Christie Burger Henk Hattingh

Benchmarking tool for small hydropower
operations and maintenance

Christie Burger & Henk Hattingh
Project Engineer & General Manager
REH Operations & Maintenance
South Africa
Application rather than Perfection
All models are wrong but some are useful

George E.P. Box
Hydropower Plant Operations &
Maintenance
How to use O&M as the leveraging factor to increase
generation revenue by making reference to a WMO
benchmarking technique and world class practices.
Background on REH
REH is the only hydro-group in South-Africa to
develop, own, and operate its hydro-plants.
REH has been active since 2003 and raised R500
million in project financing to date.
Current Assets
Sol Plaatje 2.3 MW Merino 3.7 MW
Stortemelk 4.5 MW
REH Asset Summary
Installed O&M
Power Plant COD Generation M&E Contractor
Capacity Contractor
Sol Plaatje Nov-09 2.3 MW 16 GWh BFL (India) REH O&M
Merino Aug-10 3.7 MW 25 GWh BFL (India) REH O&M
Stortemelk Jul-16 4.5 MW 28 GWh Andritz (Austria) REH O&M
Integrated Hydro Model
Weighted Maintenance Objects
(WMOs)
The WMOs concept is based on the principle that the

complexity of the technical assets of a Hydropower
Plant is the primary O&M cost driver.
The WMO analysis allows comparison between

different sized and technology Hydropower Plants on an
equal basis.
WMO Complexity Assessment
Hydropower Plant Complexity (WMO)
WMO Benchmarking Technique
The WMO Benchmarking Technique bridges the
inherent complications when comparing unique
Hydropower Plants.
Benchmarking Graph
Bethlehem Hydro Benchmarked
An external audit and technical capacity building
program was initiated by Norfund and REH in 2015.
The audit indicated a benchmarking score for REH
O&M of 13.2 kUSD/WMO for the operation of
Bethlehem Hydro (April 2015).
The O&M performance, based on a benchmarking

score of 13.2 kUSD/WMO and annual availability
of 98%, was regarded as Almost a World Class
Organization according to the Norwegian
Consultant.
Benchmarking Results
Benchmarking Results
Now that we can quantify our O&M performance, how

do we improve?
What is world class O&M?
World Class O&M can be defined as the following:

Zero Lost Time Injuries
More than 98% technical availability
A never-ending chase for revenue/ cost margins
No breaches to internal and external regulations
Plans, analysis and documentation for core activities
A WMO cost level at, or below Nordic average
year after year after year after year.
The Path to Best Practice/World Class
O&M
World Class O&M
ASSET MANAGEMENT PLAN
Asset Management
Plan
Introduction
Process
Planning Framework
Life Cycle Managm
GENERATION & TRANSMISSION ASSETS
Plan
Example
Performance Planning
RAV CMMS RCM

RISK AND VULNERABILITY COMPUTARIZED RELIABILITY CENTERED
ASSESTMENT MAINTENANCE MAINTENANCE
KPI MANAGEMENT SYSTEM OPEX OPTIMIZATION
GWH
%AVAILABILITY
%RELIABILITY
RCA
ROOT CAUSE ANALYSIS
$/WMO
RISK & ASSET CONDITION
LCCA
LEVEL LIFE CYCLE COST ANALYSIS
HSE KPI (TOOLBOX)
JOB SAFETY ANALYSIS CAPEX OPTIMIZATION
LEGAL COMPLIANCE PERMIT TO WORK
KPI - MEASURE CONDITION ANALYSIS

GWH VISUAL INSPECTION
%AVAILABILITY OPERATING CONTROLS
%RELIABILITY OFF LINE TEST
Refurbishments/Upgrading ON LINE MEASUREMENT
$/WMO
RISK & ASSET CONDITION CORRELATION ANALYSIS
LEVEL
NPV
HSE KPI
LEGAL COMPLIANCE
RISK ASSESTMENT
REFURBISHMENTS/
N UPGRADING - NEEDS??
OPERATE &
MONITOR PLAN UNAVAILABILITY COMPLY WITH
POWER OPERATIONAL
GENERATION STANDARDS
Business Plan Asset Management Plan (AMP)
The AMP shall include overall processes required for
managing the assets.
Business Management Documentation System(BMDS) -
(Integrated Management System)
Business Plan
KPI/Goals
Operation and Maintenance Strategy
HSE in an Operational phase.
Risk And Vulnerability Assessment (RAV)
Root Cause Analysis (RCA)
Reliability Centered Maintenance (RCM)
Maintenance Strategy
Choosing the correct maintenance strategy has a direct impact

