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White Moutain Report & Concept Design Waste Heat Recovery 1991
REPORT AND CONCEPT DESIGN WHITE MOUNTAIN WASTE HEAT RECOVERY February 14, 1991 LEA Frank Moolin & Associates, Inc. A Subsidiary of ENSERCH Alaska Services, Inc. EN WHITE MOUNTAIN WASTE HEAT RECOVERY 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 5.1 White Mountain School Complex 5¢1.1 High School Belee School Gym 5.1.3 Elementary School 5.2 Community Buildings Saal City Hall/Library 5.2.2 Clinic 5.2.3 Corporation Store 5.2.4 IRA Building 53255 Lodge 6.0 RIGHT -OF -WAY/EASEMENT 7.0 CONCEPT DESIGN 8.0 ECONOMIC DATA 9.0 FAILURE ANALYSIS 10.0 CONCLUSIONS AND RECOMMENDATIONS APPENDICES 1. Calculations 2. Cost Estimates 3. Raw Data WTHTWM/RCD REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 LIST OF FIGURES AND TABLES Power Plant Photographs White Mountain Power Generation Data White Mountain Power Plant Fuel Use - Graph 1 White Mountain Power Plant Power Production - Graph 2 High School Photographs School Gymnasium Photographs Elementary School Photographs School Complex Overall Heating Fuel Consumption Data 4-3 4-4 4-5 4-6 5-4 5-6 5-8 5-9 City Hall/Library Photograph 5-11 City Hall/Library Heating Fuel Consumption Data 5-12 Clinic Photographs 5-14 Clinic Heating Fuel Consumption Data 5-15 Corporation Store Photographs 5-17 Corporation Store Heating Fuel Consumption Data 5-18 IRA Building Photographs 5-20 Lodge Photographs 5-22 Lodge Heating Fuel Consumption Data 5-23 Figure 1 - Legend 7-6 Figure 2 - System Site Plan 7-7 Figure 3. - Power Plant Floor Plan 7-8 Figure 4 - Power Plant Cooling Schematic 7-9 Figure 5 - System Schematic 7-10 Figure 6 - High School Floor Plans 7-11 Figure 7 - High School System Schematic 7-12 Figure 8 - School Gymnasium Floor Plans 7-13 Figure 9 - School Gymnasium System Schematic 7-14 Figure 10 - Typical Trench Section 7-15 Graph 3 10-2 Graph 4 10-3 WTHTWM/RCD WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 1.0 EXECUTIVE SUMMARY A potential for waste heat recovery exists in the community of White Mountain. White Mountain is a community of approximately 190 people on the Seward Peninsula 80 miles East of Nome. The waste heat from the coolant of the diesel engine generator sets owned and operated by the City of White Mountain could be recovered and circulated to heat buildings in the community. Present power plant loads provide the equivalent waste heat of approximately 13,800 gallons of fuel annually with the equivalent of approximately 11,200 gallons available to users. This is not enough to heat all of the publicly owned buildings in the vicinity of the power plant. The School complex, which is adjacent to the power plant, is a primary target though there is not enough waste heat to heat even the School complex. This complex includes the High School, School Gymnasium, Elementary School, and ancilliary buildings. Scenarios for waste heat recovery vary only in which buildings in the complex are connected. Proposed Scenario - The High School and the Gymnasium would be connected to the waste heat recovery system. The High School, Elementary School and the Gym are the closest buildings to the power plant and would be excellent candidates for the waste heat. The Elementary School is in a different direction than the High School and Gym. The recommended scenario is to run the waste heat piping to the High School and Gym only. Serving only these two buildings would utilize all of the available waste heat in the cold months and provide the shortest piping runs and simplest equipment installation. The entire School complex could utilize the equivalent of 24,700 gallons of fuel annually. The High School/Gym combination could use the equivalent of approximately 12,500 gallons of fuel if it was available. Total Estimated Project Cost $559,074 Total Fuel Oi] Savings 9,900 Gallons Total Annual Fuel Cost Savings $ 11,100 (O&M Cost $ 6,000) Additional scenarios could be developed to serve alternate buildings in the School complex (primarily the Elementary School) or the following community buildings: City Hall/Library, Clinic, Corporation Store, IRA building, and Lodge. These buildings are close to the School, the power plant and to each other, and they would be able to utilize a relatively short piping loop. However, these buildings would require additional piping and equipment installations and do not present any advantages over the buildings in the Proposed Scenario. Information is presented in this report to describe these buildings in order to identify their potential for future expansion of the waste heat system only. Alternate scenarios using these buildings are not recommended. WTHTWM/RCD 1-1 ol WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 Other possible waste heat users in the community include the Washateria and the Post Office. These buildings are comparatively far from the power plant and, by inspection, would not be logical candidates for waste heat recovery. These facilities were not considered in this study. Decision Criteria Economic and public policy decisions will consider some or all of the following factors: Ll) Proximity The cost of running the waste heat recovery piping and the individual heat exchangers in each client building may make the pay back period too long for a particular client. This factor will limit this project to the buildings in the immediate area of the power plant. 1.1.2 Potential Future Users and Expansion. At the time of the site investigation (March, 1990), there were plans to add 15 new houses and a sewage treatment facility to the town during 1990. These facilities should increase the power plant load and the waste heat available but will not be located close enough to be served by waste heat. 1.1.3. Community Desires and Priorities The Mayor and City council members, that were interviewed, indicated a priority for using waste heat at the School. They supported using any excess waste heat in community buildings and realized the impracticality of getting heat to the Washetaria and Post Office. A summary of the construction cost estimates along with design and SIOH costs is included in the Cost Estimate Appendix for each alternative. WTHTWM/RCD ae 2.0 Zeal ie 3) WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 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 White Mountain. 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: is 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. as Field Investigation: 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 also photographed. Available fuel costs and heating records were obtained from each interested potential recipient of waste heat (in general this information was not available or not complete). 35 Office Analysis: Additional information regarding weather and historical trends were collected. Where specific fuel use records were not available approximate heat loss calculations were made to estimate fuel use. This information was used to produce a model 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 White Mountain is a community of approximately 190 people, located on the Seward Peninsula, 15 miles inland from Norton Sound, and 80 miles East of Nome. It is situated on the North bank of the Fish River, upstream of the Fish River’s mouth on Golovnin Lagoon. White Mountain is 15 miles Northwest of Golovin, 33 miles East of Solomon, and approximately 500 air miles from Anchorage. Aside from the schools and the stores, the main employment in the community is commercial fishing and subsistance activities. Fire fighting, construction, and other seasonal work also provide employment. Fuel cost at the time of the site visit was $1.12 per gallon for the City. WTHTWM/RCD Shu WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 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) WTHTWM/RCD 2)-\2 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 3.0 DESCRIPTION OF SITE VISIT Two Frank Moolin engineers visited White Mountain March 9 to March 10, 1990. They visited every facility listed in this report and obtained copies of fuel usage and copied or sketched floor plans and piping diagrams. Contacts: Tom Grey - 638-3971 - Mayor - City Clerk Lincoln Simon - Power Plant operator Mike Simon - 638-3361 - Power Plant Operator John Oksoktaruk - 638-3971 - Utilities George Ihly - 638-3021 - Principal Howard Lincoln - 638-3091 - U.S. Post Office Peter Buck - 638-3081 - IRA - 638-3431 - Lodge Willie Aglonia - 638-3451 - Store WTHTWM/RCD 3-A 4.0 4.1 4.2 4.3 4.4 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 POWER PLANT DESCRIPTION Narrative Description The power plant is housed in an approximately 16’ x 20’ metal skinned building with internal switchgear and shop space. The building is located directly next to the School’s old power plant. Power is generated by three generators with approximate prime power cabability as follows: #1 - Detroit 3-71 - 50KW (scheduled to be replaced with a 125KW genset) #2 - Cummins LTA-10 running at 1200 rpm - 110KW #3 - Detroit 4-71T - 125KW The generators use number 1 fuel oil year round. Each engine is cooled by an external radiator on the river side (south) of the power plant. The radiators are actually vertical unit heaters, with a circumferential core, turned 90 degrees to blow horizontally. They are mounted on the exterior wall of the building. Each engine/radiator set is piped independantly. As part of the waste heat modifications, it is proposed that the gensets and the existing radiators be manifolded together. The external radiators would be common to all three gensets. The first would cool whichever genset was on line and the second and third would provide back-up for the first. The radiators and gensets could be isolated through valving from the waste heat system for maintenance. 