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HomeMy WebLinkAboutNoatak District Heat Report & Concept Level Design 1990 Noatak District Heat Report & Concept Level Design Prepared For State of Alaska | Alasica Energy Authority 701 East Tudor Road PO. Box 190869 Anchorage, Alaska 99519-0869 December 1990 polarconsult alaska, inc. ENGINEERS ¢ SURVEYORS ¢ ENERGY CONSULTANTS 1503 WEST 33RD AVE.e ANCHCRAGE, ALASKA 99503 PHONE: (907) 258-2420 FAX: (907) 258-2419 State of Alaska NN Walter J. Hickel. G Alaska Energy Authority A Public Corporation May 23, 1991 Mr. Earle Ausman Polarconsult Alaska, Inc. 1503 West 33rd Avenue Anchorage, Alaska 99503 Subject: Noatak 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. lL. Cover page - arrow on map shows location of Naotak, not Noatak. Noatak is located approximately 60 miles north of Kotzebue. Coordinate. 2 Executive panna, page i - change "Project Cost for concept #1" in table to "Project Cost for Concept #2." Also, capitalize "C" in "concept #2" in last paragraph. 3: Executive Summary, page ii - paragraph 3, change "three" to "two", "trips to... each year." 4, Table of Contents: IV.B - Change "Building" to "Plant." IV.B.4 - Should be page 18, not 17. VI.D - Should be page 37, not 39. VILA - Should be page 39, not 38. Appendix A - Include worksheet calculations. MOOW> Ss List of Figures: A. Figure IV.6 - Change "Building" to "Plant" in both the figure on page 19 and List of Figures. B. Figure V-7 - "Same as above." 6. List of Tables: A. IV-B - Change "Building" to "Plant" on both page v and 18. QO PO.BoxAM Juneau, Alaska 99811 (907) 465-3575 1 oF DEerPOX 190869 701 EastTudor Road Anchorage, Alaska 99519-0869 (907) 561-7877 Governor Mr. Earle Ausman May 23, 1991 Page 2 TI Section I.C.3 - Figure 1 is on page 20, not 19. 8. Section I.E - Northwest Arctic "Borough" School District, add "Borough." 9. Section I], paragraph 1 - change "building" to "plant" in water treatment "building." 10. Section II, paragraph 2 - add "Borough" to Northwest Arctic "Borough" School District. 11. Section III.A - paragraph one contradicts itself. It says "Equipment.... will be installed...." and then goes on to say "Position No. 1 now has... and positions No.4 & 5 now have....". Coordinate with table III-A. Also, replace "stand by unity" with "stand by unit." 12. Table HI-A- KTA 1150's are 1200 rpm. 13. Section ILC - last line, change "Figure III-2" to "ITI-3." 14. Section III.D - figure V-2 is on page 21. Figure V-3 is on page 22. 15. Section [V.A.3 - Fuel consumption in school buildings Blo one 1 does not agree with table IV.A. Should paragraph one read: "20,000 gallons used by the high school and "Junior High School"? Coordinate. 16. Section IV.A.4 - clarify that the heating coil will be located in the "return" duct. 17. Figure V-2 - correct arrow directions on "new distribution piping." 18. Figure V-3: A. Engine and heat exchanger piping is crossing connected. B. Coolant piping bypasses radiators. C. _KTA 1150 heat rejection to coolant is 560,000 BTU/HR. Why is the primary heat exchanger only 300,000 BTU/HR. D. The cooling system as shown can not function. Correct. 19. Figures V-5 through 7 - Figure V-1 indicates Arctic ici is 3" diameter. Figures V-S through 7 indicate Arctic Piping is 2" diameter. Coordinate. 20. Section VI, page 30 - last paragraph, replace "engine" with "primary" in first line. 21. — Section VIII.A - paragraphs 1 and 2, figure V-3 is on page 22. 9102\JD0797(2) Mr. Earle Ausman May 23, 1991 Page 3 22, 23. 24. 255 26. Section VIILB - paragraphs 1 and 2. Correct page numbers for figures V-4 through 7. Also, change "building" to "plant" in paragraph 2. Section VIILC - paragraph 1, change "three" to "two" "times per year." Table VIII.A: AS Add to table VIII.A: 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. Appendix A: A. Waste heat worksheets and other calculations are missing. B. Module air changers with a KTA 1150 should be: 13 + 1 = 14 AC/HR, not 24. (This is based 7 module size of 12'x 12'x 30' = 4320 feet? and 930 cfm = 55,800 ft3/hr. 55,800/4320 = 13 AC/HR.) Revise. Appendix B: A. Number 2 - were discussions with "ADEC", or "PHS" or possibly "vVSW"? B. Number 6 - most of second paragraph is missing. If you have any questions, please call me at 561-7877 or 261-7282. Sincerely, Steven Stassel Rural Systems Engineer SS:jd 9102\JD0797(3) polarconsult Noatak District Heating Executive Summary Noatak is a bush community with a population of 350, located in Northwest Alaska on the west bank of the Noatak River, approximately 60 river miles upstream from Kotzebue Sound. 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. With the 1990 cost of heating oil ranging from $1.67 to $2.80 per gallon, a considerable amount of money is 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 radiators. At the radiator the heat is transferred to the air which heats the building. A district heating system works in the same manner, with the exception that the engine performs the same function as the boiler, and provides waste heat instead of burning fuel. This report discusses how this heat may be used in Noatak, and what results may be expected. The water system and schools were studied as likely candidates to be served by a district heating system in Noatak. The first combination included the water treatment building, the junior high, high school, and elementary school buildings. A second combination, and the most economical, included connecting the water treatment facility, junior high, and high school. This combination would utilize 100% of the heat available at the power plant during the winter months. A third combination included just the water treatment building and the junior high building. Project cost, annual amount of fuel saved and fuel cost savings for concept #2 are as follows: Project Cost for concept # 1 $567,183 Amount of Fuel Saved per Year 13107 Annual Savings $25,422 Straight Pay Back in Years 22:3 polarconsult Noatak District Heating Total project cost includes design, supervision, inspection, administration and construction. The project includes construction of a new module at the power plant to house the district heating equipment, renovations to the AVEC power plant cooling system and the school-complex heating system, 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 $2,450 per year to repair actual failures in the district heating system. Routine maintenance will be performed during three trips to Noatak 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 2, is 22.3 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 Northwest Alaska communities to reduce Noatak's share of the high mobilization, shipping, travel, and supervision costs required. ii polarconsult Noatak District Heating CONTENTS EX@CUbI Ve) SUMIMATY) cee eresercsescsesccestsessossececscesesucecasncncscenccsuscosnstassocaussusuststsesssceceesescseston i MISO BISUTeS era iessssesesencessesasusassesnesteesesteuessaresccsssstsseceusosssesscsnessactreccascsaseteesesscsccsces v MEiSHOLPADIES) ev erscessesnsecscsusesersscsonesecetecscsccrensscutscessccorscsceacecuseotecacecavecscseergacneessteesesscens Vv Glossary I. Introduction AN ODIOCUVE | /eressssessescsecessssscecesseseassacecsccessssucesosenscnocscacensecscoesersessesestassetsasnestensareay 1 B. District Heating System 1 Cu Methadology, |.....cesss-csssasessssenesssscsucocososensssssesessasssssatstssexsssasseussavasasassasnsesevessaess 1 DH Community/DEScription) cvrassecscesccsccceccscoccnccsesesssesssenstooresscenesseveseneessssnessessssesesy 3 E) Projected Load! Changes) tsc.sss.cecsscsecevssssssosencevenencncesstessseesecssesnensosseccnsacaensecssasee 3 TINS 1Gey VaSit se cecsceceresrsrsssorsesscarancacneseacrecesctsotcnssoconenonenescaensersonssesenasesueceneneesnerssssenssssseses 4 II. Power Plant xsi GENET All Loess cencvecetussisssssvastaseasevsssarsnelaccsstcessasesorcassetoseneessessseessssaveseuocnssaeestasseest ) B: Available Load Information & Available Heat: ..00......