ABB Service Singapore 2010file/ABB+Service_Singapore_2010.pdf · Power system service © ABB Group April 1, 2010 | Slid e 8 ABB Service overview Typical plant power and automation

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© ABB Group April 1, 2010 | Slide 1

ABB Service in SingaporeExperience with power and automation service professionals

Xu Xiao Ming, AP Services, March 2010


� ABB Service overview

� Typical plant power and automation installation

� Life cycle service and offering

� Start up service

� Spare parts service

� Training service

� Proactive maintenance

� Workshop services

� Modernization and upgrading

� Energy service

� Case book

� Summary

ABB Service _ SingaporePower and automation service professionals

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World wide serviceLocal delivery with global support

USA

Mexico

Colombia

Brazil

Netherlands

Argentina

UK

Norway

Sweden

Finland

Estonia

Latvia

Germany

Poland

France

Spain

Switzerland

Denmark

Portugal

China

South AfricaAustralia

Lithuania

Austria

Korea

Japan

Taiwan

Belgium

Canada

Italy

India

SingaporeVenezuela

Turkey

Chile

Peru

New Zealand

MalaysiaSaudi Arabia

UAE

Hungary

Thailand

Egypt

Russia

Oman

Quatar

Kuwait

More than 22,000 service professionals worldwide�


Complete range of servicesOne stop for power and automation

� Wide range of products

� Analytical Products

� Control Systems

� Drives

� Force Measurement

� Instrumentation

� Low Voltage Products

� Motors

� Propulsion Systems

� Robotics

� Turbochargers

� Non-ABB products

� Across industries

� Chemical

� Life Sciences

� Manufacturing

� Marine

� Minerals & Metals

� Oil & Gas

� Pulp & Paper

� Power Generation

� Utilities

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ABB Service _ SingaporeOverview

� Started back in early 1970’.

� Complete service portfolios for power and automation.

� Active in all major industries.

� Life cycle service concept.

� More than 250 service professionals.

� Availability, performance and efficiency.


ABB Service _ SingaporeHighlights

Spacious and equipped workshops

� Motor and generator service

�Transformer service

�Turbo charging service

State of art facilities

� Drive service

�Training center

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ABB Service _ SingaporeHighlights

Regional centre:

�DCS service

�Drive service

�Machine service _ Leap

�Analytical and instruments

�Training center

�Marine service

�Pulp & paper service

�OGP service

�Power system service











� Energy service

� Case book

� Summary


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Typical plant installationIntegrated electrical system

22 or 66kV

400/230V

LV Distribution Transformers

Battery UPS LV distribution board

Generator MV or HV

LV Motors

Indoor GIS

LV Drives

LV

Distribution Transformers

LV MSB/MCC

Indoor AIS

Power

Transformers

MV6.0, 6.6, 11kV

400VRectifier

Transformers

MV Motor

Utility

MV Drives

•Compressors

•Pumps

•Fans

•Etc

ENMC


Typical plant installationAutomation system

MCC

Variable Speed Drives

S800 I/O

S900 I/O (Ex)

Workplaces

Control Network

Remote Clients

System Servers

Fieldbus High Speed Linking Devices(FF HSE/H1, PB DP/PA)

Process Automation

Process Automation and Safety

Operator EngineeringMaintenance

Safety

Process instrumentations

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� Energy service

� Case book

� Summary



Life Cycle Service Concept:

Time

Val

ue

New build phase

Operation Extended life-time

Commissioning

ABB training service�Safety �Operations� Maintenance

Start up service•Installation and commissioning

Spare Parts� Installation surveys� Recommended essential maintenance parts list� Genuine and correct ABB parts

Proactive maintenance�Condition monitoring�Predictive maintenance� Scheduled preventive maintenance

24/7 Service� Agreement based service contract� On call service

Corrective service•On site repair•Workshop repair

System Improvement� Product enhancements� Functional upgrades

Modernizations/Replacement� Design and engineering� Project management� Iinstallation and

commissioning

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Start Up/Commissioning Service Assuring performance right from beginning

� High and effective ABB service OHS competence

� Well trained ABB service professionals for right jobs

� Standard and effective installation/commissioning sheets/procedures

� Fast handover to customer

� Faster return on customer’s investment

� Future failure rate/downtime largely reduced


Spare parts serviceRight parts at right time

� Spare parts audit

� Install base survey

� Operation appreciation

� Start up kits

� Operational kits

� Preventive maintenance kits

� Capital and complete kits

� Regional logistical center

� Excellent order management

� Timely and quality delivery

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Training serviceSharing and improvement

Highlights:

�Certified regional training centre for 800XA system and drives

�Global training centre for marine academy

Features:

�Comprehensive Training Facilities

�Practical-based Learning Solutions

�Customer-focussed Training

�Qualified & Experienced Trainers

�Accredited Courses by our partners in learning…..


