2013 AEP BRO

2013 AEP BRO

Pulverizer Pulverizer

Breakout Breakout

SessionSession

July 2013July 2013

By Michael Leadmon

By Michael Leadmon

Ed DillowEd Dillow

Safe

ty B

rief

Safe

ty B

rief

Emergencies – Call “HELP”

Emergencies – Call “HELP”

(4357) on house phones,

(4357) on house phones,

and the Conference center

and the Conference center

will initiate the response.

will initiate the response.

Fire Alarms will sound if

Fire Alarms will sound if

there is a fire. Instructions

there is a fire. Instructions

will be announced over the

will be announced over the

PA system. Follow the

PA system. Follow the

evacuation instructions.

evacuation instructions.

Severe weather, Power

Severe weather, Power

outages, or other

outages, or other “situations” will be

“situations” will be evaluated and taken care of

evaluated and taken care of

by the Convention Center,

by the Convention Center,

again announcements will

again announcements will

be made as required.

be made as required.

Changin

g

Changin

g

tim

es

!ti

mes

!

2011 - 2011 - Pulverizer

Pulverizer Curtailments $10,300,000

Curtailments $10,300,000

total with 92% at units

total with 92% at units

without spare mills. 4th

without spare mills. 4th

Leading contributor of

Leading contributor of

Equivalent forced outage rate

Equivalent forced outage rate

among the 5 – 800 series

among the 5 – 800 series

units. Focus : additional

units. Focus : additional

throughput to eliminate

throughput to eliminate

curtailments, improve

curtailments, improve

reliability and capture the

reliability and capture the

“money left on the table”.

“money left on the table”.

2012 – 2012 – No industrial load,

No industrial load,

curtailments covered with

curtailments covered with

“excess power”, gas plants

“excess power”, gas plants

running and taking coal load,

running and taking coal load,

not much justification for

not much justification for

spending money for pulverizer

spending money for pulverizer

load curtailments!

load curtailments! 2013 –

2013 – Coal and Gas battle

Coal and Gas battle

for market,, pure economics !!

for market,, pure economics !!

Throughput again becomes an

Throughput again becomes an

issue! Capture the $

issue! Capture the $

whenever available.

whenever available.

Why

focu

s on

Why

focu

s on

Pulv

eri

zers

?

Pulv

eri

zers

?

90%

5% 4%1%

Coal Maintenance Chemicals Other

Pulv

eri

zers

mean

Pulv

eri

zers

mean

Fuel D

eliv

ery

Fuel D

eliv

ery

Flexibility – Boilers were designed

Flexibility – Boilers were designed

considering the location of the mine,

considering the location of the mine,

and will probably not be burning the

and will probably not be burning the

coal today it was designed to burn 3-5

coal today it was designed to burn 3-5

decades ago!

decades ago! Dispatch cost - Real, and we are

Dispatch cost - Real, and we are

starting to educate our employees

starting to educate our employees

about this. Survival of the fittest! Small

about this. Survival of the fittest! Small

incremental improvements, do not

incremental improvements, do not

expect single events to make a

expect single events to make a

tremendous impact!

tremendous impact! Idea generation – Employee

Idea generation – Employee

involvement will create lots of ideas on

involvement will create lots of ideas on

how to improve ! Do not overlook this

how to improve ! Do not overlook this

valuable resource.

valuable resource. Reality Check - Make sure you are not

Reality Check - Make sure you are not

asking your equipment to do more that

asking your equipment to do more that

it is capable of doing! Original design

it is capable of doing! Original design

basis did not include any “frills”!

basis did not include any “frills”!

Changin

g

Changin

g

Opera

ting

Opera

ting

Condit

ions

Condit

ions

Low Loads at night – Pushing

Low Loads at night – Pushing

established limits to keep

established limits to keep

from loosing money during

from loosing money during

off peak hours.

off peak hours. Safety Point

Safety Point : :

Make provisions to ensure

Make provisions to ensure

the coal conduit minimum

the coal conduit minimum

velocities are maintained

velocities are maintained

(3000ft/min)

(3000ft/min)Ash content – higher ash,

Ash content – higher ash,

less energy, more volume,

less energy, more volume,

greater slagging potential.

greater slagging potential.

Moisture – more heat input

Moisture – more heat input

needed to drive off the

needed to drive off the

moisture. Air heaters ! More

moisture. Air heaters ! More

equipment will be involved ,

equipment will be involved ,

look more at systems !

look more at systems !

