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O&M and Analytics Services Case Study I Introduction to O&M
Disclaimer The information contained in this document is the proprietary and exclusive property of Mahindra SustenPvt. Ltd. (MSPL) except as otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of MSPL. The information contained in this document is subject to change without notice. The information in this document is provided for informational purposes only. MSPL specifically disclaims all warranties, express or limited, including, but not limited, to the implied warranties of merchantability and fitness for a particular purpose, except as provided for in a separate license agreement.
Introduction to O&M O&M Responsibility Duration Levers to deliver Owner Expectations Maximised generation 3 Months Robust Design 1 The Core responsibility of the team is to Operate and Maintain the plant to deliver guaranteed plant performance during the O&M period and delight the Customer. 6 Months 2 Quality Execution Longevity of plant life Maintenance Operations 6 0 – 120 Months 3 Efficient O & M • Plant Supervision • Performance Monitoring • Security • Plant Operation • Energy Forecasting • Planned Downtime • Performance Engineering • Trend Analysis • Cleaning Cycle Planning • Failure Detection • Spare Part Management • Guarantee • Plant Availability • Performance Ratio • Compliance • Reporting • Generation • Failures • Safety • Plant Maintenance • Scheduled • Preventive • Conditional • Break-Down • Services • Module Cleaning • Weed Removal • Waste Management Proper plant up-keep to ensure streamlined plant operations • O&M is a long term association with the Customers
Maintenance Activities- Key Responsibilities Breakdown Maintenance Attending to equipment which has tripped or is in breakdown due to abnormal conditions Predictive Maintenance Real time plant remote monitoring to ensure avoid and alert in case of a breakdown or failure. • Preventive Maintenance • Routine inspection and servicing of equipment • Timely and proper maintenance to ensure maximised plant uptime
Preventive Maintenance Keyparameters: Routine inspection Pre-defined schedule Can be scheduled or need-based Key drivers : OEM guidelines – Conforming to manufacturer recommended guidelines and frequencies Past Experience - Benchmarked to past failure track record Plant Specific Factors - Equipment type, environmental conditions like - dust levels, humidity, seasonal variations Conditional Maintenance – Testing of equipment to identify the current level of KPIs and then decide upon the need for preventive maintenance • Optimised maintenance schedules for efficient on-site O&M
Breakdown Maintenance Key parameters: Equipment repair post failure Reactive in nature Ensure reduced response time to reduce plant downtime Key drivers : Breakdown impact analysis- Manage critical spares depending upon the impact on down-time caused due to equipment breakdown Contract Management - Manage Contracts and SLA’s to ensure back to back warranty and quick response Clustered Spares- Take advantage of scale to optimise spares and invest in higher % of spares in the central locations • Quick troubleshooting for minimal downtime post failure
Predictive Analytics Key parameters: Real-time plant performance monitoring and analysis Proactive identification Instant alerts and reduced equipment failure Ensures reduction in plant downtime Experienced team to assist in remote troubleshooting Historical trend analysis and insights Key Drivers: Data analysis - Detailed analysis of plant performance data to predict future trends and potential failures Investigation and experiments- Post failure Root cause analysis (RCA) and Preventive action (PA) Equipment Benchmarking- Inter and Intra plant Benchmarking across equipment makes and type for maximising the generation • Proactive response to enhance plant performance and longevity
O&M Key Challenges and Mitigations • Indian O&M Scenario calls for plant specific, dynamic, and localised solutions
Mahindra Susten Best Practices IMS Processes followed and complied to ISO 9001-2015 | ISO 14001-2004 | OHSAS 18001-2007 3 Dimensional SOPs focussing on Quality | Safety | Environment Operation Excellence – Continual improvement cycle Job Authorization for Skill Development Cluster based Spares (including transformers) Soiling analysis Operations In-house HT Testing team Specialised testing equipment Breakdown Impact analysis Experience across multiple makes of Equipment Maintenance Real time monitoring and trouble-shooting by domain experts with real time support to On-Site team Plant Health check-up Trend Analysis Analytics • Adhering to standards to ensure enhanced plant availability
Mahindra Susten Track Record Portfolio Level Performance Results • Portfolio size to reach 1GW by FY17 • Plant Uptime 99.5%across portfolio Operations • More than 800days MTBF for 2 plants • 1.8 Million Safe working man-hours Maintenance • Performance Ratio across portfolio above 104 %of guaranteed PR Analytics • Track record of setting Industry Benchmarks
Thank you Visit us at: www.mahindrasusten.com/o-and-m.php For questions Sandeep Jadhav Head, O&M jadhav.sandeep@mahindra.com AbhayTilwankar Head, Performance Analytics, O&M tilwankar.abhay@mahindra.com Ruhi Gupta Manager, Strategy, O&M gupta.ruhi@mahindra.com If you found this reading useful, please follow us for more information and similar publications Copyright ©2016 Mahindra SustenPvt. Ltd.. All Rights Reserved.