The University of Texas at Austin Utilities and Energy Management Overview 1
Introduction Program Objectives Create a standard training curriculum in a modular, self-paced format Provide fundamental knowledge and skills needed to understand the operation of the facility Provide Plant and Site Specific Modules to train employees to operate and maintain specific facility systems and equipment Certify employees for their current positions using a validated test based process in an easy to use manner 2 Create an incentive based approach for employees to certify within the University s policies and procedures
3 Job Title by Section Chiller Station Maintenance Maintenance Mechanic I Maintenance Mechanic II Electrical & Instrument technician I Electrical & Instrument technician II Chiller Station Operations Chiller Station Operator Water Treatment Laboratory Technician Electrical Distribution T raining Program Electrician Power Systems Technician Emergency Systems Technician Mechanical Distribution Maintenance Mechanic I Maintenance Mechanic II Steam Fitter Utilities Insulator Utilities Plumber Power Plant Electrical Maintenance T raining Program Electrical & Instrument Technician I Electrical & Instrument Technician II Power Plant Machine Shop Power Plant Machinist Power Plant Mechanical Maintenance Program Maintenance Worker I Maintenance Mechanic II Maintenance Mechanic III Utilities Welder Utilities Insulator Power Plant Operations Utilities Station Operator I Utilities Station Operator II Utilities Station Operator III Water Treatment Laboratory Technician
Introduction Development and Implementation Process Define Employee Job Requirements Modular Training Program Outline Generic Training Materials Training Plan Plant Specific Training Materials Training Needs Assessment Program Training Progress Monitoring Cards 4
Define Plant Operator Job Requirements Job requirements for Utilities employees were gathered and developed by IRI Generic lists of job requirements were combined and/or modified to fit each specific job positions requirements Facility technical documents, plant system and equipment lists were reviewed Current facility employees were interviewed and plant operation and maintenance practices were observed Existing training materials and records were reviewed 5
Modular Training and Certification Program Outline Next a Modular Outline Was Created With The Modules Arranged in Categories Advanced Operation and Skills Training UTA Facility Specific Training Basic General Knowledge and Theory Safety Training 6
Module Outline Module Outline The Following Slides Demonstrate the Operator Modules Other Job Position Module Arrangements are similar 7
Module Outline Operator Training AOPBP Plant Science/ Basic Principles AOPBE Plant Science/ Basic Electrical Principles AOPHE Plant Science/ Heat AOPHT Plant Science/ Heat Transfer AOPFS Plant Science/ Fluid Systems AOPLM Plant Science/ Forces & Machines AOPGF Plant Science/ Gases & Flowing Liquids AOPSL Plant Science/ Solids & Liquids AOPBC Plant Science/ Basic Electrical Circuits AOIB1 Industrial Math/ Basic Operations 1 AOIB2 Industrial Math/ Basic Operations 2 AOIFC Industrial Math/ Formulas, Graphs & Trends AOIAL Industrial Math/ Algebra AODB1 Diagrams/ Basic Diagrams & Symbols 1 AODB2 Diagrams/ Basic Diagrams & Symbols 2 AODUF Diagrams/ Flow & Electrical AODUI Diagrams/ Piping & Instrumentation AOVB1 Valves/ Basic Types & Operation 1 AOVB2 Valves/ Basic Types & Operation 2 AOVEH Valves/ Electric & Hydraulic Actuators AOVIA Valves/ Introduction to Actuators AOELB Equipment Lubrication/ Lubricants & Bearings AOEUL Equipment Lubrication/ Using Lubricants AOPBT Pumps/ Basic Types & Operation AOPFC Pumps/ Fundamentals of Centrifugal Types AOPER Pumps/ Performance & Inspection AOPRE Pumps/ Reciprocating Positive Displacement Types AOFIN Furnaces/ Introduction 8
Module Outline Operator Modules Continued AOFOC Furnaces/ Operating Conditions AOFSS Furnaces/ Startup & Shutdown AOHIN Heat Exchangers/ Introduction AOHOS Heat Exchangers/ Operation of Shell & Tube Types AOHCT Heat Exchangers/ Cooling Towers AOHCR Heat Exchangers/ Condensers & Reboilers AOCIN Compressors/ Introduction AOCCA Compressors/ Centrifugal & Axial AOCOC Compressors/ Ops of Centrifugal & Axial Types AOCPD Compressors/ Positive Displacement AOEBP Equipment Drive Components/ Couplings AOEGB Equipment Drive Components/ Gear, Belt & Chain Drives AOPAB Piping & Auxiliaries/ Basic Components & Functions AOPAS Piping & Auxiliaries/ System Components & Functions AOBBP Boilers/ Basic Principles & Types AOBOW Boilers/ Combustion, Water & Steam AOBCO Power Plant Boilers/ Combustion & Operation AOBWS Power Plant Boilers/ Water & Steam AOBSS Power Plant Boilers/ Startup & Shutdown AOBNO Power Plant Boilers/ Normal Operations 9
