Perspectives From The End-User Community HYDRAULIC INSTITUTE ’16 ANNUAL CONFERENCE MONDAY, FEBRUARY 15, 2016 2:30 – 4 PM

Platinum Sponsor & Session Moderator

Jon Christensen, Superintendent of Operations & VP of Intermountain Power Services Corporation (IPSC)

• IPSC operates and maintains a 1900 MW coal fired generating station, AC Switchyard, and DC Converter Station.

• Since starting with IPSC in 1986, he has been a maintenance supervisor; lead engineer responsible for pumps, fans, motors and generators; supervising engineer; and the Assistant Superintendent of Technical Services responsible for all of the electrical and instrument technicians.

• Jon graduated from Brigham Young University with a Bachelor of Science degree in Electrical Engineering. He is a registered professional engineer in Utah and a senior member of the Institute of Electrical and Electronics Engineers.

Intermountain Power Project

Jon P. Christensen, P.E. Vice President

2016 Annual Conference

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Intermountain Power Project History

Owner Intermountain Power Agency Operating Agent Los Angeles Department of Water & Power Operator Intermountain Power Service Corp.

• Construction began 1982 • Unit 1 Commercial Operation 1986 • Unit 2 Commercial Operation 1987

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Intermountain Power Project

• Intermountain Generating Station (two 950 MWg units)

• Intermountain Switchyard and Converter Station

• Intermountain Railcar (five unit trains)

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Intermountain Power Plant Site

Intermountain Power Project

• There are 768 pumps itemized as assets in the plant maintenance system.

• About 14% of these pumps are over 100 HP.

• Between 5% to 7% of all maintenance hours are spent on

pumping systems.

Intermountain Power Project

HP Quantity Service

100 5 Stator Cooling Water Pump

100 3 Mist Eliminator Pump

125 3 Onsite Reservoir Pump

150 5 Converter Station Fine Water Pump

300 4 Well Pump

300 5 Circulating Water Makeup Pump

300 9 Bottom Ash Transfer Pump

350 5 Ash Sluice Water Pump

500 5 Closed Cycle Cooling Water Pump

500 38 Scrubber Spray Pump

600 6 Booster Boiler Feed Pump

1750 7 Condensate Pump

2050 9 Circulating Water Pump

7000 2 Standby Boiler Feed Pump

Intermountain Power Project

Pump Work 2010 through 2014

YEAR

TOTAL HOURS WORKED PUMP HOURS WORKED PERCENTAGE OF

WORK

2010 419,617.25 21,371.00 5.0%

2011 379,643.25 26,114.25 6.8%

2012 361,651.00 24,754.25 6.8%

2013 369,807.75 25,014.25 6.8%

2014 339,335.75 21,539.25 6.3%

Intermountain Power Project Pump Operating Experience

• Because of system redundancy, pump problem have not caused units trips but have occasionally required derating the generating units for repairs.

• Initially, after the generating units were commissioned, most pumping systems worked

reliably. We had a few minor problems because of design issues. These included metallurgy (circulating water pumps) and cavitation (stator cooling water pumps) problems.

• After the first few years of operation, when we started disassembling pumps for overhaul and preventive maintenance inspections we determined that the documentation provided by the original equipment manufacturers was inadequate to perform good maintenance. The documentation was not detailed enough to restore the pumps (circulating water and condensate) to new condition. But by using OEM/ repair shop support and through trial and error we created our own rebuild specifications. Our mechanics became experts at troubleshooting and repairing pumping systems.

Intermountain Power Project Pump Operating Experience

• Now we are operating the generating station differently. We are no longer base loaded. We cycle the units from minimum to full load chasing renewable energy.

• OEM support is no longer as good because of parts obsolescence, manufacturer consolidation and limited technical staffing.

• Our experienced employees are retiring. • There may be unintended consequences in system design changes

(stator cooling water pumps).

Intermountain Power Project Pump Operating Experience

• Currently we are reviewing and updating maintenance instructions to try and retain expertise gained through years of experience.

• A few months ago, we transitioned to Maximo and we are developing

key performance indicators to track pump maintenance performance.

• We have retained a consultant to look at our top ten worst acting pumps to help us develop plans to restore these pumping systems performance.

• We have established cross functional teams with engineering, planning

and operating personnel to evaluate pumping systems. Members of these teams have attended conferences and training classes to increase their knowledge.

• Our goal is to adopt best practices in pump system design, operating and maintenance.

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Othman Mjahed, Pump Component Engineer, AZ Public Service Palo Verde Nuclear Plant

• Senior Pump Engineer responsible for the maintenance and operation of all pumps at the Palo Verde Nuclear Generating Station in Tonopah.

• Duties includes oversight of all repairs, refurbishment, replacement, and analysis of predictive maintenance data.

