The new central hall at Liszt Ferenc Airport, named "Sky Court", was inaugurated recently. This representative building, home to several exclusive retailers, is wedged between the two existing wings of Terminal 2. Nothing demonstrates better the size and importance of this investment than the fact that the new installation allows the passenger volume of the airport to nearly double.

The key elements of the technical servicing system have been installed at the basement level of this multi-storey building. Our company designed and manufactured the 0.4 kV switchgears. Following installation of the switchboards, busbar systems and cabling, we performed procedures for testing and putting into service the system, working in conjunction with other companies involved. For understandable reasons, all on-site work was subject to ensuring the uninterrupted operation of Terminals A and B.

The switchgears and distribution boards presented (briefly) below are allocated to Terminals A and B, but supply also the Sky Court Building.

10 kV mains power is supplied by the metalclad sub-distribution boards of the Terminals from the internal, looped distribution network. The distribution board of Terminal A (ZS1 model - 8 cells, ABB) was installed in the current phase of development, while the existing distribution board of Terminal B (ZS8, ABB) was "only" expanded and supplemented.

The 0.4 kV mains network of the two terminals have been constructed separate from each other, but using essentially the same layout, which can be described by the vertically dependent structure of distribution boards.

• The 0.4 kV mains distribution units of both Terminals A and B are each supplied by 3 transformers with a power rating of 2.0 MVA. The busbars are rated to 5000 A, and consist of segments A, B and, C, with two longitudinal clutch sections between each busbar segment.
• The distribution units that can be supplied from a diesel generator in case of a loss of mains power, and whose nominal current rating is 2500 A provide power to key consumers, who in addition to mains power also require a diesel source of power for their operations. The distribution unit that can be supplied from a diesel generator in case of a loss of mains power can be supplied from any busbar segment of the given mains distribution unit.
• Consumers with safety concerns are supplied by two uninterruptible power supply distribution units with nominal current ratings of 2000 A. Shuttered supply sources have been installed from the uninterruptible busbar of the distribution board marked GEN.B, and from the distribution board that can be supplied from a diesel generator in case of a loss of mains power.

The distribution board marked GEN.B, with a nominal current rating of 4000A operates with a split busbar, for which mains power is provided by the distribution boards that can be supplied from a diesel generator in case of a loss of mains power. In case of a loss of mains power, a rapid start-up (8 sec) Caterpillar brand diesel generator group with a power rating of 2500 kVA steps in. Another, so-called uninterruptible busbar segment of the distribution unit marked GEN.B is supplied by an Active Power dynamic energy storing and transforming unit, with a power rating of 4x250 kVA, and a nominal bridging time of 12 seconds. In the event of a malfunction of the uninterruptible power supply, the busbar joiner circuit breaker acts as a virtual by-pass circuit breaker. Naturally, the UPS is also equipped with an internal by-pass.

The total volume of the instruments briefly presented amounts to 105 switching sections.
The high degree of safety of the planned energy supply infrastructure is completed by the application of the ARCON® arc fault protection system. This modern means of advanced operational safety covers all MODAN sections. As it is known, the essence of arc fault protection lies in the extremely rapid (2…5 msec) operation of the system. During this incredibly brief period, it is possible to stop the destructive effect of an arc fault from reaching its full extent, therefore the event does not jeopardise the safety of the operator, and following the end of the fault event the device can be switched back on within a short time, and will be able to continue performing its function.

The power supply of and internal connections between key devices required a system-level shuttering of the distribution boards concerned that does not depend on their supply direction and operational mode. For this task, we projected a compact PLC, incorporated into a network that is independent of the SCADA functions. (We must note that the automated switching functions in the event of a malfunction, the SCADA functions, etc. of the installation were solved with the use the SIEMENS-SAT system, generally used for operations at BA.)

The new office complex of MVM, with a utilisable floor area of nearly 29.000 m2 was built on the Római quay section of Szentendrei Road. Mavir Zrt., the Hungarian Transmission System Operator has also relocated from its former headquarters in the Castle to a wing of this building. For the relocation of MAVIR, in addition to ensuring the general office environment, a highly specialised infrastructure had to be developed, which was realised as result of a so-called technological location project involving many participants. It was of fundamental importance to find a solution that can provide the most reliable electrical energy supply possible for the telecommunications and informatics systems that service the system control activities and for several workplaces that provide special controlling functions. In the following, we shall briefly present the technological electrical energy supply solution implemented for MAVIR.

