ABB CUSTOMER WORLD, MARCH 13-16, 20 17

Disrupt ive Innovat ions in Medium Volt age Product s

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Ra y Ca t le t t , Te chnica l Co ns ult a nt ; Dwa ra ka Pa d im it i, Bus ine s s De ve lo p m e nt Ma na g e r
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Speakers
Ra y Ca t le t t
Te chnica l Co ns ult a nt
ABB
St . Lo uis , MO
Dwa ra ka Pa d im it i
Bus ine s s De ve lo p m e nt Ma na g e r
ABB
Ho us t o n

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Fo o d & b e ve ra g e Te chno lo g y &

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Oct o b e r 10 , 20 17 Slid e 5 Kno w yo ur s urro und ing s

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Kat ie re int g e n 919-831-3176 he lp s up p o rt

Oct o b e r 10 , 20 17 Slid e 7
Technological Innovat ion: Dual Pat h - Out line

Def init ion

Ma nufa ct uring inno va t io n p a t hs

S curve s

Inno va t io n d ile m m a
Def init ion
Technological Innovat ion: Dual Pat hs

Sust aining t echnologies:

Product changes t hat have a sust aining impact on an est ablished
t raject ory of perf ormance improvement . Makes a product perf orm
bet t er in t he market t hat cust omers already have.

Disrupt ive Innovat ions:

Changes an est ablished t raject ory of perf ormance or redef ines what
perf ormance means. Can open new market s t hat were closed bef ore
due t o physical / t echnical / economic limit at ions.

Source: H.B.S., Christ ensen, 2002,

Technology S Curves
As t echnology becomes more mat ure, a product s perf ormance levels of f , even as more engineering
ef f ort is invest ed. Ex: 50kA => 63kA => 80kA. Product s cost s increases; R.O.I. becomes quest ionable.

The syst ems overall perf ormance result s f rom t he complex int eract ion of t he many subcomponent s
perf ormance(s).

We can push convent ional t echnology beyond it s perceived physical limit s; t hose limit s are just
moving t arget s.

Source: H.B.S., Christ ensen, 2002

Innovat ion Dilemma: Cust omer Absorpt ion

Source: H.B.S., Christ ensen, 2002,

Innovat ion Dilemma: Cust omer Absorpt ion

Source: H.B.S., Christ ensen, 2002,

Current market sit uat ion / response
Power syst ems are changing f ast er t oday.
Re s p o ns e fro m co m p e t it io n is t o co nt inue t o a d d co s t , d rive la rg e r e q uip m e nt a t hig he r fa ult
le ve ls .
Ma nufa ct ure rs a re p us hing o ld t e chno lo g y a nd no t inve s t ing in R&D
Te chnica l kno wle d g e is d ro p p ing a t co m p e t it io n a s m o re a nd m o re re s o urce s a re m o ve d int o
t he cha nne l. (Op p o rt unit y)
Mo s t p ro d uct s d o nt s o lve s ys t e m p ro b le m s s t a nd a lo ne
Wha t is la cking is t he a p p lica t io n o f ne w t e chno lo g y.
Ma rke t Acce p t a nce - SKIP, DUMP

Accept ance by engineers, cust omers, paramount t o success.

Engineering software tools lower the risk for consultants
Ex: Relays / Breakers in software used in system design
High level technical team (EP FAE Consulting team) showing the way.
EX: City of Seattle, ALNG
Large cost savings / current economic climate drive acceptance.
Papers / Case Studies make change possible, lower risk levels with acceptance
Too much technology risk at once complicates acceptance.
Pilot projects help drive industry acceptance
Product and syst em conf igurat ion

Disconnect Swit ch (DS1)

Is-Limit er (ISL) & HD Saf egear

Product Applicat ion Mat irx

Combinat ion of all Disrupt ive Equipment on one SLD
Disconnect Swit ch (DS1)

Why is t his disrupt ive?

Opens up the pipeline design markets, by changing the power

syst em one-line, f or cost , f oot print , mot or size et c..
Could potentially change pipeline economics:
Larger pump stations; less station quantities

What t o look f or on t he Single Line Drawings & Specif icat ion

MV capacitor banks for MVAR support ; ut ilit y f eeds

Synchronous condensers for HV grid support, (maybe)
MV motor soft starters
VFD driven MV Motors
DS1: Swit ching Concept

Synchro niza t io n wit h AC ne t wo rk Solid-s t a t e Te chno lo g y

Transient -f ree
Pre/ Rest rike-f ree
Ca p Swit ching
DS1: Innovat ion t hat Fit s
Transient -f ree
Eliminates overvoltage during cap bank closing
Minimizes current inrush current during cap bank disconnection
Pre/ Rest rike-f ree
- No contact welding or restrike possible (typical for a MV breaker)
St at e-of -t he art Operat ion
Operates each pole independently
Closes each phase independent ly at zero volt age crossing
Opens each phase independent ly at zero current crossing
Int egrat ed Cont rol Unit
Synchronization with upstream network
Continuous system diagnostics & watch dog unit
Control unit provides status of device
Maint enance-f ree
- Only visual inspect ion
Disconnect Swit ch (DS1)
Advant ages:

Synchronous and transient -f ree swit ching of capacit or banks; opening or closing
No voltage transients due to switching;
Improved plant power quality
Surge reactors & pre-insert ion resist ors not needed
Can replace complicated motor soft starters
Major capital reduction
No other major manufacturer has this product or solution!

