David Gerke Specialist Civil Engineer - ESI-Africa.com · 2019-09-02 · 1. Carry out safety risk...
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David Gerke Specialist Civil Engineer Entura/Hydro Tasmania Australia
Transcript of David Gerke Specialist Civil Engineer - ESI-Africa.com · 2019-09-02 · 1. Carry out safety risk...
David GerkeSpecialist Civil
EngineerEntura/Hydro TasmaniaAustralia
Hydro Tasmania
• Owned by the Government of Tasmania
• Nearly 100 year history developing, constructing & operating renewable energy & associated power & water infrastructure
• Australia’s largest producer of renewable energy, producing 60% of the country’s renewable energy (11,000 GWhr/annum)
• Australia’s largest water manager, with flow of 14 trillion litres of water through the system every year
• Employing 800 people, assets worth $4.8 billion
Entura
• Provide consulting expertise to Hydro Tasmania for its hydropower system
• Expertise in dams, hydropower, civil, hydrology, environmental, electrical & power engineering and associated disciplines
• 350 technical, scientific & consulting specialists
• Worked internationally all over the world incl. Africa
• Clients include corporate, government and semi-government clients across a range of regions.
• Design & construction of 30 hydro power developments ranging from 0.75MW to 430 MW
• Design & construction of over 50 large dams
• Coordination of water monitoring programs for Hydro Tasmania to identify & manage aquatic environmental issues & associated risks
• Worked on over 60 wind farm developments
• Connected to mainland Australia National Electricity Market (NEM) via Basslink, a DC submarine cable with capacity 600MW
100 Years of Experience
Lake Margaret – 1914 – 8.4MW
Tarraleah Canal – 1938 onwards
Gordon Dam – 1978 - 432 MW
Unique owner/operator perspective
• Involved in daily electricity generation operational issues
• Remotely controlled from Hobart
• Many stations are unmanned
• Balancing of catchment flows, rainfall & power required for dispatch
• Daily involvement in dam asset maintenance and dam safety issues
• Historical knowledge of full asset lifecycle
Operational Background
Upper & Lower Derwent Catchment
Upper & Lower Derwent Catchment
What is Asset Management?
OPERATION & MAINTENANCE MANAGEMENT or ASSET MANAGEMENT
Systematic and co-ordinated activities and practices through which an organisation optimally and sustainably manages its physical assets & asset systems, their associated performance, risks & expenditure over their life cycles for the purpose of achieving its organisational strategic plan.
What does this mean to a business?
• Assets should achieve the lowest possible maintenance cost over the life of the asset
• Assets needs to meet their required targets for:
• Reliability Can it be relied upon to work?
• Capability Can they fulfil their function?
• Availability Generate power when needed?
• Operability Do they operate as intended?
• Safety No harm to public & environment?
• Assets need to meet and/or exceed their design life
• No Surprises – difficult & costly to plan for
Asset Life Cycle
30Years of service
% o
f rem
aini
ng li
fe
Design Life
Poorly Maintained
0
Refurbishment
Evolution of Asset Management
Inactive
Breakdownoriented
Reactive
Fire-brigadementality
Corrective
Remedial
Preventive
Interval based
Predictive
Condition based
Proactive
Maximisevalue
Best
PracticeWhat is “BEST PRACTICE”
Safety firstEmpowered and accountable workforceStrategy drivenImplementation focusedMarket responsiveRisk managedPerformance targetedCondition basedEconomically optimised
Prog
ressing
towards best
practice
Progression
Asset Management Plan
Condition Based Maintenance Plan
OptimisationCorporate Vision
Operational Requirements
Business appetite for Risk
Environment and Governance
Financial Position
Asset Management Plan Process
Main asset management plan to consist of;
1.Asset valuation
2.Condition assessment
3.Identify Business risk and exposure
4.Asset Management Plan development & review
5.Condition Based Maintenance audit
6.Asset Performance review
7.Our experience
Step 1 - Asset Valuation
• Based on total lifecycle cost verses the remaining life of the asset in conjunction with the current condition
• Tailored Condition Assessments based on an asset criticality should be based on rigorous or rudimentary with a focus on credible failure modes
• Establish the current value of each asset in relativity to each other
Step 2 - Condition & Performance Assessments
AIM
Increase the knowledge of asset life cycle condition by providing a systematic procedure for assessing residual life. A complimentary purpose is to provide a procedure for assessing the confidence of asset life cycle condition assessments.
