Automation Technologies – Services

Performance and Productivity

2 ABB

Less capital spendingThere is significant pressure to lighten the balancesheet, increase cash flow and improve earnings. It isbecoming increasingly important to focus on makingoptimum use of existing assets and maximisinginvestment.

Fast technology-change is drivingoutsourcingThe fast pace of change, and the continuing pressureto reduce cost by reducing personnel makestechnology difficult to manage. Companies todaymust look outside for the expertise they used to havein-house.

Maximise your investment

Emerging technologies demand newknowledge needsEmerging automation technologies increase the needfor new knowledge. Ensuring that the company’spersonnel use the best cutting-edge technology isbecoming more and more challenging.

Increased focus on core businessIn today’s highly competitive environment, it is criticalto focus on core business activities and seekalternate means of handling non-core, yet essential,aspects of operations.

These are challenging issues.We can help you address them.

ABB in India

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ABB is one of the world’s largest automationcompanies with a wide range of automation products,systems and solutions offerings and an extensive,global installed base of control, motion and roboticproducts and systems.

Providing world-class support to ensure maximumperformance of your automation equipment is asimportant to us as it is to you.

Our complete portfolio of service offering – fromconsulting, optimisation and outsourcing services tospare parts – can help to maximise your investmentby:

� Improving equipment productivity

� Minimising costs throughout the life of theequipment

� Extending useful equipment life

With more than 10,000 service professionalsworldwide, we get the job done, when it’s needed,where it’s needed in the most efficient manner, and tothe most exacting technological standards.

Automation Technologies – Service Offering

Analytical Control Force Instru- Low Voltage PropulsionProductsProductsProductsProductsProducts Products Systems Drives Measurement mentation Products Motors Systems Robotics Turbochargers

IndustriesIndustriesIndustriesIndustriesIndustries Automotive • • • • •Buildings • • •

Chemicals • • • • • • •Consumer • • • • • • •

Manufacturing • • • • • •Marine • • • • • •Metals • • • • • • • •

Minerals • • • • • • • •Mining • • • • • • • •

Paper • • • • • • • •Petroleum • • • • • • • •

Pharmaceuticals • • • • • • • •Printing • • • • • •

Transportation • • • •Utilities • • • • • • •

Service Portfolio

� Installation and commissioning� Training� Maintenance and field services� Spare parts and repairs� Support and remote services� Consulting� Optimisation� Migration and retrofits

Key Deliverables:

� Discrete manufacturing� Marine� Process industries� Utilities

Sectors Served

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Maintenance & Field Services

Our highly competent global service team is equipped to provide fast andefficient response to your service needs. Our service professionals are trainedand certified to help you avoid downtime and get you back online as quickly aspossible. We know that the key to providing world-class service is not only torespond quickly, but also to provide better and competitive solutions.

capabilities needed to maintain site asset performanceat the required level. Agreements range from ‘call-up’support services to complement a self maintenancestrategy, to service contracts with resident engineers.Some of the key areas covered: Drives, Automation,QCS and Analytics.

Our service systems professionals can help youidentify and implement effective contract maintenanceprogrammes that help reduce cost and improve up-time by maintaining equipment at peak performancelevels.

Benefits� Expanded maintenance capabilities

� Improved equipment utilization

� Effective maintenance planning

Preventive Maintenance Kits for AC DrivesThe primary objectives of the Preventive MaintenanceProgramme for AC drives are to optimise both thereliability and the efficiency of the electrical drive as wellas to help with maintenance planning. Reasonablemaintenance intervals for an AC drive depends upon theprevailing ambient conditions and the recommendationsin the Maintenance Schedule. From past experience andmanufacturer recommendations, it is possible to specifytypical intervals for replacing certain components. Thesecomponents are included in the Preventive Maintenancekits (PM kits) and are a part of the well-planned standardmaintenance programme.

Installation & CommissioningABB’s service engineers provide expert on-siteinstallation & commissioning of products andsystems. Our startup and commissioning servicesspan from installation support to full projectmanagement.

Benefits� Smoother installations

� Faster start up at lower cost

� Improved efficiency

Preventive and CorrectiveEffective Predictive, Preventive and Correctivemaintenance practices maximise the performance ofyour automation and production equipment. ABB’sservice personnel are trained in the latest diagnostic,repair and maintenance practices to ensure high returnon your maintenance investment. Maintenancesolutions such as condition monitoring help to predictequipment failure and prevent costly downtime.

