KR101010717B1 - Condition-based plant operation and maintenance management system - Google Patents

Abstract

PURPOSE: A condition-based plant operation and a maintenance management system are provided to help a user to manage all maintenance works through same procedure by standardizing maintenance works. CONSTITUTION: An administration unit(100) comprises a facility master and a work order part and manages a process of maintenance work. An operation management unit(200) receives the operation information of the facility and inquires a maintenance record and detail information. A performance management unit(300) calculates performance and efficiency at unit facility. A management department(400) evaluates the comprehensive performance of maintenance and operation of the generator.

Description

Condition-based plant operation and maintenance management system {CONDITION-BASED PLANT OPERATION AND MAINTENANCE MANAGEMENT SYSTEM}

The present invention relates to a state-based power plant operation and maintenance management system, which standardizes the facility classification system of the maintenance management unit, the reliability management unit, and the risk management unit to facilitate the linkage of information between them, and the maintenance target facility through the cost-time analysis unit. And a state-based power plant operation and maintenance management system capable of determining an optimal maintenance point for a maintenance target facility.

A power plant consists of a combination of many kinds of unit equipment and materials with different characteristics, and even if one of the facilities fails, the entire process is interrupted and causes a large loss, requiring systematic maintenance and management. With the introduction of the Enterprise Resource Plan (ERP), the importance is increasing. However, in the conventional system using independent computerized maintenance management system (CMMS) or some of the functions of the ERP system, it is difficult to transmit the operation, failure and maintenance information between the operator, the designer and the maintenance worker. Due to the incomplete management of history, the company is in the role of history management of simple maintenance work. Therefore, it takes much time for quick and accurate decision-making, and predictive maintenance for selecting systematic maintenance and optimal maintenance cycles through statistical and analysis work. It is falling short of the management level. In addition, policies that reflect the deterioration and deterioration due to long-term use in real-time monitoring of changes in the performance and the degree of damage by reflecting the results of maintenance and operation are not established.

Conventional power plant operation management system acquires real-time information from Distributed Control System (DCS) and Programmable Logic Controller (PLC) for the operation management of power plant. Since the model cannot be accessed, information cannot be obtained, and it is difficult to use the acquired operation information for functions such as preventive inspection performance management because it is difficult to systematically connect with the maintenance management system. In addition, the conventional power plant operation management system is a situation that can not support maintenance management.

On the other hand, the performance management system consists of a simple system that is mostly subordinate to the DCS facility and has been managed only by the operation department. Although the performance management system has recently introduced a single system, performance management is possible only when operation management is established as an infrastructure facility, and even though it has a function of performance management, there is a lack of definition of the related tasks and procedures related to facility and maintenance management. . Since the performance management system is operated independently without any business connection with other management systems, it is impossible to analyze the effect of facility status or maintenance work, and thus does not substantially reduce failure or improve the reliability of the facility.

Although RCM and RBI analysis technologies are applied to some power plant facilities for state-based maintenance work management and system composition, facility classification system and various code classification systems are different from those of CMMS and various code classification systems. As a result of the analysis, it is impossible to continuously utilize the CMMS.

Reliability Centered Maintenance (RCM) analysis has been procedurally used since the 1970s, but is mostly done by professional paperwork, and only analysis results have been entered and used in CMMS. In addition, despite the computerized RCM analysis tools, due to the different management systems, additional data conversion is required to reflect the RCM analysis results and to obtain information for RCM living. It was not done. Therefore, RCM analysis technology has been promoted only by service professionals and there is no record of operating in conjunction with CMMS through a separate computerized analysis program.

Moreover, in order to implement the RCM, the equipment list and the fault code system of the CMMS must be the same as the RCM system. Therefore, it is difficult to accurately implement the RCM with the conventional CMMS, and requires a large part of the program modification, which entails enormous costs. In addition, the RCM living task of evaluating the effectiveness of preventive tasks by analyzing the maintenance history of the CMMS and establishing new preventive tasks is also performed by humans, and it is difficult to apply them in the field because it is done through a separate information conversion task.

Risk Based Inspection (RBI) analysis technology has few cases applied to practice at home and abroad, and qualitative analysis is performed in the form of service by experts. In order to connect with the conventional CMMS, a significant program modification is required as in RCM, and only limited offline RBI analysis is possible.

Most power plant equipments have a limited lifespan, so they cannot operate indefinitely, and in case of sudden breakdowns or stoppages due to long-term use, the damage is large. Although time-based maintenance (TBM) has been carried out at regular intervals, the application of this TBM method is very time-consuming, since damage and failure rarely occurs until the aging is fully progressed after the initial stabilization period. This is causing a lot of losses in terms of cost.

On the other hand, a single power plant operates a maintenance management system in the form of “operation management-performance management”, and includes “operation management-performance management-maintenance management”, “RCM technology-maintenance management” or “RBI technology-maintenance management”. There are some power plants that operate maintenance management system. However, maintenance management system that organically links `` maintenance management, operation management, performance management, maintenance management (RCM analysis), risk management (RBI analysis), cost-time analysis '' No power plant has operated or applied.

Accordingly, the present invention has been made in order to solve the above problems, the first object of the present invention is to standardize the maintenance work procedures in the maintenance management unit, maintenance work in the same procedure for all maintenance work regardless of the work type The purpose is to provide a state-based power plant operation and maintenance management system that can be managed.

The second object of the present invention is a state-based power plant operation and maintenance management system capable of designing costs for maintenance work in a state-based power plant operation and maintenance management system by linking information with ERP, and having an accounting settlement and asset accounting processing function. The purpose is to provide.

The third object of the present invention is that the information management unit and the operation management unit are systematically linked by the PI tag number, so that the information management unit can manage the results of the preventive inspection and the performance of the preventive maintenance through the operation information of the operation management unit. It aims to provide a state-based power plant operation and maintenance management system.

The fourth object of the present invention is to standardize the facility classification system and code classification system in the maintenance management unit, so that the operation management unit, the performance management unit, the operation management unit, the reliability management unit, the risk management unit, and the cost-time analysis unit are organically linked with the maintenance management unit. To provide a state-based power plant operation and maintenance management system.

A fifth object of the present invention is to provide a state-based power plant operation and maintenance management system capable of performing RCM analysis and RBI analysis through information provided from a maintenance management unit without any separate processing by standardizing a facility classification system. do.

A sixth object of the present invention is to provide a state-based power plant operation and maintenance management system that can minimize maintenance costs by determining an optimal maintenance time point for a facility through a cost-time analysis unit and prevent damage and failure of the facility. For the purpose.

In accordance with the location, system and type of the equipment of the present inventors, the location number, system number and type number for each facility are stored in the facility master 121 and the facility master 121 in connection with the facility master 121. The work order unit 120 receives the information about the system number and the type number, and generates a work order for the facility according to the standard procedure 130 that standardizes the procedures for the maintenance work as one procedure. Including, the maintenance management unit 100 is a batch management process for the maintenance work of the facility; The operation information of the facility is provided from the power plant control facility system 270 in real time, the operation information is analyzed to determine an abnormal operation state of the facility, and the plant information PI tag (Plant Imformation Tag) number, which is the operation information, is provided to the facility master 121. Operation management unit 200 is linked to the facility master 121 by being registered is possible to query the maintenance history for the facility and detailed information of the facility; A performance management unit 300 for calculating performance and efficiency for each unit based on operation information provided in real time from the operation management unit 200; The operation management unit receives information from the maintenance management unit 100, the operation management unit 200, the performance management unit 300, and the ERP (Enterprise Resource Plan, 900), and evaluates the overall performance of the plant's maintenance and operation activities through the information. 400; Receiving the information on the maintenance history and failure history of the facility from the maintenance management unit 100, and the operation information of the facility from the operation management unit 200, the RCM living (Reliability Centered) Confidence in determining the type and frequency of preventive maintenance and preventive maintenance based on the results of the RCM analysis by performing the maintenance living analysis to evaluate the effectiveness of the auxiliary prevention service (511) of the auxiliary equipment, and executing the Reliability Centered Maintenance (RCM) analysis. Management unit 500; The inspection result and work order of the material of the facility are provided from the maintenance management unit 100, the operation information is received from the operation management unit 200 in real time, and RBI (Risk Based Inspection) analysis is performed, and the power plant is generated through the RBI analysis result. A risk management unit 600 for determining an inspection time, an inspection subject, and an inspection site for the remaining life of the main equipment and the next preventive maintenance of the main equipment; And a cost-time analyzer 700 for presenting maintenance target equipment and maintenance time points for the maintenance target equipment through the information provided from the reliability management unit 500 and the risk management unit 600. It is done.