Step 2 - Condition & Performance Assessments
Identify the present position of key assets on their life cycle curve and estimate residual life by:•Using a consistent statewide “Asset Life Cycle Condition” methodology. •Applying assessment criteria to determine asset life cycle condition.•Flagging an attention code Y or an urgent code X that if neglected, will lead to asset life reduction.•Assign an Asset Confidence rating.•Providing clear signals for asset testing / condition monitoring or refurbishment / replacement.•Ensure that condition monitoring and testing data is considered in determining the residual life.
Step 2 - How is this achieved?
Requirements are defined by a consistent methodology
• Systems and components that are “critical” to delivering the required outcome or “production lines”
• Understanding the most credible ways that critical systems can fail “Failure Modes”
• Develop a management strategy to address each failure mode “maintenance activity” & most appropriate timing
• Where applicable incorporate key monitoring, testing and inspections to obtain vital condition information to predict failures and take action before they happen “condition based maintenance”
• Identify and maintain critical spares
Step 2 – Why this Approach?
• Poor or inadequate design
• Poor Maintenance or construction
• Incorrect operation
• Inadequate or ill-directed maintenance effort
• Failure to identify early signs of failure
Hazard and Operation (Hazop) process
Asset Maintenance plans and project scope
Operator training, operating procedures and standards
Budgets, management and accountabilities
Understanding failure mechanisms and asset condition
Because there are the conditions that may stop an asset from achieving its functional requirements?
Step 3 - Business Risk & Exposure
Need to determine for the business what are their objectives. This includes;
•Service standards
•Revenue streams
•Credible failure modes
•Critical spares
•Development of tailored reporting systems
Step 3 - Business PrioritiesL ASSET VALUE H
5 4 3 2 1
BG CL LE LR RO TC
MB PA RE WI CA FI LM TR WA BA CE DG JB LY MA TR TU
GO PO RC TAStations
Non Key Assets
DSignificant
Performance Issues or P3
4 4 3 2 1
CMedium
Performance Issues or P2
6 5 4 3 2
BSlight
Performance Issues
7 6 5 4 3
ANo Performance Issues or P1
8 7 6 5 5
Condition Code Performance
AS
SE
T C
AP
AB
ILIT
Y
Increasing Value
Dec
reas
ing
Con
ditio
nor
Per
form
ance
Increasing Priority
Step 4 - Asset Management Plans
Asset Management plans needs to incorporate
•Development and review of policy’s and procedures
•Asset data sheets
•Standard activity audits and reviews
•Review and development of maintenance management systems
Step 4 - Asset Conditioning
Mechanical - Turbines, Gates, Main Inlet Valves, etc
Civil - Dams, Canals, Flumes and Pipelines, etc
Electrical - Excitation Systems, Protection, Controls, Power Supply, etc
Asset conditioning could include
•Routine inspections (daily to monthly)
•Annual inspections by professional personnel
•Survey – deformation, movement
•Specific equipment testing – such as flow range, response time, Non Destructive Testing (NDT), etc
Step 4 - Maintenance activity
GENERATION DIVISION STANDARD ACTIVITY REPO RT
N um ber: A0 0 1 0 1 0 1 Prio rity : 3
Job Tit le: Station M aintenance Routine (LY 2 W KS) Facility : LY : Liapootah A ctivity Type: Inspect/Test/O perate Est Duration (Hrs): 8 A ctivity Cause: Condition M onitoring Originator : Brendan Flack
Instructions SCOPE: To fill out the checklist as described, noting an y defects or abnormal operation of an asset. Any defects or abnormal operation of an asset should be noted in the closure of this job ticket and reported to the Production M anager. CHECK LIST R ESPONSES W hen entering a reading, a num ber only is to be entered in the check list. W hen topping up a compartm ent w ith oil, a number only should be entered in the checklist to show the amount used. The default responses are set to "OK". These responses m ust be changed as necessary to reflect the inspection findings. For item s that do not m eet the standard and require a detailed description, enter the word "reported" in the checklist then in the rem arks describe the problem in detail and report the item to the station Team leader. If a checklist item is un achievable the word reported should be entered in the checklist and a reason entered in the remarks. If the M /C is shutdown arrange if possible a suitable time to return and obtain results required, if not place a reason as to why the reading w as not record in the remarks section of this job ticket. Note: A ll oil levels that are checked should be topped up if required so that inadvertent alarms are not generated. MANDATORY SAFETY INSTRUCTIO NS: 1. Carry out safety risk assessment using appropriate take 5 or JSA tem plate as found under Hydro safe on Insite. 2. All work to com ply with the PSI& AP and the TEC. 3. Sign on the appropriate permit to w ork, confined spaces permit and or hot work perm it. 4. Take precautions to elim inate electrical inductions. 5. All mem bers of the work party are responsible for ensuring their site introduction is current. 6. Ensure the correct equipm ent is selected, identical equipment is adjacent. 7. Ensure all correct PPE is w orn.
