2006 Annual Portfolio

Substation Preventive Maintenance (PM) and Predictive Maintenance (PdM) Program Assessment

Can a program of predictive maintenance improve system reliability while also reducing maintenance costs? Which data and analysis can predict the likelihood of equipment failure? How can you avoid unnecessary maintenance, which may actually lead to system failure?

Utilities today face demands for increasing levels of service reliability. At the same time, maintenance budgets are being reduced or held constant while senior personnel retire. As a result, more utilities are requesting help to modify their maintenance basis by developing a best practice preventive maintenance (PM) and predictive maintenance (PdM) program. A PdM program moves from time-based to condition-based maintenance so that expenditures can be targeted to the most critical components or systems. A comprehensive PdM program complements existing online monitoring systems, and can streamline maintenance practices, reduce unnecessary repair/replacement costs, avoid equipment failures and system outages, and improve system reliability. In addition, recent failures of switchyard/substation equipment have resulted in nuclear plant shutdowns and/or load reductions. These equipment reliability issues resulted in the issuance of a Significant Operating Experience Report (SOER-99-1) and a draft report (SOER-20023). Many generating station organizations across the U.S. nuclear industry are in the process of reviewing the SOERs and evaluating maintenance responsibility and program initiatives as applied to switchyard/substation components. Effective PM and PdM programs are critical to ensuring the reliability of the switchyard.

Our Approach
EPRI Solutions has a comprehensive knowledge base in the technology application, program development, and data interpretation areas of substation PM and PdM. We have captured maintenance benchmarking data and experience through years of application services. In addition, we constantly revise and update this knowledge based on new information and developments. EPRI Solutions experts guide utility personnel through each step of the assessment process, including the on-site training.

Substation Preventive Maintenance (PM) and Predictive Maintenance (PdM) Program Assessment

PM and PdM Program Assessments

EPRI Solutions experts guide the clients maintenance team through a comprehensive assessment of their organizations current PM and PdM policies, procedures, programs and technology applications. These system-specific maintenance procedures are compared to EPRI Solutions database of industry acceptable and best practice maintenance practices and standards. We assess all aspects of the current nuclear plant and/or substation PM and PdM programs as applied to switchyard/substation components. EPRI Solutions uses a Maintenance Excellence Matrix to guide utilities through the process of identifying gaps between their current practices and best practices that prevent the organization from achieving optimum performance. The matrix also helps to identify the practices and technologies that will close those gaps. As utilities work through this matrix, the results are plotted in spider charts, which illustrate the organizations ranking compared to world class/best practice performance and pinpoint specific opportunities for improvement. EPRI Solutions team of PM and PdM program experts map into spider charts the 14 key elements of a PdM program (per the EPRI PdM Guidelines) and the 10 key elements of a PM program as applicable for your organization (see Figures 1 and 2).

Figure 1. Predictive Maintenance (PdM) Program Spider Chart (example)

Equipment Condition Indicator Matrix Continuous Improvement Customer Satisfaction 10 8 6 Metrics/Cost Benefit Tracking 4 2 0 Financial Basis/Plan Organization/Roles & Responsibilities Charts PDM Coordination/ Leadership Technology Application PDM Work Process

World Class

Quantifiable Goals Schedule Training & Qualifications

Communication Formats Equipment Condition Status Report

2006 Annual Portfolio

Substation Preventive Maintenance (PM) and Predictive Maintenance (PdM) Program Assessment

Figure 2. Preventive Maintenance (PM) Program Spider Chart (example)

Preventive Maintenance Process/Procedures Continuous Improvement (PAM Process)

10 8 6
Maintenance Task Basis

PM Program Metrics

4 2 2 0 0

Organization/Roles & Responsibilities Charts

World Class
Management Support /Leadership

PM Task Closeout/ data capture

Technology Utilization Communication Formats

Accountability

The Maintenance Excellence Matrix and associated spider charts serve as the cornerstone for the assessment and the high-level dashboard capturing the current condition of the PM and PdM programs. EPRI Solutions develops an independent evaluation report that includes observations and specific recommendations for improvement activities for each of the appropriate elements and the respective key sub-elements as delineated in the Maintenance Excellence Matrix and spider charts. Two EPRI Solutions experts spend 4.5 days on site at the clients facility evaluating your current PM and PdM programs. Participation by key client personnel is required to ensure our experts have access to the personnel and information required to evaluate the current PM and PdM programs. The concentration of effort is adjusted to meet the clients specific needs.
Training

The EPRI Solutions expert team conducts a half-day Level-ofAwareness Training for the on-site PM and PdM teams. We train personnel in the possible structure and appropriate elements of a comprehensive PM and PdM program.

2006 Annual Portfolio

Substation Preventive Maintenance (PM) and Predictive Maintenance (PdM) Program Assessment

Benefits
EPRI Solutions assessment approach is designed to gain support from the key organizational stakeholders on both the critical issues and the improvements required. Follow-on program improvement implementation plans can yield the following results:

Reduced operations and maintenance expenses as high as 60% Improved manpower utilization as high as 40% Improved equipment availability improvements as high as 50% Improved productivity as high as 40% Return on investment in less than one year Significantly higher percentage of planned versus unplanned maintenance tasks Significantly higher percentage of condition-based maintenance tasks Structured work-week management

The Maintenance Excellence Matrix and associated spider charts serve as the cornerstone for the assessment and the high-level dashboard capturing the current condition of the PM and PdM programs.

Effective use of the maintenance management system as a

maintenance tool
Reduced unnecessary repair/replacement costs

Deliverables
EPRI Solutions Program Assessment provides the client with the following deliverables:

Comprehensive detailed assessment report with findings and recommendations for improvement Level-of-Awareness Training in the elements and structure of a comprehensive PM and PdM Program PdM program assessment with strengths and improvement areas within an organizations functional groups PM program assessment with strengths and improvement areas within the organizations functional groups A list of the organizational issues and objectives related to departmental cooperation, coordination, and communication Identification of technical areas in which technology application can improve organizational program effectiveness

2006 Annual Portfolio

Substation Preventive Maintenance (PM) and Predictive Maintenance (PdM) Program Assessment

Pricing
The investment required for EPRI Solutions Substation PM and PdM Program Assessmenta 4.5-day, on-site program assessment, half-day training, and associated off-site effortis $46,000.

Assumptions
The assessment price is based on the following conditions and assumptions:
The client provides adequate meeting facilities for on-site

engagements, scheduling of critical personnel, and limited administrative support.

The client designates a primary contact for the organization to

communicate with EPRI Solutions staff.

The effort is funded commercially, via an EPRI Solutions Services

Agreement, and is subject to the associated Terms and Conditions.

About EPRI Solutions

EPRI Solutions offers an integrated portfolio of engineering services, business consulting, and information productshelping energy utilities and other organizations around the world improve operational efficiency, enhance customer satisfaction, and increase profitability. EPRI Solutions' services and products leverage our unique laboratory facilities and in-depth knowledge of industry best practices, along with the science and technology resources of our parent organization, the Electric Power Research Institute (EPRI).

Contact
For more information on EPRI Solutions Substation PM and PdM Program Assessment, please contact: Mark Ostendorp, Director tel 817-234-8213 mostendorp@eprisolutions.com EPRI Solutions, Inc. info@eprisolutions.com www.eprisolutions.com

EPRI Solutions, Inc.

2006 Annual Portfolio