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ELECTRIFICATION BUSINESS AREA – DISTRIBUTION SOLUTIONS DIVISION

Life cycle management of field assets

Services for enhanced operator safety and equipment reliability
EL Distribution Solutions Service, India

© Copyright 2021 ABB. All rights reserved. Document ID.: Rev.:

Agenda

❖ ELDS Service - Team structure

➢ Core management team
➢ Sales and marketing
➢ Contract management/Order execution
❖ ELDS Service - Portfolio
➢ Installation and commissioning
➢ Training
➢ Spares and consumables
➢ Maintenance
➢ Technical support and repairs
➢ Extension, upgrades and retrofits
➢ End of life services
➢ Smart asset management – Switchgear temperature monitoring

April 6, 2021 Slide 2

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ELDS Service – Team structure
EL Distribution Solutions - Service
Core management team structure

Channabasaveshwar R. Payannavar
Business manager

Yogesh Gunjal Prashant B. Katkar Yogesh R. Gosavi1 Manas Burkule1

Spare parts management Project management Finance controller Domestic marketing

Prashant Bari Pramod Mule Prashant M. Dighe1 Amaresh Chandra1

Product management Commercials Quality Exports marketing

Sachin B. Jagtap Unmesh Pathak Ravindra S. Borse1 Prasad P. Galapure1

Factory operations Field operations Research & Development Supply chain management

Sunil K. Shirode Anil B Wagh

Engineering - Mechanical Engineering - Electrical

April 6, 2021 Slide 4 1 Solid line reporting to respective functional managers

EL Distribution Solutions - Service
Sales and marketing team structure

Manas Burkule (Domestic) Amaresh Chandra (Exports)

Swapnil Mali Jayshree Thorat Ranjit RajendraYadav

+91-8484955912 +91-9049043253 +91-8460101754

Jitendra Raghuwanshi Sameer Deshpande

+91-7208044524 +91-9579727858

Anup Chavan Vishal Aware

+91-9607991197 +91-9860261812

April 6, 2021 Slide 5

EL Distribution Solutions - Service
Contract management/Order execution team structure

Channabasaveshwar R. Payannavar
Business manager

Yogesh Gunjal Unmesh Pathak Prashant B. Katkar

Spare parts management Field operations Project management

Sambhaajie Desai Chaitalee Gosavi Kunal Damare

Mihir Patel Prajakta Adhav Bhushan S. Shimpi

Nilesh Bambhaniya TBD

April 6, 2021 Slide 6

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ELDS Service - Portfolio
Life cycle management
Distribution solutions service portfolio - covers the entire asset lifecycle

Support agreements
(Power Care)

ABB Ability™
Replacement Advanced services
11
(Smart Asset Management) Predictability
Life Cycle
9 10
Services
End of life services 8 1 Installation and commissioning (I&C)
Reliability Start-up and
maintenance
Retrofits 7.3 2 Training
services
Service
Upgrades 3 Spares and consumables Availability
7.2

Extensions 7.1 4 Maintenance

6 5

Engineering Technical support and repairs

and consultation

April 6, 2021 Slide 8

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Life cycle management
Installation and commissioning
Life cycle management
Installation and commissioning

Why ABB?

• All safety requirements are followed

• Skilled & certified professionals does the ETC

• Accurate foundation alignment check

• Proper connections of bus bars and cubicle connections

• Faster start-up

• Optimum life cycle performance

• Enhanced reliability & low risk of unscheduled outages

• Extended equipment warranty

Great investment in long-term trouble-free equipment operation

April 6, 2021 Slide 10

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Life cycle management
Training
Life cycle management
Training

Why is training required?

• Correct operation of equipment ensures optimum life cycle performance
• Enhanced personnel and plant safety
• Improved productivity
• Reduced downtime – Trained personnel with high expertise can do basic fault finding &
trouble shooting
• More motivated and qualified employees

ABB solutions for skill enhancement:

• Customized curricula to address the unique training requirements
• Demo room with operating models
• Product benches for hands on training
• Sophisticated learning aids such as simulations, product cutouts & multimedia
presentation

April 6, 2021 Slide 12

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Life cycle management
Spares and consumables
Life cycle management
Spares and consumables

Why ABB?

