Plant Engineering Programs Plant Engineering Programs Presented by: Duane Phleger, Manager Plant Engineering Programs APP Site Visit October 30 – November 4, 2006
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??