energy are resources resulting in energy efficiency evaluation and implementation can
more competitive overall and enjoy improvements being relegated down often be the difference between a
enhanced reputation. the priority list. worthy project sitting dusty on a shelf,
We’ve also found that, improving This lack of information makes it or realizing meaningful, sustainable
energy efficiency often provides difficult to build the business case for savings.
the greatest business benefits, and then For more information:
ensuring their successful implementation. www.abb.com/energyefficiency
This improved ‘energy transparency’ also
helps build the business case for future
efficiency investments, creating a process
for continuous improvement much like
those for quality and operational excellence.
contact 3 | 12 9
10. Energy efficiency
Auxiliary converters and battery chargers for WAG 9 locomotives
Keeping India on the go
Power electronics transform heavy-haul freight locomotives of the Indian Railways,
one of the top five, longest rail networks in the world.
M
ain-line locomotives are the The WAG 9 weighs in at 135 tons is its per-axle isolation. Earlier, the GTO
workhorses of the railways, compared to the 127 tons of conventional converter per bogie forced three axles out
hauling thousands of tons of engines, giving it better traction on steep of service in case of traction motor failure,
freight across long distances. inclines and increasing haulage capacity now if one wheel develops a problem; the
More than 60 percent of freight haulage from 5050 metric tons to 5500 metric tons. engine continues to run on five wheels.
takes place on the electrified section of the The IGBT technology has been successfully The ultra-modern technology brings ease
golden quadrilateral (rail tracks connecting used in high-speed trains in Europe and of use, especially as the microprocessor-
Delhi, Mumbai, Chennai and Kolkata) that Japan. based step-less control incorporates an
covers the busiest routes. Ajni Loco Shed in Central Railway’s effective slip/slide control system – for
Recently, Central Railways received six Nagpur Division will receive 15 engines the first time allowing the loco operator to
of the WAG 9 series of locomotives from in all, through the year. Explaining the maintain speed in bad terrain or weather.
Chittaranjan Locomotive Works, equipped significance of adding the new WAG 9 Technological R&D in this field continues
with the very latest insulated gate bipolar to its stable, Divisional Railway Manager, to raise blocking voltages, increase
transistor (IGBT) converters supplied by Brijesh Dikshit said, “Sandwiched as it switching frequency and reduce losses,
ABB. The youngest member of the high is between the Deccan Plateau and the and holds out even more potential for
voltage switch family, IGBT controls the Sahyadri Range, the Nagpur Division optimization in the future.
flow of high currents through a 15 volt has some of the most treacherous track For more information: www.abb.com/railway
high-impedance voltage source, using within the subcontinent. Hauling 5000-
very low control power to do so. Simply plus tons up steep gradients and through
put, IGBTs are used for the delivery and torrential monsoons has been a tremendous
control of power to the motor in the traction challenge. The fast switching that the IGBT
system of electric engines. power device allows, requires a smaller
It replaces the previous inverter braking distance and allows quick brake
generation represented by gate turn-off release when needed.”
(GTO) thyristors, offering as much as about The introduction of the IGBT-based
four times higher switching frequency. converter has improved the input power
This reduces the current requirement factor so the loco can build up power in a
and consequently the heat generated, it shorter time and maintain it for a longer time
also provides smoother acceleration and than its predecessor. However, the three-
reduces traction noise. phase WAG 9’s single, greatest advantage
10 contact 3 | 12
11. Energy efficiency
Taking the motor world
by storm
ABB’s synchronous reluctance motor and drive packages continue to raise interest
eleven months after being voted Europe’s automation product of the year.
H
igh output SynRM motors (the
motor on the right in the image Temperature scans from a thermal imaging camera
above) provide the same output
as traditional induction motors
(the motor on the left in the image above)
that are up to two frame sizes larger –
thus, enabling smaller, lighter and more
cost-efficient pump and fan installations.
And, as they provide double the power
of an induction motor of the same size,
this enables increased flow without the
need to mechanically modify the system Induction rotor Synchronous reluctance rotor
to accept a larger motor.