• Guarantee functionality of installations with original ABB

components

• Spare parts and components available for current and legacy

products

• Reliable, safe and optimal operation with certified ABB spare

parts

• Improved uptime with fast and guaranteed delivery

• Rich distributor network across India for fast delivery

• Spare parts can be viewed at Business Online

April 6, 2021 Slide 14

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Life cycle management
Maintenance
Life cycle management
Maintenance

Why ABB?
• High level of professionalism guaranteed by a continuous training process and refresher
courses
• Reduction of plant downtime thanks to rapid diagnosis using specific testing instruments
and fault identification
• Reduction in maintenance costs (direct costs of emergencies, indirect costs of production
losses)

ABB solutions:
• Various forms of annual maintenance contract (AMC) to suit your needs
• Service contract agreements - Ranging from call-up support services to complete periodic
maintenance
• Power care agreements with predictive maintenance

April 6, 2021 Slide 16

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Life cycle management
Technical support and repairs
Life cycle management
Technical support and repairs

• Switchgear & heavy products at site

• SF6 CB pole repair – Done responsibly taking care of environmental norms

for handling SF6 gas

• Relays at factory
• Multi skilled personnel
• Computer controlled calibration and testing
• Delivery time as per customer requirement and issue based
• Situated at Vadodara, India
• Remote support & software updation

April 6, 2021 Slide 18

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Life cycle management
Extension, upgrades and retrofits
Life cycle management
Panel extensions

Legacy family

VHA36 VHA12S VHE12S UniSafe

Active family

UniGear ZS1 UniGear ZS2

Adaption for non-ABB
Switchgear

April 6, 2021 Slide 20

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Life cycle management
Upgrades - Safety upgrade solutions
Life cycle management
Upgrades – Why is safety upgrades necessary?

Arc Flash

T
Thermal Stress
Pressure wave
Blinding light & deafening acoustic

Hot gases Molten GI

5000 C Copper & Polymer Shrapnel

2nd & 3rd degree burns

Fatality

April 6, 2021 Slide 22

Life cycle management
Upgrades – Safety upgrade with motorized racking
Solution
Motorized racking – Saves human lives - Motorized rack-in & rack-out operation
of medium voltage circuit breaker
- Integral Remote racking solution for VD4

Benefits
- Enhance operator safety
- Maintaining a safe distance between
personal and equipment during critical
operations such as rack-in/rack-out of CB
- Human errors related to manual operation
are prevented
- Right force application preserves mechanism
and interlocks integrity
Application
- Green field application with new VD4 CB
- Brownfield application as retrofit solution in
existing VD4 CB
- Brownfield application for non-ABB Switchgear
with modular CB retrofit

April 6, 2021 Slide 23

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Life cycle management
Retrofits
Life cycle management
Circuit breaker retrofit

• Modernization with circuit breaker retrofitting is a cost-effective alternative to complete switchgear replacement

• Retrofitting constitutes replacement of circuit breaker having similar or advanced features for
• Life extension
• Reduced maintenance
• Improved functionality

• The following basic details are necessary for providing standard retrofit solutions:
• Technical information from the data label
• Pictures from all four sides
• Compartment inner pictures
• Existing panel schematic diagram
• Dimension details

April 6, 2021 Slide 25

Life cycle management
Total effort comparison – Replacement v/s modernization

April 6, 2021 Slide 26 Total effort, including cost, time, resources

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Circuit breaker retrofits
Roll in replacements
Circuit breaker retrofit
Roll in replacements

ASEA/ABB make SF6 CB - HPA RiR for HPA ABB make VCB – VD4 classic RiR for VD4 classic

ASEA/ABB make MOCB- HKK RiR for HKK ABB make VCB- HCA RiR for HCA

April 6, 2021 Slide 28

Circuit breaker retrofit
Roll in replacements

Jyoti make MOCB - MT RiR for MT GEC Alstom make SF6 CB - FP RiR for FP

NGEF make MOCB- EKU RiR for EKU Siemens make MOCB- 3AC RiR for 3AC

April 6, 2021 Slide 29

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Circuit breaker retrofits
Roll in replacements with universal racking
Circuit breaker retrofit
Roll in replacement with universal racking - Concept
Different racking arrangement in
various non-ABB CBs
• Benefits with universal racking:

