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Digitizing Plant MaintenanceEmpowering the next generation
Dr Ricky Swanepoel
Chief Technologist, Eskom Holdings, South Africa
EPPEI Eskom Power PlantEngineering Institute
A number of challenges confront Eskom, African and global power
utilities
Utilities are struggling to maintain operational
performance and production capability with ageing infrastructure and
reduced operational budgets.
An ageing workforce and loss of critical skills.
Balancing workforce number reduction with increased
productivity and capability retention.
An urgent need to fast track engineering competency and
capability.
Workforce training preferences have significantly changed with
incoming generations of new workforce participants.
The focus is now on democratised learning with networks of specialisation,
collaboration and flexible (and virtual) delivery.
Changes in operating and business models in the
power utility space indicates a significant and rapid shift towards renewable energy
and smart generation options.
When your desire to change is greater than your desire
to stay the same
The desire to run the plant at the
highest, most cost-effective efficiency
and reliability
The desire to enable on-demand access to plant design basis information to make better and more
informed decisions
The desire to build and commission plant in a
more efficient, productive and cost-
effective manner
The desire to optimally maintain the plant
using condition based maintenance
strategies and best practice maintenance
methods
The desire to train and deploy operators that
can deal with the challenges of highly complex plant and
systems
The desire to naturally and
seamlessly embed safety, health
environmental and quality practices in
business operations
When you believe there is a better way
‘‘Education is the most powerful
weapon which you can use to change
the world.”Nelson Rolihlahla Mandela
18 July 1918 - 5 December 2013
“What is important is to have faith in people – they’re basically good
and smart and if you give them tools, they’ll do wonderful things
with them”Steve Jobs
Welcome to the new world of knowledge management,
virtual training and blended learning
The basic concept…
• Learning on demand.
• “Pull” instead of “push” learning.
• Information on demand – only what you want to know NOW
• Leveraging “Digital Twin” information and integration
• Leverage “data lakes” information by selectively building “knowledge hubs”.
• Visual access and navigation.
• Virtual and flexible – “anywhere on demand”.
Knowledge Principles
Design Basis
Lethabo Power Station
Simulations Plant Data History
01NM30D001 – Mill 1C
System Description
Design Philosophy
Drawings
Datasheets
Operating Technical Spec
Maintenance Basis
System Manuals
Life of Plant Plan
Technical Plan
Outage Philosophy
Test & Inspection Plan
3D Models
Reliability Basis
Procedures & Instructions
Design Basis
Lethabo Power Station
Simulations Plant Data History
01NM30D001 – Mill 1C
Rankine Cycle Model
Flow Simulations
CFD Simulations
Outage Simulations
Project Schedule Simulations
Operating Scenario Simulation
Maintenance Task Simulation
Design Basis
Lethabo Power Station
Simulations Plant Data History
01NM30D001 – Mill 1C
Plant Data Store (PDS)
Performance Trends
LTPH Indicators
Plant Historian
Condition Monitoring Data
RMDC Assistance
Plant Health Reports
Design Basis
Lethabo Power Station
Simulations Plant Data History
01NM30D001 – Mill 1C
Plant Data Book
Occurrences
Modifications
Maintenance History
Operating Log (FLIP)
Temporary Alterations
Specific Instructions
Outage History
Risk Analysis
Waivers & Exemptions
Certificates of Compliance
Technical Reports
Questions