High output SynRM motors are also more
energy-efficient, with 10-20 percent lower an innovative rotor design that has neither “The first SynRM high output motor
energy losses than those of IE2 induction magnets nor cage, thus virtually eliminating and drive packages are now available for
motors, thus, providing a commercially rotor losses and giving the motor a uniquely pump and fan applications,” says Linda
competitive alternative to traditional and cool operating temperature. Stenman, ABB product manager for drives.
other new motor technologies. This in turn reduces the temperature Later we will see the launch of SynRM
of the bearings and extends their service packages designed for IE4 super-premium
How is all this possible? life and maintenance intervals. As about efficiency levels that offer even more choice
“The SynRM integrates the best of two 70 percent of motor failures are related to to variable speed motor users.”
worlds,” says Ari Tammi, ABB product bearings, the lower bearing temperature For more information: www.abb.com/motors
manager for motors. “It combines the can prevent unplanned motor stoppages,
performance and efficiency of permanent thereby increasing motor availability and
magnet technology with the simplicity, reliability.
cost-efficiency and service-friendliness of Not surprisingly, the new SynRM has
induction motors.” generated major market interest, winning
From the outside, the SynRM looks like Europe’s foremost automation award at
a conventional induction motor. But on the the SPS IPC Drives Fair in Germany in
inside, it is nothing like it, instead it uses November 2011.
contact 3 | 12 11
12. Energy efficiency
Lighting the largest women’s university in the world
University lighting solution
wins international award
A winning ABB solution for the new Princess Nora Bint Abdul Rahman University in
Riyadh, Saudi Arabia, provides energy-efficient lighting and heat protection across
an eight-square-kilo meter campus.
T
he solution was named winner With strong sunlight and temperatures helping to make Princess Nora University
of the KNX Award 2012 in the of up to 50 degrees Celsius to contend a landmark in energy-efficient building
international category for Asia with, sun and heat protection are key control.
earlier this year. It is thought to features of our solution. Thousands of Not only does the i-bus reduce building
be the largest solution ever to use devices blinds provide protection from the sun’s energy consumption by around 40 percent
that comply with the global KNX standard glare and prevent high levels of solar heat compared to technologies that do not use
for energy-efficient home and building from entering the buildings. The blinds shift the KNX open standard, it has opened
automation control. automatically according to the position and the possibility for many of the university
Princess Nora University is the largest strength of the sun, or can be adjusted buildings to apply for green or gold ratings
women’s university in the world. The new manually, resuming their automatic settings within the LEED standards (Leadership in
purpose-built campus opened in January via presence detectors when people leave Energy and Environmental Design) of the
2011 and accommodates 40,000 students the room. US Green Building Council.
and 12,000 staff. It covers an area of 8 Each building is divided into zones with ABB was selected for the project by the
square kilometers and comprises 800 presence- and daylight-dependent lighting two main construction companies that built
buildings; including classrooms, halls of control. Classrooms and lecture halls are the university, Saudi Oger and SBG, and
residence, research centers, recreational equipped with dimming and darkness the two system integrators subcontracted
and sports facilities, a library, a 700-bed control to facilitate presentations, and large to install the solution on the construction
hospital, as well as kindergartens, schools, rooms and halls are divided into smaller companies’ behalf: MTTS and Honeywell
mosques and its own 10-station, driverless, lighting areas to create ambience and save HBS respectively. The KNX award was
overhead metro system. energy. When no one is present in a room, made to MTTS.
The ABB i-bus ® KNX solution enables the climate control system automatically Our i-bus KNX solution for the new
the university to automatically and remotely adjusts to eliminate waste of energy, by Terminal 3 building at Delhi Airport was
control lighting and sun protection systems shutting down air conditioning. the previous winner of the biennial KNX
in each of the 800 buildings using one By using lighting control efficiently and Award for ‘International Category – Asia’
single interface. A similar i-bus KNX solution by reducing the need for air conditioning in 2010.
controls the lighting in each of the 10 with presence detection and effective For more information: www.abb.com/knx
campus metro stations. sun and heat protection, our solution is
12 contact 3 | 12
13. Energy efficiency
Cutting the cost of
wastewater treatment
An award-winning ABB MV drive has reduced energy consumption at a
US wastewater treatment plant by more than 1 million kilowatt-hours a year.
