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Mt. Village District Heat Report & Concept Level Design 1991
Mt. Village District Heat Report & Concept Level Design PREPARED FOR State of Alaska Alaska Energy Authority 701 East Tudor Road PO. Box 190869 Anchorage, Alaska 99519-0869 January 1991 polarconsuit alaska, inc. ENGINEERS ¢ SURVEYORS e ENERGY CONSULTANTS es SD 1503 WEST 33RD AVE.e ANCHORAGE, ALASKA 99503 polarconsult Mt. Village District Heating Executive Summary Mt. Village is a bush community with a population of 700, located in Western Alaska on the North bank of the Yukon River, approximately 85 river miles upstream from the Bering Sea. This report was commissioned by the Alaska Energy Authority (AEA) to determine whether introduction of a district heating system would save money for the community. The district heating system would recover energy that is now being wasted, from the Alaska Village Electrical Cooperative (AVEC) power plant, and convert the waste heat to beneficial use for the community. The 1990 cost of a gallon of heating oil was $1.15 for the schools and $1.045 for heating water. As a result, substantial sums were expended to heat community buildings. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which transfers heat to water, and a pump to circulate the water through the baseboard heaters. At the heater the heat is transferred to the air which warms the building. A district heating system works in the same manner as the engine generates heat like the boiler, but its source is waste heat rather than fuel oil. This report discusses how this heat may be used in Mt. Village, and what results may be expected. The water system, city buildings, and school buildings were studied as likely candidates to be served by a district heating system in Mt. Village. The most economical combination would be the new elementary school, middle school, and high school buildings combined with the water systems "middle pump house." This combination would utilize 100% of the heat available at the power plant during the winter months and would be the most cost effective system. Project cost, annual amount of fuel saved and fuel cost savings for concept #6 are as follows: Project Cost $1,002,315 Amount of Fuel Saved per Year 45,725 Annual Savings $51,606 Straight Pay Back in Years 19.4 Total project cost includes design, supervision, inspection, administration and construction. The project includes construction of a new module at the power plant to State of Alaska \ Walter J. Hickel. Governor Alaska Energy Authority A Public Corporation May 23, 1991 Mr. Earle Ausman Polarconsult Alaska, Inc. 1503 West 33rd Avenue Anchorage, Alaska 99503 Subject: Mountain Village Waste Heat Recovery Pre-Final Report Dear Mr. Ausman: We have reviewed the Pre-Final Report and Concept Level Design for the above referenced project and have the following comments. Please provide written responses to all review comments indicating if comment was incorporated or providing an appropriate answer/explanation with the final submittal. 1. Executive Summary, paragraph 4, capitalize "C" in Concept. VE Table of Contents, list of figures - Tables and glossary page numbers don't correspond to actual page numbers. Coordinate. 35 Section III.A., paragraph 1 - "Module #4, 'contains"’, change to "consists." 4. Section IILB. - indicate that position #1 D3412 at 1200 rpm is used as the lead generator in the WHU worksheet and indicate basis of assumption. 5: Section IIIB: A. Program notes in Appendix A indicate that "engine manufacture's test data" was used, not the data in Table III-A. Coordinate. B. Section III.C, page 9 - Appendix A worksheets assume position #1 is lead. Coordinate. 6. Section III.D, page 10, paragraph 4, change "consist" to "consists." ue Table IV-A & IV-AA, page 13 & 14, the total fuel use for the new elementary, middle and high schools in table [V-A does not agree with table IV-AA or Appendix A, concept 6. Coordinate. 8. Section IV.A.4. are the existing circulations pumps capable of accommodating the head imposed by the heat exchanger and piping? 0! Figure V-1 - "Concept 1, 420 feet of 2" diameter pipe does not agree with Figure V-2 or appendix A, Concept 1 WHU model. Coordinate. © PO.BoxAM Juneau, Alaska 99811 (907) 465-3575 poz FO Box 190869 704 EastTudor Road Anchorage, Alaska 99519-0869 (907) 561-7877 Mr. Earle Ausman May 23, 1991 Page 2 10. Figure V-2, direction of flow arrows are incorrect. 11. _‘ Figure V-3, errors in piping arrangement. 12. Figure V-4, equipment schedule indicates 2-1/2" piping. Coordinate with figures V-1 & 2 and appendix A, Concept 6 WHU model. 13. Figure V-5, equipment schedule indicates 3" piping. Coordinate with Figures V-1 & 2 and appendix A, Concept 6 WHU model. 14. Figure V-7, equipment schedule indicates 2" piping. Coordinate with Figures V-1 & 2, and appendix A, Concept 6 WHU model. 15. Section IV.A.4: A. Add a description of the proposed waste heat tie-in to the "old" elementary school with figures. B. Page 16, in "see figures V-5" change "figures" to "figure." 16. Section IV.B.4, change "(see figure IV-6)" to "(see figures IV-6 & V-7.)" 17. Section VI.B.1.b, page 32 - replace "Engine" with "Primary" in first line of paragraph 4. 18. Section VIII.B. - include description for Concept 1, "Old" Elementary School. 19. Section VIII.D - change paragraph to reflect both concepts 1 & 6. 20. Table VILA. A. Add to table VIILA: a subtotal for "Construction Cost" for each building including a line item for "General Conditions." Also, show the "Project Cost" with "Design, SIA", and "Project Contingency" separate from Construction Cost. (Use similar format to HMS Summary Sheet.) Note: the construction cost for a building should be the same for each scenario. The "General Conditions" should include any variance in; freight, per diem, travel, profit, etc. 21. Section IV.A. - change first paragraph to read, "There is approximately 64,755 gallons..." 22. | Add months to X axis on Figure [X-2. 9102\JD0801(2) Mr. Earle Ausman May 23, 1991 Page 3 23. Appendix A: A. Power Plant Heat, according to the WHU worksheets, the D3412 at 1200 rpm is used as the basis of calculations. Please reflect this assumption in appendix A, paragraph 1 and section III, page 9. (see 5b.) B. Clarify where the value of 96,00 BTU/gallons for fuel oil is from. If you have any questions, please call me at 561-7877 or 261-7282. Sincerely, Steven Stassel Rural Systems Engineer SS:jd 9102\JD0801(3) polarconsult Mt. Village District Heating house the district heating equipment, renovations to the AVEC power plant cooling system, the middle pump house, and the school buildings heating systems, and construction of a hot water transmission line. The life of a district heating project is a function of availability of waste heat from the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance costs. In this case the requirement for electricity and space heat in the community imply an infinite project life. With proper maintenance the life of the district heating system will exceed 25 years . It is estimated that it will cost an average of $2,600 per year to repair actual failures in the district heating system. Routine maintenance will be performed during three trips to Mt. Village by a skilled crew each year. Operation will be by a local person who will monitor the system. Because annual operational and maintenance costs and economic decisions will be made by AEA, final economic conclusions are not presented in this report. The straight pay- back time for the best alternative, Concept 6, is 19.4 years. The project could be made more attractive economically by reducing its scale through minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Western Alaskan communities to reduce Mt. Village's share of the high mobilization, shipping, travel, and supervision costs required. polarconsult Mt. Village District Heating CONTENTS EXECULIVE | SUIDMANY ec cesssecccsieccscssesstersanoussccnsssaseasonsssacenceusesacacencecsecaessoesntecneseseresersesices i MEiSC Of FI GUIOS csccccscsvsccecssessssssccsvocsnceccacsssoraseseccestotesestsesusestasesasasncaceasabesceaswetsacasassseesiss Vv Mist tel ables peeerssccrrecsrececrantecscecscceseccecocscoscnsasccscensantcasscesentessesestecaseastestceceseasesestesesesses v Glossary, | eecssssscscescseosesescroscsusnesesotsteceenonctsscrtesostwonsnsesesessaswsecesasessssececuccsusesasaseccsczsstases vi I. Introduction TS ODJOCtIVE ite tesssrsssscesencssssseccsuces sencoessacascsusegessceseerssutescvestatusaccscetscstsesauensesszezs 1 ByDistrict Heating; Systemiy..1.s..c.c:-sessscsessseecacesecessoececserevecrsesusecasereeseereacrensasececsrsee 1 Gi Methodology: crccccsrsscscsssssssesescosesessrestaossesnsesseseecsssssaeaveessseaeseorsnsesnssesesateenststse 1 IDNCommunityiDeschiploneerrs sce crcctscccercrtccrscrssstscescstsecarectsetecesesrsectcecesceas 3 BeProjected! oad Changes itrrrsccceccssctscssseccccserstssecerssoastossetesssesescorscsnrersesesusrstttsests 3 NUN Site VAS tpeetrecstcerrcstccetccttssecccccrertecccerccrsertstttesecsaetastesccennsnatatsuetsecessscessstsutnrscestets: tees: 4 Ill. Power Plant ASS General eescscvccarcnsecscsusstvsssccrscerasccscsuccwensaashcossevovaastsessssssenenssesssaspeoes eapssensssensessase 5 B. Available Load Information & Available Heat ........ccccccsssessssesesseseseseseseseseees 5 GS Building Heat sicccessscsscccsssescsestsosssessesesstss ces senscscsscscssesessesrsccseocsseseqereceseseeseece see 7 IDHProposed District Heating Connection crsc...ssescssescassersesesessescesseorsesecsssecassoeseseees 9 IV. Potential District Heating Users A. School Complex US GOMEral Tecccccsccsceccnecsesecsescxcusesscsosonsosstossercuconcasscsssecsisesaseususescosseccascoessese DS LOCATION [rasesccasscxsessssescasesessusossuscousoscnsocansasessusscocsovensosteusessesosseazeswéstetse 3. Heat Use .. ASDistrict Heating} COMMECHOMN nscscccesccsossosecescosessstacciscssaccecasccocsesseedscccesessee 14 B. Middle Pump House Building 1, General 2. Location SHHCAL SCI ccscccssececsensessscssccecercossenneneortessaccescusssseuceseoksverassoscuesusetesnesatootsns 18 4. District!Heating! Connection s...cc,cc-ccccececoscessossesensonscssosesaessesscssecessescestes 19 V- Concept Design! Drawings)|iccsscssscssecessssssssstecssecsrsesesesetys Mrcreisertteresctstrerusscaercereesey 21 VI. Failure Analysis AHIMMOGUCTION ccsccsccscscesnscscesesceeascscsscsstesesesetsussesssetanneassatensesanaseetesssesnassesereeeers 29 B. Failure Analysis of District Heating System ...........cccsssssssssssssssssssseeseeseeseeees 30 1. Power Plant 2. Distribution System .. polarconsult Mt. Village District Heating 3. User Connections ......cccscssssesessesessssescsssesesessssssssssesesesesseseseseeseeeeeesenenenes 35 C. Failure Frequency and Cost ...:....s0sseassecssecscssssessssussssagesonscssnsnessensnnsesnencssereosee 38 D. Design Decisions to Minimize Failure ............ccssssssesesesesessessseeseseseseseneseenens 40 VII. Project Specifications A. Codes and Regulations «0... B. DIVISION 01 - General Requirements IC. DIVISION 02 = Site WOTK sec sccscsseccssessueensssacsevescossccssnscstassasoncansesceasussussvesseveesa D. DIVISION 13 - Special Construction . wee 42. E. DIVISION 15 - Mechanical Outline Specification oc. eessesceseeeeteeteeeees 43 F. DIVISION 16 - Electrical Outline Specification oo... teeseeseeseeteeeeeeeenees 46 VII. Project Cost Estimate A. Power Plant Heat Recovery System ............cssssssssssssssssseessersscescnscessassscesorees 49 B.. District Heating Distribution System. «1.00. ..cssesssovsnsnsnonossosesevonsssesosovsevouseonsesess 49 C. Operation and Maintenance Costs .. ee D; Projecr Cost Summary ses -se ses cscs svssessawscessts casatcscscsvsaseacncusacscabe sssssisscotenssdsonion IX. Conclusions A. Heat Availablity & Fuel Consumption ..........cscssssssssssssssesssessssssssscessssoseeees 51 Bs Project! Cost Sumi ary vateitasatssconsussononsacersotsessinsusesesdotavenesanenssseusedsvonsatassvaersen 33 C. Project SUMMATY .......ccseeessssseeeeseseseseesessseesssssssssssssssssessssssessssseessseseresenees 53 DK, RECOMIMEMAAU OMS! cs caccacesnsccas sas canscts cas cvaseossasanes sess stesacssasstssusaussssesesus SeasasssessososeeT 54 Calculations Appendix A Field Trip Notes .....c.sccscssssssssessssssesesesssesesenesesscseseseseseesssesesesssnssesesesesesessseees Appendix B COSt Etim ate. sciscsisisssesnevensvsusrvecscsssreavesvasnesovsononosvoussovssessusesiesessssecesssesousvasn Appendix C ii polarconsult Mt. Village District Heating List of Figures Il-1 Butler Building Unit Heater & Unit #3 Heat Exchanger ........ccccsceesssseseseseseees 8 Ill-2 Module #4, Building Unit Heater, Ventilation/Comb. Air Fan, Unit #5 Piping, and Building & Engine Heat Piping ..........sccsessesesseceeeseseseseseseeseeesesessseseneeees 8 IlI-3 Control Module, Module #5 & Proposed District Heating Module Location ... 11 Ill-4 Control Module & Proposed District Heating Pipe Alignment .............c cesses 11 IV-1 Proposed Location of Secondary Heat Exchanger in Elementary School ......... 15 IV-2 Proposed Connection of District Heating System to Elementary Boilers .......... IV-3_ Proposed Location of Secondary Heat Exchanger in Middle School ............... 17 IV-4 Proposed Connection of District Heating System to Middle School Boiler ...... 17 IV-5 Proposed Location of District Heating Equipment in Middle Pump House ...... 20 IV-6 Proposed Conn. of District Heating System to Boilers in Middle Pump House 20 V-1 Site Plan & Proposed District Heating System Distribution 1.0.0... eseeeeeeees 21 V=2 Proposed System Schematic s.:s..ccsernasscvecssvesesensuserendosrsonensnsiovsvsessssnesoussssessenes 22 V-3 Detail of Revisions to Existing Power Plant & District Heating Connection .... 23 V-4 Middle School Piping Connection Schematic & Floor Plan ........ceseseseeseeeees 24 V-5 High School Piping Connection Schematic & Floor Plan .......s.ssssssesesseseseseeeee 25 V-6 New Elementary School Piping Connection Schematic & Floor Plan . ... 26 V-7 Middle Pump House Schematic & Floor Plan wo... ccesssscsssesssesesesteesessseseesnees 27 V-8 Old Elementary School Piping Connection Schematic & Floor Plan ................ 28 IX-1 Heat Available vs Heat Required .... a. 52 IX+2 Gallons:of Heating Oil Displaced. «.cscscssssssssscsasessecssssssovescssscscsnsnsssstssiesvonsssorvs 52 List of Tables TWA, Engine Dat. scesisssscscescsssscssssvasexsnssssvessasescesassousessussvassestsacsssatecentosensersscssvessawsaets TH-B Monthly Power Generation & Available Heat . IV-A_ Fuel Oil Use at School Complex ....... ccc ceseeeeeeeeeeeenee sadananbceaceaseanaaoceata Tea IV-AA Estimated Distribution of Fuel Oil Use at School Complex .........ccceseseseeeeeeees 14 IV-B_ Estimated Distribution of Fuel Oil Use at Middle Pump House .. ass 19 VIII-A Summary of Alternative Project Costs... ccsescessecseescecesesseceseeeseeesaeeeeseeees 50 IX-A Annual Heating Fuel Displacement & Pipeline Heat Losses ........scsesssesseseeeee 51 IX-B Project SUMMALY ......ssssesssssssseseseseseseesesseseseseesesesssessesesssesseseseseseeeseseeesensenenees 53 iii polarconsult Mt. Village District Heating Glossary o AEA: Alaska Energy Authority, the State agency which commissioned the report. o AVEC: Alaska Village Electric Cooperative, the electric utility providing electric power to the community. o APUC: Alaska Public Utilities Commission, the body which regulates most utilities throughout the State of Alaska. o Capital Cost: Total cost to construct the project, including actual costs as well as design, management, contractor's overhead, risk and profit. o Operating Cost: Cost to keep the project operational, computed on an annual basis over the life of the project. o District Heating: Concept of recovering engine waste heat which would otherwise be lost through radiators to the air. This heat is circulated in pipes as hot water, to heat buildings. o Present Worth: The value of a future or past sum of money at a given time, usually the present, taking into account the time value of money, using an interest rate. o Net Present Worth: The value of a project where costs and income have been converted to a common time and combined. iv polarconsult Mt. Village District Heating I, Introduction A. Objective The objective of this report is to determine the feasibility of recovering and using waste heat from the Alaska Village Electric Cooperative (AVEC) power plant generators in Mt. Village. In view of the present cost of heating oil at over $1.15 per gallon, and the amount of heat presently being wasted to the outdoors through the engine radiators, the Alaska Energy Authority (AEA) determined that utilization of waste heat showed potential savings in heating costs. The scope of this report is to determine if a district heating system is feasible, identify optimal applications, and estimate the cost of constructing this system in Mt. Village. B. District Heating § A district heating system takes energy that would otherwise be wasted and converts it to beneficial use as space heat. A brief description of a district heating system follows. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which burns fuel, usually oil, and transfers the heat to water, and a pump to circulate the heated water through pipes to base board heater. At the heaters the heat is transferred to the air in the building. A district heating system works similarly, with the water heated by diesel generators in the AVEC power plant instead of being heated by a boiler. In a system without district heating the water heated by the engines is normally cooled by the radiators at the plant. In a district heating system, this heat is recovered for beneficial use instead of being tejected to the atmosphere. This report discusses how waste heat can be used in Mt. Village, and the likely results. C. Methodology The feasibility of waste heat use in Mt. Village has been investigated in the following manner: 1. Information Gathering: Prior to the site visit all pertinent and available information was gathered, including estimates of the amount of heat available and identification of potential user facilities. The field trip was coordinated with village officials and AVEC operators. polarconsult Mt. Village District Heating 2. Field Trip: The site visit was made to discuss the project with the Village Council and interested persons, to survey potential user buildings and determine possible distribution pipe routes. Criteria for potential user facilities included public ownership, substantial heat use, and proximity to the AVEC power plant. The manager or operator of each candidate building was interviewed. Information was gathered concerning: Rights-of-way; Amount, type and quality of construction equipment available in the village and the rental rates; o Availability of village-supplied labor during, the probable construction period; o Specific weather problems such as drifting snow; and o Soils information. Field trip notes are shown in Appendix B. 3. Analysis: Field trip notes, photographs, general information and additional site-specific features of the village were analyzed. Historical power production, weather information, and fuel usage records obtained during the field trip were entered into a computer model to determine the quantity of waste heat available to each potential user facility. On the basis of economics, several potential user facilities were eliminated. Specific details for hook-ups to the district heating system, including distribution pipe routing and location of user heat exchangers, were considered and included in the report. (See Figure V-1, "Site Plan and Proposed District Heating System Distribution," on page 21.) Concepts investigated included the following combinations of buildings: # Buildings 1 Old Elementary School only; 2 Headstart, Middle Pumphouse, New Elem., Middle, & High School; 3. Old Elem, Headstart, Middle Pumphouse, New Elem., Middle, & High School; polarconsult Mt. Village District Heating Old Elem, Headstart, Middle Pumphouse, Middle, & High School; Headstart, Middle Pumphouse, Middle, & High School; Middle Pumphouse, New Elem., Middle, & High School; Old Elem., Middle Pumphouse, New Elem., & Middle School. NAWnN fs 4. Initial Submittal: A preliminary report on the project was written and distributed to the Alaska Energy Authority staff for comment. 5. Final Submittal: The final report will include all comments received from AEA and other interested parties who have reviewed the interim report. D. Community Description Mt. Village is located in Western Alaska on the north bank of the Yukon River, approximately 85 miles up river from the Bering Sea. The population is made up mostly of Yupik Eskimos, and the economy is based mainly on commercial fishing and subsistence hunting. Mt. Village states it has a population of 700. The community has a water distribution system with wells, storage tanks, and booster stations throughout the community. Water is distributed throughout the community. A variety of equipment is available for rent from the City, and the City has established rental rates. Local labor is available most of the summer, although a majority of the residents participate in commercial fisheries. E. Projected Load Changes The school complex is distributed throughout the community and as a consequence uses substantial quantities of fuel. There is no indication of planned school expansion, or consolidation, from school district officials. District headquarters are located in Mt. Village. Heat requirements for the water system should grow with the community. AVEC projects an increase of 21% in the community's energy needs over the next four years with an decrease of 3% over the following three years, according to its Power Requirements Study and 10-Year Plan. This increased requirement will proportionally increase the amount of heat available for use. The community projects a population increase of 49 persons by next year, which is a 7% increase. polarconsult Mt. Village District Heating Il. Site Visit The site visit was conducted on February 7 of 1990 to discuss the project with the Village Council and interested persons, survey potential user buildings and determine possible routes for district heating distribution pipe. The principal of the school complex and operators of the water system (middle pump house) and the AVEC power plant were interviewed. Information was gathered concerning rights-of-way, soils, specific weather problems, and local availability of construction equipment and labor. Field trip notes including a list of people contacted in the field, are shown in Appendix B. polarconsult Mt. Village District Heating Ill. Power Plant A. General The power plant consists of a standard AVEC Butler type structure, two engine modules, and one control module. Butler building now houses two Caterpillar generators that are equipped with remote radiators. The two remote modules and a control module are located toward the river from the Butler building. Module #4 contains of a single engine and two remote radiators, module #5 consists of a single engine connected to the two remote radiators in module #4. The control module houses the control equipment, switchgear and day tank. Equipment listed in Table III-A is presently installed at Mt. Village. Table III-A Engine Data Position/Unit # 1 3 4 5 Engine Caterpillar Caterpillar Caterpillar Cummins Model D3412 D353 D3412 KTA2300 Speed (rpm) 1200 1200 1800 1200 Rating, Engine (kw)* 330 335 470 615 Heat Rejection** To Coolant (Btu/min) 13,281 17,500 18,483 21,450 To Stack (Btu/min) 18,420 19,930 29,572 28,000 To Ambient (Btu/min) 4,459 4,400 6,161 5,130 Water Flow (gpm) 118 145 180 250 Intake Air Flow (CFM) _ 1,020 1,000 1,470 1,650 * Engine rating at shaft. ** Rating at full load. B. Available Load Information & Available Heat Monthly power production figures for Mt. Village were obtained from AEA. The 1989 figures were rounded to the nearest 100 kwh for use in this report. The amount of waste heat available off the engines was calculated using these generation values and the engine manufacturer's heat rejection figures listed in Table III-A. System losses were subtracted from the amount of heat available off the engines to arrive at the equivalent number of gallons of fuel oil available for polarconsult Mt. Village District Heating use. System losses include building heat, distribution pipeline heat losses, radiator losses and plant piping heat losses. Table II-B _ Monthly Power Generation & Available Heat Month Power Produced Values Used Heat 1987 1988 1989 inStudy’ — Avail. (kwh) (kwh) (kwh) (kwh) __(Gal.) an MMII sc 184,440 217,320 217,300 «6,551 eb MINN oo 175,200 178,920 178,900 5,265 Mas MN oo 174,960 192,600 192,600 5,581 sori MAN eee 170,520 174,480 174,500 —5,101 May MINIM ese 138,240 163,240 163,200 4,845 Tone NM ese 131,520 150,480 150,500 4,512 July 112,560 130,080 152,520 152,500 4,597 Aug 127,200 151,440 172,080 17241 OOM 581-25 Sept 133,320 152,160 161,280 161,300 4,794 Oct 145,080 EG:O8O MN ee 184,300 5,394 Nov 162,720 1 84°80 MMM eee 205,100 6,196 Dec 176,520 2022.00 MAMAN 224,400 __ 6,793 Annual _ 1,704,409? _1,961,720° __ 2,176,720 2,176,700 _-64,755 ! Values used in this study were the 1989 kwh production figures rounded to the nearest 100 kwh. if From Jan. to Sept. the load increased 11.0% from 1988 to 1989. This rate of increase was used to project the load from Oct. to Dec. 1989. Annual production for 1987 and 1989 was estimated, as data were not available for all months. Equivalent gallons of heating oil available from District Heating Simulation Work Sheet. polarconsult Mt. Village District Heating C. Building Heat The Butler building portion of the power plant is a metal frame building with 2 inch insulation in the walls and roof. The building has an uninsulated wood frame floor. Combustion air comes from a ventilation louver by the door. The building is heated by unit heaters which use heat from the operating engines. (See Figure II-1.) Both engines utilize two horizontal radiators mounted on the back wall of the building. Each radiator has sufficient capacity to reject all of the heat produced by either engine. These radiators are equipped with variable speed fans. Two modules are used to house units # 4 and #5. These modules contain complete generation facilities with the exception of the switchgear, which is located in the control module. The modules are constructed of steel and are mounted on steel skids. Each module contains one engine and its associated piping and valves. Both engines utilize two horizontal radiators mounted in module # 4. Each radiator has sufficient capacity to reject all of the heat produced by either engine. These radiators are equipped with variable speed fans. Each module also has two exhaust air blowers which provide combustion and cooling air. (See Figure III-2.) The modules are approximately 12 feet wide by 12 feet high by 30 feet long for module # 4 and 24.7 feet long for module # 5. The control module is 10 feet wide by 34 feet in length. The modules are constructed with a metal skin inside and outside, and the walls are insulated with 3 inches of urethane foam. The floor is uninsulated. To keep the modules warm, heat from the operating engine's cooling water is delivered to unit heaters in each module. (See Figure III-2.) There is a similar unit heater in the Butler building. polarconsult Mt. Village District Heating Figure III-1 Butler Building Unit Heater & Unit #3 Heat Exchanger Figure III-2 Module #4, Building Unit Heater, Ventilation / Combustion Air Fan, Unit #5 Piping, and Bldg & Engine Heat Piping polarconsult Mt. Village District Heating Heat losses from the buildings will reduce heat availablity for distribution by the waste heat recovery system. Heat given off by the engine and generator is usually sufficient to heat the structure in which the equipment is operating. To keep the other three structures warm requires supplemental heat obtained from engine cooling fluid. Calculations show a quantity of heat equivalent to 1,928 gallons of oil per year would be required to keep the Butler building at 65°F without an operating engine, and 3,411 gallons of oil per year to keep two of the three modules warm without an operating engine, for a total of 5,339 gallons of oil per year for space heat. Insulating the floors of these buildings would reduce these requirements to 1,336 and 1,476 gallons of oil per year, respectively, for a total of 2,812 gallons of oil per year for space heat with the floors insulated. Calculations were conservative as it was assumed the operating engine is always in one of the modules. These values are based on heating each building to 65°F. The losses could be reduced by raising the structure temperature to 65°F during active maintenance periods only. The engines are to be kept warm by circulating heated coolant through their blocks. The amount of heat required to heat the engine block is less than that required to heat the module during cold weather. This means that the minimum heat requirement is the amount required to heat the engine block, so the values used are conservative. D. Proposed District Heating Connection The proposed district heating system schematic is shown in Figure V-2 (page 22) and the connection to the power plant is shown in Figure V-3 (page 23). Interconnection between the existing remote radiators is included. This will allow any one of the generators to use any one of four remote radiators. Each radiator is adequate to meet the heat rejection requirements of any engine. Connection to the existing building unit heaters and engine warming system connections are also included in the new piping, as is insulation in the floors of the Butler building and the three modules. : The primary heat exchanger will be located in a housing behind module #5. (See Figure III-3.) The expansion tank(s) and district heating pumps will be located at the user end of the system. The heat exchanger housing will use 2x4 standard wood frame construction. The unit will be mounted on a steel channel extension polarconsult Mt. Village District Heating of generation module # 5's steel skid. The unit will be insulated with fiberglass batt insulation and covered with metal siding on the exterior and plywood on the interior. Heat exchangers will be stainless steel plate type units. The primary side piping will run from the heat exchanger into module # 5 and parallel to the existing radiator piping into Module # 4. The Butler building and modules # 4 & #5 will be connected at module # 4. The piping will be black welded steel pipe with flanges for valves and other removable fittings. The piping will be insulated outside of the structures to prevent excessive heat loss. The district heating electrical systems for the new heat exchanger module, which consist of a single light and wall receptacle, will be connected through a meter to the existing station service panel in the Butler building. The cost estimate for the connection of the heat exchanger, pumps, and module at the power plant is covered in Section VIII, Project Cost Estimate. 10 polarconsult Mt. Village District Heating Figure II-3 Control Module, Module # 5 & Proposed District Heating Module Location Figure II-4 Control Module & Proposed District Heating Pipe Alignment 17 polarconsult Mt. Village District Heating IV. Potential District Heating Users A. School Complex 1. General The school has an enrollment of 209, and is operated by the Lower Yukon School District, based in Mountain Village. The school system consists of the high school, middle school, new elementary school, old elementary (BIA) school, warehouse, and 24 residential units for teachers. The old elementary school classrooms are still in use. These buildings are heated by individual hydronic and hot air heating systems. Supplying the individual buildings will require heat exchangers and pumps for each structure served. System economics favor the connection of the larger heat consumers which are the high school, middle school, and the new elementary school. The schools are reported to have the following numbers of students. High school; (9-12) cc.sc-sc-csassessssssassasesssess 53) Middle School 4-8) iecsrs<scessssscarseosresesesene 76 Elementary School, K-3 ........ssssssssesesees 80 2. Location The school complex is distributed in two areas of the community. The old elementary school, is located about 250 feet south of the power plant and the remainder of the school complex, which includes the high school, middle school, and new elementary school, is centered about 1,200 feet north of the power plant. To reach the new elementary, middle school, and high school buildings, 1,505 feet of "Arctic" distribution pipe will be buried in the power line rights-of-way to the complex, as shown jin Figures III-4, and V-1. Easements will be required to use this right-of-way. All three school buildings served by the northern pipeline are constructed on piles. 12 polarconsult Mt. Village District Heating 3. Heat Use Fuel records for the school facilities in Mt. Village were obtained from James Luke, maintenance director for the Lower Yukon School District in Mountain Village. The complex is made up of, and used the following amounts of fuel in 1988-1989. Table IV-A Fuel Oil Usage at School Complex Buildings Period Fuel use Total Old Elem School Oct-Mar 2,023/mth Apr-Sep 1,449/mth 20,832 New Elem, Middle, & Apr-Nov 5,560/mth High School Dec-Mar 11,555/mth 102,690 3 Assoc. Teach Units 4,575 4,575 24 Teacher Units* 36,360 36,360 *Note: All of the northern complex is served from large central fuel tanks by pipe lines, and quantities for individual services are not measured. Building fuel use quantities have been estimated using the building areas. Monthly fuel use was estimated by distributing the average annual fuel consumption based on the number of heating degree days per month. 13 polarconsult Mt. Village District Heating Table IV-AA Estimated Distribution of Fuel Oil Use at School Month Heating HS Mid Sch NewElem OldElem Degree Days (Gal. Oil) (Gal. Oil Gal. Oil January 1,739 8,002 3,102 3,102 2,886 February 1,627 7,485 2,901 2,901 2,700 March 1,541 7,089 2,748 2,748 2,551 April 1,185 5,453 2,114 2,114 1,967 May 697 1,604 622 622 578 June 422 0 0 0 0 July 299 0 0 0 0 August 357 821 318 318 296 September 601 2,767 1,073 1,073 998 October 1,072 4,932 1,912 1,912 1,779 November 1,436 6,609 2,562 2,562 2,384 December 1,810 8,327 3,228 3,228 3,003 Annual 12,785 53,089 20,580 20,580 20,832 Purchase Cost / *gal $1.15 $1.15 $1.15 $1.15 4. District Heating Connections The new elementary school is heated by two boilers. The domestic hot water is heated by an oil fired heater. The district heating connection will Tee off of the main lines, pass under the building and penetrate through the floor of the existing mechanical room. The heat exchanger and auxiliary equipment will be located in the corner of the existing . mechanical room. (See Figure IV-1.) The heat exchanger will be directly connected to the return line of the boilers. (See.Figures IV-2 & V-6.) A dual plate heat exchanger will heat the domestic hot water. The existing circulation pumps will accomodate the additional head across the heat exchanger for both the domestic hot water and the heating system. 14 polarconsult 7 Mt. Village District Heating Figure IV-1 Proposed Location of Secondary Heat Exchanger in Elementary School J# Figure IV-2 Proposed » | Connection of District Heating System to Elementary School Boilers 15 polarconsult Mt. Village District Heating The middle school is a two story structure heated by one boiler on the second floor. The district heating connection will Tee off of the main lines, pass under the building and penetrate through the floor of an existing mechanical room under the stairs on the first floor. (See Figures IV-3 & IV-4.) Because the boiler area is cramped, the heat exchanger and auxiliary equipment will be located in this room. The water pump and water pressure tank are also located in this room. The proposed heat exchanger will be connected to the return line of the boiler. (See Figure V-4.) There will be a dual plate unit or section of the heat exchanger which will be used to heat domestic water which is presently heated by an oil fired hot water heater. The high school is the largest user of fuel oil, and contains a gymnasium and swimming pool. The pool, which has its own boiler, was empty and is not operated due to lack of life guards according to the principal. The high school is heated by six forced air furnaces located in a second floor mechanical space above the offices and the class rooms. The district heating distribution pipes will pass under the building and penetrate through the floor of an existing storage room behind the main office on the first floor. (See Figures V-5.) The auxiliary equipment will be located on the second floor right above this room. The district heating system will connect to six individual hydronic heating coils located within each of the return air ducts. A dual plate heat exchanger would be used to heat the domestic hot water which is now supplied by two hot water heaters. 