Module Outline Operator Modules Continued AOBAC Power Plant Boilers/ Abnormal Conditions AOTBO Power Plant Turbines/ Bearings & Operation AOTSF Power Plant Turbines/ Steam Flow AOOTC Operator Responsibilities/ Introduction AOOPP Operator Responsibilities/ Plant Production & Safety AOOIM Operator Responsibilities/ Trends, Maintenance & Emergencies AOOCO Operator Responsibilities/ Communication AOEAC Electrical Equipment/ AC & DC Motors AOEEP Electrical Equipment/ Electrical Production & Distribution AOEMC Electrical Equipment/ Motor Controllers & Operation AOEBS Electrical Equipment/ Transformers, Breakers & Switches ACCHM Instrumentation & Control/ The Human-Machine Interface AOIA1 Instrumentation & Control/ Automatic Process Control 1 AOIA2 Instrumentation & Control/ Automatic Process Control 2 AOIDC Instrumentation & Control/ Density, Clarity & Moisture ACCIC Instrumentation & Control/ Control & Data Systems AOIMC Instrumentation & Control/ Measurement of Concentration AOIML Instrumentation & Control/ Measurement of Level & Flow AOIMP Instrumentation & Control/ Measurement of Pressure & Temperature AOPOS Process Sampling/ Obtaining Samples AOPTS Process Sampling/ Testing Samples 10
Heat Rate Improvement Modules HR001 Introduction to Heat Rate Improvement HR002 Principles of Heat Transfer HR003 Power Plant Thermodynamics HR004 Cycle Efficiency HR005 Analysis of Boiler Efficiency HR006 Boiler Efficiency/Air Heaters and Preheaters HR021 Boiler Efficiency/Oil & Gas- Fired Furnaces HR022 Efficient Operation of Oil & Gas-Fired Boilers HR009 Boiler Instruments & Controls HR011 Analysis of Turbine Efficiency HR012 Turbine Efficiency 1 HR013 Turbine Efficiency 2 HR014 Turbine Efficiency 3 HR015 Condenser Efficiency HR016 Efficient Condenser Operation HR017 Feedwater Heater Efficiency HR018 Efficient Pump Operation HR019 Efficient Power Plant Operation HR020 Power Plant Efficiency/Problems and Analyses 11
12 PP-MM-II Curriculum DVD Course Name (52 Courses) AEDBL Diagrams/ Blueprint Reading AOHIN Heat Exchangers / Introduction AEEES Electrical Theory/ Electrical Safety AOOTC Operator Responsibilities / Introduction AMBIN Bearings/ Fundamentals AOPBT Pumps/Basic Types & Operation AMBRB Bearings Rolling Contact AOPER Pumps / Performance & Inspection AMBSB Bearings Sliding Surface AOPFC Pumps / Fundamentals of Centrifugal Types AMCAC Compressors Reciprocating AORBC Refrigeration Systems/ Basic Concepts AMCCC Compressors Centrifugal AOTBO Power Plant Turbines / Bearings & Operation AMFOO Forklift Operation AOTSF Power Plant Turbines / Steam Flow AMGG2 Gears/ Types and Characteristics AOVB1 Valves/Basic Types & Operation 1 AMGGI Gears/ Overhauls AOVB2 Valves/Basic Types & Operation 2 AMLBA Lubrication Basics UTA-SR01 Safety Regulatory Training AMMBA Math Basics (29 elements x 45 min. each) AMMES Seals/ Mechanical Seals Site-Specific Course Name AMMFA Tools/ Mechanical Fasteners (27 Courses) AMMSG Seals/ Gaskets and Packing UTA-CS01 Cooling Tower Make-Up & Chemical Injection Systems AMPC2 Pumps/ Centrifugal Pump Overhaul UTA-CS02 Chiller No. 1 Chiller Station 2 AMPCT Pumps/ Centrifugal Pump and Trouble-shooting UTA-CS03 Chillers Nos. 2 & 3 Chiller Station 2 AMPPP Pipes and Valves Pipes and Pipe Fittings UTA-CS04 Chiller No. 1 Chiller Station 3 AMPST Pipes and Valves Steam Traps UTA-CS05 Chillers Nos. 2 & 3 Chiller Station 3 AMPV1 Pipes and Valves Types and Operations UTA-CS06 Chillers Nos. 1, 2 & 3 Chiller Station 4 AMPV2 Pipes and Valves Valve Maintenance UTA-CS07 Chillers Nos. 1 & 2 Chiller Station 5 AMRHL Rigging/ Heavy Lifting UTA-CS08 Chiller No. 3 Chiller Station 5 AMRLL Rigging/ Basic Lifting UTA-CS09 Condenser Water System Chiller Station 2 AMRLS Rigging/ Ladders and Scaffolds UTA-CS10 Condenser Water System Chiller Station 3 AMROV Rigging/ Basics UTA-CS11 Condenser Water System Chiller Station 4 AMSAF Shaft Alignment/ Fundamentals UTA-CS12 