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Kotlik Report & Concept Design Waste Heat Recovery 1991
REPORT AND CONCEPT DESIGN KOTLIK WASTE HEAT RECOVERY February 13, 1991 AEA Frank Moolin & Associates, Inc. A Subsidiary of ENSERCH Alaska Services, Inc. a KOTLIK WASTE-HEAT RECOVERY TABLE OF CONTENTS 120 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 Kotlik School 5.1.1 High School 5.1.2 Elementary School 5.1.3 School Office 5.2 Community Buildings Sees Community Center Bee Clinic 52.3 Washateria 5.2.4 Child Care 5.255 City Building/Post Office 6.0 . RIGHT-OF-WAY/EASEMENT 7.0 CONCEPT DESIGN 8.0 ECONOMIC DATA 9.0 FAILURE ANALYSIS 10.0 CONCLUSIONS AND RECOMMENDATIONS APPENDICES KOTLIK 1. Calculations 2. Cost Estimates 3. Raw Data REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 LIST OF FIGURES AND TABLES Power Plant Photographs Kotlik Power Generation Data High School Photographs Elementary School Photographs School Office Photographs School Office Fuel Data 4-3 4-4 5-3 5-5 5-7 5-8 Community Center Photographs 5-10 Community Center Fuel Data 5-11 Clinic Photographs 5-13 Clinic Fuel Data 5-14 Washateria Photographs 5-16 Washateria Fuel Data 5-17 Child Care Photograph 5-19 City Building/Post Office Photographs 5-21 Figure 1 - Legend 7-7 Figure 2 - System Site Plan 7-8 Figure 3. - Power Plant Floor Plan 7-9 Figure 4 - Power Plant Cooling Schematic 7-10 Figure 5 - Scenario 1 - System Schematic 7-11 Figure 6 - High School - First Floor Plan 7-12 Figure 7 - High School - Second Floor Plan 7-13) Figure 8 - High School - System Schematic 7-14 Figure 9 - Washateria Floor Plan 7-15 Figure 10 - Washateria System Schematic 7-16 Figure 11 - Scenario 2 - System Schematic 7-17 Figure 12 - Community Center Floor Plan 7-18 Figure 13 - Community Center System Schematic 7-19 Figure 14 - Clinic Floor Plan 7-20 Figure 15 - Clinic System Schematic 7-21 Figure 16 - Child Care Building Floor Plan 7-22 Figure 17 - Child Care Building System Schematic 7-23 Figure 18 - Typical Aboveground Piping Section 7-24 Graph 1 10-2 Graph 2 10-3 KOTLIK 1.0 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 EXECUTIVE SUMMARY A potential for waste-heat recovery exists in the community of Kotlik. Kotlik is a community of approximately 450 people, located 35 miles northeast of Emmonak in the Yukon-Kuskokwim Delta, 460 air miles from Anchorage, and 165 air miles from Bethel. The waste heat from the coolant of the diesel engine generator sets owned and operated by the City could be recovered and circulated to heat buildings in the community. Soils in Kotlik will not support buried piping. All waste-heat piping will have to be elevated above grade. This presents problems with routing to protect the piping and also to preserve the use of traveled ways. Any scenario must consider piping routing as a major factor. Present power plant loads provide the equivalent waste heat of about 14,900 gallons of fuel with the equivalent of approximately 11,500 gallons available to users. This is not enough to heat all of the publicly owned buildings; therefore, policymakers will have to choose between alternative scenarios. Scenario 1 - This alternative would serve the Washateria and High School. It would pipe waste heat from the power plant along the Curry Street right-of-way to the point where the existing sewage effluent line crosses the roadway adjacent to the Washateria. It would then tee to the Washateria and also run parallel to the existing effluent line to the High School/Gym. These two buildings could use the majority of the waste heat available. Advantages of this scenario include no new road crossings, utilization of the majority of the waste heat currently available, and the potential to use more heat if it becomes available in the future, in the School complex. Total Estimated Project Cost $526,100 Total Fuel Oil Savings 10,200 Gallons Total Annual Fuel Cost Savings $ 11,700 (0&M Cost $ 5,600) Scenario 2 - This alternative would serve the community buildings in the vicinity of the power plant including the Washateria, Community Center, Clinic, and the Child Care Building. These buildings cannot currently utilize all of the waste heat available. This scenario would require several road and traveled way crossings. The only advantage over scenario #1 is that only one customer, the City, is involved. The disadvantages include the inability to utilize all of the available waste heat and the additional expense and complexity of the system. Total Estimated Project Cost $535,100 Total Fuel Oil Savings 8,700 Gallons Total Annual Fuel Cost Savings $ 10,000 (O&M Cost $ 5,500) 1-1 KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 1.1 Decision Criteria Economic and public policy decisions will consider some or all of the following factors: 1.1.1. Proximity and piping loops. The cost of running the waste-heat recovery piping and the individual heat exchangers in each customer’s building may make the payback period too long for a particular client. This factor may limit this project to the buildings in the immediate area of the power plant. The proximity of the potential waste-heat users buildings to the power plant will allow for relatively short piping runs. 1.1.2 Permafrost The soils in the Kotlik area are very wet, ice rich, and highly frost susceptible, which collapse when thawed. For this reason all construction is on pilings and the waste- heat recovery piping will have to be aboveground. The relative proximity of the power plant and the prospective waste-heat customers makes aboveground routing of piping possible, but it should be done as total package that includes the existing water, wastewater, power, and fuel piping. The routing of all of these utility lines must also consider the traffic patterns and the future necessity of heavy equipment (including drill rigs and trucks) moving around the site. 1.1.3. Potential Future Users and Expansion At the time for the site investigation (March 1990), there was a plan to build a new Public Safety Building of approximately 860 square feet in the summer of 1990. Also an addition to the High School/Gym was scheduled for the summer of 1990. The expansion was to be 12’ x 65’. 1.1.4 Community Priorities The Mayor and City Council members, that were interviewed, indicated a preference for using waste heat in the City Building, Washateria, Child Care, and Medical Clinic. They were supportive of using waste heat at the school. A summary of the construction cost estimates along with design and SIOH costs is included in the Cost Estimate Appendix for each alternative and scenario. KOTLIK 1-2 2.0 2.1 222 253 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 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 Kotlik. 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: 1. Presite 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. Zs 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). 3), Office Analysis: Additional information regarding weather and historical trends was 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 Kotlik is a community of approximately 450 people, an over 50% increase from approximately 290 people in 1980. It is located 35 miles NE of Emmonak in the Yukon-Kuskokwim Delta, 460 air miles from Anchorage, and 165 air miles from Bethel. Kotlik is situated on the South bank of the Kotlik River at its junction with the Yukon River, five miles from the Yukon River’s mouth on Norton Sound. This location makes it easily accessible to barge traffic. Primary economic activity revolves around seasonal commercial fishing and subsistence activities. Fuel cost at the time of the site visit varied from $1.16 per gallon for the City to $1.15 per gallon for the School. eset KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Applicable Codes and Regulations The editions most recently adopted by the State of Alaska (1985 for all except as noted) of the following State of Alaska 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 (ABC) Uniform Fire Code (UFC) National Electrical Code (NEC-1990 - Pending adoption) National Fire Protection Association (MFA) 3.0 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 DESCRIPTION OF SITE VISIT Two engineers from Frank Moolin & Associates, Inc. visited Kotlik March 7 to March 9, 1990. They visited every facility listed in this report and obtained available copies of fuel usage and copied or sketched floor plans and piping diagrams. Contacts: Pius Akron - 899-4313 - Mayor Bernadette Hunt - 899-4313 - City Clerk Joe Mike - 899-4313 - President, Kotlik Utilities Board Dominic Agnostic - 899-4313 - Power Plant Operator Jerry Gates - 899-4415 - Principal, Hunt School and City Maintenance Martin Okitkun - 899-4014 - Kotlik Corp. Manager 3 = 1 4.0 4.1 4.2 4.3 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 POWER PLANT DESCRIPTION Narrative Description The power plant is housed in a 50’ x 60’ metal skinned structure on pilings with included switchgear and shop. Power is generated by two Caterpillar generators with approximate prime power capability as follows: Gen. #1 - Model 3306DI, 235 hp, Serial No. 85200866 - 150 kWh Gen. #2 - Model 3306DI, 235 hp, Serial No. 85201056 - 150 kWh The generators use number 1 fuel oil year round. Cooling for the generators is provided by internal vertical core skid-mounted radiators, ducted through an exterior wall. While skid-mounted, the radiators are electric motor driven rather than engine driven. Each gen-set package is piped for some jacket water waste-heat recovery, with a small shell and tube heat exchanger on the cooling circuit between the engine and its radiator. A thermostatic mixing valve and a coolant return piping temperature switch for the radiator fan control coolant temperature. Each gen-set is independent with all its equipment and piping packaged on its skid. Generally one gen-set runs while the other is on standby. The standby generator is kept warm by building temperature. The power plant building is much larger than needed to just house the gen-sets. It is divided into two rooms. The larger room includes approximately 75% of the building space and is used mainly as shop and storage space. The gen-sets sit in the smaller room which is approximately 32’ x 22’. Generator radiation heats the smaller room. The larger room is heated by a waste oil furnace. The heating load for this building was calculated and a portion deducted from the total waste heat available is the waste-heat calculations. The power plant provides the equivalent of approximately 14,900 gallons of recoverable waste heat. After system losses are deducted, including heating the generator plant, the equivalent of approximately 11,300 to 11,700 gallons are available for delivery to waste-heat users, depending on the scenario. Modifications to the Generator Plant As part of the waste-heat modifications, it is proposed that the gen-sets be manifolded together and the existing waste-heat systems replaced. The radiators would remain as is but would be repiped into a common system with a common AMOT valve and common plate type heat exchanger. Floor Plan and Schematics See Figures 3 and 4 for a simple floor plan and schematics of the system (located in Section 7). 4-1 KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 4.4 Photographs See the attached copies of the original color photographs of the power plant and generators. 4.5 Load information Attached Table 1 contains the utility load data for 1989. KOTLIK 4-2 cae Kotlik Power Plant Power Plant Interior Frank Moolin & Associates, Inc. KOTLIK POWER GENERATION PRODUCTION AVERAGE LOAD (KW) Notes: 1) Average load is calculated from KWH production divided by hours in month. 