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Nunapitchuk District Heating Report & Concept Level Design 1991
Nunapitchuk District Heating Report & Concept Level Design PREPARED FOR State of Alaska DS Alaska Energy Authority 701 East Tudor Road PO. Box 190869 Anchorage, Alaska 99519-0869 June 1991 polarconsult alaska, inc. ENGINEERS ¢ SURVEYORS ¢ ENERGY CONSULTANTS ) 1503 WEST 33RD AVE.* ANCHCRAGE, ALASKA 99503 PHONE: (907) 258-2420 FAX: (907) 258-2419 This study was prepared under contract with the Alaska Energy Authority by: Polarconsult Alaska, Inc. 1503 West 33rd Avenue Anchorage, Alaska 99503 The accepted conclusions are: 1. A potential for waste heat recovery has been identified in the community of Nunapitchuk. 2s Based on the proposed design and project cost estimate, the project is not economically feasible and does not appear to justify conventional financing. Alternate funding sources and/or revisions to the project _ Scope will need to be evaluated. 3. The designs presented herein are schematic in nature and should not be construed as being complete in design or function. A thorough review of content and correctness should be performed prior to use in the development of construction documents. The concept-level project cost estimate for Scenario #3 is $553,877. Final review comments and responses which were not incorporated into the report have been included in Appendix A. Accepted: _Z eve 2/24/92 Brian C. Gray Date Project Manager Accepted: Yi AUYEEFE . Smith Date Manager of Rural Projects polarconsult Nunapitchuk District Heating Executive Summary This report was commissioned by the Alaska Energy Authority (AEA) to determine whether introduction of a district heating system in Nunapitchuk, would save money for the community. Nunapitchuk is a bush community with a population of 372, located in Western Alaska approximately 26 miles Northwest of Bethel on the banks of the Johnson River. The district heating system would recover energy that is now being wasted from the Alaska Village Electrical Cooperative (AVEC) power plant, and convert the waste heat to beneficial use for the community. With the 1990 cost of heating oil at $1.29 per gallon to the School and $1.75 per gallon to the City, a considerable amount of money is expended to heat community buildings. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which transfers heat to water, and a pump to circulate the water through the baseboard radiators. At the radiator the heat is transferred to the air which heats the building. A district heating system works in the same manner, with the exception that the engine performs the same function as the boiler, and provides waste heat instead of burning fuel. This report discusses how this heat may be used in Nunapitchuk, and what Tesults may be expected. The school, community buildings, and water treatment plant were studied as likely candidates to be served by a district heating system in Nunapitchuk. The most economical combination would be the elementary school and high school. This combination would utilize 100% of the heat available at the power plant during the winter months and would be the most cost effective system. Project cost, annual amount of fuel saved and fuel cost savings for Concept #3 are as follows: Project Cost $553,877 Amount of Fuel Saved per Year 31,066 Annual Savings $40,075 Straight Pay Back in Years 13.8 polarconsult Nunapitchuk District Heating Total project cost includes design, supervision, inspection, administration and construction. The project includes construction of a new module at the power plant to house the district heating equipment, renovations to the AVEC power plant cooling system and the school-complex heating system, and construction of a hot water transmission line. The life of a district heating project is a function of availability of waste heat from the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance costs. In this case the requirement for electricity and space heat in the community imply an infinite project life. With proper maintenance the life of the district heating system will exceed 25 years . It is estimated that it will cost an average of $4,800 per year to repair actual failures in the district heating system. Routine maintenance will be performed during three trips to Nunapitchuk by a skilled crew each year. Operation will be by a local person who will monitor the system. Because annual operational and maintenance costs and economic decisions will be made by AEA, final economic conclusions are not presented in this report. The straight pay- back time for the best alternative, Concept 3, is 13.8 years. The project could be made more attractive economically by reducing its scale through minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Western Alaska communities to reduce Nunapitchuk's share of the high mobilization, shipping, travel, and supervision costs required. ai polarconsult Nunapitchuk District Heating CONTENTS Executive Summary ... List Of Figures) ....c....404-tescssscossesacsuesssoscavsssesassosssseucesopeacncesneeasscaruedonssareracseseestecseuesecesoree TEISE OF ADIOS itasessvctisss.cssnotsssseutcusasesssecusssssusyuosstssueessudescessuasseussueaseasnaseosmseriaessces cuentas vi GIOSSATY) | esstecisccetssssorsasesedencsosscnessssameessusssuseessunsenconccdusasoosadbaesssaveinianeveseeasteteesterteat vii I. Introduction IAs ODIOCHVE |:.ccslsesssoassscnvsonstsdcensbusdentntnucesnnicsiestecaeeansse sueeeriesesensavansnetvsousaerecsciaa 1 B. District Heating System .. |i C., Method logy) sass: sscstecssesssnessesnesencoussonssssasvaasseseceeessnserasesssesencenserseenssaceaznevansaseess 1 D. Community Description... ceesessssesecesecscssescseessesesesesecsesseeeseseseseseeesaes 3 H. Projected: Load Changes) tt..cssste-ssssssusesossueseorsansvososusaesssresesssesssressssesvssrarervancsey 4 TLs (Site VASit (s.sctsczcssvesensesasssssevasxsostassssewtsssssssaeaaovssstiacsecagnsnonsessacnensacsosesacsneessescsosensaeseees 4 II. Power Plant A. General 5 B. Available Load Information & Available Heat 5 C. Building Heat 7 D. Proposed District Heating Connection 0... ceesessesessessssescecesscsseeeseeeeeetaeees 10 IV. Potential District Heating Users A. School 1. General 12 Ds LOCAON cecasccsscessessucss soscssescsssssesascstsecesussuasessasuaassssccsnngnscnesnencsnesesdsaceosas 12 3. Heat Use .. 12 4. District, Heating ‘Connection jss....scscescasensanevoossscessnveat ess susvevonenearsnstesnsuecs 13 B. Water Treatment Building 1. General 17 3. Heat Use 4. District Heating Connection 2:.:ssecdsss1t21--serecqeenseesacesscsecseoccsaceossacecervenseese 18 C. Clinic, City Hall, & Community Hall 1. General 20 Dz LOCHHON cesissessessseresssccecsssusscescsencesessuazscvsassctossnsenseosscsesdesessasoosessacostscuese 20 Di ICAL USE Heotedessnacsusconssessenstaseaseccsosssssessubsnsvesedecsassesclstacancestusscossssssnssnssued 20 4. District Heating Connection ... iii polarconsult Nunapitchuk District Heating D. Public Safety, & Post Office 1. General 22 DOVES ALLOIN erect a setercenteeeereneceneretetnteceeceseeerereeassessiene? 22 Fs PICAt: WSC)...<sssnsrenconcsasesecessentonssusessososaissus cecscasesssoasusssesssessse ssesEsusTUsTOseSsd 22 4. District Heating Connection cyaccecccsccesesessrssescsssssensenssareccsussecseerosasevesesces 23 Vig CONCEPE Desi Baia WINGS wercsrasctictetersransrerscse tats asevorstcransancceroecertoceeee ca casresesnseresesaes 24 VI. Failure Analysis AL Introduction :...ssser,sssecsccsacersesnesscscocssesceancsncsussesseaesasusexerucveasessuseseseanssessovsasesess 36 B; Failure Analysis of District Heating System, <c.ss...5sscscss..+0<-0.----c-sacececosesesoessose aT PROWSG RIAN Prercceresecereresctecetccsnceccscsctosateteseseressestaseceoncerseteetetrecseceretzeces 38 ZjDistribution System yes seccocconssencessssasusvosssusanssasessessescastectonssnssenssesesesoes soca 41 3. User Connections = CyRailure Frequencyand! Costeerccmsetsseratss-teteseneroescentet teeter ntscreet eee ene crete 44 Ds DesigniDecisions|to Minimize allurevsis, ee rssrerersrsrortesesesceeceecscestersoeeseeree? 47 VII. Project Specifications AM COdES and RESUIALONS Heerrerecreeres store eres scree tsetcetsocectecstscecoccccaccaseescseseseecercees 49 BeDIVISION Olt GeneralGRequitements .r.tscccsctetscssecaccescenses-cecoestotctocssenereceat 49 (CDEVISION) 02 j<1Site WOLK: foreetevescosss caceatsre ootececosessssersssasusncess cestsessieeroecesonnesss 49 D. DIVISION 13 - Special Construction .............. pen E. DIVISION 15 - Mechanical Outline Specification .............:.csccscesssesseeeeeceeeees Di F. DIVISION 16 - Electrical Outline Specification ............ccscessssssesseeccerseseeeeees 54 VIII. Project Cost Estimate AS Power Plant Heat RECOVEDY) SYS(OM|esstt-netenscersrsesssnsstesnesacsiesctonsrsroececenesecenes 7 ByDistrict Heating Distribution Systema 1.2. ccsecsssessesecesecseeneucseesssteroneessncesseecoes a7 GC) Operation’and Maintenance Costs) nc-tctate.cssszsssusasascorsccescnsacnsnssscsusnssvsssssesesestss 58 D. Project Cost Summary IX. Conclusions A. Heat Availablity & Fuel Consumption ............cccsssssssssssscsesescscssssesesssssseseeees 39) ByProjecti Cost; Summ ary, crereecvessererecesrsosesseststoty evesesessenseseseecsseseseaser eos teensee oscars 61 C. Project Summary . XMRECOMMENCAIONS HE eetesersvensecerscesctecereransesetecesevencusseroncoserecesersueceoconsesseaseeaes Gal cuileiticons) Witeceseceserveses coceecsseszsnsenese resereencaaeesva ca wssatsasuasssnetetstsetesencesennsaesss Appendix A Field Trip Notes Appendix B Cost Estimate ... Appendix C iv polarconsult Nunapitchuk District Heating List of Figures I-1 I-2 Il-3 Ii-4 IV-1 IV-2 Iv-3 IV-4 IV-5 V-1 v-3 v-4 V-5 V-6 V-7 V-9 V-10 V-11 V-12 Ix-1 Ix-2 AVEC Butler Building & Module... . es 8 Unit #3, Bldg Unit Heater, Exhaust Air Louver, & Proposed District Heating Piping Connection Module Radiators, Air Intakes, & Proposed District Heating Module Location . 9 Unit # 4 Remote Radiator Piping, & Proposed District Heating Connection . . . 9 Proposed District Heating Pipeline Alignment to Elementary School Building . 15 Proposed District Heating Equipment Location & Connection to School Generator Bldg Furnaces... 1... ee 15 Proposed District Heating Equipment Location & Connection to Elementary School Furnaces 1... 1... cee ee ees 16 Proposed District Heating Equipment Location & Connection to Highschool FUMACES a5 6 nece eee ade & USES THEA ANA D s 16 Proposed District Heating Connection to Water Treatment Plant Furnaces . . . 19 Site Plan & Proposed District Heating System Distribution ............ 24 Proposed System Schematic... ......, eee ees 25 Detail of Revisions to Existing Power Plant & District Heating Connection . . 26 Elementary School Generator Building Piping Connection Schematic & Floor Plan si. .ocnecsnasceaee wets RTT G se RHE 27 Elementary School Building Piping Connection Schematic & Floor Plan . . . .28 High School Piping Connection Schematic & Floor Plan ............. 29 Water Treatment Building Schematic & Floor Plan ............00005 30 Clinic Building Schematic & Floor Plan... 1... ... . eee eee 31 City Hall Building Schematic & Floor Plan... ...... eee ee 32 Community Hall Building Schematic & Floor Plan... ........00000% 33 Public Safety Building Schematic & Floor Plan... .... 0.00000 vues 34 Post Office Building Schematic & Floor Plan... ... 0... 000s 35 Heat Available vs Heat Required... 1... . ee eee 60 Gallons of Heating Oil Displaced 2... es 60 polarconsult Nunapitchuk District Heating List of Tables I-A Concept Alternative Summary 1... 3 I-A Engine Data... . ee ee eens 5 IM-B Monthly Power Generation & Available Heat... 2... ee ee 6 IV-A_ Estimated Distribution of Fuel Oil Use at School»... ee 13 IV-B_ Estimated Distribution of Fuel Oil Use at Water Treatment Building ...... 18 IV-C_ Estimated Distribution of Fuel Oil Use at Clinic, City Hall, & Community Hall... ees 21 IV-D Estimated Distribution of Fuel Oil Use at Post Office, & Public Safety Building: ona caw ea saws ane eRe i mR GS 23 VII-A Summary of Alternative Project Costs... cee eee 58 IX-A_ Annual Heating Fuel Displacement & Pipeline Heat Losses ............ 59 IX-B ProjectSummary . ciass cae cceaea ennai Te HT HDT SD HEHE 61 vi polarconsult Nunapitchuk District Heating Glossary o AEA: Alaska Energy Authority, the State agency which commissioned the report. o AVEC: Alaska Village Electric Cooperative, the electric utility providing electric power to the community. o APUC: Alaska Public Utilities Commission, the body which regulates most utilities throughout the State of Alaska. o Capital Cost: Total cost to construct the project, including actual costs as well as design, management, contractor's overhead, risk and profit. o Operating Cost: Cost to keep the project operational, computed on an annual basis over the life of the project. o District Heating: Concept of recovering engine waste heat which would otherwise be lost through radiators to the air. This heat is circulated in pipes as hot water, to heat buildings. o Present Worth: The value of a future or past sum of money at a given time, usually the present, taking into account the time value of money, using an interest rate. o Net Present Worth: The value of a project where costs and income have been converted to a common time and combined. wii polarconsult Nunapitchuk District Heating I. Introduction A. Objective The objective of this report is to determine the feasibility of recovering and using the waste heat from the Alaska Village Electric Cooperative (AVEC) power plant generators in Nunapitchuk. In view of the present cost of heating oil at over $1.75 per gallon for the City and $1.29 per gallon for the School, and the amount of heat presently being wasted to the outdoors through the engine radiators, the Alaska Energy Authority (AEA) determined that utilization of waste heat showed potential savings in heating costs. The scope of this report is to determine if a district heating system is feasible, identify optimal applications, and estimate the cost of constructing this system in Nunapitchuk. B. District Heating System A district heating system takes energy that would otherwise be wasted and converts it to beneficial use as space heat. A brief description of a district heating system follows. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which burns fuel, usually oil, and transfers the heat to water, and a pump to circulate the heated water through pipes to radiators. At the radiator the heat is transferred to the air in the building. A district heating system works similarly, with the water heated by diesel generators in the AVEC power plant instead of being heated by a boiler. The water heated by the engines is normally cooled by the radiators at the plant. In a district heating system, this heat is recovered for beneficial use instead of being rejected to the atmosphere. This report discusses how waste heat can be used in Nunapitchuk, and the likely results. C. Methodology The feasibility of waste heat use in Nunapitchuk has been investigated in the following manner: polarconsult Nunapitchuk District Heating 1, Information Gathering: Prior to the site visit all pertinent and available information was gathered, including estimates of the amount of heat available and identification of potential user facilities. The field trip was coordinated with village officials and AVEC operators. 2. Field Trip: The site visit was made to discuss the project with the Village Council and interested persons, to survey potential user buildings and determine possible distribution pipe routes. Criteria for potential user facilities included public ownership, substantial heat use and proximity to the AVEC power plant. The manager or operator of each candidate building was interviewed. Information was gathered concerning: Rights-of-way; Amount, type and quality of construction equipment available in the village and the rental rates; o Availability of village-supplied labor during, the probable construction period; Specific weather problems such as drifting snow; and Soils information. Field trip notes are shown in Appendix B. 3. Analysis: Field trip notes, photographs, general information and additional site-specific features of the village were analyzed. Historical power production, weather information, and fuel usage records obtained during the field trip were entered into a computer model to determine the quantity of waste heat available to each potential user facility. On the basis of economics, several potential user facilities were eliminated. Specific details for hook-ups to the district heating system, including distribution pipe routing and location of user heat exchangers, were considered and included in the report. (See Figure V-1, "Site Plan and Proposed District Heating System Distribution," on page 24.) polarconsult Nunapitchuk District Heating The following table summarizes the concepts which were investigated and the buildings involved with each concept: Table I-A Concept Alternative Summary Concept Buildings 3 Elementry School & Generator Building and High School 4 Elementry School & Generator Building; High School; Water Treatment Plant; Clinic; City Hall and Community Hall 5 Elementry School & Generator Building; High School; Water Treatment Plant; Clinic; City Hall; Community Hall; Post Office and Public Safety Building 4. Initial Submittal: A preliminary report on the project was written and distributed to the Alaska Energy Authority staff for comment. 