Post on 24-Oct-2020
MPCProductivity Conference 2011
Sharing Company Experience
YTL Power Services Sdn Bhd
• YTL Paka808 MW CCPP
• YTL Pasir Gudang404 MW CCPP
• Kuala LumpurHead Office
Malaysia
Contractual Power Output - 7,450 GWh per Year
10% of electricity demandof Peninsular Malaysia
Malaysia
YTL Power Services - Mission
YTL Power Services is committed tohighest standards
of quality, health, safety, andenvironmental care
for areliable and efficientgeneration of power
continuous improvement
journey
innovativeO & M
programmes
additional ventures
YTL Power Services
Review & analysis of each equipment & systemFocus on design, function, recommended maintenance programmes & consequences of failure
Reliability Centered Maintenance (RCM)
Strategy
ObjectivesConclusion
Method
Challenging conventional maintenance programmes provided by the suppliers’ manualsEnhance availability, reliability, productivityReduce maintenance costs
Revision of maintenance routines & operating procedures
RCM - Implementation Schedule
• RCM analysis, 3rd phaseNovember 2000 to December 2002
• RCM analysis, 2nd phaseMay 1998 to June 2000
• Internal TrainingAugust 1995 to August 1996
• RCM analysis, 1st phaseMarch 1996 to February 1998
• RCM analysis, 2nd phaseMay 1998 to June 2000
0
1,000
2,000
3,000
4,000
5,000
Mechanical Electrical C&I
recommended by supplier's manual
after RCM introduction
recommended by supplier's manualafter RCM implementation
RCM - Reduction of Maintenance Activities
- 60%- 60%
- 30%- 30%
- 23%- 23%
Gas Turbine Availability - V94.2
WorldStandard
YTLAverage
89
90
91
92
93
94
95
96
91.20%
95.23%
0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
3.00%
3.50%
4.00%
Low “Forced Outage Rate”
< 4%
1.20%
0.32%
WorldStandard
Energy Commission
YTLAverage
1 % higher Plant Availability is equivalent to
about 15 Million RMincrease of revenue per year
• Vibration Monitoring150 equipments including gas turbines, steam turbines, pumps, compressors and diesel generators
• Thermography24 equipment areas like transformers, switchgear, distribution boards, batteries, boiler expansion joints
• Oil Analysis12 major equipments including gas turbines, steam turbines, pumps, compressors and diesel generators
Condition Monitoring
continuous improvement
journey
innovativeO & M
programmes
additional ventures
YTL Power Services
Condition Monitoring - Customers
PT YTL Jawa Timur, Paiton, Indonesia
Perak Hanjoong Cement,Taiping, PerakPahang Cement, Bukit Sagu, Pahang
Slag Cement, Southern, JohorSlag Cement, Westport, Selangor
Major Overhaul of Gas Turbines
Strategic Partner – SIEMENS19 Countries - 316 Projects - 64 Specialists
Major Overhaul of Gas Turbines - Manpower
0
10
20
30
40
50
60
70
02/03 03/04 04/05 05/06 06/07 07/08 08/09 09/10
ForemanHS OfficerSpecialist WelderGas Turbine Specialist
Erection & Commissioning Services
Strategic Partner – SIEMENS36 Countries - 78 Projects - 212 Engineers
Current Projects
Previous Projects
Erection & Commissioning Services - Manpower
ChemistCivil EngineerCoal & Ash Engineer Comm. Assist. Mgr. Mech.Comm. Engineer C&IComm. Engineer Elec.Comm. Engineer Mech.Comm. Manager Mech.Erection SupervisorExpediterHSE AdvisorOperation Supp. Engineer OperatorPTW Engineer QA Engineer Shift Charge EngineerShift CoordinatorStore ManagerSupervisorSystem AdministratorTechnical Field AdvisorTraining EngineerWarranty Engineer
