Partnering to Improve Plant Performance and Reliability

Partnering to Improve Plant

Performance and Reliability

Reliability & Plant EnginReliability & Plant Engineering Serviceseering Services

PMT is an engineering and technical services company that specializes in tactical solutions to improve plant maintenance and reliability.

Our Business MakeupCONSULTING:

Maintenance & Reliability Assessment & Planning CMMS Implementation Lubrication Management PM Evaluation & Optimization Motor Management Program Storeroom Optimization Root Cause Failure Analysis

TECHNICAL SERVICES:

Precision Shaft Alignment Precision Balancing Vibration AnalysisContinuous Monitoring Infrared Scanning Oil Analysis Ultrasound Detection Motor Analysis Other NDT Services

TRAINING:

Skills Assessment Corrective Maintenance Preventive Maintenance Predictive Maintenance Proactive Maintenance Management Track Safety

OTHER SERVICES:

Arc Flash Hazard Analysis Compressed Air Leak Surveys Energy Management Programs Equipment Start-up & CommissioningOn Sight Reliability EngineeringOn Sight Maintenance ManagementOn Sight Planning & Scheduling

PMT Staff Expertise Vibration Analysis Technicians Structural Engineer Lubrication Engineer Materials Management Specialist Maintenance Managers Motor Management Specialists Reliability Engineers Planners and Schedulers Infrared Thermographers Metallurgist

PMT Locations

Headquarters:

Kansas City, MO.

Field Offices:

St. Louis, MO

Shreveport, LA

Representative Clients

3M Corporation Astaris / FMC Calpine Corporation Independence Power & Light City of Kansas City, Missouri

(Water Services Department)

City Utilities of Springfield Church & Dwight Farmland Ford Motor Co. General Motors Griffin Pipe

Griffin Wheel Hallmark Cards Harley-Davidson ICG Viper Mine Jim Beam Brands Johns Manville Kansas City Power & Light Omaha Public Power District Pfizer Piney Creek Limited Partnership Proctor & Gamble Tenneco Automotive Vulcan Chemicals

To assist companies in moving from Cost Centered maintenance to Profit Centered maintenance

Our Goal

Yesterday It Was: “Cost-Centered Maintenance”

High priority on production Low priority on performance and maintenance Insufficient overall cost controls Inadequate planning/scheduling Generally poor stores controls Inadequate labor controls Inconsistent training Continuous “fire-fighting” Constant breakdown maintenance

Today It Is: “Profit-Centered Maintenance”

Maximizing output, performance, and safety

Improving operations and maintenance teamwork

Identifying & implementing cost reduction programs

Help establish accurate maintenance equipment records

Optimize equipment reliability Reduce auxiliary power

consumption Optimize plant resources Minimize inventory Improve maintenance

management practices

Through people and solutions, we assist organizations in moving upward toward greaterreliability and profitability

PMT Helps You Do the Right Things In the Right Order

First Step Maintenance & Reliability Assessment Evaluate existing conditions then recommend changes and methods:

Maintenance Management & Organization Maintenance Metrics Safety Corrective Maintenance Practices Preventive Maintenance Program Predictive Maintenance Technologies Lubrication Management Total Productive Maintenance Program Root Cause Failure Analysis Computerized Maintenance Management System Documents Management System Planning & Scheduling Standard Operating Procedures Outage Management Contractor Management Practices Motor Management Program Maintenance Storeroom Maintenance Training

Predictive MaintenancePredictive Maintenance (PdM) is applying

technologies to measure and quantify the condition of equipment providing quality information for

management to make quality decisions.

Reliability Goals

Help eliminate equipment breakdowns Provide management tools for meeting plant

output and capacity Help anticipate and plan for maintenance

needs Help Operations & Maintenance to function

as partners Increase profits by lowering plant

maintenance costs

An Effective ReliabilityProgram Looks Like This:

Visit our Web Site!

www.progre

ssivemaintenance.com

Strengthening PMT’s Reliability Services

PMT has partnered with Black & Veatch out of the Kansas City office.

