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Preventative Maintenance & Outage Approach

Services for Safe, Smart, & Sustainable Electrification
9AKK108467A2408_Rev A_August 2022
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Topics for Discussion

• Service at Glance & Core Pillars

• Equipment Lifecycle Considerations
• Maintenance, Lifecycle Management & Extension Approach
• Suggested Spares Strategy
• Service Support Agreements
• Life cycle process
• Q&A

August 30, 2022 Slide 2

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Service at a Glance
• Provide a superior customer experience
Vision both internal & external

11. Support of agreements 10. Advanced services

(Power of Care) (Smart Asset Management)

11 ABB Ability™ Our Mission

Safety
9. Replacement 9 10 – Reduce total cost
8 1 of ownership
8. End of life 1. Installation and
– Maximize revenue
services commissioning (I&C)
7.3 2 for our customers
7.3. Retrofits
Service 2. Training – Provide safe,
Reliability 7.2 3 smart, and
7.2. Upgrades 3. Spares and Availability reliable solutions
7.1 4 consumables for the entire
7.1. Extensions 6 5 asset life cycle
4. Maintenance Start-up and
Life Cycle 6. Engineering maintenance
Services and consulting 5. Repairs services

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August 30, 2022 Slide 3
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US Electrification Service
Core Pillars

Complete One-Line Solution for Low and Medium Voltage

Electrical Power Distribution Field Services Life Cycle Extension

– Preventative Maintenance – Breaker Retrofits / Retrofills
– Installation and Commissioning – Upgrades
– Customer Training – Protection and Control Upgrades
– Disaster Recovery – Switchgear Add-ons and Upgrades
– Testing Services – Repairs

Performance Enhancement
Power Consulting Services – ABB Ability™ energy and asset manager
– Arc Flash Mitigation Solutions – Condition Based Assessment Studies
– Arc Flash Studies – Real Time Equipment Monitoring
– Short Circuit Current Limiting Devices (temperature, humidity, partial discharge)
– Safety Personnel Training – Remote Service Offerings
– Service Agreements

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August 30, 2022 Slide 4
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Why invest in Preventative Maintenance?

Improving personnel and equipment safety

Avoiding costly downtime

Reducing service interventions

Reducing operational costs

Sustainability of electrical assets

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August 30, 2022 Slide 5
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Maintenance & Testing Services

Preventative Maintenance Testing

Maintenance is carried out at predetermined intervals or Any internal failure may have a significant impact, mainly because
according to prescribed criteria, aimed at reducing the failure risk restoration is complicated and lengthy. ABB testing services work
or performance degradation of the equipment. to prevent failures from happening and catch them early on.

Maintenance checks include: Relay Calibration

– Visual checks – Calibration testing pinpoints a defective relay before it fails to
– Apparatus cleaning act during a fault
– Mechanical components lubrication – Shows where power system needs to be adjusted
– Testing Hi Potential (Hi-pot)
– Worn parts replacement – Dielectric Withstand test, best way to uncover workmanship and
– Functional tests execution assembly defects in an electrical product that can lead to
insulation breakdown
Maintenance cycles are planned according to the need to take the
device out of service. The incidence of operating faults is reduced Partial Discharge (PD)
– Provides advanced notice of pending insulation failure

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August 30, 2022 Slide 6
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Equipment Lifecycle Extension Considerations
Typical Equipment & Safety Challenges

Equipment
• Equipment uptime
• Age (service years)
• Current Maintenance efforts no longer effective (time or usage based)
• Availability of parts and spares
• Enablement of Digital monitoring & accessability
• Reaching predictive capability

Safety & Personnel

• Equipment doesn’t meet current safety requirements
• Protection of operators & maintenance workers
• Abillity to support equipment (aging workforce, new technology)

August 30, 2022 Slide 7

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Equipment Lifecycle Extension Considerations
ABB Approach

Evaluate Maintain Monitor Extend

– Baseline equipment – data – Initiate/optimize proactive – Look at condition – Intentional spare strategy
collection, asset health maintenance programs monitoring solutions – Structured lifecycle
evaluation, lifecycle review – Routine – Support transition from extension plan that
– Review shared database of – Condition-based basic monitoring to integrates improved safety
condition findings predictive and standards compliance
– Predictive
– Sharing of continuous
improvement opportunities – Remote Assistance
– Consider solutions approach
based on site constraints
and safety

