Power Optimization Center Leveraging plant process data for advanced analytical diagnostics. June 16, 2016

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1 Power Optimization Center Leveraging plant process data for advanced analytical diagnostics June 16, 2016

2 POWER OPTIMIZATION CENTER: OVERVIEW Jamie Dugan Equipment Reliability Manager Mike Batte Fleet Performance Manager

3 POWER OPTIMIZATION CENTER: OVERVIEW Power Optimization Center Overview Video

4 POWER OPTIMIZATION CENTER: BY THE NUMBERS > 650 years Combined Operations and Technical Experience 12 Experienced Control Room Operators 25 Operations, Equipment, Performance and IT Subject Matter Experts 500,000+ Current Points Monitored 26,686 Log Entries 36 Open Log Entries 158 Issues in Tracking 19 Bachelors 11 Masters 4 MBAs 2 PhDs 17 Engineers 8 PEs

5 POWER OPTIMIZATION CENTER: OVERVIEW Optimization from 24/7 Emergent Issue Identification and Notification Optimal, targeted maintenance spending Critical Equipment Reliability Protect Unit Reliability Cost Reduction and Increased Efficiency Decreased Maintenance Costs BTU/kWh Heat Rate Improvement Annual Fuel Savings Reduce Emissions (from reduced fuel consumption) $178MM

6 POWER OPTIMIZATION CENTER: OVERVIEW ASSETS AND SYSTEMS MONITORED BY THE POC: Mechanical Systems Electrical Systems Performance Models Circulating Water Pumps Condensate / Condensate Booster Pumps Feed Water Heaters and Drains Boiler Feed Pumps Electrical and Turbine Heater Drain Pumps Electro Hydraulic Control Pumps High Pressure and Low Pressure Turbine Generator / Exciter HVAC Fans, Chillers, and Coolers Air Preheaters Draft Equipment Pulverizers Absorbers Scrubbers Electrostatic Precipitators SCRs Combustion Turbines HRSGs Reactor Coolant Pumps Recirculation Pumps Jet Pumps Centrifugal Charging Pumps Service Water / Closed Cooling Water

7 POWER OPTIMIZATION CENTER: OVERVIEW ASSETS AND SYSTEMS MONITORED BY THE POC: Mechanical Systems Electrical Systems Performance Models Main Power Transformers Station Transformers Unit Transformers Main Generator & Exciter Control Rod Drive MG Sets Recirculation MG Sets and ASDs Diesel Generators

8 POWER OPTIMIZATION CENTER: Operational Levels of Defense Control Room Alarm Crisis Control Limited Response Time Rate of Change Alarm Statistical-Based Alarm Identify Emergent Equipment Issues Identify Faulty Instrumentation Near Term Response Time Identify Emergent Equipment Issues Identify Faulty Instrumentation Extended Response Time Control Room Shift Supervisor Engineering Support Control Room Shift Supervisor Engineering Support APR Modeling Thermal Performance Modeling Start Up Reviews Coast Down Reviews Identify Long-Term Equipment Issues Identify Process Changes Identify Emergent Equipment Issues Identify Faulty Instrumentation Long to Near Term Response Time Engineering Support Plant Management

9 Equipment Condition POWER OPTIMIZATION CENTER: Operational Levels of Defense OK P (= Potential Failure) The P-F Curve Time F (=Functional Failure)

10 POWER OPTIMIZATION CENTER: OVERVIEW ASSETS AND SYSTEMS MONITORED BY THE POC: Mechanical Systems Electrical Systems Performance Models Thermodynamic Feed Water Heaters Main Condenser Pumps Boilers Air Preheaters Combustion Turbines Compressors Heat Exchangers HRSG

11 POWER OPTIMIZATION CENTER: Thermal Performance Improvement Cost Reduction and Increased Efficiency Decreased Maintenance Costs BTU/kWh Heat Rate Improvement Annual Fuel Savings Reduce Emissions (from reduced fuel consumption) BTU/kWh Heat Rate Improvement Program Elements: Base Line Assessment Cycle Isolation Daily monitoring In-depth Reviews Prioritized Improvement Heat Rate Awareness Targeted O&M Repairs Efficient Capital Spend

12 POWER OPTIMIZATION CENTER: OVERVIEW POC assists in reducing yearly O&M costs by: OPERATIONS SUPPORT Emergent issue identification providing Actionable Intelligence 24/7 Automated notifications Foster relationships with Operations, Engineering, Maintenance, and Plant Management EQUIPMENT RELIABILITY Deployment and maintenance of Advanced Pattern Recognition asset models Identification and tracking of instrument issues Coast down and Startup reviews Equipment Reliability Monitoring and Consultation THERMAL PERFORMANCE Thermal Performance Assessment Heat Rate Review Maintenance of Thermal Performance Tool Unit Startup and Monthly In-Depth Review Online Cycle Isolation Monitoring Thermal Performance Monitoring and Consultation FLEET SUPPORT Monthly cost avoidance report Monthly review with Fleet support organization Fleet Watchlist Track all identified issues to closure Knowledge transfer across Fleet Course of Action Program