The facility master 121 standardizes the location number, the system number, and the type number into the facility classification system, and the facility classification system is used in the RCM analysis of the reliability management unit 500 and used in the RBI analysis of the risk management unit 600. It is done.

The work order unit 120 is linked to the ERP 900, and the work order unit 120 includes manpower design information by labor production for each work type; Budget type material design information received from the ERP (900); Expense design information according to expense rate by type of construction; And design standards for each type of equipment are stored in data form, and the work order unit 120 generates work design proposals for maintenance work by manpower design information, material design information, expense design information, and design standards. It is done.

The standard procedure 130 includes a request procedure (131), an acceptance procedure (132), a design procedure (133), an approval procedure (134), an approval procedure (135), a completion procedure (136), and a symptom for a facility. The closing procedure 137 is performed in sequence, and the work order unit 120 is connected to the facility master 121 in the request procedure 131 to receive information about the facility from the facility master 121 and to provide a design procedure ( In step 133, if manpower design information, material design information, and expense design information for the facility are selected, a work design proposal is generated, and the work order unit 120 receives the approval procedure 134 for the quality and safety grade of the facility. According to the classification of the approval, maintenance work is approved, in the approval procedure 135, the approval rating is divided according to the quality and safety grade for the equipment, the quality and safety documents 125 are processed, and the completion procedure (136). Causes of failures, failures, maintenance work and preventive work Is 128, characterized in that the input.

Maintenance management unit 100 is connected to the work order unit 120, the history DB (database) unit 138 for storing the work order recorded the maintenance history for the facility after the end of the standard procedure (130); After the time series analysis according to the order of accident or failure of the facility, the HOPE analysis according to the human, organization, procedure and equipment is performed every time series analysis. A failure stop management unit 160 for establishing a countermeasure against the occurrence of recurrence and a similar accident and providing the countermeasure to the work order unit 120; And managing the current prevention task 511 based on the RCM analysis result in the form of waiting work for the current prevention project 115, and the planning prevention task 614 based on the RBI analysis result for the planned preventive maintenance project 116. It characterized in that it comprises a preventive maintenance maintenance unit 170 to manage in the form of waiting work.

The history DB unit 138 stores the work order in which the maintenance history and the result of the maintenance work are recorded in the form of data after the standard procedure 130, and provides the work order to the reliability management unit 500 to be used in the RCM analysis. , By providing a work order to the risk management unit 600 to be used in the RBI analysis.

The preventive maintenance maintenance unit 170 determines the result of the preventive inspection by combining the state information of the equipment input to the PDA 117, the operation information of the operation management unit 200 and the analysis result of the oil used in the equipment, The state information is characterized in that it is input into the PDA 117 is divided into a normal state, environmental failure state, initial / minor state, continuous / monitoring state and recurrence / monitoring state according to the state of the equipment.

The operation management unit 200 generates a work order for maintenance work when the facility is in an abnormal operation state, and provides the work management order for the maintenance work to the maintenance management unit 100.

The operation management unit 400 is periodically provided with the information stored in the history DB unit 138 from the maintenance management unit 100, receiving operation information from the operation management unit 200 in real time, and thermal efficiency per unit from the performance management unit 300 Is provided in real time, and receives the revenue information on the power transaction information and maintenance work indirect costs from the ERP (900), maintenance and management unit 100, operation management unit 200, performance management unit 300 and ERP (900) and It is characterized by being linked.

The operation management unit 400 divides and manages the operation indicator 420 into operation and performance indicators 451, reliability indicators 452, and maintenance management indicators 453 for each unit, and calculates the operation indicators for each unit for each unit. It is characterized by the management of the operating performance of the power plant compared to the plan by aggregating 450) by business establishment, and calculating the operating index 440 for each business establishment by company-wide management index 430.

The operation and performance indicator 451 in the operation management unit 400 is calculated through information provided in real time from the operation management unit 200 and the performance management unit 300, and includes a plurality of individual indicators, and the reliability indicator 452 is Calculated through the information provided from the reliability management unit 500, it is composed of a plurality of individual indicators, maintenance management indicator 453 is calculated through the information provided from the maintenance management unit 100, and includes a plurality of individual indicators Characterized in that.

The operation management unit 400 is characterized in that the operating performance of the individual indicators by the aggregate of the period for the plan, and by setting the reference value for each indicator in advance, based on the reference value to determine the performance of the individual indicators.

RCM analysis is performed on the wear advanced equipment, and RBI analysis is performed on the degradation advanced equipment.

The risk management unit 600 calculates the risk cost for the maintenance work through the RBI analysis, provides the risk cost to the cost-time analysis unit 700, and generates a backlog work order 631. Characterized in that provided to the maintenance management unit (100).

The state-based power plant operation and maintenance management system is linked to the ERP (900), characterized in that the material inquiry, material procurement determination, material release, material input and material retrieval processing, contract, settlement, asset accounting management.

The cost-time analysis unit 700 receives the maintenance cost according to the RCM analysis from the reliability management unit 500, generates a maintenance cost curve C1 over time, and generates the maintenance cost curve C1 according to the RBI analysis from the risk management unit 600. Given a risk cost, a risk cost curve (C2) can be generated over time, and a cost-time curve (C1) and a risk cost curve (C2) can be used to generate C3), and the optimum maintenance point of the facility is determined through the cost-time curve C3.

The cost-time analysis unit 700 applies the cost-time curve C3 for each unit to the cost-time graph for each unit, and displays the overlapping portion of the cost-time curve C3 in the cost-time graph for each unit. It is characterized by determining the optimum maintenance time, determining the equipment existing in the overlapping site as the maintenance target equipment, and presenting the maintenance target equipment and the maintenance time for the maintenance target equipment to the maintenance management unit 100.

The present invention configured as described above has the following effects.

A first effect of the present invention is to maintain a maintenance work standardized by the maintenance management unit so that maintenance work can be managed by the same procedure for all maintenance work regardless of the work type.

The second effect of the present invention is that the ERP and information are linked to enable cost design for maintenance work in a state-based power plant operation and maintenance management system, and to have accounting settlement and asset accounting processing functions.

The third effect of the present invention is that the information management unit and the operation management unit are systematically linked by the PI tag number, so that the information management unit can perform the result management of the inspection result of preventive inspection and the preventive maintenance through the operation information of the operation management unit. It is.

The fourth effect of the present invention, by standardizing the equipment classification system and code classification system in the maintenance management unit, operating management unit, performance management unit, operation management unit, reliability management unit, risk management unit and cost-time analysis unit is organically linked with maintenance management unit To make it possible.

The fifth effect of the present invention is that the equipment classification system is standardized, so that RCM analysis and RBI analysis can be executed through the information provided from the maintenance management unit without additional information processing.

