Application of R.C.M. type Maintenance Methodology within Eskom Distribution

1. Application of R.C.M. type Maintenance Methodology within Eskom Distribution Presenter: Peter Busch

2. Background Eskom The Company At 31 March 2005: • Nominal capacity – 42 011 MW • Power lines (all voltages) – 347 204 km • Coal burnt – 136,4 Mt • Revenue (Company) – R41 387m • Total sales – 256 959 GWh • Sales to countries in southern Africa (Transmission and Distribution) – 16 008 GWh • Peak demand on integrated system – 34 195 MW • Total assets (Company) – R104 994 million • Employees – 29 845 • Customers – 3 603 943

3. International Comparisons Sales Rating Country TWh by sales RAO-UES Russia 636 1 EDF France 473 2 E.On. Germany 404 3 KEPCO South Korea 294 4 TEPCO Japan 281 5 RWE Energie AG Germany 230 6 Eskom South Africa 206 7 Vattenfall Sweden 186 8 Eletrobras Brazil 178 9 Hydro Quebec Canada 169 10 Taiwan Power (TaiPower) Taiwan 159 11 Enel Italy 156 12 TVA USA 155 13 Kansai Electric Power Co. Japan 142 14 Electrabel Belgium 137 15 Endesa Spain 134 16 Chubu Japan 123 17 AEP USA 118 18 AES USA 108 19 USA 103 20 FPL Company

4. International Comparisons RAO-UES Russia 156 600 1 EDF France 122 600 2 Tepco Electric Power Co Japan 62 660 3 E.On Germany 54 000 4 KEPCO Korea 50 432 5 Enel Italy 47 000 6 AES USA 46 000 7 RWE Energie AG Germany 45 000 8 Endea Spain 43 000 9 Eletrobas Brazil 40 854 10 Eskom South Africa 39 810 11 Southern USA 39 000 12 Duke USA 38 748 13 Exelon USA 38 000 14 AEP USA 36 000 15 Kansai Electric Japan 35 434 16 Hydro Quebec Canada 34 000 17 Taiwan Power (TaiPower) Taiwan 33 290 18 TVA USA 33 189 19 Vattenfall Sweden 33 000 20 Generation capacity MW Rating by capacity Company Country Source: Data Monitor UK 2004 figures

5. Background Eskom The Company • Eskom is Africa’s largest Electricity Utility generating 60% of Africa’s electricity. It has 5 divisions, which are the following: Generation, Transmission, Distribution, Eskom Enterprises and Corporate. • Eskom Distribution is divided into 6 Regions covering all of geographic South Africa. Each Region is divided into a number of geographic areas where area staff makes use of a computerised maintenance management system to implement maintenance strategies. Within Eskom there is a lot of staff movement at this level and therefore a skill shortage as well as experience is in short supply.

6. Background Eskom The Company • Within Eskom Distribution there are approximately 4000 High Voltage Substations from 132kV to 33 kV spread around South Africa. The Substations contain approximately 4500 Power Transformers with 99 different makes and types of Tap Switches. 45000 Circuit Breakers of 400 different makes and types. 10500 M.V and H.V. lines. Eight different voltage categories are used from 132kV down to 3,3kV.

7. The Maintenance Hierarchy within Eskom Distribution National Maintenance Policy for electricity networks NRS 082. NRS 082 (1.1) 10 02 2005.doc used by the N.E.R. • Eskom maintenance policy. maintenance policy.pdf • Eskom Maintenance planning directive. • Eskom Distribution Standards per equipment type. Standard for maintenance of circuit breakers.pdf • Eskom Job Plans per maintenance intervention per Make and Type of equipment. • Eskom Work Instructions per maintenance intervention per Make and Type of equipment.

8. Maintainable Equipment • Equipment complexity. • Equipment completely automated, Under fault conditions equipment has to be removed from the fault within less than 100 milliseconds normally within 35 milliseconds. • Equipment loadings and switching control centralized. • Decentralization of equipment around the country. • H.V. Substations approximately 4000 • Power Transformers 1MVA and above approximately 4500 There are 99 different makes and types of tap changers. • H.V. Circuit Breakers approximately 45000. There are 400 different makes and types of H.V. circuit breakers which employ 4 different rupturing mediums and 5 different energy sources drive the mechanisms. • M.V. and H.V. Lines approximately 10500 • Etc.

9. Issues around skilled staff in the Industry Skill shortage experienced. • New labour entrants need experience. • Skilled staff centralized within regional offices as well as national offices. • Complex equipment de-centralized. • Technical Service Groups centralized regionally as well as nationally.

10. What strategy to follow A pure RCM pilot study was done at Brackpan North, a Substation to the East of Johannesburg. • Costing of various solution. • Decision on maintenance strategy solution. • A modified “RCM” type study to be implemented.

11. Equipment and work group format Equipment divided into groups of expertise ie. Transformers, Circuit Breakers, Cables, D.C. Batteries, Low Voltage etc. • Centralized modified “R.C.M.” studies done. • Regional representation on Work group. • National specialists on Work group.

12. Requirements for easy to use Software The software package should be user friendly. • R.C.M. knowledge by the user not required. • Experience not required by user. • Applicable to all Geographic areas. • Applicable to all network requirements. • Applicable to all customer loads.

13. Software Package Market was investigated for suitable software. • All maintenance planners have Microsoft office suite. • Written in Microsoft Access. • Results of work group studies populate tables. • Queries run on tables returning maintenance strategies depending on the options of the maintenance planner.

14. Transformer study • Transformer FMEA studies. PowerTrfr RCM Template(Prelim Findings).xls • Transformer RCM decision diagram. Decision work sheet.xls • Criticality scores. Criticality Analyses Questionaire.xls • Dissolved Gas analysis. DGA cost analysis for Transformers.xls • Software DDMMT SOFTWARE.mdb • Software Demonstration and Training Tool • DT Maintenance management tool_30_01_2007.EXE

15. Questions • Any Questions?