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Lower Kalskag Report & Concept Design Waste Heat Recovery 1991
REPORT AND CONCEPT DESIGN LOWER KALSKAG WASTE HEAT RECOVERY May 9, 1991 LEFF Frank Moolin & Associates, Inc. A Subsidiary of ENSERCH Alaska Services, Inc. a he 8. or eo) So ao > WwW 0 0 0 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN TABLE OF CONTENTS EXECUTIVE SUMMARY INTRODUCTION DESCRIPTION OF SITE VISIT POWER PLANT DESCRIPTION POTENTIAL WASTE HEAT USER BUILDING DESCRIPTIONS 5.1 Elementary School 5.2 Community Buildings : 5.2.1 Pump house 5.2.2 City Building 5.2.3 Community Center/Preschool 5.2.4 Clinic/Post Office RIGHT-OF -WAY/EASEMENT CONCEPT DESIGN ECONOMIC DATA FAILURE ANALYSIS 10.0 CONCLUSIONS AND RECOMMENDATIONS APPENDICES 1. Calculations 2. Cost Estimates 3. Raw Data WTHTLK/RCD MAY 29, 1990 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN LIST OF FIGURES AND TABLES Power Plant Photographs Lower Kalskag Power Generation Data Elementary School Photographs Elementary School Fuel Data Pump House Photographs City Building Photographs Community Center/Preschool Photographs Clinic/Post Office Photographs Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 1] Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Graph 1 Graph 2 WTHTLK/RCD Legend System Site Plan Power Plant Floor Plan Power Plant Cooling Schematic Scenario #1 - System Schematic Elementary School Floor Plan Elementary School System Schematic Pump House Floor Plan Pump House System Schematic Scenario #2 - System Schematic City Building Floor Plan City Building System Schematic Community Center/Preschool Floor Plan Community Center/Preschool System Schematic Clinic/Post Office Floor Plan Clinic/Post Office System Schematic Typical Trench Section MAY 29, 1990 OM SINS Stein eo WES Oe woe Se eee nm ae ee WHR OWONDOPWMHHO Oo 0 NS NS NS SS SNS SNS SN NNN NSN NSN OO Oo oo oS ee 1.0 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 EXECUTIVE SUMMARY A potential for waste heat recovery exists in the community of Lower Kalskag. Lower Kalskag is a community of approximately 285 people, located on the north bank of the Kuskokwim river, approximately 25 miles west of Aniak. The waste heat from the coolant of diesel engine-generator sets owned and operated by Alaska Village Electrical Cooperative (AVEC) could be recovered and circulated to heat portions of the community. A waste heat recovery system can provide enough heat to service all public buildings in Lower Kalskag. These buildings include the Pump House, Elementary School, City Building, Clinic/Post Office, and Community Center/Preschool. The proximity of the power plant to potential waste heat users makes piping runs relativity short. There appears to be no land ownership/right of way obstacles, because the school and community buildings land abuts the power plant site. One building in particular, the Elementary School, could benefit most from waste heat use and could consume approximately 30% of the gross heat available on a yearly basis and approximately 45% during its peak month. Another large user, the Pump House, uses an inordinate amount of fuel heating domestic water to nearly 70 degrees F before it is pumped around the village to the various users. Scenario #1 provides waste heat to the two (2) largest potential users. This includes the Elementary School and Pump House. Estimated Project Cost $614,022 4a Total Fuel Oil Savings 10,500 Gallons . Total Annual Fuel Cost Savings $14,000 (O&M Cost $ 7,000) Scenario #2 includes the buildings in Scenario #1 and extends a loop to three (3) smaller potential users. This includes the City Building, Clinic/Post Office, and Community Center/Preschool. Estimated Project Cost $662,800 Total Fuel Oil Savings 12,300 Gallons Total Annual Fuel Cost Savings $24,500 (O&M Cost $ 8,200) Policy makers will decide if the fuel cost savings are worth the cost of installing and maintaining the waste heat recovery system. WTHTLK/RCD lee LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 1.1 Decision Criteria 1.1.1 Proximity All potential users are very close to the power plant. Long piping runs will not be a problem. 1.1.2 Potential Future Users Expansion At the time of the site investigation (February 1990), there were no known plans to expand the village or its services. 1.1.3 Community Input/State Priorities The Mayor and City council members, that were interviewed, indicated a strong preference for using waste heat in the pump house, city building, community center/preshcool, and community clinic/post office. They were supportive of using waste heat at the elementary school. A summary of the construction cost estimates along with design and SIOH costs is included in the Cost Estimate Appendix. WTHTLK/RCD 1-2 SECTION 2 20 eal ue O23 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 29, 1990 INTRODUCTION Objective The objective of the field investigation and report is to ascertain the viability of waste heat recovery use in the community of Lower Kalskag. It has been established that there is a potential source and use for the heat energy, and that the community is interested in pursuing this project. Methodology The investigation and analysis were approached as follows: de Pre-site Visit: Information collection consisted of telephone contact with community officials, owners/operators of potential user buildings, power plant operators, and gathering land use/ownership information. a. An informational meeting was held with the Alaska Village Electric Cooperative (AVEC) to ascertain their position and requirements for waste heat recovery on the AVEC power plant in Lower Kalskag. 3h Field Investigation: Coordination with building owner/operators and local elected officials were performed. Photographs were taken of the potential user buildings as well as the boiler/furnace equipment. The power plant was photographed. Available fuel costs and heating records were obtained from each interested potential recipient of waste heat (in general, this information was not available). 4. Office Analysis: Additional information regarding weather and historical trends were collected. Where specific fuel use records were not available, approximate heat loss calculations were made to estimate fuel use. This information was used to produce a model predicting the system performance and the amount of energy recovered. 58 Report Preparation: A draft report was prepared for the prospective clients prior to final report preparation to ascertain the correctness of assumptions made and obtain approval of the approach taken. Community Description Lower Kalskag was originally a summer fishing camp for families from Upper Kalskag. Around 1930 villagers began building and living at Lower Kalskag. More families followed after the establishment of a Russian Orthodox Chapel in 1940. Both WTHTLK/RCD Cai LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 29, 1990 villages are located on the north bank of the Kuskokwim river, approximately 25 miles west of Aniak, on the Yukon/Kuskokwim Delta. Lower Kalskag is on the Kuskokwim river floodplain. The present population is approximately 285. Fuel costs for the community in February of 1990 were $2.00 per gallon. 2.4 Applicable Codes and Regulations The most recently State of Alaska adopted editions (1985 for al] except as noted) of the following codes and regulations have been used in the preparation of the concept design. These are listed below: Uniform Plumbing Code (UPC-1979) Uniform Mechanical Code (UMC) Uniform Building Code (UBC) Uniform Fire Code (UFC) National Electrical Code (NEC-1990 - Pending adoption) National Fire Protection Association (NFPA) WTHTLK/RCD 2-2 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 3.0 DESCRIPTION OF SITE VISIT Two engineers from Frank Moolin and Associates, Inc. visited Lower Kalskag on February 17, 1990. They visited every facility listed in this report and obtained available copies of fuel usage records and copied or sketched floor plans and piping diagrams. Contacts: Crim Evan - 471-2228 - Mayor Mary Rose Nook - 471-2228 - City Clerk Hank Aloysius - 471-2228 - Water Plant Operator Cal Evan - 471-2264 - Power Plant Operator Ralph Steeves - 471-2288 - Principal Sara Steer - 471-2288 - Head Teacher WTHTLK/RCD 3-1 4.0 4.1 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 29, 1990 POWER PLANT DESCRIPTION Narrative Description The power plant is housed in a 16’ by 36’ metal skinned building with internal switchgear, office, and shop space. Power is generated by three (3) Catapilar diesel fired generators rated for continuous load as follows: Gen #1- D342 turbo-250KW Gen #2- 3406DI-350KW Gen #3- D342PC-250KW The generators use number 1 fuel oi] year round. Cooling for the plant includes two external horizontal core radiators with electric fans for engines #2 and #3 and one skid mounted internal radiator on engine #1. AVEC is desirous of making all the radiators external as part of the wasteheat recovery modifications. However, since only one genset normally operates, the two existing common radiators are sufficient and no additional radiators are required. The plant burns about 66,000 gallons of diesel fuel per year with an average winter load of 88KW and a minimum winter load of 49KW. Under present conditions, one generator is able to maintain the village load with the other two maintained on warm stand-by. The #1 generator with the skid mounted radiator is not commonly used. As part of the wasteheat modifications, it is proposed that the gensets be manifolded together and the #1 genset radiator removed. AVEC has considerable experience with wasteheat recovery and has developed requirements for their plants. Features of waste heat recover installations as required by AVEC include: - dual mechanical building ventilation cooling systems - welded piping (no grooved joint) - lug style butterfly or gate valves (bolted both sides) - variable frequency drives on horizontal core external radiators - 3/4" - 1" bypass around AMOT valve to keep radiators warm - nonbladder type common expansion tank - standby gensets kept warm by auxillary electric pumps - full pipe size AMOT valves (less than manufacturer’s recommended 2 psi pressure drop) - separate heat exchanger and secondary system for plant waste heat use - main waste heat exhcanger and secondary components placed outside power plant in enclosed platform At Lower Kalskag, the ventilation systems, horizontal core radiators, AMOT valve bypass, AMOT valve, and auxillary pumps for engines #2 and #3 are existing. WTHTLK/RCD 4-1 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 29, 1990 4.2 Floor Plan and Schematics See the Figures 3 and 4 for a simple floor plan and schematic of the system (located in Section 7). 4.3 Photographs See the attached copies of the original color photographs of the power plant. 4.4 Load information Attached Table 1 contains the utility load data for 1988 and 1989 WTHTLK/RCD 4-2 Lower Kalskag Power House Power House Interior SECTION 5 Frank Moolin & Associates, Inc. LOWER KALSKAG POWER GENERATION AVERAGE LOAD (KW) AVERAGE] | 59,161 Bie at ANNUAL 7oo936] | C8421] Notes: 1) Average load is calculated from KWH production divided by hours in month. 