Transcript FORUM MATERIAL HAPUA

SPARE PART POOL PROGAM
Suparno
PT Pembangkitan Jawa Bali
Sumatera
Kalimantan
2006
2010
Sales (TWh)
3.8
4,5
7,1
No.of Cust. (M)
1.8
2
3.8
6,0
Capacity (GW)
0,7
1,3
56.9
61,9
Electrif Ratio (%)
58.7
52,9
2006
2010
Sales (TWh)
14.6
16,3
No.of Cust. (M)
6.6
Capacity (GW)
Electrif Ratio (%)
Sulawesi
2006
2010
Sales (TWh)
3.6
4,4
No.of Cust. (M)
2.1
2,6
Capacity (GW)
0.9
1,3
Electrif Ratio (%)
57.2
53,8
Others
Jawa-Bali
2006
2010
2006
2010
Sales (TWh)
3.7
5,3
87
125,9
No.of Cust. (M)
1.8
2,1
No.of Cust. (M)
23.4
27,3
Capacity (GW)
0.6
1,1
Capacity
(GW)
4/23/2020
18,6
28,3
Electrif Ratio
40.2
37,9
Electrif Ratio
63.5
69,4
Sales (TWh)
2
PLN Organisation
PLN (HOLDING)
PLN Region/Distribution BU
PLN Dispatching Center BU
PLN Training Centre BU
Subsidiary :
- Indonesia Power
- PJB (Java Bali)
- PLN Engineering
- PLN Batam
- PLN Tarakan
PJB Highlight 2008
• EXISTING :
– Installed Capacity : 6,491 MW
– Sales : 30 TWh
– Market Share (Java) : 26 %
– No. of Employees : 2,200
• JVC :
– Cilacap SPP (Coal) : 2 x 300 MW
– Asahan HEPP : 2 x 90 MW
– Gunung Megang GT : 2 x 40 MW
PJB Power Plant
MUARA KARANG
SPP (OIL) : 300 MW
SPP (Nat. Gas) : 400 MW
CCPP (Nat. Gas) : 508 MW
MUARA TAWAR
CCPP (OIL/Nat. Gas) :
920 MW
Jakarta
GRESIK
SPP (Nat. Gas) : 600 MW
GT
: 101 MW
CCPP (Nat. Gas) : 1,579 MW
MADURA
JAVA
WEST
CENTRAL
BALI
EAST
T.DUKU
GT : 35 MW
CIRATA
HEPP : 1,008 MW
INSTALLED CAP. PJB : 6,491 MW
BRANTAS
HEPP : 275 MW
PAITON
SPP (Coal) : 800 MW
Power Plant Governance PJB
PERFORMANCE
KINERJA
Finance
Prod.Cost
Keuangan : Pendapatan
Revenue and, Biaya
Produksi
Operation
Operasi
: EAF, EFOR,
EFOR,
Efisiensi
Efisiensi
Performance
Management
BSC
Maturity Level
GENERATION PLAN
Assesment Lead &
Lag Programe and
Performance
indicator
Continuous
Improvement
Manajemen
Risk
Management
Risiko
Reliability
Improvement
Management
WPC
Optimasi
Management
WPC
Outage
Management
Continous Improvement :
Continuous
Improvement
Material
Supply
Chain
Management
Management
Efficiency
Efficiency
Management
Management
SMM, SMM,
SMT(
SML, SMK3
SMK3)
Information
People
Management
& Work Culture
System
People & Work Culture
People & Work Culture
Operation
EAMS
& ME
Management
- Physical Asset
- Knowledge Asset
- Human Asset
Power Plant Performance
• Availability
• Reliability
• Thermal Effisiency
PJB
• Strategic Spares Policy
• MOU PJB – IP- PG BU PLN
• List Of Strategic spares
Material Mgt. Support
• Service Level
– Time
– Quality
– Quantity
– Price
HAPUA PP Community
• Objective :
– Spare Part Pool Program
– Sharing Information
•
•
•
•
•
•
Data share (Machine, Equipment , Spare Part)
Supplier (Manufacture, Vendor, Distributor , Agent)
Price List
OEM vs Non OEM
LTSA
E- Commercial
– Sharing Policy
Constraint
•
•
•
•
•
•
Tax Policy
Exim Policy
Corporate Policy
Accounting Policy
Transportation
Government Regulation
Material Mgt Governance PJB
PERFORMANCE
Service Level, Purchase Effectiveness,
Inventory Level, Turn Over
Maturity Level
Continuous
KPI Process
Assesment Lead &
Lag Programe and
Performance
indicator
Improvement
Procedure and Policy
Requirement
Management
Inventory
Management
Warehouse
Management
Purchasing
Management
Supplier
Management
Continous Improvement :
Information Management System
People and Work Culture
- Physical Asset
Continuous
- Knowledge Asset
Improvement
- Human Asset
MATERIAL Mgt BUSSINES PROCESS
GOAL
SERVICE LEVEL
MATERIAL
MANAGAMENT
TIME
MATERIAL
DEMAND
QUALITY
INVENTORY
LEVEL
For“Receiving”
Inventory Level
On Schedule
On Quality
On Quantity
On Cost
QUANTITY
PLANING &
CONTROLING
“REQUIREMENT”
What ?
