BorsodChem MCHZ, one of Central Europe’s leading suppliers of chemical raw materials, faced a critical challenge: modernizing a power distribution network that had been in place for over 50 years - without interrupting production. In a facility where continuous operation is essential, even short outages were not an option. In close collaboration with ABB, the company successfully carried out a full-scale reconstruction of its power infrastructure while keeping the plant fully operational.
The Ostrava plant employs nearly 400 people and spans an area equivalent to 150 football fields. It supplies chemical raw materials essential to the automotive, construction, and agricultural industries. In such a vast and technologically demanding operation, a stable and adaptable power network is essential.
“Our distribution network was built mainly in the 1960s and 1970s and it really shows. The reliability of the power supply began to decline and faults began to appear in the distribution equipment. Spare parts were not available, and some components no longer met safety standards,” said David Kupec, Head of Energy, BorsodChem MCHZ.
Reconstruction without downtime
Not only was there a need to upgrade the power infrastructure – new production units for nitrobenzene and nitric acid were also to be built. Before initiating the project, the company conducted an internal study to define technical requirements and outline potential solutions. A key condition: the entire reconstruction had to be completed while keeping production running.
The project involved installing new medium-voltage switchgear, cabling, and cable routes as well as upgrading existing switchboards. All systems were to be connected to the central power distribution control room for efficient monitoring and control. ABB provided a range of technologies, including engineering and project design.
Coordinating the reconstruction alongside ongoing production and the construction of the new production units required careful planning and strict adherence to the schedule. Every supplier and contractor had to follow the timeline precisely to ensure uninterrupted operation.
Smart solutions for demanding operations
To meet the plant’s high requirements for reliability and safety, ABB installed a new solution with 123 panels of UniGear ZS1 air-insulated switchgear, equipped with Relion® protection relays and AdvaSense™ sensors. The sensors provide accurate current and voltage measurement, which the protection relays utilize for real-time monitoring, diagnostics and efficient power management. To enhance personnel safety, remote control capability of the protection relays was a key requirement.
To further elevate safety, the company opted for a solution with ABB’s REA arc flash protection system and Ultra-Fast Earthing Switch (UFES), which can extinguish electric arcs in under 4 milliseconds.
In addition, 45 existing switchboards were upgraded with ABB’s VD4 vacuum circuit breakers, AdvaSense sensors, and Relion protection relays. ABB also installed low-voltage circuit breakers, SACE Emax 2 and SACE Tmax XT with Ekip Touch Measuring trip units, to provide visibility into low-voltage system status and electrical parameters to monitor the network efficiently and prevent outages.
The entire network is interconnected using the IEC 61850 protocol, enabling seamless integration into digital control and data acquisition systems. This makes BorsodChem MCHZ ready for future expansion of its production and power infrastructure.
123 panels of UniGear ZS1air-insulated switchgear equipped with Relion protection relays and AdvaSense sensors have been installed at the site. 
To further elevate safety, the company opted for a solution with the REA arc flash protection system and Ultra-Fast Earthing Switch (UFES), which can extinguish electric arcs in under 4 milliseconds. 
The VD4 vacuum circuit breakers are installed in both the new UniGear ZS1 panels - and used to upgrade existing switchboards at the site. 
Low-voltage circuit breakers to provide visibility into low-voltage system status 
The entire network is interconnected using the IEC 61850 protocol, enabling seamless integration into digital control and data acquisition systems.
Future-ready infrastructure
The modernization project replaced outdated technology with infrastructure that significantly improves safety and efficiency. The transformation is akin to upgrading from a basic motorcycle to a fully equipped electric vehicle - enhancing comfort, safety, reliability, and advanced functionality.
Strong collaboration was the foundation of the entire project. To ensure trouble-free and continuous operation in the years to come, comprehensive warranty and post-warranty service support is also in place.
“We were replacing equipment that was at the end of its service life, and we were well aware of how crucial a reliable power supply is for the entire site. When selecting a new solution, we placed particular emphasis on quality, reliability and operational safety – and ABB's solutions met all these requirements. The UniGear ZS1 panels we chose are robust and safe, deliveries went exactly according to plan, and we know that we have service covered for the future. From our point of view, we made the right choice,” said David Kupec.