5. Final Submittal: The final report will include all comments received from AEA and other interested parties who have reviewed the interim report. D. Community Description Nunapitchuk is located in Western Alaska on the bank of the Johnson River, approximately 33 river miles up river from its drainage into the Kuskokwim River. The community is located about 26 air miles Northwest of Bethel. The population is made up mostly of Inupiat Eskimos, and the economy is based mainly on commercial fishing and subsistence hunting. Nunapitchuk states it has a population of 372. The community has a washeteria which obtains water from a well, and a distribution line to the School. Equipment for constructing a district heating system is limited in the community. Local labor is available most of the summer, although a majority of the residents participate in commercial fisheries. E. Projected Load Changes Uniquely the power plant at Nunapitchuk also serves three other communities including West Nunapitchuk, Akula Heights, and Kasigluk. This service is polarconsult Nunapitchuk District Heating through three submarine cables under the river. Akula Heights and Kasigluk have a population near 413, which exceeds that of Nunapitchuk. The AVEC 10 year plan includes adding the community of Atmautluak in 1995. Communities have been rapidly increasing in population in the Bethel area. Such increases will likely result in increased power demands. Depending on funds, a new addition onto the high school is planned to replace the existing BIA complex. It is not anticipated to have increased electrical usage, and its heat requirements should remain constant, according to Lower Kuskokwim School District officials. The heat requirements of the water treatment system should grow with the community. AVEC projects a fairly stable energy demand in the community over the next 6 years, and then a substantial increase over the following four years, according to its Power Requirements Study and 10-Year Plan. This increased requirement will proportionally increase the amount of heat available for use. Il. Site Visit The site visit was conducted during February of 1990 to discuss the project with the Village Council and interested persons, survey potential user buildings and determine possible routes for district heating distribution pipe. The principal of the school complex and operators of the water treatment building (washeteria) and the AVEC power plant were interviewed. Information was gathered concerning rights-of-way, soils, specific weather problems, and local availability of construction equipment and labor. Mike Franks of the Lower Kuskokwim School District was contacted about fuel usage of the schools. The schools used an average of 33,298 gallons per year of fuel. Field notes including a list of people contacted in the field, are shown in Appendix B. polarconsult Nunapitchuk District Heating II. Power Plant A. General The power plant is a standard AVEC Butler type structure, and one module unit. The Butler building houses two Caterpillar generators which share one remote radiator. The module has one Caterpillar generator connected to two remote radiators. The cooling system piping does not connect the two structures at this time. Equipment with the characteristics given in Table III-A is installed in Nunapitchuk. Table I-A Engine Data Position/Unit 1 3 4 Engine Caterpillar Caterpillar Caterpillar Model D3412 D353 D3412 Speed (rpm) 1200 1200 1800 Rating, Engine (kw)* 330 335 470 Heat Rejection** To Coolant (Btu/min) 13,281 17,500 18,483 To Stack (Btu/min) 18,420 19,930 29,572 To Ambient (Btu/min) 4,459 4,400 6,161 Water Flow (gpm) 118 145 180 Intake Air Flow (CFM) 1,020 1,000 1,470 * Engine rating at shaft. ** Rating at full load. There is a vacant position for Unit 2. A pipe tee will be provided for addition of a new Unit 2 in the future. (See Figure V-3, "Detail of Revisions to Existing Power Plant & District Heating Connection", on page 26.) B. Available Load Information & Available Hea Monthly power production figures for Nunapitchuk were obtained from AEA. The 1989 figures were rounded to the nearest 100 kwh for use in this report. The amount of waste heat available off the engines was calculated using these generation values and the engine manufacturer's heat rejection figures listed in polarconsult Nunapitchuk District Heating Table III-A. System losses were subtracted from the amount of heat available off the engines to arrive at the equivalent number of gallons of fuel oil available for use. System losses include building heat, distribution pipeline heat losses, radiator losses and plant piping heat losses. Table III-B Monthly Power Generation & Available Heat Month Power Produced Values Used Heat 1987 1988 1989 in Study! Avail.4 (kwh) (kwh) (kwh) (kwh) (Gal.) Jan wre 139,928 167,040 167,000 4,887 Feb 2 ===== 139,680 139,968 140,000 4,111 Mar = =---- 140,544 150,912 150,900 4,463 Apr oe 123,840 131,616 131,600 3,998 May === 111,168 124,416 124,400 4,004 June ---- 84,096 89,568 89,600 3,633 July 82,656 87,840 93,888 93,900 3,813 Aug 111,744 108,864 122,976 123,000 3,976 Sept 122,688 118,368 131,616 131,600 4,095 Oct 136,800 140,544 = ----- 153,6002 4,584 Nov 134,208 141,986 = ----- 155,1002 4,575 Dec 149,184 163,008 ~~ ----- 178,1002 5,201 Annual 1,453,8613 1,499,8663 1,638,800 1,638,800 51,340 1 Values used in this study were the 1989 kwh production figures rounded to the nearest 100 kwh. 2 From Jan. to Sept. the load increased 9.3% from 1988 to 1989. This rate of increase was used to project the load from Oct. to Dec. 1989. 3 Annual production for 1987 and 1989 was estimated, as data were not available for all months. 4 Equivalent gallons of heating oil available from District Heating Simulation Work Sheet. polarconsult Nunapitchuk District Heating C. Building H The Butler building portion of the power plant is a metal frame building with 2 inch insulation in the walls and roof. The building has an uninsulated wooden floor. The building has two exhaust air blowers which provide combustion air. Cooling air is exhausted through motor-controlled dampers on the back of the building. (See Figures III-1 & III-2.) A module houses unit # 4. This module contains complete generation facilities with the exception of the switchgear, which is located in the Butler building. The module is constructed of steel and mounted on steel skids. The module contains one engine, its associated piping and valves, and two horizontal radiators. Each radiator has sufficient capacity to reject all of the heat produced by the engine. These radiators are equipped with variable speed fans. The module also has two exhaust air blowers which provide combustion and cooling air. (See Figure II- 3.) The module is approximately 12 feet wide by 12 feet high by 36 feet long. The module is constructed with a metal skin inside and outside, and the walls are insulated with 3 inches of urethane foam. The floor is uninsulated. To keep the module warm, heat from the operating engine's cooling water is delivered to a unit heater in the module. There are two similar unit heaters in the Butler building. (See Figure III-2.) polarconsult Nunapitchuk District Heating Figure I-1 AVEC Butler Building & Module Figure II-2 Unit #3, Building Unit Heater, Exhaust Air Louver, & Proposed District Heating Piping Connection polarconsult Nunapitchuk District Heating Figure III-3 Module Remote Radiators, Air Intakes, & Proposed District Heating Module Location Figure IIl-4 Unit #4 Remote Radiator Piping, & Proposed District Heating Connection polarconsult Nunapitchuk District Heating Heat losses from the buildings will reduce heat availablity for distribution by the waste heat recovery system. Heat given off by the engine and generator is usually sufficient to heat the structure in which the equipment is operating. To keep the other structure warm requires supplemental heat obtained from engine cooling fluid. Calculations show a quantity of heat equivalent to 1,984 gallons of oil per year would be required to keep the Butler building at 65°F without an operating engine, and 1,334 gallons of oil per year to keep the module warm without an operating engine. Insulating the floors of these buildings would reduce these requirements to 1,375 and 597 gallons of oil per year, respectively. Calculations were conservative as the primary operating engine was assumed to be in the Butler Building. Losses from heating the buildings each year are equivalent to 1,375 gallons of oil. These values are based on heating each building to 65°F, and insulated floors. Heating the structures to 65°F only during periods of active maintenance could reduce the heat requirements. The engines are to be kept warm by circulating heated coolant through their blocks. The amount of heat required to heat the engine block is less than that required to heat the module during cold weather. This means that the minimum heat requirement is that required to heat the engine block and that the values used are conservative. D. Proposed District Heating Connection The proposed district heating system schematic is shown in Figure V-2 (page 25) and the connection to the power plant is shown in Figure V-3 (page 26). Interconnection between the existing remote radiators is included. This will allow for any generator to be run off any one of three remote radiators. Connection to the existing building unit heaters and engine warming system connections are also included in the new piping, as is insulation in the floors of the Butler building and the module. The primary heat exchanger will be located in a housing module mounted on a steel channel extension of the skids for generation module number 4. (See Figure Ill-3.) The expansion tank(s) and district heating pumps will be located at the user end of the system. The heat exchanger module housing will use 2x4 standard wood frame construction. The unit will be insulated with fiberglass batt insulation and covered with metal siding on the exterior and plywood on the interior. polarconsult Nunapitchuk District Heating Heat exchangers will be stainless steel plate type units. The primary side piping will run from the heat exchanger to the radiator space of module No. 4 and into the Butler building. (See Figures III-2, IlI-4, & V-3). The piping from the Butler building will be connected to module No. 4. The piping will be black welded steel pipe with flanges for valves and other removable fittings. The piping will be insulated outside of the structures to prevent excessive heat loss. The district heating electrical systems for the new heat exchanger module will be connected into a new electric panel located in this module. The new panel will be connected through a meter to the existing station service panel in the Butler building. The cost estimate for the connection of the heat exchanger, pumps, and module at the power plant is covered in Section VIII, Project Cost Estimate. aL polarconsult Nunapitchuk District Heating IV. Potential District Heating Users A. School 1. General The school has an enrollment of 110 and is operated by the Lower Kuskokwim School District, based in Bethel. The school complex consists of the new high school, and the BIA complex. The BIA complex is heated by two separate heating systems, one in the elementry school and one in the generator building. Supplying the school will require connections for the three heating plants planned to be served: the high school, elementary school, and generator building. An expansion of the high school building is proposed, which will replace the BIA complex, although the teacher housing will be retained according to LKSD officials. The remaining buildings will be turned back to BIA. It is expected that the remaining buildings will be turned over to the City, and not dismantled. The total heating load is not expected to decrease. 2. Location The pipeline will extend from the power plant about 120 feet to reach the beginning of the school complex, the tee to the school generator building. The pipeline will extend another 80' to the elementary school, and 500 feet to the high school. (See Figures IV-1, & V-1) "Arctic" distribution pipe to the school will be buried in school and public property, as shown in Figure V-1. Easements will be required to cross the sections of public property. All three school buildings are on piles, and the district heating piping will come up through the floor into the existing mechanical rooms. 3. Heat Use Fuel records for the school facility in Nunapitchuk were obtained from Mike Franks of the Lower Kuskokwim School District in Bethel. The entire complex used 33,298 gallons in 1989. 29,378 gallons were used through February 28 1990, and 24,182 gallons were used during the same period in 1989. This implies that about 40,000 gallons will be used in 1990. Housing used 4,400 gallons in 1989, and 5,400 gallons in 1990. polarconsult Nunapitchuk District Heating A monthly breakdown of fuel consumption was not available. Monthly fuel use was estimated by distributing the average annual fuel consumption based on the number of heating degree days per month. Table IV-A_ Estimated Distribution of Fuel Oil Use at School Month Heating Generator Elem. HS. Degree Bldg. Bldg. Bldg. Days (Gal. Oil) (Gal. Oil) (Gal. Oil) January 1,840 1,241 1,861 2,062 February 1,675 1,129 1,694 1,877 March 1,635 1,102 1,654 1,833 April 1,236 833 1,250 1,385 May 752 254 380 421 June 418 0 0 0 July 315 0 0 0 August 371 125 188 208 September 591 398 598 662 October 1,085 732 1,097 1,216 November 1,415 954 1,431 1,586 December 1,825 1,231 1,846 2,046 Annual 13,158 8,000 12,000 13,298 Purchase Cost / gal $1.29 $1.29 $1.29 4. District Heating Connection The district heating pipe will be buried and will enter through the floors of the existing mechanical rooms in the two school buildings proposed to be connected. User equipment in the school generator building will be located next to the boilers, copper lines will connect the secondary side of the heat exchanger to the return header on the boilers. (See Figures IV-2, & V-4.) A heating coil will be installed in the return air ducts of the warm air furnaces located in the elementry school mechanical room. (See Figures io polarconsult Nunapitchuk District Heating IV-3, & V-5.). Copper lines will connect the district heating system to the heat transfer coils. The cost to connect the elementry school and generator building to the district heating system is covered in section VIII. 14 polarconsult Nunapitchuk District Heating Jt Figure IV-1 Proposed District Heating Pipeline Alignment to Elementary School Building Figure IV-2 Proposed District Heating Equipment Location & Connection to School Generator Bldg Furnaces LS polarconsult Nunapitchuk District Heating Figure IV-3 Proposed District Heating Equipment Location & Connection to Elementary School Furnaces FigureIV-4 Proposed District Heating Equipment Location & Connection to High School Furnaces 16 polarconsult Nunapitchuk District Heating B. Water Treatment Building 1. General The water treatment building is owned and operated by the City of Nunapitchuk. Technical assistance is provided to the City by the U.S. Public Health Service. The facility includes a water storage tank, water treatment equipment and boilers to heat the water. The water is circulated to the School only in insulated above-ground water lines. 2. Location The water treatment building is located adjacent to the High School and the City buildings. The district heating distribution pipe from the power plant to the treatment facility will be "Arctic" pipe. This buried pipe will tee off the main line to the high school and will also serve the City buildings. (See Figure V-1.) The length of the hot-water transmission line to the water treatment building branch will be 220 feet. 3. Heat Use The water treatment building's two boilers supply heat to the water treatment building, the water tank, and the circulating water in the distribution line to the school. The wooden water tank is insulated and is heated to about 40°F in the winter. Fuel records for the water treatment building were obtained from the City of Nunapitchuk. Monthly fuel use was estimated by distributing this fuel consumption, using the number of heating degree days per month. (See Appendix A for sample calculation.) Distribution was biased to match the seasonal variation in the fuel usage reported by the plant operator. polarconsult Nunapitchuk District Heating TableIV-B Estimated Distribution of Fuel Oil Use at Water Treatment Building Month Net Fuel Heating Oil Use Degree Days (Gal.) (HDD) January 620 1,840 February 585 1,675 March 576 1,635 April 492 1,236 May 390 752 June 320 418 July 298 315 August 310 371 September 356 591 October 460 1,085 November 530 1,415 December 617 1,825 Annual 5,554 13,158 Purchase Cost\ gal $1.75 4. District Heating Connection The district heating pipe will be buried and will emerge outside the water treatment building, and extend into the building through the boiler room wall. The heat exchanger will be located next to the emergency generator across the room from the boilers. The connection will be made to the return header of the existing boilers (See Figure V-7.) The cost of connecting the water treatment plant to the district heating system is covered in Section VII. polarconsult Nunapitchuk District Heating Figure IV-5 Proposed District Heating Connection to Water Treatment Plant Furnaces 19 polarconsult Nunapitchuk District Heating C. Clinic, City Hall. & Community Hall 1. General The city buildings consist of the health clinic, city hall, and the community hall. The buildings are all heated by individual hydronic or hot air heating systems. Supplying the buildings will require connection of the district heating system to the existing and new equipment as outlined herein for each building. A new clinic is planned next to the existing structure. 2. Location The pipeline will extend in a loop from the water treatment plant about 420 feet to the clinic, city hall, and community hall. (See Figure V-1.) "Arctic" distribution pipe to the buildings will be buried in school and public property, as shown in Figure V-1. Easements will be required to cross the sections of public/private property. All three buildings are on piles, and the district heating piping will come up through the floor into the existing mechanical rooms. 