J. A.

Kagal

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ROLE OF TOTAL PRODUCTIVITY MAINTENANCE IN POWER PLANT PERFORMANCE

BY PROF. J.A. KAGAL IIPE : LF 0923 The phenomenon of growing industrialization and automation in workplace and homes has brought with it a new liability of increased energy consumption. Earlier energy consumption was predominantly industry based but modernization in homes has brought along with it the luxury of installation of installation and usage of sophisticated durable white goods; some of which consume heavy power. The above effects result in an unprecedented demand for power. Unfortunately as of date the generated load far trails the demand. In India the installed capacity as of 30th November 2006 was 140,000MW whereas the demand was as high as 190,000MW.This gap threatens to widen with passage of time as the new power projects planned are not in consonance with the rate of increase in demand of power. One remedy for the above problem is to erect new power plants but this exercise is long and involved and by the time the power plant goes operational the fuel costs have gone up considerably and at times we even face the prospects of fuel shortage. Another issue which troubles power producers is the spiraling cost of crude oil as a result of which the fuel prices spiral every now and then thus making the cost per kilowatt hour of generation more uneconomical. It is therefore mandatory for power producers to plan operations as a strategic exercise and ensure that operations are protable through deployment of initiatives such as RCM, TPM, etc. There are various stages in the lifecycle of a plant from specications through EPC stage to operations and nally decommissioning.

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Various cost heads are suitably associated with each activity type. During the entire life cycle of the plant enormous information is generated ,especially in the O&M stage. Thus information can be studied to observe the behavioral pattern of the plant equipment and how events could lead to equipment deterioration and ultimate death of parts concerned. . Deployment of initiatives such as data mining, root cause analysis, failure mode effect criticality analysis enable the establishment of a cause effect link between events and enables the understanding of how failures take place .Ably assisted by proactive condition based monitoring system ,it is possible to preempt failures by taking proactive remedial measures based on behavioral pattern distortions observed above. In order to achieve the principal strategic objective of minimizing lifecycle costs of plant and ensuring longevity of life , it is mandatory to deploy initiatives such as TPM to ensure the following: -Generating power as forecast by effective capacity utilization -Minimization of plant losses and increased plant efciency -Elimination of unplanned outages -Minimization of O&M costs especially maintenance costs which today expressed as a % of revenue expenditure are : a)Thermal(14%) b) Hydel(10%) c)Combined Cycle(6%) All these initiatives are required in view of high EPC costs(Around 5 Crores Rupees per Megawatt of power Most maintenance practices in power plants are either reactive or preventive(time,meter). Recently there has been an increasing trend of moving away from preventive maintenance and increasing deployment of condition based maintenance. Within condition based maintenance the proactive avour is preferred .because it compels a root cause analysis of why a condition went beyond control .Proactive maintenance focuses on eliminating the root cause of problems.

5 WHY ANALYSIS OF FEED WATER PUMP FAILURE

FAILURE TYPE: PUMP SET FAILS WHY 1-MOTOR FAILURE WHY 2-BEARING SEIZURE WHY 3-BEARING SEAL FAILS WHY 4-IMPROPER LUBRICATION ROOT CAUSE-LUBRICATION AND INSPECTION PROCEDURES ARE NOT WELL DEFINED AND CONTROLLED IMPACT FREQUENT BREAKDOWNS LEADING TO ENHANCED MAINTENANCE COSTS AND REDUCED EQUIPMENT LIFE REMEDY-DEFINE PROPER SPECIFICATIONS FOR OPERATIONS,LUBRICANT AND HAVE A DETAILED INSPECTION PROCEDURE IN PLACE FOR INCOMING MATERIAL

TPM builds a close relationship between maintenance and productivity of generation and creates a philosophy of continuous improvement and sense of ownership in the operator for their equipment. TPM links good maintenance practices with organizational goals and ensures protable operations through higher generation and plant reliability cum uptime. TPM assists in increasing the useful life of the plant ,minimizing life cycle costs, reducing operational losses of the power plant, minimizing unplanned outages etc.

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TPM consists of eight pillars: -Workplace Management -Autonomous Maintenance -Kaizen -Planned Maintenance -Quality Maintenance -Training -Ofce TPM -Safety, Health and Environment Workplace Management ensures that the place is organized neatly, kept clean and discipline is maintained in plant. Autonomous Maintenance downloads routine maintenance jobs to operators leaving maintenance to perform value added functions. Kaizen encourages maintenance staff to continuously improve equipment working and maintenance procedures and ensure higher throughput and uptimes. Planned maintenance aims to have trouble free plant and generate power as per demand forecast. Objectives of effective planned maintenance are zero breakdowns and reduction in maintenance costs upto 20%.Quality maintenance aims at high quality maintenance performed to ensure plant runs to designed specications. Focus is on eliminating non conformance to maintenance objectives and eliminating defects at source .Training aims to multiskill workforce and upgrade operator skills to allow them to perform autonomous maintenance. Ofce TPM aims at promoting effectiveness in administration and business processes with the objective being reduction of process losses .Safety, Health and Environment ensures that all work practices are ensured for safety before they are executed. They also ensure compliance to

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procedures for maintaining health and environment standards. Major objective of TPM is to identify and eliminate operational losses which onclude: -Breakdown losses -Startup losses -Heat losses -Equipment and Capital investment losses -Losses due to unplanned outages Causes for these losses need to be ascertained with root cause analysis and impact analysis cum remedy .Minimization of operating losses result in higher Return On Assets. The most popular measure which is used to understand how well the plant is faring is Overall Plant Effectiveness. There is a need felt to study how losses impact OPE and consequently the nancials of the company. OPE relates to Return On Assets and a small increase in OPE can result in substantial increase in operating income. Operating indices should be linked to nancial ratios such as Asset Turnover, Return On Assets etc. Performance Measurement Systems such as Balanced Scorecard, Performance Prism etc can be used to link the short term goals with the long term goals and vision of the company. OPE% = Plant Availability % * Plant Efciency% * Power Frequency within range% NOTE: Plant Efciency =(100-(Boiler Losses% + Turbine Losses% + Alternator Losses%)) PLANT AVAILABILITY = 91.81% PLANT EFFICIENCY = 29% FREQUENCY QLTY = 82.60% OPE = 0.9181 * 0.2900 * 0.8260 = 0.2199 = 21.99% A very crucial calculation to be done with respect to protability of the power plant is the opportunity cost of power not put on the grid with respect to the planned generation. LOST OPPORTUNITY = (PLANNED GENERATION ACTUAL GENERATION) * PRICE / KWH PLANNED GENERATION FOR MONTH IS 457 GWH ACTUAL GENERATED FOR MONTH IS 305 GWH DEFICIT IN GENERATION FOR MONTH IS 152 GWH GENERATED POWER IS 305/457 = 66.74% OF PLANNED OPPORTUNITY COST LOST IS 152 GWH * 4.5 RS/KWH WHICH IS 152 * (10**6) * 4.5 = 684 * (10**6) = 68.4 CRORES

CONCLUSION
TPM is a strategic initiative which when implemented effectively with full participation of top management will result in protable plant operations and ensure high plant availability and capacity utilization. . =========================END===================================

REFERENCES:
1.TPM IN PROCESS INDUSTRIES BY T.SUZUKI (PRODUCTIVITY PRESS) 2.POWER PLANT ENGINEERING BY R.K.RAJPUT