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Engineering Application of Labeling System in Power Plant Chunming Wei, Zichan Zhang, Xinghai Zhao
Guoxu Wang
College of Architecture and Civil Engineering Northeast Dianli University Jilin, China E-mail: [email protected]
Production Department of Thermal Power Plant Jilin Thermal Power Plant of China Guodian Corporation Jilin, China
Abstract—KKS Labeling System in power plant is used to label the power plant. It can label the any form of power plant according to the power plant mission, the form and the place. KKS Labeling System is known to be divided into three types that the correlative process labeling, fixing spot labeling and place labeling. Adopting KKS Labeling System in power plant to istrate and maintain the safety production operation of the power plant may help enterprise to improve personnel work efficiency, to heighten the modern management level of enterprise, and also to be one of the important method that s track with the international electric power industry. Keywords-power plant; kks; place labeling; process labeling; safety
I.
INTRODUCTION
With the rapid improvement level of our power system automation and the requirement of information digital factory, a modern unified classification standard which will be formulated is a brook no delay work. KKS (German language of Kraftwerk-Kennzeichen-System) Labeling System in power plant as a naming rule can be fully considered the every professional need of the manufacturer, the production unit and the inspection agency, such as the design institute to meet the correlative labeling requirement of the relevant parties of the design, and the construction and the operation that is able to clearly label power plant unit and system. KKS Labeling System is edited by the German Association of technical Grade System VGB and published by VGB-Kraftwerkstechnik Gmbh. In addition, KKS Labeling System fully considered the relationship among DIN, IEC and ISO standards can be used to meet the additional requirements of the labeling [1]. According to the research of EPRI (American Electric Power Research Institute), 54% of all the accidents that have happened in power industry are due to incomplete or missing labeling. In order to ensure the security and reliability of the production process, it is very important to supervise and manage the equipments. Labeling system is applied for the power plant istration of design, the construction, the operation and the maintenance, in order to be convenient for facilitating communication between chinese and foreign technicians.
For our power industry, it is the important symbol to run into the international electricity market, and track with international power industry. Nowadays, there are several international coding standards, such as: •
S88.01 (ANSI/ISA-88.01) Batch Control standard (IEC 61512-1). It is suitable for the mass control of batch products in the medicine, chemical industry and etc.
•
S95.01 (ANSI/ISA-95.00.01) Enterprise/Control System Integration standard. It is the extended for the standard S88.01.
•
EIS. It is partly based on the ISO3511 standard. It is suitable for the wine production industry.
•
DEP. This standard is used to oil refineries, chemical and gas plants, exploration and production facilities. It is partly based on the ISO3511 standard. It is suitable for oil refining, chemical industry and so on.
•
KKS. It is suitable for the power plant, especially for the newly constructed units. II.
KKS LABELING SYSTEM
A. The requirements of KKS labeling system • It should be enough span and fineness to identify all systems, parts and structures. •
It should be sufficient capacity for extension to adapt to the new technologies such as IGCC.
•
It should be the same labeling in the various stages of design, evidence, construction, operation, maintenance and waste management and it should be the unified informational labeling in the whole life cycle.
•
It should be mutual applicability among the mechanical engineering, civil engineering, electrical engineering, and should have the labeling ability on the technological function, fixing point and place.
978-1-4244-4813-5/10/$25.00 ©2010 IEEE
B. The structure and characteristic of the KKS coding system 1) The structure of KKS coding system The structure of KKS coding system is showed in Fig.1. 2) The characteristic of KKS coding system: According to Fig.1, we can summarize that the KKS coding system has three characteristics, as follows: •
Using four hierarchy forms and fixed alphabet data
•
An independent labeling method of professional rule in engineering, using a uniform encoded format.
•
KKS is considered the relationships with DIN, IEC and ISO.
