Maintenance Management & Technology - Program 69

Transcription

1 Maintenance Management & Technology - Program 69 Program Description Program Overview Existing electric power generating units meet an important strategic need. To continue to meet the load demands of the bulk electric power system, the current fleet of generating units must remain highly available, reliable, and efficient. As the industry landscape shifts, achieving these goals will become more challenging. Increasingly greater demands are being placed on plant staffs to meet these availability, reliability, and efficiency standards, even as those staffs are becoming leaner and less experienced due to retirements, mergers and acquisitions, unit closings, and other events that significantly alter the size and demographics of the workforce. Many units are being operated under conditions, such as the number or types of transient conditions now being experienced, and/or the sheer age of the units, to which they have never been exposed. These changes produce an entirely new dynamic for organizations that only adds to the plant maintenance challenges they face. The Electric Power Research Institute s (EPRI s) Maintenance Management and Technology program (Program 69) helps plant owners and operators address this challenging environment by developing best practices associated with maintenance program structure and functionality. Collaborative research involving topperforming organizations is used to develop maintenance processes that identify causes of potential equipment failures, effective monitoring and assessment of equipment condition, and proactive planning for equipment maintenance. EPRI assists member companies in more effectively utilizing their staffs by increasing their proficiency in applying standard processes, facilitating peer collaboration, creating databases to support condition-based maintenance, and documenting case histories. Research Value EPRI s Operations and Maintenance programs help members transition to, and sustain, the least-costly procedures and practices associated with plant maintenance. The key attributes of an optimized program are adoption of information management needed to support a condition-based approach to maintenance, and replacement of costly corrective maintenance with proactive preventive maintenance. The focus of this program is on providing an integrated solution that addresses the needs for processes, technologies, and skilled people, which enables condition-based maintenance to support risk-informed maintenance decisions. By using the R&D in this program, members can: Achieve operation and maintenance excellence through an integrated approach that includes process improvements, related technologies, and knowledge management; Address current issues associated with the need for flexible plant operations, asset retirement, and new reliability standards; Achieve Lean maintenance through reduced use of resources; and Increase plant availability and reliability through improved outage management and staff performance. Approach The ongoing evolution of enhanced plant maintenance processes and technology is an inherently collaborative activity, involving member companies, industry experts, and EPRI staff. Involvement in the program as an advisor or participant in the various projects and user groups is the primary means by which value is received from EPRI. The project structure established to help facilitate this transfer of results includes: User groups, meetings, and workshops that provide a structure for sharing peer information about, and experience with, plant maintenance. These venues include the Plant Reliability Interest Group (PRIG), Condition-Based Maintenance User Group (CBMUG), and the Plant Manager Forum. p. 1

2 Plant maintenance processes that focus on development and improvement of both fundamental and new best practices experienced throughout the industry. Technical reports cover detailed aspects of the primary process elements such as condition-based maintenance, work management, maintenance basis, outage planning/execution, human factors, corrective action, and continuous improvement. Plant maintenance technology R&D that facilitates the deployment of advanced maintenance processes, which are essential to achieving desired performance. This R&D includes technologies to support the identification and optimization of preventive maintenance (PM) tasks, the management of predictive maintenance (PdM), diagnostics, prognostics, and risk management. The software products in this project provide databases that members can use to apply component and system knowledge and perform effective equipment analysis. Accomplishments Maintenance engineers, planners, and system owners need information, technologies, and processes to achieve high performance in plant availability, reliability, and efficiency while effectively minimizing production costs. This program has provided: Development and application of plant reliability processes and standards at members facilities; More than 100 technical reports, technical updates, and software products that cover all aspects of preventive/predictive maintenance, work planning, work execution, outage management, and human performance; A widely used enterprise software tool, PlantView, which facilitates sustained high