GRDA Expands Utilization of Maximo to its New Combined ... · Maximo to its New Combined Cycle Unit, Hydro Plants, and Transmission Facilities. Tim Brown, Executive Vice President,

GRDA Expands Utilization of Maximo to its New Combined Cycle Unit, Hydro Plants, and

Transmission Facilities.

Tim Brown, Executive Vice President, Chief Operating OfficerGrand River Dam Authority

GRDAataglance…• Non-appropriated agency of the State of Oklahoma• Generate, transmit, and sell electricity to

municipalities, electric cooperatives, and industrial customers

• Approximately 567 full-time employees• Annual Revenue of $450 million• Net Utility Plant of $1.2 billion

1,215 miles of high voltage transmission lines

Generating Capacity:

Hydro R-O-R:

Pumped Storage:

Gas:

Customer Generation:

Coal:

Wind:

2,100 MW (accredited)

254 MW

258 MW

930 MW

142 MW

520 MW

390 MW (nameplate)

GRDA control area firm loadFirm sales, Western Farmers Electric CooperativeFirm sales, Oklahoma Municipal Power AuthorityFirm sales, Kansas Municipal Energy AuthorityFirm sales, Poplar Bluff & Paragould

GRDAGenerationPortfolio

GRECUnit3

GRECUnits1&2

GRDAGenerationPortfolio

GRDAGenerationPortfolioContinued

Redbud WindPPAs

* This includes the entire ITS facilities

Total Miles of Line:

69 kV:

115 kV: (de-energized)

138 kV:

161 kV:

345 kV:

Substations:

1,215 Miles

602 Miles

13 Miles

119 Miles

371 Miles

110 Miles

83

GRDATransmissionSystem

GRDA’sObjectivesofAssetManagementProgram

•Maintain fiscal health and strong credit rating•Maintain competitive rates•Maximize asset availability to achieve high system reliability

• Improve productivity and efficiency•Optimize asset life vs. O&M costs•Meet compliance requirements•Enhance reputation as well managed utility

HistoryofAssetManagement&MaximoatGRDA• Asset Management began at GREC out of necessity due to

complexity of operating a 1,000 MW coal facility.• Primary focus was on plant availability.

• Late 80’s, early 90’s computerized GREC inventory and preventive maintenance.

• Early 90’s developed our own Maintenance Work Order system to computerize corrective maintenance.

• Later began exploring Maximo as a comprehensive system – replaced our in-house WM application, added an AM application and tied together with parts inventory and purchasing.

• Required many hours of data entry by a knowledgeable maintenance mechanic and I&C technician.

• Required the creation of thousands of PMs.

• Completed full transition ~ 2005.

ExpansionofAssetManagement&MaximoatGRDA

As we expand our utilization of Maximo, we will be applying further enhancements:• Mobile Technology• Advanced Analytics using Cognos Reporting and KPIs• Predictive Maintenance (Condition Based Maintenance)• Safety Reporting and

tracking for incident and near miss reporting.

• Calibration and Testing• Maximo Scheduler• Backlog Management using

visual dashboards based on KPIs

ExpansionofAssetManagement&MaximoatGRDAGREC Unit 2• AM Program more important

today than ever. Although plant availability is still important, Unit 2 is no longer operated as traditional base load plant.

• Now operated at much lower CF, so objective has shifted to minimizing FOM to maintain the plant as a competitive source of capacity.

• Recent upgrade to Maximo 7.6 allows for mobile capability “Maximo Anywhere.”

• Recently began utilizing the scheduler application – already have realized significant cost savings.

ExpansionofAssetManagement&MaximoatGRDA

GRECUnit3• EmploystheMitsubishiadvancedclassM501JCT,guaranteedheatrateof~6500Btu/kWh,HHV

• WillbethelowestoperatingcostCCinSPPfootprint;Maximowillhelpensurewemaintainthisdistinction.

• PlantotakefulladvantageofMaximoAnywherefunctionalitywithwifinetworkandtablets.

• Asanewfacility,wehavetheadvantageofworkingwithourgeneralcontractortoimporttheassociated9,000assetsdirectlyintoMaximofromthecontractor’staggingsystem.

• PlantomanageLTSAinMaximo.

ExpansionofAssetManagement&MaximoatGRDAHydro• Historically,Maximohadbeenusedonlyforinventoryandprocurement;didn’thavecomputerizedAMorWMsystems.