How ?
When ?
Who ?
Inventory
Policy
PLANING &
CONTROLING
“INVENTORY”
Outage
Management
Recomended
Order
What Order ?
How many Order ?
When Order?
Supplier
Management
PLANING &
CONTROLING
“PROCUREMENT”
Issue
Strategic
Spares
OPERATION & MAINTENANCE UNIT
Service
MATERIAL
REQUIREMENT
ROUTINE
PERIODIC
REQ. IDENTIFY
CORRECTIVE
OVERHAUL
PREVENTIVE
PROJECT
• INVENTORY
POLICY
• STRATEGIC
SPARE
REQ. PLANNING
• OUTAGE
MANAGEMENT
• APLICATION
PART LIST (APL)
ROP & ROQ
INVENTORY
PLANNING
JIT
PROCUREMENT PLANNING
• LTSA
• NON LTSA
• INDIVIDUAL STOCK
• ALIANCE STOCK
• CONSIMENT STOCK
STOCK METODE
Material Mgt Organisation PJB
BOD
Approval Authority
HEAD OFFICE
OWN PRICE ESTIMATE
INVENTORY CONTROLER
CORPORATE
PROCUREMENT
Process Authority
POWER PLANT
CATALOGER
PROCUREMENT
INVENTORY CONTROLER
OWN PRICE ESTIMATE
WAREHOUSING
THANK YOU
Iventory Policy PJB
Material Identify based in ABC Analisys
(Criticality, Availbility , Usage value)
Inventory Control Treatment
Purchasing Treatment
Identify based on Requirement
• Warehouse Stock
• ROP & ROQ
• Min & Max
• Consignment Stock
• Just In Time
• LTSA
Optimal item Stock and Value
Optimal Service Level
Strategic Spares PJB
Maintenance Priority Index (MPI )
Equipment
Level
Coorporate
Policy
Condition factor
1. Unit influen
2. Demage Pola
3. Need Pola
4. Assembly quantity
5. Changeable methode
6. Lead time to work/change part
7. Unit price
8. Delivery time
Strategic
Spares
Part Level
ABC Analysis
Outage Management PJB
Frame Work Outage Mgt. :
PRE
OUTAGE
OUTAGE
EXECUTION
PLANNING
18 bln
POST
OUTAGE
PREPARATION
12 bln
6 bln
3 bln
1 bln
1 Mng
0 bln
OH
R1
R2
( Skope, Anggaran, ( Skope, Anggaran,
Sparepart Utama ) Sparepart Utama )
R3
( Skope, Anggaran,
Sparepart Pendukung )
P1 , P2 , P3
( Skope, Anggaran,
Sparepart Umum )
FEED BACK ( Input next Inspection )
OH
Application Part List (APL) PJB
Store and Inventory
Supply Catalog
Searching Methods
Searching Methods
Application Part List
Equip Ref
Equip Group ID
Component Code
Modifier Code
Sequence No
Maint Sched Task
Standard Job Task
Work Order Task
Component
Component
Component
Scope Of Work
-
Major or Serious Inspection
Turbine or Mean Inspection
Combustion or Simple Inspection
6 Monthly
3 Monthly
Monthly
2 Weekly
Etc
Equip Group ID
Group Equipment
Equip Register
Equipment
WORK FLOW MATERIAL MANAJEMENT PJB
MUARA KARANG POWER PLANT
No.