performance derived from integrating process elements such as maintenance basis, predictive maintenance, system health, and risk assessments; and A cutting-edge software package to facilitate integrated equipment diagnostics (Asset Fault Signature Database and Diagnostic Advisor) and prognostics (Remaining Useful Life Database and Remaining Useful Life Advisor). These products include databases of known equipment fault indicators and failure models that are used to assist plant staff with both the diagnosis and prediction of plant equipment failures Current Year Activities The program R&D for 2012 will maintain the focus on improvements in maintenance processes and related technologies. Specific research subject areas will include some of the following topics: Guidelines for developing a preventive maintenance (PM) program Human performance improvements for the next-generation workforce Managing condition-based maintenance programs at combustion turbine (CT) and combined cycle (CC) units Managing condition-based maintenance programs for renewable generation technologies Developing software to facilitate the identification, prioritization, and implementation of preventive maintenance (PM) tasks Developing the production version of the Remaining Useful Life (RUL) Database Developing criteria for analyzing and assessing predictive maintenance (PdM) data Application and implementation of designated maintenance processes Estimated 2012 Program Funding $1.5M Program Manager Brian Hollingshaus, , bholling@eprisolutions.com Maintenance Management & Technology - Program 69 p. 2

3 Summary of Projects Project Number Project Title Description P User Groups, Meetings, and Benchmarking P Fossil Plant Maintenance Processes P Fossil Plant Maintenance Technology This project provides a collaborative forum for exchange of information relating to implementation of advanced fossil plant maintenance strategies, processes, and related technologies. This project assists members in achieving improved equipment reliability, reduced O&M costs, and efficient workforce utilization through development and implementation of advanced maintenance processes. This project conducts research to identify, develop, and apply emerging technologies that support improved fossil maintenance management processes needed to ensure viability of the existing fossil fleet. P User Groups, Meetings, and Benchmarking (062022) Key Research Question Maintenance managers, planners, system owners, engineers, and plant managers need access to information about proven processes, organizational strategies, related technologies, and successful applications to help sustain high performance in plant availability, reliability, and production costs. Obtaining this information requires participation in workshops, conferences, technical webcasts, and user groups that enable peer information exchange and technology gap identification. Collaboration to share best practices and provide a basis for selfbenchmarking is essential to improving plant reliability. Approach Technical workshops and conferences provide a structure for sharing peer information about, and experience with, plant maintenance. Webcasts are used to engage plant-level maintenance staff. Meetings include the Plant Reliability Interest Group (PRIG), EPRI's annual EPRI Condition-Based Maintenance conference (CBMUG), the semi-annual Plant Manager Forum meetings, and various workshops and training in new technologies. An annual compilation of key findings from all maintenance-related meetings is assembled and provided to program members. Impact Addresses organizational and human performance barriers to sustained high performance in areas of cost and reliability Provides tools and information to plant management to address today's business challenges Provides access to industry-proven procedures and practices through participation in workshops, conferences, and webcasts Identifies implementation strategies pertaining to advanced maintenance processes and related technologies to improve plant reliability How to Apply Results Members receive value from this project by participating in the Plant Reliability Interest Group, Plant Manager Forum, the annual EPRI Condition-Based Maintenance conference, topical webcasts, and training sessions. Members are encouraged to perform self-assessments and benchmark using best-practices and metrics shared by participating peer companies, as well as EPRI staff and other industry experts. Maintenance Management & Technology - Program 69 p. 3

