Don’t spare the details: Effective spare parts strategies

The spare parts strategy that the Lake Mainit operators have opted for is a lean, just-in-time solution: as the spare parts supplier, Voith India is responsible for providing the spare parts, Elddie San José manages the replacement process on site, and Voith experts in Germany, India, and the Philippines continuously evaluate the data generated by Hydro Pocket and can react immediately in the event of malfunction reports and make decisions together with the operators.

Shortly after the implementation of Hydro Pocket at the end of 2023, the system detected a fault. “A sensor reported abnormal pressure in Unit 3’s main inlet valve. After a thorough investigation, we discovered that the sensor, a pressure transmitter, was defective and was triggering the wrong signal. Our expert in Heidenheim was able to derive this from the data, informed me along with the Regional Digital team, and we checked it on site together with the power plant employees. The specialists from Voith India and Germany arranged for the spare part to be delivered so that the faulty sensor could be replaced with a new one,” explains Elddie San José.

With Hydro Pocket, operators can identify how much electricity is being generated without having to be physically present at the power plant. They can also assess what different messages mean or how likely it is that the system will come to a standstill. This is the best basis for deciding how many megawatts to feed into the grid at what time in order to maximize profits.”

For AGEC, precise analyses in real time and predictability are therefore essential. If the company commits to providing a certain amount of electricity for a certain time on the electricity trading market and is unable to meet this commitment due to a disruption or incorrect calculation, it must pay a penalty.

In order to achieve the best possible results, AGEC has signed a long-term service contract with Voith, which combines the use of Hydro Pocket with forward-looking consulting and planning activities by a team of Voith experts. This includes 10 hours a month during which the power plant’s maintenance teams meet with experts from Voith. These meetings are used to determine what the daily operating processes are like and which spare parts will be needed in the next three months. There’s also a quarterly meeting in which the spare parts requirements are discussed and the experts make recommendations. In addition, the service includes arranging spare parts orders and deliveries for the on-site warehouse.

A well thought-out, customized strategy like this therefore reduces costs for operators over the medium and long terms and prevents losses due to long downtimes. “It’s an effective and reliable method of managing spare parts for hydropower plants,” says Elddie San José. “Together with the expertise that Voith provides, it saves customers time and money.”

With its predictive spare parts strategy, Voith Hydro not only supports its customers with analysis and planning work, but also handles list creation and spare parts replacement, for example. “Voith experts are on hand to support the companies at all times. What’s more, a service agreement with Voith opens up a universe of comprehensive expertise for plant operators like us, with experts who exchange ideas worldwide in order to find the best possible solution for the specific issue,” says Engr. John Cortel, Operation and Maintenance Manager at AGEC.

Voith Hydro places an emphasis on collaboration and its employees are globally connected. This enables the company to increase efficiency, reduce risks, and ensure maximum capacity utilization. And as a result, it ultimately increases customer satisfaction.