issue 1 / 2008 the abb india magazine · issue 1, 2008 the abb india magazine 5 india roundup abb...

Issue 1 / 2008The ABB India Magazine

CONTACTThe ABB India Magazine2 Issue 1, 2008

Editorial Team

Harmeet S Bawa – Head, Communications, India & SAS Region

Ashish Shukul – Executive Editor

Namita Asnani – Power; Deepak Sood/Amit Sharma - Automation;

ABB Limited, GF-Corporate Communications, IndiaKhanija Bhavan, 2nd Floor, East Wing, 49, Race Course RoadBangalore - 560 001.abb.co.in/contactemail: [email protected]

Design – Shilahar Associates

Contents

Dear friends,

Rising energy prices, depletion of fossil fuel reserves and

concerns about climate changes have brought energy

efficiency and alternative energy sources on top of the

business and public agenda. The world is facing serious

energy-related challenges, the key issues being how to

secure supplies in the face of unquenchable thirst and

increasing supply risks, how to mitigate environmental impact

and tackle rising consumption. The recent hike in oil prices is

a clear example of the sort of challenges we face.

It is obvious that relying on traditional energy sources alone

cannot be the solution and it has become imperative to tap

hitherto under-leveraged alternative energy sources such as

wind, solar and tidal energy. The 'other alternative fuel' is of

course energy efficiency - after all the greenest energy is

energy saved!

ABB has a host of power and automation solutions that help

increase efficiency across the energy chain. We offer a wide

range of products, systems and support for the alternative

energy sector - be it wind, solar or tidal power. In fact, for the

wind power segment ABB offers a complete range of

electricals and automation across the value chain - almost

everything other than the mechanical portion. Our product

offering includes motors, wind generators, drives, power

quality improvement products, transformers and switchgear.

This issue of CONTACT focuses on alternative energy

sources, especially wind power and we hope you enjoy

reading it.

Yours sincerely,

Biplab Majumder

Country Manager & Managing Director, ABB India

Global Roundup 3

India Roundup 5

Harnessing the power of nature 11

Customer Interview 14Ramesh Kaymal, Managing Director, Vestas India

Customer Interview 15D V Giri, President and CEO, Pioneer Wincon Pvt. Ltd.

Technology Digest 16

Tech Bytes 20

Channel Line 21

Living our commitment to Sustainability 22


CONTACTThe ABB India Magazine 3Issue 1, 2008

Global Roundup

ABB technology wins globalaward for energy efficiency

ABB's Expert Optimizer softwarewas honored with the "Mostinnovative technology for electricalenergy efficiency" award at thesecond annual Global Fuelsconference in London. Part of ABB'sCollaborative ProductionManagement portfolio, ExpertOptimizer helps cement plants to

significantly reduce energy consumption and energy costs.Over 100 cement industry delegates from 27 countriesattended the event. The judges praised ABB's technologiesfor their effective reduction of electrical energy usage incement plants worldwide. Expert Optimizer allows cementplants to reduce their specific energy consumption throughthe intelligent use of variable speed drives in fans and kilncontrol, for implementing cooler optimization in combinationwith high-efficiency cooler multidrives, and for deployment ofmill optimization and grinding plant scheduling.

ABB to upgrade controls atEurope's largest biomass plantABB is carrying out a major'Evolution' contract for EPRL(Energy Power ResourcesLimited) to upgrade the plantcontrol systems at its 38.5MW poultry litter fuelledpower station in Norfolk, UKto provide improved controland greater energy efficiency.Scope of the project includes upgrading the plant's existingsystem to ABB's state-of-the-art System 800xA Process Portal.ABB's 'Evolution' lifecycle support strategy is designed to meetthe needs of owners and operators of ABB automation systemswho operate on tight margins but still rely on continuous,efficient operation of their process plant to remain viable. Itprovides a clearly defined path to enable their existing automationsystems to evolve, through a series of small, cost-effective steps,to meet their changing business environments, both commercialand technical.

Partnering the quest to produce cleaner fuelsABB’s Workington unit has secured twoorders for DP flow primaries of 250 Venturitubes for pipelines ranging in size from 10"(250mm) to 42" (1,050mm) diameter.The meters will be used at Shell's Pearlsite in Qatar, which is the world's largestGTL (Gas To Liquids) project. GTL plantsconvert the gas into products that aremuch easier and more economical to

handle and have a wider demand as a fuelsource. When in operation, ABB Venturi

Powering the world's largestoffshore wind farm

ABB has received an order from the Germanutility E.ON Netz GmbH to supply powerequipment that will connect the world'slargest offshore wind farm to the Germangrid. ABB will connect the 400-megawatt

(MW) Borkum-2 park using its innovative and environment-friendlyHVDC Light transmission technology, which gives utilitiescomplete control over the power supply and increases gridstability. Located more than 100 kilometers off the German coastin the North Sea, it will be the most remote wind farm in the world.The wind farm is expected to eliminate CO

2 emissions of 1.5

million tons per year by replacing fossil-fuel generation. ABB isresponsible for system engineering including design, supply andinstallation of the offshore converter, sea and land cable systemsand the onshore converter.

ABB to power Finland's largestwind farmABB will supply generators &frequency converters for windturbines in Finland's largestwind farm, Kemi Ajos. Thewind farm will be connectedto the national grid with an11-kilometer, 110 kilovoltpower line. Substations andtransformers for the wind farm will also be supplied by ABB.Kemi Ajos will also utilize frequency converters for the project.Frequency converters are used for adjusting the rotation gear inthe machine room and for auxiliary device control for generatorsand the main drives. These energy efficient ABB componentspromote sustainable development and are the natural choice forrenewable energy source utilization.

flowmeters will help reduce both theenvironmental impact of this huge projectand also the impact of globaltransportation. Their very low pressureloss characteristics result in a reducedrequirement for additional electrical powerto restore lost pressure in the process andso incur lower CO

2 emissions than other

DP devices.



Pure solar power in sun-drenched southern SpainCurrently under construction in one of thesunniest parts of Spain - the desert-likeheights of the Sierra Nevada in Andalusia -Andasol will be the largest solar energy plantin Europe, and one of the largest in the world,when completed in 2009. It will also beEurope's first parabolic trough power plant.Andasol 1 and 2 will each generate 50megawatts of emission-free electricity using

Desalination for Australia's Gold CoastABB water-cooled motors and drives willpower the first large-scale desalinationplant on the Australian east coast.Lowest harmonics, fastest switchingresponse, smallest footprint - and ABB'sunrivalled reference list of energy-efficient solutions for desalination plants- were enough reasons to choose ABB.ABB is also supplying the low voltagedrives for all the pump applications at

the plant. The ACS800 is the world'sfirst dedicated low harmonic drive - acomplete, ready-to-install drive thateliminates the need for multi-pulsetransformers or external filters andreduces current distortion to as little as3 percent. The plant will provide 125million liters a day of much-neededpotable water to an area severelyaffected by drought.

Recycling waste into clean heat and powerABB is supplying a complete power andautomation solution for a new waste-to-energy power plant - the largest of its kind inGermany - that will generate clean heat andpower. Infraserv Höchst is one of Europe'slargest industrial parks for chemical,pharmaceutical and process industries. Thenew waste-to-energy power plant at thepark will help Infraserv Höchst supply cleanpower and heat at competitive prices to the90 companies at the site. The integrated

solution encompasses the entire scope ofelectrical and automation products andsystems for the new power plant. The plantwill produce 70 megawatt of electric powerand 250,000 metric tons of steam fromrecycled municipal and commercial waste.ABB's wide-ranging scope of supplyincludes transformers, medium and lowvoltage switchgear, drives, MNSiS,distributed control system, emission controland plant optimization.