-.sccccsceasssnesesesesenssecoensesnes 3 CHBuilding Heat eee sossasesetsuscstasssucesracsness crensnsscserensusnsessvenesentaressececvesssasececee if 1D: Proposed District Heating; COMMection) Lier ccrccscssssssesenssecsorensessensoesecesesesscesecscece 9 IV. Potential District Heating Users A. School 1. General 2. Location Beat Use io... ctc.cesssessosttssuesseosssosescsceasatsssavasesssavatsossecsasssseseenvtssesusnsessesaens 14 Auli stricheating) CONMECUOMasncseerriecmencuneecsssicetacetseersserseseneunencueeate 15 B. Water Treatment Building 1S General) | ||d2iicscessssecsessesessesssscsssvessasusssvssusessecesossessacecsssososnserensesensensesenss 17 DU OCATION Meee ee crseetaecacese reer EE ENN ceansetasseseesetes 17 3. Heat Use .. 17 ANDistrictieatin g| CONNECHON Ms menssssterssustcerersestresreressecnseseerssesesseseers 17 Vi Concept Design Drawings’ |-.......sscssscocsscscsssusserensxesessecoscssnscexesesssessssssssstesesosenesaveseses 20 VI. Failure Analysis ALS TntrOduction |.:t.tcucssssssessussessssasessossascerssesesesseaseconsaseusesecssosesuseaseceasessossessacesesen 27 B. Failure Analysis of District Heating System ..........ccccsssesssessssssssessesseeeeeeeseneees 28 1. Power Plant D DAStriDUtION SYStEM |.<....0.c-.s00+-senoescccescocescecensesescnscossccsssesssecsesescensesensaces 32 Qi User, CONNECTIONS <s.cccscassetscsaseserssssecestssaseuccecestescesasectoereseceassosesseasasesestss 33 iti polarconsult Noatak District Heating (Gy Railure Prequencysand: Costistrscsscescsonccsesscccoscsessscsessesssneseccoarnensneutcousesponsseess 36 D: Design; Decisions to. Minimize Failure ciciccccscsescesosssessssvesessscocssevsscncsesesscscecoras 39 VII. Project Specifications A. Codes and Regulations B. DIVISION 01 - General Requirements CFDIVISION OZ Site WOK scsissscsscscssostsssssaccscsostecsectecsstssccccenensatveacsssatecesuseseces 39 D: DIVISION 13'-:Special| Constructtom’ :s.cc.scccecessececcccsssscacsoszccsssssasvestacscesseesssaes 40 E. DIVISION 15 - Mechanical Outline Specification ............cccsessessesseseeeeeeeeees 41 F. DIVISION 16 - Electrical Outline Specification ..........cscccsssessesesesesseeeeeeeeees 44 VIII. Project Cost Estimate (AS Power Plant HeatiRecovery System) is.cccssccasassascsssessecsecseteccssorsecsasetsesessncossecss 47 B, District heating Distribution System! 'v.°.)......:.ceccsecersecosrssescuesesesseseaessseessssseses3 47 C Operation and Maintenance! Costs scc.cccscssvocstscsesssccectesacsevscsscsesesensesecersressases 47 D. Project Cost Summary IX. Conclusions A. Heat Availability & Fuel Consumption ..............s.s-ssecssssessssecsssssesessssresososenees 49 B. Project Cost Summary .... esi GSS ProjeCtiSUMIMALY Pecccsssssesesotwccsesscessusnscnccensessssoesensersoceceesrssstecerereseeee eet 51 MG RECOMMENAALIONS -.-.5.-tacscrsessesensecscscesscessnccecsaccossssusstsncsnsesuoes sessesavsussesasrossecesonsesees ny Calculations) |ecssrseseseccsosssvenecectcssesven ee scagcesesaeacsccacesesesucecessssasccnoatsseseassoescoses Appendix A ieldl Trip NOtes| crscsessssscsecscescoessssonsscesosossasassecesesessessscatusestsessessseaseessss¥eascerto Appendix B Cost: Estimate ict ecsessessasssonsorceseorenosseenoneuceseavencossassversasuteesssensuce Appendix C iv polarconsult Noatak District Heating List of Figures IlI-1 Unit #1 Enclosed Skid-Mounted Radiator & Proposed District Heating Piping TO CAON il etivescusssssessseusssusasensesosetsusouassasesesesensusesosesensusecossusasesesusessronesesensees a Il-2 Intake and Combustion Exhaust Air Blowers ... WS TM-3: | Building: Unit Heater, .0.c.cscseccssssccecssasssecvessssuscsseseonsncsesensessnosscessossssuscvssorssssoseersea 8 Il-4 Module Number 4 & Proposed District Heating Module Location ............... 11 Ill-5 Module Number 4 Piping & Proposed District Heating Connection ................. 11 IV-1 Proposed District Heating Pipeline Alignment to Junior High Building ........... 13 IV-2 Proposed Location of Secondary Heat Exchanger in Junior High «0... 1S IV-3 Proposed Connection to Warm Air Furnace in Junior High School .............0066 15 IV-4 Proposed Connection to Boilers in High SChOOI .........cesessesesesseeseeseseseseseesees 16 IV-5 Proposed Location of District Heating Equipment in Elementary School ........ 16 IV-6 Proposed Connection of District Heating System to Boilers in Water Treatment Building ao V-1 Site Plan & Proposed District Heating System Distribution 00... sseseeeeeeees 20 V-2 — Proposed System Schematic ........scccsesessesesesssssssseseseseseseseesesessseesesesesesesseeseenes 21 V-3 Detail of Revisions to Existing Power Plant & District Heating Connection .... 22 V-4 Junior School Piping Connection Schematic & Floor Plan ......ccssssssssseseseeeees 23 V-5 High School Piping Connection Schematic & Floor Plan .........scssscsssssseseseseees 24 V-6 Elementary School Piping Connection Schematic & Floor Plan .........csseseseees 25 V-7 Water Treatment Building Schematic & Floor Plan a IX-1 | Heat Available vs Heat Required ......scccscssescsocssrsseonsssensessnoessnceossseneasersacseseente IX-2 Gailons of Heating Oil Displaced ...............-..ssrssesssssssersacsssecsnssrensersnsnsenseonsenss List of Tables MTI-A\ || gine Data vicicccsszscsessssesssesvosssssvsnsonearesssenontonsuscsnessuscasessessvesassuossenestaneesssaseseensen 5 II-B Monthly Power Generation & Available Heat wo... ccsescsseseeseseseecseseseeenenees 6 IV-A_ Estimated Distribution of Fuel Oil Use at SchOOL oo... esseseseeteeeeeesesesenesees 14 IV-B_ Estimated Distribution of Fuel Oil Use at Water Treatment Building .............. 18 VII-A Summary of Alternative Project Costs .......sccesssssseseseees + 48 IX-A Annual Heating Fuel Displacement & Pipeline Heat Losses .........scsssessseseeeeees 49 IX-B Project Summary ...............ccssssssscssersecssscsesesesececsessessecacssesssnscesecsssessensnsnsnses 51 polarconsult Noatak 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. polarconsult Noatak District Heating I. Introduction A. Objective The objective of this report is to determine the feasibility of recovering and using the waste heat from the Alaska Village Electric Cooperative (AVEC) power plant generators in Noatak. In view of the present cost of heating oil ranging from $1.67 to $2.80 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 Noatak. B. District Heating System 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 radiators. At the radiator 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. 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 rejected to the atmosphere. This report discusses how waste heat can be used in Noatak, and the likely results. C. Methodology The feasibility of waste heat use in Noatak 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 polarconsult Noatak District Heating available and identification of potential user facilities. The field trip was coordinated with village officials and AVEC operators. 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; Specific weather problems such as drifting snow; and 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 19.) 