Benefits� Reduced average time

� Increased plant performance

� Higher overall equipment effectiveness

Annual Maintenance Contract (AMC)We recognise that your specific service requirementsare based on the criticality of your assets to yourproduction process, and the level of in-houseexpertise you expect to maintain. The ABB ServiceContract Agreement is tailored to complement yourin-house expertise and provide the additional

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Plant automation provides access to abundant andvaluable process, production and equipmentfeedback. The ability to analyse and utilise this dataeffectively is the key to decision-making andresponse. ABB’s Process and Asset OptimizationServices use a proven, ‘continuous improvement’methodology, special tools and knowledge of thesystems and processes in operation to identify andrelease valuable improvement opportunities currentlyhidden in the production assets.

Optimisation Services

Overall Equipment Effectiveness (OEE)

Optimisation begins with discovery and analysis ofpotential process and asset improvement areas. OurOverall Equipment Effectiveness model applies atime-proven analysis methodology, which uncoversand measures potential benefits. This model centreson the measurement of existing relationships betweenequipment availability, efficiency, and rate of qualityproduction. Analysis of these relationships can yieldsubstantial performance improvement opportunitiesin several targeted areas.

ABB engineers can provide a customisedimplementation plan based on this analysis andintegrate the same into the site maintenance schedule.

Benefits� Quality and productivity optimisation

� ABB-specific tools for accurate analysis

� Lower maintenance costs

Review and Measurement ToolsStand-alone, targeted services are also available toreview specific areas of the systems and process.

– Power Quality & Grounding Review

– Network Communications Review

– Distributed Control Systems Services: LifecycleEvaluation, Hardware Review, Software Review,Communications Review

– Maintenance Fingerprint

The OEE Model

Faced with increasing environmental regulationand globalisation issues, a cement manufacturerneeded to change the maintenance practices andtools. The plant, built more than 40 years ago,never achieved full capacity since only two of thefour kilns were put into operation.

The customer called on ABB to modernise itsmaintenance systems.

ABB helped identify and implement immediatemaintenance actions to improve and optimiseproduction. This included a cultural change froma “break and fix” attitude to a ‘preventive’approach.

A cement plant optimises its production

OEE = Availability x Efficiency x Quality

Potential OEE improvement can beeffectively measured and comparedwith actual data after optimisationservices are implemented.

Theoretical Production Time

PlannedProductionTime

PlannedDowntime

GrossOperatingTime

UnplannedDowntime

Losses

NetOperatingTime

SpeedLosses

QualityLosses

ValuableOperatingTime

TargetedPerformanceImprovement

AreasA – Availability

E – Efficiency

Q – Quality

Defects in Process& Rework

StartupLosses

Reduced Speed

Idling & MinorStoppages

Setup &Adjustment

EquipmentFailure

6 ABB

Support & Remote Services

Advanced remote technology delivers higher servicevalue and performance. Remote Services extendassistance for a wide range of support needs. Fromtelephone and self-service web support to direct andsecure system interaction, remote services providereal-time and direct access to global technicalspecialists and service experts 24-hours a day, allyear round!

Web-Based supportOur web-based support service, SolutionsBank,provides on-line access to more than 60,000technical documents and a wide range of supportsolutions.

Web-based support provides instant access toproduct documentation, software downloads andreports that you need to support your operation.Activate Auto Notification, and receive emailnotifications of updates for products forming part ofyour installed equipment profile. View technicalinformation and video instructions, track service callprogress, download software and updates, evensolve your own support case on-line!

A SolutionsBank subscription gives you access to24-hour self-service support. A complementarysubset of ABB technical information and downloadsis also available. For additional information visitSolutionsBank on-line at:http://SolutionsBank.abb.com

Benefits� Saves time and money through self search

� 24-hour access to technical solutions

� Faster access to support resources

Knowledge Navigator, a SolutionsBank softwareadd-on, works seamlessly with ABB’s 800xAExtended Automation control systems to provideweb-based remote access to trouble shooting andsupport information. Workstation icons link directly toappropriate support material in SolutionsBank usingstandard 800xA aspects.