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 and generators. Load information Electrical load is verbally reported to vary from 105KW in cold months to 50KW in summer months. However, very little load information is available as the power plant does not have load or totalizing meters. Information is available as to power plant fuel use and also as to power sold based on building meter readings. WTHTWM/RCD 4-1 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 Attached Table 1 shows reported fuel readings at varying intervals for 1988 and 1989. This information has been adjusted to give readings on a monthly basis. The adjusted monthly fuel use varies widely and is not believed to be reliable. For purposes of this report an idealized monthly fuel use has been assumed which smoothes out month to month variations and attempts to follow the overall pattern of the adjusted monthly fuel use. The adjusted monthly fuel use for 1988 and 1989 and the idealized fuel use are shown in Table 1 and in Graph 1. KWH production has been calculated from fuel use based on an estimate of 12KWH/gallon of fuel. This was compared to the amount of power sold. Normally power sold would be less than power produced by 10-20% to account for plant use, system losses, and unmetered use such as street lighting. In this case, the difference is 40-50%, though no direct correlation was observed since the values vary widely from month to month and are not believed to be reliable. For purposes of this report an idealized monthly KWH production has been assumed which is based on the idealized monthly fuel use. KWH production calculated from adjusted monthly fuel use for 1988 and 1989, KWH sold in 1988 and 1989, and KWH production calculated from the idealized fuel use are shown in Table 1 and in Graph 2. WTHTWM/RCD 4-2 White Mountain Power Plant Power Plant Interior Jan. 25 Feb. 22 Mar. 23 Apr. 25 May 25 Jun. 24 Jul. 25 Aug. 25 Oct. 3 Oct. 28 Nov. 25 Jan. 3 (89) ANNUAL DATE FUEL USE | PERIOD RECORDED | (DAYS) * GAL) RECORDED FUEL USE RECORDED FUEL - 1988 146) 168} 167| 171 30 days for Jan. 25, 1988 reading is assumed. Adjusted fuel use for a month = (the average gallons per day for closest recorded fuel use period) x (days in month). KWH production calculation based on 12 KWH/ Gallon. Power plant does not have demand or totalizing meters. Average KW for a month = (KWH) / (hours in month). WHITE MOUNTAIN POWER GENERATION POWER SOLD SOLD AVE. (KWH) | LOAD KW) “ee 31 28} 31 30) 31 30) 31 31 30) 31 30) ADJUSTED FUEL USE & POWER PRODUCTION BY MONTH DAYS FUEL USE GAL) ** ADJUSTED FUEL USE - 1988 ADJUSTED FUEL USE - 1989 4,528 4,411 2,627 2,839) 3,715| 3,039] 3,424 3,695| 3,390] 4,831 4,492] 4,886 43,069} 516,829 CALC. PROD. KWH) *** 54,331 73} 52,936 79} ~ 31,519 42 34,071 47 44,578 60 36,473 51 41,093 55) 44,338 60 40,680 57 57,970 78 53,899 75| 58,635 550,522 [413,520] Frank Moolin & Associates, Inc. IDEALIZED FUEL USE & POWER PRODUCTION 4,656 4,545 4,240 3,823 3,406 3,101 2,990) 3,101 3,406) 3,823) 4,240) 4,545 WHITE MOUNTAIN WASTE HEAT RECOVERY - GRAPH 1 POWER PLANT FUEL USE BY MONTH 3,000 MOZOrr>g 2,000 1,000 Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. MONTH OF THE YEAR Mi ADJUSTED ADJUSTED @ IDEALIZED FUEL USE - 1988 FUEL USE - 1989 FUEL USE WHITE MOUNTAIN WASTE HEAT RECOVERY - GRAPH 2 POWER PLANT POWER PRODUCTION BY MONTH 70,000 4 60,000 + u 50,000 + 40,000 + KWH 30,000 + - 20,000) <= win n5 2 coz s mire sie ees cee mm cts ects picne ctl ein oo Mca Nam) aiierie 7% clienin ie fle) mrinria a = octal | Siueliatin a oi chin + 10/000) == S S29 6-¢ oo e)sine aes 5 Ste eo Seis Bete Mele s Scie Gs Site CN SiSe «= Ale oa > Sais = = GE Ee sieie @ =e = 0 + + + + + +— a + + +- 4 Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec. MONTH OF THE YEAR Ml ADJUSTED ADJUSTED @ SOLD - 1988 © SOLD - 1989 & IDEALIZED FUEL USE - 1988 FUEL USE - 1989 FUEL USE 5.0 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 POTENTIAL WASTE HEAT USER BUILDING DESCRIPTIONS During the site visit, all major buildings within a reasonable distance of the power plant were considered. The buildings were visited and information about them gathered. The information is presented below. Note: Figures used for the fuel consumption of buildings under consideration for waste heat usage are based on _ incomplete records and estimates by local officials. No fuel data was available for specific buildings on a monthly basis. All fuel consumption figures are assumptions based on owner provided multi-building fuel figures in the case of the school complex, verbal estimates for other buildings, and part year data for others. Heat loss and annual degree day calculations were used to check the accuracy of the reported fuel consumption and adjustments were made as noted. WTHTWM/RCD 5 - 1 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 5.1 White Mountain School The School complex fuel consumption was provided on a monthly basis but as a total for all of the School facilities, and no specific data is available for individual buildings or facilities. The School buildings use approximately 24,700 gallons of fuel per year, with a winter consumption of approximately 3,200 gallons of fuel per month, which is far in excess of waste heat available from the power plant. Approximate heat loss and domestic water heating calculations were performed for each facility proposed to be connected in order to establish individual facility use. The individual calculated values were used for the facilities as noted below. Calculations are included in Appendix 1. WTHTWM/RCD 5 - 2 5. lal WTHTWM/RCD WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 High School The High School is a wood frame structure, renovated in 1979, of approximately 4000 square feet, including a full basement and attic. It has 2x4 construction with wood Tl-11 siding and a sloped metal roof. Mechanical equipment is located in the attic. The building is heated by two (2) horizontal Jackson Church Flexaire oil-fired warm air furnaces, Model SDF-20-OSH with a rated output of 200,000 Btu/hr at a 1.8 gph fuel rate and Model SDF-15-0SH with a rated output of 150,000 Btu/hr at a 1.35 gph fuel firing rate, respectively. Domestic hot water is provided by a 52 gallon Bock oil fired hot water heater, Model 51E, with an output of approximately 99,000 Btu/hr at a 1.1 gph fuel rate. The preferred method of waste heat recovery is to install a heating coil in each of the two furnace return air ducts and a double-wall heat exchanger in the domestic hot water return line. The calculated annual fuel use of the High School is approximately 4,100 gallons. This facility is 300 feet from the power plant and will require 150 feet of additional waste heat piping (one way) from the Gym. White Mountain High School High School Attic/Mech. Room WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 5.1.2 School Gym WTHTWM/RCD The Gym is a relatively new wood frame structure of approximately 5100 square feet. It has 2x6 construction with wood Tl-11 siding and a metal roof. Mechanical equipment is located in a second story loft at the East end of the building. The building is heated by two (2) oil fired Weil McLain boilers, Model P766HE, each with a rated output of 235,000 Btu/hr at a 2.0 gph fuel firing rate. The boilers heat water which, through a shell and tube heat exchanger, heats glycol which is circulated to coils in the supply air ducts. Domestic hot water is provided by two (2) 32 gallon oil fired Bock hot water heaters, Model 32SE, each with an output of approximately 71,000 Btu/hr. The hot water heaters are piped in series. The preferred method of waste heat recovery is to install a heat exchanger is the building glycol return to the existing shell and tube heat exchanger and a double-wall heat exchanger in the domestic hot water return line. The calculated annual fuel use of the Gym is approximately 8,300 gallons. This facility is 200 feet from the power plant and will require 400 feet of waste heat piping (one way) from the power plant. White Mountain High School Gym Gym Mechanical Room WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 5.1.3 Elementary School WTHTWM/RCD The Elementary School is an older wood frame structure of approximately 5300 square feet, including a full basement and an attic. It is heated by a single oil fired boiler, American Standard Model A-505-3BJ2, with a rated output of 305,000 Btu/hr at a 3.3 gph fuel firing rate. Domestic hot water is provided by a sidearm heater in the boiler and a 30 gallon oil fired National hot water heater, with an output of approximately 73,000 Btu/hr at a 0.75 gph fuel firing rate. If connected, the preferred method of waste heat recovery would be to install a heat exchanger in the boiler heating water return line and a double-wall heat exchanger in the domestic hot water return line. The calculated annual fuel use of the Elementary School is approximately 4,000 gallons. This facility is 90 feet from the power plant and would require 150 feet of waste heat piping (one way) from the power plant. White Mountain Elementary School Elementary School Mechanical Room Frank Moolin & Associates, Inc. White Mountain SCHOOL HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING AVERAGE OF DAYS | CONSUMPTION DEGREE MONTHLY Gal DAYS | CONSUMPTION 85.35 83.03 98.45) 82.13 8.18 83.10 274.40 ; 77.68 MEAN 112.00 1809 3154 196.97 1701 2966 39.74 1767 3081 63.47 1424 2483 18.06 898 1566 565 985 430 750 17.48 463 807 53.60 676 1179 51.87 1140 1988 47.60 1447 2523 114.71 1818 3170 14,138 74,659| TOTAL FUEL ANNUALIZED DELIVERED AVERAGE CONSUMPTION 49,440 : 24,652 2/7/91 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 Suz Community Buildings In many cases, the fuel use figures reported where not reliable. When this occured, heat loss calculations were made to verify or correct the fuel usage reported. Heat loss calculations are presented in Appendix 1. 5.2.1 WTHTWM/RCD City Hall/Library A fairly new wood frame structure of approximately 3,000 square feet. It is heated by a single oil fired Weil McLain boiler with an output of 111,000 Btu/hr at a 0.95 gph fuel firing rate. This building uses approximately 2200 gallons of fuel per year and is 420 feet from the power plant. If connected, the preferred method of waste heat recovery would be to install a heat exchanger in the boiler heating water return line. 5 - 10 City Hall/Library Boiler White Mountain (Gal) 1988 Mar. ee CITY BLDG HEATING FUEL CONSUMPTION DATA NUMBER OF DAYS 517 *Assumed 32 days since Sep 1988 delivery. * Fuel figures are of questionable reliabilty. 