Central Plant Management EU 302

Transcription

1 Central Plant Management EU 302 Jay Becker, P.E. COURSE OVERVIEW Central Heating & Chiller Plants CHP / Cogeneration / High Voltage Systems Maintenance Staffing COURSE OVERVIEW, continued Contract Work Reliability & Risk Management Benchmarking Budgeting Training APPA Institute, New Orleans, January

2 OPERATIONAL GOALS Economic Reliable Emergency Preparedness Efficient & Sustainable Safety Outstanding Staff DEFINITIONS Heating Plant: steam boilers (some HW) Natural Gas, Oil, Wood (bio mass), coal, etc Chiller Plants: centrifugal / absorption CHP: combined heat and power Cogeneration: electricity and steam/hw (Turbines, HRSG s) Trigeneration (CCHP): electricity, steam/hw, and chilled water ADVANTAGES OF CENTRAL PLANTS Multiple Fuels Lower Fuel Costs Reduced Maintenance Costs APPA Institute, New Orleans, January

3 ADVANTAGES OF CENTRAL PLANTS Higher Operational Efficiency Reliability 24 Hour Staffing ADVANTAGES OF CENTRAL PLANTS, cont Increased NSF / GSF Ratio Improved Grounds Aesthetics Continuous Monitoring and Control CHALLENGES OF CENTRAL PLANTS Large Initial Investment Distribution Losses Environmental Compliance Issues APPA Institute, New Orleans, January

4 SUSTAINABILITY IN CENTRAL PLANTS Renewable Fuels High Efficiency Equipment Environmental Stewardship SUSTAINABILITY, cont ACUPCC Greenhouse Gas Emissions Climate Neutral Energy Star AASHE STARS MAINTENANCE APPA Institute, New Orleans, January

5 MAINTENANCE GOALS Minimize Cost of Operations Maximize Equipment Life Maximize Equipment Reliability Minimize Unscheduled Outages Minimize Loss of Pressure or Capacity MAINTENANCE PLAN Preventive Predictive Corrective Deferred / Capital Renewal PREVENTIVE MAINTENANCE Inspection Detection Prevention APPA Institute, New Orleans, January

6 PREDICTIVE MAINTENANCE Diagnostic Continuous Monitoring Intermittent /Intervals CORRECTIVE MAINTENANCE Spare Parts Interchangeability of Parts Valving Schemes Documentation RULE OF THUMB OVERHAUL SCHEDULES Solid Fuel Boilers (3 to 5 Years) Gas-Fired Boilers (7-10 Years) Turbines (5 to 6 Years) Chillers (5 to 7 Years) Cooling Towers (10 Years) Large Pumps (7 to 10 Years) Large Fans (10 to 15 Years) APPA Institute, New Orleans, January

7 DEFERRED MAINTENANCE Equipment Life Operating Condition & Performance Reliability Needs Capital Program STAFFING STAFFING System Complexity System Size Plant Configuration Fuels Delivery and End Use Systems 24 Hour Monitoring Reliability State & Federal Requirements APPA Institute, New Orleans, January

8 MODEST CENTRAL PLANT Central Plant Organization Plant Supervisor Operators (5) Maintenance Supervisor Maintenance Mechanic(s) COMPLEX CENTRAL PLANT CHP or Coal Fired Plant Plant Manager Office Manager Maintenance Supervisor Plant Engineer Operations Supervisor Mechanics Electricians Instrument Technicians Welder Apprentice(s) Custodial Shift Supervisor Operators Shift Mechanic Fuel Handlers Equipment Operators Water Chemistry Technicians IN-HOUSE STAFFING Overstaffing Issues Productivity / Cost Cross Training Understaffing Issues Emergency Response Coverage APPA Institute, New Orleans, January

9 OTHER STAFFING OPTIONS Use of Central Shops Use of Temporary Staff Helps maximize hours and skills THIRD PARTY CONTRACTS Specialists Emergency Response Higher hourly cost vs. FTE On Demand (flexibility) Requires Budget Contingency SPECIALIZED WORK Vibration Analyses Ultrasonic Analyses Pressure Vessel Welding Stack Repairs Breeching Repairs Refractory Repairs Machining Metal Fabrication Tube Repairs Water Treatment Insulation Asbestos Removal APPA Institute, New Orleans, January

10 SPECIALIZED WORK, cont Eddy Current Testing Refrigerant Conversions Seasonal Maintenance Pumps/Drives Testing & Maintenance DA Tank Performance Valves Heat Exchangers Pollution Control Equipment Steam Traps OPERATIONAL RELIABILITY RELIABILITY AND RISK MANAGEMENT APPA Institute, New Orleans, January

11 CENTRAL CHILLER PLANT Research Hospital Main Plant Classroom & Research Research Admin Research Poor Distribution System Design CENTRAL CHILLER PLANT Research Hospital Main Plant Satellite Plant Classroom & Research Research Admin Research Good Distribution System Design Condenser Water Pumps Manual Valve (Typical) CWP 1 CWP 2 CWP 3 CWP 4 Cooling Tower No. 1 Cooling Tower No. 2 Cooling Tower No. 3 Cooling Tower No. 4 Chiller No Tons Chiller No Tons Chiller No Tons Chiller No Tons Poor Plant Design: Condenser Water Schematic APPA Institute, New Orleans, January