A sixth effect of the present invention, through the cost-time analysis unit, it is possible to determine the optimum maintenance time for the facility to minimize the maintenance cost, and to prevent damage and failure of the facility.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 is a system diagram of a state-based power plant operation and maintenance management system according to an embodiment of the present invention. 2 is a schematic system diagram of a maintenance management unit according to an embodiment of the present invention. 3 is a system diagram for the maintenance management function of the maintenance management unit. 4 is a schematic work flow diagram for a maintenance management unit and a risk management unit of an operation management unit according to an embodiment of the present invention. 5 is a system diagram for a driving management function of the driving management unit. 6 is a schematic work flow diagram for the maintenance management unit, operation management unit and operation management unit for the performance management unit, according to an embodiment of the present invention. 7 is a system diagram for a performance management function of the performance management unit. 8 is a schematic system diagram of an operation management unit according to an embodiment of the present invention. 9 is a schematic work flow diagram for the maintenance management unit and the operation management unit of the reliability management unit, according to an embodiment of the present invention. 10 is a schematic work flow diagram for the maintenance management unit, operation management unit and cost-time analysis unit of the risk management unit, according to an embodiment of the present invention. FIG. 11A is a cost-time graph for each unit, and FIG. 11B is a cost-time graph for each unit.

As shown in Figure 1, the inventors state-based power plant operation and maintenance management system maintenance management unit 100, operation management unit 200, performance management unit 300, operation management unit 400, reliability management unit 500, risk degree The management unit 600 and the cost-time analysis unit 700 are included.

As shown in FIG. 2, the maintenance management unit 100 includes a facility master 121, a work order unit 120, a history DB unit 138, a takeover log unit 140, a current maintenance request unit 150, The failure stop management unit 160 and the preventive maintenance maintenance unit 170 is included.

The maintenance manager 100 collectively manages the maintenance work 110 for the maintenance target equipment through the work order and the standard procedure 130. The maintenance work 110 managed by the maintenance management unit 100 includes various types of construction work such as general construction 112, simple construction 113, current maintenance 114, current prevention construction 115, and planned prevention maintenance construction 116. It includes maintenance work 110, and is not limited by this embodiment.

The facility master 121 is connected to the work order unit 120 in the request procedure 131 of the standard procedure 130, and provides the work order unit 120 with information stored in the facility master 121. The facility master 121 stores the location number, system number, and type number of the facility. In addition, the facility master 121 stores not only the location number, the system number, and the type number but also the detailed information of the facility, the constituent material, the movement history, the related drawings, the PI tag number, the maintenance history, and the like.

The position number is a number indicating the position of the equipment. The location numbers are divided into five levels, from unit to unit. For example, the first level is the location of the exhalation, the second level is the location of the main equipment, such as boiler equipment, turbine equipment, generator equipment, power equipment, control computing equipment, etc. If the facilities are, for example, a boiler, the location of the boiler body, furnace, reheater, feed water supply line, reheater line, etc., the fourth level is the location of the subordinate facilities of the third level of equipment, the fifth level is Represents the location of the unit facilities that make up the subordinate facilities. In addition, a system number is a number which shows the system of a facility, and a kind number is a number which shows the kind of facility.

The facility master 121 standardizes the facility classification system into a location number, a system number, and a type number. The facility classification system of the facility master 121 is used in the RCM analysis 510 in the reliability management unit 500 and is used in the RBI analysis 610 in the risk management unit 600. Accordingly, the reliability management unit 500 and the risk management unit 600 may use the information of the maintenance management unit 100 without any additional information processing. Here, RCM means reliability centered maintenance. RBI stands for Risk Based Inspection.

Meanwhile, the work order unit 120 generates a work order according to the standard procedure 130. The work order is an instruction for maintenance work 110, which includes the location number, system number, type number, PI tag number, labor cost, expense rate, design standards, inspection standards, quality and safety documents, and It is a written record of the type, the condition of the facility, whether it is approved for the quality and safety of the facility, the status of the failure, the cause of the failure, maintenance work, preventive maintenance, preventive maintenance and maintenance. The work order confirms the maintenance history of the equipment. The standard procedure 130 will be described later.

The work order unit 120 stores reference information 123 of facilities such as labor costs, expense rates, design standards, and inspection standards. Labor cost (labour labor) refers to the employee's wages or any expenses paid in connection with labor, and labor cost (labour labor) refers to the work order unit 120 for each type of work and / or occupation. Stored by type. Expense rates are the percentage of expenses incurred by maintenance work by construction type, construction period and / or construction cost. In general, the expense rate is an average value of expense rate by construction type, expense rate by construction period, and / or expense rate by construction amount, but is not limited thereto. The design standard, on the other hand, is a standardized work design for each installation. Standardized maintenance work or routine maintenance work 114, such as planned preventive maintenance work 116, is carried out in accordance with design standards.

In addition, the work order unit 120 stores quality and safety documents 125. The quality and safety documents 125 are red tags, safety work orders, firearms permits and confined space work permits. The red tag is a manipulation prohibition table.

The work order unit 120 has a design function 122 and a technical settlement function 129. The design function 122 includes input manpower design function by labor production by work type and / or job type, required expense design function according to expense rate by construction type, construction period and / or construction amount, and material design function by budget type. The design function 122 is not implemented in the existing ERP, and the work order unit 120 may design a complete cost for the maintenance target facility through the design function 122 and the reference information 123. On the other hand, the technical settlement function 129 records the checklist, photographs, calibration values, installation positions and the number of red tags of the equipment after the maintenance work is completed.

On the other hand, the standard procedure 130 is to standardize different existing working procedures according to the type of maintenance work as a single procedure. The standard procedure 130 includes a request procedure (131), an acceptance procedure (132), a design procedure (133), an approval procedure (134), an approval procedure (135), a completion procedure (136), and a closing procedure (137). Proceed.

In the request procedure 131, the work order unit 120 is connected to the facility master 121 and receives information about the facility to be maintained from the facility master 121, that is, a location number, a system number, and a type number. In addition, the work order unit 120 is connected to the PDA 117, receives the symptoms of the maintenance target equipment from the PDA (117).

In the design procedure 133, the work order unit 120 generates a work design proposal for the input manpower and the required expenses input during the maintenance work for the maintenance target equipment through the reference information 123. The work order unit 120 is connected to the ERP 900 and receives information on material type, material quantity, inventory, specification, material cost per material, and the like from the ERP 900. Accordingly, the work order unit 120 may design a plurality of materials per budget for one work order in the design procedure 133.

In the approval procedure 134, as shown in Table 1 and Table 2, the work order unit 120 is divided into a payment grade according to the quality and safety grade for the equipment, the maintenance work 110 is approved. As shown in Tables 1 and 2, the quality and safety ratings are divided into four levels, from minor to critical maintenance. Approval of the maintenance work 110 according to the quality and safety grade is different from the payment authority according to the weight of the maintenance work (110). Accordingly, the work order unit 120 has a structure in which the payment step is simplified for the minor maintenance work 110 and the administration time is minimized. In addition, the work order unit 120 has a structure in which responsibility for the serious maintenance work 110 is strengthened. Contract request for maintenance work 110 proceeds through ERP 900 after approval procedure 134.

[Table 1] Approval and Authorization Stages by Quality Class

Classification Application criteria by grade Acknowledgment permission Design reviewer Quality reviewer Work permit R1 grade Plant-related facilities, systems or materials related work Equipment Department
Team Leader Quality safety
Department head Plant manager R2 rating Load related facility, system or material related work Equipment Department
Exaggeration quality
Exaggeration Plant manager R3 rating Maintenance work for issuance of key management facilities, weak facilities and red tags Manager of Equipment Department S grade Maintenance work related to equipment, system or material replacement other than R1 to R3 Maintenance work designer

[Table 2] Approval and Authorization Stages by Safety Level

Classification Application by Grade Acknowledgment permission design
Reviewer safety
Reviewer work
licenser S1 grade Work that is likely to cause equipment accidents Equipment Department
Team Leader Quality safety
Department head Plant manager S2 rating Work that has a high probability of equipment accidents and a minor casualty accident Equipment Department
Exaggeration safety
Exaggeration Plant manager S3 rating Minor Facility Accidents, Life and Red Tag Issuance Maintenance Work Manager of Equipment Department S4 rating Operations other than S1 to S3 Maintenance work designer

In the permitting process 135, the quality safety document 125 is processed in the payment step according to the quality and safety grade for the facility in the work order unit 120. The quality and safety ratings in the approval procedure 135 are the same as the quality and safety ratings in the approval procedure 134.