Checklist # Checklist Prompt Response 1 STATION: -
2 Visually inspect the fences and security m easures for structural integrity, vandalism etc.
ok
3 Check station securi ty system ok 4 Check station Emergency exit lighting. Report any defects to ok
What Hydro Tasmania AdoptedWater 2 Wire (W2W)
The W2W Map is a visual tool that displays the condition, performance and risks of the generation asset portfolio, assisting with monitoring deliver of the Hydro Tasmania’s Asset Strategy. Including
• Dam
• Water conveyance (i.e. canals, pipelines)• Turbine• HTV (Hill Top Valve), MIV (Main Inlet
Valve)• Gates, trashracks, stoplogs• Switchyard & Electrical equipment
Station Priority
m/c Priority
Installed MW
M/C #
Year
Age
Peakers
Dams 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 2 2 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 4 4 4 4 1 1 5 5 1 1 1 1 1 1 1 1 5 5 5 5 5 5 4 4 1 1 1 1 4 4 5 5 5 5 5 5 4 4 4 4 4 4 5 5 5 5 5 5 2 2 4 1 1 1Dam Gates & Valves 1 1 1 1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 5 5 5 5 5 5 5 5 5 5 5 5 3 4 1 1 5 5 1 1 1 1 1 1 1 1 2 3 2 3 2 3 4 4 2 3 2 3 4 4 1 1 1 1 1 1 3 2 2 2 5 5 2 2 3 4 2 2 1 1 2 4 2 2
Forebay 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5Intake 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 4 4 4 4 2 1 3 1 3 1 3 1 3 1 3 1 3 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 4 4 2 3 1 3 1 3 1 3 1 1 2 1 2 1 2 4 4 2 4 2 4 2 3 1 2 1 2 1 2 2 1 2 2 3 3 2 2 2 2 2 4 4 4 2 2 2 2Gates 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 2 1 2 1 2 1 2 1 2 1 2 1 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
Canals & Flumes 4 2 4 2 4 2 2 1 2 1 2 1 2 1 2 1 2 1 5 5 5 5 5 5 1 2 1 2 1 2 1 2 1 2 1 2 2 1 2 1 2 1 2 1 2 1 5 5 5 5 5 5 5 5 4 2 4 2 4 2 4 2 5 5 5 5 5 5 5 5 4 4 4 4 4 2 5 5 5 5 5 5 2 2 5 5 5 5 5 5 5 5 5 5 4 2 2 1 5 5Pipeline 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 1 2 1 2 1 2 5 5 5 5 5 5 5 5 5 5 5 5 4 4 4 4 5 5Tunnels 4 2 4 2 4 2 2 4 2 4 2 4 2 4 2 4 2 4 4 4 4 4 1 1 5 5 5 5 5 5 5 5 5 5 5 5 4 4 4 4 4 4 4 4 4 4 4 4 2 4 4 4 4 4 4 4 4 4 4 4 4 4 3 4 3 4 3 4 4 4 5 5 5 5 4 4 4 1 4 1 4 1 4 2 5 5 5 5 4 4 4 4 5 5 5 5 5 5 5 5
HTV 5 5 5 5 5 5 2 2 2 2 2 2 2 2 2 2 2 2 5 5 5 5 5 5 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 1 2 1 2 1 2 1 5 5 4 4 5 5 5 5 5 5 5 5 5 5 5 5 1 1 1 1 1 1 5 5 2 4 2 4 5 5 2 2 2 2 2 2 5 5 5 5 5 5 5 5 4 4 5 5 5 5 2 1 5 5Penstock 4 3 4 3 4 3 2 1 2 1 1 1 2 1 2 1 2 1 4 4 4 4 1 1 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 2 2 4 4 5 5 1 2 1 2 1 2 1 2 1 2 1 2 1 2 4 4 2 4 2 4 4 2 2 2 2 2 2 2 4 2 3 1 3 1 5 5 4 4 3 1 5 5 2 4 2 4Tailrace 5 5 5 5 5 5 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
M/C Relief Valve 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 2 3 2 2 2 2 2 2 2 5 5 3 2 5 5 5 5 1 2 4 2 5 5 5 5 2 4 2 4 2 4 5 5 5 5 5 5 5 5 2 4 2 4 2 4 5 5 5 5 5 5 5 5 2 2 5 5 5 5 2 1 2 2MIV 2 2 4 1 2 2 1 1 2 1 1 1 2 2 2 2 2 2 5 5 5 5 4 2 4 4 4 4 4 4 2 1 2 1 2 1 4 1 4 1 4 1 4 1 4 1 5 5 3 2 5 5 5 5 2 1 2 1 4 1 4 1 2 2 2 1 2 2 5 5 5 5 5 5 1 1 1 1 1 1 2 1 2 2 5 5 5 5 5 5 2 2 5 5 2 1 4 1 5 5
