Maintenance Management in

Hydro Electric Stations Using

CMMS

Resource Person:

Engr. Dr. Zafar A. Khan

Hydro Power Training Institute (HPTI) Mangla 2025

1
 Introduction

Types of Maintenance

CMMS

Computerized Maintenance
Management System
2
Background

How reliable is my
system?

• Interruption of service less or equal than two

reported
hours per year.
• 82 gigawatt-hours per year of energy not
supplied.

10 million of sterling pounds for power utilities in the UK

3
Challenges
Power industry is facing some challenges to assure
continuous service.

There is a need to incorporate innovative models to drive

more accurate reliability evaluation.

There is a need of implementing an advanced methods and

technique which is used to enhance power system reliability
by considering new technologies integrated in the system.

There is a need of developing a new smart maintenance

framework for the scheduling a proactive maintenance that
maximizes the net benefits of generation adequacy.
4
New Dimensions

Changes in the Power System

Distributed generation:
• Transition from centralized to decentralized energy systems.
• Reduced reliance on large power plants.
• Integration challenges for grid stability and operation.
• Encouragement of prosumers (consumers who produce their own energy).

Renewable generation:
• A paradigm shift from “Load Led System” to “Generation Led System”.
• Growth of wind, solar, and other renewable energy sources due to global efforts to
reduce carbon emissions.
• Variability in output requires advanced grid management and energy storage systems.
• Development of microgrids to manage localized renewable energy sources.

Energy Storage Systems (ESS):

• Increased deployment of batteries (e.g., lithium-ion), pumped hydro, and other
storage technologies.
• Storage helps address renewable energy intermittency and improves grid stability.
• Enables peak shaving, load leveling, and fast frequency response (FFR). 5
New Dimensions

Changes in the Power System

De-Carbonise:
• Climate Change.
• Kyoto protocol stared commitment to reduce carbon emissions.
• Paris Agreement, a major break through.
• Encouragement of prosumers (consumers who produce their own energy).

New Types of Loads:

• Growth in electric vehicles (EVs) and the electrification of heating and industrial
processes.
• EV charging from slow to fast chargers.
• Need for new infrastructure

Virtual Power Plants:

• All types of distributed generation.
• EVs act as both energy consumers and potential energy storage (via vehicle-to-grid
technologies).
• Increased electricity demand requires upgrades to grid infrastructure. 6
New Dimensions 2

Changes in the Power System

Dynamic Line Rating (DLR):
• Advanced monitoring systems optimize the use of transmission lines by adjusting
capacity based on real-time environmental conditions (e.g., wind speed, temperature).
• Increases transmission efficiency and reduces congestion.
• Deferment of new investment for infrastructure.

Grid Resilience and Cybersecurity:

• Increased focus on protecting the grid from physical and cyber threats.
• Measures to prevent widespread blackouts and ensure reliability during extreme
weather events.

Digitalization and AI:

• Transition from analogue systems to digital systems.
• Use of artificial intelligence, machine learning, and big data analytics for predictive
maintenance, fault detection, and load forecasting.
• Improved decision-making for utilities and grid operators. 7
New Dimensions 2

Changes in the Power System

Demand Side Management:
• Strategies and technologies used to optimize electricity usage on the consumer side of
the grid to balance demand and supply.
• Peak Shaving: Reducing demand during high-use periods.
• Load Shifting: Moving energy consumption to off-peak periods. Demand Response:
Encouraging consumers to adjust electricity usage based on price signals or
incentives or for Peer Trading.

Advanced Metering Infrastructure (AMI):

• Real-time monitoring of electricity consumption.
• Remote meter reading and fault detection.
• Supports time-of-use pricing and demand-side management.
• Can be used with AI and data analytics to improve service.

Phasor Measurement Units (PMUs):

• High-speed sensors that monitor voltage, current, and frequency in real-time across
the grid.
• Measures grid stability using synchronized data (wide-area monitoring).Detects
disturbances and supports corrective actions.
8
• Improves grid reliability by identifying and mitigating outages or instabilities quickly.
New Dimensions 2

Changes in the Power System

Smart Sensors:
• IoT-enabled devices that provide real-time data on grid conditions, such as
temperature, load, and fault locations.
• Temperature sensors for transformers.
• Vibration and acoustic sensors for fault detection in cables.

Smart Transformers:
• Transformers equipped with monitoring and control capabilities.
• Adjusts voltage levels dynamically based on grid conditions.
• Protects equipment and improves energy efficiency.
• Enhances power quality and reduces energy losses.

Decentralized Energy Management Systems:

• Systems that allow local energy generation, storage, and consumption to be managed
autonomously (e.g., microgrids).
• Operates independently or in connection with the main grid.
• Enhances energy resilience in remote or disaster-prone areas.
9
• Provides flexibility and reliability at the community level.
Power System Reliability

10
Introduction

Maintenance

CMMS

Activity
11
Maintenance and Reliability

The current key market drivers are

“lifetime extension” and
“cost reduction”,
i.e. the measure
to be taken is
Active
Asset
Management

12
 Maintenance and Reliability
Asset Management:
• According to ISO 55000:2014, asset management is the
coordinated activity of an organization to realise values from
assets.
• How do you realize value from your car?

13
 Maintenance and Reliability
Asset Management:
• Asset management integrates maintenance, monitoring, and modernization to
maximize plant availability and efficiency while minimizing risks.
• A systematic process of maintaining, upgrading, and operating physical
• assets cost-effectively.
• Focuses on reducing lifecycle costs and increasing asset longevity.