4 2012 Products Plant Reliability Interest Group: The Plant Reliability Interest Group addresses key barriers and strategies for implementing effective Lean maintenance processes in fossil power plants. It covers work management, predictive and condition-based maintenance, component health, diagnostics, and risk. The emphasis is on collaborative sharing of best practices in process and technology implementation. This project is a continuation of the annual group meetings. It includes an annual three-day conference, sessions held during the Generation Sector advisory meeting week, periodic teleconferences involving the group s steering committee, webcasts, and a web forum. User Group Meetings Proceedings and Key Findings: EPRI sponsors a number of meetings, workshops, and conferences each year relating to maintenance topics. These events include the Plant Reliability Interest Group, EPRI's annual Condition-Based Maintenance Workshop, Plant Managers Forum, Equipment User Groups, and topical webcasts. At each of these meetings, a set of key findings is developed that result from discussions and meeting presentations. This Technical Update report will assemble these key findings throughout the year for meetings, workshops, and conferences relating to Program 69. This information will be organized and formatted into a meeting synopsis and documented in this annual Technical Update that allows easier access to these key takeaways. 12/31/12 12/31/12 Technical Resource Technical Update Future Year Products Plant Reliability Interest Group: The Plant Reliability Interest Group addresses key barriers and strategies for implementing effective Lean maintenance processes in fossil power plants. It covers work management, predictive and condition-based maintenance, component health, diagnostics, and risk. The emphasis is on collaborative sharing of best practices in process and technology implementation. This project is a continuation of the annual group meetings. It includes an annual three-day conference, sessions held during the Generation Sector advisory meeting week, periodic teleconferences involving the group s steering committee, webcasts, and a web forum. User Group Meetings Proceedings and Key Findings: EPRI sponsors a number of meetings, workshops, and conferences each year relating to maintenance topics. These events include the Plant Reliability Interest Group, EPRI's annual Condition-Based Maintenance Workshop, Plant Managers Forum, Equipment User Groups, and topical webcasts. At each of these meetings, a set of key findings is developed that result from discussions and meeting presentations. This Technical Update report will assemble these key findings throughout the year for meetings, workshops, and conferences relating to Program 69. This information will be organized and formatted into a meeting synopsis and documented in this annual Technical Update that allows easier access to these key takeaways. 12/31/13 12/31/13 Technical Resource Technical Update Maintenance Management & Technology - Program 69 p. 4

5 Plant Reliability Interest Group: The Plant Reliability Interest Group addresses key barriers and strategies for implementing effective Lean maintenance processes in fossil power plants. It covers work management, predictive and condition-based maintenance, component health, diagnostics, and risk. The emphasis is on collaborative sharing of best practices in process and technology implementation. This project is a continuation of the annual group meetings. It includes an annual three-day conference, sessions held during the Generation Sector advisory meeting week, periodic teleconferences involving the group s steering committee, webcasts, and a web forum. User Group Meetings Proceedings and Key Findings: EPRI sponsors a number of meetings, workshops, and conferences each year relating to maintenance topics. These events include the Plant Reliability Interest Group, EPRI's annual Condition-Based Maintenance Workshop, Plant Managers Forum, Equipment User Groups, and topical webcasts. At each of these meetings, a set of key findings is developed that result from discussions and meeting presentations. This Technical Update report will assemble these key findings throughout the year for meetings, workshops, and conferences relating to Program 69. This information will be organized and formatted into a meeting synopsis and documented in this annual Technical Update that allows easier access to these key takeaways. 12/31/14 12/31/14 Technical Resource Technical Update P Fossil Plant Maintenance Processes (062023) Key Research Question Owners and operators of electric power generating units strive for effective and efficient maintenance processes to ensure optimum reliability and productivity of their fleet. To achieve this goal, these organizations need to sustain the optimum balance of corrective, preventive, predictive, and proactive maintenance activities in a streamlined, process-oriented program. Adoption of improved maintenance processes provides significant benefits to member organizations through Lean management principles, improved quality of maintenance, reduced outage durations, avoided unplanned downtime, and enhanced safety. The need to sustain a high level of plant performance will increase in the future as aggressive dispatching strategies will challenge equipment reliability, while at the same time reducing budget resources available for nonfuel operations and maintenance costs. Advanced management practices are needed throughout the industry in areas such outage planning/execution, preventive maintenance, backlog management, work closeout, inventory management, and human error reduction. Ongoing collaboration between member organizations and EPRI ensures that the processes and practices developed in this project can be adopted in today's fossil power industry business climate. Approach This project focuses on maintenance process development and continued improvement. EPRI works with member companies to identify gaps and improvement opportunities relating to the specific needs of today's electric power generation industry. Solutions and best practices are developed that optimize plant performance by balancing equipment reliability and maintenance costs. An emphasis is placed on condition-based maintenance processes used to facilitate risk-informed decision-making. Technical reports define desired characteristics of the primary process elements such as work management, predictive maintenance, maintenance basis, outage planning/execution, optimal capital resource allocation, and continuous improvement. This project is increasingly focused on helping organizations transition to improved processes, and then sustain high performance. Maintenance Management & Technology - Program 69 p. 5

