Power System Consulting

ABB Power System Consulting (PSC) represents a global team of engineers passionate about power system engineering and product integration into a system. We support our clients throughout the engineering process and project lifecycle, from a basic concept to project implementation.

With our global footprint, we provide consolidated knowledge of electrical products and complex power system analyses. Through our highly experienced team of experts, we are able to consult on and design a reliable future-oriented electrical network, that incorporates sustainable solutions, to reduce risk and improve the equipment lead times.

As your trusted partner for power system studies, ABB PSC offers:

A highly experienced global engineering network that leverages from ABB’s history and position as global technology leader in electrical distribution
Fail-safe and innovative processes used for refining and presenting the power system data that are based on the in-depth experience of our experts and data analytics
A safety-first approach while performing our studies and recommending solutions
Embedded sustainability in long-term solutions add to system reliability and future readiness
A trusted partner with assurance that your plant and process data is in the right hands
Access to the broader ABB technology portfolio and third-party tools used for power system studies

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Our offering

(1.) Single line diagram

(2.) Short-circuit study

(3.) Load flow study

(4.) Protection coordination study

(5.) Arc flash hazard analysis

(6.) Power quality analysis

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What does single line diagram development (SLD) development mean?

A single line diagram of the complete network forms the basis for analyzing an electrical system. It is one of the most important documents providing an overview of the complete power distribution network, sometimes also including the network´s protection and control. It is taken as first reference for planning sub-systems and must be kept updated with all changes that occur in the network over a period.

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Importance of SLD development

With time a plant goes through several major/minor changes, which normally includes, load additions, cable changes, transformer upgrades, protection device retrofits, addition of new generators, change in the operating scenarios etc. A lot of single line diagrams we receive from the clients are either completely outdated or are just updated based on the site modifications without any proper analysis of its effect on the overall power system. This is easily possible only if the key single line diagram is backed by a digital twin of the complete system that contains detailed technical data of the equipment in the network that can be used to simulate all the minor or major changes in the network as soon as they are planned. In some case even, clients do not have a single line diagram at all.

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Benefits of partnering with ABB

ABB PSC team offers a complete solution for SLD development no matter at what stage the client is looking for such requirement:

Clients with no network model of the system: For plants, where it is difficult to get the equipment data and the exiting SLDs are not at all updated, ABB PSC has formed a standard procedure to help the client. The ABB expert team is equipped with state of art data collection tools to consolidate all the information during a site survey and present it in an easy-to-understand format that can be reviewed and used as an input for the complete network modelling.
Clients with an outdated digital twin of the system: At ABB we not only use our own proprietary software tools, but we are also using all commonly used 3^rd party software tools (ETAP, SKM, EasyPower, PowerFactory, PSCAD, EMTP-ATP and others), which makes it easier for us to review and modify an existing model which has been built in any of those software tools. Based on the existing data availability and use of data analytics tools developed by ABB, we can easily identify the incorrect/missing data and form a stepwise procedure that is needed to model the network with best precision.

Based on the results and recommendations of various simulations on the digital twin of electrical network, the key single line diagram of the system can be updated to best represent the actual state of the client network.

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What is a short-circuit study?

A short-circuit study is one of the basic steps required to calculate short-circuit currents for various types of short-circuit faults in each part of the network to design, size and verify the electrification layout with all it´s components. It is essential to evaluate the integrity of the entire electrification infrastructure from point of connection to socket. It also forms the basis for several other studies (e.g., load flow, protection coordination, arc flash etc.) and is normally the first check point for network feasibility and data plausibility.

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Importance of performing short-circuit study

Normally most of the major or minor changes in the network (e.g., addition of a generator, change in operating scenario, addition of new loads, etc.) will have some effect on the short-circuit level of the overall network. Not evaluating the system short-circuit currents after regular intervals, it is possible that such major or minor changes get un-noticed until there is a breakdown caused by the thermal or dynamic energies of short-circuit currents resulting in personnel hazards and loss of property. Therefore, it is important to evaluate the system in terms of short-circuit currents at regular intervals and make necessary updates to keep system safe and reliable.

