How RWE is benefiting from its collaboration with SKF as a solution provider
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How RWE is benefiting from its collaboration with SKF
as a solution provider
Dr.-Ing. Bruno van den HeuvelRWE Power AG
Head of Diagnostics & Technical Services
SKF Capital Markets Day 2014
London
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PAGE 2RWE Power AG Dr. van den Heuvel 19.04.2023
RWE AG
FTE:Full-time employees
RWE Generation SE
Total> 17,000 FTE
Management and support functions
~ 2,000 FTE
TechnologyLigniteHydro power
Nuclear energy
Hard coal, natural gas,
biomass
~ 250 FTE
~ 600 FTE~ 900 FTE~ 5,100 FTE~ 2,800 FTE~ 150 FTE~ 1,600 FTE~ 1,000 FTE
Planning & serviceProcessing
Opencast mines
~ 11 GW~ 2 GW~ 3 GW~ 7 GW
~ 1,800 FTE
~ 10 GW
~ 900 FTE
~ 7 GW
Key figures 2012 2013 EBITDA (€ million) 4,378 2,455
Operating result (€ million) 3,275 1,384
Workforce 17,583 16,311RWE AG
2013: 98.3 mill. mt lignite 466 mill. m3 overburden
RWE today: One of the leading European utilities
RWE Innogy
Key figures 2013 EBITDA (€ million) 7,904
Operating result (€ million) 5,369
Workforce 64,896
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PAGE 3RWE Power AG Dr. van den Heuvel 19.04.2023
Opencast mining at RWE
20 spreaders
20 bucket wheel excavators
About 250 km belt conveyorsTotal capacity installed: 925 MW
High-capacity mining equipment & belt conveyors
(Replacement value of lignite production equipment ~ €7.5 billion)
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PAGE 4RWE Power AG Dr. van den Heuvel 19.04.2023 Lignite stockpile in the Neurath power plant
Train loading in the Hambach mine
Company-owned railway system
Lignite mining and transportation to the power plants
Lignite stockpile in the Hambach mineLignite seam in the Hambach mine
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PAGE 5RWE Power AG Dr. van den Heuvel 19.04.2023
Availability Cost cuttingefficiency enhancement Asset management:
Life-cycle cost Overall equipment effectiveness Total cost of ownership
Focus: Focus: Focus:
1995 2004
Maintenance at RWE Opencast Mines
€163 mill.€80 mill.
€357 mill.
Production
Depreciaton
Maintenance
Energy
€350 mill.
Primary cost at RWE lignite mines 2013: €1000 mill.
Life-cycle cost of mining equipment
Maintenance is a
core business Maintenance is a core competence for RWE
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PAGE 6RWE Power AG Dr. van den Heuvel 19.04.2023
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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PAGE 7RWE Power AG Dr. van den Heuvel 19.04.2023
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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PAGE 8RWE Power AG Dr. van den Heuvel 19.04.2023
Rolling bearings in RWE opencast mines
Approximately 1 500 000 bearings in operation
Slewing rim
Substructure with crawler tracks
Slewable superstructure
app. 1 200 000 bearings 100 mm 38 bearings 21 000 mm
The performance of bearings and bearing systems is of great importance for reliable and cost-effective operation !
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PAGE 9RWE Power AG Dr. van den Heuvel 19.04.2023
Most common root causes of bearing failures
Unsuitable lubricant
Lack of lubricantContaminations
Assembly faults and conse-
quential errors
Inappropriate bearing selection
Aged lubricant
Material or manufacturing fault(bearing manufacturer)
Reference: Dethloff, AKIDA 2002
? Experiences gained at
RWE Power
“Most bearing failures are not due to the bearing, but to something wrong in its environment”
Bearing failures and their root causes
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PAGE 10RWE Power AG Dr. van den Heuvel 19.04.2023
> We are responsible
> We need good components around the bearing
> We need competent support from a reliable partner
Unsuitable lubricant
Lack of lubricantContaminations
Assembly faults and conse-
quential errors
Inappropriate bearing selection
Aged lubricant
Material or manufacturing fault(bearing manufacturer)Experiences gained at
RWE Power
Bearing failures and their root causes
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PAGE 11RWE Power AG Dr. van den Heuvel 19.04.2023
Mercedes C63 AMG, 487 hp
Our needs and demands:
Components and services combined as part of the overall system
http://de.autoblog.com/2012/01/15/ verruckt-supercar-drift-auf-4-notradern-video/ with emergency spare wheels
The rolling bearing: Just a mechanical component, or a system?
