Presented by: Barry Rederstorff, Staff Engineer Engineering Services APP Site Visit October 30 –...
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Transcript of Presented by: Barry Rederstorff, Staff Engineer Engineering Services APP Site Visit October 30 –...
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
2
Efficiency
KEEP IT RUNNING!
What is your #1 Priority in the Power Plant?
Safety
Legal / Environmental Compliance
Capacity
3
What Determines Efficiency?
Design
Maintenance
Operation
4
AEP System vs US Average Fossil Heat Rate
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
1945
1947
1949
1951
1953
1955
1957
1959
1961
1963
1965
1967
1969
1971
1973
1975
1977
1979
1981
1983
1985
1987
1989
1991
1993
1995
1997
1999
2001
2003
2005
Hea
t Rat
e - B
tu/k
Wh
US Fossil
AEP Fossil
5
• Design–Cycle
–Equipment
–Cooling
–Emission Controls
What Determines Efficiency?
6
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.
Gavin Unit 1 – 1300MW
Cardinal Plant
7
AEP Efficiency AccomplishmentsU. S. Firsts
1924 First reheat generating unit -- Philo Plant
1941 First very high pressure (2,300 psi), natural-circulation generating 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 (1,150 F) & 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
8
• Maintenance –Inspection Interval
–Level of Refurbishment
–Availability for outages
What Determines Efficiency?
9
• Operation–Training
–Staffing
–Monitoring (availability of Data)
What Determines Efficiency?
10
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
11
CorporateCulture
12
•Corporate Culture
AccountabilityOrganization Corporate philosophy for Performance Communication Proactive programs
Efficiency Improvement for Existing Plants
13
•Corporate Culture
AccountabilityOrganization Corporate philosophy for Performance Communication Proactive programs
Efficiency Improvement for Existing Plants
Accountability
14
Accountability
• Who Does What?• What are the Incentives?
– Organizational
• Internal Competition
– Compensation
• Performance Based
– Pride
15
Organizational Accountability
Engineering, Projects& Field Service
Engineering ServicesRegion Engineering Plants
Fossil & Hydro Generation
Generation
16
•Corporate Culture
AccountabilityOrganization Corporate philosophy for Performance Communication Proactive programs
Efficiency Improvement for Existing Plants
Organization
17
Supporting Organization•Structure
– No Silos
– All Stakeholders Must be Organizationally Integrated
– Cross Organization Teams
•Generation Performance Team
•Goals Established for– Incentive Compensation
– Business Plan
– Management Overview
•Capabilities–Engineering Specialists–Experience–Thermal Performance Analysis
•Heat Balance Modeling (PEPSE)
18
•Corporate Culture
AccountabilityOrganization Corporate philosophy for Performance Communication Proactive programs
Efficiency Improvement for Existing Plants
Philosophy
19
Corporate Philosophy for Performance
“Best in Class”“L
eade
r”
IT MAKES A DIFFERENCE
“Innovator” “World Class”
20
•Corporate Culture
AccountabilityOrganization Corporate philosophy for Performance Communication Proactive programs
Efficiency Improvement for Existing Plants
Communication
21
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)
22
AEP GADS
GADS
ENERATING
VAILABILITY
ATA
YSTEM
•AEP GADS •Uses North America Electric Reliability Council Standard definitions•Data is reported to NERC•Additional data is added to generate custom internal reports
•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
AVAILABILITY
SERVICE HOURS
OUTAGE CAUSES
HEAT RATECOSTS
CAPACITY FACTOR
GENERATION
FUEL CONSUMPTION
LOAD DISTRIBUTION
BASELINE HEAT RATE
HEAT RATE DEVIATION
23
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
24
•Corporate Culture
AccountabilityOrganization Corporate philosophy for Performance Communication Proactive programs
Efficiency Improvement for Existing Plants
Proactive Programs
25
Routine Heat RateImprovement Guidelines
1. Drain Valve Leakage
2. Steam Trap Leakage
3. Reheat Steam Attemperation
4 Sootblowing Schedules
5. On-line Monitoring of Operator Controllable Losses (PI/OM Screens)
6. Auxiliary Power
7. Condensers
8. Boiler Flue Gas Exit Losses
9. Steam Temperature Thermocouple Calibration or Replacement
10. Steam Temperature Controls Tuning
11. Feedwater Heater TTD and DCA
26
Infrared Thermography
Heat Rate Improvements
at Kanawha River Plant
Unit 1
27
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
28
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
29
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
30
Drain Valve Leakage Penalty Estimator – Subcritical Unit
Additional Heat Input to Compensate fora 10,000 lb/h Steam Leak to CondenserTypical for a Subcritical Unit
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
050010001500200025003000
Full Load Pressure at Source of Leak - psia
Ad
dit
ion
al H
eat
Inp
ut
- B
tu /
h
100% Throttle Flow
75% Throttle Flow
50% Throttle Flow
40% Throttle Flow
a
31
On-Line Monitoring
Sample PI OM Screens
32
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
33
8/27/02 10:29:04 AM622 MWG.IPW
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
-0.4110
10,362
191
10,553
Bad
$48
/Mw
$34
$84
/Mw
9,274
136
9,398
597.6101.492.3
/Mw
$136
$435
/Mw
$23.22 /Mw $23.22/Mw $23.22/Mw
/Mw
$23.22 /Mw
/Mw
$23.22 /Mw
/Mw/Mw
11,11811,184
66
$14
$28
10,290
11,032
747
$94
$276
/Mw
/Mw
Current Steady-State Accuracy ($)
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 $/ Hr Lost
This information is considered proprietary and confidential in regards to system operation and should not be distributed.All information is unaudited. For audited information refer to tapis summary screens.