Disciplines:
0
10
20
30
40
50
60
70
80
90
100
2006 2007 2008 2009 2010 2011
O & M of Power Stations outside Malaysia
Deir Amar & Zahrani LebanonEach 450 MW CC Plants
Power Seraya - Singapore3100 MW Licensed CapacityCoGen, CC & ST Plants, RO Plant
Paiton II - Indonesia1200 MW Licensed CapacityCoal Fired Power Station
O & M Partnership with Petrovietnam Power
18%
51%
12%8%
11%
• Developing a Partnership with Petrovietnam Power • Founding Shareholder of Petrovietnam Power Services
• Commercial Operation of Ca Mau 1&2 in 2008, 2x750 MW CCGT, Siemens
• Commercial Operation of Nhon Trach 1 in 2008, 1x450 MW CCGT, Al t
LILAMA 18 Joint Stock Company
Comp. for Technology Development (CFTD)
PVP personnel
continuous improvement
journey
innovativeO & M
programmesadditional ventures
YTL Power Services
YTLPS Quality Excellence Journey
1994 1996 2000 2002 2005 - 2010
1st IPP in Malaysia
2003 2004
YTLPS Quality Excellence Journey
1st O&M - ISO 9002:1994
1994 1996 2000 2002 2005 - 20102003 20041994 2000
YTLPS Quality Excellence Journey
1st in Malaysia - ISO 9001:2000
1994 1996 2000 2002 2005 - 20102003 2004
YTLPS Quality Excellence Journey
World Record - Fastest Overhaul Time
1994 1996 2000 2002 2005 - 20102003 2004
YTLPS Quality Excellence Journey
NATIONAL SAFETY AWARD
1994 1996 2000 2002 2005 - 20102003 2004
YTLPS Quality Excellence Journey
INDUSTRY EXCELLENCE AWARD
1994 1996 2000 2005 - 201020042002 - 2003
YTLPS Quality Excellence Journey
HR DEVELOPMENT AWARD
1994 1996 2000 2002 2005 - 20102003 2004
YTLPS Quality Excellence Journey
ISO 9001:2008ISO 14001:2004
OHSAS 18001:2007
IMS
1994 1996 2000 2002 2005 - 20102004
YTLPS Quality Excellence Journey
QUALITY MANAGEMENT EXCELLENCE AWARD
1994 1996 2000 2002 20102004
YTL Power Services Sdn Bhd
‘the distinguishedpremier power plant
operation & maintenance company’
Front PageKeynote SpeakerDato’ Nik Zainiah Nik Abd Rahman�Advisor�Ministry of International Trade & IndustryThierry Geiger, Global Leadership Fellow, World Econimic Forum
Panel ListAmiruddin Abdul Satar A.M.N Executive Director/Chief Operating Officer, KPJ Healthcare BerhadMartin Metzger, Deputy Managing Director, YTL Power Services Sdn. Bhd.Zuheer Mohammed Majid, Senior Vice President - Trade Operations, Citigroup Transaction Services (M) Sdn. Bhd.
Stream SpeakerStream ASheikh Omar Abdul Rahman, Principal Consultant of SOAR Consulting Sdn. Bhd.Palaniappan Joseph, General Manager Of Panasonic HA Air Conditioning (M) Sdn. Bhd.Dr. Peter Woods, Head of Knowledge Management Centre, Multimedia University
Stream BY.M. Raja Dato’ Seri Aman Raja Haji Ahmad,Chairman Ahmad Zaki Resources BerhadEddy Mazuaansyah Mohd Ali MuradMinistry of Domestic Trade, Cooperative & Consumerism Salmah Bee Mohd Mydin, Head of Licensing Department Securities Commission Adrian ChippindaleOffice of Best Practice Regulation, Australia
Stream CDr. Dominic Lau, Director of Applied Research Center, UCSI Blue Ocean Strategy Regional CentreHussein Mohd Ariff, Honorary Secretary of Malaysian Association of Creativity & Innovation (MACRI) Aznir Bin Abdul MalekGeneral Manager, Productivity & Quality Management, Tenaga Nasional Bhd.
Stream DCheng Poh Guat, Director of Vita Agrotech Sdn. Bhd.Muhammad Usamah Zaid Yasin, Creative Director of Les' Copaque ProductionSyamil Fahim Mohd Fahim, Executive Director/Opration of Kumpulan Karangkraf Sdn. Bhd.