• Othman Holds a Bachelor of Science in Mechanical Engineering from Arizona State University and a MBA from Western International University.

Othman Mjahed

Sr. Component Engineer

Palo Verde Nuclear Generating Station

02/15/2016

Our Mission

To SAFELY and efficiently generate electricity for the long term

• Palo Verde is managed and operated by APS on behalf of the six other utilities that own Palo Verde from Los Angeles to West Texas. The owners and their representative share of Palo Verde are as follows:

•

Arizona Public Service, 29.1% — licensed operating company for the plant Salt River Project, 17.49%

Southern California Edison, 15.8% El Paso Electric, 15.8%

Public Service Company of New Mexico, 10.2% Southern California Public Power Authority, 5.91% Los Angeles Department of Water and Power, 5.7%

Palo Verde Ownership

• Palo Verde is located on a 4,250-acre site 55 miles west of downtown Phoenix, Arizona.

• The Palo Verde Nuclear Power Plant is the largest power producer of any kind in the United States since 1992. Its three units are capable of generating more than 4,000 megawatts of electricity

• Palo Verde is the only generating facility in the nation to ever produce more than

30 million MWh in a year, a feat that has been achieved each of the past six years and a total of 10 times. In addition, Unit 3 produced the second-highest electricity output of any nuclear unit in the world, and all three Palo Verde units individually ranked among the top six producers in the U.S.

Palo Verde Facts

• Palo Verde is the only nuclear plant in the United States that does not sit on a large body of water, but instead uses effluent water .

• Waste Water is transported to PVNGS through 36 miles of underground pipe.

Palo Verde Facts

• Over 1800 pumps at the site of various type, size, and manufacturer.

• Range from ½ Horsepower to 12000 Horsepower. • Mix of safety related and non safety grade.

• Safety related ( ASME Section III (Classes 1, 2 and 3; N, NPT and NS stamps))

• Non safety related (Commercially Available)

Safety-Related* * This term applies to structures, systems, components, procedures, and controls of a facility or process that are relied upon to remain functional during and following design basis events.

Pump Population at the Station

• Obsolescence is one of the most challenging issues facing the nuclear power

industry today. • Obsolescence, in the context of the nuclear industry, refers to components

that are no longer manufactured or qualified to the current regulated standards or are no longer available from their original fabricators.

• This need presents a unique challenge for the nuclear industry, as many manufacturing pump companies who provided original parts to the plants in the 1970s and 80s are no longer in business or are no longer appropriately certified to provide nuclear-grade parts. (Legacy brand / consolidation of brand & product).

• Failure of an obsolete pump part can lead to a number of problems such as

extended outages, loss of revenue and greater operating costs

Aging and Obsolescence

• Several Utilities including Palo Verde have used Power uprate as a way to generate more electricity.

• To increase the power output of a reactor, typically a utility will refuel with either

slightly more enriched uranium fuel or a higher percentage of new fuel. This enables the reactor to produce more thermal energy and therefore more steam, which drives a turbine to generate electricity.

• A higher power level usually involves greater steam and water flow through the systems used to convert heat into electric power. These systems and components must be able to handle the increased flows.

• This uprate uses the installed pumps to a higher degree of their maximum

capability. Pumps are therefore subject to a higher operating cycle, increased wear, etc.

Power uprate & system implication

Condition Monitoring of Pumps Vibration analysis has historically been the technique of choice for monitoring pumps and the leading indicator of pump degradation.

• Oil analysis was responsible for 40% of the defects found.

• Vibration analysis was responsible for 33%.

• Oil Analysis & Vibration combined responsible for 27% of the defects found

Often, one technique serves as the leading indicator of pump failure while the other serves as the confirming indicator

Industry / pump Challenges

End user is looking for acceptable values/parameters. For example:

What is :

The void fraction upper limit that a pump can withstand before it is unable to continue pumping water? NRC Generic Letter 2008-01

Allowable metal particles from wear counts.(ISO 4402, SAE ARP 598)

Guidance on “black Oil” Phenomenon. The process by which the lubricating oil darkens or turns black within a time period ranging from one hour to several weeks.

conclusion As an end user, we recognize the importance of utilizing the HI/ANSI standards to optimize, regain lost margin, and support decision making & troubleshooting of pumps. At PVNGS ANSI/HI Pump Standards are used very often to help determine:

• Operability of Pumps

• Get a timely response when Vendor is not available

• OEM is no longer in business

• To ensure the ability of Safety Related pumps to perform their specific design. (ASME OM code & HI Standards)

Rory Carvajal, Operations Specialist – Learning & Performance, Kiewit Power • Kiewit Engineering and Design is a design engineering firm focused on

the energy sector with a large volume of the work being execution of EPC combined cycle power projects in the US and Canada.