14
Maintenance and Reliability

► Orlando Utilities Commission Maintenance of power

generating plants
► Every year each plant is taken off-line for 1-3 weeks
maintenance
► Every three years each plant is taken off-line for 6-8
weeks for complete overhaul and turbine inspection
► Each overhaul has 1,800 tasks and requires 72,000
labor hours
► OUC performs over 12,000 maintenance tasks
each year

15
 Maintenance and Reliability
Orlando Utilities Commission
► Every day a plant is down costs Orlando Utilities
Commission $110,000
► Unexpected outages cost between $350,000 and
$600,000 per day
► Preventive maintenance discovered a cracked rotor
blade which could have destroyed a $27 million piece
of equipment

16
 Maintenance and Reliability
• Maintenance is all activities involved in keeping a system’s
equipment in working order
• Reliability is the probability that a machine will function
properly for a specified time

The objective of maintenance

and reliability is to maintain
the capability of the system.

17
Maintenance and Reliability

The objective of maintenance

and reliability is to maintain
the capability of the system.

18
 Maintenance and Reliability

Important Tactics
• Reliability
1. Improving individual components
2. Providing redundancy
• Maintenance
1. Implementing or improving preventive
maintenance
2. Increasing repair capability or speed

19
 Maintenance and Reliability

Maintenance Management
Employee Involvement
Partnering with maintenance
personnel
Skill training Results
Reward system
Employee empowerment Reduced inventory
Improved quality
Improved capacity
Reputation for quality
Maintenance and Reliability Continuous improvement
Procedures Reduced variability
Clean and lubricate
Monitor and adjust
Make minor repair
Keep computerized records

20
 Reliability
Bathtub Curve of Reliability

21
 Reliability
Bathtub Curve of Reliability

22
 Reliability
Reliability
• System reliability
• Improving individual components

Rs = R1 x R2 x R3 x … x Rn

where R1 = reliability of component 1

R2 = reliability of component 2

and so on

23
 Reliability
Overall System Reliability
100 –

Reliability of the system (percent)

80 –

60 –

40 –

20 –

0 |– | | | | | | | |

100 99 98 97 96
Average reliability of each component (percent)
24
 Reliability
Reliability Example

R1 R2 R3

.90 .80 .99 Rs

Reliability of the process is

Rs = R1 x R2 x R3 = .90 x .80 x .99 = .713 or 71.3%

25
 Reliability
Product Failure Rate (FR)
Basic unit of measure for reliability

Number of failures
FR(%) = x 100%
Number of units tested

Number of failures
FR(N) =
Number of unit*hours-hours of operating time lost

Mean time between failures

1
MTBF =
FR(N)
26
 Reliability
Failure Rate Example
20 air conditioning units for use in the international
space station operated for 1,000 hours
One failed after 200 hours and one after 600 hours

2
FR(%) = (100%) = 10%
20
2
FR(N) = = .000106 failure/unit hr
20,000 - 1,200
1
MTBF = = 9,434 hrs
.000106
27
 Reliability
Failure Rate Example
20 air conditioning units for use in the international
space station operated for 1,000 hours
One failed after 200 hours and one after 600 hours
Failure rate
2 per trip
FR(%) = (100%) = 10%
20
FR = FR(N)(24 hrs)(6 days/trip)
2
FR(N) = FR = (.000106)(24)(6)
= .000106 failure/unit hr
20,000 - 1,200
FR = .0153 failure/trip
1
MTBF = = 9,434 hrs
.000106
28
 Reliability
Providing Redundancy
Provide backup components to
increase reliability

Probability of Probability Probability of

RS = first of second needing
+ x
component component second
working working component

= (.8) + (.8) x (1 - .8)

= .8 + .16 = .96

29
 Reliability
Redundancy Example
A redundant process is installed to support the
earlier example where Rs = .713
R1 R2 R3
Reliability has
0.90 0.80 increased from
.713 to .94
0.90 0.80 0.99

RS = [.9 + .9(1 - .9)] x [.8 + .8(1 - .8)] x .99

= [.9 + (.9)(.1)] x [.8 + (.8)(.2)] x .99
= .99 x .96 x .99 = .94
30
 Reliability
Parallel Redundancy R1
Increased reliability 0.95
R2 R3
through parallel
0.975 0.975
redundancy R4
0.95
Reliability for
= R2 x R3 = .975 x .975 = .9506
the middle path

Probability of failure
= (1 – 0.95) x (1 – .9506) x (1 – 0.95)
for all 3 paths
= (.05) x (.0494) x (.05) = .00012

Reliability of new design = 1 – .00012 = .99988

31
 Activity
Build a tower using the equipment you have. The tower should
be able to withstand weight a cold drink can for one minute.
The tallest tower
which can hold
the weight will
win.

32
 Maintenance
Maintenance
• Two types of maintenance
• Preventive maintenance – routine inspection and
servicing to keep facilities in good repair
• Breakdown maintenance – emergency or priority repairs
on failed equipment

33
 Maintenance
Implementing Preventive Maintenance
• Need to know when a system requires service or is likely to fail
• High initial failure rates are known as infant mortality
• Once a product settles in, MTBF generally follows a normal
distribution
• Good reporting and record keeping can aid the decision on
when preventive maintenance should be performed

34
 Maintenance
Computerized Maintenance System CMMS)
Data Files Output Reports

Equipment file Inventory and

with parts list purchasing reports

Maintenance Equipment
and work order parts list
schedule

Repair Equipment
history file history reports

Inventory of Cost analysis

spare parts (Actual vs. standard)

Personnel data
with skills, Work orders
wages, etc.

