Improving Overhaul Process on Steam Power Plants using Lean Thinking and LCA

Abstract

Due to the limited availability and the increasing Price of both High and Medium rank coal, the pressure of providing a lower electricity price causes Indonesian Electricity Power Producer into using low-rank coal as their primary fuel (Coal Switching Program). The success of the coal switching program undertaken by the PTN Power Plant also had another impact on the condition of the equipment. Low-calorie coal with high water content disrupts to generate material which not infrequently also causes derating of the unit. Derating that occurred causes a decrease in the value of EAF (Equivalent Availability Factor) of PTN power plant from 93.07 in 2017 to 90.21 in 2018 and 89.74 (estimated EAF) in 2019. To maintain the EAF value is still above the amount of 90% or still at the Top 10% NERC then improvement is needed. Waste management process using lean thinking approach with value stream mapping and 5S visual management methods collaborated with life cycle assessment is an effective way to optimize EAF from plant outage or overhaul. With this method, it can maximize the 2019 EAF value to 90.84%, identify the environmental impacts that arise in the overhaul process and determine the best improvement recommendations.