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August 30, 2022 Slide 8
parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB
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Life Cycle Extension Solutions

ABB’s worldwide leadership and Low Voltage Solutions Medium Voltage Solutions
manufacturing excellence, in
– MCC bucket replacements – MCC
medium and low voltage products,
allows ABB to provide a variety – MCC VFD & Starter upgrades • Air to Vacuum conversion kits
of aftermarket solutions and – ACB Breaker upgrades • Relay upgrades
services for both conventional and • Direct Replacement – LIS – Arc Flash remediation upgrade
nuclear safety related applications • Cradle-in-Cradle – Roll-in Replacements
• Hard Bus – Hard-bus Retrofit
– Trip Unit upgrades & conversion kits – Arc Furnace breaker upgrades
– Power Break & HPC upgrades – Relay panel upgrades
– Circuit Breaker Evaluation & Repair – UFES Arc Protection
• Legacy ABB & GE Shops – Fault Current Limiters

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parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB
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Migration to Digital & Predictive
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Electrification ecosystem
Migration to a digital world
Predictive
ABB Ability™ Data Analytics for electrical systems

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

August 30, 2022 Slide 11

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ABB Ability™ energy and asset manager
Connections for the health of your equipment

Smart breaker technology Energy Predictive

process engineering management maintenance

Perform primary protections Reduce energy consumption Health assessment

and advanced metering Energy metering ABB or legacy GE installed
Main protections and Power Quality switching device status based on
Embedded current and voltage Spread connectivity condition monitoring, extending
sensors Avoid waste lifecycle

Advanced communications Energy billing optimization Operation strategy

Embedded communications such Tariff optimization Scheduling maintenance
as Modbus, IEC 61850, and Load shifting/Peak shaving to ensure stable running without
EtherNet/IP Cost allocation unexpected shutdown Alerting via
email/SMS

Intelligent Smart Smart

protections facility management operation and maintenance

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August 30, 2022 Slide 12
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Condition-based Assessment Studies Process
Asset assessment divided into five major steps

Specify Classify Analyze Report Action

Prepare On-Site Post-Site Post-Site On-Site

– Customer requirement – Data collection – Data evaluation – Data analysis summary – Presentation of report
– Project definition – Asset inspection – Data formatting and – Condition index and – Development of a
– Asset selection – Performance tests processing risk report remediation plan

– Evaluation of – Historical data – Statistical analysis – Risk mitigation

importance of asset in – Reliability-Risk proposal
– Operator interviews
network assessment

Keep your asset running – Operational stability

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August 30, 2022 Slide 13
parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB
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Low Voltage Switchgear Enhancements for Realtime Monitoring
ABB Ability™ Energy and Asset Manager

External solution
– Connect devices to Ekip E-Hub DIN rail module
High flexibility and extended retrofitting Cloud Platform
Easy and fast configuration via Ekip Connect wizard
Plug & play:
– LV Circuit breakers, Ekip E-Hub, Ekip UP
– Fusegear Skip E-Hub – Water
– Arc-guard, grid-feeding relays – Gas
– Temperature Input
– Energy and Power meters, Branch monitoring Cloud RS-485 Cloud Platform
– Signaling units, analog inputs, pulse meters
– MV relays

Water

Gas M-bus/RS-485

Temperature

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August 30, 2022 Slide 14
parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB
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Medium Voltage Switchgear Enhancements
SWICOM™ - Switchgear temperature, humidity and partial discharge monitoring

A monitoring and diagnostics solution for LV and MV Switchgear and MCC

(motor control center) with the following sensor packages:
– Wireless solution for temperature and PD monitoring
• SAW sensors
• UHF measurements
– Wired solution for temperature monitoring
• IR sensors
• Thermistor sensors for LV MCC buckets
– Wired solution for humidity monitoring (in combination with both above)

Spot problems as soon as they develop; reduce unplanned outages

– Available in NEW switchgear as well as a RETROFIT – Also available in ABB switchgear up to 27 kV
– Provides local and remote monitoring – Consult the Services team further for 38 kV
– Suggest monitoring aging or difficult for personnel to get to equipment applications

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August 30, 2022 Slide 15
parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB
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Medium Voltage Switchgear Enhancements
IR Sensor Temperature Sensing System

Network connection
ModBus Network Industry standard
– IR sensor has non-conductive plastic body RJ45 sockets located
on the front of the
– Sensors do not require external power unit enable simple
– Sensors provide rise over ambient (DT) reading connection to a
RS485 ModBus
– Sensors have lifetime calibration network