T
he ACS 2000 medium voltage time monitoring and diagnostics of the
variable speed drive was drive via a wall-mounted PC connected
installed in July 2011 and has to the telephone line.
achieved some remarkable Once the ACS 2000 was installed,
results within its first year of operation at the power consumption of the aeration
the City of Beloit Water Pollution Control blower system dropped by more than
Facility (WPCF) in Wisconsin, United 30 percent and total plant energy
States. consumption by 15 percent, which is
The facility treats an average of 5.5
million gallons (20.8 million liters) of
wastewater a day from the city’s 37,000
inhabitants, as well as industrial waste
from local businesses and biological
waste from food processing plants.
Like many wastewater treatment
plants, Beloit uses a conventional
activated sludge process for treating
the wastewater. At the heart of this
process are the aeration basins in which
microorganisms break down the organic
matter in the wastewater. These bacteria
require oxygen to survive, which is
provided by huge aeration blowers that
blow air through diffusers at the bottom
of the basin.
Aeration blowers typically account
for 50 percent or more of the electricity
consumed by a wastewater treatment
plant, and Beloit is no exception. Prior
to the installation of the ACS 2000, the
aeration blower system at Beloit WPCF
was controlled by an inlet throttling valve
– a common solution for blower control,
that operates at fixed speed and does Sewage water purification tank – Beloit, Wisconsin, USA
not offer the same operating and cost
benefits as variable speed drives. more than 1 million kilowatt-hours (kWh)
For Beloit WPCF these benefits a year. At an average composite rate of
are wide-ranging and include soft start $0.62/kWh, the annual savings for the
capability, ease of installation, direct-to- city of Beloit amount to $75,000.
line (transformer-less) connection to the For more information: www.abb.com/water
power supply network, minimal harmonic
distortion, non-requirement of medium How does ACS 2000 help save more?
voltage power factor correction, compact Scan to watch the video
and lightweight footprint, short payback
time and low total cost of ownership.
These benefits are enhanced by an
ABB DriveMonitor™ intelligent diagnostic
system that performs remote and real-
contact 3 | 12 13
14. Energy efficiency
Towards a sustainable
cement industry
Major players are prioritizing energy-efficient ways of improving specific
energy consumption. ABB is the leading supplier of medium voltage drives for
cement plants in India, which help users to enhance plant efficiency and overall
productivity.
ACC cement plant - Thondebhavi, Karnataka
T
he cement industry is among fans in cement production area and also cement and captive power generation
the biggest consumers of extend it to captive power plants to cover processes for assessing the current level
electrical energy. A vast amount boiler feed pump (BFP), primary air and of performance and identifying bottlenecks.
of energy is used at every stage secondary air (PA/SA) fans and induced Preventive maintenance solutions also have
of the process, accounting for more draft (ID) fans. a greater role, as does the implementation of
than 50 percent of total production Fans in the cement industry are solutions based on high-efficiency motors,
costs. India ranks as the second largest usually large and consume a major part drives, process analyzers, process control
cement producing country in the world. of electrical energy. Traditionally, Indian systems, optimization solutions, energy
This means that efficient processes cement producers use cascade converters management solutions and production
and technologies will not just lower – also called Slip Power Recovery Systems scheduling.
the nation’s consumption of a critical (SPRS) – to control the speed of process For more information: www.abb.com/cement
resource – they will effectively reduce the fans. However, due to inherent limitations www.abb.com/drives
carbon footprint of the industry. of SPRS, such as operation in weak
networks and higher harmonics, they are
Holcim now considering the variable speed drive
We received the first major order in (VSD) solution. With the use of VSDs, the Winner of the National
the energy efficiency domain from Holcim energy consumption can be reduced from
in India, to improve specific power 90 kWHs/ton to about 70 kWHs/ton of Energy Conservation
consumption of their cement plants. The cement produced. Award, 2012
ACS 5000 and ACS 2000 range of 6.6
kilovolt (kV) medium voltage (MV) drives will In the future The Grinding Unit of the
enhance energy efficiency at three plants, With the demand for cement increasing Thondebhavi ACC cement plant in
replacing existing damper controls. There by eight percent annually, Holcim has long Karnataka secured second place
is a huge potential to further enhance the term plans to increase capacity as well as for outstanding energy-efficient
efficiency by providing the MV drives for improve efficiency. What we can offer is practices in the cement industry.