3. Heat Use Fuel records for the city buildings in Nunapitchuk were obtained from the City. In 1989 the Clinic and City Hall used 16 barrels of fuel (880 gallons) each and the Community Hall used 15 barrels of fuel (770 gallons). A monthly breakdown of fuel consumed by the city buildings was not available. Monthly fuel use was estimated by distributing the average annual fuel consumption based on the number of heating degree days per month. 4. District Heating Connection The district heating pipe will be buried and will enter through the floors of the existing mechanical rooms in all three of the city buildings proposed to be connected. A heating coil will be installed in the return air duct of the warm air furnace located in the Clinics mechanical room. (See Figure V-8.) polarconsult Nunapitchuk District Heating The heat exchanger and pumps for the City Hall will be located next to the boiler in the City Halls mechanical room. The secondary side of the heat exchanger will run to heat transfer coils located in the return ducts of the warm air furnaces. (See Figure V-8.) A rack will be built to accommodate the heat exchanger and pumps above the water heater and boiler at the back of the mechanical room in the City Hall. Copper lines will connect the secondary side of the heat exchanger to the return header on the boilers. (See Figure V-9.) Two (2) new unit heaters will be installed in the Community Hall located as required. (See Figure V-10) The cost of connecting the clinic, city hall & community center to the district heating system is covered in Section VIII. Table IV-C Estimated Distribution of Fuel Oil Use at Clinic, City, & Community Halls Month Heating Clinic City Community Degree Hall Hall Days (Gal. Oil) (Gal. Oil) (Gal. Oil) January 1,840 123 123 108 February 1,675 112 112 98 March 1,635 109 109 96 April 1,236 83 83 72 May 752 50 50 44 June 418 28 28 24 July 315 21 21 18 August 371 25 25 22 September 591 40 40 35 October 1,085 73 73 63 November 1,415 95 95 83 December 1,825 122 122 107 Annual 13,158 880 880 7710 Purchase Cost / gal $1.75 $1.75 $1.75 21 polarconsult Nunapitchuk District Heating D. Public Saf P ffic 1. General The two buildings are located directly behind the AVEC power plant, and are heated by individual space heaters. Supplying the buildings will require new unit heaters and pumps for each building. 2. Location The pipeline will extend in a loop from the power plant water treatment plant about 50 feet to the post office, and hence another 40 feet to the public safety building. (See Figure V-1.) "Arctic" distribution pipe to the buildings will be buried in public property, as shown in Figure V-1. Easements will be required to cross the sections of public/private property. Both buildings are on piles, and the district heating piping will come up through the floor next to the existing space heaters. 3. Heat Use Fuel records for the two public buildings in Nunapitchuk were obtained from the City. The public safety and post office both used 15 barrels of fuel (770 gallons) each in 1989. A monthly breakdown of fuel consumed in the two buildings was not available. Monthly fuel use was estimated by distributing the average annual fuel consumption based on the number of heating degree days per month. polarconsult Nunapitchuk District Heating Table IV-D Estimated Distribution of Fuel Oil Use at Post Office, & Public Safety Month Heating Post Public Degree Office Safety Days (Gal. Oil) (Gal. Oil) January 1,840 108 108 February 1,675 98 98 March 1,635 96 96 April 1,236 72 72 May a2 44 44 June 418 24 24 July 315 18 18 August 371 22 22 September 591 35 35 October 1,085 63 63 November 1,415 83 83 December 1,825 107 107 Annual 13,158 770 770 Purchase Cost / gal $1.75 $1.75 4. District Heating Connection The district heating pipe will be buried and will enter through the floors next to the existing space heaters in both of the buildings. Two (2) unit heaters will be installed as required in the Post Office and the Public Safety Building located as required. (See Figures V-12 & V-11, respectively) The cost of connecting the public safety & post office to the district heating system is covered in Section VIII. 23 polarconsult Nunapitchuk District Heating V. Concept Design Drawings NUNAPITCHUK SITE PLAN & PROPOSED DISTRICT HEATING SYSTEM aux Wages 1. EASEMENT REQUIRED ALONG PROPOSED WASTE HEAT LINE ALIGNMENT. AIA coMPLER |/ 'Us survey Y PROPOSED WASTE HEAT USER PROPOSED WASTE HEAT LINE — —S— EXISTING SEWER LINE EASEMENT REQUIRED (SEE NOTE 1.) EXST. UG POWER LINE — —F— EXISTING FUEL LINE EXISTING POWER POLE FIGURE V-l polarconsult Nunapitchuk District Heating Ed SCRORL. NUNAPITCHUK — PROPOSED SYSTEM SCHEMATIC (SEE FIG. V-6) CLINIC r 7 — SEE. FIG. _—_ | | os CITY HALL 7 (SEE FIG. V-9) | | | CTT TTT | re | if | CONNECT C | TO USER | CONNECT | | CONNECT | L. _ SYSTEM. __ J lta user user | TO _USER SYSTEM HEAT \\I SYSTEM | [| ! ong. Lg | | IT Lele USER 4 | HEAT | = EXCHANGER | | r Vy 5 | CONNECT | | i ss | i | TO USER | os __ L __ _SYSTEM_ __ _I]} | connect | | CONNECT | OLD ELEMENTARY SCHOOL | T0_USER | TO USER (SEE FIG. V-5) SYSTEM HEATER | SYSTEM | r— Ber ese ——— HEAT | | || |us7e WATER PLANT EXCHANGER L 4 (SEE FIG, V-7> | | COMMUNITY HALL to" (SEE FIG. V-103 } CONCEPT 3 CONNECT || L 670’ - 2.5°6 TO USER 130’ - 1.5°8 LSYSTEM_ LS BURIED ELEM SCHOOL GEN BLDG ARCTIC (SEE FIG. V-4) PIPE eee eee eee MODULE S S 1s | (SEE FIGURE V-3) r , I | TO_ENGINE oh i 4 Connect | COOLING SYSTEM 2 To USER | c==T=TI SYSTEM P0_ENGINE ——L— | j COOLING SYSTEM =r PRIMARY HEAT | EXCHANGER 1. 4 L__ _§__sjd DISTRICT HEAT MODULE Spe Say BUTLER BUILDING (SEE FIG. V-3) e: (SEE FIGURE V-3) sSEE FIG, VID TT LEGEND | SOLATION VALV P<] ISOLATION VALVE | Connect | FN CHECK VALVE | TO_USER | SYS — — EXISTING | SISTEM NEW DISTRIBUTION | NEW @ USER NEW @ PLANT € USER PRIMARY DISTRIBUTION PUMPS POST OFFICE (SEE FIG, V-12> SCALE: NTS polarconsult Nunapitchuk District Heating NUNAPITCHUK DETAIL SHOWING REVISIONS TO POWER PLANT ANDO DISTRICT HEAT CONNECTION ean! DISTRICT HEAT pate | MODULE “NEW) ENGINE #3 TO DISTRICT HEAT SYSTEM 5 (SEE FIG, V-1) ) i PRIMARY HEAT EXCHANGER . | 5 cH 7 | | EXISTING | RADIATOR L——4 Lato a ENGINE #1 To | | EXISTI HKD | Hs hile 4 RADIATOR | UNIT HEATER Ein ny Tin Sti‘ EXISTING POWER PLANT ite ENGINE #4 | uke | =I (BUTLER BUILDING) UNIT HEATERS 60,000 BTU/HR 1” cu LEGEND EXISTING POWER PLANT BUTTERFLY VALVE CMODULE) AMOT VALVE NOTES: CHECK VALVE 1, PUMPED ENGINE WARM SYSTEM FOR ENGINES jn FLEX CONNECTOR #1 AND #3, EXP. TANKS AND H/E NOT SHOWN. <~ pain 2. EXISTING SYSTEM COMPRISES TWO ENGINES WITH ONE SKID MOUNTED RADIATOR. NEW PRIMARY PIPING : NEW DISTRICT HEAT PIPING FIGURE NTS V—3 polarconsult Nunapitchuk District Heating NUNAPITCHUK — OLD ELEM GENERATOR BUILDING (USER HOOK-UP) tf ZONE EQUIPMENT SCHEDULE A supPLies HEAT EXCHANGER 300,000 BTU/HR PUMPS GRUNDFOS, SERIES 200, UPC 50-80 EXPANSION TANK NOT REQUIRED PIPING: SUPPLY SIDE 1.5” STEEL, WELDED BOILER SIDE 1.5” CU EL ZONE RETURNS Ti TRICT HEAT SYSTEM EXPANSION TANK 5 qgGkyCOL FILE |< FROM DISTRICT HEAT EXCHANGER HEAT SYSTEM AIR SEPARATOR SYSTEM SCHEMATIC GENERATOR ROOM LEGEND SHELVES GATE VALVE BAL. VALVE PUMP. . CHECK VALVE ; EQUIPMENT = NEW @ USER - a i SHELVES EXISTING BUILDING EXISTING NEW DISTRIBUTION DISTRICT STRAINER HEATING TEMP CONTROL VALVE SYSTEM ——- FLOOR PLAN _ a polarconsult Nunapitchuk District Heating NUNAPITCHUK — (USER HOOK-UP) HEAT EXCHANGER N.A. NEW DUCT COILS PUMPS GRUNDFOS, SERIES INSTALLED IN 200, UPC 50-80 SEs UNS) NOT REQUIRED S| 1.5” STEEL, WELDED | oe BOILER SIDE 5" CU { 1 |FURNACE] © RETURN | GRILLE ; He GRILLE | eee ee) a | —><t fa TO DISTRICT TO FURNACE HEAT SYSTEM #3, & #4, FROM DISTRICT HEAT SYSTEM AIR SEPARATOR LEGEND GATE VALVE SPACE! BAL. VALVE ae eas EQUIPMENT PUMP. \ CHECK VALVE EXISTING BUILDING NEW @ USER [ EXISTING . S TIO DISTRICT NEW DISTRIBUTION ENC STRAINER SYSTEM TEMP CONTROL VALVE — FLOOR PLAN ot 28 polarconsult Nunapitchuk District Heating HEAT EXCHANGER NA PUMPS GRUNDFOS, 200, UPC 5 EXPANSION TANK 120 CALLON NEW DUCT COILS INSTALLED IN Foe EN AIR DUCTS ‘\ PIPING: / SUPPLY SIDE 3” STEEL, WELDED ——4 / a BOILER SIDE 1.5° CU | 1 / { 7 T a T ee |FURNACE| © RETURN | |FURNACE| © RETURN | | GRILLE | ) #2 GRILLE | See. eee! [ceererre AD, | 1. | p<} $$ $$ ______J qT STRICT ORE Rare EXPANSION TANK BQGLYCOL FILL FROM DISTRICT HEAT SYSTEM AIR SEPARATOR SYSTEM SCHEMATIC ELEC. PAN { Me oressune| T LEGEND | UNI | GATE VALVE BAL. VALVE ai DISTRICT CHECK VALVE PEATING EXISTING BUILDING SYSTEM NEW @ USER EXISTING NEW DISTRIBUTION STRAINER TEMP CONTROL VALVE SPA\ FOR USER EQUIPMENT DUTSIDE AIR FLOOR PLAN FIGURE SCALE: 1’=10' V-6 polarconsult Nunapitchuk District Heating HEAT EXCHANGER 100,000 BTLI/HR PUMPS GRUNDFOS, SERIES 200, UMC 50-80 EXPANSION TANK NOT REQUIRED PIPING: SUPPLY SIDE 1.5” STEEL, WELDED BOILER SIDE 1.5" CU TO DISTRICT Q BISTRICT HEAT SYSTEM FROM DISTRICT HEAT EXCHANGER HEAT SYSTEM AIR SEPARATOR SYSTEM SCHEMATIC Nee mya) PRESSURE ( a, =! TANK | | Puenace — 2A Ar SPACE FOR USER] \ EQUIPMEN BAL. PUMP | CHECK VALVE EXISTING BUILDING NEW @ USER EXISTING NEW DISTRIBUTION aay STRAINER HEATING TEMP CONTROL VALVE SYSTEM FLOMR Pl AN FIGURF SCALE: 1" = 15’ V-7 30 WASHETERIA TE HEAT EXCHANGER N.A. Dd GATE VALVE —— EXISTING BUILDING DR BAL. VALVE -—- NEW HEATING SYSTEM PUMPS GRUNDFOS, SERIES @ PuMP —— NEW DISTRICT HEAT PIPE 200, UMC 50-40 1 CHECK VALVE AX STRAINER EXPANSION TANK NOT REQUIRED —— NEW DH @ USER 0% ~=TEMP CONTROL VALVE PIPING: SUPPLY SIDE 1” STEEL, WELDED BOILER SIDE 1" CU SCALE: 1” = 10' : | | | | | FURNACE | | | NEW COIL IN FURNACE RETURN AIR DUCT TO DISTRICT “HEAT SYSTEM SPACE FOR USER r—4 FROM DISTRICT r+ Cts fm 2 pistrict, “CURMENT | i elienace HEAT SYSTEM HEATING —— — SYSTEM ae FLOOR PLAN SCALE: 1’ = 10° SYSTEM SCHEMATIC ez aS m > a3 = ao os Oo Cc RR Cc | vU “oO c 2 oO ynsuoorejod Sunvozy 1OMMstq ynyoudeunyy Ze Dd GATE VALVE — DRE BAL. VALVE --- € PUMP — 1 CHECK VALVE & NEW DH @ USER SPACE FOR USER EQUIPMENT a LEGEND EQUIPMENT SCHEDULE = & EXISTING BUILDING HEAT EXCHANGER 20,000 BTU/HR oO NEW HEATING SYSTEM PUMPS GRUNDFOS, SERIES it NEW DISTRICT HEAT PIPE 200, UMC 50-40 STRAINER EXPANSION TANK NOT REQUIRED z TEMP CONTROL VALVE PIPING: 5 SUPPLY SIDE 1” STEEL, WELDED x BOILER SIDE 1” cu | ce vu DISTRICT pupur Toe |, HEATING — coma oars fed EL ZONE L — — -5 SUPPLIES ZONE —— ——m — - RETURNS c TO DISTRICT HEAT SYSTEM ENTRY oe FROM DISTRICT jae rea-+€) (PS AT SYSTEM ra SHELL & TUBE BLR HEAT EXCHANGER Lae FLOOR PLAN SCALE: 1’ = 10° SYSTEM SCHEMATIC ANHOLDYNAN TIWH ALIS ynsuoorejod Sunvoy 1OMsIq ynyoudeuny ce LEGEND EQUIPMENT SCHEDULE —_ az Dd GATE VALVE — EXISTING BUILDING UNIT HEATER 20,000 BTU/HR oO S DRE BAL. VALVE -—- NEW HEATING SYSTEM PUMPS GRUNDFOS, SERIES 9 > @ PUMP —— NEW DISTRICT HEAT PIPE 200, UMC 50-40 3 bh’ CHECK VALVE & STRAINER EXPANSION TANK NOT REQUIRED = oO —— NEW DH @ USER TEMP CONTROL VALVE PIPING: ox SUPPLY SIDE 1” STEEL, WELDED A = HEATING SIDE 3/4” CU | Cc | a << Q oO = = (au = 4 =< es > _ i Sia EXISTING r 7 | | | SPACE HEATERL 4 DISTRICT Ta | | = HEATING CF SYSTEM —t,! NI 1 | _ ZONE +—-SPACE FOR USER LRETURNS - TO DISTRICT EQUIPMENT fo DH HEAT SSTEM UNIT | 1 | es i | ee S| __¢FROM DISTRICT ZONE Ps HEAT SYSTEM SUPPLIES FLOOR PLAN SYSTEM SCHEMATIC SCALE: 1° = 15’ ynsuoorejod Sunvoy IOMsiq ynyoudeuny ve LEGEND EQUIPMENT SCHEDULE >z az Dd GATE VALVE —— EXISTING BUILDING WNIT HEATER! 20.000 /BTUZHR aS DR BAL. VALVE -—- NEW HEATING SYSTEM PUMPS GRUNDFOS, SERIES as @ PuMP —— NEW DISTRICT HEAT PIPE 200, UMC 50-40 3 1” CHECK VALVE AY STRAINER EXPANSION TANK NOT REQUIRED 59 —— NEW DH @ USER = KM_SC TEMP. CONTROL VALVE PIPING: oes c SUPPLY SIDE 1” STEEL, WELDED AS 15 HEATING SIDE 3/4” CU | = 7 TU aS v S fey f= a “ > 7 m™ 2 “~ /-— SPACE FOR USER =e Vi EQUIPMENT A\ rq =-s I wearer Ca Day Blaeeaning ra SYSTEM _ Ll TD = EXISTING L UNIT| SPACE HEATER HEATER | 4 eae NS TO DISTRICT r HEAT SYSTEM UNIT | ) | HEATER, i | ee | _¢FROM DISTRICT ZONE PS HEAT SYSTEM SUPPLIES FLOOR PLAN SYSTEM SCHEMATIC SCALE: 1° = 15’ qnsuoorejod sunvoy 1oLMstq ynyoudeuny ce LEGEND EQUIPMENT SCHEDULE GATE VALVE —— EXISTING BUILDING UNIT HEATER 20,000 BTU/HR BAL. VALVE NEW HEATING SYSTEM PUMPS GRUNDFOS, SERIES PUMP —— NEW DISTRICT HEAT PIPE 200, UMC 50-40 CHECK VALVE & STRAINER NOT REQUIRED YOR EXPANSION TANK PIPING: SUPPLY SIDE 1” STEEL, WELDED HEATING SIDE 3/4" CU —— NEW DH @ USER TEMP CONTROL VALVE 15° SPACE FOR USER DISTRICT |_ 4 EQUIPMENT HEATING EXISTING Seed pealens LJ HEATER UNIT | HEATER | UNIT| HEATER | SUPPLIES SCALE: 1° = 15/ FLOOR PLAN SYSTEM SCHEMATIC ce YNZ us a9 = ae er Oo Cc TR Cc | | ~S” 7" Oo ”Y a o 9 a 5 mM TO DISTRICT “HEAT SYSTEM FROM DISTRICT PS HEAT SYSTEM ynsuoorejod sSunvoy 1oMsiq ynyoudeunyy polarconsult Nunapitchuk District Heating VI. Failure Analysis A. Introduction Failure analysis is the process of predicting the operational reliability of a system. It provides information on the probable type and frequency of failures, and indicates how the system should be designed and maintained for optimal reliability. Reliability (R) is defined as that portion of time a system is functional. Unreliability (UR) is defined as (1 - R). Reliability is determined using the total time of operation (Total Period), mean time between failures (MTBF), and mean time to repair (MTTR). A district heating system depends on a number of components to provide heat to the user. The total unreliability of the system is the sum of the unreliabilities of these components. For example, if a pipe had an MTBF (mean time between failure) of 8,760 hours, and an MTTR (mean time to repair) of 8.77 hours, the reliability would be 1-(8.76/8760) = 1-0.001 = 0.999. This means that the pipe will be operating 99.9% of the time. If there were a heat exchanger that could also fail, and it had the same reliability as the pipe, the reliability of the combined items would be 1 - (8.76 + 8.76) / 8760 = 1 - 0.002 = 0.998. This means that both the pipe and the heat exchanger would be operating 99.8% of the time and unable to deliver heat for 0.2% of the time. The system would then be out of service 0.002 x (8760 hours / year) = 17.52 hours per year. Equipment with moving parts, such as pumps, are generally less reliable than static equipment, such as pipes. It is typical practice to install two pumps for this reason, with the second acting as a stand-by. The following illustrates how reliability is calculated for a system with two or more components of which either can perform the task. The system must be such that more than one piece of equipment can perform the same function, and failure of each piece of equipment is independent, that is, it does not affect the performance of other equipment. Two circulating pumps, each capable of pumping all the necessary fluid, is a common situation that will be used as an example. Assume that one of these pumps will fail once per year and 36 polarconsult Nunapitchuk District Heating will require an entire day to repair. The system will be unable to deliver heat if both units are unable to pump. Assuming both pumps fail at the same time, system reliability would average only 0.07 hours per year, as compared to a average of 24 hours per year with a single pump installed. Expressed in percentage of the year not serviceable, the value is 0.000751% for the two-pump system. The preceding example, comparing the failure rate of one versus two pumps, illustrates how important and powerful it is to provide redundant equipment for failure-prone items. This is economically feasible only where the costs of duplication are not great. All reliability analysis has limitations. The limitations of this study are as follows: First, it is based on historical data acquired from military, nuclear, and electrical industries, and is limited to the equipment used and the specific application conditions. Because the equipment and conditions will be different for this project, the outcome will be different. Second, the analysis is based on average conditions, and it is probable that for each individual system there will be a greater or lesser number of failures than predicted. Third, actual failure rates for a large number of plants will be closer to the calculated values, on average, than results from a smaller number of plants. Although the values derived by mathematical failure analysis for these systems cannot be exact for the individual installation, because the results are average values, they do provide important information. First, performing the analysis requires the designer and builder to determine what causes system failures and to take measures to avoid them. Second, the analysis provides the basis to determine which functions need emphasis during maintenance programs. Third, some degree of scale is provided on how failure affects project income. B. Eailure Analysis of District Heating System A description of major system components, their failure modes, and impacts of failure on the system is presented below. The description starts at the power plant and works toward the served structure(s). polarconsult Nunapitchuk District Heating 1. Power Plant a. Components Engines: The engines are the source of heat; if they are not running, heat is not available to be delivered. Most AVEC plants have three engines, Nunapitchuk also has three. In general, the plants are operated so that a single engine can serve the entire community. The reported down time for AVEC generation systems during 1989 was 33 hours total. This quantity was from 12 hours forced outage of generators, 3 hours power line outages caused by storms, 8 hours planned maintenance outages, and 9 hours all other outages. Based on these values, the system will not generate heat 0.377% of the time. Cooling system: The power plant cooling system associated with the district heating system requires connecting the engines to a common manifold which, in turn, connects the primary heat exchanger and two or more radiators. As radiators are unreliable components, three will be used at Nunapitchuk to reduce failure probabilities. The primary generation system failure modes are: Failure or