Feb 2013

ABB SACE Maintenance

Preventive & Predictive Maintenance
Maintenace
Agenda

Aim
Mind-Changing
Why maintaining
Miths and Facts
Estimated lifetime

ABB SACE Maintenance portfolio:

Maintenance with ABB SACE: Benefits
Offer:
Preventive Maintenance – PMP
Predictive Maintenance -LEAP
Maintenace theory
Aim: Mind-changing

‘’Any maintenace activity is a cost’’

The customer has to understand that performing a
correct and periodic maintenance is essential to:
- Reduce the total managing costs
- Use the resources according to needs
- Standard, directives and laws
Maintenace Theory
Myths & Facts

Common Myths Proven Facts

• Circuit-breakers are Circuit-breakers are protecting
L S Efree •

FA
maintenance devices: periodical check on
functionality and maintenance
are required to guarantee the
original performance level
• Circuit-breakers • Circuit-breakers Preventive
Preventive Maintenance consists in
L
MaintenanceS Eis just checking the integrity of all the
FAdown
dusting electrical and mechanical
components to limit aging on
components and prevent faults
• The circuit-breaker is • All the mechanical and electrical
always in closed components need maintenance
soSitEdoesn’t
position L (as lubrication) in particular in
FAany
require harsh environments.
maintenance
Maintenace Theory
Why maintaining
Direct
costs Direct Costs
• Maintenance: personnel,
materials

Indirect/induced Costs:
• Higher risk in Health & Safety
• Reduction of products lifetime
• Management of urgency
• Poor quality
• Energy consumption
• Environmental impact
• Resource availabilities
Indirect • Inefficiency in personnel
costs • Insurance policies
• Production Losses
• Losses in market share
Maintenace Theory
Estimated lifetime

Based on ABB experience, it is possible to define

average component lifetimes

BUT

a SITE SURVEY is always recommended.

It is performed by a circuit breaker specialist, who

inspects the products, on-site spares, environment,
fault history, etc...

The result of a site survey is a proposal of short and

long term maintenance actions
ABB SACE Maintenance Portfolio
Maintenance with ABB - benefits

ABB technicians are skilled and properly trained:

 Before operating on the field spend at least 1
year in the production line
 Regular courses to be updated on new products
 By turns work in the internal assembly line for
repair
 Original Spare Parts
 Right tools
 Continuous communication between R&D/
Quality dep. and Service  Knowledge on CB
updates (modification for improvements)
ABB SACE Maintenance Portfolio
ABB SACE offer
(in accordance with EN 13306:2010)

Before a failure After a failure

Maintenance

Preventive Corrective

Conditioned
Predetermined
- based
Urgent Deferred

Scheduled Predictive
ABB SACE Maintenance Portfolio
Preventive maintenance

Before a failure

Preventive
Maintenance

Conditioned-
Predetermined
based
Maintenance Maintenance

Scheduled LEAP
Maintenance PMP Predictive
Maintenance +PMP
ABB SACE Maintenance Portfolio
Preventive and Scheduled Maintenance - PMP

Reduce the risk of failure and working deterioration of the low

voltage circuit-breakers installed in the plant
It is structured in a cycle of three maintenance interventions:
• 1st-2nd intervention: Ordinary Maintenance
Maintaining the original integrity of the product:
• Maintaining or restoring the efficiency of the products
• Containing the normal deterioration of use
• Guaranteeing the useful life of the product
• Facing accidental events
• 3rd intervention: Extraordinary maintenance
Extend the useful life and/or improve:
• efficiency
• reliability
• productivity
• facility of maintenance and inspection
All interventions are carried out by chief skilled technicians
ABB SACE Maintenance Portfolio
Preventive and Scheduled Maintenance for Emax

 Provides systematic
and functional means of
maintaining a specific
breaker
 Each ABB ACB series
has its own schedule
which is based on years
of experience and
knowledge of
manufacturing and
maintaining circuit
breakers

Ordinary Maintenance Extraordinary

Maintenance
ABB SACE Maintenance Portfolio
Predictive maintenance: LEAP

A system to optimize the efficiency of a New Emax CB

with a periodical analysis of the aging level:
 Monitoring of the health of the assets by means
of data acquisitions
 Recommendation of the required maintenance
activities
 LEAP implements predictive maintenance algorithms
 LEAP is integrated in FSM (Field Service Manager)
for Service activities planning tool

© ABB Group
1/29/21 | Slide 17
ABB SACE Maintenance Portfolio
Predictive maintenance: LEAP

LEAP is a condition based and predictive maintenance

based on:

 Inspection  Monitoring on location and acquiring

the normal operational parameters of the system
 Maintenance  List of maintenance activities
performed by the filed service engeneer:
components substituted, cleaning, checks, test,…
 Analysis  Studing and processing of the data
gathered in the field, and establishing trend diagrams
concerning efficiency and wear of the system that is
monitored
 Report  Generation of a detailed report that sums
up the condition of the system inspected and the
© ABB Group
possible critical conditions
1/29/21 | Slide 18
ABB SACE Maintenance Portfolio
Predictive maintenance: LEAP Offers

