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Hoonah Report & Concept Design Waste Heat Recovery 1991
REPORT AND CONCEPT DESIGN HOONAH WASTE HEAT RECOVERY February 27, 1991 Mah Frank Moolin & Associates, Inc. A Subsidiary of ENSERCH Alaska Services, Inc. a HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 TABLE OF CONTENTS 1.0 EXECUTIVE SUMMARY 2.0 INTRODUCTION 3.0 DESCRIPTION OF SITE VISIT 4.0 POWER PLANT DESCRIPTION 5.0 POTENTIAL WASTE HEAT USER BUILDING DESCRIPTIONS WATER TREATMENT PLANT NATIONAL GUARD ARMORY CITY SHOP FOREST SERVICE BLDG TOTEM LODGE CITY POOL HOONAH SENIOR CENTER POLICE STATION FIRE STATION 6.0 RIGHT -OF -WAY/EASEMENT aon ono on oo ot WOONDOLPWNMHH 7.0 CONCEPT DESIGN 8.0 ECONOMIC DATA 9.0 FAILURE ANALYSIS 10.0 CONCLUSIONS AND RECOMMENDATIONS APPENDICES IG Calculations 2 Cost Estimates 3s Raw Data WTHTHN/RCD LIST OF FIGURES AND TABLES Power Plant Photographs Power Generation Water Treatment Plant Photographs Water Treatment Plant Fuel Data National Guard Armory Photographs National Guard Armory Fuel Data HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 City Shop Photographs City Shop Fuel Data Forest Service Photographs Forest Service Fuel Data Totem Lodge Photographs (1) Totem Lodge Photographs (2) Totem Lodge Fuel Data City Pool Photographs City Pool Fuel Data Senior Center Photograph Senior Center Fuel Data Police Station Photographs Police Station Fuel Data Fire Station Photographs Fire St2ation Fuel Data Figure 1 - Legend Figure 2 - System Site Plan Figure 3 - Power Plant Floor Plan Figure 4 - Power Plant Cooling Schematic Figure 5 - Scenario #1 System Schematic Figure 6 - Water Treatment Plant Floor Plan Figure 7 - Water Treatment Plant System Schematic Figure 8 - National Guard Armory Floor Plan Figure 9 - National Guard Armory System Schematic Figure 10 - City Shop Floor Plan Figure 11 - City Shop System Schematic Figure 12 - Forest Service Floor Plan Figure 13 - Forest Service System Schematic Figure 14 - Totem Lodge Floor Plan Figure 15 - Totem Lodge System Schematic Figure 16 - Scenario #2 System Schematic Figure 17 - City Pool Floor Plan Figure 18 - City Pool System Schematic Figure 19 - Senior Center Floor Plan Figure 20 - Senior Center System Schematic Figure 21 - Police Station Floor Plan Figure 22 - Police Station System Schematic Figure 23 - Fire Station Floor Plan Figure 24 - Fire Station System Schematic Figure 25 - Arctic Pipe/Trench Cross Section Graph 1 Graph 2 WTHTHN/ RCD oe eee et ae WODAMNMIWNOUONAUMIWNHO ' W WW PO PY PD PO [PY [PO [PO PDD PDO PDO FO OP DD PDD PO DPD POD DO eH OND PWWP ee NSN NS SN OS OS NS SNS S NS SNS S SNS SNS SN NN NN NNN NNN OO OI INN IIINOIInrnrnianinS & WNHYMRKCWOONDANLSWNHKOCOWONAOPWNHHO oorre 1 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 1.0 EXECUTIVE SUMMARY A potential for waste heat recovery exists in the community of Hoonah. Hoonah is a community of approximately 867 people, located 40 miles southwest of Juneau, 600 air miles from Anchorage. The waste heat from the coolant of the diesel engine-generator sets owned and operated by Tlingit and Haida Regional Electrical Authority (THREA) could be recovered and circulated to heat buildings in the community. One building in particular, the community swimming pool, would 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. This building, like most of the major community buildings, is far from the power plant however. Piping distance from the power plant to the pool is approximately 3200’ one way. Conversely, buildings close to the power plant generally have small _ heating requirements. These buildings can not be served on an equal cost basis. Also, varying ownership and planned future use of buildings makes some buildings more attractive for providing waste heat to. Several scenarios have been evaluated and are presented here. Scenario #1 provides waste heat to five (5) buildings, of various ownership, nearest to the power house. This includes the city’s water treatment plant and shop, the National Guard armory, U.S. Forest Service building, and the Totem Lodge. Estimated Project Cost $746,950 Total Fuel Oil Savings 21,600 Gallons Total Annual Fuel Cost Savings $ 23,500 (O&M Cost $ 8,600) Scenario #2 provides waste heat to the city swimming pool as well as three (3) additional buildings along the pipe routing to the pool. This includes the senior center, police station, and fire station. Scenario #2 is independent of Scenario #1. Estimated Project Cost $1,538,700 Total Fuel Oil Savings 34,800 Gallons Total Annual Fuel Cost Savings $ 37,900 (O&M Cost $ 13,500) Scenario #3 includes all of the buildings listed above (essentially it is Scenario #1 expanded to include the additional Scenario #2 buildings). Estimated Project Cost $1,901,900 Total Fuel Oi] Savings 54,300 Gallons Total Annual Fuel Cost Savings $ 59,130 (O&M Cost $ 19,100) WTHTHN/RCD 1) HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 yal Decision Criteria ° Economic and public policy decisions will be required to choose between the various options. Aol adie Doles Proximity The cost of running the waste heat recovery piping may limit this project to the buildings in the immediate area of the power plant. Potential Long Term Users and Expansion At the time of this report (February 1990) there are two planned changes to the community. The High School is in the design stages for a new cogeneration plant to serve the school complex, excluding the pool. This will reduce the load on the THREA plant along with waste heat availability. 18 new HUD houses, to be constructed in 1990, will offset this somewhat. Community Desires/State Priorities The pool was originally built by the School but through a vote of the community, the City is now responsible for fuel expenses. The Mayor was interviewed. She was concerned that the City’s fuel usage had doubled since the acquisition of the school pool. The pool is a good candidate politically for waste heat recovery. The small buildings near the THREA plant are less of a community priority and are owned and/or occupied by a wide variety of government and private entities. A summary of the construction cost estimates along with design and SIOH costs is included in the Cost Estimate Appendix for each alternative and scenario. WTHTHN/RCD 1-2 2.0 Zal 2.2 2x3 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 INTRODUCTION Objective The objective of the field investigation and report is to ascertain the viability of waste heat recovery and use in the community of Hoonah. 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: te 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. ee Field Investigation: A representative of the electric utility was interviewed in Juneau. In Hoonah, coordination with building owner/operators and local elected officials was performed. Photographs were taken of the potential user buildings as well as_ the boiler/furnace equipment. The power plant was photographed and sketches were made of the coolant piping connections. Available fuel costs and heating records were obtained from each interested potential recipient of waste heat. 35 Office Analysis: Additional information regarding weather and historical trends were collected. Calculations were performed to fill in missing fuel use data for several of the potential users. This information was used to produce a model to predict the system performance and the amount of energy recovered. 4. Report Preparation: A draft report was prepared for the prospective clients prior to final report preparation to ascertain correctness of assumptions and obtain approval of the approach taken. Community Description Hoonah is a community of approximately 867 people 40 miles from Juneau on Chichago Island accessible only by air or water. Regularly scheduled 20 minute flights by small airplane provide air connection to Juneau, and regularly scheduled ferries provide economical public and freight transportation. Fuel cost at Hoonah varied from $0.99 per gallon for th City to $1.25 per gallon for small users at the time of the site visit. The composite weighted average was $1.09 per gallon. WTHTHN/RCD 2-1 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 2.4 Applicable Codes and Regulations The most recently State of Alaska adopted editions (1985 for all 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) WTHTHN/RCD 2-2 3.0 DESCRIPTION OF SITE VISIT HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 Two Frank Moolin engineers visited the THREA utility office in Juneau on February 6th and Hoonah February 6th to the 7th, 1990. obtained copies of fuel plans and piping diagrams. Contacts: Harry Brown Terry Butler Ben Johnson Keith Sahl George Martin Liv Gray Tom Brown Dan Donovan Judy Shoup Maj. Thorsteinson Hatty Daltion Don Brewer Nino Villareal Vickie Drorak WTHTHN/RCD 789-3196 945-3631 945-3246 945-3355 945-3355 945-3611 945-3611 789-1773 586-3492 945-3350 428-1441 945-3211 586-6233 3c] (Juneau) (Hoonah) (Hoonah) (Hoonah) (Hoonah) (Hoonah) (Hoonah) (Hoonah) (Juneau) (Anchorage) (Hoonah) (Anchorage) (Hoonah) (Juneau) They visited every facility listed in this report and usage and copied or sketched floor THREA Forest Service Plant Operator City Shop City Shop Mayor School Super. School Maint. (Pool) HUNA Corp. National Guard Mgr. Sr. Center National Guard Hoonah Seafoods Mgr. Senior Center Mgmt. 4.0 4.1 4.2 4.3 4.4 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 POWER PLANT DESCRIPTION Narrative Description The power plant is housed in a metal skinned building with plant located switchgear, an office and shop. Power is generated by three Catapiler generators rated for continuous load as follows: 1-Model D398 - 600Kw 2-Model D398 - 600Kw 3-Model 3512 - 855Kw The newer 3512 genset is the most fuel efficient and runs over 90% of the time while the other two are backup. The 3512 is reported to provide approximately 14 KWH/gallon while the D398s provide approximately 11 KWH/gallon of fuel. The backup gensets are allowed to cool so that no warm standby is provided. Each genset is piped independently to a _ remote mounted vertical core radiator, simplifying waste heat recovery installation. The generators use number 2 fuel oi] year round. The plant is clean and from all appearances very well Maintained. One of the electric utilities previous largest users, the cannery, ceased service on 10-17-89 due to installing their own co-generation. Another large user, the school, is planning to install their own cogeneration also in the near future. This will have an impact on the amount of electricity generated, although the 18 new HUD houses going in the summer of 1990 will make up for some of the loss. Power production and waste heat availability will change over the life of the waste heat projects but appear to be adequate for the potential users considered. Floor Plan and Schematics See the Figures 3 and 4 for a simple floor plan and schematics of the system (located in Section 7). Photographs See the attached copies of the original color photographs of the power plant, generators and coolant piping. Load information Attached table 1 contains the utility load data for 1989 and partial data for 1988. WTHTHN/RCD 4-1 Hoonah Power Plant Frank Moolin & Associates, Inc. HOONAH POWER GENERATION PRODUCTION AVERAGE MIN. LOAD LOAD (KW) 317,602 325,098 316,326 387,166) 290,043 364,319 278,088 295,773 378,599 315,842 335,065 401,170 iERRGE| —— 333,758 ANNUAL 8,760 4,005,091 Notes: 1) Average load is calculated from KWH production divided by hours in month. 2) Min. load was recorded between 8:00 AM and 5:00 PM and is not actual min. 2/7/91 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 5.0 POTENTIAL WASTE HEAT USER BUILDING DESCRIPTIONS During the site visit, all non-residential buildings within a reasonable distance of the power plant, one large major building (pool) remote from the plant, and non-residential building along the route to the major building were considered. The buildings were visited and information about them gathered. The information is presented below. WTHTHN/RCD 5-1 5.1 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 Water Treatment Plant This Plant is located within 100 feet of the Generation Plant, and has heating needs. It is a wood-framed slab on grade building measuring approximately 24’x61’ with an unheated garage, a small chlorination room opening only to the outside which is heated by an electric heater, and the remaining 800 square feet of the building which is heated by unit heaters supplied by an oil fired boiler. The boiler is rated 147.8 MBH water. Domestic hot water use is minimal and provided by a coil in the boiler. The preferred method of waste heat use in this building is a_ single horizontal unit heater, independent of the existing system. The Water Plant fuel records are usually combined with the Sewage Treatment Plant in City records. Fuel usage shown is estimated. WTHTHN/RCD 5-2 Hoonah Water Treatment Plant Water Treatment Plant Mechanical Room Frank Moolin & Associates, Inc. Hoonah WATER TREATMENT PLANT HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING AVERAGE OF DAYS | CONSUMPTION DEGREE MONTHLY (Gal) _ CONSUMPTION 0.43 3.43 10.39 4.47 1.66 7.16 8.58 TOTAL FUEL ANNUALIZED DELIVERED AVERAGE CONSUMPTION PT ,3 18) Fuel number represents 35% of total for water and sewer plants. 