CONFIDENTIAL

ELECTRIFICATION – DISTRIBUTION SOLUTIONS BUSINESS LINE, JUNE 2019

ABB Ability™ Condition Monitoring for switchgear

SWICOM
Reliable Asset Management
Ongoing digital revolution
Industrial revolutions are faster and faster

47 Yrs. Today – Industry 4.0

Communications between
people, services, and things

99 Yrs. 1969 – Industry 3.0

Programmable logic

158 Yrs. 1870 – Industry 2.0

Electricity is used for
Industrial Production

1712 – Industry 1.0

Thomas Newcome builds
the first steam engine

May 29, 2019 Slide 2

Short introduction
Current market and transition

Current Market ABB Ability™

• Focus on switchgear, breakers and relays ABB offers more with digital solutions:
• Minimum life of 30 years for primary equipment and 15 - Sensing equipment on board
years for electronic equipment
- Software based solutions
• Robust with low failure rates
- Communication between different layers
• Higher consequence in case of failure and tools

Electrical distribution digitalization: an ABB Ability™

May 29, 2019 Slide 3

—
Strategy
Values and expected benefits
Asset management
Find the optimum balance

Effective asset management

Effective asset management requires investment
planning. The owners need to be aware of:

– Assets condition
– Risk level
– Failures consequences
– Life cycle status
– Retrofit investments

Optimal maintenance strategy Power Distribution operational value chain

May 29, 2019 Slide 5

Asset health management
Maintenance strategies

Value and savings at fingertips with advanced maintenance strategies

May 29, 2019 Slide 6

Smart asset management
Experience intelligence

Why should I embrace ABB Ability™?

– Reduce total cost of ownership:
Optimization of maintenance schedule and Reduce total cost of ownership
increase work force efficiency
– Maximize Uptime:
Maximize uptime
Avoid unplanned outages which directly effect
revenue generation
Improve safety
– Improve safety:
Reducing catastrophic failures which impact
human and asset life

Condition monitoring Remote diagnostics Predictive analytics

May 29, 2019 Slide 7

Reduce total cost of ownership
Optimizing maintenance
End user value

100%
Asset type Maintenance Frequency of Preventive Condition
type action / per asset / per
asset
Unplanned labor cost Visual/Basic 2 years 2h 0h
doubles Circuit breaker
Plan maintenance Advance 5 years 2h 1.4 h
activities based on real
time data diagnostic Visual 0.5 years 0.5 h 0h
and prediction
Vs. Switchgear Basic 5 years 0.75 h 0h
Advance 10 years 2.5 h 1.75 h

$336 per $168 per

40% annum annum

Reduce labor costs by centralizing

data collection and analysis 30%
Decrease the duration of the
Opex cost reduction

time required for maintenance

activities

May 29, 2019 Slide 8

Maximize uptime
Avoid unexpected failures $ 1.2 M PER HOUR* $ 740 k PER OUTAGE* $ 4.4 M PER DAY*
120,500 BARRELS OF OIL
AVERAGE DOWNTIME COSTS AVERAGE DOWNTIME
FOR AN AUTOMOTIVE INDUSTRY COSTS FOR DATA LOST PER DAY OIL&GAS
SEGMENT
Before failure happen CENTERS

– Digitalization informing before $ 150 M PER OUTAGE $ 100 k PER PANEL $ 20 k PER PANEL
the system fails AIRLINE LOST A SWITCHGEAR WITH STEEL WORKS LOSS PER YEAR PER ANNUAL LOSS IN SEMI-CONDUCTOR
3.7% STOCK DROP IN 2 DAYS IN 2016 PRODUCTION
– Know-how about the current PANEL

asset
– Avoid possible failures help
reduce production and asset loss

*A 1999 Electric Power Research Institute (EPRI) study pegged total direct and indirect costs of an arc flash incident Shown: aggregated statistics for medium voltage
*news.thomasnet.com/company story/downtime-costs-auto-industry-22k-minute-survey-481017 (Source: Hartford Steam Boiler)
*Cost of Data Center Outages (D) Ponemon Institute
May 29, 2019 Slide 9 *The Economic Impact of August 2003 Blackout (E) done by ELCON
*Copper Institute (C)
Improve safety 19,000˚C (35,000° F) Hotter than you
Avoid unexpected failures can imagine
Arc Flash temperatures are hotter than the sun.

Operate more safely

Keep your personnel out
of the arc flash zone
~300 ANNUAL DEATHS IN US ALONE ARE
CAUSED BY ENERGIZED ELECTRICAL
EQUIPMENT
1,100kmph (700 mph) Projectile-
producing pressure
Arc flash can throw workers across a room.
Metal and equipment become shrapnel.