Turbine 4 2 4 2 2 2 2 1 2 1 2 1 4 4 2 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 2 3 2 1 1 1 2 2 2 2 2 2 1 1 2 2 2 2 2 1 4 1 2 2 2 2 2 2 1 1 1 1 2 2 2 2 1 2 4 4 2 2 2 2 4 4 2 1 2 1 2 2 3 2 2 2 2 1 2 2 2 2 1 2 1 1 2 2 2 2Rotor 4 3 4 3 4 4 2 4 4 4 4 4 4 4 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 4 2 4 2 4 4 4 4 4 4 3 4 4 4 4 4 4 4 2 4 4 4Stator 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 4 4 4 4 4 4 4 4 4 4 4 2 4 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 4 3 4 3 4 4 4 3 4 3 4 4 4 4 2 2 4 3 4 2 4 2 4 3 4 4 4 4 4 4 4
Alternator 4 4 4 4 3 2 2 1 2 1 4 1 3 1 2 1 4 4 4 1 4 1 4 4 4 4 4 4 4 4 4 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1 4 2 4 2 4 4 4 2 2 1 2 1 4 1 4 1 2 2 4 1 4 2 2 2 2 1 2 2 4 4 2 2 2 2 2 2 4 2 2 2 2 4 4 2 4 2 2 4 4 1 2 1 4 2Governor 4 4 4 4 4 4 1 2 1 2 1 2 4 4 1 2 4 4 4 2 4 2 4 4 4 1 4 2 4 2 2 2 2 1 2 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 3 2 1 4 4 2 4 4 4 4 4 4 2 4 2 4 2 4 4 2 1 2 1 4 4 4 1 4 1 4 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 2Actuator 4 4 4 4 4 2 2 2 2 2 2 2 4 4 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 3 2 4 4 2 2 2 2 2 2 2 2 2 2 4 4 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 1 4 4 4 4 4 4 4 2 4 2 4 4 4 4 4 1 4 1 4 4 4 2 4 2 4 4 4 4 4 2 2 4 2 2 4 2
Excitation System 4 4 4 4 4 4 2 2 2 2 2 2 4 4 4 2 4 4 4 4 4 4 4 4 2 4 2 4 2 4 2 4 2 1 2 1 4 1 2 1 2 1 2 1 2 2 2 2 2 4 4 4 2 4 4 4 4 4 4 4 4 1 2 2 1 2 1 1 4 2 4 1 4 1 4 4 2 1 2 1 2 1 2 2 4 4 4 4 2 2 3 4 4 4 2 2 2 2 4 4M/C Elec Protection 4 4 4 4 2 2 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 2 2 2 2 2 2 2 4 2 2 2 2 4 2 4 1 2 2M/C Mech Protection 4 2 4 2 4 2 2 2 2 2 2 2 4 4 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 2 2 4 4 4 4 4 4 4 4 2 2 2 2 2 2 4 4 2 2 2 2 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 2 2 2 2 4 1 2 2
M/C Unit Control 4 4 4 4 4 2 2 1 2 1 2 1 4 4 2 1 4 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 4 4 2 2 4 4 2 2 4 4 4 4 4 4 4 4 2 2 2 2 2 2 4 4 4 2 4 2 4 4 2 2 2 2 2 2 2 2 4 2 4 2 2 4 2 2 4 2 3 1 4 1 2 2M/C Synchroniser 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 1 1 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 4 2 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 2 2 2 2 2 2 2 4 2 2 2 2 4 2 4 1 2 2
Cooling Water System 4 1 4 1 2 2 2 1 2 1 2 1 4 4 2 1 2 1 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 2 1 2 1 2 1 2 1 2 1 2 2 2 2 2 2 2 4 1 1 1 1 4 4 4 4 2 1 2 1 2 1 2 2 2 1 2 1 2 2 4 4 4 4 4 4 2 1 2 1 2 1 2 2 2 2 2 1 1 1 4 1 2 2AC Supply 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 2 4 2 4 2 4 2 4 2 4 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 4 4 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4DC Supply 1 4 1 4 1 4 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 4 1 4 1 4 1 4 1 4 1 4 4 4 3 2 1 4 4 4 4 4 4 4 4 4 4 3 3 3 3 3 3 2 1 2 1 2 1 2 1 2 1 2 1 2 1 4 2 4 4 4 4 4 4 4 4 4 4 2 1 4 4 4 4