60 days allowed for Feb. 1989 fill is estimated. 2/7/91 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 5.2 National Guard Armory This building requires little heat, but its proximity to the Power Plant, and its government ownership makes it a prime candidate for waste heat. The building is a wood frame raised structured with approximately 1200 square feet. It is heated by two oil-fired space heaters rated at 72 and 43 MBH output respectively. Only one was functional. A minimal amount of domestic hot water is provided by an electric hot water heater. The preferred method of waste heat use in this building is a single horizontal unit heater, independent of the existing system. Fuel is supplied to this building only periodically (3 times in 12 months). Monthly fuel usage shown is estimated. WTHTHN/RCD 5-5 Hoonah National Guard Armory Functioning Heater Center NATIONAL GUARD Hoonah HEATING FUEL CONSUMPTION DATA FUEL (Gal) NUMBER OF DAYS DAILY CONSUMPTION Gal Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. 1.70 2.51 0.00 HEATING DEGREE Frank Moolin & Associates, Inc. AVERAGE MONTHLY CONSUMPTION TOTAL FUEL DELIVERED 30 days allowed for Dec. 1988 fill is estimated. 2/7/91 ANNUALIZED MONTHLY AVERAGE bes HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 City Shop This building could benefit from waste heat and is fairly close to the Power Plant. It is an old BIA metal sided shop with a dirt floored garage, offices, and parts storage totaling approximately 4900 square feet. The building looks in poor condition and is missing small areas of insulation in the garage but is functional. The potential exists to heat this building with waste oil from City vehicles. Heat is provided by a waste-oil furnace currently burning #2 fuel oil with an output of approximately 155 MBH with an older unit heat for backup. A minimal amount of domestic hot water is provided by an electric hot water heater. A minimal amount of domestic hot water is provided by an electric hot water heater. The preferred method of waste heat use in this building is a single horizontal unit heater, independent of the existing system. The shop fuel records have several excessive entries suggesting that vehicle fuel tank fill was combined with building fill for those months in City records. Fuel usage shown for these months is estimated. WTHTHN/RCD 5-8 Hoonah City Shop City Shop Functioning Heater Hoonah CITY SHOP HEATING FUEL CONSUMPTION DATA NUMBER OF DAYS DAILY CONSUMPTION 565 31 TOTAL FUEL DELIVERED 3,836 ee HEATING DEGREE Frank Moolin & Associates, Inc. AVERAGE MONTHLY CONSUMPTION ANNUALIZED AVERAGE CONSUMPTION Mar. 1989 records show 3030 gal. but are assumed to include vehicle tank fill of approx. 2/3. 60 days allowed for Feb. 1989 fill is estimated. 2/7/91 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 5.4 Forest Service Bldg. This building is also in close proximity to the Power Plant. It is leased by a Federal Agency, and owned by the Huna Totem Corporation. The Forest Service pays for the utilities for this building. They do not have immediate moving plans, but may put in a building on some nearby land in a few years. Fuel use for this building is estimated. The building is a wood frame raised structured with approximately 3700 square feet. It is heated by an oil-fired furnace with approximately 125 MBH output. The preferred method of waste heat use in this building is by raising the furnace and providing a single coil on the return air side of the furnace. WTHTHN/RCD 5-11 Hoonah Forest Service Building | Forest Service Mechanical Room Frank Moolin & Associates, Inc. Hoonah FOREST SERVICE HEATING FUEL CONSUMPTION DATA FUEL NUMBER (Gal) OF DAYS DAILY CONSUMPTION HEATING AVERAGE DEGREE MONTHLY DAYS CONSUMPTION » nD omooooocoocoe N So oo 975 TOTAL FUEL DELIVERED ECAC gr 30 days allowed for Oct. 1988 fill is estimated ANNUALIZED AVERAGE CONSUMPTION 515) 3.86) 2/7/91 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 525) Totem Lodge This building, owned by the Huna Totem Corporation, is a major energy user in the community. Piping distance from the power plant to the Lodge is approximately 900 feet. It is the furthest building of those located in close proximity to the Power Plant. It is a wood frame single story structure with a craw] space totaling approximately 14,000 square feet. It has undergone many additions and renovations. Fuel use for this building is based on estimates. The lodge has two separate boiler rooms, each with a single boiler. Boilers are rated at 210 and 290 MBH output, respectively. They heat the building through hot water baseboard systems and produce domestic hot water through a shell and tube heat exchanger and a boiler coil, respectively. Each serves a separate part of the building. The building has poor zoning and controls. Much heat is wasted in this building. Comfortable temperatures are achieved in rooms by use of the windows. Two separate plate type heat exchangers would be required here for waste heat recovery, and the building owner would have to upgrade the heating systems to make effective use of the waste heat. A new pump would be required to circulate building heating return water through the heat exchanger in the older boiler room (boiler rm. #1), with the system as currently installed. WTHTHN/RCD 5-14 Hoonah Totem Lodge Lodge Older Boiler Room Lodge Newer Mechanical Room Frank Moolin & Associates, Inc. Hoonah TOTEM LODGE HEATING FUEL CONSUMPTION DATA NUMBER DAILY OF DAYS CONSUMPTION Gal) HEATING AVERAGE DEGREE MONTHLY DAYS CONSUMPTION ANNUALIZED AVERAGE CONSUMPTION HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 5.6 City Pool The pool is one of the largest single users of heating fuel in the community. It is owned and operated by the School but fuel is provided by the City. The City assumed this responsibility in April, 1989 by a vote of the community. It is a modern structure totaling approximately 12,000 square feet. Due to its low temperature water heating requirement, it is a good candidate for waste heat use, although it is located a great distance from the generator plant (approximately 3200 feet piping distance one way). The pool could use approximately 30% of the gross waste heat available on a yearly basis and approximately 45% during its peak month. Fuel use based on estimate. The pool is heated by two boilers in a basement boiler room, each rated at 720 MBH output, with domestic hot water provided by a single oil fired hot water heater in the boiler room rated at 960 MBH output. The preferred method of waste heat use in this building is to provide a plate heat exchanger on the boiler system with a second heat exchanger to provide domestic hot water. Some repiping of the boiler room will be required to make room for waste heat equipment such as relocating the expansion tank and glycol makeup tank. WTHTHN/RCD 5-18 Hoonah City Pool Pool Mechanical Room Frank Moolin & Associates, Inc. Hoonah POOL HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING AVERAGE OF DAYS CONSUMPTION DEGREE MONTHLY DAYS CONSUMPTION ANNUALIZED AVERAGE CONSUMPTION Records prior to Mar. 1989 are from the School. Records after Mar. 1989 are from the City. Mar. 1989 Fuel number is estimated. 2/7/91 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 5.7 Hoonah Senior Center The Center is owned by the Tlingit and Haida Native organization and rented by the S.E. Senior Services. It would be a candidate for waste heat if waste heat is brought into town to feed the pool. Otherwise, its small usage would not warrant the cost of running the lines. Fuel use based on estimates. It is a 1200 square feet wood frame structure with an oil fired furnace rated at 81 MBH and an oil fired hot water heater rated at 65 MBH output. The preferred method of waste heat use in this building is a single coil on the return air side of the furnace. WTHTHN/RCD 5-21 Hoonah Senior Center Senior Center Mechanical Room Frank Moolin & Associates, Inc. Hoonah SENIOR CENTER HEATING FUEL CONSUMPTION DATA NUMBER DAILY OF DAYS CONSUMPTION Gal HEATING AVERAGE DEGREE MONTHLY DAYS CONSUMPTION TOTAL FUEL DELIVERED ANNUALIZED AVERAGE CONSUMPTION 30 days allowed for Sep. 1988 fill is estimated. 2/7/91 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 5.8 Police Station The Police station is owned by the City. It would be a candidate for waste heat if waste heat is brought into town to feed the pool. Otherwise, its small usage would not warrant the cost of running the lines. It is a wood frame structure with approximately 1600 square feet. Approximately 950 is occupied and heated with the remainder an unfinished addition. Fuel use for this building is estimated. The Police Station has an oil fired boiler rated at 115 MBH output with an integral domestic hot water heating coil. The preferred method of waste heat use in this building is to provide a plate heat exchanger on the boiler system. WTHTHN/RCD 5-24 (== a! Hoonah Police Station Police Station Mechanical Room Frank Moolin & Associates, Inc. Hoonah POLICE STATION HEATING FUEL CONSUMPTION DATA NUMBER OF DAYS DAILY CONSUMPTION HEATING AVERAGE DEGREE MONTHLY CONSUMPTION 143 TOTAL FUEL DELIVERED ANNUALIZED AVERAGE | CONSUMPTION 4.92 60 days allowed for Feb. 1989 fill is estimated. 2/7/91 5.9 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 27, 1991 Fire Station. The Fire Station is owned by the City. It would be a candidate for waste heat if waste heat is brought into town to feed the pool. Otherwise, its small usage would not warrant the cost of running the lines. It is a metal slab on grade building with approximately 2400 square feet. Fuel use for this building based on estimate. It has a boiler rated at 220 MBH output with hydronic unit heaters and baseboard heat for the building. Its fuel usage has doubled since last year. We noted that one of its garage doors was off, and a large tarp covered the opening. The preferred method of waste heat use in this building is to provide a plate heat exchanger on the boiler system. WTHTHN/RCD 5-27 Hoonah Fire Station Fire Station Mechanical Room Frank Moolin & Associates, Inc. Hoonah FIRE STATION HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING AVERAGE OF DAYS CONSUMPTION DEGREE MONTHLY CONSUMPTION MEAN 1087; 557 1002) 513 936) 479 768 393 639 327 412) 211 391 200 375 192) 520 266 751 384 940) 481 1034) 529 8,855 4,534 TOTAL FUEL ANNUALIZED DELIVERED AVERAGE CONSUMPTION Pp 12.42 4,534 60 days allowed for Feb. 1989 fill is estimated. 2/7/91 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 6.0 RIGHT OF WAY/EASEMENT There are no utility easements in the area of the project. Utilities are generally run in the streets. The pipe routing shown to the pool follows Douglas Drive rather than Airport Road, which would be shorter, since Airport Road is paved and Douglas Drive is not. All piping not in the roadways will be on the property being served, with the exception of the Totem Lodge. Piping can be saved by cutting across property near the Forest Service which is owned by the Huna Totem Corporation, which also owns the Lodge. WTHTHN/RCD 6-1 7.0 Tol Tse HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 CONCEPT DESIGN System Narrative Three scenarios have been investigated for waste heat recovery at Hoonah. The first is to serve only those non-residential buildings in the close proximity to the generator plant. The second is to serve the community swimming pool and several small buildings along the piping route to the Pool. The third is a combination of the first two. 7.1.1 Scenario #1: Served buildings include: WATER TREATMENT PLANT NATIONAL GUARD ARMORY CITY SHOP FOREST SERVICE BLDG TOTEM LODGE Benefits of this scenario include lower cost due to shorter piping runs. Problems with this scenario include varied ownership and occupancy; uncertain future use of the Forest Service and Lodge; possible conversion of the Shop to waste oil; and the fact that the only potential large user is the Lodge which is a privately owned and operated structure. 7.1.2 Scenario #2: Served buildings include: CITY POOL HOONAH SENIOR CENTER POLICE STATION FIRE STATION Benefits of this scenario include serving the building with the highest community desire to be served; using the majority of the waste heat available; and heating fuel for three of the buildings is provided by the city. Problems with this scenario include the long piping distance to serve the pool. 7.1.3 Scenario #3: Served buildings include all of those listed above. Primary and Secondary Piping Jacket water piping will normally only be valved to recover heat from the 3512 genset since this engine runs over 90% of the time. This will reduce piping valved open to the operating genset and reduce the chance of failure. This fits with the current THREA policy of allowing standby gensets to cool down and require manual starting. Switching another genset into operation will require manual repositioning of valving. WTHTHN/RCD va 7.3 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 In keeping with the previous AEA recommendations, the current concept design includes one flat plate heat exchanger at the power 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 a low pressure drop heat exchanger. 