35
 Maintenance
Maintenance Costs
• The traditional view attempted to balance preventive and
breakdown maintenance costs
• Typically this approach failed to consider the full costs of a
breakdown
• Inventory
• Employee morale
• Schedule unreliability

36
 Maintenance
Maintenance Costs
Total
costs

Preventive
maintenance
costs
Costs

Breakdown
maintenance
costs

Maintenance commitment
Optimal point (lowest
cost maintenance policy)

Traditional View
37
 Maintenance
Maintenance Costs
Total
costs

Full cost of
breakdowns
Costs

Preventive
maintenance
costs

Maintenance commitment
Optimal point (lowest
cost maintenance policy)
Full Cost View
38
 Maintenance
Increasing Repair Capabilities
1. Well-trained personnel
2. Adequate resources
3. Ability to establish repair plan and priorities
4. Ability and authority to do material planning
5. Ability to identify the cause of breakdowns
6. Ability to design ways to extend MTBF

39
 Maintenance
Increasing Repair Capabilities

Operator
(autonomous Maintenance Manufacturer’s Depot service
maintenance) department field service (return equipment)

Competence is higher as we
move to the right
Preventive
maintenance costs less and
is faster the more we move to the left

Increasing Operator Ownership Increasing Complexity

40
 Maintenance
Autonomous Maintenance
• Employees accept responsibility for
• Observe
• Check
• Adjust
• Clean
• Notify
• Predict failures, prevent breakdowns, prolong
equipment life
41
 Maintenance

Thinking out of box

• A simple redundancy formula
• Problems with breakdown and preventive maintenance
• Predictive maintenance
• Predictive maintenance tools
• Maintenance strategy implementation
• Effective reliability

42
 Maintenance
Providing Redundancy –
An Alternate Formula
• The reliability of one pump =
The probability of one pump not failing = 0.8
P(failing) = 1- P(not failing) = 1 - 0.8 = .2
► If there are two pumps with the same probability of not failing
P(failure of both pumps) =
P(failure) pump #1 x P(failure) pump #2
P(failure of both pumps) = 0.2 x 0.2 = .04
P(at least one pump working) =
1.0 - .04 = .96
43
 Maintenance
Problems With Breakdown Maintenance
• Run it till it breaks”
• Might be ok for low criticality equipment or redundant
systems
• Could be disastrous for critical plant machinery or
equipment
• Not permissible for systems that could imperil life or limb.

44
 Maintenance
Problems With Preventive Maintenance
• Fix it “whether or not it is broken”
• Scheduled replacement or adjustment of
parts/equipment with a well-established service life
• Sometimes misapplied
• Replacing old but still good bearings
• Over-tightening electrical lugs in switchgear
45
 Maintenance
Another Maintenance Strategy
• Predictive maintenance – Using advanced technology to
monitor equipment and predict failures
• Using technology to detect and predict imminent equipment
failure
• Visual inspection and/or scheduled measurements of
vibration, temperature, oil and water quality
• Measurements are compared to a “healthy” baseline
• Equipment that is trending towards failure can be scheduled
for repair
46
 Maintenance
Predictive Maintenance Tools
• Vibration analysis
• Infrared Thermography
• Oil and Water Analysis
• Other Tools:
• Ultrasonic testing
• Liquid Penetrant Dye testing
• Shock Pulse Measurement (SPM)
47
 Maintenance
Predictive Maintenance: Vibration Analysis
• Using sensitive transducers and instruments to detect
and analyze vibration
• Typically used on expensive, critical equipment–large
turbines, motors, engines or gearboxes
• Sophisticated frequency (FFT) analysis can pinpoint
the exact moving part that is worn or defective
• Can utilize a monitoring service

48
 Maintenance
Predictive Maintenance Infrared (IR)
Thermography
• Using IR cameras to look for temperature “hot spots” on
equipment
• Typically used to check electrical equipment for wiring
problems or poor/loose connections
• Can also be used to look for “cold (wet) spots” when
inspecting roofs for leaks
• High quality IR cameras are expensive – most pay for
IR thermography services
49
 Maintenance
Predictive Maintenance: Oil and Water
Analysis
• Taking oil samples from large gearboxes, compressors or
turbines for chemical and particle analysis
• Particle size can indicate abnormal wear

• Taking cooling water samples for analysis – can detect

excessive rust, acidity, or microbiological fouling

• Services usually provided by oil vendors and water treatment

companies
50
 Maintenance
Predictive Maintenance:
Other Tools and Techniques
• Ultrasonic and dye testing – used to find stress cracks in tubes,
turbine blades and load bearing structures
• Ultrasonic waves sent through metal
• Surface coated with red dye, then cleaned off, dye shows cracks

• Shock-pulse testing – a specialized form of vibration analysis used

to detect flaws in ball or roller bearings at high frequency (32kHz)

51
 Maintenance
Maintenance Strategy Comparison
RESOURCES/
MAINTENANCE TECHNOLOGY APPLICATION
STRATEGY ADVANTAGES DISADVANTAGES REQUIRED EXAMPLE
Breakdown No prior work Disruption of May need Office copier
required production, injury labor/parts at
or death odd hours
Preventive Work can be Labor cost, may Need to obtain Plant relamping,
scheduled replace healthy labor/parts for machine
components repairs lubrication

Predictive Impending Labor costs, costs Vibration, IR Vibration and oil

failures can be for detection analysis analysis of a
detected & equipment and equipment or large gearbox
work scheduled services purchased
services

52
 Maintenance
Maintenance Strategy Implementation

Percentage of Maintenance Time by Strategy

100%

80% Predictive

60%
Preventive

40%

20% Breakdown

0%
1 2 3 4 5 6 7 8 9 10
Year
53
 Maintenance
Is Predictive Maintenance Cost Effective?

• In most industries the average rate of return is 7:1 to 35:1 for

each predictive maintenance dollar spent.

• Vibration analysis, IR thermography and oil/water analysis

are all economically proven technologies.

• The real savings is the avoidance of generation downtime.