Station P&C 4 1 4 1 4 1 2 1 2 1 2 1 2 1 2 1 2 1 4 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 5 5 4 2 4 2 4 2 4 2 1 1 1 1 1 1 4 4 2 1 2 1 4 4 1 1 1 1 1 1 2 1 4 4 4 4 5 5 4 4 4 4 1 1 4 4 2 2Station Services 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 4 4 4 4 4 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 4 4 1 1 4 1 4 1 4 1 4 1 2 1 2 1 2 1 4 4 2 1 2 1 2 1 1 1 1 1 1 1 2 1 2 2 1 1 2 1 2 1 2 1 4 1 3 4 2 1Busbar & Cables 2 4 2 4 2 4 2 1 1 1 1 1 2 1 2 1 2 1 3 3 3 3 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 3 4 4 4 2 2 4 4 3 4 3 4 3 4 3 4 4 4 4 4 4 4 3 4 2 2 2 2 2 2 2 2 2 2 2 2 2 4 3 4 4 4 3 4 4 4 2 4 4 4 4 4 3 4
Switchgear 2 2 2 2 2 2 3 2 3 2 3 2 3 2 3 2 3 2 3 1 3 1 4 4 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 1 3 2 4 4 4 4 4 4 4 4 4 4 3 2 3 2 1 1 2 2 2 1 2 1 4 4 2 2 2 2 2 2 4 2 1 1 4 4 4 4 4 4 2 1 3 3 1 1 4 4Transformer 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 4 3 4 2 2 2 2 2 2 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 2 2 2 2 2 2 2 2 3 2 3 2 4 2 4 2 1 2 1 2 1 2 2 4 2 2 2 2 2 2 1 2 1 2 1 2 4 1 2 2 2 2 2 2 2 2 2 2 2 1 2 4 4 4
Earthing 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 1 4 1 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 4 2 4 2 4 2 4 2 2 1 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 4 2 1 1 4 4 4 4 4 4 4 4 4 4 4 1 4 4 4 4 4 4 4 4 3 4 4 4SCADA 2 4 2 4 2 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 4 4 2 1 2 1 2 1 2 1 2 1 2 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 4 4 4 4 4 4 5 5 5 5 5 5 4 2 4 4 4 4 2 2 2 2 4 4 4 2 4 2 4 4
Land & Buildings 3 1 3 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 4 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 4 4 4 2 4 1 5 5 2 2 2 2 2 2 2 2 2 1 2 1 2 1 4 4 4 4 4 4 2 2 1 1 1 1 1 1 4 4 4 1 3 3 4 4 4 4 4 4 4 2 2 4 4 4Roads 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 2 1 2 1 2 1 2 1 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 2 2 5 5 5 5 5 5 5 5 5 5 5 5
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RC
Ree
ce 1
7 8 9
GO GO PO PO PO PO PO
3 4 5 6
P
50
Poa
tina
1
1
1964
45
P
144
3
1988
2131
P
Gor
don
2
144
2
1978
31
P
Gor
don
1144
1
1978
5
TA
15
1938
1
GO
2
5 5 5 5
13 14 15 16
5
17 18
TA
Tar
rale
ah 1
Tar
rale
ah 2
Tar
rale
ah 3
Tar
rale
ah 4
Tar
rale
ah 5
Tar
rale
ah 6
TA TA TA TA
15 15 15 15
1 2 3 4
1938 1943 1943
15
5 6
1951
71 71 71 66 66 58
1938
Duty of Care Risk (Sustain, safety, Compliance, Envi)
Revenue Risk (constraints & force
High Risk (>$500K consequence per singl event). Not IBRM calibrated.Low Risk. Not IBRM calibrated.Medium Risk. Not IBRM calibrated.
