Indradjaja Hertanto – Service Development Manager – ABB Sakti Industri - June 23, 2011

Introduction to
ABB Machines Service Capabilities

© ABB Group
June 24, 2011 | Slide 1
 Industrial Service
Rotating Machines Service;

Workshop & Field Service

Asset Performance Service

Total Motor Management

Maintenance Engineering & Consulting

Motor Condition Assessment.

Variable speed drive service

Supply of spare parts.

Power and Switchgear service;

Transformers service;

Workshop & Field Service

© ABB Group
June 24, 2011 | Slide 2
 PT ABB Sakti Industri – Machines Service
Part of global ABB Machines Service network;
Fully supported by ABB Machines service and manufacturing units;
Workshops located in Tangerang and Surabaya;
Established in 1987
Total number of engineers more than 70 persons;
The largest electrical machines workshop in Indonesia, certified by ISO 9000
series since 1996 and ABB Service Worldwide. (ISO 9001-2008 on January
2010);
Certified ISO 14001 and OSHAS 18001 (since Dec 2003);
Member of Electrical Apparatus & Service Association (EASA)
Hazardous motor certification for workshops and engineers.

© ABB Group
June 24, 2011 | Slide 3
 Machines Service - Workshops
Tangerang Service Center
Jl. Gajah Tunggal km 1 .0
Tangerang 15136
Phone : +62.21. 2559 5555
Fax : +62.21. 2559 5566
e-mail : [email protected]

Surabaya Service Center

Jl. Margomulyo kav.44 E1-2
Tandes, Surabaya 60183
Phone : +62.31.2977 855/00
Fax : +62.31.2977 866/77
© ABB Group
June 24, 2011 | Slide 4
Motor Life Cycle

Spare motors

Predictive
Motor Maintenance
operation at
customer plant Systematic
Preventive
Maintenance
Electrical Machine Workshop
Customer Training Free training
Special arrangement
Basic electrical machines
maintenance
Electric Motor Installation

© ABB BU LV Motors
August, 2009 | Slide 6
What wastes energy?
Oversized installations
Inefficient motor applications
Equipment running unnecessarily long
hours
Instead of Speed Control of the motor,
implementation still often with throttling
valves in pump systems, vanes in fan
applications, or gears or belt drives in
rotating machinery.
Belt drives, gearboxes and hydraulic
couplings require the motor to run at full
speed all of the time
Unbalance, misalignment, soft-foot, etc
Mechanical drives often seem cost-
effective at first sight, but they waste
energy.

© ABB BU LV Motors
August, 2009 | Slide 7
Machines Condition Assessment

the process of collection all machine data, take detail

inspection, measuring all important parameters of a
machines during operation and stop.
Objectives:
to assess the operating condition within a machine for
proper installation, maintenance and efficient operation.
to predict the failure of components in advance which
could be use for determining the need for maintenance.

© ABB Group
June 24, 2011 | Slide 8
Life Cycle Concept

© ABB Group
June 24, 2011 | Slide 9
 Performance drop due to TEAM as aging effect
The majority of all rotor and stator failures are caused by combination of TEAM

Thermal Electrical Ambient Mechanical

Operating Terminal voltage Contaminated air, Vibration due to

condition such as dust, chemicals misalignment,
Harmonics
overload, etc unbalance, air
Humidity
Transient, voltage gaps, installation
Starting conditions
peaks in network,
such as long start,
switching surge
stalling, repeated High temperature
starts Phase unbalance Repeated starts
causing torsional
Inadequate Corrosion effect and fatigue
cooling, fouling of
coolers of filters

Act alone or in combination leading to general weakening and ultimately failure

© ABB Group
June 24, 2011 | Slide 10
Preventive Maintenance Program

© ABB Group
June 24, 2011 | Slide 11
 Maintenance Level 1 (L1)
The purpose of this maintenance is to do a quick check whether problems are
beginning to develop before they cause failures and unscheduled maintenance
breaks. It gives also suggestions what maintenance issues must be performed in the
next lager overhaul.

