Transcript 2588_RWE Power

How RWE is benefiting from
its collaboration with SKF
as a solution provider
Dr.-Ing. Bruno van den Heuvel
RWE Power AG
Head of Diagnostics & Technical Services
SKF Capital Markets Day 2014
London
RWE today: One of the leading European utilities
Key figures 2013
EBITDA (€ million)
7,904
Operating result (€ million)
5,369
Workforce
Key figures
64,896
EBITDA (€ million)
4,378
2,455
Operating result (€ million)
3,275
1,384
17,583
16,311
Workforce
RWE AG
RWE
AG
RWE Innogy
Management and support
functions
RWE Generation SE
~ 2,000 FTE
Total> 17,000 FTE
Hard coal,
natural gas,
biomass
Nuclear
energy
Hydro
power
2012 2013
Lignite
Technology
~ 250 FTE
~ 7 GW
~ 3 GW
~ 2 GW
~ 11 GW
Opencast
mines
~ 1,000 FTE
~ 1,600 FTE
~ 150 FTE
~ 2,800 FTE
~ 5,100 FTE
Processing
Planning &
service
~ 900 FTE
~ 600 FTE
FTE:
Full-time employees
~ 10 GW
~ 1,800 FTE
~ 7 GW
~ 900 FTE
2013: 98.3 mill. mt lignite
466 mill. m3 overburden
RWE Power AG Dr. van den Heuvel 17.07.2015
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Opencast mining at RWE
20 bucket wheel excavators
High-capacity mining equipment
& belt conveyors
(Replacement value of lignite
production equipment ~ €7.5 billion)
About 250 km belt conveyors
Total capacity installed: 925 MW
20 spreaders
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Lignite mining and transportation to the power plants
Lignite seam in the Hambach mine
Lignite stockpile in the Hambach mine
Train loading in the Hambach mine
Company-owned
railway system
Lignite stockpile in the Neurath
plant
RWEpower
Power AG Dr.
van den Heuvel
17.07.2015
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Maintenance at RWE Opencast Mines
2004
1995
Focus:
Focus:
Focus:
Availability
Cost cutting
efficiency enhancement
Asset management:
Primary cost at RWE lignite
mines 2013: €1000 mill.
Production
€357 mill.
€80 mill.
Energy
Maintenance
 Life-cycle cost
 Overall equipment effectiveness
 Total cost of ownership
Life-cycle cost of mining equipment
€350 mill.
€163 mill.
Depreciaton
Maintenance is a
core business
Maintenance is a core competence
for RWE
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Maintenance is RWE's core competence
> We decide on our maintenance strategies and activities
> We perform maintenance ourselves and learn from failures
> We (not our OEMs) continuously improve life cycle cost
> We choose our suppliers based on life cycle cost
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Maintenance is RWE core competence
Our needs, demands and expectations:
> Reliable products for sustainable and reliable operation
> Deep understanding and detailed knowledge of our special
assets and operating conditions
> Technical support and solutions for our special assets and
operating conditions
> Excellent delivery performance
> Continuous improvement
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Rolling bearings in RWE opencast mines
Approximately 1 500 000 bearings in operation
app. 1 200 000 bearings  100 mm
38 bearings  21 000 mm
Slewable
superstructure
Substructure with
crawler tracks
The performance of bearings and bearing systems is of
great importance for reliable and cost-effective operation
Slewing
rim
!
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Bearing failures and their root causes
Most common root causes of bearing failures
Lack of lubricant
Contaminations
Unsuitable
lubricant
Assembly faults
and consequential errors
Inappropriate
bearing selection
Aged lubricant
Reference: Dethloff, AKIDA 2002
“Most bearing failures are
not due to the bearing, but
to something wrong in its
environment”
Material or manufacturing fault
(bearing manufacturer)
?
Experiences
gained at
RWE Power
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Bearing failures and their root causes
Lack of lubricant
Contaminations
Unsuitable
lubricant
Assembly faults
and consequential errors
Inappropriate
bearing selection
Aged lubricant
Experiences gained at
RWE Power
Material or manufacturing fault
(bearing manufacturer)
> We are responsible
> We need good components around the bearing
> We need competent support from a reliable partner
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The rolling bearing:
Just a mechanical component, or a system?
