Plant

1
Plant Operation Maintenance Management System P
resented by KT Kim
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Presentation Summary
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?. EWP Who we are ?

• ltKoreagt
• 1,750 Units
• 71,989MW,
• Capacity Factor 66.7
• Efficiency 39.82

Dong Hae TPP CFBC
Il San CC
Dang Jin TPP

• One of Gen Companies
• as KEPCO group
• 6 Sites
• 39 Units
• 9,501MW,
• Capacity Factor 60.6
• Efficiency 39.91

Ul San TPP CC
Pumped-Storage
Ho Nam TPP
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?. EWP Who we are ?
7.37
0.01
22.10
Fuel Portfolio
29.47
0.02
22.10
51.57
Load Portfolio
47.36
23.15
5
?. Threat and Strategy

• ltThreatgt
• Saturation of economic growth power consumption
• High cost fuel as time passes
• Extreme competition among generation companies
• Penetration of electric market by domestic
  overseas IPP
• Try to retrofit old power plant instead of
  building new power plant
• How to survive in this environment ?

6
?. Threat and Strategy

• ltstrategygt
• Increase Generation Capacity
• - Reduce forced outage hours ? by
  optimization of work schedule
• - Prevent unforced outage ? by early warning
  system
• Decrease maintenance costs
• - Purchase material ? by statistically
  controlled BOM
• - Lighten maintenance costs ? by
  optimization of PM activities
• - Overhaul costs ? by moving from TBM to CBM
• How to monitor output ? ? by NERC Index

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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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?. POMMS Configuration Functions
Cost Time Analysis
Maintenance Planning Based on Condition
Target Equipment, Time Range
R C M
R B I
To/From ERP

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

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

Operating Management
Plant Information Sys
Plant Maintenance Sys
Performance Management

• Current Status
• NERC Index

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

• Real Time from DCS
• Statistical, Historical

• Light Heavy work
• DWG, Material, Cost

Contractor
Work Schedule Control Material, HR Time
Air Flow
Prssure
Flow
Temp
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?. POMMS Configuration Functions
P-Maintenance System
Operating Management
Plant Information Sys
Performance Management Sys
Information
Supporting
Thermal
Equipment
Work
Combined
Status
NERC Index
Display same as OIS
TBN
Activity Schedule
Maintenance History
Steam TBN
Net Generation By Unit
Operating Guide
Capacitor Factor
Estimation
BOM Procurement
Monitoring Trip Condition
Boiler
Gas TBN HRSG
Emission Control
Forced Outage Rate
Mode Guide
Red Tag Clearance
Electronic Circuit Board
Fuel Scaling
A/H, HTR Cond
Measuring Speed Regulating
Virtual Machine
Atmosphere
Non-Outage CM Backlog
GT Material
Reference DB
Report
Report
Real Time Trend
Unplanned Outage Rate
Analysis
Real Time PM
Analysis
Others
Comparison
Trend from PDA
Logging Report (W / M / Y)
Alarm Management
DWG Document
KPI NERC Index
Monitoring Aux Power Sys
Counter
PM Master Schedule
HOPE Analysis Strategy
PDA Logging
Fault Mechanism Coding Structure
RCM Analysis
RBI Analysis
Cost-Time Analysis
Predictive Failure Cost
Actual Repair Cost
Material DB
Damage Analysis
Sys Fault Code
FMEA LTA
Optimize Next Inspection Time
PMS Interface
EPRI INI PM DB
MTBF
Q A Table
PMS Interface
On-Line RBI
Off-Line RBI
PM Optimization
RCM Living
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?. POMMS Configuration Functions
POMMS
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1. Plant Operating Management (Enterprise)
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1. Plant Operating Management (Site)
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1. Plant Operating 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 IC Expert)
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2. Plant Information System (Speed Regulation)
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3. Plant Performance System (TPP)
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3. Plant Performance System (CC)
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3. Plant Performance System (Report)
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4. RCM / RBI / Cost-Time
POMMS
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A. Circulating Type CBM
Cost-Time
Work Order Design
O/H Light Maintenance
RCM RBI Trend Performance
BM CM
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B. RCM Analysis
Current
Fault
INI Ref
Others Site
Manufact
MTBF
EPRI Ref
RBI Ref
2Y
2Y
-
-
1Y
-
12M
12M
-
1M
-
1M
-
1M
-
-
5.5 M
12M
3M
-
6M
6M
12M
36M
Re-Engineering
RCM Living
Maintenance Method

• ltInterval Compgt
• - Current PM
• Each Equips MTBF
• Ave PM Interval
• Recommend by
• Other sites inform
• - EPRI DB
• - INI DB

Failure History (Initial Time)
N
Extend PM Interval ?
Y

• Comp Pre PM
• Interval
• Usage rate
• Environment

Determination Logic
RCM Recommend (Pre PM Interval)
PM Interval gt O/H Time ?
Go Run ?
PM OH Interval
Plant RBI Time Plant O/H Time
Current PM Interval (Initial time)
Final PM
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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

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C. RBI Analysis
Final S/H Final R/H Steam Pipe
MSV HP TBN
Risk PoF(t) CoF
NDT Replica
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C. RBI Analysis
Next O/H time 92 M Later
5
4
3
2
1
A
B
C
D
E
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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

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D. Cost-Time Analysis
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?. Conclusion
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A. EWP CBM Master Plan
Profit Center
Cost Center
Review
Planning
Kick-Off
Completion
CBM
CBM begins
2005. 1
2005. 6 2006 2007
2008.12
2009. 1 2013.12
2014. 1
2004. 9

• Investment

Design, Construction Test
4 mil a
2.3 mil/Unit a
1.6 mil/Unit a

• Cost Saving

• TBM ? CBM

RCM (All)
TBM
RCM (HN)
RCM (Trip/RB)
RBI (DJ)
RBI (Boiler)
RBI (TBN/BLR)
RBI (TBN-Test)

• Change O/H Ref

TBN
EOH for TPP
BLR
CC ST HRSG
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B. Operation Performance Paradigm

• Single Angle Monitoring (Central Control Room)
  
• Paper Based Work Analysis

• Cost Saving
• 4 mil a

• 360º Angle Monitoring Analysis Infra (CEO
  Employee)
• Web Based Work, Report Analysis

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C. Maintenance Paradigm
Organization
Equipment
Paper
Computer
Design

• Abolition all paper Works
• CMMS ? Effortless
• Real time process ? Timeless
• Standardization ? Simple

Individual
Information
Database
Different
Procedure
Unification
Permission
22 Steps
Max 10 Steps
Red/Yellow/Blue
Tag
Red
No Tool
Project Control
Real Time
Material
Disconnected
Interfaced
Drawing
Disconnected
Interfaced

• Cost Saving ?

Budget
Disconnected
ERP Interface
Open
Labor
Closed
Analysis
Cant
Can
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D. POMMS Center
EWP Profit Center
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Thank You Any Questions?
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