Open inspection covers

for visual inspection
Review of operating parameters
voltage, current, load, temperatures,
cooling condition, vibration
check protection, trip and alarm log
Replace filters, oil, brushes and
other consumables if needed
Preventive maintenance kit for L1

Preparation: no disconnection of terminals, machine stop only for short time

© ABB Group
June 24, 2011 | Slide 12
 Maintenance Level 2 (L2)
The purpose of this maintenance is to find out whether there are problems
in the operation of the machine and to do small repairs to ensure
uninterrupted operation.
Open inspection covers for visual inspection (same as L1)
Review of operating parameters
voltage, current, load, temperatures, cooling condition, vibration
check protection, trip and alarm log
Replace filters, oil, brushes and other consumables if needed
Measurement of insulation resistance of the stator (rotor & exciter if
applicable)
Preventive maintenance kit for L2 and suggestions from earlier
inspections

Preparation: disconnection of terminals, outage < 1 day

© ABB Group
June 24, 2011 | Slide 13
Maintenance Level 3 (L3)
The purpose of this maintenance is to repair encountered problems and replace
parts subjected to wear.

Open inspection covers for visual inspection (same as L2)

Review of operating parameters
voltage, current, load, temperatures, cooling condition, vibration
check protection, trip and alarm log
Replace filters, oil, brushes and other consumables if needed

Measurement of insulation resistance of the stator (rotor & exciter if applicable)

Inspection of bearings
Inspection and cleaning of coolers
Detailed rotor inspection
Preventive maintenance kit for L3 and suggestions from earlier
inspections
Preparation: rotor not removed, outage several days
© ABB Group
June 24, 2011 | Slide 14
Maintenance Level 4 (L4) part 1
The purpose of this maintenance is to restore the machine into a reliable operating
condition.
Review of operating (same as L3)
parameters
voltage, current, load, temperatures,
cooling condition, vibration
check protection, trip and alarm log
Replace filters, oil, brushes and
other consumables if needed

Measurement of insulation resistance of

the stator (rotor & exciter if applicable)
Inspection of bearings
Inspection and cleaning of coolers

© ABB Group
June 24, 2011 | Slide 15
Maintenance Level 4 (L4) part 2

Open the machine for rotor removal if applicable in service manual

Detailed inspection of free standing rotor and stator
Diagnostic measurements
Preventive maintenance kit for L4 and suggestions from earlier inspections

Preparation: outage several days (depending on machine), rotor removal

© ABB Group
June 24, 2011 | Slide 16
Preventive Maintenance program

© ABB Group
June 24, 2011 | Slide 17
Preventive Maintenance kits

© ABB Group
June 24, 2011 | Slide 18
 Example of expected down time
With no capital spares Downtime
Rotor failure several months
Stator failure several months
Exciter failure (synch) several weeks

With capital spares on site

Rotor failure weeks
Stator failure weeks
Exciter failure (synch) days

Complete spare motor

Any fault days

© ABB Group
June 24, 2011 | Slide 19
Item to check – motor spare installation
Processing of spare motor
Perform criticality analysis
Analysis of motor load to motor rated load
Motor delivery close to annual shut down schedule and install motor
Plan motor installation on next long shutdown schedule.
Spare motors in stock
Perform spare motors maintenance as recommended on motor manual.

© ABB Group
June 24, 2011 | Slide 20
Item to check – motor transport locking device

© ABB Group
June 24, 2011 | Slide 21
Introduction – failures in hv-machines
Failures that caused down
times in hydro power stations
W. Zwicknagl, “Zum Dauerverhalten der
Hochspannungsisolationen umlaufender
elektrischer Maschinen”, Austrian Association
of Electrical engineering, Journal für
Elektrotechnik und Maschinenbau, E und M,
Heft 6, 1998

Failures in rotating high

voltage machines –
depending on its age
K. Kimura, T. Iwabuchi, K. Morooka, Y.
Ishikawa, “A useful index for estimating
residual life of motor insulation”, IEEE
Electrical Insulation Magazine, vol. 6, no.
2, pp. 29 – 35, Apr. 1990
Basis of Analysis: Stress & Strength v/s Time

Strength

Premature Failure
Stress, strength

Failure
Transients

Stress
Residual Life

Time
© ABB Group
June 24, 2011 | Slide 23
Life Expectancy Analysis: Benefits

Strength Condition assessment and taking

suitable actions at this point.