– Sensors are UL recognized & CE certified

Data Card
Each data card can
Switchgear MCC have 8x sensor
inputs

IR sensor Internal View

Cable Joints
Cable sensors strap to the
Panel with sensors
cable & deliver ∆T
shown in position

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August 30, 2022 Slide 16
parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB
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Medium Voltage Switchgear Enhancements
Partial Discharge Monitoring

Modbus
– Measurement is based on UHF technology
– The antennas used for temperature with a humidity sensor
is used to detect partial discharge
– Suitable for ANSI/IEC

12 Sensors per panel configuration (full)

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August 30, 2022 Slide 17
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Modernization
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How to further extend equipment’s lifetime
Switchgear modernization

Upgrade solutions
– Arc fault protection
– Remote breakers racking Upgrade

Performance and reliability

– Auxiliary equipment renewal or retrofit solutions

– Interlocking and safety features

Risk and condition-
– Condition monitoring based maintenance

Repair
Retrofit solutions
No maintenance
– Relay replacement
– Circuit breaker replacement

Time

August 30, 2022 Slide 19

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Reducing the risk of failure
The right mix

Managing conditions Right maintenance Condition monitoring Modernization

Depending on the location Tailored to your assets, Online monitoring Upgrades and retrofits
of the equipment it is not according to your equipment’s Remote support
always possible to control conditions
environmental conditions Predictive algorithms
Safer electrical equipment – for
everybody!
Lower overall downtimes
Higher lifetime of your
equipment

August 30, 2022 Slide 20

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Enabled by ABB Remote Assistance
Site support from a distance
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Electrification Service Remote Assistance
Augmented reality solution enabling real remote collaboration

Remote Assistance is a live video sharing solution that improves interaction by allowing remote experts to interact with field personnel
and ‘see what they see’

On-site Active Done!

Video
technician in interaction
connection
need of support through AR*
with ABB
for maintenance, functionalities,
expert
troubleshooting, static drawing,
technical zoom, flash,
information… etc.

Augmented reality to bring ABB expertise and knowledge when and where you need it

*Augmented Reality
8/30/2022 Slide 22
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Electrification Service Remote Assistance
A unique solution for different levels of support

Monitoring Installation
Repairs &
Maintenance Technical Spares and and
Trouble
support information identification diagnostic KPI commissioning
shooting
analysis support

Support on Step by step

Remote
demand for procedures Support on
equipment Identification of
maintenance Diagnostics of demand for
inspection the correct
Information on M&D* KPI and installation and
spare parts to
Guided equipment results commissioning
Repair be replaced
maintenance operation and activities
procedures
steps use

Keep your installation up and running with the remote support of ABB experts

*Monitoring and diagnostic

8/30/2022 Slide 23
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Spares Strategy
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ABB Recommended & Critical Spares Strategy

• After site audits (as part of initial data collection or more extensive audit)
• Inventory available spares across fleet
• Initiate program to evaluate/re-certify spares (as needed)
• Provide fleet critical spares recommendations
• Locate & store strategically to respond to potential outage situations

August 30, 2022 Slide 25

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Customer Support Agreements
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ABB Power Care
Structured offering for support agreements with ABB Services

Power Care Entry Level Level 1 Level 2 Level 3

Skills Product Training Product Training Application Coaching
Development List Training Services
Services
Emergency Single Point of Contact Technical Support with Call-out Support with Spare Parts Assessment
Maintenance & Agreed T&Cs agreed response time agreed response time and Management
Services
Diagnosis Documentation of Asset Condition and Risk Asset Monitoring Remote Asset
& Condition Installed Base and Assessment Monitoring
Assessment Preliminary Survey
Self-Maintenance Installed Base Manuals and Instructions On-Line Support File Storage
Services Life Cycle On-line for Self-maintenance
Status Report
Delivered Periodic Technical Product Services Advanced Product Full Switchgear Services
Maintenance Assessment Services
Services

August 30, 2022 Slide 27

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Life Cycle Phases
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Lifecycle Phase Breakdown

Life cycle classic phase announcement Life cycle limited phase announcement Life cycle obsolete phase announcement
6-12 months 6 months 6 months