B&V Energy: Asset Management Services specializes in tactical solutions to improve plant operations and performance.

Black & Veatch CorporationBlack & Veatch CorporationBlack & Veatch is a world-wide leader for the Black & Veatch is a world-wide leader for the

development and support of energy, water, development and support of energy, water, information, and other vital infrastructure for a better information, and other vital infrastructure for a better world.world.

Global engineering, consulting, and construction companyGlobal engineering, consulting, and construction company Energy, water, information and government marketsEnergy, water, information and government markets Founded in 1915, employee-owned, 90 offices worldwideFounded in 1915, employee-owned, 90 offices worldwide Ranked 1Ranked 1stst in Power Projects by 2006 Engineering News-Record. Also in Power Projects by 2006 Engineering News-Record. Also

ranked 1ranked 1stst in Fossil Fuel and 2 in Fossil Fuel and 2ndnd in Transmission and Distribution, with a in Transmission and Distribution, with a total of 11 “Top 10” Ratings.total of 11 “Top 10” Ratings.

B&V Energy – Consulting Engineering Services Business LineB&V Energy – Consulting Engineering Services Business Line Asset Management Services including PowerPlantAsset Management Services including PowerPlantMDMD – Delivery – Delivery

of Asset Management and Optimization Solutionsof Asset Management and Optimization Solutions

AMS Staff Skills & ExpertiseAMS Staff Skills & Expertise Engineering SpecialtiesEngineering Specialties

Performance Monitoring, Fuel Analysis Specialists, Plant Engineers, Performance Monitoring, Fuel Analysis Specialists, Plant Engineers, Reliability Consultants, Optimization ExpertsReliability Consultants, Optimization Experts

Unique Skill SetsUnique Skill Sets Outage / Maintenance Planning and ExecutionOutage / Maintenance Planning and Execution Advanced Math / Statistics / Thermodynamics / OptimizationAdvanced Math / Statistics / Thermodynamics / Optimization Information Technology Integration and DevelopmentInformation Technology Integration and Development

Commercial Platform Applications DevelopmentCommercial Platform Applications Development Enhanced PI-Based Performance CalculationsEnhanced PI-Based Performance Calculations EPRI VISTA (formerly CQIM)EPRI VISTA (formerly CQIM) FuelProFuelPro OPM (Online Performance Monitoring)OPM (Online Performance Monitoring) New Applications in Partnership with NeuCoNew Applications in Partnership with NeuCo

PowerPlantPowerPlant MDMDTMTM

::Monitoring & DiagnosticsMonitoring & Diagnostics

Proactive Action is KeyProactive Action is Key Superior Performance and Reliability Achieved by:Superior Performance and Reliability Achieved by:

Ability to Better Identify/Understand/Prioritize/Act on Ability to Better Identify/Understand/Prioritize/Act on Issues (Greater Proactivity)Issues (Greater Proactivity)

Ability to Rapidly Diagnose Source of Issue, Understand Ability to Rapidly Diagnose Source of Issue, Understand the Criticality, and Act in the Most Cost Effective Manner. the Criticality, and Act in the Most Cost Effective Manner.

Monitoring & Diagnostics Provides a Powerful and Monitoring & Diagnostics Provides a Powerful and Proven Approach for Advancing the Performance Proven Approach for Advancing the Performance and Reliability Missionand Reliability Mission

The Solution: Monitoring &Diagnostics

What Do We Mean M&D?What Do We Mean M&D? It’s About “Turning Your Data Into Action”It’s About “Turning Your Data Into Action” It’s Achievable In-Plant But Long Term Success may be It’s Achievable In-Plant But Long Term Success may be

Ensured By Centralized ModelEnsured By Centralized Model It Uses Data Generation and Presentation Tools to Bring It Uses Data Generation and Presentation Tools to Bring

Added Value, But Focus isAdded Value, But Focus is

on “The Process”on “The Process” The Process IncorporatesThe Process Incorporates