2/7/91 Frank Moolin & Associates, Inc. DAILY CONSUMPTION Gal TOTAL FUEL DELIVERED 6.16 HEATING DEGREE DAYS AVERAGE MONTHLY CONSUMPTION 288) 270 281 226 143 90 68 74) ANNUALIZED AVERAGE CONSUMPTION WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 5.2.2 Clinic WTHTWM/RCD An older wood frame structure of approximately 820 square feet. It is heated by a single oil fired warm air furnace, Chevron Model FH-112R2-SOCAL- £EG114, with an output of 112,000 Btu/hr at a 1.0 gph fuel firing rate. This building uses approximately 1100 gallons of fuel per year and is 550 feet from the power plant. If connected, the preferred method of waste heat recovery would be to install a heating coil in the furnace return air duct in the ceiling above the furnace. 5 - 13 White Mountain Clinic Clinic Furnace Frank Moolin & Associates, Inc. White Mountain CLINIC HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING AVERAGE OF DAYS CONSUMPTION DEGREE MONTHLY Gal DAYS CONSUMPTION TOTAL FUEL ANNUALIZED DELIVERED AVERAGE CONSUMPTION PSEA IRS 1,711 542 | 1,152 *Assumed 57 days since Oct 1988 delivery. * Fuel figures are of questionable reliabilty. 2/7/91 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 5.2.3 Corporation Store WTHTWM/RCD An older, somewhat rundown, wood frame structure of approximately 1500 square feet. It is heated by a Williamson warm air furnace, Model 1167-18-1, with an output of 158,000 Btu/hr at a 1.3 gph fuel firing rate. This building uses approximately 2000 gallons of fuel per year and is 500 feet from the power plant. If connected, the preferred method of waste heat recovery would be to install a heating coil in the furnace return air duct above the furnace. 5 - 16 White Mountain Corporation Store Corporation Store Furnace Frank Moolin & Associates, Inc. White Mountain CORPORATION STORE HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING AVERAGE OF DAYS CONSUMPTION DEGREE MONTHLY DAYS CONSUMPTION MEAN 1809 256) 1701 241 1767| 250 1424 201 898 127 565 80 430 61 463 65) 676 96) 1140 161 1447| 205 1818 257 14,138 2,000 TOTAL FUEL ANNUALIZED | CONSUMPTION L000] 8S] 2,000 * Fuel figures are based on a reported usage of about 2000 gallons per year which was distributed monthly by heating degree days. 6/7/91 5.2.4 WTHTWM/RCD WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 IRA Building A newer wood frame structure of approximately 1,300 square feet. It is heated by a single Weil McLain boiler with an output of 207,000 Btu/hr at a 1.85 gph fuel firing rate. This building uses approximately 1100 gallons of fuel per year and is 550 feet from the power plant. If connected, the preferred method of waste heat recovery would be to install a heat exchanger in the boiler heating water return line. 5 - 19 White Mountain IRA Building IRA Building Boiler WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 5.2.5 Lodge WTHTWM/RCD The Lodge is a privately owned, seasonally used, wood frame structure of approximately 4,200 square feet. It is heated by three (3) oil fired Magic Chef warm air furnaces, two (2) Model L72-112D-17 each with an output of 112,000 Btu/hr at a 1.0 gph fuel firing rate and a Model L72-84D-18 with an output of 84,000 Btu/hr at a 0.75 gph fuel firing rate. Domestic hot water is provided by a single oil fired 100 gallon Bock hot water heater, Model 241ES, with an output of 136,000 Btu/hr at a 1.5 gph fuel firing rate. This building uses only approximately 1300 gallons of fuel per year due to seasonal use. It is 230 feet from the power plant. Existing equipment room in the mechanical spaces is very tight, leaving no room for the installation of waste heat recovery equipment. If it were to be connected to waste heat, modifications to the heating systems and building would be required to install coils in the return air ducts and a double-wall heat exchanger in the domestic hot water return line. 5 - 21 White Mountain Lodge Lodge Mechanical Room Frank Moolin & Associates, Inc. White Mountain LODGE HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING AVERAGE OF DAYS CONSUMPTION DEGREE MONTHLY Gal DAYS CONSUMPTION ANNUALIZED AVERAGE CONSUMPTION [| 4,000 * Seasonal use. 2/7/91 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 6.0 RIGHT OF WAY/EASEMENT There are apparently no right of way problems if the waste heat is used at the School. The powerplant site is contiguous to the School and the waste heat piping can be run entirely on School property. If waste heat is supplied to the nearby community buildings the piping will cross School property in order to reach community property. WTHTWM/RCD 6-1 7.0 Tol Uc WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 CONCEPT DESIGN System Narrative The location of the Power Plant is next to the School’s old power plant. The closest potential waste heat user buildings are School Buildings. The School Complex can use close to double the waste heat that the Power Plant currently generates and over double the net deliverable waste heat. Only the two largest heat using facilities are proposed for connection: the High School and Gymnasium. Between the Gymnasium and the High School, virtually all of the net deliverable waste heat can be used. 7.1.1 Proposed Scenario: Served buildings include: HIGH SCHOOL SCHOOL GYMNASIUM Benefits of this scenario include using the majority of the waste heat available currently, simplifying the waste heat system since only one user is involved, and the potential for increased future heat recovery since the buildings could use more waste heat during parts of the year than is currently available. Disadvantages include the large number of connection points (five) in order to serve two buildings and the difficulty of routing piping to the second story mechanical rooms. 7.1.2 Future Expansion: Possible buildings include: ELEMENTARY SCHOOL CITY HALL/LIBRARY CLINIC CORPORATION STORE IRA BUILDING LODGE Connection of these buildings would only be preferred as power plant output increased and additional waste heat became available. The Elementary School would be the most cost effective since it has the largest heating load and is located closest to the power plant. Primary and Secondary Piping Jacket water piping will be valved to recover heat from whichever genset is on line. Automatic control valves will bypass coolant to the external radiators to maintain coolant temperature as required. See section 4 for a discussion of proposed modifications to the power plant. WTHTWM/RCD 7-1 7.3 7.4 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 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, 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 Figure 5 for the system schematic. 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 the fewest heat exchange points possible 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. Each of the buildings in the prefered scenario includes more than one heat exchange point. Also, in addition to their heating systems, each will include a seperate heat exchanger for domestic water heating. This will be of the double-wall type to provide additional separation between the distribution system and potable water. Precautions must be taken to prevent overcooling of the generator jacket water and to prevent building system boilers from heating the waste heat distribution system. The simplest method is to not connect more users than the system can normally provide waste heat for. Each of these issues can also be addressed with controls and valving. They can also be automated to some degree but the solutions must be carefully balanced with the need for system simplicity. Site Plan/Routing The routing will be as shown on Figure 2. WTHTWM/RCD 1-22 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 735 Generator Room Plans/Schematics See the attached Figures 3 and 4 for the design concept for changes to the power plant. 7.6 User Building Plan/Schematics See the attached Figures 6 through 9 for proposed changes to each of the potential user buildings. Led Arctic Pipe/Trench Section Soils information on the exact areas that the waste heat recovery piping will be run could not be located but information on soils for the communitiy, including the hillside that the piping will be run in, was found. This information is thought to be representitive of the hillside in general, but should be verified for the piping routs prior to final design and construction. The soils in the area consist of a relatively thin organic mat and an underlying layer of silt that is typically a total of three feet deep. These "overburden" layers are underlain by - sandy-gravel which is over fractured bedrock at a depth of 5 to 6 feet. The waste heat recovery piping can be buried within the sand-gravel layer which will provide excellent support for the piping and will be free of frost heave forces. A cross section of the anticipated trench and arctic pipe configuration is shown in Figure 10. 7.8 Outline Specifications The outline specifications for the major components of the system are shown below. 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 lug-style butterfly type. Piping: Piping inside buildings shall be type ‘L’ copper or steel schedule 40 with dielectric unions at connection points of dissimilar metals. Steel pipe will be welded. WTHTWM/RCD dt el 3 15120 15250 15750 15900 WTHTWM/RCD WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 ARCTIC PIPE Arctic Pipe: Pressure pipe shall be schedule 40 steel. Insulation shall be foamed polyurethane with .25" maximum voids. Thickness of insulation to be minimum of 2 inches. Jacketing shall be steel or high density polyethylene. Arctic pipe system shall include kits or fittings for take-off connections to main line that provide water-tight seal. MECHANICAL INSULATION Piping insulation: Pipe insulation shall be fiberglass with an all-service jacket. Minimum insulation thickness shall be 1-1/2 inches. HEAT TRANSFER Heat Exchangers: Heat exchangers shall be plate and frame type with minimum 20 gage stainless steel plates, painted steel frame with head and end support, top carrying bar, bottom guiding bar, and ASME rating. Ports shall be international pipe thread or flanged. Capacity shall be as specified. Acceptable manufacturers are Bell & Gossett, APV, Tranter, and Alfa Laval. Double Wall Heat Exchangers: Potable water heat exchangers shall have two walls separating the fluids with a vented air space in between. They shall be ASME rated, tube within a tube type such as Bell & Gossett Diamondback or nested welded plate type such as Tranter Double Wall Design. 