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. 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 16 for the system schematics for Scenarios #1 and #2. Scenario #3 is simply a combination of Scenario #1 and #2. 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, by single unit heaters, or by return air coils where furnaces are existing. This will limit problems associated with damage of distribution piping and interconnection of systems. One exception to this is the Pool, 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. A second exception is the Totem Lodge, which has two seperate boiler systems requiring seperate heat exchangers 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 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. WTHTHN/RCD Nee Tx 7.4 739 7.6 lot HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 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 15 and 17 through 24 for proposed changes to each of the potential user buildings. Arctic Pipe/Utilidor Section A cross section of the anticipated trench and arctic pipe configuration is shown in the Figure 25. Outline Specifications The outline specifications for the major components of the system are shown below. Approximate sizes are shown following the specifications. 15010 GENERAL CONDITIONS The system shall be balanced by the Contractor to the flow specified in the construction documents. 15050 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 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. 15120 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. WTHTHN/RCD 1-3 15250 15750 15900 WTHTHN/RCD HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 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. Unit Heaters: Horizontal unit heaters shall have minimum .025" seamless copper coil tubes mechanically expanded into aluminum fins. Header connections brazed or welded. Casing shall provide rigid support for coil and be galvanized, painted and fitted with louver and venturi. Provide direct drive propellor fan with totally enclosed motor for ductless installations and centrifugal fan for ducted installations. Air Coils: Coils shall have minimum 5/8" seamless copper tubes mechanically expanded into aluminum fins. Header connections brazed or welded. Casing shall be double flanged minimum 16 gauge galvanized steel to provide rigid support for coil. Flanges for slip-and- drive fasteners on duct coils. 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. With duct coils on furnaces, 2-stage wall thermostats first start the fan and secondly start the burner if necessary. 7-4 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 16000 ELECTRICAL All electric equipment and installation shall comply with the National Electric Code specified. 7.9 Major Equipment List 739): 1 Scenario #1 Heating Capacity Elements Location (Hot Side) Item MBH GPM TI = TO Water Plant 199 4 180 160 ducted unit heater National Guard 199 1 180 160 unit heater City Shop 199 11 180 160 unit heater US Forest Service 199 5 180 160 duct coil Totem Lodge - #1 199 24 180 160 heat exchanger Totem Lodge - #2 199 24 180 160 heat exchanger Generator Plant 1194 350 185 177 heat exchanger Pumps Service GPM HD HP QTY Gen. Plant Secondary 69 30 1 2 Totem Lodge 22 5 0.05 1 Buried Piping Size LF ie 240 1-1/2" 420 SF 1800 WTHTHN/RCD 7-5 7.9.2 Heating Elements Pumps Buried Piping WTHTHN/RCD Scenario #2 Location Pool Boilers Pool Hot Water Htr Senior Center Police Station Fire Station Generator Plant Service Gen. Plant Secondary Size J" 1-1/4" 1-1/2" as 7-6 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 Capacity (Hot Side) MBH GPM 534 58 267 29 38 4 53 6 134 15 1026 350 GPM HD 112 70 LF 160 160 100 6480 TI 180 180 180 180 180 185 HP TO 160 160 160 160 160 178 QTY Item heat exchanger dbl-wall ht. exch. duct coil heat exchanger heat exchanger heat exchanger 7.9.3 Heating Elements Pumps Buried Piping WTHTHN/RCD HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 Scenario #3 Capacity Location (Hot Side) Item MBH GPM soTI TO Water Plant 39 4 180 160 ducted unit heater National Guard 12 1 180 160 unit heater City Shop 104 11 180 160 unit heater US Forest Service 42 5 180 160 duct coil Totem Lodge - #1 220 24 180 160 heat exchanger Totem Lodge - #2 220 24 180 160 heat exchanger Pool Boilers 534 58 180 160 heat exchanger Pool Hot Water Htr 267 29 180 160 dbl-wall ht. exch. Senior Center 38 4 180 160 duct coil Police Station 53 6 180 160 heat exchanger Fire Station 134 15 180 160 heat exchanger Generator Plant 1663 350 185 174 heat exchanger Service GPM HD HP QTY Gen. Plant Secondary 181 70 5 2 Totem Lodge 22 5 0.05" 1 Size LF ite 400 1-1/4" 160 1-1/2" 320 i 1440 4" 6120 & 360 7-7 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 RIRECUR 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 scat; __ NONE bt Frank Moolin & oare._ 2/13/91. Associates, Inc. LEGEND . y_CJP. 495 JOB _NO.: ENGINEERING e@ DESIGN @ PROJECT MANAGEMENT REVISION. 0 An Ebosco Services incorporated Engineering ond Construction Compony —h 495LEGND.DWG 7-8 FIGURE 1 COMMON DISTRIBUTION PIPE SIZES 0 200 Ft 400 Ft 600 Ft MES Frank Moolin & SYSTEM DSN. BY} oiavat | Associates, Inc. SITE PLAN pwe. erRWP | op wo: 495 | foteneiotea need dentiae Saleem HOONAH, AK om, oy 495SP302.DWG 7-9 FIGURE 2 VALVE LOCATION at REMOTE RADIATORS BG | i284 Mooiin & POWER PLANT eS Associates, Inc. FLOOR PLAN we. er_WSHLo5 no, 495 | ENGINEERING @ DESIGN @ PROJECT MANAGEMENT ‘An Boense Serdoss Incorporated Engineering and Conetrwetion Company = HOONAH, AK am 7-10 FIGURE 3 SIZE VARIES SEE SITE PLA EXPANSION TANK AND GLYCOL MAKE-UP 8’. Lb4a Frank Moolin & Associates, Inc. ENGINEERING @ DESIGN @ PROJECT MANAGEMENT An Ebeuse Services incorporeted Ongineering and Constrvetien Company POWER PLANT COOLING SCHEMATIC HOONAH, AK 7-11 FIGURE 4 RADIATOR #3 NC RADIATOR #2 RADIATOR #1 om wf eave | owe. 1 Sion wo. 495 | a lo) 495302G1.DWG TOTEM LODGE Aba Frank Moolin & SCENARIO #1 Associates, Inc. SYSTEM SCHEMATIC Ee earns oy eames tee HOONAH, AK 495P1302.DWG 7-12 FIGURE 5 BOILER/WH is PROPOSED UNIT HEATER BBM (2K Moolin & WATER TREATMENT PLANT sn none Associates, Inc. FLOOR PLAN ENGINEERING e DESIGN @ PROJECT MANAGEMENT ae HOONAH, AK nevSON 0 7-13 FIGURE 6 TO / FROM ARCTIC PIPE NEW UNIT HEATER BS Frank Moolin & WATER TREATMENT PLANT Associates, Inc. SYSTEM SCHEMATIC beeebeer bonnet digest wiitinnenlin ape HOONAH, AK 495D7302.DWG 7-14 FIGURE 7 KEROSENE SPACE HEATER OIL FIRED SPACE HEATER PROPOSED SPACE FOR UNIT HEATER LAV.& WATER HTR SCALE: NONE 4b Frank Moolin & NATIONAL GUARD ARMORY Raia; Associates, Inc. FLOOR PLAN ENGINEERING @ DESIGN @ PROJECT MANAGEMENT an Ebaaco Services incorporated Engheering end Construction Company HOONAH, AK REVISION 0 7-15 FIGURE 8 TO / FROM ARCTIC PIPE \ NEW UNIT HEATER 44 Frank Moolin & NATIONAL GUARD ARMORY Associates, Inc. SYSTEM SCHEMATIC ee eee ee HOONAH, AK 7-16 FIGURE 9 495D5302.DWG PROPOSED UNIT HEATER 44. Frank Moolin & CITY SHOP Associates, Inc. FLOOR PLAN 6. Jos No: 495 ENGINEERING e DESIGN @ PROJECT MANAGEMENT REVISION ° sn Epesce Series hcorporeed Engineering ond Construction Company HOONAH, AK 495302CS.DWG 7-17 FIGURE 10 TO / FROM ARCTIC PIPE NEW UNIT HEATER Ls Frank Moolin & CITY SHOP Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT An Ebesse Services Incorporated Engineering and Construction Campeny HOONAH, AK 495D6302.DWG 7-18 FIGURE 11 PROPOSED COIL Ss BELOW FURNACE PROPOSED PIPES FURNACE IN CRAWL SPACE in Vo SCALE: NONE Frank Moolin & U.S. FOREST SERVICE hh Associates, Inc. FLOOR PLAN 6. BYAWPT ion yo. 495 | ENGINEERING @ DESIGN e PROJECT MANAGEMENT fa Goes Sess roel appreg a estan: Canoes) HOONAH, AK a 7-19 FIGURE 12 SUPPLY AIR HOT AIR semuee/” | BURNER NEW COIL _IN HOT AIR FURNACE RETURN AIR DUCT J TO / FROM ARCTIC PIPE Lb Frank Moolin & U.S. FOREST SERVICE Associates, Inc. SYSTEM SCHEMATIC panes boii Lapel gests ea Gestocee cme HOONAH, AK 495D4302,.DWG 7-20 FIGURE 13 PROPOSED SPACE FOR FUTURE EQUIPMENT PROPOSED PIPING IN CRAWL SPACE —~| IS \ BOILER ROOM#2 Oo PROPOSED SPACE FOR eal FUTURE EQUIPMENT ——+} 4B. Frank Moolin & TOTEM LODGE Associates, Inc. FLOOR PLAN . By_RWP ENGINEERING @ DESIGN @ PROJECT MANAGEMENT An Eoosco Services hceerted Engeerhg ond Constueten Campeny HOONAH, AK 495302TL.DWG 7-21 FIGURE 14 RETURN ARCTIC PIPE EAT EXCHANGER BOILER RM.#1 DOMESTIC HOT WATER HEATER HEAT EXCHANGE! HEATIN SUPPLY? HEATING RETURN Ue! aE e LL HW CW HWC ; BOILER RM.#2 LOW WATER cl OFF DOMESTIC HOT : I BOILER WATER ~ HEATING € a HEATER SUPPLY LBS Frank Moolin & TOTEM LODGE Associates, Inc. SYSTEM SCHEMATIC Pe tM Mal HOONAH, AK 7-22 FIGURE 15 | 495D9302.DW6 | FIRE STATION Te eure | SENIOR CENTER bg T28 Moolin & SCENARIO #2 co. or__| St — NO Associates, Inc. SYSTEM SCHEMATIC owe. BY WH] oe wo, 495 | ENGINEERING @ DESIGN e PROJECT MANAGEMENT HOONAH, AK CHK. BY___. ‘An Bhoseo Services Incorporated Engineering end Construction Company 495P2302.DWG 7-23 FIGURE 16 MECH. ROOM IN BASEMENT (SEE_BSMT. BOILER ROOM) POOL FLOOR PLAN 20' BOILER BOILER 1 7— PROPOSED SPACE FOR FUTURE EQUIPMENT GLYCOL MAKE-UP’ BASEMENT BOILER ROOM BBB | Ek Mooiin & CITY POOL aie Associates, Inc. FLOOR PLAN . }0B No: 495 ENGINEERING e@ DESIGN @ PROJECT MANAGEMENT ied uaieaeiek eee HOONAH, AK mewson 0 495302PL.DWG 7-24 FIGURE 17 HW CW THW HWC THWC TQ / FROM ) , ARCTIC PIPE DOMESTIC DOUBLE-WALL HOT HEAT EXCHANGER WATER HEATER HEATING RETURN TEMPERED HEATING $—>>- RETURN ~ uJ Oo Ss <x pe oO x< Ww - < WwW ae TEMPERE. HEATING -—J | | SUPPLY | HEATING y | SUPPLY 5—<@—— {J BOILER | ST | | | Boer Absa Frank Moolin & CITY POOL oe Associates, Inc. SYSTEM SCHEMATIC owe. ey WIHT ioe wos 495 | revs | ENGINEERING @ DESIGN @ PROJECT MANAGEMENT ‘An Boeese Services incorporated Enghvearng and Construction Company HOONAH, AK CHK. BY_____ | REVISION: 9 | 49508302.DW6 | 7-25 FIGURE 18 DOWNDRAFT FURNACE PROPOSED COIL ON FRONT OF FURNACE FURNACE AND STORAGE WOMENS, KITCHEN yy) Frank Moolin & Associates, Inc. ENGINEERING @ DESIGN @ PROJECT MANAGEMENT An Exeina Sevtsss Rtpstaied Enehsaibg, gus cheasicuet Csnany SENIOR CENTER FLOOR PLAN HOONAH, AK 7-26 FIGURE 19 DSN. BY ows, By_WJH CHK. BY SCALE: NONE JOB_NO.: 495 REVISION: 0 495302SC.DWG HOT AIR i DOWNDRAFT HOT AIR FURNACE BURNER NEW FILTER GRILLE AND COIL ON FACE OF FURNACE AT RETURN AIR INLET SUPPLY AIR TO / FROM ARCTIC PIPE LAA Frank Moolin & SENIOR CENTER ; oare:_ 2/13/91 Associates, Inc. SYSTEM SCHEMATIC ESP Top no: 495 | pieced es ee crac HOONAH, AK 495D3302.DWG 7-27 FIGURE 20 PROPOSED SPACE FOR FUTURE ne }OILER/WH BBB | 2 Moolin & POLICE STATION ar Associates, Inc. FLOOR PLAN ENGINEERING e@ DESIGN @ PROJECT MANAGEMENT ‘An Ebosco Services incorporated Engineering ond Construction Campany HOON AH, AK Q REVISION 0 7-28 FIGURE 21 TO / FROM ARCTIC PIPE HEATING RETURN. > — —~— a W 0 = < = oO x W kK < W = BOILER SUPPLY 7”) Frank Moolin & POLICE STATION Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT sa Ebeee Saree capereted Engherng end Constnction Company HOONAH, AK 495D2302.DWG 7-29 FIGURE 22 BOILER/WH af PROPOSED SPACE FOR FUTURE EQUIPMENT TOILET ELECT. PANEL Frank Moolin & FIRE STATION DSN. BY MBM i ssociates. In6. FLOOR PLAN one. 680 een 495 ENGINEERING e DESIGN e PROJECT MANAGEMENT ‘An Ebasco Services incorporated Engineering ond Construction Compony HOONAH, AK CHK. BY. REVISION: 0 7-30 FIGURE 23 TO / FROM ARCTIC PIPE HEATING ( RETURN > > — ~ u Oo Zz x a. oO x Ww - < Ww x= cw $—_> —— / HEATING ( BOILER suPPLY » 4 M8 Frank Moolin & FIRE STATION Associates, Inc. SYSTEM SCHEMATIC J asciaracs sapocud piguavey ou Gooween Oa HOONAH, AK 7-31 FIGURE 24 495D1302,.DWG EXISTING GRADE BACKFILL WITH EXCAVATED NOMINAL 3° MATERIAL — COMPACT AS A PECIFI| DURING SPECIFIED YSTEM FINAL SYSTEM FINAL DESIGN WASTE HEAT SUPPLY AND RETURN PIPES — ARCTIC PIPING (SIZES VARY AS SPECIFIED) BEDDING MATERIAL — EXCAVATED MATERIAL WITH 1" TOP SIZE 4 HE BE 6°MIN. NS Bh! A Frank Moolin & Associates, Inc. TYPICAL TRENCH SECTION ENGINEERING @ DESIGN @ PROJECT MANAGEMENT 495TRNCH.DWG 7-32 FIGURE 25 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 8.0 ECONOMIC DATA Economic Data in Appendix 2. WTHTHN/RCD 8-1 9.0 9.1 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 FAILURE ANALYSIS Hoonah is a least a full day away from resupply of parts out of Anchorage or Seattle, 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 30% 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: 1. 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, 2. 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, WTHTHN/RCD 9-1 once ones HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 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. Bis 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 in winter. 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. 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. 