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Plant Maintenance Management Process Assessment

Maintenance management is a driving force in achieving competitive production costs at generating stations. Short- and long-term competitive positions are achieved through continuous improvements in power plant maintenance management processes.

Issue Background

Generating station maintenance management has become a more complex and integral component for determining the competitiveness and future of many plants throughout the country. No longer can a utility or an individual plant believe that it’s competitive just because there is an electronic maintenance management system in place and good maintenance people. Processes must be established which promote continuous improvements to be made including incremental decreases in overall plant O&M costs, heat rates, and increases in availability and reliability.

Maintenance management is a dynamic process and, as such, requires a system that can provide accurate, current, and reliable data to all personnel involved in the process. Proactive integration of information technology and personnel throughout the plant now allows the utility to assess performance on a real-time basis and adjust processes and controls as necessary to improve that performance. The Independent Power Producers have taken these steps to automate functions which place them at a competitive advantage. Utilities must evolve in a manner that recognizes the competitive forces which they face and the improvements necessary to meet them. Maintenance management strategies which result from true innovation and proactive practices are those that all power producers seek to emulate in the years ahead.

Vantage Implementation Approach

Our consultants will work directly with plant management to comprehensively assess existing maintenance management processes and their effectiveness in contributing to the achievement of the plants overall mission for the utility.

Review plant mission (i.e., baseload, cycling, or peak shaving) as it relates to the plant maintenance philosophy

Review organizational structure, staffing and skills

Review contractual work rules and its impacts on issues such as crew sizes, job assignment, staffing levels

Assess the use of work maintenance job standards

Review coordination and formal work flows between groups

Review all automated systems utilized (i.e., maintenance, material, outage, and equipment clearances)

Assess historical plant performance as it relates to availability and reliability

Assess outage management practices and

historical outage performance

Assess historical percentages of corrective, preventative, and outage related maintenance

Review responsibility of how work is initiated and related work flows

Maintenance work planning and scheduling practices review

Materials management processes

Materials requirements planning assessment

Assessment of spare parts levels

Evaluation of percentage of work performed by internal or external resources and use of overtime

Evaluate outsourcing levels and activities, rational, justification, and philosophy

Benchmark maintenance costs with comparable power plants

Assess contractor performance controls and administration

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