Partnership Development Phase Service Innovation
Fernando Tobar - Service Manager, June 05th
© ABB Group July 1, 2013 | Slide 1
© ABB Group July 1, 2013 | Slide 2
Maintenance Contract (LTSA) Definition of Service Agreement
Long Term Service Agreement (LTSA) combining all primary and specialized life cycle and maintenance activities with strong performance focus while covering all project execution phases from ramp-up to normal operation.
Cross-divisional approach with combination of high technology and traditional services in a multi module package adjustable and tailor-made according to customer needs and ABB installed base.
Holistic solution to enhance processing of plant data/information with aim to convert it into knowledge. Asset management and real time process optimization form an integral part of the delivery process.
Creation of an environment of constant awareness to improve the main electrical assets and plant profitability
© ABB Group July 1, 2013 | Slide 3
Maintenance Contract (LTSA) Values and benefits
Our contractual life-cycle and maintenance services are delivered
seamlessly through strategic partnerships with our clients to ensure
all expectations for quality, timeliness, safety are met.
KPI's form the backbone to measure our performance.
In providing unique contractual services we strive to identify
inefficiencies and duplications in manpower and material in order that
the true value of work is justified and practical.
Our success is based on cooperation and creating profitable growth
for our business partners and employees.
© ABB Group July 1, 2013 | Slide 4
Power transformer
MV switchgears
Over head lines
Power factor correction system
Distribution transformer Drive transformer
Motor control center
LV VSD
Control system
LV motor
MV VSD
MV motors
Process plant and infrastructure Field of plant services
HV switchgears
Valves
© ABB Group July 1, 2013 | Slide 5
Distinguished service products in one single agreement The service mix: portfolio
© ABB Group July 1, 2013 | Slide 6
1. Screening
& Viability
2. Pre-feasibility
ECIS budgetary
No-Bind Offer
3. PdP
Partnership
Development
Phase
4. Business
Case-Technical
Proposal
Development
6. Business
Case-Bind Offer
Development
7. Contract
Award & KPI’s
Put in-place
LTSA Long Term Service Agreement Development Process: Main phases and tasks
Approach Material Presentation Ref. Cases Aligning Objective ECIS workshop Model Concept
Basic Scope Plant Information NDA if required Agree on feasibility LoA Authorization
Pre-feasibility Scope line def. OK Basic Proposal def. Contract Model PdP Concept &Plan PdP Budget Cost PdP LoI draft List req. documents Green signal: Go
PdP Preparation: Value proposition PdP Scope Pdp Schedule PdP Cost PdP Deliverables PdP WorkteamPdP Mob/Start-up PdP Progress F-up PdP LoI signature PdP Kick-off
Maintenance
Scope Matrix Structure Org+HC CMMS & PM plan Req’d Resources
. MP
Maint. Plan + KPI’s Shutdown schedule Scope of Services
Resources Int/Ext . Early Maintenance CMMS implement Ramp-up support Tech Proposal OK
Local HR & ABB Support Processes Cost Consolidation Full Cost pre-Calc Draft Price. Check Economical
Proposal draft Legal Issues: T&C Risk Review: OK Bind Offer-Final Tech/Econ Proposal MMMP-Master Plan Offer Handover OK
Offer Negotiation Contract T&C Terms +Conditions KPI’s baseline Contract in-place Implementation Mobilization Start-up Contract & KPI’s
Management Control Actions
LoA PdP LoI Contract
Signature Econ. Offer Tech. Prop
We are entering into this phase of pre-feasibility
Workshop
Gates
PdP = Partnership development Phase
© ABB Group July 1, 2013 | Slide 7
Equipment Selection Commissioning & Start Up Construction Phase Normal Operation Detailed engineering
Maint. Strategy Definition Services
Equipment criticality analysis & Asset Management Services
Equipment Tree & Tagging System Services
Maintenance Documentation and CMMS Implement.
Commissioning Planning & Installation and Commissioning Execution Services
Preventive Maintenance Plan
Project Execution Phase Operation Phase
Competence Development Program – Training Services ABB University
Life Cycle Service Contract including : preventive maintenance activities, remote diagnostics, spare parts management , upgrades and evolution planning, 24 hours support.
Local Development Training Center facility
Life Cycle Management Concept and deliverables
© ABB Group July 1, 2013 | Slide 8
PdP: Scope of technical support to plant ramp-up Early Maint. Engineering and Test & Commissioning main activities
Main Tasks Activities to be performed by EM Team (Early Maint. during pre& commissioning/start-up)
Activities to be performed by T&C Team, (Testing & Commissioning/Start-up).