• Closed door interlock for CB racking/rack out

• Existing breaker can be still put into service in

place of retrofit breaker

• No major modifications on panel side

Universal racking

April 6, 2021 Slide 31

Circuit breaker retrofit
Roll in replacement with universal racking - Concept

Control supply
arrangement in existing Existing CB compartment
switchgear

Existing bushings

New brackets to be Contact engagement

mounted inside existing
CB compartment
Contact inside bushing

April 6, 2021 Slide 32

Circuit breaker retrofit
RiR solution with universal racking for GEC Alstom circuit breaker

GEC Alstom EPX circuit breaker Solution for GEC Alstom EPX CB Technical data

Solution VD4-EPX
Rated voltage [kV] 24
Rated current (400C) [A] 6301)

Rated power frequency

[kV 1 min] 50
withstand voltage

Rated lightning impulse

[kVp] 125
withstand voltage

Rated short circuit current [kA] 25

Short circuit current

[s] 3
duration
Peak current [kAp] 62.5

1) Higher ratings can be developed on request

April 6, 2021 Slide 33

Circuit breaker retrofit
RiR solution with universal racking for Yasakawa circuit breaker

Yasakawa OGR-6M35/M2 CB Solution for Yasakawa CB Technical data

Solution VD4-OGR-6M35/M2
Rated voltage [kV] 7.2
1250;
Rated current (400C) [A]
20001)

Rated power frequency

[kV 1 min] 20
withstand voltage

Rated lightning impulse

[kVp] 60
withstand voltage

Rated short circuit current [kA] 40

Short circuit current

[s] 3
duration
Peak current [kAp] 100
1) Different ratings can be developed on request

April 6, 2021 Slide 34

Circuit breaker retrofit
RiR solution with universal racking for NGEF/AEG circuit breaker

NGEF/AEG SFAsG circuit breaker Solution for NGEF/AEG SFAsG CB Technical data

Solution VD4-SFAsG
Rated voltage [kV] 12
1250;
Rated current (400C) [A]
16001)

Rated power frequency

[kV 1 min] 28
withstand voltage

Rated lightning impulse

[kVp] 75
withstand voltage

Rated short circuit current [kA] 25; 40

Short circuit current

[s] 3
duration
Peak current [kAp] 62.5; 100
1) Higher ratings can be developed on request

April 6, 2021 Slide 35

Circuit breaker retrofit
RiR solution with universal racking for Russian circuit breaker

Russian WBM3T1018 CB Solution for Russian CB Technical data

Solution VD4-WBM3T1018
Rated voltage [kV] 7.2
Rated current (400C) [A] 12501)

Rated power frequency

[kV 1 min] 20
withstand voltage

Rated lightning impulse

[kVp] 60
withstand voltage

Rated short circuit current [kA] 40

Short circuit current

[s] 3
duration
Peak current [kAp] 100

1) Different ratings can be developed on request

April 6, 2021 Slide 36

Circuit breaker retrofit
RiR solution with universal racking for Merlin Gerin/Voltas circuit breaker

Merlin Gerin/Voltas LF2 CB Solution for Merlin Gerin/Voltas LF2 Technical data

Solution VD4-LF2
Rated voltage [kV] 12
Rated current (400C) [A] 12501)

Rated power frequency

[kV 1 min] 28
withstand voltage

Rated lightning impulse

[kVp] 75
withstand voltage

Rated short circuit current [kA] 25; 40

Short circuit current

[s] 3
duration
Peak current [kAp] 62.5; 100

1) Different ratings can be developed on request

April 6, 2021 Slide 37

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Circuit breaker retrofits
Universal module
Circuit breaker retrofit
Universal module solution