2) Min. load is estimated as 1/2 of average load. 2/7/91 5.0 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 POTENTIAL WASTE HEAT USER BUILDING DESCRIPTIONS During the site visit, all major buildings within a reasonable distance of the power plant were considered. The buildings were visited and information about them gathered. Note: Monthly fuel consumption figures were not available or were not well documented. The fuel consumptions figures used in this report are assumptions based on verbally reported general use and estimated annual fuel consumption from heat loss calculations using heating degree days as shown in Appendix 1. The available information is presented below. WTHTLK/RCD 5-1 5.1 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Lower Kalskag Elementary School Relatively new well insulated wood frame structure of approximately 8200 square feet using circulating hot water heat with a 290,000 BTU/HR boiler-Burnham Model #RF-34 with Grundfos UMS 50-80 CV circulating pumps. Domestic hot water is provided by a single oil fired hot water heater with recirculation. This facility reportedly uses about 800 gallons of fuel per month during the Nov-Feb period and about 7000 gallons per year. The preferred method of waste heat recovery for this facility is a heat exchanger in the boiler return water piping with a second heat exchanger to provide domestic hot water. The school is about 380 ft. from the Power Plant and will require 530’ of © additional piping (one way) from the pump house. WTHTLK/RCD 4 all RG Lower Kalskag Elementary School Elementary School Mechanical Room Lower Kalskag ELEMENTARY SCHOOL HEATING FUEL CONSUMPTION DATA NUMBER OF DAYS DAILY CONSUMPTION Gal HEATING DEGREE 1989 Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Total 7,000 TOTAL FUEL DELIVERED Frank Moolin & Associates, Inc. AVERAGE MONTHLY CONSUMPTION ANNUALIZED AVERAGE CONSUMPTION 7,000 * Reported fuel quantity was provided as an approximate total for year and distributed to each month by heating degree days. 2/7/91 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Sa Community Buildings Seiced WTHTLK/RCD Pump House A 40’ x 36’ frame building with two (2) Weil-McLain P- 776E-W boilers each with a 236,000 Btu/hr heating capacity and a B&G Series 100 circulating pump. These boilers provide heat for the 10,000 gallon fresh water storage tank and village water circulating system, as well as the building space heat. The Mayor, Crim Evan, voices a strong interest in using waste heat for this facility. The immediate proximity of the power plant makes this attractive. The pump house is 50 ft. from the power plant and approximately 160’ of waste heat piping is needed (one way). The internal piping connections for utilizing waste heat recovery are already installed. Accurate fuel records were not available, but it appears that this facility uses about 3500 gallons per year, from reports by the Mayor and the plant operators. For purpose of these calculations, 2,500 gallons of fuel was assumed to be used for heating water. Some fuel savings could be realized by setting the water circulating temperature below the present 70°F. The preferred method of waste heat recovery for this facility is a heat exchanger in the boiler return water piping. Lower Kalskag Pump House Pump House Boilers LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.2.2 City Building WTHTLK/RCD A 16’x 30’ wood frame building with an oil fired 40,000 Btu/hr space heater. This facility is reported to use about 75 gallons of fuel per month during the winter months of November to February and 400 gallons per year. The preferred method of waste heat recovery for this facility is a cabinet unit heater. The City Building is 230’ from the power plant and will require 260’ of additional piping (one way). Lower Kalskag City Building City Building Heater LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.2.3 Community Center/Preschool WTHTLK/RCD A 26’x 76’ wood frame building, of which only a portion (19’ x 26’) is presently heated by an oil fired 40,000 Btu/hr space heater using approximately 75 gallons of fuel per month during the period of November to February and 400 gallons per year, as reported by the operator. This facility is 280’ from the power plant and will require 120’ of additional waste heat piping (one way) from the city building. The preferred method of waste heat recovery for this facility is a cabinet unit heater. Provision should be made for a future waste heat unit heater in the now unheated community center portion. This would allow local citizens to heat this space when they are going to have a meeting. Lower Kalskag Community Center/Preschool Preschool Heater LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.2.4 Clinic/Post Office. WTHTLK/RCD A 24’x 50’ wood frame building with a single Burnham boiler and circulating hot water heat. The boiler has a 124,000 Btu/hr capacity and a fractional horsepower Grundfos circulating pump. Domestic hot water is provided by a boiler coil and an electric hot water heater/storage tank. This facility is reported to burn about 125 gallons per month of fuel November to February and 1050 gallons per year. The preferred method of waste heat recovery for this facility is a heat exchanger in the boiler return water piping. This structure is 345’ from the power plant and will require 100’ of additional piping (one way) from the preschool. Ly eapnl Lower Kalskag Clinic/Post Office Clinic/Post Office Heater SECTION 6 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 29, 1990 6.0 RIGHT OF WAY/EASEMENT There are apparently no right of way problems in that the power plant property is contiguous to the land occupied by the community buildings and across a road from the Lower Kalskag Elementary School property. WTHTLK/RCD 6-1 SECTION 7 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 7.0 CONCEPT DESIGN 7.1 System Narrative Two scenarios have been investigated for waste heat recovery at Lower Kalskag. The first is to serve the two largest users. The second is to serve the two largest plus three smaller users. The proximity of the power plant to the potential users and the fact that the users land abuts the power plant, will allow for short piping runs and an apparent lack of right of way problems. 7.1.1 Scenario #1: Served buildings include: Elementary School Pump House Benefits of this Scenario include serving a majority of the demand while limiting the size and cost of the system. 7.1.2 Scenario #2: Served buildings include all of those listed above plus: City Building Clinic/Post Office Community Center/Preschool Benefits of this Scenario include serving all of the public buildings in Lower Kalskag. Problems include the marginal increase in fuel savings over Scenario #1 versus the increased cost. 7.2 Primary and Secondary Piping Jacket water piping will be valved to recover heat from whichever genset is on line. Automatic control valves will bypass coolant to the external radiators to maintain coolant temperature as required. See section 4 for a discussion of proposed modifications to the power plant. In keeping with the previous AEA recommendations, the current concept design includes one flat plate heat exchanger at the power plant for potential waste heat users outside of the power plant. However, per AVEC requirements, a separate heat exchanger provides heat to the plant. The flow will be without any booster pump on the engine side of the system. Since the actual operating points of the engine-mounted pumps are not known it is assumed that there is some allowance for the low pressure drop heat exchangers. On the secondary loop, a main circulation pump will be designed for the pressure drop of the furthest connected building. In addition, an air separator, and expansion tank, and a glycol make-up system is required. The pump’s design flow rate will be for the maximum heat required at a 20 degree temperature drop. WTHTLK/RCD | 7.3 7.4 7.5 7.6 7.7 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 The piping to each of the connected buildings will be through arctic pipe buried underground to protect it from damage from passage of vehicles. Two separate arctic pipes are envisioned, one for supply to the building, and one for return to the power plant. See the attached Figures 5 and 10 for the system schematics. Balancing valves are used at the connection to existing piping for two reasons. The first is to allow balancing of the flow to the heat exchanger; the second is to provide a means of measuring the flow rate at that point in the piping. Building Piping All connections to the user’s buildings will be at a single heat exchange point either by using flat plate heat exchangers to connect to the boiler systems or by single unit heaters. This will limit problems associated with damage of distribution piping and interconnection of systems. One exception to this is the Elementary School, where a second heat exchanger will be used for domestic water. This will be of the double-wall type to provide additional separation between the distribution system and potable water. Precautions must be taken to prevent overcooling of the generator jacket water and to prevent building system boilers from heating the waste heat distribution system. The simplest method is to not connect more users than the system can normally provide waste heat for. Each of these issues can also be addressed with controls and valving. They can also be automated to some degree but the solutions must be carefully balanced with the need for system simplicity. Site Plan/Routing The routing will be as shown on Figure 2. Generator Room Plans/Schematics See the attached Figures 3 and 4 for the design concept for changes to the power plant. User Building Plan/Schematics See the attached Figures 6 through 9 and 11 through 16 for proposed changes to each of the potential user buildings. Arctic Pipe/Trench Section A cross section of the anticipated trench and arctic pipe configuration is shown in the Figure 17. WTHTLK/RCD 7-2 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 7.8 Outline Specifications The outline specifications for the major components of the system are shown below. Approximate sizes are shown following the specifications. 15010 15050 15120 15250 15750 WTHTLK/RCD GENERAL CONDITIONS The system shall be balanced by the Contractor to the flow specified in the construction documents. BASIC MATERIALS AND METHODS Valves: Valves for isolation use shall be gate type rated for 150 psig. Gaskets and materials shall be compatible with glycol and with hydrocarbons on engine primary circuits. Isolation valves on engine primary circuits may be lug-style butterfly type. Piping: Piping inside buildings shall be type ’L’ copper or steel schedule 40 with dielectric unions at connection points of dissimilar metals. Steel pipe will be welded. ARCTIC PIPE Arctic Pipe: Pressure pipe shall be schedule 40 steel. Insulation shall be foamed polyurethane with .25" maximum voids. Thickness of insulation to be minimum of 2 inches. Jacketing shall be steel or high density polyethylene. Arctic pipe system shall include kits or fittings for take-off connections to main line that provide water-tight seal. MECHANICAL INSULATION Piping insulation: Pipe insulation shall be fiberglass with an all-service jacket. Minimum insulation thickness shall be 1-1/2 inches. HEAT TRANSFER Heat Exchangers: Heat exchangers shall be plate and frame type with minimum 20 gage stainless steel plates, painted steel frame with head and end support, top carrying bar, bottom guiding bar, and ASME rating. Ports shall be international pipe thread or flanged. Capacity shall be as specified. Acceptable manufacturers are Bell & Gossett, APV, Tranter, and Alfa Laval. Double Wall Heat Exchangers: Potable water heat exchangers shall have two walls separating the fluids with a vented air space in between. They shall be ASME rated, tube within a tube type such as Bell & Gossett Diamondback or nested welded plate type such as Tranter Double Wall Design. 