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Comprehensive Review of Plant Engineering Programs for Enhanced Reliability and Efficiency

This document outlines the agenda and goals of various engineering programs aimed at improving the reliability, efficiency, and safety of fossil and hydro generating fleet units. It includes a listing of key programs such as Preventive/Predictive Maintenance, Plant Reliability Optimization, and Cycle Equipment Optimization. Objectives focus on cost-benefit analysis, maintenance efficiency, and continuous improvement in operations. The team, led by experts, collaborates to identify and implement solutions that reduce maintenance costs and improve communication across all engineering initiatives.

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Comprehensive Review of Plant Engineering Programs for Enhanced Reliability and Efficiency

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  1. Plant Engineering Programs

  2. Plant Engineering Programs Review Agenda • Purpose • Goals • Engineering Programs Listing • Engineering Programs Review

  3. Purpose- Engineering Programs • Promote and coordinate engineering programs to assist with the reliable, efficient, and safe operation of the fossil and hydro generating fleet units

  4. Goals- Engineering Programs • Identify engineering programs based on cost benefit that will safely improve the reliability and efficiency of the units • Initiate the implementation of identified engineering programs and coordinate with plant staff and Engineering Services personnel to assure the programs are functional • Assist in the evaluation of the programs and benefits to identify savings, reliability improvements, and efficiency improvements

  5. Engineering Programs Listing • Preventive/Predictive Maintenance (PM/PdM) Programs • Plant Reliability Optimization (PRO) Process • Generation Performance Team • Cycle Equipment Optimization • High Pressure Heater and Condenser Program • Boiler Reliability Optimization (BRO)Program • Critical Piping Program • Electrical Equipment Optimization Program • Rotating Equipment Optimization Program • Civil Engineering Programs • Material Handling Review

  6. PM/PdM Program • Goals • Improve unit reliability, efficiency and safety through maintenance efficiency using PM/PdM • Increase the ratio of PM/PdM hours to corrective maintenance hours to reduce equipment down time • Reduce maintenance costs • Improve communication • Foster system consistency • Identify benefits- CBA

  7. PdM Tools • Vibration Analysis • Thermography • Ultrasonics • Electromagnetic Interference (EMI) Monitoring • Operator rounds and observation with AutoTour • Fleetwide Monitoring

  8. Plant Reliability Optimization (PRO) Process • Assessment/Workshop • Implementation Plan • Reliability Basis Development • Condition Based Maintenance Development • Work Control (PaSTA) • Continuous Improvement

  9. Generation Performance Team • Sponsor-Mark McCullough • Team lead- Barry Rederstorff; Coordinator- Kim Stalnaker • Core team- PEP, Engineering Services, Region Engineering, Plant Personnel • Action plan developed • Expectation- reduce system heat rate and improve performance to reduce costs and gain back generation • Website developed • Communication and Training

  10. Cycle Equipment Optimization • Identify cycle equipment that may impact unit reliability and efficiency • Equipment examples • HP Heaters • Expansion joints • Valves and pumps • Condensers • Develop teams as needed to incorporate applicable engineering programs

  11. Boiler Reliability Optimization (BRO) • Sponsor- Steve Burge • Team Lead- Jerry Journey • Identified priority areas to address • Goals • Ties to PRO - PM/PdM • Goal of zero tube leaks in coal fleet by 2006

  12. Electrical Equipment Optimization • Coordinators-Charlie Williams and Don Border • Sponsor-Steve Burge • Charter developed • Equipment identification and prioritization top 4 systems • Generator • Transformers • Switchgear/starters • Cables • Busses and motors tied • DC systems and Equipment protection

  13. Rotating Equipment Optimization • Coordinator- Matt Crockett • Sponsor- Bill Vineyard • Core team • Charter developed • First project identified-Smart Signal test at Amos U-3 • First phase complete with recommendations • Closely aligned with the PM/PdM program • Remote Monitoring Initiative

  14. Civil Engineering Programs • Coordinators-Jeff Anderson/JT Davis • Equipment identification and prioritization • Cooling towers • Stacks • Circ water systems • Bridges, dams, dikes • Roofs and ductwork • Equipment program identification and coordination with ES and Plants

  15. Critical Piping Program • Coordinators-Jeff Anderson/Donnie Robertson • Core team • Hanger system evaluation • Flow Accelerated Corrosion (FAC) • Life Fraction Expended (LFE) • Circular Letter being developed • Continuing Development

  16. Material Handling Review • Coordinator- Don Border • Equipment identification and prioritization • Conveyors and belts • Unloaders • Tanks and piping • Heavy moving equipment

  17. Plant Engineering Programs Questions??

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