Best PracticesBest Practices The Process EngagesThe Process Engages

Cross-Functional PlantCross-Functional Plant

TeamTeam

M&D Solution is a Team EffortM&D Solution is a Team Effort Monitoring & Diagnostics CenterMonitoring & Diagnostics Center

Gathers Plant Operating Data and Filters to Add ClarityGathers Plant Operating Data and Filters to Add Clarity Analyzes the Data in Light of Current Operating Issues and Analyzes the Data in Light of Current Operating Issues and

ConstraintsConstraints Communicates Potential Issues Including Cost and CriticalityCommunicates Potential Issues Including Cost and Criticality Coordinates in-Plant Diagnosis When Needed and Works to Coordinates in-Plant Diagnosis When Needed and Works to

Understand Root Cause and Action PlanUnderstand Root Cause and Action Plan Maintain Structured and Prioritized Action Lists to Ensure Issues Maintain Structured and Prioritized Action Lists to Ensure Issues

are Addressed When Appropriateare Addressed When Appropriate

Power Plant PersonnelPower Plant Personnel Focus on Mission-Critical ActivitiesFocus on Mission-Critical Activities Operations/Engineering Perform in-Plant Diagnoses as NeededOperations/Engineering Perform in-Plant Diagnoses as Needed Coordinate Resolution of Critical Issues (Immediate & ST Maint.)Coordinate Resolution of Critical Issues (Immediate & ST Maint.) Coordinate Resolution of Non-Critical IssuesCoordinate Resolution of Non-Critical Issues

ProcessesProcessesForm Performance & Reliability Improvement TeamForm Performance & Reliability Improvement TeamDetermine Communication Methods and GuidelinesDetermine Communication Methods and GuidelinesInitiate Anomaly Detection & Diagnosis ProcessInitiate Anomaly Detection & Diagnosis ProcessInitiate Monthly Meetings to Review Issues and Action PlanningInitiate Monthly Meetings to Review Issues and Action PlanningIntegrate With Other Key Processes, i.e. PdM ProgramIntegrate With Other Key Processes, i.e. PdM Program

Tools UtilizedTools UtilizedUtilize Existing Historian Data (Process and Equipment Health Data)Utilize Existing Historian Data (Process and Equipment Health Data)Compliment With B&V Anomaly Detection SoftwareCompliment With B&V Anomaly Detection SoftwareCompliment With B&V Monthly Trend Analysis SoftwareCompliment With B&V Monthly Trend Analysis SoftwareShift Reports, Production Reports, PdM Reports, Rounds DataShift Reports, Production Reports, PdM Reports, Rounds DataUtilize Other Available ToolsUtilize Other Available Tools

Typical M&D Center SupportTypical M&D Center Support

Pattern Recognition Used to Alarm Statistically Relevant DeviationsPattern Recognition Used to Alarm Statistically Relevant DeviationsAlgorithm Uses Automatic Learning MethodologyAlgorithm Uses Automatic Learning MethodologySteady-State Filtering, Load Bucketing, Multi-Variable Linear RegressionSteady-State Filtering, Load Bucketing, Multi-Variable Linear RegressionDynamic Alarming Based on Standard Error ComparisonDynamic Alarming Based on Standard Error Comparison

B&V Reviews DataB&V Reviews DataDetermines ProblemsDetermines ProblemsQuantifies CriticalityQuantifies CriticalityIssues RecommendationIssues RecommendationCoordinates Action PlanCoordinates Action Plan

Plant ActsPlant ActsOperations TroubleshootingOperations TroubleshootingOperational ChangesOperational ChangesCritical Maintenance PlannedCritical Maintenance Planned

Anomaly Detection & DiagnosisAnomaly Detection & Diagnosis

Month/Quarterly Analysis & ReviewMonth/Quarterly Analysis & ReviewAutomated Data Handling & ChartingAutomated Data Handling & ChartingPerformance & Reliability Improvement Performance & Reliability Improvement Team MeetingTeam Meeting

B&V Analyzes Performance DataB&V Analyzes Performance DataReview Low Criticality IssuesReview Low Criticality IssuesDetailed Trend AnalysisDetailed Trend AnalysisEconomic Prioritization of Economic Prioritization of Opportunities & RecommendationsOpportunities & RecommendationsEvaluate Long-Term Degradations & Evaluate Long-Term Degradations & Maintenance PlansMaintenance Plans