2) Min. load is estimated as 1/2 of average load. 3) Fuel use information was not available at the time of this report. 5.0 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 POTENTIAL WASTE-HEAT USER BUILDING DESCRIPTIONS During the site visit, all major buildings within a reasonable distance of the power plant were considered. The buildings were visited and information about them gathered. 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 on a monthly basis. All fuel consumption figures are assumptions based on owner-provided full-year fuel figures in the case of the school complex and verbal estimates for the other buildings. Heat-loss and annual degree-day calculations were used to check the accuracy of the reported fuel consumption and adjustments were made as noted. Deli. KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Schools - General The schools and ancillary buildings are located in a complex that is connected by boardwalks and utilidors. Installation of waste- heat piping on the School grounds will require close coordination with the existing boardwalks and utilidors. The fuel consumption for the school complex is recorded by measuring the tanks on a roughly monthly basis and recording the fuel on hand. The monthly differential gives the approximate monthly usage for all school buildings including teacher housing. The on site records, which were somewhat incomplete, indicated the 1989 consumption at 42,000 gallons. This figure seemed excessive and was cross checked with rough heat-loss calculations. The heat-loss calculations confirmed that the reported fuel consumption was high. Fuel records from the district headquarters in Mountain Village reported the fuel consumption as 30,444 gallons for 1989. For these calculations 30,444 was used as the estimated annual fuel consumption; however, since no records were available for individual buildings, individual building use is actually based on approximate heat- loss calculations. These calculations are included in Appendix 1. 5.1.1 High School The High School is the newest structure in the complex. It is an approximately 68’ x 124’ wood-frame metal-skinned structure on pilings. It is heated by a Burnham American Boiler, Model PF 509, rated at a gross output of 1,446,000 Btu/hr at a 12.65 g.p.h. fuel firing rate. The boiler water circulates through coils in the supply air duct work and also heats the domestic hot water. An oil-fired domestic hot-water heater was in storage and was not operating. The preferred method of waste-heat recovery is to install a heat exchanger in the boiler return water line. The calculated annual fuel use of the High School is approximately 5,800 gallons. This facility is 300 feet from the power plant and will require 180 feet of additional waste-heat piping (one way) from the Washateria. Kotlik High School High School Boiler KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.1.2 Elementary School The Elementary School consists of an ell-shaped very poorly insulated older wood frame structure’ of approximately 3,500 square feet. It is heated by two (2) American Standard Boilers, Model FRA-509-1BJ3, each with a rated output of 716,000 Btu/hr at a 7.45 g.p.h. fuel firing rate. The Elementary School heating plant also provides heat to several other buildings in the complex through the utilidor system. Total fuel use for this facility was not calculated due to uncertainties as to which other facilities were actually connected to the heating system. The preferred method of waste-heat recovery would be to install a heat exchanger in the common boiler return water line. Kotlik Elementary School Elementary School Boiler KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.1.3 School Office The School Office and water treatment equipment are located in a 20’ x 89’ wood-frame structure on pilings. It is heated by a North Coast Manufacturing Corp. hot-air furnace, model 90EBW, with a rated output of 90,000 Btu/hr at a 0.86 g.p.h. fuel firing rate. Domestic hot water is heated by two hot water heaters: a Bock model 71E, 70 gal, 150 g.p.h. recovery rate, 1.25 g.p.h. fuel firing rate and a Bock model 32E, 95 g.p.h. recovery rate, 0.75 g.p.h. fuel firing rate. The preferred method of waste-heat recovery is to install a heating coil in the refurnace return air duct and a double-wall heat exchanger in the domestic hot water return line. School Office Furnace Frank Moolin & Associates, Inc. Kotlik SCHOOLS HEATING FUEL CONSUMPTION DATA DATE FUEL NUMBER DAILY HEATING AVERAGE (Gal) OF DAYS CONSUMPTION DEGREE MONTHLY (Gal) CONSUMPTION TOTAL FUEL DELIVERED 42,057 ANNUALIZED AVERAGE CONSUMPTION 5.2 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Community Buildings pace Community Center The Community Center is 40’ x 56’ wood frame structure on pilings. It is heated by a Williamson hot-air furnace, Model 1167-10-5 D58, with an estimated output of 75,000 Btu/hr at a 0.75 g.p.h. fuel firing rate. This facility is only used occasionally. At the present use rate, the facility is reported to use four drums (220 gallons) annually. If used continually, estimated fuel use is calculated at approximately 1500 gallons per year. The preferred method of waste-heat recovery is to install a heating coil in the furnace return air duct. The waste- heat analysis uses the 220-gallon figure for calculating fuel savings but the 1500-gallon figure for selecting a heat exchanger to heat the facility. This facility is located 120 feet from the power plant and would require 160 feet (one way) of waste-heat piping from the power plant, including a road crossing. ew Kotlik Community Center Community Center Furnace Room Kotlik COMMUNITY CENTER HEATING FUEL CONSUMPTION DATA FUEL NUMBER DAILY (Gal) OF DAYS CONSUMPTION (Gal) *Fuel usage is reported as approximately 220 gal/year (occasional use). 2/7/91 Frank Moolin & Associates, Inc. ¥ HEATING AVERAGE DEGREE MONTHLY DAYS CONSUMPTION Gal ANNUALIZED AVERAGE CONSUMPTION KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.2.2 Clinic The Clinic is a 24’ x 42’ wood-frame structure on pilings. It is heated by one Kenmore hot-air furnace model RNVO840f03, with an estimated output of 75,000 Btu/hr at a 0.75 g.p.h. fuel firing rate. Fuel use for this facility was reported as 110 gallons during the coldest months. Prorating this based on heating degree days results in a calculated yearly use of approximately 825 gallons. This compares well with heat- loss calculations for a facility of this size. The preferred method of waste-heat recovery is to install a heating coil in the furnace return air duct. This facility is located 230 feet from the power plant and would require 120 feet (one way) of additional waste-heat piping from the Community Center. 5 = ¥2 Kotlik Clinic Clinic Furnace Frank Moolin & Associates, Inc. Kotlik CLINIC HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING OF DAYS | CONSUMPTION DEGREE (Gal) DAYS AVERAGE MONTHLY CONSUMPTION Gal MEAN 1855) 110 1727 102 1692 100 1294 77 834 49) 532 32) 386 23 393 23 662 39 1164 69 1505 89 1875 111 13,919 825 ANNUALIZED AVERAGE CONSUMPTION *Fuel usage reported as 110 gal/month for cold weather months. 2/7/91 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.2.3 Washateria The Washateria is a 36 x 52 wood-frame structure on pilings. The building, hot water, and dryer hot air are heated by two (2) Weil McLain boilers, Model BL-576-SW, each with a rated gross output of 336,200 Btu/hr at a 2.95 g.p.h. fuel firing rate. Total annual fuel consumption was reported as 6,467 gallons in 1987 and 6,488 gallons for 1988. The preferred method of waste-heat recovery is to install a_ heat exchanger in the boiler return water line. This facility is located 140 feet from the power plant and will require 300 feet (one way) of waste-heat piping from the power plant. One road crossing will be required to serve the Washateria. However, piping to the Washateria can utilize the existing road crossing supports adjacent to the Washateria. 9) =),15) Kotlik Washateria Washateria Boiler (Typical of Two) Frank Moolin & Associates, Inc. Kotlik WASHATERIA HEATING FUEL CONSUMPTION DATA NUMBER DAILY HEATING AVERAGE OF DAYS CONSUMPTION DEGREE MONTHLY (Gal) DAYS CONSUMPTION ANNUALIZED AVERAGE CONSUMPTION A KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.2.4 Child Care Building The Child Care Building is a 26’ x 85’ wood-frame structure on piling. It is heated by a hot-air furnace, Rheem Manufacturing Company, Model ROBB-112A, with a rated gross output of 112,000 Btu/hr at a 1.0 g.p.h. fuel firing rate. No fuel use records exist for this facility. Heat loss was calculated, and the results were compared with similar buildings where fuel records existed. After comparing these figures, and considering the buildings’ usage, the facility was assumed to have an annual fuel consumption of approximately 1,600 gallons per year. The preferred method of waste-heat recovery is to install a heating coil in the furnace return air duct. This facility is located 290 feet from the power plant and will require 300 feet (one way) of waste-heat piping from the power plant. No road crossing will be required but a section will need to be elevated to provide vehicle access to the power plant. 5 = 18 Kotlik Child Care Building KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 5.2.5 City Building/Post Office The City Building/Post Office is a 40’ x 60’ wood-frame structure on pilings. The hot-air furnace has no name plate data and was estimated to have an output of approximately 200,000 Btu/hr. No fuel use records exist for this facility. Heat loss was calculated and the results were compared with similar buildings where credible fuel records existed. After comparing these figures, and considering the buildings usage, the facility was assumed to have an annual fuel consumption of approximately 1,600 gallons per year. The preferred method of waste-heat recovery would be to install a heating coil in the furnace return air duct. This facility is located over 520 feet from the power plant and would require excessive piping distance to be served. Serving this building with waste heat is not recommended. 5 - 20 Kotlik City Building/Post Office (background) City Building Furnace 6.0 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 RIGHT -OF -WAY/EASEMENT There are apparently no right of way problems in that the power plant is owned and operated by the city and is on city property. The power plant is contiguous to the nearby city buildings and they are on city property. If the school complex is added to the waste-heat loop, the piping may be run west, along the road until it is opposite the school gym, and then across the road to the High School. Several traveled ways will have to be crossed to serve buildings with waste heat from the power plant. One elevated road crossing adjacent to the Washateria already exists. This road crossing could be used to serve the Washateria and the High School. Many of the buildings in Kotlik actually are built in the platted roadways, including the Washateria. Pipe routing will have to be carefully coordinated with actual building locations, property lines, and traveled ways. 7.0 Teal KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 CONCEPT DESIGN System Narrative Several scenarios are possible for the distribution of the waste heat from the power plant. The resulting system will have to take political, economic, and future outlook factors into account. Two scenarios have been developed as the most probable. The prime building in each scenario is the Washateria. It is close to the power plant, has a year-round fuel requirement, and is adjacent to the existing aboveground piping road crossing. The Pipe Routing Site Plan shows pipe routing to all of the buildings in the scenarios developed. 