shutdown of the engines; Failure of the radiators due to leakage; Failure of the hoses, valves and piping system; Failure of the engine block itself, and ASS YS Failure of the primary heat exchanger, piping, pumps, and valves associated with the engine. Generation plant: Full failure of the generation plant, due to shut down, will stop heat production and disable the district heating system. AVEC reports that these occurrences average 33 hours per year, out of the 8,760 hours in a year. Radiator failure: Radiators usually fail by leaking from cracks caused by rapid and extreme temperature changes. Usually radiator failures do not result in total plant shut-down but do require isolating the leaking radiator and running the system off the standby. If a radiator or engine 38 polarconsult Nunapitchuk District Heating connection hose breaks it can drain glycol coolant at a rapid rate, requiring plant shut-down. Controls are installed to shut down the plant in the event that coolant levels fall to a dangerous level. Alarms are installed to alert the operator prior to automatic shut-down. This allows the operator to isolate the leak, repair it, by-pass the leak, add additional glycol, or shut down the plant, as appropriate. The primary environmental problem associated with engine radiator failure is discharge of glycol onto the ground. Impacts on the environment from glycol leakage include thawing of permafrost, glycol contamination of groundwater, and glycol contamination of adjacent surface water bodies. Leaked glycol is difficult to recover because volumes are small, the terrain is usually rough, glycol mixes with water and ice, and it will disperse rapidly in water unless it is confined to a catchment basin. The above analysis applies to the existing system and the proposed district heating system upgrade. The only changes will be an increased potential volume of lost glycol, a slightly less reliable system as all equipment is connected to a single cooling system manifold, and a slight decrease in reliability caused by the addition of a heat exchanger. Primary heat exchanger: This component is composed of a series of formed stainless steel plates which are separated and sealed by rubber gaskets. The plates are bolted together within a steel frame to compress the gaskets and hold the plates together. The heat exchanger is used to transfer heat from the engine cooling fluid to the fluid circulated in the distribution pipes supplying the user's heat exchanger. The primary heat exchanger thus serves to isolate the power plant from the distribution system. This isolation means that failures in the distribution piping or at the user facility will not affect the power generation system. Failure modes of the primary heat exchanger are: 1. Blown or leaking gaskets; 39 polarconsult Nunapitchuk District Heating Broken frame; Valve failure and stem leaks; Cracking or corrosion of plates; Connecting piping system failure; Fouling; YNAWwWR YY Freezing while generation system is down, if water is used as coolant instead of glycol, and 8. Structural damage to exchanger supports due to fire or other events. c. Generation plant operational impact: 1. A large, sudden loss of coolant on the engine, or primary, side of the heat exchanger will shut down the engines. A slower leak on the primary side can shut down the plant as a result of low coolant levels in the engines. If found in time, the failed exchanger can be isolated with valves. It is unlikely that valves will not work during a heat exchanger failure. d. District heating system operational impact: 1, Small leak: Operation of system will continue. According to maintenance procedures the bolts will need to be tightened, valve packings tightened. new glycol added to the coolant system, and spilled glycol recovered. Large leak: If on the primary side and if too much fluid is lost before the shut-off valves can be closed, the engines will shut down under low water level control. If on the secondary side: Without fluid, the district heating system will be out of operation until repaired. Pipeline will be drained of fluid and operator will notify main maintenance office. e. Environmental Impact: Glycol spilled on the ground is the environmental impact of an exchanger failure. Glycol can escape into the ground, thawing 40 polarconsult 2. Nunapitchuk District Heating permafrost and weakening structural supports, and enter groundwater and surface water bodies. Required immediate actions: Determine cause of failure, isolate heat exchanger at valves or add additional glycol as required by procedures. Catch dripping glycol in pans and recover spilled glycol. Call maintenance office if extra help is required. Distribution System Components: Transmission pipe will range from 4 inch diameter to 1 inch diameter insulated pipe. Each 4 inch pipe will be made up of a steel carrier pipe 4.500 inches in diameter with a 0.142 inch thick wall. The carrier pipe will be covered with high density urethane foam. Encapsulated in the foam will be two tin plated copper wires. These wires will provide a method to determine if water or glycol has leaked into the insulation. Covering the insulation will be a high molecular weight polyethylene jacket with an outside diameter of 8.86 inches. The pipe will run from the district heating module, which houses only the heat exchanger, 210 feet to the elementary school generator building and then 95 feet to the elementary school, and so on. The pipe will be buried about 2 feet deep in the ground, or located on the surface on sleepers. Failure modes of the district heating transmission system are: 1. External or internal corrosion of the carrier pipe; 2. Mechanical damage to the pipe from equipment or digging into the pipe; 3. Failure of the pipe; Failure of pipe welds; and 5. Mechanical failure caused by frost heave or thaw settlement. Generation plant operational impact: None d. District heating operational impact: 41 polarconsult 3 a. Nunapitchuk District Heating 1. No operational impact from minor leaks in jacket or pipe which are detected and corrected by the maintenance crew during routine inspections. 2. Larger leaks which cause a measurable loss of glycol will require shutdown of the line with isolation valves, and pipe repair to put system back on line. Environmental impact: Glycol spilled on the ground is the environmental impact of a pipeline failure. Glycol can escape into the ground, thawing permafrost and weakening building supports, and also enter groundwater and drain into surface water bodies. Required immediate actions: Determine cause of failure, isolate pipeline at valves or add additional glycol as required by procedures. Catch dripping glycol in pans and recover spilled glycol. Cail maintenance office if extra help is required. ser Connection: Components: Each system is composed of a heat exchanger similar to the one at the power plant, two circulation pumps, an expansion tank, provisions for adding glycol coolant, a btu meter, piping, and valves. Failure modes of the heat exchanger are: Blown or leaking gaskets; Broken frame; Valve failure and stem leaks; Cracking or corrosion of the plates; Connecting piping system failure; Fouling; NAwWPRYN SE Freezing while generation system is down, if water is used as coolant instead of glycol; and 42 polarconsult 8. Nunapitchuk District Heating Structural damage to the exchanger supports due to fire or other events. Failure modes of the pumps are: No ae Failure of electrical circuit; Seal failure; Motor failure; Impeller cavitation; Pump body failure; and Connection leakage. Failure modes of the expansion tank are: i 2. 3. Water logging or bladder failure; Corrosion; and Broken sight glass. Failure modes of the piping system are: 1. 2. 3. 4 Leakage of valve stems; Failure of valves to open or close; Failures due to corrosion; and Failures due to materials or installation defects. Failure modes of each of the school connections are: Ls 2. Failure of the school system to hold fluid; and Failure of the school's circulation pumps. Generator operational impact: Failure of the above items will not affect the generation plant. District heating system operational impact: Heat exchanger: As described for the power plant, minor leaks from the heat exchanger will be corrected by catching and returning leaking glycol, tightening bolts, and scheduling the unit for gasket replacement. Major leaks of the heat exchanger will require the system to be isolated with the valves until it is repaired. 43 polarconsult Nunapitchuk District Heating Pumps: Ifa pump fails the system will be off until the failure is detected and the standby pump is put into service. If two pumps fail the system will be down until one can be repaired. Expansion tank: An expansion tank failure could be caused by the sight gage breaking, which will require system shut down until it is repaired. Corrosion is not a likely form of failure for an ASME 125 psi rated tank. Piping: Failure of the piping will generally occur at valve stems and where there are gaskets or joints. Slow leaks from these causes and from corrosion will not require shutting the system down. Shut-down of the system could be caused by a valve stem being twisted off or by a broken casting; repairs will be required before the system is returned to operation. Environmental Impact: The environmental impact will relate to glycol spillage. A large, rapid leak might enter the ground, where it could lead to thawing and structural failure. There is potential for groundwater and surface contamination. Small leaks are likely to stay in the building, but will require immediate and complete cleanup. Required Immediate Actions: For a slow leak, pans will be placed to catch leaking glycol, packings and joints will be tightened if appropriate, and fluid replaced. For a large leak, isolation valves will be closed to reduce loss of fluid. Repairs and replacements will be made, or maintenance crew notified, as required by procedures. For a pump failure, the failed pump's valves will be closed, the standby pump's valves opened, and the motor energized. If both pumps fail, one or both will require repairs. If an expansion tank fails, the tank will require recharging or repairs. For extensive repairs or replacement the maintenance crew must be notified. C. Failure Frequency and Cost The most common modes of failure are listed below, along with the associated frequency of occurrence, repair cost per occurrence, amount of down time, and a 44 polarconsult Nunapitchuk District Heating description of the effects on system life. Failure rates are calculated using the method shown in the Introduction. It should be noted that maintenance of certain items will require that the system be removed from service. This maintenance can be scheduled during a period when the power plant is out of service or when the user building does not require heat. For a school this would be in the summer. Therefore, the potential effects of loss of energy sales during routine maintenance are not included in the calculations. AVEC generation: The most common form of failure is engine failure. Frequency is variable but outage time is estimated at less than 33 hours per year as four generators will be available. Repair cost to system is $0 as it is not related to district heating system. Heat exchanger at power plant: The most common form of failure is failure of seals. Frequency of occurrence is 10.6 years. Down time is 72 hours, repair cost is $2,000. There will be no measurable effects on system life from Tepairs. District heating pipe: The most common form of failure is from poor installation. Frequency of occurrence is 2.08 years. Down time is 48 hours, repair cost is $2,000. There are no measurable effects on system life from repairs. User connections at school: The most common form of failure is the heat exchanger. Frequency of system failure for each system is estimated to be 4.3 years. The combined school system frequency of failure of one of the units is once each 1.4 years. Down time ranges from 24 to 72 hours depending on which item fails. Repair cost is $2,000. There will be no measurable effects on system life from repairs. User connection at water plant: The most common form of failure is the heat exchanger. Frequency of system failure for each system is estimated to be 4.3 years. Down time ranges from 24 to 72 hours depending on which item fails. Repair cost is $2,000. There will be no measurable effects on system life from repairs. 45 polarconsult Nunapitchuk District Heating Total system: Failure frequency of the total district heating recovery system is summarized in the following table. Figure VI-A System Component Failure Rates Item Failure Rate Heat recovery at plant 0.000507 Transmission pipe 0.002626 Post Office assembly 0.000747 Public Safety assembly 0.000747 Elem Gen Bldg assembly 0.000747 Elem school assembly 0.000747 Senior HS heat assembly 0.000747 Water heating assembly 0.000747 Clinic heating assembly 0.000747 City Hall heat assembly 0.000747 Comm. Hall heat assembly 0.000747 Total 0.009856 To make the above figures of value the subsequent table has been prepared which shows the effect of outages on the production or sale of heat. Figure VI-B Annual Hours System Components Off Line Item Failure Oil used Oil Lost Hours/yr % total Eq. hrs/yr Heat Recov. Power Plant 4.4 100.0 4.44 Common Transmission Pipe 12.9 100.0 3.64 Elementary (2 bldgs) 14.9 46.0 6.94 High School 6.8 31.0 2.10 Washeteria 9.9 13.0 1.28 City Buildings 22.6 6.0 1.33 P.O. & Public Safety 14.6 4.0 0.53 Sum (Equiv. Hours/yr) 86.1 20.26 polarconsult Nunapitchuk District Heating The weighted value can be derived by multiplying the systems savings of 34,111 gallons of oil per year x 17.60 / 8,760 which is 79 gallons of oil based on equivalent heat which is not delivered because of failures. The number of maintenance outages which are paid for by AEA will be 2.4 per year at 2,000 each for a total cost of $4,800 per year. A portion of the annual 33 hours of generation plant outage should be added to the total waste heat recovery system outage time. The proper number should be 25 hours per year (33 total hours minus the 8 hours of scheduled outage which occurs during the summer.) The 25 hours would be distributed randomly. The total time the system would be unable to deliver heat based on outage of the engines, heat exchanger, and the transmission pipe, would be about 52 hours per year, which is 0.60% of the time. The time that the nine user facilities are out would be approximately 10.5 hours per year of total equivalent outage. In terms of the delivery of salable heat, the total system outage time would be about 62.5 hours per year. D. Design Decisions Made to Minimize Failure Rate and Impacts Some of the design decisions that will be made to assure long life and reliability are the selection of corrosion resistant materials, use of duplex pumps, and use of isolation valves so a failure on one ‘eg will not necessarily shut down the entire project. Where possible, flanges will be used for valves and all interior plant pipe will be welded to improve system reliability. Items which the reliability analysis shows are of critical importance will be duplicated if economically feasible. All connections to the district heating system are separated from the power plant by isolation valves and a heat exchanger to minimize the consequences of a failure. User building heat will not be interrupted by a failure of the main district heating system, or by the failure of another user's system. The design includes the use of "Arctic" pipe which includes a steel carrier pipe butt-welded together and from | to 2 inches of insulation covered with a non- corrosive jacket. Two tin-plated copper wires are carried in the insulation to indicate the presence of moisture as an alarm. These alarm wires are read by a $1,500 alarm device which can connect to as many as four individual pipe loops. polarconsult Nunapitchuk District Heating These devices allow for failures to be detected before they have time to become a major problem. They also minimize the time required to locate the failure and reduce excavation costs. At this time we know of no failures of this piping system in Alaska. 48 polarconsult Nunapitchuk District Heating VII. Project Specifications A. Codes and Regulations The listed versions of the following codes and regulations were used in the preparation of this report: Uniform Building Code (1988) Uniform Mechanical Code (1988) Uniform Plumbing Code (1988) Uniform Fire Code (1988) National Electric Safety Code (1987) ooo0lco0lollhlUl8 B. DIVISION 01 - General Requirements This is a general information section covering the coordination of work, description of the work required for this project, regulatory requirements, definitions, payment procedure, submittals, quality control, materials and equipment, starting, testing, contract closeout and maintenance. C. DIVISION 02 - Sitework SECTION 02700 - PIPED UTILITIES A. This section covers specific requirements, products and methods of execution relating to the water distribution system for the project. The interior piping is specified elsewhere. B. Distribution will be buried "Arctic" pipe with a steel carrier pipe, polyurethane insulation and a high density polyethylene jacket. The pipe shall be IC. Moller Plus pipe, or equal and approved. 49 polarconsult Nunapitchuk District Heating D. DIVISION 13 - ial Con i SECTION 13120 - Pre-Engineered Structures A. This section includes specific requirements, products and methods of construction relating to the district heating module for the project. B. District Heating Module will be of wood frame construction insulated with fiberglass batt insulation, metal siding on exterior and plywood on the interior. Support for waste heat structure will consist of cantilevered beams connected to the Butler building floor beams. Cantilever beams and framing will be Hem-Fir 2 x material. 