The system of requirements defined by the Client was essentially identical to the highest level of requirements (the so-called Tier IV) of the global standard TIA 942 for the infrastructure of computing centres and information technology establishments. With regard to system elements and the network, this tier of requirements demands full redundancy, which in turn requires a high level of error tolerance. Error tolerance means that no malfunction or other unforeseen event may lead to a system shutdown. This ability, naturally, also implies that resolving the problem, or, in a broader context, performing repair and maintenance activities should be possible alongside the continuous operation of the system.
VÁV UNION was responsible for designing, manufacturing and implementing of the system elements of this uninterruptable power supply system.

MVM Co. chose EGI Co. as the main contractor of the service buildings. VÁV UNION Ltd. worked as EGI Co.’s subcontractor on the implementation of electric works. When accomplishing the task, VÁV UNION Ltd. did its best to consider the investor’s ideas to the greatest possible degree.
The service buildings can be divided into three main systems: fuel supplier-, sprinkler and water treatment system. The main distribution boards of each individual system were placed in the 0.4kV switching room. The MODAN 6000 switchgears’ secondary assembly and installation were carried out by VÁV UNION Ltd.
The distribution boards bear the following general technical parameters:
- the incoming and outgoing feeders are modular, fully withdrawable units
- all the equipment is designed so that drawers of the same type and loading capability are interchangeable.
- the racks can be placed against a wall, allowing access to the cable connections from the front.
For connecting cables and local operation, Rittal boxes were attached to the electric motors. The protection of the boxes, adjusted to the environmental circumstances, was IP31 or IP55.
We were able to meet all the client’s needs and expectations for the implementation.

In 2003, to prove its environmentally-centred thinking, MOL Co. decided to install a 10kW-capacity solar power plant on the site of its filling station. It is characteristic of the development of renewed energies in Hungary, that in the year of installation it was the country’s largest such energy-producing unit, capable of feeding back into the utility’s network.
MOL Ltd. entrusted Dunasolar Ltd., a company specialised in the production of solar-cells, with the execution. However, because Dunasolar does not include implementation as part of the services they offer, the preparation of the authorisation plans and the construction of the entire project was entrusted to VÁV UNION Ltd.
The scheme was completed with so-called “combisol” solar cells, which, besides producing electric power, are also capable of providing, when the sun is shining, the hot-water used in the petrol station.

Work carried out during construction:

1. Modification of the filling stations 0.4kV main distributor
2. Preparation of the solar-cells’ iron framework
3. Installation of 252 solar-cells with the necessary cabling
4. Installation of 10 “combisol” solar-cells with the necessary cabling
5. Engineering work
6. Country planning, landscaping
7. Construction of visitor centre

The project was formally handed over, on time, in the presence of the Hungarian Environment Minister and the Managing Director of MOL Ltd.

VAV UNION Ltd. won the contract to be the main contractor for the modernisation of the Petőházi Sugar Factory electric energy system, and carried out the following work:

20kV: Modification of the existing switchboards with a change of protective equipment, renovation of control system and cable transfer
6kV: Extension of existing NT12-200 switchboard with 5 panels and cable transfer
Refinery no. 2’s transformer station:
Installation of:
2MVA 6.3/0.4kV transformer
LD 0,4kV busbar trunking system between the transformer and the 0.4kV main distributor
Manufacture and installation of MODAN 0,4kV withdrawable main distributor
Cabling work
“Central” 0.4kV switchboard reconstruction work:
Installation of
2MVA 6.3/0.4kV transformer
LD 0,4kV busbar trunking system between the transformer and the 0.4kV main distributor and between the switchboards which are aligned in several rows
Manufacture and installation of MODAN 0,4kV withdrawable distributors
Reorganisation, cable transfer and ending
Installation of process control system

We had to carry out the modernisation in under three months since all the technology had to be completely ready for the start of the sugar industry’s peak season. The installed systems have been operating without fault since the handover.

