Best Practice Sharing

Roncovalgrande, January 19th, 2011

Hydro Generation Maintenance Italy

Workgroup Maintenance
Agenda

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Workgroup theme Organization Maintenance policies What is PMO? Plant monitoring Main maintenance intervention scheduling IT tools Maintenance costs

Workgroup Maintenance

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Workgroup themes

Maintenance policies of hydro plants electro-mechanical components

Tools to manage maintenance process

Italian hydro plants

225 plants

(76% with reservoir) (net) (including pumping stations generation)

12.922 MW

23.874 GWh

Water concessions last in 2029 Plants Age

(average age 58 years):

< 50 years
Number of plants Percentage 59 26%

50 to 70 years
98 44%

70 to 90 years
57 25%

> 90 years
11 5%

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Organization - GEM Division

Plants Operation & Maintenance

Technical Support

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Business Area Generation (GEN)

HDE 100 %
157

Operation Maintenance policies (PAL PAP)

Main maintenance intervention execution (SMI) Development of hydro plant (PRI)

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Structure of Hydro Business Unit (UB)

Business Unit
Operation, Environmental and Safety

Controller Technical Support

Hydro Area 1
Operation Unit 1 Operation Unit 2 Operation Unit ..

Hydro Area 2
Operation Unit 1 Operation Unit 2 Operation Unit ..

Operation & Maintenance Activities

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Technical Area Development and Plants Aid (SAI/ASP)

Maintenance policies

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Reference for Italian Plants

Program 100x100 Project hydro plants maintenance (2001-2003)

Target

In order to reduce the unavailability (both planned and unplanned) and to improve the reliability of hydro plants, we needed to choose the best maintenance policy for each electro-mechanical component of the plant.
Tool

PMO (simplified Plant Maintenance Optimization)

Policy

Condition-based maintenance (CBM) for main components Corrective maintenance for other components
Planned periodic maintenance only for few standard components (HV and MV equipment)

What is PMO?

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PMO is a simplified version of the Reliability Centered Maintenance (RCM)

Using PMO the best maintenance policy for each component is chosen using the following rules: 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 of the maintenance outage The time we need to spend to monitor the component (with unit unavailable) determine the total duration of the planned outage

What is PMO?

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Critical

Not critical

Determining

Condition-Based Maintenance Corrective Maintenance1

Condition-Based Maintenance Corrective Maintenance

Not determining

Classification of the components is customized for each plant

Result:
For each plant a customized list of monitoring actions and frequencies only on selected components
1 Critical only for unavailability of the generation unit, else CBM

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What is PMO?

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Tools for selection of the monitoring actions and frequencies: Scadenzari di manutenzione Maintenance Schedule Templates Lists of standard actions and frequencies for main components (ASP technical documents) Other ASP technical documents (including PTR Relevant Technical Problems) Customization of old lists from Guide Nazionali dei Controlli Sistematici, ed. 1996 PMO exhaustive analysis on few reference plants

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 during planned 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 control systems. 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 Code requirements and to the ASP technical suggestions (PTR), UB yearly elaborates the document Stato Impianto (Plant Condition) containing a synthetic judgement about the condition of main plant components expressed in five degrees:

1. Very bad condition 2. Bad condition

(great maintenance intervention needed as soon as possible)

Vasche di carico Sistemi ausiliari

(great maintenance intervention needed in next 5 years)

5 4 3 2 1

Opera di presa 0pere di adduzio ne Valvo la a farfalla

3. Bad condition

(little maintenance intervention needed in next 5 years)

(no maintenance intervention needed in next 5 years)

Sistema di co ntro llo

M o ntante di gruppo , stazio ne

4. Good condition

Trasfo rmato re elevato re

Co ndo tta fo rzata

5. Optimal condition

(component is like a new one)

A lternato re Suppo rti Turbine

Centrale, accesso , fabbricato Opere di scarico Valvo le di macchina

The document is useful to aggregate maintenance interventions on different components in the same outage, minimizing planned unavailability

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Main maintenance intervention scheduling

Servizi di Manutenzione Idroelettrici (SMI) elaborates feasibility studies for interventions on components in bad condition, comparing different technical solutions and estimating cost and time for each solution.

UB economically evaluates the intervention using NPV method (according to Enel investments evaluation policies)

Profitable interventions are included in Business Plan/Budget

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IT Tools SAP

SAP is the official Enels database used for budgeting, costs analysis and obtaining economic results

SAP is so used also for managing maintenance costs and information

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IT Tools SAP

In SAP the plant is represented by a tree structure:

technical units (Sedi Tecniche) on six levels

components (Equipments)

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IT Tools SAP

Maintenance Orders (Ordini di Manutenzione OdM) are SAP objects used for managing cost information about maintenance

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IT Tools SAP

Maintenance Notes (Avvisi di Manutenzione AdM) are the SAP objects used for managing technical information about maintenance (Machine Book Diario di Macchina)

AdMs also automatically register safety blocks from operation database ESIM

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IT Tools SAP

Maintenance Cycles (Cicli di Manutenzione) are the tools to plan and manage the periodic maintenance activities (monitoring actions)

Enel developed a customized version of Maintenance Cycles more flexible than the SAP one, used to manage actions lists obtained from PMO analysis

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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 the classification 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

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GEN: Poggi

(andrea.poggi@enel.com) (mauro.giovannini@enel.com),

SAI: Giovannini

Prado

(fabio.prado@enel.com)

Subgroups
GEN: BERNARDI, SUMAN, CIANCIAVICCHIA, FENU, CANNATA, CAMMISULI, RANIELLO SAI:

LAURO, BETTONI

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