SPARE PART POOL PROGAM Suparno PT Pembangkitan Jawa Bali.

SPARE PART POOL PROGAM

Suparno

PT Pembangkitan Jawa Bali

04/18/23

2

J awa-Bali 2006 2010

Sales (TWh) 87 125,9

No.of Cust. (M) 23.4 27,3

Capacity (GW) 18,6 28,3

Electrif Ratio 63.5 69,4

Sumatera 2006 2010

Sales (TWh) 14.6 16,3

No.of Cust. (M) 6.6 7,1

Capacity (GW) 3.8 6,0

Electrif Ratio (%) 56.9 61,9

Kalimantan 2006 2010

Sales (TWh) 3.8 4,5

No.of Cust. (M) 1.8 2

Capacity (GW) 0,7 1,3


Sulawesi 2006 2010

Sales (TWh) 3.6 4,4

No.of Cust. (M) 2.1 2,6



Others 2006 2010

Sales (TWh) 3.7 5,3

No.of Cust. (M) 1.8 2,1


Electrif Ratio 40.2 37,9

PLN Organisation

PLN Region/Distribution BU

PLN Training Centre BU

Subsidiary :

PLN Dispatching Center BU

PLN (HOLDING)

- PLN Engineering- PLN Batam- PLN Tarakan

- Indonesia Power- PJB (Java Bali)

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

MUARA KARANGSPP (OIL) : 300 MWSPP (Nat. Gas) : 400 MWCCPP (Nat. Gas) : 508 MW

MUARA TAWARCCPP (OIL/Nat. Gas) : 920 MW

CIRATAHEPP : 1,008 MW BRANTAS

HEPP : 275 MWPAITONSPP (Coal) : 800 MW

INSTALLED CAP. PJB : 6,491 MW

GRESIKSPP (Nat. Gas) : 600 MWGT : 101 MWCCPP (Nat. Gas) : 1,579 MW

PJB Power Plant

WEST

CENTRALEAST

MADURA

BALI

JAVA

Jakarta

T.DUKUGT : 35 MW

Power Plant Governance PJB

GENERATION PLAN

Reliability Improvement

OptimasiWPC

Outage Management

Supply Chain Management

Efficiency Management

EAMS & ME

Manajemen Risiko

People & Work Culture

Continuous

Improvement

KINERJAKeuangan : Pendapatan , Biaya Produksi

Operasi : EAF, EFOR, Efisiensi

SMM, SML, SMK3

GENERATION PLAN

Reliability Management

WPC Management

Outage Management

MaterialManagement

EfficiencyManagement

OperationManagement

Risk Management

Continuous Improvement

Information Management System

Continuous

Improvement

PERFORMANCEFinance : Revenue and Prod.Cost

Operation : EAF, EFOR, Efisiensi

SMT( SMM, SMK3)

People & Work CulturePeople & Work Culture

PerformanceManagement

BSC Maturity Level

Assesment Lead & Lag Programe and Performance indicator

Continous Improvement :

- 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

• Tax Policy

• Exim Policy

• Corporate Policy

• Accounting Policy

• Transportation

• Government Regulation

Constraint

KPI Process

Maturity Level

Continuous

Improvement

Assesment Lead & Lag Programe and Performance indicator

Continuous

Improvement

Continous Improvement :

- Physical Asset

- Knowledge Asset

- Human Asset

PERFORMANCEPERFORMANCEService Level, Purchase Effectiveness,Service Level, Purchase Effectiveness,

Inventory Level, Turn OverInventory Level, Turn Over

WarehouseManagement

Requirement Management

Inventory Management

Purchasing Management

Procedure and Policy

Information Management System

People and Work Culture

Sup

plie

r M

anag

emen

t

Material Mgt Governance PJB

MATERIAL MATERIAL DEMAND DEMAND

INVENTORY INVENTORY LEVELLEVEL

TIMETIME

QUALITYQUALITY

QUANTITYQUANTITY

Issue Issue

Service Service

SERVICE LEVEL SERVICE LEVEL

PLANING & PLANING & CONTROLING CONTROLING

“REQUIREMENT“REQUIREMENT””

PLANING & PLANING & CONTROLING CONTROLING ““INVENTORY”INVENTORY”

PLANING & PLANING & CONTROLING CONTROLING

“PROCUREMENT”“PROCUREMENT”

OP

ER

AT

ION

& M

AIN

TE

NA

NC

E U

NIT

OP

ER

AT

ION

& M

AIN

TE

NA

NC

E U

NIT

Su

pp

lier

Su

pp

lier

Man

agem

ent

Man

agem

entRecomended Recomended

OrderOrder

What ?What ?How ?How ?When ?When ?Who ?Who ?

For“Receiving” For“Receiving” Inventory Level Inventory Level

What Order ?What Order ?How many Order ?How many Order ?When Order?When Order?