Benefits� Higher value from advanced control systems

� Faster resolution using context-sensitiveinformation

� Lower support costs through self-help tools

The benefits of Knowledge Navigator, aSolutionsBank tool were immediately evident to apaper company. By providing direct, context-sensitive access to SolutionsBank from workstations, operators were able to proactivelysettle machine issues on their own, rather thanwait for the maintenance personnel to respond.

The paper plant used Knowledge Navigator totroubleshoot system-generated alarms.Operators took action based on therecommendations or escalated the issue to theiron-site maintenance staff.

ABB empowers paper plant operators withon-line maintenance information

ABB’s remote vibration analysis contract with agovernment organisation, operating a fleet ofvessels worldwide, has been in place for over 25years. The customer’s average benefit-to-costratio of over 20:1 is a product of 5,000+ annualmachine tests.

Two-thirds of the cost savings are linked toimproved selection and prioritisation of machinesscheduled for repair or overhaul. The remainingone-third of the documented savings centers onearly fault detection, resulting in prevention ofprogressive machine damage. ABB’s skilledvibration analysis and proven fault diagnosticsoftware has improved labour efficiency andmachine reliability while reducing overallmaintenance costs.

Marine industry benefits from remoteanalysis

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How ABB Provides Remote Services

Connection Layer

Marine

Industrial ITEnabled Products

& SystemsControl

Systems

Instrumentation& Low-Voltage

ProductsDrives

& Motors

Propulsionpredictivemaintenance

Assetoptimisation

Web-basedmaintenancemanagementsoftware

On-lineparts

Remotedrivemonitoring

Internet – Modem – Direct Line – Etc.Communication Layer

Analysis & Feedback Layer

Remote services utilise cutting-edgetechnologies to provide valuable diagnosticand monitoring services.

• Field Engineer• Global Resources

• Technical Support Resources• Global Centers of Excellence

8 ABB

Migration & Retrofit Services

The ABB lifecycle management model provides theframework used to develop and provide evolutionaryservices that maximise availability and performancethroughout the life of the equipment. This modelenables ABB to provide optimum support to end-users and a smooth transition to new software andequipment when a product reaches the end of itslifecycle.

Many products provide useful service for twentyyears or more. Throughout the product lifecycle, wework to provide solutions that expand thefunctionality and extend the lifecycle of yourequipment, while maintaining your core investment.

� ABB � Maestro� A-B/S � Master� AccuRay® � MOD 300� Alfa Laval � Moloney� ASEA � Network 90®

� Bailey � Schneider� BBC � Schoppe & Faeser� Fischer & Porter � Stromberg� Freelance � SYMPHONYTM

� Hartmann & Braun � Taylor� INFI® 90 � TBI� ITE/Gould/Kelman � Westinghouse� Kout

Clear evolutionary path forward for a widerange of ABB product lines

Benefits� Identify upgrade opportunities with the greatest

ROI (Return on Investment)

� Access to ABB’s evolution experts

� Cost-effective solutions

Migration ImplementationABB Migration Implementation services provide acomprehensive upgrade implementation option forequipment. Services are efficiently managed asprojects, and utilise established engineering practicesand tools to ensure that all necessary details areidentified and addressed during the project. Ourdedicated migration team ensures equipmentcompatibility and smooth transition to next-generation technology when required.

Deciding on appropriate migration or retrofit servicesfor your installation, is best accomplished throughMigration Planning Services. An annual planningsession with your ABB service team is recommendedto identify long and short-term optimisationopportunities and benefits.

Benefits� Simplify expansion and replacements

� Low risk migration

� ROI-based upgrades

Standard Migration PackagesStandard Migration Packages are available for manyABB products and systems. Software, hardware andfirmware upgrades for standard products are alsoavailable.

Benefits� Simplified upgrade process

� Reduced downtime

� Minimised maintenance costs

Product lifecycle management� Ensures spare parts and competence availability

throughout the product lifecycle

� Enables efficient product support & maintenancefor improved reliability

� Adds functionality to the initial product byfollowing the upgrade path

� Provides smooth transition to new technology atthe end of the product lifecycle

Migration PlanningABB’s Migration Planning services can help you todevelop your long-term evolution roadmap. Planningtoday can help you to budget funding for upgrades andavoid unplanned capital expenditures in the future.

