— ABB Electrical System ServiceEnsuring the efficiency and reliability of electrical assets

2 A B B E LEC TR I C A L S E RV I CE S2 CO LL A B O R ATI V E O PE R ATI O N S P U L P A N D PA PER

— Determining the status and operating condition of electrical equipment is critical to understanding potential production risks and maintenance readiness.

ABB Electrical Services provide actionable information on the electrical infrastructure in order to optimize operating efficiency and reliability.

Assess

Inspect

Confirm

ABB Electrical Lifecycle Assessment ABB Electrical Health Check ABB Electrical System Study

3 A B B E LEC TR I C A L S E RV I CE S

As equipment life cycles progress, the impact on production and availability can be significant. ABB Electrical Services provide visibility into the status and condition of electrical assets so risks can be identified and mitigated to improve overall asset and production performance.

These services include:

• ABB Electrical Lifecycle Assessment• ABB Electrical Health Check• ABB Electrical System Study

These services provide the basis for decisions regarding electrical equipment maintenance to ensure asset and production availability.

They are the foundation for maintenance planning and upgrade timing, and improve understanding of the entire electrical infrastructure so that plans align with needs, priorities and values.

Increase visibilityIncrease equipment life cycle visibility by assessing entire electrical infrastructure

ABB Electrical Services:

Identify risk Understand the impact of evolv-ing lifecycles and obsolescenceIdentify and respond to issues based on criticality

Improve maintenance Implement proactive maintenance strategies

—ABB Electrical Services

—1. ABB Electrical Lifecycle Assessment

The ABB Lifecycle Assessment provides insight into equipment status and identifies associated production risks due to limited or obsolete offerings. It also creates a visual overview of

equipment status and provides actionable information on the electrical infrastructure in order to optimize operating efficiency and reliability.

Full range of life cycle services and support is available

Full range of life cycle services and support is available but update offerings exist

Limited range of life cycle service and support available

Migration support is available

Active Classic Limited Obsolete

4 A B B E LEC TR I C A L S E RV I CE S

ABB Life Cycle Assessment Process

The ABB Electrical Lifecycle Assessment reports provide a detailed picture of the entire electrical landscape in an assessed facility. The Assessment Overview outlines overall system status health and data critical for strategic asset and maintenance planning. The Process and Location report provides

Once life cycle status has been documented, ABB meets with the customer to review the criticality of each process or application, and its impact to production, to develop recommendations that meet customer’s preventive and predictive

a picture of production equipment at each production location, and categorizes each asset by life cycle status in order to identify missing or obsolete components to determine the potential for critical problems at each location.

maintenance objectives. The Agreed Actions Outline summarizes the current status of electrical equipment and recommends areas of focus based on the criticality of processes and assets.

—01 ABB Electrical Lifecycle Assessment Process and Location report includes a visual overview of all production assets at each process location to identify potential risks and develop mainte-nance and migration plan (steel mill example).

MS1 - Main power station

SG11 - Hot rolling mill switchgear

SG21 - Cold rolling mill switchgear

SG31 - Annealing and pickling switchgear

A2A - Hot rolling mill - rough mill

A2A - Hot rolling mill - finishing mill

A2A = Hot rolling mill - down coiler

SZ1 - Cold rolling mill 1

SZ1 - Cold rolling mill 2

SZ1 - Cold rolling mill 3

AP1 - Annealing line 1

W6 - Water treatment

0% 20% 40% 60% 80% 100%

Number of products Active Classic Limited Obsolete Unknown

48

44 7 13 2

1433

123 2 5

241756

46 3 12 5 2

31377

159 79 34

6 4 4204

301 29

321123

334123 22 212

30

4 36

Establish Priority-settingProcesses are reviewed with the customer to develop an implementation strategy that prioritizes processes relative to production importance

RecommendationsABB provides a summary of equipment status and recommends areas of focus based on the criticality of processes and products

PreparationCustomer’s processes and equipment locations are identified

On-site AssessmentValidation of product types and serial numbers is conducted on-site

Value-added ReportingA graphic assessment of equipment status is generated and shared with the customer

—01

5 A B B E LEC TR I C A L S E RV I CE S

—2. ABB Electrical System Health Check

After the life cycle status of all the assets and processes have been recorded and critical areas of focus have been identified, the next step is to get a more comprehensive look at the condition of assets vital to production. Building upon the ABB Electrical Lifecycle Assessment is the ABB Electrical System Health Check, which evaluates and inspects key electrical assets. The inspections are conducted while the equipment is operating.