Reliable power for the world's largest aluminium smelterABB has received an order fromEmirates Aluminium Company (EMAL),to supply of a Gas Insulated Substation(GIS) for the world's largest singlealuminium smelter. EMAL's greenfieldaluminium smelter will operate with acapacity of appx. 700'000 tons per

annum in the first phase. ABB willprovide the GIS control and protectionsystems and substation automationfor this plant. Upon completion of thesecond phase, the smelter will havea total capacity of 1.4 million tonsper annum.

innovative technology that captures andconcentrates sunlight in two vast solar fieldsof trough-shaped parabolic mirrors. Bothpower plants will be controlled by ABB'saward-winning Extended Automation System800xA and ABB Power Generation Portal™software. Power generated at the plants willbe delivered to the local grid via ABB powertransformers and substation equipment.

ABB hoist system helps productivity jump at the world's largest potash mineAn ABB mine hoist system has increasedproductivity by 50 percent, secured gridstability from severe voltage flicker andimproved energy efficiency by an estimated5-8 percent at the world's largest potashmine in Canada. The new mine hoist systemhas enabled Mosaic, the world's leadingproducer of potash and phosphate crop

nutrients, to increase skip (buckets used tolift potash to the surface) capacity from 30tons to 45 tons at its Esterhazy potash minein Canada. As a result, its annual productioncapacity has increased by 1.1 million tonsto 5.3 million tons a year, making it the mostproductive potash mine in the world. Theturnkey solution is the largest single motor

and drive system ona friction hoist ever.An estimated 80 percent of electricalpowertrains formine hoist systemsworldwide aresupplied by ABB.



India Roundup

ABB has received major orders to provide turnkey substationsolutions’s and a range of products to Powergrid Corporationof India Ltd (PGCIL) for a new 400/220kV GIS (Gas InsulatedSubstation) at Chamera in Himachal Pradesh. ABB has beenentrusted with the design, supply, erection and commissioningof the substation. The project includes 400kV and 220kV bays,power transformer, shunt reactors and the latest IEC 61850based substation automation systems.

ABB will also be supporting PGCIL with the new 400/220kVsubstations to be set up in Pune and Solapur as well asextensions to the 400kV substations in Parli, Aurangabad andKolhapur. ABB's scope includes design and supply of thesubstations, 400/220kV power transformers and instrumenttransformers, a range of circuit breakers as well as PLCCequipments. ABB will also provide control and protection

ABB wins substation orders from Powergrid

systems, including the latest IEC 61850 compliant substationautomation based on an open systems protocol. The projectsare scheduled for completion in around 24 months.

ABB engineered, designed and delivered drives and automationsystems for the new wire rod block line of Sunflag Iron and SteelCompany Limited, Bandara - India. The project was completed inrecord time and garnered much appreciation from the customer.The solution included supply and commissioning of ACS800,

ABB engineers energy efficient automation system in record timeACS550 & DCS600 drives. Additionally, an AC450 based automationsystem with Movicon based HMI for the new wire rod line, asreplacement for the existing automation system, was also delivered.

The new system has helped increase average production by abouttwenty five percent resulting in increased mill availability for rolling,hence effective furnace utilization. This has translated into significantenergy savings. In addition, the product quality has substantiallyimproved as the finishing mill loop has been very stable during rolling.

Sunflag was facing difficulties in stabilizing the automatic loop controlat finishing stands 15 to 18. ABB’s engineering team faced a bigchallenge in pin-pointing the critical problem areas and zeroing downon a solution that could be executed with minimal mill downtime.

After a detailed site study, ABB proposed a solution to replace theexisting automation system by means of a cost-effective and timesaving alternative, without replacing the analog drive system of themill. The solution was implemented with minimal production lossand the mill was first put into operation to achieve recordproduction in the first month itself!

ABB India continued its growth momentum by posting robustresults for the year 2007. ABB India's cumulative order intake of76682 MINR for the year 2007 touched a new high and grew 36per cent over the previous year. Revenues grew 38 per cent to60014 MINR and Net Profit rose 44 per cent to 4916 MINR. "Ourcore power and automation businesses continue to grow well aswe deliver value to our utility and industry customers throughinnovative technologies backed by our domain expertise and wellacknowledged project execution capabilities. This growth is furthersupported by our products and service focus as well as thesuccess of our new revenue streams. We continue to addcapacities and expand our range to meet growing marketdemand. At the same time remain clearly focused on the bottom

ABB India growth momentum continues in 2007

line through productivity gains, operational efficiencies andkeeping a close watch on our cost base," said Biplab Majumder,Managing Director, ABB India, announcing the results.

Figures in (MINR)


In a significant innovation for remote andrural applications, ABB India has implementeda solution which helps establish remotecommunication with Autoreclosers (AR).These autoreclosers form part of eight pilotfeeders that belong to the state utilityMESCOM's 100-feeder project in ruralKarnataka. After successful implementation,ABB's autoreclosers and sectos, sent outSMS messages indicating the powernetwork status from a remote location.

Autoreclosers are being adopted the worldover for improved automation in overheadpower distribution, thereby enhancing gridreliability. Coupled with PCDs (Power

Wireless communication solution helps support rural power network

ABB India transformers achieved anothermilestone on successful completion of theshort-circuit tests on a 260 MVA, 24/420/rt3kV single phase generator transformer and a200 MVA, 400/132/33 kV three phase autotransformer. Manufactured at ABB’s factoryin Vadodara, these transformers will besupplied to National Thermal PowerCorporation's (NTPC) for its 3 X 660 MWBarh Super Thermal Power project.

The transformers were shipped to the KEMAlaboratory in Netherlands, for the tests.

Successful short-circuit test of highest rated single phase generatortransformer at KEMA

Testing of the 260 MVA, 24/420 kV singlephase Generator Step Up transformer(GSU) was a challenge, stretching thecapacities of KEMA's four mammothshort-circuit generators to the maximum.ABB uses the proven TrafostaeTM

concept in all its large and medium powertransformer factories across the world fordesign and manufacturing. Followingcommon practices across the globe ABBensures highest standards in technologyand quality.

Richard Koevets, testing manager from KEMA wasrecently at ABB's Vadodara facility. Below areexcerpts of an interview with him:

� Please give us an insight into the latest trends intransformer testing, their governing standards andthe way they have influenced on-site performance.Today major manufacturers including ABB rightly observethat successful short-circuit testing, as per the IECstandards, is a key factor to ensure the quality and life oftransformers. The initial cost may seem high, but comparedto the cost of an outage in the grid, it's truly negligible. Asfar as on-site performance is concerned utilities have clearlystated that the quality of power transformers has improvedtremendously since short-circuit tests were beingconducted.

� How has your experience been with the quality ofABB's transformers from the Vadodara facility?I have been to ABB’s Vadodara facility thrice to witnessthe testing of power transformers. In each of the three visits

I was pleased to undersign the successful performance ofroutine testing of the transformers after short-circuit testingat KEMA in the Netherlands.

� Tell us your thoughts about the manufacturing andtesting facilities at ABB's Vadodara plantThe testing facilities at ABB’s Vadodara plant meet therequirements of international standards and are certainlyclose to the highest level I have seen during many of myinspection visits to our clients' factories. The engineersinvolved are highly competent and we have achievedmany goals together

� Please throw some light on how the transformerindustry and technologies will develop in the future?No doubt the future will remain focused on quality and furthermore, on the continuously increasing importance ofenvironmental, health and safety aspects. Today in the fieldof testing several functions can be monitored on-line throughinternet based technologies across countries and continentsmaking things much faster compared to the past.