Training serviceSharing and improvement

Products Main Courses Course Developer

(i) Control Systems

� Advant OCS ABB University

� 800xA System ABB University

� Freelance 800F ABB University

• Collaborative Production Management PIP, Singapore

(ii) Drives � LV and MV Drives ABB University

(iii) Expert Workshops � Advance workshops Global Consult IT

(iv) Industry Specific Courses

� Marine Marine Academy

� Pulp & paper COE, Singapore

� Oil, Gas & Petrochemicals Global

� Power Systems COC, Singapore

(v) Analytical Systems � Measurement ABB Singapore

(vi) Appreciation courses � Various for Channel Partners/end users ABB Singapore

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Proactive maintenanceSecuring Operation, Reduce Downtime

� Joint effort from ABB and customers.

� Adaptable and right level of maintenance agreements.

� Continuous development of service solutions.

� Early identification/rectification,

� Trending of performance and predicated residual life.

� Aging parts replaced at right time.

� Valuable input for maintenance budget planning.

� Training and knowledge sharing.


Proactive Maintenance _ Asset monitoring

How

�Pre-defined intervals

�Effective and knowledge base test/analysis tools

�Equipment without stopping or temp stopping

�Executed and analyzed by ABB service professional

�OHS competence

�Tailor designed CBM service products with ABB’s in-depth knowledge of product and process

�Right level of users’involvement for joint effort

What Results Benefits

�Verify and share measured conditions

�Early detection of abnormalities if any

�Immediate/planed remedy action if any

�Detail install base survey/verification

�Valuable equipment running condition with no/temp stopping

�Increased confidence for operation needs

�Valuable inputs for other maintenance and service activities

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Proactive Maintenance _ Preventive

How

�Pre defined schedule range

�Equipments to be stopped, partially/fully dismantled

�PM spare part kits or recommended spares to be available

�Executed by ABB service professionals

�OHS competence

�Tailor designed PM service products/scope with ABB’s in-depth knowledge of product and process

�Continuous and follow up service from CBM service

�Right level of users’involvement for joint effort


�Overall equipments and critical components being inspected and tested

�Aged and worn off components being replaced

�Immediate/planed remedy action if any

�Quality work/right parts assured improved performance


�Quality/effective service documents assured traceability and future reference


Workshop ServiceHigh level of performance reclaim and improvement

How

�ISO certified, ABB service/repair workshop.

�Well equipped workshop facilities

�Original product or relevant international standard

�Executed by ABB service professionals

�OHS competence

�Major electrical/mechanical repairs

�Complete workshop diagnose test/inspection

�Complete overhaul/recondition of equipment

�Upgrading/renew insulation


�Equipment being thoroughly inspected/tested

�Components being cleaned/treated with right methods

�All defective and unsatisfactory conditions being rectified/repaired

�Possible cause of defects identified

�Quality work/right procedure assured performance

�No repeated failure

�Maintained and increased life span


�Quality service documents assured traceability and future reference

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Workshop ServicesMachine

Machine Service Workshop

� Overhauling/Refurbish

� Parts replacement

� Rewinding

� Mechanical repair

� Dynamic balancing

� Running test services

� Upgrading, life extension

� Diagnostic service (Leap, vibration analysis and etc)


Workshop ServicesDrives

Drive Service Workshop

� Cleaning services

� Repair Services

� Reconditioning services

� Exchange units

� Running test services

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Modernization, upgrading, replacementNew life of assets

How

�ABB’s abundant product and system with right solution

�Engineering and application knowledge

�Consideration of improvement on productivity, reliability, safety and energy efficiency

�OHS competence

�End of service life

�Beyond economical repair

�Limited and unavailable spare parts

�Limited and unavailable service resource

�Needs from new standard/class/operation


�Modernized aged system with new technology

�Upgraded old products with new key components

�Replaced obsolete products

�New life of asset/equipment

�Improved maintainability

�Increased confidence for future operation needs

�Improved efficiency, productivity and safety











� Energy service

� Case book

� Summary


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Energy efficiency serviceProtect your profit, protect the earth

ABB technology can double energy productivity!

Primary energy Transport Generation T&DIndustrial processes

Industrial production

Ava

ilabl

e en

ergy

More efficient fuel combustion

Higher pipeline flows

Improved well efficiency Lower line losses,

higher substation efficiency

Improved productivity

More efficient motors & drives

Drives &motors

ProcessAutomation

Marine & pipelines

Power plantautomation

Gridoperation

Processautomation


Energy efficiency serviceProtect your profit, protect the earth

� Energy measurement�Data gathering and analysis

�Clear understanding of energy consumption

� Assessment on efficiency improvement

� Definition of improvement plans�Energy management and control to reduce waste

�Technical application to increase efficiency

� Delivery of improvements

� Confirmation of improvement

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� Energy service

� Case book

� Summary


© ABB Group April 1, 2010 | Slide 28© ABB Group April 1, 2010 | Slide 28

Case BookDrive training equip customer necessary product and maintenance knowledge

Customer’s request:

�Functionality/features of drives.

�General application of dives.

�General operation, preventive maintenance guidelines.

