1. ABB SACE Maintenance Preventive & Predictive Maintenance
Feb 2013
ABB SACE Maintenance Preventive & Predictive Maintenance

2. 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

3. ‘’Any maintenace activity is a cost’’
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

4. Maintenace Theory Myths & Facts FALSE FALSE FALSE Common Myths
Circuit-breakers are maintenance free
Circuit-breakers Preventive Maintenance is just dusting down
The circuit-breaker is always in closed position so it doesn’t require any maintenance
Proven Facts
Circuit-breakers are protecting devices: periodical check on functionality and maintenance are required to guarantee the original performance level
Circuit-breakers Preventive Maintenance consists in checking the integrity of all the electrical and mechanical components to limit aging on components and prevent faults
All the mechanical and electrical components need maintenance (as lubrication) in particular in harsh environments.
FALSE
FALSE
FALSE

5. Maintenace Theory Why maintaining Direct Costs Indirect/induced Costs:
Indirect 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
Inefficiency in personnel
Insurance policies
Production Losses
Losses in market share

6. BUT 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

7. 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)
Why choosing ABB: Specialistic maintenance

8. ABB SACE Maintenance Portfolio ABB SACE offer (in accordance with EN 13306:2010)
Before a failure
Maintenance
After a failure
Preventive
Corrective
Predetermined
Urgent Maintenance: Aimed at bringing back the element in the status in which it could carry out the required function
Deferred Maintenance: At predetermined intervals of time or on the base of prescribed criteria aimed at reducing the probability of failure or the working deterioration of the element
Predetermined Maintenance is a preventive maintenance carried out in accordance with established intervals of time or number of units of use but without previous condition investigation
Conditioned-based maintenance is a combination of condition monitoring and/or inspection and/or testing, analysis and the ensuing maintenance actions
Predictive Maintenance is carried out following a forecast derived from repeated analysis or known characteristics and evaluation of the significant parameters of the degradation of the item
Conditioned- based
Urgent
Deferred
Predictive
Scheduled

9. ABB SACE Maintenance Portfolio Preventive maintenance
Before a failure
Preventive Maintenance
Predetermined Maintenance
Conditioned-based Maintenance
Scheduled Maintenance
Predictive Maintenance
LEAP+PMP
PMP

10. 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
1st-2nd intervention: ordinary maintenance in order to maintain the conservation state obtained with the previous intervention and to contain the wearing trend of the apparatus:
3rd intervention: extraordinary maintenance in order to control the condition of the apparatus and re-establish, as much as possible, the original state;

11. Extraordinary Maintenance
ABB SACE Maintenance Portfolio Preventive and Scheduled Maintenance for Emax
Ordinary Maintenance
Extraordinary Maintenance
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

12. 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
September 17, 2018 | Slide 17

13. 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 possible critical conditions
© ABB Group
September 17, 2018 | Slide 18

14. ABB SACE Maintenance Portfolio Predictive maintenance: LEAP Offers
LEAP Easy AUDIT
LEAP AUDIT
LEAP STAND ALONE
LEAP + PMP

15. ABB SACE Maintenance Portfolio Predictive maintenance: LEAP Offers
ABB Field Service Eng./
ABB certified partners
LEAP +
PMP
ABB Personel
LEAP STAND ALONE
Customer
LEAP AUDIT
LEAP EASY AUDIT
LEAP OFFERS
Free
Statistics √
Real Data
Maintenance
Multiple years Agreement

16. 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

17. 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

18. 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 =

19. 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

20. ABB SACE Maintenance Portfolio Architecture: LEAP + PMP
USB Bluetooth or Ekip T&P
LEAP CLIENT
CUSTOMER
TECHNICIAN
LEAP SERVER
ADMINISTRATOR
Phase 2:
Data Transfer and Elaboration
Phase 1:
Automatic and manual Data acquisition
WEB
Phase 3: Data Analysis
Phase 4:
Final report to Customer

21. 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

22. 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

23. 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.