ENERGY PRODUCTION
(OPERATIONS)
Mark Studenic
Energy Production Superintendent
Operations – Maintenance Interaction
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Operations:
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Determines “what” and “when” for corrective maintenance
Leads daily production meetings
Initiates repair requests
Performs minor maintenance
Maintenance:
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Determines “who” and “how”
Plans, schedules and executes maintenance work
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Preventive/predictive maintenance
Most corrective maintenance
Outage management
2
Operations - Staffing
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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
3
Operator Training & Development
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Simulator sessions
 Structured classroom training
 On the job training
 Written tests (monthly)
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•
Enhance system knowledge
Coaching process
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Operating procedure reviews (monthly)
 Other
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•
Business plan (annual)
New installations
4
Disciplined Approach
Equipment Check Sheets
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Daily
Weekly
Monthly
Quarterly
Annual
Start-up/Shut down
Outage
Performance Measures
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Commercial Availability
Dispatch Accuracy
Communications
Heat Rate
NOx Reduction Performance
Environmental Performance
Safety Performance
Knowledge Tests
5
Performance Optimization Tools
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PI (Process Information)
•
•
Trends
Scorecards
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Operating procedures
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Alarms/Annunciators
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Personnel development processes
6
C Team On Duty
626 MWG.IPW
10/11/2006 12:14:18 PM
Muskingum River Unit 5 Operator Controllable Costs
Market Price $41.40 /MW
Actual
Target
Design
PSIG
3,598
3,600
3,500
-20
50
-$13.09
-$0
Main Steam Temperature
F
1,006
1,000
1,000
-20
50
-$21.06
-$9
1st RH Steam Temperature
F
1,026
1,025
1,025
-20
50
-$7.22
-$6
2nd RH Steam Temperature
F
1,019
1,035
1,050
-20
50
$98.66
$31
1st RH Attemperation
klb/hr
170
140
12
-20
50
$69.98
$37
2nd RH Attem peration
klb/hr
0
0
1
-20
50
$0.25
$0
Excess Air
%
16.4
18.0
18.0
-20
50
-$43.77
-$17
Exit Gas Temperature
F
319
336
302
-20
50
-$288.20
-$111
Steam Coil Air Heaters
klb/hr
25
0
0
-20
50
$198.84
$58
Condensers
in. of HG
2.57
2.49
2.34
-20
50
$173.22
$59
HP Feedw ater Heaters
Btu/Kwh
-3
0
0
-20
50
-$22.53
-$13
LP Feedw ater Heaters
Btu/Kwh
16
0
0
$116.30
$40
Auxiliary Pow er
Mw
26.0
26.5
23.4
-$64.39
-$28
$196.99
$41
Units
Controllable Cost
Main Steam Pressure
Circ. Water Temp.
Unit Summary
626 Mw
600 Mw
ON
84.3 DEG F
-20
Feedw ater Flow 3,826
-20
50
50
klb/hr
Calculated Heat Rate
9347 Btu/Kw h
Fuel Flow
433 klb/hr
Air FlowOver Rangeklb/hr
Design Heat Rate
Target Heat Rate
8989 Btu/Kw h
9356 Btu/Kw h
Air/Fuel RatioCalc Failed
Guidance
Boiler Schematic
Burner Tip Temps
Full Load Readings
Cost ($/Shift)
50
-20
Total Operator Contollable Cost
Instant Gross Load
Instant Net Load
Load Control (AGC)
Deviation from Target (Btu/Kwh)
Target Deviation
9
Btu/Kw h
Opacity
SO3
Exit Gas Minimum
NOx Emission Rate
Turb/Cond Schematic FW Heaters Schematic Air Heater Schematic
Tube Temp Profiles
Unit 5 NOx Trends
CEMS
Shift Total $
3.8 %
2.64 lb/Mbtu
302 DEG F
0.61
lb/Mbtu
Sootblow er Trends
Business Summary
Operations - Challenges
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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
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•
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Disciplined approach (check sheets)
Scorecards
Cycling units (units 1-4)
8
Material Handling (Coal Yard)
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Highlights:
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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)
9
Rail Car Unloader
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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
10
Ash Utilization
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Flyash- No commercial use
Unit 5 Bottom Ash
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Units 1-4 Boiler Slag
•
•
•
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No commercial use
Used internally for dam construction and fill material
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
11
Chemical Lab
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Highlights
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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
12
Questions?
13