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 WTHTHN/RCD 9-2 9.4 955) 9.6 OFT HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 or subsurface must be cleaned up before it enters the ground water 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. WTHTHN/RCD 9-3 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 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 compatible with glycol. Dissimilar metals are to be avoided or insulated from each other. Water quality must be maintained to prevent scaling. 9.8 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. 9.9 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. WTHTHN/RCD 9-4 HOONAH WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 18, 1990 10.0 CONCLUSION 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 Hoonah. 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 oil 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. WTHTHN/RCD 10-1 2 - Ol HOONAH WASTE HEAT RECOVERY - GRAPH 1 HEAT AVAILABLE VS. HEAT REQUIRED BY MONTH HOONAH SEAFOODS DISCONNECTED HEATING FUEL EQUIV. (GAL) Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. MONTH OF THE YEAR AVAILABLE HEAT REQD- @HEATREQD- © HEAT REQD- SCENARIO #1 SCENARIO #2 SCENARIO #3 € - Ol HEATING FUEL EQUIV. (GAL.) HOONAH WASTE HEAT RECOVERY - GRAPH 2 HEATING FUEL DISPLACED BY MONTH Jun. Jul. MONTH OF THE YEAR M@ SCENARIO #1 L) SCENARIO#2 @ SCENARIO #3 APPENDIX 1 CALCULATIONS WASTE HEAT UTILIZATION SIMULATION WORK SHEET. BASIC PROJECT DATA: Location: Hoonah - Scenarios #1 HOONH_#1.XLS PROGRAM RESULTS: Date: May 7, 1990 ‘Savings, year 0, fuel gallons: 21584) Savings, year 0, fuel cost: $23,527 Annual pumping elec. cost: 1600 $/year. Annual O&M increase cost: $8,600 Annual other O&M cost: 7000 $/year. Total Savings, year 0: $14,927 Construction cost estimate: 746950 $ ‘Simple pay back time, years: 31.8} Fuel high heat value: 137500 Btu/gallon Ave. fuel cost: 1.09 $/gallon GENERATOR DATA: SYSTEM LOSS DATA: Heat rate at kw-load above: 0 3017 Btu/kwh Constant losses: Heat rate at kw-load above: 85 2852 Btu/kwh Plant piping: 16000 Btu/hr. Heat rate at kw-load above: 170 2711 Btu/kwh Subsurface piping: 47000 Btu/hr. Heat rate at kw-load above: 255 2593 Btu/kwh Engine preheating: 0 Btu/hr. Heat rate at kw-load above: 340 2498 Btu/kwh Total constant: 63000 Btu/hr. Heat rate at kw-load above: 425 2428 Btu/kwh Heat rate at kw-load above: 510 2381 Btu/kwh Variable losses: Heat rate at kw-load above: 595 2357 Btu/kwh Surface piping: 200 Btu/hr.xF Heat rate at kw-load above: 680 2357 Btu/kwh Plant heating: 0 Btu/hr.xF Heat rate at kw-load above: 765 2357 Btu/kwh Radiator losses: 0 Btu/hr.xF Heat rate at kw-load above: 850 2357 Btu/kwh GENERATION DATA: WEATHER DATA: Kwh/month: HDD/Month: January 317602 1087 February 325098 1002 March 316326 939 April 387166 768 May 290043 639 June 364319 412 July 278088 391 August 295773 375 September 378599 520 October 315842 751 November 335065 940 December 401170 1034 4005091 8858 BUILDING DATA: Fuel use, gal/mon. WATER NAT GD SHOP FOREST LODGE Wa Wa a Wa wa TOTAL January 162 48 433 173 1833 2649 February 149 44 399 160 1690 2442 March 139 41 373 149 1579 2281 April 114 34 306 122 1295 1872 May 95 28 255 102 1078 1557 June 61 18 164 66 695 1004 July 58 17 156 62 660 953 August 56 17 149 60 633 914 September 7 23 207 83 877 1267 October 112 33 299 120 1267 1830 November 140 41 374 150 1586 2291 December 154 46 412 165 1744 2520 1318 391 3527 1410 14936 ° 0 ° Oo 0 21582 Htg. Efficiency: 0.75 0.75 0.75 0.75 0.75 0.75 Page 1 POWER PRODUCTION VARIATION: Assumed hourly variation: Hour: January February March 1 0.038 0.038 0.038 2 0.036 0.036 0.036 3 0.034 0.034 0.034 4 0.034 0.034 0.034 5 0.033 0.033 0.033 6 0.034 0.034 0.034 7 0.038 0.038 0.038 8 0.042 0.042 0.042 9 0.042 0.042 0.042 10 0.047 0.047 0.047 11 0.048 0.048 0.048 12 0.047 0.047 0.047 13 0.045 0.045 0.045 14 0.047 0.047 0.047 15 0.048 0.048 0.048 16 0.048 0.048 0.048 17 0.049 0.049 0.049 18 0.046 0.046 0.046 19 0.043 0.043 0.043 20 0.040 0.040 0.040 21 0.040 0.040 0.040 22 0.041 0.041 0.041 23 0.040 0.040 0.040 24 0.040 0.040 0.040 1.000 1,000 1.000 Days: 31 28 31 HDD: 1087 1002 939 Kwh: 317602 325098 316326 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 1 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. April 0.038 0.036 0.034 0.034 0.033 0.034 0.038 0.042 0.042 0.047 0.048 0.047 0.045 0.047 0.048 0.048 0.049 0.046 0.043 0.040 0.040 0.041 0.040 0.040 1.000 768 387166 May 0.043 0.038 0.035 0.034 0.034 0.036 0.036 0.038 0.043 0.045 0.041 0.046 0.048 0.050 0.048 0.048 0.043 0.045 0.048 0.043 0.039 0.039 0.039 0.041 1.000 31 639 290043 HOONH_#1 XLS June July 0.043 0.043 0.038 0.038 0.035 0.035 0.034 0.034 0.034 0.034 0.036 0.036 0.036 0.036 0.038 0.038 0.043 0.043 0.045 0.045 0.041 0.041 0.046 0.046 0.048 0.048 0.050 0.050 0.048 0.048 0.048 0.048 0.043 0.043 0.045 0.045 0.048 0.048 0.043 0.043 0.039 0.039 0.039 0.039 0.039 0.039 0.041 0.041 1.000 1.000 30 31 412 391 364319 278088 Page 2 August 0.043 0.038 0.035 0.034 0.034 0.036 0.036 0.038 0.043 0.045 0.041 0.046 0.048 0.050 0.048 0.048 0.043 0.045 0.048 0.043 0.039 0.039 0.039 0.041 1.000 31 375 295773 Sept. 0.043 0.038 0.035 0.034 0.034 0.036 0.036 0.038 0.043 0.045 0.041 0.046 0.048 0.050 0.048 0.048 0.043 0.045 0.048 0.043 0.039 0.039 0.039 0.041 1.000 30 520 378599 October November December 0.043 0.038 0.035 0.034 0.034 0.036 0.036 0.038 0.043 0.045 0.041 0.046 0.048 0.050 0.048 0.048 0.043 0.045 0.048 0.043 0.039 0.039 0.039 0.041 1.000 31 751 315842 0.038 0.036 0.034 0.034 0.033 0.034 0.038 0.042 0.042 0.047 0.048 0.047 0.045 0.047 0.048 0.048 0.049 "0.046 0.043 0.040 0.040 0.041 0.040 0.040 1.000 30 940 335065 0.038 0.036 0.034 0.034 0.033 0.034 0.038 0.042 0.042 0.047 0.048 0.047 0.045 0.047 0.048 0.048 0.049 0.046 0.043 0.040 0.040 0.041 0.040 0.040 1.000 31 1034 8858 401170 4005091 HEAT GENERATED PER HOUR BY MONTH, BTU'S Hour: 1 2 3 4 5 6 a 8 9 10 1 12 13 14 15 16 17 18 19 20 21 22 23 24 Day: 25228862 28095049 25127502 30771195 23339615 29211253 22406781 23675221 30189656 25058797 27109687 30841652 January 972681 921488 870294 870294 876572 870294 972681 1044642 1044642 1169005 1193877 1169005 1119260 1169005 1193877 1193877 1218749 1144132 1069515 1023875 1023875 1049472 1023875 1023875 February 1071116 1044297 986281 986281 957273 986281 1071116 1183865 1183865 1299078 1326718 1299078 1243798 1299078 1326718 1326718 1354357 1271438 1212053 1127491 1127491 1155678 1127491 1127491 March 968773 917785 866797 866797 873051 866797 968773 1040445 1040445 1164308 1189080 1164308 1114763 1164308 1189080 1189080 1213853 1139535 1065218 1019762 1019762 1045256 1019762 1019762 April 1190574 1127912 1065250 1065250 1033919 1065250 1190574 1290346 1290346 1429662 1460080 1429662 1382514 1429662 1460080 1460080 1490499 1413236 1321069 1228901 1228901 1259624 1228901 1228901 May 1005159 888280 849026 824768 824768 873284 873284 888280 1005159 1051910 958407 1044853 1090282 1135710 1090282 1090282 1005159 1051910 1090282 1005159 911655 911655 911655 958407 HOONH_#1.XLS June 1243111 1120317 1031871 1031585 1031585 1061353 1061353 1120317 1243111 1300930 1208763 1329840 1387659 1431166 1387659 1387659 1243111 1300930 1387659 1243111 1149799 1149799 1149799 1208763 July 963728 851667 814031 790773 790773 837289 837289 851667 963728 1008553 918903 1030965 1045342 1088898 1045342 1045342 963728 1008553 1045342 963728 874079 874079 874079 918903 August 1025016 905828 865799 841062 841062 858153 858153 905828 1025016 1042332 977341 1065495 1111821 1158147 1111821 1111821 1025016 1042332 1111821 1025016 929666 929666 929666 977341 Sept. 1291837 1164230 1072317 1041679 1041679 1102954 1102954 1164230 1291837 1351922 1231751 1381965 1427773 1487263 1427773 1427773 1291837 1351922 1427773 1291837 1194867 1194867 1194867 1231751 October November December 1063588 967291 890926 865471 865471 916381 916381 967291 1063588 1113057 1043656 1137792 1187261 1236730 1187261 1187261 1063588 1113057 1187261 1063588 992746 992746 992746 1043656 1060369 1004560 948751 948751 920846 948751 1060369 1138817 1138817 1249645 1276233 1249645 1220161 1249645 1276233 1276233 1302821 1223057 1165932 1084588 1084588 1111702 1084588 1084588 1193843 1131009 1068175 1068175 1036758 1068175 1193843 1293889 1293889 1433587 1464089 1433587 1386310 1433587 1464089 1464089 1494591 1403086 1324696 1232275 1232275 1263082 1232275 1232275 Month: 7.82E+08 7.87E+08 7.79E+08 9.23E+08 7.24E+08 8.76E+08 6.95E+08 7.34E+08 9.06E+08 7.77E+08 8.13E+08 9.56E+08 9.75E+09 Equivalent Gallons: 7584 7628 7553 8952 7016 HEAT LOST FROM SYSTEM PER HOUR BY MONTH, BTU'S Hour: ONOANMRWH = BRRVssscazraoxnze on = O©ODNODRWOND=00 24 January 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 91013 February 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 91157 Day: 2184310 2187771 Equivalent Gallons: 657 594 March 90058 90058 90058 90058 90058 90058 90058 90058 90058 90058 90058 90058 90058 90058 90058 April 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 89120 May 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 88123 8498 June 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 86747 6736 July 86523 86523 86523 86523 86523 86523 86523 86523 86523 86523 86523 86523 86523 86523 86523 86523 86523 7117 August 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 86419 8782 Sept. 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 87467 7533 7886 9271 October November December 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 88845 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90267 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 90671 2161394 2138880 2114942 2081920 2076542 2074065 2099200 2132284 2166400 2176103 Month: 67713600 61257600 67003200 64166400 65563200 62457600 64372800 64296000 62976000 66100800 64992000 67459200 7.78E+08 650 622 636 606 624 Page 3 623 611 641 630 654 94557 7548 HEAT DEMAND BY HOUR BY MONTH, BTU'S Hour: ODBNONRWND = yk” ky cals eal cee: eh pee ea ll BSBRYSSsVsZHaREBH=AS 24 eee eee ee eee ee Day: 8814186 8995474 7589769 6435086 5181477 3452155 3170512 3040773 4357089 6089654 7876277 8384424 January 345482 338431 336668 330499 336668 341956 362227 381616 384260 386904 386904 389548 393073 384260 378972 381616 376328 381616 381616 378972 370159 367515 353414 345482 February 352587 345392 343593 337297 343593 348990 369677 389465 392163 394862 394862 397560 401158 392163 386767 389465 384068 389465 389465 386767 377772 375074 360682 352587 March 297489 291418 289900 284588 289900 294454 311908 328604 330881 333158 333158 335434 338470 330881 326327 328604 324051 328604 328604 326327 318738 316462 304319 297489 April 252230 247083 245796 241292 245796 249656 264456 278611 280542 282472 282472 284402 286976 280542 276681 278611 274751 278611 278611 276681 270247 268316 258021 252230 May 203094 198949 197913 194286 197913 201021 212937 224336 225890 227444 227444 228998 231071 225890 222781 224336 221227 224336 224336 222781 217600 216046 207756 203094 HOONH_#1.XLS June 135311 132550 131859 129443 131859 133930 141869 149463 150499 151534 151534 152570 153951 150499 148428 149463 147392 149463 149463 148428 144976 143940 138418 135311 July 124272 121736 121101 118882 121101 123004 130295 137269 138221 139172 139172 140123 141391 138221 136318 137269 135367 137269 137269 136318 133148 132197 127125 124272 August 119186 116754 116146 114018 116146 117970 124963 131652 132564 133477 133477 134389 135605 132564 130740 131652 129828 131652 131652 130740 127700 126788 121923 119186 Sept. 170781 167296 166424 163375 166424 169038 179058 188643 189950 191257 191257 192564 194307 189950 187336 188643 186029 188643 188643 187336 182979 181672 174702 170781 October November December 238691 233819 232602 228339 232602 236255 250260 263656 265482 267309 267309 269136 271571 265482 261829 263656 260002 263656 263656 261829 255740 253913 244171 238691 308719 302419 300844 295331 300844 305569 323683 341009 343371 345734 345734 348097 351247 343371 338646 341009 336283 341009 341009 338646 330771 328408 315807 308719 328637 321930 320253 314384 320253 325283 344565 363009 365524 368039 368039 370554 373908 365524 360494 363009 357979 363009 363009 360494 352111 349596 336182 328637 ee eee eS eee ES eee Month: 2.73E+08 2.52E+08 2.35E+08 1.93E+08 1.61E+08 1.04£+08 98285883 94263954 1.31E+08 1.89E+08 2.36E+08 2.6E+08 2.23E+09 Equivalent Gallons: 2650 2442 2282 1872 HEAT DELIVERED BY HOUR BY MONTH, BTU'S Hour: ONOnRWN = NMNNNNHABaBABBesewnnaan KRONA CO©MNMAHRONA CO ee eee eS SS SS 8814186 8995474 7589769 6435086 5181477 3452155 3170512 3040773 4357089 6089654 7876277 8384424 Days: January 345482 338431 336668 330499 336668 341956 362227 381616 384260 386904 386904 389548 393073 384260 378972 381616 376328 381616 381616 378972 370159 367515 353414 345482 31 February 352587 345392 343593 337297 343593 348990 369677 389465 392163 394862 394862 397560 401158 392163 386767 389465 384068 389465 389465 386767 377772 375074 360682 352587 28 March 297489 291418 289900 284588 289900 294454 311908 328604 330881 333158 333158 335434 338470 330881 326327 328604 324051 328604 328604 326327 318738 316462 304319 297489 31 April 252230 247083 245796 241292 245796 249656 264456 278611 280542 282472 282472 284402 286976 280542 276681 278611 274751 278611 278611 276681 270247 268316 258021 252230 30 1558 May 203094 198949 197913 194286 197913 201021 212937 224336 225890 227444 227444 228998 231071 225890 222781 224336 221227 224336 224336 222781 217600 216046 207756 203094 31 1004 June 135311 132550 131859 129443 131859 133930 141869 149463 150499 151534 151534 152570 153951 150499 148428 149463 147392 149463 149463 148428 144976 143940 138418 135311 30 953 July 124272 121736 121101 118882 121101 123004 130295 137269 138221 139172 139172 140123 141391 138221 136318 137269 135367 137269 137269 136318 133148 132197 127125 124272 31 914 August 119186 116754 116146 114018 116146 117970 124963 131652 132564 133477 133477 134389 135605 132564 130740 131652 129828 131652 131652 130740 127700 126788 121923 119186 31 1268 Sept. 170781 167296 166424 163375 166424 169038 179058 188643 189950 191257 191257 192564 194307 189950 187336 188643 186029 188643 188643 187336 182979 181672 174702 170781 30 1831 2291 2520 October November December 238691 308719 328637 233819 302419 321930 232602 300844 320253 228339 6295331 314384 232602 300844 320253 236255 305569 325283 250260 323683 344565 263656 341009 363009 265482 343371 365524 267309 345734 368039 267309 345734 368039 269136 348097 370554 271571 351247 373908 265482 343371 365524 261829 338646 360494 263656 341009 363009 260002 4336283 =. 