"The Siberian generation company" uses techniques of cost reduction and implements an EAM system

On December 23, 2013 the Bellwood Systems company announced end of the complex project of use of a technique "Reliability Centered Maintenance there is a maintenance of reliability of the equipment" for cost reduction on support of production assets and the implementing solution Bentley AssetWise in the company the Siberian generation company.

Project Tasks

At the enterprise it is difficult to revaluate importance of asset management. Using the corresponding techniques and technologies possibly not only to reduce costs on support of production assets, but to increase the overall performance of work, to optimize employee occupation. One of the key methodologies allowing to solve problems in the field of management of the equipment is called RCM (Reliability Centered Maintenance, a management system for reliability).

The feature of technology is that attention is paid not so much to support of this or that production asset in working order, how many support of a system in general.

The Siberian Generation Company (SGC) group applied the RCM analysis in the work.

The main tasks which were set for themselves by project participants "The Siberian generation company" and Bellwood Systems system integrator - cost reduction on repair of the equipment and maintenance and also minimizing of failures (forced idle times) at the Abakan combined heat and power plant and the Barnaul CHPP-3.

Project Progress

Implementation of the RCM analysis: on production facilities experts left. Specialists selected the equipment which is in the most critical condition or has high probability of failure. Evaluation criteria — safety of the person and the environment, damage to business (decrease in heat-and-power production) and also repair cost.

Consultants spread out the equipment to so-called "nodes" and carried out their RCM analysis. It helped to refuse planned, occasionally inefficient, transactions. In other words, only that equipment which is valid is under repair needs it. The heaviest failures, and, as a result — the most important categories of maintenance are defined by a risk matrix.

The RCM analysis gave the chance - to foretell failure on set of parameters. The set of breakdowns happens right after repair - experts call this "child mortality", and reduction of number of repairs allows to prevent it.

Project Results

Overall total value - decrease in amounts of repair work, increase in between-repairs intervals, reduction of the mentioned "child mortality".

At the Abakan combined heat and power plant and the Barnaul CHPP-3 the analysis of failures is carried out, is defined the action plan among which:

• THAT according to actual state;
• planned recovery / replacement;
• search of the hidden failure;
• work to the full;
• single changes (reconstruction, training, instructions)

Collection of data on operation of the equipment by means of the inspector with the CPC is among expected further steps or it is automated, thanks to an APCS (industrial control system), but also, additional personnel training.

The expected effect of the project

Experts of Bellwood Systems company analyzed results of pilot projects of implementation of methodology of RCM and the solutions AssetWise Ivara which are carried out at the Abakan combined heat and power plant and the Barnaul CHPP-3: in a project deliverable of implementation reducing costs for maintenance and repair of the equipment for 15% at each station for the account is expected:

• decrease in amounts of works by transfer of a part of the MRO program from scheduled-preventive service "on time" (Party of Pensioners of Russia) on predictive service "on a status";
• reductions of number of premature replacements of items of equipment / spare parts;
• optimization of between-repairs intervals for scheduled repairs.

As a result of implementation of methodology and the solution Bentley AssetWise Ivara decrease in number of forced unplanned idle times of the generating capacities by 25% for the account is expected:

• identifications of a considerable part of failures at their potential stage and use of the adjusting influences before failure led to the actual stop;
• increases in between-repairs intervals and, therefore, decrease in number of the failures arising directly after carrying out scheduled repair on the equipment ("child mortality").