13 15900 16000 WTHTLK/RCD LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Cabinet Unit Heaters: Floor mounted inverted-flow heaters shall have multispeed control, minimum 1/2" copper coil tubes mechanically expanded into aluminum fins. Cabinet 18 guage with 16 guage front pant], galvanized, and primed with top front inlet and bottom front outlet stamped steel integral grilles. Provide leveling legs. CONTROLS & INSTRUMENTATION Controls will be electric with the exception of AMOT valves in the power plant, which are self-contained. Flow of fluid in the secondary system is not automatically controlled. In buildings, unit heater fans are cycled by wall thermostats. ELECTRICAL All electric equipment and installation shall comply with the National Electric Code specified. 7.9 Major Equipment List 9 il Heating Elements Pumps Buried Piping WTHTLK/RCD Scenario #1 Location Pump House Elem. School Boiler LOWER KALSKAG WASTE HEAT RECOVERY Elem. Sch. Hot Wtr Htr. 85 Generator Plant #1 Generator Plant #2 Service Gen. Plant Secondary 38 Eng. #1 Preheat Size 1-1/4" ow sn Capacity (Hot Side) MBH GPM 86 10 169 19 9 340 100 43 100 GPM HD 30 5 5 ER 40 1060 280 Te 5 TI 180 180 180 185 177 oo ow REPORT AND CONCEPT DESIGN MAY 29, 1990 TO 160 160 160 177 176 QTY Pr Item heat exchanger heat exchanger db] wall ht. exch. heat exchanger heat exchanger LOWER KALSKAG WASTE HEAT RECOVERY 7902 Scenario #2 Heating Capacity Elements Location (Hot Side) MBH GPM Pump House 86 10 Elem. School Boilers 169 19 Elem. Sch. Hot Wtr Htr. 85 9 City Building 14 2 Comm. Ctr./Preschool 16 2 Clinic/Post Office 39 5 Generator Plant #1 *457 100 Generator Plant 43 100 Pumps Service GPM HD Gen. Plant Secondary %52 30 Engine #1 Preheat 5 5 Buried Piping Size LF 1" 380 1-1/4" 100 1-1/2" 520 2" 1060 3 280 *Includes capacity for WTHTLK/RCD TI 180 180 180 180 180 180 185 174 REPORT AND CONCEPT DESIGN MAY 29, 1990 TO 160 160 160 160 160 160 174 173 QTY future community center heating. Item heat exchanger heat exchanger dbl-wall ht. exch. cab. unit htr. cab. unit htr. heat exchanger heat exchanger heat exchanger BALANCE/ISOLATION VALVE ISOLATION VALVE NC=NORMALLY CLOSED (ALL OTHERS NORMALLY OPEN) 2-—WAY CONTROL VALVE 3-WAY CONTROL VALVE AMOT 3-—WAY VALVE CHECK VALVE STRAINER CIRCULATING PUMP FLOW METER THERMOMETER TEMPERATURE SWITCH AIR SEPERATOR WITH AUTO AIR VENT FLOW ARROW PIPE DOWN PIPE UP - NEW RETURN LINE NEW SUPPLY LINE EXISTING RETURN LINE EXISTING SUPPLY LINE NEW EQUIPMENT EXISTING EQUIPMENT PRIMARY (GENERATOR) PIPING SECONDARY (DISTRIBUTION) PIPING BUILDING PIPING NON ELECTRIC VALVE NON ELECTRIC TEMPERATURE SENSOR SCALE: NONE 44 Frank Moolin & pare. 2/13/91 Associates, Inc. LEGEND . ByCIP | og yo: 495 ENGINEERING @ DESIGN @ PROJECT MANAGEMENT REVISION 0 An Edasco Services Incorporated Engineering ond Construction Company ae 495LEGND.0WG 7-7 FIGURE 1 MLb4k Frank Moolin & SYSTEM OSN. YJ a ra3 04 Associates, Inc. SITE PLAN ows. BY-RWPL oe wo, 405 | ENGINEERING @ DESIGN @ PROJECT MANAGEMENT frevson: 0 | pamarte uae each neat aaa LOWER KALSKAG, AK tT apap 7-8 FIGURE 2 BURIED NEW WASTE HEAT BB Frank Moolin & POWER PLANT Associates, Inc. FLOOR PLAN is mas avace miapeta mpi cas Couaatae comomy LOWER KALSKAG, AK 495308GB.DWG 7-9 FIGURE 3 3” (EXCEPT WHERE NOTED) NC I ore! won LIT ree EXPANSION TANK HEAT EXCHANGER AMOT VALVE AND GLYCOL ASSEMBLY MAKE-UP 9 3/4 POWER PLANT TO WASTE HEAT EXCHANGER HEAT USERS TO POWER PLANT yy) Frank Moolin & POWER PLANT om eS Associates, Inc. COOLING SCHEMATIC pws, oy WH ENGINEERING @ DESIGN @ PROJECT MANAGEMENT [EANEERNG 6 DESICN ¢ PROVECT MANAGEMENT LOWER KALSKAG, AK om, Br seme 2 7-10 FIGURE 4 HOT WATER HEATER wy — a ne ELEMENTARY SCHOOL 4h Frank Moolin & SCENARIO #1 Associates, Inc. SYSTEM SCHEMATIC Pee pret eas ep ccatea carmen ae LOWER KALSKAG, AK 495P1308.0WG 7-11 FIGURE 5 PROPOSED SPACE FOR FUTURE EQUIPMENT SCALE: NONE LA Frank Moolin & ELEMENTARY SCHOOL : ore aaa Associates, Inc. FLOOR PLAN . By WH 495 ENGINEERING e@ DESIGN @ PROJECT MANAGEMENT LOWER KALSKAG, AK HK. BY_____ | REVISION. oO ‘An Ebosco Services Incorporated Engineering and Construction Company 495308ES.DWG 7-12 FIGURE 6 TO / FROM ARCTIC PIPE (A) x] DOUBLE WALL HEAT EXCHANGER DOMESTIC HOT WATER HEATER a W oS z x Oo x WwW kK 3 =x HEATING = SUPPLY $—— BOILER LA Frank Moolin & ELEMENTARY SCHOOL Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT smn Ehece Sertoes neorperetd Eigrerng end Cenatcton Comper” LOWER KALSKAG, AK 495D1308.DWG 7-13 FIGURE 7 GENERATOR OIL HEATER BOILERS PAD WATER STORAGE TANK PROPOSED SPACE FOR LL SFUTURE EQUIPMENT LA Frank Moolin & Associates, Inc. ENGINEERING e@ DESIGN e@ PROJECT MANAGEMENT 4a exis Sida cerns ighirkg Cation, Connany PUMP HOUSE FLOOR PLAN LOWER KALSKAG, AK 7-14 FIGURE 8 foarte: 2/13/91 JOB_NO. 495 REVISION ° 495308WP.DWG / FROM Anche PIPE D 4 FROM PLANT HEATERS FROM HEATING FOR “ WATER TANK =f <I ><] —rx ak | HEAT EXCHANGER PH J ™ 1) —P<H| EXISTING UNION (TYP.) HEATING SUPPLY 5——<— | — BOILER SEI Frank Moolin & PUMP HOUSE Associates, Inc. SYSTEM SCHEMATIC ia the Setoeelteopechd Siaety esl Gettin Cooper LOWER KALSKAG, AK 495D3308.DWG 7-15 FIGURE 9 l cry BUILDING | r CAGINET _UNTT lcomMUNITY CENTER/ | [= PRESCHOOL ALES Frank Moolin & SCENARIO #2 Associates, Inc. SYSTEM SCHEMATIC A aiass bcs Kenya egucuns a |cansaees Gap LOWER KALSKAG, AK 7-16 FIGURE 10 495P2308.0WG OIL FIRED SPACE HEATER PROPOSED SPACE FOR CABINET UNIT HEATER LA Frank Méolin & CITY BUILDING Associates, Inc. FLOOR PLAN HV tog no: 495 pee een LOWER KALSKAG, AK —— 495308CO.DWG 7-17 FIGURE 11 TO / FROM ARCTIC PIPE NEW CABINET UNIT HEATER 48 Frank Moolin & CITY BUILDING Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT sn Eoewee Serdons ncerperted Engreang end Canetrston Copy LOWER KALSKAG, AK 495D4308.D0WG 7-18 FIGURE 12 PROPOSED SPACE FOR FUTURE EQUIPMENT THAT FACILITY OWNERS MAY WANT TO INSTALL L______ | OIL FIRED SPACE HEATER PROPOSED SPACE FOR CABINET UNIT HEATER bb Frank Moolin & |COMMUNITY CENTER/PRESCHOOL Joss. ar Associates, Inc. FLOOR PLAN sella Rete sipetcne ge hata ape LOWER KALSKAG, AK 495308CC.DWG 7-19 FIGURE 13 TO / FROM ARCTIC PIPE VALVES FOR POSSIBLE FUTURE INSTALLATION OF NEW UNIT HEATER IN THE COMMUNITY CENTER NEW CABINET UNIT HEATER BB Frank Moolin & |COMMUNITY CENTER/PRESCHOOL Jo. «— [seas NONE | ’ Associates, Inc. SYSTEM SCHEMATIC pwe. ByCIP | op wo. 495 | ENGINEERING @ DESIGN @ PROJECT MANAGEMENT i eas Sa-kcs Lawpsaie’ eslieingiend ciessccees oxeeow LOWER KALSKAG, AK " 7-20 FIGURE 14 HWH TANK PROPOSED SPACE FOR FUTURE EQUIPMENT BOILER/WH bb Frank Moolin & CLINIC / POST OFFICE Associates, Inc. FLOOR PLAN ENGINEERING DESIGN PROJECT MANAGEMENT An Edosco Services sella psiitlig cot cick Company LOWER KALSKAG, AK REVISION: 495308P0.DWG pare: 2/13/91 7-21 FIGURE 15 TO / FROM ARCTIC PIPE HEATING , RETURN 7~ a WW Oo Zz <= x oO x< Wd ri x= HEATING SUPPLY 5‘ Smee. AS Frank Moolin & CLINIC / POST OFFICE Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT sm Eos Serene heorpercted Dnghaating end Corton Capory LOWER KALSKAG, AK 7-22 FIGURE 16 EXISTING GRADE BACKFILL WITH EXCAVATED . MATERIAL — COMPACT AS Se NEO DURING SPECIFIED SYSTEM FINAL DESIGN WASTE HEAT SUPPLY AND RETURN PIPES — ARCTIC PIPING (SIZES VARY AS SPECIFIED) BEDDING MATERIAL — EXCAVATED MATERIAL WITH 1” TOP SIZE BBR | 85 Moolin & alae OAM sssociates, Inc. | TYPICAL TRENCH SECTION An Ebasco Services incorporated Engineering and Construction Company ae 0 495TRNCH.DWG 7-23 FIGURE 17 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 8.0 ECONOMIC DATA Economic Data in Appendix 2. WTHTLK/RCD 8-1 9.0 9.1 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 FAILURE ANALYSIS Lower Kalskag is a least a full day away from resupply of parts out of Anchorage, and the delay might be several days longer if weather is bad. Although the heat recovery systems are relatively simple and straight forward mechanically, the system will require some maintenance and a knowledgeable person to trouble shoot the system. Lack of attention may render the system inoperative. It is also possible for inexperience people to alter the system configuration by opening and closing valves or turning off pumps. Therefore, access to the system valves and controls must be limited to knowledgeable and responsible people. The control valves must work to maintain system temperatures and the proper functioning of these valves must be checked periodically. Reports on soil conditions indicate that buried pipes should not be damaged by soil heaving or settlement if the pipes are buried correctly. The system is susceptible to mechanical damage from being hit by equipment and machinery that is used for excavation. Subsurface leaks or spills have a significant potential for soil contamination. Because of the cold temperatures, the waste heat recovery system must be filled and maintained with 60% glycol. Water without glycol must not be introduce into the system. All waste heat recovery recipients must keep their respective building heating systems on line and in proper functioning condition to heat the building in case the waste heat recovery system fails or if the power plant is not rejecting enough heat to its cooling system. Subsurface Pipe Rupture 9.1.1 Worst Case - Pipe fails underground from subsidence, earthquake, corrosion, fatigue, or material fault. Glycol/water mixture seeps unnoticed into the formation or under the snow. Fluid loss continues until the pump loses suction. This problem could go unnoticed until: ie A power plant operator notices the inlet and outlet temperatures on the primary side of the waste heat recovery heat exchanger are nearly identical or, 2s A waste heat user determines that his building is too cold or his buildings heating system is running and that the waste heat recovery system is inoperative or, WTHTLK/RCD 9-1 9.1.2 9.1.3 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 3. Some operator or maintenance person notices the secondary temperature indicating devices are not registering proper temperatures or he notices the circulating pump(s) are running dry or, 4. Someone notices glycol surfacing somewhere. 5 A low pressure alarm is indicated. A further complication could arise if other controls failed concurrently. If the secondary system lost fluid and then the control valve failed to by-pass water to the generator radiators, then the engines would trip off on overload producing a village black-out. A further problem could arise if the engine high temperature shut downs failed and the engine ran until over temperature failure. Repair The ruptured pipe section must be located and either repaired, replaced or by-passed. Unless the glycol surfaces, the location of the rupture may be difficult to find. Excavation will almost always be required and this may involve steam thawing the soil if frozen. The alternative of by-passing the failed section with temporary surface waste heat piping may be necessary. For this alternative piping should be stock piled. If these pipe supplies must be flown out of Anchorage, the delay could be as_ follows: Locating the leak, mobilizing excavating equipment, excavating leak site 2-3 days, locating pipe, ordering pipe, arranging payment and shipping 1 day, shipping 2 days, and installation of new pipe or by-pass 2-days. Total 6-7 days downtime at best. This repair is impractical in most of the winter and would be deferred until spring. The generators could function uninterrupted. Freezing/Earthquake Damage/Differential Settlement - Care must be taken to minimize potential piping damage due to differential earth movement. The sub-surface piping must be properly bedded and allowances made for known transition zones. 9.2 Above Ground Pipe Failure Leaking pipe or connection located, isolated, repaired, clean-up, 2-10 hours downtime at best. Weather delays could make this considerably longer. 