Control Devices), autoreclosers and sectos,one can check and change all parametersmiles away from the site. This is good newsfor utilities catering to far flung and ruralareas, where sending engineers for repairsand maintenance is not just physicallychallenging but also an expensive proposition.

ABB's autoreclosers with powerful micro-processor based communicable relays haveproved to be a boon for utilities, enablingdirect access to feeders from personalcomputers. Considering that todayuninterrupted power supply is a vital need,these autoreclosers are being engineered toserve these needs, especially in remote areas.


ABB has been appointed as the power consultant for GIFT(Gujarat International Finance Tec-city). It's an ambitious projectwhich will be spread over 500 acres on the banks of theSabarmati River. With a planned investment of US$ 11 to 14billion by year 2012 the project aims to become one of thelargest and most modern International Finance hubs. GIFT, aSpecial Economic Zone (SEZ) for financial services is beingundertaken by Gujarat International Finance Tec-City CompanyLimited (GIFTCL), a joint venture by the Government of Gujaratand Infrastructure Leasing and Financial Services Ltd (IL&FS).

ABB will provide domain knowledge to conceptualize and design a1000 MW power transmission and distribution network to maximizepower reliability and quality while minimizing T&D losses. ABB'sscope includes pre-design studies, design conceptualizing, detailedengineering and design & commissioning support.

ABB bags power consulting order for India's first international finance hub

The project will make use of new technologies that are scalablefor future growth. The order has been placed on ABB byFairwood India, the Project Management Consultants for GIFT.

New logistics center to increase ABB's speed to market in Western IndiaIn a buoyant market and a geographical expanse spanning a countrythe size of India, 'speed' is clearly a key differentiator for anybusiness. Proximity to customers and speed of delivery provide animportant competitive edge, ABB in India has establishedwarehouses cum logistics centers for standard products, that actas holding points for products shipped from factories around thecountry. Says Biplab Majumder, Country Manager, ABB India,"ABB in India has around 750 channel partners and these centersare a great boon to reach them product supplies within hours oforder placing in many cases." The first two were set up in Bangaloreand Faridabad to cater to the Southern and Northern customers.The state-of-the-art Pune center will service the western market.The Pune warehouse is constructed with the latest technologyspecifications and conforms to all statutory safety norms andinternational standards. The structure of the logistics centre isresistant to damage, corrosion and natural calamities like fire,earthquakes, hurricanes etc.

ABB's recognition as a highly safety conscious company receiveda shot in the arm when it received the mandate for training the newbatch of engineers for Rural Electrification Corporation Limited(RECL). ABB’s outdoor and indoor safety and quality trainingschool in Jaipur was recently set up with the objective to increasesafety and quality awareness and eliminate accidents in rural andurban electrification project sites. The school imparts training toABB employees, employees of contractors and other relatedorganizations. ABB designed a special course pertaining toDistribution System Networks for the four-day training programimparted to 14 RECL field engineers, which included class roomand hands-on training with practical demonstrations. Participantswere exposed to stringent safety and quality standards includingearthing, pole fixing and best erection practices specifically tailormade to suit their requirements.

Safety training for REC engineers at new Jaipur facility


ABB will supply the robot based press automation line atAutomotive Stampings and Assemblies Limited's (ASAL)Pantnagar Plant in Uttarakhand. ABB's technology leadership indelivering profitable press automation coupled with superiorpresence and reach has been a key factor in this success.The press automation line will manufacture roof panels, side bodiesand side doors. The solution delivered has been designed withemphasis on productivity, profitability, speed and availability.The solution includes five IRB 6600 robots, one 6650 robot andpress tooling. It also includes de-stacking tables, gravity centeringtables, oiling solutions, safety fence and control systems. Thesolution is expected to be delivered in 20 weeks.

ABB wins order for robot-based press automation line at ASAL

ABB India's ongoing training initiatives received a boost when theTraining Centre at Vadodara achieved a milestone by surpassingover 10000 mandays of training in 2007. Established in 2003, the

Power Technologies Training Centre completes 10,000 man-daysof training

training centre at Vadodara has trained more than 5000 peopleincluding customers, ABB engineers and vendors. The trainingmodules, have helped customers catch up with innovation andmodernization by reviewing fundamental principles, sharpeningexisting skills and integrating advancements in technology basedhands-on experience.

The training center includes a demo room for indoor equipment,cut models and an outdoor switchyard with EHV/HV/MV CircuitBreakers, CT, CVTs, Power Transformer, Distribution TransformerCapacitor Bank, Surge Arrestor, Ring Main Units, OLTC,Disconnector, a SCADA system integrated with switchyard andRelay panels. Modules that are highly appreciated include hands-on training in installation and maintenance, condition monitoringfor switchyard equipment, distribution automation & SCADA, HTTransformer, Protection and control and Substation engineering.Some of the center's key customers include POWERGRID, ONGC,TATA, GETCO, TNEB, PPCL, NHPC, BPC, BHPC & other utilities.

ABB has won the order to supply robot-based automation forthe suspension shop at Fiat's Ranjangaon plant. The state-of -the-art facility at Ranjangaon will have an installed capacity toproduce 100,000 cars and 200,000 engines, besidesaggregates and components. The robot based automationsolution includes spot welding robots, a Flex arc welding cell aswell as upgradation of existing ABB robots. Arc welding of theparts is also a major activity in this shop. The parts to bemanufactured at this shop are rear axle, front cross memberand swing arm assemblies.

Fiat plans to double the production capacity for both car unitsand engines in the coming years with a planned investment of650 million Euros. The new plant will manufacture the Palio Stile,Grande Punto and Linea models in addition to Tata’s passengerand next generation cars. ABB's solution was required to achievethe goal of optimum productivity by combining effective

ABB wins robot-based automation order from Fiat India

operation with maximum efficiency. Modular standardized robotcells are an established way of providing an optimized solutionfor this kind of robotic arc welding operation in a cost effectivemanner. Flex arc modular standardized arc welding cells arehence a part of the offer as a total solution to Fiat's requirement.


ABB recently participated in ELECRAMA - the bi-annual eventorganized by India's leading electrical trade association, IEEMA(Indian Electrical & Electronics Manufacturers Association).ELECRAMA is ranked among Asia's largest electrical exhibitionplatforms. The theme of the event was : "The future of Power ishere" and ABB in India appropriately dove-tailed into this theme witha campaign to attract customers, that read "Be part of the future".

ABB occupied one of the largest stall spaces at the exhibition toshowcase some of its latest technologies for power and automationcustomers across the value chain. The overall theme of ABB'sdisplay was "Energy Efficiency". ABB displayed a wide spectrumof products, systems and services that improve energy efficiencyand productivity at every stage of the energy chain - from generationto end use including its latest 765 kV offering. The company alsolaunched some new products at the exhibition, including a first-of-its-kind 33 kV Compact Substation and EFF1 PRU range of newenergy efficient motors.

One of the highlights of the power offering included a 'real-time'demo of ABB's SCADA solution for Karnataka PowerTransmission Co. Ltd. the largest-of-its-kind in the country.Another unique demonstration was the 'active filter' applicationthat helps improve quality of power. The entire power

ABB @ ELECRAMA 2008

requirements of ABB’s booth were actually run through the filter tostabilize the power supply which was distributed in variable loads.

