Continuous improvement
The plant is at the top of CPS Energy’s list of least-cost of production plants, which explains the utility’s continuing investment in improving the plant’s reliability and efficiency.
Kruse cites additional examples, such as variable frequency drive updates to the condensate pumps as well as the plant’s forced- and induced-draft fans to improve the operating efficiency and responsiveness of boiler controls. Additionally, the plant is in the process of upgrading components on its submerged scraper conveyor to improve bottom ash handling. A plant simulator also is under development that will offer new operators the opportunity to exercise a virtual plant before actually touching a switch in the control room. The simulator also will allow experienced operators to hone their skills under more complex emergency conditions.
Kruse is committed to involving employees in finding and reporting problems in the plant. There is a culture of taking ownership of the plant’s problems and developing solutions rather than just dropping a maintenance request form in a “suggestion box,” as is so common in other plants. Kruse believes a highly disciplined and respected plant staff is vital to bringing solutions to the table rather than problems seeking answers.
Spruce 1 has adopted a computerized lockout/tagout (LOTO) system, even though such systems are controversial in the industry. Many from the plant O&M staff were involved in the difficult decision to move to a computerized LOTO system and carefully considered its many pros and cons. After much discussion the staff selected a particular software program that has the potential to reduce the complexities of the LOTO process, and therefore labor costs, without compromising worker or equipment safety.
Kruse emphasized that workplace safety is his highest priority as a plant manager, but responsibility for safety must be a shared. The plant has a Safety Advisory Team composed of members from the O&M organizations who identify and address plant safety issues. The plant also uses a “People Based Safety Program” that encourages direct peer feedback. After all, safety is the common responsibility of every plant employee.
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