plant operation and maintenance management system korea

8/3/2019 Plant Operation and Maintenance Management System Korea

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POMMS(Plant Operation and Maintenance Management System)

Keun-Tae Kim,Korea East-West Power Co., Ltd


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EWP Who we are ?

Threat & Strategy

What we need to win ?

POMMS Configuration & Functions

Conclusion

Presentation Summary


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. EWP Who we are ?

One of Gen Companies

as KEPCO group

6 Sites

39 Units

9,501MW,

Capacity Factor : 60.6%

Efficiency : 39.91%

Il San CC

Dang Jin TPP

Dong Hae TPPCFBC

Ul SanTPP & CC

Ho Nam TPP

Pumped-Storage

1,750 Units

71,989MW,

Capacity Factor : 66.7%

Efficiency : 39.82%


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. EWP Who we are ?

Base LoadModdle LoadPeak LoadRenewable

CoalO ilLNGHydraulicSo lar

47.36%23.15%

29.47% 0.02%

22.10%

22.10% 51.57%

7.37% 0.01%

Fuel Portfolio

Load Portfolio


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. Threat and Strategy

Saturation of economic growth & power consumption

High cost fuel as time passes

Extreme competition among generation companies

Penetration electric market by domestic & overseas IPP

Try to retrofit old power plant instead of building new power plant

How to survive at this environment ?


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Increase Generation Capacity

- Reduce forced outage hour by optimization work schedule

- Prevent unforced outage by Early warning system Decrease maintenance cost

- Purchase material by statistically control BOM

- Light maintenance cost by optimization PM activities- Over haul cost by moving from TBM to CBM

How to monitor output ? by NERC Index

. Threat and Strategy

/


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. What we need to win ?

How to increase competitiveness ?

Do we need any management system ?

What kind of management system ?

Other companies ?

- ERP for what ? Asset management

- PI for what ? Monitoring & Early warning System- Other method ? Preventive & Predictive maintenance

What we need is

- Economic decision making support system based on reliability- Statistical plant maintenance management system

- Predictable condition analysis and guide system


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R C M

Work Schedule ControlMaterial, HR & Time

Real Time Calculation BLR, TBN, G/T, HRSG

Current Status NERC Index

H Q

. POMMS Configuration & Functions

Sites

To/From ERP

Air FlowPrssure Flow Temp

Contractor

Performance Management Plant Information Sys Plant Maintenance SysEfficiency Management

Real Time from DCS Statistical, Historical

Light & Heavy work DWG, Material, Cost

Short term Maintenance Less than 1 year MTBF EPRI & INI DB

Long Term Maintenance Longer than 3 Years Boiler & TBN On / Off line RBI

R B I

Cost Time Analysis

Target Equipment, Time & RangeMaintenance Planningbased on Condition


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POMMS

Plant Performance Management1Plant Information System2

Plant Efficiency System3

RCM / RBI / Cost-Time5

. POMMS Configuration & Functions

Plant Maintenance Management Sys4


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1. Plant Performance Management (Enterprise)


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1. Plant Performance Management (Site)


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1. Plant Performance Management (NERC Index)

Operating

Reliability

Maintenance


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2. Plant Information System (Overall Status)


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2. Plant Information System (PMS Interface)


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2. Plant Information System (for Gen Expert)


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2. Plant Information System (for TBN Expert)


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2. Plant Information System (for I&C Expert)


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2. Plant Information System (Speed Regulation)


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3. Plant Efficiency Management System (TPP)


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3. Plant Efficiency Management System (CC)


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3. Plant Efficiency Management System (Report)


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4. Plant Maintenance Management System


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4. PMS - Work Order Management

Light Maintenance ~OH = Work Order


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4. PMS - Work Order Level

Up, Cause, FF, FS, SF, SS for All W/O


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4. PMS Operator Shift Report

All Team Managers Should look at this


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4. PMS Post Accident Management

