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
Electrif Ratio (%) 58.7 52,9
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 2006 2010
Sales (TWh) 3.7 5,3
No.of Cust. (M) 1.8 2,1
Capacity (GW) 0.6 1,1
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
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
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
SPP 2 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
RPMGenerator
BRANTAS POWER PLANT BRANTAS POWER PLANT
No. Turbine Operation Capacity
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
No. Turbine Operation Capacity
Unit Merk Year Merk Volt MVA Cos Q MW
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
No. Turbine Operation Capacity
Unit Merk Year Merk Volt MVA Cos Q MW
HEPP 1 VOEST ALPINE 187,5 1988 ELIN UNION 16500 140,00 0,90 126,00
HEPP 2 VOEST ALPINE 187,5 1988 ELIN UNION 16500 140,00 0,90 126,00
HEPP 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
RPMGenerator
UNIT
Action Plan