other process critical applications like pre- an overall efficiency improvement through
heater fans, mill separator fans, cooler assessment services, fingerprinting of
14 contact 3 | 12
15. Energy efficiency
Energy efficiency tops
ACC priorities
“Not everyone knows that the Indian cement industry is second only to Japan in
global energy efficiency comparison."
What are the opportunities and and captive power generation. Research
challenges you see, especially on the
energy front?
and development in the area of blended
cement and other sustainable products is
Profile
Many challenges lie ahead of us, important to our future. We are also looking
especially when it comes to energy. at waste recovery power generation and
Energy costs (coal, coke and electricity) the generation of renewable energy.
are spiraling along with the currency
depreciation. Quality of coal and limestone What are your expectations from ABB
is an issue and availability of coal is a cause as a partner in your energy efficiency
of concern. Power shortages have been journey?
driving us to set up captive power plants As a premier electrical product supplier,
(CPPs) to fulfill our energy needs. we expect ABB to come out with innovative
Then there is the increased pressure solutions to improve the energy efficiency
of complying with mandatory energy of older plants, which will allow the industry, K N Rao
regulations such as Perform, Achieve, including ACC, to implement energy Director, Energy and Environment,
Trade (PAT), where we must meet energy efficiency across all plants. In many large ACC Limited
reduction targets and Renewable Power energy efficiency improvement projects
Obligations (RPO) where we have to either like waste heat recovery systems, high K N Rao is a post-graduate che-
buy Renewable Energy Certificates (RECs) efficiency motors and medium voltage mical engineer from IIT Madras
or generate renewable energy. In some drives have long payback periods. with more than 30 years of rich
regions, lower capacity utilization as a We have been working with ABB experience in the fields of energy
result of inadequate demand is pushing up for many years and our relationship is and environment. His current
specific energy consumption. And finally, measured in decades. We use ABB assignment includes energy con-
we must factor in the high cost of financing. products and systems in almost all our servation and associated projects
But where there are challenges, there plants with confidence as they consistently implementation; environment com-
are opportunities for long term capacity offer the desired performance. pliance and environment projects
growth. To make the most of these, our implementation, sustainable devel-
focus is on improving efficiencies across opment, CDM projects and renew-
the cement plants, captive power plants able energy projects. Prior to this
and power generation from renewable assignment, he headed the pollu-
power sources. Other opportunities include tion control systems business of
upgrading old plants, co-processing of ACC. Currently, he is working on
industrial and municipal wastes in cement behalf of ACC as co-chair for the
kilns, generating power from waste heat WBCSD – CSI India for the low
in kilns, increased usage of waste from carbon technology roadmap 2050
other industries like fly ash and slag to for the Indian cement industry, sec-
make blended cements. All these initiatives toral expert for BEE for the cement
also help in minimizing the CO 2 emissions sector for PAT methodology
in the cement manufacturing process. development and implementation,
co-chair for CII Green Cement-
How is ACC geared to address these; ech, member of CII Green Council,
what are the energy efficiency initiatives member of Sustainability Com-
being rolled out? mittee of FICCI, IMC and Bombay
ACC is taking a holistic approach Chamber of Commerce.
towards challenges and opportunities.
The focus remains on key areas for
sustainable growth: energy performance
improvement in the manufacturing process
contact 3 | 12 15
16. For a better world
ABB solves 100
year old electrical
engineering puzzle
Development of a DC breaker for high voltage transmission will
help shape the grid of the future.