6 Impact Significant benefits in plant availability and production costs can be achieved through the implementation and sustained improvement of maintenance processes. Plant availability can be increased by reducing outage duration through better planning and reduced rework due to improved execution of maintenance tasks. Standard maintenance processes are more easily adopted across fleets of generating units, leveraging scarce technical resources and ensuring consistent criteria for use of capital and operations and maintenance budgets. Documentation of structured maintenance processes provides valuable references for new staff members in planning and executing maintenance activities. How to Apply Results Members who participate in EPRI as technical advisors in process development initiatives can more easily integrate findings and processes from this project into their plant maintenance programs. In addition, technical reports produced by this project are valuable reference guides and serve as instructional tools for new staff. This project continually explores new ways to assist members in implementing advanced process elements across member organizations for example, through enterprise software tools and supporting databases Products Guidelines for Developing a Preventive Maintenance (PM) Program: Identifying, Prioritizing, and Implementing PM Tasks: This technical report is intended to provide a description of EPRI's process for identifying, prioritizing, selecting, and implementing preventive maintenance (PM) tasks to comprise a PM program. Various initiatives over the past decade address elements of this process. EPRI has continued to refine these different approaches to establish best practices associated with developing or reassessing PM programs. This technical report will illustrate these best practices. Managing Condition-Based Maintenance Programs for Combustion Turbine (CT) and Combined Cycle (CC) Units: Condition-based maintenance (CBM) programs have become an intricate part of operating pulverized coal generating units. These programs allow organizations to identify maintenance strategies that emphasize monitoring and assessing the condition of equipment to determine maintenance activities. These programs require extensive knowledge of plant equipment, including what can fail, why it will fail, and how it can be monitored. They also require extensive capabilities regarding how data is collected, managed, assessed, and used to make actionable maintenance decisions. As the landscape of electric power generation changes, combustion turbine (CT) and combined cycle (CC) units are becoming more valuable and utilized assets. Just as it did for pulverized coal units, CBM has the potential to affect CT/CC units to improve the efficiency and effectiveness of maintenance on these assets. This technical report is intended to explore how lessons learned from pulverized coal units can be applied to CT/CC units, as well as where current gaps still exist. Maintenance Management & Technology - Program 69 p. 6

7 Managing Condition-Based Maintenance Programs for Renewable Generation Technologies: Condition-based maintenance (CBM) programs have become an intricate part of operating pulverized coal generating units. These programs allow organizations to identify maintenance strategies that emphasize monitoring and assessing the condition of equipment to determine maintenance activities. These programs require extensive knowledge of plant equipment, including what can fail, why it will fail, and how it can be monitored. They also require extensive capabilities regarding how data is collected, managed, assessed, and used to make actionable maintenance decisions. As the landscape of electric power generation changes, renewable generation sources will become more valuable and utilized assets. Just as it did for pulverized coal units, CBM has the potential to affect renewable generation sources to improve the efficiency and effectiveness of maintenance on these assets. This technical report is intended to explore how lessons learned from pulverized coal units can be applied to renewable generation sources, as well as where current gaps still exist. Strategies for Human Performance Improvements for the Next Generation Workforce: Organizations currently are experiencing a transition in workforce demographics. New plant personnel have new and different skill sets, as well as less technical experience. This product will focus on techniques to improve the human performance element of this new workforce, and leverage its capabilities derived from these new and different skills. Future Year Products Risk-Based Spares