Central Plant Management EU 302 Jay Becker, P.E. KEY POINTS TAKE AWAYS Plants are vital Know Needs & Meet Needs Reliability Economics Planning & Communication O & M; Efficiency; Sustainable Staff (training, safety) COURSE OVERVIEW Central Heating & Chiller Plants CHP / Cogeneration / High Voltage Systems Maintenance Staffing APPA Institute, Scottsdale, September 2015 1
COURSE OVERVIEW, continued Contract Work Reliability & Risk Management Benchmarking Budgeting Training 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 APPA Institute, Scottsdale, September 2015 2
EU 302 Central Plant Management ADVANTAGES OF CENTRAL PLANTS Lower Overall Capital Investment Lower Fuel Costs Multiple Fuels Reduced Maintenance Costs 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 APPA Institute, Scottsdale, September 2015 3
CHALLENGES OF CENTRAL PLANTS Large Initial Investment Distribution Losses Environmental Compliance Issues SUSTAINABILITY IN CENTRAL PLANTS Renewable Fuels High Efficiency Equipment Environmental Stewardship SUSTAINABILITY, cont ACUPCC Greenhouse Gas Emissions Climate Neutral Energy Star AASHE STARS APPA Institute, Scottsdale, September 2015 4
MAINTENANCE 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 APPA Institute, Scottsdale, September 2015 5
PREVENTIVE MAINTENANCE Inspection Detection Prevention PREDICTIVE MAINTENANCE Diagnostic Continuous Monitoring Intermittent /Intervals CORRECTIVE MAINTENANCE Spare Parts Interchangeability of Parts Valving Schemes Documentation APPA Institute, Scottsdale, September 2015 6
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) DEFERRED MAINTENANCE Equipment Life Operating Condition & Performance Reliability Needs Capital Program STAFFING APPA Institute, Scottsdale, September 2015 7
STAFFING System Complexity System Size Plant Configuration Fuels Delivery and End Use Systems 24 Hour Monitoring Reliability State & Federal Requirements MODEST CENTRAL PLANT Central Plant Organization Plant Supervisor Operators (5) Maintenance Supervisor Maintenance Mechanic(s) COMPLEX CENTRAL PLANT CHP or Coal Fired Plant Office Manager Plant 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 APPA Institute, Scottsdale, September 2015 8
IN-HOUSE STAFFING Overstaffing Issues Productivity Cross Training Understaffing Issues Emergency Response Coverage OTHER STAFFING OPTIONS Use of Central Shops Use of Temporary Staff Works well if not emergency Helps maximize hours and skills THIRD PARTY CONTRACTS Specialists Emergency Response Higher hourly cost vs. FTE On Demand (flexibility) Requires Budget Contingency APPA Institute, Scottsdale, September 2015 9
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 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 APPA Institute, Scottsdale, September 2015 10
RELIABILITY AND RISK MANAGEMENT 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 APPA Institute, Scottsdale, September 2015 11
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. 1 1200 Tons Chiller No. 2 1200 Tons Chiller No. 3 1200 Tons Chiller No. 4 1200 Tons Poor Plant Design: Condenser Water Schematic 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. 1 1200 Tons Chiller No. 2 1200 Tons Chiller No. 3 1200 Tons Chiller No. 4 1200 Tons Good Plant Design: Condenser Water Schematic RELIABILITY AND RISK MANAGEMENT Staffing Contracts In Place Alternate Fuels Fuel Storage Good Maintenance Program APPA Institute, Scottsdale, September 2015 12
RELIABILITY AND RISK MANAGEMENT, cont Written Procedures Documentation Equipment Nameplate Data Maintenance Reports O&M Manuals Drawings, Schematics, System Diagrams RELIABILITY AND RISK MANAGEMENT, cont Environmental Permits Environmental Compliance Reports Firm/Excess Capacity 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 APPA Institute, Scottsdale, September 2015 13
EMERGENCY RESPONSE NIMS / ICS Damage Assessment & Control Survey & Repairs Documentation Self Insured or Group Plans ECONOMICAL OPERATIONS KEY POINTS Tracking costs Following operational trends Knowing your system Forecasting / Use Projections APPA Institute, Scottsdale, September 2015 14
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 1999-2000 2000-2001 2001-2002 2002-2003 2003-2004 2004-2005 2005-2006 2006-2007 2007-2008 2008-2009 SAVINGS AND COST AVOIDANCE, cont 5,000,000.00 Purchased Natural Gas 4,800,000.00 4,600,000.00 4,400,000.00 4,200,000.00 Mcf 4,000,000.00 3,800,000.00 1999-2000 2000-2001 2001-2002 2002-2003 2003-2004 2004-2005 2005-2006 2006-2007 2007-2008 2008-2009 RATE SETTING APPA Institute, Scottsdale, September 2015 15
RATE SETTING - EXPENSES Energy Purchases Water & Sewer Costs Plant Labor Plant Material/Equipment Distribution Labor/Material/Equipment Pollution Control Equipment O&M 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 APPA Institute, Scottsdale, September 2015 16
IMPACT OF WEATHER Cooling Degree Days (% Deviation from 30 Year Avg) 40% 35% 30% 25% 20% 15% 10% 5% 0% -5% -10% -15% 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Heating Degree Days (% Deviation from 30 Year Avg) 10% 5% 0% -5% 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006-10% -15% -20% -25% RATE SETTING - INCOME Plant Production Auxiliary Supply Chilled Water Growth Since 1998 (mmbtu) 900,000 800,000 700,000 600,000 500,000 400,000 300,000 200,000 100,000 0 505,937 586,449 628,652 548,369 611,301 654,393 705,393 720,515 732,580 765,285 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 PLANT EXPENSES 14% 6% 5% 3% 5% 49% Fuel Plant Labor Reinvestment Plant Mat'l & Equip 18% Distribution Labor, Mat'l, & Equip Electricity, Water & Sew er APPA Institute, Scottsdale, September 2015 17
BUDGET REVIEWS Monthly Variance Review Quarterly Variance Report Budget v Actual Year End Projections Adjustments Compare Rates with Competitors 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. APPA Institute, Scottsdale, September 2015 18
BENCHMARKING CENTRAL PLANTS Equipment Distribution system Annual Consumption Plant Capacity Peak Consumption Firm Capacity Fuel Costs Sq Ft Served 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 APPA Institute, Scottsdale, September 2015 19
ENERGY SAVINGS: HEATING PLANTS Economizer Stack Heat Recovery Energy Efficient Burners Blow Down Heat Recovery Compressed Air Systems Boiler Controllers Ducted Heat Insulation 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 APPA Institute, Scottsdale, September 2015 20
SOME KEY POINTS Energy Recovery Fuel Switching Load Shedding Proper and regular O&M Calibration of controls Updating of controls & equipment KISS 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 APPA Institute, Scottsdale, September 2015 21
SAFETY Right to Know /MSDS Chemical Storage / Spill Procedures Personal Protective Equipment Lock Out / Tag Out Confined Spaces Electrical Safety Welding / Fire Watch Noise 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 APPA Institute, Scottsdale, September 2015 22
QUESTION AND ANSWER Jay Becker, PE Manager of Mechanical Systems & Facilities Engineer University of Puget Sound Tacoma, WA 98416 jwbecker@pugetsound.edu APPA Institute, Scottsdale, September 2015 23