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ABB BU Machines Service

Jan 08

Maintenance
Service
BU Machines
Why maintenance?

Maximize availability
Increase reliability
Extend lifetime
Minimize unplanned stops
Hold the high safety standard
Protect the environment
Save the investment
ABB BU Machines Service
Jan 08
Type of Maintenance

Reactive
Failure or abnormal operation

Preventive
Maintenance program based on manufacturers experience

Predictive
Maintenance based on actual measurements

Proactive
Continues upgrading with latest developments
ABB BU Machines Service
Jan 08
Preventive maintenance program
Four levels
L1-L4
Interval
Depending on machine type
and application
Always check manual for instructions and actions
Level 3 and 4 maintenance to be carried out by ABB authorized
personnel
Preventive Maintenance Kits
Parts to be available and replaced at scheduled maintenance
ABB BU Machines Service
Jan 08
Preventive maintenance program

Maintenance L1 L2 L3 L4
programs

Intervals Per each machine type. Defined in user manual

0.5-1 year 1-2 year 3-5 year 8-12 year

Expected 4-8 hours 8-16 hours 5 days 10 days


work time

Manpower 1 service 1 service 2 service 2 service


engineer engineer engineers +1 engineers +2
ABB BU Machines Service

needed local technicians local technicians


Jan 08
Equivalent operating hours

Equivalent operating hours = Total operating hours + No


of starts x 20h

Considers is given to the thermodynamic and


mechanical stresses in connection with starting

The factor 20h can be altogether too low for starting of


compressors with very high inertia
ABB BU Machines Service
Jan 08
Maintenance Level 1 (L1)

Open inspection covers for visual inspection


Review of operating parameters
Voltage, current, load, temperature, cooling condition, vibration
Check protection, trip and alarm log
Replace filters, oil, brushes and other consumables if needed
Preventive maintenance kit for L1
ABB BU Machines Service
Jan 08
Maintenance Level 2 (L2)

Open inspection covers for visual inspection (same as L1)


Review of operating parameters
- Voltage, current, load, temperatures, cooling conditions, 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
ABB BU Machines Service
Jan 08
Maintenance Level 3 (L3)

Open inspection covers for visual inspection (same as L2)


Review of operating parameters
- Voltage, current, load, temperatures, cooling conditions, 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
Cleaning of coolers
Detailed rotor inspection
Preventive maintenance kit for L3 and suggestions from earlier
ABB BU Machines Service

inspections
Jan 08
Maintenance Level 4 (L4) part 1

(Same as L3)
Review of operating
parameters
- Voltage, current, load, temperatures,
cooling conditions, vibration
- Check protection, trip and alarm log
Replace filters, oil, brushes and
other consumables if needed
Inspection of bearings
Inspection and cleaning of coolers
Measurement of insulation resistance
of the stator (rotor & exciter if
ABB BU Machines Service

applicable)
Jan 08
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
ABB BU Machines Service
Jan 08
ABB BU Machines Service
Jan 08
Preventive Maintenance program
Preventive Maintenance kits

Preventive maintenance parts


replacement intervals
ABB BU Machines Service
Jan 08
ABB BU Machines Service
Jan 08