Don't confuse performance "monitoring" with performance improvement
Is the goal of your plant's performance program issuing this month's report, and then getting next month's out on time?
Collecting data is only the beginning. The real challenge is accurate analysis that leads to effective action.
This can't be done by a "package" alone. Real results require complete analysis of data, equipment, and instrumentation.
Jim Koch specializes in power plant performance testing and analysis. He's worked with leaders in the generation industry, including:
- Atlantic Generation, Inc.
- TransCanada Power Corp.
- U. S. Generating Co.
- PECO Energy
- ComElectric
- PSE&G
- Boston Edison
- Vogt-NEM, Inc.
An actual case history:
An IPP combined cycle owner suspected that his steam turbine generation was below par.
His performance monitoring package provided real time data, daily reports, and interactive color screens, but couldn't pinpoint the problem.
An experienced analyst ran a test using existing plant instrumentation. He found the problem to be HRSG fouling and condenser air binding.
To the owner's relief, steam turbine performance was actually close to design.
After some low-cost repairs, 4 MW were recovered, adding over $600,000 to the bottom line.
Are savings like this waiting to be found at your plant, too?
Today's competitive power generation business requires new answers.
Where's the "value added?"
If power sells for 2 cents/kWh, each MW of increased output adds $150,000 to the bottom line. Capacity payments add even more. Even if a plant doesn't buy its own fuel, these savings are needed by power purchasers and customers.
We already have a performance "package." What more can Jim add?
After a while, "performance monitoring" becomes data which is neither looked at nor believed. Jim carefully analyzes data to identify losses, confirming the results with various "checks" before making a recommendation.
Our plant engineer does a good job. Why have Jim duplicate his effort?
Jim's work complements the plant's engineer, who is responsible for many areas, and can't focus full time on performance issues. Jim's 15 years of test and analysis experience fits well with your staff's in-depth site expertise.
Our plant is new, and still makes capacity. What can Jim offer us?
When problems arise later, the first question is often "How was it when the plant was new?" A complete set of data, not just an "input/output" test from initial acceptance, is a valuable asset for solving problems down the road.
We know of no problems at this time, so how do I justify this expense?
Just like a routine check-up, periodic testing will uncover performance problems before they impact production cost. "Early warning" gives time to plan repairs for upcoming outages.
We already use the OEM for this type of work. Isn't that good enough?
An OEM knows his own products, but the GT vendor may not be the one to test an HRSG. Using FCYCLE and CCYCLE heat balance software, Jim brings a total-plant approach to testing, data analysis, and interpreting results.
Jim Koch provides performance testing and analysis to:Cost-effective results are possible at plants of any type or size:
- Improve Heat Rate
- Increase Capacity
- Reduce Cost
- Maximize Profits
- Combined Cycle
- Gas Turbine
- Fossil Steam
- Cogeneration
Results can be achieved without involved set-up, disruption of operation, or tying-up staff.