Application of KKS Identification System in Power Plant Enterprise Systems

Haisheng Yang, Shuping Chang Thermal Technology Depart.

Hebei Electric Power Research Institute Shijiazhuang, Hebei PRC.

haisheng.yang@gmail.com, hbdyycsp@163.com

Abstract—Power plant equipment identification system is very important for I&C and enterprise information system. The application of VGB equipment identification system (KKS) in power plant enterprises of South Hebei power grid was introduced and some common issues were discussed. It was concluded that the advantage of the KKS coding system can be realized only by introducing of the KKS system during design phase, and an agreement regarding the KKS coding application should be reached by all parties involved in the preliminary design phase, which was the key for the implementation of the KKS system.

Keywords-KKS; identification system; enterprise information system; power plant

I. INTRODUCTION The VGB power plant equipment identification system

(KKS system) was getting widely used in the past years in China, especially in the power industry. The KKS system application covers many functions of the power plant enterprise, with the MIS system always being the focus. Reference [1] and [2] give some examples of how the KKS coding is used in the power plant MIS system. Reference [3] introduces the application trend of KKS system in China projects and abroad.

In South Hebei Power Grid, the first KKS system was adopted in 1995 by the Hanfeng Power Plant. Dingzhou Power Plant adopted the KKS system from the design phase of the project, which is another successful example.

The KKS identification system is put forward and revised by the VGB organization. The membership of the VGB includes 146 power utilities and customers from 28 counties. The KKS Identification System serves to identify plants, sections of plants and items of equipment in any type of power station according to task, type and location. It can be used by all engineering disciplines such as steam water process, civil, electrical, and I&C for planning, licensing, construction, operation and maintenance.

How to integrate the KKS identification system seamlessly with the current power plant enterprise information system is a challenge facing the managers of the enterprise.

II. KKS IDENTIFICATION SYSTEM OVERVIEW KKS system provides the following features to realize the

identification requirement:

A. Levelled Coding Structures It is classified into four levels, with each level represented

by relatively fixed letters following the same rules. Four levels are as follows:

• Level 0- Plant level identification, such as unit No. identification.

• Level 1- Functional level identification, such as feedwater system.

• Level 2- Equipment level identification, such as feedwater pump.

• Level 3- Component level identification, such as the driving motor of feedwater pump.

B. Three Types of Codes for Different Applications The KKS has three different types of codes, which can be

used together or separately. These codes are the process-related code, the point of installation code and the location code.

Process related Code: Process related identification of systems and items of equipment according to their function in mechanical, civil, electrical and control and instrumentation engineering.

Point of installation Code: Identification of points of installation of electrical and control and instrumentation equipment in installation units e.g. in cabinets, panels, consoles etc.

Location Code: Identification of various structures, such as dams, tunnels, buildings, floors, and rooms and fire areas.

These codes use the same coding structures, and are subdivided into 3 and 4 break down levels, see Table I.

C. Complete and Abundant Coding Keys On the functional level, the unit is divided into several

major systems. For example, the coal handling system is represented with letter E, water treatment with letter G, and steam water cycle with letter L and etc.

Then the system is divided into more detailed subsystems. For example, take L as steam water cycle, LB as steam system, and LBC as cold reheat system.

These coding keys can be used to coding all the system, equipment and components in the power plant. With the numbering code together, different objects of the same system can be identified.

KKS has become the basic engineering language in the worldwide power generation industry. In the past 26 years, KKS has been used on 1300 units all over the world.

TABLE I. KKS TYPES AND BREAK DOWN LEVELS

Break Down Level

Level 0 Level 1 Level 2 Level 3

Process related Code

Plant Code

System Code

Equipment Code

Component Code

Point of Installation Code

Plant Code

Installation Unit Code

Installation Space Code

Location Code

Plant Code

Structure Code Room Code

III. KKS APPLICATION IN POWER PLANTS ENTERPRISES IN SOUTH HEBEI POWER GRID

A. KKS Application in Hanfeng Power Plant The major equipment in the power house of the Hanfeng

Power plant was supplied by foreign companies, such as SIEMENS and Foster Wheeler. It was decided in the contract negotiation phase that KKS coding system be utilized in the project. The reason behind was the SIEMENS TELEPERM XP control system for the units. In this control system, KKS coding is a must for all the equipment code in the process and all the signals in the control logic.

KKS system was applied in the following manners during the different stages of the project.

• For all the supplied equipment in Boiler Island by Foster Wheeler, all the equipment KKS coding must be included in the Process Instrument Diagrams. This coding was process related.

• For all the signals from domestic supplied equipment to DCS, a signal interface list must be provided and all signals should be KKS coded following the rules agreed by all parties. The rules agreed by parties must be written in the Project Information format, and approved in the various liaison meetings.

• For all the electrical and control equipment inside the Turbine house and supplied by SIEMENS, KKS coding was used in all electrical and I&C wiring diagrams and control logic diagrams.