4. Initial Submittal: A preliminary report on the project was written and distributed to the Alaska Energy Authority staff for comment. polarconsult Noatak District Heating 5. Final Submittal: This final report includes all comments received from AEA and other interested parties who have reviewed the interim report. D. Community Description Noatak is located in Northwest Alaska on the west bank of the Noatak River, approximately 60 miles up river from Kotzebue Sound. The population is made up mostly of Inupiat Eskimos, and the economy is based mainly on commercial fishing and subsistence hunting. Noatak states it has a population of 350. The community has a water distribution system originating from the water treatment plant near the power plant which is distributed throughout the village. The water is obtained from a well which taps an aquifer in the river. A variety of equipment is available for rent from the city. Local labor is available most of the summer, although a majority of the residents participate in commercial fisheries. E. Projected Load Changes Since the school complex is not scheduled for expansion, according to Northwest Arctic School District officials, its heat requirements should remain constant. The heat requirements of the water treatment system should grow with the community. AVEC projects an increase of 3% in the communities energy needs over the next three years with an increase of 9% over the following four years, according to its Power Requirements Study and 10-Year Plan. This increased requirement will proportionally increase the amount of heat available for use. polarconsult Noatak District Heating II. Site Visit The site visit was conducted during January 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 treatment building (washeteria) 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. Paul Weisner, assistant director of the Northwest Arctic School District, was contacted about fuel usage of the schools. He stated that he was very enthusiastic about waste heat systems. Several times during boiler failures at Kiana, the waste heat recovery system had kept the school in operation. He stated inclement weather during boiler failure requires a charter of an Otter aircraft, costing the district over $2,000 per trip. Field trip notes including a list of people contacted in the field, are shown in Appendix B. polarconsult Noatak District Heating Ill. Power Plant A. General The power plant is a standard AVEC Butler type structure. It now houses one Caterpillar generator which is equipped with a skid-mounted radiator, switch gear, and a day tank. There are also two remote modules which are located toward the river from the Butler building. Each of these modules contains a single engine and two remote radiators. Equipment with the characteristics given in Table III-A will be installed in Noatak. Position No. 1 now has a Caterpillar and positions No. 4 and No. 5 now have Cummins KTA 1150,s. A used John Deere JD66198A may be installed in position 3 in the Butler Building. This would be a stand by unity due to its age. Table III-A Engine Data Position/Unit 1 4 5 Engine Caterpillar Cummins Cummins Model D342 KTA1150 KTA1150 Speed (rpm) 1200 1800 1800 Rating, Engine (kw)* 160 306 306 Heat Rejection** To Coolant (Btu/min) 9,400 9,320 9,320 To Stack (Btu/min) 7,269 13,990 13,990 To Ambient (Btu/min) 2,894 2,480 2,480 Water Flow (gpm) 60 125 125 Intake Air Flow (CFM 625 930 930 * Engine rating at shaft. ** Rating at full load. B. Available Load Information & Available Heat Monthly power production figures for Noatak 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 polarconsult Noatak District Heating 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 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. Tantei 74,480 93,280 93,300 2,210 Febeqetfe 70,000 72,240 72,200 1,611 Marit ciipi ieee 70,480 69,120 69,100 1,531 Apr 61,760 60,400 60,400 1,347 Mays ffs 55,040 56,400 56,400 1,289 June ti 54,000 41,520 — 41,500 953 July 45,289 46,640 40,348 + — 40,300 1,036 Aug 55,520 53,360 51,296 51,300 1,103 Sept 66,080 62,880 75,654 75,700 1,178 Oct 70,480 73,200 --- 74,8007 1,641 Nov ele ee 83,5007 «1,812 Dec 72,400 86,400 ----- 88,2007 1,898 Annual 737,300° 790,020? + 806,744 806,700 _—:17,597 , Values used in this study were the 1989 kwh production figures rounded to the nearest 100 kwh. From Jan. to Sept. the load increased 2.1% 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 Noatak 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 wooden floor covered with steel plate. Intake air comes from a ventilation louver by the door, and cooling air from the radiator is exhausted through motor-controlled dampers behind the radiators. (See Figure III-1.) 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 Butler building. The module buildings are constructed of steel and are mounted on steel skids. Each module contains one engine, its associated piping and valves, and two horizontal radiators. Each radiator has sufficient capacity to reject all of the heat produced by the engine. These radiators are equipped with variable speed fans. The 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. 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 a unit heater in each module. (See Figure III-2.) There is a similar unit heater in the Butler building. Figure III-1 | Unit #1 Enclosed Skid Mounted Radiator & Proposed District Heating Piping Location polarconsult Noatak District Heating uit Intake and Combustion Exhaust Air Blowers Figure III-2 Figure [1-3 Building Unit Heater polarconsult Noatak District Heating Heat losses from the buildings will reduce heat availability for distribution by the waste heat recovery system. In many cases heat given off by the engine and generator is usually sufficient to heat the structure in which the equipment is operating. This is not true for the KTA 1150 which requires added supplemental heat because of combustion air requirements To keep the other two structures warm requires supplemental heat obtained from engine cooling fluid. Calculations show a quantity of heat equivalent to 2,600 gallons of oil per year would be required to keep the Butler building at 65°F without an operating engine, and 1,855 gallons of oil per year to keep the module without an operating engine warm. Insulating the floors of these buildings would reduce these requirements to 1,802 and 782 gallons of oil per year, respectively. An operating KTA 1150 engine in an insulated module will require the equivalent of 1,423 gallons of added heat, which is greater than the requirement for a module where the engine is not in operation due to combustion air requirements. Using a conservative analysis, ie., assuming the engine always operates in one of the modules, which is logical because these are the primary engines, the losses from heating the buildings each year are equivalent to 4,007 gallons of oil. These values are based on heating each building to 65°F; they could be reduced by heating the structures to 65°F only during periods of active maintenance. 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 the analysis which assumes heating the entire structure as opposed to the engine block alone is conservative. D.P i District Heating C ° The proposed district heating system schematic is shown in Figure V-2 (page 20) and the connection to the power plant is shown in Figure V-3 (page 21). Interconnection between the existing remote radiators is included. This will allow for any generator to be run off any one of four remote radiators. 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 two modules, If the John Deere is installed in the Butler building it is likely the skid mounted radiator will be removed and the unit tied into the existing remote radiators. polarconsult Noatak District Heating The primary heat exchanger will be located in a housing module behind module four (Figure III-4). The expansion tank(s) and district heating pumps will be located at the user end of the system. The heat exchanger module housing will use 2x4 standard wood frame construction. The unit will be mounted on a steel channel extension of generation module number 4's skid. The unit will be insulated with fiberglass batt insulation and covered with metal siding on the exterior and plywood on the interior. 10 polarconsult Noatak District Heating Figure II-5 Module Number 4 Piping & Proposed District Heating Connection 11 polarconsult Noatak District Heating Heat exchangers will be stainless steel plate type units. The primary side piping will run from the heat exchanger through the radiator space of module No. 4 (Figure II-4). The butler building and module No. 5 will be connected at module No. 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 will be connected into a new electric panel located in this module. The new panel will be connected through a meter to the existing station service panel in the Butler building. Electrical connections at each user facility will be provided to power the pumps used to circulate the fluid used by that facility. 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. 