13 - Coordinated Performance

8/3/2019 13 - Coordinated Performance

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Presented by:

Barry Rederstorff, Staff Engineer

Engineering Services

APP Site Visit

October 30 November 4, 2006

Coordinated

Performance Program&

Corporate Culture

Coordinated

Performance Program&

Corporate Culture


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Efficiency

KEEP IT RUNNING!

What is your #1 Priority in the Power Plant?

Safety

Legal / Environmental Compliance

Capacity


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What Determines Efficiency?

Design

Maintenance

Operation


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AEP System vs U S Average Fo ssil Hea

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HeatRate-Btu/kWh

US Foss

A EP Fos s


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Design

Cycle

Equipment

Cooling

Emission Controls



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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 1300MW

20 supercritical units

All AEP fossil units built since 1963

were supercritical (does not includeunits acquired in C&SOE & CSW

mergers.

Gavin Unit 1 1300MW

Cardinal Plant


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AEP Efficiency Accomplishments

U. S. Firsts1924 First reheat generating unit -- Philo Plant

1941 First very high pressure (2,300 psi), natural-circulationgenerating unit -- Twin Branch Plant

1949 First high-pressure, high-temperature combination (2,000 psi& 1,050 F main steam & 1,000 F reheat) -- Twin Branch Plant

1950 First heat rate below 10,000 Btu/kwh -- Philip Sporn Plant

1957 First supercritical-pressure steam (4,500 psi) and super-high temperature steam (1,150F) & double-reheat -- Philo Plant

1960 First Heat Rate below 9,000 Btu/kwh -- Clinch River Plant

1966 First control room simulator to train power plant operating personnel -- Cardinal Plant

1981 First application of sliding-pressure technique on supercritical-pressure generating units --Gen. James M. Gavin Plant


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Maintenance

Inspection Interval

Level of Refurbishment

Availability for outages



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Operation

Training

Staffing

Monitoring (availability of Data)



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What is Required

Funding ($)

Culture

Will Dedication Attitude

Culture is a driving force

Can help offset lack of resources (both $ andstaff)

The wrong culture can impair the effectiveness

of adequate resources


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Corporate

Culture


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Corporate Culture

AccountabilityOrganization

Corporate philosophy for Performance

Communication

Proactive programs

Efficiency Improvement for Existing Plants


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Corporate Culture



Communication

Proactive programs


Accountability


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Accountability

Who Does What?

What are the Incentives?

Organizational

Internal Competition

Compensation

Performance Based

Pride


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Organizational Accountability

Engineering, Projects

& Field Service

Engineering ServicesRegion Engineering Plants

Fossil & Hydro Generation

Generation


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Corporate Culture



Communication

Proactive programs


Organization


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Supporting OrganizationStructure

No Silos

All Stakeholders Must be

Organizationally Integrated

Cross Organization Teams

Generation Performance Team

Goals Established for

Incentive Compensation

Business Plan

Management Overview

CapabilitiesEngineering SpecialistsExperienceThermal Performance Analysis

Heat Balance Modeling (PEPSE)


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Corporate Culture



Communication

Proactive programs


Philosophy


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Corporate Philosophy for Performance

BestinClass

Lea

der

IT MAKES A DIFFERENCE

Innova

torWorldClass


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Corporate Culture



Communication

Proactive programs


Communication


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Communication

Information on heat rate performance is readilyavailable: 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)


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AEP GADS

G

AD

S

ENERATING

VAILABILITY

ATA

YSTEM

AEP GADSUses North America Electric Reliability Council Standard definitionsData is reported to NERCAdditional data is added to generate custom internal reports