Condenser Water System Chiller Station 5 AMSBA Safety/ Industrial Safety Basics UTA-CS13 Chilled Water System Chiller Station 2 AMSHS Safety/ Chemical Health Hazards UTA-CS14 Chilled Water System Chiller Station 3 AMSRD Shaft Alignment/ Reverse Dial and Laser UTA-CS15 Chilled Water System Chiller Station 4 AMSRF Shaft Alignment/ Rim and Face UTA-CS16 Chilled Water Supply Chiller Station 5 AMTIH Tools/ Introduction to Hand Tools UTA-MM01 Air Compressors AMTIP Tools/ Introduction to Power Tools UTA-MM07 Valves AMTMI Tools/ Precision Measurement UTA-MM08 Bearing And Seals AOCIN Compressors / Introduction UTA-MM09 Bench Grinder AODB1 Diagrams/Basic Diagrams & Symbols 1 UTA-MM10 Band Saw AODB2 Diagrams/Basic Diagrams & Symbols 2 UTA-MM11 Drill Press AOEBP Equipment Drive Components / Couplings UTA-MM12 Steam Traps AOEGB Equipment Drive Components / Gear, Belt & Chain Drives UTA-MM13 Portable Threader AOELB Equipment Lubrication / Lubricants & Bearings UTA-MM16 Coupling/Shaft Alignment AOEUL Equipment Lubrication / Using Lubricants UTA-MM19 Centrifugal Pumps AOEWP Environmental Protection/ Water Pollution & Waste Disposal UTA-MM20 Silver Solder
13 Initial Estimates of Times Required to Complete Primedia and IRI s Calculated for Hours/Month and Number of Weeks At 6 Hours/Week Job Title by Section Total Hrs Hrs/Mo Weeks at Total Hrs Total Hrs Weeks at Primedia 18-Mos 6 Hrs/Wk IRI Primedia 6 Hrs/Wk Only Primedia Primedia Only & IRI For Both Chiller Station Maintenance Maintenance Mechanic I 95 5 16 28 123 21 Maintenance Mechanic II 137 8 23 108 245 41 Electrical & Instrument technician I 117 7 20 28 145 24 Electrical & Instrument technician II 145 8 24 72 217 36 Chiller Station Operations Chiller Station Operator 123 7 21 80 203 34 Water Treatment Laboratory Technician 97 5 16 36 133 22 Electrical Distribution Electrician 86 5 14 108 194 32 Power Systems Technician 99 6 17 56 155 26 Emergency Systems Technician 99 6 17 52 151 25 Mechanical Distribution Maintenance Mechanic I 63 4 11 20 83 14 Maintenance Mechanic II 101 6 17 68 169 28 Steam Fitter 83 5 14 52 135 23 Utilities Insulator 75 4 13 36 111 19 Utilities Plumber 69 4 12 56 125 21 Power Plant Electrical Maintenance Electrical & Instrument Technician I 115 6 19 28 143 24 Electrical & Instrument Technician II 147 8 25 56 203 34 Power Plant Machine Shop Power Plant Machinist 99 6 17 31 130 22 These are liberal assumptions; they assume the maximum of Power Plant Mechanical Maintenance Program Maintenance Worker I 44 2 7 28 72 12 Maintenance two tests Mechanic per module II for all of 119 7 20 28 147 25 Maintenance Mechanic III 177 10 30 140 317 53 Utilities Primedia's Welder and IRI's courses. 85 5 14 28 113 19 Utilities Insulator 55 3 9 16 71 12 Actual hours spent will usually be less. Total period allowed is Power Plant Operations Utilities Station Operator I 140 8 23 0 140 23 Utilities 18 months. Station Operator All II numbers are 140 8 23 66 206 34 Utilities Station Operator III * (see no 191 11 32 66 257 43 Water rounded Treatment to whole Laboratory numbers. Technician 97 5 16 64 161 27 * Note : PP US-OP-III Primedia training includes 51 hours of video cassettes
Generic Training Materials Generic s Safety, Basic Knowledge & Theory, and Advanced Operations are on Primedia Programs on Server and Laptop Hard Drives Heat Rate Improvement is in Video Format Others as needed 14
Plant Specific Training Materials Written Materials on Hard Drive and Server in MS Word Format Include: System and Maintenance Descriptions System Operating Procedures Maintenance Procedures On the Job Training Guides Review Questions 15
Plant Specific Training Materials System and Maintenance Descriptions System or Equipment Function System Flow Path or Equipment Overview Description of System and Parameters Major Component Detail and Specifications System Operation or Maintenance Procedure 16
Plant Specific Training Materials System or Maintenance Procedures Purpose of Procedure Precautions, Limitations and Set points Procedure 17
Plant Specific Training Materials OJT Training Guides Location of System or Equipment Components Location of Valves, Control Panels or Breakers Preparations for Operation of System or Equipment Startup, Inspection and Shutdown Maintenance Procedure or Actions Safety Precautions 18