16 contact 3 | 12
17. For a better world
R
ecently, ABB announced a The logical next step is to connect the
breakthrough in the ability to lines and optimize the network. We are
interrupt direct current, solving already working on the construction of
a 1 0 0 - y e a r- o l d e l e c t r i c a l multi-terminal systems and the latest DC
engineering puzzle and paving the way breaker innovation is a major step in the
for a more efficient and reliable electricity evolution of HVDC grids. In parallel to the
supply system. new hybrid breaker development, we have
After years of research, we have an established HVDC grid simulation center
developed the world’s first circuit breaker developing solutions for future DC overlay
for high voltage direct current (HVDC). grid operations.
It combines very fast mechanics with Fast, reliable and nearly zero-loss HVDC
power electronics, and will be capable of breakers and current limiters based on the
‘interrupting’ power flows equivalent to hybrid HVDC breaker concept have been
the output of a large power station within verified at component and system levels at
5 milliseconds – that is thirty times faster ABB’s high-power laboratories in Sweden
than the blink of a human eye. and Switzerland, for HVDC voltages up to
The breakthrough removes a 100-year- 320 kilovolt (kV) and rated currents of 2.6
old barrier to the development of DC kiloampere (kA). Thus, HVDC grids can now
transmission grids, which will enable be planned. The next step is to deploy the
the efficient integration and exchange breaker in a real HVDC transmission line to
of renewable energy. DC grids will also test under continuous full load conditions.
improve grid reliability and enhance the
capability of existing alternating current How does hybrid HVDC breaker work?
(AC) networks. We are in discussions with Scan here
power utilities to identify pilot projects for
the new development.
“ABB has written a new chapter in
the history of electrical engineering,” said
Joe Hogan, CEO of ABB. “This historical
breakthrough will make it possible to build DC Breaker – why we need it
the grid of the future. Overlay DC grids
will be able to interconnect countries and – Fast and reliable
continents, balance loads and reinforce – Isolates faults
the existing AC transmission networks.” – Clears faults in milliseconds
The Hybrid HVDC breaker development – Prevents collapse of common HVDC grid voltage
has been a flagship research project for – Minimizes disturbances in converter operation
our company, which invests over $1 billion
annually in R&D activities. The breadth AC grids vs DC grids
of our portfolio and unique combination
of in-house manufacturing capability for – High active power conduction – Relatively low active power
power semiconductors, converters and losses conduction losses
high voltage cables (key components of – Reactive power conduction – Zero reactive power
HVDC systems) were distinct advantages losses conduction losses
in the new development.
HVDC technology is needed to facilitate
the long distance transfer of power from
hydropower plants, the integration of
offshore wind power, the development
of visionary solar projects, and the
interconnection of different power networks.
ABB pioneered HVDC nearly 60 years ago
and continues to be a technology driver
and market leader with many innovations
and developments. With over 70 HVDC
projects, our company accounts for around
half the global installed base, representing
an installed capacity of more than 60,000
megawatts (MW).
Deployment of HVDC has led to an
increasing number of point-to-point
connections in different parts of the world.
contact 3 | 12 17
18. For a better world
Electric vehicles - a source of clean,
off-road energy
Chevrolet Volt battery reuse
GM’s partnership with ABB results in a prototype back-up power storage unit that
uses electric vehicle batteries to power homes for the first time in the world. The
energy storage project is also being readied for testing on the power grid.
T
ogether, General Motors and ABB or small commercial buildings during a market research and product development.
demonstrated the next stage in power outage, allow for storage of power As the world’s largest EV fast-charging
battery reuse, the repackaging of during inexpensive periods for use during company and leader in smart grid and
five used Chevrolet Volt batteries expensive peak demand, or help make up energy storage, we work with other auto
into a modular unit capable of providing for gaps in solar, wind or other renewable companies, battery manufacturers and
two hours of electricity needed by three power generation. utilities to help make electric power and
to five average American homes. The These functions, along with frequency industrial operations more productive and
prototype unit provided 25 kilowatts (kW) regulation on electric distribution systems, efficient.
of power and 50 kilowatt-hours (kWh) of could someday be used by utilities to reduce GM is focused on ensuring that battery
energy to power all the support lighting cost to customers and improve the quality systems used in future Chevrolet, Buick,
and audiovisual equipment in an off-grid of power delivery. These applications are GMC and Cadillac vehicles provide
structure used for the event. referred to as community energy storage environmental and societal benefits beyond
"In many cases, when an EV battery has to distinguish them from substation-size their use in the vehicle.