� Basic fault tracing and trouble shooting guidelines.

ABB’s response:

�Dedicated training program for end users.

�Training with full facilities in the classroom environment.

�Demo units, actual hardware and software to practice.

�Focus on basic operation and maintenance needs.

Customer’s benefits

�Appreciated functionality of drives.

�Able to perform the basic operation/maintenance on the drives

�Source to get help in case of further assistance needed from ABB.

�Reliability of drive greatly improved with joint efforts from ABB and customers.

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Case BookAutomation maintenance contract enable customer focus on main business


�Competent service provider to look after maintenance of the plant control and safety systems.

� Maintain the overall plant control and safety system reliability and availability.

� Securing the system optimized for the operation needs.

ABB’s response:

Comprehensive maintenance support agreement comprises of:

�Preventative, predictive and corrective maintenance services

�24 x 365 availability telephone call and email support, emergency engineer mobilization for site support

�Spare parts agreement

Customer’s benefits:

� Minimize the cost for corrective maintenance

� High reliability of the production assets.

� Immediate response in case of unplanned stoppages

� Focus resource to core business


Case BookLeap service boosts customer confidence on MV motor operation

Stress

Strength

Failure

Transient faults

Residual Life

Premature Failure

Time

Stre

ss,

stre

ngth

Customer Request

� An ABB MV motor was over loaded than spec by >10%

� Great concern on reliability and safety due to the overloading.

� To analysis the situation for solution for immediate and future needs.

ABB Response

�Leap service.

�Unique predicative service for MV machine insulation.

�Analysis software predicated shortened life span than designed (10 vs 25)

�No immediate failure base on current stress level.

Customer Benefits

�No rush to change overloaded equipments.

�Current production guaranteed with improved confidence.

�Clear plan for PM actives and future upgrades.

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Case BookGenerator repair for FPSO customer with improved reliability

Customer Request

�3 units of 5300kw /4160V generators windings were grounded during operation

� Improve generator structure to suit harsh environmental.

�Generators to be repaired in rush

ABB Response

�Site damage inspection

�3 generators sent to ABB Singapore workshop for rewind.

�Generators were rewound and sent back progressively.

�Enhanced structure to suit harsh environment

Customer Benefits

�Reduced production loss from ABB fast total response and quality repair.

�No repeated failure expected.

�Improved reliability and confidence of production.


Case BookMV breaker upgrade give aged breakers new life


�14 units of 22kV oil type medium voltage circuit breaker approaching the end of service life.

�Great concerns of functionality of these breakers and availability of spare parts.

�Life extension or replacement of these breakers became important agenda for continuous business operation.

ABB’s response:

�Cost effective upgrade proposal to retrofit the existing MV breakers.

�All breakers were replaced with latest vacuum type switching components while remain the breaker frame.

�Executed the complete retrofit over a span of about 2 months without interruption to normal customer’s business.


�New service life of aged breakers

�Latest environment friendly vacuum type switching components

�Cost-effective way to extend the life span of breakers

�Improved confidence for continuous business operation.

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Case BookEnergy saving

Customer’s request:•Completely new feed pump starter.

•Better control flow process

•Less mechanical stress on motor during starting

•More serviceability and reliability

ABB’s response:•Electrification with main components of

•2 units ACS1000 MV Drives; 3300 V;

•AMB 560L2L MV Motors;2271 kW, 3371 rpm2601 kW, 3422 rpm


•Total energy consumption, 10% reduction

•Significant CO2 emission reduction

�Good flow controllability

�Soft starting of motor & pump

�“Start-on-time” responsibility from one stop solution provider


Summary

� Complete service portfolio/capability in power and automation

� Pool of expertise in various products, process and application

� Quality and effective service planning and implementation

� Excellent OHS competence

� Responsive and solutions to customers

� Share same value with customers (Quality, safety, efficiency…)

� World wide service network and resources

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Summary

Please contact us for your detail service needs:

Main office Tuas office Gul office Marsiling OfficeNo 2, Ayer Rajah Crescent No 2, Tuas Lane No 1, Gul Crescent 6 Marsiling LaneSingapore 139935 Singapore 638611 Singapore 629517 Singapore 739145Tel: (65) 6776 5711 Tel: (65) 6861 9722 Tel: (65) 6861 2954 Tel: (65) 6369 7532Fax: (65( 6778 0222 Fax: (65) 6861 4355 Fax: (65) 6861 0037 Fax: (65) 6365 2692

Contact center:

Hot line: (65) 6222 7778 ; Fax: (65) 6778 0222; Email: [email protected]

�Mrsling

�Ayer Rajah Crescent

�Tuas�Gul

Turbo charging,

Machine service Workshop

Transformer serviceABB Singapore

Main office

�Changi Airport

�Pasir Panjang Port Terminal

Analytical system and service


Documents

ABB Service Singapore 2010file/ABB+Service_Singapore_2010.pdf · Power system service © ABB Group April 1, 2010 | Slid e 8 ABB Service overview Typical plant power and automation