16 polarconsult Mt. Village District Heating Figure IV-3 Proposed Location of Secondary Heat Exchanger in Middle School Figure IV-4 Proposed Connection of District Heating System to Middle School Boiler 17 polarconsult Mt. Village District Heating B. Middle Pump House Building 1. General The water distribution system is owned and operated by the City of Mt. Village. Technical assistance is provided by the U.S. Public Health Service. The facility includes a number of wells, several water storage tanks, water treatment equipment, and boilers to heat the water. The water is circulated throughout the community in insulated below-ground water lines in two separate loops. The loop that is of interest serves the southern section of the community, which includes the schools. The loop to be served has a large insulated water tank located just west of the high school. Water for this loop is chemically treated, heated, and pumped around the distribution loop at the middle pump house, which houses the treatment equipment, two boilers and auxiliary equipment. 2. Location The middle pump house is located 900 feet north of the power plant and 40 feet off of the proposed route for the district heating pipes serving the school complex. The district heating distribution pipe from the tee off the main line, to the middle pump house, will be buried "Arctic" pipe. (See Figure V-1.) 3. Heat Use Heat is supplied to the water distribution loop by two boilers. The heat in the water also keeps the storage tank warm as the water is circulated throughout the system. The water tank is insulated and is heated to about 40°F in the winter. Monthly fuel records for the water system, and the middle pump house, were obtained from the City of Mt. Village. (See table IV-B on the following page.) During the summer no heat was used by the Middle Pump House according to the City records. 18 polarconsult Mt. Village District Heating Table IV-B Estimated Distribution of Fuel Oil Use at the Middle Pump House Month Net Fuel Heating Oil Use Degree Days (Gal.) (HDD) January 1,300 1,739 February 1,400 1,627 March 1,200 1,541 April 1,000 1,185 May 700 697 June 0 422 July 0 299 August 0 357 September 600 601 October 900 1,072 November 1,100 1,436 December 1,300 1,810 Annual 9,500 12,785 Purchase cost / gal. $1.045 4. District Heating Connection The two district heating pipes will be buried and will emerge outside the middle pump house, and extend into the building through the boiler room wall. The heat exchanger will be located adjacent to the entry way across the room from the boilers. (See Figure IV-5.) The connection will be made to the return header of the existing boilers. (See Figure IV-6.) 19 polarconsult Mt. Village District Heating Middle Pump House Figure IV-6 Proposed Connection to Middle Pump House Boilers 20 polarconsult Mt. Village District Heating V. Concept Design Drawings MT. VILLAGE SITE PLAN PROPOSED RISTRICT HEATING ae —— —_ Pens OFFICE CENTER | =a y eS SHOP $ - 3 oO i | O77] ELEMENTARY Vso OL ae" “e CONCEPT 6 1,510’ 4°f 140° 30. » 5" 64 CONCEPT 1 420° 278 —-S--- EXISTING SEWER LINE = ~ EXST. UG POWER LINE ke -7F EXISTING POWER POLE EXISTING FUEL LINE DISTRICT HEAT USER DISTRICT HEAT LINE ry y polarconsult LEGEND P<] ISOLATION VALVE J CHECK VALVE — — EXISTING ——— NEW DISTRIBUTION NEW @ USER NEW @ PLANT @ USER PRIMARY DISTRIBUTION PUMPS NTS Mt. Village District Heating HIGH SCHOOL ia (SEE FIG. V-5> CONNECT rato oI petto user | 1 | SYSTEM | | | | 9 USER | —KHEAT CONNECT jaar | | EXCHANGER | | SYSTEM i | | ' | oS Lomo MIDDLE SCHOOL — SEAS Vb 1 arctic “GEE Fla V2) CONNECT PIPE i inne |TO USER | | | SYSTEM | lo CONCEPT 6 140’ 3° 1510’ 4° | connect | iS |TO USER USER | — | SYSTEM HEAT | Heer i | I EXCHANGER EXCHANGER | Sl es le oy MT. VILLAGE — PROPOSED SYSTEM SCHEMATIC ELEMENTARY SCHOOL (SEE FIG. V-6> 1 CONNECT [70 USER j SYSTEM Q | 140’ 38 | OLD ELEMENTARY SCHOOL (SEE FIG. V-8) PRIMARY HEAT EXCHANGER DISTRICT HEAT MODULE, “SEE FIGURES V-3) CONCEPT 1 22 polarconsult Mt. Village District Heating EQUIPMENT SCHEDULE MOUNTAIN VILLAGE HEAT EXCHANGER 1,000,000 BTU/HR DETAIL SHOWING REVISIONS TO POWER PLANT RADIATORS YOUNG, SERIES 33 AND DISTRICT HEAT CONNECTION PLANT PIPING 4” STEEL, WELDED UNIT HEATER EXISTING -_~_—_T TS ee yn existG Fe tH J existc 1 RADIATOR = [RADIATOR | . “H] | z T i Yi SEE NOTE 2. a “9 r --- 5-7 - EXISTING POWER PLANT BUTLER BUILDING Od | ENGINE MODULE i ze x a Oo. iw Zz — (a 2) — x uJ CONTROL MODULE EXISTING PLANT EXISTING EXISTING (see RADIATOR | | | | | | | | | | = EXISTING PLANT PRIMARY HEAT ENGINE MODULE EXCHANGER LEGEND |] BUTTERFLY VALVE 14 AMOT VALVE fN CHECK = VALVE NOTES: \il| © FLEX CONNECTOR . LOCATION OF POSSIBLE BOOSTER PUMP. ———— NEW PRIMARY PIPING . HEAT EXCHANGERS SERVING PUMPED ENGINE WARM SYSTEMS PUMP. = ome: EXISTING AND MODULE UNIT HEATERS, AND EXP. TANKS NOT SHOWN. NEW DISTRICT HEAT PIPING . EXISTING SYSTEM COMPRISES THREE MODULES WITH REMOTE RADIATORS. REMOTE RADS WILL BE INTER CONNECTED THRU NEW HEAT EXCHANGER. FIGURE SCALE: NTS V-3 TO DISTRICT HEAT SYSTEM DISTRICT HEAT MODULE (NEW? 23 CEGEND GATE VALVE EXISTING BUILDING HEAT EXCHANGER 300,000 BTU/HR BAL. VALVE EXISTING PUMPS GRUNDFOS, SERIES PUMP NEW DISTRICT HEAT PIPE 200, UPCD 65-160 CHECK VALVE STRAINER EXPANSION TANK 8 GAL. NEW @ USER TEMP CONTROL VALVE PIPING: SUPPLY SIDE 2-1/2 STEEL, WELDED BOILER SIDE 2” CU ynsuoorejod JOVTIIA “LW (dN-YOOH YSN) ONIDMNG TOOHOS FICGIN EXISTING SCHOOL UTILITY ROOM ZONE SUPPLIES ZONE EXISTING RETURNS SPACE FOR USER EQUIP. HEAT SYSTEM EXPANSION TANK C gGlLyCoL FILL }_<FROM DISTRICT HEAT EXCHANGER > HEAT SYSTEM DISTRICT AIR HEATING SEPARATOR SYSTEM FLOOR PLAN SYSTEM SCHEMATIC SCALE: 1’=10’ Sunvopy IOMNSIC OSeTTIA “WW LEGEND EQUIPMENT SCHEDULE =~ = Cc GATE. VALVE EXISTING BUILDING HEAT EXCHANGER NONE REQUIRED DB : BAL. VALVE - EXISTING PUMPS GRUNDFOS, SERIES L a< PUMP NEW DISTRICT HEAT PIPE 2.5 M8 c CHECK VALVE STRAINER EXPANSION TANK 11 GAL. Ss > —— NEW @ USER TEMP CONTROL VALVE SIPING: Oo @ : ; SUPPLY SIDE 3” STEEL, WELDED A SCALE: 1" = 30 HEATER SIDE _2”_‘CU b \ U TYP OF 6 — = HEATERS o WY RETURN RETURN RETURN oO AIR | AIR | |AIR 7 ———— | | 1521 | | 5 DIRECT NEW DUCT COIL | l | ia 2 [FIRED ATTACHED TO HEATER| O_O Le a bo = rl EXISTING | | EXISTING | | EXISTING | Cc WARM AIR WARM AIR WARM AIR = DIRECT HEATER | | HEATER | \ Heater | oO FIRED | #1 #2 #3 | > AHU oO EXISTING |--—1 es Peers sa>= 4 >poRaS==—4=—= Sa=>SsS=st= DIRECT UTILITY a a | i | i; ; ere ROOM | SUPPLY | | SUPPLY | | SUPPLY | DIRECT TO DISTRICT ee SHEAT SYSTEM EXPANSION TANK BQgGLYCOL FILL | FROM DISTRICT il a HEAT SYSTEM AIR HEATING 4 SEPARATOR SYSTEM FLOOR PLAN SYSTEM SCHEMATIC SCALE: 1'=30' ynsuoorejod SunvoH IOLNSICL OBUTTLA “TW LEGEND EQUIPMENT SCHEDULE GATE. VALVE EXISTING BUILDING HEAT EXCHANGER 300,000 BTU/HR BAL. VALVE EXISTING PUMPS GRUNDFOS, SERIES PUMP NEW DISTRICT HEAT PIPE 200, UPCD65—180 CHECK VALVE STRAINER EXPANSION TANK 260 GAL. NEW @ USER TEMP CONTROL VALVE PIPING: SUPPLY SIDE 2” STEEL, WELDED BOILER SIDE 2” CU JOVTTIIA “LN = ec Y m A oe oO Oo os | = aS) 4 zs m = ™ m = m z= 4 > A =< DY GD aes 2 o = ® Sc Cc = i Q se 4 et --t-5 poskenny | 1 | | BOILER #1! 'BOILER #2 ZONE = = | | SUPPLIES W BL #2 _ hoon ZONE RETURNS ~ GLYCOL ( \MAKE-UP LS EXPANSION TANK EXISTING UTILITY ROOM ‘ qatycoL rau FROM DISTRICT HEAT EXCHANGER HEAT SYSTEM Il AIR hs SEPARATOR DISTRICT HEATING SYSTEM FLOOR PLAN SYSTEM SCHEMATIC SCALE: 1’=10' ynsuoorejod SuNvoY IOMSIC OBeTTTA IW polarconsult Mt. Village District Heating MT. VILLAGE — MIDDLE PUMPHOUSE & WATER TREATMENT (USER HOOK-UP) A SUPPLIES HEAT EXCHANGER 200,000 BTU/HR PUMPS GRUNDFOS, SERIES 200, UPCD65—160 EXPANSION TANK 120 GAL. PIPING: SUPPLY SIDE 2” STEEL, WELDED BOILER SIDE 1-1/2" CU EXISTING ZONE RETURNS CAPPED OFF ce) TO DISTRICT 5 EXPANSION TANK NEW. ZONE HEAT SYSTEM RETURNS . 4GbYCOL FILL _FROM DISTRICT HEAT EXCHANGER [yt HEAT SYSTEM AIR SEPARATOR SYSTEM SCHEMATIC «c, DISTRICT HEATING SYSTEM } rt | | 7 ¥3N39 =a) 1 Lo Y3LV3H 0 aay A LEGEND GATE VALVE BAL. VALVE PUMP. CHECK VALVE EXISTING BUILDING NEW @ USER EXISTING NEW DISTRIBUTION STRAINER TEMP CONTROL VALVE ; , FLOOR PLAN FIGURE LN3WdINDS yasn aod aavd$ \ = FLOOR PLAN SCALE: 1'=30' Dd GATE ~VALVE EXISTING BUILDING HEAT EXCHANGER NONE REQUIRED DK BAL. VALVE -—- EXISTING PUMPS GRUNDFOS, SERIES @ PUMP —— NEW DISTRICT HEAT PIPE 200, UPCD65-180 -’ CHECK VALVE AY STRAINER EXPANSION TANK 12 GAL. —— NEW @ USER TEMP CONTROL VALVE RING: —- SUPPLY SIDE 2” STEEL, WELDED SCALE: 1" = 30 HEATER SIDE 2” CU DISTRICT HEATING 2 ——————————~— a TO DISTRICT SYSTEM & ===> HEAT SYSTEM _ A EXISTING | —_ aa | RETURN RETURN [ | | AIR | AIR | | | | | | x 2 NEW DUCT COIL \y I oO oO — A ATTACHED TO HEATER| © © bo rT ~~ TIEXISTING | EXISTING | , EXISTING | ly | ZONE | WARM AIR WARM AIR j RETURN | | HEATER | | HEATER | |BLR #1 | | | | #e | | | | | | . | | lpeccumgl' = aeeomgl =| pirect| ! 4——-+= rior J---4- FIRED] | ®m | | | | ZONE S71 AHU | 1 SUPPLY | 1 SUPPLY | SUPPLY | DIRECT FIRED] ie Oo AHU EXISTING EXISTING EXPANSION TANK UTILITY UTILITY J ayers, Fn -FROM DISTRICT I HEAT SYSTEM AIR SEPARATOR SYSTEM SCHEMATIC (dN-YOOH YaSN) TOOHOS AYVLNAWS1S G10 JOVTIIA “LW ynsuoorejod Sunvoyy OMNSIC S8eTIIA “I polarconsult Mt. Village District Heating VI. Failure Analysis A. Introduction Failure analysis is the process of predicting the operational reliability of a system. It provides information on the probable type and frequency of failures, and indicates how the system should be designed and maintained for optimal reliability. Reliability (R) is defined as that portion of time a system is functional. Unreliability (UR) is defined as (1 - R). Reliability is determined using the total time of operation (Total Period), mean time between failures (MTBF), and mean time to repair (MTTR). A district heating system depends on a number of components to provide heat to the user. The total unreliability of the system is the sum of the unreliabilities of these components. For example, if a pipe had an MTBF (mean time between failure) of 8,760 hours, and an MTTR (mean time to repair) of 8.77 hours, the reliability would be 1 - (8.76 / 8,760) = 1 - 0.001 = 0.999. This means that the pipe will be operating 99.9% of the time. If there were a heat exchanger that could also fail, and it had the same reliability as the pipe, the reliability of the combined items would be 1 - (8.76 + 8.76) / 8,760 = 1 - 0.002 = 0.998. This means that both the pipe and the heat exchanger would be operating 99.8% of the time and unable to deliver heat for 0.2% of the time. The system would then be out of service 0.002 x (8,760 hours / year) = 17.52 hours per year. Equipment with moving parts, such as pumps, are generally less reliable than static equipment, such as pipes. It is typical practice to install two pumps for this reason, with the second acting as a stand-by. The following illustrates how reliability is calculated for a system with two or more components of which either can perform the task. The system must be such that more than one piece of equipment can perform the same function, and failure of each piece of equipment is independent, that is, it does not affect the performance of other equipment. Two circulating pumps, each capable of pumping all the necessary fluid, is a common situation that will be used as an example. Assume that one of these pumps will fail once per year 29 polarconsult Mt. Village District Heating and will require an entire day to repair. The system will be unable to deliver heat if both units are unable to pump. Assuming both pumps fail at the same time, system unreliability would be only 0.07 hours per year, as compared to 24 hours per year with a single pump installed. Expressed in percentage of the year not serviceable, the value is 0.000751% for the two-pump system. The preceding example, comparing the failure rate of one versus two pumps, illustrates how important and powerful it is to provide redundant equipment for failure-prone items. This is economically feasible only where the costs of duplication are not great. All reliability analysis has limitations. The limitations of this study are as follows: First, it is based on historical data acquired from military, nuclear, and electrical industries, and is limited to the equipment used and the specific application conditions. Because the equipment and conditions will be different for this project, the outcome will be different. Second, the analysis is based on average conditions, and it is probable that for each individual system there will be a greater or lesser number of failures than predicted. Third, actual failure rates for a large number of plants will be closer to the calculated values, on average, than results from a smaller number of plants. Although the values derived by mathematical failure analysis for these systems cannot be exact for the individual installation, because the results are average values, they do provide important information. First, performing the analysis requires the designer and builder determine what causes system failures and take measures to avoid them. Second, the analysis provides the basis to determine which functions need emphasis during maintenance programs. Third, some degree of scale is provided on how failure affects project income. B. i nalysis of District Heatin. A description of major system components, their failure modes, and impacts of failure on the system is presented below. The description starts at the power plant and works toward the served structure(s). 30 polarconsult Mt. Village District Heating 1. Power Plant a. Components Engines. The engines are the source of heat; if they are not running, heat is not available to be delivered. Most AVEC plants have three engines, Mt. Village has four. In general, the plants are operated so that a single engine can serve the entire community. The reported average down time for AVEC generation systems during 1989 was a total of 33 hours per year at each plant. This quantity was from 12 hours forced outage of generators, 3 hours power line outages caused by storms, 8 hours planned maintenance outages, and 9 hours all other outages. Based on these values, the system will not generate heat 0.377% of the time. Cooling system: The power plant cooling system associated with the district heating system requires connecting the engines to a common manifold which, in turn, connects to the primary heat exchanger and two or more radiators. As radiators are unreliable components, four are used at Mt. Village which reduces the probability of failure. The primary generation system failure modes are: Failure or shutdown of the engines; Failure of the radiators due to leakage; Failure of the hoses, valves and piping system; Failure of the engine block itself, and SS) Se Failure of the primary heat exchanger, piping, pumps, and valves associated with the engine. Generation plant: Full failure of the generation plant, due to shut down, will stop heat production and disable the district heating system. AVEC reports that these occurrences average 33 hours per year, out of the 8,760 hours in a year. Radiator failure: Radiators usually fail by coolant leakage from cracks which are caused by rapid and extreme temperature changes. Usually radiator failures do not result in total plant shut-down but do require isolating the leaking radiator and running the system off the standby. If a radiator or engine connection hose breaks it can drain glycol coolant at 31 polarconsult Mt. Village District Heating a rapid rate, requiring plant shut-down. Controls are installed to shut down the plant in the event that coolant levels fall to a dangerous level. Alarms are installed to alert the operator prior to automatic shut-down. This allows the operator to isolate the leak, repair it, by-pass the leak, add additional glycol, or shut down the plant, as appropriate. The primary environmental problem associated with engine radiator failure is discharge of glycol onto the ground. Impacts on the environment from glycol leakage include thawing of permafrost, glycol contamination of groundwater, and glycol contamination of adjacent surface water bodies. Leaked glycol is difficult to recover because volumes are small, the terrain is usually rough, glycol mixes with water and ice, and it will disperse rapidly in water unless it is confined to a catchment basin. The above analysis applies to the existing system and the proposed district heating system upgrade. The only changes will be an increased potential volume of lost glycol, a slightly less reliable system as all equipment is connected to a single cooling system manifold, and a slight decrease in reliability caused by the addition of a heat exchanger. Engine heat exchanger. This component is composed of a series of formed stainless steel plates which are separated and sealed by elastomeric gaskets. The plates are bolted together within a steel frame to compress the gaskets and hold the plates together. The heat exchanger is used to transfer heat from the engine cooling fluid to the fluid circulated in the distribution pipes supplying the user's heat exchanger. The engine heat exchanger thus serves to isolate the power plant from the distribution system. This isolation means that failures in the distribution piping or at the user facility will not affect the power generation system. Failure modes of the primary heat exchanger are: 1. Blown or leaking gaskets; 2. Broken frame; 32 polarconsult Mt. Village District Heating Valve failure and stem leaks; Cracking or corrosion of plates; Connecting piping system failure; Fouling; ana S Freezing while generation system is down, if water is used as coolant instead of glycol, and 8. Structural damage to exchanger supports due to fire or other events. Generation plant operational impact: 1 A large, sudden loss of coolant on the engine, or primary, side of the heat exchanger will shut down the engines. A slower leak on the primary side can shut down the plant as a result of low coolant levels in the engines. If found in time, the failed exchanger can be isolated with valves. It is unlikely that valves will not work during a heat exchanger failure. District heating system operational impact: 1. Small leak: Operation of system will continue. According to maintenance procedures the bolts will need to be tightened, valve packings tightened, new glycol added to the coolant system, and spilled glycol recovered. Large leak: If on the primary side and if too much fluid is lost before the shut-off valves can be closed, the engines will shut down under low water level control. If on the secondary side: Without fluid, the district heating system will be out of operation until repaired. Pipeline will be drained of fluid and operator will notify main maintenance office. Environmental Impact: Glycol spilled on the ground is the environmental impact of an exchanger failure. Glycol can escape into the ground, thawing permafrost which can weaken structural supports, and enter groundwater 33 polarconsult Mt. Village District Heating and surface water bodies. Required immediate actions: Determine cause of failure, isolate heat exchanger at valves or add additional glycol as required by procedures. Catch dripping glycol in pans and recover spilled glycol. Call maintenance office if extra help is required. 