7.1.1 Scenario 1: Served buildings include: HIGH SCHOOL WASHATERIA This alternative would pipe waste heat from the power plant along the Curry Street right-of-way to the point where the sewage effluent line crosses the road and then along the effluent line to the Washateria and the High School. The school complex uses the equivalent of over 30,000 gallons of fuel per year, which is close to three times the net deliverable waste heat. Any piping from the power plant to the school complex must cross by the Washateria. The waste heat could be supplied to any or all of the school complex buildings, but the High School could utilize all of the now available waste heat after the Washateria is served. The High School is the newest building and has the newest heating plant. As the available waste heat increases in the future the other school buildings could be added to the waste-heat recovery system. With future expansion in mind the waste-heat piping should be over sized. 7.1.2 Scenario 2: Served buildings include: WASHATERIA COMMUNITY CENTER CLINIC CHILD CARE BUILDING This alternative supplies waste heat to the community buildings closest to the power plant. The total waste heat utilized from this alternative would be approximately the equivalent of 9,200 gallons of fuel annually, which is less than the net deliverable waste heat available. Future increased utilization of the Washateria and Community Center could increase the heat utilization by another 2000 gallons which would be close to fully utilizing the available waste heat. de 7.3 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 The waste-heat piping would run almost directly from the power plant to these buildings, which are located in different directions. This alternative produces longer overall piping runs and additional road crossings. The only advantage over scenario 1 is that only one customer, the city, is involved. The disadvantages include the inability to utilize all of the available waste heat and the expense of and complexity of the system including four heat exchangers. Primary and Secondary Piping Jacket water piping will be valved to recover heat from whichever gen-set is on line. An automatic control valve will bypass coolant to the radiators to maintain coolant temperature as required to insure engine cooling. See section 4 for a discussion of proposed modifications to the power plant. In keeping with 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, an expansion tank, and a glycol makeup 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 carried on aboveground supports designed to protect it from damage from passage of vehicles and equipment. Two separate arctic pipes are envisioned: one for supply to the building and one for return to the power plant. See the attached Figures 5 and 11 for the system schematics. Balancing valves are used at the connection to existing piping for two reasons. The first is to allow balancing of the flow to the heat exchanger; the second is to provide a means of measuring the flow rate at that point in the piping. Building Piping All connections to the user’s buildings will be at a single heat exchange point either by using flat plate heat exchangers to connect to the boiler systems or by return air coils where furnaces exist. This will limit problems associated with damage of distribution piping and interconnection of systems. Precautions must be taken to prevent overcooling of the generator jacket water and to prevent building system boilers from heating 7.4 Lo 7.6 eed 738 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 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 be addressed with controls and valving. They can also be automated to some degree but the solutions must be carefully balanced with the need for system simplicity. Site Plan/Routing The routing will be as shown on Figure 2. Generator Room Plans/Schematics See the attached Figures 3 and 4 for the design concept for changes to the power plant. User Building Plan/Schematics See the attached Figures 6 through 10 and 12 through 17 for proposed changes to each of the potential user buildings considered in scenarios 1 and 2. Arctic Pipe/Aboveground Piping Section During the site visit, data was available for a test hole at the lagoon site drilled on February 24, 1982. It shows the soils as being mainly silts, unfrozen below 2 feet, with high organic content down to 12 feet, medium-soft to stiff. The recommended method of installation of waste-heat piping is overhead due to the high susceptibility of the soils to frost action. The supports could be four-legged wooden towers with a perimeter base and bracing below grade to carry the vertical loads and to act as an anchor against overturning forces. Frost heave movement of the towers could occur, and it should be minimized by provisions like sufficient depth of bury of the base, horizontal insulation and bond breakers for the legs. As an alternate, the support could be provided by individual steel pipes driven to a depth sufficient to resist frost jacking. Soils data should be gathered during the system’s final design. A cross section of the anticipated pipe support and arctic pipe configuration is shown in Figure 18. 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. if] KOTLIK 15050 15120 15250 15750 KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 BASIC MATERIALS AND METHODS Valves: Valves for isolation use shall be gate type rated for 150 psi. Gaskets and materials shall be compatible with glycol and with hydrocarbons on engine primary circuits. Isolation valves on engine primary circuits may be lug-style butterfly type. Piping: Piping inside buildings shall be type "L" copper or steel schedule 40 with dielectric unions at connection points of dissimilar metals. Steel pipe will be welded. ARCTIC PIPE Arctic Pipe: Pressure pipe shall be schedule 40 steel. Insulation shall be foamed polyurethane with .25-inch maximum voids. Thickness of insulation to be minimum of 2 inches. Jacketing shall be steel for aboveground installations. Arctic pipe system shall include kits or fittings for take-off connections to main line that provide watertight 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-gauge 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 Wal] 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. Cabinet Unit Heaters: Floor-mounted inverted-flow heaters shall have multispeed control, minimum 1/2-inch copper coil tubes mechanically expanded into aluminum fins. 7-4 KOTLIK 15900 16000 KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Cabinet 18-gauge with 16-gauge front panel, galvanized, and primed with top-front inlet and bottom-front outlet stamped steel integral grilles. Leveling legs shall be provided. 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 school. Since the fans run continuously for ventilation, 2-stage wall thermostats first open and control valve and, second, start the burner if necessary... In buildings unit-heater fans are cycled by wall thermostats. ELECTRICAL All electric equipment and installation shall comply with the National Electric Code specified. 7129 KOTLIK Major Equipment List Tipclaal Heating Elements Pumps Arctic Piping 739).2 Heating Elements Pumps Buried Piping KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Scenario 1 Capacity Location (Hot Side) MBH GPM High School Boiler 188 21 Washateria Boilers 148 Wi Generator Plant 408* 60 Service GPM HD Gen. Plant Secondary 38 20’ Size LE 2" 380 3" 600 Scenario 2 Capacity Location (Hot Side) MBH GPM Washateria Boilers 148 7, Community Ctr. Furnace 48 6 Clinic Furnace 27 3 Child Care Furnace 54 6 Generator Plant 408* 60 Service GPM HD Gen. Plant Secondary 32 20’ Size 1° 1-1/4" Q" 3" * Generator heat exchanger LF 240 880 580 20 TI 180 180 185 HP 0.33 TI 180 180 180 180 185 HP 0525 TO 160 160 170 QTY TO 160 160 160 160 170 QTY Item heat exchanger heat exchanger heat exchanger Item heat exchanger duct coil duct coil duct coil heat exchanger oversized to take full generator capacity. ba BALANCE/ISOLATION VALVE bd ISOLATION VALVE NC) NC=NORMALLY CLOSED (ALL OTHERS NORMALLY OPEN) 2—-WAY CONTROL VALVE 3—-WAY CONTROL VALVE AMOT 3-—WAY VALVE STRAINER CIRCULATING PUMP FLOW METER THERMOMETER ie) TEMPERATURE SWITCH FL AIR SEPERATOR WITH AUTO AIR VENT —<— FLOW ARROW > PIPE DOWN © PIPES UP <=) esa NEW RETURN LINE ———— NEW SUPPLY LINE Sadia EXISTING RETURN LINE —— EXISTING SUPPLY LINE ————— NEW EQUIPMENT SS EXISTING EQUIPMENT by xl CJ N CHECK VALVE = © —M)- PRIMARY (GENERATOR) PIPING (RED) SECONDARY (DISTRIBUTION) PIPING (BLUE) BUILDING PIPING (GREEN) o NON ELECTRIC VALVE NON ELECTRIC TEMPERATURE SENSOR bb Frank Moolin & Associates, Inc. ENGINEERING e DESIGN @ PROJECT MANAGEMENT ‘An Eboace Services Incorporated Engineering ond Construction Company SCALE: NONE gate: 2/13/91 JOB_NO. 495, LEGEND REVISION oO 495LEGNO.0WG 7-7 FIGURE 1 yyy | Frank Moolin & PIPE ROUTING Associates, Inc. SITE PLAN seisenciniesiessciagaaaanen euneaweer rare KOTLIK, AK 7-8 FIGURE 2 SEK Frank Moolin & POWER PLANT Associates, Inc. FLOOR PLAN ENGINEERING @ DESIGN @ PROJECT MANAGEMENT 7-9 FIGURE 3 TO WASTE HEAT USERS L__ FROM FUTURE STATION HEAT ii — GEN #1 GEN. #2 CAT CAT 3306 DI 3306 DI 3” (EXCEPT WHERE NOTED) zaedaa eee EXISTING VERTICAL CORE RAD. (TYP.) 4a Frank Moolin & POWER PLANT Associates, Inc. COOLING SCHEMATIC Pisaneriadcsieep baie 7 temic KOTLIK, AK 7-10 FIGURE 4 TO FUTURE STATION HEAT EXPANSION TANK AND GLYCOL MAKE—UP WASTE HEAT EXCHANGER AMOT VALVE ASSEMBLY owe. sy_WJH CHK. BY___ [Rewson: 0 | oO 495D1314.0WG DSN. BY___ POWER PLANT INTERNAL DUCTED HIGH SCHOOL Associates, Inc. SYSTEM SCHEMATIC owe, ey _WJHL pe era cee end eases on Caeser cea KOTLIK, AK Frank Moolin & SCENARIO #1 DSN. BY___ 495P1314.DWG 7-11 FIGURE 5 68° oe ro 1 , T z ss a a FLOOR ABOVE, SEE HIGH SCHOOL — SECOND FLOOR PLAN Ee SEP EEE IEE 1 Se COP 42° FIRST FLOOR SCALE: HIGH SCHOOL FIRST FLOOR PLAN KOTLIK, AK pare: 2/14/91 495 o 495314H1.DWG yy) Frank Moolin & Associates, Inc. ENGINEERING e DESIGN @ PROJECT MANAGEMENT ‘An Ebasco Services incorporated Engineering and Construction Compony JOB_NO.. REVISION: 7-12 FIGURE 6 PROPOSED SPACE FOR FUTURE EQUIPMENT 68° \ E] BOILER — DOMESTIC HOT ‘en a | WATER HEATER SECOND FLOOR B, Frank Moolin & HIGH SCHOOL ip iaiotl Associates, Inc. SECOND FLOOR PLAN . ey og wo: 495 ja thnss Ste ceded cles tad euch ay KOTLIK, AK ec eeasaielalars| 495314H2.0WG 7-13 FIGURE 7 TO / FROM ARCTIC PIPE a Ww g oO x Ww - a x HEATING supPLy $—<—— 44 Frank Moolin & HIGH SCHOOL ia Associates, Inc. SYSTEM SCHEMATIC ENGINEERING DESIGN PROJECT MANAGEMENT . sa thes Seve hempreted Digherng end Oretvtion Compery KOTLIK, AK . 8 49505314.DWG 7-14 FIGURE 8 PROPOSED SI FUTURE EQUI L] PACE FOR JPMENT [| 44 Frank Moolin & Associates, Inc. ENGINEERING e DESIGN e PROJECT MANAGEMENT an Goons Sardis WesrparetsdChgtemr and Conavston anos WASHATERIA FLOOR PLAN KOTLIK, AK 7-15 FIGURE 9 CHK (BY SCALE: NONE pate: 2/14/91 — 495 REVISION 0)! 