İşletmelerde bakım yönetim sistemlerinin yapılandırılması ve EÜAŞ İstanbul A doğalgaz kombine çevrim santraline uygulanması

Abstract

Günümüzde işletmelerin kar ederek ticari faaliyetlerini sağlam bir şekilde sürdürmek amacı doğrultusunda, hizmet verdiği kurumlara veya kişilere istedikleri ürün ve hizmeti sunabilmesi bakım yönetim sistemlerinin işletmeye uygulanabilirliği ile uyuşmaktadır. Bakım yönetim sistemlerinin işletmelerde uygulanabilmesi ile beraber işletmede üretilen ürünün birim maliyet fiyatı düşmekte ve bu gelişmeye bağlı olarak firmalar rekabet ortamında rakipleri arasında öne çıkma şansı yakalamakta, daha tercih edilebilir bir duruma gelmektedirler. Son yıllarda teknolojinin gelişmesine bağlı olarak bakıma verilen önem de gittikçe artmaya başlamıştır. Geçmişte işletmelerin arıza durumunda sisteme dahil olması durumu günümüzde yerini planlı bakımlara bırakmıştır. Ülkemizde daha popüler olan periyodik bakımlar belli periyotlarda üretici önerileri veya çalışanların tecrübeleri doğrultusunda yapılan yenileme işlemlerini, kestirimci bakım ise ölçümler ve analizler sonucunda arıza olasılığı olan ekipmanların bakım islerini içerir. Çalışmaya konu olan İstanbul Doğalgaz Kombine Çevrim Santrali İstanbul Avcılar ilçesinde yer alan ülkemizin en büyük kamu santrallerinden bir tanesidir. Son yılların verileri incelendiğinde yüksek emre amadelik oranı ile ülkemizin elektrik enerjisi talebinin büyük bir oranını karşılamaktadır. Bu çalışmanın ilk bölümünde kabul görmüş bakım sistemleri hakkında genel bilgi aktarılmış, daha sonra işletmeye ait teknik veriler belirtilerek bakım uygulamalarının işletmeye uygulanabilirliği incelenmiştir. Elde edilen bilgiler doğrultusunda bakımın son derece önem kazandığı endüstri dünyasında pek çok çeşidi olan bakım yaklaşımlarından en uygununun seçilerek endüstriye uyumu sağlanmalı ve uygulanmalıdır.

Today, for the purpose of maintaining profits and steady continuity of commercial activities, providing desired products and services to institutions or individuals is consistent with applicability of maintenance management systems to businesses. Together with the implementation of maintenance management system to the businesses, unit costs of the products decrease with which the businesses get the chance to stand out among its competitors in a competitive environment and become more preferable. The main purpose in production based enterprises is to present the requests to the customers in time within requested quality and to provide customer satisfaction. In the past periods enterprises established with serious investments have been worked below the nominal working hours due to the insufficiency of the maintenance systems which result critical failures and cause financial losses. However the enterprise maintenance importance raised as a result of comparing expenses caused by maintenance defects and the damage caused by operations of critical failures with the maintenance costs Today, competition environment is increasing due to technological developments and market share based on globalization. In this context, the enterprises apply the necessary investments in order to exist. In the enterprises it is important to ensure continuity of the production, to provide the required quality, to reduce the unit costs and to apply the maintenance systems on the conditions suitable for the operation in order to continue of profitability. The main goal of the maintenance management system is to optimize operating resources to minimize unforeseen failures and to maximize efficiency As mentioned throughout the study, maintenance management systems have importance especially in plants with manufacturing purposes, in terms of ensuring safe working conditions, production continuity and maximum performance at minimum cost. However, in our country, the enterprises can't see the necessity of the maintenance management systems. In order to ensure continuity of their daily production they keep maintenance plans on the second plan. In line with this development, there are production losses in the enterprises due to unscheduled failures. Unlike other developed countries, in our country predictive and periodic maintenance applications that required in terms of maintenance systems can't be implemented adequately and necessary investments can't be made for AR-GE studies supporting planned maintenance applications. Besides, new trend maintenance methods started to be implemented worldwide also can't be implemented in enterprises. In recent years, the emphasis on maintenance is continuously increasing due to the development of technology. Planning of maintenance systems and turning them into business culture is becoming widespread especially in institutional enterprises and itis being brought to performance criterion and monitored. In this context, some corporate enterprises in our country have been awarded worldwide. In order to reduce the unit costs to the minimum and to ensure maximum profit margins in line with the above mentioned information, enterprises should make necessary investments in the maintenance systems in order to extend the life span of the equipment and increase the machine productivity. The return periods of the investments to be made with the maintenance systems should be calculated and reported to the top management. Today, involvement of seller to the process only in case of failure is replaced with planned maintenance. Periodic maintenance that is more popular in our country, consists of renovations in accordance to the experiences of the staff or the recommendations of the manufacturer, while predictive maintenance consists of maintenance of equipment that are likely to malfunction determined with measurements and analyses. Maintenance has become extremely important in the industry, therefore the most appropriate maintenance system among the others should be selected and implemented .The most important criterion here is the cost, and a maintenance policy that does not contradict the purpose of profit should be applied. The subject of this study, Istanbul Natural Gas Combined Cycle Power Plant, located in Avcılar is one of the largest public power plants with respect to annual production amount about 8,000,000,000 kWh , %70 capacity factor and %90 availability in the country. The data of recent years showed that with a high availability rate, it provides a large proportion of the electricity demand of the country. Power plant consists of 3 combinations with the same characteristics and has a total installed power of 1350,9 MW. Each combination consists of two gas turbines, two waste heat boilers and one steam turbine. In the first chapter of this study, general information on the well-established maintenance systems followed by feasibility study of maintenance systems to the plant including technical data of the plant is provided. In the center section, the maintenance strategies of the operating subject are examined in detail; the application and results of conservative, predictive and corrective maintenance methods have been analyzed. When we analyzed in terms of failures, approximately %30 of failures constitute scheduled maintenance activities and %70 of failures constitute unscheduled maintenance activities which is originate because of momentary faults in plant. In the last part, the numerical analysis of operational failure data was examined and numerical statistics were extracted. Pareto analysis, Ishikawa diagram and principle component analysis methods are applied in order to get numerical analysis. The standings between the years 2013 and 2016 were examined and the following results were obtained. The most important reason why the units are stopped is due to boiler pipe breaks. So, the energy that cannot be produced due to boiler pipe failure between 2013-2016 is measured as 0,479 TWh. Again in the same period, this breakdown caused 3600 hour energy production stoppage in the power plant. In this context, it is observed that the most important fault that occurred operator is the boiler pipe boom. As the boiler pipe breaks are resolved in operation, the unit stops will reduce and the capacity of the plant will increase.The problem of erosion especially seen in the environment and material sub-units shortens the life of the boiler, which causes the energy production capacity reduction in the plant. In this context, the maintenance team is required to record the causes that cause abrading and to carry out studies that can bring solutions and, if necessary, to obtain outsourced support. Nevertheless, it is necessary to increase the control frequency of pure water data which is important in order to prevent erosion inside boiler pipes. It is seen that the most frequent faults and those causing the most production loss are boiler pipe breaks and failures caused by vibration. By minimizing these failures, a significant increase in the system's availability rate can lead to a more efficient system operation. As there are vast varieties of maintenance systems and its importance became vital, most appropriate maintenance approach should be selected and implemented to the plant in accordance to the information obtained.