POMMS

(Plant Operation and Maintenance Management System)

Keun-Tae Kim,

Korea East-West Power Co., Ltd

Presentation Summary

EWP Who we are ? Threat & Strategy What we need to win ? POMMS Configuration & Functions Conclusion

. EWP Who we are ?

<Korea> 1,750 Units
Il San CC Dong Hae TPP CFBC

71,989MW, Capacity Factor : 66.7% Efficiency : 39.82%

Dang Jin TPP

One of Gen Companies

Pumped-Storage Ul San TPP & CC

as KEPCO group 6 Sites 39 Units 9,501MW, Capacity Factor : 60.6% Efficiency : 39.91%

Ho Nam TPP

. EWP Who we are ?

7.37% 22.10%
Coal Oil LNG Hydraulic Solar

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 and Strategy

<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 ?

. Threat and Strategy

<strategy>
Increase Generation Capacity - Reduce forced outage hour by optimization work schedule - Prevent unforced outage Decrease maintenance cost - Purchase material - Light maintenance cost - Over haul cost How to monitor output ? by statistically control BOM by optimization PM activities by moving from TBM to CBM by NERC Index by Early warning system

. 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 ? - PI for what ? - Other method ? What we need is - Economic decision making support system based on reliability - Statistical plant maintenance management system - Predictable condition analysis and guide system Asset management Monitoring & Early warning System Preventive & Predictive maintenance

. POMMS Configuration & Functions

Cost Time Analysis Target Equipment, Time & Range
Maintenance Planning based on Condition

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

Plant Information Sys

Efficiency Management

Plant Maintenance Sys

Current Status NERC Index

Real Time from DCS Statistical, Historical

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

Light & Heavy work DWG, Material, Cost

Contractor

Prssure

Flow

Temp

Air Flow

Work Schedule Control Material, HR & Time

. POMMS Configuration & Functions

Performance Management
Status
Net Generation By Unit Emission Control Atmosphere Real Time Trend

Plant Information Sys

Information
Display same as OIS Monitoring Trip Condition Fuel Scaling

Efficiency Management Sys

Thermal
TBN Boiler A/H, HTR & Cond Report

Maintenance Management Sys

Work
Activity Schedule Estimation Red Tag & Clearance Reference DB

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 Configuration & Functions

Plant Performance Management

Plant Information System

POMMS
5

3 4

Plant Efficiency System Plant Maintenance Management Sys

RCM / RBI / Cost-Time

1. Plant Performance Management (Enterprise)

1. Plant Performance Management (Site)

1. Plant Performance Management (NERC Index)

Operating

Reliability

Maintenance

2. Plant Information System (Overall Status)

2. Plant Information System (PMS Interface)

2. Plant Information System (for Gen Expert)

2. Plant Information System (for TBN Expert)

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

2. Plant Information System (Speed Regulation)

3. Plant Efficiency Management System (TPP)

3. Plant Efficiency Management System (CC)

3. Plant Efficiency Management System (Report)

4. Plant Maintenance Management System

4. PMS - Work Order Management

Light Maintenance ~OH = Work Order

4. PMS - Work Order Level

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

4. PMS Operator Shift Report

All Team Managers Should look at this

4. PMS Post Accident Management

Correcting Order & Feedback by Work Order, No Paper

4. PMS PM - Maintenance

4. PMS PM - Measurement

4. PMS - FMEA

4. PMS Menu Table

5. RCM / RBI / Cost-Time

Circulating type CBM

RCM Analysis

POMMS
E

C D

RBI Analysis Cost-Time Analysis

CBM Strategic

A. Circulating type CBM

Cost-Time Work Order Design

RCM RBI Trend Performance

O/H & Light Maintenance

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

INI Ref 3~6M

EPRI Ref 12M 1M 6M

RBI Ref 12M 12M

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

Current PM Interval (Initial time)

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

Time Material Inform

500 400 300 200 100 00 1 2 4 5

Risk= PoF(t) CoF

On-Line Stress Analysis

NDT Replica

Temp

Pr

Load

Design Info

PoF Cal

Inspection Info

C. RBI Analysis

Next O/H time : 92 M Later

DJ TPP #1 Steam Turbine HP Turbine
HP Rotor HP Inner Casing HP Nozzle Box HP Blade HP Diaphragm Next Inspect 92 M 112 M 138 M 98 M 92 M 106 M Risk Rate

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

EWP CBM Master Plan

Operation & Performance Paradigm

C D

Maintenance Paradigm POMMS Center

A. EWP CBM Master Plan

Cost Center
Review 2004. 9 Planning 2005. 1 Kick-Off 2005. 6 2006 2007 Completion 2008.12 CBM begins 2009. 1 ~ 2013.12

Profit Center
CBM 2014. 1~

Investment

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) RBI (Boiler)

RCM (All) RBI (TBN/BLR) TBN

RBI (TBN-Test) Change O/H Ref EOH for TPP BLR

CC ST & HRSG

B. Operation & Performance Paradigm

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

Cost Saving = 4 mil $ +

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

Gen Operating Team Gen Planning Team

Tech Expert Team

Outsourced Expert R & D Resources

EWP Profit Center

Thank You Any Question ?