2. Distribution System a. b. Components: Transmission pipe to feed the north complex will be mostly 4 inch diameter insulated pipe. Each pipe will be made up of a steel carrier pipe 4.500 inches in diameter with a 0.142 inch thick wall. The pipe serving the old elementary school will be 2 inches in diameter. The carrier pipe will be covered with high density urethane foam. Encapsulated in the foam will be two tin plated copper wires. These wires will provide a method to determine if water or glycol has leaked into the insulation. Covering the insulation will be a high molecular weight polyethylene jacket with an outside diameter of 8.86 inches. The pipe will run from the district heating module, which houses only the heat exchanger, north 950 feet to the junction with the middle pump house. The pipeline will continue north 300 feet to the Tee for the new elementary school, an additional 50 feet to the tee to the middle school, hence 140 feet to the high school. The ground is reported not to be permafrost and to have a seasonal frost penetration depth of 8 feet. As a consequence the pipe will be buried about 2 feet deep in the ground with the exception of vehicle traffic ares where it will be buried deeper. Failure modes of the district heating transmission system are: 1. External or internal corrosion of the carrier pipe; 2. Mechanical damage to the pipe from equipment or digging into the pipe; 3. Failure of the pipe; Failure of pipe welds; and 5. Mechanical failure caused by frost heave or thaw settlement. 34 polarconsult Mt. Village District Heating Generation plant operational impact: None District heating operational impact: 1. No operational impact from minor leaks in jacket or pipe which are detected and corrected by the maintenance crew during routine inspections. 2. Larger leaks which cause a measurable loss of glycol will require shutdown of the line with isolation valves, and pipe repair to put system back on line. Environmental impact: Glycol spilled on the ground is the environmental impact of a pipeline failure. Glycol can escape into the ground, thawing permafrost and weakening building supports, and also enter groundwater and drain into surface water bodies. Required immediate actions: Determine cause of failure, isolate pipeline at valves or add additional glycol as required by procedures. Catch dripping glycol in pans and recover spilled glycol. Call maintenance office if extra help is required. 3. User Connections a. Components: Each system is composed of a heat exchanger similar to the one at the power plant, two circulation pumps, an expansion tank, provisions for adding glycol coolant, a btu meter, piping, and valves. Failure modes of the heat exchanger are: 1. Blown or leaking gaskets; Broken frame; Valve failure and stem leaks; Cracking or corrosion of the plates; aS SP Connecting piping system failure; 35 polarconsult Mt. Village District Heating Fouling; Freezing while generation system is down, if water is used as coolant instead of glycol; and Structural damage to the exchanger supports due to fire or other events. Failure modes of the pumps are: Dy Se |) tS) Failure of electrical circuit; Seal failure; Motor failure; Impeller cavitation; Pump body failure; and Connection leakage. Failure modes of the expansion tank are: I. 2. 3. Water logging or bladder failure; Corrosion; and Broken sight glass. Failure modes of the piping system are: I. 2. 3. 4 Leakage of valve stems; Failure of valves to open or close; Failures due to corrosion; and Failures due to materials or installation defects. Failure modes of each of the school connections are: I 2. Failure of the school system to hold fluid; and Failure of the school's circulation pumps. Generator operational impact: Failure of the-above items will not affect the generation plant. District heating system operational impact: Heat exchanger: As described for the power plant, minor leaks from the heat exchanger will be corrected by catching and returning leaking glycol, tightening bolts, and scheduling the unit for gasket replacement. 36 polarconsult Mt. Village District Heating Major leaks of the heat exchanger will require the system to be isolated with the valves until it is repaired. Pumps: Ifa pump fails the system will be off until the failure is detected and the standby pump is put into service. If two pumps fail the system will be down until one can be repaired. Expansion tank: An expansion tank failure could be caused by the sight gage breaking, which will require system shut down until it is repaired. Corrosion is not a likely form of failure for an ASME 125 psi rated tank. Piping: Failure of the piping will generally occur at valve stems and where there are gaskets or joints. Slow leaks from these causes and from corrosion will not require shutting the system down. Shut-down of the system could be caused by a valve stem being twisted off or by a broken casting; repairs will be required before the system is returned to operation. Environmental Impact: The environmental impact will relate to glycol spillage. A large, rapid leak might enter the ground, where it could lead to thawing and structural failure. There is potential for groundwater and surface contamination. Small leaks are likely to stay in the building, but will require immediate and complete cleanup. Required Immediate Actions: For a slow leak, pans will be placed to catch leaking glycol, packings and joints will be tightened if appropriate, and fluid replaced. For a large leak, isolation valves will be closed to reduce loss of fluid. Repairs and replacements will be made, or maintenance crew notified, as required by procedures. For a pump failure, the failed pump's valves will be closed, the standby pump's valves opened, and the motor energized. If both pumps fail, one or both will require repairs. If an expansion tank fails, the tank will require recharging or repairs. For extensive repairs or replacement the maintenance crew must be notified. 37 polarconsult Mt. Village District Heating C. Failure Frequency and Cost The most common modes of failure are listed below, along with the associated frequency of occurrence, repair cost per occurrence, amount of down time, and a description of the effects on system life. Failure rates are calculated using the method shown in the Introduction. It should be noted that maintenance of certain items will require that the system be removed from service. This maintenance can be scheduled during a period when the power plant is out of service or when the user building does not require heat. For a school this would be in the summer. Therefore, the potential effects of loss of energy sales during routine maintenance are not included in the calculations. AVEC generation: The most common form of failure is engine failure. Frequency is variable but outage time is estimated at less than 33 hours per year as four generators will be available. Repair cost to system is $0 as it is not related to district heating system. Heat exchanger at power plant: The most common form of failure is seal failure. Frequency of occurrence is 10.6 years. Down time is 72 hours, repair cost is $2,000. There will be no measurable effects on system life from repairs. District heating pipe: The most common form of failure is from poor installation. Frequency of occurrence is 3.4 years. Down time is 48 hours, repair cost is $2,000. There are no measurable effects on system life from repairs. User connections at schools: The most common form of failure is the heat exchanger. Frequency of system failure for each system is estimated to be 4.3 years. The combined school system frequency of failure of one of the units is once each 1.4 years. Down time ranges from 24 to 72 hours depending on which item fails. Repair cost is $2,000. There will be no measurable effects on system life from repairs. User connection at water plant: The most common form of failure is the heat exchanger. Frequency of system failure for each system is estimated to be 4.3 years. Down time ranges from 24 to 72 hours depending on which item fails. Repair cost is $2,000. There will be no measurable effects on system life from repairs. 38 polarconsult Mt. Village District Heating Total system: Failure frequency of the entire district heating recovery system is summarized in the following table. Item Failure Rate Heat recovery at power plant 0.000507 Transmission pipe 0.00294 Water heating assembly 0.0005897 HS heat assembly 0.000597 Middle S. heat assembly 0.000597 Elem. S. Heat mbl. 0. Total 0.005828 To make the above figures of value the subsequent table has been prepared which shows the effect of outages on the production or sale of heat. Item Failure Oil used Oil Lost Hours/yr % total Eq. hrs/yr Heat Recovery Power Plant 4.4 100.0 4.40 Transmission Pipe 21.0 100.0 21.00 Middle Pump House 6.5 12.6 82 High School 6.5 53.9 3.50 Middle School 6.5 16.7 1.09 Elementary School 6.5 16.7 1.09 Sum (Equiv. Hours/yr) 51.4 31.90 The weighted value can be derived by multiplying the systems savings of 45,725 gallons of oil per year x 31.9 / 8,760 which is 166 gallons of oil based on equivalent heat which is not delivered because of failures. The number of maintenance outages will be 1.31 per year at 2,000 each for a total cost of $2,600 per year. *Note: Outage of one of the users means that only that unit's fraction of the heat is lost. This assumes that the isolation valves function. In a case where only a small amount of heat is being lost, maintenance may be performed on 39 polarconsult Mt. Village District Heating a scheduled basis rather than on an emergency basis. In that case the repair costs are considerably reduced. A portion of the annual 33 hours of generation plant outage should be added to the total waste heat recovery system outage time. The proper number should be 25 hours per year. (33 total hours minus the 8 hours of scheduled outage which occur during the summer.) The 25 hours would be distributed randomly. For 57 hours per year, which is 0.65% of the time, the system would be unable to deliver heat. This figure was based on forced outage of the engines and the weighted average of the distribution system. D. Design Decisions Made to Minimize Failure Rate and Impacts Some of the design decisions that will be made to assure long life and reliability are the selection of corrosion resistant materials, the use of duplex pumps, and the use of isolation valves so a failure on one leg will not necessarily shut down the entire project. Where possible, flanges will be used for valves and all interior plant pipe will be welded to improve system reliability. Items which the reliability analysis shows are of critical importance will be duplicated if economically feasible. All connections to the district heating system are separated from the power plant by isolation valves and a heat exchanger to minimize the consequences of a failure. User building heat will not be interrupted by a failure of the main district heating system, or by the failure of another user's system. The design includes the use of "Arctic" pipe which includes a steel carrier pipe butt-welded together and from 1 to 2 inches of insulation covered with a non- corrosive jacket. Two tin-plated copper wires are carried in the insulation to indicate the presence of moisture as an alarm. These alarm wires are read by a $1,500 alarm device which can connect to as many as four individual pipe loops. These devices allow for failures to be detected before they have time to become a major problem. They also minimize the time required to locate the failure and reduce excavation costs. At this time we know of no failures of this piping system in Alaska. 40 polarconsult Mt. Village District Heating VII. Project Specifications A. Codes and Regulations The listed versions of the following codes and regulations were used in the preparation of this report: Uniform Building Code (1988) Uniform Mechanical Code (1988) Uniform Plumbing Code (1988) Uniform Fire Code (1988) National Electric Safety Code (1987) ooo06UmcoDmlhlCUOD B. DIVISION 01 - General Requirements This is a general information section covering the coordination of work, description of the work required for this project, regulatory requirements, definitions, payment procedure, submittals, quality control, materials and equipment, starting, testing, contract closeout and maintenance. C. DIVISION 02 - Sitework A. Support for waste heat structure will consist of a steel channel extension of the skids and supporting frame for engine-generator module # 4. The foundation for the engine-generator module will also provide the support for the structure SECTION 02700 - PIPED UTILITIES A. This section covers specific requirements, products and methods of execution relating to the water distribution system for the project. The interior piping is specified elsewhere. B. Distribution will be buried "Arctic" pipe with a steel carrier pipe, polyurethane insulation and a high density polyethylene jacket. The pipe 41 polarconsult Mt. Village District Heating shall be I.-C. Moller Plus pipe, or equal and approved. D. DIVISION 13 - Special Construction SECTION 13120 - Pre-Engineered Structures A. This section includes specific requirements, products and methods of construction relating to the district heating module for the project. The foundation is specified elsewhere. B. District Heating Module will be of wood frame construction insulated with fiberglass batt insulation, metal siding on exterior and plywood on the interior. 42 polarconsult Mt. Village District Heating E. DIVISION 15 - Mechanical Outline Specification SECTION 15010 - GENERAL PROVISIONS This is a general information section correlating mechanical work to other divisions of the specifications, defining terms, referencing codes and standards, itemizing submittal requirements, and defining submittals and information required for operation and maintenance manuals. SECTION 15050 - BASIC MATERIALS AND METHODS A. This section includes a description of specific requirements, products, and methods of execution which are typical throughout the mechanical work for this project. Additional requirements for the specific systems will be found in the sections specifying those systems, and supersede other requirements. B. Piping inside the buildings shall be type L hard copper or black sch. 40. Steel piping shall be welded and flanged. Valves shall be 150 psig. butterfly or gate for isolation, plug type for balancing. SECTION 15160 - NOISE AND VIBRATION CONTROL A. This section lists specific requirements, products, and methods of execution which relate to the isolation of all mechanical systems for limitation of transmission of vibration and sound to acceptable levels. B. All connections to engines and radiators, and between the power plant and the district heating module, shall be stainless steel flexible type. SECTION 15180 - INSULATION A. This section describes specific requirements, products, and methods of execution which relate to the insulation of ducts, pipes, and other surfaces of the mechanical installation. 43 polarconsult Mt. Village District Heating Insulation is provided for the following purposes: Energy conservation; Control of condensation; and Safety of operating personnel. Piping inside the power plant shall be uninsulated. Piping inside the district heating module and user buildings shall be insulated 1" thick rigid F/G, with all-service jacket. Piping outside and between the Butler building and the engine-modules which connects to the heat exchanger will consist of i.c. Moller or equal "Arctic" insulated steel pipe. SECTION 15191 - OUTSIDE TRENCH EXCAVATION, BACKFILL, COMPACTION This section describes general requirements, products, and methods of execution relating to excavation, backfill, and compaction of utility trenches outside of buildings. SECTION 15600 - HEAT GENERATION A. This is a description of specific requirements, products, and methods of execution for interrelated systems, necessary for the generation of heat which will be distributed to the locations shown. The method of distribution of this heat is specified elsewhere. Heat generation (transfer) will be accomplished with stainless steel plate heat exchangers, as manufactured by Tranter, or equal and approved. Primary heat exchangers will be located in the district heating module and will interface with the power plant. Secondary heat exchangers will be located in the user facility and will interface with the user's heating system. polarconsult Mt. Village District Heating SECTION 15650 - COOLING SYSTEMS A. This section describes specific requirements, products, and methods of execution relating to the cooling systems for the project. The work of this section includes provision of systems and equipment for removal and transfer of excess heat from the locations shown, including the furnishing of interface apparatus and controls and the connection at interfaces with other mechanical systems. B. Generator cooling systems will consist of existing Young horizontal radiators, controlled by Volkman variable speed controllers. SECTION 15850 - BALANCING AND TESTING This section covers general requirements and methods of execution relating to the testing and balancing of the mechanical systems provided on this project. SECTION 15900 - CONTROLS AND INSTRUMENTATION This section describes specific requirements, products, and methods of execution relating to the system of temperature controls and instrumentation for the project. 