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Best Practice SharingHydro Generation Maintenance Italy
Roncovalgrande, January 19 th , 2011
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Workgroup MaintenanceAgenda
Workgroup theme Organization
Maintenance policies
What is PMO?
Plant monitoring
Main maintenance intervention scheduling IT tools
Maintenance costs
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Workgroup Maintenance
Workgroup themes
Maintenance policies of hydro plants electro-mechanical components
Tools to manage maintenance process
Italian hydro plants
225 plants (76% with reservoir)
12.922 MW (net)
23.874 GWh (including pumping stations generation)
Water concessions last in 2029
Plants Age (average age 58 years) :
< 50 years 50 to 70 years 70 to 90 years > 90 years
Number ofplants 59 98 57 11
Percentage 26% 44% 25% 5%
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Organization - GEM Division
PlantsOperation &Maintenance
TechnicalSupport
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Business Area Generation (GEN)
HDE100 %
157
Operation
Maintenancepolicies
(PAL PAP)
Mainmaintenanceintervention
execution(SMI)
Developmentof hydro plant
(PRI)
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Structure of Hydro Business Unit (UB)
Controller
Technical Support
Hydro Area 1 Hydro Area 2
Operation,Environmental and
Safety
Operation Unit 1
Operation Unit 2
Operation Unit ..
Operation Unit 1
Operation Unit 2
Operation Unit ..
Operation & MaintenanceActivities
Business Unit
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Technical Area Development and Plants Aid (SAI/ASP)
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Maintenance policies
Reference for Italian Plants
Program 100x100 Project hydro plants maintenance (2001-2003)
Target
In order to reduce the unavailability (both planned and unplanned) and toimprove the reliability of hydro plants, we needed to choose the bestmaintenance policy for each electro-mechanical component of the plant.
Tool
PMO (simplified Plant Maintenance Optimization)
PolicyCondition-based maintenance (CBM) for main components
Corrective maintenance for other components
Planned periodic maintenance only for few standard components (HV and MVequipment)
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What is PMO?
PMO is a simplified version of the Reliability Centered Maintenance (RCM)Using PMO the best maintenance policy for each component is chosen using the followingrules:
Is component critical? (effects of the failure)The component is critical if its failure causes:
Safety damages
Environmental damages Plant damages Law violations Unavailability of the generation unit
Is component determining? (duration of the outage)The component is determining if:
The time we need to spend to maintain the component increase the total duration ofthe maintenance outage
The time we need to spend to monitor the component (with unit unavailable)determine the total duration of the planned outage
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What is PMO?
Classification of the components is customized for each plant
Result:
For each plant a customized list of monitoring actions and frequencies onlyon selected components
1 Critical only for unavailability of the generation unit, else CBM
Critical Not critical
Determining Condition-BasedMaintenanceCondition-Based
Maintenance
Not determining CorrectiveMaintenance 1Corrective
Maintenance
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What is PMO?
Tools for selection of the monitoring actions andfrequencies:
Scadenzari di manutenzione MaintenanceSchedule Templates Lists of standard actionsand frequencies for main components (ASPtechnical documents)
Other ASP technical documents (including PTR Relevant Technical Problems)
Customization of old lists from GuideNazionali dei Controlli Sistematici, ed. 1996
PMO exhaustive analysis on few referenceplants
Experience and knowledge of plant operators
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Plant monitoring
According to the lists of monitoring actions and frequencies :
Plant operators monitor the plant during operation and check components duringplanned outages
Specialized checks are normally performed by ASP technicians
Some specialized checks are performed by third parts
In case of failure plant operators check and repair faulted components.
If a great failure happens on main components, ASP technicians are involved.
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Plant monitoring - automatic
In main plants, some parameters are constantly monitored through automatic controlsystems. These parameters are:
Temperature (bearings, electrical machinery)
Oil gas level (transformers)
Vibration (rotating machinery) Partial discharge (stator winding insulation)
Vibration can be also remote monitored by ASP technicians through SMAV system
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Main maintenance intervention scheduling
According to the results of monitoring actions, to the operation events, to new Grid Coderequirements and to the ASP technical suggestions (PTR), UB yearly elaborates thedocument Stato Impianto ( Plant Condition ) containing a synthetic judgement aboutthe condition of main plant components expressed in five degrees:
1. Very bad condition (great maintenance intervention needed as soon as possible)
2. Bad condition (great maintenance intervention needed in next 5 years)
3. Bad condition (little maintenance intervention needed in next 5 years)
4. Good condition (no maintenance intervention needed in next 5 years)
5. Optimal condition (component is like a new one)
The document is useful to aggregate maintenance interventions on different componentsin the same outage, minimizing planned unavailability
1
2
3
4
5Vasche di carico
Opera di presa
0pere di adduzione
Valvola a farfalla
Condotta forzata
Centrale, accesso, fabbricato
Opere di scarico
Valvole di macchinaTurbine
Supporti
A lterna to re
Trasformato re elevatore
M ontante di gruppo, stazione
Sistema di controllo
Sistemi ausiliari
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Main maintenance intervention scheduling
Servizi di Manutenzione Idroelettrici (SMI) elaborates feasibility studies for interventionson components in bad condition, comparing different technical solutions and estimatingcost and time for each solution.
UB economically evaluates the intervention using NPV method (according to Enelinvestments evaluation policies)
Profitable interventions are included in Business Plan/Budget
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IT Tools SAP
SAP is the official Enelsdatabase used for
budgeting, costs analysisand obtaining economic
results
SAP is so used also formanaging maintenancecosts and information
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IT Tools SAP
In SAP the plant isrepresented by a tree
structure:
technical units ( SediTecniche ) on six levels
components ( Equipments )
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IT Tools SAP
Maintenance Orders( Ordini di ManutenzioneOdM ) are SAP objects used
for managing costinformation about
maintenance
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IT Tools SAP
Maintenance Notes ( Avvisidi Manutenzione AdM )are the SAP objects usedfor managing technical
information aboutmaintenance ( Machine
Book
Diario diMacchina )
AdMs also automaticallyregister safety blocks fromoperation database ESIM
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IT Tools SAP
Maintenance Cycles ( Ciclidi Manutenzione ) are thetools to plan and manage
the periodic maintenanceactivities (monitoring
actions)
Enel developed acustomized version of
Maintenance Cycles moreflexible than the SAP one,
used to manage actions
lists obtained from PMOanalysis
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Maintenance costs
Maintenance costs are available from SAP database.
Cost details are available for each Sede Tecnica and Equipment of the SAP tree structure.
Cost details are available for different kinds of maintenance according to theclassification available for OdMs (main kinds below):
Corrective maintenance
Planned maintenance:
Preventive maintenance
Predictive maintenance
Monitoring actions with or without outage Extraordinary maintenance
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Maintenance costs: opex/capex
Maintenance costs are normally opex .
Main interventions costs can be classified as capex if the interventions:
improve the availability and the reliability of the plant ( Stay in Business investments)
are compulsory in order to conform the plant to Law or Grid Code new requirements(Mandatory investments)
refurbish the plant (substitution of all electromechanical components: Development investments PRI interventions)
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Workgroup MAINTENANCE
Workgroup members
GEN: Poggi ([email protected])
SAI: Giovannini ([email protected]) , Prado ([email protected])
Subgroups
GEN:
BERNARDI, SUMAN, CIANCIAVICCHIA, FENU, CANNATA, CAMMISULI, RANIELLO
SAI:
LAURO, BETTONI