Unit
Turbine
Merk
Operation
RPM
Year
Merk
Generator
Capicity
Volt MVA Cos Q MW
SPP 1
MITSUBHISHI
3000
1979
MITSUBHISHI
11500
125.00
0.8
100.00
SPP 2
MITSUBHISHI
3000
1979
MITSUBHISHI
11500
125.00
0.8
100.00
SPP 3
MITSUBHISHI
3000
1979
MITSUBHISHI
11500
125.00
0.8
100.00
SPP 4
MITSUBHISHI
3000
1981
MITSUBHISHI
18000
250.00
0.8
200.00
SPP 5
MITSUBHISHI
3000
1982
MITSUBHISHI
18000
250.00
0.8
200.00
GT 1.1
GE
3000
1992
GE
11500
142.00
0.8
107.86
GT 1.2
GE
3000
1992
GE
11500
142.00
0.8
107.86
GT 1.3
GE
3000
1992
GE
11500
142.00
0.8
107.86
ST1.0
GE
3000
1995
GE
11500
237.50
0.8
185.00
MUARA TAWAR POWER PLANT
No.
Turbine
Unit
Merk
GT 1.1
ABB
GT 1.2
RPM
Operation
Generator
Capacity
Years
Merk
Volt
MVA
Cos Q
MW
3000
1997
ABB
16000
182,70
0,8
145,00
ABB
3000
1997
ABB
16000
182,70
0,8
145,00
GT 1.3
ABB
3000
1997
ABB
16000
182,70
0,8
145,00
ST1.0
ABB
3000
1997
ABB
16000
182,70
0,8
225,00
GT 2.1
ABB
3000
1997
ABB
16000
182,70
0,8
145,00
GT 2.2
ABB
3000
1997
ABB
16000
182,70
0,8
145,00
GRESIK POWER PLANT
No.
Turbine
Unit
Merk
SPP 1
TOSHIBA
SPP 2
RPM
Operatin
Generator
Capacity
Yaer
Merk
Volt
MVA
Cos Q
MW
3000
1981
TOSHIBA
13200
125.00
0.8
100.00
TOSHIBA
3000
1981
TOSHIBA
13200
125.00
0.8
100.00
SPP 3
TOSHIBA
3000
1988
TOSHIBA
15000
250.00
0.8
200.00
SPP 4
TOSHIBA
3000
1988
TOSHIBA
15000
250.00
0.8
200.00
GT 1
ALSTHOM
5100
1978
ALSTHOM
11000
25.13
0.8
20.10
GT 2
ALSTHOM
5100
1978
ALSTHOM
11000
25.13
0.8
20.10
GT 4
GE
5100
1993
GE
11500
30.40
0.67
20.10
GT 5
GE
5100
1993
GE
11500
30.40
0.67
20.10
GT 1.1
MITSUBHISHI
3000
1992
SIEMENS
10500
153.75
0.8
112.45
GT 1.2
MITSUBHISHI
3000
1992
SIEMENS
10500
153.75
0.8
112.45
GT 1.3
MITSUBHISHI
3000
1992
SIEMENS
10500
153.75
0.8
112.45
ST1.0
MITSUBHISHI
3000
1993
SIEMENS
15750
251.75
0.8
188.91
GT 2.1
MITSUBHISHI
3000
1992
SIEMENS
10500
153.75
0.8
112.45
GT 2.2
MITSUBHISHI
3000
1992
SIEMENS
10500
153.75
0.8
112.45
GT 2.3
MITSUBHISHI
3000
1992
SIEMENS
10500
153.75
0.8
112.45
ST 2.0
MITSUBHISHI
3000
1993
SIEMENS
15750
251.75
0.8
188.91
GT 3.1
MITSUBHISHI
3000
1993
SIEMENS
10500
153.75
0.8
112.45
GT 3.2
MITSUBHISHI
3000
1993
SIEMENS
10500
153.75
0.8
112.45
GT 3.3
MITSUBHISHI
3000
1993
SIEMENS
10500
153.75
0.8
112.45
ST 3.0
MITSUBHISHI
3000
1993
SIEMENS
15750
251.75
0.8
188.91
BRANTAS POWER PLANT
UNIT
No.
