1. Maintenance 2012 @ Vattenfall Europe Mining AG
Overview of VEM
Methods and Measures
Maintenance organization
Results
Cottbus,

2. What we did in VEM over the last years?
Maintenance = core business
Clear functional divide between maintenance and operation
Outsourcing of part of maintenance to competitive local market
Modernization of equipment
Centralization of strategy, planning and budgeting
Unification of components
One central warehouse for 5 mines and 12 power plants
Concentration of production and performance increase
Implementation of sophisticated diagnostic systems
Implementation of SAP; TIS, ZEDAS and other software systems
Continuous improvement process with process line approach
Management tool to measure the success of maintenance - PMB
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3. The Lusatian Lignite Mining Area – 5 active mines
Status:
Vattenfall Records 2010
Guben
Jänschwalde-Nord
Lignite Production
Jänschwalde
Cottbus-Nord
Welzow-Süd
Nochten
Reichwalde
56.7 mill. t
11.5 mill. t
5.8 mill. t
20.7 mill. t
18.7 mill. t
0.0 mill. t
Spree
Jänschwalde power plant
Spreeaue
Jänschwalde mine
Brandenburg
Cottbus-Nord mine
Cottbus
Jänschwalde storage site
Overburden Removal
Jänschwalde
Cottbus-Nord
Welzow-Süd
Nochten
Reichwalde
406.3 mill. m³
121.4 mill. m³
24.6 mill. m³
137.9 mill. m³
118.6 mill. m³
3.8 mill. m³
Forst/ Lausitz
Neiße
Bagenz-Ost
Welzow-Süd mine
Overburden Ratio ,17 m³/t
Republic
of Poland
Partial section II,
Welzow-Süd
Spremberg
Spremberg-Ost
Mining field 2, Nochten
Power plants (installed capacity)
Jänschwalde
Boxberg
Schwarze Pumpe
7,175 MW
3,000 MW
2,575 MW
1,600 MW
Schwarze
Pumpe
Nochten mine
Weißwasser
Storage site „Spreyer Höhe“
Hoyerswerda
Reichwalde mine
Spread of the 2nd Lusatian coal seam
Mined out seam areas
Saxony
Boxberg power plant
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4. Principle of Opencast Mine Process in Lusatia
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5. Overview Heavy Opencast Mine Equipment
Overburden Conveyor Bridges
5 units
Bucket wheel excavators
19 devices
Bucket chain excavators
27 devices
Spreader &
Belt wagon
19 units
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6. Quantity structures of active plants (Plan 2011)
Designation
Number / Length
Overburden conveyor bridges 5
Excavator, reclaimer 46
Spreader, belt wagon 19
Belt conveyor systems    
96 km
Cables and overhead lines
600 km
110 kV Transformer stations 6
Locomotives 76
Rail cars
967
Track network incl. equipment tracks
553 km
Track shifting Machines 39
Dewatering Pumps
6797
Pit water purification plants 4
Control centres
Raw coal production mill. t
Overburden removal mill. m3
Water pumpage mill. m3
Drilling meter km
Sealing wall tsd. m2
Men-hours tsd. h
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7. Applied maintenance methods and their shares
Travelling gears
thereof rail cars
Limit switches
Air-conditioning systems
Digging tools
Belts
Drums
Motors
Gearboxes
Transformers
Control systems
Converter
Cables
Lines
Ropes
Linings
Crawler track shoes
Idlers and garlands
Aprons
Track wheels
Value percentage of process allocation 2010
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8. Typical maintenance measures for mining equipment
Service
Planned weekly repair (8-12h)
Annual overhaul (14 days in the first and 28 days in second year)
Trouble shooting and defect removal
Ad hoc repairs parallel to other stand stills
Project measures – technical reconstruction, life time extensions
Complex modernization and rehabilitation measures
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9. Organisational Structure of Opencast Mine Safety
Laws,
Standards &
Regulations
VEM Board of Directors
Technical Services
Mining Department
Securing and proof of
technically necessary standard
For the requirements of mining
Use of plants and equipment
with authorized personnel
according to current technical
documentation
Recognized experts for
heavy opencast mine equipment
Mining authorities
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10. Structure of Vattenfall Europe Mining in 20103