Our unique service approach to migration planningfollows your strategy – not ours. We provide thetechnical information you need to determine whichevolution strategy is compatible with your currentsituation and would provide the maximum benefit.Our structured criticality analysis and productsupportability report will provide you clear “Replace,Migrate, or Maintain” options.

We can help you plan a strategy which fits yourbudget, allows maximum benefit from yourinvestment, and ensures that your existing capitalinvestments help maintain top performance.

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Migration ManagementWe map our customers’ technology needs, explorealternative solutions, and leverage emergingtechnologies to ensure that we deliver engineeringsolutions for tomorrow.

Based on existing requirements and lifecycle status,ABB migration teams recommend and developtimely, cost-effective solutions that efficiently addressevolving market opportunities and demands.

Lifecycle ManagementABB’s Product Lifecycle Management modelcomprises of four phases: Active, Classic, Limited, andObsolete. It is reviewed regularly to ensure thatsupport options are available and evolutionaryprograms are in place to maintain your core investmentthroughout the product lifecycle.

Evolution products simplify the upgrade process, byextending product life-span and optimising systemand component performance, while maximising returnon investment and delaying obsolescence.

Step-up Programs simplify the upgrade process,provide enhanced performance capabilities, andmaximise the value of installed systems andcomponents. ABB Step-up programs also helpminimise maintenance costs and reduce downtime.As an added advantage, all Step-up services aredesigned to allow existing data to be used withupgraded systems. Complete upgrade support isavailable and provided by ABB Step-up teams.

In 2002, a cement plant decided to expand theinstalled capacity to 6.5 Mtpa from 4.5 Mtpathrough de-bottle necking. A new pre-calcinerstring and roll press were added. The fly ashaddition system was also introduced.

The existing automation configuration was basedon 35 nodes of classic MP200/0 and MV8000/0systems with S100 I/Os. A detailed siteinvestigation was conducted by ABB and newconfiguration based on 8 nos. AC450 and server-client architecture of OperateIT was accepted bycustomer in April 2003. After detailedengineering, the system commissioning startedfrom Dec. 2003 in various phases and wascompleted in Nov. 2004. The complete jobprogressed smoothly as the existing wiring wasnot disturbed and hence could be executed inphases.

Evolution Through Enhancement

Software Management Programs range fromsoftware consulting to complete softwaremanagement program, SoftCare. SoftCare providessoftware management for ABB automation products,combining software subscription services with basicsoftware support. ABB’s service support engineersare available to assist your personnel or completelymanage your software program, including softwarearchiving and validation.

ABB’s Migration PlanningServices simplify theprocess of upgradingyour existing technology,while maintaining yourcurrent systeminvestment.

Control System “Evolution Though Enchancement” strategiesare available for Harmony/INFI 90,MOD 300, DCI, Melody,Master, Satt, Contronic and Freelance Control Systems.

10 ABB

warning only when the motor failure is imminent,based on the nature of motor faults. The warningusually does not include information regarding the‘remaining life’ or the minimum time needed to repairor replace the motor component. If the ‘remaining life’of motor components can be reliably estimated, it isextremely advantageous since it allows service to beperformed during planned downtime rather thanduring a costly emergency.

During the lifetime of a machine, opportunities formaintenance and inspections are available whileoperating or when there is an outage of the machine.Depending on the length of the outage, there mightonly be enough time available to perform aninspection or maintenance on the electric machine inthe following machine states:

� During operation of the machine

� During machine stoppage when the machine is inan assembled condition

� During the machine stoppage when the machine ispartially dismantled (e.g. end covers of themachine or inspection windows removed)

� During the machine stoppage when the rotor iswithdrawn from the stator.

The four levels of maintenance and inspections (Level Ito IV) can help to clearly formulate a plan for thecondition based life cycle management of themachine.

An important part of Machine LifeCycle ManagementThe average annual failure rate of large electricmachines is estimated to be at least 3%. In industriesthat require the motor to be operated under hostileconditions and rigorous environment, such as miningor pulp and paper, the annual failure rate can be ashigh as 12%. In order to get the most from the returnon investment of this installed base, it is imperativethat we operate and maintain the machines in amanner that maximises availability and reliability,improves operational efficiency and enhancesproductivity. Life Cycle Costing (LCC) tools can beeffectively applied to evaluate the costs associatedwith a specific activity, for example, the effects ofdifferent maintenance concepts/approaches, to covera specific part of the motor (such as insulation) or tocover only selected phases of the motor's life cycle.The ownership costs in many cases exceedacquisition costs and are generally difficult to predictdue to inadequate information on failure rate ormachine life.

