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

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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

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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)

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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)

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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

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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

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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

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Questions?