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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 ?