9.3 Clean-up Of Spilled Glycol Glycol clean up from facilities may be relatively easy but glycol is a health hazard and care must be taken to ensure that no one ingest the glycol mix. Glycol that spills on the ground or subsurface must be cleaned up before it enters the ground water WTHTLK/RCD 9-2 9.4 9.5 9.6 9.7 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 or surface run off. The glycol must not contaminate wells, streams, lakes or salt water. Vibration, Thermal, And Corrosion Damage To Piping 9.4.1 Vibration Insulation Devices - Must protect piping from vibration transmission particularly adjacent to vibration exciters like the diesel engines. Inadequate vibration isolation will produce cracked, broken, and leaking piping and gaskets. 9.4.2 Thermal Expansion - Joints must be installed to allow for pipe growth from thermal expansion. Inadequate provision for thermal growth will stress the system and result in strain on piping, pumps, and the heat exchangers. 9.4.3 Corrosion - Contaminates in the system or soils can accelerate the Corrosion of the piping. Corrosion inhibitors may be required. Care must be utilized to avoid dissimilar piping materials that could accelerate the Corrosion process. Particular attention must be paid to areas around welds and whenever there is a pressure drop in the system. Primary Heat Exchanger Failure Glycol leaks from heat exchanger - Operator finds leak, valves off heat exchanger and the gen-sets utilize radiators for cooling. Operators order new exchanger. If the exchanger is an “off the shelf" item, a new one could be on site in a week or 10 days. If not, it could take 10 weeks or more. Should this leak go unnoticed, gensets will shut down on low pressure or high temperature. The leaking area can be valved off immediately but the system must be recharged and air bled out before restarting the gensets. Downtime of gensets 2-3 hours. Secondary Heat Exchanger Failure Leaking or plugged secondary heat exchanger is identified, valved off, and by-passed. A replacement is ordered and the building is heated by the buildings heating plant. Down time 5 days to 6 weeks. Heat Exchanger Failure Modes 9.7.1 Mechanical Damage - Heat exchangers can be made to leak if damaged by dropping or by impacting them with power equipment, cranes, pipes, etc. Proper care must be exercised to limit exposure to mechanical damage. 9.7.2 Chemical Damage - The water/glycol fluid must be monitored to prohibit developing a corrosive mixture. Also particular attention must be paid to piping gaskets and valve seat material to ensure that the materials are WTHTLK/RCD 9-3 9.8 9.9 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 compatible with glycol. Dissimilar metals are to be avoided or insulated from each other. Water quality must be maintained to prevent scaling. Pump Failures The pumps are subject to thermally induced casing stress, seal failure, over-heating, voltage fluctuations, and frequency droop. The pump alignment must be checked with the piping at operative temperature. The air circulation/cooling around the pumps must not be impaired. The pump must be protected by circuit breakers from low voltage, frequency droop, and overload. The pumps must be in parallel pairs and capable of individual isolation for replacement. The coolant in the system must not contain contaminants that will destroy the seals. Recharging the system must be done with contaminate free water and glycol. When a pump fails from anyone of a variety of causes, the stand- by pump is activated and the failed pump valved off and repaired/replaced. System down time 0-12 hours. Replacement pump replaced 2 hrs. to 1 week. Control Failures Controls must be protected from power fluctuations and mechanical damage. Unauthorized persons must be precluded from adjusting control set points. Authorized persons must be familiar with the system and the inter-relationships of the components. In some cases it is possible for the waste heat customers to over-cool the waste heat recovery secondary piping and thermally shock the heat exchanger. It is also possible to have the waste heat customers actually heating the secondary loop coolant and then heating the generator coolant. These potential problems can be avoided by properly operating controls. Controls must be maintained and protected from corrosion and/or scaling. WTHTLK/RCD 9-4 LOWER KALSKAG WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 28, 1991 10.0 CONCLUSIONS AND RECOMMENDATIONS The final economics will be completed by the Alaska Energy Authority so a definitive conclusion is not made at this time concerning the feasibility of a waste heat installation at Lower Kalskag. Some conclusions that can be made are that the project is technically feasible, that the people and agencies in the community seem quite enthusiastic about the project, and that if the economics prove acceptable, a waste heat system for the community can be recommended. To make this project more economically attractive on option would be to include this project with the construction of other waste heat systems in neighboring communities. This would help to reduce the mobilization charges. Shipping, travel and other supervision and management costs could also be combined and pro- rated for lower cost to each village. Economics are not the only yardstick by which this project should be measured. The political and social problems involved in our nations oi] supply should motivate us to actively seek out ways like this to reduce our oi] consumption. Environmental costs are also present with the consumption of any fossil fuel, granted they are small but present. The communities enthusiasm to participate is an important factor in the final decision to go with the project or delay until the economic situation changes to a more favorable one. WTHTLK/RCD 10-1 c - Ol LOWER KALSKAG WASTE HEAT RECOVERY - GRAPH 1 HEAT AVAILABLE VS. HEAT REQUIRED BY MONTH HEATING FUEL EQUIV. (GAL.) Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. MONTH OF THE YEAR : @ AVAILABLE CHEAT REQD- HEAT REQD - SCENARIO #1 SCENARIO #2 €- Ob LOWER KALSKAG WASTE HEAT RECOVERY - GRAPH 2 HEATING FUEL DISPLACED BY MONTH HEATING FUEL EQUIV. (GAL) Jun. Jul. MONTH OF THE YEAR Mi SCENARIO #1 [1] SCENARIO #2 APPENDIX 1 CALCULATIONS WASTE HEAT UTILIZATION SIMULATION WORK SHEET. BASIC PROJECT DATA: Location: Lower Kalskag - Scenario #1 Date: May 29, 1990 Annual pumping elec. cost: Annual other O&M cost: Construction cost estimate: Fuel high heat value: Average fuel cost: GENERATOR DATA: 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: Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above: GENERATION DATA: Kwh/month: January 76,561 February 69,828 March 65,760 April 57,960 May 48,935 June 35,800 July 44,620 August 43,400 September 54,960 October 65,380 November 72,692 December 73,960 709856 BUILDING DATA: Fuel use, gal/mon. SCHOOL January 1049 February 905 March 875 April 602 May 341 June 169 July 126 August 182 September 303 October 584 November 807 December 1057 7000 Htg. Efficiency: 0.75 1000 $/year. 6000 $/year. 614022 $ 132000 Btu/gallon 2.00 $/galion ° 3741 Btu/kwh 21 3537 Btu/kwh 42 3361 Btu/kwh 63 3215 Btu/kwh 84 3098 Btu/kwh 105 3011 Btu/kwh 126 2952 Btu/kwh 147 2923 Btu/kwh 168 2923 Btu/kwh 189 2923 Btu/kwh 210 2923 Btu/kwh WEATHER DATA: HDD/Month: 2018 1740 1683 1157 656 325 243 350 583 1123 1552 2033 13463 PUMP 1* PUMP 2°* na 150 208 129 208 125 208 86 208 49 208 24 208 18 208 26 208 43 208 83 208 115 208 151 208 1000 2496 0 0.75 0.75 LKAL_#1.XLS PROGRAM RESULTS: Savings, year 0, fuel gallons: Savings, year 0, fuel cost: Annual O&M increase cost: Total Savings, year 0: Simple pay back time, years: SYSTEM LOSS DATA: Constant losses: Plant piping: Subsurface piping: Engine preheating: Total constant: Variable losses: Surface piping: Plant heating: Radiator losses: wa Page 1 n/a Wa 6000 Btu/hr. 24000 Btu/hr. 4000 Btu/hr. 34000 Btu/hr. 50 Btu/hr.xF 200 Btu/hr.xF 100 Btu/hr.xF na na na TOTAL 1407 1242 1208 896 598 401 352 416 554 875 1130 1416 0 fo) ° 10496 0.75 POWER PRODUCTION VARIATION: Assumed hourly variation: LKAL_#1.XLS Hour: January February March April May June July August Sept. October November December 1 0.038 0.038 0.038 0.038 0.043 0.043 0.043 0.043 0.043 0.043 0.038 0.038 2 0.036 0.036 0.036 0.036 0.038 0.038 0.038 0.038 0.038 0.038 0.036 0.036 3 0.034 0.034 0.034 0.034 0.035 0.035 0.035 0.035 0.035 0.035 0.034 0.034 4 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 5 0.033 0.033 0.033 0.033 0.034 0.034 0.034 0.034 0.034 0.034 0.033 0.033 6 0.034 0.034 0.034 0.034 0.036 0.036 0.036 0.036 0.036 0.036 0.034 0.034 7 0.038 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.036 0.036 0.038 0.038 8 0.042 0.042 0.042 0.042 0.038 0.038 0.038 0.038 0.038 0.038 0.042 0.042 9 0.042 0.042 0.042 0.042 0.043 0.043 0.043 0.043 0.043 0.043 0.042 0.042 10 0.047 0.047 0.047 0.047 0.045 0.045 0.045 0.045 0.045 0.045 0.047 0.047 1 0.048 0.048 0.048 0.048 0.041 0.041 0.041 0.041 0.041 0.041 0.048 0.048 12 0.047 0.047 0.047 0.047 0.046 0.046 0.046 0.046 0.046 0.046 0.047 0.047 13 0.045 0.045 0.045 0.045 0.048 0.048 0.048 0.048 0.048 0.048 0.045 0.045 14 0.047 0.047 0.047 0.047 0.050 0.050 0.050 0.050 0.050 0.050 0.047 0.047 15 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 16 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 17 0.049 0.049 0.049 0.049 0.043 0.043 0.043 0.043 0.043 0.043 0.049 0.049 18 0.046 0.046 0.046 0.046 0.045 0.045 0.045 0.045 0.045 0.045 0.046 0.046 19 0.043 0.043 0.043 0.043 0.048 0.048 0.048 0.048 0.048 0.048 0.043 0.043 20 0.040 0.040 0.040 0.040 0.043 0.043 0.043 0.043 0.043 0.043 0.040 0.040 21 0.040 0.040 0.040 0.040 0.039 0.039 0.039 0.039 0.039 0.039 0.040 0.040 22 0.041 0.041 0.041 0.041 0.039 0.039 0.039 0.039 0.039 0.039 0.041 0.041 23 0.040 0.040 0.040 0.040 0.039 0.039 0.039 0.039 0.039 0.039 0.040 0.040 24 0.040 0.040 0.040 0.040 0.041 0.041 0.041 0.041 0.041 0.041 0.040 0.040 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 Days: 31 28 31 30 31 30 31 31 30 31 30 31 HDD: 2018 1740 1683 1157 656 325 243 350 583 1123 1552 2033 13463 Kwh: 76561 69828 65760 57960 48935 35800 44620 43400 54960 65380 72692 73960 709856 HEAT DEMAND VARIATION: Assumed hourly variation: Hour: Winter” Summer" 1 0.039 0.039 2 0.038 0.038 3 0.038 0.038 4 0.038 0.038 5 0.038 0.038 6 0.039 0.039 7 0.041 0.041 8 0.043 0.043 9 0.044 0.044 10 0.044 0.044 11 0.044 0.044 12 0.044 0.044 13 0.045 0.045 14 0.044 0.044 15 0.043 0.043 16 0.043 0.043 1% 0.043 0.043 18 0.043 0.043 19 0.043 0.043 20 0.043 0.043 21 0.042 0.042 22 0.042 0.042 23 0.040 0.040 24 0.039 0.039 1.000 1.000 * Winter: Nov. - Apr. * Summer: May - Oct. Page 2 HEAT GENERATED PER HOUR BY MONTH, BTU'S Hour: OODNOOSWNH = een ennn nin 24 Day: 7589727 7634194 6633825 6115957 5160406 4032887 4758803 4628687 5846948 6616081 7455524 7340878 January 290780 275476 269989 269989 262048 269989 290780 321388 321388 349470 356905 349470 334599 349470 356905 356905 364341 342034 319728 306084 306084 313736 306084 306084 February 293623 278169 262715 262715 264610 262715 293623 324531 324531 352887 360395 352887 337870 352887 360395 360395 367903 345379 322854 309077 309077 316804 309077 309077 March 259182 245541 231900 231900 225079 231900 259182 276048 276048 308910 315483 308910 295765 308910 315483 315483 322056 302338 282620 262903 262903 269475 262903 262903 April 236054 223631 211207 211207 204995 211207 236054 260902 260902 281345 287331 281345 269373 281345 287331 287331 293317 275359 267114 248478 248478 254690 248478 248478 Month: 2.35E+08 2.14E+08 2.06E+08 1.83E+08 Equivalent Gallons: 2377 2159 2077 1853 May 218247 201636 185717 180411 180411 191024 191024 201636 218247 228398 208096 233473 243624 253775 243624 243624 218247 228398 243624 218247 206942 206942 206942 208096 LKAL_#1.XLS June 172487 152431 147722 143501 143501 144408 144408 152431 172487 180510 164465 184521 192544 200567 192544 