1 Barcelona May 2003 INFORMATICAL SYSTEM INTEGRATING THE RELIABILITY CENTERED MAINTENANCE THE SYSTEM IMPLEMENTATION

2 Barcelona May 2003 INDEX 1.- INTRODUCTION 2.- DESCRIPTION OF THE SOLUTION 3.- PROJECT´S IMPLEMENTATION 4.- CONCLUSIONS

3 Barcelona May INTRODUCTION Transelectrica the Romanian TSO and Soluziona a Union Fenosa Group Company have designed, developed and implemented an informatics system in order to put in practice the Reliability Centered Maintenance (RCM). Purpose :  Optimize the Annual Maintenance Plan  Daily management of maintenance  Priority to tasks  Keep low budget RCM PROJECT: PURPOSES

4 Barcelona May 2003 INTRODUCTION RCM PROJECT: OBJECTIVES CORRECTIVE (OWN PERSONNEL) CORRECTIVE (CONTRACTED) PREVENTIVE PREDICTIVE RELIABILITY (RCM) Specialised Human Resources Improvement of availability Stronger quality criteria Investment profits Effort focus on critical elements Increase of safety Procedures and data homogenisation Process and Facility Optimisation Contract control and work scheduling improvement NEEDS MANAGEMENT

5 Barcelona May DESCRIPTION OF THE SOLUTION The Reliability Centered Maintenance concept allows the prioritization of the maintenance works, taking into account:  The technical condition of each piece of equipment  The importance of each piece of equipment within the Romanian Power Grid  The cost of each maintenance work The above criteria are developed by the following software :  standard TECHMAIN  CCT (for determination of the Technical Condition)  DIMPEQ (for the determination of the importance within Romanian Power Grid)  MAINTENANCEPLAN (for optimize Annual Maintenance Plan) OVERVIEW

6 Barcelona May 2003 TECHNICAL CONDITION TC: values between 0 and 100 TC = 0 : The piece of equipment in perfect condition TC = 100 : The piece of equipment with no life left Formulas : TC = 100 x Q Where : 1 – exp (-T/Tf) evaluation with mathematical regression Q = 1 – exp (- T) evaluation with statistics events T : the time from the last maintenance work Tf : the time between two maintenance works (recommended by the manufacture) : the rate of failures DESCRIPTION OF THE SOLUTION OVERVIEW

7 Barcelona May 2003 IMPORTANCE IM : values between 0 and 100 Based on the Romanian National Dispatch information about lines and nodes (bus bars and power transformers) IM = 0 : the piece of equipment has not relevant operational importance IM =100 : the piece of equipment is critical one for operational point of view. DESCRIPTION OF THE SOLUTION OVERVIEW

8 Barcelona May 2003 DESCRIPTION OF THE SOLUTION OVERVIEW

9 Barcelona May 2003 DESCRIPTION OF THE SOLUTION TECHMAIN: FUNCTIONAL SCOPE PHYSICAL ASSETS WAREHOUSE SCHEDULED MAINTENANCE WORK ORDERS MANAGEMENT PERSONNEL CONTRACTS WORK REQUISITIONS DOCUMENTATION REPORTS & GRAPHICS TOOLS MAINTENANCE DEFINITIONS MANAGEMENT CONTROL IMPORT & EXPORT FACILITIES BUDGET CONTROL TECHMAIN MODULES

10 Barcelona May 2003 DESCRIPTION OF THE SOLUTION TECHMAIN: WORK FLOW BASIC DATA PHYSICAL ASSETS SCHEDULED MAINTENANCE PLAN PROCEDURES, CHECKLIST, INSTRUCTIONS.. STAFFCONTRACTSSPARE PARTSDOCUMENTS TECHMAIN PROCESSES SCHEDULED MAINTENANCE WORK ORDER GENERATION WORK REQUISITIONS Work Requisition Management W.O. Planning W.O. Printing Fault information W.O. CONTROL Incurred costs Service statistics Alarms TPM BUDGET CONTROL WORK ORDER MANAGEMENT Costs imputation MANAGEMENT CONTROL WAREHOUSE & PURCHASE MANAGEMENT LOCKOUTS MANAGEMENT Manual W.O Generation OVERHAUL

11 Barcelona May PROJECT´S IMPLEMENTATION Phases :  Developement of unique data base for the equipment inventory : type, specific location, manufacturer, technical caracteristcs, history  Management of the maintenance activity by means of the integrated software tools  Drafting the Annual Maintenance Plan by means of reliability methods and objectively indentifing the technical condition and importance of each piece of equipment

12 Barcelona May 2003 PROJECT´S IMPLEMENTATION METHODOLOGY CLASSIFICATION OF MAINTENANCE ACTIONS TYPES :  Technical inspection  Measurements  Technical revisions  Current repairs  Capital repairs (overhauls)

13 Barcelona May 2003 PROJECT´S IMPLEMENTATION IMPLEMENTATION IMPLEMENTATION:  Carrying out the technical specifications  The TECHMAIN software developing and customizing  Implementing the new procedures within Transelectrica’s subsidiaries (branches)  Harmonize the internal maintenance regulations with the RCM concept

14 Barcelona May 2003 CONCLUSIONS RCM PROJECT´S CONCLUSION 4.- CONCLUSIONS RCM implementation means : a)Follow the manufacturer instructions (included in TECHMAIN data base) b)Management of fixed assets maintenance accordingly with the Annual Maintenance Plan drawn up by the integrated software c)Implementation of the risk management