54
 Maintenance
Predictive Maintenance and Effective
Reliability
• Effective Reliability (Reff) is an extension of Reliability that includes
the probability of failure times the probability of not detecting
imminent failure
• Having the ability to detect imminent failures allows us to plan
maintenance for the component in failure mode, thus avoiding
the cost of an unplanned breakdown
Reff = 1 – (P(failure) x P(not detecting failure))
55
 Maintenance
How Predictive Maintenance Improves
Effective Reliability
• Example: a large gearbox with a reliability of .90 has vibration
transducers installed for vibration monitoring. The probability of early
detection of a failure is .70. What is the effective reliability of the
gearbox?
Reff = 1 – (P(failure) x P(not detecting failure))
Reff = 1 – (.10 x .30) = 1 - .03 = .97
• Vibration monitoring has increased the effective reliability from .90 to
.97!
56
 Maintenance
Effective Reliability Caveats
• Predictive maintenance only increases effective reliability if:
• You select the method that can detect the most likely
failure mode.

• You monitor frequently enough to have high likelihood of

detecting a change in component behavior before failure.

• Timely action is taken to fix the issue and forestall the

failure (in other words you don’t ignore the warning!)

57
 Maintenance
Increasing Repair Capabilities
1. Well-trained personnel
2. Adequate resources
3. Proper application of the three maintenance
strategies
4. Continual improvement to improve equipment/system
reliability

58
Predictive Maintenance 2

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Preventive/Predictive Maintenance 2

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Preventive/Predictive Maintenance 2

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Preventive/Predictive Maintenance 2

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Preventive/Predictive Maintenance 2

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Preventive/Predictive Maintenance 2

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Predictive Maintenance 2

75
 Predictive Maintenance 2

Reference: Sartor, Matheus, et al. "Assets Performance Management systems for

hydroelectric power plants—A survey." Electric Power Systems Research 228 (2024): 76
110080.
 Predictive Maintenance 2

Case Study of NBEHPP

• It was observed that for the three years Unit’s monthly maintenance (required shutdown) has
been carried out mainly for the carbon brush checking and replacements.
UNIT WISE BRUSH CONSUMPTION

From August, 2013 to March, 2016

Unit Carbon Brushes Replaced No of Inspection/replacement done No of Months Average replacement per month
1 87 29 29 3

2 50 29 29 2

3 57 30 29 2

4 68 26 29 2

Note: Above data reveals that consumption of carbon brushes in unit-01 is more than all three units, so Unit-01
is taken a pilot project for presenting the case to SOC.

77
 Predictive Maintenance 2

Case Study of NBEHPP

Monthly Maintenance

• Avoid shutdown Maintenance- Generation loss- Impact-

22Million PKR a Year
• Plan to carry out only on opportunity- High Availability
• To analyze shutdown requirements- Optimization of Resources

78
Predictive Maintenance 2

Case Study of NBEHPP

CHANGE IN MAINTENANCE REGIME
• Migration From Monthly To IMPACT
High Availability
Quarterly maintenance Maximum Use of Hydrology-
– Review present time more generation
based Maintenance and Less wear And tear due to
interval start stop.
– Risk based Inspection More Revenue
(RBI)
– Toward TPM – Total
productive Maintenance

IMPACT
•Optimization of Annual High Availability
Maintenance Plan Cost Reduction by reducing
Minimize Down Time involvement of third party
Split Annual Maintenance Manpower
Activities

79
 Predictive Maintenance 2

Case Study of NBEHPP

• An analysis has been carried out to show that brush wear is more when positive polarity is on
head race side – a study carried out during high hydrology period, hence during the months
with maximum running. ANALYSIS TO SHOW THAT BRUSH WEAR IS MORE WHEN POLARITY IS POSITIVE ON HEAD RACE SIDE-SUTDY CARRIED OUT DURING HIGH HYDROLOGY PERIOD HENCE
DURING THE MONTHS WITH MAXIMUM RUNNING
Head Race Tail Race
Running Monthly
Month No Wearing Monthly Wear Wearing
Hours Initial Final Polarity Previous Current Wear Polarity
(mm/hr) (mm) (mm/hr)
(mm)
1 50 36.89 0.015 11.01 28.63 23.03 0.007 4.70

2 39.36 30.22 0.011 7.68 50 43.72 0.007 5.28

September, 2015
3 39.52 30.34 0.011 7.71 37.22 29.6 0.009 6.40

Negative
Positive
4 39.61 29.95 0.011 8.12 34.51 28.94 0.006 4.68

857
5 39.97 32.9 0.008 5.94 35.42 29.29 0.007 5.15
6 31.68 17.23 0.017 12.14 26.96 21.31 0.007 4.75
7 45.27 23.67 0.025 18.15 38.3 32.45 0.007 4.91
8 40.02 33.39 0.008 5.57 38.02 33.58 0.005 3.73
9 39.76 31.65 0.009 6.81 36.66 31.74 0.006 4.13
1 36.89 32.04 0.006 4.45 40.7 28.75 0.015 10.97
2 30.22 25.93 0.005 3.94 43.72 37.34 0.008 5.86
3 30.34 25.98 0.006 4.00 29.6 21.9 0.010 7.07

October, 2015
4 29.95 23.82 0.008 5.63 28.94 18 0.014 10.05

Negative

positive
5 32.9 28.49 0.006 4.05 29.29 18.93 0.013 9.51

784
6 43.09 37.58 0.007 5.06 43.37 31.47 0.015 10.93
7 48.27 41.63 0.008 6.10 32.45 24.79 0.010 7.03
8 33.39 29.66 0.005 3.43 33.58 27.33 0.008 5.74