495314WA.DWG TO / FROM ARCTIC PIPE a WwW oO Zz = oO x< WwW bE a <= HEATING supply ¢—~——— BOILER po | | | sus Secuencia BOILER Bb | E28! Moolin & WASHATERIA ess ae Associates, Inc. SYSTEM SCHEMATIC ows ENGINEERING @ DESIGN @ PROJECT MANAGEMENT aoe 0 sn Eoeoe Sartens hesrperated rghearhg end Conetucten Company KOTLIK, AK 7-16 FIGURE 10 POWER PLANT INTERNAL RADIATORS [community il | CENTER WASHATERIA | i i Frank Moolin & | SCENARIO #2 ven, ov___ FE NONE] Associates, Inc. | SYSTEM SCHEMATIC LE oe nos ENGINEERING DESIGN PROJECT MANAGEMENT ioe aes oe as Go eas ce KOTLIK, AK CHK. BY. somes} 4.0WG 7-17 FIGURE 11 EXISTING UPDRAFT FURNACE "he U COIL BELOW FURNACE (FURNACE RAISED) —~ SCALE NONE bb Frank Moolin & COMMUNITY CENTER ! ~V oare: 2/14/91 Associates, Inc. FLOOR PLAN 5. BY_CIP | og yo. 495 ENGINEERING e@ DESIGN @ PROJECT MANAGEMENT An EbaneoSardess Incorporated Enghearhg ond Consivcton Compony KOTLIK, AK REVISION Q 495314CH.OWG 7-18 FIGURE 12 SUPPLY AIR HOT AIR ninDA NEW COIL IN HOT AIR FURNACE RETURN AIR DUCT My TO / FROM ARCTIC PIPE BB Fi28k Mooiin & COMMUNITY CENTER Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT ‘An Ebesce Services Incerperated Engineering end Construction eee KOTLIK, AK 7-19 FIGURE 13 COIL BELOW FURNACE +EXISTING UPDRAFT (FURNACE aise) a . |scave: __NONE _ LD Frank Moolin & CLINIC phe By onre: 2/14/91 Associates, Inc. FLOOR PLAN ows, sy_CJP_ ines msseemede crete aed KOTLIK, AK om, ov oox 9 49531 4CL.0WG 7-20 FIGURE 14 SUPPLY AIR HOT AIR see BURNER NEW COIL IN HOT AIR FURNACE RETURN AIR DUCT 1 TO / FROM ARCTIC PIPE LA Frank Moolin & CLINIC Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT ‘An Eoesce Services Incerperated Engineering end Construction Company KOTLIK, AK ‘ 7-21 FIGURE 15 COIL IN RETURN AIR ODUCT ee |— EXISTING | FURNACE SCALE: NONE Frank Moolin & CHILD CARE care: _2/14/! Aa Associates, Inc. FLOOR PLAN ay_CJP | og = = ENGINEERING @ DESIGN @ PROJECT MANAGEMENT Pee ete eroey An Ebasco Services incorporated Engineering and Construction Company KOTLIK, AK CHK. BY_____ | REVISION. 0 495314CD.0WG 7-22 FIGURE 16 SUPPLY AIR HOT AIR A BURNER NEW COIL IN HOT AIR FURNACE RETURN AIR DUCT My TO / FROM ARCTIC PIPE BG FE Moolin & CHILD CARE Associates, Inc. SYSTEM SCHEMATIC ENGINEERING @ DESIGN @ PROJECT MANAGEMENT ‘An Bhosce Services Incorporated Engineering and Construction Company KOTLIK, AK 7-23 FIGURE 17 WASTE HEAT SUPPLY AND RETURN PIPES - ARTIC PIPING (SIZES VARY AS. SPECIFIED) AS SPECIFIED TREATED WOOD fee GRADE TO DRAIN J GRADE TO DRAIN | BRACING 1 BRACING | AS SPECIFIED AS SPECIFIED | : L FRONT VIEW SIDE VIEW ALTERNATE: DRIVEN STEEL PIPE TO PROVIDE 10° EMBEDMENT. SIZE AND SPACING AS SPECIFIED SCALE: NONE MM SS Meoln & ABOVE GROUND PIPING ee owe 24a | Owc. sy _WJH 495 ENGINEERING e@ DESIGN @ PROJECT MANAGEMENT TYPICAL SECTION = REVISION: ‘An Ebosco Services Incorporated Engineering ond Construction Company CHK: GY) ci 4950GPPG.DWG 7-24 FIGURE 18 KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 8.0 ECONOMIC DATA Economic Data in Appendix 2. KOTLIK 8-1 920 onl KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 FAILURE ANALYSIS Kotlik 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 inexperienced 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 would be damaged by soil heaving or settlement due to frost heaving and thermal subsidence caused by melting permafrost. Therefore the piping must be elevated above grade and set on piling as it crosses between buildings. The system is susceptible to mechanical damage from being hit by equipment and machinery that is moving around the buildings. Surface 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 percent glycol. Water without glycol must not be introduced 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. Pipe Rupture 9.1.1 Worst Case - Pipe fails from support subsidence, earthquake, corrosion, fatigue, material fault, or physical damage. Glycol/water mixture seeps unnoticed into or under the snow. Fluid loss continues until the pump loses suction. This problem could go unnoticed until: Ie A power plant operator notices the inlet and outlet temperatures on the primary side of the waste-heat recovery heat exchanger are nearly identical, or 2s A waste-heat user determines that his building is too cold or his buildings heating system is running and that the waste-heat recovery system is inoperative, or 952) KOTLIK Oe ).2; oles KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Sis Some operator or maintenance person notices the secondary temperature indicating devices are not registering proper temperatures or he notices the circulating pump(s) are running dry, or 4. Someone notices the actual glycol leak, or 5. A low pressure alarm is indicated. A further complication could arise if other controls failed concurrently. If the secondary system lost fluid and the control valve failed to bypass water to the generator radiators, the engines would trip off on high temperature producing a village blackout. A further problem could arise if the engine high temperature shutdowns failed and the engine ran until overtemperature failure. Repair Ruptured pipe sections must be located and either repaired, replaced or bypassed. Depending on weather and snow conditions, the location of a rupture may be difficult to find. For this type of repair, an arctic pipe supply should be maintained by the Energy Authority in Anchorage. As pipe supplies would have to be flown out of Anchorage, a delay could be as_ follows: locating the leak, mobilizing equipment, 1-2 days; locating pipe, ordering pipe, arranging payment and shipping 1 day; shipping 2 days; and installation of new pipe or bypass 2 days for a total 5-6 days’ downtime at best. If all equipment and repair piping were readily at hand a leaking pipe or connection could be located, isolated, and repaired in a minimum of 2-10 hours’ downtime. 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 piping supports must be properly installed and allowances made for settlement. Cleanup of Spilled Glycol Glycol cleanup from facilities may be relatively easy but glycol is a health hazard and care must be taken to ensure that no one ingests the glycol mix. Glycol that spills on the ground or subsurface must be cleaned up before it enters the ground water or surface runoff. The glycol must not contaminate wells, streams, lakes, or salt water. 9.3 9.4 9.5 9.6 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Vibration, Thermal, And Corrosion Damage To Piping 9.3.1 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. 9.3.2 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. 9.3.3 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, gen-sets 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 gen-sets. Downtime of gen-sets 2-3 hours. Building Heat Exchanger Failure Leaking or plugged secondary heat exchanger is identified, valved off, and bypassed. 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 9.6.1 Mechanical Damage - Heat exchangers can be made to leak if damaged by dropping or by impacting them with power equipment, cranes, pipes, et cetera. Proper care must be exercised to limit exposure to mechanical damage. 9.6.2 Chemical Damage - The water/glycol fluid must be monitored to prohibit developing a corrosive mixture. Also particular attention must be paid to piping gaskets and valve seat material to ensure that the materials are compatible with glycol. Dissimilar metals are to be avoided or insulated from each other. Water quality must be maintained to prevent scaling. 9-3 9.7 9.8 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 Pump Failures The. pumps are subject to thermally-induced casing stress, seal failure, overheating, 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 any of a variety of causes, the standby pump is activated and the failed pump valved off and repaired/replaced. System downtime 0-12 hours. Replacement pump replaced 2 hours 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 interrelationships of the components. In some cases it is possible for the waste-heat customers to overcool 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. 10.0 KOTLIK KOTLIK WASTE-HEAT RECOVERY REPORT AND CONCEPT DESIGN FEBRUARY 13, 1991 CONCLUSIONS AND RECOMMENDATIONS The final economics will be completed by the Alaska Energy Authority so a definitive conclusion is not made at this time concerning the feasibility of a waste heat installation at Kotlik. Some conclusions that can be made are that the project is technically feasible, that the people and agencies in the community seem quite enthusiastic about the project, and that if the economics prove acceptable, a waste heat system for the community can be recommended. To make this project more economically attractive on option would be to include this project with the construction of other waste heat systems in neighboring communities. This would help to reduce the mobilization charges. Shipping, travel and other supervision and management costs could also be combined and pro- rated for lower cost to each village. Economics are not the only yardstick by which this project should be measured. The political and social problems involved in our nations oil supply should motivate us to actively seek out ways like this to reduce our oil 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. 10 - 1 c - Ol KOTLIK WASTE HEAT RECOVERY - GRAPH 1 HEAT AVAILABLE VS. HEAT REQUIRED BY MONTH HEATING FUEL EQUIV. (GAL.) Jan. Feb. Mar. Apr. May Jun. -Jul. Aug. Sep. Oct. Nov. Dec. MONTH OF THE YEAR Wi AVAILABLE - AVAILABLE- ®HEATREQD- © HEAT REQD- SCENARIO #1 SCENARIO #2 SCENARIO #1 SCENARIO #2 €- Ol -—_ = _ r - 1400 1200 1000 HEATING g00 KOTLIK WASTE HEAT RECOVERY - GRAPH 2 HEATING FUEL DISPLACED BY MONTH FUEL EQUIV. pa ae a (GAL.) 600 = see 5D SRE See a Fein Sa t M00 Fw re tt te re ee te tee nt ee ee eee rh ee ee ee ree PX) 0 t t t t +t t t e t t 1 Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. MONTH OF THE YEAR Mi SCENARIO #1 SCENARIO #2 APPENDIX 1 KOTLIK CALCULATIONS KTLK_#1.XLS WASTE HEAT UTILIZATION SIMULATION WORK SHEET. BASIC PROJECT DATA: Location: Kotlik - Scenario #1 Date: July 26, 1990 Savings, year 0, fuel gallons: 10180} Savings, year 0, fuel cost: $11,707 Annual pumping elec. cost: 640 $/year. Annual O&M increase cost: Annual other O&M cost: 5000 $/year. Total Savings, year 0: Construction cost estimate: 526100 $ Simple pay back time, years: Fuel high heat value: 132000 Btu/gallon Average fuel cost: 1.15 $/gallon GENERATOR DATA: SYSTEM LOSS DATA: Heat rate at kw-load above: 0 3369 Btu/kwh Constant losses: Heat rate at kw-load above: 16 3185 Btu/kwh Plant piping: 2400 Btu/hr. Heat rate at kw-load above: 31 3027 Btu/kwh Subsurface piping: 0 Btu/hr. Heat rate at kw-load above: 47 2895 Btu/kwh Engine preheating: 0 Btu/hr. Heat rate at kw-load above: 62 2790 Btu/kwh Total constant: 2400 Btu/hr. Heat rate at kw-load above: 78 2711 Btu/kwh Heat rate at kw-load above: 93 2658 Btu/kwh Variable losses: Heat rate at kw-load above: 109 2632 Btu/kwh Surface piping: 105 Btu/hr.xF Heat rate at kw-load above: 124 2632 Btu/kwh Plant heating: 500 Btu/hr.xF Heat rate at kw-load above: 140 2632 Btu/kwh Radiator losses: 0 Btu/hr.xF Heat rate at kw-load above: 155 2632 Btu/kwh GENERATION DATA: WEATHER DATA: Kwh/month: HDD/Month: January 38,888 1855 February 37,458 1727 March 57,602 1692 April 42,785 1294 May 41,424 834 June 35,419 532 July 43,436 386 August 41,570 393 September 39,946 662 October 43,017 1164 November 45,282 1505 December 48,839 1875 515666 13919 BUILDING DATA: Fuel use, gal/mon. HIGH SCH WASH1* WASH2"* na na na Wa wa na nwa TOTAL January 773 197 417 1387 February 720 183 417 1320 March 705 180 417 1302 April 539 137 417 1094 May 348 89 417 853 June 222 56 417 695 July 161 41 417 619 August 164 42 417 622 September 276 70 417 763 October 485 124 417 1026 November 627 160 417 1204 December 781 199 417 1397 5800 1478 5004 Oo 0 0 0 0 0 ° 12282 Hig. Efficiency: 0.75 0.75 0.75 0.75 Page 1 ~ “A POWER PRODUCTION VARIATION: Assumed hourly variation: Hour: ODNMANRWD = MNONNNHaABBAeannnnanan BONA COMNMAMAERWONM=AO Days: HDD: Kwh: KTLK_#1.XLS January February March April May June July