Asset Lifecycle Management Program

customer:
Aluminum Producer
Application:
Transformer Fleet
Country:
Africa

Customer Challenge

An aluminum plant increased its production capacity and was, at the same time, experiencing recurrent forced outages. The 19 power transformers that are critical to production were approaching 30 years of life with no clear indication of their health status and with no replacement plan in place. The company required a solution enabling a comprehensive asset lifecycle management approach.

GE's Solution

GE deployed an Asset Lifecycle Management Program to manage the risks and minimize the overall OPEX and CAPEX. The project scope included:

  • Initial asset health assessment
  • Evaluation of each assets’ criticality in coordination with the customer
  • Estimation of each asset’s real residual life based on their health status
  • Maintenance recommendation for each transformer

Customer Benefits

  • Reduced unplanned outages, maintenance costs and production losses
  • 100% ROI in one year from implementation of the ALM Program

Extended Lifetime Warranty

customer:
Utility
Application:
Static Var Compensator
Country:
North America

Customer Challenge

A Static Var Compensator (SVC) system which comprises over 900 components and more than 40 asset types was integrated into the utility’s electrical network. The utility wanted to secure the performance of the critical power electronics system and required the SVC system’s operation and maintenance to be managed during its entire life.

GE's Solution

GE implemented a 30-year lifetime system warranty enabled by GE’s Asset Lifecycle Management Services. The project scope included:

  • Installation of a remote monitoring solution on critical assets
  • Deployment of a reliability centered maintenance approach
  • Implementation of an advanced data collection techniques
  • Supply and configuration of GE APM application including optimal and systematic data analytics

Customer Benefits

  • Known and fix cost for all planned and unplanned maintenances including parts and labor
  • Optimized reliability centered maintenance strategy and costs delivered by the OEM
  • No obsolescence surprise

Advanced data collection strategy

customer:
Offshore Wind Farm Operator
Application:
HVDC
Country:
Germany

Customer Challenge

A wind farm operator required a solution to ensure optimal availability of its offshore substations which are critical for the energy supply to the region. The North sea’s weather conditions and the safety constraints limited access to the offshore platform, negatively impacting the service response time in case of a problem.

GE's Solution

GE provided an ALM services solution adapted to the substation location. The scope included:

  • Deployment of transformer remote monitoring solution
  • Implementation of accurate and robust inspection process supported by mobile and advanced tools such as smart glasses and x-ray inspections
  • Integration of collected data in an Enterprise Asset Management (EAM) platform

Customer Benefits

  • Efficient support to help customer’s transition from a time base to reliability centered maintenance approach
  • 50% reduction of emergency interventions on monitored assets
  • Reduced number visits on off-shore platform substations to assess the asset condition and provide diagnosis
  • Optimized on site data collection efficiency and quality
  • Efficient data analysis and optimized maintenance planning

Grid Substation Fleet management

customer:
Utility
Application:
Transmission & Distribution assets
Country:
Qatar

Customer Challenge

A utility had an ambitious business goal to control failure risk of their 150,000 electrical assets across over 15,000 distribution and 300 transmission substations by collecting asset condition data and turning it in actionable information to prioritize and plan asset maintenance and replacement.

GE's Solution

GE implemented a comprehensive asset inspection plan and an Asset Performance Management system. The scope included:

  • Deployment of efficient site inspection utilizing an advanced data collection approach
  • Implementation of GE APM software for data management and analysis
  • Automatic upload of oil tests results from GE labs to APM platform
  • Selection of analytics focused on health, risk and end-of-life assessment

Customer Benefits

  • Optimized maintenance strategy resulting in over 50% reduction of failure rate
  • Optimized replacement strategy resulting in 20% asset life extension
  • 182% of return on investment after 2 years