Availability, reliability, and optimization · Simple and effective LV motors (

Motor and Generator ServicesAvailability, reliability, and optimization

Xu Xiao Ming, 19th of July 2012

© ABB Group July 26, 2012 | Slide 2

BU service global overview

SG local service key milestone

Key service highlights

Summary

Contact information

Contents

How ABB is organizedFive global divisions

Power Products

Power Systems

Discrete Automation and Motion

Process Automation

$10 billion34,000

employees

$6.8 billion18,000

employees

$5.6 billion25,800

employees

$7.4 billion28,100

employees(2010 revenues)

Low Voltage Products

$4.5 billion21,000

employees

Electricals, automation, controls and instrumentation for power generation and industrial processesPower transmissionDistribution solutionsLow-voltage products

Motors and drives

Intelligent building systems

Robots and robot systems

Services to improve customers productivity and reliability

ABB’s portfolio covers:

© ABB GroupJuly 26, 2012 | Slide 3

Discrete Automation and Motion division: Business unitsTogether, we drive our customer‘s industrial productivity and energy efficiency

Low voltage AC drives from 0.12 to 5600 kWDC Drives from 4 kW to 15000 kWWind turbine drivesSolar convertersPLCs, HMIs, and wireless sensors and actuatorsSoftware toolsEnergy saving toolsService

LV Drives

Low voltage motors from 0.25 to 1000 kWHigh voltage motors and generators up to 70 MWHigh speed motorsTraction motorsWind power generatorsDiesel generatorsGas and steam turbine generatorsHydro generators, tidal waves, etcService

Motorsand Generators

Advanced power electronicsConverter productsExcitation and synchronizing systemsHigh power rectifiersPower quality productsTraction convertersMedium voltage drives from 315 kW to more than 100 MWServiceEV charging infrastructure

Power Electronicsand MV Drives

Industrial robotsRobot controllers and softwareIndustrial software productsApplication equipment and accessories Robot automation systems for automotive, foundry, packaging, metal, solar, wood, plastics, etc. industriesService

RoboticsNumber 1 or 2 in all markets where we operate



Customer needsABB Service solutions

To solve problems quickly and effectively to restore its operation

To solve problems quickly and effectively to restore its operation

To increase process reliability to avoid unplanned interruption in its operation

To increase process reliability to avoid unplanned interruption in its operation

To optimize operation to increase production capacity

To optimize operation to increase production capacity

Technical supportEmergency field service resourcesSpares availabilityOnsite and workshop repairTrainingService contract

Installation and commissioningPreventive maintenanceDiagnosis, condition monitoringService contract

Engineering andconsultingSpares rationalizationEnergy , performance and reliability appraisalUpgrade – replacementLife cycle costingRisk management

Safe

ty

Availability

Optimization

Reliability

What are the customer needs? ABB Service solutions


Service operations, Motor and GeneratorABB’s service network

ABB Global Technical Support Centers

ABB Local Service Centers and third party Service Partners

Champagne, France

Shanghai, China

Mumbai, India

Alrode, South-Africa

Osasco, Brazil

Betim, Brazil

Helsinki, FinlandVästerås, Sweden

Vittuone, Italy

Birr, Switzerland

Singapore


SG local service key milestoneHistory of local understanding, ready for new era

Early 1970s’ 1987 2011 2012…

Two prestige service workshops from ASEA and BBC

ABB workshop merged from ASEA and BBCCombined knowledge and experience

Upgraded workshop with enhanced service capabilitySupport increased demand for key industries

Predicative serviceRemote servicePrecise reliability and optimizationComplete service portfolio


Key service highlightsAvailabilities

Facilities:• Rightly equipped expanded workshop

(up to 1120mm machine)• VPI system (up to 2.4m x 4m)• 8MW MV motor no loading testing• 400KW LV motor load testing

Expertise:•Major overhaul, repair and upgrade service for LV/MV motor/generators•Certified Ex machine service from ABB, IEC, and UL•ISO 9001 certified workshop






DC MeasurementsPolarization current De-Polarization current

Unique Life expectation analysis on

any MV(>3.3kV) machine Insulation

Key service highlightReliability, Leap

AC MeasurementsNon Linear BehaviorTan and CapacitancePartial Discharge

ABB unique insulation analysisIdentify and calculate the abnormal stressLifetime is estimated with confident level (80% and above) base on test packageClear plane for possible further inspection, maintenance, or replacement.