9 31.65 27.17 0.006 4.11 31.74 24.68 0.009 6.48

1 32.04 18.04 0.017 12.01 28.75 21.08 0.009 6.58

2 50 37.96 0.014 10.33 37.34 32.71 0.006 3.97
November, 2015
3 50 38.95 0.013 9.48 50 44.82 0.006 4.45

Negative
4 50 39.33 0.013 9.16 50 43.41 0.008 5.66

Positive
839
5 28.49 9.49 0.023 16.31 50 44.63 0.006 4.61
6 37.58 23.88 0.016 11.76 31.47 20.98 0.013 9.00
7 41.63 24.87 0.020 14.38 50 40.27 0.012 8.35
8 29.66 15.07 0.017 12.52 27.33 20.81 0.008 5.60
9 27.17 11.27 0.019 13.64 50 44.65 0.006 4.59
1 50 44.25 0.009 6.82 50 44.51 0.009 6.51
2 37.96 34.45 0.006 4.16 32.71 25.97 0.011 7.99
3 38.95 34.93 0.007 4.77 44.82 40.77 0.007 4.80
December,2015

4 39.33 35.06 0.007 5.06 43.41 37.25 0.010 7.31

Negative

positive
5 50 44.7 0.009 6.29 44.63 40.08 0.007 5.40
607

6 50 44.9 0.008 6.05 50 40.14 0.016 11.70

7 50 45.33 0.008 5.54 40.27 30.28 0.016 11.85

8 50 44.75 0.009 6.23 50 41.32 0.014 10.30

9 50 43.41 0.011 7.82 44.65 40.75 0.006 4.63
1 50 28.76 0.019 13.46 50 44.99 0.004 3.18
2 50 15.44 0.030 21.90 50 44.50 0.005 3.49
3 50 29.70 0.018 12.87 50 45.10 0.004 3.11
March,2016

Negative
4 50 32.94 0.015 10.81 50 44.36 0.005 3.57

Positive
1136

5 50 29.15 0.018 13.21 50 44.31 0.005 3.61

6 50 36.72 0.012 8.42 50 44.81 0.005 3.29
7 50 38.42 0.010 7.34 50 45.05 0.004 3.14
8 50 33.37 0.015 10.54 50 44.62 0.005 3.41
9 50 31.74 0.016 11.57 50 44.04 0.005 3.78 80
 Predictive Maintenance 2

Case Study of NBEHPP

• The brushes wears on the head race side & tail race side and with Positive Polarity have been
added up and average monthly wear is calculated, which is extrapolated first to two months
and then three month (before Annual Maintenance)
Before Annual Maintenance
Brush wear w.r.t position, polarity (+) on Head race side Brush wear w.r.t position, polarity (+) on tail race
Brush replacment length Brush replacment length
wear 20mm wear 20mm
Avg Expected Avg Expected
mm in mm in
No Monthly Quarterly No Monthly Quarterly
two brush length brush length two brush length brush length
Wear Wear Wear Wear
months after 2 after 3 months after 2 after 3
months months months months
1 23.03 11.51 34.54 26.97 15.46 1 17.49 8.74 26.23 32.51 23.77
2 18.01 9.01 27.02 31.99 22.98 2 13.85 6.93 20.78 36.15 29.22
3 17.20 8.60 25.79 32.80 24.21 3 11.88 5.94 17.81 38.12 32.19
4 17.27 8.64 25.91 32.73 24.09 4 17.35 8.68 26.03 32.65 23.97
5 22.24 11.12 33.37 27.76 16.63 5 14.91 7.46 22.37 35.09 27.63
6 23.90 11.95 35.85 26.10 14.15 6 22.62 11.31 33.94 27.38 16.06
7 32.53 16.26 48.79 17.47 1.21 7 18.88 9.44 28.33 31.12 21.67
8 18.09 9.05 27.14 31.91 22.86 8 16.04 8.02 24.05 33.96 25.95
9 20.46 10.23 30.69 29.54 19.31 9 11.11 5.55 16.66 38.89 33.34

81
 Predictive Maintenance 2

Case Study of NBEHPP

• After Annual Maintenance, all 18 new brushes were installed in Unit-01 and the wear is
averaged to one month from the values and then extrapolated to two and three months, for
the brushes having positive polarity on both head race and tail race side. Also the duration
based analysis is carried out for reference .

After Annual Maintenance

After Annual Maintenance (March, 2016) After Annual Maintenance (April, 2016)
Brush wear w.r.t position, polarity (+) on Head race side Brush wear w.r.t position, polarity (+) on Tail race side
Brush replacment length Brush replacment length
Duration Avg Expected 20mm Duration Avg Expected 20mm
No (Months) Monthly Quarterly brush length brush length No (Months) Monthly Quarterly brush length brush length
Actual Wear Wear after 2 after 3 Actual Wear Wear after 2 after 3
months months months months
1 13.46 40.39 23.08 9.61 1 7.34 22.03 35.31 27.97
2 21.90 65.71 6.19 -15.71 2 20.22 60.65 9.56 -10.65
3 12.87 38.60 24.27 11.40 3 7.32 21.97 35.36 28.03
4 10.81 32.44 28.37 17.56 4 8.69 26.07 32.62 23.93
5 1.58 13.21 39.64 23.57 10.36 5 1.03 24.03 72.08 1.95 -22.08
6 8.42 25.25 33.17 24.75 6 8.87 26.61 32.26 23.39
7 7.34 22.02 35.32 27.98 7 7.16 21.47 35.69 28.53
8 10.54 31.62 28.92 18.38 8 11.22 33.65 27.56 16.35
9 11.57 34.72 26.85 15.28 9 8.35 25.06 33.30 24.94 82
 Predictive Maintenance 2

Case Study of NBEHPP

• Duration after the change.