The behemoth of the Hungarian chemical industry is the Tisza Vegyi Kombinát Co. Owing to the chemical industry’s large energy and water requirements it is one of the country’s largest consumers of hot and saltless water.
Due to TVK Power Station Ltd, as a new consumer, and the development of the Tisza Vegyi Kombinát Co., the demand for desalinated water significantly increased. With this increase in demand and as a result of stringent environmental regulations the existing TKV Co. water treatment plant was not able to continue operating with its outdated technology. Because of the qualitative changes mentioned above, TVK Rt. decided to outsource the production of desalinated water and asked Sinergy Ltd. to satisfy the TVK Co. and TVK Power Ltd. long-term desalinated water needs with the implementation of a new water treatment plant.
The main contractor, GEA-EGI Co., entrusted VÁV UNION with the installation of the electric energy supply.

Work done during implementation:

1. Cables connection in the existing 6kV distribution board
2. Construction of transformer cabins, installation of disconnectors, transformers and protective equipment, primary bars.
3. Installation of LD 0.4kV busbar trunking system from the transformer secondary terminals to the main distributor incoming feeders.
4. Installation of MODAN 0,4kV main distributor equipped with PLC-controlled automatic change-over switch between the feeders and coupling
5. Installation of frequency converters and soft starters,
6. Manufacture and installation of local operation boxes,
7. Cabling in galvanized NIEDAX-produced cable channels

The system installed by VAV UNION Ltd. was handed over in the summer of 2003, since when it has been operating faultlessly.

The production of essential basic materials for the manufacture of TVK end products takes place in different plants. The liquid materials are transported in pipes between the plants. During wintry periods the liquids circulating must not freeze or congeal, and to meet the technological requirements of certain products, the temperature of materials from the production plants must also not dip below a certain level during the possibly several kilometre delivery to the end user.

TVK Automatika Ltd., one of the main contractors of the recently-built Olefin-2 and Polietilen-4 plants, entrusted VÁV UNION with the installation of the heating cable system.

Work done during implementation:

1. Installation of feeding points in existing 0,4kV main distributors with four-pole hand-operated circuit breakers and metering system.
2. Manufacturing and installation of electric heating distributors in RITTAL panels.
3. Relocation of the existing maintenance distributors and integration into feeder network
4. Laying of Raychem heating cables with the necessary sensors and connection boxes
5. Installation of Tyco-Raychem Moni Trace data collection and control systems. Data is also transferred from the MONI 200N control unit via serial ports to the TVK Co. advanced supervisory SCADA system.
6. Construction of cable track, cabling in suitable cable channels and in certain sections is buried.

The handover of the VAV UNION-installed system took place at the beginning of 2003, since when it has been functioning smoothly without fault.

The entire electric planning and implementation of the SOTAV gas-engine power plant, twice the size of GYORHO, was carried out by our company. The main contractor was KIPCALOR. The work was complemented with the complete 120kV side reconstruction of the 120/35/20/10kV transformer station (equipment bases with frames, new circuit breakers, combined current and voltage transformers, installation of surge arrestors, complete replacement of protection system, metering system, process control system, telecommunications, construction of URIK system) on a live system.

At SOTAV, 6 10kV each 1,2MW JENBACHER-produced gas-powered units provide the electric and heating energy.
The transfer of energy occurs via a 120/10kV 16MVA transformer and 120 kV cabling into the EDASZ Sopron East Transformer Station. Procuring these cables and relocating them, as well as getting the plans’ approval, caused nearly four months’ delay to the commencement of implementation, which had been scheduled for May 01, 2003.. Because of this delay, it was not possible to finish the implementation before the onset of cold weather - bearing in mind the construction work had only started in August- and thus only 2 of the 3 planned incoming aerial-line branches had been finished. The third aerial-line branch was finally connected in 2004.

Apart from the feeder cable problems, the installation of the 6 machine units was successfully finished, after a 72-hour test run, on March 12, 2004, without any problem.

