Mechanical Engineer (Utilities & Energy) - Full Task Guide for Onboarding and
Execution
1. Energy Strategy & Decarbonization Planning
Point-by-Point Breakdown
1.1 Understand Site Boundaries
• Action: Obtain the most recent Utility Layout Drawings and P&IDs.
• Whom to Ask: Site Facilities Manager or Engineering Lead.
• What to Check:
o Boundaries for gas, electric, and water feeds.
o Meter location and equipment served.
o Confirm labeling matches bills and meters (use site walkdown).
1.2 Collect Utility Bills
• Action: Ask Accounts Payable or Facility Admin for:
o 12 months of electric, gas, and water bills.
o Ensure you get: kWh/therms/gallons used, peak demand, and total cost.
• Utilities to Check:
o Electric (e.g., SCE, SDG&E, ConEd): kWh, $/kWh, peak demand.
o Gas (e.g., SoCalGas, PG&E): therms, BTU, $/therm.
o Water (e.g., Irvine Ranch Water District): gallons, tiered cost.
• Tools Needed: Excel to log each month’s data for baseline.
1.3 Confirm Meter IDs
• How:
o On-site walkdown with Maintenance or Engineering Tech.
o Cross-reference physical meter numbers with utility account statements.
o Photograph each meter and note GPS coordinates or locations.
• Optional Tool: ArcGIS Collector for tagging site utility meter map.
1.4 Categorize Consumption
• Approach:
o Check if you have submetering (BMS/PLC/IoT meters).
o Use existing power meters (e.g., Schneider iEM3150, Siemens PAC3200) or
clamp-on meters.
o Use flow meters (e.g., Siemens MAG 5100W, Panametrics PT878) for chilled
water.
• Whom to Ask: Controls Engineer, BMS Technician.
1.5 Establish Baseline
• How:
o Create an Excel dashboard logging all 12 months.
o Group by system: HVAC, Chillers, Air Compressor, General Load.
o Add weather data (degree days) from NOAA to normalize.
• Normalization:
o kWh/sq ft (offices), kWh/unit (production), therms/hr.
1.6 Visualize Data
• Tools:
o Excel with pivot tables.
o Use color-coded heatmaps, line graphs, and pie charts.
• What to Show:
o Monthly trend.
o % contribution by system.
o Cost per unit.
1.7 Estimate Carbon Footprint
• Emission Factors:
o Electricity: 0.41 kg CO2/kWh (varies by region).
o Natural Gas: 5.3 kg CO2/therm.
• How to Calculate:
o CO2e = kWh × factor + therms × factor + water × 1.5 kWh/1,000 gal.
1.8 Identify Waste
• Tools:
o FLIR Thermal Camera (for pipe insulation loss).
o Sonic Leak Detector (UE Systems Ultraprobe 9000).
• Whom to Talk:
o O&M Technician: Ask where they see short cycling, overheating, high
runtime, etc.
1.9 Strategy Deck
• Contents:
o Slide 1: Baseline summary.
o Slide 2: Top 5 inefficiencies.
o Slide 3: Project ideas (VFD, BMS tuning, controls).
o Slide 4–6: Financial model (payback, ROI).
• Tools: PowerPoint, use site logo, executive language.
2. ISO 50001 Certification - Deep Dive
2.1 Get the Standard
• How:
o Ask Quality Manager or EHS Lead.
o ISO 50001:2018 is the current standard.
o You can also buy online at iso.org ($150).
2.2 Gap Assessment
• Checklist Items:
o Is there an Energy Policy?
o Are SEUs documented?
o Are there KPIs?
• Tool: Use Excel template with ISO 50001 clauses vs. current status.
2.3 Create Documents
• Energy Review: List all energy sources and consumers.
• SEU Register: Identify biggest loads (chillers, compressors).
• KPI Tracker: kWh/ton chilled water, kWh/CFM, etc.
2.4 Internal Audit
• Steps:
o Interview operators.
o Review SOPs and actual logs.
o Issue internal audit report.
• Output: Gap findings, CAPAs, timeline.
3. Utility System Optimization Projects
Cooling Towers
• Models Seen: Marley NC Cooling Towers, Evapco AT Series.
• Optimization Steps:
o Install VFDs on fan motors (e.g., ABB ACH550).
o Set control logic to vary speed based on leaving water temp.
o Monitor conductivity and automate blowdown.
o Adjust COC from 3 to 5 (chemical + meter-controlled).
Chillers
• Chiller Types: Carrier 30XW, Trane RTWD, York YMC2.
• Steps:
o Log delta-T and flow (GPM).
o Confirm staging logic.
o Adjust chilled water setpoint (e.g., from 42°F to 44°F in winter).
Air Compressors
• Brands: Atlas Copco GA VSD+, Ingersoll Rand RS-Series.
• Steps:
o Check control panel for load/unload cycles.
o Use leak detection (above).
o Add VFD if missing, tune pressure band (e.g., 90–100 psi to 85–95 psi).
Generators
• Steps:
o Log monthly runtime from controller (e.g., Cummins PowerCommand).
o Check load factor during testing.
o Report NOx, CO emissions based on fuel type.
4. MEP Drawing Management - In Detail
How to Update
• Tools: Bluebeam Revu for PDF markup, AutoCAD for CAD files.
• Process:
1. Request current files from Document Control.
2. Mark changes during install.
3. Upload redlines to shared folder.
4. Submit for drafting team update.
5. Receive final and archive.
5. Cross-Functional Presentation
Strategy:
• Weekly: Utility Engineering Check-In.
• Monthly: Leadership Energy Review.
• Deck Format:
o Executive Summary
o Baseline
o Key Projects
o CO2e Savings
o Next Steps
6. Risk Assessment in GMP Facilities
Template:
• Failure: Cooling tower fails during chiller run.
• Effect: Temp excursion in HVAC.
• Severity: High.
• Mitigation: Backup fan, QA signoff, SOP change.
• Documentation: Use site Change Control Form from Quality.
7. Safety, GxP, and SOPs
Steps:
• Ask Quality or Validation for:
o SOP for utility modifications.
o Change control trigger matrix.
• Review:
o Calibration logs.
o PM completion rates (Maximo/Blue Mountain).
8. BMS Integration
Platforms Seen: Siemens Desigo, Trane Tracer, Honeywell EBI
• Steps:
o Identify equipment on BMS.
o Request access (read-only).
o Add trending for key tags: kW, temp, GPM.
o Set alarms (e.g., if chiller delta-T < 5°F for 10 mins).
o Build dashboards via graphics team or Niagara framework.
Summary Action Plan
Phase Focus Output
Month 1 Utility mapping, bills, metering Full baseline, meter log, site walk list
Month 2 Strategy, documentation Decarb deck, ISO gap report
Month 3-6 Retrofits BOMs, install reports, updated MEPs
Month 7-9 Tracking & reporting KPI dashboards, project updates
Month 10-12 Audit prep ISO internal audit, QA support