ABB's leading presence in automation solutions across theindustry spectrum and its unparalleled range of automationproducts were also on display at the event. A major crowd pullerincluded a live demo of the IRB 140 robot (picking and handingout leaflets), the EIB-based building management system and the800xA automation platform. ABB got an overwhelming responseat the exhibition and was commended for the wide range andscope of offering on display.

New 33 kV Compact Secondary Substation

ABB launched its pioneering 33 kV CSS, which houses aVacuum Circuit Breaker (VCB) as the main switching deviceon the HT side. It has been indigenously developed andtested as per IEC standards by ABB's Nashik facility. ABB's33 kV CSS facilitates supply of reliable power. It is verycompact and in many cases, can save up to 80% space. Thisis a fully factory-assembled substation, and is ready to installin distribution networks. What makes the product even more

fitting for a wide range of applications is the assurance ofutmost safety - with no live parts exposed, accompanied byan appealing polyurethane-painted exterior.

The 33 kV CSS also offers wind power producers acomprehensive power-distribution solution, facilitating cleanelectricity into the local grid. Since, compared to other non-conventional sources of energy, wind power has a relativelysmall ecological footprint, ABB's 33 kV CSS fully complimentsthe eco-friendly set-up by changing very little of the landscape.

ABB showcases complete offering for Metals business in DohaABB participated in the 8th International Arab Iron and SteelConference held recently at Doha, Qatar. The three-dayconference cum exhibition saw ABB’s Metals businessshowcase its latest range of automation and power solutionsfor the steel industry. The conference was held in thebackdrop of unprecedented growth in the steel sector in theregion. The Arab steel industry reached a new peak in 2007by achieving production exceeding 23 million tons of finishedproducts. Many new projects are likely to be added in thecoming years, thereby adding new capacities and high valueadded products.

The concurrently running conference was attended by theleading steel players of the region across long products, flatproducts, tubes and pipes ; steel traders, original equipmentmanufacturers, research and development establishments andtechnology suppliers. The exhibition was a resoundingsuccess and went a long way in establishing ABB's presencein the Metals space in the region.


ABB showcased its wide range of offeringfor operation and up-gradation of PowerStations at the operation and maintenance(O&M) exposition cum conferenceorganized by National Thermal PowerCorporation (NTPC) at Noida in theoutskirts of Delhi. It was an ideal platformfor demonstrating ABB's offerings foroperation, maintenance and refurbishmentof power plants. The displays includedsubstation automation system on the IEC61850 protocol, the recently developedSUE 3000 Fast Bus transfer scheme, MVRetrofit Module - NGEF MOCB with ABB's

ABB showcases offering for operation and upgradation of power stations

vacuum circuit breaker, power plantautomation solutions, SWAS (Steam and

Oil, Gas and Marine solutions on display at OCEANTEX 2008ABB recently participated in OCEANTEX-2008, an international exhibition cumconference held in Mumbai. ABBshowcased a range of its productsand services for both upstream anddownstream sectors, including oiland gas exploration & production,processing, refining and storagedevelopment. In the turbochargingspace, ABB showcased its turbo

ABB recently participated in a summiton 'Mining to Steel Making' jointlyorganized by Indian Chamber ofCommerce and Ministry of Steel in NewDelhi. The summit presented anoverview of the Indian steel & miningindustry, future outlook of raw materialfor steel plants, infrastructure andlogistics requirement, as well as futurechallenges and opportunities. It also

ABB at ‘Mining to Steel Making’ summit

charging TPL-61 cartridge, used toenhance specific power of a dieselengine utilising its exhaust gas energyefficiently, thereby multiplying the outputof power. Also displayed were a rangeof products for the maritime industryincluding reconditioned bearings forVTR-354, reconditioned lube oil pumpsfor VTR-564 and new compressor wheelfor VTR354-P11 and rotor of VT-250.

ABB Robots mesmerize crowds at the ROBO EXPO 2008Robotic solutions from ABB help industryaddress issues like productivity, quality andworker safety. CII (Confederation of IndianIndustry) - recently organized the 1st RoboExpo 2008 as part of the 9th Auto Expo2008 organized in New Delhi recently. Noless than four 'live' robots acrossapplications & solutions were on display atthe ABB pavilion. These included the Flexarc 250 R Cell - complete modular

manufacturing cell, Flex PLP (ProgrammableLean Positioner), IRB 52 painting robot and6600 robot with press automation tooling.ABB engineers also showcased thesimulation of robotic applications likemachine tending, arc welding andpalletizing etc., using the ROBOT STUDIOoffline programming software. UnionFinance Minister P Chidambaram, was oneof the prominent visitors to ABB’s stall.

focused on the changing dynamics ofthe steel industry, particularly volatilepricing and demand- supply issues witha short term and long term perspective.

Prominent speakers at the summit were:Ram Vilas Paswan, Union Minister ofSteel, M Sengupta, CMD, MSTC Ltd.,Partha S Bhattacharyya, CMD, CoalIndia, S K Roongta, Chairman, Steel

Water Analyzer System dry panel and wetpanel), magnetic flow meters, pressure andtemperature transmitters, controllerrecorders, continuous emission analyzersand turbo generator cooling hydrogenanalyzers.

Inaugurated by Union Power MinisterSushil Kumar Shinde, the internationalexhibition cum conference was attended byover 500 delegates including seniormanagement of NTPC and policy makerssuch as CEA (Central Electricity Authority)and CERC (Central Electricity RegulatoryCommission).

Authority of India and Dr. T SubbaramiReddy, Minister of State for Mines.


The high levels of fossil fuels we burn every day are contributingto climate change and polluting the air and surroundingenvironments. The use of more natural and renewable energysources is needed to take the burden off our current dependencyon fossil fuels. Utilities and consumers alike are becomingincreasingly aware of the need for, and benefits of, alternativemethods of generating electricity that will reduce emissions, cutcosts and improve reliability.

For India, over the last few decades, the demand for power andtransportation fuels has increased significantly, primarily due tohigh economic growth, rising urbanization and rapidindustrialization. This demand is expected to rise further goingahead. According to a Planning Commission report on theIntegrated Energy Policy, for India to maintain its GDP growth of 8per cent a year for the next 25 years, the country would berequired to increase its power generation capacity to 800,000 mwcompared with the current capacity of 160,000 mw (includingcaptive plants).

While this not only provides an opportunity, it also brings along abig challenge considering that the conventional sources of energysuch as coal and gas for power generation are limited, besides theconcerns over rising prices and environmental degradation causedby such inputs. Since about 65 per cent of India's powergeneration capacity is powered by coal, gas or oil, there arecertainly more challenges to overcome before India's dream of selfsufficiency in power can be achieved.

Alternative energy is understood as an energy source to replacefossil fuels, and is interchangeable with renewable energy, whicheffectively uses natural resources such as sunlight, wind, rain, tidesand geothermal heat that are naturally replenished. Renewableenergy technologies range from solar power, wind power, hydroelectricity, biomass and biofuels for transportation.

In India, the installed generation capacity for renewable energy hasincreased over ten-fold during the last decade to 9,220 mw or 7.3

Harnessing the power of natureper cent of the total installed capacity. India is estimated to havestrong potential in terms of generation of renewable energy, mainlysolar, biomass and wind power. As per projections of the Ministryof Non-Conventional Energy, of the 240,000 mw total powercapacity planned for 2012, 24,000 MW will come from renewablesources of energy.

India ranks in the top five in terms of wind and solar energypotential. Many opportunities become economically viable onlyafter accounting for government assistance in form of fiscalincentives and subsidies. They will help lower the impact of thehigh capital cost involved with most alternative energy projects.