12 polarconsult Noatak District Heating IV. Potential District Heating Users A. School 1. General The school has an enrollment of 95 and is operated by the Northwest Arctic Borough School District, based in Kotzebue. The school complex, consisting of the high school, junior high school, elementary school, warehouse, and residential buildings are all heated by individual hydronic and hot air heating systems. Supplying the school will require heat exchangers and pumps for each structure planned to be served: the high school, junior high school, and elementary school. 2. Location The pipeline will have to be extended from the power plant about 800 feet to reach the beginning of the school complex, the Junior High Building, (Figure V-1) "Arctic" distribution pipe will be buried in the Main Street and Government Street rights-of-way to the school, as shown in Figure V-1. Easements will not be required as the pipeline is on public property. All three school buildings are on piles, and the district heating piping will come up through the floor into the existing mechanical rooms. FigureIV-1 Proposed District Heating Pipeline Alignment to Junior High Building 13 polarconsult Noatak District Heating 3. Heat Use Fuel records for the school facility in Noatak were obtained from Paul Weisner of the Northwest Arctic Borough School District in Kotzebue. He indicated that the entire complex used 35,000 gallons in 1989: 20,000 gallons were used by the high school, 10,000 gallons were used by the elementary school, and 5,000 gallons were used by auxiliary buildings. A monthly breakdown of fuel consumed by the school complex was not available. Monthly fuel use was estimated by distributing the average annual fuel consumption based on the number of heating degree days per month. Domestic water is heated by the primary boilers with the exception of the junior high school where a small heat exchanger will be used across the hot water heater. Table IV-A Estimated Distribution of Fuel Oil Use at School Month Heating Jr High HS Elem Degree Days (Gal. Oil) (Gal. Oil Gal. Oil January 2,052 778 1,815 1,296 February 2,108 799 1,864 1,332) March 2,202 835 1,947 1,391 April 1,764 669 1,560 1,114 May 1,208 458 1,068 763 June 801 0 0 0 July 608 0 0 0 August 616 233 545 389 September 825 313 730 521 October 1,296 491 1,146 819 November 1,683 638 1,488 1,063 December _2.076__787 44,836 4.311 Annual 17,239 6,000 14,000 10,000 Purchase Cost/gal__$1.67__ $1.67 _$1.67 14 polarconsult Noatak District Heating 4. District Heating Connection The district heating pipe will enter through the floors of the existing mechanical rooms in all three of the connected school buildings. A mezzanine will be built over the door in the junior high mechanical room to accommodate the pumps and expansion tank. (See Figure IV-2.) Copper lines will run to heat transfer coils located in the duct of the warm air furnace.(See Figure IV-3.) A separate small heat exchanger, pump and thermostat will supply heat to the hot water tank. Figure IV-2 Proposed Location of Secondary Heat Exchanger in Junior High Figure IV-3 Proposed Connection to Warm Air Furnace in Junior High School 15 polarconsult Noatak District Heating There is an open area in front of the four boilers in the High School that will easily accommodate the heat exchanger, pumps and expansion tank. The secondary side of the heat exchanger will be connected to the return header of the boilers. (See Figure IV-4) The connection to the elementary school will be similar to that of the high school, with the exception that a small platform will be constructed over the fresh air vent in front of the three boilers.(See Figure IV-5) Figure IV-5 Proposed Location of District Heating Equipment in Elementary School polarconsult Noatak District Heating B. Water Treatment Building 1. General The water treatment building is owned by the City of Noatak and operated under the direction of the U.S. Public Health Service. The facility includes a water storage tank, water treatment equipment and boilers to heat the water. The water is circulated throughout the community in insulated above-ground water lines. 2. Location The water treatment building is located adjacent to the power plant on the banks of the Noatak River. The district heating distribution pipe from the power plant to the treatment facility will be "Arctic" pipe. This pipe will be buried in an easement along the east side of an alignment along Main Street (Figure V-1). From this point the pipe will cross the street and continue to the school complex. The length of the hot-water transmission line to the water treatment building branch will be 100 feet. 3. Heat Use The water treatment building's three boilers supply heat to the water treatment building, the water tank, and the circulating water in the distribution lines. The wooden water tank is insulated and is heated to about 40°F in the winter. Fuel records for the water treatment building were obtained from the City of Noatak. Monthly fuel use was estimated by distributing this fuel consumption, using the number of heating degree days per month. (See Appendix A for sample calculation.) 17 polarconsult Noatak District Heating Table IV-B Estimated Distribution of Fuel Oil Use at Water Treatment Building Month Net Fuel Heating Oil Use Degree Days Gal. D January 319 2,052 February 324 2,108 March 333 2,202 April 291 1,764 May 239 1,208 June 201 801 July 182 608 August 183 616 September 203 825 October 247 1,296 November 284 1,683 December 321 2,076 Annual B27, 17,239 Purchase cost / gal. $2.80 4. District Heating Connection The two district heating pipes will be buried and will emerge outside the water treatment building, and extend into the building through the boiler room wall. The heat exchanger will be located in front of the boilers just off the north wall. The connection will be made to the return header of the existing boilers (Figure IV-6). The cost of connecting the water treatment plant to the district heating system is covered in Section VIII. 18 polarconsult Water Treatment Plant Figure IV-6 Proposed Connection of District Heating System to Boilers in Water Treatment Building Noatak District Heating 19 polarconsult Noatak District Heating V. Concept Design Drawings NOATAK SITE PLAN PROPOSED DISTRICT HEATING SYSTEM US SURVEY NO,3778 LOT NO.2 LEGEND VA PROPOSED WASTE HEAT USER PROPOSED WASTE HEAT LINE —S-— EXISTING SEWER LINE 7 EASEMENT REQUIRED ——-— EXST. UG POWER LINE — EXISTING FUEL LINE © EXISTING POWER POLE FIGURE SCALE: 1” = 125’ V-| polarconsult ELEMENTARY SCHOOL (SEE FIG. V-6) HIGH SCHOOL (SEE FIG. V-5) NOATAK — PROPOSED SYSTEM SCHEMATIC Noatak District Heating EXCHANGER | EXCHANGER coer tt! TTT OT | | | CONNECT | . e-sTO USER | | | SYSTEM | ee | | ° USER | ITO USER USER 3. HEAT Puee HEAT | | JUNIOR HIGH BURIED WATER TREATMENT CSEE FIG. V-4) ) farcric (SEE FIG. V-7) TC ad PIPE fT] | CONCEPT 1 | | | | 870’ 36 | | 160’ 2°f CONNECT |TO USER usER | SYSTEM HEAT c EXCHANGE! Lol CONNECT [TO USER Q SYSTEM PRIMARY HEAT EXCHANGER DISTRICT HEAT MODULE SEE FIGURES V~-3) LEGEND _ <I ISOLATION VALVE NO CHECK VALVE — — EXISTING NEW DISTRIBUTION NEW @ USER @ USER PRIMARY DISTRIBUTION PUMPS NEW @ PLANT FIGURE V-2 21 polarconsult Noatak District Heating NOATAK DETAIL SHOWING REVISIONS TO POWER PLANT AND DISTRICT HEAT CONNECTION TO DISTRICT HEAT SYSTEM SEE FIGURE VI-1 & NOTE 4, DISTRICT HEAT MODULE «NE W> 0 0 \see FIG. 3A NOTE 2 PRIMARY HEAT EXCHANGER 5 | | \ cf (HO thy 5 | ; | i || i | LHI | Hi | ENGINE #4 ae THI = EXISTING POWER PLANT CBUTLER BUILDING) a3LV3H LINA | | | | | | EXST, PLANT (MODULE #4) EQUIPMENT SCHEDULE nT ef — HEAT EXCHANGER 300,000 BTU/HR 7 PLANT PIPING 3” STEEL, WELDED! iC tt Ht a 45, 2 a on yaLV3H unt | | | LEGEND | BUTTERFLY VALVE AMOT VALVE NOTES: CHECK VALVE 1, PUMPED ENGINE WARM SYSTEM FOR ENGINE lil] FLEX CONNECTOR #1 AND EXP. TANK NOT SHOWN. NEW PRIMARY PIPING . EXISTING SYSTEM COMPRISES TWO MODULES, EACH WITH ONE ENGINE AND (2) REMOTE 4) PUMP = — — EXISTING RADIATORS, & (1) BUTLER BUILDING WITH ONE ENGINE WITH SKID MOUNTED RADIATOR, lhe ain cL SKID MTD RAD WILL BE REMOVED. —j| 3. LOCATION OF POSSIBLE BOOSTER PUMP.