Brush wear w.r.t position, polarity (+) on Head race side Brush wear w.r.t position, polarity (-) on Head race side
Brush Expected Brush Expected
Brush Brush
lenghts on Actaul Length If unit lenghts on Actaul Length If unit
Lengths No of days Lengths No of days
No 11th Running remain in No 11th Running remain in
on 16th Passed on 16th Passed
March, (days) operation for March, (days) operation for
Jan, 2016 Jan, 2016
2016 60 days 2016 60 days
1 50 28.76 23.08 1 50 44.99 6.35
2 50 15.44 6.19 2 50 44.50 6.97
3 50 29.70 24.27 3 50 45.10 6.21
4 50 32.94 28.37 4 50 44.36 7.15
5 50 29.15 55.50 47.33 23.57 5 50 44.31 55.50 47.33 7.21
6 50 36.72 33.17 6 50 44.81 6.58
7 50 38.42 35.32 7 50 45.05 6.27
8 50 33.37 28.92 8 50 44.62 6.82
9 50 31.74 26.85 9 50 44.04 7.55 83
 Predictive Maintenance 2

Hydrology Pattern of three PPA years analyzed, by

Case Study of NBEHPP
studying indent variation during each month to find
• opportunity
Impactavailability
of Changing In Maintenance
Regime
• An additional Hydrology Pattern of three PPA years analyzed, by studying indent variation
Hydrologymonth to find opportunity availability
during each
Hydrology Pattern of three PPA years analyzed, by studying indent variation during each month to find opportunity availability
Indent variation Ist PPA Year (2013-2014) Indent variation 2nd PPA Year (2014-2015) Indent variation 3rd PPA Year (2015-2016)
Average Average Average
Month Variation Opportunity Month Variation Opportunity Month Variation Opportunity
Indent Indent Indent
Mar-13 33,667 35000-32000 NO Mar-14 23,333 30000-20000 YES Mar-14 17,553 38000-15000 YES
Apr-13 33,867 40000-22000 YES Apr-14 34,167 50000-15000 YES Apr-14 15,667 10000-50000 YES
May-13 38,935 45000-25000 NO May-14 45,613 60000-30000 NO May-14 62258 90000-25000 NO
Jun-13 22,933 44000-15000 YES Jun-14 43,810 60000-20000 YES Jun-14 43500 70000-30000 NO
Jul-13 15,000 15000-15000 YES Jul-14 19,355 40000-10000 YES Jul-14 59677 60000-50000 NO
Aug-13 13,710 20000-10000 YES Aug-14 22,516 45000-10000 YES Aug-14 26903 60000-15000 YES
Sep-13 29,533 10000-48000 YES Sep-14 20,500 45000-15000 YES Sep-14 39667 55000-15000 YES
Oct-13 35,452 48000-25000 NO Oct-14 32,484 45000-25000 NO Oct-14 40742 50000-30000 NO
Nov-13 34,333 29000-45000 NO Nov-14 45,833 30000-55000 NO Nov-14 42400 60000-33000 NO
Dec-13 28,645 40000-10000 YES Dec-14 35,000 50000-10000 YES Dec-14 25355 35000-6000 YES
Jan-14 8,710 30000-5000 YES Jan-15 13,774 6000-30000 YES Jan-15 6452 6000-20000 YES
Feb-14 34,000 40000-30000 NO Feb-15 45,536 30000-55000 NO Feb-15 58448 60000-30000 NO
Mar-14 33,545 45000-25000 NO Mar-15 60,243 75000-35000 No Mar-15 YES
Apr-15 YES
Note: Remained on conservative side 25000cfs indent considered as no opportunity. 84
 Predictive Maintenance 2

Case Study of NBEHPP

Findings:
The data revealed that brush can last for quarter easily. However, it is noticed that due
to uneven pressure, sometime one or two brushes wear more than the others and
there is a need of replacing those brushes.

Proposal:
With available data and analysis, following options are suggested:
• To change Maintenance regime from Monthly to Quarterly, it is suggested that after
resolving the issue of brush pressure, unit-01 should be taken as pilot project to
increase the maintenance interval to quarterly.
• To change Maintenance regime from Monthly to Bi Monthly as based on the current
data analysis.
• To do the Maintenance on opportunity when ever available, based on the current
data analysis.

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Predictive Maintenance 2

Was this really a predictive maintenance?

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Predictive Maintenance 2

Lets consider real predictive maintenance with Industry 4.0.

Has it got any kind of prediction?

Has it used any IoT?
Has it used any cyber-physical system or any machine
learning/artificial intelligence system techniques?

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 Predictive Maintenance 2

Penas Blancas Hydroelectric Power Plant Costa Rica

38 MW Plant
• Data collected given in table.
• Assembled the 18 input variables with the data corresponding to the List of Events as a function of time.
• The Recurrent Neural Network has an accuracy of 99% to predict a failure in the Generator Axial Bearing
temperature, it has a promising capacity to predict other types of failures such as low pressures in the
Hydraulic Power Unit, future Emergency Shutdowns and forced pressures in the Turbine piping since they
are types of failures that in the training of the model are trained with oversampling of synthetic data and
having a sample with more values of these types of failures could have the capacity to predict them.

Reference: Velasquez, Victor, and Wilfredo Flores. "Machine Learning Approach for Predictive
Maintenance in Hydroelectric Power Plants." 2022 IEEE Biennial Congress of Argentina 88
(ARGENCON). IEEE, 2022.
 Predictive Maintenance 2

Gulpur Hydro Project

Monitoring and Sensing:

Shaft seal sensor: Predicts seal condition

Temperature sensor for shaft seal-

Generator bearing vibration sensor.