MATERIAL MATERIAL MANAGAMENTMANAGAMENT

On ScheduleOn ScheduleOn QualityOn QualityOn QuantityOn QuantityOn CostOn Cost

GOALGOAL

MATERIAL Mgt BUSSINES PROCESSMATERIAL Mgt BUSSINES PROCESS

Inventory Inventory PolicyPolicy

Outage Outage ManagementManagement

Str

ateg

ic

Str

ateg

ic

Sp

ares

Sp

ares

MATERIAL REQUIREMENT

ROUTINE PERIODIC

PREVENTIVE PROJECT

• OUTAGE MANAGEMENT

• APLICATION PART LIST (APL)

ROP & ROQ JIT

• INDIVIDUAL STOCK• ALIANCE STOCK• CONSIMENT STOCK

• INVENTORY POLICY

• STRATEGIC SPARE

CORRECTIVE OVERHAUL

• LTSA• NON LTSA

REQ. PLANNING

INVENTORY PLANNING

PROCUREMENT PLANNING

REQ. IDENTIFY

STOCK METODE

Material Mgt Organisation PJB

WAREHOUSINGINVENTORY CONTROLER

CATALOGER

OWN PRICE ESTIMATE

PROCUREMENT

INVENTORY CONTROLER CORPORATE

OWN PRICE ESTIMATE

PROCUREMENT

HEAD OFFICE

POWER PLANT

BOD

Process Authority

Approval Authority

THANK YOU

Iventory Policy PJBIventory Policy PJB

Material Identify based in ABC Analisys(Criticality, Availbility , Usage value)

Inventory Control Treatment Purchasing Treatment

Optimal Service Level

• Warehouse Stock • ROP & ROQ• Min & Max

• Consignment Stock • Just In Time• LTSA

Identify based on Requirement

Optimal item Stock and Value

Strategic Spares PJB

Strategic Spares

Equipment Level

Part Level

Condition factor 1. Unit influen2. Demage Pola 3. Need Pola 4. Assembly quantity5. Changeable methode 6. Lead time to work/change part7. Unit price8. Delivery time

ABC Analysis

Maintenance Priority Index (MPI )

Co

orp

orate

Po

licy

Frame Work Outage Mgt. :Frame Work Outage Mgt. :

R1 ( Skope, Anggaran,Sparepart Utama )

6 bln

0 bln

3 bln1 bln

1 Mng

PRE PRE OUTAGEOUTAGE

OUTAGEOUTAGEEXECUTIONEXECUTION

POST POST OUTAGEOUTAGE

OHOHOHOH

FEED BACK ( Input next Inspection )

PLANNINGPLANNING PREPARATIONPREPARATION

R2

( Skope, Anggaran, Sparepart Utama )

18 bln12 bln

OH

R3 ( Skope, Anggaran,

Sparepart Pendukung )

P1 , P2 , P3 ( Skope, Anggaran,

Sparepart Umum )

Outage Management PJB

Application Part List

Equip RefEquip Group IDComponent CodeModifier CodeSequence No

Supply Catalog

Searching Methods

Store and Inventory

Searching Methods

Equip Register

Equipment

Equip Group ID

Group Equipment

Work Order Task

Component

Standard Job Task

Component

Maint Sched Task

Component

Scope Of Work

- Major or Serious Inspection- Turbine or Mean Inspection- Combustion or Simple Inspection- 6 Monthly- 3 Monthly- Monthly- 2 Weekly- Etc

Application Part List (APL) PJB

WORK FLOW MATERIAL MANAJEMENT PJBWORK FLOW MATERIAL MANAJEMENT PJB

MUARA KARANG POWER PLANT MUARA KARANG POWER PLANT

No. Turbine Operation Generator CapicityUnit Merk Year Merk Volt MVA Cos Q MW

SPP 1 MITSUBHISHI 3000 1979 MITSUBHISHI 11500 125.00 0.8 100.00





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

RPM

MUARA TAWAR POWER PLANT MUARA TAWAR POWER PLANT

No. Turbine Operation Capacity

Unit Merk Years Merk Volt MVA Cos Q MW

GT 1.1 ABB 3000 1997 ABB 16000 182,70 0,8 145,00

GT 1.2 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

RPMGenerator

GRESIK POWER PLANT GRESIK POWER PLANT

No. Turbine Operatin Capacity

Unit Merk Yaer Merk Volt MVA Cos Q MW

SPP 1 TOSHIBA 3000 1981 TOSHIBA 13200 125.00 0.8 100.00




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



ST1.0 MITSUBHISHI 3000 1993 SIEMENS 15750 251.75 0.8 188.91




ST 2.0 MITSUBHISHI 3000 1993 SIEMENS 15750 251.75 0.8 188.91




ST 3.0 MITSUBHISHI 3000 1993 SIEMENS 15750 251.75 0.8 188.91

RPMGenerator

BRANTAS POWER PLANT BRANTAS POWER PLANT


Unit Merk Year Merk Volt MVA Cos Q MW

SUTAMI HEPP 1 TOSHIBA 250 1973 TOSHIBA 11000 39 0,9 35,00

2 TOSHIBA 250 1973 TOSHIBA 11000 39 0,9 35,00

3 TOSHIBA 250 1974 TOSHIBA 11000 39 0,9 35,00

WLINGI HEPP 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

SIMAN HEPP 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

GOLANG HEPP 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

NGEBEL HEPP 1 B.MAIER 1000 1968 AEG 6300 2,75 0,8 2,20

RPMGenerator

UNIT

PAITON POWER PLANTPAITON POWER PLANT



SPP Coal 1 TOSHIBA 3000 1993 TOSHIBA 18000 473.00 0.85 400.00

2 TOSHIBA 3000 1993 TOSHIBA 18000 473.00 0.85 400.00

RPMGenerator

UNIT

CIRATA POWER PLANT CIRATA POWER PLANT



HEPP 1 VOEST ALPINE 187,5 1988 ELIN UNION 16500 140,00 0,90 126,00








RPMGenerator

UNIT

Action Plan

SPARE PART POOL PROGAM Suparno PT Pembangkitan Jawa Bali.

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Transcript of SPARE PART POOL PROGAM Suparno PT Pembangkitan Jawa Bali.