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, with the exception of the return air coils in the High School. Since the fans run continuous for ventilation, 2-stage wall thermostats first open a control valve and secondly start the burner if necessary. 7.9 16000 ELECTRICAL WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 All electric equipment and installation shall comply with the National Electric Code specified. Major Equipment List Te9o0 Proposed Scenario Heating Elements Location High School Furnace 1 High School Furnace 2 High Sch. Hot Wtr Htr. School Gym Boilers Sch. Gym Hot Wtr Htrs. Generator Plant #1 Pumps Service Gen. Plant Secondary Buried Piping Size on 3" WTHTWM/RCD Capacity (Hot Side) MBH GPM 52 6 52 6 26 3 172 19 86 10 388 84 GPM HD 44 25 LE 500 600 aS TI 180 180 180 180 180 185 HP 0.5 TO 160 160 160 160 160 175) QTY 2 Item duct coil duct coil db] wall ht. exch. heat exchanger dbI wall ht. exch. heat exchanger BALANCE/ISOLATION VALVE ISOLATION VALVE NC=NORMALLY CLOSED (ALL OTHERS NORMALLY OPEN) 2-WAY CONTROL VALVE 3-WAY CONTROL VALVE AMOT 3-WAY VALVE CHECK VALVE STRAINER CIRCULATING PUMP FLOW METER THERMOMETER TEMPERATURE SWITCH AIR SEPERATOR WITH AUTO AIR VENT FLOW ARROW PIPE DOWN PIPE UP NEW RETURN LINE NEW SUPPLY LINE EXISTING RETURN LINE EXISTING SUPPLY LINE NEW EQUIPMENT EXISTING EQUIPMENT PRIMARY (GENERATOR) PIPING SECONDARY (DISTRIBUTION) PIPING BUILDING PIPING NON ELECTRIC VALVE NON ELECTRIC TEMPERATURE SENSOR SCALE 44 Frank Moolin & ate: 2/13/91 | Associates, Inc. LEGEND owe, ay_CJP. 495 JOB_NO. ENGINEERING @ DESIGN e PROJECT MANAGEMENT REVISION: An Ebaace Services Incorporated Engineering and Construction Company CHK. BY VISION 0 495LEGND.DWG FIGURE 1 [scwe: NONE | LA Frank Moolin & PIPE ROUTING DSN. BY——[ 2/15/91 | Associates, Inc. SITE PLAN owe. ey_CIP Top yo: 495: AMMEN DENN 9 PROUTET MUODAENT WHITE MOUNTAIN, AK ox sn a 7-7 FIGURE 2 WASTE HEAT RECOVERY LINES TO USERS GEN. #3 DETROIT 4—71T GEN HEAT EXCHANGER ; 2 CUMMINS LTA 10 AMOT VALVE ASSEMBLY aa EXISTING RADIATOR (VERTICAL UNIT HEATER TURNED 90° — TYP.) 4b4a Frank Moolin & POWER PLANT Associates, Inc. FLOOR PLAN ipsa atndihee bani llearsapadll WHITE MOUNTAIN, AK 7-8 FIGURE 3 GEN. #2 CUMM. LTA 10 GEN #3 DETROIT 4—71T TO WASTE HEAT USERS FROM FUTURE , STATION HEAT GEN. #1 DETROIT 3-71 3° (EXCEPT WHERE NOTED) CC” Frank Moolin & Lb Associates, Inc. ENGINEERING @ DESIGN @ PROJECT MANAGEMENT ‘An Boesce Services Incerporated Engineering and Construction Company AMOT VALVE ASSEMBLY —a_ NC X EXISTING RADIATOR (TYP.) POWER PLANT COOLING SCHEMATIC WHITE MOUNTAIN, AK 7-9 FIGURE 4 TO FUTURE STATION HEAT EXPANSION TANK AND GLYCOL MAKE-UP WASTE HEAT EXCHANGER REVISION: oO 495D6312.DWG HIGH SCHOOL COILS IN DUCTS (issih SCHOOL GYM POWER PLANT GEN. #2 BB Frank Moolin & WASTE HEAT RECOVERY Associates, Inc. SYSTEM SCHEMATIC join setae coogi ecierg eu omnes casa WHITE MOUNTAIN, AK 495P1312.DWG 7-10 FIGURE 5 PROPOSED SPACE FOR FUTURE EQUIPMENT: FURNACE \ g0" H O u PROPOSED SPACE fae DOMESTIC HOT FOR FUTURE WATER HEATER EQUIPMEN oe eta | FURNACE FIRST FLOOR JJ BASEMENT SCALE: NONE ba Frank Moolin & HIGH SCHOOL ome:_2/15/91 Associates, Inc. FLOOR PLAN ACIP caiman «1405, ENGINEERING DESIGN PROJECT MANAGEMENT 1 Geis Sena eerted Cig ahaCeetvatan’ Canes WHITE MOUNTAIN, AK RESON: 0 495312HS.DWG 7-11 FIGURE 6 — SUPPLY AIR HOT AIR FURNACE #2 BURNER (TYPICAL) SUPPLY AR NEW COIL IN HOT AIR FURNACE RETURN AIR DUCT (TYPICAL) DOUBLE WALL HEAT EXCHANGER DOMESTIC HOT TO WATER ARCTIC PIPE HEATER Babb Fish Molin & HIGH SCHOOL Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT a eee occas eecnccid tops fod Gases Oampa WHITE MOUNTAIN, AK 7-12 FIGURE 7 BOILERS PROPOSED SPACE FOR FUTURE EQUIPMENT DOMESTIC HOT WATER HEATERS HATCHWAY U O OO SPACE OVERHEAD Yin L¥9 FOR EXCHANGER SECOND FLOOR MECH. RM MECHANICAL ROOM / ON SECOND FLOOR > 54" FIRST FLOOR BBB EEK Mooiin & SCHOOL GYM cn oy Associates, Inc. FLOOR PLAN owe, ov SP |g 095 ENGINEERING e@ DESIGN @ PROJECT MANAGEMENT WHITE MOUNTAIN AK CHK. BY REVISION: 0 ’ An Ebosco Services Incorporated Engineering ond Construction Company 49531 2GY.0WG 7-13 FIGURE 8 HEATING suPPLy (-—&——— EXISTING HEAT EXCHANGER Lb Frank Moolin & Associates, Inc. ENGINEERING @ DESIGN @ PROJECT MANAGEMENT ‘An Ebesee Serdoss Incorporated Engheering and Construction Company To / FROM ARCTIC PIPE DOUBLE—WALL HEAT EXCHANGER a Wi g oO x< ai & a = BOILER BOILER SCHOOL GYM SYSTEM SCHEMATIC WHITE MOUNTAIN, AK 7-14 FIGURE 9 495D4312.DWG EXISTING GRADE BACKFILL WITH EXCAVATED MATERIAL — COMPACT AS SPECIFIED WASTE HEAT SUPPLY AND RETURN PIPES — ARCTIC PIPING (SIZES VARY AS SPECIFIED) BEDDING MATERIAL — EXCAVATED MATERIAL WITH 1" TOP SIZE bt Frank Moolin & Associates, Inc. ENGINEERING e@ DESIGN @ PROJECT MANAGEMENT An Ebasco Services Incorporated Engineering and Construction Company Pa . Zi Cre Lf Cy: Leal “TYAS 7-15 FIGURE 10 TYPICAL TRENCH SECTION NOMINAL 3° AS SPECIFIED DURING SYSTEM FINAL DESIGN SCALE: NONE pare: 2/15/91 iH ow. ey WIHT og no 495 DSN. BY CHK. BY __ | Revision 495TRNCH.DWG WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 8.0 ECONOMIC DATA Economic Data in Appendix 2. WTHTWM/RCD 8 - 1 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 9.0 FAILURE ANALYSIS White Mountain is a least a full day away from resupply of parts out of Anchorage, and the delay might be several days longer if weather is bad. Although the heat recovery systems are relatively simple and straight forward mechanically, the system will require some maintenance and a knowledgeable person to trouble shoot the system. Lack of attention may render the system inoperative. It is also possible for inexperience people to alter the system configuration by opening and closing valves or turning off pumps. Therefore, access to the system valves and controls must be limited to knowledgeable and responsible people. The control valves must work to maintain system temperatures and the proper functioning of these valves must be checked periodically. Reports on soil conditions indicate that buried pipes should not be damaged by soil heaving or settlement if the pipes are buried correctly. The system is susceptible to mechanical damage from being hit by equipment and machinery that is used for excavation. Subsurface leaks or spills have a significant potential for soil contamination. Because of the cold temperatures, the waste heat recovery system must be filled and maintained with 60% glycol. Water without glycol must not be introduce into the system. All waste heat recovery recipients must keep their respective building heating systems on line and in proper functioning condition to heat the building in case the waste heat recovery system fails or if the power plant is not rejecting enough heat to its cooling system. 9.1 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, oes 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, 3. Some operator or maintenance person notices the secondary temperature indicating devices are not WTHTWM/RCD 9 )-)\1 9.1.2 9.123 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 registering proper temperatures or he notices the circulating pump(s) are running dry or, 4. Someone notices glycol surfacing somewhere. 5. A low pressure alarm is indicated. A further complication could arise if other controls failed concurrently. If the secondary system lost fluid and then the control valve failed to by-pass water to the generator radiators, then the engines would trip off on overload producing a village black-out. A further problem could arise if the engine high temperature shut downs failed and the engine ran until over temperature failure. Repair The ruptured pipe section must be located and either repaired, replaced or by-passed. Unless the glycol surfaces, the location of the rupture may be difficult to find. Excavation will almost always be required and this may involve steam thawing the soil if frozen. The alternative of by-passing the failed section with temporary surface waste heat piping may be necessary. For this alternative piping should be stock piled. If these pipe supplies must be flown out of Anchorage, the delay could be as_ follows: Locating the leak, mobilizing excavating equipment, excavating leak site 2-3 days, locating pipe, ordering pipe, arranging payment and shipping 1 day, shipping 2 days, and installation of new pipe or by-pass 2-days. Total 6-7 days downtime at best. This repair is impractical in most of the winter and would be deferred until spring. The generators could function uninterrupted. Freezing/Earthquake Damage/Differential Settlement - Care must be taken to minimize potential piping damage due to differential earth movement. The sub-surface piping must be properly bedded and allowances made for known transition zones. 9.2 Above Ground Pipe Failure Leaking pipe or connection located, isolated, repaired, clean-up, 2-10 hours downtime at best. Weather delays could make this considerably longer. 9.3 Clean-up Of Spilled Glycol Glycol clean up from facilities may be relatively easy but glycol is a health hazard and care must be taken to ensure that no one ingest the glycol mix. Glycol that spills on the ground or subsurface must be cleaned up before it enters the ground water WTHTWM/RCD WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 or surface run off. The glycol must not contaminate wells, streams, lakes or salt water. WTHTWM/RCD 9-3 9.4 9.5 9.6 9.7 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 Vibration, Thermal, And Corrosion Damage To Piping 9.4.1 Vibration Insulation Devices - Must protect piping from vibration transmission particularly adjacent to vibration exciters like the diesel engines. Inadequate vibration isolation will produce cracked, broken, and leaking piping and gaskets. 9.4.2 Thermal Expansion - Joints must be installed to allow for pipe growth from thermal expansion. Inadequate provision for thermal growth will stress the system and result in strain on piping, pumps, and the heat exchangers. 