Академический Документы
Профессиональный Документы
Культура Документы
Improving
Equipment Reliability
And
Plant Efficiency
Through
PM Optimization
Laurence P. Johnson
President
3651-E Peachtree Parkway, Suite 303
Suwanee GA, 30024
Tel: 1 (770) 886-9655
lpjohns@fractalsoln.com
Improving Equipment Reliability and Plant Efficiency
Through PM Optimization
At Kewaunee Nuclear Power Plant
Laurence Johnson
President
Fractal Solutions
Fractal Solutions, Inc.
Suwanee, Georgia
PM Optimization Process
PM Optimization Software
The program started by forming the PM Optimization
When the original RCM program was started in 1989,
team. Positions were solicited through the KNPP Re-
evaluation information was kept as hard copy documents.
source Allocation Process and respondents were selected
Every step in the program was documented by hand and
based on their skills, knowledge, and experience. The PM
filed away in a department file cabinet. This was a labor-
Optimization process was modified to incorporate KNPP’s
intensive process and did not lend itself to a sustainable
corporate objectives and goals and to integrate with exist-
living program.
ing plant programs. The consultant’s experience, latest
In 1991 the RCM team developed an application in industry practices4, INPO guidelines5 6, and EPRI reports7
8 9
ORACLE. This made it easier to perform system evalua- were used as references for program development. The
tions and retrieve stored information. In 1994, when the old RCM program instructions were modified and used as
transition from RCM to PM Optimization took place, it desktop instructions during the first pilot system evalua-
was recognized that tion. The PM Optimization process flow is depicted in
Figure 1.
the RCM application could not support a streamline proc-
ess without extensive modification. KNPP reviewed in- A final adjustment to PREMO XPERTS™ was made to
dustry publications, talked to industry contacts and con- meet the KNPP-specific data configuration and to model
sultants, and ultimately selected PREMO XPERTS™ for the evaluation process, making full range evaluation pos-
their PM Optimization software. PREMO XPERTS™3 sible and providing the base for the Outlier evaluation and
was designed in MS Access™ and provided support for all the Living Program.
phases of the PM Optimization program.
There are two phases in the PM Optimization program.
Once a component is evaluated in PREMO XPERTS™, Phase One’s starting point is the current PM program.
that information is readily available and is automatically Current PM tasks are compared to critical functions to
retrieved if that component is identified in subsequent ensure that appropriate failure mechanisms are being ad-
systems. Thus, as system evaluations are completed, there dressed. This is appropriate for a mature PM program, as
are a diminishing number of unique components to be it is safe to assume that past performance and maintenance
evaluated. This eliminates like components from previous history has dictated the current program content. How-
evaluations not being recognized and evaluation efforts ever, this does not preclude the addition of PM tasks when
duplicated. recent plant or industry experiences warrants. Phase Two
focuses on components outside the current PM program.
Another benefit of PREMO XPERTS™ is the linkage of
A screening process identifies components that are Func-
inter- and intra- disciplinary PM tasks in the Planning and
tionally Significant (FSI), while eliminating from further
Scheduling system. This is especially helpful during plant
consideration those components considered inherently
outages when tasks are rescheduled. In the past, KNPP’s
reliable or functionally insignificant. The FSIs are then
outage task scheduling relied heavily on personnel cogni-
evaluated similar to Phase One components.
zance of related or dependent tasks. There was no auto-
matic link between those tasks and, as a result, when one Phase One: Legacy Evaluation
item was rescheduled, others impacted were not necessar-
System Selection and Function Identification
ily identified at the most opportune time. This was espe-
cially crucial if there is a very small window of availability KNPP’s shift to a 18 month cycle dictated that all 65 plant
in which there was to perform all of the related tasks. systems were to be included in the PM Optimization pro-
PREMO XPERTS™ provided that automatic link making gram. The initial program scope was limited to electrical
scheduling and schedule manipulation much easier and and mechanical components. The KNPP I&C department
less time consuming.
Pre-Screen to Select
Collect Performance
Functionally Significant
and Failure Data
Items
3.
Perform Failure
Mode Analysis
4.
6.
Track Implementation
Progress
8.
Living Program
9.
Although a mature legacy PM program should contain all • Number of PM tasks added was 109. Annualized
components that affect critical system functions, screening number was 71.
components outside the program will ensure no critical • Total cost for PM Optimization program, including
components were excluded. Components that are not be- direct labor and consultant costs was $650,000.00.
ing addressed by a PM task have a screening methodology
applied to identify FSI’s, while eliminating those compo- • Time to recover program costs was 10 months.
nents that are considered inherently reliable or function- • Total annual saving is $809,000.00 or $12,500.00 per
ally insignificant from further consideration. Using system per year.
PREMO XPERTS™, the PMEL is compared to the MEL
and a list is generated of all non-PM components. At the • First years savings were $159,000.00.
end of the screening process only those FSIs lacking asso-
• A cumulative saving in five years after implementa-
ciated PM tasks remain and are labeled as “Outsiders”.
tion is $3,295,000.00.
The Outsiders are then evaluated similar to Phase One
components. The Outlier Evaluation results in adding
appropriate PM tasks for components not previously ad-
dressed in the PM program.
Cost-Benefit Analysis
While the PM Optimization Living Program and its re-
lated plant availability improvement measurement will