Controlling crew cost and raising competency by ABB Service UK

Stuart Melling, manager for marine and crane service, ABB Ltd

Top concerns for the marine sector Controlling crew cost and raising competency ÂŠ ABB Inc. February 11, 2013 | Slide 1

Top concerns for the marine sector Controlling crew cost and competency 

Marine industry’s challenge: 

To recruit crew with relevant competence and experience at right price

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Crew costs are one of highest operational costs

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Outsourcing specialist tasks such as electrical plant healthcare and maintenance can help to: 

realise lower crew training costs (including periodic recertification which may be needed)

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reduce need for specialisation

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keep abreast of latest technological developments 

supplier brings a range of advanced monitoring, measuring and reporting tools

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efficiently keeps plant up and running

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can significantly cut maintenance cost

Top concerns for the marine sector Controlling crew cost and competency 

ABB adds significant value by offering maintenance and engineering support through: 

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Step 1: use of ABB engineers 

trained in various marine-standard electrical, automation and instrumentation disciplines

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can join vessels globally

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make quick impact on engineering efficiency of on-board plant

Step 2: using a series of highly advanced engineering tools, like remote diagnostics: 

major impact on vessel performance

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dramatically cut the cost of maintenance

Step 3: competency management – marine academies 

ABB’s marine academies’ train staff with broad range of engineering, power and automation courses.

Top concerns for the marine sector Step 2: Highly advanced engineering tools 

Remote diagnostics

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Remote diagnostic services (RDS):

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monitor, measure and alert to faults

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from vessel thruster systems, motors, drives, switchgear, circuit breakers to protection relays, instrumentation and automation systems

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although very advanced functions RDS is straightforward to implement and user-friendly

RDS comprises: 

remote connection

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diagnostic solutions

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service agreements

Top concerns for the marine sector Step 2: Highly advanced engineering tools 



Remote connection: 

links up vessel’s engineers at sea with a qualified ABB service engineer, located onshore

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ABB engineer can monitor, analyse and troubleshoot

ABB Computer Center: 

Central network of high-availability servers at onshore ABB Computer Center manage all customers’ systems

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Can be accessed via RDS and their authorised users

Top concerns for the marine sector Step 2: Highly advanced engineering tools 

Remote connection 

Virtual service engineer (VSE): 

software package installed on ABB computers on customer’s side

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acts as a software-site-manager

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sets up secure, encrypted communication with service centre

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signals its availability and readiness for a remote maintenance session

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with VSE-installed PC connected to internet from anywhere, VSE will automatically contact service centre to make remote connection

Top concerns for the marine sector Step 2: Highly advanced engineering tools 

Remote connection 

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ABB service engineer: 

authorised ABB service engineer can log on to service centre

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request permission to connect to a vessel’s installed diagnostics system

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series of diagnostics can be carried out to help

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helps operator determine status of equipment

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in event of a problem, source rapidly identified

Modularity 

system completely modular

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allows expansion from monitoring and diagnosis of a few critical components or subsystems, to a full multi-disciplinary diagnostic system of power plant and electric propulsion system

Top concerns for the marine sector Step 2: Highly advanced engineering tools 

Diagnostic solutions 

Purpose built hardware platform 

allows collection and correlation of data for condition monitoring and troubleshooting from variable-speed drives, PLCs and switchboard relays

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device allows sharing of data collected from individual components or sub-systems 

simple and intuitive functions for on-demand monitoring of signals

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storage of all recorded data in database for later reference

Top concerns for the marine sector Step 2: Highly advanced engineering tools 

Service agreements 

Provides fast and efficient remote support of ABB’s full marine technology portfolio

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Service agreements configured to suit individual customer needs 

Troubleshooting - on demand connection by an ABB service engineer

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Prevention - in addition to the above, ABB service engineer periodically connects to remote system, performs a detailed health-check and advises corrective measures

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Continuous - in addition to the above, critical alarms and process statuses are relayed to ABB service centre from where countermeasures can be launched

Top concerns for the marine sector Step 2: Highly advanced engineering tools 

Service agreements 

Scheduled and unscheduled cases are handled by ABB marine RDS Operations Center in Norway 

manned 24/7/365

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RDS team trained to support all ABB marine systems included in RDS programme

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all incidents and requests are logged by engineer on duty

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on-call service initiated by remote support and is performed by qualified service personnel from closest ABB global marine services centre

Top concerns for the marine sector Step 3: Competency management – marine academies 

Training is priority throughout marine sector

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Having high level of crew competency ensures efficient and safe vessel operations

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ABB compiled comprehensive schedule of courses:

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Marine academies in Singapore or Finland

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Interactive on-board training sessions

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e-learning

Courses are: 

tailored towards particular vessel types and DNV approved

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cover general, safety and advanced system training

Top concerns for the marine sector Step 3: Competency management – marine academies 

Target groups: 

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Technical crew: 

technical crew, deck crew, other marine professionals

electrical engineers and mechanical engineers

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Dedicated courses are provided for deck officers

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General courses introduce ABB on-board system 

contents tailored according to actual customer installation

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advanced courses deepen customer’s knowledge by focusing on one sub-system at a time

Top concerns for the marine sector Step 3: Competency management – marine academies 

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Safety courses for marine high voltage systems and Azipod confined spaces 

provides knowledge and skills for managing risks

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adapt safe working methods of high voltage environments and confined spaces

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contents in accordance with accepted international standards, rules and regulations

Hands-on learning environments for: 

existing marine drive types

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switchgear equipment

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full-size large Azipod hydraulic steering unit

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Azipod C systems

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marine automation

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diesel electric Azipod vessel operation

Top concerns for the marine sector Step 3: Competency management – marine academies 

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On-board training approach is about co-operation and learning together 

ABB marine field engineer is instructor

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Engineer executes, together with a crew, a list of tasks agreed in advance

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Training objectives stated together with the actual crew

electronic Maintenance Support Tool (eMST®) 

Novel concept enabling just-in-time access to highly focused e-learning material

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delivers instructions for daily crew maintenance tasks

Top concerns for the marine sector Step 3: Competency management – marine academies 



Produced by specialised ABB organisation that includes: 

full-time project management personnel

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experienced ABB marine maintenance specialists

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complete network of subcontractors from area of graphical and usability design

eMST® objectives always agreed with customer and depends on: 

scope of ABB equipment

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amount of crew tasks

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desired competence level of crew

Learning content is exclusively system specific and includes: 

photos, videos, animations and instructional texts produced for the actual on board system

Top concerns for the marine sector Summary

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Many variables to consider

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Marine operators should take great care to implement strategy that meets business needs and financial constraints

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Combination of managing crew competency with outsourced assistance for irregular or specialised operations

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While many traditional maintenance techniques are still applicable, new technology is allowing vessel operators to: 

reduce training and crew costs

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whilst improving equipment effectiveness