reached the end of its life in an automotive energy storage projects. For more information:
application, only 30 percent or less of its “We showed today how fast this research www.abb.com/electricvehicles
life has been used,” said Pablo Valencia, concept is turning into reality,”said Allen
GM senior manager of battery life cycle Burchett, ABB’s senior vice president for How can ABB help to build an
management. Business Development in North America. e-mobility infrastructure? Scan here
Last year, GM and ABB demonstrated “We will be installing it on the grid soon
how a Chevrolet Volt battery pack could be to complete the technical evaluation,
used to collect energy and feed it back to and this will tell us all what smart grid
the grid and deliver supplemental power applications are possible, like back-up
to homes or businesses. power, reducing energy cost, strengthening
This time, the energy storage system utilities' distribution systems and storing
was run in a ‘remote power back-up’ surplus renewable energy.”
mode where 100 percent of the power Our research center in Raleigh, North
for the facility came from Volt batteries Carolina, conducted the research and
through ABB’s Energy Storage Inverter development, and the Medium Voltage
system. A similar application could one business unit in Lake Mary, Florida, is
day be used to power a group of homes managing the proof-of-concept testing,
18 contact 3 | 12
19. For a better world
Another European port
goes green
Ystad, one of Sweden’s fastest growing cargo and ferry terminals installs an ABB
shore-to-ship power connection that enables it to use shore-side electricity while
in port, thereby reducing noise pollution and cutting CO2 emissions by 98 percent.
shore-side power connection for the
Swedish port of Gothenburg in 2000.
Since then, we have provided ports
throughout Asia and Europe with shore-
to-ship solutions, the most recent of which
– prior to Ystad – was inaugurated in July
this year at the Hoek of Holland in the
Netherlands.
We also supply turnkey shipside
solutions for shore-side power connections,
and have provided solutions for all types
of vessels worldwide, including container
ships, bulk carriers, liquefied natural gas
(LNG) carriers, cruise liners and floating
storage and off-loading (FSO) vessels.
For more information: www.abb.com/marine
Ystad shore-to-ship
Eliminating CO2 emissions at the Port of Ystad installation wins
environmental award
L
ocated on the southern tip of designed ABB substation equipped with On September 27, the port of
Sweden on the Baltic coast, powerful frequency converters. Ystad was awarded Sweden’s
Ystad is Sweden’s fifth largest With a power rating of 6.25 megavolt foremost marine environmental
port, handling some 3,500 amperes (MVA), the frequency converters award by Maritime Forum, “for
sailings annually, including daily ferry are the most powerful in operation at any investing in a flexible shore-to-
services to Poland and Denmark, as well shore-to-ship installation in the world. ship solution for both 50 and 60
as cruise ships in the summer and cargo They convert the power from 50 Hz, the Hz. The solution minimizes the
vessels all year round. standard grid frequency in Europe, to the shipside investment requirements
Thanks to a strong and ambitious 60 Hz load frequency at which most vessels for shipping companies, while
investment program, the port has enjoyed operate. From the substation, the power is improving the environment for the
double-digit growth in tonnage over the transferred via high voltage underground port’s immediate surroundings.”
past three years – one of the few ports cables to shore-side cranes that connect
to grow in the current economic climate. the cables to the vessels.
Part of that forward-looking program is a Our solution has a unique flexibility, in
bid to become the region’s greenest port that it adapts both the voltage level and
Efficient shore-to-ship solutions – a
by equipping all its berths with shore-side frequency to match those of each vessel possibility.
power connections. – enabling multiple vessels to be powered Scan here to watch the video.
Local partner, Processkontroll Elektriska, simultaneously at the port, regardless of
selected us to provide a turnkey shore-to- any differences in the ships’ voltage level
ship solution for all five berths at the port. or system frequency.