{ FIGURE NTS V—3 EXISTING POWER PLANT (MODULE #5) Zz Dd GATE VALVE —— EXISTING BUILDING HEAT EXCHANGER 200,000 BTU/HR 2 DRE BAL. VALVE -—- EXISTING PUMPS GRUNDFOSS, SERIES 3 €& PUMP —— NEW DISTRICT HEAT PIPE 200, UPC50—160 ~ 1 CHECK VALVE AN STRAINER EXPANSION TANK 66 GAL. NEW @ USER TEMP CONTROL VALVE PIPING: (dN-MOOH YaSN) | 7 : SUPPLY SIDE 2" STEEL, WELDED = SCALE: 1" = 10 HEATER SIDE 2 cu S o 2 = | a j RETURN r AIR | NEW DUCT COIL o ATTACHED TO HEATER = DISTRICT 5 1G = HEATING i 5 SYSTEM EXISTING | EXISTING | = TT UTILITY ROOM WARM AIR aD tT | HEATER | 1 | | ijkK-=-7 | | {DIRECT | - FIRED | ion i" AHU Hines ee ee al | | | Prost | SUPPLY | | | UB NEW PLATFORM TO DISTRICT WH , EXPANSION TANK Lp I] 4x5’ FOR USER HEAT SYSTEM Lx 4] EQUIPMENT, et a deteal bpp FROM DISTRICT HEAT SYSTEM AIR SEPARATOR FLOOR PLAN SYSTEM SCHEMATIC ynsuoorejod Suneoqy IOLNSIC eIVON LEGEND EQUIPMENT SCHEDULE az = Dd GATE VALVE —— EXISTING BUILDING HEAT EXCHANGER __300,000_BTU/HR WY 2 DK BAL. VALVE -—- EXISTING PUMPS GRUNDFOSS, SERIES q > & PUMP —— NEW DISTRICT HEAT PIPA 200, UPC50-160 x bt’ CHECK VALVE SS STRAINER EXPANSION TANK 66 GAL. S | —— NEW @ USER 0% = TEMP CONTROL VALVE REG: oS i SUPPLY SIDE 2” STEEL, WELDED ~ 10 BOILER SIDE 2" CU | Cc 70 ——Z ONITING TOOHIS HOIH | | i | an in ae eral | EXISTING SCHOOL | © || F lielei UTILITY ROOM i 2 4 im i}. | ey -—e—-5 ZONE 8 ap Bos! a Lp —-5 SUPPLIES GLycoL |; L——_ ioe ieee pe i TANK [= | | | | -—*-—-—5 ZONE Ee ne es ee ee ee) | RETURNS HEAT. SYSTEM EXPANSION TANK . Sky Col FILL FROM DISTRICT HEAT SYSTEM DISTRICT HEATING HEAT EXCHANGER SYSTEM AIR SEPARATOR FLOOR PLAN _SYSTEM SCHEMATIC SCALE: 1’=10' ynsuooreyjod Sunvoy OLNSIG yeIwoNn LEGEND EQUIPMENT SCHEDULE a>aZz Cc Dd GATE VALVE —— EXISTING BUILDING HEAT EXCHANGER 200,000 BTU/HR ae DX BAL. VALVE -—- EXISTING PUMPS GRUNDFOSS, SERIES Ci = €& PUMP — NEW DISTRICT HEAT PIPING 200, UPC50-160 q tb’ CHECK ~VALVE & STRAINER EXPANSION TANK 66 GAL. oS | —— NEW @ USER TEMP CONTROL VALVE PIPING: oO SUPPLY SIDE 2” STEEL, WELDED ~ BOILER SIDE Fo) | eS U “— ar 2 & potaa roa | | | | | | | ONITIING TOOHOS AYVLNSWATS ry | | cr ZONE I] on Lasag=— t= RETURNS lporer #1! 'poier #2 = ZONE DISTRICT | | | —we —-s5 SUPPLIES HEATING L—>—H4 L—>—4 SYSTEM a — aiid wW =| | a| | L ¢ PE DISURICT EXPANSION TANK Su —_ a oes PST GLYCOL FILL jBLR; ;BLR; -—- — [>< Bese | WH | ar FROM DISTRICT a —— HEAT EXCHANGER HEAT SYSTEM = AIR EXISTING UTILITY ROOM SEPARATOR FLOOR PLAN SSI STEMESCHENS TIE: SCALE: 1’=10' qnsuoorejod Sunvozy IOLNSIC| YeIVON LEGEND EQUIPMENT SCHEDULE GATE. VALVE EXISTING BUILDING HEAT EXCHANGER 100,000 BTU/HR BAL. VALVE EXISTING PUMPS GRUNDFOSS, SERIES PUMP —— NEW DISTRICT HEAT PIPING 200, UPC50-160 CHECK VALVE Ay STRAINER EXPANSION TANK 12 GAL. —— NEW @ USER tf TEMP CONTROL VALVE SRinee ; SUPPLY SIDE 2" STEEL, WELDED So ae BOILER SIDE 1” CU ynsuoorejod AVIVON (dN-YOOH Yasn) JOVYOLS 8 LNAWLVSYNL YSLVM ZONE t SUPPLIES : 4 4 qrctt4 WATER TANK AL rots rt | | | 1 | | | | | || | |BOILER | |BOILER we) {BOILER #3) ~T T PRESSURE i PRESSURE YANKS TRUMPS 1 I qe Se Nae ° = i EXISTING ZONE RETURNS CAPPED OFF (2) = BU aq TO DISTRICT B UMPB SPACE © EXPANSION TANK BLA we EU SPACE op NEW ZONE HEAT SYSTEM = #3 BLA °° SQgGLYCOL FILL EQUIPMENT RETURNS || |_<FROM DISTRICT Jyh HEAT EXCHANGER “HEAT SYSTEM AIR DISTRICT oAlR, HEATING oe SYSTEM FLOOR PLAN _SYSTEM_SCHEMATIC SCALE: 1’=10’ Suneozy IOLNSIC YeIwON polarconsult Noatak 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-(8.76/8760) = 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) / 8760 = 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 (8760 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 and 27 polarconsult Noatak District Heating B. 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. Failure Analysis of District Heating System 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). 28 polarconsult Noatak 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, Noatak will have four. In general, the plants are operated so that a single engine can serve the entire community. The average reported 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 will be used at Noatak to reduce failure probabilities. The primary generation system failure modes are: 1. Failure or shutdown of the engines; 2. Failure of the radiators due to leakage; 3. Failure of the hoses, valves and piping system; 4. Failure of the engine block itself, and 5. 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 29 polarconsult Noatak District Heating a radiator or engine connection hose breaks it can drain glycol coolant at 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. Primary heat exchanger. This component is composed of a series of formed stainless steel plates which are separated and sealed by rubber gaskets. The plates are bolted together within a steel frame to compress the gaskets and hold the plates together. The primary 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 engine heat exchanger are: 1. Blown or leaking gaskets; 30 polarconsult Noatak District Heating Broken frame; Valve failure and stem leaks; Cracking or corrosion of plates; Connecting primary piping system failure; Fouling; Be) Roa ay es ad (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. c. 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. d. District heating system operational impact: a 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. e. Environmental Impact: Glycol spilled on the ground is the environmental impact of an exchanger failure. Glycol can escape into the ground, thawing 31 polarconsult Noatak District Heating permafrost which can weaken structural supports, and enter groundwater 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. Components: Transmission pipe will be mostly 3 inch diameter insulated pipe. Each pipe will be made up of a steel carrier pipe 3.500 inches in diameter with a 0.126 inch thick wall. 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 7.87 inches. The pipe will run from the district heating module, which houses only the heat exchanger, 100 feet to the water plant and then 700 feet to the junior high school, and so on. The pipe will be buried about 2 feet deep in the ground. 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. Generation plant operational impact: None 32 polarconsult Noatak District Heating d. 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 which can weaken 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: Blown or leaking gaskets; Broken frame; Valve failure and stem leaks; Cracking or corrosion of the plates; Connecting piping system failure; Fouling; Sy AS Freezing while generation system is down, if water is used as coolant instead of glycol; and 33 polarconsult Noatak District Heating 8. Structural damage to the exchanger supports due to fire or other events. Failure modes of the pumps are: Failure of electrical circuit; Seal failure; Motor failure; 1 2 3 4. Impeller cavitation; 5. Pump body failure; and 6. Connection leakage. Failure modes of the expansion tank are: 1. Water logging or bladder failure; 2. Corrosion; and 3. Broken sight glass. Failure modes of the piping system are: 1. Leakage of valve stems; 2. Failure of valves to open or close; 3. Failures due to corrosion; and 4. Failures due to materials or installation defects. Failure modes of each of the school connections are: 1. Failure of the school system to hold fluid; and 2. Failure of the school's circulation pumps. c. Generator operational impact: Failure of the above items will not affect the generation plant. d. 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. Major leaks of the heat exchanger will require the system to be isolated with the valves until it is repaired. 34 polarconsult Noatak District Heating 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. 35 polarconsult Noatak 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 failure of seals. 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 4.55 years. Down time is 48 hours, repair cost is $2,000. There are no measurable effects on system life from repairs. User connections at schoo, 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. 