45 polarconsult Mt. Village District Heating F. DIVISION 16 - Electrical Outline Specification SECTION 16010 - GENERAL PROVISIONS This is a general information section correlating electrical work with other divisions of the specifications, defining terms and indexing the various Division 16 sections, referencing codes and differences from Division 01 requirements, and defining submittals and information required for operation and maintenance manuals. SECTION 16031 - DEMONSTRATION OF ELECTRICAL SYSTEMS This section includes procedures to be used during final inspection, instruction of operating personnel, and a certificate of completion for the convenience of the Contractor and Owner to determine whether each item has been completed. SECTION 16040 - IDENTIFICATION This section covers labels and name plates for equipment, branch circuit panel board directories, and other identification needed for electrical equipment. SECTION 16050 - BASIC MATERIALS AND METHODS A. A major part of the electrical specification, this section covers the workmanship, coordination, and standards necessary for the electrical work. The products covered include raceways, conductors, and connectors. Installation techniques to cover various construction methods are noted so that fireproofing is maintained, water penetration and moisture migration through raceway systems are prevented, and the proper connectors are used for various conductor terminations and splices. B. Only copper wires and cables shall be used. Raceways shall be rigid galvanized, sherardized steel conduit or electrical metallic tubing with compression or set screw type fittings, for all conduits concealed in the walls, above the ceilings or exposed in work areas. 46 polarconsult Mt. Village District Heating SECTION 16130 - BOXES, CABINETS, AND PANEL BOARDS A. This is a general section that outlines various standards to follow in the construction of these items, with specific notation on certain types of cabinets to suit various systems. Mounting heights for outlets and cabinets are covered in this section. B. Panel boards shall have copper busing with bolt-on type circuit breakers. SECTION 16140 - WIRING DEVICES A. Receptacles, switches, device plates, and special purpose outlets are covered in this section. B. All outlet devices shall be specification grade or better. SECTION 16150 - MOTORS AND CONNECTIONS Motor specifications regarding voltage, phase, and temperature rise are covered in this section. Distinctions between which motors and control items are included in Divisions 15 vs. contract or responsibilities are also shown. Appliance and miscellaneous equipment connections, whether owner- furnished or contractor-furnished, are covered to provide suitable connection techniques. SECTION 16160 - MOTOR STARTERS AND DISCONNECTS Specific requirements for overload and phase failure protection to be included in motor starters are covered. Also included is a listing of various devices suitable for use as equipment disconnects. SECTION 16180 - OVERCURRENT PROTECTIVE DEVICES This section contains a general listing of various devices suitable for overcurrent protection, such as circuit breakers, fuses, and current limiters. 47 polarconsult Mt. Village District Heating SECTION 16190 - SUPPORTING DEVICES This section covers, in a general way, the various supporting, fastening, hanging, and securing techniques approved for use by the contractor in the installation of the electrical work. SECTION 16450 - GROUNDING This section itemizes complete grounding requirements and techniques for connections. SECTION 16480 - BRANCH AND FEEDER CIRCUITS This section clarifies drawing preparation technique as being diagrammatic rather than "as-built" and gives the contractor flexibility in conduit routing and circuiting, as may be determined by job site conditions. SECTION 16500 - LIGHTING A. Light fixture construction for both interior and exterior fixtures, lamps, and ballasts are covered in this section. B. Interior light fixtures shall be fluorescent, of industrial design. Exterior fixtures shall be high pressure sodium wall packs controlled by photocell. 48 polarconsult Mt. Village District Heating VII. Project Cost Estimate A. Power Plant Heat Recovery System The first cost component is construction of the building to house the district heating system. This includes the mechanical and electrical equipment inside the module and the connection to the modified AVEC power plant as shown in Figure V-3 on page 23. The second cost component is the modification of the existing power plant system. This includes the connections of Unit #1, Unit #3, Unit #4, and Unit #5 to acommon manifold and to the heat exchanger as shown in Figure V-3 on page 23. B. District Heating Distribution System The connection of the north school complex to the district heating system includes installation of piping from the face of the district heating module to the three school buildings, and all equipment and connections within the school mechanical rooms, as shown in Figures V-4, V-5, and V-6 on pages 24, 25, and 26. The connection of the middle pump house building to the district heating system includes installation of the piping from the tee off the main line to the schools to the middle pump house, and all equipment and connections within the mechanical room as shown in Figure V-7 on page 27. C. Operation and Maintenance Costs Annual operation and maintenance costs are determined by the regular system maintenance required as well as the number of failures. Regular maintenance will be performed three times per year by a skilled maintenance crew. Day to day operation will be by a local person who will monitor the system and notify the maintenance department of any failures or problems. Repair of these failures will result in an additional 1.31 trips per year to Mt. Village by a skilled repairman. With a cost of $2,000 per incident the result is an average cost of $2,600 per year to repair failures. Cost of the three annual maintenance trips must be added to 49 polarconsult Mt. Village District Heating this failure repair cost to arrive at the total annual operation and maintenance cost. D. Project Cost Summary Total project costs for the north connection are shown below. Variations can be made by adding or subtracting items. Table VII-A Summary of Project Costs Concept 6 1 Module Construction $75,290 $86,828 Plant Piping Revisions $20,936 $39,233 Middle Pump House Conn. $125,618 --- Junior High Conn. $218,637 “- High School Conn. $248,847 --- New Elem School Conn. $310,987 --- Old Elem School Conn. --- $156,023 Total Project Cost $1,002,315 $282,084 Total project cost includes design, supervision, inspection, administration and construction. The complete cost estimate is included in Appendix C of this report. 50 polarconsult Mt. Village District Heating IX. Conclusions A. Heat Availabli Fuel Consumption There are presently over 64,755 gallons of equivalent fuel oil per year available as waste heat at the Mt. Village power plant. The district heating system can displace the following amounts of the proposed user heat requirements: Table IX-A Annual Heating Fuel Displacement & Pipeline Heat Losses Concept 6 1 Heat off Engines 64,755 64,755 Annual Heat Loss in Dist. Pipes 7,392 838 Heat Available to User 57,363 63,917 Bldg. Heating Fuel Required 103,495 20,830 Amount of Fuel Displaced by District Heating System 45,725 20,830 Percent of Available Heat Used 719.7% 32.6% During the winter months the system would use all of the heat available, as can be seen in Figure IX-1 on the next page. As the system grows, and more heat becomes available, the old elementary school or buildings adjacent to the proposed distribution pipeline can be connected. 51 polarconsult Mt. Village District Heating Pos Heat (Gallons of Oil) s § CL J Tanks p J Yf) Tee 0 Mh hy’ YM U7 LILLIE bho Mee MM Y J bs) RLLLLLTT 7x VA S I Leer RSD PSR GF) METRES ERROR RRRKKKKK KK IO OSLER EEO OOOO OY SK De MOO OOOO Jan Feb Mar Apr May Jun Jul Month ee Middle Pump House Middle School 4 Z High School —a- Available Heat Figure IX-1 Heat Available vs Heat Required S S 4 st KY cS 3 BRR 2 4000 LESS RREG S| RSE PRE RRM Oo OX KK OOOO KREG 2 PRKKKK KK SSSR & 3000} PAS X< CXKQN SKS CSSA 3 DeSSES Cx oO XY <<XS ZERREKRKG g BERRA XOOD Coe EERE RRA s Breweries <o24 LLL 2 EXER KKK SS S| COCO 4 Ey 2000 | Reereeernrrernrrnrnrnn OS OOO SSIES. erences oe ROSSER <\ LEESON RRR RINK EX EEE 1000 | —BeEcoceeoe ego OOOO RK CX EERE Ro RSS ON K SAKREKR ERR vor BERKRKERRK SSM TAC aietetetatetatatetatetstetstatstatetetstetes 9 L BER ESS OOS Month of the Year oo B88 concept 1, Old Elem Concept 5, Preschool, Water, Middle, & H Ky Concept 6, Water, Middle, Elem, & High S —- Available Heat at Plant Figure IX-2 Gallons of Heating Oil Displaced 52. polarconsult Mt. Village District Heating B. Project Cost Summary The school paid $1.15 per gallon, and the city paid $1.045 per gallon for heating fuel during 1989. The annual savings is computed using these costs for heating fuel. The concepts are summarized in the following table. Table IX-B_ Project Summary Concept 6 1 Amount of Fuel Saved 45,725 20,830 Annual Savings $51,606 23,956 Total Project Cost $1,002,315 $282,084 Straight Pay Back (yrs) _ 19.4 10.5 C. Project Summary The life of a district heating project is a function of availability of waste heat off the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance. The requirement for electricity and the need for space heat in the community imply an infinite project life. With proper maintenance the life of the district heating system will exceed 25 years. Because annual operational and maintenance costs and economic decisions will be made by AEA, final economic conclusions are not presented in this report. The straight payback time for the best alternative, Concept 6, is 19.4 years. 53 polarconsult Mt. Village District Heating X. Recommendations One way to make the project more economically attractive is to reduce its scale by minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste heat projects in other Western Alaskan communities to reduce Mt. Village's share of the high mobilization, shipping, travel, and supervision costs required. 54 polarconsult Mt. Village District Heating APPENDIX A Calculations polarconsult Mt. Village District Heating Power Plant Heat The amount of heat required to keep the power plant building at 65°F was calculated. The number of air changes in the building was assumed to be equal to the amount of combustion air required by the engines plus 2. This added up to 37 air changes per hour in the Mt. Village power plant. The conduction heat loss was then added to the infiltration heat loss and the amount of heat rejected to the ambient air off the engine subtracted to come up with the hourly heat requirements for the building. User's Monthly Fuel Oil Usage The annual fuel oil usage, as obtained from the users, was distributed over 12 months using the number of heating degree days (HDD) as follows: School (Monthly HDD) x (Annual Fuel Consumption) Monthly fuel oi] usage = «—-~--------------------=----- "= 222 -n nnn nnn nnn nnn nnn nnnnnnennnnnen ( Annual HDD ) Middle Pump House = Monthly fuel records from the City of Mt. Village Available Waste Heat & User Heat Displaced The amount of waste heat available at the power plant and the amount of heat required by the user were calculated using a computer model with the following input and assumptions: 1. Historical monthly power generation data for the power plant, annual users' heating oil consumption, and monthly heating degree days were input. 2. The amount of heat available off the engines versus power production, from the engine manufacturer's data, was input. 3. The heat losses for the proposed piping system, plant heat, etc. were input. The hourly diurnal power generation variation per month and the hourly diurnal heating requirements were input to distribute the power and heat data over a one- year period in the model. 5. The amount of heat usable by the proposed users is summed up for each month to determine the equivalent number of gallons of oil which will be displaced by the district heating system each year. Program Notes: a. The amount of heat available off the engines listed in Table III-A is from the polarconsult Mt. Village District Heating engine manufacturer's engine specs. The amount of heat available off the engines used in Appendix A comes from the engine manufacturer's test data which they indicated was good to * 5%. We used 95% of their test data values for use in Appendix A as the heat available off the engines. 01/23/91 04:20 PM Mt. Village 1 Old Elem GENERATOR DATA: Cat 3412, 1200 RPM Concept Mt. Village Jan-91 WASTE HEAT UTILIZATION SIMULATION WORK SHEET Location Date: wet ! ! o! alin 4190000 oe! G 1000 a1m a sie BI \ZEEEE ZEEZEEE El as Bic | SEESEESEEEE d| 8 dis \ K&S , Ua ! 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SH INNAANAAANAAAANAANAANNN |B Si I NAAAAAAANANNANANANANNN AN > =. © eal De! wT 1a << ae | —~ 1 Iq aot a : | tt OG IMMBBDADMOOMOMOMOOrOOMMMoO WO DG ITE NDNOD-ONNNHOOMR NEMO sTaT IO LL ITO NDNON-ONNNDOWLN NTT Ors SY Ll AOOOMOADDODOMWODWDATAGH4O0OM A HOV INAIOTNMNOODOWOOONNNNHMWMNTIMN 1O BY INAHOTNMNOOOOOONMNNNNN TIMMY Oh [OonnNNNSOCRARR ARE r SOCOM FAH MMAMAMMMMMMMMMMMeAMMemeAmeme | w EH LOMAMMAMMMMMMAMeMe|M«aMaam . - wo gt ast we Ost 1 Bz! a en) in Sal eal z| PQ 1LOITMMNMDKK—MMMAMMMAOTDDOO OD AD | DODNATHOITTOOHNDNDONNAE@ In QIDONNANTHDATTOOHNDNDOMMNEO ED INDDDODNADDDODTODWDOWHNNOS BD 9 IH OOOMADANNNNAMNN AAA AAAOOOr 10 HO IER OODOKDHANANANMN AAA HAOOOr oe H WNW NNMN OOO OF EDDA wowwr' 4 fe ' MMMOMMNNMVsTT TTT TST STS STIMM H a o- IMMMNNNMS TST TTS TST SSTTIMM ~ 3 ! wot in a i > & 1 in = | 2 Rt HE ENO OF NDD HAGA ANOL NNO: > ES IMNDOADOAIMMWOAANNHWOAMONMAFHOTH Is E IMOOHDOAMMWOADANNOAMDOIMAIO SH BD INN AADANOOME NOWELL AMAANATO OD AT | CNM TNODOCCOFHOCONOCOMNDEW 10 Bd lOMMTNHODOCOCCOHHOOCONOOCOMN@rw S2 H WOOONM OOK KH AADAAHDAADAN™ OwWr a s AND i MMMM SSF SITTITCIMSTIMMMM | Oo on | MMMM OMY SSSTCSTCISCIMS TIMI - 1o wy 1 oom 1@ ot My ' 3 1 iN > t a | 2 P| wr a HH LANMITNOFDNOAINMNTNOFADHAOINMY 1 DH LANMTNHOFDAOANMTNOFDAOAINMST oat & pl AAAI | goa! FAA AAAS oO ! fom} a om Io Mure | ai ‘3 8 I is $e | a1 ogt le a= ot os] e | 16 a > ' | 1a @ a1 ' 1 1 a 1 1c ! I4 vot 1B ow | io 2 | is 3 | iB 8 = ot 1= = te ad 20,832 PG 2 OF 3 2,593 3,268 1,935 99,883 178,009 238546 300546 1,916,153 1,086 322 0 29,638 0 880 629 , 2,140 304 259 255869 196,810 57 2,782 270169 2,937 313 266 y Heat Displaced Heat Demand 288804 3,140 343 292 Maximum Hourly Heat Available KW Gallons Peak KW Maximum Hourl Maximum Hourl BTU’s Avg 2 Concept: Old Elem WASTE HEAT UTILIZATION SIMULATION WORK SHEET —- Concept: 1 Old Elem Mt. Village *% Main HE | ** ** User HE ** 06/12/90 ®) Hot < | * Cola i * | Hot ®)* (Cold ® Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 118.00 42.18 Gpm (Max Heat Demand) /8,000 Calc. 38.16 38.24 33.24 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/ft*3 Spec Heat 0.863 0.859 0.854 Btu/lb F Ther Cond 0.233 0.234 0.234 Btu/Hr Ft F Viscosity 0.759 0.819 0.900 cP Pipe Ground Temp. In 190 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 42.18 gpm Length 260 ee to: Elem School Size 2.0 in 0.16667 feet Heat Loss 18.33 Btu/Hr/Ft Heat Loss 4,767 Btu/Hr 4,767 Used above Velocity 3.74 Ft/Sec Friction Factor 0.0425 From Calc. Below Pipe Head Loss 14.33 Ft Darcy-Weisbach Pipe Head Loss 6.21 psi Calc. PAGE 3 OF 3 18 PM 01/23/91 04 Mt. Village = a ° o N a 2 Upper, all GENERATOR DATA: Cat 3412, Concept 100% 365 12,785 Annual KWH (KWH / / 4 / Z 7, / / if, i, ) OTTO TOV OM N-DOHOMMBDAND MOMMMNMNMTT ITT TTT TTT TONS BSO000G0000000000000000 OOOOCCOSGOCCG0000000000 (BTU/HR} (BTU/HR (BTU/HR) (BTU/HR) / (KWH Dec 0.038 Dec 31 1,810 OTTO TO AVA OM ODADOMOOHiND OMMMMOTTIT TTS TTT TIONS OSCCOOGOGGGGGGGG0000000 OOCOCCDOCCCOCCCCSCCCC000 30 405 1,436 WOO DANA AD 1,405 1, Nov 0.038 Nov ONDO90000 QNOGOGOSOOOS DOANADAN AY ANNAN WDIGHLADTON-AGHDATONTOOON OMMMMOMTINTTO TIT T TITS S SOSS96G00000000000060, QCCCDCCSDCCRCCCCC000000 777 Oct Oct 31 1,072 3,777 044 0.039 QO onas©o00000 FIANOMANAIMAM ANMMMMM MM DOP IO ASONN AIAATONTOOON MMMMMMOMGTIMNGTCOT ITT TT ITTIS OOCOC08G0G0) 0000000 OOOSCS0CCCO: OCOCCCCO 30 601 s - 1 ! ' ! 1 1 1 Bt et Go! At 1 1 1 1 vi a at at ol ot oO} { zl ae 1 t 1 ! 601 044 Sept Sept Sept ° a v 9. o = ° & v o o = v = a v Z 3° QO DOP IHATONNAIAATONTOOON MOMMMOMONMGIMNTTCOT TTT T TTS IOOOSSSSSOSS0G000000000 DOCCCOCDOCSCCOCCCCCOCCCO Aug 357 31 357 a 3 < Aug 172,100 161,300 1 0.044 DOP SLAP ONN-AIANTONTOOON MOMMOMNMGIMNTCOT IIIT IIT POCOCSS9GGOSG00000000000 oCCCCCCCCCCSCCCCCCCCC0O 500 172,100 161,300 184,300 205,100 224,400 2,176,700 118 gpm 299 31 299 > a 3 5 July , 0.044 IPSS ATONMAADATONTOOON MOMMMMMNTIOT COSTS TTT STIS OOCCSGG0S000000000000, OCCCSSCCC0C00C00000000 Pipe Loss 838 013 632 eh rh 4 30 422 500 152 (Btu/Ft) (GAL/YR) a 1 4 June June 0.044 0.039 , QP IORATONNAGAATONTOOON MOMMOMOMNTIMNTTOTTTT STS SSS OOSCCSSSCSSC0000000000, OCCCCCSCCCCCCSCCCCSCCCO Heat rate at kw-load above Heat rate at kw-load abovs Heat rate at kw-load abov load abov Heat rate at kw- Heat rate at kw-load abo’ Heat rate at kw-load abo’ Heat rate at kw-load abov Heat rate at kw-load abov Heat rate at kw-load abov Heat rate at kw-load abovs Heat rate at kw-load above Flow Rate 31 697 200 150 May > = Heat Loss 18.33 , 23.05 23.05 044 0.039 0 PIMTOANAR OP NR DDAOMOOHNO MOMNNMVTTTT TST TTT TNOTTS OSSS0G660G000000000000, ecocecoeeseCeCCCSCCCCC000 30 185 500 163 (IN) 2.0 4.0 038 0.036 ’ 1,185 Pipe Dia. April April 1, 0 er month, Gallons Apr. i March SPIO TOA ONE DOHNOMB@HNO MMMMMNTTIT TTT T TTT TONS OOOOCOGGGGG0000000000, OoCCCCCOCCCCCCOCCCCCDCO 31 038 036 1,541 Pi March 1,541 Ba March March 0 WOTSPO SONA OM N-DDHOMBNANO MMMOMMTTI TTI TT TTT TOOTS IIODOOOGGSGOGGGG000000000 OOOCOSSCSSSSCSCDCCCC000000 Feb 038 Feb 28 1,627 Feb 1,627 $0 Btu/hr.xF QO 0 Btu/hr. QO Btu/hr. 2,757 Btu/hr.xF 77,618 Btu/hr. DOTIMTOANNLOMNKODHOMOODANG HOTOM MNNMNNNTI TTT TTT TINTS coon Sse ie) T1828. a) Ba, eee eee ae SOOOCS9000000' OOCCCCO om 300 178,900 192,600 174 100 Btu/hr.xF Jan Jan 31 739 Jan 5 5 1,739 In , , 1 Gallons of Oil used PAGE 1 OF 3 Mt. Village Jan-91 WASTE HEAT UTILIZATION SIMULATION WORK SHEET Location: Date in 77,618 Btu/hr. in e A hea onstant ing ng Pip iping ace p. Plant heat E pre! Paging Total ci Variable losses Radiator losses Plant Subsur. Surface Feb Kwh/Mth:217,300 178,900 192,600 174, As HDD/Mth AT. D. GENERATION DATA: WEATHER Non- SeasonalSeasonal Use ? BUILDING DATA: Fuel use, gallons Elem Schoo Headstart/ Middle Pum Middle Sch 2! New Elem. High Schoo 5 Building in use; l=yes, O=no Power Plant Production & Hourly Variation ANM TNO DHDOTAMTNOLONOFAMS AANA Hour 2D | NODDOAD AM TTT TOTMMMMMMANOD MONNNNMGTT TTT TTT TTT TT TIO S8C0000000000000000000000 ecceeoeCCCCCCC0000000000 Summer DOOOANAM TIP GMOTMMMMMMANOD MOMMNOMTTTIT TITS TTT TTI OSCC00C0CCG0' ooocCc0cG SOOOOOSSCCCO! oooCcCeCc0O 039 0 Assumed Diurnal Heat Winter Demand Variation 217 house a ip Middle School Da HDD New Elem. Ss: ‘1s kwh Elen School = | 0 .0 0 | Headstart High School Total Use Gone 1g Middle Pum Compound boiler eff.: Building Seasonal cons., gl. Power year factor Non-seas. Year no. Annual Mt. Village Dec 647 Nov 609 Oct 609 Sept 546 Aug 569 July $19 2 Upper, all June 529 May 533 - Concept: 530 April onth (1,000 BTU’s) Jan Feb March per hour by m WASTE HEAT UTILIZATION SIMULATION WORK SHEET Hour Heat available DADAM NINTH TAT NOR LEHO QWODOTANIM AT AMMDANT TON @ WNNNN OK