• Immediatelyembracedbyhydromanagementbutencounteredsomeinitialresistancefromtechnicalstaff.

• AkeystaffmemberwithknowledgeofallthreefacilitieswasappointedhydroAssetManager.

• TheAssetManagerwithinputfromthePlantSuperintendentsdevelopedthehierarchyforeachplant.Thenwithmanyhoursofdataentrywithassistancefromcollegeinterns,over800locationswithover2,000assetsweredefinedandentered.

• ManyPMworkordershavebeencreatedandcontinuetobecreated.

• CMworkordersarebeingcreatedasweexperienceequipmentfailure.

ExpansionofAssetManagement&MaximoatGRDATransmissionSubstations• Historically,Maximohadbeenusedonlyforinventoryandprocurement;didn’thaveacomputerizedAMsystem.PMsweretrackedinalegacysystem.

• Hierarchyhasbeenbuiltwithlocationsandassetsforallsubstations.

• CMsarebeingenteredasincurredtodevelopahistoryforrecurringissuesoneachasset.

• PMscreatedfor6-monthinspections:e.g.,checknitrogenintransformers,transformeroil,SF6gasinbreakers,breakeroperations,etc.

• Plantotieinventorytosubstationassets;willallowcheckingofsparepartsininventory.

• Eachassetwillhaveitsownlistofrecommendedparts.

ExpansionofAssetManagement&MaximoatGRDA

TransmissionLines• Historically,Maximohadbeenusedonlyforinventoryandprocurement;didn’thavecomputerizedAMorWMsystems.

• TheexceptionisFleet,whichhasbeenusingMaximoforAMandWM.

• Walkinginspectionsevery3-yearsandaerialinspectionsforcertainlines2-timesperyear.

• CMWOsfromtheinspectionswerewrittenandfiled;nowWOsforPMinspectionsaregeneratedinMaximoandtheCMdetailsarethenenteredintoMaximo.

• Assetdatafor345kVand161kVstructureshasbeenentered.Intheprocessofentering138kVstructures.

• Alifeextensionmeasureforarustissuediscoveredon1980’svintagesteelstructuresisbeingmonitored inMaximo.

• Theprocessofenteringthelinedatarevealedproblemswithtransmissionlinedrawings:incorrectormissingdataandP&Psthathadn’tbeenupdatedwithfieldchangesovertheyears.

• SecondarybenefitoftheAMprojecthasbeenthecorrectionofthetransmissionlinedrawingswhichwillbebeneficialtotheEngineering andT&Ddepartments.

• Neededcorrectionforcorrosionon345kVstructures• --- milesoftransmissionline• --- structuresofthismanufacture

AnAssetManagementExample

• GRDAexploredchangingoutpole-topsections

• Replacedupperpolesectionson11structuresusinginternalstaffinthefallof2014

AnAssetManagementExample

Prototypebraceunitwithstooda125%bendingload

AnAssetManagementExample

Installed Brace Assembly

AnAssetManagementExample

MaximoUpgradeProcess

• In early 2016, we began the upgrade from version 7.1 to 7.6.

• GRDA’s leadership was committed to doing this right.• Knowledge transfer and training were paramount to successful

user adoption and managing change for continuous improvement.• GRDA’s IT team is relatively small so engaged a business

partner to help with the upgrade.• A software industry expert provided for best practices and assisted

with change management• Going forward goal is self-sufficiency in user support and

maintenance.• Revisited business processes and standards.• Procurement process was streamlined to ready GRDA for

an ERP implementation.

MaximoUpgradeDetails

• Custom interfaces significantly reduced by utilizing Maximo Integration Framework: Integrated systems:

• Fuel, AP, GL, People & Labor, Equipment. • 152 custom reports were migrated.• 27 custom JavaScript processes replaced with Maximo automation scripts and an additional 18 replaced with Maximo conditional expressions.

• Allowed for the removal of a third party product in favor Maximo tailoring.

• 152 security groups streamlined to 38. • Custom dashboards retired in favor of standard role based dashboards.

Upgrade=>OpportunitytoImprove

Recommendations:

• Remove Customizations where possible.• Revisit Business processes for continuous improvement

• Revisit Reporting and Analytics; what is needed?• Revisit Asset Management goals; adapt to change.• Revisit standards.• Review new product offerings; stay current.

ThankYou