80
Personnel must enter arc
flash zone. OF ALL ELECTRICAL ACCIDENTS
4000 injuries occur in ARE CAUSED BY ARC FLASH
the US each year *
% INCIDENTS +2,000 burns More than one way to
burn you
Each year 2,000+ people seek treatment for
serious Arc flash burns.

Vs. 3 meters (10 feet) Too close for

1M TO 15M
comfort
Remote communications enabled, data can Arc flash can reach out 3 meters to take a life.
be safely transmitted to a remote location $ Serious-injury zone is even larger.

POTENTIAL COST OF ONE ARC FLASH

INCIDENT*
140 dB An assault on your senses
Light and sound bursts can cause vision and
hearing loss.

www.ecmweb.com/contractor/electrical-safety-foundation-international-unveils-how-do-you-know-workplace-safety-progr
*A 1999 Electric Power Research Institute (EPRI) study pegged total direct and indirect costs of an arc flash incident
May 29, 2019 Slide 10
Perceived benefits
Costs and savings balance

Availability
Reliability
Predictability

May 29, 2019 Slide 11

Customers approach

“We need to track the health condition of our

assets, and predict potential failure. Solve a
failure here can be very complex.
[…]
For our budgeting and planning it is very
important to get best estimation of remaining
useful life”
Electrical Services Manager,

“This is the most important attraction…... We need

highest availability and predictability […]
Here it is not a matter of loss production […].
ABB has to work with engineers and consultants, to
ensure that new switchgear tenders will contain
diagnostic.”
Director of Operations

May 29, 2019 Slide 12

—
ABB Ability™
Electrification ecosystem
Electrification ecosystem
A digital world
Predictive
ABB Ability™ Data Analytics for electrical systems
(ESDAY)
Algorithm Layer

Assessment without sensors Condition monitoring with sensors IoT 4.0 cloud solution
ABB Ability™ Life Cycle Assessment for ABB Ability™ Condition Monitoring for breakers ABB Ability™ Asset Health for electrical
electrical systems (MySiteCondition) (MySiteCare) systems (MyRemoteCare)
ABB Ability™ Condition Monitoring for switchgear
(SWICOM)

Data Analysis Summary

May 29, 2019 Slide 14

Electrification ecosystem
A digital world

ABB Ability™ platforms

1. MyRemoteCare: the cloud based
condition monitoring dashboard
2. MySiteCare: all existing MV switchgear
can be digitally enabled
1
3. SWICOM: all new MV switchgear are
5
digitally enabled
4. MNS Digital LV switchgear
5. EDCS: electrification performances can
be further expanded

4 2
3

1. Asset Health for electrical systems

2. Condition Monitoring for breakers
3. Condition Monitoring for switchgear
May 29, 2019 Slide 15
4. Condition Monitoring for electrical systems
5. Electrical Distribution Control System
Electrification ecosystem
A digital world

ABB Ability™ platforms

1. SWICOM:
- Main target: new switchgear1
- Primary sensing equipment: IEC 1
61850 based protection relays
- Setup: one device per lineup
2. MySiteCare:
- Main target: existing switchgear2
- Primary sensing equipment: itself
2
- Setup: one device per panel

Both can be connected to other sensors

e.g. for temperature monitoring.

1. Also existing switchgear when equipped with IEC 61850 based protection relays either natively or after a relays retrofitting program.
May 29, 2019 Slide 16 2. Also new switchgear when not equipped with suitable IEC 61850 based protection relays.
Electrification ecosystem
A digital world
ABB Ability™ Condition Monitoring for
switchgear - SWICOM
– IoT enabler for all switchgear lineups
(primary and secondary distribution
AIS and GIS)
– Building block of Industry 4.0-IoT Cloud
solution by ABB
– Relion’s relays on IEC61850 as primary
sensing infrastructure
– Ready for additional sensors on
demand like temperature sensors
– One unit handles a whole switchgear
lineup and even up to 24 panels
– It can be installed on ABB and non-ABB
medium voltage assets

May 29, 2019 Slide 17

—
ABB Ability™ Condition Monitoring for switchgear
SWICOM
SWICOM
Switchgear monitoring

- On premises solution
- Circuit breaker monitoring retrieving Ethernet

data from the relays:

- Opening and closing times
estimation and analytics
- Operation, trip counting etc.
- Contact wearing etc.
- Health indication and diagnosis on the
touch HMI and mobile App
- Extension to ABB cloud possible

