Reliability, performance, and safety in Motion on board · Standard Basic Data ... ABB has developed UNIQUE analytical tools to identify, characterize and quantify defects that could

© ABB Group December 14, 2010 | Slide 1

Motor & Drive ServicesReliability, performance, and safety in Motion on board

Xu Xiao Ming, 26 Nov 2010, ABB Singapore


Electric machine and drive on board

Customer’s needs in marine service

Motor, generator and drives service in Singapore

Service highlights

Summary

Contents


What does reliability and safety mean on board

When: Nov, 2011

Who: 3000+ passengers and 1000+ Staffs on board one of the world’s biggest cruise ship

What: Cruising 70km offshore



What’s wrong:

Engine room fire

All generator stopped, total power loss,

One day on ocean being adrift before rescue arrival

Two day on ocean being tugged back to port



What’s the result:

No hot food, hot water, air conditioning and casino for 3 days

Terrible smell on board

Angry passengers left in dark

Dream cruise became nightmare


Electrical machines and drive on boardPower and motion for ships

Control

Power Distribution

Generators

Main switchboards

TransformersPropulsion

and thrust

Automation

Drives


Customer needs in marine service

Operational needs

Reliability

Performance

Safety

Efficiency

Organizational needs

Responsiveness/availability

Regulation/compliance

Knowledge sharing

Easy to do business

Long term partner


Motor and drive service in Singapore Two competent regional service Hub

Drive Service facts:

Facilities: Start of art dedicated workshopRegional logistic center

HC: >40 dedicated professional service, sales and order handling staffs

Expertise:Life cycle and application service in LV/MV drive and excitation

Region: Local and SAS Hub responsibility



Drive service offering:

TrainingSpare parts (loose, kits and module)Commissioning /start upPreventive maintenanceCondition monitoringSite trouble shooting/repairWorkshop recondition, repairWorkshop testing and evaluation (Full current test for module up to 580kva/690V)Upgrading/retrofitting for life extensionEnergy efficiencyMotion application serviceWarranty serviceFailure analysis



Motor/Generator Service facts:

Facilities: Rightly equipped expanded workshop (up to 1120mm machine)

HC: > 30 dedicated professional service, sales and order handling staffs

Expertise:Life cycle and major repair/upgrade service in LV/MV motor/generatorCertified Ex machine service

Region: Local and SAS Hub responsibility



Motor/Generator Service offering:

TrainingSpare parts (Loose, kits, capital..)Installation and alignmentCommissioning /start upPreventive maintenanceCondition monitoring/Predicative service (Leap and Machsense equine from ABB)Site trouble shooting/repairWorkshop overhaul/rewinding, repairWorkshop testing and evaluation(Test up to 8MW and full load to 400kw)Upgrading/retrofitting for life extensionEnergy efficiencyWarranty serviceFailure analysis


Service highlightsLeap for MV windings, power in predicative service

LEAP is not just a package of inspections; it is a systematic approach to managing Machine

Maintenance

What is LEAP?

Lifetime Expectancy Analysis Program or LEAP is aunique Predicative Maintenance Tool for the StatorWinding Insulation of Electric Machines.

LEAP provides information on Machine winding and expected residual life, and will optimize the MachineMaintenance Plans

LEAP developed by ABB Machines Service R&D team, is in use for over 12 years, with a database of measurements and analysis in excess of 4000 machines worldwide

Measurements are performed by Local or Global ABBService centers and data analyzed at the LEAP Center ofExcellence


Service highlightsLeap for MV windings

LEAP LevelsSolution Levels Packages Deliverables

Basic Data collection (on site or remote):

Operational hours, voltage, current, power, slip, Starts/Stops, Temperature (Winding, Coolant and Ambient), Duty cycle & loading pattern, Failure and Maintenance history, Information on power supply, breaker-cable configuration, etc

Life Expectancy Analysis 80% Confidence LevelCondition Based Inspection and Maintenance Plan

Standard Basic Data Collection Polarization Depolarization Current Analysis – PDCA Tan Delta & capacitance Analysis Non-Linear Insulation Behavior Analysis Partial Discharge Analysis

Condition Assessment of Stator Windings for Contamination, ageing, looseness,delamination, stress grading system Life Expectancy Analysis 80% Confidence LevelCondition Based Inspection and Maintenance Plan

Advanced Standard Data Collection Visual Inspection on end windings Partial Discharge Probe measurements & Dynamic Mechanical Response of Windings Stress analysis of End-windings

Condition Assessment of Stator Windings with Standard Package + End-winding assessmentLife Expectancy Analysis 85% Confidence LevelCondition Based Inspection and Maintenance Plan

