Plant Engineering

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Plant Engineering Programs
Presented by Duane Phleger, Manager Plant Engineering Programs APP Site Visit October 30 November 4, 2006
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Plant Engineering Programs Review Agenda

• Purpose
• Goals
• Engineering Programs Listing
• Engineering Programs Review

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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

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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

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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

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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

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PdM Tools

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

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Plant Reliability Optimization (PRO) Process

• Assessment/Workshop
• Implementation Plan
• Reliability Basis Development
• Condition Based Maintenance Development
• Work Control (PaSTA)
• Continuous Improvement

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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

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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

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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

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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

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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

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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

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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

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Material Handling Review

• Coordinator- Don Border
• Equipment identification and prioritization
• Conveyors and belts
• Unloaders
• Tanks and piping
• Heavy moving equipment

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Plant Engineering Programs
Questions??