9.4.3 Corrosion - Contaminates in the system or soils can accelerate the Corrosion of the piping. Corrosion inhibitors may be required. Care must be utilized to avoid dissimilar piping materials that could accelerate the Corrosion process. Particular attention must be paid to areas around welds and whenever there is a pressure drop in the system. Primary Heat Exchanger Failure Glycol leaks from heat exchanger - Operator finds leak, valves off heat exchanger and the gen-sets utilize radiators for cooling. Operators order new exchanger. If the exchanger is an “off the shelf" item, a new one could be on site in a week or 10 days. If not, it could take 10 weeks or more. Should this leak go unnoticed, gensets will shut down on low pressure or high temperature. The leaking area can be valved off immediately but the system must be recharged and air bled out before restarting the gensets. Downtime of gensets 2-3 hours. Secondary Heat Exchanger Failure Leaking or plugged secondary heat exchanger is identified, valved off, and by-passed. A replacement is ordered and the building is heated by the buildings heating plant. Down time 5 days to 6 weeks, Heat Exchanger Failure Modes 9.7.1 Mechanical Damage - Heat exchangers can be made to leak if damaged by dropping or by impacting them with power equipment, cranes, pipes, etc. Proper care must be exercised to limit exposure to mechanical damage. 9.7.2 Chemical Damage - The water/glycol fluid must be monitored to prohibit developing a corrosive mixture. Also particular attention must be paid to piping gaskets and valve seat material to ensure that the materials are WTHTWM/RCD 9-4 9.8 9.9 WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 compatible with glycol. Dissimilar metals are to be avoided or insulated from each other. Water quality must be maintained to prevent scaling. Pump Failures The pumps are subject to thermally induced casing stress, seal failure, over-heating, voltage fluctuations, and frequency droop. The pump alignment must be checked with the piping at operative temperature. The air circulation/cooling around the pumps must not be impaired. The pump must be protected by circuit breakers from low voltage, frequency droop, and overload. The pumps must be in parallel pairs and capable of individual isolation for replacement. The coolant in the system must not contain contaminants that will destroy the seals. Recharging the system must be done with contaminate free water and glycol. When a pump fails from anyone of a variety of causes, the stand- by pump is activated and the failed pump valved off and repaired/replaced. System down time 0-12 hours. Replacement pump replaced 2 hrs. to 1 week. Control Failures Controls must be protected from power fluctuations and mechanical damage. Unauthorized persons must be precluded from adjusting control set points. Authorized persons must be familiar with the system and the inter-relationships of the components. In some cases it is possible for the waste heat customers to over-cool the waste heat recovery secondary piping and thermally shock the heat exchanger. It is also possible to have the waste heat customers actually heating the secondary loop coolant and then heating the generator coolant. These potential problems can be avoided by properly operating controls. Controls must be maintained and protected from corrosion and/or scaling. WTHTWM/RCD Fie WHITE MOUNTAIN WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 14, 1991 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 White Mountain. Some conclusions that can be made are that the project is technically feasible, that the people and agencies in the community seem quite enthusiastic about the project, and that if the economics prove acceptable, a waste heat system for the community can be recommended. To make this project more economically attractive on option would be to include this project with the construction of other waste heat systems in neighboring communities. This would help to reduce the mobilization charges. Shipping, travel and other supervision and management costs could also be combined and pro- rated for lower cost to each village. Economics are not the only yardstick by which this project should be measured. The political and social problems involved in our nations oi] supply should motivate us to actively seek out ways like this to reduce our oi] consumption. Environmental costs are also present with the consumption of any fossil fuel, granted they are small but present. The communities enthusiasm to participate is an important factor in the final decision to go with the project or delay until the economic situation changes to a more favorable one. WTHTWM/RCD 10 - 1 2 -.Ol 1200 HEATING 4099 FUEL EQUiV. (GAL.) 800 600 400 200 WHITE MOUNTAIN WASTE HEAT RECOVERY - GRAPH 3 BY MONTH 4 4 t t t t t t + Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. MONTH OF THE YEAR Mi AVAILABLE HEAT REQUIRED ‘€ -.01 HEATING FUEL EQUIV. (GAL.) WHITE MOUNTAIN WASTE HEAT RECOVERY - GRAPH 4 HEATING FUEL DISPLACED BY MONTH Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. MONTH OF THE YEAR APPENDIX 1 CALCULATIONS WMNTN_#1.XLS WASTE HEAT UTILIZATION SIMULATION WORK SHEET. BASIC PROJECT DATA: Location: White Mountain - Scenario #1 Date: August 1, 1990 Savings, year 0, fuel gallons: 9934) Savings, year 0, fuel cost: $11,126 Annual pumping elec. cost: 910 $/year. Annual O&M increase cost: $5,910 Annual other O&M cost: 5000 $/year. Total Savings, year 0: Construction cost estimate: 559074 $ Fuel high heat value: 132000 Btu/gallon Average fuel cost: 1.12 $/gallon GENERATOR DATA: SYSTEM LOSS DATA: Heat rate at kw-load above: 0 3084 Btu/kwh Constant losses: Heat rate at kw-load above: 11 2915 Btu/kwh Plant piping: 2400 Btu/hr. Heat rate at kw-load above: 22 2770 Btu/kwh Subsurface piping: 21000 Btu/hr. Heat rate at kw-load above: 33 2650 Btu/kwh Engine preheating: 0 Btu/hr. Heat rate at kw-load above: 44 2554 Btu/kwh Total constant: 23400 Btu/hr. Heat rate at kw-load above: 55 2481 Btu/kwh Heat rate at kw-load above: 66 2433 Btu/kwh Variable losses: Heat rate at kw-load above: 77 2409 Btu/kwh Surface piping: 10 Btu/hr.xF Heat rate at kw-load above: 88 2409 Btu/kwh Plant heating: 100 Btu/hr.xF Heat rate at kw-load above: 99 2409 Btu/kwh Radiator losses: 0 Btu/hr.xF Heat rate at kw-load above: 110 2409 Btu/kwh GENERATION DATA: WEATHER DATA: Kwh/month: HDD/Month: January 55,877 1809 February 54,537 1701 March 50,877 1767 April 45,877 1424 May 40,877 898 June 37,217 565 July 35,877 430 August 37,217 463 September 40,877 676 October 45,877 1140 November 50,877 1447 December 54,537 1818 550,522 14138 BUILDING DATA: Fuel use, gal/mon. H. SCHL GYM Wa na wa na Wa Wa Wa a TOTAL January 525 1068 1593 February 493 1005 1498 March 512 1044 1556 April 413 841 1254 May 260 530 791 June 164 334 498 July 125 254 379 August 134 273 408 September 196 399 595 October 331 673 1004 November 420 855 1274 December 527 1074 1601 4100 8350 0 0 0 0 0 0 0 0 12450 Hig. Efficiency: 0.75 0.75 0.75 Page 1 POWER PRODUCTION VARIATION: Assumed hourly variation: January February Hour: ONAKMRwWD = NNN Oe ee ee ee RBRBXSSaIVAArBH=So Days: HDD: 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 1809 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 28 1701 March 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 1767 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 30 1424 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 31 898 WMNTN_#1 June 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 30 565 XLS July 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 31 430 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 31 463 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 30 676 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 1140 1447 1818 14138 Kwh: 55876.84 54537.09 50876.84 45876.84 40876.84 37216.59 35876.84 37216.59 40876.84 45876.84 50876.84 54537.09 550522.1 HEAT DEMAND VARIATION: Assumed hourly variation: Winter” Summer" Hour: O2NAHkwWNH = RPRRXVssssaeoraxrse ON = O©ODBNODROND ACO 0.039 0.038 0.038 0.038 0.038 0.039 0.041 0.043 0.044 0.044 0.044 0.044 0.045 0.044 0.043 0.043 * 0.043 0.043 0.043 0.043 0.042 0.042 0.040 0.039 1,000 * Winter: Nov. - Apr. 0.039 0.038 0.038 0.038 0.038 0.039 0.041 0.043 0.044 0.044 0.044 0.044 0.045 0.044 0.043 0.043 0.043 0.043 0.043 0.043 0.042 0.042 0.040 0.039 1.000 * Summer: May - Oct. Page 2 HEAT GENERATED PER HOUR BY MONTH, BTU'S Hour: C@OnNOOAS WH = BSBXSesisarGnrs 24 January 166653 161008 152063 152063 147590 152063 166653 184195 184195 204082 208424 204082 195398 204082 208424 208424 212766 199740 186713 175424 175424 179809 175424 175424 February 180084 170606 161128 161128 159486 161128 180084 197070 197070 220530 225223 220530 211146 220530 225223 225223 229915 215838 201762 187686 187686 192378 187686 187686 March 154745 146600 138456 138456 138298 138456 154745 167713 167713 185820 189774 185820 179692 185820 189774 189774 193728 183685 171706 162889 162889 163720 162889 162889 Day: 4380122 4706824 4016051 Equivalent Gallons: 1372 1331 1258 April 144188 136599 132768 132768 128863 132768 144188 159366 159366 174875 178596 174875 167434 174875 178596 178596 182317 171154 163160 151777 151777 155572 151777 151777 May 140688 127950 117849 114482 114482 121216 121216 127950 140688 147232 138052 150504 157047 163591 157047 157047 140688 147232 157047 140688 131318 131318 131318 138052 WMNTN_#1.XLS June 136215 120376 115057 111770 111770 114041 114041 120376 136215 138517 129880 141595 147751 153907 147751 147751 136215 138517 147751 136215 123544 123544 123544 129880 July 127076 116537 107337 104270 104270 110404 110404 116537 127076 132987 121166 135942 137838 143581 137838 137838 127076 132987 137838 127076 115255 115255 115255 121166 August 131821 116493 111345 108164 108164 114527 114527 116493 131821 137953 125690 137027 142985 148943 142985 142985 131821 137953 142985 131821 119559 119559 119559 125690 Sept. 145378 132215 121777 118298 118298 125257 125257 132215 145378 152140 138616 155521 162282 165762 162282 162282 145378 152140 162282 145378 135695 135695 135695 138616 October November December 157897 159903 162657 139537 151487 157147 132264 143071 148417 128485 143071 148417 128485 138863 144052 136043 143071 148417 136043. 