Solar Power

With its wide experience in powerdistribution and D.C. applications, ABBserves solar power customers with specificproducts and knowledge around solarapplications. Our in-depth know-how,years of experience and thorough

understanding of both solar inverters and solar trackersapplications and solar power installations have made ABB aleading partner for the solar power industry.

Tidal Power

Many approaches to capturing the energyin tidal- and ocean waves are beingpursued around the world. ABB is globallycommitted to developing environmentallyfriendly energy solutions based on

renewable resources. ABB has been a partner in many wavepower projects globally and is heavily involved in developmentof technology to harness this energy on a large scale.

Biofuel

ABB provides a wide portfolio of automationand electrical products for biofuel processeseither directly to the end user, package unitsupplier or via an engineering company.From the small biodiesel plants to large

bioethanol production units, ABB application experts aresupporting the complete life cycle from design through supply,implementation and ongoing maintenance strategies.

Fuel Cells

ABB has developed partnerships with severalfuel cell makers, building on its extensiveexperience in power conversion to help makefuel cell technology more reliable and competitive.

ABB has also expanded its scope of product offerings to fuel cellmanufacturers, including controls, instruments and other electricalcomponents. ABB's inverters convert the DC current generatedby fuel cells into AC current. ABB's Power Conditioning Systemoffers customer-oriented design with compact size.

Among the different renewable energy sources, wind energy iscurrently making a significant contribution to the installed capacityof power generation, and is emerging as a competitive option.With its 20 years of experience, ABB serves wind powercustomers at every stage of the process. Our in-depth know-how,years of experience and thorough understanding of both windturbine applications and power systems have made ABB a leadingpartner for the wind power industry. Today, ABB is the biggestsupplier of electrical components, systems and services to thewind power industry.

BIG OPPORTUNITY

Source of energy Potential Existing capacity

Wind 45,000 7,660Small 15,000 1,850Hydroelectric 150,000 33,941Biomass 19,500 950Solar photovoltaic 50,000 30Waste-based power 70,000 34.95

Industry estimates in megawatts (MW)

ABB’s wind pConsulting

studies/ gridplanning

Engineering,ProcurementConstruction

Components for turbines

ABB wind power plantsolutions:

� System studies

� Substations

� Grid connections

� Static VarCompensation systems

� FACTS

� MicroSCADA

� Compact SecondarySubstations

� HVDC Light® foroffshore wind farms

� Service andmaintenance

ABB components forwind turbines:

� Generators

� Converters

� Transformers

� Switchgear

� Low voltage products

� Low voltage motors

� Cables

ConvertersSwitches and

Breakers

GeneratorsMotors & Drives

ABB helps harness

Generators,motors& drives

LV equipment Transformers

power offeringOperation &Maintenance

Grid connection

HVDC Lightand controlequipment

SubstationsCables

SVCStatic Var

Compensation

FACTS(AC grid)

HVDC Light(underground

or subseaconnections to

the grid)

Robotic paintsystems

Powerelectronics

(control “unstable”power flows)

CompactSecondary

Substations

Control ProductsMV SwitchgearTransformers

s the power of wind


Customer Interviews

Vestas is a leading producer ofhigh technology wind energysolutions across the globe. VestasWind Technology is among the keyplayers in the alternative energysegment in India. We caught upwith Ramesh Kymal, ManagingDirector, Vestas India, to knowmore about the company'soperations in India and the future ofwind power sector in India.

Could you briefly tell us about Vestas', and its marketpresence, in the wind energy segment?All over the world, people must prepare to use new forms ofenergy. The sharp rise in energy consumption calls for asustainable resource that does not create more greenhousegases, pollution or waste for future generations. Wind power is arenewable, predictable and clean source of energy. Capacity canbe built up quickly, offering the energy independence demandedby the world's largest and fastest-growing economies. This is whywe call wind power, modern energy.

Vestas core business comprises the development, manufacture,sale and maintenance of wind technology that uses the energy ofwind to generate electricity. Our expertise covers more than justwind turbines. We specialize in planning, installation, operation andmaintenance and our competence covers everything from siteselection to service and maintenance.

With a 23 per cent market share, Vestas is the world's leadingsupplier of modern energy solutions. We have installed more than35,000 wind turbines in 63 countries on five continents. We installan average of one wind turbine every four hours! In fact, our windturbines generate more than 60 million MWh of energy a year -enough electricity to supply millions of households.

Vestas India has world class manufacturing facilities in Chennaiand Puducherry. In India, Vestas offers 750 kW and 1650 kWturbines and will continue its focus on higher capacity turbines.

What are the opportunities and challenges in the windenergy sector in India and how is Vestas addressingthem?India is one of the world's most interesting markets when it comesto wind energy. The potential for wind energy in this vast country isenormous - and due to the pressing need for energy to sustain thecountry's high growth rate, the focus on wind potential is increasing.Moreover, India dependence on coal and oil is worrying. In addition,there is growing concern for the environment, so the need foralternative energy sources is becoming apparent.

India is now the 4th largest market in the world when it comes towind energy. But the challenge is that, different states have

different policies to promote wind power. What is now required isa National Renewable Energy law which will create a level playingfield for the renewable energy sector.

With a favorable policy regime, current demand for power in thecountry and the environment concerns, India has the potential tobecome a world leader in wind power.

What is the role of power and automationtechnologies in when it comes to wind power?With "Wind Mills" emerging as modern day power plants the levelof wind power penetration into the grid is increasing day by day,resulting in utility companies specifying grid codes. So we believethat the role of power and automation technologies in wind powerwill be as critical as in any other conventional power plants.

Please tell us about your experience of working withABB.Vestas India shares a good business association with ABB, andwe hope that ABB will extend its full co-operation in our futureinitiatives. We look forward to continuing the partnership.

Cutting-edge technologies toharness the power of wind

Installed Wind Power Capacity (MW)

Source - Global Wind Energy Council

Rank Nation 20071 Germany 22,2472 United States 16,8183 Spain 15,1454 India 8,0005 China 6,0506 Denmark (& Faeroe Islands) 3,1297 Italy 2,7268 France 2,4549 United Kingdom 2,38910 Portugal 2,15011 Canada 1,85612 Netherlands 1,74713 Japan 1,53814 Austria 98215 Greece 87116 Others 5602

World total (MW) 93,849


Aiming for sustainable,collaborative growth

Pioneer Wincon is one of the fastestgrowing windfarm developers in Asia.It is part of the Pioneer Asia Groupwhich has diverse interests in industrieslike paper, textiles, timber, finance andchemicals. Mr D V Giri, President andCEO, Pioneer Wincon Private Limitedis also the Chairman of Indian Wind TurbineManufacturers Association (IWTMA). Inthis interview he shares his views aboutthe opportunities and challenges inthe wind power sector in India.

Could you briefly tell us about the present scenario ofwind power generation in India?India's potential capacity for wind power is approximately 45,000mw, but it can be scaled up to 1,00,000 MW. We are ranked 4th inthe world in terms of installed capacity which currently stands at8,000 mw. India has state-of-the-art technology for wind powerincluding stall and pitch regulated, variable speed and variablepitch mechanism. The Ministry of New and Renewable Energy hasspecified 250 kW as the smallest size of installation.

So far, ten states have declared policies for wind energydevelopment. Tamil Nadu holds the first place in terms of installedcapacity followed by Maharashtra and Karnataka. At present there isno uniformity in the policy and tariff among these states. The IWTMAclosely interacts with policy makers in the Ministry, Center for WindEnergy Technology, electricity boards and regulatory commissions.