C. The Format of KKS Coding System There are three different KKS labeling coding which use the same four schemes of grade (see Fig.2). 1) The correlative process coding The correlative process labeling for system and equipment is labeled according to their function in mechanism, construction, electric and instrument. 2) The fixing spot coding The labeling is fixed on the installed unit (such as the switchgear, , console and etc). 3) The place coding The place labeling of the structure of building is on the floor and in the space, also in the fire protection area and specify terrain. 4) Classified coding and labeling are established on the base of the non-specific project: • In the grade one, F1/F1F2/F1F2F3 as the labeling keywords for the function. •
In the grade two, A1/A1A2 as the labeling keywords for the equipment unit.
•
In the grade three, B1/B1B2 as the labeling keywords for part of equipment.
5) The meaning of keyword can be redefined for specific projects which should be revised by the both sides of the project. 6) Some reserved fields in the main group are reservation in advance for the new process and system engineering. They can only be distributed by the grade department of the VGB technology committee. 7) Coding elements G, F0, FN, AN, A3 and BN are the coding number items. 8) In the specific project, all parties of participation should make an agreement on the coding number system and the direction of the coding number. 9) Universal principles: • As a rule, when the first coding number of element changed, the coding number should be restarted. •
The coding number can be successive or grouped.
•
The coding number also can be discontinuous.
•
Once the rule of the coding is established, it should not be changed. Even if the process of design changing, the coding number should not be changed.
It is introduced the rule of the KKS labeling system in the above briefly. For specific project, it should be referring to the specific regulation in the corporate standard of project owner. There is a specific project example as follows, which will illustrate the application of the KKS labeling system in the process of power plant construction [2, 3, 4]. III.
THE APPLICATION OF KKS LABELING SYSTEM IN THE DESIGN OF NEWLY-BUILT POWER PLANT PROJECT
A. Engineering Situation The newly-built large power plant with the four subcritical parameters 600MW coal-fired units, it is located in the economically developed area and load center. The main equipments of this project are supplied by the Shanghai Boiler Works, Shanghai Turbine Works, and Shanghai Generator Works. The owner of power plant attached great importance in the management of the project and made clear regulation of the design institute in the design contract, and gave a specific requirement of KKS coding in the formal document . 1) The particularity provision of the actual engineering application KKS coding work asks for higher requirement for engineer.The engineer should have not only overall plan of the coding work but also be versed in knowledge of the design. So all details of the KKS coding work must be done in advance. It is responsibility and obligation of KKS coding work for designer in order to improve efficiency, reduce fault and loss for the power plant operation in future. There is an explanation for the project with detailed coding rule. 2) The specific rule of for the coding format is shown in Fig.2, • Unit coding of power plant: unit or public system is labeled on grade "0". Grade "0" of the project is agreed as follows: "1" representing Unit 1, "2" representing unit2, "3" representing unit 3, "4" representing the unit 4 and "0" representing public system. •
Public system: There are many public systems in power plant, such as public system of whole power plant, public system of 1 and 2 unit, public system of 2 and 3unit, public system of 3 and 4 unit. The cooperation between the Grade “0”and the “F0”of the Grade “1” is used to represent the common systems of the project which adopt "01", "02", "03" and so on continuous labeling the common systems of power plant.
•
"F1 F2 F3" of the Grade "1" as systematic classification: According to the KKS keywords, we can grade
0 Grade
1 Grade
2 Grade
3 Grade
The correlative process labeling =
The whole power plant
The coding of system/device
The coding of equipment unit
The coding of part
The fixing spot labeling +
The whole power plant
The coding of installation equipment
The whole power plant
The structural coding
The grade serial number
The place labeling
+
•
The coding of installing space The space coding
Figure 1. The structure of KKS coding system The grade serial number
0 Grade
1 Grade
The data character labeling
G
F0
The data character type =
A or N
(N)
F1
F2 F3
A A
A
2 Grade FN
A1 A2
NN
A A
3 Grade
AN
A3
NNN (A)
B1 B2
BN
A A
NN
Figure 2. KKS coding format
•
systems and devices of power plant; Systematic number "FN": the systems and devices are subdivided into subsystem and device.