Correcting Order & Feedback by Work Order, No Paper


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4. PMS PM - Maintenance


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4. PMS PM - Measurement


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4. PMS - FMEA


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4. PMS Menu Table

/ /


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5. RCM / RBI / Cost-Time

POMMS

Circulating type CBMA

RCM AnalysisB

RBI Analysis

C

Cost-Time AnalysisD

CBM StrategicE

A Ci l i CBM


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A. Circulating type CBM

RCMRBITrendPerformance

Cost-Time Work Order Design

O/H & LightMaintenance

BM & CM


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B RCM


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B. RCM

Before

- Do Light PM for all equipment

- Limit : Maintenance Resource (HR, Material, Budget)After

- Run to Fail Equipment Breakdown Maintenance

- Concentrating resources on core equipments

- Maximize ROI

RCM Living

- Interval : 2 Years

- Tool for the improvement PM & putting off PM Interval

C RBI Analysis


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On-LineStress Analysis

Risk= PoF(t) CoF

Risk100

9080

7060

50

4030

20

10

Time

Design Info Inspection InfoPoF Cal

C. RBI Analysis

Final S/HFinal R/HSteam PipeMSVHP TBN

Temp Pr Load

100

200

300

400

500

1 2 300 4 5

NDTReplica

Material Inform

C RBI Analysis


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4

3

2

1

AB

CD

E

Design Info

InspectionData

Operating info

RiskAssessment

C. RBI Analysis

5

DJ TPP #1

Steam Turbine

HP Turbine

LP Turbine

IP Turbine

HP Diaphragm

HP Inner Casing

HP Nozzle Box

HP Blade

HP Rotor

Boiier

Next Inspect Risk Rate

92 M 1 E

106 M 2 C

HP Diaphragm

138 M 2 DHP Inner Casing

98 M 2 D

HP Nozzle Box

92 M 1 DHP Blade

112 M 1 E

HP Rotor

Next O/H time : 92 M Later

C RBI Analysis


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C. RBI Analysis

Before

- Time Based Maintenance (TBM) for O/H

- Loss of resources and decrease of income

After

- Depend on the condition of TBN & BLR

(A Class : HP TBN, B & C Class : BLR)

- Increase income & reliability

- Decrease maintenance cost

D Cost Time Analysis


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D. Cost-Time Analysis

Conclusion


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Operation & Performance ParadigmB

Maintenance Paradigm

C

POMMS CenterD

. Conclusion

EWP CBM Master PlanA

A EWP CBM Master Plan


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A. EWP CBM Master Plan

Investment

Review Planning Kick-Off Completion CBM begins CBM

2004. 9 2005. 1 2005. 6 2006 2007 2008.12 2009. 1 ~ 2013.122014. 1~

Design, Construction & Test

Cost Saving 4 mil $ + 1.6 mil$/Unit + 2.3 mil$/Unit +

TBM CBM TBM RCM (HN)

RBI (DJ)

RCM (Trip/RB) RCM (All)

RBI (Boiler)

RBI (TBN-Test)

RBI(TBN/BLR)

Change O/H Ref EOH for TPP BLR TBN

CC ST & HRSG

Cost Center Profit Center

B Operation & Performance Paradigm


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Single Angle Monitoring (Central Control Room)

Paper Based Work & Analysis

360 Angle Monitoring & Analysis Infra (CEO ~ Employee)

Web Based Work, Report & Analysis

B. Operation & Performance Paradigm

First Aid SpecialGeneral

Expert

Patient

EngineerOperatorPlant

Cost Saving

= 4 mil $ +

C Maintenance Paradigm


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Abolition all paper Works

CMMS EffortlessReal time process Timeless

Standardization Simple

C. Maintenance Paradigm

Organization Equipment

Design

Information

Procedure

Permission

Project Control

Material

Drawing

Budget

Analysis

Labor

Paper

Individual

Different

22 Steps

No Tool

Disconnected

Disconnected

Disconnected

Cant

Closed

Computer

Database

Unification

Max 10 Steps

Real Time

Interfaced

Interfaced

ERP Interface

Can

Open

TagRed/Yellow/Blue Red

Cost Saving ? ?

D POMMS Center


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Post Accident Managet

Plan / Actual Managet

Performance Managet Equipment reinforcement

Early Warning System

Data Cleansing

Provide technical advicefor special fields

Life time assessment

Analysis Operating &Maintenance result

Real time trend Analysis Technical Support RBI & RCM Analysis O/H Support

D. POMMS Center

Tech Expert Teamen Operating TeamGen Planning Team

Outsourced ExpertR & D Resources

EWPProfit Center


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Thank You

Any Question ?

plant operation and maintenance management system korea

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