Adv. 1: No Premature Failure

Transients

Failure
Stress

Residual Life
Adv. 2: Increase in Life

© ABB Group
June 24, 2011 | Slide 24
LEAP …… not just a step ahead
What is LEAP?
Lifetime Expectancy Analysis Program or LEAP
is a unique Maintenance Tool for the Stator
Winding Insulation of Electric Machines.
LEAP provides information on Machine winding
and expected life, and will optimize the
Machine Maintenance Plans
LEAP developed by ABB Machines Service,
India, 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 ABB Service centers and data analyzed
LEAP is not just a package of at the LEAP Center of Excellence
inspections; it is a systematic
approach to managing Machine
Maintenance

© ABB Group
June 24, 2011 | Slide 25
Level Based Inspections

Opportunities for Inspections Inspection Schedule

Basic When the machine is Every 5% of the estimated lifetime

operating
Standard
Standard When the
the machine
machineisis Every
Every 10%
10% of
of the
theestimated
estimatedlifetime
stopped
stopped but
butassembled
assembled lifetime
Advanced When the machine is Every 25% of the estimated lifetime
stopped and partially
dismantled
Premium When the machine is Every 50% of the estimated lifetime
stopped and rotor removed

90
Confidence Level

75

60

45
Basic Standard Advanced Premium

© ABB Group
June 24, 2011 | Slide 26
Level Based Inspections
Solution Levels Packages Deliverables

Basic Data collection (on site or remote): Life Expectancy Analysis 65% Confidence
Level
Operational hours, voltage, current, power, slip,
Condition Based Inspection and Maintenance
Starts/Stops, Temperature (Winding, Coolant and Ambient),
Plan
Duty cycle & loading pattern, Failure and Maintenance
history, Information on power supply, breaker-cable
configuration, etc

Standard
Standard Basic Data
Basic DataCollection
Collection ConditionAssessment
Condition Assessment of of Stator
Stator Windings
Windings for for
PolarizationDepolarization
Polarization Depolarization Current
Current Analysis
Analysis PDCA
PDCA Contamination,ageing,
Contamination, ageing, looseness,
looseness,
Delta && capacitance
Tan Delta capacitanceAnalysis
Analysis delamination,stress
delamination, stress grading
grading system
system
Life Expectancy
Life ExpectancyAnalysis
Analysis 80%80% Confidence
Confidence
Non-LinearInsulation
Non-Linear InsulationBehaviour
Behaviour Analysis
Analysis
Level
Level
Partial Discharge
Partial DischargeAnalysis
Analysis ConditionBased
Condition BasedInspection
Inspection andand Maintenance
Maintenance
Plan

Advanced Standard Data Collection Condition Assessment of Stator Windings with Standard
Visual Inspection on end windings Package + End-winding assessment
Life Expectancy Analysis 85% Confidence
Partial Discharge Probe measurements & Dynamic Level
Mechanical Response of Windings
Condition Based Inspection and Maintenance
Stress analysis of End-windings Plan

Premium Advanced Data Collection Condition Assessment of Stator Windings with

Wedge Tightness Map & Coupling resistance measurements Advanced Package + slot region assessment
Visual inspection, including slot areas Life Expectancy Analysis 90% Confidence
Level
Stress analysis of Windings Condition Based Inspection and Maintenance
Plan

© ABB Group
June 24, 2011 | Slide 27
LEAP methodology
Collection of Data
Operating data, test measurements and machine
information
Analysis of Data
ABB has developed UNIQUE analytical tools
aimed at life assessment
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
Possible further inspections, maintenance,
replacements or even upgrades are drawn up

© ABB Group
June 24, 2011 | Slide 28
 LEAP Standard package
P o la r i z a t io n - D e p o l a r iz a t io n C u r r e n ts

Pol-Depol Currents (microAmp) 1 00

U PH AS E
DC Measurements
10
Polarization De-Polarization
1 Current Analysis
0 .1
1 10 1 00 10 00
T im e (s e c )