36 polarconsult Noatak District Heating Total system: Failure frequency of the total district heating recovery system is summarized in the following table. Item Failure Rate Heat recovery at power plant 0.000507 Transmission pipe 0.00121 Water heating assembly 0.0005897 Junior HS heat assembly 0.000597 Senior HS heat assembly 0.000597 Elem. school heat assemb. 0.000597 Total 0.004705 Average outage rate 36 hours/yr* *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 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. The total time the system would be unable to deliver heat based on outage of the engines and the transmission pipe, would be about 40 hours per year, which is 0.46% of the time. The time that the five user facilities are out would be approximately 5 hours per year of total equivalent outage. In terms of the delivery of salable heat, the total system outage time would be about 45 hours per year. 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 37 polarconsult Noatak District Heating 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. 38 polarconsult Noatak 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) oooecm0dhlUlo8 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 No. 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. 39 polarconsult Noatak District Heating B. Distribution will be buried "Arctic" pipe with a steel carrier pipe, polyurethane insulation and a high density polyethylene jacket. The pipe 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. 40 polarconsult Noatak District Heating 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. 41 polarconsult Noatak 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. 42 polarconsult Noatak 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. 43 polarconsult Noatak District Heating F. DIVISION 16 - Electrical Outline Specificati 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. polarconsult Noatak 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. 45 polarconsult Noatak 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. polarconsult Noatak District Heating VIII. Project Cost Estimate A. PB lant Heat Recov 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 21. The second cost component is the modification of the existing power plant system. This includes the connections of Unit #1, Unit #4, and Unit #5 to a common manifold and to the heat exchanger as shown in Figure V-3 on page 21. B. District Heating Distribution System The connection of the 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 22, 23, and 24. The connection of the water treatment building to the district heating system includes installation of the piping teeing off from the main line to the schools to the water treatment building, and all equipment and connections within the mechanical room as shown in Figure V-7 on page 25. 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 1.2 trips per year to Noatak by a skilled repairman. With a cost of $2,000 per incident the result is an average cost of $2,400 per year to repair failures. Cost of the three annual maintenance trips must be added to this failure repair cost to arrive at the total annual operation and maintenance cost. 47 polarconsult D. Project Cost Summary Noatak District Heating Total project costs for the three alternative concepts are shown below. Table VII-A Summary of Alternative Project Costs Concept 1 2 5 WTP, JH, WTP, JH WTP, JH HS & ELEM & HS Module Construction $96,136 $99,300 $81,367 Plant Piping Revisions $13,768 $12,390 $13,956 Water Treatment Conn. $64,155 $65,889 $67,814 Junior High Conn. $145,008 $186,216 $329,480 High School Conn. $144,988 $203,388 --- Elem School Conn. $174,487 --- --- Total Project Cost $638,542 $567,183 $492,617 Total project cost includes design, supervision, inspection, administration and construction. The complete cost estimate is included in Appendix C of this report. 48 polarconsult IX. Conclusions Avail: Noatak District Heating There are presently over 17,500 gallons of equivalent fuel oil per year available as waste heat at the Noatak 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 1 2 3 WTP, JH, WTP, JH WTP, JH HS & ELEM & HS Heat off Engines 17,520 17,520 17,520 Annual Heat Loss in Dist. Pipes 3,996 3,367 2,794 Heat Available to User 13,523 14,153 14,726 Bldg. Heating Fuel Required 33,125 23,126 95127 Amount of Fuel Displaced by District Heating System 12,585 13,107 9,093 Percent of Available Heat Used 93.1% 92.6% 61.8% During the winter months the school complex would use all of the heat available, as can be seen in Figure [X-1 on the next page. Heat lost from an additional distribution pipe, to the elementary school building, for example, would reduce the total available useful heat. This would make the elementary school building a net loss to the system in the winter, if included, as the distribution line would remain heated but would provide no heat to the building during the winter. Heat at the elementary school building is displaced by the district heating system during 7 months of the year. 49 ” y — — y To. A AS 5 NSS Jan WT,JH,HS,ELEM [J WTP, JH, HS E Gal of Heat Avail WTP, JH Figure IX-2 Gallons of Heating Oil Displaced polarconsult Noatak District Heating B. Project Cost Summary The school paid $1.67 per gallon, and the city paid $2.80 per gallon for heating fuel during 1989. The annual savings is computed using these costs for heating fuel. The three concepts are summarized in the following table. Table IX-B_ — Project Summary Concept 1 2 5 WTP, JH, WTP, JH WTP, JH HS & ELEM & HS Amount of Fuel Saved 12,585 13,107 9,093 Annual Savings $24,550 $25,442 $18,719 Total Project Cost $638,542 $567,183 $492,617 Straight Pay Back (yrs) 26.1 22.3 26.3 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 2, is 22.3 years. 51 polarconsult Noatak 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 Northwest Alaska communities to reduce Noatak's share of the high mobilization, shipping, travel, and supervision costs required. 52 APPENDIX A Calculations polarconsult Noatak 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 1.5 for the Butler building and 1.0 in the modules. This added up to 24 air changes per hour in the Cummins power portion of the Noatak 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. d il 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 oil usage = —-~---------------------------------=--- 222-2 nena nnn nnn nnnnn en ( Annual HDD ) Water Treatment Building (Monthly HDD) x (Annual Fuel Cons. - 12 x 125) Monthly fuel oil usage = 125 + ----------------------------------------------2--00-22---0-=- ( Annual HDD ) The base unit of 125 gallons per month was used to make the distribution conform to the fuel usage indicated by the plant operator. 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. Appendix A Page polarconsult Noatak District Heating 4. 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-B is from the 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 *y 5%. We used 95% of their test data values for use in Appendix A as the heat available off the engines. b. The assumed heating value of a gallon of oil is derived by utilizing a 73% burner efficiency with 132,000 BTU/gallon oil to arrive at equivalent of 96,000 BTU output per gallon of oil. Appendix A Page polarconsult Noatak District Heating APPENDIX B Field Trip Notes polarconsult Noatak Field Trip Notes January 11, 1990 Earle Ausman, Leslie Moore, PCA Met with: Tom Sage, Chief Operator - Ph 485-2128 Jacki Adams, Council Administrator - Ph 485-2173 Harold Steele, School Principal - Ph 485-2150 Noatak is unincorporated and is organized under the Indian Reorganization Act, IRA. Noatak is governed by a tribal council. 