Industrial equipment servicing in India has gradually shifted towards proactive intervention. This change is driven by Original Equipment Manufacturers (OEMs), who are leveraging services as a unique selling proposition and revenue model. Simultaneously, end-users are demanding comprehensive lifecycle support for their equipment’s optimal performance. Independent service providers, more so the OEM authorized service providers, are enhancing the service value chain with their expertise, agility, and competitiveness.

Large and medium-sized businesses are transitioning from time-based maintenance to predictive and prescriptive maintenance. This shift is facilitated by advanced condition monitoring tools and systems, many of which employ Industrial Internet of Things (IIoT) devices for real-time data collection. This data is then analysed using AI and Machine Learning tools to provide actionable insights, leading to improved performance, uptime, reduced operating costs, and optimised maintenance costs. 

All the above is applicable for motors and generators as well, and for these rotating electric machines, the solutions are tending to be make agnostic brining convenience and benefits to the users

At ABB, we are harnessing predictive maintenance technologies to help industries minimise unplanned downtimes and enhance asset performance from many years. Our ABB Ability™ LEAP program has been analysing and managing stator winding insulation conditions in high voltage motors and generators for over two decades.

In the era of Industry 4.0 and digitalisation ABB's predictive maintenance approach involves the use of Industrial IoT (IIoT), AI, and advanced analytics. By combining data from physical and soft sensors, ABB can predict anomalies in equipment health, performance, reliability, and operational parameters well in advance. This holistic asset performance management helps customers cut down operational costs by around 25%.

ABB's six-step approach to predictive maintenance includes gaining visibility of data, understanding gaps, analysing key trends, predicting faults, optimising maintenance strategies, and establishing a reliability culture. 

Industries today aim to focus on their core business while optimising asset utilisation and reducing workforce stress but often face challenges like unexpected equipment failures resulting in high operational costs. ABB's advanced Motors and Generators Services address these issues, offering sophisticated monitoring systems and IoT-enabled solutions that can be deployed on any make of machine, both old and new.

ABB Ability™ Machine Guardian performs online condition monitoring and current signature analysis, detecting anomalies early. For low voltage (LV) motors, ABB's smart sensor provides condition monitoring, using advanced analytics to preempt potential issues and prevent unplanned downtime.

These IoT systems facilitate the transition to data-driven maintenance practices. ABB also uses advanced technologies like the ABB Ability™ Air Gap Inspector, which is equipped with cameras to inspect the stator and rotor of motors and generators without removing the rotor. This enhances inspection quality and builds an extendable platform for further tests, inspections, and maintenance. 

Over and above these, ABB’s experienced team of field service engineers conduct various maintenance activities, backed by engineering, quality and project management experts.

Outcome-based service models in the drive, motors, and generators service business are centered on delivering specific results, such as reliability, availability, and productivity. These models utilise digital solutions and data analysis to optimise performance and efficiency across various equipment, including motors, generators, and drives.

In contrast, traditional service models typically adopt a transactional approach, focusing on delivering services and charging based on the time or resources utilised. Traditional models often operate on a break/fix basis, providing services reactively in response to issues or failures.

Energy efficiency and sustainability are indeed key priorities today. Electric motors, which consume over 45% of the world’s electricity, present a significant opportunity for energy conservation. There are more than 300 million electric motor-driven systems consuming 70% of the total electricity consumed by industry. According to a study by the International Energy Agency, upgrading to high-efficiency electric motors could cut global energy consumption by up to 10%.

In India, there is a significant scope for improvement as over 85% of the installed base of motors are of IE2 efficiency or lower. Transitioning to higher-efficiency motors, specifically IE3 and IE4, which have significantly lower energy losses, is crucial. However, businesses are sensitive to ROI and wish to choose the right motors for replacement, considering factors like capital cost, energy rates, motor KW, operating load, operating hours, and reliability needs.

ABB’s energy appraisal on motor-driven systems is a unique offering that helps customers estimate energy and CO2 emission savings, total investment, asset prioritisation, ROI, and payback time by transitioning to higher efficiency solutions. We provide comprehensive reports using basic motor rating plate data and IIoT sensors on motors and offer complete appraisal and replacement solutions with ABB’s offerings of IE4 and IE5 efficiency motors and the latest technology drives. We also offer to refurbish and upgrade existing low voltage motors to better efficiency, promoting the concept of circular economy. 

ABB adheres to and emphasises high level of safety standards, integrity, sustainability, and compliance across various sectors. 

For manufacturing, we provide preventive and condition-based maintenance to enhance equipment performance and minimise disruptions. Our service engineers ensure regular maintenance, either on-site, remotely, or in specialised workshops.

In utilities, ABB focuses on compliance and efficiency, providing swift intervention and recovery services through our global network of over 600 service engineers. We ensure timely component replacement, maximising plant availability and minimising unplanned interventions.

For process industries, ABB offers digital solutions for improved decision-making and data-driven actions. Our digital suite includes asset performance management, condition monitoring, predictive maintenance, and advanced process control, enabling higher efficiency and productivity.

The future of motors and generators servicing lies in co-creating tailored services based on the unique blend of customer type, equipment & application, and investing in resources. This co-creation would involve customers, OEMs, and service partners for maintenance, repairs, and digital offerings.

Innovative business models, such as Reliability/Availability as a Service (RaaS), performance-based contracts, Pay-per-use, and Equipment as a Service (EaaS), could evolve based on demand, value creation, and costs. Technologies like AI, ML, AR, VR, digital twin and 3D printing will continue to evolve the future. 

India is in a prime position for creating service platforms where various OEMs and service providers offer services with clear accountability and service delivery KPIs. At ABB, we are already leveraging many of these technologies and venturing into new areas to create an ecosystem where value-based services can thrive, thus enhancing industrial productivity and reliability.