Turbidity sensor- helps improve life of runner

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 Prediction Time!!! 2

It is time for me to predict!!!

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Prediction 2

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Predictive Maintenance 2

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Maintenance Planning and Scheduling

MAINTENANCE PLANNING AND SCHEDULING

Effective planning and scheduling contribute significantly to

the following:
• Reduced maintenance cost.
• Improved utilization of the maintenance workforce by
reducing delays and interruptions.
• Improved quality of maintenance work by adopting the
best methods and procedures and assigning the most
qualified workers for the job.

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Maintenance Planning and Scheduling

Planning and Scheduling Objectives

• Minimizing the idle time of maintenance workers.

• Maximizing the efficient use of work time, material,

and equipment.

• Maintaining the operating equipment at a responsive

level to the need of production in terms of delivery
schedule and quality.

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Maintenance Planning and Scheduling
Classification of Maintenance Work According to
Planning and Scheduling Purposes

• Routine maintenance: are maintenance operations of a

periodic nature. They are planned and scheduled and in
advance. They are covered by blanket orders.
• Emergency or breakdown maintenance: interrupt
maintenance schedules in order to be performed. They
are planned and scheduled as they happened.

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Maintenance Planning and Scheduling

• Design modifications: are planned and scheduled and they depend

on eliminating the cause of repeated breakdowns.

• Scheduled overhaul and shutdowns of the plant: planned and

scheduled in advanced.

• Overhaul, general repairs, and replacement: planned and

scheduled in advanced.

• Preventive maintenance: planned and scheduled in advanced.

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Maintenance Planning and Scheduling

• An essential part of planning and scheduling is to

forecast future work and to balance the workload
between these categories.

• The maintenance management system should aim to

have over 90% of the maintenance work planned and
scheduled.

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Maintenance Planning and Scheduling

Planning

Planning is the process by which the elements required to perform a

task are determined in advance of the job start.

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Maintenance Planning and Scheduling

Planning
• It comprises all the functions related to the preparation of:

1. The work order

2. Bill of material
3. Purchase requisition
4. Necessary drawings
5. Labor planning sheet including standard times
6. All data needed prior to scheduling and releasing the work order.

• Good planning is a prerequisite for sound scheduling.

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Maintenance Planning and Scheduling

Planning Procedures
• Determine the job content.
• Develop work plan. This entails the sequence of the activities in the
job and establishing the best methods and procedures to accomplish
the job.
• Establish crew size for the job.
• Plan and order parts and material.
• Check if special tools and equipment are needed and obtain them.
• Assign workers with appropriate skills.

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Maintenance Planning and Scheduling

Planning Procedures
• Review safety procedures.
• Set priorities for all maintenance work.
• Assign cost accounts.
• Complete the work order.
• Review the backlog and develop plans for
controlling it.
• Predict the maintenance load using effective
forecasting technique.

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Maintenance Planning and Scheduling

Basic Levels of Planning Process

(Depend on The Planning Horizon)

1. Long-rang planning: it covers a period of 3 to 5

years and sets plans for future activities and long-
range improvement.
2. Medium-range planning: it covers a period of 1
month to 1 year.
3. Short-rang planning: it covers a period of 1 day to 1
week. It focuses on the determination of all the
elements required to perform maintenance tasks in
advance.
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Maintenance Planning and Scheduling

Long and Medium-Range Planning

Needs to utilize the following:

1. Sound forecasting techniques to estimate the

maintenance load.
2. Reliable job standards times to estimate staffing
requirements.
3. Aggregate planning tools such as linear
programming to determine resource requirements.

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Maintenance Planning and Scheduling

Long-Range Planning

sets plans for future activities and long-range

improvement.

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Maintenance Planning and Scheduling

Medium-Range Planning

• Specify how the maintenance workers will operate.

• Provide details of major overhauls, construction
jobs, preventive maintenance plans, and plant
shutdowns.
• Balances the need for staffing over the period
covered.
• Estimates required spare parts and material
acquisition.

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Maintenance Planning and Scheduling

Short-Range Planning

It focuses on the determination of all the elements

required to perform maintenance tasks in advance.

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Maintenance Planning and Scheduling

Scheduling

Is the process by which jobs are matched with

resources and sequenced to be executed at a certain
points in time.

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Maintenance Planning and Scheduling

Scheduling

• Scheduling deals with the specific time and phasing

of planned jobs together with the orders to perform
the work, monitoring the work, controlling it, and
reporting on job progress.

• Successful planning needs a feedback from

scheduling.

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Maintenance Planning and Scheduling

Reliable Schedule Must Take Into

Consideration

• A job priority ranking reflecting the criticality of

the job.
• The availability of all materials needed for the work
order in the plant.
• The production master schedule.
• Realistic estimates and what is likely to happen.
• Flexibility in the schedule.

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Maintenance Planning and Scheduling

Elements of Sound Scheduling

Requirements for effective scheduling:

• Written work orders that are derived from a well-
conceived planning process. (Work to be done,
methods to be followed, crafts needed, spare parts
needed, and priority).
• Time standards.
• Information about craft availability for each shift.
• Stocks of spare parts and information on restocking.

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Maintenance Planning and Scheduling

Elements of Sound Scheduling

Requirements for effective scheduling:

• Information on the availability of special equipment
and tools necessary for maintenance work.
• Access to the plant production schedule and
knowledge about when the facilities will be
available for service without interrupting
production schedule.
• Well-define priorities for maintenance work.
• Information about jobs already scheduled that are
behind the schedule (backlog).
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Maintenance Planning and Scheduling

Maintenance Schedule Can be Prepared at

Three Levels (Depend on The Time Horizon)

1. Long-range (master) schedule

2. Weekly schedule

3. Daily schedule

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Maintenance Planning and Scheduling

Long-Range (master) Schedule

• Covering a period of 3 months to 1 year.