•
"A1 A2" of Grade "2" representing for equipment units classification: According to the labeling character, KKS is classified into mechanical equipments, electrical and instrument equipments; "AN" representing the coding of equipment units: The number of mechanical equipments, electrical and instrument equipments; The additional coding of "A3": The additional coding of the equipment units can be omitted and the KKS coding of the "equality" systems and equipment units in this project can make use of the additional encoding "A3" to distinguish each other.
•
"B1 B2" in the Grade "3" representing parts coding: By keywords of KKS, the coding can represents component, signal or signal application; "BN" representing part number: The coding number of parts, the signal or the signal application.
3) Example of the KKS labeling code used in the power plant project a) The example of labeling method of the whole power plant The Grades “0” combined with “F0”of the Grade “1” are used to label the whole power plant (see Fig.3). The systems and structures of the unit 1 are labeled by the Grade "0" combined with "F0"of the Grade “1”: “10”. The systems and structures belong to the unit2 are labeled by the Grade "0" combined with "F0"of the Grade "1": “20”. All the shared systems and structures of the unit1 and 2 are labeled by the Grade "0" combined with "F0"of the Grade "1": “01”, “02”, “03”, and etc. b) The KKS coding labeling of the related process flow
The "A3" of the Grade "2" is used in the project based on the bilateral negotiation between the owner and design institute. The KKS labeling coding of "equality" systems and equipments can be made use of additional coding "A3" to distinguish each other, the KKS labeling codes such as "10LAF30AA002A" and "10LAF30AA002B" or "10LAF30BP001A" and "10LAF30BP001B", the expression methods will enable the staff of power plant to have more intuitive understanding of the equipment management and also can effectively use coding resources. Items and Equipments for Both Units 01
Turbine and Bop Systems Unit1 10
Turbine and Bop Systems Unit2 20
Boiler Unit1 10
Boiler Unit2 20
01UHN Figure 3. The labeling method of the whole power plant
IV.
CONCLUSION
A. LIMITATIONS The KKS coding is a practical and highly technical tool, it does not belong to any particular profession which has nothing to do with professional skill and it is just a labeling method, So a few people are willing to make an effort to study. In addition the relevant information about KKS coding is by translated German into English which becomes more obscure to understand. If people want to understand and to be able to label
the various parts of the power plant correctly, they should understand some professional knowledge of the power plant and some engineering experience. As for the KKS labeling, it needs engineers and technicians to digest, understand, absorb and conclude the relevant information, and convert to meet the practical need of the domestic power plant project construction. The work of KKS coding is tedious and complex, which needs the consensus, communication, coordination and regulation between owner and design institute, manufacture, construction, supervision and so on. B. Future prospect After China entering WTO, the domestic market of electric power design and power equipment manufacturing market will be faced with opening to the outside world. Electric power design enterprise and power manufacturing enterprise will be faced with keen competition, and at the same time we also welcome in the opportunity of expanding foreign business and running into the international power industry, which will require that our power industry should have regulation and stipulation consistent with standards of the international power industry. The power plant labeling system is one of the important ways to communicate with the international power industry. In a word, our power industry should do comprehensive and painstaking research in the power plant labeling system and do a certain technical reserve, in order to guide and standardize the work of the future power plant labeling system. ACKNOWLEDGMENT This study is ed by National Natural Science Foundation of China (No. 50908037)；Education Department of Jilin Province (No.200850), and the Scientific Research Funds of Doctor of Northeast Dianli University (No. BSJXM200706). REFERENCES [1]
[2] [3]
[4]
X. H. Zhao, C. M. Wei, and G. H. Xin, “Discussion and application example of KKS labeling system in power station”, Boiler Technology, vol.37, Jul.2006, pp.60-64. W. Wu, “Application of KKS codes to equipment management for power plants”, East China Electric Power, vol.35, Sep.2007, pp.88-90. L. Ru and T.Shi, “Taking about the application of KKS code in engineering design”, Sci-tech Information Development & Economy, vol.17, Jul.2007, pp.23-25. Z. W. Ren, “KKS power station marking system application”, Journal of shangdong college of electric power, vol.7, Jul.2004, pp.22-24.