RAADADDAADADODOOOR DO ANON MAMMAddOddHOKAATOW I~ MMANDDDOMONODMOTOOOUNT DI MININGOCDDDDODDADROGOOO Dr AHOODATANAAAAAGAANNINN NOH AVAVNOTANNONDOOTOO TSS OTTTONNGONOOOOSOOBINNININD WOAAOOOONOGODDHDAONACI AN DAANNOOCANPR ANITA AT Ait PPT TTA TINO ONIN OININININID mNOOwLN Aan se TETTIAATAMMMD ADP SOOD AON AAT TTONTOMMMM OTT T TANIN OOOO OIINOINININININ OWddNNODCONNMONNNONAT TI DADON NN ATAMOGCDOOATOGOOO TOMM TT TION TIN Tt ADMANAADAMAOMOMMANMMANMAM WN ODOMMMN AMIN THOM rAMEALELO STOO SST TAIN TUNIN BIN LN INL TLD SNOOTS IMAM TAT TMATMODOO DNA MN OAIOOD-OMBOMOGOMAADAN TIT TTT TION TNOOSONNONT TTD DNNANDAADADM@ACAMMaANINOOTOM DOOTPOMOOTOTATOORMAMMNAM TIT TTONNGOWOOWUOOONINNNOIN MOOMOWMA AM AN ANANADONNWAN®D MOQDOPFAADANOGDG AAR AT TOON NNN TAN COCR COOTER ROCHON NMNNTNMNCOOrOr-DODOVOIHwOLIN MAHOATOOAMATAMNMTAOT SGN Or TMT NOOWODTDOONOANNO TO DDI OF DADDDAAAD™OOwODo ANAM TOR OROTAMTNLrAROdAMS AAA AAAI 5269773 57,293 6,155 566126 5,581 4,760 4,183 4,495 3,967 7902 3 4,213 4,487 4,945 Heat demand by hour by month (1,000 BTU’s) 454854 412,720 387,530 358,948 364,903 413,460 384,769 437863 513343 431293 4,689 5,914 543964 Gallons BTU’s Month I~ MrWDNOTTADOMNONNAANTOW WINN DAHONMMTFOVHOMCOATANS DODOOA AAA AAA AOAOAAOOONA AAA AA ANNNNNNNNNNNNNNN AAMANDODOONDOTONOOTINOd AMOMMTMTOOCrOTAMNAMMND-OM DUO DWNOF ERA ERA EERE TR eOeNn tdidtdtdtdtdidtddtdiddtdiddaddddded ANON MOTMANAAMOSTE TTOWOHIN NADAMOOK MOA NOTOONNAES AAQAANNANNNMNNNANANNAN et ddd TANT TMOMMONOrMAMMrOMnG WOON OM ANN OOGOM NTO TON TMNAD WOOOCSCE EEE REREEEEEEE ROO MANDAN CMDAT OTA TAOAT PRORRDADAAADDAAAAAADODOR AN ddd WWOWOWCOCORFEEFKEOOVDVWWVOWOU DODDDANOOCDOCOCOAAAAAAAAAD adda DOCOCANDANDDAONOWWAHOMs AHOANSTR ERR OOR er err onnan SUSI TTT TTT TTT TTS olmololmtolololololulololololololoimetubd AE TRAOTHOORONMTATIMAOMG NNNNNM STEP TTT TTT TT IMM MM ttt ddtdddteatddedtdeted DOM NAAT TOMAODTANOINAOO DDNDAQDANAMN GOAL DADTIMON DIMM OR DOVODDOR AA AL EER oOOo dtd NMAMAMOMNADTMMNOFHOONRANS ONAN DAOANNTOAOORCOOMATO DODDDA AA AAA A AOMOAAOOONA AAAI ANN NNNNNNNNNNNNN WOMOTANAMMMNAGHRMNNATONM DON D ANAMMONCGCOMANAAN HORM PFA ROACOCCOCOCSCCOONGCCONADD AAA AIAN NNNNNNNN NNN et NM TNO ONOAAMTNOFORDOFAMS AAA AAA ANN 9713579 626 521,433 905,301 1202749 1507379 7632 139, 4 6,541 Total Demand 1449685 1358124 1287863 997677 337,569 6,541 4,632 139,626 521,433 905,301 1202749 1507379 9713579 Total Demand Heat Delivered Annual RODAIAM NNT ANOrredO TFOOONOTANAMALAMMNANT TOMO CWBNNNNOKRAADAOADAAAD DOOR OO Dec AWM R MAMMA AO AHOTADTOW I~ MMAMIDDODONODDOTOOCOUNT NINN GOGCCDDDODDDAD-OGoGoOMo Nov 609 Ar AAOONAGANAGADAAAANNNN NOLL ANNO TANONDDOTOOTST ST LNT TTA NGSONOOT OOSOWOINININ Oct 609 WOO AAOOOONGDODNDAAONANOIAAN ADAMANNGODTRAANI SAAT dds POT TTT TIN TINOOOOIINSININININD Sept 546 MADAM CMBAGOTMNANN TAOS RRORRADAAANDAADAAAAADOwOR AN ttt Aug 177 July 6 6 6 6 6 6 6 6 2. 7 7 4 ii iz 6 6 6 6 6 6 6 6 6 6 ADDDDDANODOCOCCOAAAAADAAAN ddd June DODONDANBOAONOANd Ors AAOANTR ORR OOM OR orn onnan SPST CST TST TSS ST 427 May DUNN ANIDADOMOOOMMANNOOTO DOOTOMOGOTOTATOORMOMMNAM TIT TONNOGOCGOOOWULVOINNINOW 530 April WNCOMOMAHMANANANADONNNAD PMNOOWDOTAAADADOAGAAR ATION WMODNTANOCOrOCOFRFRLLINNOIN month (1,000 BTU’s) March Feb TRADOATOOAMNATANOTAOT TG NOTIMTNCODOOTOOONLGANNOS CWNNNNNORROADDOAAAOr OCOD Jan ANMTNORDACIAMSTNORAHOdN™: ddI Heat delivered by hour by Hour 6,155 46,022 5,581 ” a a on o _ v © _ a © © o o” s ” ” a a) ” wo o 4,183 4,760 1,518 50 4, 6,541 71 3,668 1 1 1 1 1 1 ! ! 1 1 1 1 1 1 1 { ' ' 0 337,382 4,945 4,487 4,689 5,914 Gallons 2 Upper, all Concept wo os on 313 266 y Heat Displaced 343 292 Peak KW Avg KW PG 2 OF 3 y Heat Demand Maximum Hourly Heat Available Maximum Hourl Maximum Hourl WASTE HEAT UTILIZATION SIMULATION WORK SHEET 2 Upper, all Mt. Village ** Main H fe ** ~=6User HE ** 06/12/90 ® Hot, * ™ (Cold * * Hot * * Cold * Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 118.00 119.72 Gpm (Max Heat Demand) /8,000 Calc. 108.33 108.56 153.29 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/ft*3 Spec Heat 0.863 0.859 0.854 1.004 Btu/lb F Ther Cond 0.233 0.234 0.234 0.383 Btu/Hr Ft F Viscosity 0.759 0.819 0.900 0.425 cP Pipe Ground Temp. In 190 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 119.72 om. Length 930 Ze to: Preschool/Teen Center Size 4.0 in 0.33333 feet Heat Loss 23.05 Btu/Hr/Ft Heat Loss 21,438 Btu/Hr 38,809 Used above Velocity 2.75 Ft/Sec Friction Factor 0.0377 From Calc. Below Pipe Head Loss 12.30 Ft Darcy-Weisbach Pipe Head Loss 5:33 psi Calc. PAGE 3 OF 3 WASTE HEAT UTILIZATION SIMULATION WORK SHEET —- Concept: 2 Upper, all Mt. Village ** Main HE ** ** User HE ** 06/12/90 * Hot * * Cold * * Hot * * Cold * Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 118.00 119.72 Gpm (Max Heat Demand) /8,000 Calc. 108.33 108.56 153.29 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/ft*3 Spec Heat 863 0.859 0.854 1.004 Btu/lb F Ther Cond 0.233 0.234 0.234 0.383 Btu/Hr Ft F Viscosity 0.759 0.819 0.900 0.425 cP Pipe Ground Temp. In 190 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 119.72 gpm Length 1090 Fe to: Middle Pumphouse Size 4.0 in 0.33333 feet Heat Loss 23.05 Btu/Hr/Ft Heat Loss 25,126 Btu/Hr 38,809 Used above Velocity 2.75 Ft/Sec Friction Factor 0.0377 From Calc. Below Pipe Head Loss 14.41 Ft Darcy-Weisbach Pipe Head Loss 6.25 psi Cale. PAGE 3 OF 3 01/23/91 04:15 PM Mt. Village 1200 RPM 3 Elem & Upper GENERATOR DATA: Cat 3412, Concept Village Jan-91 Mt. WASTE HEAT UTILIZATION SIMULATION WORK SHEET Location Date: 365 12,785 Annual 126,479 PAGE 1 OF 3 (0606 6 0 0 0 0 3m Bd oo SSS: BEB en ca 6a OP TM TO NA OM IN DMDAOMMDHNO AMMAN GIT TTT TT TO TT ASOCCCGGGGG000000000000 IDOOCOOSGGOCSG0GCG000000 31 1,810 BTU/H! BTU/H BTU/H! BTU/H Dec 0.038 Dec OP TM TOU OM IN DDAOMODANO AMON GIG TTT TTT IMM TS O9000006000000000000000, [ole lolololelolololololololalolololololalolo} 866 933 895 893 Nov Nov 30 1,436 , 1,405 15,668 19,654 0.038 +0 WIPO ATONNAIADATONTOOON MOMMMOMTITOTTOGT TTT TTS OCSOCOOGG0GG000000000600, OOCCCDSCOCCCCCCCCCCC0c0 31 1,072 Oct 1,072 Oct 0.044 0.039 Oct 500 152,500 172,100 161,300 184,300 205,100 224,400 2,176,700 11,776 OPP ATONMAADATONTOOON MMMOMOMNTIMOTTOTT TTI ISS 2000000000) O000G00000, oSccccCcGG CCCCCCCCO 30 601 039 Sept "601 Sept 2 044 Sept Output Heat To Heat To OPT ATODMAIADATONTOOON MMOMMMNGTINTTCOT IT TIT TTI IIOOOOSGGSGSGGGG0000000 OOOCOCOCDSGCOGSCCCCCCOCCO Aug "357 May Aug Aug 31 357 0.044 0.039 OPPO ATPFONNAAIDATONTOOON MMMMMMTIMTTOT I TTT OSOCSS0SCGG00000000000 OoooCeCCCCCCCCCCCCCCCSCO 31 299 July O 152,500 172,100 161,300 184,300 20 299 July July 0.044 0.039 OPTRA ATONNAGDATONTOOON OMMMMOMTIMOT COT TT TTT 2990000000! OOOSG000C0GGR Sdddccccc0 OOOCCCCCCO 422 -039 30 422 June Pipe Loss (Btu/Ft) (GAL/YR) 6 5 1 4 June oeoae ’ OITORATONNAGHDATONTOOON MOMMMONTINTTOVTTTITTSTSS OOCOCOSOGSGGGGGGGGG0000, eoCCCCCCCCCSCSCCCSCCCCC00 Heat rate at kw-load above: Heat rate at kw-load above Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above: Heat rate at ki Heat rate at ki 200 150 Heat Loss 0.044 +039 May 31 697 0 , Gallons 1,185 Pipe Dia. (IN) 20 20 20 0. 0. 0. 0. 0. 0. 0. 0. 0 0. 0. 0. 0 0 0 0 0 0 0 0 April 30 1,185 April Elem School Headstart April 3217, HDD/Mth =: per month 31 1,541 wow S8SSS8SSSSSSSSSSSSSSSSES March March , 16,782 12,985 March 1,541 Pi bist Elem Schoo 20 Headstart/ ODOTIMTONNE OPN DDAOMBORINO ONMNNNNNVTITITIITIT TIONS O80000000000000000000000, [olololololololololalolololololololololololololo} 28 Feb 1627 Feb 1,627 Feb , Boiler Effic. 1 0 Btu/hr. ipin 87,151 Btu/hr. P. ea O Btu/hr. 87,151 Btu/hr. OPFIMTFOVAOMMRDODHOMMMAHNO HOw MOMMOMMNMGT TTT TTI TS BOOSC9SSG99009000000000 IPOOSOSSSSSOS0000000000 50 Btu/hr.xF 2,757 Btu/hr.xF 31 1,739 217,300 178,900 192,600 174,500 163 a ° oS . = aa a 2 3 © a oO a ° So ov ©. iS a ° o m7 100 Btu/hr.xF Jan 1,739 Jan 000 it Jan Jan Power Plant Production & Hourly Variation 0.038 Gallons of Oil used 18,899 17,701 29,23 3 6 ANMTNOFDDOFAMTNOrAnOKAMS AAA AAA ANNNNN Ein ng sses Hour a Radiator lo ! ' ! ! ' ' ' ' ' ' 1 1 1 1 1 ' ' ' ' ' ' ' ! ! 1 ! ! ' 1 1 1 \ ! 1 1 1 1 1 ! 1 ! ! ! ' ' ! ! ' ! ! ! ! ' 1 ! 1 1 1 1 | ! ! ' ' ' ! ! ' ! ! ' 1 1 1 ! 1 1 1 1 1 1 ' ' ' ! ! ' 1 1 ! ! ! 1 1 1 ! 1 ! 1 ! ! ' 1 ! ' ' iping ace preh al constant piping: Kwh/Mth 1s. a is Da HDB kwh Sons. 0g. Compound boiler eff.: DOD AMT TIT TOMMMMMANOD OMGILI GTI GTS PTT TTI 2999999900090906000800000 SSSdcCCddCSCSdSCeGsdd000 bg ine 832 7154 5 8 8 9 2038 Summer 0.039 0.038 SeasonalSeasonal Use Total Use Middle Pumphouse Plant Subsur. Eng To Surface Plant heat. 2 Building Middle School New Elem. High School 2, 6 0 0 High Schoo 53 Building in use; l=yes, O=no DOONAN Terr TOTMMMMMMANON OMOOG GIS GTS SST TTT TTI DoDENSSSSSSSSess99esssco 3S0S0d00d00d00d00d00000 0.039 b-038 Assumed Diurnal Heat Winter Demand Variation Power year factor Year no. Seasonal cons., SYSTEM LOSS DATA: Non-seas. GENERATION DATA. WEATHER DATA: BUILDING DATA Fuel use, Variable losses gallons Constant losses: Middle Pum Middle Sch 2 New Elem. Mt. Village 3 Elem & Upper - Concept: WASTE HEAT UTILIZATION SIMULATION WORK SHEET Fe Jan Heat available per hour by month (1,000 BTU’s) jour AGOCODOOPGoOTA TOON MODOOAD DGOTOMAGONOOONNTOAIMMACR DIDO AANADAD NAD D0 0000 MOO CANN ddd IADANAO WNAVONAL HME MANE LAMNADANAIM NIM NN GODDDDDDDDDOININODO ODA AAOONOMONDSCONOOWWwWH AI OCOAAANOMATDADDOMBDIMMMO NTT TNH SON DOKOOSINNINIA Smarr eroanmaanwcanaanan DNA ANNDMODDOMOOMGOMO0OM PITTI TTTONTNOOOOIINSNINININ DOWOOMrMOOMOHTTTTOOVOMNMMD OTMMA~HOOADOOMOMMOAMSAANM LPT TT TINININ DOW OOININOININININID OMdHMMOANOwWNANNANNAT TIN FOL AATOMTAUMNINOMNOMNNA SOOM TTT TONNNINNNINT OMAANNOOMOR SIT TONTOT TIN DAMA ANA ANAMOAOCGANON OOOO SOMME TO TNNNNNININNS S TNOOMN SMATOTATIMATMAAHO ADOT TRAM ODAADANNANVDOD TPT TPT TON TNNONININNNN STN DOCVOOHOOOTONOTTANOT ATED DNNTFNAVOOMINMOMNNOANRANTON TIT TMNNOCOSOOWOOOINININGIN WAAMANANONOAONAADANINNAD NAA AMGODODNMBCCHOAMMANG OPIS THOOOROOORRROOIINNOIN PONURINTOOWNUH ONIN TOR ddA INADODONNANOSCO-COONOMNNSw LWINMNTHNCCROR LOR ODHOONNOOIN WRADAANOONTONIMsTTINAMNdA AR MMAMN AAA AMADA GEM CINUINNCGCCHHDDDDDDAWOEOOWHO ANMTMNOFDHOFAMTNOLODnOGAMS Sad AANA 506479 5,506 4,683 430770 4,109 3,890 4,418 7828 3 7136 447761 405,856 380,437 352,084 357,810 406,367 377,905 4,868 4,412 4 424886 4,619 5,837 536871 Heat demand by hour by month Gallons BTU’s 7367 377,905 430770 506479 559033 51 Month April (1,000 BTU’s) March Feb Jan Hour 1 1 ' 1 1 1 ' ' ' 1 | 1 ' ' 1 ' ' 1 ' ' ! ! 1 1 ! ' 1 ! i ' ' ' ! I ' ! ' 1 1 1 1 1 1 1 ! ' CADP AMmNMOOndMaANOMNBANDOO DMADNCANTOSOROTONANNOTMMO ANNAN MNNNNINONIN TMNT TON AANANNANNNANNNNNNNNNNNNNNN MMM AM TTOTAAMNMTOOHOOWOMOM DIMOMOKDAOCONTAGCDNDVOAOND DNDDDDNOOAAAACCOOCCOGOOAD AAA AAA ANNNNNNNNNNNNNNN CAMOMCONMTTTOMIMAMMMOArAdO SIMAMNMANIMSNNOTAGAOONOR MAMAN MTNNNNHNNNN TMH ss AAA ddd Ndr AMAe MAAN MONTE MOOTON ADALADONAOCOANDADDAADAR OMA DEKKER DDDADAAAADOODDDDMOOD TOANANTOODOCOHMANOMwWOINnDAT AAOOCOCHANMM SST TIMMMMMIMANNd AANNAANNANNNNNANANNANANAN WWOOOOOONEA EF OCOOWVWOWUWOOO DDDDDDANDOOCDCOCOAAAAAAADAD tet OM OMNTANCOOTALOANANDOONAO JAD DANNNGOCONM TN TONTMMAS TPT TTL INIA IN INIA INNA, FAAMANOTOCODOWLONTOTTANOLK CAANANTMAMNTTORMANGNNHR ODO WMO TOMOREEEEEERR RRR wOnN dtdidididtdiddtdidtdidididididdddidddd ANNE ANOCHOCNHHHOOBOOH TORN WAOWVOM TNE DOONAN TNNANN TARA ANADDANOT AANA AAA OOO AAAS AANNNNNNNNNNNANNNNN GS ANAHAOGOMNMMOMNO@MMBBONNAD RMADANAAMNNRAMNGAOAGOTAM AANTANNMDINNNINNNNN TMNT TON NANANNNNNNNNNNNNNNNANNNN WMAMANONHONANDANdOTOODANOAD DN TOTRONTOOROTHNANNHONTOD AAMT SST COST TIM ST IONIAN NANANANNNNNANNNNNNNN ANNAN ANM TWOP OAOFAMTNLLANOGAMS FSA ANNAN 4,632 169,264 621,316 ********1441296 1807925 11634732 6,541 Demand 1738488 1626293 1543732 1194487 395,449 6,541 4,632 169,264 621,316 ********1441296 1607925 11634732 Total Demand Annual WNOCCOCOoLO TOT Ad TOOr MADD ADGOTPOMAGONOCONNTOIMMAC CMNMNMNNOKR RK AADADAADAADODOOOGOHDO Dec AMOOM CDN ddI AO DAONAONAR RNR NR raAMAnANAM MMNNMMNNNGCDDDDDDODDOOIINODO Nov COMA AHOOMOBONDOONDOWWLD OAR OOHANOMNTDADDOMOOMMMO ON TT TINNNOCONOLROLobSowvsonunnn Oct Serene eronmaarwarnany MONAANNDMOGHDOMGOMGOMD900M OST TTT TON TNOOSONNSNNINNIN Sept TOMNANTOBDOCOHMANOMOONA®BAT AAOCOKAMM SST TIMMMNMMMMANNI ANAAANNNANANNNNNNANNNNN Aug COOCOCOOLOFFEFFROLOOVDVWOOOO July ADDDDDDANDOODODOAAAAAAAAAD daa June TNOOMMTMATTACOAIMAAUMADA I HOOTTR ANE CON TNANNNDVOS TUTTI STON THN TS 500 May MOWOWNOODTONOTIANOdI SED DNN TNAVOOMNMOMNNOALANTON TIT TOMNCOOSOOOOOLINNNINSIN April $21 WA AMANANONONOAADAANNNAD NAA ANGODODNDOCGOAMMANO LN TITTNSSOROOORRE CONN month (1,000 BTU’s) 535 March 'y WONT NAOOWONOHONN TOM ddA ADODONWANAVOCOMCOCONQMNNO-O ND TAN OO DR OR DODOOINSOIN ur b} Feb 551 y hol PAAAANOOMTMAMN TITIAN AM AMADA ARM AAINOGAR ON LIN CGCOGDDDODDDAD-OWOwww Jan 615 ANM SNC ODOdANMSTNLrANnoKFANS AAA ANNO Heat delivered b' Hour Heat Delivered ! Im oa 1 4 jn 4 In © Is IN Is Is Im @ Ion 10 0 Ia 1 © 10 ' ' In © I~ Oo Is 1o os lo w ir) ' ! om in @ I © low 19 is 1 190 0 jac Ins > jo Ist Oo wos iu @ In a 1o Iq 1 In oO 1 10 1s is ' ! ! Iai iso mw Is 10 ! ! ! oon ms ju Oo In s its yo lou mo jo = ms 1o I+ Ia @ 1o © I~ @ Im os iss is ' ! 1Oo lo 10 © Is os In is ! 1 5 o oO wo a S 6 = 3 a oO ue o a oo D> re} Qo 9g 2 6 Oo 4 O 355 249 PG 2 OF 3 355 302 313 266 Heat Demand Maximum Hourly Heat Available 343 292 imum Hourly Heat Displaced Peak KW Avg KW Max. Maximum Hour] WASTE HEAT UTILIZATION SIMULATION WORK SHEET —- Concept: 4 Elem & Upper - New Elem Mt. Village Location: Mt. Village 01/23/91 Date: Jan-91 GENERATOR DATA: Cat 3412, 1200 RPM 04:15 PM Output Heat To Heat To SYSTEM LOSS DAT. Flow Rate 118 gpm kw Coolant Ambient 100% Constant qosses Heat rate at kw-load above 3,777 1,405 (BTU/HR) / (KWH) Plant piping: QO Btu/hr. Heat rate at kw-load above: 3 3,777 1,405 (BTU/HR) / (KWH) Sub: surface p pipin 86, p28 Btu/hr. Heat rate at kw-load above: 149 = 2,800 866 (BTU/HR) / (KWH) Engine preheatin QO Btu/hr. Heat rate at kw-load above: 224 = 2,692 933 (BTU/HR) / (KWH) Total constant: 86,526 Btu/hr. Heat rate at qyetoad above: 306 2,960 895 (BTU/HR) / (KWH) Heat rate above: 330 2,960 893 (BTU/HR) / (KWH) Variable losses: Heat rate above: 330 2,960 893 (BTU/HR) / (KWH) Surface piping: 50 Btu/hr.xF Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) Plant heating: 2,757 Btu/hr.xF Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) Radiator losses: 100 Btu/hr.xF Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) GENERATION DATA: Kwh/Mth:21 WEATHER DATA: HDD/Mth: 1,541 1,185 697 422 299 57 Bo 7300 178,900 193 600 174,500 163,200 150,500 152,500 172, 499 1 , , , , ’ 7739 = 1,627 1,072 1,436 1,810 12,785 BUILDING DATA: Pipe Pipe Heat Pipe Fuel use, Non- In. Boiler Dist. Dia. Loss Loss gallons SeasonalSeasonal Use ? Effic. (FT) (IN) (Btu/Ft) (GAL/YR) Elem Schoo 20,832 QO 1 0.73 260 2.0 18.33 838 Headstart/ 2,154 ° az 0.73 930 4.0 23.05 4,013 Middle Pum 6, 250 3,000 1 0.73 160 4.0 23.05 632 Middle Sch 20, 588 0 a 0.73 420 4.0 23.05 1,774 New Elem. 0 0 0.73 0 2.0 18.33 174 High Schoo 53,098 0 L 0.73 190 3.0 19.42 448 Building in use; 1l=yes, O=no Assumed Diurnal Heat Power Plant Production & Hourly Variation Demand Variation: . . . 4 +038 38 Z 36 0.036 0.036 0.036 0.039 0.039 0.039 0.039 0.039 0.038 38 3 34 0.034 0.034 0.034 0.035 0.035 0.035 0.035 0.035 0.035 0.034 0.038 0.038 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 0.038 0.038 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 0.039 0.039 6 0.034 0.034 0.034 0.034 0.037 0.037 0.037 0.037 0.037 0.037 0.034 0.034 0.041 0.041 7 0.038 0.038 0.038 0.038 0.037 0.037 0.037 0.037 0.037 0.037 0.038 0.038 0.043 0.043 8 0.042 0.042 0.042 0.042 0.039 0.039 0.039 0.039 0.039 0.039 0.042 0.042 0.044 0.044 9 0.042 0.042 0.042 0.042 0.044 0.044 0.044 0.044 0.044 0.044 0.042 0.042 0.044 0.044 10 0.047 0.047 0.047 0.047 0.046 0.046 0.046 0.046 0.046 0.046 0.047 0.047 0.044 0.044 aa 0.048 0.048 0.048 0.048 0.039 0.039 0.039 0.039 0.039 0.039 0.048 0.048 44 44 12 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.045 45 13 45 0.045 0.045 0.045 0.049 0.049 0.049 0.049 0.049 0.049 0.045 0.045 0.044 44 14 47 0.047 0.047 0.047 0.051 0.051 0.051 0.051 0.051 0.051 0.047 0.047 0.043 43 15 0.048 0.048 0.048 0.048 0.049 0.049 0.049 0.049 0.049 0.049 0.048 0.048 0.043 43 16 0.048 0.048 0.048 0.048 0.049 0.049 0.049 0.049 0.049 0.049 0.048 0.048 0.043 43 17 0.049 40.049 0.049 0.049 0.044 0.044 0.044 0.044 0.044 0.044 0.049 0.049 0.043 43 18 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.043 43 19 0.043 0.043 0.043 0.043 0.049 0.049 0.049 0.049 0.049 0.049 0.043 0.043 0.043 43 20 0.038 0.038 0.038 0.038 0.044 0.044 0.044 0.044 0.044 0.044 0.038 0.038 0.042 42 21 0.038 0.038 0.038 0.038 0.040 0.040 0.040 0.040 0.040 0.040 0.038 0.038 0.042 42 22 0.041 0.041 0.041 0.041 0.040 0.040 0.040 0.040 0.040 0.040 0.041 0.041 40 40 23° 0.045 0.045 0.045 0.045 0.040 0.040 0.040 0.040 0.040 0.040 0.045 0.045 0.039 39 24 0.040 0.040 0.040 0.040 0.042 0.042 0.042 0.042 0.042 0.042 0.040 0.040 Power year factor Hl Year no. Seasonal cons., gls. 29,23 Non-seas. cons.,qgls.: 3,000 Compound boiler eff.: 6.73 Jan Feb March es a June July Aug =e Oct Nov Dec Annual pays aT. 28 31 43 33 31 31 30 31 365 HD! 1,739 1,627 1,541 1, 185 631 29 357 60a 072 1,436 1,810 12,785 kwh: 217,300 178,900 192,600 174,500 163,200 150, $00 152, 300 172,100 161,300 184" 306 205,100 224,400 2,176,700 Gallons of Oil used per month Sellen Building Jan Feb March April June July Aug Sept Oct Nov Dec Annual Elem School 3,140 2,937 2,782 2,139 629 0 oO 322 1,086 1,935 2,593 3,267 20,830 Headstart 293 274 260 200 117 71 50 60 101 181 242 305 2,154 Middle Pumphouse 1,262 1,202 1,156 966 705 QO 0 Oo 654 905 1,100 1,299 9,249 Middle School 3,102 2,901 a ue 2,114 622 Oo 0 318 1,073 1,912 2,562 3,228 20,578 New Elem. 0 0 QO 0 0 9 0 oO 0 QO 0 0 High School 8,002 7,485 1, 083 5,453 1,604 0 0 821 2,767 4,932 6,609 8,327 53,089 Total Use 15,797 14,799 14,034 10,871 3,677 71 $0 1,522 5,682 9,865 13,106 16,426 105,901 PAGE 1 OF 3 Mt. Village 4 Elem & Upper - New Elem - Concept: WASTE HEAT UTILIZATION SIMULATION WORK SHEET Annual DADOHOBOONCNANOCCOMADMORAr MADOGTOMAGONOCOONATOIMMACH WMNNNNOKRAADADAADAADODDOOODO Dec MOWDBCOTTANATANANTNOOMAS ONNONOE ENR NANEPAMACOMAM INN N GOCDDDDDDMDDDOOSOODO Nov 600 ODAUNANNDONOMONDCONDOWWOWD JN OOAAAIOMUTOADDOMBOMMMO NTI TANN GON GO OOSOOSININININ Oct 600 erranrrrernrdoncoaroa: MOAAANNOMODOAMAIMOK OPTI TT TTNNTNOOCONNL! 