1. Construction Wages: Power Plant Operator earns $10.60 per hour for extra work like installing steel floors or interior walls. His normal salary is about $1,500 per month. Weather: During February, and March, north winds blow which cause deep snow drifts which are worst on the west side of the buildings. The weather station most representative of Noatak is Cape Lisburne. Soils: Permafrost soils have a active layer up to 4 feet. Soils are very ice rich with clear ice lenses, and have poor materials over top. Because of soil weakness when thawed, water line construction during the summer restricted excavated trench lengths to twenty feet. Most of the water lines are above grade. Transportation: One barge per year supplies Noatak. Except at breakup water depths are to shallow for larger barges. During the balance of the year transportation is by air or over the ice during the winter. Population: The community said that there are 350 people in the village. Alaska Department of Community and Regional Affairs gives the population as 329. Appendix B polarconsult Noatak Field Trip Notes January 11, 1990 2. Utilities: Water: Noatak has a above ground water distribution system. While we were in Noatak the system was inoperable as it was frozen. It had been allowed to run out of circulating water. The village safe water man, Toby Shields, who was trying to return it to service, stated there possibility the system will be upgraded, at a estimated cost of four million dollars. Discussions with ADEC in Anchorage disclosed that there have been two system freeze ups which were the result of operator error. So at this time it is not known if the above ground system will be replaced. It is likely that the existing water treatment facility will be replaced in the near future or at least augmented with an additional 150,000 gallon water tank. ADEC believes it is probable that the school will continue to get water via pipeline. If the distribution system is not rebuilt, a washeteria will be installed. This facility is likely to be located at the school. The washeteria in the School will increase the need for hot water there. With new water tanks and the elimination of most of the water distribution system the amount of oil used for heating tanks will increase the amount of oil used at the treatment plant. The amount of oil used to heat water in the piping system will decrease. The present main water piping system is comprised of a four inch PVC carrier pipe, four inches of insulation and a 12 diameter corrugate metal jacket. Sewer: The sewage lagoon was destroyed by river bank erosion. This bank erosion is said to be threatening the airfield. As Noatak is on ice rich permafrost, sewage must be disposed of above ground. Electrical System: The electrical distribution system at Noatak is above ground. This single phase system operates at 7.2/12.4 Kv. Appendix B polarconsult Noatak Field Trip Notes 5! 6. January 11, 1990 Fuel: City paid $148.40 / 53 gallon drum ($2.80 / gallon). Rights of Way There is some question on rights of way. As it is understood that some of the buildings are not located on their designated lots???? Equipment The community has a Insley Backhoe and a JD 450 front end loader. A second JD backhoe is associated with the airport and it is not known whether it is available for use constructing a waste heat system. Water Plant: Oil deliveries are in barrels with a cost of $148.40 / 53 gallon barrel which equals $2.80 per gallon. 1/5/88 106 3/2 265 8/24 265 1/6 159 3/18 106 10/5 424 1/25 212 3/26 159 10/27 212 2/3 106 4/8 212 11/16 265 2/18 53 4/25 106 12/6 318 2/19 106 6/22 53 otal S327) The water plant gets its water from a well located in the Noatak River. This well was reported to be frozen and there was discussion regarding replacing it. The water plant is located a few feet from the power plant and is slightly above it. The water plant has slope support and protection which is constructed of earth filled 55 gallon oil drums. School The school is run by the Northwest Arctic Borough School District which has is district offices in Kotzebue. The borough states the school used 35,000 gallons of fuel last year. Of this, 20,000 gallons were used in the High School, 10,000 gallons in the elementary school and 5,000 gallons in other adjacent buildings. Appendix B polarconsult Noatak Field Trip Notes January 11, 1990 costs over $2,000. This is because the piston planes will not fly at temperatures below -30°F. The high school, elementary and Junior high schools are connected, thereby forming a single building which has individual heating plants which are equipped as follows: High school: Hydronic System Elementary School: Hydronic System Junior High School: Warm air furnace 7. Guest Quarters Noatak has a small wood frame building located next to the power plant that they utilize for transient visitors. They stated that they would like to connect this building to the waste heat system. A rough estimate of heat use is about 500 gallons per year. 8. AVEC 1) Caterpillar D342 2) Vacant 3) Vacant 4) JD 6619A 5) KTA 1150 The plant is comprised of a Butler building housing one unit. There are also two modules containing units #4 and #5 as listed above. There is a new KTA 1150 replacement unit stored outside which is to replace the unit in #4. The power plant operator said he had problems with the JD which broke a fuel line. That the plant was to get new batteries replacing those which were installed in 1972. Appendix B polarconsult Noatak Field Trip Notes January 11, 1990 Module #5 had a leaky radiator so only one radiator was in service. The Butler building is on piling and has steel plate on floor that the operator recently installed. The operator cut the plate with a electric jig saw before bolting it to the floor. The module skids are supported by timbers. Appendix B polarconsult Noatak District Heating APPENDIX C Cost Estimate HMS 9022 * CONSTRUCTION COST STUDY WASTE HEAT RECOVERY SYSTEM NOATAK, 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 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from seven (7) 8 1/2"x11" sketches and outline specifications linking two facilities in 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 Spring 1991. Removal of hazardous material has not been considered in this cost estimate. CONCEPT #1 - Water Treatment Building, Junior High, Senior High and Elementary School Buildings $ 638,542 CONCEPT #2 - Water Treatment Building, Junior High and Senior High School Buildings $ 567,183 CONCEPT #3 - Water Treatment Building and Junior High School Building Only $ 492,617 WASTE HEAT RECOVERY SYSTEM PAGE 2 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 CONCEPT #2 CONCEPT #3 CONSTRUCTION COST 01 General Conditions, Overhead and Profit 155,937 142,322 122,968 02 Sitework 12777192 117,594 111,208 05 Metals 1,281 1,281 17220 06 Wood and Plastics 1,200 1,200 1,200 13 Special Construction 4,250 4,250 4,150 15 Mechanical 82,438 65,664 48,118 16 Electrical 1775 14 9,142 7,699 Subtotal 384,412 341,453 296,563 Estimate contingency for elements of project not determined at this early level of design (10%) 38,441 34,145 29,656 Esclation at .50% per month ( 4%) 16,914 15,024 13,049 TOTAL CONSTRUCTION COST 439,767 390,622 339,268 PROJECT COST Design (10%) 43,977 39,062 33,927 SIA (Supervision, Inspection and Administration) (20%) 96,749 85,937 74,639 Project Contingency (10%) 58,049 51,562 44,783 TOTAL PROJECT COST 638,542 567,183 492,617 WASTE HEAT RECOVERY SYSTEM PAGE 3 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 WASTE HEAT RECOVERY SYSTEM PAGE 4 NOATAK, 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 37,000 LBS 45 16,650 Supervision, equipment, utilities clean site, tools and protection 12 WKS 3100.00 37,200 Per diem 390 DAYS 110.00 42,900 Travel costs, including time in travel 6 RT 1375.00 8,250 Bond and insurance 2625 % 7,690 Profit 10 % 34,947 WASTE HEAT RECOVERY SYSTEM PAGE 5 NOATAK, 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 1,030 LF 12.50 12,875 3" diameter Schedule 40 pipe with insulation and arctic pipe protection 1,740 LF 55 cal 5) 95,961 2" ditto 320 LF 41.50 13,280 3" bend 16 EA 215.25 3,444 2" bend 6 EA 147.50 885 3" tee 4 EA 248.50 994 2" tee 2 EA 176.25 353 WASTE HEAT RECOVERY SYSTEM PAGE 6 NOATAK, 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 NOATAK, 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 