• Based on existing maintenance work orders
(blanket work order, backlog, PM, anticipated EM).
• Balancing long-term demand for maintenance work
with available resources.
• Spare parts and material could be identified and
ordered in advance.
• Subject to revision and updating to reflect changes
in the plans and maintenance work.

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Maintenance Planning and Scheduling

Weekly Schedule

• Covering 1 week.
• Generated from the master schedule.
• Takes into account current operations schedules and
economic considerations.
• Allow 10% to 15% of the workforce to be available for
emergency work.
• The schedule prepared for the current week and the
following one in order to consider the available backlog.
• The work orders scheduled in this week are sequenced based
in priority.

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Maintenance Planning and Scheduling

Daily Schedule

• Covering 1 day.
• Generated from weekly schedule.
• Prepared the day before.
• Interrupted to perform EM.
• Priorities are used to schedule the jobs.

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Maintenance Planning and Scheduling

Scheduling Procedures (Steps)

• Sort backlog work orders by crafts.

• Arrange orders by priority.
• Compile a list of completed and carry over jobs.
• Consider job duration, location, travel distance, and
the possibility of combining jobs in the same area.
• Schedule multi-craft jobs to start at the beginning of
every shift.
• Issue a daily schedule (not for shutdown
maintenance).
• Authorize a supervisor to make work assignments
(dispatching).
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Maintenance Planning and Scheduling

Maintenance Job Priority System

• Priorities are established to ensure that the most

critical work is scheduled first.
• It is developed under coordination with operations
staff.
• It should be dynamic.
• It must be updated periodically to reflect changes in
operation and maintenance strategies.
• It typically includes three to ten levels of priority.

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Maintenance Planning and Scheduling

Priorities of Maintenance Work

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Maintenance Planning and Scheduling

Scheduling Techniques

The objective of the scheduling techniques is to

construct a time chart showing:

• The start and finish for each job.

• The interdependencies among jobs.
• The critical jobs that require special attention and
effective monitoring.

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Maintenance Planning and Scheduling

Scheduling Techniques

Such techniques are:

• Modified Gantt chart

• CPM
• PERT
• Integer and stochastic programming.

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Maintenance Planning and Scheduling
Industrial Engineering Example

Maintenance
Scheduling

Scheduling
Techniques

Example
Gantt Chart

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 Introduction

Types of Maintenance

CMMS

Hands-on Exercise for

Maintenance Management
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Computerized maintenance management system

How do you plan a maintenance activity in your plant?

Create some drawings on the papers you have.

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CMMS Needs Assessment

• Do you have an effective way to generate and track work orders? How do you verify the
work was done efficiently and correctly? What is the notification function upon completion?
• Are you able to access historical information on the last time a system was serviced, by
whom, and for what condition?
• How are your spare-parts inventories managed and controlled? Do you have either excess
inventories or are you consistently waiting for parts to arrive?
• Do you have an organized system to store documents (electronically) related to O&M
procedures, equipment manuals, and warranty information?
• When service staff are in the field what assurances do you have that they are compliant with
all life, health and safety issues (e.g., lock and tag) and are using the right tools/equipment
for the task?
• How are your assets, i.e., equipment and systems, tracked for reporting and planning?

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Computerized maintenance management system

Power Equipment Condition Assessment is loaded into Maximo® using three

component applications and their screens:
1. Job Plan Application
• A Job Plan stores definitions that define the ratings that assess the condition of a
class of power equipment.
• A Maximo® job plan has been created for each class of equipment, e.g., turbine
runner, transformer, etc.
• The Job Plan, along with its operation steps and measurement point names, is the
first component of Maximo® that must be loaded.
• This part provides the information, screen images, and cut and paste text to
facilitate the loading of condition assessment measurements. 127
Computerized maintenance management system

2. Preventative Maintenance Application

• A Preventative Maintenance (PM) links the Job Plan to a specific piece
of equipment.
• The PM transforms the condition assessment process from equipment
classification (e.g., transformer) to a specific piece of equipment.
• To load the PM, a user needs a Job Plan and the specific equipment
number.
• After the PM record is established, the PM schedule is set to generate
work orders on an annual interval.

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Computerized maintenance management system

3. Condition Monitoring Application

• The Condition Monitoring application establishes and links measurement
points to specific equipment.
• The condition assessment process rates equipment conditions using
measurement point values entered in Condition Monitoring or on work
orders. These points can be thought of as specific measurement points that
measure a condition of equipment.
• The condition assessment process defines the name of measurement points.

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Computerized maintenance management system

3. Condition Monitoring Application

The sequence used to load condition assessment into Maximo® is:
1. Select the appropriate equipment.
2. Create measurement points for every Condition Assessment point
identified. (It is critical that each site use the exact measurement point name
to ensure all the reports will work.)
3. Enter the Job Plan. If it is possible, the Condition Assessment operational
steps can be incorporated into existing Job Plans.
4. Create Preventive Maintenance Plans to schedule the assessment.

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Computerized maintenance management system

3. Condition Monitoring Application

The sequence used to load condition assessment into Maximo® is:
1. Select the appropriate equipment.
2. Create measurement points for every Condition Assessment point
identified. (It is critical that each site use the exact measurement point name
to ensure all the reports will work.)
3. Enter the Job Plan. If it is possible, the Condition Assessment operational
steps can be incorporated into existing Job Plans.
4. Create Preventive Maintenance Plans to schedule the assessment.

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management system

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Avoiding delays
• Integrating CMMS for all Hydal Stations in Pakistan.

• NBE and Gulpur agreement.

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Continue the journey of learning

End of day, journey of learning continues….

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