Though short-circuit studies are simple to perform they could be underestimated when performed using simple excel tools for a complex network. It is seen more than often that while calculating the critical cases for maximum and minimum short-circuit current motor contributions are not given due attention. Several times in projects we have seen these studies being done at a superficial level (e.g., considering no motor loads or taking wrong assumptions for lumped motor loads, taking assumed and unrealistic cable data etc.) which could impose significant changes during detail engineering or even require equipment replacement after it is already installed.

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Benefits of partnering with ABB

The experts from ABB PSC have developed standard procedures to calculate short-circuit faults in a network keeping in view the phase of a project and availability of data. With our long experience of performing these studies, we understand where these calculations can go wrong and what are the important checks required during the network modelling stage that would result in minimum changes later.

Apart from this, the ABB PSC team has experts who specialize in products that deal with short-circuit protection and require short-circuit studies done in a specific way to decide the technical suitability and detail design. For example:

Fault current limiters (I_S-limiters, FC-Protector)
Standard current limiting devices (current limiting reactors, current limiting fuses)
Current limiting circuit breakers
Generator circuit breakers

With the detailed product knowledge available within ABB, it is easier for us to consult on the best techno-commercial solution.

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What is a load flow study?

The load flow and short-circuit analysis of a network go hand in hand to lay the foundation for planning a power system network. Both studies have an inter-dependency when it comes to deciding about the architecture of the power system how power is flowing from source to load. A load flow study is used to ensure that electrical equipment such as cables, transformers, switching devices, bus bars, fuses etc. are not overloaded and sized correctly. It is used to determine the steady-state voltage magnitude, active and reactive power flows in all branches of the network for all relevant operating scenarios.

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Importance of performing a load flow study

Performing detailed load flow studies can be a tedious process especially for old existing plants where exact load related data (e.g., load list, motor technical parameters, soft starter details, cable data, etc.) is hard to get and there is slim possibility of getting actual load measurement data at different plant locations at different times. This makes it very challenging to calculate the actual flow of active/ reactive power and derive a worst-case simulation model for evaluating the existing system performance as well as planning a system extension. It is easier to finish the job with simpler assumptions but that may not mimic the actual system where motor loadings change with plant operation and result in a false basis for other studies based on an over simplified system model with many assumptions. It takes a lot of simulation, fine tuning, product and field experience to prepare a network model which provides meaningful load flow results.

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Benefits of partnering with ABB

Keeping all this in mind we at ABB PSC have developed our proprietary load modelling tool which is based on the experience of our global experts, clients, and data analytics to find the missing / inaccurate data and predict the best suited assumption in case of lack of data.

In addition to this the ABB PSC team has experts that specialize in products that deal with overload, reactive power compensation and load-shedding solutions, which can be selected and designed based on load flow study results derived for a network. These are for example:

PML630 load-shedding controller or AC500 PLC with load-shed libraries in combination with Relion® relays, RIO600 device, third-party devices, etc.
Power factor correction units

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What is a protection coordination study?

The protection system of an electrical network typically consists of instrument transformers/ sensors for transforming measurement signals, protection devices (like relays) for processing the measured signals and circuit breakers/ fuses for isolating the faulty network. The main aim of a protection coordination study, sometimes also referred to as a selectivity study, is to determine the protection setting parameters for various protection functions and devices which will result in fast and reliable tripping at the time of a fault. It is important that the coordination/selectivity between various protection devices achieves minimum possible disturbance to rest of the network and only faulty part of the network is isolated. A detailed short-circuit analysis and load flow study is the essential basis for a protection coordination study and the protection setting determination. More sophisticated protection functions sometimes require further system studies like transient stability/ harmonics analysis to decide the settings.

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Importance of performing a protection coordination study

The protection coordination has been made simple by the state of art coordination modules available in modern power system study tools, but it is also the area where we find most of the errors, which can lead to un-necessary trips and delayed tripping of devices, which could result in personnel safety hazards or a complete black-out in an electrical network. Within complex power system networks with multiple sources, motors, buses etc. the network configuration changes are quite frequent, and we observe that the effect of these changes on the protection settings is not properly considered leading to coordination/selectivity issues. Very often we also find clients not utilizing the full functionality of new relays, when, as an example, relays were replaced and previously used settings are applied. Lots of issues affecting the reliability and stability of the power supply can be avoided if the protection concept, coordination, and settings are evaluated keeping in view the instrument transformer ratings and performance.