May 29, 2019 Slide 19

SWICOM
Advanced switchgear monitoring

- Temperature sensors across the panels

- Covering failure modes in busbar, circuit Ethernet

breaker and cables compartments

- Flexible installation
- IEC 61850 not requirement for this
specific purpose

CAN+Modbus
- Other sensors also possible e.g. ambient

Temp

Temp

Temp
Temp

Temp
Temp

Temp

Temp
Temp

Temp
temperature and humidity

Temp

Temp

Temp
Temp

Temp
Temp

Temp

Temp
Temp

Temp
Other Sens.
May 29, 2019 Slide 20
SWICOM
Scenario overview

- Assets condition is visible on site via a SCADA

touch HMI CLOUD

- A mobile app provides data via smart

devices
Ethernet
- Also SCADA connection through
Ethernet TCP/IP is possible
- SWICOM connects to the
MyRemoteCare cloud based
dashboard showing the asset health

CAN+Modbus
status remotely

Temp

Temp

Temp
Temp

Temp
Temp

Temp

Temp
Temp

Temp
Temp

Temp

Temp
Temp

Temp
Temp

Temp

Temp
Temp

Temp
USB
Config

Other Sens.
Tool

May 29, 2019 Slide 21

SWICOM
More and more features

Human Machine Interface Mobile Application

– Lineup overview – Point to Point secure Wi-Fi connection
• Connected Bay • In front of the panel Wi-Fi enabling
• Status of every Bay (traffic lights) • Single access (security restrictions)
– Overall status (LED) panel details
• KPIs (health indexes)
• Measurements and Events

Local files storage Always available

– Documents downloading and reading – USB powered by PC, mobile, tablet or
from integrated SD-Card battery pack
• Drawings • HMI and Mobile Applications running
• User manuals also without auxiliary
• Movies • Data and files accessible to users also
• Procedures… with hands-on unpowered equipment
during maintenance or repairing

May 29, 2019 Slide 22

—
Condition monitoring
Wireless temperature sensors
Condition monitoring
Temperature monitoring

Arc flash hazards

– Connection faults
– Insulators degradation
– Overload
– Aging
– Oxidation

Avoid unwanted outages

May 29, 2019 Slide 24

Condition monitoring
Temperature monitoring

SAW technology solution

− Wireless battery-less sensors
− Analysis and connectivity
− Easy to install for brown and green field

Brown Green
Retrofit
field field

May 29, 2019 Slide 25

Condition monitoring
Temperature monitoring applications

1 2

1. Cable terminations temperature monitoring on GIS (main busbar are also applicable when outside the gas tank)
May 29, 2019 Slide 26 2. Circuit breaker fixed contacts temperature monitoring on AIS (cables and main busbar are also applicable)
Condition monitoring
Temperature monitoring applications

May 29, 2019 Slide 27 Retrofitting circuit breaker fixed contacts temperature monitoring (cables and main busbar are also applicable)
Condition monitoring
Temperature monitoring

Hot-spots thermal monitoring

SWICOM algorithm combines properly two

principles:
− Temperatures comparison: looking for
temperature differences among phases
− Temperature influence: compare the
monitored temperature with ambient
temperature detecting hot spot
conditions also at low load
Measurements and analytics results are
available on SWICOM locally and
MyRemoteCare remotely

May 29, 2019 Slide 28

Condition monitoring
Temperature monitoring

Operation of SAW
− The transceiver sends an electromagnetic
signal to the sensor (~ mono-static
RADAR).
− The antenna of the sensor captures the
signal, IDT converts it into a Surface
Acoustic Wave and reflects these modified
signals back to the transceiver.
− The transceiver computes, processes and
translates the signal into an exploitable
data: temperature from -25 to 150°C.

May 29, 2019 Slide 29

SAW sensors
The inside life

May 29, 2019 Slide 30

—
ABB Ability™ Asset Health for electrical systems
MyRemoteCare
MyRemoteCare
Assets health and performance management

User
Azure
3G mobile platform
network

ABB

Local monitoring Private channel Remote monitoring

May 29, 2019 Slide 32

MyRemoteCare
Assets health and performance management

Typical journey
– Dedicated and secure private network
– State-of-the-art cyber security
– One way communication without control
capability
– Warning and alarms delivered to operators
– Immediate support from ABB
– Automated reports as per customer wish

Secure & fast support

May 29, 2019 Slide 33

MyRemoteCare
Assets health and performance management

The power of cloud analytics

– Avoid unscheduled downtime: predict faults before they
happen
– Optimize maintenance: condition-based maintenance
– Improve asset life-cycle
– Dashboard, reports and alert notifications available on
laptop, tablet and smartphone
– Cloud application to run advanced analytics: algorithms
calculating the Probability Of Failure (POF) and
Remaining Useful Life (RUL)
– Circuit breakers and switchgear health condition
analysis and remote support by ABB Service
– Cloud application: very low TCO, always updated, secure

May 29, 2019 Slide 34