Turbine
Unit
Merk
1
TOSHIBA
2
RPM
Operation
Generator
Capacity
Year
Merk
Volt
MVA
Cos Q
MW
250
1973
TOSHIBA
11000
39
0,9
35,00
TOSHIBA
250
1973
TOSHIBA
11000
39
0,9
35,00
3
TOSHIBA
250
1974
TOSHIBA
11000
39
0,9
35,00
1
TOSHIBA
143
1978
MEIDENSHA
11000
30
0,9
27,00
2
TOSHIBA
143
1980
MEIDENSHA
11000
30
0,9
27,00
LODOYO HEPP
1
TOSHIBA
150
1983
MEIDENSHA
6600
5,3
0,85
4,50
SENGGURUH
1
BOVING
176,5
1988
ELIN
11000
16,2
0,9
14,50
HEPP
2
BOVING
176,5
1988
ELIN
11000
16,2
0,9
14,50
TULUNG AGUNG
1
VOEST ALPINE MCE
375
1993
ELIN
11000
20
0,9
18,00
HEPP
2
VOEST ALPINE MCE
375
1993
ELIN
11000
20
0,9
18,00
MENDALAN
1
ESCHER WYSS
750
1930
OERLIKON
6000
7
0,8
5,60
HEPP
2
STORK HOLLAND
750
1955
SCHORH
6000
7,25
0,8
5,80
3
STORK HOLLAND
750
1955
SCHORH
6000
7,25
0,8
5,80
4
STORK HOLLAND
750
1955
SCHORH
6000
7,25
0,8
5,80
1
ESCHER WYSS
600
1955
BBC
6000
4,5
0,8
3,6
2
ESCHER WYSS
600
1931
OERLIKON
6000
4,5
0,8
3,6
3
ESCHER WYSS
600
1955
BBC
6000
4,5
0,8
3,6
SELOREJO HEPP
1
EBARA
500
1973
MEIDENSHA
6600
5,6
0,8
4,48
GIRINGAN HEPP
1
STROK HENGELO
1000
1955
SMITH.S.
6300
1,28
0,7
0,90
2
STROK HENGELO
1000
1955
SMITH.S.
6300
1,28
0,7
0,90
3
ESCHER WYSS
1000
1937
HEEMAF
6300
2,00
0,7
1,40
1
NEYRPIC
1000
1959
ALSTHOM
6300
1,28
0,7
0,90
2
NEYRPIC
1000
1959
ALSTHOM
6300
1,28
0,7
0,90
3
NEYRPIC
1000
1959
ALSTHOM
6300
1,28
0,7
0,90
1
B.MAIER
1000
1968
AEG
6300
2,75
0,8
2,20
SUTAMI HEPP
WLINGI HEPP
SIMAN HEPP
GOLANG HEPP
NGEBEL HEPP
PAITON POWER PLANT
UNIT
SPP Coal
No.
Turbine
Unit
Merk
1
TOSHIBA
3000 1993 TOSHIBA 18000 473.00 0.85
400.00
2
TOSHIBA
3000 1993 TOSHIBA 18000 473.00 0.85
400.00
RPM
Operation
Generator
Capacity
Year Merk Volt MVA Cos Q MW
CIRATA POWER PLANT
No.
Turbine
Unit
Merk
HEPP
1
VOEST ALPINE
HEPP
2
HEPP
UNIT
RPM
Operation
Year
Generator
Merk
Capacity
Volt
MVA
Cos Q
MW
187,5
1988 ELIN UNION 16500
140,00
0,90
126,00
VOEST ALPINE
187,5
1988 ELIN UNION 16500
140,00
0,90
126,00
3
VOEST ALPINE
187,5
1988 ELIN UNION 16500
140,00
0,90
126,00
HEPP
4
VOEST ALPINE
187,5
1988 ELIN UNION 16500
140,00
0,90
126,00
HEPP
5
VOEST ALPINE
187,5
1997 ELIN UNION 16500
140,00
0,90
126,00
HEPP
6
VOEST ALPINE
187,5
1997 ELIN UNION 16500
140,00
0,90
126,00
HEPP
7
VOEST ALPINE
187,5
1998 ELIN UNION 16500
140,00
0,90
126,00
HEPP
8
VOEST ALPINE
187,5
1998 ELIN UNION 16500
140,00
0,90
126,00
Action Plan