Strategy
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11. Maintenance Department HO: Systems Engineering
Equipment strategy planning
Investment planning
Life time extension
Modernization planning
R&D activity planning
Innovation planning
Performance increase planning
System integration planning
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12. Maintenance Department 1: Field Service
Structure:
Mechanical Field Service Team mines Jänschwalde / Cottbus N
Electrical Field Service Team mines Jänschwalde / Cottbus N
Mechanical Field Service Team mines Nochten / Reichwalde
Electrical Field Service Team mines Nochten / Reichwalde
Mechanical Field Service Team mine Welzow
Electrical Field Service Team mine Welzow
Staff unit (Planning and works preparation)
Central power supply and network service
Tasks
Supervision and evaluation of equipment condition
Identification and specification of repair measures (works, spares), Involvement and supervision of outside service companies
Standard repairs, planned repairs and defect removal
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13. Mechanical Field Service Team mines J/CN
Substructure:
Field teams for process lines (precut, bridge, coal system)
Trouble shooting and defect removal group
Local workshop repairs
Work and repair preparation group
Example for involvement of outside services and personnel in a typical weekly repair (8-12h):
VEM supervision Contract worker
Precut
Conv. Bridge
Coal system
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14. Maintenance Department 2: Technical Office
Planning and implementation of innovations
Planning and preparations of complex reconstructions / modernizations
Technical process optimization and bottleneck removal
Supervision and maintaining of mine equipment safety
Component unification
Setting and adjusting of internal technical standards
Administration of all technical documentation of VEM
Elaboration of technical solutions for special areas
Coordination of outside and inside works and supplies
Preparation of technical specifications and tender documents for complex rehabilitation measures
Project Management and Implementation Supervision for large and complex project measures
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15. Maintenance Department 3: Central Workshop
Tasks:
Defect removal / service and maintenance of rolling stock repair of railway equipment, reconditioning of wheels, drives,…
Repair of underground motor and waste water pumps
Repair of mechanical mine equipment components and units:
Buckets, bucket chains, belt drums, gearboxes, turas, crawler plates, travel gears, wheels, other
Reconditioning of standard components
Component and material management
Measuring and test service
Features:
50 million EUR turnover per annum
SAP repair jobs and work orders per annum
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16. Central warehouse and logistics
Schleswig-Holstein
Rostock
Mecklenburg-Vorpommern
Hamburg
Schwerin
Brandenburg
GTKW Ahrensfelde (G)
Bremen
GTKW Thyrow (G)
Berlin
Niedersachsen
Jänschwalde, Cottbus (M),
KW Jänschwalde (G)
Hannover
Magdeburg
Schwarze Pumpe (M),
KSP Schwarze Pumpe (G)
Sachsen-Anhalt
Cottbus
Welzow (M)
PSW Wendefurt (G)
Halle
Leipzig
Nochten / Reichwalde (M)
Boxberg (G)
Sachsen
Dresden
KW Lippendorf (G)
Erfurt
Thüringen
PSW Niederwartha (G)
PSW Hohenwarte / PSW Bleiloch (G)
Saalfeld
Chemnitz
PSW Markersbach (G)
PSW Goldisthal (G)
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17. Maintenance Department 4: Central Warehouse
Timely and efficient supply of spares, materials and components
Material, spares and component disposition
Storage, commissioning, distribution and shipment
av. Spare parts and material stock for mining 66 million €
5 internal petrol stations
annual value of mining outtake: 103 million EUR
Annual number of spare supply orders:
Annual number of SAP material orders:
Annual number of transports for mining:
Annual number of claims: 700
Workforce: 34 employees full time
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18. Already implemented Equipment Optimisations at VEM
