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The Seven Traits of Highly Effective Performance Programs
Presentation to The 2012 Symposium
Marcus CaudillJanuary 18, 2012
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Trait 1: Business Case
Efficiency alone may not sell Expand the definition of “Performance” to include:
– Capacity– Emissions– Equipment reliability– Maintenance scheduling– Fuel flexibility– Others?
Without a business case support and funding is unlikely
What’s My Motivation to Improve Performance?
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Trait 2: Management Support
Need a high-level management sponsor Need support of all levels at the plant What is the personnel budget for performance? Is there a budget (capital / O&M) for performance? Continuous and visible management interest in
performance goes a long way!
Do I have Personnel and a Budget?
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Trait 3: A Goal
A: Figure out where you are– Plant Assessment– Performance Benchmark– Performance Target
B: Decide where you are going– Define a realistic end goal or target
Until you have A and B, you don’t know which direction to go
“Begin with the end in mind.”
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Trait 4: A Plan
Focus on cost effective efforts Define milestones on the way to the goal Milestones provide useful means to measure progress High return programs
– Cycle Isolation Program– Condenser Performance Monitoring– Controllable Losses Monitoring– Boiler Optimization
Periodic Testing Program Others
“Be Proactive”
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A 10-Step Program to Improve Your Life Through Isolation
1. Identify the key “high to low energy” leakage paths
2. Review FWH heater isolation (e-drains, bypass, startup vents and vent bypass)
3. Check steam traps for proper operation, and assure bypasses are closed.
4. Assure auxiliary steam is supplied from the lower energy source.
5. Make sure boiler feed pump recirculation valves close at higher loads.
6. Develop a plant specific list of these key valves. The list will usually include 20 to 30.
7. Use the isolation list immediately after startup.
8. Use the isolation list weekly to verify changes.
9. An IR temp gun can be used to check for leakage.
10. If a valve is leaking, first assure it is closed. Close manual block valves if it can be done without risk to the plant. Get the leaking valve on the maintenance list. Prioritize by highest to lowest energy loss.
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Condenser Performance Monitoring
Compare condenser pressure to target as a function of load and circ water inlet temp– Measured = Target Cond Probably OK, check CW source– Measured < Target Problem with target or measurement– Measured > Target Underperforming
Heat load– If you are monitoring cycle isolation, you should have a good
handle on this already
Air in-leakage Cooling water flow Tube fouling
Is condenser pressure where it should be?
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Heat Rate and Capacity Sensitivity
Parameter Deviation from Target
Generation Impact (MW)
Heat Rate Impact
(Btu/kWh)
Fuel Cost Impact ($/yr)
Main Steam Temp
-10◦F 0.2 18 $90
Hot Reheat Temp
-10◦F -2.4 12 $60k
Final FW Temp -5◦F 2.2 11 $55k
Main Steam Press
-10 psi -2.1 2.5 $12.5k
Condenser Press
+0.1InHga -0.5 10 $50k
Econ O2 + 0.5% point - 16 $80k
AH Exit Temp +10◦F - 30 $150k
Others
Controllable Losses
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Boiler Optimization
Air heater / Exit gas temperature Sootblowing / Spray flow Economizer O2
Combustibles in refuse
Key areas to review for boiler losses
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Periodic Testing Program
Adds to ability to diagnose process changes Helps in maintenance planning and scheduling Provides an excuse for detailed cycle review Helps detect anomalies that are masked by normal
operational changes
Repeatable testing using station instruments
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Daily Review
Review controllable losses– Condenser pressure– Exit gas temp– Final FW temp– Auxiliary power
Review major component efficiency, if available– HP / IP / LP efficiency– Boiler efficiency
Review heat rate vs. capacity if available Cycle isolation
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Traits 5: I&C Component
Critical Measurements Controls / Controls Tuning Instrument Calibration / Maintenance Program
– Documentation of as-found / as-left– Improvements in instrument quality make this more important– Calibration equipment must be maintained– Temperature calibrations often mis-understood
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Critical Measurements
Pressures– Main Steam– Condenser
Temperatures– Main Steam, HRH Steam– Final Feedwater
Flows– Feedwater– SH and RH spray
Economizer O2
Air Heater Exit Gas
Power – Gross, Aux, Net
Pressures– 1st Stage Steam– Cold Reheat Steam– Hot Reheat Steam– Crossover Steam
Temperatures– Cold Reheat Steam– Crossover Steam
Primary Instruments Secondary Instruments
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Controls / Controls Tuning
Just because the DCS says it doesn’t mean it’s right! Well tuned controls can maintain controllable parameters
at optimum levels
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2350
2360
2370
2380
2390
2400
2410
2420
2430
2440
2450
03/29/07 04/03/07 04/08/07 04/13/07 04/18/07 04/23/07 04/28/07 05/03/07 05/08/07
MS
Pre
ss (
psia
)
Time
Main Steam Pressure
THROTTLE PRESS AVG
One month of main steam pressure vs. time data
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Main Steam Pressure
2350
2360
2370
2380
2390
2400
2410
2420
2430
2440
2450
300 350 400 450 500 550 600 650 700
Gross Power (Mw)
MS Press
One month of main steam pressure vs. load data
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Trait 6: Communications
Highlight key performance drivers to staff Good relationship between performance and operations Ops has constant eyes on the plant Maintenance activities impact performance Close the loop on investigated issues Make periodic summary reports available Communicate in cost!
“Seek first to understand (then be understood)”
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Trait 7: Team Approach
Leverage existing plant resources and knowledge Share best practices Everybody in the plant can have an impact on
performance Spreads performance duties Improves communications and information sharing Demonstrates management support Integrates performance into the work culture
“Synergize”
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Trait 8: Training
Top down and bottom up– Management– Engineering / Technical– Operations
Everyone needs to speak the same language! Make sure you walk the walk!
“Sharpen the Saw”
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Trait 9: Tools
Clipboard, calculator, brain Heat balance modeling Data Tools
– archival and retrieval– validation– trending and comparison
Performance monitoring Condition monitoring Alerting Reporting
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Trait 10: Evolve
Evaluate activities frequently Quantify results $$$$ Positive results Keep it up Negative results Figure out why
– Fix it– Ditch it
Keep watching the industry and evaluate new technology
Or Become Extinct
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The Seven Traits of Highly Effective Performance Programs
1. Business Case2. Management Support 3. A Goal4. A Plan
1. Cycle Isolation Program2. Condenser Performance
Monitoring3. Controllable Losses
Monitoring4. Boiler Optimization5. Periodic Testing6. Others
5. I&C Component6. Communications7. Team Approach8. Training9. Tools10.Evolution
0th Trait: Learn to Count
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Consider these “seven” traits to help you reach the pinnacle of performance!