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Benefits of partnering with ABB

At ABB PSC we have protection experts who have an ingrained knowledge of protection devices and mastered various domains of power system protection. We have developed internal algorithms to make sure a system is not under-protected or un-necessarily overprotected. In addition to the knowledge of different third-party software tools used for protection coordination, we have developed our own proprietary tools to verify the selection of relays and cross-verify the protection coordination at various voltage levels. Though our protection experts are well equipped to recommend solutions when it comes to ABB or non-ABB protection devices, we have a unique value addition with our internal knowledge for projects with ABB devices in it.

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What is an arc flash hazard analysis?

An arc flash incident can be catastrophic given the high amount of energy dissipated at the time of a such a fault. It is one of the biggest safety concerns while designing a power system, which has a network of open-air distribution and metal-enclosed switchgears prone to arc faults due to multiple reasons. The arc flash hazard analysis factors in various inputs of a system like, short-circuit fault current, standard proximity of a personnel working on the equipment, worst case fault clearing time, equipment dimensions etc. to calculate the severity of an arc fault at various system locations and types of faults.

The arc flash hazard analysis includes the following key elements:

Determining the arc flash energy of the respective enclosure / compartment
Determining the required level of personal protective equipment (PPE)
Provision of arc flash labels
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Importance of performing an arc flash study

Based on our experience of reviewing various client networks from all over the world, we can surely say that there are different ways how clients take precautions to manage the hazards related to arc flashes. Some clients are very advanced in regularly assessing the arc flash hazard of their plants and taking the highest level of precaution implementing mitigation measures, but, at the same time, we see plant networks where no arc flash assessment has been done at all, or for a very long time, and it becomes a burning topic only when an arc flash incident happens.

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Benefits of partnering with ABB

ABB PSC team has experts with long standing experience in performing arc flash analysis and in-depth knowledge of the methods used for arc flash mitigation. Apart from the passive methods used for arc flash mitigation our team specializes in the products used for active arc mitigation for example:

Arc mitigation with fast circuit breaker tripping using light sensors (detecting the intense light at the time of an arc flash) and a current signal (products REA, TVOC etc.)
Ultra-fast earthing switch to achieve fastest arc fault protection and mitigation

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What is a power quality analysis?

The term power quality can be used for a wide range of electromagnetic phenomena occurring in an electrical network, which includes voltage unbalance, interruptions, flickers, transients, and harmonic distortion. In general, power quality related issue could be defined as a problem that deals with voltage, current or frequency deviation resulting in supply interruptions and equipment failures.

As per our experience we see that when clients talk about a power quality related issue, they are mostly interested in a harmonic distortion analysis. The harmonic analysis is critical for systems which contain a large portion of non-linear loads such as UPS, rectifiers, inverters, variable frequency drives and other power electronics-based equipment.

A load flow and short-circuit study of a system is normally the first step to assess the basic parameters like power factor compensation and check the model correctness before upgrading the software model to observe power quality aspects in terms of overall system performance.

Harmonic sources are defined based on the type and size of loads along with the mode of operation. In case of an existing plant the input should be further augmented with the actual site measurements in various operating scenarios.

The network is then analyzed for the total harmonic distortion at various locations, current and voltage harmonics are analyzed and cross compared with applicable grid codes (requirements are to be provided by the client) and IEEE 519 limitations. The outcome of the study are recommendations whose implementation will lead to the cost-effective suppression of harmonics to the acceptable level.

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Importance of performing a power quality analysis

With the increasing awareness about overall power system efficiency, the demand of electronic devices (e.g., variable frequency drives, battery storage systems, static compensators, rectifiers etc.) in the network regulating power flow has tremendously increased over the past 30 years. This has resulted in increase in the harmonic levels, where we see clients struggling with the unwanted overvoltage issues, higher losses in the network, cable overload and unwanted device operation.