C h arging D is c h a rg in g

TAN DELTA MEASUREMENTS

AC Measurements
4.00

3.50

3.00
Non Linear Behavior Analysis
Tan Delta (%)

2.50

2.00
Tan and Capacitance Analysis
1.50

1.00

0.50
1 2 3 4 5 6 7 8
Partial Discharge Analysis
Voltage (kV)

U Phase V Phase W Phase UVW Phase

Remark: DC tests are sensitive to the surface

condition, and AC tests give more information on
the insulation volume

© ABB Group
June 24, 2011 | Slide 29
DC measurements
Polarization-Depolarization Currents
UVW PHASE
Parameters
100 Derived
Time constants

Po l-D epo l Cu rrents (m icro Am p)

T1, T2, T3
Q1, Q2 10

Charge storage
1
: Q1, Q2, Q3
Q3 Ageing Factor
0.1
Dispersion
Ratio
(1+Q1+Q2+Q3)
0.01
1 10 100 1000 Volume
Time (sec)
Resistivity
Charging Discharging

Remark: Polarization - De-polarization Current Analysis

Conventional IR
& PI Besides leakage and absorption current, PDCA test gives an idea of
Measurements
may have
quantity and location of charge storage within the machine
satisfactory
values even Identifies contamination even when IR, PI values are “acceptable”.
with highly
contaminated Determines state of the winding insulation, ageing, looseness, etc.
windings

© ABB Group
June 24, 2011 | Slide 30
AC measurements
INSTANTANEOUS CAPACITANCE VARIATIONS
@ 5.8 kV

CAPACITANCE (Arbitrary Units)

110

65

20

-25

-70
40 42 44 46 48 50 52 54 56 58 60

TIME (msecs)
U - PHASE V - PHASE W - PHASE UVW - PHASE

Non Linear Behavior Analysis, Tan and Capacitance Analysis,

Partial Discharge Analysis
Confirm the results from DC Measurements
Assess the condition of Corona protection shield
Determine the extent of de-lamination or void content in terms of a
Remarks: percentage of discharging Air Volume to Insulation Volume
Conventional
measurement Assess condition of the Stress Grading system at slot ends
interpretation
is generally Trend Ageing effects
based on
trends

© ABB Group
June 24, 2011 | Slide 31
ABB MACHsense-P
Advanced Inspections

© ABB Group
June 24, 2011 | Slide 32
ABB MACHsense-P
ABB MACHsense-P
Development has been done by ABB Motors
& Generators Service based on intensive
R&D carried out in our corporate research
centers
Measurement is done on the operating
machine

Measurements & Analysis of Data &

Report
Measurements are performed by ABB
Local Service Centers
A summary report is delivered
automatically on-site
Detailed report is later delivered by
Regional Technical Center (RTC)

© ABB Group
June 24, 2011 | Slide 33
Advantages of MACHsense-P vs. other methods
Unique motor specific analysis tool.
Simultaneous measurements
Estimates slip-as name plate slip is not
reliable.
Comprehensive analysis
Current, voltage and vibration in a single
automated analysis
Summary status report issued on site
Application specific preventive
maintenance plan with final detailed
report
Reduction in unplanned downtime
Early warning provides adequate time
for maintenance plan
Improves accuracy of diagnosis

© ABB Group
June 24, 2011 | Slide 34
ABB MACHsense-P
Standard Inspections

Solution Measurements
Inspection Deliverables When
levels Requirement
• Standard • Vibration, voltage, • Cage rotor package • Measurements of • Every six
current, temperature • rotor winding defects the machine at months
(winding, cooler, • air gap eccentricity operating louad
ambient) and speed • unbalance
• looseness
• static and dynamic shaft bends
• Operation history and
• internal misalignment
maintenance and
• Anti-friction bearing package
failures records
• bearing defects
• bearing assembly defect,
• lubrication interval estimates
• Installation
• soft foot
• misalignment
• foundation resonance
•Power supply
• harmonics and distortion
• unbalance
• over/under voltage
• frequency
• Maintenance and inspections recommendation

© ABB Group
June 24, 2011 | Slide 35
ABB MACHsense-P
Advanced Inspections

Solution Measurements
Inspection Deliverables When
levels Requirement
• Advanced • Vibration, voltage, • Same as Standard • Measurements of the • When defect is
current, temperature • Cooler machine at operating load suspected either
(winding, cooler, • Fouling and multiple loads or/and from standard
ambient) and speed • Root Cause Analysis start-up measurement or from
observed problems
• Operation history and and there is a need
maintenance and for further
failures records investigation

