Transformers, substations + the grid: Products + services
A new level of reliability in MV switchgear
* Improved safety * Flexible system design allowing for future load expansion * Smaller footprint and reduced substation size * Reduced copper wiring * Shorter project lead times * Lower carbon footprint * Better asset visibility and maintenance planning * Optimised production and plant uptime. He adds that in the mining sector, UniGear Digital switchgear with condition monitoring is now being adopted at scale. It is also in use in petrochemical plants where safety and reliability are critical – and in critical infrastructure environments where uptime and asset visibility are essential. Interestingly, mining has become one of the leading adopters of the technology. In the past, van Zyl says, petrochemicals companies were the early movers, but mining companies now want real-time visibility into asset health, performance, and maintenance requirements so they can optimise production and investment decisions. The importance of condition monitoring Customers want to understand the real condition of their assets before spending maintenance budget. Instead of replacing equipment blindly, with digital insights they can see exactly where possible unsafe conditions are, what assets need attention, and when intervention is actually required. This allows them to ensure continuous safe operation, optimise production, reduce unnecessary maintenance costs, and improve plant uptime and efficiency. Van Zyl notes that some customers prefer to analyse the data themselves and others choose a service agreement with ABB, where ABB analyses the data, provides reports, and recommends actions. He also says the system can be simple or very sophisticated, depending on the customer’s needs. Designed for flexibility The UniGear Digital solution is designed to be flexible. Customers may not know their future load requirements at the time of installation. With the built-in sensor technology, the system can accommodate growth without requiring hardware changes. This is especially valuable in renewable energy and infrastructure projects, for example, where load profiles often change over time. Key success factors In closing van Zyl highlights the key factors that support UniGear’s success: the quality and robustness of the equipment and ABB’s technology leadership. ABB invests substantially in R&D, in the advance of smart solutions like sensor technology and condition monitoring, and many other technologies. He emphasises that as a company, ABB controls the quality of its products and continues to develop new capabilities. “Reliability is critical, and we do not release technology that is not proven,” he says.
ABB’s UniGear Digital switchgear offers a new level of reliability in medium-voltage switchgear, combining ABB’s globally trusted UniGear platform with digital sensing, advanced protection relays and full IEC compliance. With real-time monitoring, improved accuracy, and built-in self-supervision, UniGear Digital helps utilities and industry reduce outages, enhance safety and meet international performance standards. Electricity + Control put some questions to Jan van Zyl, Product Line Manager Primary Switchgear at ABB Electrification Distribution Solutions, ABB South Africa, to learn more about the digital switchgear and the advantages it offers. Van Zyl explains that the solution consists of two layers. First, advanced sensor technology is built directly into the switchgear, replacing conventional instrument transformers. Second, a data and analytics layer captures information from the switchgear and makes it available via on-site servers or secure cloud platforms. The digital monitoring and control system includes both hardware and software. The sensors, communication devices, and data infrastructure work together with analytics software and dashboards to provide full visibility of asset performance and condition. Dashboards are built in and views are customisable – customers can adapt the interface and data outputs to suit their operational and reporting requirements. Van Zyl says the system can be supplied as part of a new installation or retrofitted to existing equipment, dependent on certain technical requirements. For example, digital current and voltage sensors can be installed on existing switchgear and, although some technical considerations need to be addressed to ensure reliable operation, full replacement is not always required. The platform is designed for easy integration into existing power management networks, but it can also operate as a standalone system if required. Local installations ABB has already established several local installations, in mining, industry, commercial buildings, and other sectors. “We cannot disclose specific customer names, but the technology has been well received,” van Zyl says. He points to the key benefits for customers: Testing and commissioning a UniGear Digital switchgear installation.
For more information visit: www.abb.com/africa
24 Electricity + Control MARCH 2026
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