Concerns:

Not on breaker truck at this time in our switchgear lineup

Limited to 600A & 15kV at this time
Disconnect Swit ch (DS1) MV Mot or St art ing

Analyze and det ermine proper size:

Maint ain bus at 90%

Pre DS1 insert ion

Tot al est imat ed cost $935k

Disconnect Swit ch (DS1) MV Mot or St art ing

Post DS1 insert ion

Tot al est imat ed cost $650k

Capit al Cost Reduct ion:

Pre Insert ion: $935k $650k= $285k (post insert ion)

Tot al savings of about 30%

Addit ional benef it s:

Lower AF levels;
Lower transformer losses;
Less construction & smaller real estate
Disconnect Swit ch (DS1) MV Mot or St art ing

Alternate starting method: across the line of a low inrush designed

6000HP via a 20MVA xfmr

Regrets:

Motor capital cost, 30 50% increased capital cost

Full load efficiency 1.0 - 2.0% decrease Higher operating costs
Running motor PF is lower, 0.5 - 2.0% decrease
Drives up buss amp consumption; limits future load expansion
Possible motor frame change
Shaft to sole-plate alignment to driven equipment issue
Disconnect Swit ch (DS1) MV Mot or St art ing
Following t able shows t he comparison of mot or paramet ers f or a normal inrush (1) against a low inrush
(2) medium volt age 6000HP induct ion mot or.
Motor FL Motor p.f.
S. No Voltage (kV) Motor HP Motor LRC% Motor RPM Capital Cost
Efficiency (%) (Avg)
1 13.2 6000 96.48 0.85 680 1792 140K
2 13.2 6000 94.72 0.86 384 1767 210K
Delta - - -1.76% +0.01 -296 - +70K

Net present value (NPV) of mot or ef f iciency savings is calculat ed based on t he f ollowing assumpt ions:

Average cost of Energy $0.08 $/ kW-HR

Mot or Size 6,0 0 0 HP
No. of Operat ing Hours per Day 24 Hrs .
No. of Operat ing Days per Year 335 Da ys
Tot al Mot or Lif e 29 Ye a rs
Int ernal Rat e of Ret urn 10 %
Disconnect Swit ch (DS1) MV Mot or St art ing
Total energy savings for an end user is quite significant. (Total NPV of ~$600K)

Below is the NPV calculation of motor savings of above two motors over a period of 29 years.
IsLimit er (ISL) & HD Saf egear
What could not be accomplished prior t o t his int egrat ion?
Op e ra t ing wit h a ll 15kV m a ins / t ie s clo s e d fe e d ing 14 0 +MVA o f lo a d
Hig h SCC e xce e d s s wg r ra t ing s
Ha d t o ins t a ll 35 o r 69kV int e rm e d ia t e s ys t e m : HV=>MV=>MV
Large mot ors needed a sof t st art er t o come up t o speed
63kA swgr most ly required when main bus exceeds 3000A
Bus kV vs. bkr I.C. vs. bus amps was always a check on each ot her

+
IsLimit er (ISL) & HD Saf egear- SKIP????

What t o look f or on t he Single Line Drawings & specif icat ions

Two o r m o re s o urce s fe e d ing MV line up
63kA, lo ng MV s wg r line up ,
MV m o t o r ra ng e o f 50 0 0 +HP
MV m o t o r s o ft s t a rt e rs a nd / o r a ut o -t ra ns fo rm e r s t a rt ing
Thre e le ve ls o f t ra ns fo rm a t io n; HV=>MV=>MV
Fo ur o r m o re b re a ke r/ re la ys in s e rie s a t t he s a m e MV le ve l
Ha rm o nic m it ig a t io n e q uip m e nt
Ha rm o nic filt e rs ; SVC
IsLimit er (ISL) & HD Saf egear
Why is t his disrupt ive?:
MV s ys t e m ca p a b ilit y va s t ly e xce e d s o t he r m a rke t o ffe ring s
So lve s p ro b le m s s im p ly t ha t we re co ns id e re d co m p le x fo r 80 + ye a rs

Ad va nt a g e s :
Sys t e m o p t im iza t io n p o s s ib le ; 10 0 s o f ne t wo rke d MVA a ll a t 15kV
La rg e ca p it a l co s t re d uct io n, $m illio ns s a ve d
Sys t e m s t a b ilit y im p ro ve m e nt
Po we r q ua lit y im p ro ve m e nt s
Le s s m a int e na nce