Management Strategies: Spares management requires an effective decision-making process that seeks to optimize the cost and benefit associated with the inventory. This report will focus on identifying applications of a risk-informed process to the management of equipment spares. Specific emphasis will be given to the financial implications of keeping certain spares in stock versus other alternatives. Configuration Management for New Fossil Power Plants: The future operating costs, reliability, and safety of today s newly commissioned power plants will be strongly influenced by institution of a disciplined approach to plant configuration management. It is vitally important to not get behind in this process, which would require a costly future effort to bring records up to date. This technical report will outline strategies that can be cost-effectively employed today to maintain effective configuration management into the future. New technology solutions will be described, as well as the potential role of computerized maintenance management system (CMMS) in integrating configuration management into the daily work. Effective Communication Strategies to Sustain Operations and Maintenance Process Improvements: Plant reliability initiatives require organizations to disseminate a structured vision and strategy throughout multiple levels of the organization. Steering teams must convey the strategies and concepts to incorporate technical teams, plant management teams, plant technical personnel, and many other types of employees. This product will identify best practices for spreading these strategies and concepts to these different levels. Communication packages will be developed that target a variety of personnel. 12/31/13 Technical Report 12/31/13 Technical Report 12/31/13 Technical Report Maintenance Management & Technology - Program 69 p. 7

8 Guidelines for Creating Corporate Directives to Support Fossil Plant System Reliability Programs: One of the most influential aspects of a reliability improvement program or initiative is executive foresight and support. One key resource that helps organizations explicitly illustrate this executive sponsorship is a corporate directive. EPRI currently uses templates to create these directives for programs such as Boiler Tube Failure Reduction (BTFR). This product will consist of templates for each of the plant systems that are consistent with the format and structure of the BTFR corporate directive. Comprehensive Maintenance Program Model: A technical update report will be issued in December 2010, documenting the development progress of a standard maintenance program model. This model is intended to provide the ability to assess and compare current aspects of a company's maintenance program, as well as identify opportunities for improvement. Although such models exist in certain sectors of the power industry, fossil power generation lacks any form of standardized process model. This model will provide a unifying framework to which all other programs/initiatives (plant reliability optimization, maintenance optimization, and outage management) can be mapped. Further development of this model will continue in 2013, focused on specific elements and processes within a maintenance program. 12/31/14 Technical Report 12/31/14 Technical Report P Fossil Plant Maintenance Technology (062024) Key Research Question Technology is a vital element in that it can significantly improve efficiency. Technology also has the ability to standardize and dictate how processes function. Plant maintenance is an area greatly influenced and improved by the use of technology. Technology primarily is used to support information management in areas such as predictive maintenance (PdM), work management, equipment diagnostics, equipment health, and risk assessment. Technology solutions must be cost-effective and easily integrated with existing enterprise systems. Technology gaps inhibit many maintenance organizations from maximizing their performance capabilities. Advancements in maintenance technology will improve the ability of plant personnel to conduct condition assessments of plant equipment, diagnose equipment anomalies, and utilize risk management practices. This improvement will allow plants to optimize the use of scarce resources and maximize availability. The challenge to sustaining a high level of plant performance will increase as plants are cycled, new tighter regulatory restrictions are applied, and investors demand continued reductions in operating costs. Approach This project seeks opportunities to apply emerging technologies to address industry needs in plant maintenance processes. In some cases, process improvements developed under Project (Plant Maintenance Processes) are considered as candidates for development of technology to assist implementation. The research and development in this project includes: Development and demonstration of new databases for supporting maintenance decision-making. These databases include those that apply component and system knowledge to fault diagnostics, as well as databases that supply information related to prognostics and equipment remaining life. Other technology topics that support work execution, predictive maintenance, scheduling, and configuration management. Maintenance Management & Technology - Program 69 p. 8

