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October 31, 2005

Conemaugh Keystone Power Projects. Engineering Consultants Group and JRM Energy Consulting. October 31, 2005. Capabilities and Features Jim Scavuzzo, Vice President, ECG. Fuel Flexibility Jim Mooney Consultant & ECG Sales Representative. Today’s Discussion. Total Solution

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October 31, 2005

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  1. ConemaughKeystonePower Projects Engineering Consultants GroupandJRM Energy Consulting October 31, 2005

  2. Capabilities and Features • Jim Scavuzzo, Vice President, ECG • Fuel Flexibility • Jim Mooney • Consultant & ECG Sales • Representative Today’s Discussion • Total Solution • Mike Santucci, President • ECG

  3. Agenda Part 1: Why AccuTrack? a. Strengths-Weakness-Opportunity-Threats b. World Class Operations-Tools & People c. Short and Long Term recommendations

  4. 1970’s POWER PLANT THEN

  5. Blue Plume Wallboard plant Opacity SO2 Ammonia Or Urea 2 or more Fuel Soda Ash NOW PRB Trona NOx MgOh SBS Hg Sorbent GYPSUM FGD LIMESTONE Lime Bottom and Fly ashes

  6. CONEMAUGH STRENGTHS • Positives: • Comparatively simple to get coal to numerous Yard locations with 2 S/R’s. • Yard appears well-instrumented through Plantscape. • Equipment appears to be in good condition • Truck and Rail unloading capability, quality info available from suppliers • Blending experience (Hi and Lo vol plus truck) • 3 feed points (Including emergency reclaim) • Experienced Staff

  7. Typical Fuel Management supplied data from an “Accounting System” Weakness Coal sampled at delivery is sent to a lab and results are typically recorded into a Fuel Management System within 24 to 72 hours. The delay in reporting ACTUAL quality renders most fuel management systems irrelevant to improving power plant operations.

  8. WEAKNESSES • Negatives: • Plant silo capacity only 6 hours requiring near continuous fuel loading. • Blending is hit and miss approximation and not precise. • Train unloading is labor intensive through rotary dumper. • Quality Analysis time delayed

  9. On Site Blending without Tracking. Average Above average Truck Silos Below average Weakness

  10. Increase Profit for Owners OPPORTUNITY PSEG • Conemaugh and Keystone plants make up 32% of the lowest cost power for PSEG, and 6% of PSEG total fossil fleet. • PSEG has targeted $60 to $70 million in performance improvement over 36 months…clock started in 2004. To this owner Conemaugh-Keystone target is 6% of the total or $3.6 to $4.2 million of the target.

  11. Increase Profit for Owners OPPORTUNITY Reliant • Conemaugh – Keystone Projects are 13.6% of the Reliant Baseload Target • The C-K contribution to this owners target is $952,000/year for each 1% availability • Improvement.

  12. OPPORTUNITY Baseload and Intermediate contribution from C-K = $3.4-$9.5 Million

  13. OPPORTUNITY Opportunity Fuels Deregulation, plant dispatch cost, and increasing coal costs have increased utility interest in opportunity fuels. Forty Years ago PRB was an Opportunity Fuel. Today it is a dominant mainstream source of BTU’s. “The array of opportunity fuels available is as broad and diverse as the ingenuity of the engineering community.” Fuels of Opportunity, David A. Tillman and N. Stanley Harding, 2004, Elsevier Publishing. CWS

  14. OPPORTUNITY Optionality supplied from the plant is Negotiating Power to Fuel Procurement groups Consol estimated permitting and opening new Mines will take 6 years, and won’t be Started without contracts averaging $60 to $70 ton Contract coal Price/ton avg 2005 Optionality

  15. THREATS • Owners experiencing losses have less money to put into O&M • Bonuses tied to Performance Factors for availability are not met resulting in lower payouts, and poor morale. • More environmental restrictions. • Savings not found in Fuel (80% of the cost of plant operation, will be looked for in O&M) • Increasing Fuel Cost leads to wider variety of sources for Btu’s. Each source will bring different threat to performance and needs to PROVE its cost/benefit. • Rail Transportation costs forecasting increases to improve infrastructure, utilities that invest in unloading equipment could receive benefit at negotiating table. • Plant may be sold. (Sometimes this is an opportunity!)

  16. THREAT – Synfuel is worth about $1/MWhr $$$ SYNFUEL

  17. When plants put AccuTrack on the table, tied to Plantscape in real time, fuel contributions to whatever problem exists can be ruled in, or out. • About 75% of the time, fuel quality contributes to the operating problem, or could contribute to a solution! • When you KNOW what’s on the belt you can be proactive in providing the right solution. • When you start measuring delivered coal you will find problem coal will go somewhere else! Hopefully to a competitor and not Keystone! World Class Operations ?

  18. Accutrack brings Fuel Management to the Plant for Performance issues. FMS data Plantscape AccuTrack FMS + Plantscape =

  19. Yard Goals Reduce Overtime Build Inventory Reduce O&M expense The Present State of Many Organizations Fuel Supply Teams • Reduce fuel cost through increased use of “Hi-value” coal. • Minimize demurrage • Contract negotiation JRM Energy Consulting, 2005

  20. Short and Long Term Recommendations • Precision blending through addition of an on-line analyzer and reconfiguration of yard fuel handling. (Tools & People) • Maximized long term recommendations include additional equipment investment in coal yard to provide improved use of manpower and additional flexibility. (Potential uses for equipment currently used for Synfuel.)

  21. Short Term Recommendations Truck quality from FMS to AccuTrack provides pile quality information An On Line Analyzer provides valuable data. AccuTrack makes the data actionable for Operators. NEW As fired sampling and on-line analyzer at Crusher House output to AccuTrack

  22. Rearrange Piles#1&3 to be Contract Spec or +12,400BTU 2% Sulfur <16%Ash #1 #3

  23. Pile # 2 becomes “High Value” Synfuel and Truck Coal #2

  24. Utilize Emergency Reclaim as “High Value Feed” through new conveyor controllable to 300 tons per hour #2

  25. Maximized Fuel Flexibility Recommendations (Long Term) • BRADFORD BKR CONVEYOR TO PILE 3 from RAIL Dump • UNDERGROUND FEEDERS TO CRUSHER HOUSE • Investigate RDRU replacement for Rotary Dump • On-Line Analyzer at Truck Coal receiving 2400 TPH 72"BELT Possible use of SYNFUEL Equipment post 2007

  26. Problem: Plant silo capacity only 6 hours requiring near continuous fuel loading. Blending is hit and miss approximation and not precise. Train unloading is labor intensive through rotary dumper. Quality Analysis time delayed Solutions: An on-line-analyzer allows fast changes through on the belt blending to improve performance. Accuracy improves through addition of E/R feed point and modifications in yard layout. Rapid Discharge Rail Unloader OLA and FMS info to AccuTrack compares delivery to plant performance in real time. Issues addressed

  27. AccuTrack Features & Capabilities PART II • General Features • Bunker Model Details • End-User Interfaces • Customer Responsibilities • Maintenance • Goals • Intellectual Property Statement

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