Commercially available motor health monitoringprograms focus on monitoring the general health ofthe motor and its components, and recognising thedevelopment of faults as they occur. Whether it iscontinuous on-line monitoring, off-line monitoring, or a‘walk-around’ type monitoring, the limitation of suchfault detection systems is that they give a reliable

Lifetime Assessment

Maximises value of equipment and maintenance investments

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The purpose of the inspections is to gather data, tobe used as inputs in lifetime assessment evaluations.The more the data collected, the greater will be theaccuracy and the confidence level of the lifetimeassessment. Based on the consumed life and theanticipated rate of the degradation of the weakest linkin the machine, a clear plan can be devised foradministering the necessary machine maintenance.

Assessing Machine LifeThermal, electrical, ambient (or environmental) andmechanical stresses, act on various components ofa machine either independently or in combination,(thermo-mechanical, electro-thermal, electro-mechanical, etc), with varying intensities, dependingon design, manufacturing, installation, operating,maintenance and storage conditions. This leads toweakening (ageing, defect formation) of thestructure of the machine component, (bearing,shaft, winding, insulation, etc) and ultimately resultsin breakdown or failure.

It is therefore important to understand how thesestresses are brought about and how they affect thelife and performance of the machine. For example,thermal stresses or increased temperatures couldbe the result of sustained overloading, repeatedmachine starts, unbalanced voltage (power supply)conditions, harmonics in the power supply, changesin the system voltage or supply frequency,blockages in the ventilation or cooling system, orincreased ambient temperatures. Increasedtemperatures lead to depolymerisation (ageing) ofthe resin used in the insulation system, reducing it'smechanical strength, as well as its electricalbreakdown strength. The rate of reduction in thetensile strength of the insulation can be modelled bya chemical rate equation, or Arrhenius model. Whena physical property, (say its tensile strength orbreakdown voltage) of the component (insulation, inthis case) reduces to a predetermined value, (say50% of its initial value), the risk of failure is said tobe high and the component is said to have reachedthe end of its serviceable life.

What should we target?The area that has the maximum potential for reductionin failures besides bearings, is the stator winding.

A fresh approach is required - one that combinesknowledge of electro-physics and electro-chemistrywith simple instrumentation, to relate measurementswith the physical attributes of insulation.

ABB offers a unique package of DC and ACmeasurements, to look at problems or defectslocated on the surface of the windings, as well aswithin the main insulation body.

Stress Analysis & Remnant LifeEstimation:As part of ABB’s life assessment programme formachines, stresses are computed using a three-dimensional finite element (FEM) analysis. Criticalparameters from advanced diagnostic tests areused to evaluate and model the coil looseness inslots, contamination and insulation ageing.

The developed stress values may be estimated toplot the stress curve. The intersection of the strengthreduction and stress developed curves, will yield apoint beyond which the risk of failure is high and thiscondition could be classified as the end of serviceablelife.

Extending Machine LifeThe early detection of problems such ascontamination, machine running hot, lack of coil withslot control, and partial discharges, that causereduction in ultimate insulation strength andappropriate maintenance actions, like cleaning/overhauling of the machine can help in restoring thetensile strength. By improving the cooling efficiencies,better heat dissipation, removal of blockages inventilating ducts, removal of contaminants etc. It ispossible to alter the rate of deterioration of the tensilestrength and extend the life of the machine.

12 ABB

Remote Motor Maintenances Services

Thermal Life Degradation Analysis

Failure of winding insulation is the second largestcause of electric machine failure, (the first beingbearing failure) and on an average accounts for 30-40% of all failures in large motors. Ageing of insulationgenerally follows a chemical rate degradation curveand is severely affected by the number and frequencyof stops and starts, as well as large load variations. Inaddition, the stresses imposed on the insulationdesigned today are at levels higher than ever before,thereby increasing the requirement to assess machinereliability more frequently and with greater accuracy.To assess insulation degradation, we need details likethe total number of hours of operation, number andfrequency of starts/stops, measurements of certainstarting parameters, historical data on pastmaintenance/repair and faults witnessed, temperatureprofile, loading details, etc. through e-mail, which willessentially be as per standard templates.