Guoxu Wang
College of Architecture and Civil Engineering Northeast Dianli University Jilin, China E-mail: [email protected]
Production Department of Thermal Power Plant Jilin Thermal Power Plant of China Guodian Corporation Jilin, China
Abstract—KKS Labeling System in power plant is used to label the power plant. It can label the any form of power plant according to the power plant mission, the form and the place. KKS Labeling System is known to be divided into three types that the correlative process labeling, fixing spot labeling and place labeling. Adopting KKS Labeling System in power plant to istrate and maintain the safety production operation of the power plant may help enterprise to improve personnel work efficiency, to heighten the modern management level of enterprise, and also to be one of the important method that s track with the international electric power industry. Keywords-power plant; kks; place labeling; process labeling; safety
I.
INTRODUCTION
With the rapid improvement level of our power system automation and the requirement of information digital factory, a modern unified classification standard which will be formulated is a brook no delay work. KKS (German language of Kraftwerk-Kennzeichen-System) Labeling System in power plant as a naming rule can be fully considered the every professional need of the manufacturer, the production unit and the inspection agency, such as the design institute to meet the correlative labeling requirement of the relevant parties of the design, and the construction and the operation that is able to clearly label power plant unit and system. KKS Labeling System is edited by the German Association of technical Grade System VGB and published by VGB-Kraftwerkstechnik Gmbh. In addition, KKS Labeling System fully considered the relationship among DIN, IEC and ISO standards can be used to meet the additional requirements of the labeling [1]. According to the research of EPRI (American Electric Power Research Institute), 54% of all the accidents that have happened in power industry are due to incomplete or missing labeling. In order to ensure the security and reliability of the production process, it is very important to supervise and manage the equipments. Labeling system is applied for the power plant istration of design, the construction, the operation and the maintenance, in order to be convenient for facilitating communication between chinese and foreign technicians.
For our power industry, it is the important symbol to run into the international electricity market, and track with international power industry. Nowadays, there are several international coding standards, such as: •
S88.01 (ANSI/ISA-88.01) Batch Control standard (IEC 61512-1). It is suitable for the mass control of batch products in the medicine, chemical industry and etc.
•
S95.01 (ANSI/ISA-95.00.01) Enterprise/Control System Integration standard. It is the extended for the standard S88.01.
•
EIS. It is partly based on the ISO3511 standard. It is suitable for the wine production industry.
•
DEP. This standard is used to oil refineries, chemical and gas plants, exploration and production facilities. It is partly based on the ISO3511 standard. It is suitable for oil refining, chemical industry and so on.
•
KKS. It is suitable for the power plant, especially for the newly constructed units. II.
KKS LABELING SYSTEM
A. The requirements of KKS labeling system • It should be enough span and fineness to identify all systems, parts and structures. •
It should be sufficient capacity for extension to adapt to the new technologies such as IGCC.
•
It should be the same labeling in the various stages of design, evidence, construction, operation, maintenance and waste management and it should be the unified informational labeling in the whole life cycle.
•
It should be mutual applicability among the mechanical engineering, civil engineering, electrical engineering, and should have the labeling ability on the technological function, fixing point and place.
978-1-4244-4813-5/10/$25.00 ©2010 IEEE
B. The structure and characteristic of the KKS coding system 1) The structure of KKS coding system The structure of KKS coding system is showed in Fig.1. 2) The characteristic of KKS coding system: According to Fig.1, we can summarize that the KKS coding system has three characteristics, as follows: •
Using four hierarchy forms and fixed alphabet data
•
An independent labeling method of professional rule in engineering, using a uniform encoded format.
•
KKS is considered the relationships with DIN, IEC and ISO.