357979 263656 341009 363009 263656 341009 363009 261829 338646 360494 255740 330771 352111 253913 328408 349596 244171 315807 336182 238691 308719 328637 31 30 31 21584 a 2.73E+08 2.52E+08 2.35E+08 1.93E+08 1.61E+08 1.04£+08 98285883 94263954 1.31E+08 1.89E+08 2.36E+08 2.6E+08 2.23E+09 Equivalent Gallons: 2650 2442 2282 1872 1558 1004 953 Page 4 914 1268 1831 2291 2520 21584 WASTE HEAT UTILIZATION SIMULATION WORK SHEET. BASIC PROJECT DATA: Location: Hoonah - Scenarios #2 Date: May 7, 1990 Annual pumping elec. cost: 5500 $/year. Annual other O&M cost: 8000 $/year. Construction cost estimate: 1538700 $ Fuel high heat value: 137500 Btu/gallon Ave. fuel cost: 1.09 $/gallon GENERATOR DATA: Heat rate at kw-load above: 0 3017 Btu/kwh Heat rate at kw-load above: 85 2852 Btu/kwh Heat rate at kw-load above: 170 2711 Btu/kwh Heat rate at kw-load above: 255 2593 Btu/kwh Heat rate at kw-load above: 340 2498 Btu/kwh Heat rate at kw-load above: 425 2428 Btu/kwh Heat rate at kw-load above: 510 2381 Btu/kwh Heat rate at kw-load above: 595 2357 Btu/kwh Heat rate at kw-load above: 680 2357 Btu/kwh Heat rate at kw-load above: 765 2357 Btu/kwh Heat rate at kw-load above: 850 2357 Btu/kwh GENERATION DATA: WEATHER DATA: Kwh/month: HDD/Month: January 317602 1087 February 325098 1002 March 316326 939 April 387166 768 May 290043 639 June 364319 412 July 278088 391 August 295773 375 September 378599 520 October 315842 751 November 335065 940 December 401170 1034 4005091 8858 BUILDING DATA: Fuel use, gal./mon. Wa Wa Wa Wa January February March April May June July August September October November December 0 0 0 0 Htg. Efficiency: HOONH_#2.XLS PROGRAM RESULTS: Savings, year 0, fuel gallons: 34804) Savings, year 0, fuel cost: $37,936 Annual O&M increase cost: $13,500 Total Savings, year 0: Simple pay back time, years: SYSTEM LOSS DATA: Constant losses: Plant piping: 16000 Btu/hr. Subsurface piping: 168000 Btu/hr. Engine preheating: 0 Btu/hr. Total constant: 184000 Btu/hr. Variable losses: Surface piping: 200 Btu/hr.xF Plant heating: 0 Btu/hr.xF Radiator losses: 0 Btu/hr.xF na POOL SENIOR POLICE FIRE 3335 160 220 557 3074 147 203 513 2872 138 190 479 2356 113 156 393 1961 94 130 327 1264 61 84 211 1200 58 79 200 1151 55 76 192 1595 77 105 266 2304 111 152 384 2884 138 191 481 3172 152 210 529 0 27169 1303 1795 4534 0.75 0.75 0.75 0.75 Page 1 Wa TOTAL 4272 3938 3678 3018 2511 1619 1537 1474 2951 3694 4064 0 34800 0.75 POWER PRODUCTION VARIATION: Assumed hourly variation: HOONH_#2.XLS Hour: January February March April May June July it 0.038 0.038 0.038 0.038 0.043 0.043 0.043 2 0.036 0.036 0.036 0.036 0.038 0.038 0.038 3 0.034 0.034 0.034 0.034 0.035 0.035 0.035 4 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 6 0.034 0.034 0.034 0.034 0.036 0.036 0.036 7 0.038 0.038 0.038 0.038 0.036 0.036 0.036 8 0.042 0.042 0.042 0.042 0.038 0.038 0.038 9 0.042 0.042 0.042 0.042 0.043 0.043 0.043 10 0.047 0.047 0.047 0.047 0.045 0.045 0.045 11 0.048 0.048 0.048 0.048 0.041 0.041 0.041 12 0.047 0.047 0.047 0.047 0.046 0.046 0.046 13 0.045 0.045 0.045 0.045 0.048 0.048 0.048 14 0.047 0.047 0.047 0.047 0.050 0.050 0.050 15 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 17 0.049 0.049 0.049 0.049 0.043 0.043 0.043 18 0.046 0.046 0.046 0.046 0.045 0.045 0.045 19 0.043 0.043 0.043 0.043 0.048 0.048 0.048 20° 0.040 0.040 0.040 0.040 0.043 0.043 0.043 21 0.040 0.040 0.040 0.040 0.039 0.039 0.039 22 0.041 0.041 0.041 0.041 0.039 0.039 0.039 23 0.040 0.040 0.040 0.040 0.039 0.039 0.039 24 0.040 0.040 0.040 0.040 0.041 0.041 0.041 1.000 1.000 1.000 1.000 1.000 1.000 1.000 Days: 31 28 31 30 31 30 31 HDD: 1087 1002 939 768 639 412 391 Kwh: 317602 325098 316326 387166 290043 364319 278088 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 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. Page 2 August 0.043 0.038 0.035 0.034 0.034 0.036 0.036 0.038 0.043 0.045 0.041 0.046 0.048 0.050 0.048 0.048 0.043 0.045 0.048 0.043 0.039 0.039 0.039 0.041 31 375 Sept. 0.043 0.038 0.035 0.034 0.034 0.036 0.036 0.038 0.043 0.045 0.041 0.046 0.048 0.050 0.048 0.048 0.043 0.045 0.048 0.043 0.039 0.039 0.039 0.041 520 378599 October November December 0.043 0.038 0.038 0.038 0.036 0.036 0.035 0.034 0.034 0.034 0.034 0.034 0.034 0.033 0.033 0.036 0.034 0.034 0.036 0.038 0.038 0.038 0.042 0.042 0.043 0.042 0.042 0.045 0.047 0.047 0.041 0.048 0.048 0.046 0.047 0.047 0.048 0.045 0.045 0.050 0.047 0.047 0.048 0.048 0.048 0.048 0.048 0.048 0.043 0.049 0.049 0.045 0.046 0.046 0.048 0.043 0.043 0.043 0.040 0.040 0.039 0.040 0.040 0.039 0.041 0.041 0.039 0.040 0.040 0.041 0.040 0.040 1.000 1,000 1.000 31 30 31 751 940 1034 8858 315842 335065 401170 4005091 HEAT GENERATED PER HOUR BY MONTH, BTU'S Hour: @O@nNOKHRWOND = © 10 1 12 13 14 15 16 m7 18 19 20 21 22 23 24 Day: 25228862 28095049 25127502 30771195 23339615 29211253 22406781 23675221 30189656 25058797 27109687 30841652 January 972681 921488 870294 870294 876572 870294 972681 1044642 1044642 1169005 1193877 1169005 1119260 1169005 1193877 1193877 1218749 1144132 1069515 1023875 1023875 1049472 1023875 1023875 February 1071116 1044297 986281 986281 957273 986281 1071116 1183865 1183865 1299078 1326718 1299078 1243798 1299078 1326718 1326718 1354357 1271438 1212053 1127491 1127491 1155678 1127491 1127491 March 968773 917785 866797 866797 873051 866797 968773 1040445 1040445 1164308 1189080 1164308 1114763 1164308 1189080 1189080 1213853 1139535 1065218 1019762 1019762 1045256 1019762 1019762 April 1190574 1127912 1065250 1065250 1033919 1065250 1190574 1290346 1290346 1429662 1460080 1429662 1382514 1429662 1460080 1460080 1490499 1413236 1321069 1228901 1228901 1259624 1228901 1228901 May 1005159 888280 849026 824768 824768 873284 873284 888280 1005159 1051910 958407 1044853 1090282 1135710 1090282 1090282 1005159 1051910 1090282 1005159 911655 911655 911655 958407 HOONH_#2.XLS June 1243111 1120317 1031871 1031585 1031585 1061353 1061353 1120317 1243111 1300930 1208763 1329840 1387659 1431166 1387659 1387659 1243111 1300930 1387659 1243111 1149799 1149799 1149799 1208763 July 963728 851667 814031 790773 790773 837289 837289 851667 963728 1008553 918903 1030965 1045342 1088898 1045342 1045342 963728 1008553 1045342 963728 874079 874079 874079 918903 August 1025016 905828 865799 841062 841062 858153 858153 905828 1025016 1042332 977341 1065495 1111821 1158147 1111821 1111821 1025016 1042332 1111821 1025016 929666 929666 929666 977341 Sept. 1291837 1164230 1072317 1041679 1041679 1102954 1102954 1164230 1291837 1351922 1231751 1381965 1427773 1487263 1427773 1427773 1291837 1351922 1427773 1291837 1194867 1194867 1194867 1231751 October November December 1063588 967291 890926 865471 865471 916381 916381 967291 1063588 1113057 1043656 1137792 1187261 1236730 1187261 1187261 1063588 1113057 1187261 1063588 992746 992746 992746 1043656 1060369 1004560 948751 948751 920846 948751 1060369 1138817 1138817 1249645 1276233 1249645 1220161 1249645 1276233 1276233 1302821 1223057 1165932 1084588 1084588 1111702 1084588 1084588 1193843 1131009 1068175 1068175 1036758 1068175 1193843 1293889 1293889 1433587 1464089 1433587 1386310 1433587 1464089 1464089 1494591 1403086 1324696 1232275 1232275 1263082 1232275 1232275 Month: 7.82E+08 7.87E+08 7.79E+08 9.23E+08 7.24E+08 8.76E+08 6.95E+08 7.34E+08 9.06E+08 7.77E+08 8.13E+08 9.56E+08 9.75E+09 Equivalent Gallons: 7584 7628 7553 8952 7016 HEAT LOST FROM SYSTEM PER HOUR BY MONTH, BTU'S Hour: January 1 212013 2 212013 3 212013 4 212013 5 212013 6 212013 7 212013 8 212013 9 212013 10 212013 11. 212013 12 212013 13 212013 14 212013 15 212013 16 212013 17 212013 18 212013 19 212013 20 212013 21 212013 22 212013 23 212013 24 212013 Day: 5088310 Month: 1.58E+08 Equivalent Gallons: 1530 February 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 212157 5091771 1.43E+08 1382 March 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 211058 5065394 1.57E+08 1523 April 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 210120 5042880 1.51E+08 1467 May 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 209123 5018942 1.56E+08 1509 8498 June 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 207747 4985920 1.5E+08 1450 6736 July 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 207523 4980542 1.54E+08 1497 Page 3 7117 August 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 207419 4978065 1.54E+08 1496 8782 Sept. 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 208467 5003200 1.5E+08 1455 7533 7886 9271 October November December 209845 211267 211671 209845 211267 211671 209845 211267 211671 209845 211267 9211671 209845 211267 211671 209845 211267 211671 209845 9211267 9.211671 209845 9211267 211671 209845 9211267 211671 209845 211267 211671 209845 211267 211671 209845 211267 211671 209845 211267 9211671 209845 211267 9211671 209845 211267 9211671 209845 §=211267 211671 209845 211267 211671 209845 211267 211671 209845 211267 211671 209845 211267 211671 209845 211267 211671 209845 9211267 9211671 209845 §=211267. 211671 209845 211267 211671 5036284 5070400 5080103 1.56E+08 1.52E+08 1.57E+08 1514 1475 1527 94557 1.84E+09 17826 HOONH_#2.XLS HEAT DEMAND BY HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 557072 568530 479687 406709 327478 218182 200382 192182 275376 384877 497794 529910 545703 556927 469897 398408 320795 213730 196292 188260 269756 377022 487635 519096 542861 554026 467450 396333 319124 212616 195270 187279 268351 375058 485096 516392 532913 543874 458884 389071 313276 208720 191692 183848 263433 368186 476206 506929 542861 554026 467450 396333 319124 212616 195270 187279 268351 375058 485096 516392 551387 562728 474792 402558 324137 215956 198337 190221 272566 380949 492715 524503 584073 596086 502937 426421 343351 228757 210094 201497 288723 403531 521922 555595 615337 627993 529858 449247 361730 241002 221340 212283 304178 425132 549860 585334 9 619600 632344 533529 452360 364236 242672 222874 213754 306285 428077 553669 589390 10 623864 636695 537200 455472 366742 244342 224407 215224 308393 431023 557479 593445 11 623864 636695 537200 455472 366742 244342 224407 215224 308393 431023 557479 593445 12 628127 641046 540871 458585 369248 246012 225941 216695 310500 433968 561289 597501 13 633811 646847 545766 462735 372590 248238 227985 218656 313310 437895 566368 602908 14 619600 632344 533529 452360 364236 242672 222874 213754 306285 428077 553669 589390 15 611074 623642 526187 446134 359224 239333 219807 210812 302070 422186 546050 581279 16 615337 627993 529858 449247 361730 241002 221340 212283 304178 425132 549860 585334 17 606810 619291 522516 443022 356717 237663 218273 209341 299963 419241 542240 577224 18 615337 627993 529858 449247 361730 241002 221340 212283 304178 425132 549860 585334 19 615337 627993 529858 449247 361730 241002 221340 212283 304178 425132 549860 585334 20 611074 623642 526187 446134 359224 239333 219807 210812 302070 422186 546050 581279 21 596863 609139 513950 435759 350870 233767 214695 205909 295045 412368 533351 567761 22 592599 604788 510279 432647 348363 232097 213161 204439 292938 409422 529541 563705 23 569862 581583 490700 416046 334997 223191 204982 196594 281698 393713 509223 542076 24 557072 568530 479687 406709 327478 218182 200382 192182 275376 384877 497794 529910 Day: 14212438 14504755 12238125 10376256 8354874 5566429 5112294 4903095 7025590 9819265 12700105 13519467 Month: 4.41E+08 4.06E+08 3.79E+08 3.11E+08 2.59E+08 1.67E+08 1.58E+08 1.52E+08 2.11E+08 3.04E+08 3.81E+08 4.19£+08 3.59E+09 Equivalent Gallons: 4272 3938 3679 3019 2512 1619 1537 1474 2044 2952 3695 4064 34804 ONONA WD = HEAT DELIVERED BY HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 1 557072 568530 479687 406709 327478 218182 200382 192182 275376 384877 497794 529910 2 545703 556927 469897 398408 320795 213730 196292 188260 269756 377022 487635 519096 3 542861 554026 467450 396333 319124 212616 