How RWE is benefiting from its collaboration with SKF as a solution provider

How RWE is benefiting from its collaboration with SKF

as a solution provider

Dr.-Ing. Bruno van den HeuvelRWE Power AG

Head of Diagnostics & Technical Services

SKF Capital Markets Day 2014

London

PAGE 2RWE Power AG Dr. van den Heuvel 19.04.2023

RWE AG

FTE:Full-time employees

RWE Generation SE

Total> 17,000 FTE

Management and support functions

~ 2,000 FTE

TechnologyLigniteHydro power

Nuclear energy

Hard coal, natural gas,

biomass

~ 250 FTE

~ 600 FTE~ 900 FTE~ 5,100 FTE~ 2,800 FTE~ 150 FTE~ 1,600 FTE~ 1,000 FTE

Planning & serviceProcessing

Opencast mines

~ 11 GW~ 2 GW~ 3 GW~ 7 GW

~ 1,800 FTE

~ 10 GW

~ 900 FTE

~ 7 GW

Key figures 2012 2013 EBITDA (€ million) 4,378 2,455

Operating result (€ million) 3,275 1,384

Workforce 17,583 16,311RWE AG

2013: 98.3 mill. mt lignite 466 mill. m3 overburden

RWE today: One of the leading European utilities

RWE Innogy

Key figures 2013 EBITDA (€ million) 7,904

Operating result (€ million) 5,369

Workforce 64,896


Opencast mining at RWE

20 spreaders

20 bucket wheel excavators

About 250 km belt conveyorsTotal capacity installed: 925 MW

High-capacity mining equipment & belt conveyors

(Replacement value of lignite production equipment ~ €7.5 billion)

PAGE 4RWE Power AG Dr. van den Heuvel 19.04.2023 Lignite stockpile in the Neurath power plant

Train loading in the Hambach mine

Company-owned railway system

Lignite mining and transportation to the power plants

Lignite stockpile in the Hambach mineLignite seam in the Hambach mine


Availability Cost cuttingefficiency enhancement Asset management:

Life-cycle cost Overall equipment effectiveness Total cost of ownership

Focus: Focus: Focus:

1995 2004

Maintenance at RWE Opencast Mines

€163 mill.€80 mill.

€357 mill.

Production

Depreciaton

Maintenance

Energy

€350 mill.

Primary cost at RWE lignite mines 2013: €1000 mill.

Life-cycle cost of mining equipment

Maintenance is a

core business Maintenance is a core competence for RWE


Maintenance is RWE's core competence

> We decide on our maintenance strategies and activities

> We perform maintenance ourselves and learn from failures

> We (not our OEMs) continuously improve life cycle cost

> We choose our suppliers based on life cycle cost


Maintenance is RWE core competence

Our needs, demands and expectations:

> Reliable products for sustainable and reliable operation

> Deep understanding and detailed knowledge of our special assets and operating conditions

> Technical support and solutions for our special assets and operating conditions

> Excellent delivery performance

> Continuous improvement


Rolling bearings in RWE opencast mines

Approximately 1 500 000 bearings in operation

Slewing rim

Substructure with crawler tracks

Slewable superstructure

app. 1 200 000 bearings 100 mm 38 bearings 21 000 mm

The performance of bearings and bearing systems is of great importance for reliable and cost-effective operation !


Most common root causes of bearing failures

Unsuitable lubricant

Lack of lubricantContaminations

Assembly faults and conse-

quential errors

Inappropriate bearing selection

Aged lubricant

Material or manufacturing fault(bearing manufacturer)

Reference: Dethloff, AKIDA 2002

? Experiences gained at

RWE Power

“Most bearing failures are not due to the bearing, but to something wrong in its environment”

Bearing failures and their root causes


> We are responsible

> We need good components around the bearing

> We need competent support from a reliable partner

Unsuitable lubricant

Lack of lubricantContaminations

Assembly faults and conse-

quential errors

Inappropriate bearing selection

Aged lubricant

Material or manufacturing fault(bearing manufacturer)Experiences gained at

RWE Power

Bearing failures and their root causes


Mercedes C63 AMG, 487 hp

Our needs and demands:

Components and services combined as part of the overall system

http://de.autoblog.com/2012/01/15/ verruckt-supercar-drift-auf-4-notradern-video/ with emergency spare wheels

The rolling bearing: Just a mechanical component, or a system?

http://de.autoblog.com/2012/01/15/


Using SKF Solution Factory for easyaccess to SKF's knowledge and offerings

SKF platforms

RWE

SKF

Solution

Factory

SK

F

Sale

s

DemandSolution


Engineering consultancy and service– Design and calculation

– Selection of maintenance strategies

– Condition monitoring and diagnostics

– Various services

– Remanufacturing

Seals Lubrication systems Mechatronics

RWE – SKF: Examples of a valuable cooperation


Typical belt conveyor drive station (8 MW driving power)