In the completion procedure 136, the work order unit 120 is coded 128 is input to the cause of the failure, failure phenomenon, maintenance work 110 results and preventive work for the maintenance target equipment. The information input to the work order unit 120 in the completion procedure 136 is used by the reliability management unit 500 during the RCM analysis, and used by the risk management unit 600 during the RBI analysis, without additional information processing, as will be described later. .

In addition, in the completion procedure 136, the type of oil used in the maintenance target equipment, such as lubricating oil, insulating oil or hydraulic oil, is input. On the other hand, the analysis value for the oil is input to the work order unit 120 for each unit, it is possible to analyze the trend line. The analysis value for the oil is analyzed in the preventive maintenance maintenance unit 170.

After the completion procedure 136, the work order unit 120 may be linked to the ERP (900) to perform accounting settlement and asset accounting for the maintenance target equipment. In addition, the work order unit 120 stores various inspection information and inspection results for each facility portion in the form of data, which is used for future maintenance history analysis.

After the closing procedure 137, the work order unit 120 generates a work order in which the maintenance history and detailed information of the maintenance target equipment are recorded. The work order that has passed through the closing procedure 137 is stored in the history DB unit 138.

On the other hand, the history DB unit 138 is stored in the work order recorded in the maintenance history for the maintenance target equipment after the standard procedure 130 is linked to the work order unit 120. The work order stored in the history DB unit 138 is provided to the reliability management unit 500 for use in the RCM analysis 510, and is provided to the risk management unit 600 for use in the RBI analysis.

The takeover log 140 is capable of managing the red tag, gas and fire management, and preventive inspection of the facility by the operator.

The minor maintenance request unit 150 requests the minor maintenance to the head office, a technical expert team, an operator, a facility department, or a maintenance company.

The failure stop management unit 160 establishes and manages a similar failure prevention plan 111 to prevent recurrence of the same accident and occurrence of a similar accident. The failure stop management unit 160 performs time series analysis according to the occurrence sequence of an accident or a failure of the facility. Thereafter, at each time-series analysis step, HOPE analysis is performed to establish a similar failure prevention plan 111. Here, the HOPE analysis is a method of analyzing the root cause of the failure of the equipment to be maintained by human, organization, procedure, and equipment. The failure stop management unit 160 provides a similar failure prevention plan 111 to the work order unit 120 when the similar failure prevention plan 111 is established. Similar failure prevention plan 111 is executed in accordance with the standard procedure 130 in the work order unit 120, and after the closing of the standard procedure 137, is stored in the history DB unit 138. Through the work order stored in the history DB unit 138, it is possible to check whether or not the similar failure prevention plan 111 is executed without a separate report.

The preventive maintenance maintenance unit 170 manages the current prevention task 511 suggested by the reliability management unit 500 in the form of waiting work for the current prevention project 115, and the planned prevention task suggested by the risk management unit 600. 614 is managed in the form of waiting work for the planned preventive maintenance work 116.

Preventive maintenance maintenance unit 170 includes a preventive maintenance maintenance master. The preventive maintenance maintenance master has a preventive maintenance cycle consisting of a maintenance cycle obtained through the RCM analysis and an arbitrary maintenance cycle input by the user, and an inspection cycle obtained through the RCM analysis and an arbitrary maintenance cycle input by the user. Are stored per plant. In addition, a preventive maintenance master is set a starting point for the preventive maintenance cycle and preventive maintenance cycle. Accordingly, the preventive maintenance and preventive maintenance work is performed according to the preventive maintenance cycle and the preventive maintenance cycle set in the preventive maintenance maintenance master for each facility based on the starting point.

In addition, the preventive maintenance maintenance unit 170 establishes a maintenance plan for preventive maintenance and preventive maintenance, through the information provided from the reliability management unit 500 and the risk management unit 600. The plan established by the preventive maintenance maintenance unit 170 is stored in the history DB unit 138.

The preventive maintenance maintenance unit 170 receives operation information from the operation management unit 200 according to a preset preventive maintenance and preventive maintenance cycle. Preventive maintenance maintenance unit 170 includes a preventive maintenance management unit 171 and preventive maintenance management unit 172.

The preventive check management unit 171 generates a preventive check plan through the type and cycle of the preventive check provided from the reliability management unit 500 and provides the preventive check plan to the PDA 117, that is, the personal information terminal. The preventive check management unit 171 manages the results of the preventive check through trend line analysis. The preventive inspection management unit 171 manages the current prevention task 511 according to the result of the RCM analysis 510 of the reliability management unit 500 in the form of waiting work for the current prevention construction 115. Here, the current prevention service 511 is a current prevention check and a current prevention maintenance.

On the other hand, the PDA 117 records the state of the facility for the maintenance target facility, and provides the recorded information to the preventive inspection management unit 171. During the preventive check, the preventive check management unit 171 stores the result of the preventive check which combines the status information of the facility input to the PDA 117, the operation information of the operation management unit 200, and the analysis result of the oil used in the facility. . Preventive maintenance is the recording of test and operating values for a facility. The state information of the facility is divided into normal state, environmental failure state, initial / minor state, sustained / monitored state and recurrence / monitored state as shown in Table 3 according to the state of the facility. The preventive check result through the trend line analysis can be viewed in the preventive check management unit 171.

Preventive maintenance management unit 172 generates a preventive maintenance plan through the type and cycle of preventive maintenance received from the reliability management unit 500, and preventive maintenance plan in the form of backlog work order 631 work order unit 120 To provide. Preventive maintenance management unit 172 manages preventive maintenance performance. The preventive maintenance management unit 172 manages the plan prevention task 614 according to the RBI analysis result of the risk management unit 600 in the form of waiting work for the plan preventive maintenance work 116. The planning preventive service 614 is planned preventive maintenance and planned preventive maintenance. On the other hand, the work order unit 120 provided with the preventive maintenance plan from the preventive maintenance management unit 172 generates a preventive maintenance work order for the maintenance target equipment, and the preventive maintenance work order PDA (117) of the maintenance company and the operator ) By the maintenance company, the expected maintenance result 136 and subsequent work results 136 for the maintenance target equipment are input to the history DB unit 138.

Preventive maintenance maintenance unit 170 is to be able to establish and manage a comprehensive plan by adding a target separately, even if the RCM and RBI management target equipment.

[Table 3] Classification of Hazards by Equipment Condition

Risk level Rating condition Detail
Stage 1
A
normal ◎ Equipment normal condition
◎ Facility operation and operation status after maintenance work (110)

2 steps

B

Environmental ◎ No problem but bad driving environment
◎ cleaning and cleaning
◎ Contamination by foreign substances such as dust, water and oil
◎ If you are concerned about the impact of pollution by surrounding facilities
3 steps
C
Initial / Minor ◎ Initial matters after maintenance work (110)
◎ Operator's Field Action
◎ Simple measures during maintenance inspection

4 steps

D

Sustain / Watch ◎ When the abnormal state of a certain level continues
-On-site action is impossible
-I need constant monitoring
Maintenance request is unnecessary
* Working with work requests when the above abnormalities are severe

5 steps

E

Recurrence / Monitor ◎ When the abnormal state recurs after the maintenance work (110)
-On-site action is impossible
-I need some level of abnormality monitoring
-No rework requests needed

On the other hand, as shown in Figure 3, the maintenance management function of the maintenance management unit 100, the location, system and type of equipment, materials, equipment specifications, drawing information, fabrication, labor costs, expenses, planned preventive maintenance (O / H, overhaul) There is information management function according to work design standard, light maintenance work standard, facility and work grade, quality and safety grade, and real-time operation information linkage. In addition, the maintenance and management unit 100 is a normal maintenance work, preventive maintenance work, general construction, simple construction, services, forensic inspection, red tag, work permit, safety permit, firearms use, approval and permission flow chart, ERP (900) It has maintenance and management functions such as linked design, contract and settlement, material billing, goods issue and return. Maintenance management unit 100 is for equipment maintenance history management, asset accounting management, high temperature components, electronic cards, equipment components, RCM, RBI, failure stop management, HOPE analysis to establish measures to prevent similar failures, air tools and measuring instruments There is facility management function. In addition, the maintenance management unit 100 receives the power plant operation indicators from the operation management unit in connection with the operation management unit, maintenance work operation status, maintenance / facility statistical analysis, operator takeover, statistical analysis, daily maintenance meeting, development plan / performance Management and so on.

