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Plant Operation and Maintenance Management System Korea
Plant Operation and Maintenance Management System Korea
Keun-Tae Kim,
Presentation Summary
EWP Who we are ? Threat & Strategy What we need to win ? POMMS Configuration & Functions Conclusion
as KEPCO group 6 Sites 39 Units 9,501MW, Capacity Factor : 60.6% Efficiency : 39.91%
Ho Nam TPP
0.01%
Fuel Portfolio
29.47%
0.02% 22.10%
Bas e Load Moddle Load Peak Load Renewable
51.57%
Load Portfolio
47.36% 23.15%
<Threat>
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 ?
RCM Short term Maintenance Less than 1 year MTBF EPRI & INI DB
RBI Long Term Maintenance Longer than 3 Years Boiler & TBN On / Off line RBI
HQ Sites
To/From ERP
Performance Management
Efficiency Management
Prssure
Flow
Temp
Air Flow
NERC Index
Capacitor Factor Forced Outage Rate Non-Outage CM Backlog Unplanned Outage Rate
Supporting
Operating Guide Mode Guide Measuring Speed Regulating
Combined
Steam TBN Gas TBN & HRSG Virtual Machine Report
Equipment
Maintenance History BOM & Procurement Electronic Circuit Board GT Material
Real Time PM
Trend from PDA Logging Report (W / M / Y) Counter
Analysis
Comparison Alarm Management Monitoring Aux Power Sys
Analysis
KPI & NERC Index HOPE Analysis & Strategy Fault Mechanism Coding Structure
Others
DWG & Document PM Master & Schedule PDA Logging
RCM Analysis
Sys Fault Code EPRI & INI PM DB PM Optimization FMEA & LTA MTBF RCM Living
RBI Analysis
Material DB Q & A Table On-Line RBI Damage Analysis PMS Interface Off-Line RBI
Cost-Time Analysis
Predictive Failure Cost Optimize Next Inspection Time Actual Repair Cost PMS Interface
POMMS
5
3 4
Operating
Reliability
Maintenance
4. PMS PM - Maintenance
4. PMS PM - Measurement
4. PMS - FMEA
RCM Analysis
POMMS
E
C D
CBM Strategic
BM & CM
B. RCM Analysis
ID Fan PM Analysis
Method Dissemble Oil Level OIL Analysis Current 2Y 1M 12M Fault 6M MTBF 5.5 M Others Site Manufact
RCM 2Y 1M 5M
Interval 1Y 1M 5M
2Y 3M
1Y 1M -
Maintenance Method
RCM Living
Re-Engineering
<Interval Comp>
Current PM Each Equips MTBF Ave PM Interval Recommend by Other sites inform EPRI DB INI DB
Failure History (Initial Time) Determination Logic RCM Recommend (Pre PM Interval) Comp Pre PM Interval - Usage rate - Enviroment
N
Extend PM Interval ?
N
PM Interval > O/H Time ?
Y
Go Run ? Plant RBI Time = Plant O/H Time PM = OH Interval
Final PM
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
Final S/H Final R/H Steam Pipe MSV HP TBN
Risk
100 90 80 70 60 50 40 30 20 10
NDT Replica
Temp
Pr
Load
Design Info
PoF Cal
Inspection Info
C. RBI Analysis
5
1E 1E 2D 2D 1D 2C
4 3 2 1
HP Blade HP Diaphragm HP Inner Casing HP Nozzle Box
HP Rotor
IP Turbine
Design Info
LP Turbine Boiier
Inspection Data Operating info
Risk Assessment
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
. Conclusion
C D
Profit Center
CBM 2014. 1~
Investment
Cost Saving
4 mil $ +
TBM CBM
TBM
CC ST & HRSG
Single Angle Monitoring (Central Control Room) Paper Based Work & Analysis
Patient
First Aid
General
Special
Plant
Operator
Engineer
Expert
360 Angle Monitoring & Analysis Infra (CEO ~ Employee) Web Based Work, Report & Analysis
C. Maintenance Paradigm
Organization
Paper Individual Different 22 Steps Red/Yellow/Blue No Tool Disconnected Disconnected Disconnected Closed Cant Design Information Procedure Permission Tag Project Control Material Drawing Budget Labor Analysis
Equipment
Computer Database Unification Max 10 Steps Red Real Time Interfaced Interfaced ERP Interface Open Can
Abolition all paper Works CMMS Effortless Real time process Timeless Standardization Simple
Cost Saving ?
D. POMMS Center
Post Accident Managet Plan / Actual Managet Performance Managet Equipment reinforcement
Analysis Operating & Maintenance result Real time trend Analysis Technical Support RBI & RCM Analysis O/H Support
Early Warning System Data Cleansing Provide technical advice for special fields Life time assessment