C. The Format of KKS Coding System There are three different KKS labeling coding which use the same four schemes of grade (see Fig.2). 1) The correlative process coding The correlative process labeling for system and equipment is labeled according to their function in mechanism, construction, electric and instrument. 2) The fixing spot coding The labeling is fixed on the installed unit (such as the switchgear, , console and etc). 3) The place coding The place labeling of the structure of building is on the floor and in the space, also in the fire protection area and specify terrain. 4) Classified coding and labeling are established on the base of the non-specific project: • In the grade one, F1/F1F2/F1F2F3 as the labeling keywords for the function. •
In the grade two, A1/A1A2 as the labeling keywords for the equipment unit.
•
In the grade three, B1/B1B2 as the labeling keywords for part of equipment.
5) The meaning of keyword can be redefined for specific projects which should be revised by the both sides of the project. 6) Some reserved fields in the main group are reservation in advance for the new process and system engineering. They can only be distributed by the grade department of the VGB technology committee. 7) Coding elements G, F0, FN, AN, A3 and BN are the coding number items. 8) In the specific project, all parties of participation should make an agreement on the coding number system and the direction of the coding number. 9) Universal principles: • As a rule, when the first coding number of element changed, the coding number should be restarted. •
The coding number can be successive or grouped.
•
The coding number also can be discontinuous.
•
Once the rule of the coding is established, it should not be changed. Even if the process of design changing, the coding number should not be changed.
It is introduced the rule of the KKS labeling system in the above briefly. For specific project, it should be referring to the specific regulation in the corporate standard of project owner. There is a specific project example as follows, which will illustrate the application of the KKS labeling system in the process of power plant construction [2, 3, 4]. III.
THE APPLICATION OF KKS LABELING SYSTEM IN THE DESIGN OF NEWLY-BUILT POWER PLANT PROJECT
A. Engineering Situation The newly-built large power plant with the four subcritical parameters 600MW coal-fired units, it is located in the economically developed area and load center. The main equipments of this project are supplied by the Shanghai Boiler Works, Shanghai Turbine Works, and Shanghai Generator Works. The owner of power plant attached great importance in the management of the project and made clear regulation of the design institute in the design contract, and gave a specific requirement of KKS coding in the formal document . 1) The particularity provision of the actual engineering application KKS coding work asks for higher requirement for engineer.The engineer should have not only overall plan of the coding work but also be versed in knowledge of the design. So all details of the KKS coding work must be done in advance. It is responsibility and obligation of KKS coding work for designer in order to improve efficiency, reduce fault and loss for the power plant operation in future. There is an explanation for the project with detailed coding rule. 2) The specific rule of for the coding format is shown in Fig.2, • Unit coding of power plant: unit or public system is labeled on grade "0". Grade "0" of the project is agreed as follows: "1" representing Unit 1, "2" representing unit2, "3" representing unit 3, "4" representing the unit 4 and "0" representing public system. •
Public system: There are many public systems in power plant, such as public system of whole power plant, public system of 1 and 2 unit, public system of 2 and 3unit, public system of 3 and 4 unit. The cooperation between the Grade “0”and the “F0”of the Grade “1” is used to represent the common systems of the project which adopt "01", "02", "03" and so on continuous labeling the common systems of power plant.
•
"F1 F2 F3" of the Grade "1" as systematic classification: According to the KKS keywords, we can grade
0 Grade
1 Grade
2 Grade
3 Grade
The correlative process labeling =
The whole power plant
The coding of system/device
The coding of equipment unit
The coding of part
The fixing spot labeling +
The whole power plant
The coding of installation equipment
The whole power plant
The structural coding
The grade serial number
The place labeling
+
•
The coding of installing space The space coding
Figure 1. The structure of KKS coding system The grade serial number
0 Grade
1 Grade
The data character labeling
G
F0
The data character type =
A or N
(N)
F1
F2 F3
A A
A
2 Grade FN
A1 A2
NN
A A
3 Grade
AN
A3
NNN (A)
B1 B2
BN
A A
NN
Figure 2. KKS coding format
•
systems and devices of power plant; Systematic number "FN": the systems and devices are subdivided into subsystem and device.