On the other hand, maintenance management unit 100 is associated with the ERP (900). When the work order is closed after the closing procedure 137 of the standard procedure 130, the maintenance manager 100 provides the ERP 900 with information on the construction cost for each level, for example, the first to fifth levels. Therefore, the asset accounting management for the construction cost is made in the ERP (900), the maintenance management unit 100 can be designed cost through the information provided from the ERP (900).

As shown in Figure 4, the operation management unit 200 is operation information of the equipment from the power plant control equipment system 270 to the unit to the unit, for example, unit temperature, pressure, vibration, rotational speed, number of times and operation of each unit Operation information about the time 200 is provided in real time.

Since the PI tag number registered in the operation management unit 200 is registered in the facility master 121, the operation management unit 200 is associated with the facility master 121. Accordingly, the operation management unit 200 may be provided with detailed operation information 210 for the maintenance target equipment from the facility master 121. The operation manager 200 may query the maintenance history of the maintenance target equipment, detailed information of the maintenance target equipment, drawings, photos, and procedures through the detailed operation information 210. In addition, the operation management unit 200 generates a work order (W / O) for the maintenance target equipment directly through the work order unit 120, if the maintenance target equipment is in abnormal operation state, the work order (W / O) ) Is provided to the maintenance management unit (100).

The driving management unit 200 receives real-time driving information 220 for each unit from the power plant control facility system 270 in real time. The real time type operation information 220 includes temperature, pressure, vibration, rotation speed, start frequency, operation time, etc. of the maintenance target equipment. Operation management unit 200 through the real-time operation information 220 of the maintenance target equipment, the damage information for the facility for each unit, for example, damage information for the turbine casing, rotor, valve, boiler tube, header, boiler pipe, etc., respectively Analyze the operating condition. Accordingly, the present inventors state-based power plant operation and maintenance management system is capable of predictive maintenance through a real-time preventive check for each unit through the operation management unit 200.

The driving management unit 200 provides the driving information to the preventive maintenance maintenance unit 170 automatically or at the request of the user according to the preventive maintenance cycle set in the maintenance management unit 100. The operation information is provided to the preventive maintenance maintenance unit 170 in real time through the PI tag number registered in the maintenance management unit 100. The operation manager 200 analyzes the information and the driving information inputted to the PDA 117 in a trend line to determine the state of the facility.

On the other hand, the driving management unit 200 provides the offline RBI analysis operation information 220 and the offline RBI analysis damage information 230 to the risk management unit 600. Through the damage information 230 and the operation information 220 of the maintenance target facility, the risk management unit 600 may calculate the remaining life and the planned preventive maintenance point of the maintenance target facility in real time, and execute online and offline RBI analysis. On the other hand, control systems of power plants include programmable logic controllers of outdoor stand-alone equipment, mobile equipment, and small equipment, and control equipment systems of turbines, boilers, and auxiliary equipment.

As shown in FIG. 5, the driving manager 200 has a driving information function, a driving support function, a driving analysis function, a performance management function, and an alarm management function. The operation information function receives real-time operation information (digital signals and / or analog signals) from the plant control facility system and displays them through bar graphs and / or trend line graphs to monitor the operation status of each unit or system. . The operation management unit 200 may detect an abnormal state of the facility early through the operation information function, and at the same time, confirm the validity of the maintenance work result. Operational information functions include, for example, operation status management of the facility, trend / bar management, PI tag number management, rotor vibration management, key facility information support, power plant stop analysis logic (TRIP LOGIC) analysis and coal weighing. Management and so on.

Operation support functions include facility operation guide, operation mode guide, speed adjustment rate calculation, computerization of log sheets, and maintenance management linkage. The operation analysis function is, for example, a comparison of air condition by unit, a screen dedicated to the facility department, an on-line RBI, real-time on-site load, power schematic, and high temperature parts management. Reports, monthly reports and annual reports are generated, and the alarm management function is to provide, for example, integrated alarm management, linkage and analysis of a sequence of events (SOE), alarm analysis, alarm counting, and alarm charts.

As shown in Figure 6, the performance management unit 300 manages the efficiency and performance of the facility. The performance management unit 300 receives operation information, for example, temperature, pressure, vibration, and the like from the operation management unit 200 in real time. The performance management unit 300 calculates the performance and efficiency of the facility for each unit from the unit to the exhalation unit through the operation information. In addition, the performance management unit 300 generates a daily report on the performance and efficiency of the facility, and provides it to the maintenance management unit (100).

The performance management unit 300 is set in advance the reference efficiency value and the reference performance value for the facility for each unit. The performance management unit 300 receives the operation information from the reference efficiency value and the operation management unit 200 and calculates a deviation between the measured efficiency values of the analyzed equipment. The performance management unit 300 manages the deviation between the reference efficiency value and the measured efficiency value in real time through trend line analysis. If the deviation between the reference efficiency value and the measured efficiency value is large, the performance management unit 300 provides the maintenance management unit 100 with a long-term maintenance plan for the preventive maintenance service, while the deviation between the reference efficiency value and the measured efficiency value is small. Provide short term maintenance plan for facility reinforcement to the maintenance management unit (100).

The performance management unit 300 calculates a performance influence factor for each unit. The performance management unit 300 analyzes the change of the performance influence factor in real time, and presents the maintenance operation unit 110 to the maintenance management unit 100 for the performance recovery and improvement of the facility. Through the information provided by the performance management unit 300, maintenance operation 110, such as planned preventive maintenance, replacement of old equipment or installation of new equipment is executed in the maintenance management unit 100. The performance management unit 300 confirms the result of the maintenance work through the recovery of the trend line comparing the deviation before the maintenance work and the deviation after the maintenance work.

Performance management unit 300 provides a thermal efficiency for each unit to the operation management unit 400. On the other hand, the present inventors state-based power plant operation and maintenance management system through the performance management unit 300 by obtaining the operation information of the equipment necessary for the performance measurement and performance analysis of the unit equipment in real time, to detect the abnormal operation state of the equipment early Can be.

As shown in Figure 7, the function of the performance management unit 300 is as follows. The performance management unit 300 monitors power plant comprehensive performance, boiler / turbine comprehensive performance monitoring, boiler efficiency and loss monitoring, boiler heat absorption rate monitoring, air preheater performance monitoring, turbine expansion leading monitoring, operating value inquiry, turbine heat balance monitoring, Turbine internal efficiency monitoring, turbine shaft power monitoring, turbine cycle efficiency monitoring, feedwater heater performance monitoring, condenser performance monitoring, complex comprehensive performance monitoring, virtual simulation module monitoring, gas turbine efficiency management, steam turbine efficiency management, condenser efficiency management, heat exchange It has functions such as recovery of boiler efficiency, generator performance management, and performance monitoring between nitrogen oxide and power generation output.