© ABB Group
June 24, 2011 | Slide 36
 Broken Rotor Bars
Broken rotor bars can
cause sparking
cause healthy bars to carry more
current and hence elevated
temperatures causing it to break
cause torque and speed
oscillations in the rotor, provoking
premature wear of bearings and
other driven components
lift out of the slot due to
centrifugal force and strike against
the stator winding causing a
catastrophic motor failure

© ABB Group
June 24, 2011 | Slide 37
Air gap eccentricity

Static- position of minimum air gap remains constant.

Dynamic-Position of minimum air gap keeps rotating

© ABB Group
June 24, 2011 | Slide 38
Mounting of Probes
Current Probe

Check Connection Diagram.

Identify CT terminal points.

Always take help of the Concerned Electrical

Engineer.

Mount probes as per R Y B

© ABB Group
June 24, 2011 | Slide 39
Mounting of Probes
Voltage Probe

Check Connection Diagram.

Identify PT terminal points.

Always take help of the Concerned Electrical

Engineer.

Mount probes as per R Y B

© ABB Group
June 24, 2011 | Slide 40
Ideal Location to Mount Transducer

© ABB Group
June 24, 2011 | Slide 41
 Motor Life Cycle
Motor
Replacement

Modernization Reception Spare motor

at the plant
Mounting,
Overhaul & alignment, and
repair commissioning
Spare parts

Predictive
MotorMotor
operation Maintenance
Transport operation
at costumer at
plant plant
customer Systematic
Preventive
Maintenance
Dismounting
Troubleshooting
Diagnostic:
Diagnostic:
-Technical
- Technical
© ABB BU LV Motors
-Economic
- Economic
August, 2009 | Slide 42
 Round the clock service

We are ready to give

quality solutions
for your machines
problem
round the clock
24 hours a day
for 365 days

© ABB Group
June 24, 2011 | Slide 43
 Motor Life Cycle
Motor
Replacement

Modernization Reception Spare motor

at the plant
Mounting,
Overhaul & alignment, and
repair commissioning
Spare parts

Predictive
Motor operation Maintenance
Transport at costumer
plant Systematic
Preventive
Maintenance
Dismounting
Troubleshooting
Diagnostic:
- Technical
© ABB BU LV Motors
August, 2009 | Slide 44
- Economic
 Introduction to
Rotating Machines Workshop

© ABB Group
June 24, 2011 | Slide 45
 Technical Supports
• All
our service activities are
supported by ABB manufacturer
and also we are member of
EASA (Electrical Apparatus
Service Association).

• Weare also link to ABB

workshop worldwide network

© ABB Group
June 24, 2011 | Slide 46
 Quality system
Our service activities has certified by
ISO 9000 – 2008, all activities should be:
Every repair / service activities should be
recorded and keep properly and
traceable. We use SAP for CMMS.
Every test equipment should be
calibrated, and we have standard
instruments for internal calibration;
Continuous improvement, by using Small
Group Activities (SGA), Opex
(Operational excellences) and
performance certification, etc.
Development based on customer
satisfaction evaluation,
etc.

© ABB Group
June 24, 2011 | Slide 47
 Workshop Facilities
Workshop is located in Tangerang
and Surabaya;
Workshop area is 1080 sqm
Two overhead cranes (10 tons and
5 tons) and jib crane. Could handle
machine weight 25 tons.
Testing area, dismantling / re-
assembling area, cleaning area,
winding area, machining area and
training room area

© ABB Group
June 24, 2011 | Slide 48
 Workshop Capabilities
Rewinding of electrical
machines (generators, DC/AC
electric motors, LV/MV/HV)

Reconditioning of electrical
machines.

Mechanical repair (Dynamic

Balancing, Bearing
Replacement, metal spray)

Supply of HV Coils and DC

Coils, wedges, carbon
brushes, collectors, Slip-rings,
brush holders.