Technical data:
Rated voltage [kV] 12 36
Rated power frequency withstand
[kV 1 min] 28 70
voltage
Rated lightning impulse withstand
[kVp] 75 170
voltage
Rated frequency [Hz] 50 50
Rated short time
[kA 3 s] 25…40 25…31.5
withstand current
Peak current [kAp] 62.5…100 62.5…78.7
1250,1600,2000,
Rated current (400c) [A] 1250
2500,31501

▪ Circuit breaker compartment fully carved out from internal arc proof New generation UniGear Panel thus replicating the inherent
advantages
▪ Close door operation(Rack-in/out, Manual on/off) enabled with all safety interlocks
▪ Cassette Design enabling superior features of new generation CBs
▪ Module built with AluZinc sheet - environmentally friendly solution

April 6, 2021 Slide 39 1 With forced ventilation

Circuit breaker retrofit
7.2kV switchgear retrofitted with Universal module

Before retrofit After retrofit

April 6, 2021 Slide 40

Circuit breaker retrofit
36kV switchgear retrofitted with Universal module

April 6, 2021 Slide 41

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Circuit breaker retrofits
12kV cradle solution
Circuit breaker retrofit
Cradle solution - concept

Cradle is one of the retrofit technical solutions used

by ABB. It is the latest ABB retrofit design concept in
order to easily connect the new breaker to a wide
range of existing non-ABB panels.

Concept: Cradle solution comprises a frame that hosts a

standard circuit-breaker connected to the existing switchgear by
an adaptation system.

The adaptation system allows a completely standard ABB

withdrawable apparatus to be fitted to the original switchgear. The
result is a great improvement in reliability, safety, maintenance and
12kV Cradle retrofit solution for circuit breaker
performance.

April 6, 2021 Slide 43

Circuit breaker retrofit
Cradle solution - Benefits

• Maintenance and repair aspect:

• The new apparatus mounts all standard spare parts with all
the benefits in terms of delivery time and price
• Equipment and spare parts are interchangeable with new
ABB extension panels (UniGear) and additional switchgear
• Same operational interface and maintenance approach for
the equipment installed in Cradle and new ABB panels
• Modernization process:
• The use of standard breakers makes them ready without
any modification for future ABB replacement switchgear,
providing an optimized investment for the next substation
renewal
• Ease of use:
• Modular operating mechanism
• Inbuilt spring charging handle for CBs

April 6, 2021 Slide 44

Circuit breaker retrofit
Cradle solution - Benefits

• Safety upgraded:
• The original shutter system and all the relevant interlocking
are replaced with new standard ones installed from the
factory on the Cradle solution
• Shutter and circuit breaker movement are interlocked to
enable all necessary safety features
• Integrated with solenoid coil interlock during installation
for preventing removal of control plug in service position
of CB
• Option for remote racking of apparatus
• Optionally integrated with temperature monitoring
sensors near apparatus spouts
• Technology:
• Cradle solutions are fully type tested according to IEC
62271-100

April 6, 2021 Slide 45

Circuit breaker retrofit
Cradle solution – Example and technical data

ABB VHE12S Switchgear

Technical data:
Rated voltage [kV] 7.2 12
Rated power frequency withstand
[kV 1 min] 20 28
voltage
Modernization with Rated lightning impulse withstand
[kVp] 60 75
voltage
cradle solution Rated frequency [Hz] 50 50
Rated short time
[kA 3 s] 25…40 25…40
withstand current
Peak current [kAp] 62.5…100 62.5…100
Rated current (400c) [A] 1250 1250

ABB VHE12S panel retrofitted with cradle solution

April 6, 2021 Slide 46

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Circuit breaker retrofits
36kV cradle solution for HPA36
Circuit breaker retrofit
Cradle solution for SF6 gas circuit breaker HPA 36

Panel with SF6 CB type HPA36 Panel with cradle retrofit with VD4 CB

April 6, 2021 Slide 48

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Relay retrofit
Relay retrofit
Protection & control upgrades with latest technology
Relay Retrofits
There is need to retrofit relays due to reliability threat posed by old relays in MV system
ABB Uniquely offers relay retrofit solutions based on IEC 61850.Modbus IEC 61850-5-
103, RS-485 and FO, DNP 3 TCP/IP
ABB Offers
➢ Complete metering box or metering door with latest design,
➢ New comprehensive Numerical relays
➢ New switches , meters and all accessories
➢ Arc Protection functions