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Benefits of partnering with ABB

At ABB PSC we have expertise of working on power quality solutions from analysis stage to recommending the best solution based on the type of power quality issue. We are working in close collaboration with ABB colleagues having detailed knowledge of products that are used to enhance the power quality in a network:

Powerline DPA 250 S4 UPS (50 - 1,500 kW)
Power conditioning solutions like HiPerGuard MV UPS, PCS100 UPS-I, PCS100 Static frequency converter, SureWave, PCS100 ESS
Single Phase UPS
Harmonic filters

(7.) Motor starting analysis

(8.) Power system stability analysis

(9.) Insulation coordination studies

(10.) Instrument transformer sizing

(11.) Over pressure calculation

(12.) Disturbance / Fault root cause analysis

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What is a motor starting analysis?

The objective of the motor starting analysis is to determine the performance indicators such as voltage drop (e.g., on the motor terminals, supply switchboard, and other loads) under the worst-case starting conditions before/during/after starting. As worst-case conditions the maximum system transient impedance and the maximum loading is considered to determine the voltage drop. The study determines if a motor can be successfully started in different operating scenarios and if the system is subjected to voltage variations which are within limits while starting the motor. In addition, the study also suggests if the power sources (generators, grid transformers etc.) are suitably sized and protection devices are set properly to handle the transients due to motor starting.

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Importance of performing a motor starting analysis

As per IEEE Std 3002.7-2018 starting large motors can cause disturbances to the motor and other loads. In the worst cases, the starting motor may stall and be unable to start the driven load. In general, a motor starting study should be made if the motor rated power exceeds approximately 30% of the rated power of the supplying transformer. Likewise, if a motor is to be started from an islanded network, a motor starting study should be performed if the motor rated power exceeds 10% to 15% (typical) of the generator power rating, depending on actual generator characteristics. The study should also recognize contingent condition(s), i.e., the loss of a source (if applicable). Motor starting studies should be performed prior to purchasing large motors, such that the motor can be installed with confidence that the motor’s life and performance will be satisfactory, and the remainder of the power distribution system will not be adversely affected.

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Benefits of partnering with ABB

ABB PSC team has expertise in motor starting analysis and motor protection. We have been involved in many projects where clients had issues either related to motor starting or nuisance tripping of motor protection functions. ABB is a global supplier of medium and low voltage drives, and other motor starting solutions. We collaborate with our ABB experts from the drives division who have thorough knowledge of all applications from pumps, fans and compressors through to conveyors, extruders, winders and marine applications. The expertise extends across entire electrical installations from correct selection, dimensioning and installation through to operation and maintenance of drives, PLCs, motors, transformers, relays, switches, and contactors and all the way to transducers and meters. Our cutting-edge technology in soft-starter and drive segment positions us as market leaders with products like:

ABB soft starters- PSTX, PSE, PSR
ABB LV drives consisting of also drives for ultra-low harmonics- ACS55 to ACS880
ABB MV drives- ACS1000 – ACS6080
DC drive- DCS880, DCS880-S and DCS550-S

With this combined knowledge of the client power system network and the various products related to motor starting and protection, we are best suited to recommend the appropriate solution after our analysis.

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What is a power system stability analysis?

The formal definition of power system stability as defined in various IEEE papers is, the ability of the electrical power system for a given initial condition, to regain a state of operating equilibrium when subjected to a physical disturbance with most system variables bounded” so that practically the entire power system remains intact. As per the latest IEEE Transactions on Power Systems (Volume: 36, Issue: 4, July 2021), the power system stability is subdivided into below categories as indicated in the below figure.

Source: IEEE Transactions on Power Systems (Volume: 36, Issue: 4, July 2021)

As a simplified version of this, if we categorize the stability based on magnitude and duration of the disturbance, there are two main types of stability:

Steady-state stability – It refers to the ability of the system to regain its synchronism after slow and small disturbance which occurs due to gradual power changes. For example, a normal load fluctuation or voltage regulation. In case this change violates the permissible power flow for various circuits leading to the loss of sync for machines in the network it is said that the system has lost the steady state stability. Therefore, it is important to analyze the permissible disturbances in a system without loss of its steady state stability.

Transient stability – This refers to the ability of a system to stabilize or remain in synchronism after a large disturbance in the network condition (e.g., sudden loss of big load, switching operations, line or source side faults, etc.)

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Importance of performing a power system stability analysis

The purpose of a system stability analysis is to verify that the system can respond to transient conditions and disturbances such as loss of generation capacity, short-circuit faults and motor starting. Thus, for the purpose of assessing the existence of a system instability in the complete electrical network the generator rotor angle, voltage and frequency performance are analyzed.

