1 Larry Pope, Senior Mechanical Engineer BC Hydro, Vancouver, Canada BC Hydro’s Reliability Evolution

2 Who We Are  A provincial Crown Corporation owned by the people of British Columbia  Accountable to the provincial government and the regulator, the BC Utilities Commission  Annual Revenue of $ 4.31 billion  Number of Customers: 1.7 million (94% of BC residents)

Where We Are Vancouver, British Columbia, Canada

4 reliable power, at low cost, for generations Our Purpose

5 BC Hydro Affiliates Construction Business Unit (CBU) –Field Services Powertech Labs –Testing and research services ABSU –Computer services Powerex –Electricity trade activities BC Transmission Corporation (BCTC) –Responsible for the province’s publicly owned transmission system

6 Rate Comparisons

BC Hydro at a Glance 2nd largest Canadian electric utility 4200 employees Installed generating capacity of over 11,000 megawatts (MW) Up to 54,000 GWh of electricity generated annually 61 dams at 42 sites 45 generating facilities –30 hydroelectric generating facilities –3 thermal generating facilities –12 stationary & mobile diesel stations

8 Old and Aging Fleet Many generating assets approaching end-of-life where performance declines & cost to maintain increases Performance/condition unacceptable above this line Performance/condition acceptable below this line

9 Generator at a Glance Draft Tube Scroll Case Turbine Rotor Stator Exciter Bearing Wicket Gates Shaft

10 In 1999 BC Hydro’s existing Preventative Maintenance Program was lacking technical basis and commercial focus Maintenance procedures were not well understood or followed Crews were frustrated as they were left to perform what maintenance tasks they believed were appropriate Maintenance procedure revision history was not well documented There was no methodology for how procedures and documents were to be created and maintained Maintenance History

11 RCM History Goals: Evaluate the benefits of doing a RCM analysis Results –Improve commercial availability: »Average availability increased by 5 days/year –Addressed FM’s related to known forced outages – Developed and fostered good teamwork –Captured retiree’s knowledge –Met WCB requirements, EOR signoff RCM Pilot Project – Ruskin 1999

12 RCM Project core and strategic plants on “water to wires” systems (except civil structures and protection equipment) BCH engineers and technical staff were used and less consultants – goal was a cultural change Program documentation and Engineer of Record Equipment analyzed: –H20 Passages –Turbine –Generator –Governor –Exciter –Switching By April , an RCM Program had been implemented at 23 key BC Hydro Generating Stations The planned cost was $4.5M. The actual cost was $3.7M

13 Availability: annual unit availability increased by approximately 1,000 GWh (annual benefit of $3M) Reliability: downward trend of forced outages at plants without significant capital upgrades Maintenance Costs: estimated that planned maintenance labour was reduced by 3% (annual savings of $68k) Project Costs: actual costs for the project were 18% under the approved budget Benefit/Cost Ratio of 5 for RCM project (business case estimate was 3.1) and numerous intangible ones Tangible Benefits

14 Tasks to the shop floor PI/OI not well used Passport - entry into CMMS –Schedules a number, does not store the maintenance results –Failure/fault codes not used Project did not define a Benefits measurement criterion Project did not define a Sustainability element Challenges

15 Turbo Tools Turbo Tools were created to assist with RCM Turbo database manipulation Excel spreadsheets with Macro’s –Database Integrity Check –Engineer of Record –Information Transfer –Maintenance Instruction + Preload –Passport Preload –RCM Failure Analysis

16 Database Integrity Turbo Tools

17 FMEA – RCM Failure Analysis Turbo Tools

18 Information Transfer Turbo Tools

19 Maintenance Instructions + Preload Turbo Tools

20 Passport Preload Turbo Tools

21 Summary RCM Sustainability RCM Workload –RCM new systems, update existing New Maintenance Engineers RCM Audit Equipment Health Rating –RCM schedules tasks Significant equipment challenges Present Situation

22 Summary Planning and Scheduling Integration Reduce Process Burden Passport Audit Reliability Optimization Life Cycle Costing Root Cause Analysis Predictive Software Interfacing Moving Forward

23 Integration better than best of breed –Still some consideration for the data warehouse concept The RCM process burden associated with the RCM Turbo- Passport interface should be reduced Add Turbo Tool functionality within Turbo –Maintenance Instructions This is causing use problems – beta testing/programming support –Failure Mode and Effects Analysis (FMEA) Passport Audit –Business rules are not being followed, add root cause codes Consider “All” maintenance within Turbo Moving Forward

24 The BC Hydro Dam Safety group is asking for higher system reliability – From 1 in 100 to 1 in 10,000 risk of failure Least Risk Cost and a Reliability Optimizer Moving Forward

25 Turbo – also use as a design tool, upload to RBD ie GoldSim GoldSim is a Monte Carlo simulation software solution for dynamically modeling complex systems GoldSim supports decision and risk analysis by simulating future performance while representing the uncertainty inherent in all complex systems Moving Forward

26 Root Cause Analysis Understand root causes and find solutions A basic one, non proprietary, BC Hydro Safety Group is using Systems Approach Strategies Record causes and solutions Moving Forward

27 Predictive Analysis Software Capability Add intelligence to PI/OI Data ERP went out, 5 replies, piloting the best two Moving Forward

28 Interface Software Collects equipment condition data from visual inspections, predictive maintenance technologies, controls, sensors, and data historians Consolidates and analyzes all condition data, identifying potential failures and recommending corrective actions The results are presented visually through flashing alarms and trending graphs Passport Analysis Software - RCM Turbo InterfaceSoftware

29 Questions? When it comes to reliability we are all on the same page!