Mercedes C63 AMG, 487 hp
http://de.autoblog.com/2012/01/15/ verrucktsupercar-drift-auf-4-notradern-video/
with emergency spare wheels
Our needs and demands:
Components and services combined as
part of the overall system
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Using SKF Solution Factory for easy
access to SKF's knowledge and offerings
RWE
Solution
Demand
SKF platforms
Sales
SKF
SKF
Solution
Factory
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RWE – SKF: Examples of a valuable cooperation
Engineering consultancy and service
– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
 Seals
 Lubrication systems
 Mechatronics
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Typical belt conveyor drive station (8 MW driving power)
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Benefiting from simulation and design validation
SKF solution:
 Engineering consultancy provides
design validations and significant design
improvements using e.g. a calculation tool
for analysing the kinematics of components
in cylindrical roller bearings
SKF
Roller centred
brass cage
Pierced rollers
and pin cage
Benefit for RWE:
> Extended rating life
> Significantly extended service life
> Substantially reduced life-cycle cost
Source: SKF Report: Dynamische Lageruntersuchung von Zylinder-rollenlagern für
innengelagerte Bandtrommeln der RWE Power AG
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RWE – SKF: Examples of a valuable cooperation
Engineering consultancy and service
– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
 Seals
 Lubrication systems
 Mechatronics
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Maintenance strategies (DIN 13306)
DIN 13306: Reactive (repair of damage)
DIN 13306 Preventive (prevention of damage)
Failure-based
Time-based
Condition-based
Repair after malfunction occurs
Fixed intervals for maintenance
measures as a function of the
components’ operating hours
Maintenance depends on
condition assessment /degree
of wear
At RWE maintenance consists of several maintenance strategies
and is defined separately for each machine!
Failure-based
Time-based
Condition-based
Idlers
Railway
Bucket-wheel drive
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Selection of suitable maintenance strategies
SKF solution:
SKF RCM Reliability Centered Maintenance
Benefits for RWE:
> Best strategies according to reliability, risk,
costs and profit, based on our maintenance
experience
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RWE – SKF: Examples of a valuable cooperation
Engineering consultancy and service
– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
 Seals
 Lubrication systems
 Mechatronics
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Condition monitoring and diagnostics for reliable
production planning
SKF solution:
 Structure-borne, sound-based machinery diagnostics on gear units and drivelines
Data acquisition
Time signal of vibration acceleration
via 'Information'
Data mining
Generation of information
to 'Decision'
Deduction of right
maintenance decision
Signal processing and
conditioning
Beschl. [mg]
Pitting
from 'data'
Vibration level acceptable
Event
no activities
Frequency [Hz]
Benefits for RWE:
> Identify and solve problems before they become serious
> Significantly reduced unplanned downtime
> Significantly reduced consequential damages
> Substantially reduced life-cycle cost
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Preventing failures of an induced draught fan
SKF solution:
> New housings, unique sealing and
lubrication system
> Online condition monitoring system
for early detection of upcoming
failures
Benefit for RWE:
> Increased operational availability
> Significantly extended service life
> Substantially reduced life-cycle cost
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RWE – SKF: Examples of a valuable cooperation
Engineering consultancy and service
– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
 Seals
 Lubrication systems
 Mechatronics
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Alignment of track rollers of rotary tube dryers
Benefit for RWE:
> Extended bearing service life
> Higher performance and availability
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Ensuring accuracy of flange flatness
Erection and installation of 6 MW offshore wind turbine
Benefit for RWE:
> Mobile application
> Control and documantation of quality
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Analysing slewing rims in bucket wheel excavators
Inspection after 30 years of operation: Are the balls reusable or scrap?
SKF solution:
> Radiographical examination of residual stresses
> Scanning electron microscopic examinations of the surface
Results:
• No typical rolling fatigue
• Repair is possible
• Necessary metal removal rate: 0.2 mm
Benefit for RWE:
> Significantly reduced life-cycle cost
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RWE – SKF: Examples of a valuable cooperation
Engineering consultancy and service
– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
 Seals
 Lubrication systems
 Mechatronics
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Remanufacturing of bearings
Since 1980: cleaning, polishing, preserving,
packaging, stocking of bearings for conveyor
drums by RWE Power's Maintenance &
Engineering Center
SKF solution:
 Remanufacturing (since 2004)
Benefit for RWE:
> Recycling-rate significantly increased
> Life-cycle cost substantially reduced
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RWE – SKF: Examples of a valuable cooperation
Engineering consultancy and service
– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Maintenance services
– Remanufacturing
 Seals
 Lubrication systems
 Mechatronics
RWE Power AG Dr. van den Heuvel 17.07.2015
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Bearing failure after severe grease contamination
Operating time: 34 months
Analysis of lubricant/grease: 99,700 mg silicon/kg
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Sealing solution to prevent severe grease contamination
SKF solution:
 New tailor-made unique sealing
system for the non-locating bearing of
the bucket wheel shaft
Benefits for RWE:
> Increased operational availability
> Significantly extended service life
> Substantially reduced life-cycle cost
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Why SKF?
What do we value at SKF?
> High-quality products for sustainable and reliable operation
> Offering of services and solutions
> Knowledge about bearing systems and knowledge of RWE's assets, needs
and special operating conditions
> High service level
> Excellent delivery performance
Conclusion:
 SKF meets RWE's needs, demands and expectations
 SKF is the preferred supplier for bearings and related products
 SKF is RWE's strategic partner for delivering sustainable and added
value
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The rolling bearing:
Just a mechanical component, or a system?
http://cloudlakes.com/data_images/models/mercedesbenz-c63-amg/mercedes-benz-c63-amg-13.jpg
Perfect system! Excellent performance!
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A valuable cooperation built on trust
between RWE and SKF:
The sustainable recipe for success!
THANK YOU FOR YOUR ATTENTION