ABB Contact 3/12 (India) Energy Efficiency Issue
- 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: [email protected] • 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
- 23. Executive editor: Karen Wilds Editor-in-chief: Sanaj Natarajan Production team: Ali Kelani, Anita Ramkumar, Claire Hill, Devaashish S. Savant, Giridhar Sharma, Michael Wachter, Natasha Mathebula, Peter Stierli, Philip Lewin, Rakesh Shastri, Rubi Rakha, Sanaj Natarajan, Tamara Chetty, Tuija Elomaa-Maenpaa, Wendy Joseph Contact is published in English for circulation among ABB customers and stakeholders with an interest in ABB offerings, products and technologies. Partial reprints or reproductions are permitted subject to full acknowledgement. Complete reprints require the publisher’s written consent. Publisher and copyright ©2012 ABB Asea Brown Boveri Ltd. Disclaimer The information contained herein reflects the Preview 1|13 views of the authors and is for informational Revitalizing the purposes only. Readers should not act upon the information contained herein without seeking professional advice. We make publications available with the understanding that the authors are not rendering technical or other professional power grid advice or opinions on specific facts or matters and assume no liability whatsoever in connection with their use. With demand for electricity rising year The companies of the ABB Group do not make on year and concern for the environment any warranty or guarantee, or promise, expressed or implied, concerning the content or accuracy of bringing more renewable energy sources the views expressed herein. online, transmission system operators are under increasing pressure to enhance the flexibility of their grids to improve capacity and accommodate the demands of deregulated power markets. ABB's expertise in power transmission systems and electrical optimization, grid reliability and blackout prevention offers sustainable solutions to the challenges of today, and tomorrow. From Flexible Alternating Current Transmission systems that enhance the security, capacity and flexibility of power transmission networks, to High Voltage Direct Current power superhighways, there are comparatively inexpensive and faster ways to provide more power and control in existing networks. Read the next issue of Contact to see how it’s done. contact 3 | 12 23
- 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.