Benefits:� Life degradation analysis and remaining life

estimation for the stator windings at 65-70%confidence level

� Scheduling a maintenance plan based on rate ofinsulation degradation, which will includemaintenance actions, machine criticality, conditionassessment planning

Loss Analysis

Power losses in a motor include copper losses, ironlosses, stray losses and friction and windage relatedloss while in operation. These losses are influenced byvarious design, constructional, maintenance, loadingand operational factors. As a first step in determiningactions required to improve machine and plantefficiency, it is required that the losses be estimatedwhile the machine is in operation. Our engineers helpyou track efficiency while the machine is in operation,based on standard templates. Advisory services arealso provided on motor design modifications, motor-load matching, supply modifications etc. directedtowards improving machine/system efficiency.

Benefits:� Motor efficiency audit and study of impact of

system on motor performance

� Facilitates decision making for machinereplacement/modification

� Machine life extension by reduction in thermalstress, when appropriate action is taken tominimize losses

Thermal SnifferCopper losses, iron losses, straylosses and friction and windagerelated losses are dissipated in amotor in the form of heat. The resultanttemperature rise is a combined function of such losses,ambient conditions and heat removal or coolingsystems in the motor. Our software compares thistemperature, measures using RTDs with idealtemperature for the machine to detect abnormalities likeblocked ventilating ducts, inefficiencies in the coolingsystem, stator-rotor rubbing etc.

Benefits:� Early warning system for temperature rise

� Early detection of motor abnormalities such asblocked ventilating ducts

� Proactive maintenance and increased machine lifedue to proper management of thermal stresses

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Vibration Advisor

Vibration problems in motors are often complicatedby electro-magnetically-related loads of symmetriespresent in the motor. Besides the typical problems ofimbalance and misalignment, motor vibrationproblems are often caused by air gap eccentricity dueto internal motor misalignment, soft foot, or othercomplex dynamic rotor behaviour. At times, defects inrotor windings also contribute significantly tovibrations. ABB provides consultancy services,wherein the user can optimise the utilisation ofavailable FFT analysers or vibration spectrumanalysers, by performing measurements in-house orby local service providers. The data collected can besubmitted to enable advice with regards to the mostprobable vibration sources, and suitable remedialaction. We can also provide training on collectingappropriate and relevant data for vibration and statorline current spectrum analysis.

Benefits:� Effective utilisation of in-house resources

� Early detection of electromagnetic and mechanicalabnormalities within the motor

� Centralised expertise

Note:The tests are designed for squirrel cage induction motor. If you needsimilar services for slip-ring induction motors or synchronous motors,kindly contact us.

The above tests can be packaged as per specific customerrequirements. We also provide complete practical on-site trainingfor PDCA test.

Polarisation – Depolarisation CurrentAnalysis (PDCA)

While performing IR and PI measurements inmachines with modern day insulation systems, it isoften noticed that good/acceptable IR and PI valuesare obtained in spite of the machine windings beingexcessively contaminated. This is mainly due to thefact that IR and PI measurements are largely reflectiveof charge transport rather than charge storagemechanisms. ABB's patented PDC Analysis is usedto quantify and characterise charge storagemechanisms, and is therefore a reliable indicator ofpresence of contamination (major contributor tomotor winding failures)*. Besides, information on theextent of contact of coil with core, resin condition,leakage current sources can also be made available.The measurements can be performed using basicinstrumentation like motorized/electronic Megger®

and a specified digital multimeter, and sent to us foranalysis. We will be pleased to offer on-site training forperforming measurements on request.

Benefits:� Evaluation of present machine condition without

opening the machine

� No old test data required

� Maintenance planning and scheduling based onmachine condition

� Provides proper focus on actions to beperformed during maintenance operations

� Effectively utilises resources required forperforming measurements

14 ABB

Spare Parts & Repair Services

ABB’s global logistics network is strategicallypositioned to provide quick response, repair serviceand spare parts based on standardised processes,tools and metrics.

Parts

Availability of spare parts is critical to operationalperformance. We maintain a stock of spare parts at alltimes, guaranteeing instant availability. For emergencyreplacement parts, our service centres and partnersare available 24 hours a day to provide immediateresponse.