Workshop could handle

machines up to 25 MVA.
© ABB Group
June 24, 2011 | Slide 49
 Testing facilities In order to achieve high quality
service, our workshop has
Test bench with 350 kVA with
voltage 0–6600 volts, ac/dc;
Dynamometer for load test up to
300 hp.
Surge comparison test up to 24
kV with computerized software;
Vibration analyzer and balancer
(VibXpert II);
Digital low resistance ohmmeter;
High voltage insulation tester;
Shaflign laser alignment;
MACHsense and Leap
MCA tools and Empath software
Profiler (Collector and shaft
analyzer);
Tangent Delta, Partial Discharge,
Non Linier Insulation Behaviour
Analysis (NLIBA)
© ABB Group
June 24, 2011 | Slide 50
 Winding equipment & facilities
Winding machines,
Varnish tank
Drying oven & vacuum
chamber.
Burnt off oven
DC coil forming machines
Rotor pole winding machine
Rotor banding machine
Transformer winding machine
VPI impregnation system
(Vacuum Pressure
Impregnation)

© ABB Group
June 24, 2011 | Slide 51
 Insulation technology
VPI = Vacuum Pressure
Total VPI process Impregnation - process

1. Pre-heating of complete
stator (core + winding)
2. Air is pumped out of the tank;
a vacuum is created.
3. Tank is filled with pre-heated
resin.
4. Overpressure is applied to
maximise the penetration of
resin and to minimise the size of
gas bubbles.
5. Resin is pumped back to the
reservoir tank
6. Stator is placed in the oven
ABB Oy Electrical Machines

OHK / PEE 2002

for curing the impregnation resin
 Rewinding materials
All winding insulation materials
store in our warehouse with
temperature control.
Copper wire (Essex, class H)
Impregnation varnish (Isonel)
Insulating materials, class F
(155 ° C) and H (180 °C);
RTD’s, space heaters etc.
HV coils and its accessories
from ABB NZ Coil Centre;
We could supply also HV Coils,
wedges, collector, slip-rings

© ABB Group
June 24, 2011 | Slide 53
 Mechanical repair capability
In order to make repair time faster and
control work quality, ABB has equipped
the workshop with :
Dynamic balancing machine up to 8 tons.
Metal spray equipment,
TIG welding machine.
Lathe machine.
Milling machine
Subcontractor workshop for larger
machines

© ABB Group
June 24, 2011 | Slide 54
 Field Service Activities
Reconditioning / overhaul of electrical
machine onsite.
Rewinding on site for electrical machines.
Predictive Maintenance.
On-line Condition Monitoring.
Vibration Analysis, laser alignment, in-situ
balancing,
Installation, Supervision & Commissioning
of electrical machines.
Customer training.
Modification & engineering of electrical
machines.
etc.

© ABB Group
June 24, 2011 | Slide 55
 Field Service Facilities
Our field service engineers equipped
with portable equipment such as:
Optical Laser Alignment.
Computerized Vibration Analyzer / Balancer.
Predictive Maintenance Software's (Collex).
Portable Surge Comparison Tester.
DC Commutator Bar Analyzer.
Rotor Bar Checker for DC armature
Infrared Thermometer.
High Voltage Insulation Tester.
Earth Resistance Measurement.
Digital Low Resistance Ohm-meter.
Air flow measurement
Hydraulic torque wrench
Tangent delta, partial discharge and NLIBA
PDCA equipment

© ABB Group
June 24, 2011 | Slide 56
Spare-parts Supply Service
MV coils
Bearings – antifriction and sleeve bearings
Labyrinth seals
Temperature sensors – RTD’s
Rotating diodes
etc
LP/DM Struktur April 2010 NO | Slide ‹#›
Machines Service – Organizational chart

© ABB Group
June 24, 2011 | Slide 59
 Motor Life Cycle
Motor
Replacement

Modernization Reception Spare motors

at the plant
Mounting,
Overhaul & alignment, and
repair commissioning
Spare parts

Predictive
MotorMotor
operation Maintenance
Transport operation
at costumer at
plant plant
customer Systematic
Preventive
Maintenance
Dismounting
Troubleshooting
Diagnostic:
- Technical
© ABB BU LV Motors
August, 2009 | Slide 60
- Economic