Plant ActsPlant ActsAdditional PrioritizationAdditional PrioritizationNon-Critical Maintenance PlannedNon-Critical Maintenance Planned

Action-Centric Team Collaboration EnvironmentAction-Centric Team Collaboration EnvironmentSearchable Knowledge Base of Diagnostic InformationSearchable Knowledge Base of Diagnostic Information

PowerPlantPowerPlantMDMD.com.com

The Results: M&D Experienceand Examples

B&V Monitoring & Diagnostics CenterB&V Monitoring & Diagnostics Center40 Units, 13,000+ MW40 Units, 13,000+ MW

WKE Coleman (3 units) – ’02WKE Coleman (3 units) – ’02MN Power Boswell (2 units) – ’03MN Power Boswell (2 units) – ’03AmerenUE (11 units) – ’03AmerenUE (11 units) – ’03CUOS Southwest – ’03CUOS Southwest – ’03Alcoa Warrick (4 units) – ’04Alcoa Warrick (4 units) – ’04WKE Green (2 units) – ’04WKE Green (2 units) – ’04IPL Petersburg (3 units) – ’05IPL Petersburg (3 units) – ’05SaskPower (9 units) – ’05SaskPower (9 units) – ’05

Sioux U2 BFP Recirc Valve Leak (difference in ECON and BFP suction Flow)

4/23/04 6/12/04 8/1/04 9/20/04 11/9/04 12/29/04 2/17/05 4/8/05

Remoted monitoring start

Monthly plant meeting. Plant Isolated recirc valve to check and confirmed leak.

Unit Load. All data filtered for > 400

Trend of: Flow Error = ECON FW FLOW - (HPBFP Suction - RH spray Flow)First recognized on 12/29/04.

Reference Available Reference Available @ Any Site!@ Any Site!

Basin Electric AVS (2 Units) – ’07Basin Electric AVS (2 Units) – ’07WPSR Weston (1 Unit) – ’07WPSR Weston (1 Unit) – ’07Hawaiian Electric (2 Units) – ’07Hawaiian Electric (2 Units) – ’07

Case Study SummariesCase Study SummariesMinnesota PowerMinnesota Power11 – –

Boswell Unit 3Boswell Unit 3

Annualized heat rate savings of $480,000Annualized heat rate savings of $480,000 Improved % of planned/scheduled maintenanceImproved % of planned/scheduled maintenance Integrated operations & maintenance teamsIntegrated operations & maintenance teams

Western Kentucky Western Kentucky EnergyEnergy22 – –

Green Units 1&2Green Units 1&2

Annualized heat rate savings of $530,000Annualized heat rate savings of $530,000 Recovered 5-15 MW in typical summer unit deratingRecovered 5-15 MW in typical summer unit derating Improved outage planning and prioritizationImproved outage planning and prioritization

AmerenAmeren33 – –Regional Regional

Performance GroupPerformance Group

Annualized heat rate savings over 7 times program costAnnualized heat rate savings over 7 times program cost Mitigation of reliability and replacement power cost riskMitigation of reliability and replacement power cost risk Improved information flow and communication with plantsImproved information flow and communication with plants

AlcoaAlcoa44 – –Warrick Units 1-4Warrick Units 1-4

Zero up front capital costZero up front capital cost $3.1M net savings over first 2.5 years$3.1M net savings over first 2.5 years Strategic alliance to achieve plant optimization goalStrategic alliance to achieve plant optimization goal

1 Summary of paper by Matt Wood and Tom Geiselman presented at Coal-Gen Conference 2004.2 Summary of paper by Greg Tanck and George Hollander presented at EPRI HRI Conference 2005.3 Summary of paper by Kelly Whittenberg and Joe Sind presented at Electric Power Conference 2005.4 Summary of paper by Matt Wood and DeWayne Todd presented at Electric Power Conference 2007.

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