Page 343 - Sustainable On-Site CHP Systems Design, Construction, and Operations

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energy conservation measures. Having knowledgeable, trained plant operators is essential
for CHP plants, and, therefore, ongoing operator training is essential to sustainability. No
matter how much an individual knows, more can be learned. Additionally, technology con-
tinues its rapid advance and continuous training/education is required to maintain profi-
ciency. Also, rules and regulations change, and facilities operators need to be familiar with
any items affecting their facility. Changing priorities may also require education, for exam-
ple, as energy efficiency/pollution reduction become more important to a facility’s overall
mission.

Maintenance
Thorough, ongoing maintenance is essential to sustainable CHP plant operations. Every
plant must have a preventive maintenance (PM) system, and planned maintenance
shutdowns must be carefully coordinated. If the CHP plant was designed with backup
equipment, unexpected failures can be successfully handled without disruptions to
operations. Unplanned disruptions to CHP plant operations can be minimized with
good operations and maintenance, by operating the plant in a stable and safe manner,
and by maintaining equipment in good working order. There are number of software
programs and systems available to manage maintenance operations, with different
degrees of sophistication. However, the basic concept is to track each and every piece of
equipment, heat exchanger, valve, control device, and every device needing mainte-
nance along with the corresponding required maintenance items for each item (e.g.,
change oil, change fluids, lubricate fittings, change belts, and check clearances) as well
as the schedule for those maintenance items (e.g., daily, monthly, quarterly, and annu-
ally) to develop an overall plant maintenance schedule.

Reserve Funds
All equipment, no matter how well maintained, eventually wear out and must be
replaced. Facilities can and should plan for equipment replacements by establishing a
reserve fund. A CHP plant reserve fund is another equipment matrix that lists each and
every piece of equipment along with the equipment’s respective:

• Date put into service
• Remaining life expectancy in years
• Current cost to replace
• Future cost to replace
• Current reserve amount
• Calculated current reserve requirement
• Current reserve amount versus calculated current reserve amount (surplus or
deficit)
• Annual amount needed to be added to the reserve fund

The future cost to replace is estimated by escalating the current cost to replace by
the number of years of equipment life remaining. The calculated current reserve require-
ment is also determined from the future cost to replace and the remaining equipment