538 502 502 502 533 AONAMNMAOR Ae MAMMOrMOMNNN OOS AAMT LO UI IMI HULL SO ONO PT LOUD SLA I INO LA LAL LOIN St $10 SCOTOONNCOTOONNINNOSHMOVsCN ANADODANHANAMODOONNONOOWO) DTOMNM TT TON TONINNNNONNNST SoS June TOOT NMM TANONMMNTANTAAAD NE AOCOTSTR ANE OANAANNANDVOOe OTT TET TON TNNONNNNNN TS sI0 May NAGCOWNDOATANAT TOMAS TOWN TNAVGOMNMOMNMRARANTSO OTTTTTONNOGOOOCCOLONNNING: 529 April COAATAOMMOMOMOMMOAAOGOWMA MNAA-AMDODOBNBDOONGHAIMMOANO MO TTTTNOOOROCURFFOCNNNON March AP OCOCOHOOOOWWVNOOONADAIMAO MADDDOMANCCOrCOONOMINHORD MNNNTHNOCOR OR LR ODODOOINOOIN jonth (1,000 BTU’s) Feb MOOCCHOMNd age TAT THMONNANM Pe ipttean hdelalalstalstuletatabel stetetelptule) WIVNNNCCOCODDDDODDAD-OwOWDO per hour by m Jan ANN TNOROHROdAMTNLCRAHAOGAMS tt AANA Hour Heat available 5191735 56,444 559498 6,083 3,895 4,423 4,113 4,688 5,511 3,833 7141 4 4,417 873 Heat demand by hour by month (1,000 BTU’s) , 18248 406,306 380,902 352,534 358,275 406,832 378,355 431235 506929 4,624 537336 425306 5,842 BTU’s Gallons Month Annual ANNONIMONOOTTNCONOOWR ATH AP ONODOANTINRNDTOGTOATONG DDDDDDOA AAA AOROHAOOOND AAA AA ANNNNNNNNANNNNNN Dec MMMM MANONTTONNDOCVCCOM@OH PF IMOMNNTNOCRONATATTNOR A DNMONMORR RRR eee OwONn iid Nov RvODDoMrwnNnsNCarornaader SAAAAMOCLBOHOMMCNOONAAES AAA OAANNANNNM ANNAN AAA Oct MANMNOOTANNOK ADT IE TIAVOAM DOOMOR ANNOOR RTH TON TMAAD WOOOBOOR EEE EEEEEEEEEE Ow Sept RMANAAHNCOrMBOdE TOMoELTOOKIE ROR ORROAAADDCOAAAAAAAADONR NN tdi Aug 1 1 ! 1 ! ! ! ' 1 1 ' 1 ' ! i ' 1 1 1 ! 1 1 { 1 1 1 1 1 1 { ! 1 1 1 1 i ' ! ' ' 1 ' ' ' 1 WOWOWOOOE EAH OOOWBWOWWOWO DWDODDDANANOOCDDCOADAAADAAAAAA adda DMA MONVOAADAMOANONNADNOO AAOANTE EER OOrerernonnan Tr TTS errs QMONMOMAMMAEMMNMMMMMOOrN OMNIS TN OO ONMTATIMOAVO ANNAN SSS T STSCI TT IMAM, Addicted DAA AOWAMN DOOM NAMOMMAAOON JDNONMAAOIANTN ARNON CONTORM LIN O~ DODDODA-D- DOr roo i tdtdididtddiddtderrcticicicticted >> M-WODNHOTTABOAMONHANrOwW WN NN DAONMMTFONHOMOCOATANG DOVDDA AAA AA AOAOAAOOONA AAA AAA ANNNNNNNNNNNNNNN POn@ANWOTMONOSNOTOONMAWOr MODDWAAGAMTONRATAIMOMMAOWOM 1 ! 1 ' ' ! 1QOrMRANDDDOCODDDOADOCONAwD” Jan INM TOO DAOIAMTNCMOROGAMS Fatt tN 9741758 4,632 139,985 522,641 907,454 1205635 1511015 Total Demand 1453178 1361393 1290958 1000058 338,269 6,541 4,632 139,985 522,641 907,454 1205635 1511015 9741758 Total Demand Annual WACO HOMBOONCNANHCGOOMABOrAD MANOOTOMATONOCGONNTOAIMMAG CNMMNMNNORRAADADDAADAADOOOCO0 Dec IMOODOOTTANAAANANINOOMAS WNNONOR ORNL EAMADOOMAIM IM DOCGCDDDDDDDDODOOGOCW0 Nov 600 ODWNNNNOONOMONDOONOOWwVLD IN OOAAANOMATOADDOMDOMMMO NTT PNNNGONOLO-OOSWOONNINN Oct 600 PAA Ronn dOnoC@roanaam DNA AANDMOGODAMAAIMOAIMOOOM TIT TTT TIN TNOOOONINONNNINN Sept 538 MNANNOCrODOKdE TOMLBLOTOOIE PEORLDAADANDOAAAAAAAADOMR ANN ttt Aug 177 WWOCO8WWLVLE Err oOoowwvwwowuww July DODDDDANBOOCODOAAAAAAAAAA el June DAOAAMNACANAROANOANADNDO ANAHOON TE Er oorererronnan veresevevererses rere ers May ANMNOCGOWONDOATOANATTONONANED ANOWN SN VGOMNMOMNNEARANTON OTTTTTNNNHOCOCOOOWOWOINNINNSIN April (1,000 BTU’ s) COAATHOMMOMOMONMOAROOOMA ANADA-AMGODOON DOOKU AMMDNo MOTT TITNGSORCOORFEOONNNON month March AT OODOAOOOOONOOON ADAMO DADDDOWANCOOrCOONAMNNOKD MNDNTHNCORDE OF DDOOONNOON hour b: us Feb i MBOCHOMd ase sas TNMOMMANIM AS SSN SADA ARM DDN mI CWINMNNCCOCHHDBDDDHDOAD™-Owwwo Jan ANAM TNO OHOdAMNTHLCrAROdAMNS ANNAN Heat delivered b Hour Heat Delivered 4,632 139,985 378,355 431,235 506929 559498 4,181,611 6,541 BIU’s 537336 425306 448226 406,306 337,262 6,541 4,632 139,985 378,355 431,235 506929 559498 4, BTU’s 4 Elem & Upper - NewGallons Concept: 45,462 4,113 4,688 5,511 6,083 1,522 4,624 4,873 4,417 3,667 71 50 5,842 3 2 PG 2 OF 3 313 266 y Heat Displaced Heat Demand 343 292 Maximum Hourly Heat Available Peak KW Avg KW Maximum Hour]: Maximum Hourl WASTE HEAT UTILIZATION SIMULATION WORK SHEET - Concept: 5 Upper - Elem Mt. Village Location: Mt. Village 01/23/91 Date: Jan-91 GENERATOR DATA: Cat 3412, 1200 RPM 04:13 PM Output Heat To Heat To Ss 118 w Coolant Ambient 100% QO 3,777 1,405 (BTU/HR) / (KWH) 0 Btu/hr. Heat rate at kw-load above: 75 3,777 1,405 (BTU/HR) / (KWH) Plant. piping Bi in 76, 992 Btu/hr. Heat rate at kw-load above: 149 2,800 866 (BTU/HR) / (KWH? Engine preheatin 0 Btu/hr. Heat rate at kw-load above: 224 2,692 933 (BTU/HR) / (KWH) Total constant: 76,992 Btu/hr. Heat rate at kw-load above: 306 2,960 895 (BTU/HR) / (KWH) Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) Variable losses: Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) Surface piping: 50 Btu/hr.xF Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) Plant heating: 2,757 Btu/hr.xF Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) Radiator losses: 100 Btu/hr.xF Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) Heat rate at kw-load above: 330 2,960 893 (BTU/HR) / (KWH) GENERATION DATA: Kwh/Mth: , ’ WEATHER DATA: HDD/Mth: 1,810 12,785 BUILDING DATA: Pipe Pipe Heat Pipe Fuel use, Non- In Boiler Dist. Dia. Loss Loss gallons SeasonalSeasonal Use ? Effic. (FT) (IN) (Btu/Ft) (GAL/YR) Elem Schoo 0 9 0 0.73 0 2.0 18.33 838 Headstart/ 2,154 0 1 0.73 930 4.0 23.05 4,013 Middle Pum 6,250 3,000 dL. 0.73 160 4.0 23.05 632 Middle Sch 20,580 0 dL, 0.73 420 4.0 23.05 1,774 New Elem. 0 0 0 0.73 0 2.0 18.33 174 High Schoo 53,094 0 1 0.73 190 3.0 19.42 448 Building in use; l=yes, O=no Assumed Diurnal Heat Power Plant Production & Hourly Variation Demand Variation: Winter Summer Hour: Jan Feb March April May June July Aug Sept Oct Nov Dec 9.039 0.039 a 0.038 0.038 0.038 0.038 0.044 0.044 0.044 0.044 0.044 0.044 0.038 0.038 0.038 0.038 2 0.036 0.036 0.036 0.036 0.039 0.039 0.039 0.039 0.039 0.039 0.036 0.036 0.038 0.038 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 0.038 0.038 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 0.038 0.038 3 0.033 0.033 0.033 0.033 0.034 0.034 0.034 0.034 0.034 0.034 0.033 0.033 0.039 0.039 6 0.034 0.034 0.034 0.034 0.037 0.037 0.037 0.037 0.037 0.037 0.034 0.034 0.041 0.041 7 0.038 0.038 0.038 0.038 0.037 0.037 0.037 0.037 0.037 0.037 0.038 0.038 0.043 0.043 8 0.042 0.042 0.042 0.042 0.039 0.039 0.039 0.039 0.039 0.039 0.042 0.042 0.044 0.044 9 0.042 0.042 0.042 0.042 0.044 0.044 0.044 0.044 0.044 0.044 0.042 0.042 0.044 0.044 10 0.047 0.047 0.047 0.047 0.046 0.046 0.046 0.046 0.046 0.046 0.047 0.047 0.044 0.044 11 0.048 0.048 0.048 0.048 0.039 0.039 0.039 0.039 0.039 0.039 0.048 0.048 0.044 0.044 12 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.047 0.045 0.045 13 0.045 0.045 0.045 0.045 0.049 0.049 0.049 0.049 0.049 0.049 0.045 0.045 0.044 0.044 14 0.047 0.047 0.047 0.047 0.051 0.051 0.051 0.051 0.051 0.051 0.047 0.047 0.043 0.043 15 0.048 0.048 0.048 0.048 0.049 49 0.049 0.049 0.049 0.049 0.048 48 0.043 0.043 16 0.048 0.048 0.048 0.048 0.049 49 0.049 0.049 49 0.049 0.048 48 0.043 0.043 17 0.049 0.049 49 0.049 0.044 44 0.044 0.044 44 0.044 0.049 49 0.043 0.043 18 0.046 0.046 46 0.046 0.046 46 0.046 0.046 46 0.046 0.046 46 0.043 0.043 TG) 0.043 0.043 43 0.043 0.049 0.049 0.049 0.049 49 0.049 0.043 0.043 0.043 0.043 20 0.038 0.038 0.038 0.038 0.044 0.044 0.044 0.044 0.044 0.044 0.038 0.038 0.042 0.042 21 0.038 0.038 0.038 0.038 0.040 0.040 0.040 0.040 0.040 0.040 0.038 0.038 0.042 0.042 22 0.041 0.041 0.041 0.041 0.040 0.040 0.040 0.040 0.040 0.040 0.041 0.041 0.040 0.040 23 0.045 0.045 0.045 0.045 0.040 0.040 0.040 0.040 0.040 0.040 0.045 0.045 0.039 0.039 24 0.040 0.040 0.040 0.040 0.042 0.042 0.042 0.042 0.042 0.042 0.040 0.040 Power year factor i Year no. 0 Seasonal cons., gls.: 8,404 Non-seas. cons.,gls.: 3,000 Compound boiler eff.: 6.73 Jan Feb March April May June July Aug Sept Oct Nov Dec Annual Days 31 28 31 30 31 30 31 31 30 31 30 31 365 HDD: 1,739 1,627 1,541 1,185 697 422 299 357 601 1,072 1,436 1,810 12,785 kwh: 217,300 178, 900 192,600 1 0 163,200 150,500 152,500 172,100 161,300 184,300 205,100 224,400 2,176,700 Gallons of Oil used per month, Gallons Building Jan Feb March Apr. Elem School 0 0 9 Headstart 293 274 260 Middle Pumphouse 1,262 }e 202 1,156 Middle School 3,102 a 2,748 2,114 New Elem. 0 0 9 High School 8,002 Total Use 12,658 11,863 11,252 8,732 3,048 71 50 1,200 4,596 7,930 10,513 13,159 85,071 PAGE 1 OF 3 - Concept: 5 Upper - Elem Mt. Village May June July Aug Sept Oct Nov Dec Annual April March jonth (1,000 BTU’s) Jan Feb Hour WASTE HEAT UTILIZATION SIMULATION WORK SHEET Heat available per hour by m DACCOCOCOCv0 PETA TOONMADOOAE FORO TANNA IMMMANTTONO CONNNNORRAAADAAAADOOOR DO OMOCOR COMMA ddd ANTNOONHO AK MMAMADDOODONODHOTOG ONT CNNMNNGOCBODDDDOADEOOOHDO COMAdHHAHOONOMONDOONCOwWwWLHD AMD AAMATMNANDAGTOA GTS ON TTTNNNCCINLLCEOLOVOOoONNNIN meena er damon weonanan TAMNNCODNTHOAAN Ter dtddds OVITIT TT THN TNOOOLUNNLNNNNN OOLC0OrrWOOONNTNNOOMOTTT7O RAS TOOKROdA TR ST STROTR MMS ON TI TTTNNOINOOOOUN SOI DOMWANAMMOANOVMANMANMATTIN AD ANDO ATNMOOOOATOMOOOD OTM TT THON TNNNNNNNNHS ToS CoroOoNNCOTONvHvwOrwTONeTN AMOQOCAAMMOMMOTNONNAME AERO OT IOMeT TCH TNNGNNNNHN seo MPO AMON SONTOPTMSIMATMAAHND MOVNAANNDMOD-OMOOMOOMAAAN OPTI TT TT TONTNOOOONN ONT TSN PHAOVOOHOCOOTONOTTONOI ASD MAODOHOMR KS TOTAITOOOMOMMNAM OTT TTTNNNOOOOVOOOONNNNHLEIN MOAT AMANOAONONAADANMINGD PMOQWDOTAAAGAODI ANE TOON ONMNTNONOCCE OOCrFroOoNNNnoN AM OCOOHOOOMLHONN TAR GAMA ONAADAOMNMAIADAGAMATOOCAOD DNNNTNNOCrOrvrononoonnoon WN OOF OMA AN TMANMTTHNAMNANM NOMMNMNNOODOM@TOOCONOANNOTO CNNMNNNORRDADDDAADO-OOODO ANMTNORDHOGAMTNLOLOAnOKAMST FAA AANA 5275249 57,352 566591 6,160 4,765 5,586 4,188 4,500 7972 3 »907 3 4,218 4,492 ePete 413,170 387,995 359,398 365,368 413,925 385,219 438328 513793 , 4 4,694 Heat demand by hour by month (1,000 BTU’s) 431713 5,919 544429 Gallons “pru’s 544429 431713 455319 8 365,368 413,925 385,219 438328 513793 566591 5275249 Month 7825605 DAT AOD ANT SONOS HAND, AROAGONOGANTORADOAAM Soi TETTOOORE ERR OWOoOowowun: dtd ttt ttttted) 531 , a DADA ANONINNDNOBVOD BOTTOMS MAQMMNADOGANMODAM ADDON TAO ANNAN MS TIS TIMMMMMMMMAN dtd MANAMM-AOMMOADOAAN ADAM: QDDAAOANMMSTAAAONAAOOS ADODDAANGCCOCOCODSSGSCOaA Na: tdi 922 ADDON HNOTANMOTOONOOLN@NN: PONV AAI IANNGIONOGAONDO! MNUIIMIN GCOGOGOGOOSOSOOSNININI 552 WMODOTINOOMANMTATIMADM 09.9 0 09 9 FLD LA LALO LN LA LN LN LALA INL se a a ea 140 7347 422,758 729,445 967088 1210469 WWOOOOOEF EEK OOOwWwWwwwww 7632 110 4 DWODDAIAAGDOOOOOAAAADAAAA ddd 9 6,541 POON ANA TEOOOMNTANONNDOR™ PTO SO DAANGONDAD ANDO 0 MAMMMMAMMMMTIMMMMMMMMMM 355 Total Demand DWAPFMAOAMNN MTR AANADITOS NAVONMOMLErOAONNTONINAAS COCC Od dt ttt dtd tO A ttt dtttttettteteted) 049 , 803248 280,388 1 h ANNAN NOODODOAWOWOWWWWAAD DI HN PHOO~ DNMTA TIM NAAN SESE TTT TT TTT TOM ttt ettetetted 309 , a OA ANAT AGANOADOM SE mOMINM: IDO OD ACD AA ANM AM DODO Mauro; TITTNOOOH ER OOOVBWOWWONN tddiddddddddddddddriceted 1,528 NNO TOM AnoMrNoToonrve TMOMNTAMTTONMANONNHE OO! TI TFTTNOOOOOWVWVOOSOOOONIIN tttdttddtdttdtetetteted 472 1 1164375 1091224 1035089 INMPNOrDAOAAMNTNO-OHNOdAMS AAA AANA month (1,000 BTU’s) iy ur b Feb Heat delivered by ho’ Heat Delivered Annual DNOCCODOOTOTHTOOMMABVOAr FORR OR TANNA AMMNANT TOMO COMNNN ORR AADADAADAADOOCOK OO Dec MOO COMMA AAIANINOON NO I~ MMAM ADDODONCGDDOTOS ONT NINN OGOGODODDDDOADWwowoww Nov 610 QO AHA MHOONDMONDOONOOWWWH MOM ANMATMONANDANATOA GS NTTTNNNOONOLEOLBLbLbHbuunnnn Oct 610 mane ere dawworworanang MAN CONTR ANION TR tds STITT TCM TNOOSONNONNNNN Sept 547 497 PT WMCDOTNOOMANMTATIMADMO MMM MM TNNINNINNNINNNNNN TTS FAI dtd ddd Aug 140 COCCOOCOLOLOE AFF OOOBbWbUwUOOO July DDDDMDANDOCCOCOANAAAAAAAAD a June WRMAWMANATE NON TANLANDONWN WOPIMGORAADACCNDADAADOroN MAMMAMMMAMMMAMTIMMMMMMMMMME May HAOWCOCHOCOOTONOTTOMNVAAITD MAAOOMOME KR TOTATOOCDMAMMNAG MITT TINNNOOOCOOOKBLINNNNLN April NOAA TADANONONONAAAANNNAD FMOODO SAAD ADODA ANE AT THOM NMMND TAN COCR OOO FE OONNNLID March Ar OCMBCHOOOHMLHONNTANGAMAWH OCNAADAOMMNATADAAIAMATOOADAD NNWNTINNOCr Or Lr DDDooNNwooN MrOOHOMA AM TMNT SNAANMHANT NOMNMANCOCDODTOOONOANNDTO CMNNNNNCGRRDADDOAAANO™-OOGCODo Jan AAMTMOFAOHOFAMTNOrAHOdANS AAA ANNAN Hour 45,102 5,586 6,160 4,765 1,200 4,166 4,632 110,347 383,225 438,328 513793 566591 4,148,477 50 6,541 71 3,048 455319 413,170 280,388 4,492 4,950 431713 4,694 5,919 BTU’s 544429 431713 455319 413,170 280,388 6,541 4,632 110,347 383,225 438,328 513793 566591 4,148,477 BTU’s Gallons 5 Upper - Elem Concept na os oN 280 233 248 206 313 266 343 292 Peak KW Avg KW PG 2 OF 3 y Heat Displaced Heat Demand Y Maximum Hourly Heat Available Maximum Hourl Maximum Hourl ! er ! ! 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In 205 180 Temp Out 190 200 T Avg. 197.5 190 Flow 118.00 Calc. 108.33 Fluid Glycol50Glycol 50 Density 63.34 63.53 Spec Heat 0.863 0.859 Ther Cond 0.233 0.234 Viscosity 0.759 0.819 Temp. In Temp Out T Avg. Flow Length Size Heat Loss Heat Loss Velocity Friction Factor Pipe Head Loss Pipe Head Loss e Pp ro <) ° we an DEON w 0 eeteted Orem OF RaIUNO: Ox BOWD THIAARG ON WOOO ** User HE ** * Hot * * Cold * 190 160 170 180 180 170 119.72 Gpm 108.56 149.32 Gpm Glycol 5 Water 63.78 62.40 lb/ft*3 0.854 1.004 Btu/lb F 0.234 0.383 Btu/Hr Ft F 0.900 0.425 CP Ground deg F 30.0 deg F om Fe to: Middle Pumphouse in 0.33333 feet Btu/Hr/Ft Btu/Hr 38,809 Used above Ft/Sec Ft psi From Calc. Below Darcy-Weisbach Calc. Concep’ 6 Upper - Preschool Mt. Village 06/12/90 (Max Heat Demand) /8,000 PAGE 3 OF 3 11 PM 01/23/91 04 Mt. Village 1200 RPM 7 Elem, Water, Middle, & Elem GENERATOR DATA: Cat 3412, Concept ge WASTE HEAT UTILIZATION SIMULATION WORK SHEET Jan-91 Location: Mt. 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AAA A AAA Bi 4 “ Di ort Isa 10 Hom! 1 ‘a1 Dba oO ic og | erat 1aa ig po | aio t 1a0 @ le az I Ges | ! — 1d a mab ft 1 oy 1a @ at 1 ho] ! a au 1 1s 14 Biop t ipo oy 16 2 arog t '<c 4 1p 9 <i ot 1g @ 10 o Zaz i 1S = te x 43,671 355 249 PG 2 OF 3 355 302 563077 4,016,886 6,122 5,549 244 434,815 510393 4,727 ’ 3,830 O 88,196 352 959 0 0 4,455 2,578 4,912 304 259 313 266 4,659 Heat Demand Maximum Hourly Heat Available 343 292 imum Hourly Heat Displaced Maximum Hourl 540916 428540 451805 409,770 237,130 5,881 KW Ft x, Peak KW Av BTU’s Ma: 7 Elem, Water, MiddlGallons Concept Mt. Village (Insulation added in Floors) Building Heating Summary One Std. Butler Bldg.; Insulation added in floor. 01/23/91 Fuel 0i1? 96,000 BTU/Gal Engine: poke ae 3412, 1200 RPM Combustion Air: 1020 CFM . . Airchanges/Hr: 12.93 with eng. 1.5 without eng. runni Heat to Ambient: 4,459 Btu/Min Heat to Coolant: 13,281 Btu/Min Engine Rating: 330 Kw Genérator Eff.: 93.4% Bldg_Conduction Heat Loss: 270.9 BIU/hr/E Infil. Heat Loss: 98.1 BTU/hr/F/AC Heat to Bldg Heat Heat to Additional Bldg H Kwh HDD Coolant Req’d Ambient w/ eng w/o eng Jan 217,300 1, use 5,852 669 1,965 0 182 Feb 178,900 1, Gad 4,818 626 1,618 0 170 Mar 192,600 1,941 5,187 593 1,741 0 161 oe 174,500 1,185 4,699 456 1,578 0 124 ay 163,200 697 4,395 268 1,476 0 73 Jun 150,500 422 4,053 162 1,361 Q 44 Jul 1527000 299 4,107 115 1,379 0 31 Aug 172,100 357 4,635 137 1,556 Q 37 Se 161,300 601 4,344 231 1,458 0 63 Oc 184, 300 1,072 4,963 412 1,666 0 ia Nov 205,100 1,436 5,524 DOS 1,854 0 150 Dec 224,400 1,810 6,043 696 2,029 0 189 2,176,700 ID ATS 58,620 4,920 19,681 0 1,336 Kwh = Historical Records Input HDD = Historical Records Input co, Airchanges/Hr = (Combustion Air/Building Volume) + 2.0 Heat to Coolant = Heat rejected to coolant by engine (gallons of Oil) , Bldg. Heat = Heat Loss from bldg at Soe w/-eng running (gal of Oi Heat to Ambient = Heat rejected to ambient by engine (Gal of Oil) Additional Heat Required: (Gal of Oil) , w/ eng = (Bldg Heat w/ eng) - ee Ambient) . = Heat to keep bldg at 65F with one engine running w/o eng = Heat to keep bldg at 65F with no engines running Module with engine #4; Insulation added in Floor , Engine: Caterpillar 3412, 1800 RPM Combustion Air: 1470 CFM : . Airchanges/Hr: 37.00 with en 1.0 without eng. runni Heat to Ambient: 6,161 Btu/Min Heat to Coolant: 18,483 Btu/Min Engine Rating: 470 Kw Genérator Eff.: 93.4% Bldg_Conduction Heat Loss: 134.3 BTU/hr/F Infil. Heat Loss: 47.1 BTU/hr/F/AC Heat to Bing Heat Heat to Additional Bldg H Kwh HDD Coolant eq’d Ambient w/ eng w/o eng Jan 217,300 1,739 5,118) 816 1,906 Q 719 Feb 178,900 1,627 4,708 763 1,569 0 74 Mar 192,600 1,541 5,068 123 1,689 Q 10 — 174,500 1,185 4,592 556 7532 0 54 ay 163,200 697 4,295 327 11 43% 0 32 Jun 150,500 422 3,960 198 1,320 0 19 Jul 152,500 299 4,013 140 1,338 0 14 Aug 172,100 3517 4,529 167 LAO LO 0 16 Se 161,300 601 4,245 282 1,415 Q 27 Oc 184,300 1,072 4,850 503 1,617 0 49 Nov 205,100 1,436 57,3971 674 1,799 0 65 Dec 224,400 1,810 5,905 849 1,968 0 82 NO . bP x oO s x oO So BR to s x © on ol x s Nh © o uo < wo wo wo B io . °o io Ww °o ol co So Mt. Village (Insulation added to Floors) Building Heating Summary Module with engine #5; Insulation added in Floor 04/11/90 Engine: Cummins KTA 2300, 1200 RP Combustion Air: 1650 CFM . . Airchanges/Hr: 30.06 with eng. 1.0 without eng. runni Heat to Ambient: 5, 139 Btu/Min Heat to Coolant: 21,450 Btu/Min Engine Rating: 615 Kw Genérator Eff.: 93.4% Bldg_Conduction Heat Loss: 166.9 BTU/hr/F Infil. Heat Loss: 63.5 BTU/hr/F/AC Heat to nan Heat Heat to Additional Bldg H Kwh HDD Coolant eq’d Ambient w/ eng w/o eng Jan 217,300 1,739 5,072 902 1,213 Q 100 Feb 178,900 1,627 4,175 844 999 0 94 Mar 192,600 1,541 4,495 199 1,075 Q 89 Apr 174,500 1,185 4,073 615 974 0 68 May 163,200 697 3,809 362 911 Q 40 Jun 150,500 422 37913 219 840 Q 24 Jul 152,500 299 3,959 155 851 Q 17 Aug 172,100 Soll 4,017 185 961 0 2i Se 161, 300 601 3,765 312 900 Q 35 Oc 184,300 Orne 4,301 556 1,029 0 62 Nov 205,100 1,436 4,787 745 1,145 0 83 Dec 224,400 1,810 Sr2o7 939 1253 0 104 2,176,700 12,785 50,802 6,635 127,150 0 736 Control Module; Insulation added in Floor , Engine: None Combustion Air: Q CEM Airchanges/Hr: 1.00 with eng. 1.0 without eng. runni Heat to Ambient: Q Btu/Min Heat to Coolant: Q Btu/Min Engine Rating: 0 Kw Generator Eff. 93.4% Bldg Conduction Heat Loss: 170. 8 BTU/hr/F Simei. Heat Loss: 60.6 BTU/hr/F/AC Heat to nine nya Heat to Additional Bldg H Kwh HDD Coolant eq Ambient w/ eng w/o eng Jan 217,300 1,739 0 101 0 101 101 Feb 178,900 102d 0 94 Q 94 94 Mar 192,600 1,541 0 89 0 89 89 ed 174,500 785 0 69 0 69 69 ay 163,200 697 0 40 0 40 40 Jun 150,500 422 0 24 0 24 24 Jul 152,500 299 0 17 0 17 17 Aug 172,100 357 Q 21 0 21 21 Se 161,300 601 0 35) Q 35 35 Oc 184,300 1,072 0 62 Q 62 62 Nov 205,100 1,436 0 83 0) 83 83 Dec 224,400 1,810 0 105 0 105 105 NO s pan ~ °) s x o S Bb to s x o a ro} x na ° ° x n= iS) x ES °o Mt. Village (No Insulation added in Floors) Building Heating Summary One Std. Butler Bldg.; No Insulation in floor. 