RCM - A Case Study

Presented by: Stephen P. Cross RCM Manager Bonneville Power Administration

Objectives for Today...

Discuss the history of RCM at BPA, and current results Discuss the ERP (Enterprise Resource Plan)/RCM implementation Discuss where we are today with RCM/Passport and its future...

 One year ago today the West coast would be into planned rolling brownouts/blackouts and that prices could have gone from $22 MWH to peaks of $5000 MWH! (22,700%!) Who now has the nerve to say our industry is ho hum and NOT volatile?

 Current events are why, now more than ever, RCM and good asset management is so important in helping to sustain system Reliability and Availability across the region.

BPA General Info

BPA established Pacific Northwest population Transmission line (circuit miles) BPA-owned substations Employees (staff years) 1937 10,677,083 15,328 388 2,727

Service area size (square miles) 300,000

Service territory:
Washington, Oregon, Idaho & western Montana

170 83 90,000 7 26

Customers Microwave repeater sites Wood poles Regional Offices Maintenance Districts within the 7 Regions including personnel specializing in...

Substation Maintenance Transmission Line Maintenance System Protection and Maintenance Power System Control

Other Facts
About 80 percent of the power BPA sells is hydroelectric. BPAs owns and operates more than three-fourths of the high-voltage transmission grid in the Pacific Northwest.

 Preserving the Function of our assets throughout their useful lives, to the satisfaction of Owners of assets Users of assets And society (Environment, Safety etc.)

Look at the following events, all of which could have been prevented by a good RCM program

Recent Electric Utility Maintenance Related Stories Auckland, New Zealand

Mercury Energy
February 1998

Cable Failure of two 110kV gas cables

Failure due to lifetime cyclic expansion and contraction Additional causespoor installation, unstable ground, poor backfill resistivity

 Insufficient investigation was undertaken by AEPB/Mercury in assessing the causes of repetitive electrical faults on the gas filled cables... Mercury does not have an adequate maintenance policy for 110kV gas and oil filled cables...

 Blackout for 2 weeks Cost over $1 billion US dollars Mercury energy is in the throes of bankruptcy

 Seven nuclear plants shut down Causepoor maintenance practices Costs - $10 billion CDN

 Two, 100 year old blue chip companies As of January, 2001 $12 billion in debt On the verge of bankruptcy or Govt bailout Spending $11 million/day No short term solution

 The original RCM recommendations helped the industry move from 60 crashes per million take offs, to <2 per million, with only .3% of those crashes being equipment related. Also, RCM allowed jet aircraft to financially be able to fly.

ORNL - Feasibility Study - the Alvey Project

Mid to late 1980s

EPRI Substation RCM Project the Santiam Project

Early 90s

Reverse RCM
Early 90s

Classical RCM Analysis in Chemawa District

Mid 90s

Streamlined RCM on remainder of System

Mid 90s - Ongoing program

BPAs RCM program is focused on:

Optimizing the maintenance program using classical RCM analysis Developing a streamlined process to reduce the time and cost of applying RCM Using software to schedule RCM recommended PM Program system-wide Implementing a Living RCM Program

1. 2. 3. 4.

Applied Common Sense Focused on Power System Reliability Documents Our Maintenance Program Measures and Optimizes Our Maintenance Program 5. Relies on field input for the making of maintenance decisions.

BPA uses Indus Passport as a CMMS

(Computerized Maintenance Management System)

Focused on critical equipment as per RCM philosophy n Data Loads came from legacy CMMS

BPA uses Indus Passport as a CMMS

How we loaded data and trained
n

n n

While their local asset data was being converted from legacy system to Passport, we provided Training to Field Maintenance Crews Loaded data one Maintenance District at a time When the crews returned from training their data had been loaded.

BPA uses Indus Passport as a CMMS

How we loaded data and trained
n

n n

This process allowed them to see their own real data on Monday, just like they had been training on last Friday... Training was then fresh in their minds Oh by the way, on Monday we turned off, district by district, the old legacy system for their local district

Challenges Presented during Implementation

Keeping the customers happy by linking old services to new This included rapid development of management reports (we use brio/IKW) Creating work arounds for previous automatic legacy features

Challenges Presented during Implementation

Biggest challenges were:

Not being able to use Complex triggers in Passport Not having easy access to making Mass changes in Passport No ability to Cascade tasks in Passport

Challenges Presented during Implementation

Workaround for Complex triggers

These triggers are not time-based or conditional triggers, but rather involve a level of math to help determine when to do proactive maintenance There is no work around for this issue. We use condition or time based triggers and are pursuing an API (App with 3rd party vendor

Challenges Presented during Implementation

Workaround for making mass changes

We needed the ability to make changes across classes of equipment, i.e. - change the PM trigger for all Microwave radios This is a manual, one at a time process in Passport We use a 3rd party product to make these changes possible

Challenges Presented during Implementation

Workaround for Cascading triggers

These triggers provide for taking credit for lower level maintenance by doing a higher level maintenance, sometimes called nesting Our workaround was to manually go into the product and credit a current occurrence

What Happens to You As a Maintenance Organization As You Practice RCM?

Learn your objectives
Corporate Plant/System Profit Intangibles
Safety Environment Costs

What Happens to You As a Maintenance Organization As You Practice RCM in conjunction with a CMMS?

Gain profound understanding of:

Equipment Technology Statistics Failure

You become very good at your core business

Changes in Our Approach To Maintenance

OLD
Experts Make Decisions Preserve Equipment Prevent Equipment Failure Purpose of Maintenance is to Optimize Availability and Cost

NEW
Field Crews Know Equipment Best Preserve Function Prevent Consequences of Failure Maintenance Affects Safety, availability, customer service, power quality, cost etc.

Changes in Our Approach To Maintenance

OLD
Most failures are related to age/usage of equipment The easiest way to upgrade performance is to replace or redesign equipment

NEW
Most failures are not age/usage related The easiest way to improve performance is to improve the maintenance practices

1. Interview dispatchers and local operators . 2. Provide general RCM training. 3. Introduce the RCM templates. 4. Identify equipment needs. 5. Complete an RCM evaluation and assign maintenance tasks

IMPLEMENTATION
Review Assigned Tasks with Field Load Tasks into CMMS
(Computerized Maintenance Management System)

Install CMMS Software Provide CMMS Training

The key to success 1. 2. 3. 4. Investigate equipment failures. Identify failure characteristics. Apply new technologies. Provide input for design and construction. 5. Update for changing Power System conditions. 6. Provide RCM education.

Stephen P. Cross Bonneville Power Administration P.O. Box 3621 Portland, OR 97208-3621

Phone 360-418-2115 Fax 360-418-8378 email - spcross@bpa.gov