195270 187279 268351 375058 485096 516392 4 532913 543874 458884 389071 313276 208720 191692 183848 263433 368186 476206 506929 5 542861 554026 467450 396333 319124 212616 195270 187279 268351 375058 485096 516392 6 551387 562728 474792 402558 324137 215956 198337 190221 272566 380949 492715 524503 7 §84073 596086 502937 426421 343351 228757 210094 201497 288723 403531 521922 555595 8 615337 627993 529858 449247 361730 241002 221340 212283 304178 425132 549860 585334 9 619600 632344 533529 452360 364236 242672 222874 213754 306285 428077 553669 589390 10 623864 636695 537200 455472 366742 244342 224407 215224 308393 431023 557479 593445 11 623864 636695 537200 455472 366742 244342 224407 215224 308393 431023 557479 593445 12 628127 641046 540871 458585 369248 246012 225941 216695 310500 433968 561289 597501 13 633811 646847 545766 462735 372590 248238 227985 218656 313310 437895 566368 602908 14 619600 632344 533529 452360 364236 242672 222874 213754 306285 428077 553669 589390 15 611074 623642 526187 446134 359224 239333 219807 210812 302070 422186 546050 581279 16 615337 627993 529858 449247 361730 241002 221340 212283 304178 425132 549860 585334 17 606810 619291 522516 443022 356717 237663 218273 209341 299963 419241 542240 577224 18 615337 627993 529858 449247 361730 241002 221340 212283 304178 425132 549860 585334 19 615337 627993 529858 449247 361730 241002 221340 212283 304178 425132 549860 585334 20 611074 623642 526187 446134 359224 239333 219807 210812 302070 422186 546050 581279 21 596863 609139 513950 435759 350870 233767 214695 205909 295045 412368 533351 567761 22 592599 604788 510279 432647 348363 232097 213161 204439 292938 409422 529541 563705 23 569862 581583 490700 416046 334997 223191 204982 196594 281698 393713 509223 542076 24 557072 568530 479687 406709 327478 218182 200382 192182 275376 384877 497794 529910 14212438 14504755 12238125 10376256 8354874 5566429 5112294 4903095 7025590 9819265 12700105 13519467 Days: 31 28 31 30 31 30 31 31 30 31 30 31 4.41E+08 4.06E+08 3.79E+08 3.11E+08 2.59E+08 1.67E+08 1.58E+08 1.52E+08 2.11E+08 3.04E+08 3.81E+08 4.19£+08 3.59E+09 Equivalent Gallons: 4272 3938 3679 3019 2512 1619 1537 1474 2044 2952 3695 4064 34804 Page 4 WASTE HEAT UTILIZATION SIMULATION WORK SHEET. BASIC PROJECT DATA: Location: Hoonah - Scenarios #3 Date: May 7, 1990 Annual pumping elec. cost: Annual other O&M cost: Construction cost estimate: Fuel high heat value: Ave. 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 317602 February 325098 March 316326 April 387166 May 290043 June 364319 July 278088 August 295773 September 378599 October 315842 November 335065 December 401170 4005091 BUILDING DATA: Fuel use, gal/mon. WATER January 162 February 149 March 139 April 114 May 95 June 61 July 58 August 56 September 77 October 112 November 140 December 154 1318 Htg. Efficiency: 0.75 9100 $/year. 10000 $/year. 1901900 $ 137500 Btu/gallon 1.09 $/gallon 0 3017 Btu/kwh 85 2852 Btu/kwh 170 2711 Btu/kwh 255 2593 Btu/kwh 340 2498 Btu/kwh 425 2428 Btu/kwh 510 2381 Btu/kwh 595 2357 Btu/kwh 680 2357 Btu/kwh 765 2357 Btu/kwh 850 2357 Btu/kwh WEATHER DATA: HDD/Month: 1087 1002 939 768 639 412 391 375 520 751 940 1034 8858 NATGD SHOP FOREST 48 433 173 44 399 160 41 373 149 34 306 122 28 255 102 18 164 66 17 156 62 17 149 60 23 207 83 33 299 120 41 374 150 46 412 165 391 3527 1410 0.75 0.75 0.75 HOONH_#3.XLS LODGE 1833 1690 1579 1295 1078 695 877 1267 1586 1744 14936 0.75 PROGRAM RESULTS: Savings, year 0, fuel gallons: Savings, year O, fuel cost: Annual O&M increase cost: Total Savings, year 0: Simple pay back time, years: SYSTEM LOSS DATA: Constant losses: Plant piping: 16000 Btu/hr. Subsurface piping: 205000 Btu/hr. Engine preheating: 0 Btu/hr. Total constant: 221000 Btu/hr. Variable losses: Surface piping: 200 Btu/hr.xF Plant heating: 0 Btu/hr.xF Radiator losses: 0 Btu/hr.xF POOL SENIOR POLICE FIRE 3335 160 220 557 3074 147 203 513 2872 138 190 479 2356 113 156 393 1961 94 130 327 1264 61 84 2i1 1200 58 79 200 1151 55 76 192 1595 7 105 266 2304 111 152 384 2884 138 191 481 3172 152 210 529 27169 1303 1795 4534 0.75 0.75 0.75 0.75 Page 1 na TOTAL 6921 6380 5960 4890 4069 2623 2490 2388 3311 4782 5985 6584 0 56382 0.75 8858 HOONH_#3.XLS POWER PRODUCTION VARIATION: Assumed hourly variation: 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: 1087 1002 939 768 639 412 391 375 520 751 940 1034 Kwh: 317602 325098 316326 387166 290043 364319 278088 295773 378599 315842 335065 401170 4005091 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 1 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. Page 2 HEAT GENERATED PER HOUR BY MONTH, BTU'S Hour: OnNOnHRwWH = BBYISTGSATSSIS © 24 January 972681 921488 870294 870294 876572 870294 972681 1044642 1044642 1169005 1193877 1169005 1119260 1169005 1193877 1193877 1218749 1144132 1069515 1023875 1023875 1049472 1023875 1023875 February 1071116 1044297 986281 986281 957273 986281 1071116 1183865 1183865 1299078 1326718 1299078 1243798 1299078 1326718 1326718 1354357 1271438 1212053 1127491 1127491 1155678 1127491 1127491 March 968773. 917785 866797 866797 873051 866797 968773 1040445 1040445 1164308 1189080 1164308 1114763 1164308 1189080 1189080 1213853 1139535 1065218 1019762 1019762 1045256 1019762 1019762 April 1190574 1127912 1065250 1065250 1033919 1065250 1190574 1290346 1290346 1429662 1460080 1429662 19382514 1429662 1460080 1460080 1490499 1413236 1321069 1228901 1228901 1259624 1228901 1228901 May 1005159 888280 849026 824768 824768 873284 873284 888280 1005159 1051910 958407 1044853 1090282 1135710 1090282 1090282 1005159 1051910 1090282 1005159 911655 911655 911655 958407 HOONH_#3.XLS June 1243111 1120317 1031871 1031585 1031585 1061353 1061353 1120317 1243111 1300930 1208763 1329840 1387659 1431166 1387659 1387659 1243111 1300930 1387659 1243111 1149799 1149799 1149799 1208763 July 963728 851667 814031 790773 790773 837289 837289 851667 963728 1008553 918903 1030965 1045342 1088898 1045342 1045342 963728 1008553 1045342 963728 874079 874079 874079 918903 August 1025016 905828 865799 841062 841062 858153 858153 905828 1025016 1042332 977341 1065495 1111821 1158147 1111821 1111821 1025016 1042332 1111821 1025016 929666 929666 929666 977341 Sept. 1291837 1164230 1072317 1041679 1041679 1102954 1102954 1164230 1291837 1351922 1231751 1381965 1427773 1487263 1427773 1427773 1291837 1351922 1427773 1291837 1194867 1194867 1194867 1231751 October November December 1063588 967291 890926 865471 865471 916381 916381 967291 1063588 1113057 1043656 1137792 1187261 1236730 1187261 1187261 1063588 1113057 1187261 1063588 992746 992746 992746 1043656 1060369 1004560 948751 948751 920846 948751 1060369 1138817 1138817 1249645 1276233 1249645 1220161 1249645 1276233 1276233 1302821 1223057 1165932 1084588 1084588 1111702 1084588 1084588 1193843 1131009 1068175 1068175 1036758 1068175 1193843 1293889 1293889 1433587 1464089 1433587 1386310 1433587 1464089 1464089 1494591 1403086 1324696 1232275 1232275 1263082 1232275 1232275 Day: 25228862 28095049 25127502 30771195 23339615 29211253 22406781 23675221 30189656 25058797 27109687 30841652 Month: 7.82E+08 7.87E+08 7.79E+08 9.23E+08 7.24E+08 8.76E+08 6.95E+08 7.34E+08 9.06E+08 7.77E+08 8.13E+08 9.56E+08 9.75E+09 Equivalent Gallons: 7584 7628 7553 8952 7016 HEAT LOST FROM SYSTEM PER HOUR BY MONTH, BTU'S Hour: OnNOnkwWNn = BBXSSeLZARBNAS © 24 January 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 249013 February 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 249157 Day: 5976310 5979771 Equivalent Gallons: 1797 1624 March 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 248058 April 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 247120 May 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 246123 8498 June 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 244747 6736 July 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 244523 7117 August 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 244419 8782 Sept. 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 245467 7533 7886 9271 94557 October November December 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 246845 248267 248671 5953394 5930880 5906942 5873920 5868542 5866065 5891200 5924284 5958400 5968103 Month: 1.85E+08 1.67E+08 1.85£+08 1.78E+08 1.83E+08 1.76E+08 1.82E+08 1.82E+08 1.77E+08 1.84E+08 1.79E+08 1.85E+08 2.16E+09 1790 1725 1776 1709 1764 Page 3 1763 1714 1781 1733 1794 20969 HEAT DEMAND BY HOUR BY MONTH, BTU'S Hour: OnNOOALWND = nr at ci ae oe et at ed oe ok ce SBRSSBISHAPBHASoO 24 Day: 23026624 23500230 19827893 16811342 13536350 9018585 8282806 7943868 11382680 15908919 20576382 21903891 January 902553 884134 879529 863412 879529 893344 946300 996953 1003860 1010768 1010768 1017675 1026885 1003860 990046 996953 983139 996953 996953 990046 967022 960114 923275 902553 February 921117 902319 897619 881171 897619 911718 965763 1017458 1024508 1031557 1031557 1038606 1048005 1024508 1010409 1017458 1003359 1017458 1017458 1010409 986911 979862 942265 921117 March 777176 761315 757350 743472 757350 769245 814845 858462 864410 870357 870357 876305 884236 864410 852514 858462 846566 858462 858462 852514 832688 826740 795019 777176 April 658939 645491 642129 630362 642129 652215 690877 727858 732901 737944 737944 742987 749711 732901 722815 727858 717773 727858 727858 722815 706006 700963 674067 658939 May 530572 519744 517037 507562 517037 525158 556288 586065 590126 594186 594186 598247 603661 590126 582005 586065 577944 586065 586065 582005 568470 564409 542753 530572 HOONH_#3.XLS June 353493 346279 344475 338163 344475 349886 370627 390466 393171 395876 395876 398582 402189 393171 387760 390466 385055 390466 390466 387760 378743 376037 361609 353493 July 324654 318028 316372 310574 316372 321341 340389 358610 361094 363579 363579 366063 369376 361094 356125 358610 353640 358610 358610 356125 347843 345358 332107 324654 August 311368 305014 303425 297865 303425 308191 326460 343935, 346318 348701 348701 351084 354261 346318 341552 343935 339169 343935 343935 341552 333609 331226 318517 311368 Sept. 446156 437051 434775 426808 434775 441604 467781 492821 496235 499650 499650 503064 507617 496235 489406 492821 485992 492821 492821 489406 478025 474610 456400 446156 October November December 623567 806514 858547 610841 790054 841025 607660 785939 836645 596525 771537 821314 607660 785939 836645 617204 798284 849786 653791 845605 900160 688787 890868 948344 693559 897041 954914 698332 903213 961485 698332 903213 961485 703104 909385 968055 709467 917615 976816 693559 897041 954914 684015 884696 941773 688787 890868 948344 679243 878524 935203 688787 890868 948344 688787 890868 948344 684015 884696 941773 668108 864122 919871 663336 857949 913301 637884 825030 878258 623567 806514 858547 Month: 7.14£+08 6.58E+08 6.15E+08 5.04E+08 4.2E+08 2.71E+08 2.57E+08 2.46E+08 3.41E+08 4.93E+08 6.17E+08 6.79E+08 5.82E+09 Equivalent Gallons: 6922 6381 5960 4891 HEAT DELIVERED BY HOUR BY MONTH, BTU'S Hour: OnNOAnkWND = YVNANN at ak ek ok Sh ek es Ok RBBNYSSBUFHREBNASO 19252552 21780267 18642454 16811342 13536350 9018585 8282806 7943868 11382680 15908919 20058467 21806101 Days: January 723668 672475 621281 621281 627559 621281 723668 795629 795629 919992 944864 919992 870247 919992 944864 944864 969737 895119 820502 774862 774862 800459 774862 774862 31 February 821959 795140 737124 737124 708116 737124 821959 934708 934708 1031557 1031557 1038606 994641 1024508 1010409 1017458 1003359 1017458 962896 878334 878334 906521 878334 878334 28 March 720715 669727 618739 618739 624993 618739 720715 792387 792387 870357 870357 876305 866705 864410 852514 858462 846566 858462 817160 771703 771703 797198 771703 771703 31 April 658939 645491 642129 630362 642129 652215 690877 727858 732901 737944 737944 742987 749711 732901 722815 727858 717773 727858 727858 722815 706006 700963 674067 658939 30 4069 May 530572 519744 517037 507562 517037 525158 556288 586065 590126 594186 594186 598247 603661 590126 582005 586065 577944 586065 586065 582005 568470 564409 542753 530572 31 2624 June 353493 346279 344475 338163 344475 349886 370627 390466 393171 395876 395876 398582 402189 393171 387760 390466 385055 390466 390466 387760 378743 376037 361609 353493 30 2490 July 324654 318028 316372 310574 316372 321341 340389 358610 361094 363579 363579 366063 369376 361094 356125 358610 353640 358610 358610 356125 347843 345358 332107 324654 31 2388 August 311368 305014 303425 297865 303425 308191 326460 343935 346318 348701 348701 351084 354261 346318 341552 343935 339169 343935 343935 341552 333609 331226 318517 311368 31 3311 Sept. 446156 437051 434775 426808 434775 441604 467781 492821 496235 499650 499650 503064 507617 496235 489406 492821 485992 492821 492821 489406 478025 474610 456400 446156 30 4782 5986 6584 October November December 623567 610841 607660 596525 607660 617204 653791 688787 693559 698332 698332 703104 709467 693559 684015 688787 679243 688787 688787 684015 668108 663336 637884 623567 31 806514 756293 700484 700484 672580 700484 812102 890550 890550 903213 903213 909385 917615 897041 884696 890868 878524 890868 890868 836321 836321 857949 825030 806514 30 858547 841025 819504 819504 