Active Classic Limited Obsolete

Guaranteed component support Limited component support

10 years equipment support typical1

Active phase Classic phase Limited phase Obsolete phase

– Available for sales – Product is still available, but not – Product is no longer actively promoted – Product is withdrawn from sales
extensively promoted (a substitution by the sales force
– Full manufacturing – No longer manufactured as a complete
product will be identified with cross-
– Service support is ensured, including product
– Actively promoted in assigned countries reference in most cases)
retrofit kits, spare parts and accessories
– Retrofits kits, where applicable, are
– Available to all (authorized) customers – No further enhancements and
– Product is no longer manufactured or available for most applications
developments
– Full technical and customer support limited production might be available
– Spare parts availability may diminish
available – Spare parts fully available
– Life extensions may be available under a over time with decrease in production
– Periodically enhanced through R&D and Customer Support Agreement, which volumes
product improvements provide “ Active Phase”- like support
from ABB Service team
– Fulfill availability of a spare parts
– Extended warranty available for
application

1. Privileged & confidential – prepared for review by counsel. INTERNAL DISTRIBUTION ONLY
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parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB
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Service Agreements

Maintaining Equipment Active Classic Limited Obsolete

– Equipment reliability will decrease Service Agreements

as the equipment ages. If not Installation and commisioning
properly maintained the risk for
an unexpected failure dramatically Installation & Safety
increases
Spare parts
– After a long useful life, all
electrical equipment will start to Maintenance
show its’ age, in that case an Repairs
upgrade or retrofit can be utilized
to further extend its useful life as Engineering and consulting
well as increase performance with Advanced services
the latest technology available
Extensions
– Regularly maintaining and
upgrading equipment will Upgrades
increase overall safety with
Retrofits
reduced risk for arc faults, as well
as meeting new safety End of life services
requirements
Replacements

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August 30, 2022 Slide 30
parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB
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Supported Products

Active Classic Limited Obsolete Switchgear Switchboards Circuit Breakers

Status Product is Product will be Limited Product is no Low Voltage Med Voltage Low Voltage Low Voltage Med Voltage
actively replaced but is still manufacturing/ longer available Vacuum/Air
marketed and available for sales, stock availability nor sellable
sold mainly for spares and ReliaGear SG SafeGear ReliaGear SB Molded Case Power AMVAC
expansion projects MNS SG AR Advance PowerBreak II Tmax XT EMAX2 ADVAC
Entellisys 5.6 SecoGear AV3 Spectra Entelliguard VMAX
Entellisys PowerVac PowerBreak I Insulated Case New EMAX SecoVac
Max SG HKII PowerBreak II K-Line PowerVac
K-Line HK PowerBreak KDON VHK
Product AKD-20 MagneBlast K-Line Plus VHK-X
available for ● ● Not guaranteed ● AKD 10, 8, 6, 5 EMAX HK
sales K-Line Plus WavePro MagneBlast
MB AKR SecoVac R
Spares LK AK
● ● ● Not guaranteed MB
availability
LK

Product on Motor Control Centers (MCCs) Outdoor Load Interrupter Switches (LIS)
● ● Not guaranteed ● Breakers
stock
Low Voltage Med Voltage Med Voltage Med Voltage
Available in ReliaGear LimitAmp RMAG BreakMaster LIS
● ● ● ●
online tools MCC SafeGear V Breaker BreakMaster V
MNS MCC AR MCC R Breaker
E9000 Advance
Maintenance
● ● ● Not guaranteed 8000 Series MCC
and repair
7700 Series

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August 30, 2022 Slide 31
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ABB Services & Call Center
+1 888 434 7378 or +1 540 387 8617

General Services Call Center Contract Customers

– Local Service & Sales Team Initiated – Toll Free & Direct Dial Numbers – Toll Free & Direct Dial Numbers
– Installation, startup and commissioning – 24 x 7 x 365 emergency services and – Assigned a customer profile
– Feasibility/engineering studies parts – List of equipment covered
– Assessment/inspection/testing – Calls for equipment under warranty – Notes on customer drawings &
– Preventative Maintenance – Field Engineer or Tech Dispatch configuration

– Outage support – Time & Material Quotes @ Published – Customer notification email list
rates – Primary and Secondary Field Engineers
– Repair and product replacement
contacted to support
– Training
– Escalation procedure to local Service and
Account Managers as needed
– Contract rates for dispatch

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August 30, 2022 Slide 32
parties or utilization of its contents – in whole or in part – is forbidden without prior written consent of ABB