159903 162657 139537 173303 179779 157897 173303 179779 162033 192014 199189 150553 196100 203427 165633 192014 199189 172835 185682 190713 180036 192014 199189 172835 196100 203427 172835 196100 203427 157897 200185 207665 162033 187929 194951 172835 177429 184059 157897 165051 171218 143209 165051 171218 143209 169177 175498 143209 165051 171218 150553. 165051 171218 3778034 3314705 3146224 2963007 3060871 3413838 3663791 Month: 1.36E+08 1.32E+08 1.24E+08 1.13E+08 1.03E+08 94386735 91853215 94887008 1.02E+08 1.14E+08 1.24E+08 1.33E+08 1.36E+09 1145 1038 HEAT LOST FROM SYSTEM PER HOUR BY MONTH, BTU'S Hour: OnNOnskwn — B23 0© BRBXSseusazrG 24 Day: Equivalent Gallons: January 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 30869 740857 232 February 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 31133 747180 211 March 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 30720 737280 231 April 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 29671 712112 216 May 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 27636 953 June 26522 26522 26522 26522 26522 26522 26522 26522 26522 26522 928 July 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 25976 663275 636520 _ 623419 208 193 195 Page 3 958 26093 26093 26093 26093 1034 Sept. 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 26929 1147 4130922 4276923 1252 1339 October November December 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 28495 626230 646288 _683884 Month: 22966560 20921040 22855680 21363360 20561520 19095600 19326000 19413120 19388640 21200400 21424080 22990320 2.52E+08 196 196 214 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 29756 714136 216 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 30901 741623 232 13756 2540 WMNTN_#1.XLS HEAT DEMAND BY HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 199425 207610 194795 162215 98996 64362 47403 51041 77007 125674 164835 200417 195355 203373 190819 158905 96976 63049 46436 50000 75435 123109 161471 196327 194338 202314 189826 158077 96471 62720 46194 49739 75042 122468 160630 195304 190776 198607 186347 155180 94703 61571 45348 48828 73667 120224 157687 191726 194338 202314 189826 158077 96471 62720 46194 49739 75042 122468 160630 195304 197390 205492 192807 160560 97986 63705 46920 50520 76221 124392 163153 198372 209091 217673 204236 170078 103794 67482 49701 53515 80739 131765 172825 210131 220283 229325 §9=215169' 179182 109350 71094 52361 56380 85061 138819 182076 221379 221809 230914 216660 180423 110108 71586 52724 56770 85650 139780 183337 222913 10 223336 232502 218150 181664 110865 72079 53087 57161 86240 140742 184599 224447 11 223336 §=©6232502. «218150 181664 110865 72079 53087 57161 86240 140742 184599 224447 12 224862 234091 219641 182906 111623 72571 53450 57552 86829 141704 185860 225981 13 226897 236210 221629 184561 112633 73228 53933 58073 87615 142986 187542 228026 14 221809 230914 216660 180423 110108 71586 52724 56770 85650 139780 183337 222913 15 218757 227736 213678 177940 108592 70601 51999 55989 84472 137857 180814 219845 16 220283 229325 215169 179182 109350 71094 52361 56380 85061 138819 182076 221379 17 217231 226147 212187 176699 107835 70109 51636 55599 83882 136895 179553 218312 18 220283 229325 215169 179182 109350 71094 52361 56380 85061 138819 182076 221379 19 220283 229325 215169 179182 109350 71094 52361 56380 85061 138819 182076 221379 20 218757 227736 213678 177940 108592 70601 51999 55989 84472 137857 180814 219845 21 213670 222440 208709 173802 106067 68959 50789 54687 82507 134651 176609 214733 22 212143 220851 207218 172560 105309 68467 50427 54297 81918 133689 175348 213199 23 204004 212377 199267 165939 101269 65840 48492 52213 78775 128559 168620 205019 24 199425 207610 194795 162215 98996 64362 47403 51041 77007 125674 164835 200417 Day: 5087880 5296711 4969754 4138555 2525659 1642053 1209391 1302205 1964651 3206293 4205400 5113193 Month: 1.58E+08 1.48E+08 1.54E+08 1.24E+08 78295415 49261592 37491123 40368349 58939533 99395071 1.26E+08 1.59E+08 1.23E+09 Equivalent Gallons: 1593 1498 1556 1254 791 498 379 408 595 1004 1274 1601 12451 O©OONONRWH = HEAT DELIVERED BY HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 1 135784 148952 124025 114517 98996 64362 47403 51041 77007. = 125674 96130147. 1131756 2 130139 139474 115880 106928 96976 63049 46436 50000 75435 111042 121731 126246 3 121194 129996 107736 103097 90213 62720 46194 49739 75042 103769 113315 117516 4 121194 129996 107736 103097 86846 61571 45348 48828 73667 99990 113315 117516 5 116721 128353 107578 99192 86846 62720 46194 49739 75042 99990 109107 113151 6 121194 129996 107736 103097 93580 63705 46920 50520 76221 107548 113315 117516 7 135784 148952 124025 114517 93580 67482 49701 53515 80739 107548 130147 131756 8 153326 165937 136993 129695 100314 71094 52361 56380 85061 111042 143547 148878 9 153326 165937 136993 129695 110108 71586 52724 56770 85650 129402 143547 148878 10 173213 189398 155100 145204 110865 72079 53087 57161 86240 133537 162259 168288 11 177555 194090 159054 148925 110415 72079 53087 57161 86240 122058 166344 172526 12 173213 189398 155100 145204 111623 72571 53450 57552 86829 137138 162259 168288 13 164529 180014 148972 137762 112633 73228 53933 58073 87615 142986 155926 159812 14 173213 189398 155100 145204 110108 71586 52724 56770 85650 139780 162259 168288 15 177555 194090 159054 148925 108592 70601 51999 55989 84472 137857 166344 172526 16 177555 194090 159054 148925 109350 71094 52361 56380 85061 138819 166344 172526 17 181897 198782 163008 152645 107835 70109 51636 55599 83882 129402 170429 176764 18 168871 184706 152965 141483 109350 71094 52361 56380 85061 133537 158173 164050 19 155844 170629 140986 133489 109350 71094 52361 56380 85061 138819 147674 153158 20 144555 156553 132169 122106 108592 70601 51999 55989 84472 129402 135295 140317 21 144555 156553 132169 122106 103681 68959 50789 54687 82507 114714 135295 140317 22 148940 161245 133000 125900 103681 68467 50427 54297 81918 114714 139421 144597 23 «144555 156553 132169 122106 101269 65840 48492 52213 78775 =114714 135295 = 140317 24 144555 156553 132169 122106 98996 64362 47403 51041 77007 122058 135295 140317 3639265 3959644 3278771 3065922 2473798 1642053 1209391 1302205 1964651 2945541 3416786 3535300 Days: 31 28 31 30 31 30 31 31 30 31 30 31 1.13E+08 1.11E+08 1.02E+08 91977666 76687737 49261592 37491123 40368349 58939533 91311760 1.03E+08 1.1E+08 9.83E+08 Equivalent Gallons: 1140 1120 1027 929 775 498 379 408 595 922 1035 1107 9934 Page 4 HEATLOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: |WHITE MOUNTAIN PROJ NO: |495-412 CALC FOR: |HIGH SCHOOL DATE: {8/1/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70|°F 14138|°F DAYS EXTERIOR: -27|/°F ROOM: HEIGHT= 24) AREA= 1800 WIDTH= 20 VOLUME= 43200 LENGTH= 90 AC/HR= 0.5 SURFACE AREA| * U-VALUE | * (Ti- Te) | = BTU/HR TOTAL COMMENTS WALL 1 4180 0.076) 97 30815 WALL 2 1100 0.052) 97 5548 FLOOR 0} 0 97 0 CEILING 2700 0.055 97, 14405 GLASS 100 0.5 97 4850 DOORS 84) 0.25) 97 2037 PERIMETER LENGTH| * F-VALUE | * (Ti- Te) | = BTU/HR BASEMENT WALL 97 ) SLAB 1800 0.05 97 8730 AIR EXCH. CFM| * FACTOR | * (Ti- Te) | = BTU/HR INFILT. 360 1.08 97| 37714 104098 TOTAL BTU/HR= 104,098 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS=| 364,142,852 TOTAL GAUYR @ 140,000 BTU/GAL, 70% EFFICIENCY= 3,716 ua HEATLOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: |WHITE MOUNTAIN PROJ NO: |495-412 CALC FOR: |SCHOOL GYM DATE: [8/1/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70|°F 14138/°F DAYS EXTERIOR: -27|°F ROOM: HEIGHT= 24) AREA= 5076 WIDTH= 54) VOLUME=| 121824 LENGTH= 94 AC/HR= 0.5 SURFACE AREA| * U-VALUE | * (Ti- Te) | = BTU/HR TOTAL COMMENTS WALL 1 5624 0.052 97 28367 WALL 2 1480 0.052) 97 7465 FLOOR 0 0 97 0 CEILING 5076 0.055) 97 27080 GLASS 100 0.5 97 4850 DOORS 84 0.25 97 2037 PERIMETER LENGTH| * F-VALUE | * (Ti- Te) | = BTU/HR BASEMENT WALL 97| 0} SLAB 5076 0.1 97| 49237 AIR EXCH. CFM| * FACTOR | * (Ti- Te) |_ = BTU/HR INFILT. 1015) 1.08} 97| 106352) 225390 TOTAL BTU/HR= 225,390 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS=| 788,426,720 TOTAL GAV/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 8,045 HEATLOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: |WHITE MOUNTAIN PROJ NO: [495-412 CALC FOR: [ELEMENTARY SCHOOL DATE: [8/1/90 TEMPERATURES HEATING DEGREE DAYS | INTERIOR: 70°F 14138|°F DAYS EXTERIOR: -27|°F | ROOM: HEIGHT= 24 AREA= 2072! WIDTH= 28 VOLUME=| __ 49728 LENGTH= 74 AC/HR= 0.5 SURFACE AREA| * U-VALUE| *(Ti- Te)| _=BTU/HR TOTAL COMMENTS WALL 1 3876 0.076 97 28574) WALL 2 1020 0.052 97 5145] FLOOR 0 0 97 0 CEILING 3108 0.055 97 16581 GLASS 100 0.5 97 4850 DOORS 84 0.25) 97 2037 PERIMETER LENGTH| * F-VALUE | *(Ti- Te)| =BTU/HR BASEMENT WALL 97 0 SLAB 2072 0.05) 97) 10049] AIR EXCH. CFM| * FACTOR | *(Ti- Te)| =BTU/HR INFILT. 414 1.08 97) 43413 110649 TOTAL BTU/HR= 110,649 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS=| 387,055,913 TOTAL GAL/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 3,950 [BESELOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: |WHITE MOUNTAIN PROJ NO: |495-412 CALC FOR: |CITY BUILDING (1 OF 2) DATE: [3/22/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70) °F 14138/°F DAYS EXTERIOR: -27/°F ROOM: : HEIGHT= 10 AREA= 2400) WIDTH= 40 VOLUME= 24000 LENGTH= 60 AC/HR= 0.5 SURFACE AREA| * U-VALUE | * (Ti- Te) | _=BTU/HR TOTAL COMMENTS WALL 1 400 0.052) 97 2018 WALL 2 600 0.052 97 3026 FLOOR 0 0 97 0 CEILING 2400 0.055) 97 12804 GLASS 97 0 DOORS 97 ) | PERIMETER LENGTH| * F-VALUE | * (Ti- Te) |_ = BTU/HR BASEMENT WALL 97 0 SLAB 200 0.65) 97 12610 AIR EXCH. CFM| * FACTOR | * (Ti- Te) | =BTU/HR INFILT. 200 1.08) 97 20952 51410 TOTAL BTU/HR= 51,410 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS=| __ 179,835,360 TOTAL GAL/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 1,835 HEATLOSS CALCULATION |BASIC PROJECT INFORMATION PROJECT: |WHITE MOUNTAIN PROJ NO: |495-412 CALC FOR: |CITY BUILDING (2 OF 2) LIBRARY DATE: |3/22/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70|°F 14138|°F DAYS EXTERIOR: -27|°F ROOM: HEIGHT= 10 AREA= 576 WIDTH= 24 VOLUME= 5760 LENGTH= 24 AC/HR= 0.5 SURFACE AREA| * U-VALUE | * (Ti - Te) = BTU/HR TOTAL COMMENTS WALL 1 240 0.052) 97) 1211 WALL 2 240 0.052) 97) 1211 FLOOR 0 0 97) 0 CEILING 576 0.055) 97 3073) GLASS 97 0 DOORS 97 0 PERIMETER LENGTH| * F-VALUE | * (Ti- Te) | = BTU/HR BASEMENT WALL 97 0 SLAB 96 0.65 97) 6053 AIR EXCH. CFM! * FACTOR | * (Ti- Te) | =BTU/HR INFILT. 