13 POWER OPTIMIZATION CENTER: OVERVIEW WHAT MAKES THE POC SUCCESSFUL YEAR AFTER YEAR? Human Capital (PLU) People Like Us POC is staffed by experienced plant operators/engineers that deliver Actionable Intelligence Relationship with Control Room Robust 24x7 Service Monitoring All 24x7 monitoring is done within POC as compared to supplementing international support or other limited service ability Service is Primary Focus POC provides proactive identification and notification of generation critical issues Complete Operations Package POC offers a complete monitoring package for multiple types of plant (Coal, Gas and Nuclear) Future expansion into renewables Proprietary Process POC has developed formal protocols and procedures for responding to emergent issues through years of operations These processes serve as a vehicle to deliver immediate actionable intelligence for customers Continuous improvement process in place for knowledge transfer

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15 Primary Air Fan

16 Primary Air Fan High Vibration

17 Primary Air Fan High Vibration Action Taken Plant notification and subsequent investigation

18 Primary Air Fan High Vibration Action Taken Plant notification and subsequent investigation Corrective Action Added oil, replaced bearing during planned outage

19 Main Power Transformer

20 Main Power Transformer High Winding Temperatures Winding Temperature Gross Load

21 Main Power Transformer High Winding Temperatures Action Taken Plant notification and subsequent investigation

22 Main Power Transformer High Winding Temperatures Action Taken Plant notification and subsequent investigation Corrective Action Cooling pumps and fans returned to service

23 Forced Draft Fan

24 Forced Draft Fan Reservoir Level decrease 7 Reservoir Level

25 Forced Draft Fan Reservoir Level decrease Action Taken Contacted plant control room

26 Forced Draft Fan Reservoir Level decrease Action Taken Contacted plant control room Corrective Action Dispatched operator, corrected level

27 Bowl Mill Motor

28 deg F POWER OPTIMIZATION CENTER: SUCCESS STORIES Bowl Mill Motor Bearing temperature increase 200 Motor OB Bearing Temp

29 Bowl Mill Motor Bearing temperature increase Action Taken Contacted plant control room

30 Bowl Mill Motor Bearing temperature increase Action Taken Contacted plant control room Corrective Action Plant dispatched operator, removed mill from service

31 Turbine Drain Valve

32 Turbine Drain Valve Turbine High Backpressure Condenser Backpressure Unit Heat Rate 5 11, , , , , , , , , , ,100

33 Turbine Drain Valve Turbine High Backpressure Action Taken Plant notification and subsequent investigation

34 Turbine Drain Valve Turbine High Backpressure Action Taken Plant notification and subsequent investigation Corrective Action Controller restored to automatic operation

35 Main Steam System

36 Main Steam System Cycle Isolation Losses Unit Heat Rate Gross Load 11, ,000 10,800 10, , ,200 10,000 9, ,600 0

37 Main Steam System Cycle Isolation Losses Action Taken Prioritized cycle isolation valve list provided

38 Main Steam System Cycle Isolation Losses Action Taken Prioritized cycle isolation valve list provided Corrective Action Valves repaired during outage

39 Feedwater Heaters

40 BTU/kWh POWER OPTIMIZATION CENTER: SUCCESS STORIES Feedwater Heaters Turbine Cycle Heat Rate Increase

41 Feedwater Heaters Turbine Cycle Heat Rate Increase Action Taken Plant notification and investigation

42 Feedwater Heaters Turbine Cycle Heat Rate Increase Action Taken Plant notification and investigation Corrective Action Vented Feedwater Heaters

43 Circulating Water Pump

44 Circulating Water Pump Lower than expected backpressure 5 Backpressure

45 Circulating Water Pump Lower than expected backpressure Action Taken Investigation and recommendation

46 Circulating Water Pump Lower than expected backpressure Action Taken Investigation and recommendation Corrective Action Secured one Circulating Water Pump

47 Primary Air Fan Main Power Transformer Forced Draft Fan Bowl Mill Motor Turbine Drain Valve Main Steam System Feedwater Heater Circulating Water Pump High Vibration High Winding Temperatures Oil Reservoir Level Decrease Bearing Temperature Increase Turbine High Backpressure Cycle Isolation Losses Turbine Cycle Heat Rate Increase Lower than expected backpressure

48 POWER OPTIMIZATION CENTER: SUMMARY Cost Reduction Increased Efficiency Reduced Emissions 24/7 Actionable Intelligence Subject Matter Experts Continuous Improvement

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