For most of our clients who are concerned about system stability, they would like to verify the transient stability of their system before deciding on a change in the network such as the addition of large new loads, plant extensions with new generation, change in the operating scenario etc. While some clients manage to get the system stability analysis performed before changes in their network are implemented, we still see a lot of plants where this analysis only comes as a requirement when a client has already faced the consequences of an instability mostly leading to complete blackouts in the system. As the world is moving towards more distributed power generation and there is significant integration of converter interfaced generation technologies, loads and transmission devices, the power system stability has become even more complex and a mandatory check point.

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Benefits of partnering with ABB

ABB PSC understands the complexity of performing a power system stability analysis. We have experts with experience in working on a number of green field system stability projects, as well as brown field projects, where the system is being extended. The combination of decentralized weak networks and synthesized power can result in stability issues due to limitations in renewable generation rotating energy or inertia reserve. We closely collaborate with our colleagues responsible for synchronous condensers (SCs) which boost grid stability by providing additional inertia. ABB synchronous condensers are tailored based on network studies for the specific location where grid support is needed.

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What is an insulation coordination study?

As per IEC 60071-1:2019 the insulation coordination studies represent the selection of the dielectric strength of equipment in relation to the operating voltages and overvoltage which can appear in the system for which the equipment is intended and taking into account the service environment and the characteristics of the available preventing and protective devices.

Simply put, it is to find out if the equipment selected is reasonably protected against all over-voltages that can occur due to various system transients. There are many possible causes for each of the different types of overvoltage. Some of the common types of overvoltage as defined in IEEE Std. 1313.2-1999 are

a) Temporary overvoltage that is caused by faults, load rejection, line energizing, resonance conditions, ferroresonance, or by a combination of these factors.

b) Switching (slow-front) overvoltage that is caused by switching operations, fault initiation, or remote lightning strokes.

c) Lightning (fast-front) overvoltage that is caused primarily by lightning strikes but can also be caused by some switching operations or fault initiation.

d) Very fast-front overvoltage that is the result of switching operations or faults and is usually associated with high voltage disconnecting switching operation, GIS, and cable connected motors.

A comprehensive representation of various classes and shapes of overvoltage is given in Table 1 of IEC 60071-1:2019, shown below.

sss

Source: Table 1 of IEC 60071-1:2019

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Importance of performing an Insulation coordination study

It is evident that the voltage ratings or insulation levels are decided most of the times based on the Tables 2 and 3 of IEC 60071-1:2006 and IEC 60071-1:2006/AMD1:2010, which reflect the experience of the world, taking into account modern protection devices and methods of overvoltage limitation. Though selection of a particular standard insulation level should be based on the insulation co-ordination procedure described in IEC, it is not always followed as specified in IEC 60071-1 & 2. As a consequence, it is seen that a lot of client networks face insulation failures during system transients, which could be caused by switching, lightning, change of environmental conditions (e.g., rain together with pollution
can drastically reduce the insulation strength).

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Benefits of partnering with ABB

ABB PSC experts are well-versed with the standard requirement and have already performed many insulation coordination studies for existing plants as well as upcoming equipment installations. Our experience enables us to simulate worst-case operating conditions in a plant to predict the maximum overvoltage for which the system should be protected. With our expertise in industrial networks, circuit breakers, switches, protection devices and surge-mitigation methods (e.g., surge arresters, snubber circuits, etc.), we are a natural partner for our clients to perform the insulation coordination studies and recommend the best possible solutions.

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Why is instrument transformer sizing required?

The current and voltage transformers form one of the very important and basic part of any power system protection and monitoring system. Current transformers are designed for the required operating current of the respective circuit but must at the same time have sufficient accuracy in transient fault conditions (short-circuits, switching operations), so that the currents can be correctly evaluated by the protective device connected to the respective current transformer.