192544 172487 180510 192544 172487 156442 156442 156442 164465 July 208048 183856 169341 164503 164503 174179 174179 183856 208048 208258 198371 212886 222142 231398 222142 222142 208048 208258 222142 208048 188694 188694 188694 198371 August 202359 178829 164711 160005 160005 169417 169417 178829 202359 202564 192947 207065 216068 225071 216068 216068 202359 202564 216068 202359 183535 183535 183535 192947 Sept. 253288 223836 206165 209378 209378 212055 212055 223836 253288 265069 241508 261107 272459 283812 272459 272459 253288 265069 272459 253288 229727 229727 229727 241508 October November December 280987 285288 280901 257685 270273 266117 237341 264890 260817 230560 264890 260817 230560 257099 253146 244122 264890 260817 244122 285288 280901 257685 315318 310470 280987 315318 310470 294056 342870 337597 267918 350165 344780 300591 342870 337597 313660 328280 323232 317482 342870 337597 313660 350165 344780 313660 350165 344780 280987 357460 351963 294056 335575 330414 313660 322826 317862 280987 300303 295685 264466 300303 295685 264466 307811 303078 264466 300303 295685 267918 300303 295685 1.6E+08 1.21E+08 1.48E+08 1.43E+08 1.75E+08 2.05E+08 2.24£+08 2.28E+08 2.24E+09 1616 HEAT LOST FROM SYSTEM PER HOUR BY MONTH, BTU'S Hour: January 1 72534 2 72534 3 = 72534 4 72534 5 72534 6 72534 7 = 72534 8 72534 9 72534 10 72534 "1 72534 12 72534 13 72534 14 72534 15 72534 16 72534 17 72534 18 72534 19 72534 20 72534 21 72534 22 = 72534 23072534 24 72534 Day: 1740813 Equivalent Gallons: 545 February 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 71500 1716000 485 March 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 68752 1650039 517 April 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 63248 1517960 460 May 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 57156 1222 June 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 53542 1490 July 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 52494 1371755 1285000 1259845 Month: 53965200 48048000 51151200 45538800 42524400 38550000 39055200 39954000 40717200 46447200 48856800 54091200 5.49E+08 430 389 394 Page 3 1449 August 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 53702 1288839 404 1772 Sept. 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 56552 2072 2259 2299 October November December 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 62429 67857 72703 1628560 1744877 1357240 1498297 411 469 494 546 22645 5544 LKAL_#1.XLS HEAT DEMAND BY HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 176156 172134 151235 115844 74838 51889 44115 52075 71721 109578 146207 177271 172561 168621 148149 113480 73311 50830 43215 51012 70257 =107341 143223 173654 171662 167742 147377 112888 72929 50565 42990 50747 69892 106782 142477 172749 168516 164669 144677 110820 71592 49639 42202 49817 68611 104825 139866 169584 171662 167742 147377 112888 72929 50565 42990 50747 69892 106782 142477 172749 174358 170377 149692 114662 74074 51360 43665 51544 70989 108459 144715 175463 184694 180477 158566 121459 78465 54404 46254 54599 75197 114889 153293 185864 194580 190137 167053 127960 82665 57316 48730 57522 79223 121038 161499 195813 195928 191455 168211 128847 83238 57713 49067 57920 79772 +121877 162618 197169 10 197276 192772 169368 129733 83811 58111 49405 58319 80320 122716 163737 198526 11 197276 192772 169368 129733 83811 58111 49405 58319 80320 122716 163737 198526 12 198624 194089 170526 130620 84384 58508 49742 58717 80869 123554 164856 199883 13 200422 195846 172069 131802 85147 59037 50193 59249 81601 124672 166347 201691 14 195928 191455 168211 128847 83238 57713 49067 57920 79772 121877 162618 197169 15 193232 188820 165896 127073 82093 56919 48392 57123 78674 120200 160380 194456 16 194580 190137 167053 127960 82665 57316 48730 57522 79223 121038 161499 195813 17 191884 187503 164738 126187 81520 56522 48054 56725 78125 119361 159261 193099 18 194580 190137 167053 127960 82665 57316 48730 57522 79223 121038 161499 195813 19 194580 190137 167053 127960 82665 57316 48730 57522 79223 121038 161499 195813 20 193232 188820 165896 127073 82093 56919 48392 57123 78674 120200 160380 194456 21 188738 184429 162038 124118 80184 55595 47267 55795 76844 117405 156650 189934 22 187390 183111 160880 123232 79611 55198 46929 55396 76295 116566 155531 188577 23 180200 176086 154708 118503 76556 53080 45128 53271 73368 112093 149564 181341 24 176156 172134 151235 115844 74838 51889 44115 52075 71721 109578 146207 __177271 Day: 4494214 4391601 3858429 2955491 1909323 1323835 1125505 1328577 1829805 2795626 3730136 4522682 Month: 1.39E+08 1.23E+08 1.2E+08 88664744 59189020 39715038 34890668 41185883 54894154 86664396 1.12E+08 1.4E+08 1.04E+09 Equivalent Gallons: 1407 1242 1208 896 598 401 352 416 554 875 1130 1416 10497 OODNOAOAWNH = HEAT DELIVERED BY HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 1 176156 172134 151235 115844 74838 51889 44115 52075 71721 109578 146207 177271 172561 168621 148149 113480 73311 50830 43215 51012 70257 107341 143223 173654 171662 167742 147377 112888 72929 50565 42990 50747 69892 106782 142477 172749 168516 164669 144677 110820 71592 49639 42202 49817 68611 104825 139866 169584 171662 167742 147377 112888 72929 50565 42990 50747 69892 106782 142477 172749 174358 170377 149692 114662 74074 51360 43665 51544 70989 108459 144715 175463 184694 180477 158566 121459 78465 54404 46254 54599 75197 114889 153293 185864 194580 190137 167053 127960 82665 57316 48730 57522 79223 121038 161499 195813 9 195928 191455 168211 128847 83238 57713 49067 57920 79772 121877 162618 197169 10 197276 192772 169368 129733 83811 58111 49405 58319 80320 122716 163737 198526 11. 197276 192772 169368 129733 83811 58111 49405 58319 80320 122716 163737 198526 12 198624 194089 170526 130620 84384 58508 49742 58717 80869 123554 164856 199883 13 200422 195846 172069 131802 85147 59037 50193 59249 81601 124672 166347 201691 14 195928 191455 168211 128847 83238 57713 49067 57920 79772 121877 162618 197169 15 193232 188820 165896 127073 82093 56919 48392 57123 78674 120200 160380 194456 16 194580 190137 167053 127960 82665 57316 48730 57522 79223 121038 161499 195813 17 191884 187503 164738 126187 81520 56522 48054 56725 78125 119361 159261 193099 18 194580 190137 167053 127960 82665 57316 48730 57522 79223 121038 161499 195813 19 194580 190137 167053 127960 82665 57316 48730 57522 79223 121038 161499 195813 20 193232 188820 165896 127073 82093 56919 48392 57123 78674 120200 160380 194456 21 188738 184429 162038 124118 80184 55595 47267 55795 76844 117405 156650 189934 22 187390 183111 160880 123232 79611 55198 46929 55396 76295 116566 155531 188577 23 180200 176086 154708 118503 76556 53080 45128 53271 73368 112093 149564 181341 24 176156 172134 151235 115844 74838 51889 44115 52075 71721 109578 146207 177271 4494214 4391601 3858429 2955491 1909323 1323835 1125505 1328577 1829805 2795626 3730136 4522682 ONOnhRwWND Days: 31 28 31 30 31 30 31 31 30 31 30 31 1.39E+08 1.23E+08 1.2E+08 88664744 59189020 39715038 34890668 41185883 54894154 86664396 1.12E+08 1.4E+08 1.04E+09 Equivalent Gallons: 1407 1242 1208 896 598 401 352 416 554 875 1130 1416 10497 Page 4 WASTE HEAT UTILIZATION SIMULATION WORK SHEET. BASIC PROJECT DATA: Location: Date: May 29, 1990 Annual pumping elec. cost: Annual other O&M cost: Construction cost estimate: Fuel high heat value: Average fuel cost: GENERATOR DATA: 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: Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above: GENERATION DATA: Kwh/month: January 76,561 February 69,828 March 65,760 April 57,960 May 48,935 June 35,800 July 44,620 August 43,400 September 54,960 October 65,380 November 72,692 December 73,960 709856 BUILDING DATA: Fuel use, gal/mon. SCHOOL January 1049 February 905 March 875 April 602 May 341 June 169 July 126 August 182 September 303 October 584 November 807 December 1057 7000 Htg. Efficiency: 0.75 Lower Kalskag - Scenario #2 1200 $/year. 7000 $/year. 662800 $ 132000 Btu/gallon 2.00 $/gallon 0 3741 Btu/kwh 21 3537 Btu/kwh 42 3361 Btu/kwh 63 3215 Btu/kwh 84 3098 Btu/kwh 105 3011 Btu/kwh 126 2952 Btu/kwh 147 2923 Btu/kwh 168 2923 Btu/kwh 189 2923 Btu/kwh 210 2923 Btu/kwh WEATHER DATA: HDD/Month: 2018 1740 1683 1157 656 325 243 350 583 1123 1552 2033 13463 PUMP 1* PUMP 2”* CITY BLD 150 208 58 129 208 50 125 208 48 86 208 33 49 208 19 24 208 9 18 208 z 26 208 10 43 208 17 83 208 32 115 208 44 151 208 58 1000 2496 385 0.75 0.75 0.75 LKAL_#2.XLS PROGRAM RESULTS: Savings, year 0, fuel gallons: Savings, year 0, fuel cost: Annual O&M increase cost: Total Savings, year 0: Simple pay back time, years: SYSTEM LOSS DATA: Constant losses: Plant piping: 6000 Btu/hr. Subsurface piping: 24000 Btu/hr. Engine preheating: 4000 Btu/hr. Total constant: 34000 Btu/hr. Variable losses: Surface piping: 50 Btu/hr.xF Plant heating: 200 Btu/hr.xF Radiator losses: 100 Btu/hr.xF PST OFF PRE-SCH na na wa Wa TOTAL 158 66 1689 136 57 1485 132 55 1443 91 38 1057 51 21 689 25 1 447 19 8 386 27 1 465 46 19 636 88 37 1032 122 51 1347 159 66 1700 1055 440 0 0 0 0 12376 0.75 0.75 0.75 Page 1 POWER PRODUCTION VARIATION: Assumed hourly variation: LKAL_#2.XLS Hour: January February March April May June July August Sept. October November December 1 0.038 0.038 0.038 0.038 0.043 0.043 0.043 0.043 0.043 0.043 0.038 0.038 2 0.036 0.036 0.036 0.036 0.038 0.038 0.038 0.038 0.038 0.038 0.036 0.036 3 0.034 0.034 0.034 0.034 0.035 0.035 0.035 0.035 0.035 0.035 0.034 0.034 4 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 5 0.033 0.033 0.033 0.033 0.034 0.034 0.034 0.034 0.034 0.034 0.033 0.033 6 0.034 0.034 0.034 0.034 0.036 0.036 0.036 0.036 0.036 0.036 0.034 0.034 7 0.038 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.036 0.036 0.038 0.038 8 0.042 0.042 0.042 0.042 0.038 0.038 0.038 0.038 0.038 0.038 0.042 0.042 9 0.042 0.042 0.042 0.042 0.043 0.043 0.043 0.043 0.043 0.043 0.042 0.042 10 0.047 0.047 0.047 0.047 0.045 0.045 0.045 0.045 0.045 0.045 0.047 0.047 11 0.048 0.048 0.048 0.048 0.041 0.041 0.041 0.041 0.041 0.041 0.048 0.048 12 0.047 0.047 0.047 0.047 0.046 0.046 0.046 0.046 0.046 0.046 0.047 0.047 13 0.045 0.045 0.045 0.045 0.048 0.048 0.048 0.048 0.048 0.048 0.045 0.045 14 0.047 0.047 0.047 0.047 0.050 0.050 0.050 0.050 0.050 0.050 0.047 0.047 15 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 16 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 17 0.049 0.049 0.049 0.049 0.043 0.043 0.043 0.043 0.043 0.043 0.049 0.049 18 0.046 0.046 0.046 0.046 0.045 0.045 0.045 0.045 0.045 0.045 0.046 0.046 19 0.043 0.043 0.043 0.043 0.048 0.048 0.048 0.048 0.048 0.048 0.043 0.043 20 0.040 0.040 0.040 0.040 0.043 0.043 0.043 0.043 0.043 0.043 0.040 0.040 21 0.040 0.040 0.040 0.040 0.039 0.039 0.039 0.039 0.039 0.039 0.040 0.040 22 0.041 0.041 0.041 0.041 0.039 0.039 0.039 0.039 0.039 0.039 0.041 0.041 23 0.040 0.040 0.040 0.040 0.039 0.039 0.039 0.039 0.039 0.039 0.040 0.040 24 0.040 0.040 0.040 0.040 0.041 0.041 0.041 0.041 0.041 0.041 0.040 0.040 1.000 1.000 1.000 1.000 1,000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 Days: 31 28 31 30 31 30 31 31 30 31 30 31 HDD: 2018 1740 1683 1157 656 325 243 350 583 1123 1552 2033 Kwh: 76561 69828 65760 57960 48935 35800 44620 43400 54960 65380 72692 73960 HEAT DEMAND VARIATION: Assumed hourly variation: Hour: Winter* Summer* 1 0.039 0.039 2 0.038 0.038 3 0.038 0.038 4 0.038 0.038 5 0.038 0.038 6 0.039 0.039 ie 0.041 0.041 8 0.043 0.043 9 0.044 0.044 10 0.044 0.044 11 0.044 0.044 12 0.044 0.044 13 0.045 0.045 14 0.044 0.044 15 0.043 0.043 16 0.043 0.043 17 0.043 0.043 18 0.043 0.043 19 0.043 0.043 20 0.043 0.043 21 0.042 0.042 22 0.042 0.042 23 0.040 0.040 24 0.039 0.039 1.000 1.000 * Winter: Nov. - Apr. * Summer: May - Oct. 