BPS HYDRO Maintenance Italy

8/12/2019 BPS HYDRO Maintenance Italy

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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

Documents

BPS HYDRO Maintenance Italy