01/23/91 Fuel Oil: 96,000 BTU/Gal Engine: Cabesyar 3412, 1200 RPM Combustion Air: 1020 CEM Airchanges/Hr: 12.93 with eng. 1.5 without eng. runni Heat to Ambient: 4,459 Btu/Min Heat to Coolant: 13,281 Btu/Min Engine Rating: 330 Kw Genérator Eff.: 93.4% Bldg_ Conduction Heat Loss: 456.1 BTU/hr/F Infil. Heat Loss: 98.1 BTU/hr/F/AC Heat to Bldg Heat Heat to Additional Bldg H Kwh HDD Coolant Req’d Ambient w/ eng w/o eng Jan 217,300 1,739 5,852 190 1,965 0 262 Feb 178,900 1,627 4,818 701 1,618 0 245 Mar 192,600 1,541 5,187 664 1,741 0 232 Apr 174,500 1,185 4,699 Sl 1,578 0 719 ay 163,200 697 4,395 300 1,476 0 105 Jun 150,500 422 4,053 182 1,361 Q 64 Jul 152,500 299 4,107 129 1,379 0 45 Aug 172,100 397 4,635 154 1,556 0 54 Se 161,300 601 4,344 259 1,458 0 91 Oc 184,300 NF Ore 4,963 462 1,666 Q 162 Nov 205,100 1,436 5,524 619 1,854 0 217 Dec 224,400 1,810 6,043 780 2,029 0 23 2,176,700 12,785 58,620 5pol2 19,681 0 1,928 Kwh = Historical Records Input HDD = Historical Records Input . Airchanges/Hr = (Combustion Air/Building Volume) + 2.0 . Heat to Coolant = Heat rejected to coolant by engine (gallons of Oil) | pea Heat = Heat Loss from bldg at etn” w/' eng oe (gal of Oi Heat to Ambient = Heat rejected to ambient by engine (Gal of Oil) Additional Heat Required: (Gal of Oil) . w/ eng = (Bldg Heat w/ eng) - Ses ee Ambient) . = Heat to keep bldg at 65F with one engine running w/o eng = Heat to keep bldg at 65F with no engines running Module with engine #4; No Insulation in Floor ,Engine: Caterpillar 3412, 1800 RPM Combustion Air: 1470 CEM . . Airchanges/Hr: 37.00 with eng. 1.0 without eng. runni Heat to Ambient: 6,161 Btu/Min Heat to Coolant: 18,483 Btu/Min Engine Rating: 470 Kw Generator Eff.: 93.4% Bldg_Conduction Heat Loss: 358.4 BTU/hr/F Infil. Heat Loss: 47.1 BTU/hr/F/AC Heat to Baek Heat Heat to Additional Bldg H Kwh HDD Coolant eq’d Ambient w/ eng w/o eng Jan 217,300 1, 139 5,718 913 1,906 0 176 Feb 178,900 1,627 4,708 854 1,569 0 165 Mar 192,600 1,541 5,068 809 1,689 0 156 a 174,500 1,185 4,592 622 oe oo 0 120 lay 163,200 697 4,295 366 1,432 0 71 Jun 150,500 422 3,960 222 1,320 0 43 Jul 152,500 299 4,013 Bane 1,338 0 30 Aug 172,100 S5i7 4,529 187 1,510 0 36 Se 161,300 601 4,245 316 1,415 0 61 Oc 184,300 1,072 4,850 563 1,617 0 109 Nov 205,100 1,436 5,397 7154 1,799 Q 146 Dec 224,400 1,810 5,905 952 1,968 0 183 NO s bP x o) s x oO So b N s x © a ao x s NO © oO o7 s x o wo s o wo w oO = . ND Oo o Mt. Village (No Insulation in Floors) Building Heating Summary Module with engine #5; No Insulation in Floor 04/11/90 ,Engine: Cummins KTA 2300, 1200 RPM Combustion Air: 1650 CFM . . Airchanges/Hr: 30.06 with eng. 1.0 without eng. runni Heat to Ambient: 5,130 Btu/Min Heat to Coolant: 21,450 Btu/Min Engine Rating: 615 Kw Generator Eff.: 93.4% Bldg_Conduction Heat Loss: 469.3 BTU/hr/F Infil. Heat Loss: 63.5 BTU/hr/F/AC Heat to aE Heat Heat to Additional Bldg H Kwh HDD Coolant eq’d Ambient w/ eng w/o eng Jan 217,300 1, 139 5,072 1,034 yee 0 232 Feb 178,900 A O2M, 4,175 967 999 0 217 Mar 192,600 1,541 4,495 916 1,075 Q 205 fen 174,500 1,185 4,073 7105 974 Q 158 ay 163,200 697 3,809 414 911 Q 93 Jun 150,500 422 Sole 251) 840 0 56 Jul 152,500 299 37059 178 851 Q 40 Aug 172,100 357 4,017 212 961 0 48 Se 161, 300 601 3,765 358 900 Q 80 Oc 184, 300 1,072 4,301 637 1,029 0 143 Nov 205,100 1,436 4,787 854 1,145 ) 191 Dec 224,400 1,810 5,257 1,076 L293 0 241 2,176,700 12,785 50,802 7,601 12,150 0 1,703 Control Module; No Insulation in Floor ,Engine: None Combustion Air: Q CEM . . Airchanges/Hr: 1.00 with eng. 1.0 without eng. runni Heat to Ambient: Q Btu/Min Heat to Coolant: Q Btu/Min Engine Rating: 0 Kw Genérator Eff.: 93.4% Bldg Conduction Heat Loss: 473.8 BTU/hr/F Infil. Heat Loss: 60.6 BTU/hr/F/AC Heat to =e Heat Heat to Additional Bldg H Kwh HDD Coolant eq’d Ambient w/ eng w/o eng Jan 217,300 1,739 0 232 0 232 232 Feb 178,900 1,627 Q 217 0 217 217 Mar 192,600 1,541 0 206 0) 206 206 ine 174,500 1,185 0 158 Q 158 158 ay 163,200 697 0 93 0 93 93 Jun 150,500 422 Q 56 0 56 56 Jul 152,500 299 0 40 0 40 40 Au 172,100 357 0) 48 Q 48 48 Se 161, 300 601 0 80 Q 80 80 Oc - 184,300 1,072 0 143 0 143 143 Nov 2057100 1,436 0 192 0 192 192 Dec 224,400 1,810 0 242 0 242 242 t S ay x oO) < x o °o RB ND s ay © uo S Bb s x °o © °o R - x o © bP . x S © polarconsult Mt. Village District Heating APPENDIX B Field Trip Notes polarconsult Mt. Village Field Trip Notes February 7, 1989 Leslie Moore, Michael Dahl, PCA Met with the following people in Mt. Village and discussed the project and their concerns. Spoke to the City Manager by phone. Walton B. Smith City Manager 591-2929 Joyce Brown City Clerk 591-2929 Joey Sheppard Water Operator 591-2929 Pat Langford RMW 591-2929 Patricia School Prin. 561-2140 Raymond Peterson AVEC 591-2432 Lower Yukon School District (Mt. Village, Scammon Bay, Pilot Sta.) James Luke Maint. Dir. 591-2411 Eunice Beans Secretary 591-2411 1. Weather: Inland weather influence. Drifting and blowing snow a problem with lots of snowfall and wind. Population: 700, 749 projected for next year. In summers most people are commercial fishing, although a couple are still in town and like to work. 2. Utilities: Water: Year-round distribution. Water tank located next to the high school above the main pumphouse. New water treatment plant is located up the hill from AVEC and provides all the heat and pumping to the lower distribution loop and water tank, upper pumphouse located on the hill above town heats and pumps water in the upper distribution loop. Lower pumphouse is a booster only and is right below AVEC. Use about 10,000 gal/yr for water heating and pumping. Paid $1.045/gal last year. Middle pump house (2) Burnham 460 mbh PF-36, SN 7537951. Sewer: Gravity to sewage treatment building. Elec: Overhead distribution. Fuel: Barged in. 3. Right of Way Need easement to run piping parallell to the existing AVEC overhead distribution 1 polarconsult Mt. Village Field Trip Notes February 7, 1989 line to the water treatment building and the school. 4. Equipment See attached equipment rental rate sheet. 5. Down by river dig down 6 - 8' to thawed ground. Soils either mud over gravel, or gravel right under the tundra. 6. City owned water treatment building provides heat to the building, water tank and the water distribution system. It also houses the water treatment and well. Building is founded on gravel pad. 7. School, Patricia , Principal. Total enrollment of 205. School has forced air in the Old Elem, and HS, and boilers in the Middle School and New Elem. buildings. Fuel from James Luke in Mt. Village, Lower Yukon School District. Old School (K-3), (3) seperate furnaces in three seperate rooms. 1. Weil McLain P468BWT 131 mbh (Kindergarten, new addition). 2. Lennox OH4168 134 mbh, Hot water heater, Trageser Copper Works NY, NY model OFG70A, SN 77493, 1969. 3. Lennox forced air furnace. High School (with unused pool) (6) independant forced air units Middle School Burnham V-36 302 mbh, SN7569601. Hot water heater PVI 85g, 140,000 input, SN 1.0.G.85A0 New Elementary, 2 rooms only, needs to be expanded. (2) Weil McLain BL-776W5 417.4 mbh set @ 200°F. Hot water heater PVI model 3.8-N-250-A-O, SN585- 55586, 250g, 308 gph input, 540,000 Btu/Hr input @ 136°F. Lots of room. 8. Community Hall: Single Boiler in large mech. rm (1) Slant F model 78225, 209.6 mbh, SN 787878. 9. Clinic: Singer furnace 85,000btu, model OD0108514m, SN C21759K10. Hot water heater Bock 95gal/hr recovery, 32 gal. model 32E SN 1181751P. polarconsult Mt. Village Field Trip Notes 10. 11. 12. 13. February 7, 1989 City Hall. Single Boiler, Weil McLain P-668V-WT 190 mbh CP1648274. Preschool/Headstart. Burnham V-15A 158 mbh, SN22059012. Hot water heater AERO CF-332T, 32gal., 102gph recovery. Teen center; no hot water heater, Weil McLain P-566EWT, 150.4 mbh. Very crowded. AVEC Station service panel 120/240V 1ph, 4 open on top, 2 open on bottom. Panel "B" in module 5 120/208V 3ph. Panel "a" & "b" in module 4. All engines connected to remote radiators.Covers keep snow off radiators, 2 sets of rads for 4 total. 2 attached to Butler building and 2 in module # 4. Unit #4 & #5 connected to remote rads in module #4. Heat exchanger connected in module #4 for building and engine heat. New radiator this summer, leaking coils. Electric heat not used on engines, waste heat system keeps them warm. Highest loads when windy, 470 kW. Maybe from small electric heaters which are common in back rooms. 1) Caterpillar 3412 2) None Installed. 3) Caterpillar D353 4) Caterpillar 3412 - 1800 rpm 5) Cummins KTA 2300 polarconsult Mt. Village District Heating APPENDIX C Cost Estimate HMS 9022 CONSTRUCTION COST STUDY WASTE HEAT RECOVERY SYSTEM MT. VILLAGE, ALASKA Cost Consultant Engineer HMS, Inc. Polarconsult Alaska 4103 Minnesota Drive 1503 W. 33rd Street, Suite 310 Anchorage, Alaska 99503 Anchorage, Alaska 99503 (907) 561-1653 November 29, 1990 (907) 562-0420 FAX WASTE HEAT RECOVERY SYSTEM PAGE 1 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from eight (8) 8 1/2"x11" sketches and outline specifications linking five facilities in different configurations at the village, as detailed by Polarconsult. 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 Summer 1991. Removal of hazardous material has not been considered in this cost estimate. CONCEPT #1 - Old Elementary $ 282,084 CONCEPT #6 - Middle Pumphouse, Junior High, New Elementary and High School Buildings $ 1,002,315 WASTE HEAT RECOVERY SYSTEM PAGE 1 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from eight (8) 8 1/2"x11" sketches and outline specifications linking five facilities in different configurations at the village, as detailed by Polarconsult. 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 Summer 1991. Removal of hazardous material has not been considered in this cost estimate. CONCEPT #1 - Old Elementary $ 282,084 CONCEPT #6 - Middle Pumphouse, Junior High, New Elementary and High School Buildings $ 1,002,315 WASTE HEAT RECOVERY SYSTEM PAGE 2 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 CONCEPT #6 CONSTRUCTION COST 01 General Conditions, Overhead and Profit 96,985 207,526 02 Sitework 20,636 278,176 05 Metals 1,281 1,281 06 Wood and Plastics 1,200 1,200 13 Special Construction 4,910 4,910 15) Mechanical 37,964 98,350 16 Electrical 6,843 11,965 Subtotal 169,819 603,408 Estimate contingency for elements of project not determined at this early level of design (10%) 16,982 60,341 Esclation at .50% per month ( 4%) 7,472 26,550 TOTAL CONSTRUCTION COST 194,273 690,299 PROJECT COST Design (10%) 19,427 69,030 SIA (Supervision, Inspection and Administration) (20%) 42,740 151,866 Project Contingency (10%) 25,644 91,120 TOTAL PROJECT COST 282,084 1,002,315 WASTE HEAT RECOVERY SYSTEM PAGE 3 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 WASTE HEAT RECOVERY SYSTEM PAGE 4 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 01 - GENERAL CONDITIONS, OVERHEAD AND PROFIT QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,300 Freight 24,000 LBS 745 10,800 Supervision, equipment, utilities clean site, tools and protection 10 WKS 3100.00 31,000 Per diem 180 DAYS 110.00 19,800 Travel costs, including time in travel 6 RT 1375.00 8,250 Bond and insurance 2.25 % 3,397 Profit 10 % 15,438 WASTE HEAT RECOVERY SYSTEM PAGE 5 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 02 - SITEWORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 140 LF 12.50 1,750 3" diameter Schedule 40 pipe with insulation and arctic pipe protection 280 LF 55.15 15,442 Bend 16 EA 211 5:52.95) 3,444 WASTE HEAT RECOVERY SYSTEM PAGE 6 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1.05 1,281 WASTE HEAT RECOVERY SYSTEM PAGE 7 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 06 - WOOD AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200 WASTE HEAT RECOVERY SYSTEM PAGE 8 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #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 2600.00 2,600 Hole through exterior wall for heating pipes 10 EA 110.00 1,100 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 WASTE HEAT RECOVERY SYSTEM PAGE 9 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 72.50 145 Form hole through existing wall for heating pipes 2 EA 195.00 390 4" diameter black steel welded piping 120 LF 34.50 4,140 Fittings 30 EA 63.50 1,905 Butterfly valves 5 EA 490.00 2,450 Control valve 1 EA 89.00 89 Insulation to pipe, 4" diameter 120 LF 7.74 929 Booster pump 1 EFA 1590.00 1,590 Heat exchanger, 400,000 BTUH 1 FA 3850.00 3,850 WASTE HEAT RECOVERY SYSTEM PAGE 10 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Unit Heater (1 Each) (7 - Module Building) Unit heater, 60 BTUH, including thermostat 1 EA 330.00 330 1" diameter piping including fittings 40 LF 9.70 388 Gate valves 2 EA 77.00 154 Insulation 40 LF 4.30 172 Hook-up Form hole through existing wall for heating pipes 2 EA 195.00 390 2" diameter black steel piping 120 LF 21.10 2,532 Gate valves 10 EA 260.00 2,600 Check valves 2 EA 260.00 520 WASTE HEAT RECOVERY SYSTEM PAGE 11 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Strainer 2 EA 58.00 116 Balancing valve 3 EA 58.00 174 Temperature control valve 1 EA 225.00 225 2" insulation 120 LF 5183 700 Heat exchanger, 200,000 BTUH 1 FA 3440.00 3,440 Expansion tank, 12 gallon capacity 1 EA 956.66 957 Air separator 1 EA 495.00 495 Pumps, circulation Grundfoss 200, 2" diameter 2 EA 680.00 1,360 Connection to existing piping system 2 EA 72.50 145 Make-up glycol system connection, including tank 1 FA 610.00 610 WASTE HEAT RECOVERY SYSTEM PAGE 12 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Glycol 110 GAL 8.80 968 Test and balance system 36 HRS 75.00 2,700 Controls and Instrumentation Generator building and new module 1 LOT 2,000 Hook-up inter ties 1 LOT 1,500 WASTE HEAT RECOVERY SYSTEM PAGE 13 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 2 EA 175.00 350 Connection to motor 3 EA 115.00 345 Disconnect switch 1 EA 330.00 330 3/4" EMT conduit 70 LF 3.10 217 #8 copper 280 LF -78 218 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 277 Panel 1 EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light fixtures 6 EA 190.00 1,140 WASTE HEAT RECOVERY SYSTEM PAGE 14 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) Switch 1 EA 55.00 55 Duplex outlets 4 EA 68.00 27:2 Equipment connection 1 EA 115.00 115 1/2" conduit 70 LF 2.80 196 #12 copper 210 LF -D2. 109 Hook-Up Breaker in existing panel 1 EA 175.00 175 Connection to motor 2 EA 115.00 230 Disconnect switch 2 EA 330.00 660 3/4" EMT conduit 120 LF 3.10 372 #8 copper 400 LF -78 312 WASTE HEAT RECOVERY SYSTEM PAGE 15 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 WASTE HEAT RECOVERY SYSTEM MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE CONCEPT #6 01 - GENERAL CONDITIONS, OVERHEAD AND PROFIT QUANTITY UNIT UNIT RATE PAGE 16 NOVEMBER 29, 1990 ESTIMATED COST Mobilization Freight Supervision, equipment, utilities clean site, tools and protection Per diem Travel costs, including time in travel Bond and insurance Profit 14 WKS 500 DAYS 6 RT 2125) % 10 % 45 3100.00 110.00 1375.00 43,400 55,000 8,250 12,071 54,855 WASTE HEAT RECOVERY SYSTEM PAGE 17 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 02 - SITEWORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 1,720 LF 12250 211,500 4" diameter Schedule 40 pipe with insulation and arctic pipe protection 3,020 LF 75363 228,403 3” ditto 280 LF 55). 15 15,442 2" ditto 140 LF 41.50 5,810 4" bend 10 EA 293.50 2,935 4" tee 8 EA 315.00 2,520 3" bend 4 EA 215).25 861 2" tee 4 EA 176.25 705 WASTE HEAT RECOVERY SYSTEM PAGE 18 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1305 1,281 WASTE HEAT RECOVERY SYSTEM PAGE 19 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE ; NOVEMBER 29, 1990 CONCEPT #6 06 - WOOD AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200 WASTE HEAT RECOVERY SYSTEM PAGE 20 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 13. - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8'0"x8'0O" building module with floor, exterior wall structure and roofing complete 1 EA 2600.00 2,600 Hole through exterior wall for heating pipes 10 EA 110.00 1,100 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 WASTE HEAT RECOVERY SYSTEM PAGE 21 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 15 —- MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 712.50 145 Form hole through existing wall for heating pipes 2 EA 195.00 390 4" diameter black steel welded piping 120 LF 34.50 4,140 Fittings 30 EA 63.50 1,905 Butterfly valves 5 EA 490.00 2,450 Control valve 1 EA 89.00 89 Insulation to pipe, 4" diameter 120 LF Wich 4 929 Booster pump 1 EA 179.00 179 Heat exchanger, 1,000,000 BTUH 1 EA 12250.00 127250 WASTE HEAT RECOVERY SYSTEM PAGE 22 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Unit Heater (1 Each) (1 - Module Building) Unit heater, 60 BTUH, including thermostat 1 EA 330.00 330 1" diameter piping including fittings 40 LF 9.70 388 Gate valves 2 EA 77.00 154 Insulation 40 LF 4.30 172 Hook-up Form hole through existing wall for heating pipes 8 EA 195.00 1,560 3" diameter black steel piping 120 LF 26.22 3,146 2 1/2" diameter ditto 120 LF 22.10 2,652 2" ditto 240 LF 17597 4,313 WASTE HEAT RECOVERY SYSTEM PAGE 23 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Fittings, 2 1/2" and 3" diameter 60 EA 41.00 2,460 3" gate valves 10 EA 325.00 3,250 2 1/2" ditto 10 EA 290.00 2,900 2" ditto 10 EA 260.00 2,600 3" check valves 2 EA 325.00 650 2-1/2" 4attto 2 EA 290.00 580 2" ditto 4 EA 260.00 1,040 Strainer 8 EA 58.00 464 Balancing valve 12 EA 58.00 696 Temperature control valve 4 EA 225.00 900 TOTAL ESTIMATED COST: Continued WASTE HEAT RECOVERY SYSTEM PAGE 24 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) 3" insulation 120 LF 7.10 852 2 1/2" ditto 120 LF 6.46 ia 2" ditto 240 LF 5.183 1,399 Heat exchanger, 300,000 BTUH 2 EA 3660.00 7,320 Ditto, 200,000 BTUH 1 EA 3440.00 3,440 Expansion tank, 26 gallon capacity 1 EA 1260.00 1,260 Ditto, 12 gallon or less 3 EA 956.66 2,870 Air separator 4 EA 495.00 1,980 Pumps, circulation Grundfoss 200, 3" diameter 2 EA 1090.00 2,180 WASTE HEAT RECOVERY SYSTEM PAGE 25 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Pumps, circulation Grundfoss 200, 2 1/2" diameter 2 EA 815.00 1,630 2d tco! 4 EA 680.00 2,720 Connection to existing piping system 8 EA 2ZeiD0 580 Make-up glycol system connection, including tank 4 EA 610.00 2,440 Glycol 440 GAL 8.80 3,872 Test and balance system 84 HRS 75.00 6,300 Controls and Instrumentation Generator building and new module 1 LOT 2,000 Hook-up inter ties 4 LOTS 1500.00 6,000 WASTE HEAT RECOVERY SYSTEM PAGE 26 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 2 EA 175.00 350 Connection to motor 3 EA 115.00 345 Disconnect switch 1 EA 330.00 330 3/4" EMT conduit 70 LF 3.10 217 #8 copper 280 LF 2718 218 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 20g Panel 1 EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light fixtures 6 EA 190.00 1,140 WASTE HEAT RECOVERY SYSTEM PAGE 27 MT. VILLAGE, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #6 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) Switch 1 EA 55.00 55 Duplex outlets 4 EA 68.00 272 Equipment connection 1 EA 115.00 AS, 1/2" conduit 70 LF 2.80 196 #12 copper 210 LF 52 109 Hook-Up Breaker in existing panel 4 EA 175.00 700 Connection to motor 8 EA 115.00 920 Disconnect switch 8 EA 330.00 2,640 3/4" EMT conduit 480 LF 3.10 1,488 #8 copper 1,440 LF -78 W023 TOTAL ESTIMATED COST