Post on 24-Dec-2015
Mark StudenicEnergy Production Superintendent
ENERGY PRODUCTION(OPERATIONS)
2
Operations – Maintenance Interaction Operations:
• Determines “what” and “when” for corrective maintenance• Leads daily production meetings• Initiates repair requests• Performs minor maintenance
Maintenance:• Determines “who” and “how”• Plans, schedules and executes maintenance work
Preventive/predictive maintenance Most corrective maintenance Outage management
3
Operations - Staffing Four rotating shift teams
Job Title Number/Team Total
Energy Production Supervisor I 1 4
Energy Production Supervisor II 2 8
Unit Operator 6 24
Equipment Operator 8 32
Control Technician 1 4
Maintenance Mechanic 1 4
Trainer 1
Coordinator 1
Total 19 78
4
Operator Training & Development
Simulator sessions Structured classroom training On the job training Written tests (monthly)
• Enhance system knowledge• Coaching process
Operating procedure reviews (monthly) Other
• Business plan (annual)• New installations
5
Disciplined Approach
Equipment Check Sheets
Daily Weekly Monthly Quarterly Annual Start-up/Shut down Outage
Performance Measures
Commercial Availability Dispatch Accuracy Communications Heat Rate NOx Reduction Performance Environmental Performance Safety Performance Knowledge Tests
6
Performance Optimization Tools PI (Process Information)
• Trends• Scorecards
Operating procedures
Alarms/Annunciators
Personnel development processes
Muskingum River Unit 5 Operator Controllable Costs
Unit Summary Boiler Schematic Turb/Cond Schematic FW Heaters Schematic Air Heater SchematicGuidance
Instant Gross Load Calculated Heat Rate
Design Heat Rate
Target Deviation
626 9347
8989
9
626 MWG.IPW10/11/2006 12:14:18 PM
Controllable Cost Units Actual DesignTarget Deviation from Target (Btu/Kwh) Cost ($/Shift)
PSIG
F
F
F
klb/hr
klb/hr
klb/hr
in. of HG
Btu/Kwh
Btu/Kwh
Mw
%
F
Main Steam Pressure
Main Steam Temperature
1st RH Steam Temperature
2nd RH Steam Temperature
1st RH Attemperation
Excess Air
Exit Gas Temperature
Steam Coil Air Heaters
Condensers
HP Feedwater Heaters
LP Feedwater Heaters
Auxiliary Power 26.0
16
-3
2.57
25
0
170
1,019
1,026
1,006
3,598
16.4
319
3,500
1,000
1,025
1,050
2.34
0
0
18.0
0
23.4
1
12
302
0
0
0
18.0
26.5
-$21.06
-$7.22
$98.66
$69.98
$0.25
$198.84
$173.22
-$22.53
$116.30
-$64.39
-$43.77
-$13.09
$196.99
-$288.20
3,600
1,000
1,025
1,035
140
336
0
2.49
-20 50
-20 50
Mw Btu/Kwh
Btu/Kwh
Feedwater Flow
Fuel Flow
Btu/Kwh
klb/hr
klb/hr
3,826
433
2nd RH Attemperation
-20 50
-20 50
-20 50
-20 50
-20 50
-20 50
-20 50
-20 50
-20 50
-20 50
-20 50
-20 50
Load Control (AGC) Air FlowON
600Instant Net Load Mw
Over Rangeklb/hr
Total Operator Contollable Cost
Sootblower Trends
Target Heat Rate 9356 Btu/Kwh
Market Price $41.40 /MW
Circ. Water Temp.
Opacity
DEG F
%
84.3
3.8
Business SummaryCEMSUnit 5 NOx Trends
Shift Total $
-$0
-$9
-$6
$31
$37
$0
-$17
-$111
$58
$59
-$13
$40
-$28
$41
Tube Temp ProfilesFull Load Readings
C Team On Duty
NOx Emission Rate 0.61 lb/Mbtu
Burner Tip Temps
Exit Gas Minimum DEG F
SO3 2.64
302
lb/Mbtu
Air/Fuel RatioCalc Failed
8
Operations - Challenges
Aging workforce – loss of knowledge Aging plant – increased system failures (cables,
piping, etc.) Training – new hires, new processes, new technology Environmental performance optimization Raising standards for excellence
• Disciplined approach (check sheets)• Scorecards
Cycling units (units 1-4)
9
Material Handling (Coal Yard) Highlights:
• Burn approximately 2.72 million tonne/year (3 million tons/year)
• All coal received by train• Rapid discharge rail car unloader
Coal cost
$/tonne
($/ton)
Sulphur
Kg/Million Kcal
(lbs/MMBtu)
Units 1-4 $31 - $41
($35 - $45)
6.3 – 10.8
(3.5 - 6.0)
Unit 5 $36 - $45
($40 - $50)
2.9 – 6.3
(1.6 - 3.5)
10
Rail Car Unloader One of a kind in AEP
System; 1995 Completely automated Unloads train at 3,356
tonnes per hour (3,700 tons per hour)
Train moves continuously at 0.48 Km/hour (0.3 MPH)
Equipped with top mount traveling rail car shaker
11
Ash Utilization
Flyash- No commercial use Unit 5 Bottom Ash
• No commercial use• Used internally for dam construction and fill material
Units 1-4 Boiler Slag• 79% is processed and sold for roof shingles and sand
blasting agent• 19% is sold to local townships for roadway ice control• 2% is stored on site as waste product
Cenospheres
12
Chemical Lab
Highlights• Oxygenated feedwater treatment- unit 5• Reverse Osmosis System- unit 5• Circulating water copper corrosion inhibitor- unit 5• Cycle water sample conditioning system• Caustic feedwater treatment- units 1-4• On-line cycle water instrumentation
13
Questions?