We designed, engineered, supplied and built ABB pioneered shore-to-ship technology
the entire solution, which feeds electricity at the beginning of the millennium by
from the local power grid to a specially delivering the world’s first high voltage
contact 3 | 12 19
20. Product news
Just launched
New technology solutions from India include a family of low voltage products,
while a class-leading modular UPS comes to the Middle East market.
Low voltage product Low voltage product
Formula Earth
MCCB leakage
Customizable mid-range relays
circuit breakers for India
IEC 947-compliant
protection relays in India
Formula MCCB has evolved from the Earth protection relays allow monitoring
Tmax range of MCCB. Potential market of the low voltage distribution network
segments include critical power market and with this new series we can now
(OEs from UPS, Genset market) and the offer a complete solution for earth
telecom market that primarily require leakage protection. We can offer B-type
lower fault-level circuit breakers. protection feature complying with IEC
947 as well as IEC 61009 (With B-type
RCCBs). The complete range is tested
Advantages in conjunction with MCCB and MCBs to
−− Conforms to IEC 60947-2 comply with IEC 947 stipulations under
−− No de-rating up to 50° C Annexure M.
−− Compact dimensions
−− Common range of
accessories Advantages
−− Available in 1P, 2P, 3P and − − Adjusts sensitivity and
4 Pole versions tripping times
−− Line-load reversibility − − Improved fail-safe function
− − Auto resets after fault is
rectified
− − Frequency filtering for
improved effectiveness
− − Fault memory LED
− − Digital display
20 contact 3 | 12
21. Product news
Low voltage product Power electronics and MV drives
M2M meters DPA system
New measurement device High-power, modular UPS now available in
in India Middle East
The made-to-measure device provides UPS systems based on decentralized module has its independent:
transparency on energy consumption, parallel architecture (DPA) do not share – logic control
be it single phase or three-phase supply. any common components. Each module – control panel
Meant specifically for medium voltage contains all hardware and software – rectifier
and low voltage electrical panels, the required for full system operation. What – inverter
product provides real-time analysis on does this mean for the customer? Very – battery charger
parameters such as voltage, current, high power availability, increased flex- – static switch
frequency, power factor and active and ibility, lower total cost of ownership and Concept power DPA modules can
reactive power. One of the outstanding improved energy efficiency. Modular be connected in parallel to provide
features of this meter is that it provides systems based on DPA are free of single redundancy or capacity, to 1.5 Mva.
instant information on CO2 emission- points of failure and maximize the mean The class-leading design provides the
based energy consumption: important time between failure, while minimizing highest power density/m2 available.
information for green building solution. mean time between repair.
With DPA technology each UPS
Advantages
Advantages − − Lower cost of ownership
−− Multiple integrated − − Simple installation and
functions service
−− 360° analysis of system − − Optimizes energy
performances − − Advanced, scalable
−− Anticipates malfunctions architecture
−− Easy to install − − True safe-swap modularity
−− Intuitive, easy-to-use
keypad
−− Auto-diagnostic function
contact 3 | 12 21
22. In focus
Innovative marine
propulsion
Breaking the ice
Ice-going ships from tankers to container
ships with Azipod VI® propulsion can do what
was once considered impossible – combine
excellent ice-breaking and open water
characteristics. In 1990, MV Seili, a buoy
tender was the first to be fitted with Azipod,
followed by MT Uikku a 16,000 DWT ice-
breaking tanker in 1993 and Azipod-equipped
icebreaker, IB Rothelstein on the Danube river,
which became the first double acting ship in
the world in 1995 – running in open water
and astern in ice. The Azipod combines the
advantage of the diesel-electric powertrain with
the manoeuvrability of the azimuth thruster,
offering design flexibility and great space
saving, as well as 360°steering that provides
full torque and thrust in any direction.
For more information: www.abb.com/marine
22 contact 3 | 12
24. Cities that consume 30% less energy?
As a leading producer of energy-efficient solutions, ABB helps
deliver major power savings, without compromising performance.
Our lighting control systems can deliver power savings of up to
50 percent, and our building automation up to 60 percent. While
everyone else is talking about energy prices, power shortages
and climate change, ABB is doing something about it, right here,
right now. www.abb.com/betterworld Certainly.