Training Needs Assessment Training and Personnel Record Review Plant Management & Training Committee Recommendations Individual Training Progress Monitoring Cards 19
Implementation Policy Reviewed And Approved by HRS and EEOC Existing Employees in Current Positions Career Path for Existing Employees New Employees and Promoted Employees 20
21 Existing Employees in Current Positions 18 Months to Certify Pay up to 6 hours of OT per week: Primedia - To work on modules Not to exceed Primedia recommended times OT Paid when each module is completed Employee responsible for reporting time Total accumulated time is cross checked in the database To work on Site Specific Training Pay OT for IRI recommended times when they pass written final exam and on-the-job demonstration Employee responsible for reporting time
Existing Employees in Current Positions 22 Modify Job Descriptions to reflect that certification is a job requirement Following an 18 month grace period all employees not certified will receive a does not meet the minimum job requirement score (1) on a new evaluation criteria for certification Certified employees receive an exceeds the job requirement score of (3) for the new criteria
Career Path Opportunities 23 Cannot certify for another position until they are certified for existing position Request for certification for another position formally submitted to Training Coordinator No overtime payments Receive preferential hiring if pre-certified for a position over applicants not-certified If existing employee not pre-certified is selected for a position will be required to certify for the new position in 18 months, using same process described above Same consequences as above if not certified in 18 months
Promoted Employee and New Employee 18 Months to Certify Pay up to 6 hours of OT per week To work on Primedia modules Not to exceed Primedia recommended times OT Paid when each module is completed Employee responsible for reporting time Total accumulated time is cross checked in the database 24
Promoted Employee and New Employee Pay up to 6 hours of OT per week To work on Site Specific Training Pay OT for IRI recommended times when they pass written final exam and on-the-job demonstration Employee responsible for reporting time Same consequences as above if not certified in 18 months 25
Requirements Training Progress Monitoring Cards Employee Required to Manage Lists Individual Training Requirements Requirements are signed off by Supervisor and other designated personnel as completed Cards are collected and personnel records updated on a monthly basis 26
Requirements Typical Training Progress Monitoring Card Sections Chiller Operator Employee s Name (print) Work Location: Supervisor s Name (print): Module No. Module Title Start Date Required Completion Date Completed Initials JPM Test Safety/Regulatory Training UTA-SR01 Back Safety Classes of fires and Extinguishers Confined Space Entry Driving Safety Electrical Safety Electrical Safety For All Workers Electrical Safety for Electrical Workers Ergonomics 27 Fall Protection
Requirements Module No. Module Title Start Date Required Completion Date Completed Initials JPM Test Module No. Industrial Math - Formulas, Graphs and Trends Module No. Industrial Math - Algebra Module No. Diagrams - Basic Diagrams and Symbols 1 Module No. Diagrams - Basic Diagrams and Symbols 2 Module No. Diagrams - Flow and Electrical Module No. Diagrams - Piping and Instrumentation Module No. Equipment Lubrication - Lubricants and Bearings Module No. Equipment Lubrication - Using Lubricants Module No. Pumps Centrifugal Pump Overhaul 28
Requirements Training Progress Monitoring Card Final Sign Off Sheet for Job Position Comments: I certify that has performed the above duties as evaluated. Supervisor s Signature: Date: Employee s Signature: Date: 29
Implementation Schedule and Cost Started in 2003 and rolled out 9/1/05 Phase I design Phase II development and implementation planning Phase III implementation Deliverables Validated Training and Certification Plan Individual Training and Certification Books for each title Validated Tests and Job Performance Measures Training Materials Cost - Approximately $400,000 30
Progress To-Date (started 9/1/05) 6 employees have completed their curriculum 105 out of 130 employees enrolled in program 1250 DVD course completed (laptop and desktop) Developed pins to recognize progress 31