Predictive maintenance

LEAP Easy AUDIT

LEAP AUDIT

LEAP STAND ALONE

LEAP + PMP
ABB SACE Maintenance Portfolio
Predictive maintenance: LEAP Offers

ABB Field Service Eng./

ABB certified partners

ABB Personel

Customer LEAP

LEAP STAND +
LEAP EASY LEAP AUDIT ALONE PMP
LEAP
OFFERS AUDIT Free

Statistics √
Real Data √ √ √
Maintenance √ √
Multiple years
Agreement
√

© ABB Group
1/29/21 | Slide 20
ABB SACE Maintenance Portfolio
LEAP Easy AUDIT (web)
1. User: Customer
2. Frequency: once for S/N / Customer
3. ACCESS:
 Registration in ABB website
 Login & Password
 WEB Leap access
4. Limited Input data:
 CB S/N,
 Application segment,
 Mech operations number,
 Enviromental conditions
5. Maintenance: NO
6. Limited Report:
- CBs factory data
- Theoric CB life status
7. Free of charge
ABB SACE Maintenance Portfolio
LEAP AUDIT
1. User: Service Promoters
2. Frequency: once for S/N / Customer
3. ACCESS:
 Registration in ABB website
 Login & Password
 Leap access
4. Limited Input data:
 Manual data
 Automatic data from the TU
5. Maintenance: NO
6. Limited Report:
- CBs factory data
- Real CB life status
7. Free of charge
ABB SACE Maintenance Portfolio
LEAP Stand Alone
1. User: ABB service technicians/
partners
2. Frequency: on demand
3. Data input: full set:
 Automatic data acquisition
from the TU (PR12x)
 Manual Data acquisition:
=  environmental,
 application,
 working conditions
 maintenance carried out
4. Report and Analysis:
• complete LEAP Report on
selected CBs with
maintenance
• Limited LEAP report on
remaining CBs without
maintenance
ABB SACE Maintenance Portfolio
LEAP + PMP

1. User: ABB service technicians/ partners

2. Frequency: PMP contracts:
Heavy  6 months; Standard 12 months ; Light  18 months

3. Data input: full set:

 Automatic data acquisition from the
TU (PR12x)
 Manual Data acquisition:
 environmental,
 application,
 working conditions
 maintenance carried out

4. Maintenance: YES according to the PMP

program
5. Report: Complete with:
 life analysis of the CB
 suggested maintenance
6. Price: included into PMP
ABB SACE Maintenance Portfolio
Architecture: LEAP + PMP
USB
Bluetooth
or Ekip T&P

Phase 2:
Data Transfer and
Elaboration

Phase 1: LEAP CLIENT WEB ADMINISTRATOR

Automatic and manual
Data acquisition

Phase 3: Data Analysis

TECHNICIAN CUSTOMER

Phase 4: LEAP SERVER

Final report to
Customer
ABB SACE Maintenance Portfolio
LEAP: Data acquisition
Automatic data acquisition  Ekip Connect Software
 Directly from Trip Unit of ACB:
 CB type and relevant info

 Electrical / Mechanical operations

 Alarms / Trip History / Event logs

 Number of operations (Open/Close)

Manual data acquisition  LEAP Client Software

 Software for manual collection data
 Electrical Plant Info
 Enviromental data:
• Temperature range/ Moisture / Saltness/ Dust level/
Corrosive level/ Altitude
 Application data:
Vibration/ Application/ Utilization/ Load Type/ Load
Percentage
ABB SACE Maintenance Portfolio
LEAP: Benefits
 Circuit breaker efficiency/reliability preservation
 Extention of the CB life
 Guaranteeing the plant & people safety
 Probability of unwanted shut-downs reduction
 Providing the best management of maintenance costs
 Direct costs: Direct maintenance : technicians, spare parts…
 Indirect costs: non-production, accident, failure, maintenace
management, …
 Customer support during all product life phases
 ABB professional competence guaranted:
 Preventive, predictive and corrective maintenance to increase:
performances, reliability, availability of circuit breakers and
systems
 Detailed and objective diagnostic for each circuit breaker
 Dedicated tool based on an ABB certified and unique algorithm
ABB SACE Maintenance Portfolio
Summary

 Maintenance management maximizes the value of

circuit breakers and customers investments.
 All the circuit breakers have aging and wearing in
components: a proper preventive maintenance is
required
 Maintenance schedule specifies the recommended
maintenance actions for preventive maintenance
 LEAP Predictive maintenance:
 detailed analysis of the CB aging
 definition of specific actions to be performed
 estimation of the residual life od the product.