Leading by example

Ineffective operation and maintenance (O&M) at hydropower facilities can mean that the full benefits of hydropower are not realised, as can often be the case in developing countries.

Following hydropower meetings in Switzerland in 2016 and Ethiopia a year later, key stakeholders agreed on the need to prepare hydropower O&M strategies for countries with low O&M capabilities and challenging business environments. The World Bank teamed up with different representatives from the hydropower community and recently published the report entitled Operation and Maintenance Strategies for Hydropower— A Handbook for Practitioners and Decision Makers (See p42 of the May 2020 issue of IWP&DC for more details). 

The International Hydropower Association (IHA) lent its support to the project and provided six case studies which have been published in a separate report. Their aim is to illustrate the lessons learned from the implementation of selected O&M strategies, while sharing views on remaining challenges and future directions. The case studies are:

  • Statkraft’s Assets (180MW - six facilities) in Brazil.

  • Mount Coffee (88MW) in Liberia.

  • Kainji and Jebba (1338MW - two facilities) in Nigeria.

  • New Bong Escape hydropower project (84MW) in Pakistan. 

  • Nalubaale and Kiira (380MW - two facilities) in Uganda. 

  • Salto Grande (1890MW) in Uruguay/Argentina.

Statkraft Energias Renovaveis, Brazil

In July 2015, Statkraft took over Brazilian company Statkraft Energias Renovaveis (SKER), an existing company with almost 316MW of installed capacity of which 188MW is hydropower generation. Statkraft implemented its O&M optimisation methodologies for the Brazilian plants which created to annual savings of US$3.7 million and a projected increase in profits of US$29 million after 2017. Recent expansion of Statkraft’s operations in Brazil led to the acquisition of eight additional operational hydropower plants in the state of Espírito Santo in 2018, representing a total installed capacity of 131.9 MW. Plans are underway to bring these hydro plants to standard O&M levels by 2020. 

The development of new renewable energy technologies is creating new challenges for operating hydropower assets worldwide, and will result in some key trends in O&M: 

  • Increased penetration of variable renewable technologies can result in increased operating costs and underscores the need for even greater overall efficiency as a key target. 

  • Since contract and business models are changing, a competency-based continuous improvement process will need to be implemented. 

  • Digitalisation offers solutions for revenue optimisation and cost reduction through automated, smarter O&M processes, enabled by enhanced digital monitoring systems and predictive analytics.

Mount Coffee Hydropower Plant, Liberia

After years of civil unrest in the 1990s, culminating in the destruction of the Mount Coffee hydropower site, the facility has been fully rebuilt. Over this time, Liberia Electricity Corporation (LEC) ost its experience and expertise in operating hydropower facilities. So in 2016, in an effort to secure sustainable generation, LEC awarded a five-year O&M and training contract to Swiss firm Hydro Operation International (HOI). This means that HOI will: 

  • Be responsible for the O&M of the plant according to international standards for a period of five years, during the anticipated development period of the transmission and distribution grid in Liberia. 

  • Establish O&M procedures for sustainable operation of the plant and be responsible for its implementation over the five-year period. 

  • Train local staff and share skills so that they have the necessary skills to operate the plant with little to no assistance.

However, it became apparent that after receiving on-the-job training, there is a tendency for outward migration of staff who choose to leave the plant for other utilities or the private sector, particularly if more competitive salaries are offered by external companies with better on-site living conditions. Long-term sustainable O&M is only achieved if the O&M is locally staffed, with managers and technicians duly trained and motivated. 

As Mount Coffee is a relatively remote site, it became clear that it needs to be provided with suitable housing, health, recreation, and other facilities for O&M staff to allow permanent residence onsite. While an individual performance reward system was needed to acknowledge progress, commitment, and dedication of trainees. 

Other lessons learned include:

  • Preparing multi-year budgets in advance and allocating reserves for major maintenance works and overhauls. 

  • Having a properly funded maintenance programme would allow additional protection and monitoring systems to ensure early detection and monitoring of damage caused by grid instability issues. 

The Mount Coffee hydropower plant

Kainji-Jebba Hydropower Complex, Nigeria

Since Mainstream Energy Solutions Lt. (MESL) took over the Kainji-Jebba hydropower complex in 2013, the company has undertaken a capacity recovery programme to restore the two plants. Capacity has doubled from 460MW to 922MW, out of an overall installed 1340MW. Through a 30-year concession agreement with the government of Nigeria, MESL is responsible for O&M at the Kainji-Jebba complex.

Commissioned in 1968 and 1984 respectively, Kainji and Jebba hydropower plants are operating at 69 percent of installed capacity, with plans to reach full capability by 2025. MESL has plans to implement overall improvement in the O&M processes and practices through: 

  • Implementation of computerised maintenance management systems. 

  • Implementation of reliability-centred maintenance to optimise asset availability and minimise maintenance costs.

  • Measures geared toward obtaining certification under ISO 9001. 

  • Optimisation of the inflow forecast system and operation tools for more accurate flood management and generation projections, plus better understanding and coordination of operations with downstream water users. 

  • Increasing overall plant capability. The Kainji facility was originally designed for 12 generating units but only eight have been installed - even though the intake gates, penstock, foundation, and civil structure at the machine hall level have all been constructed for the remaining units. A 200MW capacity extension should be completed in about five years, with commercial operation expected to start at the end of the year 2023.

New Bong Escape Hydropower Project, Pakistan

Laraib Energy Limited is a subsidiary of the Hub Power Company in Pakistan, and is the owner and developer of the 84MW run-of-river New Bong Escape (NBE) Hydroelectric Power Complex, on the Jhelum River in Azad Jammu and Kashmir. The complex was commissioned in 2013 but a number of reliability issues were experienced during the first year of operation, which led to lower overall availability.