In April 2002, following ten months of preparation, the contract for the entire electric planning and implementation was signed, covering approval of the plans for the technical contents below:
-10kV 2x6 MW Wärtsilä-produced gas-powered generator,
- Auxiliary distributors, control panels, a process control system and their installation
- Primary and secondary connecting cabling with 2 receiving EDASZ transformer stations (in total approximately 52,000m of cable).

Because of the drawn-out preparations, the implementation schedule had to be shortened. Following the July 2002 commencement of implementation, the electric works, including the manufacture of switchgears, were all ready for testing by that October. We carried out this work with 36 colleagues of our own as well as sub-contractors. Overtime was common.
After a successful test run and before the October deadline, the Power Plant had become fully-operational, although the official and the ceremonial handover took place in November.

We also carried out the planning and installation of the 3rd gas-powered generator (6MW) in September 2003, the handover of which took place in November 2003.

The Metropolitan Water Works provides the drinking water supplies for more than two million people besides supplying industrial water for the whole of the capital and 21 towns and villages surrounding Budapest.

More than 700 drinking water production pumps currently operate on Szentendre, Csepel and Margit islands as well as along both banks of the Danube and these are able to supply in total 1.2million m³ of drinking water on a daily basis. One of the important requirements of a safe water supply is to safeguard the power supply to the pumps in the service buildings.

The Krisztina Machine House has safeguarded the energy supply to the water production plants in the Buda hills since the 1920’s.

The Metropolitan Water Works regard important tasks such as the modernisation of old machine houses taking into consideration the preservation of the original architectural values. This was also the case with this machine house.
The modernisation of the machine house took place between the end of 2002 and the start of 2004 in several stages, thus ensuring an uninterrupted water supply throughout.

Work done during reconstruction:
Reconstruction of the protection system of the existing 10kV switchgear and integration into the telemechanic system,
Dismantling of old equipment,
Site installation of:
- Disconnector in the transformer chambers,
- LD busbar trunking from the transformer to the 0,4kV main distributor
Manufacture and installation of:
- VAV UNION/Moeller-produced MODAN 0,4kV main distributor and capacitor bank,
- VAV UNION/Moeller-produced MODAN auxiliary distributor and motor local operation boxes,
- Frequency converters
Construction of a Budasensor-produced Thermomonitor system,
Cabling,
Complete construction of the telemechanic system

The full handover of the VAV UNION-installed system took place at the beginning of 2003, since when it has been operating without fault.
We are glad to taken part in providing a safe supply of water for Budapest and the surrounding area.

The Metropolitan Water Works provides the drinking water supplies for more than two million people besides supplying industrial water for the whole of the capital and 21 towns and villages surrounding Budapest.

More than 700 drinking water production pumps currently operate on Szentendre, Csepel and Margit islands as well as along both banks of the Danube and these are able to supply in total 1.2million m³ of drinking water on a daily basis. One of the important requirements of a safe water supply is to safeguard the power supply to the pumps in the service buildings.

The Káposztásmegyer machine house no. 4 is, as regards the supply of electric energy, one of the most important service buildings for the Northern Production Plants. Unfortunate circumstances led to the machine house fire in 2002 in which it was completely gutted. Following the fire, reconstruction work began.
In early 2003, having submitted a tender, VAV UNION won the application to be the main contractor on its electric works. Throughout the implementation ABB Ltd. supplied the motors for the pumps and other medium-voltage switchgears. The cabling tasks were carried out by a subcontractor.

Work done during reconstruction:
Installation of:
- Siemens-Csepel-produced auxiliary and small-power transformers,
- ABB-manufactured 0,69kV pump-motors and frequency converter,
- ABB-manufactured 10kV capacitor bank,
Manufacture and installation of
- ABB/VAV UNION-produced ZS1 10kV main distributor,
- Moeller/VAV UNION-produced MODAN 0,4kV main distributor and capacitor bank,
- VAV UNION/RITTAL-produced DC auxiliary distributor,
- Modified control panel,
- Local operation boxes,
Modification of the existing telemechanic system,
Construction of cable tracks, cabling

The full handover of the VAV UNION-installed system took place at the beginning of 2004, since when it has been operating without fault.
We are glad to taken part in providing a safe supply of water for Budapest and the surrounding area.

