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ABB puts Caterpillar on track for major energy savings

Caterpillar chose ABB because it was looking for a professional maintenance partner which could bring value to its business rather than merely delivering 'lubrication' and 'wrench-turning' services. ABB Full Service® is a performance-based partnership agreement that is designed to improve overall plant performance while optimizing maintenance costs.

Around 1000 people work at Caterpillar’s Tiruvallur site, which is home to several of the company’s production lines, including those for Backhoe Loaders, Wheel Loaders, Quarry and Mining Trucks, and Off-highway Trucks.

In 2011 ABB’s Full Service team took over responsibility for the ongoing management and execution of maintenance at the site. The focus was to implement a preventive and proactive strategy, aimed at identifying and reducing losses and breakdowns.

The site’s new paint plant was identified by ABB as having strong potential for energy saving. It is equipped with two compressors, the main one being a 250 kilowatt (kW) Atlas Copco unit. This 250 kW compressor was found to be running for 23 hours per day, even though its only duty outside the normal eight-hour shift was to operate a paint mixture regulating pump. This extended running time represented a daily electricity consumption of 800kWh and a significant operational cost to Caterpillar India.

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