50 polarconsult Nunapitchuk District Heating E. DIVISION 15 - Mechanical Outline Specification SECTION 15010 - GENERAL PROVISIONS This is a general information section correlating mechanical work to other divisions of the specifications, defining terms, referencing codes and standards, itemizing submittal requirements, and defining submittals and information required for operation and maintenance manuals. SECTION 15050 - BASIC MATERIALS AND METHODS A. This section includes a description of specific requirements, products, and methods of execution which are typical throughout the mechanical work for this project. Additional requirements for the specific systems will be found in the sections specifying those systems, and supersede other requirements. B. Piping inside the buildings shall be type L hard copper or black sch. 40. Steel piping shall be welded and flanged. Valves shall be 150 psig. butterfly or gate for isolation, plug type for balancing. SECTION 15160 - NOISE AND VIBRATION CONTROL A. This section lists specific requirements, products, and methods of execution which relate to the isolation of all mechanical systems for limitation of transmission of vibration and sound to acceptable levels. B. All connections to engines and radiators, and between the power plant and the district heating module, shail be stainless steel flexible type. SECTION 15180 - INSULATION A. This section describes specific requirements, products, and methods of execution which relate to the insulation of ducts, pipes, and other surfaces of the mechanical installation. polarconsult Nunapitchuk District Heating Insulation is provided for the following purposes: Energy conservation; Control of condensation; and Safety of operating personnel. Piping inside the power plant shall be uninsulated. Piping inside the district heating module and user buildings shall be insulated 1" thick rigid F/G, with all-service jacket. Piping outside and between the Butler building and the engine-modules which connects to the heat exchanger will consist of ic. Moller or equal "Arctic" insulated steel pipe. SECTION 15191 - OUTSIDE TRENCH EXCAVATION, BACKFILL, COMPACTION This section describes general requirements, products, and methods of execution relating to excavation, backfill, and compaction of utility trenches outside of buildings. SECTION 15600 - HEAT GENERATION A. This is a description of specific requirements, products, and methods of execution for interrelated systems, necessary for the generation of heat which will be distributed to the locations shown. The method of distribution of this heat is specified elsewhere. Heat generation (transfer) will be accomplished with stainless steel plate heat exchangers, as manufactured by Tranter, or equal and approved. Primary heat exchangers will be located in the district heating module and will interface with the power plant. Secondary heat exchangers will be located in the user facility and will interface with the user's heating system. 52 polarconsult Nunapitchuk District Heating SECTION 15650 - COOLING SYSTEMS A. This section describes specific requirements, products, and methods of execution relating to the cooling systems for the project. The work of this section includes provision of systems and equipment for removal and transfer of excess heat from the locations shown, including the furnishing of interface apparatus and controls and the connection at interfaces with other mechanical systems. B. Generator cooling systems will consist of existing Young horizontal radiators, controlled by Volkman variable speed controllers. SECTION 15850 - BALANCING AND TESTING This section covers general requirements and methods of execution relating to the testing and balancing of the mechanical systems provided on this project. SECTION 15900 - CONTROLS AND INSTRUMENTATION This section describes specific requirements, products, and methods of execution relating to the system of temperature controls and instrumentation for the project. 53. polarconsult Nunapitchuk District Heating F. DIVISION 16 - Electrical Outline Specification SECTION 16010 - GENERAL PROVISIONS This is a general information section correlating electrical work with other divisions of the specifications, defining terms and indexing the various Division 16 sections, referencing codes and differences from Division 01 requirements, and defining submittals and information required for operation and maintenance manuals. SECTION 16031 - DEMONSTRATION OF ELECTRICAL SYSTEMS This section includes procedures to be used during final inspection, instruction of operating personnel, and a certificate of completion for the convenience of the Contractor and Owner to determine whether each item has been completed. SECTION 16040 - IDENTIFICATION This section covers labels and name plates for equipment, branch circuit panel board directories, and other identification needed for electrical equipment. SECTION 16050 - BASIC MATERIALS AND METHODS A. A major part of the electrical specification, this section covers the workmanship, coordination, and standards necessary for the electrical work. The products covered include raceways, conductors, and connectors. Installation techniques to cover various construction methods are noted so that fireproofing is maintained, water penetration and moisture migration through raceway systems are prevented, and the proper connectors are used for various conductor terminations and splices. B. Only copper wires and cables shall be used. Raceways shall be rigid galvanized, sherardized steel conduit or electrical metallic tubing with compression or set screw type fittings, for all conduits concealed in the walls, above the ceilings or exposed in work areas. 54 polarconsult Nunapitchuk District Heating SECTION 16130 - BOXES, CABINETS, AND PANEL BOARDS A. This is a general section that outlines various standards to follow in the construction of these items, with specific notation on certain types of cabinets to suit various systems. Mounting heights for outlets and cabinets are covered in this section. B. Panel boards shall have copper busing with bolt-on type circuit breakers. SECTION 16140 - WIRING DEVICES A. Receptacles, switches, device plates, and special purpose outlets are covered in this section. B. All outlet devices shall be specification grade or better. SECTION 16150 - MOTORS AND CONNECTIONS Motor specifications regarding voltage, phase, and temperature rise are covered in this section. Distinctions between which motors and control items are included in Divisions 15 vs. contract or responsibilities are also shown. Appliance and miscellaneous equipment connections, whether owner- furnished or contractor-furnished, are covered to provide suitable connection techniques. SECTION 16160 - MOTOR STARTERS AND DISCONNECTS Specific requirements for overload and phase failure protection to be included in motor starters are covered. Also included is a listing of various devices suitable for use as equipment disconnects. SECTION 16180 - OVERCURRENT PROTECTIVE DEVICES This section contains a general listing of various devices suitable for overcurrent protection, such as circuit breakers, fuses, and current limiters. 55 polarconsult Nunapitchuk District Heating SECTION 16190 - SUPPORTING DEVICES This section covers, in a general way, the various supporting, fastening, hanging, and securing techniques approved for use by the contractor in the installation of the electrical work. SECTION 16450 - GROUNDING This section itemizes complete grounding requirements and techniques for connections. SECTION 16480 - BRANCH AND FEEDER CIRCUITS This section clarifies drawing preparation technique as being diagrammatic rather than "as-built" and gives the contractor flexibility in conduit routing and circuiting, as may be determined by job site conditions. SECTION 16500 - LIGHTING A. Light fixture construction for both interior and exterior fixtures, lamps, and ballasts are covered in this section. B. Interior light fixtures shall be fluorescent, of industrial design. Exterior fixtures shall be high pressure sodium wall packs controlled by photocell. 56 polarconsult Nunapitchuk District Heating VIII. Project Cost Estimate A. Power Plant Heat Recov stem The first cost component is construction of the building to house the district heating system. This includes the mechanical and electrical equipment inside the module and the connection to the modified AVEC power plant as shown in Figure V-3 on page 26. The second cost component is the modification of the existing power plant system. This includes the connections of Unit #1, Unit #3, and Unit #4 to a common manifold and to the heat exchanger as shown in Figure V-3 on page 26. B. District Heating Distribution System The connection of the school complex to the district heating system includes installation of piping from the face of the district heating module to the three school buildings, and all equipment and connections within the school mechanical rooms, as shown in Figures V-4, V-5, and V-6 on pages 27, 28, and 29. The connection of the water treatment building to the district heating system includes installation of the piping teeing off from the main line to the schools to the water treatment building, and all equipment and connections within the mechanical room as shown in Figure V-7 on page 30. The connection of the three city buildings to the district heating system includes installation of the piping past the line to the water treatment building to the next building, and all equipment and connections within the mechanical rooms as shown in Figures V-8, V-9, and V-10 on pages 31, 32, and 33. The connection of the post office and the public safety buildings to the district heating system includes installation of the piping from the power plant to the post office and to the public safety building, and all equipment and connections within the buildings as shown in Figures V-11, and V-12 on pages 34, and 35. polarconsult Nunapitchuk District Heating C. Operation and Maintenance Costs Annual operation and maintenance costs are determined by the regular system maintenance required as well as the number of failures. Regular maintenance will be performed three times per year by a skilled maintenance crew. Day to day operation will be by a local person who will monitor the system and notify the maintenance department of any failures or problems. Repair of these failures will result in an additional 2.4 trips per year to Nunapitchuk by a skilled repairman. With a cost of $2,000 per incident the result is an average cost of $4,800 per year to repair failures. Cost of the three annual maintenance trips must be added to this failure repair cost to arrive at the total annual operation and maintenance cost. D. Project Cost Summary Total project costs for the three alternative concepts are shown below. Table VIH-A Summary of Alternative Project Costs Concept 3 4 5 Elem Elem, HS, PO, PS, Elem & HS WTP, CH, HS, WTP CH,&CL CH,CH,&CL Module Construction $68,5970 $66,145 $68,727 Plant Piping Revisions $20,8060 $20,421 $22,671 Elem Gen Bldg Conn. $118,160 $89,186 $83,042 Elem School Conn. $78,774 $59,457 $55,361 High School Conn. $267,540 $114,375 $101,895 Water Treatment Conn. --- $127,062 $130,780 Clinic Conn. --- $111,354 $114,600 City Hall Conn. --- $114,364 $117,669 Comm. Hall Conn. --- $106,947 $110,030 Post Office Conn. --- --- $34,038 Public Safety Conn. --- --- $34,038 Total Project Cost $553,877 $809,311 $872,851 Total project cost includes design, supervision, inspection, administration and construction. The complete cost estimate is included in Appendix C of this report. 58 polarconsult Nunapitchuk District Heating IX. Conclusions A. Heat Availablity & Fuel Consumption There are presently over 34,300 gallons of equivalent fuel oil per year available as waste heat at the Nunapitchuk power plant. The district heating system can displace the following amounts of the proposed user heat requirements: Table IX-A Annual Heating Fuel Displacement & Pipeline Heat Losses Concept 3 4 5 Elem Elem, HS, PO, PS, Elem & HS WIP; CH, HS, WIP CH,&CL CH,CH,&CL Heat off Engines 51,340 51,340 51,340 Annual Heat Loss in Dist. Pipes 3,336 4,973 5,168 Heat Available to User 48,004 46,367 46,172 Bldg. Heating Fuel Required 33,295 41,379 42,919 Amount of Fuel Displaced by District Heating System 31,066 33,829 34,111 Percent of Available Heat Used 64.7% 73.0% 73.9% During the winter months the nine buildings connected would use all of the heat available, as can be seen in Figure IX-1 on the next page. Heat lost from an additional distribution pipe would reduce the total available useful heat. This would make any additional building connections a net loss to the system in the winter, if included, as the distribution line would remain heated but would provide no heat to the building during the winter. ing t i n al H e : t ic} et a i t hu k ite ap ni N u It U. c o n s la r é p o ! $ il) Oil f ol Gal w t( s a ¢ se x yy S I i ON BG Y Y , es Vo s i j Le 47 , GG o e Hae I \ ti t e Z e LLL; 5 Ja n Cc De Nov t O c t P S e g U; A Jul Ju n ay M p r A a r M b F e l Ja n dg B e n 1G 0) ho . at Se H e l e m b l e i l a ! o a t h “ M _ sh e h o o ! W a Se igh a y Hy H a l & 0) ic h o = Sc cl tem ee d ire: ir qui Re at Hea I iS ae il al Ay t al He 1 igure Fi 60 0 0 50 0 0 S R <> O S85 eon ae oe f q SS _ | g _ _ n _ Ja _ _ C SS S 5 Co N cy ee S r, ae cl e1 ae fe) ‘at Se Se Ww. ss HS, SN S58 aN \\ Re » > xx em, 2 ox oS ug 1 A <A oe 4B \ ' La e¥, = YN Li aS ce \ Or f ni x fe) Co Ay un th . on Z, 2 “ = on _ aa 5 a Som c 6 3 — P’ = i A al S ae 55 Or b 2 ar no s 000 a M Scl 2 2 eS 3 ee igh 3 SS eb H a 1000 Bx F & ai a 0 3, t cep n it lan P it ta’ a He: ble ila -_ ic ae la isp H, Di © il H, Oi Gi tat H _ s, co H ns 5 lo: lem al EI G 5, pt 2 nce Ix- Co: igure Fi 6 0 polarconsult Nunapitchuk District Heating B. Project Cost Summary The school paid $1.29 per gallon, and the city paid $1.75 per gallon for heating fuel during 1989. The annual savings is computed using these costs for heating fuel. The three concepts are summarized in the following table. . Table IX-B_ Project Summary Concept 3 4 5 Elem Elem, HS, PO, PS, Elem & HS WTP, CH, HS, WTP CH,&CL CH,CH, & CL Amount of Fuel Saved 31,066 33,829 34,111 Annual Savings $40,075 $47,358 $48,430 Total Project Cost $553,877 $809,311 $872,851 Straight Pay Back (yrs) 13.8 17.1 18.0 C. Project Summary The life of a district heating project is a function of availability of waste heat off the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance. The requirement for electricity and the need for space heat in the community imply an infinite project life. With proper maintenance the life of the district heating system will exceed 25 years. Because annual operational and maintenance costs and economic decisions will be made by AEA, final economic conclusions are not presented in this report. The straight payback time for the best alternative, Concept 3, is 13.8 years. polarconsult Nunapitchuk District Heating X. Recommendations One way to make the project more economically attractive is to reduce its scale by minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Western Alaska communities to reduce Nunapitchuk's share of the high mobilization, shipping, travel, and supervision costs required. 62 polarconsult Nunapitchuk District Heating APPENDIX A Calculations polarconsult alaska, inc. ENGINEERS ¢ SURVEYORS * ENERGY CONSULTANTS Alaska Energy Authority February 5, 1992 P.O. Box 19086 Anchorage, Ak. 99519-0869 Atm.: Brian Gray Rural Systems Engineer Re: Waste Heat Reports for nine Villages. Dear Brian: We are transmitting this letter as requested in response to your technical questions on the nine waste heat recovery reports prepare for AEA. The questions are from the second review of these reports by Steven Stassel of AEA. Copies of the review comments are included with this letter. There were a number of basic assumptions made during the progress of these reports. As the projects are to be constructed in AVEC power plants, the modifications and connections within the plant were to meet with their requirements. We feel that there are a number of ways to decrease the cost of these projects without major impact on the reliability of the power plants by revising the piping connection schematics. Electric demand at the plants varies both hourly and seasonally. As the use of engines is entirely up to the local operator, it is difficult to determine which single engine, or which combination of engines, will be running at any one time. AVEC is also in the process of replacing aging or failed engines, and increasing the size of some plants due to demand as part of their normal maintenance. New engines are mostly Cummins engines that are more efficient. These engines produce less waste heat than the older engines they are replacing. These two factors have a major impact on the amount of waste heat available. Our analysis assumed that the most efficient engine at each plant would run continuously. Station heat requirements were based on having the engine requiring the greatest amount of supplementar\ waste heat to keep the buildings warm, running continuously as shown in the builling summary sheets in Appendix A. 1503 WEST 33RD AVENUE ® SUITE 310 * ANCHORAGE. ALASKA 99503 PHONE (907) 258-2420 ¢ TELEFAX (907) 258-2419 polarconsult alaska, inc. February 5, 1992 istrict Heat Report Engine manufacturer's specification data is listed in Table III-A. Waste heat utilization simulation work sheets used more detailed heat rejection information at various loads, supplied by the engine manufacturer's. Heat loss figures input into the station heat loss section of the waste heat utilization simulation work sheets were for the engine requiring the most waste heat to keep all the AVEC buildings at 65°F. Heat content of 96,000 BTU for a gallon of heating oil was used for this report. This value was arrived at by using a gross heating value of 132,000 BTU for arctic grade diesel times an estimated