The analysis identifies under-performing areas and provides corrective and preventive recommendations to enhance and improve system reliability and minimize risk. The ABB Electrical System Health check covers hardware, software, spare parts and maintenance practices.

Assets evaluated• Switchboards • Protection Relays• Bus Ducts• Transformers• Current Limiters• Electrical Control• Generator Control• Drives • Soft Starters• Motors• Uninterruptible Power Supplies

ABB Electrical System Health Check Process

Risk ReductionHighlight most critical recommendations and corrections to improve system reliability

PreparationCollect equipment list and prepare assessment template

On-site AssessmentInspect electrical system and equipment, take thermography readings and review maintenance practices software backup routines

Value-added ReportingReport summary of findings with improvement recommendations and suggest areas for further analysis

—02 The inspection of Low Voltage Switchboards, during an ABB Electrical System Health Check, confirms the condition of all components.

—02

6 A B B E LEC TR I C A L S E RV I CE S

—3. ABB Electrical System Study

The ABB Electrical Lifecycle Assessment and the Health Check allows customers to gain insights on the status and visual condition of electrical assets. The ABB Electrical System Study takes it further and simulates critical systems at a facility to confirm optimal asset and process performance and availability.

The ABB Electrical System Study provides essential information to ensure electrical systems comply with utility connections agreements and ensures a safe and secure energy source. The study simulates how an electrical system operates over a complete range of operating scenarios and provides recommendations for facility operations and modifications.

An ABB Electrical System Study can identify low- current capacity, flicker, spurious trips, unexpected equipment heating, equipment rating issues, loading and protection coordination issues.

The studies generate actionable information to optimize electrical assets and help maintain:

• Compliance with guidelines and standards• Reduced maintenance costs due to the extended

lifetime of the network components• Increased availability and reliability due to

reduced downtimes in the network• Reduced energy costs

Modeling of NetworkABB service personnel works with the customer to generate an accurate modeling of the electrical network, making the details on the existing installed equipment available so the electrical studies can be executed effectively.

Short Circut StudyThe Short Circuit Study checks whether there is any violation in the equipment short circuit ratings with the existing and confirmed load list information to ensure availability.

Protection Coordination StudyThe Protection Coordination Study is performed to measure sensitivity, speed, selectivity and reliability to isolate faults from the rest of the system and minimize possible losses due to faults under foreseen system operation conditions.

Load Flow StudyThe Load Flow Study is performed to determine the voltage profile and to mitigate, if possible, the voltage (drop) profile issues with the existing and 100% confirmed load list to prevent system losses and protect performance under emergency conditions.

Harmonics StudyThe Harmonic Study verifies that total harmonic distortion (THD) are within limits, and identifies solutions to mitigate violations. Motor Starting StudyThe Motor Starting Study is conducted to check system behavior during the start of a large motor in the electrical system. High starting currents while starting motors can cause voltage dips at the motor connected bus and in the system. Effect of HarmonicsThe Harmonic currents and voltages impact to the motors, transformers and capacitor banks is analyzed to prevent overheating or voltage stress issues. Arc Flash StudyInformation gathered from the short circuit and coordination studies is calculated to evaluate boundary distances and incident energy to improve personal safety.

—03 The ABB Electrical Sys-tem Study simulates elec-trical operations to detect under performing areas, including equipment rat-ing, loading and protec-tion coordination issues.

—03

7 A B B E LEC TR I C A L S E RV I CE S

The ABB Electrical Services are the first step in electrical asset optimization and can be delivered separately or combined. Choose options that meet your needs:

—4. Let’s get started

Lifecycle Assessment System Health Check System Study

Level 1• List of equipment

• Lifecycle status

Level 2

• List of equipment

• Lifecycle status

• Preventive Maintenance programs

• Competence development program

Level 3

• List of equipment

• Lifecycle status

• Preventive maintenance programs

• Competence program

• Service history

• Maintenance & upgrade plan for

future

• Spare parts gap analyses

• Lifecycle Assessment

• Equipment condition evaluation

• Software back-up practices

• Maintenance practices

• Manuals, documentation

• Lifecycle Assessment

• System Health Check

• Modelling of network

• Short circuit study

• Protection coordination study

• Load flow study

• Harmonics study

• Effects of Harmonics

• Motor Starting Study

• Arc Flash Study

—abb.com

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© Copyright 2017 ABB. All rights reserved. Specifications subject to change without notice.

ABB Inc. Industrial Automation Service579 Executive Campus DriveWesterville, OH 43082-8870USAE-Mail: automation.service@us.abb.com