August Sept. October November December 0.038 0.038 0.038 0.038 0.043 0.043 0.043 0.043 0.043 0.043 0.038 0.038 0.036 0.036 0.036 0.036 0.038 0.038 0.038 0.038 0.038 0.038 0.036 0.036 0.034 0.034 0.034 0.034 0.035 0.035 0.035 0.035 0.035 0.035 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.033 0.033 0.033 0.033 0.034 0.034 0.034 0.034 0.034 0.034 0.033 0.033 0.034 0.034 0.034 0.034 0.036 0.036 0.036 0.036 0.036 0.036 0.034 0.034 0.038 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.036 0.036 0.038 0.038 0.042 0.042 0.042 0.042 0.038 0.038 0.038 0.038 0.038 0.038 0.042 0.042 0.042 0.042 0.042 0.042 0.043 0.043 0.043 0.043 0.043 0.043 0.042 0.042 0.047 0.047 0.047 0.047 0.045 0.045 0.045 0.045 0.045 0.045 0.047 0.047 0.048 0.048 0.048 0.048 0.041 0.041 0.041 0.041 0.041 0.041 0.048 0.048 0.047 0.047 0.047 0.047 0.046 0.046 0.046 0.046 0.046 0.046 0.047 0.047 0.045 0.045 0.045 0.045 0.048 0.048 0.048 0.048 0.048 0.048 0.045 0.045 0.047 0.047 0.047 0.047 0.050 0.050 0.050 0.050 0.050 0.050 0.047 0.047 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.049 0.049 0.049 0.049 0.043 0.043 0.043 0.043 0.043 0.043 0.049 0,049 0.046 0.046 0.046 0.046 0.045 0.045 0.045 0.045 0.045 0.045 0.046 0.046 0.043 0.043 0.043 0.043 0.048 0.048 0.048 0.048 0.048 0.048 0.043 0.043 0.040 0.040 0.040 0.040 0.043 0.043 0.043 0.043 0.043 0.043 0.040 0.040 0.040 0.040 0.040 0.040 0.039 0.039 0.039 0.039 0.039 0.039 0.040 0.040 0.041 0.041 0.041 0.041 0.039 0.039 0.039 0.039 0.039 0.039 0.041 0.041 0.040 0.040 0.040 0.040 0.039 0.039 0.039 0.039 0.039 0.039 0.040 0.040 0.040 0.040 0.040 0.040 0.041 0.041 0.041 0.041 0.041 0.041 0.040 0.040 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 31 28 31 30 31 30 31 31 30 31 30 31 1855 1727 1692 1294 834 532 386 393 662 1164 1505 1875 38888 37458 57602 42785 41424 35419 43436 41570 39946 43017 45282 48839 HEAT DEMAND VARIATION: Assumed hourly variation: Hour: Winter” Summer" 1 0.039 0.039 2 0.038 0.038 3 0.038 0.038 4 0.038 0.038 5 0.038 0.038 6 0.039 0.039 7 0.041 0.041 8 0.043 0.043 9 0.044 0.044 10 0.044 0.044 11 0.044 0.044 12 0.044 0.044 13 0.045 0.045 14 0.044 0.044 15 0.043 0.043 16 0.043 0.043 17 0.043 0.043 18 0.043 0.043 19 0.043 0.043 20 0.043 0.043 21 0.042 0.042 22 0.042 0.042 23 0.040 0.040 24 0.039 0.039 1.000 1.000 * Winter: Nov. - Apr. * Summer: May - Oct. Page 2 13919 515666 HEAT GENERATED PER HOUR BY MONTH, BTU'S I Hour: January y 1 138012 2 136691 3 129097 { 4 129097 5 125300 6 129097 7 138012 8 152539 9 152539 10 170699 11 174331 12 170699 13 163435 14 170699 15 174331 16 174331 17 177963 18 167067 19 156171 " 20 145276 21 145276 \ 22 148907 23° 145276 24 145276 Day: 3660118 3849883 5109499 4065225 3846647 3475346 4000882 3860205 3833046 3962288 4282297 4436352 February 147180 139434 137673 137673 133624 137673 147180 162673 162673 175419 179151 175419 174292 175419 179151 179151 182883 178165 166546 154926 154926 158799 154926 154926 March 196993 186625 176257 176257 177529 176257 196993 211567 211567 236754 241791 236754 226679 236754 241791 241791 246828 231716 216604 207361 207361 212545 207361 207361 April 156903 148645 140387 140387 136258 140387 156903 173420 173420 187008 190987 187008 179050 187008 190987 190987 194966 183029 177549 165162 165162 169291 165162 165162 May 166356 147012 135406 137516 137516 139274 139274 147012 166356 174093 158618 177962 178947 186403 178947 178947 166356 174093 178947 166356 150881 150881 150881 158618 KTLK_#1.XLS June July 146981 174436 135795 154152 125074 141982 121500 137926 121500 137926 128647 146039 128647 146039 135795 154152 146981 174436 153818 175911 140145 166322 157236 179820 164072 187638 170908 195456 164072 187638 164072 187638 146981 174436 153818 175911 164072 187638 146981 174436 139368 158209 139368 158209 139368 158209 140145 166322 August 166942 147530 135883 138001 138001 139765 139765 147530 166942 174707 159177 178589 179577 187060 179577 179577 166942 174707 179577 166942 151412 151412 151412 159177 Sept. 165767 146492 134927 137030 137030 138782 138782 146492 165767 173477 158057 177333 178314 185744 178314 178314 165767 173477 178314 165767 150347 150347 150347 158057 October November December 172753 166061 173327 152665 157321 164205 140613 148581 155082 136595 148581 155082 136595 144210 150521 144630 148581 155082 144630 166061 173327 152665 176866 184606 172753 176866 184606 174214 197922 206583 164718 202133 210978 178085 197922 206583 185828 189500 197792 193571 197922 206583 185828 202133 210978 185828 202133 210978 172753 206344 «9.215374 174214 193711 202188 185828 181078 189002 172753. 174801 =: 175815 156683 174801 175815 156683 179171 180211 156683 174801 175815 164718 174801 175815 Month: 1.13E+08 1.08E+08 1.58E+08 1.22E+08 1.19E+08 1.04E+08 1.24£+08 1.2E+08 1.15E+08 1.23E+08 1.28E+08 1.38E+08 1.47E+09 Equivalent Gallons: 1146 1089 1600 1232 1205 1053 1253 “ HEAT LOST FROM SYSTEM PER HOUR BY MONTH, BTU'S Hour: January February March April May June July 1 49627 50741 46446 39521 29701 24154 20958 2 49627 50741 46446 39521 29701 24154 20958 3 49627 50741 46446 39521 29701 24154 20958 4 49627 50741 46446 39521 29701 24154 20958 5 49627 50741 46446 39521 29701 24154 20958 i 6 49627 50741 46446 39521 29701 24154 20958 7 49627 50741 46446 39521 29701 24154 20958 8 49627 50741 46446 39521 29701 24154 20958 9 49627 50741 46446 39521 29701 24154 20958 10 49627 50741 46446 39521 29701 24154 20958 1 49627 50741 46446 39521 29701 24154 20958 12 49627 50741 46446 39521 29701 24154 20958 13 49627 50741 46446 39521 29701 24154 20958 14 49627 50741 46446 39521 29701 24154 20958 15 49627 50741 46446 39521 29701 24154 20958 16 49627 50741 46446 39521 29701 24154 20958 17 49627 50741 46446 39521 29701 24154 20958 18 49627 50741 46446 39521 29701 24154 20958 19 49627 50741 46446 39521 29701 24154 20958 20 49627 50741 46446 39521 29701 24154 20958 21 49627 50741 46446 39521 29701 24154 20958 22 49627 50741 46446 39521 29701 24154 20958 23 49627 50741 46446 39521 29701 24154 20958 24 49627 50741 46446 39521 29701 24154 20958 Day: 1191058 1217773 1114711 948496 712835 579688 502997 Month: 36922800 34097640 34556040 28454880 22097880 17390640 15592920 Equivalent Gallons: 373 344 349 287 223 176 158 Page 3 1209 August 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 21095 506276 15694560 159 1162 Sept. 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 26775 642608 1241 1298 1389 October November December 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 36142 867403 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 43776 1050620 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 50018 1200426 19278240 26889480 31518600 37213200 195 272 318 376 14875 3.2E+08 3229 KTLK_#1.XLS Hour: January February March April May June July August Sept. October November December 173628 182954 162958 141469 106795 89928 77470 77928 98721 128396 155741 174937 170084 179221 159632 138582 104616 88092 75889 76338 96706 125776 152563 171367 169199 178287 158801 137860 104071 87634 75494 75940 96202 125121 151768 170474 166098 175020 155891 135334 102164 86028 74110 74549 94440 122828 148987 167350 169199 178287 158801 137860 104071 87634 75494 75940 96202 125121 151768 170474 171856 181088 161295 140026 105705 89010 76679 77133 97713 127086 154152 173152 182043 191822 170857 148326 111971 94286 81225 81705 103506 134620 163290 183416 191788 202090 180002 156266 117965 99333 85573 86079 109046 141825 172031 193234 193117 203490 181249 157349 118782 100022 86165 86675 109802 142808 173223 194573 A HEAT DEMAND BY HOUR BY MONTH, BTU'S ONOAnRwWD = -_ o 10 194445 204890 182497 158431 119600 100710 86758 87271 110557 143791 174414 195912 11 194445 204890 182497 158431 119600 100710 86758 87271 110557 143791 174414 195912 | 12 195774 206291 183744 159514 120417 101398 87351 87868 111313 144773 175606 197250 13 197546 208157 185406 160957 121507 102316 88142 88663 112320 146084 177196 199035 14 193117 203490 181249 157349 118782 100022 86165 86675 109802 142808 173223 194573 \ 15 190459 200690 178755 155183 117148 98645 84980 85482 108291 140843 170839 191895 16 191788 202090 180002 156266 117965 99333 85573 86079 109046 141825 172031 193234 17 189130 199290 177508 154101 116330 97957 84387 84886 107535 139860 169647 190556 191788 202090 180002 156266 117965 99333 85573 86079 109046 141825 172031 193234 191788 202090 180002 156266 117965 99333 985573 86079 109046 141825 172031 193234 190459 200690 178755 155183 117148 98645 84980 85482 108291 140843 170839 191895 poo oon 21 186030 196023 174598 151574 114423 96351 83003 83494 105772 137567 166866 187433 22 184701 194622 173351 150492 113606 95663 82411 82898 105017 136585 165674 186094 23 177614 187155 166700 144717 109247 91992 79249 79717 100987 131344 159317 178953 24 173628 182954 162958 141469 106795 89928 77470 77928 98721 128396 155741 _174937 Day: 4429725 4667673 4157512 3609273 2724637 2294302 1976469 1988160 2518641 3275743 3973393 4463125 Month: 1.37E+08 1.31E+08 1.29E+08 1.08E+08 84463753 68829052 61270554 61632948 75559221 1.02E+08 1.19E+08 1.38E+08 1.22E+09 Equivalent Gallons: 1387 1320 1302 1094 853 695 619 623 763 1026 1204 1398 12283 HEAT DELIVERED BY HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 1 88384 96439 150547 117383 106795 89928 77470 77928 98721 128396 122285 123310 87064 88693 140179 109125 104616 88092 75889 76338 96706 116524 113545 114187 79470 86933 129811 100867 104071 87634 75494 75940 96202 104471 104805 105065 79470 86933 129811 100867 102164 86028 74110 74549 94440 100454 104805 105065 75673 82883 131082 96738 104071 87634 75494 75940 96202 100454 100435 100503 79470 86933 129811 100867 105705 89010 76679 77133 97713 108489 104805 105065 88384 96439 150547 117383 109573 94286 81225 81705 103506 108489 122285 123310 102912 111932 165121 133899 117310 99333 85573 86079 109046 116524 133091 134588 9 102912 111932 165121 133899 118782 100022 86165 86675 109802 136611 133091 134588 10 121071 124678 182497 147487 119600 100710 86758 87271 110557 138072 154146 156565 11. 124703 128411 182497 151466 119600 100710 86758 87271 110557 128576 158357 160961 12 121071 124678 183744 147487 120417 101398 87351 87868 111313 141943 154146 156565 13. 113808 123552 180233 139529 121507 102316 88142 88663 112320 146084 145724 147775 14 121071 124678 181249 147487 118782 100022 86165 86675 109802 142808 154146 156565 15 124703 128411 178755 151466 117148 98645 84980 85482 108291 140843 158357 160961 16 124703 128411 180002 151466 117965 99333 85573 86079 109046 141825 158357 160961 § 17 128335 «132143. 