efficiency of 73% for boilers. Since the report conclusions are entirely in gallons of oil saved, these assumptions are critical. The BTU content of oil varies depending on the source, blending and grades used, so results can vary plus or minus 5% due to variations in heat content. Further, oil fired equipment efficiencies vary greatly which introduces another plus or minus 5% possible variation in the results. All reports assumed that three trips would be made to each village by a skilled crew each year, to perform routine maintenance. Follows are answers to review comments for each report, as well as copies of the review comments. Sincerely Yours Earle V. Ausman wh9; WHOLO9GB.DOC State of Aiaska DN Naiter J Hickel. Governor Alaska Energy Authority A Public Corporation January 24, 1992 Mr. Earl Ausman Polarconsult Alaska, Inc. 1503 West 33rd Avenue Anchorage, Alaska 99503 Subject: Nunapitchuk and Tununak Waste Heat Recovery Pre-Final Reports Dear Mr. Ausman: Per our letter of understanding dated June 12, 1991, please provide responses to the following questions regarding the Nunapitchuk Waste Heat Report. Also, please rovide the assumed GPM and head-loss data for all circulating pumps for both the unapitchuk and Tununak reports. There are no questions or comments on the Tununak report. I look forward to receiving this information, and the corresponding information outlined in our letter of understanding for the other four reports, at your earliest convenience so that we may finalize the reports and process any outstanding invoices. Nunapitchuk Waste Heat Section 4.A.4 Include information on connection of the waste heat system to the high school heating system. Figure V-3. A. Please explain intended operation of cooling system connection between Butler Building, SMI module, and Module. Some of the flow arrows appear reversed and the amot valve at the butler building is short circuited. Are the amot valves installed in a "mixing" or "bypass" mode? B. Note three, indicates a "skid mounted" radiator. Is this correct? Figure V-2,4,5,6 | V-2 shows 2.5" pipe to the elementary school, high school, and generator building. This does not agree with figure's V-4, 5 & 6 supply side piping. Please explain. Section VI, B.2.a (page 41) Please correlate Arctic pipe diameters with piping runs to high school, elementary school and generator building. Sincerely, Steve Stassel = Remote Systems Engineer II SS:jd O PO, Box 110809 Juneau, Alaska 99811-0809 (907) 465-3575 XW PO. Box 190869 701 East Tudor Road Anchorage, Alaska 99519-0869 (907) 561-7877 92Q1\ID2351(1) polarconsult alaska, inc. February 5, 1992 District Heat Report Nunapitchuk Waste Heat Recovery 1. _ The district heating pipe will be buried and will come up through the floor in the mechanical room of the High School Building. User equipment will be located next to the furnaces in the mechanical room and will connect to a heating coil installed in the return air duct of the two furnaces. (See Figure IV-4.) 2.A. Cooling system is designed so that all the engines run through the primary heat exchanger, then to any of the three remote radiators for additional cooling if required. The amot valves are installed in a "mixing" mode. If return water from the heat exchanger is still too hot, the amot will open and allow coolant to flow to the radiators. A small hole would be required to be drilled in the amot valve to allow for a small amount of water to circulate through the radiators to alleviate cold shocking. Supply and return piping between the SMI module and the WH module, and the Butler Building cross over. Direction arrows are correct. 2.B. One engine has an existing skid mounted radiator which would be removed, and the engine connected to the common cooling system as shown in Figure V-3. 3. The distribution piping in Figure V-1 and V-2 is 2-1/2" diameter as shown. The supply piping in Figure V-4 and V-5 is 1-1/2" as shown. The piping necks down from 2 1/2" down to 1 1/2" at the building. The supply piping in Figure V-6 should be 2-1/2", not 3" as shown. Larger diameter distribution piping is used to keep the pipe head losses down, which in turn keeps the pump sizes and annual operation cost down. 4. | Transmission pipe ranges from 2 1/2" diameter to 1 1/2" diameter, not 4" to 1" as indicated on page 41. polarconsult Nunapitchuk District Heating Power Plant Heat The amount of heat required to keep the power plant building at 65°F was calculated. The number of air changes in the building was assumed to be equal to the amount of combustion air required by the engines plus 2. This added up to 24 air changes per hour in the Nunapitchuk power plant. The conduction heat loss was then added to the infiltration heat loss and the amount of heat rejected to the ambient air off the engine subtracted to come up with the hourly heat requirements for the building. d mn 1 Oi The annual fuel oil usage, as obtained from the users, was distributed over 12 months using the number of heating degree days (HDD) as follows: School (Monthly HDD) x (Annual Fuel Consumption) Monthly fuelfoil usage = ( Annual HDD ) Water Treatment Building (Monthly HDD) x (Annual Fuel Cons. - 12 x 231) Monthly fuel oil usage = 231 + -------------------------------- ( Annual HDD ) Available Waste Heat & User Heat Displaced The amount of waste heat available at the power plant and the amount of heat required by the user were calculated using a computer model with the following input and assumptions: 1. Historical monthly power generation data for the power plant, annual users’ heating oil consumption, and monthly heating degree days were input. 2. The amount of heat available off the engines versus power production, from the engine manufacturer's data, was input. 3. The heat losses for the proposed piping system, plant heat, etc. were input. 4. The hourly diurnal power generation variation per month and the hourly diurnal heating requirements were input to distribute the power and heat data over a one- year period in the model. 5. The amount of heat usable by the proposed users is summed up for each month to determine the equivalent number of gallons of oil which will be displaced by the district heating system each year. Appendix A Page ib polarconsult Nunapitchuk District Heating Program Notes: a. The amount of heat available off the engines listed in Table III-A is from the engine manufacturer's engine specs. The amount of heat available off the engines used in Appendix A comes from the engine manufacturer's tabulated data which they indicated was good to *+/_ 5%. We used 95% of these tabulated values for use in Appendix A as the heat available off the engines. Appendix A Page 2 100% 07/03/90 11:14 AM Nunapitchuk Heat To Heat To kw Coolant Ambient Output & Public Safty Az Cat 3412, 1200 RPM a) Flow Rate GENERATOR DA’ Concep' Nunapitchuk Jul-90 WASTE HEAT UTILIZATION SIMULATION WORK SHEET Location: Date KWH KWH KWH 7 (KWH KWH 7 (KWH BTU/HR) / (KWH a 4 4 BTU/HR) / BTU/HR) BTU/HR) BTU/HR: BIU/UR / KWH BTU/HR) / BTU/HR) BTU/HR) / (KWH BTU/HR) / (KWH 1,405 405 { 6 3 $ 3 Ky 3 3 3. 3 1 ONDOOO000 TODNOGGOOOOO FP DOAANAAA NANA 3,777 Q WNAT.COOOOOO PTANOMMAMAM ANAMMMMMM @ 1 D>>>>>DD 1 20000000 ' 2.0.9.0.9.9.0.0 ! TIITIIOG 1 UVVUUVUUT 1 HVIITING 1 00000000 1 Atte tettt 1 reiriryy ' Z3 5353333 ! eee MRS ' vopovoeD ! BVVDITHG 1 ©XVOOOOO 1 PevovvED ! BVVITIDG ! PERCE CERES EY] 1 wovuvvED 1 QVISIIDG ' GVOVOOOD ' Terese ea 1 1 1 1 ag Es fag eed SK ace ae SSSS SSS S355 3535 bobo DoD aamm mmm Cm0M Onn 2 HO oo 5 aa a ec “ ae we 8 Ov oeo wade OM paed acu Ecvv aro doom ADA Bove oa 9.2.0 ow On "0 oO HO 20D BEd agug ate OWE QD YHaD B52 4208 Ouse ona a @ a a 9 a u s > June 600 9 418 89 May Apri. 1,236 1,635 March Feb 1,675 Jan 67,000 140,000 150,900 131,600 124,400 1,840 Kwh/Mt! HDD/Mth: GENERATION DATA: WEATHER DATA: Pipe Loss AL/YR) a BUILDING DATA: Fuel use, Elem Schoo High Schoo Hall x Hall Washeteria Public Saf Elem Gen B Comm. Clinic cit: AHOOOC00O Power Plant Production & Hourly Variat OSCC00CO IOOCCCCCO ie Summer Building in use; l=yes, O=no Winter Assumed Diurnal Heat Demand Variation: 1 | OWTTMTONAE ONE DDAOMMDHNO ONNNMNNMTTI TTT TT TTT TONS OOOCCOGGGOGGGGGGCGG00000 ODCCCOCSGDDD00000000000 OTTO TONNE ONE DMHOMODANO OMNNNNMTT TT TTT TTT TON TTS OCGOGOCGGGGG000000000 COCCSCOSDDDODODGO000000000 WOTTON ATONNAAHAATOATOOON MMMNMNMONMTT OT TOT TTT TSS 90000 200000 ADOT IRNATONNAIAATOATOOON MMMM STOP ROTI TTT STITT ST O00000CGG00000000000000 [oYolelelolalololololololololololololololololo} DNFIA A ATOANAAAATOATOOON MOMMNMNOMTIN TTT TTI IS OSDOCOGCOGGGGG00000000 DOPCCCCCCCCCCOCCCeCCCCCO NTT ATONNAIAATOATOOON Al seommonnnssorTOsTsesTes TS SS80000000000000000000000 Dl Oe Ss vinie ee 6 see leis 61s see lore @ | POpCCOCCDDDCCCG0C000000000, DOS TROATOANAIANTONTOOON OMNNNNMNTIOT TOTS TTT OOSCODGSGOGGGGGGGGGG000 WTTMTOANE OPN DDAOMBOAND MOMMMMOG TSI SFT T IS TOOTS OOCCCBOOGGGGG0000000000 DOTIN TONNE OF NE DOROMaHANO ONNNNMNMNTI TTT TTS TONS S S8000CCGG000000000000000 cococceeccCccCCCCCCCCCCCO FIMTONAEONNRODAOMBOANO 21D 2 QanannnvesrseesTeSINN STS oo DOOO00G000 OOCC000G DOTTMTONNE OM NR MOHOMODANO OMNNNMNNNT TTI TTT TTT TONS STS DCCCDGDGCC00C000000000 AAMNTNOROVNOAAMTNORAROGAMS FAA AANA DOWMWDOAD dT TTNTMMMMMMANOD ONnNNOvsTe TESS SSS eo0000000000000000000000, IOOPCCCCCCCO DODODOAD AMT TTNTMMMMMMANOD ONNNMNOVE TTT SoecocoDCCCCCCCCCCGGCCCCG ecoocecocoCeCOoCCCCCCCCCOCCO June July Aug Sept Oct Nov Dec Annual 1 lay April March Feb Jan Power year factor Year no. Seasonal cons., gls Non-seas. cons., Compound boiler eff 365 13,158 31. 825 , 30 1,415 1 600 155,100 178,100 1,638,800 31 085 31 30 372 591 000 131,600 153 123, a2 a) 31 90 93, ono AAO 4 89,6 30 236 28 31 675 1,635 1, 1, 31 840 a 167,000 140,000 150,900 131,600 124,400 Gallons er month Gallons of Oil used ' a 1ooooccoccO sine sice ¢! a ' ! t t vinrmoooo°ceo @100 Alaa ! ! ' Pp IMMOCOCOCCOCO Q1ao Zl t ! ! y| pgoooecce gies Oo! ! t ! | vy 1LMMOCCCCCO alae ol ao! t ! DINNOOCOCCOO ZINN a ! ! ' m1 @DOOOOC0O aldacd a! el ! t ¢|ggooccose Bisa at ie | phesaaabone: pies «4 | procoocce rub a el ! | 1 WWOOCCCSCO 2.0 1 ao wt £ t ' t H glesenccccs OIanan we ! ! ! { & 1 @DWOOOCCOCO g100 5 | ad t ! ! ! ! 1 ! aD to vo 1004-44 1OwUMo04 @ Iag COda4 DIHN CooL a4 ci eooraod mI1OoOnHM THY UOlow sO alee § &¢ c 2) sak these QIAN rOUZO 196 193; 145 88 49 37 43 69 127 166 214 1,540 PAGE 1 OF 3 Total Use ~~~—<215.~=~W‘SSSS~dSSSCaMSSS*~<SC“‘“ ASSOS*#*T”SO™#~#~*~#C3~~SS~C~d27?~*~«aCSS*~*~ASSC«'Y SO Total Use Nunapitchuk a oS n o a a a 3 a WASTE HEAT UTILIZA‘ DOMME OOMOMAMOOTOIrrON OMMAM AMM ANVADANN ST MNDAND: DMNMNNMN OOF RE OF RRR OoNnNnow DOOWODOOMOMNMOWONHDONN DDDOOMAAD TMF ATMO VAMMOAO DITTTOMINOOOOOOW WOON WOW SN TFON AD TOO FOOTANHAC NOON AADAVAAD YAM OMMAADM AMMO NTT TTONNNOCODDO UNINC DAADANKOMMNATARDOMADAAAM AL TT TONN OCOD ADONNONE EEO TON TTT TNNONINNNNMN STs WODAMNMOMOOHOATAAMOAMDODO MARS AAMAAMANANNNAKNAT SSR TOMM TTT TON THN TOMS ITS WATNMEKAVWAANKANOONOAAAM QNDE CONDON THT TOOTOT TSO TIMMM STITT TON THM TNT TIS AMA AOONATNNDOM@NTONR END DANAGOOTIADONAMOMMDOMONMMN TINONNN STN TNNNNN TMT TTS AMON ONHMrarARAAdTOOONNG MOOMOMCOOMOTOR RAN ANNATO TITS CONNNNNNNNNNN TSS April 456 OM ANDOMOMOMOOATMNNOON FMMMNOBGONOGOMNANAOOTOM TIT THN OOCOGOOOOINNNNOIN March $05 ONNONOTTOVONOAUAININDODONO DOOTP OAR AMAA AMMTOOAAONS TITTTMONNOCOONOOOOBINININNIIN Feb 518 DAADATAANNNOANDAOUAINMODATAD DAAADANAADOGDOMODHAN ANN OMO MN TTTTONNCOOOOOOOOONNOOIN Jan ANMTNORMAOIAMSNORAHOdAMS Ft AANA Heat avaiTebre per hour by month (1,000 BTU’s) jour 5,172 4,549 4,560 4,075 3,957 3,614 3,794 7982 3 7974 3 7435 ao738e 365,500 366,298 332,392 348,957 3 4,085 (1,000 BTU’s) Feb 4,858 446810 375737 Heat demand by hour by month Gallons BTU’s "446810 375737 407966 365,500 366,298 332,392 348,957 3 Month Annual Wee TTNOr OMMBMORK Keer wONN NANNNNNANNNNN ANNAN Dec QDADAAOGAANANAAMANNNNAANHOO NAA AANA NAAN NNN Nov TIT TONLE Er LOwWoVwwwwoonn ttt ttt etettetetetet Oct DODODDDAAAAADAADAAAAADAAAAD Sept MMMNNNNNOCOCOCOW\WWWWWWWWINNI Aug Severs ecNNNMMNMNNNNNHMNNNS aan SE Ga |S EE 0 aR = a July WOCCOCOOOLE EEF OOWOWOWWOWWO June COCONINO AAA de edt 10 10 May Re Krraananconannnannnmor ttt NN titted April AAA ANOMNMNNNN THM ss TON NANNAANANNNNANN ANNAN March MMM TNNCHMDDOOAODOM-MMOoOrrwown ANANNNN ANNAN ANNAN MN TTTNCDDDDHOOMOrwMarnnrown NANNANNNNNNNNNNNNNNNNNNNN Jan ANM TNO DVOHAMTNOROHOGAMS FA tA ANNI Hour 141,653 1,540 SITTIN DDDMMOMK errr enn NANANAN ANNAN ANNAN 214 PAGE 2 OF 3 19,647 19, ADNAN ANAANNAMANNAANA HOO AA AANA ANNAN 166 15,233 15,233 ITT OOM MH OOVWWVOWOBOININ SA tdtdtdettdtedetetet 11,681 11,681 127 9 DODOON ANANDA AAAAAAAAAAA AN 6,362 6,362 6 DIMM NOOOWOBOOWWOWWWONINININ 43 3,994 3,994 7 Sos TININNNNININNNNNMNM 3,391 3,391 E} 9 CCOOCOOOOONN AAA OOOOVVwUwUwww 4,500 June 4,500 4 COCCOOd AANA didddddtdOO gtd ddd 8,096 May 8,096 5 88 QO Btu/Hr Q Btu/Hr 3 Btu/Hr 2 Kw 8 Kw aeeerraananconanaaanawar tt ttt dt ANd April 14 2872 2872 4390 28 18 13,306 T 13,306 AANA MNNMNNNIN SHH s ON NAANANNANNNNNNNNNANNANNNNNNN month (1,000 BTU’s) 191 17,602 March 17,602 Y 6 MNNTNNCOBDDDADDOr-HMMOrrw;n AANANANNANNNNNANNANNNNNN 18,032 ur by Feb 18,032 19 y Heat Displaced Heat Available Heat Demand Peak KW y ho} Gy MMT TNOMMDDOMOROrwMarrnrwon ANAANNNANNNN NAAN 1 y Y iy 2 Average Hourly Peak KW 19,809 Jan 19,809 Maximum Hourl ANMTNON DVCAM TNOLOROIAMS AAA AA AAA AANA Hour 1 1 1 ' 1 ' 1 ' 1 ' ' ' 1 1 1 1 ' ! ' ' ! 1 ! 1 1 ' 1 ! 1 1 1 1 1 1 1 1 1 1 1 1 1 ! 1 1 1 1 i 1 1 1 1 ! ! ! ' ! 1 1 ' ' ! 1 1 1 1 | ' 1 ' 1 ' 1 ! 1 1 1 1 1 1 1 1 1 1 1 1 ' ! i ' ' 1 1 1 1 ! 1 ' Heat delivered b: BTU’s Maximum Hour] Maximum Hourl Maximum Hourl P.O. & Public SaftGallons Total Demand Heat Delivered 1 Concept: ZATION SIMULATION WORK SHEET —- Concep’ 1 P.O. & Public Safty Nunapitchuk Main HE ** User HE ** 07/03/90 * Hot * * Cold * Hot * * Cold * Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 118.00 3.59 Gpm (Max Heat Demand) /8,000 Calc. 3.25 3.26 2.83 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/ft*3 Spec Heat 0.863 0.859 0.854 1.004 Btu/lb F Ther Cond 0.233 0.234 0.234 0.383 Btu/Hr Ft F Viscosity 0.759 0.819 0.900 0.425 cP Pipe Ground Temp. In 156 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 3.59 m. Length 90 ee to: Public Safety Size 0.8 in 0.0625 feet Heat Loss 11.38 Btu/Hr/Ft Heat Loss 1,024 Btu/Hr 1,024 Used above Velocity 2.01 Ft/Sec Friction Factor 0.0728 From Calc. Below Pipe Head Loss 6.51 Ft Darcy-Weisbach Pipe Head Loss 2.82 psi Cale. PAGE 3 OF 3 AM 07/03/90 100% 11312 Nunapitchuk Heat To Heat To kw Coolant Ambient Output 1200 RPM 118 gpm 2 Elem School GENERATOR DATA: Cat 3412, Flow Rate Concept =90 Nunapitchuk Jul Location: SYSTEM LOSS DAT, WASTE HEAT UTILIZATION SIMULATION WORK SHEET Date: KWH KWH KWH KWH KWH KWH 7 (KWH KWH KWH KWH 7 (KWH BTU/HR) / BTU/HR) / / if 4 4 BTU/HR) / BTU/HR 1,405 1,405 866 3. 9 9 9 9 9 9 9 {~ONDODD000 ~DOAANANAY TANNA 3,777 7 0 9 6 6 6 6 6 6 6 0 WMATGOOOCDO RFANOMAAMANM dNAMMMMom © IDDD>DDD>>DD>DD 100000000000 109000000009 [oCorTTIOTTG I VVUUVVUVDUUT 1DDDTTITTITG 100000000000 DV tetetttetetetetet iia seers o | 33333333335 | RRRRERER RES lyppupvupvun | SoqcTCGTIIG 100000000000 lpppopvonnnyn 1GGGHTTHTTGTG [BM Ba hee Be lyopovvvovnn 19GOTTGTGGTG 190000000000 [EERE EEeaee 1 ! ' (a gag ! eed Tou 1 secs sce rSSs ys SSS ' aoaas | Aris 1 DoDD DDD | anam mam 1 orer Onn 1 6 © Han a 5 loan a lodaea ' ! ce - to odde #8 o 1 Boy oeo lo owdge ow 1 waAod eu 1 6 ‘cy rio 1 aOOB avd 1 Bone aa 52.0 Os On "O oc0 HO #0 Db Qy5E4 agua 1Ocadg Owed 1ogQoH anad lasseo 2349 1Oaagie ona, 1a a Ie @ 1c a 19 a to ‘@ 1a a Ic u 10 s 10 > Annual 13,158 Dec 825 i, Nov 415 1, Oct oss 1, Sept 591 Aug 371 315 July 93,900 123,000 131,600 153,600 155,100 178,100 1,638,800 7600 418 June 752 May April 1,236 1,635 March 000 150,900 131,600 124,400 89 Feb 1,675 Jan Kwh/Mth:167,000 140 HDD/Mth: 1,840 GENERATION DATA: WEATHER DATA s! onal mo an! oo AON! v4 aA! - <i a Ol = POY LDWODMMNOONO Dah immransrnsn gge [Rann EAD LAHADAAMMONM Bladesances ai a @ +1 MNMNOCOCCOMNO ggg imrocecene Mea erececeesetcaet BA==}e2 ' @ *-~ 1000000000 BI an aloo ais al t t SA manananc Bull cecerercs Bg IRRRRRRRRR dull Gdccdddde Owl aul _* foonnococe Hol a! 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Seasonal cons., Non-seas. eoanccc0o Da an na Annual cone00000 os ND aa Dec cor400000 mm as Nov a courccoco] ma ro Oct commccc0O an mn Sept comnmccoco No dea Aug [oYolololololololo) July eocecc0c0o June oTOOOCCO mo am May e0mMa00000 on on a convooo0o on ao ad ooawroo000 NO oO Feb ConnCCCCO zo No aa Jan yy ig ! ! ! 1 1 1 1 ! 1 1 1 1 1 1 1 1 1 1 ! 1 ! 1 ' 1 ! 1 ' 1 ' ! ! 1 1 1 1 ! 1 1 1 1 ! 1 1 1 1 1 1 1 1 1 1 1 ! 1 1 1 ' 1 1 1 ! 1 1 1 ! 1 ! 1 ! 1 ' ! 1 1 ' ! ! ! ' 1 ! { 1 1 1 1 1 1 1 1 ! ! ! ! 1 ' 1 1 ' ' ' I! 1 1 1 1 1 1 ' ' 1 1 1 ! ' Hall Hall teria Ke Post Office Clinic Public Safet Elem Gen Bld Elem School High School Comm. cit Was 313 996 1,829 2,385 3,076 19,998 PAGE 1 OF 3 0 Total Use —~—~«3,102~«2,824+~«2,756+~«2,084 «+634 ~«=«=«0~S*SC*«S*~<CS~«SSS*«CG:SCdOZD—2, 38H. -3,076 «19,998 Total Use 20,000 3,077 PAGE 2 OF 3 2,386 1 t t ! ! at 1 al 1a ' al wo ol iN ' 3) oO a! wo ! g! es ¢! tos = cl 12 gs! 1a a <t wn al 1m 1m ! ! 1@ 1@ t ! ts Ps t { ta 1d ! 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Y a, 102 Average Hourly Peak KW 3 Maximum Hour] Maximum Hourl Gallons Elem School WASTE WORK SHE! napitchuk Main HE User 07/03/90 * Hot * * Cold * * Hot.® * 1d Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 118.00 $1.71 Gpm (Max Heat Demand) /8,000 Calc. 46.79 46.89 40.75 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/ft*3 Spec Heat -863 0.859 0.854 1.004 Btu/lb F Ther Cond 0.233 +234 0.234 0.383 Btu/Hr Ft F Viscosity 2759 0.819 0.900 0.425 CP Pipe Ground Temp. In 180 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow $1.71 Length 340 ee" to: Elem School Size 2.0 in 0.16667 feet Heat Loss 18.33 Btu/Hr/Ft Heat Loss 6,234 Btu/Hr 6,234 Used above Velocity 4.59 Ft/Sec Friction Factor 0.0402 From Calc. Below Pipe Head Loss 26.59 Ft Darcy-Weisbach Pipe Head Loss 11.52 psi Cale. 