EMA-POWER Ltd. is an energy production and supply company in the Dunaferr Co. which in part provides electric energy and necessary steam to the Metalwork Company, and also takes part in the provision of heat and hot water to the consumer population of Dunaújvaros. The company’s boilers and feed pumps, as well as the numerous consumers, were all supplied by 9 10/0,4kV oil transformers and redundant low-voltage switchgears.
In 2000, in order to increase operating safety, and following several years of preparation, the management of the service company decided to begin the reconstruction of the 10/0,4kV auxiliary power supply, i.e. replacement of it’s transformers and an old 0,4kV distributor system.
EMA-POWER Ltd entrusted VÁV UNION with the reconstruction work which took several years, the details of which are shown below.

1. Professional dismantling of 9 disused oil transformers, oil extraction and transformer removal, ballast excavation and professional disposal of the dangerous waste matter.

2. Construction of 6 METAB plate-covered transformer stations, in which the transformers are secured and protected and also suitably ventilated. The steel structure is placed in 20cm-deep base concrete and the transformers are retracted using runners.

3. Installation of 6 2,5MVA 10/0,4kV transformers along with primary and secondary work in the new transformer station outside, in front of the switching rooms.

4. Installation of new 0,4kV MODAN6000 (4000A, IP54, 65kA/0,1s) distribution boards for the incoming and outgoing feeders, as well as the connection of the transformer and distribution boards via LD busbar trunking systems.

5. Installation of energy supervisory system for the effective operation and control of the new distributor system.

You can obtain a detailed technical description of reconstructions carried out since 1993 by having a look at the reconstruction works of the National Microwave Centre (NMC) on the Széchenyi-hegy.

The energy supply of the NMC is of utmost importance as, if it fails, the national AM-micro system, as well as the television and USW systems of Budapest and its surrounding areas will be paralysed. If the system’s electric power supply cannot be restored within a short period of time, the whole country’s microwave connection (TV, USW, AM-micro, satellites and some of the telephone lines) ceases to exist.

With this in mind, the replacement of the old 10 and 0.4kV distributors manufactured by VÁV, as well as the alterations, had to be carried out whilst maintaining continuous operation, which required a high level of task management.
The energy supply of the microwave centre can basically be divided into four parts:
- 10kV distribution board
- 0,4kV main distributor (high-energy)
- 0,4kV broadcasting room distributors (low-energy)
- Auxiliary distributors

We built vacuum circuit-breakers into the NT12 metal-clad medium-voltage switchgear manufactured by VÁV UNION Ltd.
The 0.4kV distribution boards are MODAN6000, the secondary assembly, installation and launch of which were also carried out by our company. The installed MODAN6000 panels are designed to be withdrawable distributors, which enables failure management to happen smoothly, causing only minimal voltage cut-off as only the specific drawer has to be replaced.
The built-in modern switching devices and distribution boards comply with the strictest safety engineering- and fire protection regulations. This way, it was possible to place the medium-voltage distributor, which previously required a separate room, into one room shared with the main 0.4kV distribution board as well as the auxiliary distribution board. The central control panel was also installed in this room.
An overall PLC (Programmable Logic Controller) system makes it possible for the distributors to be controlled easily.
Given the stricter constructional safety regulations, particularly in the NMC, we also had to install wired automation as a backup for the PLC automation, and the possibility of manual operation, too.

Commands coming from the control panel reach the 10kV and the 0.4kV fields via the PLC, thus sparing a considerable amount of secondary cabling.
The user side of the supervisory system is run using three computers, which run a WINDOWS-based display system. One of the computers monitors the high-energy distributor, another the low-energy. The third is the so-called master computer. Its low-energy distributor PLC system provides separate information for the telemechanic system of ANTENNA HUNGÁRIA Co.

Expectations regarding the power supply system were high along with the increasing technical level of technology.

MATÁV Rt. pioneered applying intelligent distribution boards, due to which multiple operational security was achieved.

With the help of built-in process control systems, the switchgears are able to connect to VÁV UNION’s supervisory system, and in this way, if problems arise, our experts can get there promptly and fully-prepared.