Dams
Priority 1: Duty of Care
Priority 2: Reliability & Availability, establilsh 27 strong p roduction lines No assessment, insufficient information to assess.Asset type not applicable
Performance Assessment (fit for purpose)
Condition Assessment (remaining reliable asset life)
Asset Issues to be addressed within 5 years with high confidence assessmentHigh confidence good fit for purpose and good conditionAcceptable fit for purpose & condition, low confidence in assessment
W2W Cond & Perf MAP│2006 SNAPSHOTW2W MAP │ Asset Management Strategy – Priority & Asset Component
Priority 3b : 23 production lines(receiving less focus and investment)
Priority 1: Discharge all Safety, Operational Compliance, Duty of Care and Legislative Obligations
Priority 2: Address Key Delivery Chain Assets on a risk prioritised basis tomaintain the productive capability of the entire portfolio
Priority 3a : 27 ‘strong’ and reliable production lines
Station Priority
m/c Priority
Installed MW
M/C #
Year
Age
Peakers
Dams 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 2 2 2 2 2 2 2 2 2 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 2 0 2 0 2 0 0 0 0 0 0 0 0 4 3 4 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 # #Dam Gates & Valves 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 3 0 3 0 0 2 2 2 2 2 2 0 0 0 0 0 0 2 0 0 0 0 2 0 0 0 0 0 0
Forebay 4 3Intake 3 2 3 2 3 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 2 2 2 2 2 2 2 2 2 2 2 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 1 0 1 0 1 0 1 3 3 3 3 3 3 0 0 2 3 2 3 4 3 4 3 4 3 4 3 5 2 0 0 0 0 2 2 2 8 0 0 0 0 1 4 2 8Gates 2 2 2 2 2 2 2 2 2 2 2 2 2 0 0
Canals & Flumes 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 5 4 5 4 5 4 5 4 5 4 5 0 0 0 0 0 0 0 0 0 0 0 2 0 2 0 2 0 2 0 0 0 0 0 1 0 0 0 1 0 2 0Pipeline 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 3 4 3 4 3 0 0 0 0Tunnels 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
HTV 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 2 6 2 0 0 0 0 0 0 0 0 0 0Penstock 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 3 4 3 4 3 4 3 0 0 0 0 0 0 0 0 2 2 1 0 1 0Tailrace 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
M/C Relief Valve 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0MIV 1 1 1 1 1 1 0 0 1 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 3 3 0 0 0 0 0 0 0 0 0 0 0 0 4 3 4 3 4 3 0 0 7 5 2 2 0 0
Turbine 0 0 0 0 1 1 0 0 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 3 4 3 0 0 0 0 4 3 4 3 4 3 0 0 4 4 4 3 0 0 4 4 4 4 4 4 0 0 0 0 0 0 0 0 # 9 0 0 2 1 0 0 3 5Rotor 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0Stator 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 0 0 0 0 0 0 0 0
Alternator 0 1 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 1 1 1 3 0 0 0 0 4 3 3 2 3 2 0 0 4 1 5 1 0 0 3 1 3 1 3 1 0 1 0 0 2 0 0 0 0 1 1 0 2 0 0 0 0 0Governor 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 3 2 3 2 0 0 2 0 2 2 2 2 3 1 3 2 1 2 2 0 2 0 1 2 2 2 2 5 1 3
Excitation System 0 0 0 0 0 0 1 0 1 0 1 1 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 3 3 3 1 2 2 0 3 2 3 2 0 0 2 4 2 4 2 4 0 0 0 0 0 0 1 2 0 0 0 0 0 3 1 1 0 0M/C Protection 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 # 8 # 8 # 8 0 0 0 0 0 0 0 0 # 8 0 0 6 5 0 0 3 8