EFOR

AVAILABILITY

SERVICE HOURS

OUTAGE CAUSES

HEAT RATECOSTS

CAPACITY FACTOR

GENERATION

FUEL CONSUMPTION

LOAD DISTRIBUTION

BASELINE HEAT RATE

HEAT RATE DEVIATION


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AEP GADS Standard Reports

Consolidated Data

Operating Performance Data Summary

Event Data

Unit Descriptive Listing of Outages & Curtailments

Continuous Operation Report Unit Performance Hours

Unit Performance Statistics Cause Code Summary

Performance & Cost Data

Generating Plant Production Cost Data Coal & Production Expense Summary

Plant Performance & Fuel Consumption Unit Performance & Fuel Consumption Heat Rate Statistics HR Deviation by Series

Unit Loading & Starts


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Corporate Culture

Accountability

Organization


Communication

Proactive programs


Proactive Programs


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Routine Heat Rate

Improvement Guidelines

1. Drain Valve Leakage

2. Steam Trap Leakage

3. Reheat Steam Attemperation

4 Sootblowing Schedules

5. On-line Monitoring of OperatorControllable Losses (PI/OMScreens)

6. Auxiliary Power

7. Condensers

8. Boiler Flue Gas Exit Losses

9. Steam TemperatureThermocouple Calibration orReplacement

10. Steam Temperature ControlsTuning

11. Feedwater Heater TTD andDCA


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Infrared Thermography

Heat Rate Improvements

at Kanawha River PlantUnit 1


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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


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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


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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


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Drain Valve Leakage Penalty Estimator Subcritical Unit

Additional Heat Input to Compensate fora , lb/h Steam Leak to Condenser88888

Typical for a Subcritical Unit

8

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Full Load Pressure at Source of Leak - psia

AdditionalHeatInput-Btu/h

% Throttle Flow888

% Throttle Flow88% Throttle Flow88

% Throttle Flow88

a


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On-Line Monitoring

Sample PI OM Screens


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PI/OM Screens (Partial Listing)

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


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/ / : : AM88888888888

MWG.IPW888

Current Comm. Avail. per Hr ($)

Unaudited Total Shift P&L $$ $ $

Net Load (Mw)

Dispatch Cost

Current Hourly Market Price

Current Spark Spread

Actual Heat Rate (Btu/kWh)

Dispatch Load Mw (High/Low)

Mw Error

Shift Total Unaudited ICP Score Card

Target HR Dev. (Btu/Kwh)

Target Heat Rate (Btu/Kwh)

Fuel Efficiency per Hr ($)

Bad

Bad

Bad

- .88888

,11111

888

,11111

Bad

$8 8

/Mw

$88

$88

/Mw

,8888

888

,8888

.8888.8888.888

/Mw

$88 8

$111

/Mw

$ .888 8/Mw $ .8888/Mw $ .8 888/Mw

/Mw

$ .8888/Mw

/Mw

$ .8888/Mw

/Mw/Mw

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,88888

88

$88

$88

,88888

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$88

$111

/Mw

/Mw

Current Steady-State Accuracy ($)

Comm. Avail. Credited Load

Extended Load Credit

Fuel Efficiency Total

Dispatch Accuracy Total

Commercial Avail. Total

Unaudited P&L per Shift

Current CA Left on Table $/ Hr Lost

This information is considered proprietary and confidential in regards to system operation and should not be distributed.

All information is unaudited. For audited information refer to tapis summary screens.

Ext. Load Avail. per Hr ($)

1118111888888

$ .8888$ .1111$ .8888$ .8888$ .8888

$ .888$ .888$ .888$ .888$ .888

88

$88 8

$88 8

$-88 8$88$88 8$88

8 8 8 8

$8 $8 $8 $8

$8 $8 $8 $- ,888 8

Total CA Left on Table Lost

$8

$8 $8 $8 $- ,88 8 8 $8

$8

88

Current Ramp Rate Accuracy ($)

$8

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$8

$8

$8

$8

$8

$8

$8

$8

$88 8 $111 $88 8 $- ,88 8 8 $ ,88 8 8

Muskingum River

8

$8

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$8 $8 $-8

$88 8 $88 8 $88 8 $- ,88 8 8

$-88

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$ ,88 88

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Unit 8

Unit 8

Unit 8

Unit 8

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Unit 8

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-

Dispatch Acc. Fuel Eff. Comm. Avail.