•
"A1 A2" of Grade "2" representing for equipment units classification: According to the labeling character, KKS is classified into mechanical equipments, electrical and instrument equipments; "AN" representing the coding of equipment units: The number of mechanical equipments, electrical and instrument equipments; The additional coding of "A3": The additional coding of the equipment units can be omitted and the KKS coding of the "equality" systems and equipment units in this project can make use of the additional encoding "A3" to distinguish each other.
•
"B1 B2" in the Grade "3" representing parts coding: By keywords of KKS, the coding can represents component, signal or signal application; "BN" representing part number: The coding number of parts, the signal or the signal application.
3) Example of the KKS labeling code used in the power plant project a) The example of labeling method of the whole power plant The Grades “0” combined with “F0”of the Grade “1” are used to label the whole power plant (see Fig.3). The systems and structures of the unit 1 are labeled by the Grade "0" combined with "F0"of the Grade “1”: “10”. The systems and structures belong to the unit2 are labeled by the Grade "0" combined with "F0"of the Grade "1": “20”. All the shared systems and structures of the unit1 and 2 are labeled by the Grade "0" combined with "F0"of the Grade "1": “01”, “02”, “03”, and etc. b) The KKS coding labeling of the related process flow
The "A3" of the Grade "2" is used in the project based on the bilateral negotiation between the owner and design institute. The KKS labeling coding of "equality" systems and equipments can be made use of additional coding "A3" to distinguish each other, the KKS labeling codes such as "10LAF30AA002A" and "10LAF30AA002B" or "10LAF30BP001A" and "10LAF30BP001B", the expression methods will enable the staff of power plant to have more intuitive understanding of the equipment management and also can effectively use coding resources. Items and Equipments for Both Units 01
Turbine and Bop Systems Unit1 10
Turbine and Bop Systems Unit2 20
Boiler Unit1 10
Boiler Unit2 20
01UHN Figure 3. The labeling method of the whole power plant
IV.
CONCLUSION
A. LIMITATIONS The KKS coding is a practical and highly technical tool, it does not belong to any particular profession which has nothing to do with professional skill and it is just a labeling method, So a few people are willing to make an effort to study. In addition the relevant information about KKS coding is by translated German into English which becomes more obscure to understand. If people want to understand and to be able to label
the various parts of the power plant correctly, they should understand some professional knowledge of the power plant and some engineering experience. As for the KKS labeling, it needs engineers and technicians to digest, understand, absorb and conclude the relevant information, and convert to meet the practical need of the domestic power plant project construction. The work of KKS coding is tedious and complex, which needs the consensus, communication, coordination and regulation between owner and design institute, manufacture, construction, supervision and so on. B. Future prospect After China entering WTO, the domestic market of electric power design and power equipment manufacturing market will be faced with opening to the outside world. Electric power design enterprise and power manufacturing enterprise will be faced with keen competition, and at the same time we also welcome in the opportunity of expanding foreign business and running into the international power industry, which will require that our power industry should have regulation and stipulation consistent with standards of the international power industry. The power plant labeling system is one of the important ways to communicate with the international power industry. In a word, our power industry should do comprehensive and painstaking research in the power plant labeling system and do a certain technical reserve, in order to guide and standardize the work of the future power plant labeling system. ACKNOWLEDGMENT This study is ed by National Natural Science Foundation of China (No. 50908037)；Education Department of Jilin Province (No.200850), and the Scientific Research Funds of Doctor of Northeast Dianli University (No. BSJXM200706). REFERENCES [1]
[2] [3]
[4]
X. H. Zhao, C. M. Wei, and G. H. Xin, “Discussion and application example of KKS labeling system in power station”, Boiler Technology, vol.37, Jul.2006, pp.60-64. W. Wu, “Application of KKS codes to equipment management for power plants”, East China Electric Power, vol.35, Sep.2007, pp.88-90. L. Ru and T.Shi, “Taking about the application of KKS code in engineering design”, Sci-tech Information Development & Economy, vol.17, Jul.2007, pp.23-25. Z. W. Ren, “KKS power station marking system application”, Journal of shangdong college of electric power, vol.7, Jul.2004, pp.22-24.
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