Ext. Load Avail. per Hr ($)
6100205190190
$13.94$17.98$18.35$18.59$18.78
$9.27$5.24$4.86$4.63$4.43
35
$698
$325
$-987$85$106$96
0 0 0 0
$0 $0 $0 $0
$0 $0 $0 $-1,074
Total CA Left on Table Lost
$0
$0 $0 $0 $-1,715 $0
$0
90
Current Ramp Rate Accuracy ($)
$0
90/ /100 100 /0 0 /600 600/110 110
$0
$0
$0
$0
$0
$0
$0
$0
$142 $189 $146 $-1,560 $1,584
Muskingum River
2
$0
1 -0 -0
$0 $0 $-8
$169 $464 $230 $-1,519
$-21
-3
$1,998
50
10
90
300
700
10
90
-1
1
0
16
Unit 5
Unit 4
Unit 3
Unit 2
-10
290
9000
10600
9000
10600
-10000
40000
Unit 1
-25000
16
80
230
80
230
80
230
80
230
-7
0
-1
1
10
70
10
70
-10
290
-140
0
-500
0
Dispatch Acc. Fuel Eff. Comm. Avail.
300
630
300
630
300
630
-140
60
-160
0
300
630
Dispatch Acc.
Units 1-5 Left on Table
80
230
80
230
80
230
80
230
-1
1
-1
1
Dispatch Acc. Fuel Eff.
-20
120
9000
10500
9000
10500
80
160
10
70
16
22
-20
120
-3000
0
-25000
0
Comm. Avail.
Dispatch Acc.
80
230
80
230
80
230
80
230
-100
100
-80
0
Fuel Eff.
100
220
9000
10500
20
50
9000
10500
Comm. Avail.
10
70
14
21
100
220
-1
1
-30
0
Dispatch Acc.
80
230
80
230
80
230
80
230
-40
50
-250
0
Fuel Eff.
-50
250
9500
11500
-15
25
8500
12500
Comm. Avail.
10
70
15
21
-50
250
-1200
0
-1800
0
Fuel Eff. Comm. Avail.
9000
9800
300
650
9300
10100
0
300
-20000
14000
Units 1-5 Comm. Avail.
Unit 1 Unit 2 Unit 3 Unit 4 Unit 5
Total NOx Projection $/shift
Current NOx Projection $/hr $847
$2,857 $-125
$-95 $224
$1,660
0
2
0
300
0
2
0
2
NOx Trend
0.5
1.5
0
300
0.5
1.5
0.5
1.5
NOx Trend
0
700
0
2
0
2
0
2
0
2
NOx Trend
0
25
0
25
0
25
0
25
0
25
0
250
Business Summary Screen
34
Heater PenaltyHigh
Adjust Levelto design set point
Done
CheckHeaterVenting
Done
DidDCAIncrease
Did TTDIncrease
DidDCAIncrease
Yes Yes
No No
Is thereHigh HtrLevel ?
Yes
No
Partion PlateMaybe Leaking
Write J.O. to check partion
plater
Done
Check for heatertube leaks & inc.drain flow
Write J.O. to check for tubeleaks. take htr out if necessary
Done
No
Yes
Check for low heater level
Adjust Level toset design set
point
Done
Heater Troubleshooting Guideline
Feedwater Heaters Help Screen
35
36
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
37
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
38
F&H MgtSponsor
F&H MgtSponsor
EngineeringServices
EngineeringServices
PlantsPlants
RegionEngineering
RegionEngineering
GenerationPerformance
Team
GenerationPerformance
Team
GPT Make-up
39
Team Organization
GenerationPerformance
Team
Region HRChampions
Plant HRChampions
40
Roles and Responsibilities
Generation Performance Team
Establish and coordinate the overall program
Engineering Services
Provide a system heat rate overview and Expertise
Region Engineering (Region Heat Rate
Champions)
Support Plant Heat Rate Champions and plants
Plant Heat Rate Champions
Support heat rate monitoring and improvement activities at their plant
41
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
42
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
43
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
44
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.
45
46
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.
47
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
48
HRDR Summary Screen
49
HRDR Summary Screen(Lower Portion)
50
HRDR Detail Screen
51
Questions?
52
Come Join Us
Performance Focus Session
53
Performance Focus Session
• Generation Performance Team– Charlie Powell– Kim Stalnaker– Dan Keck– Warren Ashton
• Engineering Services– Tom McCartney– Bill Reinhart– Bal Sood
• Barry Rederstorff, Engineering Services– Generation Performance Team Lead