788087 819504 900160 948344 954914 961485 961485 968055 976816 954914 941773 948344 935203 948344 948344 941773 919871 913301 878258 858547 31 56388 5.97E+08 6.1E+08 5.78E+08 5.04E+08 4.2E+08 2.71E+08 2.57E+08 2.46E+08 3.41E+08 4.93E+08 6.02E+08 6.76E+08 5.59E+09 Equivalent Gallons: 5787 5914 5604 4891 4069 2624 2490 Page 4 2388 3311 4782 5835 6555 54250 APPENDIX 2 COST ESTIMATES Hoonah waste heat report Simple Payback Ignores O&M costs Scenario #1 Scenario #2 Prodject cost $ 746,950 $ 1,538,700 Fuels cost Savings $ 23,500 $ 37,900 Years for payback 31.8 40.6 Fuel cost savings based on $1.09 per gallon Price of fuel required for 10 year payback Prodject cost $ 746,950 $ 1,538,700 Gallons fuel saved 21,600 34,800 Cost of fuel per gallon for 10 year payback $3.46 $4.42 2/20/91 Scenario #3 $ 1,901,900 $ 59,200 32.1 $ 1,901,900 54,300 $3.50 HMS 9119 CONSTRUCTION COST ESTIMATE WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA COST CONSULTANT ENGINEER HMS Inc. Frank Moolin & Associates, Inc. 4103 Minnesota Drive 550 W. 7th Avenue Anchorage, Alaska 99503 Anchorage, Alaska 9950 (907) 561-1653 February 19, 1991 (907) 562-0420 FAX = —_ : = WASTE HEAT RECOVERY SYSTEM PAGE 1 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from a February 13, 1991 report, including a concept design dated May 18, 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 - To Serve Water Treatment Plant, National Guard Armory, City Shops, Forest Service Building and Totem Lodge SCENARIO #2 - To Serve Pool Heat and Water Heating, Senior Center, Fire Station and Police Station SCENARIO #3 - To Serve Water Plant, National Guard Armory, City Shops, Forest Service Building, Totem Lodge, Pool Heat and Water Heating, Senior Center, Fire Station and Pole Station WASTE HEAT RECOVERY SYSTEM PAGE 2 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SUMMARY SCENARIO #1 SCENARIO #2 SCENARIO #3 CONSTRUCTION COST ESTIMATE 01 - General Conditions, Overhead and Profit 169,693 253,338 304,317 02 - Sitework 144,373 556,357 674,320 15 - Mechanical 134,060 117,848 166,016 16 - Electrical 3,063 1,900 4,145 SUBTOTAL 451,189 929,443 1,148,798 Estimate contingency for elements of project not determined at this early level of design 10.00% 45,119 92,944 114,880 Escalation at .50% per month to Spring 1992 7.50% 37,223 76,679 94,776 TOTAL CONSTRUCTION COST: 533,531 1,099,066 1,358,454 PROJECT COST Design 10.00% 53,353 109,907 135,845 SIA (Supervision, Inspection and Administration) 20.00% 106,706 219,813 271,691 Project Contingency 10.00% 53,353 109,907 135,845 TOTAL PROJECT COST: 746,943 1,538,693 1,901,835 = . —_. WASTE HEAT RECOVERY SYSTEM —= HOONAH, ALASKA CONSTRUCTION COST STUDY 2/18/91 SCENARIO #1 WASTE HEAT RECOVERY SYSTEM =u * HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 01 - GENERAL CONDITIONS QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 6,000.00 6,000 Freight 77,000 LBS 0.35 26,950 Supervision, equipment, utilities, clean site, tools and protection 14 WKS 3,500.00 49,000 Per diem 420 DAYS 85.00 35,700 Travel costs, including time in travel 8 RT 250.00 2,000 SUBTOTAL 119,650 Bond and insurance 2.25 % 9,026 Profit 10.00 % 41,017 TOTAL ESTIMATED COST: 169,693 a > WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA CONSTRUCTION COST STUDY SCENARIO #1 PAGE 5 2/19/91 02 - SITE WORK Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 3" diameter Schedule 40 pipe with insulation and arctic pipe protection 1 1/2" ditto 1" ditto 3" bend 1 1/2" bend 1" bend 3" tee 11/2" tee 1" tee TOTAL ESTIMATED COST: QUANTITY 1,230 1,800 420 240 10 14 10 UNIT UNIT RATE ESTIMATED COST LF LF 5 ie] > BB EF Ss 12.50 55.15 35.10 28.70 215.25 151.00 132.50 231.00 160.00 126.00 15,375 99,270 14,742 6,888 2,153 1,208 1,855 2,310 320 252 144,373 WASTE HEAT RECOVERY SYSTEM = HOONAH, 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 3 EA 72.50 218 Ditto radiators 3 EA 72.50 "218 Form hole through existing wall for heating pipes 2 EA 195.00 390 Black steel welded pipe: 8" diameter pipe 140 LF 65.50 9,170 5" diameter pipe 110 LF 44.30 4,873 4" diameter pipe 80 LF 35.30 2,824 3" diameter pipe 20 LF 26.22 524 8" diameter fittings 12 EA 130.50 1,566 5" diameter fittings 24 EA 79.20 1,901 4" diameter fittings 6 EA 60.00 360 3" diameter fittings 2 EA 46.35 93 WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA CONSTRUCTION COST STUDY SCENARIO #1 15 - MECHANICAL Exc a e connections Continue Black steel welded 8g" 5" 4" 3" 8" 5" 4" 3" diameter diameter diameter diameter diameter diameter diameter diameter gate gate gate gate pipe: (Continued) valves valves valves valve check valve check valves check valves check valve Balance valves Control valves Insulation to Pipes: 8" diameter QUANTITY 12 140 UNIT UNIT RATE BB EES § BB BS 1,510.00 860.00 520.00 325.00 1,510.00 860.00 520.00 325.00 121.00 89.00 12.10 PAGE 7 2/19/91 ESTIMATED COST 12,080 10,320 4,680 325 1,510 1,720 1,040 325 363 178 1,694 Vv WASTE HEAT RECOVERY SYSTEM —_*" HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Insulation: (Continued) 5" diameter 110 LF 8.50 935 4" diameter 80 LF 7.70 616 3" diameter 20 LF 7.10 * 142 Heat exchanger, 1,663 MBH, 350 GPM al EA 16,275.00 16,275 Pump, 181 GPM, 70'0" head, 5 HP 2 EA 1,855.00 3,710 Gauges 4 EA 68.50 274 Air separator with vent 1 EA 495.00 495 Expansion tank 1 EA 1,350.00 1,350 Glycol tank, pump and make-up system 1. LOT 1,025.00 1,025 Glycol 440 GALS 8.80 3,872 Temperature switch 3 EA 147.50 443 a7 —_: =? —_ _ 7 9 WASTE HEAT RECOVERY SYSTEM PAGE HOONAH, 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 10 EA 195.00 1,950 Unit heaters, 199 MBH 2 EA "610.00 1,220 Duct unit heater, 199 MBH, 4 GPM 1 EA 705.00 705 Duct coil, 199 MBH, 5 GPM 1 EA 1,885.00 1,885 Heat exchanger, 199 MBH, 24 GPM 2 EA 3,435.00 6,870 Pump, 22 GPM, 5’0" head, fractional HP 1 EA 735.00 , 735 3" diameter black steel piping 400 LF 26.22 10,488 3" fittings 21 EA 46.35 973 1 1/2" ditto 60 LF 17.97 1,078 1" ditto 120 LF 11.10 1,332 3" gate and check valves 7 EA 325.00 2,275 1 1/2" ditto a EA 134.90 135 1" ditto 3 EA 77.00 231 =_> 5 _? = y Ld WASTE HEAT RECOVERY SYSTEM TIA HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) Control valves 6 EA 89.00 534 Connections to existing 1 LoT 300.00 300 3" insulation 400 LF Tol 2,840 1 1/4" insulation 60 LF 5.20 312 1" insulation 120 LF 4.50 540 Temperature switch 1 EA 147.50 148 Test and balance system 60 HRS 75.00 -4,500 Controls and Instrumentation Generator building 1 LOT 2,000.00 2,000 Hook-up inter ties 5 LoTs 1,500.00 7,500 TOTAL ESTIMATED COST: 134,060 WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA CONSTRUCTION COST STUDY SCENARIO #1 16 - ELECTRICAL PAGE 11 2/19/91 Motor Connections Breaker in existing power panel Connection to motor Disconnect switch 3/4" EMT conduit #8 copper TOTAL ESTIMATED COST: QUANTITY 130 520 UNIT UNIT RATE 5 B BS 175.00 115.00 330.00 3.20 0.85 ESTIMATED COST 525 690 990 416 442 3,063 GE 12 WASTE HEAT RECOVERY SYSTEM - HOONAH, ALASKA CONSTRUCTION COST STUDY 2/18/91 SCENARIO #2 WASTE HEAT RECOVERY SYSTEM meee tt HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 01 -— GENERAL CONDITIONS QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization aE LOT 6,000.00 6,000 Freight 145,000 LBS 0.35 50,750 Supervision, equipment, utilities, clean site, tools and protection 14 WKS 3,500.00 49,000 Per diem 500 DAYS 85.00 42,500 Travel costs, including time in travel 8 RT 250.00 2,000 SUBTOTAL 150,250 Bond and insurance 2.25 % 18,593 Profit 10.00 % 84,495 TOTAL ESTIMATED COST: 253,338 WASTE HEAT RECOVERY SYSTEM PAGE 14 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 3,450 LF 12.50 43,125 4" diameter Schedule 40 pipe with insulation and arctic pipe protection 6,480 LF 75.63 490,082 1 1/2" ditto 100 LF 35.10 3,510 1 1/4" ditto 160 LF 31.90 5,104 1" ditto 160 LF 28.70 4,592 4" bend 20 EA 293.50 5,870 1 1/2" ditto 4 EA 151.00 604 1 1/4" ditto 4 EA 132.50 530 1" ditto 4 EA 105.00 420 4" tee 8 EA 315.00 2,520 TOTAL ESTIMATED COST: 556,357 WASTE HEAT RECOVERY SYSTEM PAGE 15 HOONAH, 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 2 EA 72.50 218 Ditto radiators 3 EA 72.50 218 Form hole through existing wall for heating pipes 2 EA 195.00 390 Black steel welded pipe: 8" diameter pipe 140 LF 65.50 9,170 5" diameter pipe 110 LF 44.30 4,873 4" diameter pipe 100 LF 35.30 3,530 8" diameter fittings 12 EA 130.50 1,566 5" diameter fittings 24 EA 79.20 1,901 4" diameter fittings 8 EA 60.00 480 8" diameter gate valves 8 EA 1,510.00 12,080 5" diameter gate valves 12 EA 860.00 10,320 WASTE HEAT RECOVERY SYSTEM PAGE 16 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Black steel welded pipe: (Continued) 4" diameter gate valves 10 EA 520.00 5,200 a" diameter check valve 1 EA 1,510.00 1,510 5" diameter check valves 2 EA 860.00 1,720 4" diameter check valves 3 EA 520.00 1,560 Balance valves 3 EA 121.00 363 Control valves 2 EA 89.00 178 Insulation to Pipes: 8" diameter 140 LF 12.10 1,694 5" diameter 110 LF 8.50 935 4" diameter 100 LF 7.70 770 Heat exchanger, 1,026 MBH, 350 GPM 1 EA 14,470.00 14,470 Pump, 112 GPM, 70’0" head, 3 HP 2 EA 1,585.00 3,170 WASTE HEAT RECOVERY SYSTEM PAGE 17 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST er a Connections Co: ie Gauges 4 EA 68.50 274 Air separator with vent 1 EA 495.00 495 Expansion tank 1 EA 1,350.00 1,350 Glycol tank, pump and make-up system 1 LOT 1,025.00 1,025 Glycol 495 GALS 8.80 4,356 Temperature switch 3 EA 147.50 443 OOoK— Form hole through existing wall for heating pipes 8 EA 195.00 1,560 Heat exchanger, 534 MBH, 58 GPM 1 EA 2,955.00 2,955 Double wall heat exchanger, 267 MBH, 29 GPM 1 EA 4,880.00 4,880 Duct coil, 38 MBH, 4 GPM al EA 1,225.00 1,225 WASTE HEAT RECOVERY SYSTEM wee De HOONAH, ALASKA CONSTRUCTION COST S'I'UDY 2/19/91 SCENARIO #2 15 - MECHANICAL QUANTITY — UNIT UNIT RATE ESTIMATED COST Hook-Up __ (Continued) Heat exchanger, 53 MBH, 6 GPM 1 EA 1,005.00 1,005 Ditto, 134 MBH, 15 GPM 1 EA 1,350.00 1,350 4" diameter pipe 20 LF 35.65 713 Fittings 4 EA 55.00 220 3" diameter pipe 40 LF 26.22 1,049 Fittings 8 EA 46.35 371 2" diameter pipe and fittings 40 LF 21.50 860 1 1/2" ditto 20 LF 17.97 359 1 1/4" ditto 40 LF 12.05 482 1" ditto 40 LF 11.10 444 Connect to existing, 3" diameter 2 EA 50.00 100 Ditto, 2" diameter 2 EA 35.00 70 Ditto, 1 1/2" diameter 2 EA 30.00 60 WASTE HEAT RECOVERY SYSTEM = > HOONAH, ALASKA CONSTRUCTION COST STUDY ' 2/19/91 SCENARIO #2 . 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up __ (Continued) Connection to existing, 1 1/4" diameter 2 EA 30.00 60 Gate and check valves, 3" diameter 3 EA 325.00 975 Ditto, 2" diameter 1 EA 181.00 181 Ditto, 1 1/2" diameter 3 EA 134.90 405 Ditto, 1 1/4" diameter 3 EA 105.50 317 Ditto, 1" diameter 1 EA 77.00 vid Balance valves 9 EA 89.00 801 4" diameter insulation 40 LF 7385 314 3" diameter ditto 40 LF 7.10 284 2" diameter ditto 40 LF 6.25 250 1 1/2" diameter ditto 20 LF 5.20 104 1 1/4" diameter ditto 40 LF 4.70 188 1" diameter 40 LF 4.50 180 WASTE HEAT RECOVERY SYS'TEM PAGE 20 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up ___ (Continued) Test and balance system 50 HRS 75.00 3,750 Controls and Instrumentation Generator building 1 LoT 2,000.00 2,000 Hook-up inter ties 4 LOTS 1,500.00 6,000 TOTAL ESTIMATED COST: 117,848 WASTE HEAT RECOVERY SYSTEM anew ae HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #2 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 2 EA 175.00 350 Connection to motor 2 EA 115.00 230 Disconnect switch 2 EA 330.00 660 3/4" EMT conduit 100 LF 3.20 320 #8 copper 400 LF 0.85 340 TOTAL ESTIMATED COST: 1,900 PAGE 22 WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA CONSTRUCTION COST STUDY 2/18/91 SCENARIO #3 PAGE 23 WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #3 01 - GENERAL alien QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 6,000.00 6,000 Freight 170,000 LBS 0.35 59,500 Supervision, equipment, utilities, clean site, tools and protection 18 WKS 3,500.00 63,000 Per diem 540 DAYS 85.00 45,900 Travel costs, including time in travel 10 RT 250.00 2,500 SUBTOTAL 176,900 Bond and insurance 2.25 % 22,981 Profit 10.00 % 104,436 TOTAL ESTIMATED COST: 304,317 WASTE HEAT RECOVERY SYSTEM PAGE 24 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #3 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including , backfilling and spread and level surplus 4,400 LF 12.50 55,000 5" diameter Schedule 40 pipe with insulation and arctic pipe protection 360 LF 94.50 34,020 4" ditto 6,120 LF 75.63 462,856 3" ditto 1,440 LF 55.15 79,416 1 1/2" ditto 320 LF 35.10 11,232 1 1/4" ditto 160 LF 31.90 5,104 1" ditto 400 LF 28.70 11,480 5" bend 2 EA 390.00 780 4" ditto 18 EA 293.50 5,283 3" ditto 10 EA 215.25 2,153 1 1/2" ditto a EA 151.00 604 1 1/4" ditto a EA 132.50 530 WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA CONSTRUCTION COST STUDY SCENARIO #3 02 - SITE WORK QUANTITY UNIT UNIT RATE PAGE 25 2/19/91 ESTIMATED COST tilities ontinued 1" bend 5" tee 4" tee 3" tee TOTAL ESTIMATED COST: BB Fs 105.00 410.00 315.00 231.00 420 2,460 2,520 462 674,320 WASTE HEAT RECOVERY SYSTEM Mii HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling 72.50 218 system of generators 3 EA Ditto radiators 3 EA 72.50 218 Form