Modern switchgears which take up little space were installed in the existing old distributing rooms. The individual system’s main low-voltage distribution boards are MODAN6000 switchgears. The secondary assembly and installation of switchgears were also carried out by our company. The equipment bears the following general technical parameters:

- Circuit breakers in the incoming feeders are withdrawable,

- The outgoing feeders contain motor-operated circuit-breakers that can be remote controlled,

- We took into consideration the ability to attach extra cubicles during the configuration of busbar systems,

- The busbars are protected against the formation of arc spots.

- Drawers of the same type and loading capability are interchangeable,

- a Moeller ARCON arc fault protection system can be built in,

- apart from increasing operational safety, the double busbar system ensures the possibility of simultaneous power supply, whilst dividing the consumers, partly from the network, and partly from a backup power supply,

- the outgoing feeders are divided into functional groups, which can be supplied through one of the main busbars, using a pair of bar couplers supplying dropper bars. The bar couplers are electrically interlocked, so it is not possible to simultaneously switch on both sides, i.e. to couple the two main busbars together.

 

The implementation was carried out in accordance with a definite project plan compiled by OLAJTERV Co.

In order to provide electric power for the containers at the refinery, a new 6/0, 4kV transformer station was installed, in which two 1MVA transformers provide the energy demand of the current two 80,000m3 containers. This output will be sufficient to satisfy the energy-demand of two future containers with similar capacities.

The new station is supplied by the reserve outgoing feeders of the 6kV distribution board nearest to it. The old EIB breakers and the protection system were replaced when installing the outgoing feeders. After altering the existing frame, the minimum-oil circuit-breakers were replaced by ABB vacuum circuit-breakers. DTI digital protection systems were installed into the new AEG relay racks. For the purpose of measurement, DATCON DT530 digital multimeters were installed. The connection between the existing energy supervisory system, as well as an electric supervisory system to be implemented during the course of another project, is facilitated by Moeller PLCs.

The reception of the 6kV cables in the 6/0.4kV station happens in NBK 10-100 disconnector cells manufactured by VÁV UNION. The transformers’ temperature relays were placed in the reception cells’ secondary section. The single-core cables lead from the reception cells to the 1MVA transformers.

LD busbar trunking systems, connecting from above to the MODAN6000 withdrawable main distribution board, connect the transformers’ secondary side. The two lines of switchgears facing each other are connected by the same type of busbar trunking. Between the incoming feeders, a PLC-controlled change-over switch was installed.

In the other station room a MODAN6000/IVS lighting distributor was installed, as well as a relay panel which ensures instrumental connection. We have also carried out implementation of explosion-proof equipment as the main contractor.

 

Our company completed the planning and implementation of the electricity supply system of Eger Tobacco Factory as the principal contractor. After several years of preparation by both companies, implementation took place between March 1999 and March 2000.

 

The first and most significant phase of the implementation was the scheduling of processes to be carried out to the day – in some of its phases, to the hour – given that the factory could not afford a halt in its continuous operation; production had to continue. The successful execution and completion of the project proved that painstaking preparation and planning are indispensable elements in the reconstruction of an electric power supply system that determines a factory’s existence.

The entire renovation of the network did not only mean electric work, but also involved various  specialist jobs, such as some architectural alteration, the renovation of distributor rooms and building a new cable channel, tasks we outsourced to subcontractors.

 

Some elements of the electric power supply system:

- ABB ZS8, 6-panel intelligent 10kV medium-voltage switchgear, manufactured by VÁV UNION Ltd

- 2 TG6441G, 2500/10 transformers

- 0,4kV main- and sub-distribution boards that constitute the pillars of the network, as well as technological equipment from MODAN6000 distribution boards

- after dismantling the old distribution centres and in order to ensure continuous operation, we employed provisional distribution boards until the architectural work was finished and the new distribution boards were installed

- installing and renovating an exterior cable network

- in order to provide continuous energy supply to the factory, we installed an automatic 500kVA self-contained diesel generator under the control of a supervisory system

- we installed a computer-controlled supervisory system responsible for managing the newly-created energy supply system. In accordance with Philip Morris’s policies, SIEMENS supplied the system

- Central PLC cabinets, located in the main switching rooms, are connected to supervisory computers, placed in two different spots, via an optic cable network.