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LOSE IIpOsl LOZLIZ OO6lEZ SiizoZ E8669% Z'8092 O68P92 IPELEZ S91902 IIZP9l +PE69L e2ldpl LIASB8L LOZLIZ OO6IEc sSidz9e ER6Ege £ Liig9z €22022@ S89LS2 9EBEZS G6CBBLL YSBEBL LEPcSL YEQIOZ LE9ECS IPSSrPe 691842 BLPSLe 2 to6ose s8zse2 86082 s8zese ESEzOe spos0Z LBPZLL L¥cBle PSO9EZ cBl6Se Ec9E62 084062 | JEQWE0eG JEQWIBAON 1eqo}WO =: des. isn6ny = Ainr eunr Kew judy youeyw Areniqga4 Arenuer = :unoy S.N.LE ‘HLNOW Ad YNOH Yd G3LVYAN3SD LV3H s1x@# Ww HEAT DEMAND BY HOUR BY MONTH, BTU'S Hour: O©OMDNONLWND = ee eee ee 24 January 211433 207118 206039 202264 206039 209276 221681 233547 235165 236783 236783 238401 240559 235165 231929 233547 230311 233547 233547 231929 226535 224917 216287 211433 February 205810 201610 200560 196885 200560 203710 215786 227336 228911 230486 230486 232061 234162 228911 225761 227336 224186 227336 227336 225761 220511 218936 210535 205810 March 180656 176970 176048 172822 176048 178813 189413 199552 200934 202317 202317 203699 205543 200934 198169 199552 196787 199552 199552 198169 193560 192178 184804 180656 April 136744 133953 133255 130814 133255 135348 143372 151046 152093 153139 153139 154186 155581 152093 150000 151046 148953 151046 151046 150000 146511 145465 139883 136744 84544 84104 82563 84104 85425 90489 95333 95993 96654 96654 97314 98195 95993 94672 95333 94012 95333 95333 94672 92470 91810 88287 86306 LKAL_#2.XLS June 57760 56581 56286 55255 56286 57171 63801 64243 65127 65717 64243 63359 63801 62917 63801 63801 63359 61886 61444 59086 57760 Day: 5394238 5250785 4609044 3488712 2201898 1473616 Month: 1.67E+08 1.47E+08 1.43E+08 1.05E+08 68258836 44208468 38250371 46024961 62954676 1.02E+08 1.33E+08 1.68E+08 1.23E+09 Equivalent Gallons: 1689 1485 1443 HEAT DELIVERED BY HOUR BY MONTH Hour: 1 2 3 4 5 6 7 8 9 10 1 12 13 14 15 16 17 18 19 20 21 22 23 24 Days: January 211433 202942 197455 197455 189514 197455 218246 233547 235165 236783 236783 238401 240559 235165 231929 233547 230311 233547 233547 231929 226535 224917 216287 211433 February 205810 201610 191215 191215 193110 191215 215786 227336 228911 230486 230486 232061 234162 228911 225761 227336 224186 227336 227336 225761 220511 218936 210535 205810 March 180656 176789 163148 163148 156328 163148 189413 199552 200934 202317 202317 203699 205543 200934 198169 199552 196787 199552 199552 194151 193560 192178 184804 180656 1057 , BTU'S April 136744 133953 133255 130814 133255 135348 143372 151046 152093 153139 153139 154186 155581 152093 150000 151046 148953 151046 151046 150000 146511 145465 139883 136744 689 May 86306 84544 84104 82563 84104 85425 90489 95333 95993 96654 96654 97314 98195 95993 94672 95333 94012 95333 95333 94672 92470 91810 88287 86306 447 June 57760 56581 56286 55255 56286 57171 60560 63801 64243 64685 65127 65717 64243 63359 63801 62917 63801 63801 63359 61886 61444 59086 57760 July 48363 47376 47130 46266 47130 47870 50708 53422 53792 54162 54162 54532 55026 53792 53052 53422 52682 53422 53422 53052 51818 51448 49474 48363 August 58193 57006 56709 55670 56709 57600 61014 64280 64725 65171 65171 65616 66210 64725 63835 64280 63389 64280 64280 63835 62350 61905 59530 58193 Sept. 82253 80574 80154 78685 80154 81413 86239 90855 91485 92114 92114 92744 93583 91485 90226 90855 89597 90855 90855 90226 88128 87498 84141 82253 October November December 129209 126572 125913 123606 125913 127891 135472 142723 143712 144701 144701 145690 147008 143712 141735 142723 140746 142723 142723 141735 138438 137450 132176 129209 1233883 1484676 2098489 3296481 386 July 48363 47376 47130 46266 47130 47870 50708 53422 53792 54162 54162 54532 55026 53792 53052 53422 52682 53422 53422 53052 51818 51448 49474 48363 465 August 58193 57006 56709 55670 56709 57600 61014 64280 64725 65171 65171 65616 66210 64725 63835 64280 63389 64280 64280 63835 62350 61905 59530 58193 636 Sept. 82253 80574 80154 78685 80154 81413 86239 90855 91485 92114 92114 92744 93583 91485 90226 90855 89597 90855 90855 90226 88128 87498 84141 82253 174242 170686 169797 166686 169797 172464 182688 192466 193800 195133 195133 196467 198245 193800 191133 192466 189800 192466 192466 191133 186688 185355 178243 174242 212811 208468 207382 203582 207382 210639 223126 235069 236698 238327 238327 239955 242127 236698 233441 235069 231812 235069 235069 233441 228012 226383 217697 212811 4445398 5429396 1032 1347 1700 October November December 129209 174242 208198 126572 170686 193414 125913 169797 188114 123606 166686 188114 125913 169797 180443 127891 172464 188114 135472 182688 208198 142723 192466 235069 143712 193800 236698 144701 195133 238327 144701 195133 238327 145690 196467 239955 147008 198245 242127 143712 193800 236698 141735 191133 233441 142723 192466 235069 140746 189800 231812 142723 192466 235069 142723 192466 235069 141735 191133 222982 138438 186688 222982 137450 185355 226383 132176 178243 217697 129209 174242 212811 5344889 5215826 4546888 3488712 2201898 1473616 1233883 1484676 2098489 3296481 31 28 31 30 31 30 31 31 30 31 4445398 5295110 30 31 12377 1.66E+08 1.46E+08 1.41E+08 1.05E+08 68258836 44208468 38250371 46024961 62954676 1.02E+08 1.33E+08 1.64E+08 1.22E+09 Equivalent Gallons: 1674 1475 1424 1057 689 447 386 Page 4 465 636 1032 1347 1658 12290 HEATLOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: |LOWER KALSKAG : [495-306 CALC FOR: |PUMP HOUSE : {2/15/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70\°F 13323/°F DAYS EXTERIOR: -39|°F ROOM: HEIGHT= 12 AREA= 1440 WIDTH= 36 VOLUME= 17280 LENGTH= 40 AC/HR= 0.5 SURFACE AREA| * U-VALUE | * (Ti- Te) | | =BTU/HR TOTAL COMMENTS _| WALL 1 324) 0.053 109 1872) WALL 2 360 0.053 109 2080 FLOOR 1440 0.053 109 8319 CEILING 1440 0.053 109 8319 GLASS 109 0 DOORS 109 0 PERIMETER LENGTH] * F-VALUE | * (Ti- Te) | = BTU/HR BASEMENT WALL 0 0 SLAB 0 0 | AIR EXCH. CFM| * FACTOR | * (Ti- Te) | = BTU/HR INFILT. 144 1.08) 109 16952 37541 TOTAL BTU/HR= 37,541 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS=| __ 110,126,426 TOTAL GAL/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 1,124 * Fuel usage for the year was reported as 3496 gallons. To make a more realistic fuel usage distribution, 1000 gallons was used for building heat, and 2496 gallons was used for heating the city water supply. HEATLOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: |LOWER KALSKAG PROJ NO: /|495-306 CALC FOR: |CITY BUILDING DATE: |2/15/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70|°F 13323|°F DAYS EXTERIOR: -39/°F ROOM: HEIGHT= 8 AREA= 384 WIDTH= 16 VOLUME= 3072 LENGTH= 24 AC/HR= 0.5 SURFACE AREA| * U-VALUE | * (Ti- Te) | = BTU/HR TOTAL COMMENTS WALL 1 128 0.074) 109 1032 WALL 2 192 0.074 109 1549 FLOOR 384 0.074 109 3097 CEILING 384 0.074 109 3097; GLASS 109 0 DOORS 109 0 PERIMETER LENGTH| * F-VALUE | * (Ti- Te) | = BTU/HR BASEMENT WALL 0 0 SLAB 0 0 AIR EXCH. CFM| * FACTOR | * (Ti- Te) |_ = BTU/HR INFILT. 26 1.08 109) 3014 11789) TOTAL BTU/HR= 11,789 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS= 34,584,376 TOTAL GAL/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 353 * Note: Fuel usage was reported to be about seven 55 gallon drums (385 gallons) per year. HEATLOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: |LOWER KALSKAG PROJ NO: |495-306 CALC FOR: |COMMUNITY CENTER / PRESCHOOL DATE: |2/15/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70/°F 13323|°F DAYS EXTERIOR: -39|°F ROOM: HEIGHT= 8 AREA= 468) WIDTH= 18 VOLUME= 3744 LENGTH= 26) AC/HR= 0.5) SURFACE AREA| * U-VALUE | *(Ti- Te) |__ = BTU/HR TOTAL COMMENTS WALL 1 144 0.074 109 1162) WALL 2 208 0.053 109) 1202) FLOOR 468 0.053 109 2704) CEILING 468 0.053 109 2704) GLASS 109 0 L- DOORS 109 0 PERIMETER LENGTH| * F-VALUE | * (Ti- Te) | = BTU/HR BASEMENT WALL 0 0 SLAB 0 0 AIR EXCH. CFM) * FACTOR | * (Ti- Te) |_=BTU/HR INFILT. 31 1.08) ~ 109) 3673 11443 TOTAL BTU/HR= 11,443 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS= 33,568,844 TOTAL GAL/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 343 * Fuel usage for the Preschool was reported as about eight 55 gallon drums (440 gallons) a year. eto CALCULATION BASIC PROJECT INFORMATION PROJECT: |LOWER KALSKAG PROJ NO: |495-306 CALC FOR: |CLINIC / POST OFFICE DATE: |2/15/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70°F 13323|°F DAYS EXTERIOR: -39)°F ROOM: HEIGHT= 8 AREA= 1200 WIDTH= 24) VOLUME= 9600 LENGTH= 50 AC/HR= 0.5 SURFACE AREA| * U-VALUE | * (Ti- Te) | | = BTU/HR TOTAL COMMENTS WALL 1 192 0.074 109 1549) WALL 2 400 0.074 109 3226) FLOOR 1200 0.074 109 9679 CEILING 1200 0.074 109 9679 GLASS 109) 0 DOORS 109) 0 PERIMETER LENGTH] * F-VALUE | * (Ti- Te) | =BTU/HR BASEMENT WALL 0 0 SLAB 0 0 AIR EXCH. CFM| * FACTOR | * (Ti- Te) | =BTU/HR INFILT. 80 1.08 109 9418 33551 TOTAL BTU/HR= 33,551 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS= 98,422,224 TOTAL GAL/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 1,004 * Fuel records were rough and showed : approximately 1055 gallons used in 1989. | APPENDIX 2 COST ESTIMATES Lower Kaskag waste heat report Simple Payback Ignores O&M costs Scenario #1 Scenario #2 Prodject cost $ 614,022 $ 662,800 Fuels cost Savings $ 20,994 $ 24,600 Years for payback 29.2 26.9 Fuel cost savings based on $2.00 per gallon Price of fuel required for 10 year payback Prodject cost $ 614,022 $ 662,800 Gallons fuel saved 10,500 12,300 Cost of fuel per gallon for 10 year payback $5.85 $5.39 2/20/91 HMS 9119 CONSTRUCTION COST ESTIMATE WASTE HEAT RECOVERY SYSTEM LOWER KALSKAG, ALASKA cos SU rT ENGINEER HMS Inc. Frank Moolin & Associates, Inc. 4103 Minnesota Drive 550 W. 7th Avenue Anchorage, Alaska 99503 Anchorage, Alaska 99501 (907) 561-1653 February 19, 1991 (907) 562-0420 FAX WASTE HEAT RECOVERY SYSTEM PAGE 1 LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from a February 14, 1991 report, including a concept design dated May 29, 1990, by Frank Moolin & Associates. 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. SCENARIO #1 - Elementary School and Pump House SCENARIO #2 - Elementary School, Pump House, City Building, Community Center/Preschool and Clinic/Post Office WASTE HEAT RECOVERY SYSTEM LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY CONSTRUCTION COST ESTIMATE 01 - General Conditions, Overhead and Profit 02 - Sitework 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% SUMMARY SCENARIO #1 152,838 128,513 11,004 4,670 67,084 6,789 370,898 37,090 30,599 438,587 43,859 87,717 43,859 614,022 SCENARIO #2 164,904 138,345 5,000 4,450 79,982 7,662 400,343 40,034 33,028 473,406 47,341 94,681 47,341 662,768 PAGE 2 2/19/90 PAGE 3 WASTE HEAT RECOVERY SYSTEM LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/90 SCENARIO #1 WASTE HEAT RECOVERY SYSTEM | LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 01 - GENERAL CONDITIONS QUANTITY UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,500.00 8,500 Freight 58,000 LBS 0.50 29,000 Supervision, equipment, utilities, clean site, tools and protection 10 WKS 3,500.00 35,000 Per diem 4 280 DAYS 110.00 30,800 Travel costs, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 111,700 Bond and insurance 2.25 % 7,420 Profit 10.00 % 33,718 TOTAL ESTIMATED COST: 152,838 WASTE HEAT RECOVERY SYSTEM —= LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 02 - SITE WORK QUANTITY UNIT RATE ESTIMATED COST Piles Mobilize 1 LOT 10,000.00 10,000 Wood piles 20 EA 650.00 13,000 Drill pile hole 400 LF 25.00 10,000 Slurry 15 cy 280.00 4,200 Freeze back 20 EA 220.00 4,400 Test and demobilize 1 LOT 3,000.00 3,000 Piped Utilities Excavate trench for arctic pipe, including backfilling for spread and level surplus 810 LF 12.50 10,125 3" diameter Schedule 40 pipe with insulation and arctic pipe protection 280 LF 55.15 15,442 2" ditto 1,060 LF 41.50 43,990 1 1/4" ditto 280 LF 31.90 8,932 3" tee 4 EA 231.00 924 WASTE HEAT RECOVERY SYSTEM © LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities (Continued) 3" bend 8 EA 215.25 1,722 2" bend 10 EA 167.00 1,670 1 1/4" bend 8 EA 138.50 1,108 TOTAL ESTIMATED COST: 128,513 PAGE 7 WASTE HEAT RECOVERY SYSTEM LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 06 - WOODS AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Glulam beams to support new module 120 LF 40.00 4,800 Wood deck 96 SF 11.50 1,104 Miscellaneous metals 2,000 LBS 1.75 3,500 Access steps 1 EA 325.00 325 Handrail and balustrade 30 LF 42.50 1,275 TOTAL ESTIMATED COST: 11,004 WASTE HEAT RECOVERY SYSTEM PEGE © LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 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 6 EA 110.00 660 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 TOTAL ESTIMATED COST: 4,670 WASTE HEAT RECOVERY SYSTEM PAGE 9 LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 6 EA 72.50 435 Connect to existing radiators 4 EA 72.50 290 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 140 LF 26.22 3,671 Fittings 26 EA 46.35 1,205 Gate valve 19 EA 325.00 6,175 Amot three-way valve 1 EA 405.00 405 Balance valves 1 EA 325.00 325 Check valve 3 EA 325.00 975 3/4" diameter black steel welded piping including fittings 40 LF 8.50 340 Gate valve 15 EA 69.00 1,035 Check valve 2 EA 69.00 138 WASTE HEAT RECOVERY SYSTEM oo LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 15 - MECHANICAL | QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Insulation to pipe, 3" diameter 140 LF 7.10 994 Ditto, 3/4" diameter 40 LF 4.20 168 Booster pumps, 38 GPM, 30’0" head, 1/2 HP 2 EA 1,310.00 2,620 Circulating pumps, 5 GPM, 5’0" head, fractional HP 1 EA 735.00 _ 735 Heat exchanger, 340 MBH, 100 GPM x EA 4,150.00 4,150 Ditto, 43 MBH, 100 GPM 1 EA 2,950.00 2,950 Air separator with vent 1 EA 495.00 495 Gauges 4 EA 68.50 274 Expansion tank 1 EA 770.00 770 Glycol tank, pumps and make-up system a EA 1,025.00 1,025 Glycol 750 GALS 8.80 6,600 WASTE HEAT RECOVERY SYSTEM il LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up Form hole through existing wall for heating pipes 4 EA 195.00 780 2" diameter black steel piping including fittings 100 LF 17.97 1,797 1 1/4" ditto 120 LF 12.05 1,446 1 1/4" gate valves 4 EA 124.00 496 2" ditto 3 EA 260.00 780 1 1/4" balance valves 1 EA 89.00 89 2" ditto 2 EA 260.00 520 1 1/4" insulation 120 LF 4.90 588 2" ditto 100 LF 5.85 585 80 MBH heat exchanger 1 EA 3,075.00 3,075 169 MBH heat exchanger 1 EA 3,375.00 3,375 Double wall heat exchanger 1 EA 4,880.00 4,880 WASTE HEAT RECOVERY SYSTEM siaamelia LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT RATE ESTIMATED COST Hook-Up (Continued) Connection to water heater a EA 72.50 73 Connection to existing piping system 6 EA 72.50 435 Test and balance system 80 HRS 75.00 6,000 Controls and Instrumentation Generator building and new module 1 LOT 2,000.00 2,000 Hook-up inter ties 2 Lots 2,000.00 4,000 TOTAL ESTIMATED COST: 67,084 WASTE HEAT RECOVERY SYSTEM i LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 2 EA 175.00 350 Connection to motor 7 EA 115.00 805 Disconnect switch 3 EA 330.00 990 3/4" EMT conduit 120 LF 3.20 384 #8 copper 480 LF 0.85 408 New Module Main feeder and conduit 40 LF 8.80 352 Breaker in existing distribution panel 1 EA 277.00 277 Panel : 1 EA 800.00 800 Exterior light fixture 2 EA 330.00 660 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 Pane: 44 LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) 1/2" conduit 60 LF 3.00 180 #12 copper 210 LF 0.55 116 TOTAL ESTIMATED COST: 6,789 PAGE 15 WASTE HEAT RECOVERY SYSTEM LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 PAGE 16 WASTE HEAT RECOVERY SYSTEM LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 01 - GENERAL CONDITIONS QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,500.00 8,500 Freight 69,000 LBS 0.50 34,500 Supervision, equipment, utilities, clean site, tools and protection 10 WKS 3,500.00 35,000 Per diem 310 DAYS 110.00 34,100 Travel santa, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 120,500 Bond and insurance 2.25 % 8,009 Profit 10.00 % 36,395 TOTAL ESTIMATED COST: 164,904 WASTE HEAT RECOVERY SYSTEM ——— ie LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY ; 2/19/91 SCENARIO #1 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piles Mobilize ; 1 LoT 10,000.00 10,000 Wood piles 6 EA 650.00 3,900 Drill pile hole 120 LF 25.00 3,000 Slurry 5 cy 280.00 1,400 Freeze back 6 EA 220.00 1,320 Test and demobilize 1 LOT 3,000.00 3,000 Piped Utilities Excavate trench for arctic pipe, including backfilling for spread and level surplus 1,170 LF 12.50 14,625 3" diameter Schedule 40 pipe with insulation and arctic pipe protection 280 LF 55.15 15,442 2" ditto 1,060 LF 41.50 43,990 1 1/2" ditto 520 LF 35.10 18,252 1 1/4" ditto 100 LF 31.90 3,190 1" ditto 380 LF 28.70 10,906 WASTE HEAT RECOVERY SYSTEM _— LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities (Continued) 3" tee 4 EA 231.00 924 1 1/2" tee 4 EA 160.00 640 3" bend 8 EA 215.25 1,722 2" bend 10 EA 167.00 1,670 1 1/2" bend 16 EA 151.00 2,416 1 1/4" bend 8 EA 138.50 1,108 1" bend 8 EA 105.00 840 TOTAL ESTIMATED COST: 138,345 WASTE HEAT RECOVERY SYSTEM LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY UNIT RATE PAGE 19 2/19/91 ESTIMATED COST SCENARIO #2 06 - WOODS AND PLASTICS QUANTITY UNIT Glulam beams to support new module 60 LF Miscellaneous metals 800 LBS Access steps, including handrail and base 1 LOT TOTAL ESTIMATED COST: 40.00 1.75 1,200.00 2,400 1,400 1,200 5,000 WASTE HEAT RECOVERY SYSTEM PAGE 20 LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 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 a LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 6 EA 72.50 435 Connect to existing radiator 4 EA 72.50 290 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 140 LF 26.22 3,671 Fittings 26 EA 46.35 1,205 Gate valve 19 EA 325.00 6,175 Amot three-way valve a EA 405.00 405 Balance valves i EA 325.00 325 Check valve : 3 EA 325.00 975 3/4" diameter black steel welded piping including fittings 40 LF 8.50 340 Gate valve 15 EA 69.00 1,035 Check valve , 2 EA 69.00 138 WASTE HEAT RECOVERY SYSTEM —sa LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Insulation to pipe, 3" diameter 140 LF 7.10 994 Ditto, 3/4" diameter 40 LF 4.20 168 Booster pumps, 38 GPM, 30’0" head, 1/2 HP 2 EA 1,310.00 2,620 Circulating pumps, 5 GPM, 5’0" head, . fractional HP 1 EA 735.00 735 Heat exchanger, 340 MBH, 100 GPM 1 EA 4,150.00 4,150 Ditto, 43 MBH, 100 GPM 1 EA 2,950.00 2,950 Air separator with vent 1 EA 495.00 495 Gauges 4 EA 68.50 274 Expansion tank 1 EA 770.00 770 Glycol tank, pumps and make-up system 1 EA 1,025.00 1,025 Glycol 985 GALS 8.80 8,668 PAGE 23 WASTE HEAT RECOVERY SYSTEM LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up Form hole through existing wall for heating pipes 10 EA 195.00 1,950 2" diameter black steel welded piping 100 LF 17.97 1,797 11/2" ditto 60 LF 15.25 915 1 1/4" ditto 160 LF 12.05 1,928 1" ditto 30 LF 10.85 326 2" gate valves 3 EA 260.00 780 1 1/4" ditto 7 EA 124.00 868 1" ditto 4 EA 95.00 380 2" balancing valve 2 EA 124.00 248 1 1/4" ditto 2 EA 89.00 178 1" ditto 3 EA 79.00 237 Insulation to pipe, 2" diameter 100 LF 5.83 583 WASTE HEAT RECOVERY SYSTEM —e LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) Insulation, 1 1/2" diameter 60 LF 5.20 312 Ditto, 1 1/4" diameter 160 LF 4.70 752 Ditto, 1" diameter 30 LF 4.50 135 Double wall heat exchanger 1 EA 4,880.00 4,880 Heat exchanger, 169 MBH, 19 GPM 1 EA 3,375.00 3,225 Ditto, 86 MBH, 10 GPM 1 EA 3,075.00 3,075 Ditto, 39 MBH, 5 GPM 1 EA 2,950.00 2,950 Connection to existing piping system 8 EA 72.50 580 Test and balance system 80 HRS 75.00 6,000 Controls and Instrumentation Generator building and new module 1 LOT 2,000.00 2,000 Hook-up inter ties : 5 Lots 1,500.00 7,500 TOTAL ESTIMATED COST: 79,982 WASTE HEAT RECOVERY SYSTEM ee LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 5 EA 175.00 875 Connection to motor 10 EA 115.00 1,150 Disconnect switch 3 EA 330.00 990 3/4" EMT conduit 180 LF 3.20 576 #8 Copper 720 LF 0.85 612 New Module Main feeder and conduit 40 LF 8.80 352 Breaker in existing distribution panel 1 EA 277.00 277 Panel 1 EA 800.00 800 Exterior light fixture a 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 PAGE 26 LOWER KALSKAG, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST e' lodule Cont ed 1/2" conduit 50 LF 3.00 150 #12 copper 150 LF 0.55 83 TOTAL ESTIMATED COST: 7,662 APPENDIX 3 RAW DATA H_D_DAY.XLS HEATING DEGREE DAY WEATHER DATA | Note: Community names in lower case are close to site and are used when actual info is not available. MONTH HDD HDD HDD MONTH HDD HDD HDD MONTH HDD HDD ___|HDD MEAN 1988) 1989 MEAN 1988) 1989 [MEAN 1988) 1989) a HOONAH COLD BAY | CORDOVA Juneau > JAN 1087| 1217) JAN 1126| 1318 JAN 1157) 1255) FEB 1002) 1144 FEB 1055) 834 FEB [ 967) 1017 MAR 936) 1097] MAR 1098} 1034 MAR 1001 1024 APR 768) 663) APR 952 917) APR 809 708 MAY 639) 491 MAY 782 751 MAY 637) 584 JUN ii 412) 283 JUN 578 564 JUN 434 | 403 JUL 391 338) 159 JUL 448 427) 432) JUL 356 315} 202 AUG 375) 338) 210 AUG 416 423 353) AUG 360 324} 236 ISEP 520/ 497 370 SEP 517 537| 447) SEP 503 481) 400 OCT 751 641 713} OCT 779) 755) 695 OCT 737| 665) 717 NOV 940) 855) NOV 907) 970) 975 NOV 927) 873 990 DEC 1034 1040} DEC 1075) 1050) 1054 DEC 1115 950 868) TOTAL 8855) TOTAL 9733) 9374) TOTAL 9003 8404 ANVIK, RUSSIAN MISSION, & LOWER KALSKAG Holy Cross ——--————------> Anak annem St. Marys onsessccccnnoomms : JAN 2018 JAN 1958 2508) JAN 1739) [2370 FEB 1740) FEB 1617 1163 FEB 1627 [1128 MAR 1683| MAR 1605 MAR 1541 1418 APR 1157] APR 1163) APR 1185) 1087 MAY 656 MAY | __715 764) MAY 697) 868 JUN 325] JUN 380) 338 JUN 422! 361 JUL 243 JUL 310) 112 JUL 299) 143| 367 AUG 350] AUG 395] 425) AUG 357/317; 380) SEP 583] SEP 619| 697 S11 SEP 601 554] 527/ OCT 1123) OCT 1121] 1247 OCT 1072] 1180 1047 NOV 1552 NOV 1488] 1823) NOV 1436] 1671] 1650) DEC 2033 DEC 1986) DEC 1810| _1756| 1566) TOTAL 13463 TOTAL 13357 TOTAL 12786] 12769| Note: for analysis, use Holy Cross Data | | | KOTLIK WHITE MOUNTAIN Unalakleet --—----—-------> Nome -----—---—-----> JAN 1855) JAN 1809 FEB 1727, FEB 1701 MAR 1692! MAR 1767, 1 APR 1294 APR 1424) MAY 834) MAY 898) { | JUN 532] JUN 565) [ JUL 386! JUL 430) | . AUG 393 AUG 463 | SEP 662 SEP 676 OCT 1164 oct 1140 NOV 1505 NOV 1447 DEC 1875) DEC 1818 TOTAL | __ 13919 TOTAL 14138 | | Note: St. Marys is closer than Unalakleet to Kotlik but has less HDD than typical coastal communities. Unalakleet is the | closest listed coastal community to Kotlik. Nome is the closest listed coastal community to White Mountain. | I. Page 1 Engine Heat balance charts for modern diesel engines indicate one-third of fuel required for engine operation results in heat absorbed by the jacket water. This heat must be totally removed to assure dependable engine performance. % 30 4 exaust FUEL ENERGY % LOAD TYPICAL HEAT BALANCE DIESEL ENGINE (PRECOMBUSTION CHAMBER — TURBO-CHARGED AFTERCOOLER) Figure 101 The amount of heat removed is regulated by engine thermostats. They permit efficient engine operation by disconnecting the exter- nal cooling system until jacket water temper- atures exceed 175°F (79°C). Never operate without thermostats when utilizing the nor- mal 175°F (79°C) cooling system. EXCERPT FRom “ CATERPILLAR APPLICATION AND INSTALLATION “ MANUAL (AUG. gs) - PE. OC. DEMoOnSTRATES “THat BETWEEN 607, £ 1007, Load , PeRCeEwT oF EWERLY “To JACKET WATER 1S ESSENTIAUN CONSTAWT . PER CEWTAGES OBTAWED FRon PRIME Lond DATA SHoulLdD BE APPLICABLE IN “THIS RANGE. GENSETS.XLS GENSET DATA LOCATION |GENSET | HOONAH, CATAPILER 3512 @ 851 KW PRIME (W/O FAN) - NOTE 1 iC. BAY INPUT: 143198} btu/min OUTPUT: | Work: 52320) 36%! Exhaust: 52832| 37% Radiation: 6369) 4% Water: 32075 22%| Aftercooler: 3697|btu/min _| (included in jacket water) -----> 0 Oilcooler: 7166) btu/min__| (included in jacket water) -----> 0 Total: 143596) btu/min WATER % LOAD KW. GPH |KWH/GAL| BTU/HR_ | BTU/KWH| BTU/GAL | 100) 851 62.0 13.7 1924500] 2261 31049 [ake 75) 638 | 50| 426 C. BAY CATAPILER 3512 @ 683 KW PRIME (W/O FAN) - NOTE 2 INPUT: 121417) btu/min OUTPUT: | Work: 43392 36% Exhaust: 44984) 37% Radiation: 6028 5% Water: 27070 22% Aftercooler: 1934|/btu/min _| (included in jacket water) -----> 0} Oilcooler: 6085/btu/min _| (included in jacket water) -----> 0} Total: 121474) btu/min WATER % LOAD KW. GPH_ |KWH/GAL| BTU/HR_|BTU/KWH| _BTU/GAL | 100) 683 52.6 13.0) 1624200) 2378) 30905} _ 75| 512 L L 50 342 HOONAH CATAPILER D398 @ 600 KW PRIME (W/O FAN) INPUT: 48.2|gph ° 19590} btu/Ib hhv * 7.076) Ib/gal / 60} min/hr = 111357 btu/min OUTPUT: | Work: 636] kw engine * 3412) btu/kwh / 60} min/hr = 36167] 33%) Exhaust: 37400 34%) Radiation: 5300) 5% Water: 32200) 29% Total: 111067) btu/min WATER % LOAD KW GPH _|KWH/GAL| BTU/HR_|BTU/KWH! _BTU/GAL 113 675) 56.1 12.0) 2190000) 3244 39037 100 600 48.2 12.4) 1932000) 3220 40083 75 450 36.1 12.5] 50) 300) 25.3} 11.9 L. KALSKAG |CATAPILER 3406 TA @ 210 KW PRIME (W/O FAN) - NOTE 3 | INPUT: 16.5] gph * 19590) btu/Ib hhv * 7.076) Ib/gal / 60| min/hr = 38120) btu/min OUTPUT: |Work: 224/ kw engine * 3412) btu/kwh / 60) min/hr = 12738! 