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Importance of performing instrument transformer sizing

There are many general guidelines and rule of thumb applied for the sizing of instrument transformers, especially current transformers (CTs) and a lot of times it results in over-dimensioning of current transformers or even worse, in an under-dimensioning in some cases. As per our experience at ABB PSC, when proper CT dimensioning is neglected at the beginning of a new project, for example for an extensive switchgear supply scope, it might result in over-dimensioned CTs being used for lot of typical feeders that are detected as incompatible only after the CTs are already manufactured, relay settings are to be implemented or worst of all when protection devices fail to operate in a fault scenario due to incompatible CTs/ relay setting combinations. In other cases, CT ratings are just decided based on the rated current requirement without paying attention to the saturation characteristics of a CT for various system fault scenarios. This can result in delay in operation, no operation or even system black-out in certain worst-case scenarios. Therefore, it is needless to mention how important the detailed sizing of instrument transformers is, as per the actual power system parameters and protection functions that CTs are serving.

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Benefits of partnering with ABB

At ABB PSC, we have developed our proprietary tools for instrument sizing calculations. We have been involved in CT/VT sizing for projects all over the world, serving both IEC as well as ANSI specifications. We understand the complexity of integrating new state of art relays with old existing CTs that may not be replaced during a relay retrofit or when coordination must be achieved between an existing old network and an extended new network. The instrument transformer sizing depends a lot on the requirements set by a relay manufacturer for various protection functions. With our strong power system knowledge, collaboration with our CT/VT manufacturing units and relay teams, the instrument transformer dimensioning is one of our main excellences.

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What is an overpressure calculation?

Operators and manufacturer of electrical equipment and devices must follow strict and clearly defined guidelines to offer a reliable and safe operating power supply system. Even though the chance of an internal arc fault is improbable, it has the potential to cause significant damage, which may endanger personnel, installations rooms, entire buildings, the environment as well as the whole safety of power supply.

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Importance of performing overpressure calculation

The energy generated by an internal arc fault inside a switchgear system heats the filling gas inside the metal-enclosed or metal-clad switchgear, resulting in a pressure rise expanding throughout the compartment. To control this phenomenon pressure relief openings and ducts are commonly used in switchgears and are built to withstand the thermal and mechanical stress.

The determination of the maximum overpressure inside switchgear compartments and the installation room is an essential task for the equipment design as well as for the installation room design. It is required to dimension the release openings and/or flaps, and to ensure that the civil works design of the room (size, wall material etc.) can withstand the overpressure. Therefore, overpressure calculations are widely used for this purpose, which provides spatially averaged results inside different rooms (or compartments) represented as separate volumes.

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Benefits of partnering with ABB

After years of research, at ABB we have developed our proprietary overpressure calculation tools for performing the pressure calculations. The results generated from the calculation tools have been verified by actual tests performed on real switchgear in our own ABB test lab. We have performed overpressure calculation for switchgear installations for many years and for projects all around the world.

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What is a root cause analysis (RCA)?

A root cause analysis or RCA comes into picture when it is not exactly known why a certain incident has occurred. It could be a short circuit fault or an equipment failure or unwanted tripping of a circuit-breaker for which the cause is not directly known from manual inspection. A root cause analysis means collecting the data available before and after a failure and analyzing it analytically to find the cause and a solution to prevent the re-occurrence of the same event.

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Importance of performing RCA

After a failure the first priority is to get the system up and running as soon as possible for most of the customers. Of course, RCA has the second priority and at times it is just a formality to close the topic, when system is again in running condition. If due respect is not paid to detail root cause analysis and its findings, it is seen more often that similar events occur up again and may lead to even bigger problems. Therefore, is important to collect the data in a chronological order diligently after a fault has occurred even if the cause is visible to the naked eye. RCA not only tells us why the fault occurred at the first place, but it also gives a lot of important information about the correct working of system under stress condition. May be the cause is sometimes easy to find but it can also help to assess the health of various equipment’s involved at the time of fault.

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Benefits of partnering with ABB

Conducting a root cause analysis is a challenging job, keeping in mind that not always we have complete data available that is required to perform a root cause analysis. The more RCA’s you have done the easier it gets to assume the missing data and predict the cause. At ABB, we have developed standard procedures for performing the RCA and tools that help use the data from similar analysis. Having ABB installations all over the world, we get opportunity to analyze a variety of network issues, collaborate with our product experts and use the ABB proprietary tools to analyze a failure.

Our team has vast experience of performing root cause analysis for various power system failures like:

Unwanted protection trip
Over voltage issues
Under voltage trips during motor starting
Equipment failure due to over-current

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