on cost effective operations and directly influences the assets
useful life.
REH adopted the Reliability Centred Maintenance Strategy
Consequence Matrix, to determine the probability and

severity of failure.
Maintenance may take a

condition based, preventative, or run
to failure approach.
Reliability Centred Maintenance
REH Operations & Maintenance: Consequence Matrix (Sol Plaatje)
Likelyhood
Very High More than once a year More than 70%
High Once/1 to 3 years Between 30% to 70%
Medium Once/3 to 20 years Between 5% to 30%
Low Once/20 to 100 years Between 1% to 5%
Very Low Once/100 year + Below than 1%
IMPACT
Small Moderate Major Severe
Injury/illness with Injury/illness with Injury leads to permanent Event leads to fatality
minor absence or short extended temporary disability
temporary disability disability
Safety
Minor on-site damage Minor off-site damage. Moderate off-site damage. Major off-site damage.
Environment Resititution time < month Resititution time < year Resititution time > year
Moderate local impact. Major local impact, Major national impact. Criminal proceedings
May cause project moderate regional impact. Threaten position of against REH top managers.
delay or require May cause procject company in country. May May efect possibility to
disciplinary action. cancellation or production lead to criminal charges continue as company.
Reputation, stop. May lead to criminal against senior management
charges against local senior or widespread fraud by local
CSR, ethics management. management.
< 10 kUSD 10 - 15 kUSD 15 - 25 kUSD > 25 kUSD

Direct Cost
< 200 MWh 200 - 350 MWh 350 - 600 MWh > 600 MWh
Availability
Maintenance Strategy
Component Maintenacne Action Mitigation
Type
Generator CBM Vibration tests Adapt measurement
Infrared scanning frequency according
Oil Analysis to condition.
Transformer CBM Gas schematic Adapt measurement
frequency according
to condition.
Turbine Hub Preventative Seal replacement Scheduled
Oil exchange replacement
LOS Filters Preventative Filter Replacement Scheduled
replacement
Cooling water Run to Fail Visual nspection Spare pump in stock
pump
Cabling Run to Fail Inspection Readily available
Condition Based Maintenance
Gas Schematic Analysis
Tests:
PCBs
Furan
Water
kV
Acidity
DGA
FURAN Analysis (Transformer)
Analysis (Transformer)
Preventative maintenance
Scheduled maintenance &
inspections
Visual inspection
Measuring of clearances
Oil replacement
Seal replacement
Condition monitoring
Light Analysis
Identify equipment as per maintenance strategy
Method of monitoring (oil analysis, thermal imaging, vibration
monitoring etc.)
Parameters as per manufacturer's specification
Convert the data into a life curve model
Data to be summarized into a high level Light analysis Report
Maintenance gates
Intake Structure
Cooling System
Hydraulic unit
Overall Plant
Transformer
Power Plant
Switchgear
Generator
Condition
Gearbox
Turbine
Merino 11/2015
Sol Plaatje 04/2016
Stortemelk
The Bottom Line
Increase seen in the Ratio of Generational Revenue

to Operational Expenditure.

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Benchmarking tool for small hydropower

operations and maintenance

All models are wrong but some are useful

Sol Plaatje 2.3 MW Merino 3.7 MW

The WMOs concept is based on the principle that the

The WMO analysis allows comparison between

The O&M performance, based on a benchmarking

Now that we can quantify our O&M performance, how

World Class O&M can be defined as the following:

RAV CMMS RCM

KPI - MEASURE CONDITION ANALYSIS

Choosing the correct maintenance strategy has a direct impact

REH adopted the Reliability Centred Maintenance Strategy

Consequence Matrix, to determine the probability and

Maintenance may take a

Very High More than once a year More than 70%

High Once/1 to 3 years Between 30% to 70%

Medium Once/3 to 20 years Between 5% to 30%

Low Once/20 to 100 years Between 1% to 5%

Very Low Once/100 year + Below than 1%

< 10 kUSD 10 - 15 kUSD 15 - 25 kUSD > 25 kUSD

Sol Plaatje 04/2016

Increase seen in the Ratio of Generational Revenue

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