As shown in FIG. 8, the operation management unit 400 determines the overall performance of the maintenance and operation activities of the power plant through the operation status 410 and the operation indicator 420. The operation manager 400 is connected to the maintenance manager 100, the operation manager 200, the performance manager 300, and the ERP 900. In detail, the operation management unit 400 is periodically provided with the information stored in the history DB unit 138 from the maintenance management unit 100, receiving the operation information in real time from the operation management unit 200, from the performance management unit 300 Received real-time thermal efficiency of each unit, received from the ERP (900) power transaction information and maintenance information (110) indirect cost revenue information, maintenance management unit 100, operation management unit 200, performance management unit 300 And in conjunction with the ERP (900), monitor the operating status of the power plant (410) in real time. Operation status of the power plant (410) is the amount of electricity generated by each exhalation, power consumption in the power plant by each exhalation, efficiency by each unit, emission characteristics, atmospheric temperature, humidity, barometric pressure, 24-hour trend line, national power system status and company power system status .

The operation management unit 400 manages operation indicators for each unit. The operation index 450 for each unit is divided into an operation and performance index 451, a reliability index 452, and a maintenance management index 453. In addition, the operation management unit 400 manages the maintenance work 110 and the fuel inventory status 454 in real time. The operation management unit 400 aggregates the operation indicators 450 for each unit managed by each unit as operation index 440 for each establishment, and aggregates the operation index 440 collected for each establishment in real time as the enterprise management index 430. In addition, the operation performance of the power plant against the plan is managed in real time.

The operation indicator 420 is generated from a relational database of the maintenance manager 100, a real-time database of the operation manager 200 and the performance manager 300. The relational database 470 that the operation management unit 400 is periodically provided from the maintenance management unit 100 includes maintenance start and end results, direct costs for the maintenance work 110, fuel inventory, fuel usage, and failure stop of the equipment. Performance information. In addition, the operation management unit 400 is a real-time type database 480 provided in real time from the operation management unit 200, the information on the amount of power generation, transmission amount and power consumption in the site.

The operation index 420 is a key performance index (KPI) that is an item-level indicator managed by the North America Electric Reliability Community (NERC). The operation indicator 420 is managed by being divided into an enterprise operation indicator 430, an operation indicator 440 for each establishment, and an operation indicator 450 for each unit.

Operation index per unit 450 is composed of operation and performance indicators 451, reliability indicators 452, maintenance management indicators 453, fuel inventory indicators, waiting work indicators and progress work indicators.

Operation and performance indicators 451 are calculated via a real-time database 480 and include individual indicators for power generation, transmission, power in the plant, thermal efficiency, and power transaction revenue. Reliability indicator 452 is calculated through relational database 470, and includes individual indicators for equipment reliability, utilization, operation rate and operation rate, maintenance management indicator 453 is calculated through relational database 470, Includes separate indicators of planned preventive maintenance air compliance rates, work closure rates, maintenance maintenance and safety incidents. Fuel inventory indicators include individual indicators for baseline inventory and daily inventory, and standby work indicators include individual indicators for in-service, out-of-stop, preventive, weighing and breakdown operations. Include individual indicators for class, safety class and permit class.

The operation management unit 400 checks the integrity of the data between the data of the relational database 470 and the data of the real-time database 480 through information linkage between the relational database 470 and the real-time database 480 for each individual indicator. (461), to confirm the accuracy of the data. In the operation management unit 400, a reference range is set for each individual indicator, and the individual indicators are divided into over, normal, or under, based on the performance of the reference range. For example, in the operation management unit 400, the performance of the plan for each individual indicator for a certain period of time in the past, for example, for the past three months, is accumulated as daily information and displayed in the form of monthly aggregation. If the plan's performance exceeds the standard range, it is displayed in red, and if it is within the standard range, it is displayed in green. Accordingly, the inventors state-based power plant operation and maintenance management system allows the operation management unit 400 to intuitively recognize the operating performance of the power plant. In addition, through the operation management unit 400, each of the individual indicators can be analyzed trend line, the user can easily recognize the past operating performance and corrective measures of the insufficient indicators.

As shown in FIG. 9, the reliability management unit 500 compares the preventive work statistical data by the work order provided by the history DB unit 138 with the information provided from the operation management unit 200 with respect to the power plant auxiliary facilities. RCM analysis. The reliability management unit 500 determines whether to continuously carry out preventive checks and preventive maintenance on the auxiliary equipment subject to the RCM analysis through the RCM analysis. Here, the preventive work statistical data is the data recorded in the work order provided from the history DB unit 138, that is, the data quantifying the maintenance history and failure history of the facility.

The reliability management unit 500 is a unit for a certain period of time, for example, every three years for the power plant auxiliary facilities, the mean failure period (MTFT), the US Power Research Institute (EPRI) database, INI (International) stored in the preventive service DB 520 Nominal Internal) RCM Living Analysis (530) is performed on the maintenance history and failure history of the facility based on the database or manufacturer's reference information to evaluate the effectiveness of current injuries.

The reliability management unit 500 performs the RCM analysis 510 through the results of the RCM living analysis 530 to set the type and cycle of new preventive inspection and preventive maintenance on the maintenance target equipment. The reliability management unit 500 provides the type and cycle of preventive maintenance to the preventive maintenance management unit 171 in consideration of the operation of the facility, and provides the type and cycle of preventive maintenance to the preventive maintenance management unit 172. do.

Here, the RCM analysis 510 refers to analyzing a malfunction of a power plant system, analyzing a failure mechanism for each type of facility, and determining whether to continuously perform preventive tasks, that is, preventive inspection and preventive maintenance for each facility. For example, the RCM analysis 510 analyzes whether a failure will occur when the facility is used to some extent based on the quantified statistical data.

The equipment to be analyzed for RCM is mainly power plant auxiliary equipment such as air compressors, differentiators and valves with wear-prone components. Facilities subject to RCM analysis are subject to routine preventive maintenance, such as parts replacement, measurement and disassembly.

The reliability management unit 500 is provided with a work order in which the maintenance history is recorded in connection with the history DB unit 138 in which the facility maintenance history and the facility failure history of the facility and the facility failure history of the facility are stored. Reliability management unit 500 is a statistic, such as the failure phenomenon, the cause of the failure, the action at the time of the failure, the time required for the maintenance work 110, etc. that occur mainly in the auxiliary equipment for each of the auxiliary equipment through the above work order. The reliability management unit 500 uses the work order to determine the type of preventive work of the corresponding auxiliary equipment, the type of the maintenance work 110, the failure phenomenon, the cause of the failure, the action according to the failure, and the time required for the maintenance work 110. Therefore, an RCM living analysis is conducted to analyze the effectiveness of the preventive task, the average failure cycle, and the average maintenance cycle. Here, the RCM living analysis 530 is a three-year unit that analyzes maintenance history, failure history, and certified preventive maintenance statistical data (520-EPRI DB, INI DB, and manufacturer's standards, etc.) to preventive inspection and preventive maintenance by unit. Evaluate the effectiveness of sustaining practices to establish new preventive work types and cycles.

In addition, the reliability management unit 500 is associated with the facility master 121. RCM analysis 510 system of the reliability management unit 500 is the same as the facility classification system of the maintenance management unit 100, it is possible to use the information of the facility master 121 without additional processing.

The reliability management unit 500 executes the RCM analysis 510 analyzing the system malfunction, the failure mechanism by type, and the preventive task by facility through the information provided from the facility master 121. After the RCM analysis 510, the reliability management unit 500 divides the execution state of the preventive work into the operation of the facility or the operation of the facility, and sets the type and cycle of the new preventive inspection or the type and cycle of the preventive maintenance, and the maintenance management unit. Provided to the preventive maintenance maintenance unit 170 of (100). The frequency of preventive maintenance and preventive maintenance can vary depending on the installation. The preventive maintenance maintenance unit 170 generates an inspection or maintenance plan of the facility through the information provided from the reliability management unit 500, manages the inspection result after the inspection and manages the maintenance result through the trend line.

The present inventors state-based power plant operation and maintenance management system can establish a maintenance strategy to prevent future failures through the RCM living and can derive preventive work recommendations.