48 1.08} 97) 5028 16575) TOTAL BTU/HR= 16,575 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS= 57,981,635 | TOTAL GAL/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 592 HEATLOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: [WHITE MOUNTAIN PROJ NO: [495-412 CALC FOR: [CLINIC DATE: (3/22/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70|°F 14138|°F DAYS EXTERIOR: -27/°F ROOM: HEIGHT= 10 AREA= 768 | WIDTH= 24 VOLUME= 7680 LENGTH= 32 AC/HR= 0.5 | SURFACE AREA| * U-VALUE| *(Ti- Te)| _=BTU/HR TOTAL COMMENTS WALL 1 240 0.08 97/ 1862 WALL 2 320) 0.08 97 2483 FLOOR 0 0 97 0 CEILING 768 0.032 97 2384) GLASS 97 0 DOORS 97 0 : PERIMETER LENGTH| * F-VALUE | *(Ti- Te) | =BTU/HR BASEMENT WALL 97) 0 SLAB 132! 0.65 97 8323 AIR EXCH. CFM| * FACTOR | *(Ti- Te)| =BTU/HR INFILT. 64 1.08 97 6705 21757 TOTAL BTU/HR= 21,757 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS=| 76,106,324 TOTAL GAL/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 777 HEATLOSS CALCULATION BASIC PROJECT INFORMATION PROJECT: |WHITE MOUNTAIN PROJ NO: |495-412 CALC FOR: |IRA BUILDING DATE: [3/22/90 TEMPERATURES HEATING DEGREE DAYS INTERIOR: 70|°F 14138|°F DAYS EXTERIOR: -27|°F ROOM: HEIGHT= 10 AREA= 1344) WIDTH= 28) VOLUME= 13440 LENGTH= 48 AC/HR= 0.5 SURFACE AREA| * U-VALUE | * (Ti - Te) = BTU/HR TOTAL COMMENTS WALL 1 280 0.052) 97 1412 WALL 2 480) 0.052) 97 2421 FLOOR 0 0) 97 0 CEILING 1344) 0.055) 97 7170 GLASS 97 0 DOORS il 97| 0 PERIMETER LENGTH| * F-VALUE | * (Ti- Te) | = BTU/HR BASEMENT WALL 97| 0 SLAB 152 0.65) 97 9584 AIR EXCH. CFM * FACTOR | *(Ti- Te) | =BTU/HR INFILT. 112 1.08 97 11733) 32320 TOTAL BTU/HR= 32,320 TOTAL BTU/YR BASED ON HEATING DEGREE DAYS=| _ 113,058,758 TOTAL GAV/YR @ 140,000 BTU/GAL, 70% EFFICIENCY= 1,154 APPENDIX 2 COST ESTIMATES White Mountain waste heat report 2/21/91 Simple Payback Ignores O&M costs Scenario #1 Prodject cost $ 559,074 Fuels cost Savings $ 11,100 Years for payback 50.4 Fuel cost savings based on $1.12 per gallon Price of fuel required for 10 year payback Prodject cost $ 559,074 Gallons fuel saved 9,900 Cost of fuel per gallon for 10 year payback $5.65 HMS 9119 CONSTRUCTION COST ESTIMATE WASTE HEAT RECOVERY SYSTEM WHITE MOUNTAIN, ALASKA COST CONSULTANT : ENGINEER HMS Inc. Frank Moolin & Associates, Inc. 4103 Minnesota Drive 550 W. 7th Avenue Anchorage, Alaska 99503 Anchorage, Alaska 99501 (907) 561-1653 February 20, 1991 (907) 562-0420 FAX WASTE HEAT RECOVERY SYSTEM PAGE 1 WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from a February 12, 1991 report, including a concept design dated June 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 - High School and Gym WASTE HEAT RECOVERY SYSTEM WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY CONSTRUCTION COST ESTIMATE 01 - General Conditions, Overhead and Profit 02 - Sitework 06 - Wood and Plastics 13 - Special Construction 15 - Mechanical 16 - Electrical SUBTOTAL Estimate contingency for elements of project not determined at this early level of design 10.00% Escalation at .50% per month to Spring 1992 7.50% TOTAL CONSTRUCTION COST: PROJECT COST Design 10.00% SIA (Supervision, Inspection and Administration) 20.00% Project Contingency 10.00% TOTAL PROJECT COST: SUMMARY SCENARIO #1 139,357 104,507 11,004 4,670 70,020 8,149 337,707 33,771 7,86 399,339 39,934 79,868 39,934 559,074 PAGE 2 2/20/91 WASTE HEAT RECOVERY SYSTEM aan WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 WASTE HEAT RECOVERY SYSTEM PAGEL WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 01 - GENERAL CONDITIONS QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,500.00 8,500 Freight 45,000 LBS 0.50 22,500 Supervision, equipment, utilities, clean site, tools and protection 10 WKS 3,500.00 35,000 Per diem 250 DAYS 110.00 27,500 Travel costs, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 101,900 Bond and insurance 2.25 % 6,756 Profit 10.00 % 30,701 TOTAL ESTIMATED COST: 139,357 WASTE HEAT RECOVERY SYSTEM PAGE 5 WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 02 - SITE WORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piles Mobilize a LOT 10,000.00 10,000 Wood piles 20 EA 650.00 13,000 Drill pile hole 400 LF 25.00 10,000 Slurry 15 cy 280.00 4,200 Freeze back 20 EA 220.00 4,400 Test and demobilize 1 LoT 3,000.00 3,000 Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 550 LF 12.50 6,875 3" diameter Schedule 40 pipe with insulation and arctic pipe protection 600 LF 48.30 28,980 2" ditto 500 LF 41.50 20,750 3" bend 6 EA 215.25 1,292 2" bend 12 EA 167.50 2,010 3" tee 2 EA 231.00 462 TOTAL ESTIMATED COST: 104,507 WASTE HEAT RECOVERY SYSTEM PAGE 6 WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 06 - WOODS AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Glulam beams to support new module 120 LF 40.00 4,800 Wood deck 96 SF 11.50 1,104 Miscellaneous metals 2,000 LBS 1.75 3,500 Access steps 1 EA 325.00 325 Handrail and balustrade 30 LF 42.50 1,275 TOTAL ESTIMATED COST: 11,004 WASTE HEAT RECOVERY SYSTEM WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY SCENARIO #1 PAGE 7 2/20/91 13 - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE Pre-engineered 8’0"x8’0" building module with floor, exterior wall structure and roofing complete a EA 2,800.00 Hole through exterior wall for heating pipes 6 EA 110.00 Exterior door | 1 EA 710.00 Louver 1 EA 500.00 TOTAL ESTIMATED COST: ESTIMATED COST 2,800 660 710 500 4,670 WASTE HEAT RECOVERY SYSTEM PAGE 8 WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 6 EA 72.50 435 Ditto existing radiator 6 EA 72.50 435 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 150 LF 26.22 3,933 Fittings 44 EA 46.35 2,039 Gate valve 29 EA 325.00 9,425 Drain valves 2 EA 360.00 720 Balance valves At EA 325.00 325 Check valve 6 EA 325.00 1,950 Amot three-way valve 2 EA 405.00 810 Insulation to pipe, 3" diameter 150 LF TsO) 1,065 Booster pumps, 44 GPM, 25’0" head, 1/2 HP 2 EA 1,310.00 2,620 WASTE HEAT RECOVERY SYSTEM WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE PAGE 9 2/20/91 ESTIMATED COST Exchanger and Connections (Continued) Heat exchanger, 388 MBH, 84 GPM Air separator with vent Control valves Gauges Expansion tank Glycol tank, pumps and make-up system Glycol ook- Form hole through existing wall for heating pipes 2" diameter black steel piping including fittings 1 1/4" ditto 1" ditto 385 80 140 80 BBE ES GALS LF 4,875.00 495.00 89.00 68.50 770.00 1,025.00 8.80 195.00 OLY 12.05 10.85 4,875 495 178 274 770 1,025 3,388 780 1,438 1,687 868 WASTE HEAT RECOVERY SYSTEM o-oo WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up __ (Continued) 1 1/4" gate valves 3 EA 124.00 372 Control valves 3 EA 89.00 . 267 Check valves 1 EA 124.00 124 2" insulation 80 LF 5.83 466 1 1/4" insulation 140 LF 4.70 658 1" insulation 80 LF 4.50 360 Duct coil 2 EA 885.00 1,770 Double wall heat exchanger, 26 MBH 1 EA 4,205.00 4,205 Ditto, 86 MBH 1 EA 4,880.00 4,880 Heat exchanger, 172 MBH, 19 GPM 1 EA 3,550.00 3,550 Connection to water heater 1 EA 72.50 73 Connection to existing piping system 12 EA 72.50 870 Test and balance system 80 HRS 75.00 6,000 WASTE HEAT RECOVERY SYSTEM PAGE 11 WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Controls and Instrumentation Generator building and new module 1 LoT 2,000.00 2,000 Hook-up inter ties 3 LoTS 1,500.00 4,500 TOTAL ESTIMATED COST: 70,020 WASTE HEAT RECOVERY SYSTEM PAGE 12 WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 6 EA 175.00 1,050 Connection to motor 7 EA 115.00 805 Disconnect switch 4 EA 330.00 1,320 3/4" EMT conduit 170 LF 3.20 544 #8 copper 680 LF 0.85 578 New Module Main feeder and conduit 40 LF 8.80 352 Breaker in existing distribution panel 1 EA 277.00 277 Panel 1 EA 800.00 800 Exterior light fixture 2 EA 330.00 660 Light fixtures 6 EA 190.00 1,140 Switch a EA 55.00 55 Duplex outlets 4 EA 68.00 - 272 WASTE HEAT RECOVERY SYSTEM PAGE 13 WHITE MOUNTAIN, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) 1/2" conduit 60 LF 3.00 180 #12 copper 210 LF 0.55 116 TOTAL ESTIMATED COST: 8,149 APPENDIX 3 RAW DATA H_D_DAY.XLS [HEATING DEGREE DAY WEATHER DATA | Note: Community names in lower case are close to site and are used when actual info is not available. MONTH HDD HDD HDD MONTH HDD HDD HDD MONTH HDD HDD HDD MEAN 1988] 1989) MEAN 1988) 1989 MEAN 1988} 1989 HOONAH_|_ COLD BAY =| CORDOVA Juneau > JAN 1087) 1217] JAN 1126) 1318 JAN 1157, 1255 FEB 1002) |___ 1144 FEB 1055) 834} FEB 967, 1017] MAR 936 A} 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 ve 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) 717| NOV 940] 855) NOV 907| 970) 975) NOV 927 873) 990) DEC 1034 1040) DEC 1075) 1050) 1054} DEC 1115) 950} 868) TOTAL 8855) TOTAL 9733) 9374) TOTAL 9003} |_ 8404 [ | | aie | | ANVIK, RUSSIAN MISSION, & LOWER KALSKAG Holy Cross ----------------> Aniak -—---- => oe = JAN 2018; 4 fal JAN 1958) 2508} JAN 1739) | 2370 FEB 1740 FEB [1617] _ 1163] FEB 1627 [1128] MAR 1683 MAR 1605] a} MAR 1541 1418 APR 1157] APR 1163) APR 1185) 1087) MAY 656) MAY 715) 764! MAY 697 868 JUN 325) JUN 380) 338) JUN 422) 361 JUL 243 JUL 310) 112) JUL 299) 143) 367) AUG 350 AUG |_395 425 AUG 357) 317 380 SEP 583 SEP 619) 697) $11 SEP 601 554 $27] OCT 1123 |OCT 1121 1247| OCT 1072! 1180 1047] NOV 1552 __[Nov 1488] 1823] NOV 1436{ 16711650 DEC 2033) DEC 1986 DEC 1810) 1756) 1566 TOTAL 13463} aan 13357) TOTAL 12786 |__12769 Note: for analysis, use Holy Cross Data | | | T [ | KOTLIK WHITE MOUNTAIN | Unalakleet -------—-------> Nome -----—---------> | JAN 1855) JAN 1809 FEB 1727| FEB 1701 a |e MAR 1692) MAR 1767| APR 1294) APR 1424) MAY 834) MAY 898) JUN 532! JUN 565) JUL 386) JUL 430 t AUG 393} AUG 463) ISEP 662| SEP 676 | i 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. [. Page 1 Engine Heat balance charts for modern diesel engines indicate one-third of fuel required for engine operation results in heat absorbed by the jacket water. This heat must be totally removed to assure dependable engine performance. FUEL % 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. ‘g5) - PL. GL. DEMONSTRATES THAT BETWEEN G07, £ 1007, LoaAD , PeRCepT oF EWERLY “To JACKET WATER 1S ESSENTIALLY CONSTANT . PERCENTAGES OBTAWED FRon PRIME LonD DATA SHouLD BE APPLICABLE IN THIS RANGE p GENSET DATA GENSETS.XLS LOCATION GENSET HOONAH, CATAPILER 3512 @ 851 KW PRIME (W/O FAN) - NOTE 1 Cc. BAY INPUT: 143198} btu/min OUTPUT: | Work: 52320] 36% Exhaust: 52832 37% Radiation: 6369) 4% Water: 32075) 22% Aftercooler: 3697|btu/min _| (included in jacket water) -----> 0 Oilcooler: 7166|btu/min__| (included in jacket water) -----> 0 Total: 143596] btu/min WATER % LOAD | KW GPH_ |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 100) 851 62.0) 13.7 1924500} 2261 31049} 75| 638 r 50) 426 iC. BAY CATAPILER 3512 @ 683 KW PRIME (W/O FAN) - NOTE 2 INPUT: 121417} btu/min OUTPUT: |Work: 43392 36% Exhaust: 44984 37% Radiation: 6028; 5% Water: 27070! 