888

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Dispatch Acc.

Units - Left on Table88

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88

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Di spat ch Acc. Fu el Eff.

-88

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88

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88

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88

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Comm. Avail.

Dispatch Acc.

88

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88

88

Fuel Eff.

888

888

88

88

Comm. Avail.

88

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Dispatch Acc.

88

888

88

88

Fuel Eff.

-88

888

88

88

Comm. Avail.

88

88

88

88

Fuel Eff. Comm. Avail.

8888

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88

88

-88888

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Units - Comm. Avail.88

Unit 8 Unit 8 Unit 8 Unit 8 Unit 8

Total NOx Projection $/shift

Current NOx Projection $/hr $88 8

$ ,88 88 $-88 8

$-88 $88 8

$ ,888 8

8

8

8

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NOx Trend

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8

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NOx Trend

8

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NOx Trend

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Business Summary Screen


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Heater Penalty

High

Adjust Level

to design set

pointDone

Check

Heater

Venting

Done

Did

DCA

Increase

Did

TTD

Increase

Did

DCA

Increase

Yes Yes

No No

Is thereHigh Htr

Level ?

Yes

No

Partion Plate

Maybe Leaking

Write J.O. tocheck partion

plater

Done

Check for heater

tube leaks & inc.

drain flow

Write J.O. tocheck for tube

leaks. take htr

out if necessary

Done

No

Yes

Check for lowheater level

Adjust Level to

set design set

point

Done

Heater Troubleshooting Guideline

Feedwater Heaters Help Screen


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GPT Mission

Develop an integratedperformance monitoring

program for the entire Fossil & Hydro Generation

fleet in order to provide a disciplined approach to

monitoring and tracking of performance to supportthe 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


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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


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F&H Mgt

Sponsor

F&H Mgt

Sponsor

Engineering

Services

Engineering

Services

PlantsPlants

Region

Engineering

Region

Engineering

Generation

Performance

Team

Generation

Performance

Team

GPT Make-up


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Team Organization

Generation

Performance

Team

Region HR

Champions

Plant HRChampions


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Roles and Responsibilities

GenerationPerformanceTeam

Establish and coordinate the overallprogram

Engineering

Services

Provide a system heat rate overview and

Expertise

RegionEngineering(Region Heat RateChampions)

Support Plant Heat Rate Champions andplants

Plant Heat RateChampions

Support heat rate monitoring andimprovement activities at their plant


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Education Program

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

T


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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 andOrganization 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


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Formal Testing

Requirements Corporate Guideline identifies tests and frequency

Instructions for Performing Tests & CalculatingResults In-house developed Performance Test Manual

Type of Instrumentation Dedicated Test Instrumentation

Installed Plant Instrumentation PI Data Collection System

Combination of the above


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Components of an Integrated Program

Data Evaluation and Test Trends Automate to the extent possible

Lookat 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.


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Heat Rate Deviation Report (HRDR)

The Heat Rate Deviation is the difference betweenthe Actual Heat Rate and Baseline Heat Rate.

This tool is designed to breakdown the unitdeviation into individual equipment and operational

components.


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HRDR Benefits

Replaces time consuming, manual to semi-automated data collection and calculations requiringa high level of expertise with limited availability ofresults to others outside of the plant

Engineering or management tool, unlike real timedisplays that are more of an operations tool

Provides consistent results across the system foreasy unit to unit comparison

Widespread data availability


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HRDR Summary Screen

HRDR Summary Screen


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HRDR Summary Screen(Lower Portion)


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HRDR Detail Screen


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Questions?


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Come Join Us

Performance Focus Session


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Performance Focus Session

GenerationPerformance Team

Charlie Powell

Kim StalnakerDan Keck

Warren Ashton

EngineeringServices

Tom McCartney

Bill ReinhartBal Sood

Barry Rederstorff,Engineering Services

Generation Performance Team Lead

13 - Coordinated Performance

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