Please tell us about Pioneer Wincon (PW), its marketshare and operations in the wind energy sector?Pioneer Wincon is one of the first companies in the wind energysegment in India, having installed the first grid connected WindTurbine Generator in 1989. The company is part of the Pioneer AsiaGroup with over 19 years experience in the industry. We have aleading presence in Tamil Nadu, Andhra Pradesh, Karnataka,Madhya Pradesh and Maharashtra. The company has around 30%market share in India and is a strong player in the 250 kW segment.

What are the opportunities and challenges in the windenergy sector in India and how is PW addressing them?Rising costs of fossil fuels and the ever-increasing per capitapower requirement will push wind energy on the fast track. TheGovernment is also considering generation-linked incentives topromote faster development. This will attract foreign directinvestment (FDI) in large wind farm projects. While the 250 kWturbine will continue to be utilized, we have now seen theemergence of turbine size up to 1,650 kW in India

What are your growth plans and strategy going forward ?We plan to relaunch turbines with higher capacities by the end ofthis year. Pioneer Wincon strives to meet customer expectations

by providing them maintenance free solutions. Our mission is to protectthe interest of all our stakeholders, work with the industry and interactwith policy makers to create 5,000 MW plus capacity per annum.

Please tell us about your experience of working with ABB.Working with ABB gives a feeling of an international culture. ABBhas the complete range of electrical products and solutions for thewind power segment. So far we have procured wind generatorsand LV switchgear from ABB and are very satisfied with thequality. We are working closely with ABB to offer customizedsolutions to our customers. There is a great scope to furtherstrengthen our relationship.

State-wise Wind Power Installed Capacity In India

State Gross Total TechnicalPotential Capacity Potential(MW) (MW) till (MW)

31.12.07

Andhra Pradesh 8275 122.4 1750

Gujarat 9675 874.8 1780

Karnataka 6620 917.2 1120

Kerala 875 2.00 605

Madhya Pradesh 5500 70.3 825

Maharashtra 3650 1646.3 3020

Rajasthan 5400 495.7 895

Tamil Nadu 3050 3711.5 1750

West Bengal 450 1.10 450

Others 2990 3.2 -

Total(All India) 45195 7844.5 12875

Source: Ministry of New and Renewable Energy.


Technology Digest

More muscle,less wasteABB’s workout program realizes sustainable energysavings and reduces costs in process plantsJim McCabe

Maintaining the good health of a process plant is prime tosecuring its long-term profitability. With concerns over energyprices on the rise, operators are finding that it pays to invest inways of slimming their consumption. But what is the best wayto optimize efficiency?

Wasted energy can take many forms. These can include suchwidely different causes as inadequate scheduling and planning,suboptimal setpoints in control loops or inappropriate or incorrectlyused equipment. It is often accentuated by leaks or theinadequate lagging of boilers and pipes.

ABB’s Energy Improvement Program is designed to identify anddeliver energy savings in process plants, achieving sustainablesavings of up to 20 percent.

Process Innovations


In the face of fluctuating fuel prices andtightening legislation on emissions,reducing energy consumption andgreenhouse gas emissions are two of thebiggest concerns affecting companies inthe process industry today.

Energy and utility systems provide manifoldopportunities for savings – especially whenit is the entire system rather than just someindividual subsystems that are available forscrutiny. Considerable potential for savingsis possible by reducing the consumption ofprocess utilities (such as steam, chilledwater and compressed air), minimizingdistribution losses and improvinggeneration efficiency. In fact, a successfulimplementation of these measures canyield up to 20 percent reduction in energyconsumption.

But what is a successful implementation?The dangling carrot of potential benefits isonly part of the equation. An informeddecision on optimization must weigh suchgains against the costs and possible risks.

Enter ABBEnergy is a fundamental ingredient inalmost any manufacturing process. In aprocess plant, the principal means ofdelivering energy are electricity and theprocess utilities mentioned above. Asenergy represents an increasing proportionof the operating costs of many companies,the focus of optimization is increasinglyshifting towards these utilities and where

Process Innovations

they are consumed in the productionprocess.

Drawing on years of experience in processoperations, ABB Engineering Servicessupports plant operators in their efforts byidentifying improvement opportunities andimplementing a program to make surethese benefits are delivered – and this asquickly as possible. More than 50companies around the world have alreadybenefited from this support. In such aprogram, ABB’s experienced energy andutilities consultants apply a structuredprocess to assess the overall potential ofenergy savings at a manufacturing sitebefore developing and implementingenergy conservation projects

1 . As well as the huge energy savingsthat were attained in these projects, manycompanies have through this processacquired the skills and motivationnecessary to develop their own sustainableimprovements in energy efficiency.

The dangling carrot ofpotential benefits isonly part of theequation. An informeddecision on optimizationmust weigh such gainsagainst the costs andpossible risks.

Identifying opportunitiesAn efficiency improvement process beginswith an overview of the site’s energybalance and an assessment of the savingspotential. All aspects of the energy chainare considered; from utility generationthrough distribution to consumption.Improvements can range from low- or no-cost “quick wins” to the implementation ofenergy efficient technologies. Quick winsmay involve simple housekeeping activitiessuch as maintaining insulation and repairingleaks or may require more fundamentalchallenges to “the way we’ve always doneit”; e.g., turning off main plant items insteadof keeping them running, or challenging theset points of process control loops in utilitydistribution temperatures, pressures orflowrates.

When it comes to efficiency-boostingtechnologies, numerous options areavailable: These range from variable speeddrives to advanced process control. Thelarger challenge lies in identifying which ofthese are suitable for the situation inquestion – and this requires a carefulanalysis of benefits and risks. Benefits areusually related to the delivered energysavings but may include other non-energyrelated advantages such as improvedreliability or increased capacity.

ABB frequently receives praise from itscustomers for the pragmatic nature of itsanalyses. In the words of the director of a

1 The steps of an energy efficiency improvement program 2 A preliminary audit carried out for a European chemicalsmanufacturer predicted savings equivalent to ten percent of thetotal site utility costs


Process Innovations

UK ingredients company, “We’ve had noend to audits that either tell us to turn thelights off or invest millions of pounds. WhatI like about [ABB’s] approach is that [they]concentrate on the practical.”

The practical approachA preliminary audit carried out for aEuropean chemicals manufacturer 2

predicted savings equivalent to ten percentof the total site utility costs. The followingsection investigates in more detail how thisfigure was achieved.

To start, numerous opportunities for utilitycost reduction were identified during areview of the site’s energy consumption. Abenefit and risk analysis narrowed thesedown to four priority areas: tariffmanagement, steam distribution, heatrecovery and the application of variablespeed drives.

Tariff managementABB engineers observed that during thewinter months, the electricity supply tariffstructure for the site included a very highrate for a period of three hours every day.The total cost of electricity consumedduring these three hours was equivalent tothat consumed during the rest of the day.Significant savings potential at no capitalcost were identified by schedulingproduction to minimize the operation ofprocesses with high electrical demandduring this period.

1 The steps of an energy efficiencyimprovement program

2 A preliminary audit carried out for a European chemicals manufacturer predictedsavings equivalent to ten percent of the total site utility costs

A further interesting savings potential wasobtained in the area of two 160 kW pumpsfor cooling water. These are backed up bydiesel-driven pumps. The spare pumpswere tested for two hours every week andthis test occurred outside the high-costelectricity period. It was shown thatrescheduling the test to coincide with thisperiod had the potential to save £3,000 perannum. Increasing the operating hours ofthe diesel pumps to cover the high-rateperiod five days a week could deliverannual savings of £14,000.