Premium Advanced Data Collection Wedge Tightness Map & Coupling resistance measurements Visual inspection, including slot areas Stress analysis of Windings

Condition Assessment of Stator Windings withAdvanced Package + slot region assessmentLife Expectancy Analysis 90% Confidence LevelCondition Based Inspection and Maintenance Plan


Service highlightsLeap for MV windings

Collection of Data

Operating data, test measurements and machine information is collected using a package of measurements

Analysis of Data

Data collected is analyzed to identify the process of insulation degradation

ABB has developed UNIQUE analytical tools to identify, characterize and quantify defects that could be present within the insulation system

Calculation of Stresses

Life Expectancy Analysis is performed and factors and conditions that affect lifetime are identified

Estimating Life & Condition Based Maintenance

Lifetime is estimated with different Confidence levels depending on the LEAP package

Clear plans for possible further inspections, maintenance, replacements or even upgrades are drawn up


DC Measurements

Polarization De-Polarization Current Analysis

AC Measurements

Non Linear Behavior Analysis

Tan and Capacitance Analysis

Partial Discharge Analysis

Polarization-Depolarization CurrentsU PHASE

0.1

1

10

100

1 10 100 1000Time (sec)

Pol-D

epol

Cur

rent

s (m

icro

Am

p)

Charging Discharging

INSTANTANEOUS CAPACITANCE VARIATIONS@ 5.8 kV

-70

-25

20

65

110

40 42 44 46 48 50 52 54 56 58 60

TIME (msecs)

CAP

ACIT

ANCE

(Arb

itrar

y Un

its)

U - PHASE V - PHASE W - PHASE UVW - PHASE

TAN DELTA MEASUREMENTS

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

1 2 3 4 5 6 7 8

Voltage (kV)

Tan

Del

ta (%

)

U Phase V Phase W Phase UVW Phase

LEAP standard package

Remark:

DC tests are sensitive to the surface conditionAC tests give more information on the insulation volume


IR >>1000 MPI >> 2

Case studyLEAP findings





© ABB GroupDecember 14, 2010 | Slide 19

Service highlightsMACHsense-P, power in condition monitoring

ABB MACHsense-P Development has been done by ABB Machines Service based on intensive R&D carried out in our corporate research centersMeasurement is done on the operating machine

Measurements & Analysis of Data &Report

Measurements are performed by ABBLocal Service CentersA summary report is deliveredautomatically on-siteDetailed report is later delivered byRegional Technical Center (RTC)


ABB MACHsense-P

EquipmentA single analyzer for the mechanical and electrical measurements

Measurements4 Vibration Sensors3 Voltage clamps3 Current clampsTemperature sensors (optional)Speed sensor (optional)

Measurements


ABB MACHsense-P

Cage Rotor Rotor winding defects

Air gap eccentricityUnbalance

Lamination loosenessStatic and dynamic shaft bends

Internal misalignment

Anti-Friction BearingBearing defectsBearing assembly defects

Lubrication interval estimates

Standard Inspection Analysis


ABB MACHsense-P

InstallationSoft foot

MisalignmentFoundation resonance

CoolerFouling

Power Supply QualityHarmonics and distortionUnbalance

Over/under voltage, frequency

Standard Inspection Analysis


Service highlightsAVR upgrade, life extension of generator

UNITROL 1000-7

Single print AVR designField current 7 A (70°C ambient)Suitable for harsh environmentalconditionsEN, ANSI normsCE certified, Design acc. UL, CSA


Automatic Voltage RegulatorField current: 15 AInstalled Base > 5’000 unitsOutstanding functionality, including

Power Factor ControlRotating Diode MonitoringSynchronizing FunctionPower System Stabilizer

Local display and operationSerial interface Modbus

UNITROL 1000-15



Redundant System for High Availability

Auto changeover

Auto follow

100 % redundancy



UNITROL 1000-40 Power Module

UNITROL 1000-PM40 Power ModuleUsed in conjunction with UNITROL 1000-15 AVR

Field current: up to 40 A

Utilizes internal CAN Bus interface

CAN Bus

UNITROL 1000-40



Service highlightsDrive exchange module, plug & play in maintenance

Logistic Centre Drive Service Workshop

ABB workshop Customer site


Summary

Complete service portfolio with pool of expertise and committed facilities

More predicable reliabilities with continuous R&D efforts

Share same value with customers (Reliability, safety, efficiency…)


Summary

Together

We make

Every cruise

Safe, Pleasant, Enjoyable


Reliability, performance, and safety in Motion on board · Standard Basic Data ... ABB has developed UNIQUE analytical tools to identify, characterize and quantify defects that could

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