12 Condenser Water Pumps CWP 1 CWP 2 CWP 3 CWP 4 Cooling Tower No. 1 Cooling Tower No. 2 Cooling Tower No. 3 Cooling Tower No. 4 Control Valve (Typical) Chiller No Tons Chiller No Tons Chiller No Tons Chiller No Tons Good Plant Design: Condenser Water Schematic RELIABILITY AND RISK MANAGEMENT Staffing Contracts In Place Alternate Fuels Fuel Storage Good Maintenance Program RELIABILITY AND RISK MANAGEMENT, cont Written Procedures Documentation Equipment Nameplate Data Maintenance Reports O&M Manuals Drawings, Schematics, System Diagrams APPA Institute, New Orleans, January

13 RELIABILITY AND RISK MANAGEMENT, cont Environmental Permits Environmental Compliance Reports Diesel Generators Thermal Storage SECURITY Infrastructure Impact Tunnels Hospital and Patient Care Research and Animal Care Resident Students What proactive steps can be taken? Emergency Drills and Response EMERGENCY RESPONSE NIMS / ICS Damage Assessment & Control Survey & Repairs Documentation Self Insured or Group Plans APPA Institute, New Orleans, January

14 ECONOMICAL OPERATIONS KEY POINTS Tracking costs Following operational trends Knowing your system Forecasting / Use Projections SAVINGS AND COST AVOIDANCE 100,000,000 90,000,000 80,000,000 70,000,000 60,000,000 50,000,000 Purchased Electricty 40,000,000 KWh 30,000,000 20,000,000 10,000,000 0 APPA Institute, New Orleans, January

15 SAVINGS AND COST AVOIDANCE, cont 5,000, Purchased Natural Gas 4,800, ,600, ,400, ,200, Mcf 4,000, ,800, RATE SETTING RATE SETTING - EXPENSES Energy Purchases Water & Sewer Costs Plant Labor Plant Material/Equipment Distribution Labor/Material/Equipment Pollution Control Equipment O&M APPA Institute, New Orleans, January

16 RATE SETTING EXPENSES, cont Deferred Maintenance / Capital Renewal Improvements / Expansions Energy Conservation Environmental fees (permits) Overhead Support Other WHAT AFFECTS EXPENSES? Energy Consumption Projections Metering Information Square Footage Weather Other Fuel Projections Suppliers NIST Energy News Reports IMPACT OF WEATHER Cooling Degree Days (% Deviation from 30 Year Avg) 40% 35% 30% 25% 20% 15% 10% 5% 0% -5% -10% -15% Heating Degree Days (% Deviation from 30 Year Avg) 10% 5% 0% -5% % -15% -20% -25% APPA Institute, New Orleans, January

17 RATE SETTING - INCOME Plant Production Auxiliary Supply Chilled Water Growth Since 1998 (mmbtu) 900, , , , , , , , , , , , , , , , , , ,285 0 PLANT EXPENSES 14% 6% 5% 3% 5% 49% Fuel Plant Labor Reinvestment Plant Mat'l & Equip 18% Distribution Labor, Mat'l, & Equip Electricity, Water & Sewer BUDGET REVIEWS Monthly Variance Review Quarterly Variance Report Budget v Actual Year End Projections Adjustments Compare Rates with Competitors APPA Institute, New Orleans, January

18 METERING AND BILLING Finds Energy Hogs Identifies Distribution Losses Identifies System Problems Enables Square Foot Based Evaluations Enables Monthly & Yearly Comparisons Helps Manage Energy Use & Cost Enables Benchmarking BENCHMARKING Continuous process of measuring, understanding, and improving or adding more effective processes. BENCHMARKING CENTRAL PLANTS Equipment Distribution system Annual Consumption Plant Capacity Peak Consumption Firm Capacity Fuel Costs Sq Ft Served APPA Institute, New Orleans, January

19 BENCHMARKING YOUR SYSTEMS Historical Data (create data bases) Data from Utility Companies EPA/Energy Stars Energy Performance Indicators (EPI s) Portfolio Manager (rating system) ENERGY SAVINGS ENERGY SAVINGS: HEATING PLANTS Economizer Stack Heat Recovery Energy Efficient Burners Blow Down Heat Recovery Compressed Air Systems Boiler Controllers Ducted Heat Insulation APPA Institute, New Orleans, January

20 ENERGY SAVINGS: CHILLER PLANTS Economizer Free Cooling Building Controls Pumping & Piping Thermal Storage Process Chilled Water Units Base Load Optimization REFRIGERANT MANAGEMENT Refrigerant types / GWP Leaks Changing Refrigerant Oil Venting Certification Design & Code Issues Monitors SCBA SOME KEY POINTS Energy Recovery Fuel Switching Load Shedding Proper and regular O&M Calibration of controls Updating of controls & equipment KISS APPA Institute, New Orleans, January

21 TRAINING RESOURCES Mentors & OJT In-House Faculty & Staff Vendors / Suppliers Local Trade Schools & CC s Local Agencies On-Line State Apprentice Program TRAINING PROGRAM Tool Box Meetings Work Place Audits Testing Safety Equipment & Supplies Record Keeping & Monitoring Reward & Recognition SAFETY Right to Know /MSDS Chemical Storage / Spill Procedures Personal Protective Equipment Lock Out / Tag Out Confined Spaces Electrical Safety Welding / Fire Watch Noise APPA Institute, New Orleans, January

22 SAFETY, cont Ladders / Scaffold Fall Protection Forklifts / Mobile Equipment Vehicles Excavation / Trenching Emergency Procedures First Aid / CPR Hazardous Materials REVIEW Importance of Central Plants Reliability Maximize Efficiency Minimize Costs Maintenance Emergency Preparedness Training Safety QUESTION AND ANSWER Jay Becker, PE Manager of Mechanical Systems & Facilities Engineer University of Puget Sound Tacoma, WA jwbecker@pugetsound.edu APPA Institute, New Orleans, January