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Coordinated Performance Program & Corporate Culture

Coordinated Performance Program & Corporate Culture. What is your #1 Priority in the Power Plant?. Safety Legal / Environmental Compliance. KEEP IT RUNNING!. Capacity. # 1. Efficiency. What Determines Efficiency?. Efficiency. Maintenance. Operation. Design.

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Coordinated Performance Program & Corporate Culture

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  1. Coordinated Performance Program & Corporate Culture

  2. What is your #1 Priority in the Power Plant? • Safety • Legal / Environmental Compliance KEEP IT RUNNING! • Capacity # 1 Efficiency

  3. What Determines Efficiency? Efficiency Maintenance Operation Design

  4. What Determines Efficiency? • Design • Cycle • Equipment • Cooling • Emission Controls

  5. AEP Operated Coal-fired Units • First & Largest Operator of Double Reheat Units (worldwide) • 10 Active – 450 to 800 MW • 2 Retired • Largest Coal-fired Units – 6 x 1300 MW • 20 supercritical units • All AEP fossil units built since 1963 were supercritical (does not include units acquired in C&SOE & CSW mergers. Cardinal Plant Gavin Unit 1 – 1300MW

  6. AEP Efficiency AccomplishmentsU. S. Firsts

  7. What Determines Efficiency? • Maintenance • Inspection Interval • Level of Refurbishment • Availability for outages

  8. What Determines Efficiency? • Operation • Training • Staffing • Monitoring (availability of Data)

  9. What is Required • Funding ($) • Culture • Will – Dedication – Attitude • Culture is a driving force • Can help offset lack of resources (both $ and staff) • The wrong culture can impair the effectiveness of adequate resources

  10. CorporateCulture

  11. Efficiency Improvement for Existing Plants • Corporate Culture • Accountability • Organization • Corporate philosophy for Performance • Communication • Proactive programs

  12. Accountability Efficiency Improvement for Existing Plants • Corporate Culture • Accountability • Organization • Corporate philosophy for Performance • Communication • Proactive programs

  13. Accountability • Who Does What? • What are the Incentives? • Organizational • Internal Competition • Compensation • Performance Based • Pride

  14. Organizational Accountability Generation Fossil & Hydro Generation Engineering, Projects & Field Service Region Engineering Plants Engineering Services

  15. Organization Efficiency Improvement for Existing Plants • Corporate Culture • Accountability • Organization • Corporate philosophy for Performance • Communication • Proactive programs

  16. Supporting Organization • Capabilities • Engineering Specialists • Experience • Thermal Performance Analysis • Heat Balance Modeling (PEPSE) • Structure • No Silos • All Stakeholders Must be Organizationally Integrated • Cross Organization Teams • Generation Performance Team • Goals Established for • Incentive Compensation • Business Plan • Management Overview

  17. Philosophy Efficiency Improvement for Existing Plants • Corporate Culture • Accountability • Organization • Corporate philosophy for Performance • Communication • Proactive programs

  18. Corporate Philosophy for Performance # 1 “World Class” “Innovator” “Best in Class” “Leader” IT MAKES A DIFFERENCE

  19. Communication Efficiency Improvement for Existing Plants • Corporate Culture • Accountability • Organization • Corporate philosophy for Performance • Communication • Proactive programs

  20. Communication • Information on heat rate performance is readily available: • Actual/Design/Baseline Information • GADS (Generating Availability Data System • Heat Rate Deviation Report (HRDR) • Heat Balances • Thermal Performance Kits • On-line heat rate monitoring system - PI/OM • Communicating/Sharing across System • Region Heat Rate Meetings • Generation Performance Team (GPT)

  21. AEP GADS G A D S FUEL CONSUMPTION ENERATING VAILABILITY ATA YSTEM SERVICE HOURS AVAILABILITY BASELINE HEAT RATE OUTAGE CAUSES HEAT RATE DEVIATION COSTS HEAT RATE GENERATION CAPACITY FACTOR LOAD DISTRIBUTION • AEP GADS • Uses North America Electric Reliability Council Standard definitions • Data is reported to NERC • Additional data is added to generate custom internal reports EFOR

  22. AEP GADS Standard Reports

  23. Proactive Programs Efficiency Improvement for Existing Plants • Corporate Culture • Accountability • Organization • Corporate philosophy for Performance • Communication • Proactive programs

  24. Routine Heat RateImprovement Guidelines

  25. Infrared Thermography Heat Rate Improvements at Kanawha River Plant Unit 1

  26. Before 2004 GBIR • Managers used the vent stack to determine if the unit was on-line • Average 15,000 #/hr make up to the boiler

