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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 Group April 1, 2010 | Slide 2
� 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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© ABB Group April 1, 2010 | Slide 3
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�
© ABB Group April 1, 2010 | Slide 4
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 Group April 1, 2010 | Slide 5
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 Group April 1, 2010 | Slide 6
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 Group April 1, 2010 | Slide 7
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
© ABB Group April 1, 2010 | Slide 8
� 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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© ABB Group April 1, 2010 | Slide 9
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
© ABB Group April 1, 2010 | Slide 10
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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© ABB Group April 1, 2010 | Slide 11
� 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
© ABB Group April 1, 2010 | Slide 12
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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© ABB Group April 1, 2010 | Slide 13
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
© ABB Group April 1, 2010 | Slide 14
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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© ABB Group April 1, 2010 | Slide 15
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…..
© ABB Group April 1, 2010 | Slide 16
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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© ABB Group April 1, 2010 | Slide 17
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.
© ABB Group April 1, 2010 | Slide 18
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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© ABB Group April 1, 2010 | Slide 19
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
What Results Benefits
�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
�Increased confidence for operation needs
�Quality/effective service documents assured traceability and future reference
© ABB Group April 1, 2010 | Slide 20
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
What Results Benefits
�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
�Increased confidence for operation needs
�Quality service documents assured traceability and future reference
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© ABB Group April 1, 2010 | Slide 21
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)
© ABB Group April 1, 2010 | Slide 22
Workshop ServicesDrives
Drive Service Workshop
� Cleaning services
� Repair Services
� Reconditioning services
� Exchange units
� Running test services
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© ABB Group April 1, 2010 | Slide 23
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
What Results Benefits
�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
© ABB Group April 1, 2010 | Slide 24
� 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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© ABB Group April 1, 2010 | Slide 25
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
© ABB Group April 1, 2010 | Slide 26
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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© ABB Group April 1, 2010 | Slide 27
� 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
© 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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© ABB Group April 1, 2010 | Slide 29
Case BookAutomation maintenance contract enable customer focus on main business
Customer’s request:
�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
© ABB Group April 1, 2010 | Slide 30
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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© ABB Group April 1, 2010 | Slide 31
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.
© ABB Group April 1, 2010 | Slide 32
Case BookMV breaker upgrade give aged breakers new life
Customer’s request:
�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.
Customer’s benefits
�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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© ABB Group April 1, 2010 | Slide 33
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
Customer’s benefits
•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
© ABB Group April 1, 2010 | Slide 34
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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© ABB Group April 1, 2010 | Slide 35
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
© ABB Group April 1, 2010 | Slide 36