• Rory provides professional development to engineering staff focusing on development of entry level engineers, and support of project design reviews, plant testing, and warranty work.

• Rory attended Kansas State University and has a Bachelor of Science in Mechanical Engineering

Pump Design Basis

An EPC Contractor’s View

Major Entities in EPC Contracts

Plant Design

Owner

Owner’s Engineer

EPC Contractor Maintenance

Operations

What Cost Model is Applicable?

Total Life Cycle Cost

• Owner Type (typical) • Utilities • Build/Own/Operate Firms

• Owner’s Engineer • Higher influence

• Focus • Operability, maintainability, accessibility, reliability (redundancy

options), materials of construction • Load Profile (plant output power variation during the day)

What Cost Model is Applicable?

• Owner Type (typical) • Independent Power Producers (IPP)

• Owner’s Engineer • Less influence, more performance based.

• Focus • Performance and reliability (redundancy options)

• 2x100% Redundancy standard.

Initial Capital Cost

Redundancy: What Does 2x100% Mean? • The typical terminology for redundancy is 2x100% capability. • Generally applied, this indicates at any possible operating condition, a single pump is to handle

the conditions. • Plant with heavy supplemental/duct firing, there can be a large difference between Combustion

Turbine baseload operating cases.

Condensate Pump Boiler Feed Pump Operation Flow, gpm Head, feet Flow, gpm Head, feet Low Load – Unfired 2,019 507 949 3,065 Base Load - Unfired 2,769 747 1,558 6,994 Base Load - Fired 3,660 1,121 2,404 8,241

• Providing the lowest total initial cost system means not providing variable speed drives on boiler feed pumps.

• Providing a fully redundant pump for this scenario would impact performance even at normal unfired base load conditions.

• Would an option for this be 2x100% at unfired conditions, and then 2x50% at fired conditions? • If the plant Operations and Maintenance personnel are not engaged during the design, some of

the redundancy clarifications such as the detailed meaning of 2x100% may not meet their expectations.

Redundancy: What Does 2x100% Mean?

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(fee

t)

Flow (gpm)

Example Combined Cycle Boiler Feedwater Pump

Operating Points 2x100% - All Cases 2x100%-Unfired, 2x50%-Fired

Base Load Operation - Fired

Base Load Operation - Unfired

Low Load Operation - Unfired

Redundancy: What Does 2x100% Mean?

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0 500 1000 1500 2000 2500 3000 3500 4000 4500

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(fee

t)

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Example Combined Cycle Condensate Pump

Operating Points 2x100%-All Cases 2x100%-Unfired, 2x50%-Fired

Base Load Operation - Fired

Base Load Operation - Unfired

Low Load Operation - Unfired

Optimization vs Schedule • As can be seen, sometimes low initial cost (e.g, no variable speed drives) and 2x100%

operation can cause operational conflicts depending on the plant load profile.

• Would it be possible to perform detailed cost/load profile optimizations during design?

• Unfortunately, due to the current constraints of schedules these days, unless specifically required in the EPC Contract, planned studies are not included in schedules. The EPC Contractor drives the schedule based on the final agreed upon EPC Contract requirements.

• In addition, even if this study was to be performed during detailed design, the challenge of forecasting an appropriate load profile still remains.

• This leads to potential avenues where plant efficiency optimizations are not fully realized due to schedule constraints and not including studies as part of the EPC Contract.

Notice to Proceed NTP to

Commercial Operation: 28-

30 months

Schedules vs Professional Development

• Studies: • Not normally included in EPC contract schedules. • An excellent learning opportunity – missed!

• Challenges to learning: • Impacts to production • Standard templates “hide” the details, don’t

explain “why”? • Short bid-evaluate-award cycles a hindrance • Flanging up learning opportunities on projects

with learning needs

Learning & Development Challenges for EPC Contractors

• In addition to the impacts of the of short duration schedules on learning and development indicated above, another challenge is the best means to deliver learning opportunities.

• EPC Contractors execute various projects simultaneously. Rarely do any two project schedules line up such that large classroom training provides effective training for the engineers. This is because only a small portion of them actively use that training when going back to their project work.

• This means that the learning materials need to be made available to engineers in a just-in-time manner when they are just about to or are currently working on the design to maximize reinforcement of the learning.

Summary EPC Contractors are presented with the following challenges:

• Pre-defined technical requirements. • Time-sensitive schedules

This results in minimized time available for full optimizations of facilities and learning opportunities for younger engineers.

The Challenge

Provide concise, readily accessible, learning materials that explain the reasoning behind the guidelines and templates used for design such that designs are more complete earlier in the design (i.e, minimize revisions) and younger engineers can understanding the why of what is being done to allow them to explore other options and optimize systems in the future.

THANK YOU!

Questions?