177508 ~=154101 = 116330 97957 84387 84886 107535 136611 162568 165356 ONOnNAWD 18 117439 127425 180002 143508 117965 99333 85573 86079 109046 138072 149935 152170 19 106544 115805 170158 138028 117965 99333 85573 86079 109046 141825 137302 138984 20 95648 104186 160915 125641 117148 98645 84980 85482 108291 136611 131025 125798 21 95648 104186 160915 125641 114423 96351 83003 83494 105772 120541 131025 125798 ‘ 22 99280 108059 166099 129770 113606 95663 82411 82898 105017 120541 135395 130193 ~ 23 95648 104186 160915 125641 109247 91992 79249 79717 100987 120541 131025 125798 24 95648 104186 160915 125641 106795 89928 77470 77928 98721 128396 131025 125798 2469060 2632110 3898433 3115385 2721584 2294302 1976469 1988160 2518641 3043701 3231677 3235926 Days: 31 28 31 30 31 30 31 31 30 31 30 31 76540858 73699085 1.21E+08 93461547 84369112 68829052 61270554 61632948 75559221 94354742 96950303 1E+08 1.01E+09 Equivalent Gallons: 773 744 1221 944 852 695 619 623 763 953 979 1013 10180 Page 4 -_ =a KTLK_#2.XLS WASTE HEAT UTILIZATION SIMULATION WORK SHEET. BASIC PROJECT DATA: Location: Kotlik - Scenario #2 Date: July 26, 1990 ‘Savings, year 0, fuel gallons: Savings, year 0, fuel cost: Annual pumping elec. cost: 530 $/year. Annual O&M increase cost: Annual other O&M cost: 5000 $/year. Total Savings, year 0: Construction cost estimate: 535100 $ Simple pay back time, years: Fuel high heat value: 132000 Btu/gallon Average fuel cost: 1.15 $/gallon GENERATOR DATA: SYSTEM LOSS DATA: Heat rate at kw-load above: ° 3369 Btu/kwh Constant losses: Heat rate at kw-load above: 16 3185 Btu/kwh Plant piping: 2400 Btu/hr. Heat rate at kw-load above: 31 3027 Btu/kwh Subsurface piping: 0 Btu/hr. Heat rate at kw-load above: 47 2895 Btu/kwh Engine preheating: 0 Btu/hr. Heat rate at kw-load above: 62 2790 Btu/kwh Total constant: 2400 Btu/hr. Heat rate at kw-load above: 78 2711 Btu/kwh Heat rate at kw-load above: 93 2658 Btu/kwh Variable losses: Heat rate at kw-load above: 109 2632 Btu/kwh Surface piping: 135 Btu/hr.xF Heat rate at kw-load above: 124 2632 Btu/kwh Plant heating: 500 Btu/hr.xF Heat rate at kw-load above: 140 2632 Btu/kwh Radiator losses: 0 Btu/hr.xF Heat rate at kw-load above: 155 2632 Btu/kwh GENERATION DATA: WEATHER DATA: Kwh/month: HDD/Month: January 38,888 1855 February 37,458 1727 March 57,602 1692 April 42,785 1294 May 41,424 834 June 35,419 532 July 43,436 386 August 41,570 393 September 39,946 662 October 43,017 1164 November 45,282 1505 December 48,839 1875 515666 13919 BUILDING DATA: Fuel use, gal/mon. | WASH1* WASH2**COMCTR- CLINIC CHILD na n/a wa na wa TOTAL January 197 417 18 110 219 961 February 183 417 18 102 204 925 March 180 417 18 100 200 915 April 137 417 18 77 153 802 May 89 417 18 49 99 672 June 56 417 18 32 63 586 July 41 417 18 23 46 544 August 42 417 18 23 46 546 September 70 417 18 39 78 623 October 124 417 18 69 138 765 November 160 417 18 89 178 862 December 199 417 18 111 222 967 1478 5004 216 825 1645 0 0 oO ° 0 9168 Hig. Efficiency: 0.75 0.75 0.75 0.75 0.75 0.75 Page 1 KTLK_#2.XLS POWER PRODUCTION VARIATION: Assumed hourly variation: Hour: January February March April May June July August Sept. October November December 1 0.038 0.038 0.038 0.038 0.043 0.043 0.043 0.043 0.043 0.043 0.038 0.038 2 0.036 0.036 0.036 0.036 0.038 0.038 0.038 0.038 0.038 0.038 0.036 0.036 \ 3 0.034 0.034 0.034 0.034 0.035 0.035 0.035 0.035 0.035 0.035 0.034 0.034 4 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 0.034 5 0.033 0.033 0.033 0.033 0.034 0.034 0.034 0.034 0.034 0.034 0.033 0.033 6 0.034 0.034 0.034 0.034 0.036 0.036 0.036 0.036 0.036 0.036 0.034 0.034 7 0.038 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.036 0.036 0.038 0.038 8 0.042 0.042 0.042 0.042 0.038 0.038 0.038 0.038 0.038 0.038 0.042 0.042 9 0.042 0.042 0.042 0.042 0.043 0.043 0.043 0.043 0.043 0.043 0.042 0.042 10 0.047 0.047 0.047 0.047 0.045 0.045 0.045 0.045 0.045 0.045 0.047 0.047 1 0.048 0.048 0.048 0.048 0.041 0.041 0.041 0.041 0.041 0.041 0.048 0.048 12 0.047 0.047 0.047 0.047 0.046 0.046 0.046 0.046 0.046 0.046 0.047 0.047 13 0.045 0.045 0.045 0.045 0.048 0.048 0.048 0.048 0.048 0.048 0.045 0.045 14 0.047 0.047 0.047 0.047 0.050 0.050 0.050 0.050 0.050 0.050 0.047 0.047 : 15 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 16 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0,048 0.048 0.048 0.048 0.048 17 0.049 0.049 0.049 0.049 0.043 0.043 0.043 0.043 0.043 0.043 0.049 0.049 18 0.046 0.046 0.046 0.046 0.045 0.045 0.045 0.045 0.045 0.045 0.046 0.046 19 0.043 0.043 0.043 0.043 0.048 0.048 0.048 0.048 0.048 0.048 0.043 0.043 20 0.040 0.040 0.040 0.040 0.043 0.043 0.043 0.043 0.043 0.043 0.040 0.040 21 0.040 0.040 0.040 0.040 0.039 0.039 0.039 0.039 0.039 0.039 0.040 0.040 22 0.041 0.041 0.041 0.041 0.039 0.039 0.039 0.039 0.039 0.039 0.041 0.041 23 0.040 0.040 0.040 0.040 0.039 0.039 0.039 0.039 0.039 0.039 0.040 0.040 24 0.040 0.040 0.040 0.040 0.041 0.041 0.041 0.041 0.041 0.041 0.040 0.040 1.000 1.000 1.000 1.000 1,000 1.000 1.000 1.000 1.000 1.000 1,000 1.000 Days: 31 28 31 30 31 30 31 31 30 31 30 31 HDD: 1855 1727 1692 1294 834 532 386 393 662 1164 1505 1875 13919 Kwh: 38888 37458 57602 42785 41424 35419 43436 41570 39946 43017 45282 48839 515666 J HEAT DEMAND VARIATION: Assumed hourly variation: Hour: Winter” Summer” 1 0.039 ~—0.039 2 0.038 += 0.038 3 0.038 + 0.038 : 4 0.038 —0.038 5 0.038 + 0.038 6 0.039 0.039 7 0.041 0.041 8 0.043 0.043 9 0.044 0,044 10 0.044 0,044 110.044 (0.044 12 0.044 0.044 13 0.045 0.045 140.044 0.044 a 15 0.043 0,043 16 0.043 0.043 17 0.043 (0.043 18 0.043 0,043 , 19 0.043 0,043 20 0.043 ~0.043 21 0.042 ~—0.042 22 0.042 ~—0.042 23 0.040 ~=—0.040 24 0.039 0.039 1.000 1.000 * Winter: Nov. - Apr. * Summer: May - Oct. Page 2 KTLK_#2.XLS HEAT GENERATED PER HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 1 138012 147180 196993 156903 166356 146981 174436 166942 165767 172753 166061 173327 2 136691 139434 186625 148645 147012 135795 154152 147530 146492 152665 157321 164205 3 129097 137673 176257 140387 135406 125074 141982 135883 134927 140613 148581 155082 4 129097 137673 176257 140387 137516 121500 137926 138001 137030 136595 148581 155082 5 125300 133624 177529 136258 137516 121500 137926 138001 137030 136595 144210 150521 6 129097 137673 176257 140387 139274 128647 146039 139765 138782 144630 148581 155082 7 138012 147180 196993 156903 139274 128647 146039 139765 138782 144630 166061 173327 8 152539 162673 211567 173420 147012 135795 154152 147530 146492 152665 176866 184606 9 152539 162673 211567 173420 166356 146981 174436 166942 165767 172753 176866 184606 10 170699 175419 236754 187008 174093 153818 175911 174707 173477 174214 197922 206583 11 174331 179151 241791 190987 158618 140145 166322 159177 158057 164718 202133 210978 12 170699 175419 236754 187008 177962 157236 179820 178589 177333 178085 197922 206583 13 163435 174292 226679 179050 178947 164072 187638 179577 178314 185828 189500 197792 14 170699 175419 236754 187008 186403 170908 195456 187060 185744 193571 197922 206583 15 174331 179151 241791 190987 178947 164072 187638 179577 178314 185828 202133 210978 16 174331 179151 241791 190987 178947 164072 187638 179577 178314 185828 202133 210978 17 177963 182883 246828 194966 166356 146981 174436 166942 165767 172753 206344 215374 18 167067 178165 231716 183029 174093 153818 175911 174707 173477 174214 193711 202188 19 156171 166546 216604 177549 178947 164072 187638 179577 178314 185828 181078 189002 20 145276 154926 207361 165162 166356 146981 174436 166942 165767 172753 174801 175815 21 145276 154926 207361 165162 150881 139368 158209 151412 150347 156683 174801 175815 22 148907 158799 212545 169291 150881 139368 158209 151412 150347 156683 179171 180211 23 «145276 4154926 207361 165162 150881 139368 158209 151412 150347 156683 174801 175815 24 145276 154926 207361 165162 158618 140145 166322 159177 _158057__ 164718 ~—174801__—*175815 Day: 3660118 3849883 5109499 4065225 3846647 3475346 4000882 3860205 3833046 3962288 4282297 4436352 Month: 1.13E+08 1.08E+08 1.58E+08 1.22E+08 1.19E+08 1.04E+08 1.24£+08 1.2E+08 1.15E+08 1.23E+08 1.28E+08 1.38E+08 1.47E+09 Equivalent Gallons: 1146 1089 1600 1232 1205 1053 1253 1209 1162 1241 1298 1389 14875 HEAT LOST FROM SYSTEM PER HOUR BY MONTH, BTU'S Hour: January February March April May June July August Sept. October November December 1 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 2 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 3 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 4 54573 55741 51234 43965 33659 27836 24482 24625 30587 = 40418 48431 54982 5 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 6 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 7 ~~ =54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 8 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 9 54573 55741 51234 43965 33659 27836 24482 24625 30587 = 40418 48431 54982 10 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 1 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 12 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 13 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 14 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 15 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 16 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 17 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 18 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 19 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 20 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 21 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 22 54573 55741 51234 43965 33659 27836 24482 24625 30587 = 40418 48431 54982 23 54573 55741 51234 43965 33659 27836 24482 24625 30587 = 40418 48431 54982 24 54573 55741 51234 43965 33659 27836 24482 24625 30587 40418 48431 54982 Day: 1309742 1337781 1229609 1055152 807805 668056 587563 591004 734096 970037 1162340 1319574 Month: 40602000 37457880 38117880 31654560 25041960 20041680 18214440 18321120 22022880 30071160 34870200 40906800 3.57E+08 Equivalent Gallons: 410 378 385 320 253 202 184 185 222 304 352 413 3609 Page 3 HEAT DEMAND BY HOUR BY MONTH, BTU'S Hour: OODNONRWNH = B&YXVssstceraoxnzce On = O©OBNOnNRWOND=0 24 January 120331 117875 117261 115112 117261 119103 126163 132916 133837 134758 134758 135679 136907 133837 131995 132916 131074 132916 132916 131995 128926 128005 123093 120331 February 128191 125574 124920 122631 124920 126883 134404 141598 142579 143560 143560 144541 145849 142579 140617 141598 139636 141598 141598 140617 137347 136366 131134 128191 March 114542 112205 111620 109575 111620 113373 120094 126522 127399 128275 128275 129152 130321 127399 125646 126522 124769 126522 126522 125646 122724 121847 117172 114542 April 103755 101638 101109 99256 101109 102697 108784 114607 115401 116196 116196 116990 118048 115401 113813 114607 113019 114607 114607 113813 111167 110372 106138 103755 May 84073 82357 81928 80427 81928 83215 88148 92866 93510 94153 94153 94797 95655 93510 92223 92866 91580 92866 92866 92223 90078 89435 86003 84073 KTLK_#2.XLS June 75794 74247 73860 72507 73860 75020 79467 83721 84301 84881 84881 85461 86234 84301 83141 83721 82561 83721 83721 83141 81207 80627 77534 75794 Day: 3069963 3270495 2922285 2647087 2144937 1933702 Month: 95168865 91573855 90590845 79412610 66493043 58011067 53910508 54107111 61662249 75761428 85338760 95730585 9.08E+08 Equivalent Gallons: 961 925 915 802 HEAT DELIVERED BY HOUR BY MONTH, BTU'S Hour: ONOnNkWON = 9 10 1 12 13 14 15 16 17 18 19 20 21 22 23 24 Days: January 83439 82118 74525 74525 70728 74525 83439 97967 97967 116126 119758 116126 108862 116126 119758 119758 123390 112494 101599 90703 90703 94335 90703 90703 February 91439 83693 81932 81932 77883 81932 91439 106932 106932 119678 123410 119678 118551 119678 123410 123410 127143 122424 110805 99185 99185 103059 99185 99185 March 114542 112205 111620 109575 111620 113373 120094 126522 127399 128275 128275 129152 130321 127399 125646 126522 124769 126522 126522 125646 122724 121847 117172 114542 April 103755 101638 96423 96423 92294 96423 108784 114607 115401 116196 116196 116990 118048 115401 113813 114607 113019 114607 114607 113813 111167 110372 106138 103755 672 May 84073 82357 81928 80427 81928 83215 88148 92866 93510 94153 94153 94797 93510 92223 92866 91580 92866 92866 92223 90078 84073 2350376 2512102 2922285 2624479 2144937 31 28 31 30 31 586 June 75794 74247 73860 72507 75020 79467 83721 84301 84881 84881 85461 86234 84301 83141 83721 82561 83721 83721 83141 81207 80627 77534 75794 July 68164 66773 66425 65208 66425 67468 71468 75293 75815 76337 76337 76858 77554 75815 74772 75293 74250 75293 75293 74772 73033 72511 69729 68164 1739049 545 July 68164 66773 66425 65208 66425 67468 71468 75293 75815 76337 76337 76858 77554 75815 74772 75293 74250 75293 75293 74772 73033 72511 69729 68164 August 68412 67016 66667 65446 66667 67714 71728 75568 76091 76615 76615 77139 77837 76091 75044 75568 74521 75568 75568 75044 73299 72776 69983 68412 1745391 547 August 68412 67016 66667 65446 66667 67714 71728 75568 76091 76615 76615 77139 77837 76091 75044 75568 74521 75568 75568 75044 73299 72776 69983 68412 1933702 1739049 1745391 30 31 31 Sept. 78920 78509 77070 78509 79742 84469 88990 89607 90223 90223 91662 89607 88374 88990 87757 88990 88990 88374 86319 85702 82414 80564 October November December 95792 111498 121041 93837 109223 118571 93348 108654 117953 91638 106663 115792 93348 108654 117953 94814 110360 119806 100435 116902 126908 105811 123160 133701 106544 124013 134627 107277 124867 135553 107277. 