Title: Delivering Asset Reliability in a Competitive Market Environment Azeez Ahamat Reliability Improvemen
1Delivering Asset Reliability in a Competitive
Market Environment Azeez AhamatReliability
Improvement EngineerSnowy Hydro Limited
2Introduction
- Company background
- The reliability journey
- What has worked for us
- Tools and Processes
- Organisational Culture
- Where to from here?
3The Snowy Mountains Scheme
4Snowy Hydro has a significant asset base
- 16 large dams, 145 km tunnels
- 9 power stations and 1 pumping station
- 39 generating units
- 3,756 MW installed hydro capacity
- 600 MW Pumped Storage capacity
- 625 MW Gas Turbine capacity
- 4,900 GWh per annum energy
- Voltage, frequency control and system restart
5Snowy Hydro Plant Characteristics
- Responsive
- Reliable
- Available
- Flexible
- Clean, Green and Safe
6The Reliability Journey
7Plant Performance
Performance Trends
8Performance Trends
Maintenance Performance
9Asset Management Overview
- Two levels
- Tactical - Short to Medium Term
- Strategic - Medium to Long term
- Responsibility shared between
- Production Team
- Strategic Engineering and Projects Team
- Information and Control Systems Team
10Asset Management Overview
Asset Management Overview
- Facility Plans
- Long term capability planning
- Business impact
- Asset Strategy
- Plant Condition Assessments
- Asset life-extension and replacement
- Plant Maintenance and Capability Plan
- Managing existing capability
- Operations and maintenance regimes
- Delivery of asset capability to meet market
demands
11How does it fit together?
12Asset Management Overview
Maintenance Philosophy
- Classical CI model (Plan/Do/Check/Act)
- Business drivers (from Strategic Planning
process) - Asset and Plant Strategy
- Maintenance Strategy (derived from Asset and
Plant strategies) - Maintenance Requirements Analysis (RCM)
- Routine Maintenance Program
- Plan implementation optimised against market
conditions (OMS/ Workplanner) - Performance review and improvement
13Maintenance Model
Asset Management Overview
Market Requirements (Outage Mgt)
- Equipment item
- Maint. task
- Maint. Frequency
- Resources
Business Drivers
14Maintenance Philosophy
Asset Management Overview
- How well is this working?
- We started applying this philosophy in the 1990,s
- Performance trends show that it is in the ball
park - Routine Maintenance Program is giving us
flexibility in the market without affecting
reliability - Not enough review and improvement
- Untapped opportunities
15Asset Management Overview
Reliability Model
16Asset Management Overview
Reliability Tools and Processes
- Maintenance Requirements Analysis (RCM Cost)
- Enterprise Asset Management System (Mincom
Ellipse) - Defects Management
- Performance Management
- Reliability modelling (AVSim)
- LOA - Outage Analyser
17Building the Machine to Get There
Organisational Culture
The Critical Cogs
18Three areas of focus
Organisational Culture
- Corporate Values and Behaviours
- Organisational Culture and Effectiveness
- Leadership
- Foundations of Leadership
- Leadership Impact surveys
- Continuous Improvement culture
- Green Book
- 6-Step problem solving process
- CI-on-a-page
- Root Cause Analysis
19Snowy Continuous Improvement Hand Book
Organisational Culture
- Overview of Snowy CI
- Team Roles
- Rules of conduct
- 6-step CI process
- CI Principles
- CI Tools
206 Step Improvement Process
Organisational Culture
21CI on a page
Organisational Culture
22Root Cause Analysis
Organisational Culture
- No formal process
- Starts with application of 6 step process
- Event-line and 5-whys mostly used
- Not perfect, but huge improvement on where we
were - Learnings shared through Defects Management
process
23Outage Analyser
24Lost Opportunities
- Understand and manage the value of all Lost
Profit Opportunity - What is the gap between our installed capacity/
and the capacity available for trading? - What is this gap worth to the business?
- What is causing this gap?
- Can we eliminate it?
- Need to keep identifying and evaluating lost
profit opportunities as they occur and take
action if justified.
25Asset Utilisation
- Understanding value of Lost Opportunity (Example)
100 Capacity
Planned Outages
Risk Allowance for uncertainties (forced outages,
transmission failures etc...)
Nameplate Capacity
Spot Capacity
Contractible Capacity
26Asset Utilisation
- Asset Utilisation Tradeable Capacity
- Nameplate Capacity
- Capacity Available at acceptable
certainty Nameplate Capacity
27Performance Trends
28How did we get here?
- Sound asset management principles
- Selective use of reliability/ asset management
tools and technology - Constant review of progress
- Shift in organisational culture
29Where to from here?
- Good reliability performance
- Incrementally harder to extract further
improvements - Further opportunities exist
- Close the gap between CI and reliability
improvement
30Maintenance Model
Asset Management Overview
Step 1 IDEA
Step 2 DEFINITION
Step 3 ANALYSE
Step 4 ACT
Step 5 MEASURE
Step 6 STANDARDISE
31Business as usual or new directions?
Maintenance Improvement plus defects management
Defects Management
Current Process
32Summary
- Sound basic principles
- Several small steps
- Supportive organisational culture
- Its not rocket science!
33Questions?
Cabramurra Township