Dispatch Dispatch Cost of Cost of $36.00$36.00

Figure used Figure used to calculate to calculate

the $9.5M the $9.5M curtailmentscurtailments

Fuel Cost & Handling

Fuel Cost & Handling

($/MWh) $ 32.40

($/MWh) $ 32.40 Maintenance

Maintenance

($/MWh) $ 1.95

($/MWh) $ 1.95 Major Chemicals

Major Chemicals

($/MWh) $ 1.58

($/MWh) $ 1.58 Other

Other

($/MWh) $ 0.07

($/MWh) $ 0.07The target is obvious!

The target is obvious!

How

do w

e c

ut

How

do w

e c

ut

dis

patc

h

dis

patc

h

cost

s???

co

sts?

??

Fuel cost represents 90%

Fuel cost represents 90%

of the dispatch cost so it

of the dispatch cost so it

is the most likely place

is the most likely place

to find improvement.

to find improvement. To drop the dispatch cost

To drop the dispatch cost

$1.00, it takes about a

$1.00, it takes about a

$2.00 cost per ton

$2.00 cost per ton reduction for delivered

reduction for delivered

coal (average, you

coal (average, you actual cost may change)

actual cost may change)

$20.00 price variation

$20.00 price variation

for our 12,000 Btu/# AEP

for our 12,000 Btu/# AEP

coal is across the

coal is across the eastern fleet . So

eastern fleet . So improvements are

improvements are possible!possible!

Dro

ppin

g c

oal

Dro

ppin

g c

oal

pri

ces!

pri

ces!

Caution, each unit was

Caution, each unit was

originally designed to run on

originally designed to run on

a specific coal

a specific coal A drop in coal price usually

A drop in coal price usually

means increased ash, lower

means increased ash, lower

heating value, or some other

heating value, or some other

undesirable characteristic.

undesirable characteristic.

Example, given a heat rate

Example, given a heat rate

of 10,000 BTU/KWhr and a

of 10,000 BTU/KWhr and a

coal heating value of

coal heating value of

12,000BTU/#, saving $2/ton

12,000BTU/#, saving $2/ton

for the same coal reduces

for the same coal reduces

the dispatch cost about

the dispatch cost about

$1.00! Saving that

$1.00! Saving that same$2/ton and loosing 500

same$2/ton and loosing 500

BTU/# raises your dispatch

BTU/# raises your dispatch

cost by the same $1.00!

cost by the same $1.00!

Realit

y :

You g

et

Realit

y :

You g

et

what

you g

et

!

what

you g

et

!

Rarely do we get the coal

Rarely do we get the coal

the units are design for!

the units are design for!

It is up to the pulverizer

It is up to the pulverizer

owners and operators to

owners and operators to

get the load from the

get the load from the

pulverizers. Know your

pulverizers. Know your

mills, and the modifications

mills, and the modifications

required to get them to

required to get them to

where you want to be!

where you want to be!

Wholesale replacements

Wholesale replacements

are not always necessary.

are not always necessary.

Our speakers today are

Our speakers today are

here to help by providing

here to help by providing

options for coal condition

options for coal condition

flexibility and throughput

flexibility and throughput

increases! increases!

Prese

nta

tions

Prese

nta

tions

B&W – Our alliance partner will discuss

B&W – Our alliance partner will discuss

upgrades that have made overseas, the

upgrades that have made overseas, the

real data showing improvements in

real data showing improvements in

performance, and the importance of

performance, and the importance of

knowing what you want and expect to

knowing what you want and expect to

achieve with your modifications!

achieve with your modifications!

Alstom – Rotating classifier vs. modified

Alstom – Rotating classifier vs. modified

stationary classifier accompanied by

stationary classifier accompanied by

throat mods and wide tires. Buy only the

throat mods and wide tires. Buy only the

upgrades that you need.

upgrades that you need.

Smartburn – Explores modeling of the

Smartburn – Explores modeling of the

MPS89 and pre-mod analysis.

MPS89 and pre-mod analysis.

Illinois Basis Coal – Possible solution to

Illinois Basis Coal – Possible solution to

economic problems? Pat Malone will

economic problems? Pat Malone will

discuss AEP test burns.

discuss AEP test burns.

Stock Equipment – Will discuss feeder

Stock Equipment – Will discuss feeder

design criteria to meet NFPC

design criteria to meet NFPC

requirements and how our old equipment

requirements and how our old equipment

may be pushing those limits. Inspection

may be pushing those limits. Inspection

guidelines, repair procedures and

guidelines, repair procedures and

preventative action suggestions!

preventative action suggestions!

AEP Big Sandy - Real data and

AEP Big Sandy - Real data and

experiences from AEP’s first rotating

experiences from AEP’s first rotating

classifier installation!

classifier installation!

Thank

You

Thank

You

! !