Question on staffing recommendations for O&M of new CHP/HRSG & chillers
Len
Posted for Lloyd Greenard, P.E., UTMB Galveston:
I am an IDEA member from the University Texas Medical Branch – Galveston. We are approximately 24 months away from the installation and start-up of a 7.5 MW CHP. Our total campus sq. footage is approximately 8M. The total chilled water capacity is approximately 24,200 ton with two (2) production plants. We also, have four( 4) satellite plants that we monitor.
My question is: How should we staff up for O&M of a new 7.5 MW CHP GT, heat recovery boiler, and (2) 3,350 ton chillers? Any help would be greatly appreciated.
Lloyd Greenard, P.E.
District Energy Program Director
ltgr...@utmb.edu
Office: 409.747.2950
Cell: 409.354.0656
Edward T. Borer Jr.
Lloyd,
Princeton’s energy plant is:
· 15 MW gas turbine + 180,000 #/hr HRSG
· (2) 150,000 #/hr auxiliary boilers
· 20,000 tons of cooling including (5) electric chillers and (3) steam-driven chillers
· Thermal storage
· Real-time economic dispatch
· Many smaller and auxiliary components
We do all management, operations, and most maintenance with a staff of 24. Three of those 24 are professional a.k.a. “management”. Minimum operations staff is 3 per shift. The balance are I&C, and maintenance.
I would say the staffing is somewhat proportional to equipment capacity but also very dependent on the complexity, and level of automation, and what portion of maintenance you self-perform or sub-contract.
Good luck with your new plant!
Ted Borer, PE, CEM, LEED AP
Princeton University
Energy Plant Manager
MacMillan Building, Elm Drive
Princeton, NJ 08543-2158
Cell: (609) 731-2327
Home: (609) 466-3322
Learn about our plant on YouTube: http://www.youtube.com/watch?v=xwHhbDvpdS4
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Greenard, Lloyd T.
Ted,
Thanks for your input, I have one other question do the 3 operators per shift monitor the BAS and dispatch techs to spaces/areas on campus?
Edward T. Borer Jr.
Our central plant operators do not monitor BAS or dispatch techs for building issues. They do monitor and perform daily routine checks at a nominally “unmanned” energy plant that supports our remote data center about 3 miles away. They also monitor a 5 MW solar field and some other unique devices around our energy distribution systems.
Greenard, Lloyd T.
Ted,
Thanks for your reply. I have one more question Do your operators work a 8 or 12 hours shift?
Edward T. Borer Jr.
Lloyd,
It’s a hybrid of 8’s and 12’s that was developed in-house.
Ted
Moser, Paul
Good Afternoon Lloyd,
Penn State operates 2 CHP plants with Distributed Steam System and an evolving Centralized Chilled Water plant.
Steam System
- East Campus Steam Plant:
o 1 Solar Taurus 70 w/ Rentec HRSG rated at 117,000 pph/300 psig MAWP/saturated [placed in operation 2010]
o 2 Keeler D-boilers rated 100,000 pph/300 psig MAWP/saturated
o Staff: 1 operator per shift
- West Campus Steam Plant
o Currently being converted from Coal to Gas for Boiler MACT. Completed project alignment
§ 2 Indeck boilers rated 150,000 pph/300 MAWP/540 oF [project completion: Jan. 2017]
§ 1 derated coal boiler converted to natural gas rated at 50,000 pph/300 MAWP/540 oF.
o 2 Back pressure steam turbines [240psig to 13psig] supplying campus with low pressure steam
o Staff: 2 operators. 1 operator, 1 lead operator
- Steam Distribution System
o 13 psig Low Pressure Steam
o 150 psig Medium Pressure Steam
- Shift schedule
o 40 hour weeks; no built in OT
o 6 teams of 3 operators [1 at East plant, 2 at west plant]. Relief cover maintenance when not operating.
o M,T,Th,F: three 8-hr shifts [7a-3p; 3p-11a; 11p-7a]
o S,S,W: two 12-hour shifts [7a-7p; 7p-7a]
- Staff
o Plants
§ 18 operators
§ 8 daylight maintenance
§ 2 supervisors
o Distribution
§ 7 daylight maintenance
o 2 staff assistants
o 1 Superintendent
Chilled Water System
- 3 central plant locations; Many individual building systems
- Total central plant Chilled Water capacity: about 16,000 tons
- Shift schedule
o the same as Steam System
o 1 operator/shift
- Staff
o Plants
§ 8 operators total: 6 operators, 2 Leads
o Maintenance
§ 7 daylight maintenance
o 1 supervisor
I attached our Utility Fact Sheet.
Others supervise Chilled Water. I can get you more information if you’d like.
Feel free to contact me with any questions.
Best Regards,
Paul Moser
Paul Moser, PE, CEFP
Superintendent – Steam Services
Office of Physical Plant
The Pennsylvania State University
University Park, PA 16802-1118
814-865-6515 (plant)
814-863-3178 (desk)
814-321-3760 (mobile)
From: distribut...@googlegroups.com [mailto:distribut...@googlegroups.com]
On Behalf Of Len
Sent: Thursday, June 05, 2014 4:07 PM
To: distribut...@googlegroups.com
Subject: {Distribution Forum} Question on staffing recommendations for O&M of new CHP/HRSG & chillers
Posted for Lloyd Greenard, P.E., UTMB Galveston:
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