Cooling Water System 0 0 0 0 2 1 0 0 1 0 1 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 3 4 3 4 3 0 0 1 4 1 4 1 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 3 0 0 0 1 0 0 0 3AC Supply 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 0 4 0 0 0 4 0 4 0 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0DC Supply 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Station P&C 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 4 3 4 3 4 3 0 0 1 2 1 2 0 0 8 # 8 # 8 # 0 4 0 0 0 0 0 0 0 0 0 0 2 # 0 0 9 8Station Services 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 3 0 3 0 3 0 3 0 3 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 3 0 3 0 0 0 0 0 0 0 0 1 # 1 # 1 # 0 0 0 0 0 0 0 0 2 # 0 0 2 6 0 0 0 2Busbar & Cables 0 0 0 0 0 0 0 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 8 6 8 6 8 1 1 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0
Switchgear 0 0 0 0 0 0 0 1 0 0 0 1 0 1 0 1 0 1 0 1 0 1 0 0 4 3 4 3 0 2 0 2 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0Transformer 0 2 0 2 2 5 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 4 3 4 3 4 3 0 0 0 0 0 0 0 0 0 1 0 1 0 1 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0
Earthing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 2 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0SCADA 4 1 4 1 4 1 0 0 0 0 0 0 0 0 0 0 0 0 2 0 2 0 0 0 4 3 4 3 4 3 4 3 4 3 4 3 1 0 1 0 1 0 1 0 1 0 2 0 1 0 2 3 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 1 3 1 3 1 3 1 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0
Land & Buildings 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 1 0 1 0 1 0 1 0 2 0 2 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
P
51
PPP
48 48 51 51
P
3
1957 1957 1957
11
1
1968
40
32
1
1956
52
P
14
1
1951
57
17
1
1967
41
P
31
1
1971
37
P
28
1
1972
36
28
1
1968
40
P
40
1
1967
41
P
13 13 13
1
43
1
1973
35
2
83
1
1993
15
80
1
1983
25
1962 1962
46 46
24 24
1 2
25
50
RO
Row
alla
n 1
24
49
LE
Lake
Ech
o 1
23
48
BG
But
lers
Gor
ge 1
22
47
CL
Clu
ny 1
21
46
WL
Wilm
ot 1
20
45
PL
Pal
oona
1
19
44
RE
Rep
ulse
1
18
43
MB
Mea
dow
bank
1
17
42
FS
Fis
her
1
16
41
WY
Way
atin
ah 3
16
40
WY
Way
atin
ah 2
16
39
WY
Way
atin
ah 1
15
38
AN
Trib
ute
1
14
37
CA
Cat
agun
ya 2
14
36
CA
Cat
agun
ya 1
13
35
BA
Bas
tyan
1
12
33
LY
Liap
oota
h 2
12
34
LY
Liap
oota
h 3
48
28 28
1 2 3
1960 1960
P
12
32
LY
Liap
oota
h 1
28
1960
P
20
4
1955
53
P
20
3
1955
53
20
2
1955
53
P P P
20
1
1955
53
P PP P
60
1
1969
39
80
1
1982
26
51
1
1969
39
86
1
1971
37
11
31
TR
Tre
vally
n 4
11
30
TR
Tre
vally
n 3
11
29
TR
Tre
vally
n 2
11
28
TR
Tre
vally
n 1
10
27
DG
Dev
ils G
ate
1
9
26
MA
Mac
kint
osh
1
8
25
LM
Lem
onth
yme
1
7
24
CE
Cet
hana
1
6
23
TU
Tun
gatin
ah 5
25
1953
6
21
TU
Tun
gatin
ah 3
6
22
TU
Tun
gatin
ah 4
55 55
25
1 2
55 55
25 25 25
1956
3 4
1953 1953 1953
52
6
19
TU
Tun
gatin
ah 1
6
20
TU
Tun
gatin
ah 2
5
P
12
4
JB
16
John
But
ters
1
144
1
1992
Gor
don
3
1977
31
P
Poa
tina
2
Poa
tina
3
Poa
tina
41964
Poa
tina
5
Poa
tina
6
2 3 32 2 2 21 1 1 2
5
50 50
6
44
P P
4444
P
44
11
50
2
1964 1964
3
50 50
4
1964
2
116
Ree
ce 2
RC
P P
21
1987
116
1
1986
22
PO
10
RC
Ree
ce 1
