ABB Service _ Singapore Power and automation service professionals

Transcription

1 Xu Xiao Ming, AP Services, March 2010 ABB Service in Singapore Experience with power and automation service professionals April 1, 2010 Slide 1 ABB Service _ Singapore Power and automation service professionals 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 April 1, 2010 Slide 2 1

2 World wide service Local delivery with global support Netherlands Denmark Norway USA Canada Belgium UK France Portugal Spain Switzerland Sweden Finland Estonia Latvia Lithuania Poland Turkey Russia China Korea Japa n Mexico Colombia Venezuela Italy Germany Austria Hungary Oman UAE Quatar Kuwait Saudi Arabia India Malaysia Thailand Singapore Taiwan Peru Egypt Brazil Chile Argentina South Africa More than 22,000 service professionals worldwide Australia New Zealand April 1, 2010 Slide 3 Complete range of services One 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 April 1, 2010 Slide 4 2

3 ABB Service _ Singapore Overview Started back in early 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. April 1, 2010 Slide 5 ABB Service _ Singapore Highlights Spacious and equipped workshops Motor and generator service Transformer service Turbo charging service State of art facilities Drive service Training center April 1, 2010 Slide 6 3

4 ABB Service _ Singapore Highlights Regional centre: DCS service Drive service Machine service _ Leap Analytical and instruments Training center Marine service Pulp & paper service OGP service Power system service April 1, 2010 Slide 7 ABB Service _ Singapore Power and automation service professionals 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 April 1, 2010 Slide 8 4

5 Typical plant installation Integrated electrical system Utility ENMC MV or HV Generator 22 or 66kV Power Transformers 6.0, 6.6, 11kV MV Distribution Transformers Indoor AIS Indoor GIS Rectifier Transformers 400V LV LV MSB/MCC LV Distribution Transformers MV Drives Compressors LV Drives Pumps 400/230V Fans Etc LV Motors Battery UPS MV Motor LV distribution board April 1, 2010 Slide 9 Typical plant installation Automation system Remote Clients Workplaces Maintenance Engineering Operator System Servers Control Network Process Automation and Safety Process Automation Safety S800 I/O Variable Speed Drives S900 I/O (Ex) MCC Fieldbus High Speed Linking Devices (FF HSE/H1, PB DP/PA) Process instrumentations April 1, 2010 Slide 10 5

6 ABB Service _ Singapore Power and automation service professionals 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 April 1, 2010 Slide 11 Life Cycle Service Concept: Value Operation Extended life-time New build phase Commissioning Time 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 April 1, 2010 Slide 12 6

7 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 April 1, 2010 Slide 13 Spare parts service Right 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 April 1, 2010 Slide 14 7

8 Training service Sharing and improvement Highlights: Features: Certified regional training centre for 800XA system and drives Global training centre for marine academy Comprehensive Training Facilities Practical-based Learning Solutions Customer-focussed Training Qualified & Experienced Trainers Accredited Courses by our partners in learning.. April 1, 2010 Slide 15 Training service Sharing and improvement Products Main Courses Course Developer (i) Control Systems Advant OCS 800xA System Freelance 800F Collaborative Production Management ABB University ABB University ABB University PIP, Singapore (ii) Drives LV and MV Drives ABB University (iii) Expert Workshops Advance workshops Global Consult IT (iv) Industry Specific Courses Marine Pulp & paper Oil, Gas & Petrochemicals Power Systems Marine Academy COE, Singapore Global COC, Singapore (v) Analytical Systems Measurement ABB Singapore (vi) Appreciation courses Various for Channel Partners/end users ABB Singapore April 1, 2010 Slide 16 8

9 Proactive maintenance Securing Operation, Reduce Downtime April 1, 2010 Slide 17 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 What How Results Benefits Tailor designed CBM service products with ABB s in-depth knowledge of product and process Right level of users involvement for joint effort Pre-defined intervals Effective and knowledge base test/analysis tools Equipment without stopping or temp stopping Executed and analyzed by ABB service professional 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 OHS competence April 1, 2010 Slide 18 9

10 Proactive Maintenance _ Preventive What How Results Benefits 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 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 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 April 1, 2010 Slide 19 Workshop Service High level of performance reclaim and improvement What How Results Benefits Major electrical/mechanical repairs Complete workshop diagnose test/inspection Complete overhaul/recondition of equipment Upgrading/renew insulation ISO certified, ABB service/repair workshop. Well equipped workshop facilities Original product or relevant international standard Executed by ABB service professionals OHS competence 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 April 1, 2010 Slide 20 10

11 Workshop Services Machine 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) April 1, 2010 Slide 21 Workshop Services Drives Drive Service Workshop Cleaning services Repair Services Reconditioning services Exchange units Running test services April 1, 2010 Slide 22 11

12 Modernization, upgrading, replacement New life of assets What How Results Benefits End of service life Beyond economical repair Limited and unavailable spare parts Limited and unavailable service resource Needs from new standard/class/opera tion 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 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 April 1, 2010 Slide 23 ABB Service _ Singapore Power and automation service professionals 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 April 1, 2010 Slide 24 12

13 Energy efficiency service Protect your profit, protect the earth Primary energy Transport Generation T&D Industrial processes Industrial production ABB technology can double energy productivity! Available energy Improved well efficiency Higher pipeline flows More efficient fuel combustion Lower line losses, higher substation efficiency Improved productivity More efficient motors & drives Process Automation Marine & pipelines Power plant automation Grid operation Process automation Drives & motors April 1, 2010 Slide 25 Energy efficiency service Protect 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 April 1, 2010 Slide 26 13

14 ABB Service _ Singapore Power and automation service professionals 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 April 1, 2010 Slide 27 Case Book Drive 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. April 1, 2010 Slide 28 14

15 Case Book Automation 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 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 April 1, 2010 Slide 29 Case Book Leap service boosts customer confidence on MV motor operation Stress, strength Stress Strength Transie nt faults Residual Life Time Premature Failure Failu re 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. April 1, 2010 Slide 30 15

16 Case Book Generator 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. April 1, 2010 Slide 31 Case Book MV 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. April 1, 2010 Slide 32 16

17 Case Book Energy 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 rpm 2601 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 April 1, 2010 Slide 33 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 April 1, 2010 Slide 34 17

18 Summary Analytical system and service Mrsling Turbo charging, Machine service Workshop Transformer service Tuas Gul Ayer Rajah Crescent Pasir Panjang Port Terminal Changi Airport ABB Singapore Main office Please contact us for your detail service needs: Main office Tuas office Gul office Marsiling Office No 2, Ayer Rajah Crescent No 2, Tuas Lane No 1, Gul Crescent 6 Marsiling Lane Singapore Singapore Singapore Singapore Tel: (65) Tel: (65) Tel: (65) Tel: (65) Fax: (65( Fax: (65) Fax: (65) Fax: (65) Contact center: Hot line: (65) ; Fax: (65) ; contact.center@sg.abb.com April 1, 2010 Slide 35 April 1, 2010 Slide 36 18