• For all the BOP systems outside of the main power house, the design followed the domestic rules.

• For the equipment delivery, it was agreed that the KKS coding must be used to the equipment level, for convenience of the acceptance and storage. KKS code must be input into the information system when the

goods were received to facilitate the inquiry of the equipment.

• In the operation phase, all the tags of the equipment inside the power house must be labeled with KKS code.

B. KKS Application in Dingzhou Power Plant The major equipment in the power house of the Dingzhou

Power plant was supplied by domestic suppliers. It was decided in the feasibility study phase that KKS coding system be utilized in the project. SIEMENS TELEPERM XP control system was selected for the units.

KKS system was applied in the following manners during the different stages of the project.

• KKS equipment coding must be included in all Process Instrument Diagrams. This coding was process related.

• KKS coding was used in all equipment in the process and all signals used in the control logic.

• KKS coding was used in all control logic diagrams.

• In the operation phase, all the tags of the equipment inside the power house must be labeled with KKS code.

• In the maintenance phase, all the Work Permit and maintenance measures were processed by the BFS++ system, in which all involved equipment must be marked with KKS code.

• In the Plant Information system, the real time operation data was provided by the PI system, and same KKS coding was used as the DCS control system.

IV. DISCUSSION ON APPLICATION OF THE KKS SYSTEM

A. When the KKS system should be introduced Based on the previous experience, the application of the

KKS system is a project, in which many of the departments will be involved and coordinated.

KKS system was firstly used in domestic project in which the major equipment was imported from Europe. A typical example is the SIEMENS supplied I&C system. KKS system plays an important role for the unified equipment coding in process diagram and signal coding in control logic diagram. Other functions in logistics, operation and maintenance are concomitant effects. Therefore, introduction of the KKS in design phase will maximize its functions and advantages.

It should be cautious to introduce the KKS coding in certain management area. It is likely that the expected functions can’t be realized because of the unfamiliar behavior of the relevant production departments. Management serves to the production, and if the production is not ready to take the KKS coding system, the implementing in other functional areas will be hindered.

In [4], the introduction of the KKS system in MIS system, gave an example of the situation mentioned. Some questions

were also raised in [4] regarding the point of installation code and location code. This reflected from another side the necessity to introduce the KKS system from the design phase, because two coding systems were not necessary for an operated power plant.

B. Further Discussion of the KKS Application It can be summarized that the KKS coding is applicable in

certain situations. The following aspects should be emphasized.

• In the design phase, especially the preliminary design phase, an agreement regarding the KKS coding application should be reached by all parties involved.

• In the design phase, all the drawings should be KKS coded clearly on the cover to the system functional level, or to the equipment level.

• In the design phase, the KKS coding in the process instrument diagrams and I&C control logic diagrams should be coded to the equipment level. All the interface signals into the DCS, should be coded following the unified KKS rules.

• In design phase, the installation drawings of the electrical and I&C equipment can be labeled with KKS point of installation code, or in domestic manners. But all the signals should be labeled to KKS equipment level.

• In design phase, it is suggested that the production facilities and buildings should be KKS coded to the room level. All the KKS location code should be marked on the civil plan drawings. All the doors of the production facilities should be marked clearly with the KKS code during construction phase.

• In the equipment ordering phase, clear requirement for KKS equipment code must be made to the supplier, including equipment markings and transport markings.

• In operation phase, operation is directly related to the process KKS code. All the operated equipment should be labeled with KKS code to the equipment level.

• In maintenance phase, all the equipment included in the Work Permit and related must be marked clearly with KKS equipment code.

• In equipment storage management, all the equipment should be marked with KKS equipment code. Simultaneously, the position information can be coded with industry coding system.

• It should be emphasized that KKS coding is designed for systems and equipment, but not for coding of project management and business processes, such as cost and budget control, schedule control, and quality control and etc. It is not necessary to code the different kinds of management with a unified coding system. In [5], all the business involved in the electric power construction is unified with a complicated coding system, which makes the coding work too complex.

CONCLUSION The advantage of the KKS coding system can be realized

only by introducing of the KKS system during design phase. In the preliminary design phase, an agreement regarding the KKS coding application should be reached by all parties involved, which is the key for the implementation of the KKS system.

KKS coding system can be integrated with other management tools such as project management software, MIS software, thus providing a shared bridge between different management systems for the equipment level information.

ACKNOWLEDGMENT

REFERENCES [1] ZHU Ji-tao, “KKS coding problems in power plant design and KKS

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[3] CHEN Jing, “Application of power plant identification system in hydro power industry” in Hydro Power, vol. 35, pp. 80–85, August 2009.

[4] ZHOU Qiang-yan, “Application of KKS coding and material coding in Taipingyi power plant MIS project” in Hydro Power Plant Design, vol. 3, pp. 64–67, June 2005.

[5] CHEN Bin, “The built-up and development of the coding management system for electric power construction phase” in Zhejiang Electric Power, vol. 4, pp. 43–45, April 2004.