Key service highlightsReliability, Machsense

Equipment•A single analyzer for the mechanical and electrical measurements•Powerful tool for induction motor condition and performance evaluation

Measurements•4 Vibration Sensors•3 Voltage clamps•3 Current clamps•Temperature sensors (optional)•Speed sensor (optional)


Key service highlightsOptimization, Engineering and consulting service

* Information provided by Machine Monitor based on survey of 6000 motors

Installation

1 %

Purchase

2.7 %

Cost of repair

4.9 %

Reliability

17.4 %

Electricity

74 %TCO includes:

Purchase priceSpecification

TransportationStorage

InstallationQuality

AssuranceReliabilityElectricity

RepairsAdministration

Inventoryand others

Life cost of motor


To optimize energy, reliability and performance costs, and subsequently lifecycle costs, motor owners can examine how their assets are operating

Motor status can be evaluated on the basis of

Energy efficiency appraisals

Reliability assessments

Performance analyses

The process involves careful inspection of motors during operation usingABB´s unique, purpose-designed analysis tools

Energy efficiency

Reliability

Performance

Motor status

Optimal solutions






Huge reliability cost from breakdown and repair

High stress level and inefficiency from time base shut down turn around exercise

Sourcing for external support at rush with unsatisfied solution

High volatility in maintenance cost and effectiveness

Key service highlightsContract service, Motor Care

Motor care is a multi-level service coverage

Simple and effective LV motors (<= 690V) complete reliability solution

Flexible/expandable levels to chose base on customer available in house resource and needs

Fix annual fee base, easy for maintenance planning and budgeting

Assured reliability for large quantity of motors and knowledge support/sharing

Level 1Level 1 Level 2Level 2 Level 3Level 3Workshop remediation for

reliability restoration

• Initial one round site fine tune if any for optimal motor performance

(Like realignment and etc) • Workshop overhaul and bearing

replacement if needed identified from site condition monitoring

• Workshop rewind and other major repair in case failure happens

• Workshop replacement with equivalent motor for beyond repair

if any • Local transportation for pick up

and delivery between ABB workshop and customer warehouse

Plus Level 1

Half yearly site walk around for• General motor external inspection

for abnormalities • Motor running parameters record

and review • Motor vibration measurement and

review• Site trouble shooting if any

PlusSite removal and reinstallation• Remove motor from base and transfer to lorry pick up points at

customer site • Transfer motor from lorry drop off

point at customer site to base• Reinstallation of motor on base

and start up

Plus Level 1

Cov

erag

e

Plus Level 1

Half yearly site walk around for• General motor external inspection

for abnormalities • Motor running parameters record

and review • Motor vibration measurement and

review• Site trouble shooting if any

ORSite removal and reinstallation• Remove motor from base and transfer to lorry pick up points at

customer site • Transfer motor from lorry drop off

point at customer site to base• Reinstallation of motor on base

and start up

Plus Level 1Option: Guaranteed site response timeOption: Guaranteed site response timeOption: Critical spare motor pool accessOption: Critical spare motor pool access

Key service highlightsContract service, Complete care for LV motors


Key service highlightsContract service, easy yet comprehensive

• Globalized service contract meeting customer needs

• Comprehensive portfolio services

• Fixed price agreement, premium service agreement

• Inspiration and seriousness in partnership


Summary

Complete service portfolio/capability for motor and generator

Quality and effective service planning and implementation

Excellent OHS competence

Committed continuous investment and R&D efforts

Strong value on Reliability, Efficiency, Performance and Safety

World wide service network and resources

Contact informationABB SG, Motor and Generator Service

Address: Contact detail: ABB Contact centerNo 2, Tuas Lane Tel: +65 6861 9722 Tel: +65 6222 7778

Singapore 638611 Fax: +65 6861 4355 Email: [email protected]

Email: [email protected]

Website: ABB Motors and Generators


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Availability, reliability, and optimization · Simple and effective LV motors (