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When operational challenges and declining human resources at the coal-fired Logan Generating Plant (LGP) presented unprecedented concerns for safety, reliability, and efficiency, Primex was brought in to improve and optimize performance assurance.

On a strategic basis, Primex interprets critical system parameters, provides crucial troubleshooting, diagnostic, and responsive action support. Primex works directly with O & M personnel producing and interpreting key performance indicator trends, providing diagnosis and correlations affecting reliability and efficiency, and communicating critical information and action recommendations including assessing prospective threats or opportunities.

Results and success factors include performance improvements, significant reduction in manual control interventions, no limitations in generation capacity from scrubber operations, continuous access to technical expertise, successful plant personnel education, recognition and reward system with clear goals, roles and accountability among team members.

With real-time continuous access to plant operating data by Primex, LGP now operates the most efficient dry scrubber east of the Mississippi river.

 

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SITUATION

Like many coal-fired generating facilities, the Logan Generating Plant (LGP) was designed for base load operation. As competition intensified and output declined in recent years, the plant faced new technical challenges associated with prolonged periods of low and transient load operation. Internal expertise and supervisory capacity also declined due to retirements, staff reduction and turnover. These technical challenges and resource constraints potentially compromised plant safety, reliability and efficiency.

SOLUTION

LGP management engaged Primex to develop a performance assurance program. On a weekly basis, Primex interprets critical FGD system parameters affecting safety or reliability. Potential issues are communicated directly to plant personnel along with preliminary troubleshooting and responsive action information. Primex tracks key performance indicators with monthly reporting and interpretation that identifies reliability or efficiency improvement opportunities. The monthly reports include prioritized action recommendations and work-in-progress status updates. On a quarterly basis, Primex facilities onsite meetings with plant personnel to review overall performance and support action planning.

RESULTS

Despite the technical challenges and internal resource constraints, LGP now operates the most efficient dry scrubber east of the Mississippi river. Performance continues to improve as issues affecting safety, reliability or efficiency are identified and corrected. Additional benefits include personnel knowledge and engagement, 100% scrubber availability and operating cost reductions in reagent consumption and flyash disposal.

CRITICAL SUCCESS FACTORS

The performance assurance program continues to develop collaboratively between LGP and Primex management teams. Critical success factors include plant personnel education, recognition and reward system with clear goals, roles and accountability among team members as well as real-time continuous access to plant operating data by Primex.

“As facilities continue to restructure and accomplish more with fewer resources, Primex is a perfect fit for remote monitoring and feedback ensuring process safety, reliability and cost effectiveness. Primex is an important part of our team with great knowledge and communication skills that add value from top to bottom at our facility. Partnering with Primex has allowed our facility to be the best in the business.”

– Jim Apostolico, LGP Plant Manager