Energiewende and Maintenance 4.0

Maintenance of conventional Power plants in the course of time

Altered operations of conventional power plants, resulting from the politically enforced submission, away from the capacity market to the capacity reserve, require a new orientation of the power plant operation.

Massive cost reductions, including in the field of maintenance, are an inherent consequence of the new economic challenges associated with this. With the enormous reduction in the power plant, and thus also the maintenance personnel, a change in the maintenance strategies can be observed. If previously preventive maintenance measures (faults) were the focus of the maintenance activities, this now changes to a condition-oriented maintenance strategy (proactive maintenance – avoidance of failures).

The requirements for an EAM software resulting from the failure-oriented maintenance are already fulfilled by the current EAM software solutions by means of the service request (fault message) and the workorder (work order).

With respect to proactive maintenance, the premises for the power plant operators have changed elementarily: The condition of an installation / component has to be evaluated in a much more detailed way and the resulting measures derived.

This process is to be achieved under the term “industry 4.0” and derived therefrom “maintenance 4.0” among other things by increased use and exchange of process and machine data as well as their evaluation and analysis. In addition to the availability of the data in particular, an extended qualification of the employees is necessary in order to ensure a sound use and evaluation of the available data.

The requirements for an EAM software resulting from the measures for failure-oriented maintenance (malfunction) are already covered by the current EAM software solutions by means of the service request (fault message) and the workorder (work order).

For the first steps in the direction of “Maintenance 4.0”, the data of relevant plant areas, whose process and machine data are not yet recorded electronically, can also be determined and processed manually. In the further integration of machines / systems and apparatus into the system, the amount of data that is generated and analyzed is very fast to reach dimensions which are beyond a purely local processing. Here, the need arises to set up a production DB, which is fed via interfaces with the resulting data. Data, which are then processed and processed by analysis programs and on the basis of which the necessary maintenance measures can be derived and initiated by the EAM software.
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In order to implement the philosophy “Maintenance 4.0” (proactive maintenance strategy), the connection of a production database to the EAM software is indispensable. This means that the degree of automation can be increased and thus the reduced headcount in the area can be met.