22% Aftercooler: 1934}btu/min _| (included in jacket water) -----> oO} Oilcooler: 6085|btu/min _|(included in jacket water) -----> 0 Total: 121474] btu/min WATER % LOAD KW GPH_ |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 100) 683) 52.6 13.0 1624200) 2378) 30905) 75 512) 50] 342! |HOONAH CATAPILER D398 @ 600 KW PRIME (W/O FAN) INPUT: 48.2! gph * 19590) btu/b hhv * 7.076} Ib/gal / 60} minv/hr = 111357] btu/min OUTPUT: |Work: | 636| kw engine * 3412|btu/kwh / 60| min/hr = 36167| 33% Exhaust: 37400) 34% Radiation: 5300) 5% Water: | 32200] 29% Total: fu! 111067|btu/min WATER | % LOAD | KW GPH_|KWH/GAL| BTU/HR_|BTU/KWH|_ BTU/GAL 113) 675 56.1 12.0 2190000} 3244) 39037! 100} 600) 48.2) 12.4 1932000} 3220 40083 75| _-450) 36.1 12.5} 50 300 25.3) 11.9 L. KALSKAG |CATAPILER 3406 TA @ 210 KW PRIME (W/O FAN) - NOTE 3 [ | INPUT: 16.5/gph * 19590) btu/Ib hhv * 7.076|Ib/gal / 60} minvhr = 38120) btu/min OUTPUT: | Work: 224/kw engine * 3412/btu/kwh / 60} min/hr = 12738} 33%| | Exhaust: 13700} 36% Radiation: 1900 5% Water: 10000) 26% Total: 38338] btu/min WATER % LOAD | KW GPH_ |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 124 260) 20.6 12.6) 726000 2792) 35243) 100) 210 16.5 12.7 600000 2857| 36364) 75| 158) 12.6 12.5 | 50| 105 9.0 11.7 Se ee TO TT GENSETS.XLS CATAPILER D342 T @ 160 KW PRIME (W/O FAN) - NOTE 4 INPUT: 12.5} gph * 19590) btu/lb hhv * 7.076} Ib/gal / 60} min/hr = 28879) btu/min OUTPUT: | Work: 235|bhp engine * 2545] btu/bhp-hr / |. 60| min/nr = 9969 34% Exhaust: 1340| CFM @ 710) F ---------- > 8157, 28% Radiation: 2100 7%) Water: 9400) 32% Total: 29626) btu/min WATER % LOAD | KW | GPH |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 143} 229 too 160|__—‘12.5 12.8| 564000] 3525] 45120) 75| 120) 9.8 12.2 50) 80] 7.0) 11.4) KOTLIK CATAPILER 3306 TA @ 155 KW PRIME (W/O FAN) - NOTE 5 [ je INPUT: 12.3} gph * 19590} btu/lb hhv * 7.076} Ib/gal / 60| min/hr = 28417 btu/min OUTPUT: | Work: 1 167|kw engine * 3412|btu/kwh / 60| min/hr = 9497, 52% Exhaust: 10500) 57% Radiation: 1700 9% Water: 6800} 37% Total: 28497] btu/min WATER % LOAD | KW GPH_|KWH/GAL| BTU/HR |BTU/KWH| BTU/GAL 116) 180) 14.5) 12.4 468000) 2600; 32276) 100} 155) 12.3) 12.6) 408000; 2632, 33171 75) 116) 9.3 12.5 50} 78 6.5 11.9) |R. MISSION _[CATAPILER 3304T @ 90 KW PRIME (W/O FAN) - NOTE 6 INPUT: 7.6}gph * 19590} btu/b hhv * 7.076|Ib/gal / 60| min/hr = 17558} btu/min OUTPUT: | Work: | 99/kw engine * 3412) btu/kwh / 60| min/hr = 5630) 31% Exhaust: 5801 31% Radiation: 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} 100 90 7.6 11.8) 300300} 3337, 39513 75 68) 5.6) 12.1 50) 45) 3.9) 11.5 R. MISSION, |CUMMINS LTA 10 @ 110 KW PRIME (W/O FAN) - NOTES 7 & 8 WHITE MT. _|INPUT: 8.0/gph * 19590] btu/Ib hhv * 7.076|Ib/gal / 60} min/hr = 18536) btu/min OUTPUT: |Work: 166] bhp engine * 2545|btu/ohp-hr/ | 60|min/hr = 7042| 38% Exhaust: 9382) * 166| / 235] = 6627| 36% Radiation: 745] * 166] / 235| = 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/Ib 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% Exhaust: az Radiation: ? Water: 150| bhp engine * 32 btu/bhp-min = 4800) 24% l Total: 2|btu/min Page 2 GENSETS.XLS WATER | % LOAD | KW GPH_ |KWH/GAL} BTU/HR_ |BTU/KWH| BTU/GAL | 125) 125) 10.3 12.1 360000 2880 34951 100! 100) 8.5) 11.8 288000) 2880) 33882! 75) 75) 6.7| 11.2 50} 50) 5.0 10.0 ANVIK ALLIS CHALMERS 3500 @ 60 KW PRIME (W/ FAN) - NOTE 10 INPUT: 5.1}gph * 19590) btu/b hhv * 7.076} Ib/gal / 60| min/hr = 11783) btu/min OUTPUT: | Work: 87|bhp engine * 2545] btu/bhp-hr / 60} min/hr = 3691 31% | Exhaust: 7 Radiation: 2? Water: 87|bhp engine * 32|btu/bhp-min = 2784 24% Total: 2 btu/min WATER % LOAD | KW GPH |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 125) 75| 6.7 11.2) 208800 2784) 31164} 100} 60) 5.2 11.5 167040} 2784) 32123} 75| 45) 3.8 11.8) 50) 30 2.7} 111 ANVIK ALLIS CHALMERS 2900 @ 50 KW PRIME (W/ FAN) - NOTE 10 INPUT: 4.26| gph * 19590) btu/b hhv * 7.076} Ib/gal / 60] min/hr = 9842) btu/min OUTPUT: | Work: 73) bhp engine * 2545|btu/bhp-hr / 60| min/hr = 3097| 31% Exhaust: 2 Radiation: 2 Water: 73/bhp engine * 32) btu/bhp-min = 2336) 24% Total: 2\|btu/min WATER % LOAD | KW GPH |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 120) 60 5.2 11.5 168192 2803 32345) 100) 50! 4.26) 11.7 140160) 2803} 32901 75| 38 3.23} 11.6 50) 25 2.3} 10.9) SUMMARY RESULTS: WEIGHTED SITE LOCATION _|GENSET BTU/KWH| BTU/GAL| WGHT % |BTU/KWH|_ BTU/GAL HOONAH CAT D398 3220) 40083} 5 2357 31953} CAT 0398 3220! 40083 5| CAT 3512 (851 KW) 2261 31049) 90] Cc. 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 ° 2924) 37239 CAT 3406TA 2857) 36364! 90] CAT 0342T 3525) 45120 10 R. MISSION _|CUMMINS LTA10 2409) 33117, 50) 2873) 36315} CAT 3304T 3337, 39513} 25 CAT 3304T 3337, 39513} 25 | ANVIK AC 11000 2880) 33882 33} 2822 32969) | AC 3500 2784| 32123 33 | AC 2900 2803} 32901 33 \ KOTLIK CAT 3306TA 2632 33171 50| 2632 33171 | CAT 3306TA 2632) 33171 50} Le ere ee ee ec ester ec rec ee ee Page 3 WHITE MT. GENSETS.XLS CUMMINS LTA10 2409) 33117 100} 2409) 33117 DETROIT 4-71T So DETROIT 371 ° NOTES: General) Engine input and output are from manufacturer's data except as shown. KWH/GAL, BTU/KWH, and BTU/GAL are calculated. 1) Fuel use is listed in manufacturer's data as 143198 btu/min input. Fuel use in gph is calculated as btu/min / 19590 btu/b hhv / 7.076 Ib/gal * 60 min/hr_= gph. 2) Fuel use is listed in manufacturer's data as 121417 btu/min input. Fuel use in gph is calculated as btu/min / 19590 btu/b hhv / 7.076 Ib/gal * 60 min/hr = gph. 3) Nameplate info recorded on engine #2 as 3406DI however AVEC data lists 375HP/257KW for this genset which corresponds to a 3406TA. A 3406DITA is rated at 433HP/310KW. Generator nameplate data lists 350KW prime. 3406TA data is used here. 4) One genset nameplate info recorded as D342turbo and one as D342PC. They have a skid mounted fan and) remote radiator, respectively. Typical AVEC data for 0342T with fan is 335HP/223KW peak and without fan is 335HP/229KW peak. This corresponds to a D342T. D342T data without fan is used here. 5) Nameplate info recorded on engines as 3306DI and on generators as 1SOKW prime. Both gensets have skid mounted fan. 150 KW prime with fan corresponds to a 3306TA. 3306TA data without fan is used here. 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 1SOKW prime. Typical AVEC data for AC11000 is 195HP/130KW peak. This is an 1800 rpm genset. Only output data available is for fuel vs. generated KW electrical power from one publication and heat output at 2200 rpm only from another (constant 32 btu/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. 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 90KW. The AC2900 is even smaller. For purposes of this report the gensets are treated as DES-60 and DES-50, respectively. These gensets use the AC2900 engine. For each genset only 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 Pp IPELOSS.XLS BURIED PIPING, SINGLE PIPE, 3° PU INSULATION K=| 0.014] Btu/tthr-°F’ R=|In(Do/Dp)/2:Pi-K QA=|(Tp-ToyR To=|__0|°F (ground Tp=| _180|°F (fluid) Pipe Size|_ Type’ Dp (in): Do(in)| Rifthr°F| — QA(Btu Sa (inches) /Btu) Mart) i|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 79) 16.2| 14.4 aps | 2.38 838] 14.3] 12.6 3|IPS 3.5 95 11.4 15.9] 4jIPS 45 10.5) 9.6 18.7 S|IPS 5.56 11.56 8.3 21.6 6|IPS 6.63 12.63 73) 24.6 g|IPS 8.63 14.63| 6.0) 30.0) BURIED PIPING, SINGLE PIPE, 2" PU INSULATION 1IPS 1.32 5.32| 15.8 11.4 1.25/IPS 1.66 5.66 13.9 12.9) 1.5]1PS 1.9] 5.9) 12.9 14.0 | 2iPs 2.38 6.38 11.2 16.1 [ [IPS 3.5] 75| 8.7 20.8] [i | 4/IPs 45] 8.5 7.2| 24.9) S|IPS 5.56| 9.56| 6.2| 29.2! 6lIPS 6.63 10.63| 5.4 33.5| ast ABOVE GRADE PIPING, SINGLE PIPE, 1.5" FG INSULATION K=|_ 0.023] Btu/tthr:°F! R-=|In(Do/Dp)/2:PiK Q/-=|(Tp-Toy/R To=| _ 80|°F (room) Tp=| 180) °F (fluid) iIPS 1.32] 4.32! 8.2| 12.2 | 1.25|IPS 1.66] 4.66 7140 | 1.5|IPS 1.9 49 6.6 15.3) | 2IPS 2.38) 5.38 5.6) 17.7| 3[IPS 3.5 65 4.3) 23.3) 4jIPS 45 75| 3.5| 28.3) b ‘| 5|IPS 5.56 8.56 3.0) 33.5) 6|IPS 6.63 9.63| 2.6 38.7 glIPS 8.63 11.63] 241 48.4 ABOVE GRADE PIPING, SINGLE PIPE, NO INSULATION QA from ASHRAE Fundamentals (1989), Chapter 22, Table 9 & 10 Tos} _80|°F (room) Tp=|_ 180) °F (fluid) Pipe Size! Type’ Dp (in)|_ _ QA(Btu! inches) Jor-ft 1[IPS 1.32 89 [ 1.25|IPS 1.66 110] I 1lIPS__| 1.9 124] 2\IPS 2.38) 152| 3/IPS 3.5| 216| 4|IPS 45 272| 5|IPS 5.56| 330) 6|IPS 6.63 387| 8 8.63 493] Page 1 CAPACITY.XLS WASTE HEAT SYSTEM - HEAT TRANSFER COMPONENT CAPACITY REQUIREMENTS COLDEST MONTH = JAN.| HDD = 1126 Tave=| _65-(HDD/31) = 29(°F ml ACTICAL MINIMUM = itd oO diff- max temp diff =| (70-0) (70- 29) = i Example: |DOT/PF Shop: 681|gal/ month worst month i ; 1.7| multiplier 31|days / month 24/hours / day 1.56|gal / hour worst hour “| 140000] btu / gal | *__075lett 163000) btu / hour heating unit required ne FACTO! 240) fuel use = 163000 / 681 = R capacity - FLUID FLOW @ 20°F TEMP. DROP =| 163000 / (20 * 460) = 18/gpm FACTOR capacity - flow = 20 * 460 = 9200} ** HOONAH COLDEST MONTH = JAN.| _HDD =! 1087| | Tave = 65 - (HDD / 31) = 30°F PRACTICAL MINIMUM = O}°F RATIO ave temp diff - max temp diff =| (70 - 0) / (70 - 30) = Tee L. KALSKAG COLDEST MONTH = JAN. HDD = 2000] ave R. MISSION ANVIK Tave = 65 - (HDD / 31) = Ol°F KOTLIK IW. MOUNT. PRACTICAL MINIMUM = -40|°F RATIO ave temp diff - max temp diff = [(70 - (-40)) / (70 - 0) = 1.6|"" CONCLUSION: USE OVERALL TYPICAL FACTORS AS FOLLOWS:! RATIO ave temp diff - max temp diff = 17) OVERALL FACTOR capacity - fuel use = 240 OVERALL FACTOR capacity - flow = 9200)