9 Impact Using information technology to integrate predictive maintenance with component and system health provides a basis for performing the right maintenance at the right time. Technology that facilitates the assembly and dissemination of key information on component health and risk of failure will enable more efficient use of maintenance resources and capital. The creation of shared industry databases that support fault diagnoses and remaining useful life assessment can effectively share knowledge and expertise from a broad segment of the fossil power industry. How to Apply Results Results of this project can be implemented as information databases that support advanced maintenance process elements such as diagnostics, prognostics, and risk-informed decision-making. In addition, technical reports or webcasts will assess emerging technology in related industries and strategies for successful implementation in fossil power generation. Peer collaboration at meetings such as the Plant Reliability Interest Group, the Condition-Based Maintenance User Group, and the Plant Manager Forum will enable sharing of best practices related to technology application Products Maintenance Basis Optimization Software: As part of the ongoing effort to help members use existing resources to improve reliability and cut costs, this project will develop a maintenance basis tool with a focus on determining the maintenance tasks of highest value and improving current task plans. This software tool will help members integrate the failure rate and task effectiveness data contained in more than 150 previous equipment data tables within their enterprise systems to optimize task strategies for all plant equipment. This tool will leverage the existing and proven optimization algorithms while providing a platform to include new reasoning and diagnostic capabilities delivered in other program offerings. The goal of the project will be to develop a tool that will eliminate the obstacles to developing comprehensive and informed understanding of the risks associated with each failure mode, and to develop a cost-effective strategy. Remaining Useful Life (RUL) Database: In 2010 and 2011, EPRI developed the Remaining Useful Life (RUL) Database and RUL Advisor, first as a demonstration version of software, then as a test version of software. In 2012, EPRI will incorporate feedback from both previous versions of this software into the first production version of the software. This software will collect, store, manage, and provide information necessary for plant personnel to create remaining life estimations for all manner of plant equipment using a wide range of forecast methods or models. Following completion of the production version, content will continually need to be developed to populate the RUL Signatures contained within the database. This project will help create such signatures. Criteria for Assessing Predictive Maintenance (PdM) Data: Technical personnel are required to collect predictive maintenance (PdM) data using a variety of technologies and numerous applications of the technology. Capturing this data and translating it into useful condition assessment information regarding the equipment is a vital aspect of the PdM process, but requires guidance through use of criteria. This product will provide the guidance to assist technical personnel in evaluating PdM technology data and translating this data into useful information. 12/31/12 Software Maintenance Management & Technology - Program 69 p. 9

10 Applications of Predictive Maintenance (PdM) Technologies: The traditional predictive maintenance (PdM) technologies (vibration, tribology/lubrication, infrared thermography, acoustics, and motor testing) are a fairly mature set of technologies. The extensive knowledge and understanding of these technologies represent a positive knowledge source for the industry; however, most applications of these technologies in electric power generation are for traditional equipment types in traditional systems in fossil or nuclear generating units. With the changing landscape of the power generation industry, new types of equipment and systems are being installed and operated. This project will explore applications of PdM technologies to these new systems and equipment types. Future Year Products Functional Specification for Effective Integration of Technology Examination Data: Effective condition-based maintenance requires that predictive maintenance results and other technology examination data be effectively assessed and archived for efficient trending. Top-performing plants employ enterprise software to manage and standardize the process of turning technology examination data into component/system health and actionable information. This project will create a functional specification document that includes the essential elements of effective technology examination data processing in an enterprise software environment. Specification for a Database to Support Maintenance Work Package Development: There is an ongoing need in the power generation industry is to improve the work planning capabilities of plant maintenance programs. Effective planning is central to reducing maintenance cost and avoiding rework. A resource that has been identified as a potential opportunity to improve