Benefiting from simulation and design validation

Roller centred brass cage

Source: SKF Report: Dynamische Lageruntersuchung von Zylinder-rollenlagern für innengelagerte Bandtrommeln der RWE Power AG

Pierced rollers and pin cage

SKF

SKF solution: Engineering consultancy provides design validations and significant design improvements using e.g. a calculation tool for analysing the kinematics of components in cylindrical roller bearings

Benefit for RWE: > Extended rating life> Significantly extended service life> Substantially reduced life-cycle cost






– Remanufacturing




Repair after malfunction occurs Fixed intervals for maintenance measures as a function of the components’ operating hours

Maintenance depends on condition assessment /degree

of wear

Failure-based Time-based Condition-based

DIN 13306: Reactive (repair of damage) DIN 13306 Preventive (prevention of damage)

Maintenance strategies (DIN 13306)

At RWE maintenance consists of several maintenance strategies and is defined separately for each machine!

Bucket-wheel driveIdlers Railway Failure-based Time-based Condition-based


Selection of suitable maintenance strategies

Benefits for RWE:> Best strategies according to reliability, risk,

costs and profit, based on our maintenance experience

SKF RCM Reliability Centered Maintenance

SKF solution:






– Remanufacturing




Signal processing and conditioning

Frequency [Hz]

Bes

chl.

[mg]

SKF solution: Structure-borne, sound-based machinery diagnostics on gear units and drivelines

Data acquisition Data mining Generation of informationDeduction of right

maintenance decision

from 'data'

Time signal of vibration acceleration

Pitting

Vibration level acceptable

no activities

to 'Decision' via 'Information'

Condition monitoring and diagnostics for reliable production planning

Benefits for RWE: > Identify and solve problems before they become serious> Significantly reduced unplanned downtime> Significantly reduced consequential damages> Substantially reduced life-cycle cost

Event


Preventing failures of an induced draught fan

Benefit for RWE: > Increased operational availability> Significantly extended service life> Substantially reduced life-cycle cost

SKF solution:

> New housings, unique sealing and lubrication system

> Online condition monitoring system for early detection of upcoming failures






– Remanufacturing




Alignment of track rollers of rotary tube dryers

Benefit for RWE:> Extended bearing service life> Higher performance and availability


Ensuring accuracy of flange flatness

Erection and installation of 6 MW offshore wind turbine

Benefit for RWE:> Mobile application> Control and documantation of quality


Analysing slewing rims in bucket wheel excavatorsInspection after 30 years of operation: Are the balls reusable or scrap?

> Radiographical examination of residual stresses> Scanning electron microscopic examinations of the surfaceResults:

• No typical rolling fatigue• Repair is possible• Necessary metal removal rate: 0.2 mm

Benefit for RWE: > Significantly reduced life-cycle cost

SKF solution:






– Remanufacturing




Remanufacturing of bearings

Since 1980: cleaning, polishing, preserving, packaging, stocking of bearings for conveyor drums by RWE Power's Maintenance & Engineering Center

SKF solution: Remanufacturing (since 2004)

Benefit for RWE:> Recycling-rate significantly increased > Life-cycle cost substantially reduced





– Maintenance services

– Remanufacturing




Operating time: 34 monthsAnalysis of lubricant/grease: 99,700 mg silicon/kg

Bearing failure after severe grease contamination


SKF solution: New tailor-made unique sealing system for the non-locating bearing of the bucket wheel shaft

Benefits for RWE:> Increased operational availability > Significantly extended service life> Substantially reduced life-cycle cost

Sealing solution to prevent severe grease contamination


Why SKF?

What do we value at SKF?

> High-quality products for sustainable and reliable operation

> Offering of services and solutions

> Knowledge about bearing systems and knowledge of RWE's assets, needs and special operating conditions

> High service level

> Excellent delivery performance

Conclusion: SKF meets RWE's needs, demands and expectations SKF is the preferred supplier for bearings and related products SKF is RWE's strategic partner for delivering sustainable and added

value


Perfect system! Excellent performance!

http://cloudlakes.com/data_images/models/mercedes-benz-c63-amg/mercedes-benz-c63-amg-13.jpg

The rolling bearing: Just a mechanical component, or a system?

THANK YOU FOR YOUR ATTENTION

A valuable cooperation built on trust between RWE and SKF:

The sustainable recipe for success!

Documents

How RWE is benefiting from its collaboration with SKF as a solution provider