As shown in FIG. 10, the risk management unit 600 receives information from the maintenance management unit 100 for a turbine, a boiler, a generator, and the like, which are deterioration-type equipments. The risk management unit 600 analyzes the information based on RBI (Risk Based Inspection), analyzes the inspection result and the operation history of the facility after the planned preventive maintenance work, determines the current state of the facility, and then predicts the next inspection point, the inspection subject, and the inspection site. do.

The risk management unit 600 is associated with the facility master 121. RBI analysis system of the risk management unit 600 is the same as the facility classification system of the maintenance management unit 100, it is possible to use the information of the facility master 121 without additional processing.

The risk management unit 600 receives a work order from the maintenance management unit 100, receives the operation information from the operation management unit 200 in real time, and executes the RBI analysis 610. The work order provided by the risk management unit 600 from the maintenance management unit 100 records detailed information on the equipment such as equipment inspection results such as non-destructive inspection, tissue inspection, specimen test inspection, and failure history of the equipment. Meanwhile, the risk management unit 600 analyzes operation information (eg, temperature, pressure, flow rate) and damage in real time from the operation management unit 200 on the basis of the damage probability and the damage size of the equipment stored in the history DB unit 138. Information (eg damage rates) is provided to analyze the risk and remaining life of the installation and update future inspection points to reflect the operating or shutdown status of the installation.

After the RBI analysis, the risk management unit 600 provides the maintenance prevention unit 100 with the planned preventive maintenance (O / H, overhaul) time point 613 and the planned preventive service 614.

The risk management unit 600 calculates the risk cost 612 of the maintenance work 110 through the RBI analysis, and provides the cost-time analysis unit 700 with information about the risk cost 612. In addition, the risk management unit 600 generates a backlog work order 631 and provides the preventive maintenance manager 172 of the maintenance manager 100. The backlog work order 631 is a work order in the waiting state. The backlog work order 631 is issued before the expected maintenance time arrives. The backlog work order 631 in which the inspection result and the facility history 138 are re-analyzed is used as the RBI analysis 610 input information for presenting the next inspection point 630 for the new remaining life 620 of the facility.

Here, the RBI analysis 610 predicts the risk cost 612 due to the failure of the facility by analyzing the detailed risk 611 by receiving the results of the non-destructive inspection, the histological examination, and the sample test of the material of the facility from the maintenance management unit 100. Then, the change in the operating environment and the operation rate information are acquired from the operation management unit 200 to analyze the remaining life of the equipment and the next maintenance time 630. The risk management unit 600 may evaluate the operation state 621 of the facility through the RBI analysis.

On the other hand, RBI analysis is classified into offline RBI analysis and online RBI analysis. The offline RBI analysis is the same as the RBI analysis used conventionally. On-line RBI analysis receives real-time operation information and damage information from the operation management unit 200 to analyze the remaining life (620) and the next inspection point (630) of the facility, the analysis result is maintained through the backlog work order (631) The preventive maintenance maintenance unit 170 of the management unit 100 is registered.

The cost-time analysis unit 700 presents the maintenance target equipment, the maintenance timing, and the maintenance range through the information provided from the reliability management unit 500 and the risk management unit 600. In detail, the cost-time analysis unit 700 receives the maintenance cost from the reliability management unit 500 for each unit through the RCM analysis 510 for each part, and the risk cost from the risk management unit 600 through the RBI analysis for each part. 612 is provided for each unit. The cost-time analysis unit 700 generates a cost-time curve C3 in which the curve C1 of the maintenance cost and the curve C2 of the risk cost cross each other in the cost-time graph for each unit.

The cost-time analysis unit 700 determines that the intersection point of the maintenance cost curve C1 and the risk cost curve C2 in the cost-time graph for each unit shown in FIG. 11A is the optimum maintenance point of the unit. do. In addition, the cost-time analyzer 700 determines a maintenance target, a range, and a maintenance time point by applying a cost-time curve C3 for each unit to a cost-time graph for each unit.

The expiratory cost-time graph shown in FIG. 11B shows, for example, a pump C3 _p , a boiler C3 _b , a generator C3 _g , a turbine C3 _t , and ventilation for each unit. The cost-time curve C3 for the fan C3 _f is shown. The cost-time analyzer 700 determines an overlapping portion of the cost-time curves C3 _p , C3 _g , C3 _b , and C3 _{t for each} unit in the cost-time graph for each unit as an optimal maintenance point. It is determined that the equipment existing within the optimum maintenance time frame is the optimum maintenance target. On the other hand, the optimal maintenance point of the cost-time curve C3 _f of the ventilation fan is a vertex portion of the curve.

The maintenance cost is a correction of the ordinary maintenance cost to the planned preventive maintenance work cost obtained from the maintenance management unit 100, and is a result of the RCM analysis for each part of the reliability management unit 500. The maintenance cost is continuously reduced if the continuous operation is performed without stopping after the implementation of the planned preventive maintenance work (116). On the other hand, if the risk cost 612 is continuous operation without stopping after the implementation of the planned preventive maintenance 116, the probability of failure of the equipment is increased to the contrary, increases. Risk cost 612 is the result of an RBI analysis. In the risk management unit 600, a risk cost 612 for a material cost, a labor cost, a work cost, an economic loss cost, etc. is calculated and set in advance according to the type of damage for each inspection site of the RBI management target facility.

On the other hand, cost-time analysis is to determine the optimum time of maintenance in consideration of the change in the state of the facility according to the use time of the facility. The cost-time analysis forms a cost-time curve (C3) to analyze the economic equipment point of time for each unit.

The exemplary embodiments described above are intended to be illustrative, not limiting, in all aspects of the invention. Accordingly, the present invention is capable of many modifications and detailed implementations which may be obtained from those contained within the specification by those skilled in the art. All such modifications and variations are to be considered as within the scope and spirit of the invention as defined by the following claims.

1 is a system diagram of a state-based power plant operation and maintenance management system according to an embodiment of the present invention.

2 is a schematic system diagram of a maintenance management unit according to an embodiment of the present invention.

3 is a system diagram for the maintenance management function of the maintenance management unit.

4 is a schematic work flow diagram for a maintenance management unit and a risk management unit of an operation management unit according to an embodiment of the present invention.

5 is a system diagram for a driving management function of the driving management unit.

6 is a schematic work flow diagram for the maintenance management unit, operation management unit and operation management unit for the performance management unit, according to an embodiment of the present invention.

7 is a system diagram for a performance management function of the performance management unit.

8 is a schematic system diagram of an operation management unit according to an embodiment of the present invention.

9 is a schematic work flow diagram for the maintenance management unit and the operation management unit of the reliability management unit, according to an embodiment of the present invention.

10 is a schematic work flow diagram for the maintenance management unit, operation management unit and cost-time analysis unit of the risk management unit, according to an embodiment of the present invention.

FIG. 11A is a cost-time graph for each unit, and FIG. 11B is a cost-time graph for each unit.