Benefits
New Relays shall be SCADA compatible with latest communication protocol.
Factory assembled metering box shall be offered, so that less commissioning time is
required
Life & reliability of protection system will be enhanced
Esthetic looks of metering box/ door be enhanced

April 6, 2021 Slide 50

Relay retrofit
Protection & control upgrades with latest technology

April 6, 2021 Slide 51

Relay retrofit
Protection & control upgrades with latest technology

Before retrofit After retrofit

April 6, 2021 Slide 52 Old relay door and wiring plate replacement done
Relay retrofit
Protection & control upgrades with latest technology

Before retrofit After retrofit

April 6, 2021 Slide 53 Complete relay & metering (LV) box replacement done
—
End of life services
Life cycle management
End of life services

Key features:

• Decommissioning

• Dismantling & scraping

• Buy back policy for SF6 poles/SF6 CBs

• Proper evacuation & handling of SF6 gas according to

environmental norms

• SF6 gas and components are scrapped/recycled responsibly

• ABB supports national and international efforts to reduce green

house emissions towards commitment of clean environment

Peace of mind for customers for handling SF6 gas

April 6, 2021 Slide 55

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Smart asset management
Switchgear temperature monitoring
Switchgear failure causes
Why is temperature monitoring crucial?

❖ Loose Connections or parts – Contributes 30% of overall failure

causes

❖ Loose Connections – Creates hotspot on primary circuit

❖ Insulation close to hot spot can suffer serious deterioration due

to excessive heating

❖ Excessive heating dramatically affects life of insulation

❖ As a rule of thumb, insulation lifetime is reduced by half for each

rise of 100 C in insulation average temperature

❖ Over a period, insulation failure results in arc flash

❖ Arc flash can result in long-term power supply outage and huge
consequential damages

April 6, 2021 Slide 57

Temperature monitoring
Current scenario

Temp. monitoring with thermography thru’ IR Window

– Up to now, thermal surveys are performed using IR thermography
technology

– Surveys are performed only on a scheduled basis (usually 6, 12 or 24

months)

– Periodic surveys do not always alert maintenance teams early enough

when there is fast deterioration at connection points

– Performed in close proximity to live electrical equipment, putting

personnel at risk due to exposure to arc faults

– Limited accessibility and visibility of the contact points (eg. Bus bar joints,
multiple runs of cables), so positioning the camera can be challenging

April 6, 2021 Slide 58

Asset management
With 24X7 continuous temperature monitoring

Why should I embrace ABB temp. monitoring ?

– Maximize Uptime
Avoid unplanned outages which directly affect
revenue generation
– Improve safety:
Reducing catastrophic failures which impact
human and asset life

Maximize uptime

Improve safety

Temperature monitoring

April 6, 2021 Slide 59

Asset management
Temperature monitoring

SAW Technology solution

− Wireless battery-less sensors
− Connectivity with HMI with transceiver
− Easy to install for brown and green field

Brown Green
Retrofit
field field

April 6, 2021 Slide 60

SAW Sensors
Surface acoustic wave technology

Operation of SAW
− The transceiver sends an electromagnetic
signal to the sensor through antennas
− The antenna of the sensor captures the
signal, converts it into a Surface Acoustic
Wave and reflects these modified signals
back to the transceiver
Transceiver Antennas Sensors
− The transceiver computes, processes and
translates the signal into an exploitable
data: temperature from -25 to 150°C
HMI will show the values of
− Temperature value is displayed on HMI surface temperature where
sensors are mounted

April 6, 2021 Slide 61

Switchgear temperature monitoring
Switchboard mounted HMI

❖ HMI Type : ABB make, CP604

❖ Color display with touch screen

❖ Control Voltage : 24V DC

❖ Flush mounting on LV compartment

❖ Graphical display possible

❖ No limitation of number of pages

❖ Configuration by ABB Service experts

❖ 10 transceivers can be lopped and connected to HMI

April 6, 2021 Slide 62