Steam distributionSteam leakage was reduced by improvedmaintenance of steam traps. Overall steamconsumption was furthermore reducedthrough enhanced heat recovery. Heatexchangers using the hot effluent from asteam stripping column to preheat the feedto the column were found to be undersizedwith the result that not all of the availableheat was being recovered.

A preliminary auditcarried out for a Europeanchemicals manufacturerpredicted savingsequivalent to ten percentof the total site utility costs.

Variable speed drivesEngineers found that slurry pumps and air

fans around the drying plant were oversized:In many cases they were operating at lessthan half their nominal load. Such situationsare an ideal application area for variablespeed drives. These can reduce the energyconsumed by the pump and fan motors byas much as 60 percent)1.

A successful projectIn another example, a specialized chemicalmanufacturer 3 required reliable low-temperature refrigeration capacity for themanufacturing of several key products. Asthe cooling capacity of the installedrefrigeration system deteriorated,production volumes were limited andenergy efficiency was reduced because itwas necessary to run two compressorsinstead of one.

The original installation comprised tworeciprocating compressors (one operating,one standby) with R22 as the primaryrefrigerant, an oil separator, a throttle valveand evaporator with an oil rectificationsystem, and an additional oil separator.The system was designed to operate attemperatures down to – 48°C.

ABB carried out a detailed review of theprocess and mechanical performanceissues. Following plant trials and dataanalysis, the problems were traced tomechanical faults and heat exchangerfouling. Cleaning these exchangersimmediately increased plant capacity. ABBalso specified mechanical modifications for


Process Innovations

> Source: ABB Review

phased implementation in order to preventfuture fouling. In the final phase of theimprovement program, an up-rated heatexchanger was installed to increase thecapacity of the refrigeration system.

The improvements to the refrigerationcapacity have allowed shorter batch cycletimes and increased production rates andreaction yields. Refrigeration systemreliability has also improved and the use ofa single compressor has delivered energysavings to the tune of £48,000 per annum.

Targets and improvementsAs with any improvement program, it isimportant to be able to set performancetargets and verify progress against thosetargets. As the program is developed, thescope, budget, timescale and expectedreturns for each energy conservationproject are agreed upon with the client anda means of performance verification is putin place. When possible, an energymanagement system is installed includingmetering, data collection and analysis.

Setting the right improvement targets is a keyelement of most energy efficiency programs.If goals are unachievable, the motivation forimprovement is quickly lost. On the otherhand, unambitious targets compromise costand emissions reduction. The problem isparticularly acute for operators of plants inwhich utility demands are strongly time-variant; for example, batch production of finechemicals or pharmaceuticals. In suchfacilities, the load profile of the utilityinfrastructure will vary from hour to hour andfrom day to day, depending on the mix ofproducts and the specific cycle time, and theutility requirements of each batch. There is nostraightforward answer to the question “howmuch utility?” in multi-product plants. Thismakes setting effective targets a toughchallenge.

Targets are often based on historicalenergy and utility consumption, anapproach referred to as Monitoring andTargeting (M&T). One weakness of thisapproach is that it is highly dependentupon the quality of the input data, and inparticular the conditions when the historical

data was collected. A steam trap may havebeen passing or there may have been asignificant leak from a compressed air lineduring the data collection period. Becausethese inefficiencies are not apparent fromthe data, this inefficient performancebecomes the baseline for futurecomparison. In addition, M&T does nottake the capacity of the current utilityinfrastructure into account and cannotidentify bottlenecks in the utility distributionnetwork.

Minimum Practical Energy is a robustmethod used by ABB to determinebenchmarks for energy and utilityconsumption and to set improvementtargets based both on sound theory andreal production schedules. Areas whereactual energy use is significantly differentfrom the minimum practical requirement –eg, where a process is consuming moresteam than expected – are identifiedquickly. This allows improvement targets tobe pinpointed and provides a basis fortracking performance against the target.The demand profile for a particularproduction slate is compared to thecapacity of the utilities infrastructure,highlighting bottlenecks and allowing theutility plant to be operated for maximumefficiency. Careful scheduling can reducepeaks in utility demand and eliminate theneed for capital expenditure.

Setting the rightimprovement targets isa key element of mostenergy efficiencyprograms.

ABB has used this concept to identifyannual savings of around £ 100,000 for theoperator of an active pharmaceuticalingredient (API) plant. A simulation model ofthe utility infrastructure calculates theminimum practical energy requirement.Mass flows and pressure drops arerigorously modeled throughout the sitedistribution networks for each fluid utility (eg,steam, compressed gases and water). Thedynamic utility system model predicts flows,

pressures and velocities based on the time-dependent demand profile 4 arising from thedaily activities in each unit. Production andnon-production areas such as reservoirs,effluent plants and electricity for offices andcanteens are included in the analysis.

The utility demand can be entered manuallyfor each unit operation – heating or cooling,mixing or adding reactant – or calculatedfrom the sequenced activities in the batchrecipe. Individual batches can be combinedto simulate a complete productionschedule, and the demand profilecalculated over a time period lasting fromone day to five years. Climatic data are alsoincorporated to account for the demandfrom space heating or air conditioning.

This model of expected utility demand iscompared with the known capacity of theutility systems, facilitating the identification ofinstantaneous or sustained capacityconstraints. Process control schemes forthe utility systems can be incorporated,allowing different utility sources to bebrought online to meet demand fluctuation.The simulation allows the operator to predictthe level of utility required to meet theproduction schedule – for instance, howmany boilers need to be fired at any onetime. Future production schedules can beoptimized to minimize excessive fluctuationin utility loads and to prevent them fromcreating peak demands that exceed utilitysystem capacity. The model also allows theuser to identify areas where the actualenergy and utility consumption exceeds theminimum practical energy value and henceidentify opportunities and targets for futureenergy conservation efforts.

The ABB Energy Improvement Program is astructured process with well developedtools that identify and deliver energy savingsto operators of process plants while theyconcentrate on core activities. Participatingcompanies can realize savings of up to 20percent of energy costs and develop theirown capability to make sustainableimprovements in energy efficiency.


Tech Bytes

ABB's intelligent building installation system, ABB i-bus® EIB/KNX, is equipping partially and totally paralyzedpatients with the necessary tools to perform the essential tasks of daily life. Patients with severe spinal cordinjuries at the spinal unit of Niguarda Hospital in Milan, Italy, are preparing for life outside the hospital with thehelp of ABB's i-bus EIB/KNX intelligent installation system. The patients suffer from either partial or totalparalysis of the lower body or of all four limbs. To help them through the difficult process of readjusting todaily life, the hospital has equipped and furnished two small apartments at the clinic where the patients canlearn to be as independent as possible when they return to their homes. ABB i-bus is ideally suited for thispurpose. It enables the patients to control and manage their home environment through a wide variety ofsophisticated interfaces that can be personalized to meet the needs of each patient's functional disabilities.

ABB building systems help paralytic patients return to daily life

Northeast Foods, one of the largest suppliers of buns to the fast-food chain McDonald's in theUnited States, has installed ABB robots to take on the task of final inspection of buns beforedispatch. Most operations in the plant were fully automated; the final inspection and lanebalancing relied on a conveyor and two employees. While the method provided accuracy andconsistency, the company recognized that with the repetitiveness of the job and the challengesof inspecting and balancing 5,000 dozen buns an hour, it would be difficult to find and retainqualified employees. With the installation of a high-speed robot and vision systems, Northeast

Foods' plant automated the final inspection and lane balancing operations of its six lane, 5,000-dozen-per-hour hamburger bunproduction line. Northeast Foods' automation solution uses an ABB IRB 340 FlexPicker and two vision systems. With the newsystem, final inspection and lane balancing are done with 100 percent accuracy on a conveyor moving at 120 feet-per-minute.