Co nce rns :
Sys t e m p e rfo rm a nce incre a s e is jus t t oo f ast over short t ime f rame
Perf ormance oversupply; can we sell it ?
High ISL selling price complexit y vs. solut ion decision benef it s
EPC: Too new t hinking, we have not applied t he product bef ore
Is-Limit er (ISL) & HD Saf egear: Hist orical vs. ABB MV Syst em Capabilit y
Is Limit er (ISL) & HD Saf egear Gas Plant
Is Limit er (ISL) & HD Saf egear Gas Plant - Opt ion
TG1 TG2 TG3 TG4

TB B-C ISL B-C

M1 TB A-B M2 M3 M4
N.O. TB C-D
LOAD BUS A N.C. LOAD BUS B N.C. LOAD BUS C N.C. LOAD BUS D Operat ions:
TB B-C ISL B-C Full N-2 design
N.O. TB A-F
Alternate
Aut o syst em rest orat ion
option
in 1-2s post f ault
ISL A-D

TG6 TG5

TB E-D ISL E-D

M6 TB F-E M5
N.O.
LOAD BUS F LOAD BUS E N.C.
N.C. LOAD BUS D

TB E-D ISL E-D

Savings not considered:
This simple MV solut ion delet es: Const ruct ion: can be built in
(6) 80MVA xf mrs modules
(6) 66MVA xf mrs Real est at e
(27) 69kV GIS bkrs Maintenance
~ $20M t ot al reduct ion. Power cable
Is Limit er (ISL) & HD Saf egear LNG
Is Limit er (ISL) & HD Saf egear LNG Opt ion
TG1 SG3

TB K-A M1
TB A-B M2 TB B-L This simple MV solut ion delet es:
LOAD BUS K N.C. LOAD BUS A N.C. LOAD BUS B N.C. LOAD BUS L (8) ??MVA xf mrs
TG2 SG1 (19) ??MVA xf mrs
(36) 69kV GIS bkrs
TB K-C M3 TB C-D M4 TB D-L
Miles of 69kV cables
N.C. LOAD BUS C N.C. LOAD BUS D N.C.
TB K-C/E ISL K-C/E ISL D/F-L TB D/F-L Probably $26M t ot al.
N.O. RACKED RACKED N.C.
TB K-E TB E-F TB F-L
IN LOAD BUS E LOAD BUS F IN
N.C. M5 N.C. M6 N.C.

TG3 SG4
Savings not considered:
LOAD BUS K TB K-G LOAD BUS G TB G-H LOAD BUS H TB H-L LOAD BUS L Const ruct ion
N.C. M7 N.C. M8 N.C.
Can be assembled in modules
Real est at e
TG4 SG2

Operat ions: Maintenance

Full N-2 design Power cable
Aut o syst em rest orat ion in 1-2s post f ault
IsLimit er (ISL) & HD Saf egear Gas plant & LNG Opt ions

Bot h opt ions operat e wit h all main & t ie breakers normally closed
Each main bus has about 10 f eeder breakers
ALL breakers f or bot h opt ions have t o be C37.013 rat ed
All sources are act ive and carrying load, no hot st andbys
Bounceless bet ween source t ransf ers
The gas plant will be built in modules of 3000 5000 t ons each
Perf ect arrangement f or t he 15kV swit chgear
Gas plant swit chgear can be inst alled on t hree modules (t wo gens per
module) and syst em connect ed in t he f ield
Is Limit er (ISL) & 35kV ZX2 GIS St eel Plant
Is Limit er (ISL) & 35kV ZX2 GIS St eel Plant - Alt ernat e
Is Limit er (ISL) & 35kV ZX2 GIS St eel Plant - Alt ernat e
Results:
Direct transformer conversion from 765kV to 35kV at 500MVA of load.
138kV system is deleted; cost savings of $20M.
Higher reliability with all mains and ties operated normally closed.
Lower system impedance; improved system wide voltage regulation.
Unplanned, secondary benefit:
SCC = 4500MVA (75kA) at 35kV
Lower total Thevenin impedance up t o ut ilit y source
Static var compensator (SVC) not needed due to low harmonic levels.
$5M capital cost reduction
Total capital cost reduction = $25M
Not considered: construction

Job was canceled in 1st Q 2009; plant s cust omers were GM, Ford,
Chrysler!
Q&A and Cont act inf ormat ion
If you have quest ions, please cont act me f urt her

Speakers
Ra y Ca t le t t Dwa ra ka Pa d im it i
ABB ABB
618-34 3-0 150 281-687-7154
Ra y.ca t le t t @us .a b b .co m Dwa ra ka .s .p a d im it i @us .a b b .co m

Oct o b e r 10 , 20 17 Slid e 38
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