Maintenance Management

in Power Plant and

its effectiveness
 Maintenance Management
• Aimed at Optimum Plant Availability
• Maximising Capacity Utilization
• It is very critical in ABT regime
• Revenue Loss due to loss of Production is
much higher than Maintenance Cost
• Maximum resource utilization
• Safety in work, equipment & environment
When to carry out maintenance?

As per requirement

How to carry out ?

Optimal way
 Maintenance Management
Knowledge & Awareness
about
Process & Equipments

Methods
Tools Operation & Maintenance
& Requirements
Technologies
 Power Plant Systems & Equipments
• Main Power Generation & Evacuation Systems & Equipments
eg Boiler, Turbine, Generator,Generator Transformer and SWYD
equipments (breakers, isolators) with instruments & control systems

• Auxiliaries provided for safe & efficient operation of above main

equipments & systems
eg ID,FD, PA fans, BFP, CEP, excitation system, with instruments
& control systems

• Auxiliaries Plants installed to process & handle

- Inputs like water, air and fuel (oil and coal) eg DM Plant,CHP
- By product eg, AHP

• Other systems for providing safety& suitable working environment

eg Fire fighting system, AC, Air washer & Ventilation systems
 Maintenance Concepts
• Preventive Maintenance
• Corrective (Break down )maintenance
• Predictive Maintenance
• Opportunistic Maintenance
• Design-for/ Design-out Maintenance
• Health Usage Maintenance System
 Preventive Maintenance
• Planned Maintenance
• Periodic inspection of Plant & equipment
to prevent break downs before they occur
• Repetitive Servicing, upkeep and overhaul
of equipment
• Adequate Lubrication, cleaning and House
Keeping
 Preventive Maintenance …contd.
• Proper Identification of equipment
• Adequate records covering Volume of
Cost & Work
• Inspection on Definite schedule
• Use of Checklist by maintenance Person
• Well qualified Maintenance Staff
• Frequency and schedule is decided
 Preventive Maintenance …contd.
• Proper Procedure for fulfillment and
follow up
• Formal Procedure for planning and
scheduling the work
• Time standards for all maintenance works
• Record of Equipment behaviour, failure
History & inspection findings
 Advantages of P.M.
• Greater Safety for workers
• Decreased Production Downtime
• Better Conservation of Assets
• Increased Life Expectancy
• Reduction in large scale & repetitive
failures
 Advantages of P.M. …contd.
• Less standby equipment required
• Better Spare Parts Control
• Lower Unit Cost of production due to
planned Maintenance
• High Equipment Reliability
 Disadvantages of P.M.
• Many Times Maintenance is done well
before it is needed
• Increased cost of maintenance
• Wastage of Resources
 Corrective Maintenance
• Often it is an emergency
• Maintenance becomes Repair Work
• Very High Loss of Production
• Downtime is not only of time taken to
complete the job but also delay due lack of
resources
 Corrective Maintenance …contd.
• High Maintenance Cost
• Low Availability
• Less effectiveness
• Unplanned Demand for Maintenance
• Less effectiveness
• Stressing and Dangerous work
 Predictive Maintenance
• This is Condition Based Maintenance
• Bath Tub Curve Analysis
• It is an strategy to carry out Preventive
Maintenance at irregular Interval
• Shut down is planned when resources are
available and assessing Generation
Schedule
Steps of Predictive Maintenance
• Selecting Critical Machine for Programme
• Establishing a Programme specifying the
parts to be examined and method of
examining them
• Establishing danger limits of parameter
e.g. Vibration, Temperature, sound etc.
• Selecting Proper Examination Frequency
Steps of Predictive Maintenance
• Importance of machine in process flow
chart, availability of standby machine &
operating condition
• Finding Cost of examination & Overall
cost of Failure & maintenance
• Training of Inspectors and examiners
• Establishing Schedule and budget of
maintenace
 Basic Methods of Monitoring
• Visual Monitoring
• Vibration Monitoring
• Wear and Debris Monitoring
• Performance Monitoring
• Corrosion Monitoring
• Structural Integrity Monitoring
 Advantages of CBM
• Increased Plant Availability
• Improved safety
• Reduced Maintenance Cost
• Better Resource Utilisation
• Experience leading to better specification
for future Plant and Machinery
 Limitations of CBM
• Access of Probe not foreseen at design
stage
• Machine with in accessible parts
• Parts which collapse suddenly due to
failure
 Types of Maintenance in Power Plant

• Routine Maintenance
• Preventive Maintenance
• Scheduled Maintenance
• Break Down Maintenance
• Diagnostic or Periodical Maintenance
 Maintenance Management in
TPP
• Routine Maintenance
• Annual Overhaul
• Defect Rectification
• Work Request
• Scheduling & measuring of work
• Quality checks
• Production Calculation
• Different Management Ratio
 Scope of Maint. Planning
• Over all Time and resource Planning
• Scheduling of Resources
• Issue and work Control
• Progress Monitoring
• Assessment of Productivity
• Reduce Plant Outages
• Condition Monitoring
 Scope of Maint. Planning ….Contd.
• Monitoring Maintenance Cost
• Improve resource Utilisation
• Forecasting Target Dates
• Long Term Planning
• Short Term Planning
• Outage Planning
• Spare Parts Planning
 Scope of Maint. Planning ….Contd.
• To develop five years Rolling Plan
• To develop Station Annual Plan
• To Create Standard Data Bank for
reference
• Overhauling Management
 Essential Inputs
• Detailed and defined work Activity
• Standard work hour pattern and job duration
• Overall Time of outage
• Types of crafts men and skill required, their
availability and productivity
• Requirement of spares & Consumables, tools &
Plants etc., their source of availability
 Essential Inputs…….Contd.
• Mobilisation of resources within given time
• Progress Monitoring of work
• Quality Checks
• Feedback System
• Budget i.e. Finance
• Generation Budget
• Fuel Budget
• Spares Budget
• Manpower Budget
• Revenue Budget
 Function of LTP
• Compilation of Station Five year Rolling
Plan
• To Prepare and ensure all necessary
arrangement for the year’s overhaul work
programme
• Produce, Distribute and Monitor major
overhaul and control programme
 Function of LTP …..Contd.
• Operate Section of PTW system Before,
during and after major overhaul
• Custody of all licences of equipments
under Indian Boiler Regulation Act, Indian
Electricity Act, Indian Explosive Act and
other safety Rules.
 Function of STP
• Development & Monitoring of Station
work control system
• Co-ordinate with maintenance sections and
apprise them about plant reports
• Information about proposed shut down if
any, cooling, drains or constraints that
might delay the availability of permit to
start maintenance work
 Function of STP ……Contd.

• Liasion with Operation department for the

planning of defects rectification & apprise them
about maintenance work and delay if any.
• Allocation of station maintenance manpower to
achieve short term and long term objectives
• Maintain and Improve co-ordination between
plant operation and maintenance
• Plant Inspection Programme and progress
• Scheduling based on inputs from long term
planning
 Function of STP ……Contd.

• To organise and provide service to daily

plant meeting.
• To maintain history of all equipments, Plant
inventory cards and spare list cards
• Updates and maintain work order cards
• To maintain on-going lists of priority work
and to ensure that short term plant overhaul
programme is prepared and issued as
required.
 Handling Outage
• Daily Outage Meeting
• Work Progress Reporting system
• Manpower Reporting system
• Recommissioning checks
• Documentation of data
 Changing Paradigm
• Reliability Centered maintenance
• Risk evaluation and Priortisation
• Total Productive Maintenance