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In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 118.00 83.96 Gpm (Max Heat Demand) /8,000 Calc. 75.97 76.14 67.85 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/ft*3 Spec Heat 0.863 0.859 0.854 1.004 Btu/lb F Ther Cond 0.233 0.234 0.234 0.383 Btu/Hr Ft F Viscosity 0.759 0.819 0.900 0.425 cP Pipe Ground Temp. In 190 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 83.96 gpm Length 850 Fe to: Elem School Size 3.0 in 0.25 feet Heat Loss 19.42 Btu/Hr/Ft Heat Loss 16,504 Btu/Hr 17,039 Used above Velocity 3.25 Ft/Sec Friction Factor 0.0392 From Calc. Below Pipe Head Loss 21.72 Ft Darcy-Weisbach Pipe Head Loss 9.41 psi Cale. PAGE 3 OF 3 03 AM 07/03/90 11 Nunapitchuk Heat To Heat To cL CH, 1200 RPM CH, WIP, HS, 4 Elem, Location: Nuna GENERATOR DATA: Cat 3412, Concept: itchuk P50 WASTE HEAT UTILIZATION SIMULATION WORK SHEET Jul Date: Output wer ! ! 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OF | POCO CE EPP EROOrr esr ninnt {2 o TITTTNNNOCOONOWOWOWOOUNNNNN : it eu sv ow OT is o an a 1 eo > a] 2 "a a Al q a HLANMITNOFDANOANMNTNOFDAOINMS | o IN CYP O™ OHNOANM PMWM DANIAN a ‘ 83 AANA ANNNNN Ss pol AAAS AANA | UO AAAI AANA o aol o Dl am a = 1s wo og 4 Ot tc og Bi a go ct ia Po ano Oo @ 1 le a 3 5 | ig 3 0 oD it t a as 1 ti v 2 vot 1a vw j § 2 | is 3 = = = a = 33,829 4,774 PAGE 2 OF 3 400 358 902 2,129 3,702 4,164 1,590 83 Btu/Hr 14 Btu/Hr 83 Btu/Hr 3,588 4,037 3,725 Maximum Hourly Heat Displaced Heat Available Heat Demand Peak KW ry Y yy 4,460 Average Hourly Peak KW Maximum Hour]: Maximum Hourl Maximum Hour] CH, Gallons WIP, Concept 4 Elem, HS, ATION SIMULATION WORK SHEET - Concept: _ 4 Elem, HS, WIP, CH, CH, CL Nunapitchuk Main HE ** ** User HE ** 07/03/90 * Hot * * Cold * * Hot * * Cold * Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 118.00 86.84 Gpm (Max Heat Demand) /8,000 Calc. 78.57 78.74 80.94 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/ft*3 Spec Heat 0.863 0.859 0.854 1.004 Btu/lb F Ther Cond 0.233 0.234 0.234 0.383 Btu/Hr Ft F Viscosity 0.759 0.819 0.900 0.425 cP Pipe Ground Temp. In 150 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 86.84 ope Length 250 to: Elem School Size 4.0 in 0.33333 feet Heat Loss 23.05 Btu/Hr/Ft Heat Loss 5,763 Btu/Hr 25,634 Used above Velocity 2.00 Ft/Sec Friction Factor 0.0413 From Calc. Below Pipe Head Loss 1.90 Ft Darcy-Weisbach Pipe Head Loss 0.83 psi Cale. PAGE 3 OF 3 i 0 07/03/90 11 Nunapitchuk cL WIP, CH, CH, 1200 RPM HS, Elem, 5 PO, PS, GENERATOR DATA: Cat 3412, Concept Nunapitchuk Jul-90 WASTE HEAT UTILIZATION SIMULATION WORK SHEET Location Date 100% KWH KWH { ( ¢ ¢ ( ( az / (BTU/HR) / WAST (ic } (BTU/HR) / (KWH (BTU/HR} (BTU/HR (BTU/HR 405 6 3 9 9 9 9 9 9 9 0.000 60 co 4.40. 00.00 1,405 a ONDCOO000 QHOGGGOGO DOANAANDAG ANNAN 777 777 3 kw Coolant Ambient OMaAsTo©O00000 RTANOMMANAM ANAMMMMMM, Output Heat To Heat To $ 8 @ O' 9 ° 118 gpm oo BS 88 ao” UU O90 Ke} TT z BE py oO” oo po oo MM py O90 oo = Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above: Heat rate at kw-load above Heat rate at kw-load above Flow Rate Heat rate at ki 1 1 1 1 1 1 ! ! 1 1 ' ! ! ' ' 1 ' 1 1 ' 1 ' 1 ' I 1 ' 1 ' QO Btu/hr. 315 Btu/hr. OQ Btu/hr. 50 Btu/hr.xF 791 Btu/hr.xF 75 Btu/hr.xF 53,315 Btu/hr. 1, ipin 53, eatin Pp. iping ng eet Radiator losses: onstant Pp iping ace preh z alc Subsur gine Surface Plant he En To’ Plant Variable losses SYSTEM LOSS DATA Constant losses Annual 13,158 Sept Oct Nov Dec 371 $91 1,085 1,415 1,825 Aug 315 93,900 123,000 131,600 153,600 155,100 178,100 1,638,800 July 418 1)236 1,635 1,675 ’ 1,840 st Kwh/Mth HDD/Mth: GENERATION DATA WEATHER DATA s! 00 larnMars0OM BUH | A-OOR AGA AON aA AONMOW aad as 1 daa oI aI VAY |MaMNnAOONO BD Ute IMMMOTMMTM DON} etre erees EAS lddomammom Bl dtd a) = ® +S 1MNDCOCONO QGazinnerereee AA 8 Oded aaA~ 100 | ' ® +~10000009000 BYE LTO ADA abe | MO Net and 1 a! ' \ oe Lo mmmmmmam DORR eee etrifiesosecsee 4 1 OOCCOCCOO owt coud | ! OP ttettetteietet S Hol a SI ! ! at 1a | COODCCOrO ect c oot 6 Zal 5 at “ ® at at § | COOQMOOrO gISROOnr area gi nrconrere ag of wonm A & ot diet aout a Loumood ~ bag 0 Oda VO Wneccadh Zoi Coomag Asc1000nn xbo a3t od 2 Od dal ecg gee res Hod! aad doevud DSO! OS Ont 4 AG OI Gado rOUSO O=no l=yes, Building in use; DOTIMTOAVAE OPN MDOHOMOOHIND AMMO GS PPG SSI SPT OO TTT O0G000000000000000000000, [lololololololololololololololelolololelololole} DOP IM TPFOAUAE OME DOHOMOOANO OMMNOMOMNT TTT TTT TTT TOOTS Q90000000000000000000000, COGCCD000000000000000000 [olelolololololololololololololelolololololololey DVI SP FS DSP OADM AAVNH TFONTFOOON AAMT POP GO GSE IPITTTT TS 1 OSO000000000000000, OOOOC0000000000000 DOF SHS ANPON AINA TONTOOON OOM OOOO SO PTL PS SS OO000000000000000000000 OOCCCGOOSOG000000000000 POM PIO OATONNAGAATONTOOON TPOMNMMMNMNTIN TINS TTS T TTS S S90000000000000000000000 OOCOCSOOSSGCG0000000000 DOGS ANPONS AAAATONTOOON OOOO OOF SOF MO GS It 20000 90000 DPI ATONRAIAATONTOOON OMMMNNNMTIMOT TOG TIT TT ITS S9000000000000000000000 eoCCCCCCCCCCC0000000000 OTTOTOANAIE ORIN DDAOM@DAHIND OMMMNM OG IA IGT T TTT TON est O8000000000000000000000 OCCCCCGCD00000000000000 OPPO POV OMI DDAOMMDHNO OOM OO GSA PGMS TIT st O900000000000000000 POOOO0COGC000000000 OPO SPO NI OLN OD HNOM DO AND MMOMMMOG ST PT TT TITS TS OBOOCGGGG00000000000000 OOCSCGGG00000000000000 WOT TOU OM IN ODAOMMOHNO OOM GIFT IGT TOOTS S00000000000000000000000 OCCSSSGSGSG000000000000 Power Plant Production & Hourly Variation JNAPFNOODVNOAAM TNO OHNOGAMS Att IAAI DODOOA AM TTT TO TMMMMMMANON OOM GAIA GST GK GGG TTI TTT O99000000000000000000000 DODOOOCCOGGCDG00000000000 DODOAN AM Tr MATMOMMMMMANOD OOM OT SH NT SS TIO O9S90000900000000000000 OOCCCGCDCCCCCCCC000000 Assumed Diurnal Heat Demand Variation doorm oh an <0 on o glee cons.» qls Power year factor Compound boiler eff. Year no. Seasonal cons Non-seas. Annual 365 13,158 ae Dec 1,825 30 Nov 1,415 as Oct 1,085 ’ 93,900 123,000 131,600 153,600 155,100 178,100 1,638,800 Sept 30 $91 Aug 31 371 July 31 315 June 30 418 May 31 752 Gallons 30 1,236 131,600 124,400 89,600 April Post Office Public Safet April er month Ps 31 635 900 March March 1, 28 Feb 1,675 31 1,840 167,000 140,000 150, Jan Gallons of Oil used AMTAIOMNOW DWONMODAMD arn ad CAE OMMOM WOM DAO Om ron ac Oct 63 WNDOAUNGCO ADNOM BS mmo # Sept 35 MINMMAUNOW INNVOONN IN dan Aug 22 MMOCOMHOd ded ANN “ May INMONAMAM >A D~ C.V0 ovum ada 72 WATMOAOA ADOMMACHO AOD ind dad 96 DOATr ONION OV Feb WAHNOMOM OTOBONAN ANDO aad Jan 108 y ig Building Elem Gen Bld Elem School High School Comm. Hall cry, Hall Washeteria Clinic 42,919 6,353 5,804 5,671 4,343 1,678 449 395 945 2,198 3,841 4,939 6,303 PAGE 1 OF 3 Total Use Nunapitchuk CH, CL HS, WIP, CH, Elem, 5 PO, PS, - Concept: WASTE HEAT UTILIZATION SIMULATION WORK SHEET ! t ' at is al o al m al oa at 1o at o gs! fos s! a st 1@ el = al is at ” t ia ! a t ts t = ' Im H a ' SPANO NO TINE VANE MOOWWDes VO IMOTATONOM AA TOTONOOTMNOONM It O LOTANONOTTAL NANO MOOWOONINM 10 AD DO WFD DOr OMWOr— ATO TSO! ® IMAFOANOAANNANMGONAAHODDONM 1O ® I TADDODTOODOrOMOreATOTTIOMN 1O ITD TT TMIMNOOOOOGOOOOOM INNO A a aca Eas CoCo 0 CO CO aa A LMM TTTTONNOOOWOUOOOWOOONNNOW 10 é ' 2 ' in ' 1 I~ ! ‘ Ho ! t t DO DV DV DV LD A 40 ALL OVE OVE > HO P LTADDDDNOOMMADNOAOr OOM ST Im PLE DADA OM GNAMANNAL AK AMO BIVENS LACABAGOImnwoAS BL Ree O PBN MSS S SLSR RG MRAMMON | 3 BRANINwTeAGABASSUNNowMoS Sees SRRASRAASSoniNS san 8 MRR ROSS ESS e CSO OCCEe 1S Fee eS eR RASRKASSEONS TNH t ts ' ' 1 | t m9 ' i i i ' sorroormevounwenc~arcen |e 4 lrenrnv@mr cover ommmamoonne 1 bp [R@@rworrovs@romnanoowr TSS Se eee BESS Te SSeSEr ISS BI SAARASSRaSBSSagaaaaacens 1s BI SBASSSINGSRSSaRaaaaaren SSE SSIERSGoMANOATeTO ING GO| SeeeeswewaAaHeTTTeT TTT TT | 8 | SSSSSTSSIRGRRIessesesss : A | 4 a ' om ' ' wm ' s ' yo ! * WOO 4 ALPE ALI COM COCO 41COr COM: a BETA MM AK NTOOWDATONDNNOMHIOT Is PISO MM AL NTOODATONDNNOMAOT IS ADNAN ANG OGAMOMM OME ANN io A. OCNNMNOKADADADANHAONANDAANADOM-O 1 QL ONOMNOK DANDAHDOANAANDAANADO™O 19 THTOMSTRTARNAT HOTT ITT |Oo GL NAAAUANAAAAA NANA ot G | SARRRANAANAABNATATT NN | ot an 4 al : nm ! in ' x 1 to ! So ' is | is NADGAANEONAIMNIMMEOME- MMM iN DOD ME DNANMMTNNAHONAADOE NO IO DLODM— NE ANANMNMNTNNAHOMAAIOMNO 10 RSLLAALABASSSSBRRBNSOOS ISS J | SVSSSSSANNAIAANAARAAAAGNS |S 31 SSS8SSANNAAAANNA RANA 18 eee eee eee aee La BL SSISSANNNAASANANSN cris 1 BONN IN ASN Sricteicd | we ES} i ' n bel t wo ! - t 1@ ' oa | | 1 JAA DO NAN NMNMNOADMAANNANOOO ‘OV Pl OOM TONODAAGANNTOTNONHONAO IW ONNPNODAGGAANNTHOROTNHONArO 1H BIRRSSSIESLACAALSALARSS Ie FT SSLITSLVHARASASRGRARRSSES 1S Pees ESSAAREASRBHRASSSSSS 1B SasAanssencenssssrenmas iam Bt 1s 8 eae ill fe > 7 ! oO wo I im ao I ! ' ' OMNANNOD GROOMS MAEAAAN IAN 2 | EMMAMMECODOMHOMONOOMA@MNS 1H amanm-ooootOnOnoCON@Rns 19 PISSALNRRLSRASASARAHASSSON INN FL SHRIBRFSSSSSCSASTSSARHAS | A BABRAGESSSSSSSASASSARHAS 1A §[Shasisemsensenseserenans 1sN ST 1s a aS si is 3 a ek 1a : ' Is 3 LOMNMwLrAROIE TOMOLOTADOoK DVO AANA rire OOO: AANA ANNNA NAAN DlOwMNAAMHTONTrArrOoMroMMN DIM OTTAAT MN CBODOMNAMDOO ZS lewoes ese srs sess TT TMM 3,568 ! wo D | 2 & ee ae cigs pense ream memerrmemcs ai legesesgamenmnazcnsesyse (pe diseserercenenaneerneagsnie © 4 | saesoersannannsesscoss “| SR eTeceees En Tener |n «© yl /eamauneeernnemenanecess 7 m 3 2 8 pe Lay <l 1a ~ & -~ i! 1a a E | jf 3 OG PTO AHDOATOOAUNNANNNOMNNT TWO A DS LOOMAMMNAADTAANTOTIAONATEH NNO IT s. I~ ADHDONTPFOONNANANNWNOMNT TNA 107 SV LOANADADANCOM OM TNOOMONNWMAS IN BO LP OTIMTNOAANMNMMTOMANANNNOOrW IH ve NADDNNCOOM OM TNWOOMONNMNATA Iv S] | Pcacimeeees |e RelSEGUScnenerneeNc |e fa |onanermmeannmenemmreaes | cz - ost Iq E in 3 34} la ig 5 5 eR ° Sg | encososene or scemeessor nc ig nmmneowennnngacemmnn nner | ee < MAAN AONNVODOTODDOANMOWO SS 4 =D I PMNANTOAUMMMTFOMANINNNODNOT 1 wy MAAN AONNODOTFODDANMOOOTA | O 2 TT TO STM NIN NIN INL SL wed gah LISESE EIS 0060 20 60 COC OO OD Ore tes | a Esa St STII <ANED 9 HD DLL) MOEA) LEPINE) SY Er DUES mom pil Im x I > et im is a BI as 2 i uy OM NOT TOGO OMIINNDDOME om EI DTOMCANONE EK MANAONWOHNOOD It Or VOT TOGO OAANNDOOME@ Ir 2 I~ FIM TFOTTAMADAMMTONOOWD: TZ ADL MNNONME ANNAN TNASIOMAAIDOWM | vo FIO TFOTTAIMADAMMTONDOMO™ | Oo ic TIT TTNMNNWOWOONOOOOON NINN a ae OSE Cas 0.0 2S Se CO aa ad o SESE XE SW PEEPEEDNG LO Nip SOO ONENO NDIENE PED) sou is o 1@ uw a 1 1@ > 1o & 3 * ts i= NM PNW DHNOINMPNOM-DAOING a HLANMTNOFDHNOANMTNOFDAOAINMS I o NMOTMO-DNOANMTNOFDNOANMS ig Att AANA ie pot AAA AAAIAAANNNNN | ge AAA AAAAINNNN a anol ! a a =I Iv Mw a +4 UO I tc oa a Ss cit 16 Po a oagt 1e az ot 9 —e t to a > o | 1a @ 0 oa I ! a t Ia 2 vil Ia v s o |! Ie a @ @t to o = zt 1 = 34,111 PAGE 2 OF 3 3,572 1,678 449 395 945 2,198 3,794 4,148 4,757 4,021 Maximum Hourly Heat Displaced Maximum Hourl’ 3,710 Heat Available Heat Demand Peak KW Y y, Y 4,443 Average Hourly Peak KW Maximum Hourl' Maximum Hourl' Gallons HS, Elem, 5 Concept PS, PO, Nunapitchuk (Insulation added to Floors) One Std. Butler Bldg.; Insulation added _in Floor. 06/04/91 Fuel Oil: 96,000 BTU/Gal Engine: Caterpillar 3412, 1200 RPM Combustion Air: 1020 CEM ; , Airchanges/Hr: 12.93 with en 1.5 without eng. runni Heat to Ambient: 4,459 Btu/Min Heat to Coolant: 13,281 Btu/Min Engine Rating: 330 Kw Generator Eff.: 93.4% Bldg Conduction Heat Loss: 270.9 BTU/hr/F Infil. Heat Loss: 98.1 BTU/hr/F/AC Heat to Bldg Heat Heat to Additional Bldg H Kwh HDD Coolant Req’d lent w/ eng w/o eng Jan 167,000 1,840 4,497 108 17510 0 192 Feb 140,000 17625 87210 644 1,266 Q 175 Mar 150, 900 1,635 4,064 629 1,364 0 171 Apr 131,600 1,236 3,544 476 1,190 0 129 ay 124, 400 752 37350 289 1,125 0 719 Jun 89,600 418 2,413 161 810 0 44 Jul 93,900 S15 2,929 r20 849 0 33 Aug 123,000 S71 3,312 143 1 12 0 39 Se 131,600 591 3,544 228 1,190 0 62 Oc 153,600 1,085 4,137 418 1,389 Q 113 Nov 155), 100 1,415 4 ad 544 1,402 0 148 Dec 278,200 1,825 4,796 702 1,610 0 191 1,638,800 137,.25)7 44,134 5,063 14,818 0 T7375 Kwh = Historical Records Input HDD = Historical Records Input Airchanges/Hr = (Combustion Air/Building poem + 2210 Heat to Coolant = Heat rejected to coolant b aes (gallons oe Oil) Bead =. = Heat Loss from bldg at 65 oe w/ oo oeas | $3} of Oi Heat to Ambient = Heat rejected” to ambient by engine (Gal o Oot Additional Heat rE vel of Oil) w/ eng = (Bldg Heat w/ eng be to Ambient) = Heat to keep pidg. at _65F with one engine running w/o eng = Heat to keep bldg at 65F with no engines running Module with engine #4; Insulation added in Floor Engine: Caterpillar 3412, 1800 RPM Combustion Air: 1470 CEM . . Airchanges/Hr: 37.00 with eng 1.0 without eng. runni Heat to Ambient: 6,161 Btu/Min Heat to Coolant: 18,483 Btu/Min Engine Rating: 470 Kw Genérator Eff. 93.4% Bldg_Conduction Heat Loss: 134.3 BTU/hr/F Infil. Heat Loss: 47.1 BTU/hr/F/AC Heat to a Heat Heat to Additional Bldg H Kwh HDD Coolant eq’d Ambient w/ eng w/o eng Jan 167,000 1,840 4,395 863 1,465 Q 83 Feb 140,000 1, OS 3,684 7186 1,228 0 76 Mar 150, 900 1,635 37 971 167 1,324 0 714 Apr 131,600 1,236 3,463 580 1, 154 0) 56 ay 124,400 152 3,274 353 1,091 0 34 Jun 89,600 418 2,358 196 7186 0 19 Jul 93,900 31:5 2,471 148 824 0) 14 Aug 123,000 Si. 37.2371 174 1,079 0 17. Se 131,600 591 3,463 278 T7754 0 27 eda ES Ob a eB ov , , , , Dec 178,100 1,825 4,687 856 1,562 0 83 1, 638,800 1357 43,125 6,174 L435 0 597 Nunapitchuk One Std. Butler Bldg.; No Insulation in Floor 06/04/91 Fuel Oil? 96,000 BTU/Gal Engine: cenit wes 3412, 1200 RPM Combustion Air: 1020 CFM ; . Airchanges/Hr: 12.93 with eng. 1.5 without eng. runni Heat to Ambient: 4,459 Btu/Min Heat to Coolant: 13,281 Btu/Min Engine Rating: 330 Kw Genérator Eff. 93.4% Bldg_Conduction Heat Loss: 456.1 BTU/hr/F Infil. Heat Loss: 98.1 BTU/hr/F/AC Heat to Bldg Heat Heat to Additional Bldg H Kwh HDD Coolant Req'd Ambient w/ eng w/o eng Jan 167,000 1,840 4,497 7193 175.0) 0 277 Feb 140,000 17, Oro 3,770 722 1,266 0 2502 Mar 150, 900 1,635 4,064 705 1,364 0 247 Apr 131,600 1,236 3,544 533 1,190 Q 186 ay 124,400 ioZ 37.350 324 a, 25 0 pi} Jun 89,600 418 2,413 180 810 0 63 Jul 93,900 81S 2,029) 136 849 0 48 Aug 123,000 371 37,a02 160 1, a2 0 56 Se 131,600 591 3,544 255 1,190 0 89 Oc 153,600 1,085 4,130 468 1, 389 Q 164 Nov 15571100 17 a5 4,177 610 a, 202 0 213 Dec 178,100 1,825 4,796 787 1,610 0 275 1,638,800 13 pL5w 44,134 57 672 14,818 0 1,984 Kwh = Historical Records Input HDD = Historical Records Input Airchanges/Hr = Bld Heat to Amb Additional Heat recntrgds w/ eng = = Heat to keep w/o eng = Heat to Keep bl Module with engine #4; No Engine: Combustion Air: Airchanges/Hr: Heat to Ambient: Heat to Coolant: Engine Rating: Generator Eff.: Bldg_Conduction Heat Loss Infil. Heat Loss: Kwh HDD Jan 167,000 1,840 Feb 140,000 17675 Mar 150, 900 1,635 Apr 131, 600 1,236 ay 124, 400 qo2 Jun 89,600 418 Jul 93,900 S15 Aug 123,000 1: Se 131,600 391 Oc 153, 600 1,085 Nov 155,100 1,415 Dec 178,100 1,825 1,638,800 137, L5o7 ient = Heat rejected”. to ambient” by Soins (Bldg Heat w/ eng pida (Combustion Air/Building eo ums) 2h Heat to Coolant = Heat rejected to coolant Heat = Heat Loss from bldg Repl ene oa Gili) Weeeos A 33} of Oi (Gal o 627 2 a at 65 de Pe ae peal of Oil) spent to Ambient) at a. 5F_with one engine running g at 65F with no engines running Insulation in Floor Caterpillar 3412, 1800 RPM 1470 CFM ; , 37.00 with eng. 1.0 without eng. runni 6,161 Btu/Min 18,483 Btu/Min 470 Kw 93.4% 358.4 BTU/hr/F 47.1 BTU/hr/F/AC Heat to oa! Heat Heat to Additional Bldg H Coolant eq’d Ambient w/ eng w/o eng 4,395 966 1,465 0 187 3,684 880 1,228 0 170 3,971 859 1,324 Q 166 3,463 649 1,154 0 125 3,274 395 1,091 0 76 2,358 220 7186 0 42 2,471 166 824 0 32 8,237 195 1,079 0 38 3,463 311 1,154 Q 60 4,042 570 1,347 0 110 4,081 743 1,360 Q 143 4,687 958 17062 0 185 437425 6,911 14,375 0 1,334 polarconsult Nunapitchuk District Heating APPENDIX B Field Trip Notes polarconsult Nunapitchuk Field Trip Notes March 20, 1990 Leslie Moore, PCA Met with the Village Council and discussed the community, the project and their concerns. Eli Wassillie Administrator 527-5327 Jimmy Stevens Sr. Water/sewer sup 527-5327 Nicholai Parks AVEC Fred Dewey Council Member 963-3441 Joe O'Neil Principal school Sunny Cook Assist Principal 963-3441 Wayne Thomas Assist Principal 963-3441 Roger Nassuk, Sr. Water Plant Oper. 963-3441 1. Weather: More of an inland weather influence, Bethel weather records are representative of the area. Drifting can be a problem. The highest recorded snow falls are in December and March. Temperatures have been as low as -46.0 OF. The mean minimum temperature is -1.6 OF in February. Population: Population is 372 people. The community is stated to be growing at the trate of 10 people per year. 2. Utilities: Water: Distributed to school. Watering point at washeteria. Source from well. Water sold at 8 cents per gallon to the school. Water storage is a steel insulated 10,000 gallons tank. Sewer: Washeteria and school to bunkers. Elec: Overhead and underground. Cable across river serves West Nunapitchuk, Akula Heights and Kasiluk. Fuel: Fuel delivered by barge up Johnson River. City buildings: Get their fuel from Village Cooperative @ $96/bbl. Washeteria fuel costs $1.29 per gallon. Fuel use and fuel price is provided as follows: Washeteria 5554 gallons @ $1.29/gal City Office 880 gallons @ $1.75/gal Public Safety 770 gallons @ $1.75/gal Community Bldg. 770 gallons @ $1.75/gal Appendix B polarconsult Nunapitchuk Field Trip Notes March 20, 1990 3. Rights-of-Way Power Plant is located on AVEC land. The schools are located on school land. Service to the elementary school appears possible without crossing third party land. Service to the high school appears to cross city land for which a Right-of-way will be needed. 4. Equipment The city has a snow plow and a small Dozer. If excavation is required, equipment will need to be brought in. 5. Soils The soil composed of peat moss over permafrost and all of the buildings are on piling. The materials are likely ice rich fined grained material which is highly frost susceptible. Access between structures is on boardwalks. 6. Labor Local labor can be acquired for $10 per hour plus overhead. 