planning is a database of work packages that includes standard templates for typical maintenance tasks. These templates would help guide new planners in generating improved work packages. EPRI will work closely with members to develop an outline of the desired specifications for this proposed template database. Benchmarking Predictive Maintenance (PdM) Technologies: During the 1990s and early 2000s, Predictive Maintenance (PdM) became an integral part of power plant condition-based maintenance. Technologies and applications of these technologies were a significant focus for EPRI Program 69. The capabilities of PdM technologies and related data acquisition/processing have expanded significantly over the past decade. This product will focus on these changes and identify the newest PdM technologies, as well as the latest applications of existing PdM technologies that support Lean condition-based maintenance. 12/31/13 Technical Report 12/31/13 Technical Report 12/31/14 Technical Report Maintenance Management & Technology - Program 69 p. 10

11 Plant Reliability Interest Group (066929) Supplemental Projects Background, Objectives, and New Learnings Organizations in the electric power industry are faced with the task of designing and implementing plant programs and processes that promote optimal equipment reliability while minimizing operating and maintenance costs. The objective of the Plant Reliability Interest Group (PRIG) is to provide an active forum for Electric Power Research Institute (EPRI) member companies to share successful strategies related to the design and implementation of these programs and processes. The challenges of implementation can be successfully addressed by peer-sharing, and the generation of strategies that result can benefit all members of the group. EPRI s former Plant Reliability Optimization User Group (PROUG) served this industry need until 2010 by providing assistance with the implementation of the Plant Reliability Optimization (PRO) process. The new PRIG will continue this effort with the opportunity to broaden the scope to include emerging topics of generic interest to fossil plant maintenance such as Lean process principles and human performance improvement. Project Approach and Summary The intent of the PRIG is to provide a forum for participants including generating plant, power delivery, and corporate personnel to address common issues, problems, and resolutions related to proactive maintenance strategies. The value of the interest group is in sharing information between those seeking solutions and those who either have successfully implemented process improvements, or have a common interest in developing a solution. A series of sessions within the annual meetings will cover different aspects of maintenance and reliability, such as predictive maintenance, maintenance basis, and continuous improvement. Benefits Members who participate in the PRIG will share information on practical approaches to achieving plant reliability as well as the effectiveness of enabling technologies. Benefits of this interest group include: improved equipment reliability, optimized maintenance costs, and improved decision-making. Maintenance Management & Technology - Program 69 p. 11

12 Guidelines for Managing Flexible Operation (071859) Background, Objectives, and New Learnings Reduced industrial demand and increased fuel price variability are forcing changes to fossil asset dispatching. In addition, increased deployment of renewable generation over the next decade will force coal and combinedcycle plants to provide system load-balancing service. Specific operational changes expected for coal and gas plants include two-shifting, high ramp rates, high unit turndown, and reserve shutdown. These operational changes accelerate damage mechanisms such as creep fatigue, thermal fatigue, and corrosion, increasing the rate of component life consumption. This wear-and-tear increases the overall costs of generation, including direct costs such as fuel, water treatment, and maintenance. The project objective is to provide the industry with a comprehensive knowledge resource that can guide a successful transition to flexible operation. This project will facilitate utilization of existing EPRI research results on component-level cycling impacts and mitigation. In addition, the project will compile lessons learned and strategies used by organizations worldwide to address plant cycling. This collaborative approach to addressing industry needs will to create new learning on plant impacts and mitigation strategies. Project Approach and Summary Proven strategies for managing the transition to flexible plant operation will be documented by engaging directly with experienced plant staff tasked with past projects. This information will be organized and integrated with key knowledge contained in past EPRI research to create a single industry resource. The organization and format of this resource will be developed collaboratively by project participants and EPRI to ensure that it addresses the industry needs. Access to this industry resource during its development will provide project participants timely information for use in their fleet flexible operation strategy development. This access by participants also will facilitate peer review of the resource content to ensure