33%| Exhaust: | | 13700] 36% Radiation: 1900) 5% | Water: 10000] 26% Total: toy 38338) btu/min WATER % LOAD KW GPH_|KWH/GAL| BTU/HR_|BTU/KWH/ _BTU/GAL 124 260) 20.6) 12.6 726000; 2792) 35243) 100} 210) 16.5 12.7| 600000) 2857) 36364 75|__158| ‘12.6 12.5 il 50) 105) 9.0 11.7] GENSETS.XLS CATAPILER D342 T @ 160 KW PRIME (W/O FAN) - NOTE 4 INPUT: 12.5|gph * 19590) btu/Ib hhv * 7.076} Ib/gal / 60} min/hr = 28879) btu/min OUTPUT: | Work: 235) bhp engine * 2545) btu/bhp-hr / 60} min/hr = 9969) 34% Exhaust: 1340|CFM @ 710)F ----------> 8157) 28% Radiation: 2100 7% Water: 9400) 32% Total: 29626) btu/min WATER _| % LOAD KW GPH |KWH/GAL| BTU/HR_|BTU/KWH|_ BTU/GAL 143] __ 229) _| 100) 160 12.5) 12.8 564000) 3525) 45120 | 75| 120 9.8 12.2 50) 80 7.0 11.4) KOTLIK CATAPILER 3306 TA @ 155 KW PRIME (W/O FAN) - NOTE 5 - INPUT: 12.3| gph * 19590} btu/Ib hhv * 7.076} Ib/gal / 60) min/hr = 28417|btu/min OUTPUT: | Work: 167|kw engine * 3412) btu/kwh / 60} min/nr = 9497 52% Exhaust: 10500) 57% Radiation: 1700) 9% Water: 6800 37% Total: 28497|btu/min WATER % LOAD Kw GPH_ |KWH/GAL| BTU/HR_|BTU/KWH} BTU/GAL 116 180) 14.5) 12.4 468000) 2600) 32276 100 155 12.3) 12.6 408000) 2632) 33171 —__| | 75) 116 9.3 12.5) 50 78) 6.5) 11.9) R. MISSION _|CATAPILER 3304T @ 90 KW PRIME (W/O FAN) - NOTE 6 | T INPUT: 7.6|gph * 19590) btu/Ib hhv * 7.076} Ib/gal / 60) min/hr = 17558} btu/min OUTPUT: | Work: 99/kw engine * 3412) btu/kwh / | 60|min/hr = 5630) 31% Exhaust: _| 5801 31%) Radiation: 1 | 1990] 11% Water: ap 5005| 27% Total: 18426] btu/min WATER % LOAD KW GPH |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 117 105) 9.2 11.4) 341220) 3250) 37089 100 90) 7.6 11.8) 300300} 3337 39513 75) 68 5.6 12.1 50 45 3.9) 11.5) R. MISSION, |CUMMINS LTA 10 @ 110 KW PRIME (W/O FAN) - NOTES 7 &8 WHITE MT._[INPUT: 8.0|gph* 19590]btufb hhv * 7.076|Ib/gal / 60|min/hr =| 18536|btu/min OUTPUT: |Work: 166] bhp engine * 2545|btu/ohp-hr/ | _60|min/hr = 7042| 38%! Exhaust: 9382| * 166| / 235| = 6627| 36% Radiation: 745] * 166| / 235] = I 526] 3% Water: | 6251] * 166| 7 235] = 4416] 24%] - Total: 18611|btu/min WATER al % LOAD | KW | GPH |KWH/GAL| BTU/HR |BTU/KWH| BTU/GAL 100] 110 8.0 13.8] 264936) 2409) 33117, 75| 83 50| 55 ANVIK ALLIS CHALMERS 11000 @ 100 KW PRIME (W/ FAN) - NOTE 9 INPUT: 8.5] gph * 19590] btu/b hhv * 7.076| Ib/gal / 60|min/hr =| __ 19638] btu/min OUTPUT: | Work: 150] bhp engine * 2545|btu/ohp-hr/ _|_60|min/hr = 6363, 32% {Exhaust: 2 Radiation: L 2 Water: 150| bhp engine * 32)btu/bhp-min = 4800) 24%| Total: Page 2 GENSETS.XLS % LOAD | KW GPH_|KWH/GAL| BTU/HR_|BTU/KWH| BTU/GAL 125 125 10.3) 12.1 360000) 2880) 34951 100 100} 8.5) 11.8) 288000) 2880) 33882 75) 75) 6.7) 11.2 50 50) 5.0) 10.0) ANVIK ALLIS CHALMERS 3500 @ 60 KW PRIME (W/ FAN) - NOTE 10 | INPUT: 5.1}gph * 19590] btu/lb hhv * 7.076} Ib/gal / 60} min/nr = 11783} btu/min OUTPUT: | Work: 87/bhp engine * 2545|btu/bhp-hr / 60 min/hr = 3691 31% Exhaust: 2 Radiation: 2 Water: 87|bhp engine * 32|btu/bhp-min = 2784) 24%| Total: 2\btu/min | WATER | % LOAD | KW GPH_|KWH/GAL| BTU/HR_ |BTU/KWH|_ BTU/GAL 125 75) 6.7 11.2 208800; 2784) 31164 100 60) 5.2 11.5 167040 2784) 32123 75) 45 3.8 11.8 50) 30) 2.7) 11.1 ANVIK ALLIS CHALMERS 2900 @ 50 KW PRIME (W/ FAN) - NOTE 10 INPUT: 4.26|gph * 19590] btu/lb hhv * 7.076} Ib/gal / 60} min/hr = 9842) btu/min OUTPUT: | Work: 73) bhp engine * | 2545) btu/bhp-hr / 60} min/hr = 3097) 31% | Exhaust: 2 Radiation: 2 Water: 73/bhp engine * 32) btu/bhp-min = 2336 24%) Total: 2\btu/min WATER % LOAD | KW GPH_ |KWH/GAL| BTU/HR_|BTU/KWH|_ BTU/GAL 120 60) 5.2) 11.5) 168192 2803) 32345 100 50 4.26 11.7} 140160 2803) 32901 75) 33) 3.23 11.6) 50) 25) 2.3 10.9 SUMMARY RESULTS: 1 ml WEIGHTED SITE LOCATION _|GENSET BTU/KWH| BTU/GAL| WGHT % |BTU/KWH} BTU/GAL HOONAH CAT D398 3220) 40083, 5) 2357, 31953 CAT D398 3220) 40083 5) CAT 3512 (851 KW) 2261 31049) 90) iC. BAY CAT 3512 (683 KW) 2378) 30905 33) 2339! 30953 CAT 3512 (851 KW) 2261; 31049 33 CAT 3512 (683 KW) a 30905 33 | L. KALSKAG | CAT D342T 3525 45120 0} 2924 37239 CAT 3406TA 2857| 36364) 90) CAT D342T 3525 45120 10) R. MISSION _|CUMMINS LTA10 2409 33117) 50) 2873) 36315 CAT 3304T 3337) 39513) 25) CAT 3304T 3337) 39513) 25) | | ANVIK AC 11000 2880) 33882) 33) 2822) 32969 AC 3500 2784) 32123) 33) { AC 2900 2803 32901 33 | KOTLIK CAT 3306TA 2632 33171 50) 2632 33171 CAT 3306TA 2632 33171 50) GENSETS.XLS CUMMINS LTA10 DETROIT 4-71T DETROIT 371 except as shown. KWH/GAL, BTU/KWH, an 1) | Fuel use is listed in manufacturer's data as 143198 btu/min input. Fuel use in gph is calculated as btu/min / 19590 btuAb hhv _/ 7.076 Ib/gal * 60 min/hr_ = gph. 2) | Fuel use is listed in manufacturer's data as 121417 btu/min input. Fuel use in gph is calculated as btu/min / 19590 btu/b hhv / 7.076 Ib/gal * 60 min/hr_= gph. 3) |Nameplate info recorded on engine #2 as 3406DI however AVEC data lists 375HP/257KW for this genset which corresponds to a 3406TA. A 3406DITA is rated at 433HP/310KW. Generator nameplate data lists | 350KW prime. 3406TA data is used here. 4) |One genset nameplate info recorded as D342turbo and one as D342PC. They have a skid mounted fan and) temote radiator, respectively. Typical AVEC data for D342T with fan is 335HP/223KW peak and without fan is 335HP/229KW peak. This corresponds to a D342T. D342T data without fan is used here. 5) |Nameplate info recorded on engines as 3306DI and on generators as 150KW prime. Both gensets have skid mounted fan. 150 KW prime with fan corresponds to a 3306TA. 3306TA data without fan is used here. 6) | Two gensets nameplate info recorded as 3304DT however AVEC data lists 3304B at 192HP/128KW peak which exceeds manufacturer's standby data. Both gensets have skid mounted fan. 3304T data without fan is used here. + 7) |At Russion Mission, nameplate info recorded on engine as Cummins LTA10 and on generator as 110KW prime. Typical AVEC data for LTA10 is 276HP/189KW and for LTA1OL (low speed 1200 rpm) is 184HP/126KW peak. Only output data available for fuel & power is from one publication and heat output at 1800 rpm only from another. They are very questionable. Values used are all calculated from 1800 rpm values reduced proportionally from 235HP to 166HP (which corresponds to 110KW prime). 8) |At White Mountain, nameplate info recorded on engine as Cummins LTA10 and on generator as 140KW prime. This is a 1200 rpm genset. Values used are the same as described above. 9) |Nameplate info recorded on engine as AC11000 and on generator as 1SOKW prime. Typical AVEC data for AC11000 is 195HP/130KW peak. This is an 1800 rpm genset. Only output data available is for fuel vs. generated KW electrical power from one publication and heat output at 2200 rpm only from another (constant 32 btu/ohp-min.). Fuel vs. engine power is given in the 2nd publication and does not correlate well with 1st publication. All values are very questionable. Except for fuel vs. generated KW electrical power, all values used are calculated. | | | 10) |Nameplate info recorded on engines as AC2900 and AC3500. These are 1800 rpm gensets. Typical AVEC data for AC3500 is 159HP/10SKW peak however this genset reportedly does not meet normal weekday loads which peak at less than 90KW. The AC2900 is even smaller. For purposes of this report the gensets are treated as DES-60 and DES-50, respectively. These gensets use the AC2900 engine. For each genset onl output data available is for fuel vs. generated KW electrical power from one publication and heat output at 2600 rpm only and 2400 rpm only , respectively from another (constant 32 btu/bhp-min.). Fuel vs. engine power is given in the 2nd publication and does not correlate well with 1st publication. All values are very questionable. Except for fuel vs. generated KW electrical power, all values used are calculated. [a Page 4 PIPELOSS.XLS PIPE HEAT LOSS) BURIED PIPING, SINGLE PIPE, 3" PU INSULATION Ke|_ 0.014) Btustt-hr°F R=|In(Do/Dpy/2-Pi-K Qh-=|(Tp-ToyR To=|__0|°F (ground) ‘| Tp=|_180|°F (fluid) Pipe Size} Type’ Dp (in) Do(in)} R(ft-hr-°F net, (inches) 7Btu)) Tort) tIPS 132] 7.32) —=«192«5) 9.2 1.25]IPS 1.66] 7.66 17.4 10.4 1.5|IPS 19 7916.2 11.4 [ 2\IPs 2.38) 8.38 14.3 12.6 SIPS 3.5 9.5) 11.4 15.9) 4|IPS 45 10.5 96 18.7 SIPS 5.56, 11.56 a3) 216 6|IPS 663, 12.63) 73) 246 aliPs 8.63, 14.63: 60] 30.0 BURIED PIPING, SINGLE PIPE, 2" PU INSULATION qIPS 1.32! 5.32 15.8) 11.4) 1.25/IPS 1.66 5.66 13.9 12.9 | 1.5/IPS 1.9 5.9) 12.9) 14.0 a 2|IPS 2.38 6.38 11.2) 16.1 3[IPS 3.5) 75 8.7 20.8 | 4|IPS 45| 85] 7.2 24.9 5|IPS 5.56 9.56 6.2! 29.2 6|IPS 6.63) 10.63) 5.4) 33.5 + — ABOVE GRADE PIPING, SINGLE PIPE, 1.5" FG INSULATION K=| 0.023) Btu/ft-hr-°F! R=|In(Do/Dp)/2:Pi-K Q/=|(Tp-To)y/R To=| 80|°F (room) Tp=| 180) °F (fluid) 1JIPS 1.32! 4.32 8.2| 12.2| 1.25|IPS 1.66) 4.66 7A 14.0 1.5|IPS 19 49) 66) 15.3) 2iIPS 2.38 5.38) 56 17.7 3/IPS 3.5) 6.5 43) 23.3 4|IPS 45| 75| 3.5) 28.3 5|IPS 5.56) 8.56 3.0) 33.5 6|IPS 6.63 9.63 26 38.7) [ ml 8|IPS 8.63) 11.63 24 48.4 | an | ABOVE GRADE PIPING, SINGLE PIPE, NO INSULATION il Q/ from ASHRAE Fundamentals (1989), Chapter 22, Table 9 & 10 To=|} _80/°F (room) Tp=|_180|°F (fluid) Pipe Size|_Type| _Dp(in)) _Q/(Btu (inches) /ar-tt) 1IPS 1.32 89 1.25||PS 1.66 110 1.5/IPS 1.9 124 2\IPS 2.38 152! SIPS 35 216 4/IPS 45) 272 a3 5|IPS 5.56 330 6IPS 6.63 387 8 8.63) Page 1 WASTE HEAT SYSTEM - HEAT TRANSFER COMPONENT CAPACITY REQUIREMENTS CAPACITY.XLS COLD BAY COLDEST MONTH = JAN] HDD = 1126 Tave=| _65-(HDD/31) = 29)°F PRACTICAL MINIMUM = O|°F RATIO ave temp diff- max temp diff =| (70 - 0)/ (70 - 29) =| tas Example: |DOT/PF Shop: 681/gal / month worst month . 1.7|multiplier L i / 31}days / month | ] 24|hours / day | 1.56|gal / hour worst hour *[_ 140000] btu 7 gal : 0.75|eff. 163000| btu / hour heating unit required FACTOR capacity - fuel use = 163000 / 681 = 240|"* — FLUID FLOW @ 20°F TEMP. DROP = | 163000 / (20 * 460) = 18|gpm FACTOR capacity - flow = [20 * 460 = 9200|** |HOONAH COLDEST MONTH = JAN) HDD = 1087| Tave=| _65-(HDD/31)= 30/°F PRACTICAL MINIMUM = OF T RATIO ave temp diff - max temp diff =| (70 - 0)/(70 - 30) = 1.8|"" [ L. KALSKAG COLDEST MONTH = JAN| HDD = 2000] ave R. MISSION ANVIK Tave=| _65-(HDD/31) = [°F KOTLIK [ |W. MOUNT. PRACTICAL MINIMUM = -40|°F : | RATIO ave temp diff - max temp diff = |(70 - (-40)) / (70 - 0) = 1.6|"* CONCLUSION: USE OVERALL TYPICAL FACTORS AS FOLLOWS: RATIO ave temp diff - max temp diff = 1.7 | | OVERALL FACTOR capacity - fuel use = 240) OVERALL FACTOR capacity - flow = 9200 |