Service Scope
Contribute, facilitate, follow-up, assist, provide tech. support, information and help solution in case of emergencies, during the commissioning & start-up warranty phase.
Management + execution of T&C/start-up and warranty program. Execute schedule chart, job activities, documentation delivery, test records, final test reports for: pre-commissioning, commissioning, start-up and warranty phases: conditioning, cold run, hot run, idle run, normal & commercial run.
Service Performance
Inspect, evaluate, follow-up the T&C/start-up activities progress and the factory acceptance tests in order to ensure that the assets are performing as contractually specified and according to proper engineering practices
Do the jobs, perform, and execute all T&C tasks: pre-commissioning, commissioning, start-up, warranty and stand-by operation. Check functionality of equipment before energize.
Punch-list Monitoring and ensuring quality completion of punch-list and the clearance of construction pending points. Back-log clearance follow-up
Complete clearance of all pending points, eliminating the possible passive/backlog of construction phase (punch list)
Documentation
To proceed implementation of the Maint. Technical Documentation mgmt. system. Assistance to design reviews documentation “as-built”.
Execution of protocols, procedures and communication of documents revision. Manage the execution of documentation “as-built” by the EPC company. Prepare and fulfill documents, test routines, sequences, check-lists, technical & safety procedures, switch-on process, applied standards, test records, calibration reports, acceptance certificates,
Equipment Reception
Assistance in equipment handover from commissioning
Perform all the final acceptance tests for warranty effectiveness.
Stand-by operation
Work with the operational people for plant technical assistance after start-up
Prepare and supply the work team for stand-by operation, according to contract EPC
EM Team T&C Team
Next Step after Budget estimation: PdP approval
"July 1, 2013 | Slide 9
PdP = Partnership development Phase.
The PdP delivery document is a Complete Bid Offer for the Service Agreement business case, with respective Maintenance Management & Implementation Maintenance Plan and covering
since Pre-Commissioning and Start-up period to 03/05 years normal operation.
RDS (Remote Diagnosis Services)
GMD Services Agreement
Material Handling Service Agreement
SEMA (Smart Electrical
Maintenance Agreement)
© ABB Group July 1, 2013 | Slide 10
Pre-startup services
Spare parts
Site mainte-nance
Remote support
Extension
Repla-cement
Consumables
Logistics and dispatch
Parts kits
Software upgrades
Hardware upgrades
Extensions
Retrofit
Maintenance strategy
SolutionsBank
Data engineering
Training
Parts optimization
Asset optimization
Consulting
Energy and water efficiency
Cyber security Installation and commissioning
Optimi-zation
OPEX team
Predictive maintenance
Asset and reliability
engineering
Maintenance management
system
Design reviews
OHSE and scorecard
Inspections and diagnostics
Remote condition monitoring
Edu-cation
Exchange units
Replacement of active products
Ramp up services
Engineering support
Maintenance master plan
Parts and inventory
management Consulting
Corrective maintenance
Replacement of non active products
Integrity management
Equipment criticality
Commissioning plan
Training development
plan
Maintenance organization
structure
Inventory audit
Smart spares software
Preventive maintenance
Integrity management
Warehousing and repair
Site training facilities
ABB training centers
Blended learning
Learning management
system
Virtual tutorials
Competence assessment
Extended start-up support
Training demo units
Competence matrix
Train-the-trainer
Metrics, KPI’s and ROI
Risk management
Apprenticeships
Certification
Command center
Inventory audit
ServicePort
Process optimization
Smart electrical maintenanceTM Portfolio
© ABB Group July 1, 2013 | Slide 10
• Long Term Service Agreement combining primary and specialized life cycle and maintenance activities with strong performance focus, while covering all project execution phases from ramp-up to normal operation.
• Combination of high technology and traditional services tailor-made according to customer needs. • Co-sourcing arrangement – Work together determine optimal maintenance and optimization approach
July 1, 2013 | Slide 11 © ABB Group
GMD Condition Monitoring Dashboard
Plots are scalable
Multi-page message
panel
Current information on winding
temperature and heat
exchanger
Current information on voltage,
current, power and
speed
Service Infrastructure: Remote-enabled service Apps
Drives OCS Operator Stations Historian Instruments/Actuators
Customer-Defined Access
Service Capabilities
APC Scan/Track Services
Control Tuning Optimization
Services Event
Notification Support Services
Software Support
Remote Troubleshooting
System Health Check
DriveScan/Track LoopScan/Track HoistScan/Track ServicePro
Troubleshooting Services
System Scan/Track
Engineering Stations
Local Remote Secure Access
Customer-Defined Access
Secure Tunnel
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