Main drives on excavators: (equipment and construction)
direct drives at bucket chain excavators
extension of digging tools
optimisation of bucket chains
new design of bucket wheel boom head
Belt drives
converter drives at belt conveyor systems
new generation of drives
conveying lines on overburden conveyor bridge systems
Conveyors:
(design and construction)
transfers / chute design
baffle plate construction
idler garland geometry / dimensioning
noise emission
Control systems and process instrumentation and control
centralised operation control (central control rooms)
complex systems of production coor- dination and coal quality management
tools of plant diagnosis
complex automation functions at large opencast mine equipment
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Confidentiality - None (C1),

19. Extended Process Data Acquisition by Systems Engineering
Drums
Bearing
Belt
Gearboxes
Undercarriage
Idlers
drive, operating time
PLANT CONDITION
Analysis
Modelling
Optimization
Trend
Knowledge
Parameters
History
Structure
Diagnosis
Operating time, reference model
Condition, operating time
Temperature, vibration
tension force, reference model
speed, moment, lubrication
Process data in functional context (temperature, vibrations, process data)
SAFETY
AVAILABILITY
COSTS
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20. Internal Diagnosis-Specialist External Service partner
Plant - and Process Diagnostics Maintenance
Drive Station
Monitoring
System
Monitoring
System
Monitoring
System
Monitoring
System
Monitoring
System
Monitoring
System
Monitoring
System
Monitoring
System
Monitoring
System
LAN Ethernet (LWL) TCP/IP
Internal Diagnosis-Specialist
Firewall
Control centre
Systems engineer
ISDN-
Access-
Router
WAN-
connection
Router
LAN Ethernet TCP/IP
PC-Network Schwarze Pumpe
PC-Network opencast mine
LAN Ethernet TCP/IP
Modem
Telephone network
External Service partner
System maintenance
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21. Time balance @ Precut system Jaenschwalde
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22. Performance increase Precut system with SRs 2000 (1557)
14,7 Mio.m³
18,5 Mio.m³
19,8 Mio.m³
20,9 Mio.m³
23,3 Mio.m³
18,2 Mio.m³
19,0 Mio.m³
16,4 Mio.m³
21,9 Mio.m³
4.561 m³/h
4.798 m³/h
5.231 m³/h
4.373 m³/h
4.112 m³/h
4.009 m³/h
3.753 m³/h
4.573 m³/h
3.223 m³/h 5 10 15 20 25 30 35 40 45
2001
2002
2003
2004
2005
2006
2007
2008
2009
1.000
1.500
2.000
2.500
3.000
3.500
4.000
4.500
5.000
5.500
[Mio.m³]
[m³/h]
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23. Maintenance cost per m³ BWE-belt-spreaders system JW
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24. Breakdown rate 2011 for BWE – belt-spreader systems
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25. Breakdown rate 2011 for Conveyor bridges
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26. Breakdown rate 2011 for Coal belt systems
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27. Life resource growth vs. maintenance cost: bucket chains
Life resource development of one bucket chain in million. m³
Specific cost for bucket chain maintenance in cent/m³
cent/m³
Mio.m³/EK 16 14 12 10 8 6 4 2 8 6 4 2
/ / / / / / /
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28. Maintenance costs mining 1995-2010
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29. Split of maintenance cost in 2010
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30. Summary and outlook
VEM Maintenance has to ensure an extended equipment fleet service life without performance restrictions having an average age of approx. 38 years
Cost reduction and efficiency increase is possible by a systematic identification of potentials and cost drivers in the ongoing operating process
Efficient division of responsibilities between commercial data network and process data net-work
The data-technical link between
Preparation/ Planning,
Execution/ Maintenance ,
Operating Control
is the key for a mining-related total process optimization
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31. Thank you for your attention!