Claims (17)

According to the location, system and type of the facility, the location number, system number and type number for each facility is stored in the facility master 121, and the location number from the facility master 121 in association with the facility master 121 The work order unit receives the information about the system number and the type number, and generates a work order for the facility according to a standard procedure 130 that standardizes a procedure for maintenance work as a single procedure. Maintenance management unit 100, including 120, the process for the maintenance work of the facility is collectively managed; The operation information of the facility is provided from the power plant control facility system 270 in real time, the operation information is analyzed to determine an abnormal operation state of the facility, and the PI tag (Plant Imformation Tag) number, which is the operation information, is the facility. An operation management unit 200 which is registered with the master 121 so as to be connected with the facility master 121 and inquire the maintenance history of the facility and detailed information of the facility; A performance management unit 300 for calculating performance and efficiency for each unit based on the operation information provided in real time from the operation management unit 200; Received information from the maintenance management unit 100, the operation management unit 200, the performance management unit 300 and the ERP (Enterprise Resource Plan, 900), through the information comprehensive performance of the maintenance and operation activities of the power plant Evaluating the operation management unit 400; Receive the information on the maintenance history and failure history of the facility from the maintenance management unit 100, and the operation information of the facility from the operation management unit 200 for the auxiliary facilities of the power plant on a predetermined basis. And evaluating the effectiveness of the current preventive task 511 of the ancillary equipment by performing an analysis of RCM Living (Reliability Centered Maintenance Living), and performing a preventive check and preventive maintenance through the results of the RCM analysis by performing a Reliability Centered Maintenance (RCM) analysis. Reliability management unit 500 for determining the type and period of the; Receiving the inspection result and the work order for the material of the facility from the maintenance management unit 100, and receives the operation information from the operation management unit 200 in real time to execute RBI (Risk Based Inspection) analysis, A risk management unit 600 determining an inspection time, an inspection object, and an inspection site for the remaining life of the main equipment of the power plant and the next preventive maintenance through the RBI analysis result; And It includes a cost-time analysis unit 700 for presenting the maintenance target equipment and the maintenance time point for the maintenance target equipment through the information provided from the reliability management unit 500 and the risk management unit 600. State-based power plant operation and maintenance management system, characterized in that. The method of claim 1, The facility master 121 standardizes the location number, the system number, and the type number into a facility classification system. The facility classification system is used in the RCM analysis of the reliability management unit 500, the state-based power plant operation and maintenance management system, characterized in that used in the RBI analysis of the risk management unit (600). The method of claim 1, The work order unit 120 is associated with the ERP 900, The work order unit 120 Manpower design information by labor product by work type; Material design information for each budget type received from the ERP (900); Expense design information according to expense rate by type of construction; And The design standard for each type of the facility is stored in the form of data, The work order unit 120 is a state-based power plant operation and maintenance management, characterized in that the work design for the maintenance work is generated by the manpower design information, the material design information, the expense design information and the design standard system. The method of claim 3, wherein The standard procedure 130 includes a request procedure (131), an acceptance procedure (132), a design procedure (133), an approval procedure (134), an approval procedure (135), and a completion procedure (136) in which symptoms for the facility are input. ), And the closing process (137) in sequence, The work order unit 120 is In connection with the facility master 121 in the request procedure 131, receiving information about the facility from the facility master 121, If the manpower design information, the material design information, and the expense design information for the facility are selected in the design procedure 133, generate the work design proposal, The work order unit 120 In the approval process 134, the payment grade is divided according to the quality and safety grade for the facility, the maintenance work is approved, In the permit procedure 135, the payment grade is divided according to the quality and safety grade for the facility, and the quality and safety documents 125 are processed, In the completion procedure (136), the cause of the failure, failure phenomenon, maintenance work result and preventive work for the facility is coded (128) is input, characterized in that the power plant operation and maintenance management system. The method of claim 1, wherein the maintenance management unit 100 A history DB unit 138 that stores the work order in which the maintenance history of the facility is recorded after the standard procedure 130 is linked to the work order unit 120; After the time series analysis according to the order of occurrence of the accident or failure of the facility, the HOPE analysis according to the human, organization, procedure, and equipment is performed for each time series analysis. A failure stop management unit 160 for establishing a countermeasure for preventing a recurrence of an accident and occurrence of a similar accident and providing the countermeasure to the work order unit 120; And The current preventive work 511 based on the RCM analysis result is managed in the form of waiting work for the current preventive work 115, and the planned preventive maintenance work 614 based on the RBI analysis result is performed by the planned preventive maintenance work 116. State-based power plant operation and maintenance management system, characterized in that it comprises a preventive maintenance maintenance unit 170 for managing in the form of waiting work. The method of claim 5, wherein the history DB unit 138 is After the standard procedure 130, the work order in which the maintenance history and the result of the maintenance work are recorded is stored in the form of data. Providing the work order to the reliability management unit 500 to be used in the RCM analysis, State-based power plant operation and maintenance management system, characterized in that for providing the work order to the risk management unit 600 to be used in the RBI analysis. The method of claim 5, The preventive maintenance maintenance unit 170 is The result of the preventive check is determined by combining the status information of the facility input to the PDA 117, the operation information of the operation management unit 200 and the analysis result of the oil used in the facility, The state information of the facility is classified into a normal state, an environmental defect state, an initial / minor state, a sustained / monitored state, and a recurrence / monitoring state according to the state of the facility and is input to the PDA 117. Power plant operation and maintenance management system. According to claim 1, wherein the operation management unit 200 When the facility is in an abnormal operation state, a work order for maintenance work is generated, and a state-based power plant operation and maintenance management system, characterized by providing the maintenance work work order to the maintenance management unit (100). According to claim 1, wherein the operation management unit 400 Periodically received information stored in the history DB unit 138 from the maintenance management unit 100, receiving the operation information in real time from the operation management unit 200, the thermal efficiency of each breath from the performance management unit 300 Received in real time, and receives the revenue information on the power transaction information and maintenance work indirect costs from the ERP (900), State-based power plant operation and maintenance management system, characterized in that associated with the maintenance management unit (100), the operation management unit (200), the performance management unit (300) and the ERP (900). The method of claim 9, wherein the operation management unit 400 The operating indicators 420 are classified and managed by operation into performance and performance indicators 451, reliability indicators 452, and maintenance management indicators 453. Aggregate by operation unit (450) for each of the units collected by the unit, The operation index 440 for each establishment counted by each establishment is aggregated as an enterprise management index 430, State-based power plant operation and maintenance management system, characterized in that the management of the operating performance of the power plant compared to the plan in real time. The method of claim 10, wherein in the operation management unit 400 The driving and performance indicator 451 is calculated through the information provided in real time from the driving management unit 200 and the performance management unit 300, and includes a plurality of individual indicators, The reliability indicator 452 is calculated through the information provided from the reliability manager 500, and consists of a plurality of individual indicators, The maintenance management index 453 is calculated through the information provided from the maintenance management unit 100, the state-based power plant operation and maintenance management system, characterized in that it comprises a plurality of individual indicators. The method of claim 11, wherein the operation management unit 400 By calculating the operating results compared to the plan for the individual indicators for each period, by setting a reference value for the individual indicators in advance, A state-based power plant operation and maintenance management system, characterized in that for determining the operating performance of the individual indicators based on the reference value. The method of claim 1, The RCM analysis is performed on the wear progress facility, Wherein said RBI analysis is performed on a deteriorated advanced plant. According to claim 1, wherein the risk management unit 600 Through the RBI analysis, the risk cost for the maintenance work is calculated, and the risk cost is provided to the cost-time analysis unit 700, State-based power plant operation and maintenance management system, characterized in that to generate a backlog work order (631, backlog work order) to provide to the maintenance management unit (100). According to claim 1, wherein the state-based power plant operation and maintenance management system The state-based power plant operation and maintenance management system, characterized in that the material inquiry, material procurement determination, material release, material input and material return processing, contract, settlement, asset accounting management in connection with the ERP (900). The method of claim 1, wherein the cost-time analysis unit 700 Receiving the maintenance cost according to the RCM analysis from the reliability management unit 500, generates a maintenance cost curve (C1) over time, By receiving the risk cost according to the RBI analysis from the risk management unit 600, generates a risk cost curve (C2) over time, Through the maintenance cost curve (C1) and the risk cost curve (C2), to generate a cost-time curve (C3) in the cost-time graph for each unit, The state-based power plant operation and maintenance management system, characterized in that for determining the optimum maintenance time of the facility through the cost-time curve (C3). The method of claim 16, wherein the cost-time analysis unit 700 The cost-time curve C3 for each unit is applied to the cost-time graph for each unit, In the cost-time graph for each breath, the optimum maintenance time is determined for the overlapped portion of the cost-time curve C3, the facility existing at the overlapped portion is determined to be the maintenance target equipment, and the maintenance target equipment and the maintenance State-based power plant operation and maintenance management system, characterized in that to present the optimum maintenance time for the target facility to the maintenance management unit (100).

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