hole through existing wall for heating pipes 2 EA 195.00 390 Black steel welded pipe: 8" diameter pipe 140 LF 65.50 9,170 5" diameter pipe 110 LF 44.30 4,873 4" diameter pipe 100 LF 35.30 3,530 8" diameter fittings 12 EA 130.50 1,566 5" diameter fittings 24 EA 79.20 1,901 4" diameter fittings 8 EA 60.00 480 8" diameter gate valves 8 EA 1,510.00 12,080 5" diameter gate valves 12 EA 860.00 10,320 WASTE HEAT RECOVERY SYSTEM PAGE 27 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #3 15 - MECHANICAL QUANTITY © UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Black steel welded pipe: (Continued) 4" diameter gate valves 10 EA "520.00 5,200 8" diameter check valve 1 EA 1,510.00 1,510 5" diameter check valves 2 EA 860.00 1,720 4" diameter check valves 3 EA 520.00 1,560 Balance valves 3 EA 121.00 363 Control valves 2 EA 89.00 178 Insulation to Pipes: 8" diameter 140 LF 12.10 1,694 5" diameter 110 LF 8.50 935 4" diameter 100 LF 7.10 770 Heat exchanger, 1,663 MBH, 350 GPM 1 EA 16,275.00 16,275 Pump, 181 GPM, 70’0" head, 5 HP 2 EA 1,855.00 3,710 WASTE HEAT RECOVERY SYSTEM PAGE 28 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST c era Connections Continued Gauges 4 EA 68.50 274 Air separator with vent 1 EA 495.00 495 Expansion tank nl EA 1,350.00 1,350 Glycol tank, pump and make-up system aL LoT 1,025.00 1,025 Glycol 550 GALS 8.80 4,840 Temperature switch 3 EA 147.50 | 443 Hook-Up Form hole through existing wall for heating pipes 16 EA 195.00 3,120 Heat exchanger, 534 MBH, 58 GPM 1 EA 2,955.00 2,933 Double wall heat exchanger, 267 MBH, 29 GPM 1 EA 4,880.00 4,880 Duct coil, 38 MBH, 4 GPM 1 EA 1,225.00 1,225 WASTE HEAT RECOVERY SYSTEM a HOONAH, ALASKA CONSTRUCTION COST STUDY 7 2/19/91 SCENARIO #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) Heat exchanger, 53 MBH, 6 GPM 1 EA 1,005.00 1,005 Ditto, 134 MBH, 15 GPM 1 EA 1,350.00 1,350 Unit heaters, 199 MBH 2 EA 610.00 1,220 Duct unit heater, 199 MBH, 4 GPM 2 EA 705.00 705 Duct coil, 199 MBH, 5 GPM A EA 1,885.00 1,885 Heat exchanger, 199 MBH, 24 GPM 2 EA 3,435.00 6,870 Pump, 22 GPM, 5’0" head, fractional HP 1 EA 735.00 35 4" diameter pipe 20 LF 35.65 73) Fittings 4 EA 55.00 220 3" diameter pipe 440 LF 26.22 11,537 Fittings 29 EA 46.35 1,344 2" diameter pipe and fittings 40 LF 21.50 860 fT (1/2".ditto 80 LF 17.97 1,438 WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA CONSTRUCTION COST STUDY SCENARIO #3 PAGE 30 2/19/91 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) 1 1/4" diameter pipe and fittings 40 LF 12.05 482 1" ditto 160 LF 11.10 1,776 Connect to existing, 3" diameter 2 EA 50.00 100 Ditto, 2" diameter 2 EA 35.00 70 Ditto, 1 1/2" diameter 6 EA 30.00 180 Connection to existing, 1 1/4" diameter 6 EA 30.00 180 Ditto, 1" diameter 2 EA 25.00 50 Gate and check valves, 3" diameter 10 EA 325.00 3,250 Ditto, 2" diameter 1 EA 181.00 181 Ditto, 1 1/2" diameter 4 EA 134.90 540 Ditto, 1 1/4" diameter 6 EA 105.50 633 Ditto, 1" diameter 1 EA 77.00 77 Balance valves 15 EA 89.00 1,335 WASTE HEAT RECOVERY SYSTEM HOONAH, ALASKA CONSTRUCTION COST STUDY SCENARIO #3 15 - MECHANICAL Hook-Up (Continued) 4" diameter insulation 3" diameter ditto 2" diameter ditto 11/2" diameter ditto 1 1/4" diameter ditto 1" diameter Test and balance system Controls and Instrumentation Generator building Hook-up inter ties TOTAL ESTIMATED COST: QUANTITY 40 440 40 80 40 160 100 9 UNIT UNIT RATE LF LF LF LF LF LF LOT LOTS PAGE 31 2/19/91 ESTIMATED COST 7.85 7.10 6.25 5.20 4.70 4.50 75.00 2,000.00 1,500.00 314 3,124 250 416 188 720 7,500 2,000 13,500 166,016 WASTE HEAT RECOVERY SYSTEM PAGE 32 HOONAH, ALASKA CONSTRUCTION COST STUDY 2/19/91 SCENARIO #3 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 4 EA 175.00 . 700 Connection to motor 7 EA 115.00 805 Disconnect switch 4 EA 330.00 1,320 3/4" EMT conduit 200 LF 3.20 640 #8 Copper 800 LF 0.85 680 TOTAL ESTIMATED COST: 4,145 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 |HOD MONTH HDD HDD HDD ° MONTH HDD HDD HDD MEAN | 1988 1989) MEAN 1988) 1989 MEAN 1988 1989 HOONAH _|COLD BAY CORDOVA Juneau > JAN 1087| 1217| JAN 1126) 1318} JAN 1157, 1255| FEB 1002 1144 FEB 10585) 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 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 SEP 520 497 370) SEP 517 537| 447 SEP 503 481 400) OCT 751 641 713 OCT 779) 755 695) OCT 737| 665 Ti 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 ----------------> Aniak -—------- ———-> St. Marys ------------------ > 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| 1 APR 1163} APR 1185 1087) MAY 656). MAY 715 764 MAY 697) 868 JUN 325) 4 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) 511 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) 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. 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. % 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) - PC. CL. DEMOMSTRATES “THAT BETWEEN 607, £ 1007, LoAD , PERCeEDT OF EXERLY “To JACKET WATER IS ESSENTIAUN CONSTAWT . PERCENTAGES OBTAWED FRon PRIME LOAD DATA SHouLD BE APPLICABLE IN THIS RANGE. GENSETS.XLS IGENSET DATA | LOCATION _|GENSET CATAPILER 3512 @ 851 KW PRIME (W/O FAN) - NOTE 1 INPUT: —_ |OUTPUT: | Work: | Exhaust: Radiation: Water: Aftercooler: Oilcooler: Total: ai % LOAD | KW | too] 851|_ a) 50} 426) CATAPILER 3512 @ 683 KW PRIME (W/O FAN) - NOTE 2 INPUT: 121417) OUTPUT: | Work: 43392) Exhaust: Radiation: Water: ‘Aftercooler: biu/min _|(included in jacket water) ——-> imiaian th ; =) Oilcooler: btu/min__| (included in jacket water) -----> Total: WATER | _ % LOAD |_KW KWH/GAL| BTU/HR_|BTU/KWH| _BTU/GAL 0| 1624200 __ 2378 30905 . too] 683] 52.6] 13. 75|__512| 50] 342) CATAPILER D398 @ 600 KW PRIME (W/O FAN) INPUT: _| 48.2| gph * 19590] btu/ib hhv © OUTPUT: | Work: 636 Exhaust: Radiation: Water: 36.1 25.3) ( KALSKAG | |CATAPILER 3406 TA @ 210 KW PRIME (W/O FAN’ INPUT: 16.5[gph" | 19590 OUTPUT: |Work: | | 224 Exhaust: Radiation: Water: Total: % LOAD GPH_|KWH/GAL BTU/GAL 124 20.6 126 35243] L 100} 16.5 12.7 36364] 75 12.6 12.5| 50) 9.0) 11.7 GENSETS.XLS L. KALSKAG |CATAPILER D342 T @ 160 KW PRIME (W/O FAN) - NOTE 4 12.5|gph * 19590] btu/b hhv * 7.076|Ib/gal / 60|min/nr = 28879] btu/min | 235] bhp engine * 2545|btwohp-hr/ | 60|min/nr = 9969] 34% = 1340|CFM @ 710/F > 8157| 28% 2100) 7% ; 9400] 32% | 29626] btu/min WATER KW_| GPH |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 229] | a=] | 160] 12.5] 12.8) 564000] 3525 45120 120) 9.8 12.2 |_| 80 7.0) 11.4 | CATAPILE 155 KW PRIME (W/O FAN) - NOTE 5 INPUT: 12.3[gph * | __19590[btuib hhv * 7.076] Ib/gal / 60] min/hr = 28417|btu/min OUTPUT: ; 167|kw engine * 3412|btu/kwh / 60|min/nr = 9497| 52% ...... 10500] _ 57%| J 1700 9%| 6800[ 37% 28497] btu/min WATER KW_| GPH |KWH/GAL| BTU/HR |BTU/KWH| BTU/GAL 180| ‘14.5! 12.4) 468000) 2600! 32276| 155] 12.3) 12.6 408000] 2632| 33171 116 9.3) 12.5) 78 6.5) 11.9 R. MISSION _|CATAPILER 3304T @ 90 KW PRIME (W/O FAN) - NOTE 6 INPUT: Zegeh = 19590) btu/lb hhv * 7.076} Ib/gal / 60} min/hr = 17558} btu/min OUTPUT: | Work: 99/kw engine * 3412) btu/kwh / 60} mirvhr = 5630) 31% Exhaust: 5801 31% Radiation: 1990] 11% Water: 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] | SS! 100 90] 7.6 11.8} 300300) 3337 39513] 75| 68] 5.6 12.1 50] 45] 3.9) 11.5] | ee ee = R. MISSION, |CUMMINS LTA 10 @ 110 KW PRIME (W/O FAN) - NOTES 7 &8 WHITE MT. | INPUT: 8.0|gph * 19590) btu/b hhv * 7.076|Ib/gal / 60) mirvhr = 18536) btu/min OUTPUT: |Work: 166) bhp engine * 2545) btu/bhp-hr / 60} min/hr = 7042) 38% Exhaust: 9382) * 166} / 235) = 6627) 36% Radiation: 745) * 166) / 235) = 526) 3% Water: | 6251) * 166} / 235) = 4416 24% Total: 18611] btu/min WATER % 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/lb hhv * 7.076| Ib/gal / 60) min/hr = 19638] btu/min OUTPUT: | Work: 150|bhp engine * 2545) btu/bhp-hr / 60| min/hr = 6363 32%) : Ta —T Exhaust: 2 Radiation: z| 2 Water: 150} bhp engine * 32) btu/bhp-min = 4800) 24% Total: Pa btu/min | GENSETS.XLS WATER L % LOAD | KW | GPH |KWH/GAL| BTU/HR_|BTU/KWH| BTU/GAL 125] 125 103) 12.1 360000 2880) 34951 100| 00/5 11.8] _288000| 2880 33882) | a 75] 75|_ «6.7 11.2 L 50] _50|—+5.0 10.0) Tt ANVIK ALLIS CHALMERS 3500 @ 60 KW PRIME (W/FAN)- NOTE 10_| INPUT: 5.1] gph * 19590] btu/ib hhv * 7.076|Ib/gal / 60|min/hr =| __11783|btu/min OUTPUT: | Work: 87|bhp engine * 2545|btu/ohp-hr/_|_60|min/hr = 3691] 31% Exhaust: L [| 2 Radiation: ? Water: 87|bhp engine * 32] btu/ohp-min = 2784| 24% Total: = ?| 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) —a7 11.4 ANVIK ALLIS CHALMERS 2900 @ 50 KW PRIME (W/ FAN) - NOTE 10 INPUT: 4.26|gph * 19590] btu/ib hhv * 7.076|Ib/gal / 60|min/nr = 9842] btu/min OUTPUT: |Work: - 73) bhp engine * 2545) btu/bhp-hr / 60} min/hr = 3097, 31% Exhaust: i Radiation: ? Water: 73|bhp engine * 32|btu/ohp-min = | 2336] 24%! Total: ?\btu/min L WATER % LOAD | KW | GPH |KWH/GAL| BTU/HR |BTU/KWH| BTU/GAL L 120/60] «52 11.5 168192| 2803] 32345 100] 50 4.26 11.7|___ 140160 2803 32901 75| 38] 3.23 11.6 50] 25] S28 10.9) fa a SUMMARY RESULTS: | WEIGHTED SITE LOCATION _|GENSET BTU/KWH| BTU/GAL| WGHT % [BTU/KWH] BTU/GAL HOONAH _|CAT D398 ao20| 40088 5| 2357 31953 CAT D398 3220| 40083) 5| CAT 3512 (851 KW) 2261 31049 a I C. BAY CAT 3512 (683 KW) | _ 2378| 30905 33] 2339) 30953] CAT 3512 (851 KW) _ | 2261] 31049] 33) CAT 3512 (683 KW) 2378| 30905] 33 L.KALSKAG |CAT D342T __ | 3525[ 45120 o| 2024) 37239 CAT 3406TA 2857| 36364! 90 CAT D342T 3525, 45120 10) R. MISSION_|CUMMINS LTA10 2409) 33117) 502873) 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 DETROIT 4-71T CUMMINS LTA10 100} 0 0} DETROIT 371 Engine input and output are from manufacturer's data except as shown. KWH/GAL, BTU/KWH, and BTU/GAL are calculated. Fuel use is listed in manufacturer's data as 143198 btu/min input. Fuel use in gph is calculated as btu/min / 19590 btub hhv / 7.076 Ib/gal * 60 min/nr_= gph. Fuel use is listed in manufacturer's data as 121417 btu/min input. Fuel use in gph is calculated as btu/min / 19590 btub hhv / 7.076 Ib/gal * 60 min/hr_= gph. 3) Nameplate info recorded on engine #2 as 3406D! however AVEC data lists 375SHP/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 0342T. 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. I 8) 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. 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 LTA10L (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 150KW prime. Typical AVEC data = 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/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. _| f 10) Nameplate info recorded on engines as AC2900 and AC3500. These are 1800 rpm gensets. Typical AVEC data for AC3500 is 159HP/105KW peak however this genset reportedly does not meet normal weekday loads which peak at less than 9OKW. 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. Page 4 PIPELOSS.XLS PIPE HEAT LOSS| ] BURIED PIPING, SINGLE PIPE, 3" PU INSULATION ; K=| 0.014] Btu/tt-hr-°F R-=|In(Do/Dp)/2:Pi-K Qh=| (Tp-To)/R Tom| _0/°F (ground Tp=|_180]°F (fluid) Pipe Size|_ Type! Dp (in)| Do(in)| A(fthr°F) — Q/(Btu} | (inches) /Btu) Mnr-tt)) 1|IPS 1.32 7.32! 19.5 9.2| | 1.25|IPS 1.66 7.66| 17.4 10.4 1.5|IPS 1.9] 7.9) 16.2 14.4 [ 2|IPS 2.38 8.38 14.3) 12.6) [IPS 3.5| 9.5) 11.4 15.9 4[IPs 45| 10.5 9.6 18.7| 5|IPS 5.56| 11.56| 8.3 21.6 6|IPS 6.63 12.63] 73) 24.6 SIPS 8.63 14.63] 6.0) 30.0) BURIED PIPING, SINGLE PIPE, 2" PU INSULATION T 1IPS 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 2|IPS 2.38) 6.38 11.2 16.1 3|IPS 35 75 87| 20.8 | 4[iPs 45) 8.5| 7.2 24.9) : S|IPS 5.56 9.56) 6.21 29.2] | IPS 6.63 10.63 5.4) 33.5) | : | 1 ABOVE GRADE PIPING, SINGLE PIPE, 1.5" FG INSULATION | K=| 0.023] Btu/tt-hr-°F| R-=|In(Do/Dp)/2:Pi:K Qh=|(Tp-Toy/R To=| _80|°F (room) Tp=| 180] °F (fluid) | 1IPS 1.32 4.32 8.2] 12.2 1.25[1PS 1.66 4.66 7A 14.0 1.5|IPS 19 49 6.6 15.3 / 2liPs 2.38 5.38 5.6 17.7 3[IPS 3.5] 65 4.3) 23.3 4[IPS 45] 7.5] 3.5| 28.3) | S|IPS 5.56| 8.56 3.0) 33.5) [ 6|IPS 6.63] 9.63 2.6 38.7| glIPS 8.63] 11.63 24 48.4 ABOVE GRADE PIPING, SINGLE PIPE, NO INSULATION QA from ASHRAE Fundamentals (1989), Chapter 22, Table 9 & 10 To=| _80)°F (room) Tp=|_ 180|°F (fluid) Pipe Size} _ Type Dp(in)} — QA(Btu} (inches)| Jor-ft)) 1IPS 1.32 89 1.25/IPS 1.66 110 1.5/IPS 1.9) 124 2iIPs 2.38 152] 3|IPS 3.5 216| 4jIPs 45) 272! SIPS 5.56 330) 6|IPS 6.63 387| 8 8.63 Page 1 CAPACITY.XLS WASTE HEAT SYSTEM - HEAT TRANSFER COMPONENT CAPACITY REQUIREMENTS | _ COLD BAY COLDEST MONTH = JAN. HDD = 1126) Tave -|___65-(HDD/31) =| ~ ACTICAL MINIMUM = O|°F RATIO ave temp diff - max temp diff =| (70 - 0) / (70 - 29) = 1.7\"" Example: _|DOT/PF Shop: 681/gal / month worst month : 1.7|muhtiplier 31 ] days / month CL 7 24|hours / day 1.56} gal / hour worst hour “| 140000|btu/gal_| | | 0.75\eft. 163000]btu / hour heating unit required - 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 731) = 30|°F PRACTICAL MINIMUM = O|°F RATIO ave temp diff - max temp diff = | (70 - 0)/ (70 - 30) = 1.8)" T L. KALSKAG COLDEST MONTH = JAN.| HDD = 2000) ave R. MISSION ANVIK Tave = 65 - (HDD / 31) = O|°F KOTLIK [ W. MOUNT. PRACTICAL MINIMUM = IE -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 = 17 a OVERALL FACTOR capacity - fuel use = 240 OVERALL FACTOR capacity - flow = 9200 =