7. Joe O'Neil, Principal. Sonny Cook and Wayne Thomas Assistants. Buildings; Elementary is an old BIA building and the high school is a newer building. The elementary school has 80 students and is heated by two furnaces as described below: Furnace 1 2 Manuf. Lear Siegler* Same Model# CMF 80-PO Same Serial# Same Output 80Mbtu Same Input 64.4 Mbtu Same Fuel use as provided by Nikefa Chris is as follows: Mar 2844 Jul 1540 Nov 2666 Apr 2902 Aug 0 Dec 3851 May 948 Sep 772 Jan 3139 Jun 0 Oct 1540 Feb 4172 Appendix B polarconsult Nunapitchuk Field Trip Notes March 20, 1990 High school has 30 students, and has two furnaces and one oil burning hot water heater. The high school furnace room is crowded. The available space is near the entry door. The forced air and hot water heater information is described as follows: Furnace 1 2 Water Manuf. Jackson/Church,PA Alaska Winter Model# SDF-25-02FH Same PVI 10-N-8S-A-0 Serial# Output 250Mbtu Same Input 313Mbtu Same Blower 3Hp/240v Same CFM 2720 @ 1" Same Stor gal 85 Recov.gal 134 Fuel obtained in the field is as follows: Date Tank Used Aug 29 38,696 Sep 29 37,535 1,161 Oct 31 36,107p 1,428 The fuel use figure provided by the lower Kuskokwim School District for FY 1989 for both schools was 33,298 gallons. The cost was $1.07 per gallon. This years predicted cost is $1.055 per gallon. 8. Washeteria Village council owned Washeteria uses 5,554 gallons of oil per year. Temperature gages for heat exchanger used to heat the water tank showed 60 °F water temperature into the tank and 48 OF water temperature returning from the tank. The operator claims the water temperature in the tank is normally 35 °F. The temperature of the water being distributed to the community was 42 OF, The water plant has two boilers as described below: Boiler 1 2 Manuf. Burnham Same Model# PF-3S Same Serial# 7547984 Output 375Mbtu Same Appendix B polarconsult 9. Public Safety Building The public safety building is only 100 feet from the power plant. The building used 770 gallons of oil last year. The oil cost $1.29 per gallon. The building is heated with a forced air furnace described as follows. 12. Furnace 1 Manuf. Lear Siegler* Model# CMF 80-PO Serial# Output 80Mbtu Input 64.4 Mbtu AVEC Nunapitchuk Field Trip Notes March 20, 1990 Uses about 127,000 gallons of fuel annually. The engines at the power plant are as listed below. Unit No. 3 is connected to the radiator for unit No.1. The external radiator is a Young No. 33D. Table I-A Engine Data Position/Unit 1 Engine Caterpillar Model D3412 Speed (rpm) 1200 Rating, Engine (kw)* 330 Heat Rejection** To Coolant (Btu/min) 13,281 To Stack (Btu/min) 18,420 To Ambient (Btu/min) 4,459 Water Flow (gpm) 118 Intake Air Flow (CFM) 1,020 3 Caterpillar D353 1200 335 17,500 19,930 4,400 145 1,000 Caterpillar D3412 1800 470 18,483 29,572 6,161 180 1,470 * Engine rating at shaft. ** Rating at full load. Appendix B polarconsult Nunapitchuk District Heating APPENDIX C Cost Estimate HMS 9022 CONSTRUCTION COST ESTIMATE WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA COST CONSULTANT ENGINEER HMS Inc. Polarconsult Alaska 4103 Minnesota Drive 1503 West 33rd Street, Suite 310 Anchorage, Alaska 99503 Anchorage, Alaska 99503 (907) 561-1653 February 18, 1991 (907) 562-0420 FAX WASTE HEAT RECOVERY SYSTEM PAGE 1 NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from twelve (12) 8 1/2"x11" sketches and outline specifications linking three facilities in the village, as detailed by Polarconsult. Unit prices and costs indicated in this estimate are based on current knowledge. The possible effects of current hostilities in the Middle East have not been considered in the preparation of this estimate. This estimate is a statement of probable construction cost only, and is priced using A.S. Title 36 prevailing labor rates and current materials, freight and equipment prices, and to reflect a competitive bid in Spring 1992. Removal of hazardous material has not been considered in this cost estimate. CONCEPT #3 - Elementary and High School CONCEPT #4 - Elementary, High School, Water Treatment, Clinic, City Office and Community Hall CONCEPT #5 - Elementary, High School, Water Treatment, Clinic, City Office, Community Hall, Post Office and Public Safety WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY SUMMARY CONSTRUCTION COST ESTIMATE 01 - General Conditions, Overhead and Profit 02 - Sitework 05 - Metals 06 - Wood and Plastics 13 - Special Construction 15 - Mechanical 16 - Electrical SUBTOTAL Estimate contingency for elements of project not determined at this early level of design Escalation at .50% per month to Spring 1992 TOTAL CONSTRUCTION COST: PROJECT COST Design SIA (Supervision, Inspection and Administration) Project Contingency TOTAL PROJECT COST: 10.00% 7.50% 10.00% 20.00% 10.00% CONCEPT #3 151,758 89,495 1,403 1,200 4,450 75,564 10,698 334,568 33,457 27,602 395,627 39,563 79,125 39,563 553,877 CONCEPT #4 199,201 150,617 1,403 1,200 4,450 116,810 15,181 488,862 48,886 40,331 578,079 57,808 115,616 57,808 809,311 CONCEPT #5 224,328 159,991 1,403 1,200 4,450 118,706 17,165 527,243 52,724 43,498 623,465 62,346 124,693 62,346 872,851 PAGE 2 2/18/91 PAGE 3 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY PAGE 4 2/18/91 CONCEPT #3 01 - GENERAL CONDITIONS QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,500.00 8,500 Freight 65,000 LBS 0.50 32,500 Supervision, equipment, utilities, clean site, tools and protection 10 WKS 3,500.00 35,000 Per diem 275 DAYS 110.00 30,250 Travel costs, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 114,650 Bond and insurance 2.25 % 6,693 Profit 10.00 % 30,415 TOTAL ESTIMATED COST: 151,758 WASTE HEAT RECOVERY SYSTEM PAGE © NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 800 LF 12.50 10,000 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 1,340 LF 48.25 64,655 2 1/2" ditto 260 LF 37.50 9,750 2 1/2" bend 16 EA 180.50 2,888 1 1/2" bend 4 EA 135.50 542 2 1/2" tee 8 EA 207.50 1,660 TOTAL ESTIMATED COST: 89,495 WASTE HEAT RECOVERY SYSTEM — NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 0S - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1.15 1,403 TOTAL ESTIMATED COST: 1,403 WASTE HEAT RECOVERY SYSTEM as NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 06 - WOODS AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base a LOT 1,200.00 1,200 TOTAL ESTIMATED COST: 1,200 PAGE 8 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 13 - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8’0"x8’0" building module with floor, exterior wall structure and roofing complete aL EA 2,800.00 2,800 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 1 EA 710.00 710 Louver - EA 500.00 500 TOTAL ESTIMATED COST: 4,450 PAGE 9 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 72.50 145 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 80 LF 26.22 2,098 Fittings 16 EA 46.35 742 Butterfly valves 9 EA 325.00 2,925 Insulation to pipe, 3" diameter 80 LF 7.10 568 Booster pump d. EA 1,450.00 1,450 Heat exchanger, 800,000 BTUH 1 EA 9,650.00 9,650 Unit heater, 60 MBH including thermostat 1 EA 330.00 330 1" diameter piping including fittings 40 LF 9.70 388 Gate valves | 2 EA 77.00 154 Insulation 40 LF 4.30 172 WASTE HEAT RECOVERY SYSTEM aaa NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up Form hole through existing wall for heating pipes 6 EA 195.00 2,470 3" diameter black steel piping including fittings 60 LF 25.62 L537, 1 1/2" (aitto 40 LF 14.75 590 1 1/2" copper piping including fittings 60 LF 14.95 897 Gate valves 36 EA 260.00 9,360 Check valves 6 EA 260.00 1,560 Strainer 6 EA 58.00 348 Balancing valve 9 EA 53.00 477 Temperature control valve 3 EA 225.00 675 Insulation 160 LF 5.83 933 Heat exchanger, 300,000 BTUH a EA 3,750.00 3,750 Expansion tank, 100 gallon capacity a EA 2,117.00 2117 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY PAGE 11 2/18/91 CONCEPT #3 15 - MECHANICAL Hook-up (Continued) Air separator Pumps, circulation Grundfoss 200, 2" diameter Connection to existing piping system Make-up glycol system connection, including tank Glycol Test and balance system Controls and Instrumentation Generator building and new module Hook-up inter ties TOTAL ESTIMATED COST: QUANTITY UNIT UNIT RATE ESTIMATED COST 3 EA 495.00 1,485 10 EA 680.00 6,800 6 EA 72.50 435 2 EA 610.00 1,220 960 GAL 8.80 8,448 110 HRS 75.00 8,250 1 LOT 2,000.00 2,000 3 LOTS 1,500.00 4,500 75,564 WASTE HEAT RECOVERY SYS'TEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY CONCEPT #3 16 - ELECTRICAL Hook-Up Breaker in existing power panel Connection to motor Disconnect switch 3/4" EMT conduit #8 copper New Module Main feeder and conduit Breaker in existing distribution panel Panel Exterior light fixture Light fixtures Switch Duplex outlets QUANTITY 12 ae 260 1,040 40 UNIT 5 LF LF LF 5 EA EA PAGE 12 2/18/91 UNIT RATE ESTIMATED COST 175.00 525 115.00 1,380 330.00 3,630 3.20 832 0.85 884 8.50 340 277.00 277 800.00 800 330.00 330 190.00 1,140 55.00 55 68.00 272 PAGE 13 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) 1/2" conduit 50 LF 3.00 150 #12 copper 150 LF 01.55 83 TOTAL ESTIMATED COST: 10,698 PAGE 14 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 WASTE HEAT RECOVERY SYS'TEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY PAGE 15 2/18/91 CONCEPT #4 _ QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,500.00 8,500 Freight 89,000 LBS 0.50 44,500 Supervision, equipment, utilities, clean site, tools and protection 12 WKS 3,500.00 42,000 Per diem 378 DAYS 110.00 41,580 Travel costs, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 144,980 Bond and insurance 2.25 % 9,779 Profit 10.00 % 44,442 TOTAL ESTIMATED COST: 199,201 WASTE HEAT RECOVERY SYSTEM Page af NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 1,534 LF 12.50 19,175 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 1,630 LF 48.25 78,648 Las" ditto 1196 LF 37.50 44,850 2 1/2" bend 16 EA 180.50 2,888 1 1/2" bend 22 EA 135.50 2,981 2 1/2" tee 10 EA 207.50 2,075 TOTAL ESTIMATED COST: 150,617 WASTE HEAT RECOVERY SYSTEM PAGE 17 NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED CosT Structural steel support welded to existing skid 1,220 LBS 1.15 1,403 TOTAL ESTIMATED COST: 1,403 WASTE HEAT RECOVERY SYS'TEM a NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 06 - WOODS AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200.00 1,200 TOTAL ESTIMATED COST: 1,200 WASTE HEAT RECOVERY SYSTEM i NUNAPITCHUCK, ALASKA ; CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 13 - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8'0"x8‘'0" building module with floor, exterior wall structure and roofing complete 1 EA 2,800.00 2,800 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 TOTAL ESTIMATED COST: 4,450 WASTE HEAT RECOVERY SYSTEM —_ 20 NUNAPITCHUCK, ALASKA . CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 72.50 145 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 80 LF 26.22 2,098 Fittings 16 EA 46.35 742 Butterfly valves 9 EA 325.00 2,925 Booster pump 1 EA 1,450.00 1,450 Heat exchanger, 800,000 BTUH 1 EA 9,650.00 9,650 Unit heater, 60 MBH including thermostat 1 EA 330.00 330 1" diameter piping including fittings 40 LF 9.70 388 Gate valves 2 EA 77.00 154 Insulation 40 LF 4.30 72 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY CONCEPT #4 15 - MECHANICAL QUANTITY Hook-up Form hole through existing wall for heating pipes 3" diameter black steel piping including fittings 1 1/2" ditto 1" ditto 1 1/2" copper pipes ditto 1" ditto 3/4" ditto Gate valves Check valves Strainer Balancing valve Temperature control valve 14 60 80 60 80 40 20 60 12 il 14 UNIT UNIT RATE EA LF LF LF LF LF LF EA EA EA 195.00 25.62 14.75 9.65 14.95 10.07 7.95 260.00 260.00 58.00 53.00 225.00 PAGE 21 2/18/91 ESTIMATED COST 2,730 1,537 1,180 579 1,196 403 159 15,600 3,120 638 742 1,575 WASTE HEAT RECOVERY SYSTEM tah NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Insulation 340 LF 5.83 1,982 Heat exchanger, 300,000 BTUH 1 EA 3,750.00 3,750 Ditto, 100,000 BTUH 1 EA 3,175.00 3,175 Ditto, 20,000 BTUH al EA 1,815.00 1,815 Expansion tank, 100 gallon capacity al EA 2,117.00 2,217 Air separator 5 EA 495.00 2,475 Pumps, circulation Grundfoss 200, 2" diameter 16 EA 680.00 10,880 20,000 BTUH unit heater uf EA 300.00 300 Connection to existing piping system 14 EA | 72.50 1,015 Make-up glycol system connection, including tank 2 EA 610.00 1,220 Glycol 1,560 GAL 8.80 13,728 Test and balance system 186 HRS 75.00 13,950 E 23 WASTE HEAT RECOVERY SYSTEM —_ NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Controls and Instrumentation Generator building and new module 1 LOT 2,000.00 2,000 Hook-up inter ties 7 LOTS 1,500.00 10,500 TOTAL ESTIMATED COST: 116,810 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY CONCEPT #4 16 - ELECTRICAL Hook-Up Breaker in existing power panel Connection to motor Disconnect switch 3/4" EMT conduit #8 copper New Module Main feeder and conduit Breaker in existing distribution panel Panel Exterior light fixture Light fixtures Switch Duplex outlets QUANTITY 21 16 420 1,680 40 PAGE 24 2/18/91 UNIT UNIT RATE EA EA EA LF LF LF EA EA EA EA EA 175.00 115.00 330.00 3.30 8.50 277.00 800.00 330.00 190.00 55.00 68.00 ESTIMATED COST 1,225 2,415 5,280 1,386 1,428 340 277 800 330 1,140 55 272 WASTE HEAT RECOVERY SYSTEM aaa an NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #4 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) 1/2" conduit 50 LF 3.00 150 #12 copper 150 LF 0.55 83 TOTAL ESTIMATED COST: 15,181 PAGE 26 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 GE 27 WASTE HEAT RECOVERY SYSTEM Pa NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 01 - GENERAL CONDITIONS QUANTITY UNIT RATE ESTIMATED COST Mobilization Zz LOT 8,500.00 8,500 Freight 107,500 LBS 0.50 53,750 Supervision, equipment, utilities, clean site, tools and protection 14 WKS 3,500.00 49,000 Per diem 420 DAYS 110.00 46,200 Travel costs, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 165,850 Bond and insurance 2.25 % 10,547 Profit 10.00 % 47,931 TOTAL ESTIMATED COST: 224,328 WASTE HEAT RECOVERY SYSTEM siiealiatal NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 1,624 LF 12.50 20,300 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 1,630 LF 48.25 78,648 1 1/2" ditto 13176 LF 37.50 51,600 2 1/2" bend 16 EA 180.50 2,888 i 1/2” ditto 30 EA 135.50 4,065 2 1/2" tee 12 EA 207.50 2,490 TOTAL ESTIMATED COST: 159,991 GE 29 WASTE HEAT RECOVERY SYS''EM i : NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1.15 1,403 TOTAL ESTIMATED COST: 1,403 =_—n WASTE HEAT RECOVERY SYSTEM eae ee NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 06 - WOODS AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200.00 1,200 TOTAL ESTIMATED COST: 1,200 WASTE HEAT RECOVERY SYSTEM — NUNAPITCHUCK, ALASKA CONSTRUCTION COST S'TUDY 2/18/91 CONCEPT #5 13 - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8’0"x8‘0" building module with floor, exterior wall structure and roofing complete Al EA 2,800.00 2,800 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 2 EA 710.00 710 Louver a EA 500.00 500 TOTAL ESTIMATED COST: 4,450 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY CONCEPT #5 15 - MECHANICAL QUANTITY UNIT UNIT RATE PAGE 32 2/18/91 ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators Form hole through existing wall for heating pipes 3" diameter black steel welded piping Fittings Butterfly valves Insulation to pipe, 3" diameter Booster pump Heat exchanger, 800,000 BTUH Unit heater, 60 MBH including thermostat 1" diameter piping including fittings Gate valves Insulation 80 16 80 40 40 EA EA LF EA LF 5 LF LF 72.50 195.00 26.22 46.35 325.00 7.10 1,450.00 9,650.00 330.00 9.70 77.00 4.30 145 390 2,098 742 2,925 568 1,450 9,650 330 388 154 172 WASTE HEAT RECOVERY SYSTEM ——” NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up Form hole through existing wall for heating pipes 18 EA 195.00 37510 3" diameter black steel piping including fittings 60 LF 25.62 17537 1 1/2" ditto 80 LF 14.75 ‘1,180 1" qitto 100 LF 9.65 965 1 1/2" copper piping including fittings 80 LF 14.95 1,196 1" ditto 40 LF 10.07 403 3/4" ditto 60 LF 7295 477 Gate valves 66 EA 260.00 17,160 Check valves 14 EA 260.00 3,640 Strainer 13 EA 58.00 754 Balancing valve 14 EA 53.00 742 Temperature control valve 9 EA 225.00 2,025 WASTE HEAT RECOVERY SYS'l'EM PAGE 34 NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED. COST Hook-up (Continued) Insulation 420 LF 5.83 2,449 Heat exchanger, 300,000 BTUH a EA 3,750.00 anv 50 Ditto, 100,000 BTUH al} EA 3,175.00 375 Ditto, 20,000 BTUH 1 EA 1,815.00 1,815 Expansion tank, 100 gallon capacity al EA 1,470.00 1,470 Air separator 5 EA 495.00 2,475 Pumps, circulation Grundfoss 200, 2" diameter 18 EA 680.00 12,240 20,000 BTUH unit heater a EA 300.00 900 Connection to existing piping system 18 EA 72.50 1,305 Make-up glycol system connection, including tank 2 EA 610.00 1,220 Glycol 495 GAL 8.80 4,356 Test and balance system 206 HRS 75.00 15,450 WASTE HEAT RECOVERY SYSTEM —— NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Controls and Instrumentation Generator building and new module 1 LOT 2,000.00 2,000 Hook-up inter ties 9 LOTS 1,500.00 13,500 TOTAL ESTIMATED COST: 118,706 PAGE 36 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #5 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up Breaker in existing power panel 9 EA 175.00 1 7578 Connection to motor 23 EA 115.00 2,645 Disconnect switch 18 EA 330.00 5,940 3/4" EMT conduit 500 LF 3.30 1,650 #8 Copper 2,000 LF 0.85 1,700 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 277 Panel 1 EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light fixtures 6 EA 190.00 1,140 Switch 1 EA 55.00 55 Duplex outlets 4 EA 68.00 272 WASTE HEAT RECOVERY SYSTEM NUNAPITCHUCK, ALASKA CONSTRUCTION COST STUDY CONCEPT #5 16 - ELECTRICAL PAGE 37 2/18/91 QUANTITY UNIT UNIT RATE New Module (Continued) Equipment connection a EA 115.00 1/2" conduit 70 LF 3.00 #12 copper 210 LF 0.55 TOTAL ESTIMATED COST: ESTIMATED COST 115) 210 116 17,165