7 8 9
GO GO PO PO PO PO PO
3 4 5 6
P
50
Poa
tina
1
1
1964
44
P
144
3
1988
2030
P
Gor
don
2
144
2
1978
30
P
Gor
don
1
144
1
1978
5
TA
15
1938
1
GO
2
5 5 5 5
13 14 15 16
5
17 18
TA
Tar
rale
ah 1
Tar
rale
ah 2
Tar
rale
ah 3
Tar
rale
ah 4
Tar
rale
ah 5
Tar
rale
ah 6
TA TA TA TA
15 15 15 15
1 2 3 4
1938 1943 1943
15
5 6
1951
70 70 70 65 65 57
1938
Performance assessment (fit for purpose)
Condition assessment (estimate remaining
reliable asset life)
Asset issue needs to be addressed within 5 years with high confidence assessment
High confidence good fit for purpose and good condition.
Acceptable fit for purpose and condition but with low confidence in assessment.
No assessment, insufficient information to assess.
Asset not applicable.
Dams
Duty of Care
Reliability &
Availability
Duty of Care Risk (Sustain, Safety,
Compliance, Envi)
Revenue Risk (constraints & forced outage)
HIGH RISK
Low RISK
MEDIUM RISK
No assessment, insufficient information to assess.
Asset not applicable.
W2W RISK MAP │Nov 2007
50% of Projected Annual Revenue70% of Projected Annual Revenue
10 Stations, 27 production lines
W2W RISK MAP
Step 5 - Information Review
Tying it all together;
•Asset Structure
•Function Requirements &
Description
•Acceptance Criteria
•Reliability Centred Maintenance
failure modes & effects analysis
•Establishment of routines
•Collection and analysis
•Action and Ongoing review
RCM Process
Policy Statement
Asset Management
Strategy
Asset Structure
Acceptance Criteria
Functional Descriptions
Asset Type GroupsEquipment
Data
Statutory
Requirements
Trading Strategy
Inspection and Maintenance Routines
Asset Health Ratings
Asset Issues Register
Secondary
Inspection or Testing
Mitigation Register
Secondary Risk Assessment
Information Required
Risk
Assessment Required
Detailed Justification Required
Asset Risk Ratings
Asset Risk Assessment and
Register
Yes
No
Yes
No
No
Yes
Asset Health Map Asset Risk Map
Outage Plan
Step 6 - Condition Based Maintenance audit
• Identification and implementation of appropriate maintenance strategy's tailored to asset risk and exposure
• Benchmarking of current Condition Based Maintenance program
• Condition monitoring effectiveness
• Condition monitoring mentoring and support
Step 7 – Our Experience
• Co-ordinated state wide programs for all power stations & dam infrastructure implemented based on reliability monitoring since late 1990’s
• Hydro Tasmania reliability >95% compared to approx. 80-90% for Africa
• Budget of R 400 Million/year achieved for last 5 year based on Water2Wire project -reduction of 10-20% cost savings
• Specific targeted maintenance - Canal roughness
Summary
Overall by undertaking a co-ordinated and planned operational and maintenance program with ongoing reviews and audits
•Understanding of the assets and behaviour
•Implement cost effective maintenance strategies based on exposure of assets
•Importantly saves both time and money for a business
•Asset management works!
What Poor Asset Management can lead potentially to!
2009 Russian hydro incident – loose top cover bolts + machine vibration seized the machine. Failure of protection system and gates couldn’t close & floode d station. People killed
