Mark Studenic

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ENERGY PRODUCTION(OPERATIONS)

• Mark Studenic
• Energy Production Superintendent

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Operations Maintenance Interaction

• Operations
• Determines what and when for corrective
  maintenance
• Leads daily production meetings
• Initiates repair requests
• Performs minor maintenance
• Maintenance
• Determines who and how
• Plans, schedules and executes maintenance work
• Preventive/predictive maintenance
• Most corrective maintenance
• Outage management

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Operations - Staffing

• Four rotating shift teams

Job Title Number/Team Total
Energy Production Supervisor I 1 4
Energy Production Supervisor II 2 8
Unit Operator 6 24
Equipment Operator 8 32
Control Technician 1 4
Maintenance Mechanic 1 4
Trainer 1
Coordinator 1
Total 19 78
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Operator Training Development

• Simulator sessions
• Structured classroom training
• On the job training
• Written tests (monthly)
• Enhance system knowledge
• Coaching process
• Operating procedure reviews (monthly)
• Other
• Business plan (annual)
• New installations

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Disciplined Approach

• Equipment Check Sheets
• Daily
• Weekly
• Monthly
• Quarterly
• Annual
• Start-up/Shut down
• Outage

• Performance Measures
• Commercial Availability
• Dispatch Accuracy
• Communications
• Heat Rate
• NOx Reduction Performance
• Environmental Performance
• Safety Performance
• Knowledge Tests

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Performance Optimization Tools

• PI (Process Information)
• Trends
• Scorecards
• Operating procedures
• Alarms/Annunciators
• Personnel development processes

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Operations - Challenges

• Aging workforce loss of knowledge
• Aging plant increased system failures (cables,
  piping, etc.)
• Training new hires, new processes, new
  technology
• Environmental performance optimization
• Raising standards for excellence
• Disciplined approach (check sheets)
• Scorecards
• Cycling units (units 1-4)

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Material Handling (Coal Yard)

• Highlights
• Burn approximately 2.72 million tonne/year (3
  million tons/year)
• All coal received by train
• Rapid discharge rail car unloader

Coal cost /tonne (/ton) Sulphur Kg/Million Kcal (lbs/MMBtu)
Units 1-4 31 - 41 (35 - 45) 6.3 10.8 (3.5 - 6.0)
Unit 5 36 - 45 (40 - 50) 2.9 6.3 (1.6 - 3.5)
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Rail Car Unloader

• One of a kind in AEP System 1995
• Completely automated
• Unloads train at 3,356 tonnes per hour (3,700
  tons per hour)
• Train moves continuously at 0.48 Km/hour (0.3
  MPH)
• Equipped with top mount traveling rail car shaker

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Ash Utilization

• Flyash- No commercial use
• Unit 5 Bottom Ash
• No commercial use
• Used internally for dam construction and fill
  material
• Units 1-4 Boiler Slag
• 79 is processed and sold for roof shingles and
  sand blasting agent
• 19 is sold to local townships for roadway ice
  control
• 2 is stored on site as waste product
• Cenospheres

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Chemical Lab

• Highlights
• Oxygenated feedwater treatment- unit 5
• Reverse Osmosis System- unit 5
• Circulating water copper corrosion inhibitor-
  unit 5
• Cycle water sample conditioning system
• Caustic feedwater treatment- units 1-4
• On-line cycle water instrumentation

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Questions?