124867 = 135553 108010 125720 136480 108988 126858 137715 106544 124013 134627 105078 122307 132774 105811 123160 133701 104345 121453 131848 105811 123160 133701 105811 123160 133701 105078 122307 132774 102634 119462 129687 101901 118609 128760 97991 114058 123820 95792 111498 121041 2055408 2443917 2844625 3088083 623 Sept. 80564 78920 78509 77070 78509 79742 84469 88990 89607 90223 90223 90840 91662 89607 88374 88990 87757 88990: 88990 88374 86319 85702 82414 80564 765 862 967 October November December 95792 111498 118345 93837 108890 109223 93348 100150 100100 91638 100150 100100 93348 95780 95539 94814 100150 100100 100435 116902 118345 105811 123160 129624 106544 124013 129624 107277 124867 135553 107277 124867 135553 108010 125720 136480 108988 126858 137715 106544 124013 134627 105078 122307 132774 105811 123160 133701 104345 121453 131848 105811 123160 133701 105811 123160 133701 105078 122307 120833 102634 119462 120833 101901 118609 125228 97991 114058 120833 95792 111498 _ 120833 2055408 2443917 2806190 2955213 30 31 30 31 9169 72861658 70338845 90590845 78734360 66493043 58011067 53910508 54107111 61662249 75761428 84185705 91611607 8.58E+08 Equivalent Gallons: 736 710 915 795 672 586 545 Page 4 547 623 765 850 925 8669 APPENDIX 2 COST ESTIMATES KOTLIK Kotlik waste heat report 2/20/91 Simple Payback Ignores O&M costs Scenario #1 Scenario #2 Prodject cost $ 526,100 $ 535,100 Fuels cost Savings $ 11,700 $ 10,000 Years for payback 45.0 53.5 Fuel cost savings based on $1.15 per gallon Price of fuel required for 10 year payback Prodject cost $ 526,100 $ 535,100 Gallons fuel saved 10,200 8,700 Cost of fuel per gallon for 10 year payback $5.16 $6.15 HMS 9119 CONSTRUCTION COST ESTIMATE WASTE HEAT RECOVERY SYSTEM KOTLIK, ALASKA COST CONSULTANT GINE 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 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from a February 14, 1991 report, including a concept design dated February 13, 1991, 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 Washeteria SCENARIO #2 - Washeteria, Community Center, Clinic and Child Care WASTE HEAT RECOVERY SYSTEM PAGE 2 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SUMMARY SCENARIO #1 SCENARIO #2 CONSTRUCTION COST ESTIMATE 01 - General Conditions, Overhead and Profit 140,845 148,805 02 - Sitework 103,471 98,677 06 - Wood and Plastics 11,004 5,000 13 - Special Construction 4,670 4,450 15 - Mechanical 51,138 59,312 16 - Electrical 6,642 6,938 SUBTOTAL 317,770 323,182 Estimate contingency for elements of project not determined at this early level of design 10.00% saga 32,318 Escalation at .50% per month to Spring 1992 7.50% 26,216 26,663 TOTAL CONSTRUCTION COST: 375,763 382,163 PROJECT COST Design 10.00% 37,576 38,216 SIA (Supervision, Inspection and Administration) 20.00% 73,153 76,433 Project Contingency 10.00% 37,576 38,216 TOTAL PROJECT COST: 526,068 535,028 PAGE 3 WASTE HEAT RECOVERY SYSTEM KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 WASTE HEAT RECOVERY SYSTEM i" KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 ENERAL CONDITIONS QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization al LOT 8,500.00 8,500 Freight 48,000 LBS 0.50 24,000 Supervision, equipment, utilities, clean site, tools and protection 10 WKS 3,500.00 35,000 Per diem 270 DAYS 110.00 29,700 Travel costs, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 105,600 Bond and insurance 2.25 % 6,357 Profit 10.00 % 28,888 TOTAL ESTIMATED COST: 140,845 WASTE HEAT RECOVERY SYSTEM PAGE 5 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 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 490 LF 12.50 6,125 3" diameter Schedule 40 pipe with insulation and arctic pipe jacket 600 LF 55.15 33,090 2" ditto 380 LF 41.50 15,770 3" tee 4 EA 231.00 924 3" bend 6 EA 215.25 1,292 WASTE HEAT RECOVERY SYSTEM cron a KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities (Continued) 2" bend 10 EA 167.00 1,670 TOTAL ESTIMATED COST: 103,471 WASTE HEAT RECOVERY SYSTEM PRSE ? KOTLIK, 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 i EA 325.00 325 Handrail and balustrade 30 LF 42.50 1,275 TOTAL ESTIMATED COST: 11,004 WASTE HEAT RECOVERY SYSTEM PAGE & KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 13 - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8’0"x8’0" building module with floor, exterior wall structure and roofing complete 1 EA 2,800.00 2,800 Hole through exterior wall for heating pipes 6 EA 110.00 660 Exterior door 1 EA 710.00 710 Louver 1. EA 500.00 500 TOTAL ESTIMATED COST: 4,670 WASTE HEAT RECOVERY SYSTEM PAGE 5 KOTLIK, 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 4 EA 72.50 290 Ditto to radiator 2 EA 72650 145 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 140 LF 26.22 3,671 Fittings 40 EA 46.35 1,854 Gate valve 27 EA 325.00 8,775 Balance valves 1 EA 325.00 325 Check valve 5 EA 325.00 1,625 Amot three-way valve 2 EA 405.00 810 Insulation to pipe, 3" diameter 140 LF 7.10 994 Booster pumps, 38 GPM, 20’0" head, 1/3 HP 2 EA 1,310.00 2,620 Heat exchanger, 408 MBH, 60 GPM 1 EA 5,050.00 5,050 WASTE HEAT RECOVERY SYSTEM PAGE 10 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Air separator with vent a) EA 495.00 495 Gauges a EA 68.50 274 Expansion tank L EA 770.00 770 Glycol tank, pumps and make-up system 1 EA 1,025.00 1,025 Glycol 350 GALS 8.80 3,080 Hook-Up . Form hole through existing wall for heating pipes 4 EA 195.00 780 2" diameter black steel piping including fittings 120 LF 17.97 2,156 2" gate valves 2 EA 260.00 520 2" insulation 120 LF 4.70 564 Heat exchanger, 188 MBH, 21 GPM a EA 3,550.00 3,550 Ditto, 148 MBH, 17 GPM 1 EA 3,375.00 3,375 WASTE HEAT RECOVERY SYSTEM PAGE 11 KOTLIK, ALASKA , CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up __ (Continued) Test and balance system 40 HRS 75.00 3,000 Controls and Instrumentation Generator building and new module 1 LOT 2,000.00 2,000 Hook-up inter ties 2 Lots 1,500.00 3,000 TOTAL ESTIMATED COST: 51,138 WASTE HEAT RECOVERY SYSTEM PAGE 12 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 2 EA 175.00 350 Connection to motor 4 EA 115.00 460 Disconnect switch 4 EA 330.00 320 3/4" EMT conduit 100 LF 3.20 320 #8 copper 400 LF 0.85 340 New Module Main feeder and conduit 40 LF 8.80 352 Breaker in existing distribution panel 1 EA 277.00 277 Panel 1 EA 800.00 800 Exterior light fixture 2 EA 330.00 660 Light fixtures 6 EA 190.00 1,140 Switch 1 EA 55.00 55 Duplex outlets 4 EA 68.00 ara WASTE HEAT RECOVERY SYSTEM PAGE 13 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST e lo Cont ed 1/2" conduit 60 LF 3.00 180 #12 copper 210 LF 0.55 116 TOTAL ESTIMATED COST: 6,642 PAGE 14 WASTE HEAT RECOVERY SYSTEM KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 WASTE HEAT RECOVERY SYSTEM PAGE 15 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,500.00 8,500 Freight 57,000 LBS 0.50 28,500 Supervision, equipment, utilities, clean site, tools and protection 10 WKS 3,500.00 35,000 Per diem 296 DAYS 110.00 32,560 Travel costs, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 112,960 Bond and insurance 2.125 % 6,465 Profit 10.00 % 29,380 TOTAL ESTIMATED COST: 148,805 WASTE HEAT RECOVERY SYSTEM PAGE 16 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 QUANTITY UNIT UNIT RATE ESTIMATED COST Piles Mobilize 1 LOT 10,000.00 10,000 Wood piles 6 EA 650.00 3,900 Drill pile hole 120 LF 25.00 3,000 Slurry 5 cy 280.00 1,400 Freeze back 6 EA 220.00 1,320 Test and demobilize 1 LOT 3,000.00 3,000 Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 860 LF 12.50 10,750 3" diameter Schedule 40 pipe with insulation and arctic pipe jacket 20 LF 55.15 Los 2" ditto 580 LF 41.50 24,070 1 1/4" ditto 880 LF 31.90 28,072 at ditto 240 LF 28.70 6,888 WASTE HEAT RECOVERY SYSTEM PAGE 17 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 \ ORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities (Continued) 3" tee 2 EA 231.00 462 2" tee 2 EA 176.24 352 11/4" tee 2 EA 138.50 277 3" bend 4 EA 215.25 861 2" ditto 6 EA 167.00 1,002 1 1/4" ditto 12 EA 132.50 1,590 1" bend 6 EA 105.00 630 TOTAL ESTIMATED COST: 98,677 WASTE HEAT RECOVERY SYSTEM _— ae KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 06 — WOODS AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Glulam beams to support new module 60 LF 40.00 2,400 Miscellaneous metals 800 LBS 1.75 1,400 Access steps, including handrail and base 1 Lor 1,200.00 1,200 TOTAL ESTIMATED COST: 5,000 WASTE HEAT RECOVERY SYSTEM ay ae KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 13 - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8’0"x8’0" building module with floor, exterior wall structure and roofing complete 1 EA 2,800.00 2,800 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 TOTAL ESTIMATED COST: 4,450 WASTE HEAT RECOVERY SYSTEM PAGE 20 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger d_ Connections Connection to existing piping to cooling system of generators 6 EA 72.50 435 Ditto radiators 2 EA 72.50 145 Form hole through existing wall for heating pipes 4 EA 195.00 780 3" diameter black steel welded piping 100 LF 26.22 2,622 1 1/4" ditto 120 LF 17.97 2,156 30 a 27 EA 325.00 8,775 3" balance valves 1 EA 325.00 325 3" check valves 5 EA 325.00 1,625 Amot three-way valve ZL EA 405.00 405 1 1/2" diameter black steel welded piping including fittings 30 LF 13.40 402 Gate valve 3 EA 134.95 405 Balance valve 2 EA 89.00 178 WASTE HEAT RECOVERY SYSTEM FANE 21. KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST changer da Connections Continued 3" fitting 40 EA 46.35 1,854 Insulation to pipe, 3" diameter 100 LF 7.10 710 Ditto, 1 1/4" diameter 120 LF 4.70 564 Booster pumps, 32 GPM, 20’0" head, 1/4 HP 2 EA 1,310.00 2,620 Heat exchanger, 408 MBH, 60 GPM 1 EA 5,050.00 5,050 Air separator with vent 1 EA 495.00 495 Gauges 4 EA 68.50 274 Expansion tank 1 EA 770.00 770 Glycol tank, pumps and make-up system 1 EA 1,025.00 2,025 Glycol 425 GALS 8.80 3,740 Hook-Up Form hole through existing wall for heating pipes 4 EA 195.00 780 WASTE HEAT RECOVERY SYSTEM PAGE 22 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up __ (Continued) 2" diameter black steel piping including fittings 60 LF 17.97 1,078 11/48 ditto 140 LF 12.05 1,687 1" ditto 40 LF 10.85 434 2" gate valves 1 EA 260.00 260 2" insulation 60 LF 5.83 350 1 1/4" insulation 140 LF 4.70 658 1" insulation 40 LF 4.50 180 Heat exchanger, 148 MBH, 17 GPM a EA 3,375.00 By 35 Duct coils 3 EA 885.00 2,655 Test and balance system 60 HRS 75.00 4,500 Controls and Instrumentation Generator building and new module 1 LOT 2,000.00 2,000 WASTE HEAT RECOVERY SYSTEM PAGE 23 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 15 - MECHANTCAL QUANTITY UNIT UNIT RATE ESTIMATED COST Controls a strumentatio Co: Hook-up inter ties 4 Lots 1,500.00 6,000 TOTAL ESTIMATED COST: 59,312 WASTE HEAT RECOVERY SYSTEM wane KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 5 EA 175.00 875 Connection to motor 6 EA 115.00 690 Disconnect switch 3 EA 330.00 990 3/4" EMT conduit 140 LF 3.20 448 #8 copper 560 LF 0.85 - 476 New Module Main feeder and conduit 40 LF 8.80 352 Breaker in existing distribution panel 1 EA 277.00 277 Panel a EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light fixtures 6 EA 190.00 1,140 Switch . 