ABB robots pick the best of the buns

Ilchester Cheese Ltd, the UK's biggest producer of speciality cheeses, wanted to keep up with itsglobal competition, improve labour efficiency and increase product yield. The company installed twoABB IRB 340 Flexpicker robots, capable of handling 150 picks per minute, ensuring cheese blocks aremoved quickly and precisely, one at a time, from one location to another. Almost two years after addingthe ABB robotic cells, Iichester Cheese continues to maintain improved labour and material savings.Since the installation, product consistency and levels of productivity have also improved atthe factory.

ABB robots reduce labour turnover at UK cheese factory

ABB's palm-sized FlashDrop technology can now be used to configure its ACS550 general purposedrives in the R1-R6 frame sizes. The proprietary FlashDrop provides fast and easy parameterselection and setting. It can copy parameters/configurations between two identical drives, orbetween a PC and a drive, and hide parameters-making it ideal for high-volume customization aswell as repeat programming of multiple drives or machines. Via FlashDrop, drives can be configuredwithout a power connection. It also does not need to be unpacked, or connected to the mains.

Speed, ease and power in a new palm-sized technology

Variable speed drives from ABB are increasing efficiency at the BirminghamHippodrome (Stadium for horse shows), slashing the energy consumed by motors forHeating and Ventilation (HVAC) duties by more than 25 per cent. The 29 ABB HVACdrives range from 2.2kW to 30kW and control motors on the pumps that move hotand chilled water around the building. As a result the motors have been usingbetween 25 and 30% less electricity since the drives were installed, while the cost ofrunning the fans that keep air flowing through the ventilation system has been cut bybetween 28 and 30%.

Hippodrome cuts 25 per cent energy cost with ABB drives


Channel Line

Advanced Power Systems, Mumbai

Based in Mumbai, Advanced PowerSystems is one of ABB's biggestchannel partners in the region. At 36,its CEO - Ketan Doshi is the face ofcontemporary India- dynamic andconfident, with an entrepreneurialspirit that has seen APS beingrecognized last year among ABBIndia’s fastest growing channelpartners.

APS began business in 1995,primarily focused on plastic industryapplications such as injectionmoulding, etc. Since then it hasseen remarkable growth. As Doshisays, "the growth has beenmatched by a parallel strengtheningof our organizational capabilities".APS primarily deals in drives. As apart of the Drives Alliance Program,it also provides third-levelcertification. Over the years it hasdeveloped a stellar portfolio ofcustomers including RelianceIndustries, PSL Ltd, Jain IrrigationSystems Ltd., and TimeTechnoplast Limited.

Doshi says "we have always had a greatworking relationship with the ABB team. Itis a relationship that has been built on trustand a high level of transparency in business.I believe, that we have responded to thetrust that ABB has placed in us bydelivering results on a sustained basis."

Commenting on ABBs strengths, Doshiidentifies ABB's brand image as a strong

Venture Control Systems (VCS) is oneof ABB's major channel partners inthe northern region. Munish Sharma,an alumnus of IIT Kharagpur, started

the business in partnership with twofriends in the year 2001. In less than adecade, the firm has received severalawards and accolades for its contributionto the growth of the business.

VCS is ABB's channel partner for LVSwitchgear, PLCs, drives, motors, loadcells and high current rectifiers. VCS dealsexclusively in ABB products "we are bigABB fans," says Munish. "We areextremely happy to work with ABB for thewide range of quality products that theyoffer. The management is verycooperative," he adds.

According to him, ABB's products andsolutions are very well accepted in themarket, which has helped VCS build a

reputable clientele including BhushanSteel, Essar, Ispat Group, Jindal,Magadh Precision, Sandvick, RubyMecon and Murli Group.

"The most memorable moment for ourcompany was when ABB helped us getthe orders from Murli Agro for a 250tonnes per day paper machine andfrom Ispat for a continuous galvanizingline," says Munish who has plans tomake VCS a Rs 25 crore enterprise by2009. With plans that include buildingtheir own factory, strengthen theirsecond line of management, develop astrong internet based sales model,there is little doubt that the firm isdestined for greater things.

Venture Control Systems, Noida

point. He is all praise for ABB's e-business initiatives. He says "Theportal is fantastic and has made theway we do business simple". Herecounts the invitation to dinner withABB's Board of Directors and India’sleading industry captains as being oneof his most memorable experiences.


Living our commitment to Sustainability

Journey through the universe

One of ABB India's key sustainability pillarsis to facilitate primary education forunderprivileged children. As part of thecompany's approach to support the overalllearning process of young minds in addition

to providinginfrastructure needs,the company is alsodeepening itsengagement with theschools. In keepingwith this initiative, theBangaloreSustainability teamrecently organised

an educational trip for the 7th gradestudents of NGH and RGN schools, bothof which are located near ABB's factorypremises on the outskirts of the city.

A group of 270 children accompanied byteachers were taken on an excursion which

included a visit to the Jawaharlal NehruPlanetarium in the city centre. The childrensat in the sky theatre where they embarkedon an exciting journey of the solar systemincluding a detailed description of planets,constellations and the sun! They weremesmerized, not just to see the show butat the experience of learning beyond theirwalls of the classroom. They also had anopportunity to have a picnic in the adjoiningScience Park. When asked about theirexperience, one of the students, Ashwinisaid, "Until now we have only read andseen pictures in our text books, but today itseems like we have gone on a journey to afar away land!".

Shaping little dreams in BangaloreOne of ABB India's earliest initiatives and most importantsustainability pillars is education. As part of the initiative, thecompany supports primary schools for underprivileged children. Inline with this approach, ABB recently took into its fold the Rajiv GandhiNagar Government School in Bangalore, close to the company'smanufacturing facility in Peenya. The newly renovated school wasinaugurated by Biplab Majumder, Country Manager, ABB India.

As part of its phase 1 engagement with the school, ABB hashelped renovate existing classrooms, build five new classrooms,set up washrooms and provided vital drinking water. The 600children, from grades 1 to 7, studying at the school also receive ahot mid-day meal thanks to generous contributions from ABBIndia's employees who were quick to offer their support when thesustainability team called for action.


Walking the green talkABB's commitment to the environmentextends well beyond its own precincts. Inaddition to several greening projects atits own locations such as green cover

maintenance, rain water harvesting,vermiculture etc. ABB in India alsosupports greening initiatives in its majorcities of operation. So it is notuncommon to see signs like 'GreenVadodara - ABB' or 'Green Bangalore -ABB' at prominent traffic islands andhighways across these cities. The MinskSquare traffic island at Bangalore is onesuch island maintained by ABB, adoptedby the company in 2001. It is prominentlylocated in the heart of the city at animportant traffic junction. It also has a'time temperature' clock that attractsregular attention. At a felicitation

ceremony held on 26th January, (India'sRepublic Day), this island was adjudgedas a winner in the 'medium size garden'category, by the Mysore HorticulturalSociety, a government body responsiblefor greening programmes in the city.


www.abb.co.in/contact

Harmeet S Bawa, Head, GF-Communications, ABB India & SAS Region

Depletion of fossil fuel reserves, rising costs and climate concern have certainly brought renewables onto our mainstreamagenda. As you can see from this issue of CONTACT, ABB is very much aligned to this need and our technologies areaddressing many of these issues. Energy efficiency and savings of course remain as low hanging fruits and as we term itthe 'most realistic and greenest alternative fuel' option. Happy reading!

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