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PAGE 12RWE Power AG Dr. van den Heuvel 19.04.2023
Using SKF Solution Factory for easyaccess to SKF's knowledge and offerings
SKF platforms
RWE
SKF
Solution
Factory
SK
F
Sale
s
DemandSolution
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PAGE 13RWE Power AG Dr. van den Heuvel 19.04.2023
Engineering consultancy and service– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
Seals Lubrication systems Mechatronics
RWE – SKF: Examples of a valuable cooperation
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PAGE 14RWE Power AG Dr. van den Heuvel 19.04.2023
Typical belt conveyor drive station (8 MW driving power)
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PAGE 15RWE Power AG Dr. van den Heuvel 19.04.2023
Benefiting from simulation and design validation
Roller centred brass cage
Source: SKF Report: Dynamische Lageruntersuchung von Zylinder-rollenlagern für innengelagerte Bandtrommeln der RWE Power AG
Pierced rollers and pin cage
SKF
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
Benefit for RWE: > Extended rating life> Significantly extended service life> Substantially reduced life-cycle cost
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PAGE 16RWE Power AG Dr. van den Heuvel 19.04.2023
Engineering consultancy and service– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
Seals Lubrication systems Mechatronics
RWE – SKF: Examples of a valuable cooperation
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PAGE 17RWE Power AG Dr. van den Heuvel 19.04.2023
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
Failure-based Time-based Condition-based
DIN 13306: Reactive (repair of damage) DIN 13306 Preventive (prevention of damage)
Maintenance strategies (DIN 13306)
At RWE maintenance consists of several maintenance strategies and is defined separately for each machine!
Bucket-wheel driveIdlers Railway Failure-based Time-based Condition-based
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PAGE 18RWE Power AG Dr. van den Heuvel 19.04.2023
Selection of suitable maintenance strategies
Benefits for RWE:> Best strategies according to reliability, risk,
costs and profit, based on our maintenance experience
SKF RCM Reliability Centered Maintenance
SKF solution:
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PAGE 19RWE Power AG Dr. van den Heuvel 19.04.2023
Engineering consultancy and service– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
Seals Lubrication systems Mechatronics
RWE – SKF: Examples of a valuable cooperation
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PAGE 20RWE Power AG Dr. van den Heuvel 19.04.2023
Signal processing and conditioning
Frequency [Hz]
Bes
chl.
[mg]
SKF solution: Structure-borne, sound-based machinery diagnostics on gear units and drivelines
Data acquisition Data mining Generation of informationDeduction of right
maintenance decision
from 'data'
Time signal of vibration acceleration
Pitting
Vibration level acceptable
no activities
to 'Decision' via 'Information'
Condition monitoring and diagnostics for reliable production planning
Benefits for RWE: > Identify and solve problems before they become serious> Significantly reduced unplanned downtime> Significantly reduced consequential damages> Substantially reduced life-cycle cost
Event
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PAGE 21RWE Power AG Dr. van den Heuvel 19.04.2023
Preventing failures of an induced draught fan
Benefit for RWE: > Increased operational availability> Significantly extended service life> Substantially reduced life-cycle cost
SKF solution:
> New housings, unique sealing and lubrication system
> Online condition monitoring system for early detection of upcoming failures
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PAGE 22RWE Power AG Dr. van den Heuvel 19.04.2023
Engineering consultancy and service– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
Seals Lubrication systems Mechatronics
RWE – SKF: Examples of a valuable cooperation
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PAGE 23RWE Power AG Dr. van den Heuvel 19.04.2023
Alignment of track rollers of rotary tube dryers
Benefit for RWE:> Extended bearing service life> Higher performance and availability
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PAGE 24RWE Power AG Dr. van den Heuvel 19.04.2023
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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PAGE 26RWE Power AG Dr. van den Heuvel 19.04.2023
Analysing slewing rims in bucket wheel excavatorsInspection after 30 years of operation: Are the balls reusable or scrap?
> Radiographical examination of residual stresses> Scanning electron microscopic examinations of the surfaceResults:
• No typical rolling fatigue• Repair is possible• Necessary metal removal rate: 0.2 mm
Benefit for RWE: > Significantly reduced life-cycle cost
SKF solution:
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PAGE 27RWE Power AG Dr. van den Heuvel 19.04.2023
Engineering consultancy and service– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Various services
– Remanufacturing
Seals Lubrication systems Mechatronics
RWE – SKF: Examples of a valuable cooperation
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PAGE 28RWE Power AG Dr. van den Heuvel 19.04.2023
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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PAGE 29RWE Power AG Dr. van den Heuvel 19.04.2023
Engineering consultancy and service– Design and calculation
– Selection of maintenance strategies
– Condition monitoring and diagnostics
– Maintenance services
– Remanufacturing
Seals Lubrication systems Mechatronics
RWE – SKF: Examples of a valuable cooperation
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PAGE 30RWE Power AG Dr. van den Heuvel 19.04.2023
Operating time: 34 monthsAnalysis of lubricant/grease: 99,700 mg silicon/kg
Bearing failure after severe grease contamination
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PAGE 31RWE Power AG Dr. van den Heuvel 19.04.2023
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
Sealing solution to prevent severe grease contamination
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PAGE 32RWE Power AG Dr. van den Heuvel 19.04.2023
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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PAGE 33RWE Power AG Dr. van den Heuvel 19.04.2023
Perfect system! Excellent performance!
http://cloudlakes.com/data_images/models/mercedes-benz-c63-amg/mercedes-benz-c63-amg-13.jpg
The rolling bearing: Just a mechanical component, or a system?
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THANK YOU FOR YOUR ATTENTION
A valuable cooperation built on trust between RWE and SKF:
The sustainable recipe for success!