  27. Find the Leaks • Steam Cycle places to look • Problem valves • High value valves • Blow down tank • Miscellanous Drain Tank • Condenser Drip Leg • Scans required about 24 hours total (field and reporting). After 2004 GBIR, Average 6,000 #/hr make up to the boiler

  28. Identify Benefits • Make-up Water $ Savings • Fuel $ Savings • Reduced Maintenance $ • Fewer Pulverizers needed for Full Load • Boiler less stressed • Reduced Emissions $ • Culture • Increased Support for the PdM program • Morale Improvements

  29. a Drain Valve Leakage Penalty Estimator – Subcritical Unit

  30. On-Line Monitoring Sample PI OM Screens

  31. Heat Rate Controllable Cost Main Steam Pressure Penalty MS Temperature Penalty RH Temperature Penalty Attemperation Penalty Excess Air Penalty Auxiliary Power Penalty Turbine/Condenser Screen Turbine Eff. & Penalty Condenser Penalty Waterbox Differentials Condenser Air Leakage Air Heater Schematic Dry gas loss penalty SCAH penalty Feedwater Heaters Screen HP Heater TTD HP Heater DCA LP Heater TTD LP Heater DCA Boiler Screen Tube Temperature Data Sootblower Optimization Environmental Screen Opacity NOx SO2 Business Summary Screen Dispatch Accuracy Heat Rate Commercial Availability Miscellaneous Water Loss Trends PI/OM Screens (Partial Listing)

  32. Business Summary Screen

  33. Feedwater Heaters Help Screen

  34. BTU BUSTER Generation Performance Team GPT

  35. GPT Mission • Develop an integrated performance monitoring program for the entire Fossil & Hydro Generation fleet in order to provide a disciplined approach to monitoring and tracking of performance to support the improvement of System Heat Rate • Deliver a program that includes accountability, data collection, analysis, and retention, an educational program, and a reporting/ distribution/ communication system

  36. Components of an Integrated Program • Centralized Accountability and Coordination • Education Program • Monitoring System • Test Program • Data Evaluation and Test Trends • Maintenance of Records • Management and Engineering Reports • Audit for Quality and Compliance • Benchmark other Utilities

  37. GPT Make-up F&H Mgt Sponsor Generation Performance Team Engineering Services Region Engineering Plants

  38. Team Organization

  39. Roles and Responsibilities

  40. Audience Test/Analysis Personnel Equipment/System Engineers Operators Management Subject Matter Modeling Software Test Instruments Test Procedures Test Analysis Power System Concepts Data Relevance Optimization Providers Simulator Learning Center Generation Performance Team Engineering Services Education Program T

  41. Formal Testing Program • 1960s • Extensive Program • Faded away by 1970s due to focus on capacity • 1988 • New Test Program Defined in response to Regulatory Interest • Backed by inclusion in the Incentive Compensation Plan • 1990s • Scope Reduced to Mostly Voluntary due to Staffing and Organization Issues Resulting from Restructuring for Competition • 2005 • Revised Voluntary Program to align with Instrumentation and Data Collection Improvements • Future • Full Automation of Collection & Calculation with Station Instrumentation

  42. Formal Testing • Requirements • Corporate Guideline identifies tests and frequency • Instructions for Performing Tests & Calculating Results • In-house developed Performance Test Manual • Type of Instrumentation • Dedicated Test Instrumentation • Installed Plant Instrumentation • PI Data Collection System • Combination of the above

  43. Components of an Integrated Program • Data Evaluation and Test Trends • Automate to the extent possible • Look at trends, do not just accumulate and file • Management and Engineering Reports • Formatting Important • Good Summary • Graphs of trends • Maintenance of Records • Retrievability • Completeness • For Tests, Design Basis, Computer Models, etc.

  44. Heat Rate Deviation Report (HRDR) The Heat Rate Deviation is the difference between the Actual Heat Rate and Baseline Heat Rate. This tool is designed to breakdown the unit deviation into individual equipment and operational components.

  45. HRDR Benefits • Replaces time consuming, manual to semi-automated data collection and calculations requiring a high level of expertise with limited availability of results to others outside of the plant • Engineering or management tool, unlike real time displays that are more of an operations tool • Provides consistent results across the system for easy unit to unit comparison • Widespread data availability

  46. HRDR Summary Screen

  47. HRDR Summary Screen(Lower Portion)

  48. HRDR Detail Screen

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