Benefits� High-quality, certified parts

� Improved uptime

� Global logistics network ensures fast delivery

Version ManagementVersion Management is important to the integrity ofyour system, and can directly impact performance byensuring that modules are updated and spareinventory is functionally compatible with the installedequipment. As part of a service agreement, ABBengineers will inspect and ensure that the latestrevisions are in place and will update the moduleinventory to ensure optimal system functionality.

Benefits� Minimal downtime

� Reduced potential rework

� Optimising asset performance

Legacy SupportOur Legacy Support provides replacement parts andrepairs for previous generations of ABB systems.Access to global-parts inventories facilitatesavailability of new and refurbished parts for legacysystems. Repair and parts services for ABB legacyproducts are available as long as they are technicallyand commercially feasible.

Benefits� Extended system lifecycle

� OEM-ensured parts quality

� Reduced downtime

Test & InspectionOur ISO 9002-certified testing centres deploy state-of-the-art Automated Test Equipment (ATE) forcomponent-level, multilevel, in-circuit & full-functionaltesting, and environmental stress testing. Our certifiedtechnicians are qualified to test and inspect parts fromABB and other manufacturers.

Benefits� Minimised downtime

� Improved return on parts investment

� Streamlined sourcing for parts testing

Repair & RefurbishmentRepair and refurbishment of malfunctioning or failedcomponents can be economical alternatives to newpart replacement. Our vast network provides repairs,reconditioning and version management services thatmeet or exceed original equipment specifications.

Our average cycle time for repairs is typically less thantwo weeks and emergency repairs can be completedin as little as one day.

Benefits� Maximum return on parts investment

� Extended product life

� Increased reliability

Downtime reduction (A cold rolling mill)

600

550

500

450

400

350

300

250

200

150

100

50

0

2001 2002 2003 2004

Hou

rs

551525

354

146

Downtime dropped significantly after upgrading drives andautomation in a facility which was refurbished during 2003.

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Training Services

A skilled and efficient workforce is a plant’s mostvaluable asset. We can help to increase workforce skilllevels and knowledge, providing more productiveresponse to system and process challenges. Ourtraining programmes for engineers, programmers,maintenance and operations personnel providecomprehensive and up-to-date technical expertise forexisting and new products, processes andtechnology advances. Training is available at ABBtraining facilities, as well as locally at the plant site.

Process ProgrammesEffectively tuned control loops enhance efficiency andoptimal performance – saving considerable money.Our process training programmes incorporates state-of-the-art control design, setup and demonstratetuning techniques that deliver enhanced equipmentperformance.

Benefits� Reduced raw material costs� Reduced quality rejects� Shorter problem resolution times

Research has shown that in most cases, only about 40% of equipment features are utilised. ABB University training enables customersto take maximum advantage of every bit of the technology we bring to market.

CoachingCoaching is an effective post-training and refresherstrategy for maintaining skill level and buildingcompetencies. ABB coaching services are providedon-the-job at your plant site or over the internet. Askilled ABB training professional will work with yourpersonnel through the daily routines to reinforcerequired skills.

Benefits� Increased efficiency� Accelerated learning� Access to qualified training personnel

Training AssessmentOur Training Assessment process identifies thetraining programme best suited to satisfy yourtraining needs. We offer a comprehensive range ofplant-wide skills evaluation and training deliveryprograms to fill knowledge gaps and improve skills ofplant personnel.

Benefits� More effective use of training investment� Comprehensive needs identification� Improved personnel development planning

Product ProgrammesOur operator and maintenance training ensures yourpersonnel anticipate and respond correctly to systemand process challenges, avoiding loss of production.

Benefits� Improved production� Increased uptime� Higher asset utilisation

ABB University –delivering trainingworldwide

Customised CoursewareWe offer customised programmes to address theunique training requirements of your facility. Weprovide assessment, planning, development, anddelivery of specialised programs to improveperformance and increase productivity.

Benefits� Increased employee productivity� More focused use of training investment� Access to qualified training personnel

Maintaining personnel skills through targeted training programsensures short and long-term performance benefits

ABB LimitedPlot Nos. 5 & 6, II PhasePeenya Industrial AreaBangalore 560 058Tel: +91 80 22949464Fax: +91 80 28396537

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