that it is operationally sound. Benefits A reliable supply of fossil-fueled electricity generation will remain strategically important in the worldwide generation mix. The transition to a lower-carbon asset mix will force existing conventional plants to adopt new operational practices. These new strategies will be essential to maintaining their economic viability. Owners and operators of fossil power plants today will need to consider a range of strategies for managing the increasing need for flexible operation. Access to information on the impact of flexible operations on plant equipment, damage mechanisms, costs, and mitigation strategies can be vitally important to the staff assigned to manage transition to flexible operation. Project participants will assist in the creation of a comprehensive information resource devoted to the management of flexible plant operations. Generating companies need ready access to information to educate a broad range of their workers on topics relating to the holistic management of flexible operation. Participants in this project will have access to such information, as well as opportunities to learn from experiences of peer companies and subjectmatter experts. Maintenance Management & Technology - Program 69 p. 12

13 Occupational Exposure to Physical Stressors: Intervention and Prevention (072036) Background, Objectives, and New Learnings Occupational exposures to physical stressors such as noise are prevalent within the electric utility industry. During , the EPRI Occupational Health and Safety Database, which tracks illness and injury for eighteen member utilities, showed that hearing loss or impairment resulted in 3% of total utility worker injuries. If constantly exposed to noise, workers may experience progressive hearing loss slowly over time, which in turn may affect their ability to perform safely and translate to an indirect number of acute workplace injuries. Noise-induced hearing loss has been implicated in workplace accidents. Auditory changes are progressive, possibly placing workers at risk for accidents. Traditionally, workers are enrolled in hearing conservation programs after an action level of 85 decibels (db) is met. Noise surveys capture environments requiring action but are not conducted at multiple time points; consequently, noisy environments may be underestimated. According to published studies in the aluminum industry, annual audiometry data capture hearing loss once it has occurred and the most vulnerable workers actually may fall below the accepted permissible exposure limit. Since opportunities to intervene prior to hearing loss are limited using annual audiometry, data gaps exist for workers who may be just below 85 db and who may potentially have preventable workplace hearing loss. Workers may use personal protective gear such as ear muffs and ear plugs that modify exposure; hence, measured ambient or personal exposure levels may not reflect actual exposure. Novel in-ear dosimetry technology devices that fit like an earplug and measure attenuated noise from within the ear canal could be used to address worker discomfort and potential exposure modification issues. In addition, the dosimeter could be programmed to advise the worker and/or her/his supervisor when pre-set exposure limits are exceeded. Thus, a worker would get feedback on exposure above that pre-set limit and on her/his daily dose at the end of the shift, both of which could assist in guiding personal protective equipment use. Project Approach and Summary In this project, research will evaluate the dosimeter using built-in feedback systems as an intervention method for preventing noise-induced hearing loss and will examine the relationship between noise levels and risk of acute occupational injury. Results will provide quantitative noise dosimetry, an assessment of the dosimeter as an intervention method and a potential leading indicator for noise-induced hearing loss and other injuries. By the end of the project, results should provide a method for assessing a state-of-the-art intervention method and an assessment of noise-induced hearing loss as a leading indicator for a number of acute workplace injuries. Benefits Workplace injuries are traditionally targeted using interventions proximal to the acute event, such as behavioral factors, rather than distal factors, such as other exposures. Furthermore, hearing loss is often attributed to workers lack of compliance, lack of supervision, or inappropriate use of personal protective equipment. This project assesses a potential leading indicator, not only of hearing loss, but also of workplace injuries. The developed intervention, if successfully applied, may result in reduced frequency of hearing loss and occurrence of acute injuries in the workforce, with associated potential cost savings and improved worker health and performance. Occupational hygienists, managers, and safety specialists within electric utilities may use the in-ear dosimeter as a means to train their workers on the effective use of hearing protection and to clarify whether workplace noise is a contributor to other occupational injuries. Additional benefits derived from the work include an improved method to comply with OSHA Employee Notification requirements ( ). Maintenance Management & Technology - Program 69 p. 13