1 EA 55.00 55 Duplex outlets 4 EA 68.00 a2 WASTE HEAT RECOVERY SYSTEM PAGE 25 KOTLIK, ALASKA CONSTRUCTION COST STUDY 2/20/91 SCENARIO #2 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Ne’ lodul. Continue 1/2" conduit 50 LF 3.00 150 #12 copper 150 LF 0.55 83 TOTAL ESTIMATED COST: 6,938 APPENDIX 3 RAW DATA KOTLIK ~ a HEATING DEGREE DAY WEATHER DATA | H_D_DAY.XLS 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 _HOD 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] 1097] MAR 1098 1034 MAR 1001 | 1024 APR 768| 663 APR 952| 917 APR 809 708 MAY 639) 491 MAY 782| 751 MAY 637| 584 JUN 412 283) JUN 578| 564| JUN 434 |___ 403 JUL 391 338 159) JUL 448] 427| 432 JUL 356| 315] 202 [AUG 375| 338} 210) AUG 416 423) 353 AUG 360) 324) 236 ISEP 520) 497| 370| SEP 517| ‘537 447| SEP 503} 481) 400 OCT 751 641 713) OCT 779 755| 695| OCT 737 665| 717 NOV 940) 855 NOV 907| 970 975| NOV 927 873| 990 DEC 1034] 1040 DEC 1075 1050/1054 DEC 1115) 950/868 TOTAL 8855 TOTAL 9733] 9374) TOTAL | _-9003 8404 | 4 | ANVIK, RUSSIAN MISSION, & LOWER KALSKAG | Holy Cross ----------------> Aniak --------------------- > St. Marys ------------------ > JAN 2018] JAN 1958| 2508! JAN 1739 | FEB 1740} FEB 1617 1163 FEB 1627| l MAR 1683 MAR 1605| MAR 1541] | IAPR 1157| APR 1163 APR 1185) | MAY 656 MAY 715| 764 MAY 697 | JUN 325| JUN 380 338 JUN 422 | JUL 243 JUL 310] 112 JUL 299 143} |AUG 350] AUG 395| 425| AUG 357| 317 ieee 583| SEP 619) 697| 511 SEP 601 554 OCT 1123 OCT 1121] 1247 OCT 1072] 1180 NOV 1552! NOV 1488] 1823 NOV 1436] 1671] DEC 2033} DEC 1986 DEC | 1810| 1756) TOTAL 13463| TOTAL 13357| TOTAL | _‘12786| Note: for analysis, use Holy Cross Data ! I | KOTLIK WHITE MOUNTAIN | Unalakleet -------—------- > Nome ---------------- > | | JAN 1855 JAN 1809] | FEB 1727| FEB 1701 | MAR 1692 MAR 1767| APR 1294 APR 1424 MAY 834] MAY 898 | | ‘ JUN 532 JUN 565 | | ff JUL 386 JUL 430 | | AUG 393} AUG 463 Pp SEP 662| SEP 676 | { T lOcT 1164) OcT 1140 I | NOV 1505} NOV 1447 | | DEC 1875 DEC 1818] | I 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 communi Page 1 to Kotlik. Nome is the closest listed coastal community to White Mountain. | Engine Heat balance charts for modern diesel engines indicate one-third of fuel required for engine operation results in heat absorbed by the jacket water. This heat must be totally removed to assure dependable engine performance. 40. % 30 4emmavst FUEL ENERGY % LOAD TYPICAL HEAT BALANCE DIESEL ENGINE (PRECOMBUSTION CHAMBER — TURBO-CHARGED AFTERCOOLER) Figure 101 The amount of heat removed is regulated by engine thermostats. They permit efficient engine operation by disconnecting the exter- nal cooling system until jacket water temper- atures exceed 175°F (79°C). Never operate without thermostats when utilizing the nor- mal 175°F (79°C) cooling system. EXCERPT FRom “CATERPILLAR APPLICATION AND INSTALLATION “ MANUAL (AUG. gs) - PC. CL. DEMOWSTRATES “THAT RETWEEN G07, £ 1007, LoAD , PERCE T OF EWERLY To JACKET WATER 1S ESSENTIALLY CONSTANT | PERCENTAGES OBTAINED FRon PRIME LonD DATA SHouLd BE APPLICABLE IN “THIS RANCE . GENSETS.XLS GENSET DATA 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 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) -----> 0} Oilcooler: 6085) btu/min _| (included in jacket water) -----> 0} Total: 121474] btu/min WATER % LOAD | KW GPH_ |KWH/GAL| BTU/HR_|BTU/KWH|_BTU/GAL 100 683 52.6 13.0 1624200 2378) 30905 75) 512 50) 342 |HOONAH CATAPILER D398 @ 600 KW PRIME (W/O FAN) INPUT: 48.2] gph * 19590] btu/b hhv * 7.076} |b/gal / 60] min/hr = 111357] btu/min OUTPUT: | Work: 636/kw engine * 3412) btu/kwh / 60| min/hr = 36167 33%| Exhaust: 37400 34% Radiation: 5300) 5% Water: 32200! 29%! Total: 111067] btu/min WATER % LOAD | KW GPH_ |KWH/GAL| BTU/HR_ |BTU/KWH| BTU/GAL 113} 675) 56.1 12.0) 2190000} 3244 39037, 100) 600) 48.2) 12.4) 1932000) 3220 40083) 75| 450) 36.1 12.5) 50) 300 25.3} 11.9) L. KALSKAG | CATAPILER 3406 TA @ 210 KW PRIME (W/O FAN) - NOTE 3 INPUT: 16.5|}gph * 19590} btu/Ib hhv * 7.076| Ib/gal / 60} min/hr = 38120) btu/min OUTPUT: | Work: 224/kw engine * 3412) btu/kwh / 60} min/hr = 12738 33%| Exhaust: 13700) 36%| Radiation: 1900) 5% Water: 10000! 26%| Total: 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| Page 1 ~ GENSETS.XLS L. KALSKAG |CATAPILER D342 T @ 160 KW PRIME (W/O FAN) - NOTE 4 INPUT: 12.5] gph * 19590 btu/Ib hhv * 7.076| Ib/gal / 60| min/hr = 28879] btu/min OUTPUT: |Work: 235|bhp engine * 2545] btu/bhp-hr / 60} min/hr = 9969) 34% Exhaust: 1340| CFM @ 710}F - > 8157, 28%| Radiation: 2100 7% Water: 9400 32% Total: 29626) btu/min WATER % LOAD | KW GPH_ |KWH/GAL| BTU/HR_ |BTU/KWH|_ BTU/GAL 143} 229) 100) 160} 12.5 12.8 564000} 3525) 45120 75| 120) 9.8 12.2! ) 80} 7.0) 11.4 KOTLIK CATAPILER 3306 TA @ 155 KW PRIME (W/O FAN) - NOTE 5 INPUT: 12.3} gph * 19590} btu/Ib hhv * 7.076} Ib/gal / 60] mirvhr = 28417) btu/min OUTPUT: | Work: 167|kw engine * 3412|btu/kwh / 60|min/nr = 9497, 52% | Exhaust: 10500| 57% | Radiation: 1700 9% Water: 6800| 37%) Total: 28497|btu/min WATER % LOAD | KW GPH_|KWH/GAL| _BTU/HR_|BTU/KWH|_BTU/GAL 116) 180) 14.5 12.4 468000 2600} 32276) 100) 155) 12.3 12.6) 408000; 2632) 33171 75) 116) 9.3 12.5) 50 78 6.5) 11.9) R. MISSION _|CATAPILER 3304T @ 90 KW PRIME (W/O FAN) - NOTE 6 INPUT: 7.6|gph * 19590) btu/Ib hhv * 7.076} |b/gal / 60| min/nr = 17558} btu/min OUTPUT: | Work: 99/kw engine * 3412|btu/kwh / 60} min/nr = 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/bhp-hr / 60| min/hr = 7042! 38% Exhaust: 9382) * 166] / 235] = 6627 36% Radiation: 745) * 166} / 235) = 526) 3%| Water: 6251| * 166} / 235] = 4416) 24% Total: 18611] btu/min WATER % LOAD | KW GPH_|KWH/GAL| BTU/HR_ |BTU/KWH| _BTU/GAL 100} 110] 8.0 13.8 264936 2409 33117) 75| 83} 50} 55 ANVIK ALLIS CHALMERS 11000 @ 100 KW PRIME (W/ FAN) - NOTE 9 INPUT: 8.5] gph * 19590] btu/lb hhv * 7,076|Ib/gal / 60| min/hr = 19638|btu/min OUTPUT: | Work: 150|bhp engine * 2545) btu/bhp-hr / 60| min/hr = 6363} 32%} Exhaust: 2 Radiation: 2 Water: 150| bhp engine * 32|btu/bhp-min = 4800) 24%| 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) 85 11.8 288000 2880) 33882 | 75| 75 67 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||b/gal / 60|min/hr = 11783] btu/min OUTPUT: | Work: 87|bhp engine * 2545) btu/bhp-hr / 60| min/hr = 3691] 31%| Exhaust: 2 Radiation: 2 Water: 87|bhp engine * 32|btu/ohp-min = 2784) 24% Total: 2 btu/min WATER [ % LOAD | KW | GPH |KWH/GAL| BTU/HR |BTU/KWH| BTU/GAL 125| 75| 6.7 11.2 208800 2784 31164 100] 60 5.2 11.5 167040] 2784 32123 75 45 3.8 11.8 50 30 2.7 11.1 ANVIK ALLIS CHALMERS 2900 @ 50 KW PRIME (W/ FAN) - NOTE 10 | INPUT: 4.26|gph * 19590] btu/b hhv * 7.076| |b/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 2) 25 2.3 10.9 SUMMARY RESULTS: WEIGHTED SITE LOCATION |GENSET BTU/KWH| BTU/GAL| WGHT % |BTU/KWH| BTU/GAL | | HOONAH __|CAT 0398 3220| 40083 5 2357| 31953 | CAT D398 3220] 40083 5 | CAT 3512 (851 KW) 2261 31049) 90] C. BAY CAT 3512 (683 KW) 2378] 30905 33 2339 30953 I CAT 3512 (851 KW) 2261 31049 33 | CAT 3512 (683 KW) 2378| 30905 33 | L. KALSKAG |CAT D342T 3525| 45120! 0] 2924 37239 | CAT 3406TA 2857| 36364 90 CAT D342T 3525| 45120! 10| R. MISSION [CUMMINS LTA10 2409[ 33117 50] 2873 36315 | CAT 3304T 3337| 39513] 25| CAT 3304T 3337| 39513 25| | | | ANVIK AC 11000 2880| 33882! 33} 2822! 32969] | AC 3500 2784| 32123) 33] | AC 2900 2803| 32901 33 | + | KOTLIK CAT 3306TA 2632| 33171 50 2632 33171 | CAT 3306TA 2632| 33171 50) ! l | Page 3 GENSETS.XLS CUMMINS LTA10 DETROIT 4-71T 0 DETROIT 371 0 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 btulb hhv / 7.076 Ib/gal * 60 min/nr = 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 btub 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 3306D! and on generators as 150KW prime. Both gensets have skid mounted fan. 150 KW prime with fan corresponds to a 3306TA. 3306TA data without fan is used here. 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 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 15OKW 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 1S9HP/105KW peak however this genset reportedly does not meet normal weekday loads which peak at less than 9OKW. The AC2900 is even smaller. For purposes of this report the gensets are treated as DES-60 and DES-50, respectively. These gensets use the AC2900 engine. For each genset onl output data available is for fuel vs. generated KW electrical power from one publication and heat output at 2600 rpm only and 2400 rpm only , respectively from another (constant 32 btu/bhp-min.). Fuel vs. engine power is given in the 2nd publication and does not correlate well with 1st publication. All values are very questionable. Except for fuel vs. generated KW electrical power, all values used are calculated. Page 4 == == ee.we- PFrtPra & PIPELOSS.XLS PIPE HEAT LOSS| BURIED PIPING, SINGLE PIPE, 3" PU INSULATION K=|_0.014| Btwft hr-°F R=|In(Do/Dpy/2-Pi-K Qf=|(Tp-Toy/R To=|__0|°F (ground Tp=|_180[°F (fluid) Pipe Size|_ Type! Dp (in) Do(in)| Rifthr°F| QA(Btu | | (inches) /Btu)) Mnr-ft) 1|IPS 1.32! 7.32! 19.5| 9.2! 1.25/IPS 1.66 7.66) 17.4) 10.4] | 1.5[IPS 1.9 79) 16.2 14.4 2iiPs 2.38) 8.38 14.3) 12.6 3|IPS 3.5 95 11.4 15.9 4[IPS 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| glIPS 8.63 14.63} 6.0) 30.0) BURIED PIPING, SINGLE PIPE, 2" PU INSULATION IIPS 1.32 5.32) 15.8 11.4) 1.25)IPS 1.66 5.66) 13.9) 12.9) 1.5)IPS 1.9 5.9) 12.9 14.0) 2|IPS 2.38) 6.38) 11.2 16.1 3IIPS 3.5) 75) 8.7 20.8} 4|IPS 45 8.5 7.2| 24.9) S|IPS 5.56) 9.56 6.2) 29.2! 6IIPS 6.63 10.63} 5.4 33.5) ABOVE GRADE PIPING, SINGLE PIPE, 1.5" FG INSULATION K=|_0.023| Btu/ft-hr-°F | R-=|In(Do/Dp)/2:Pi:K Q/=|(Tp-To)/R Tos} _80|°F (room) Tp=| 180] °F (fluid) 1]IPS 1.32 4.32 8.2 12.2 1.25|IPS 1.66 4.66 71 14.0 1.5|IPS 1.9) 49 6.6) 15.3 2|IPS 2.38 5.38 5.6 17.7 3|IPS 3.5 6.5 4.3 23.3} 4|IPS 45 7.5) 3.5) 28.3} SIPS 5.56 8.56 3.0 33.5 6|IPS 6.63} 9.63 2.6) 38.7) 8IIPS 8.63 11.63) 2.1 48.4 ABOVE GRADE PIPING, SINGLE PIPE, NO INSULATION QA from ASHRAE Fundamentals (1989), Chapter 22, Table 9 & 10 To=| 80°F (room) Tp=|_180|°F (fluid) Pipe Size! Type Dp (in) Q/(Btul (inches) /or-ft) IIPS 1.32 89} 1.25) IPS 1.66 110 1.5}IPS 1.9 124 2|IPS 2.38) 152| 3|IPS 3.5) 216 4|IPS 45) 272 S|IPS 5.56 330) 6IIPS 6.63} 387| 8IIPS 8.63 Page 1 CAPACITY.XLS WASTE HEAT SYSTEM - HEAT TRANSFER COMPONENT CAPACITY REQUIREMENTS COLD BAY COLDEST MONTH = JAN. HDD = 1126 Tave=|_65-(HDD/31) = 29/°F PRACTICAL MINIMUM = O}°F RATIO ave temp diff - max temp diff =| (70 - 0)/(70 - 29) = fi7\2* Example: | DOT/PF Shop: 681|gal / month worst month : 1.7| multiplier / 31|days / month / 24/hours / day 1.56] gal / hour worst hour | 140000) btu / gal : 0.75\eff. 163000] btu / hour heating unit required FACTOR capacity - fuel use = 163000 / 681 = 240|** FLUID FLOW @ 20°F TEMP. DROP =| 163000 / (20 * 460) = 18/gpm FACTOR capacity - flow = 20 * 460 = 9200)** { T HOONAH COLDEST MONTH = JAN. HDD = 1087, | Tave=| 65-(HDD/31) = 30|°F | PRACTICAL MINIMUM = Ol°F RATIO ave temp diff - max temp diff =| (70 - 0) / (70 - 30) = 1.8|"* L. KALSKAG COLDEST MONTH = JAN. HDD = 2000] ave R. MISSION| ANVIK Tave=| _65-(HDD/31) = Ol°F KOTLIK W. MOUNT. PRACTICAL MINIMUM = -40|°F RATIO ave temp diff - max temp diff = |(70 - (-40)) / (70 - 0) = 1.6|"" CONCLUSION: USE OVERALL TYPICAL FACTORS AS FOLLOWS: RATIO ave temp diff - max temp diff = 1.7| OVERALL FACTOR capacity - fuel use = 240] OVERALL FACTOR capacity - flow = 9200) Page 1