NOATAK, 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 4 EA 110.00 440 Exterior door ll EA 710.00 710 Louver 1 EA 500.00 500 —_—_-— —-—>— ——_-—a/ CP a WASTE HEAT RECOVERY SYSTEM PAGE 9 NOATAK, ALASKA CONSTRUCTION COST FSTIMATE 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 FA 195.00 390 3" diameter black steel welded piping 80 LF 26.22 2,098 Fittings 16 EA 46.35 742 Butterfly valves 3 EA 325.00 975 Insulation to pipe, 3" diameter 80 LF 7.10 568 Booster pump 1 EA 1450.00 1,450 Heat exchanger, 300,000 BTUH 1 EA 3590.00 37590 WASTE HEAT RECOVERY SYSTEM PAGE 10 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 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 2 EA 195.00 390 2" diameter black steel piping including fittings 120 LF 7397 2,156 WASTE HEAT RECOVERY SYSTEM PAGE 11 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Gate valves 9 EA 260.00 2,340 Check valves 2 EA 260.00 520 Strainer 2 EA 58.00 116 Balancing valve 3 EA 53.00 159) Temperature control valve 1 EA 225.00 225 Insulation 120 LF 5.83 700 Heat exchanger, 100,000 BTUH 1 EA 3175.00 3,5 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 WASTE HEAT RECOVERY SYSTEM PAGE 12 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) Form hole through existing wall for heating pipes 6 EA 195.00 1,170 2" diameter black steel piping including fittings 360 LF 17.97 6,469 Gate valves 24 EA 260.00 6,240 Check valves 6 EA 260.00 1,560 Strainer 6 EA 50.00 300 Balance valve 9 EA 52.00 468 Temperature control valve 3 EA 225.00 675 Insulation, 2" diameter pipe 360 LF S583 2,099 Heat exchanger, 200,000 BTUH 2 EA 3440.00 6,880 Ditto, 300,000 BTUH 1 EA 3660.00 3,660 WASTE HEAT RECOVERY SYSTEM PAGE 13 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) Expansion tank, 66 gallon 3 EA 1535.00 4,605 Air separator 3 EA 495.00 1,485 Circulation pump, 2" diameter 3 EA 680.00 2,040 Connection to existing piping system 8 EA 72.50 580 Make-up glycol system connection, including tank 4 FA 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 14 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 3 EA 175.00 525 Connection to motor i EA 115.00 805 Disconnect switch 5 EA 330.00 1,650 3/4" EMT conduit 140 LF 3.10 434 #8 copper 560 LF 318 437 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 201. Panel 1 EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light fixtures 6 EA 190.00 1,140 TOTAL ESTIMATED COS WASTE HEAT RECOVERY SYSTEM PAGE 15 NOATAK, 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 68.00 272 1/2" conduit 50 LF 2.80 140 #12 copper 150 LF «52 78 Hook-Up Breaker in existing panel 4 EA 175.00 700 Connection to motor 8 EA 115.00 920 Disconnect switch 480 LF 3.10 1,488 #8 copper 1,440 LF 78 1,123 TOTAL ESTIMATED COST: 11,514 WASTE HEAT RECOVERY SYS'TEM PAGE 16 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 WASTE HEAT RECOVERY SYSTEM PAGE 17 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 01 - GENERAL CONDITIONS, OVERHEAD AND PROFIT QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,300 Freight 32,000 LBS 45 14,400 Supervision, equipment, utilities clean site, tools and protection 12 WKS 3100.00 37,200 Per diem 330 DAYS 110.00 36,300 Travel costs, including time in travel 6 RT 1375.00 8,250 Bond and insurance 25:25) % 6,831 Profit 10 % 31,041 WASTE HEAT RECOVERY SYSTEM PAGE 18 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 02 - SITEWORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 930 LF 12.50 11,625 3" diameter Schedule 40 pipe with insulation and arctic pipe protection 1,740 LF 55.15 95,961 2"=ditto 120 LF 41.50 4,980 3" bend 16 EA 21S 25 3,444 2" bend 4 EA 147.50 590 3" tee 4 EA 248.50 994 WASTE HEAT RECOVERY SYSTEM PAGE 19 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 3105) 172/81 WASTE HEAT RECOVERY SYSTEM PAGE 20 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 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 21 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 13. - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8'0"x8'0" building module with floor, exterior wall structure and roofing complete 1 EA 2600.00 2,600 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 WASTE HEAT RECOVERY SYSTEM PAGE 22 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 15 —- MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 72.50 145 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 80 LF 26.22 2,098 Fittings 16 FA 46.35 742 Butterfly valves 3 EA 325.00 975 Booster pump 1 EA 1450.00 1,450 Heat exchanger, 300,000 BTUH 1 EA 3485.00 3,485 Unit Heater (1 Each) (7 - Module Building) Unit heater, 60 BTUH, including thermostat 1 EA 330.00 330 TOTAL ESTIMATED COST: Continued WASTE HEAT RECOVERY SYSTEM PAGE 23 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Unit Heater (1 Fach) (Continued) (1 - Module Building) 1" diameter piping including fittings 40 LF 9570 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 including fittings 120 LF 7597 2,156 Gate valves 9 EA 260.00 2,340 Check valves 2 EA 260.00 520 Strainer 2 EA 58.00 116 WASTE HEAT RECOVERY SYSTEM PAGE 24 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Balancing valve 3 EA 53.00 159 Temperature control valve 1 EA 225.00 225 Insulation 120 LF 5.83 700 Heat exchanger, 100,000 BTUH 1 EFA 3175.00 3,175 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 Form hole through existing wall for heating pipes 2 EA 195.00 390 2" diameter black steel piping including fittings 120 LF 17397 2,156 WASTE HEAT RECOVERY SYSTEM PAGE 25 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Gate valves 8 EA 260.00 2,080 Check valves 2 EA 260.00 520 Strainer , 2 EA 50.00 100 Balance valve 3 EA 52.00 156 Temperature control valve 1 EA 225.00 225 Insulation, 2" diameter pipe 120 LF 5.83) 700 Heat exchanger, 200,000 BTUH 1 EA 3440.00 3,440 Expansion tank, 66 gallon 1 EA 1535.00 1,535 Air separator 1 EA 495.00 495 Circulation pump, 2" diameter 1 EA 680.00 680 WASTE HEAT RECOVERY SYSTEM PAGE 26 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Form hole through existing wall for heating pipes 2 EA 195.00 390 2" diameter black steel piping including fittings 120 LF 17.97 2,156 Gate valves 9 EA 260.00 2,340 Check valves 2 EA 260.00 520 Strainer 2 EA 58.00 116 Balancing valve 3 EA 49.50 149 Temperature control valve 1 EA 225.00 225 Insulation 120 LF 5.83 700 WASTE HEAT RECOVERY SYSTEM PAGE 27 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Heat exchanger, 300,000 BTUH 1 EA 3660.00 3,660 Expansion tank, 66 gallon capacity 1 EA 1535.00 7,535 Air separator 1 EA 495.00 495 Pumps, circulation Grundfoss 200, 2" diameter 2 EA 680.00 1,360 Connection to existing piping system 6 EA 72650 435 Make-up glycol system connection, including tank 3 EA 610.00 1,830 Glycol 330 GAL 8.80 2,904 Test and balance system 66 HRS 75.00 4,950 WASTE HEAT RECOVERY SYSTEM NOATAK, ALASKA CONSTRUCTION COST ESTIMATE PAGE 28 NOVEMBER 29, 1990 CONCEPT #2 15 —- MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Controls and Instrumentation Generator building and new module 1 LOT 2,000 Hook-up inter ties 3 LOTS 1500.00 4,500 WASTE HEAT RECOVERY SYSTEM PAGE 29 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 2 EA 175.00 350 Connection to motor 5 EA 115.00 575 Disconnect switch 3 EA 330.00 990 3/4" EMT conduit 100 LF 3.10 310 #8 copper 400 LF tS 312 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 SYS'TEM PAGE 30 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #2 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) Switch 1 EA 55.00 55 Duplex outlets 4 EA 68.00 272 1/2" conduit 50 LF 2.80 140 #12 copper 150 LF =52 78 Hook-Up Breaker in existing panel 3 EA 175.00 525 Connection to motor 6 EA 115.00 690 Disconnect switch 360 LF 3110 1,116 #8 copper 1,080 LF 78 842 WASTE HEAT RECOVERY SYSTEM PAGE 31 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 WASTE HEAT RECOVERY SYSTEM NOATAK, ALASKA CONSTRUCTION COST ESTIMATE CONCEPT #3 01 - GENERAL CONDITIONS, OVERHEAD AND PROFIT QUANTITY UNIT UNIT RATE PAGE 32 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 10 WKS 270 DAYS 6 RT 225) % 10 % 45 3100.00 110.00 1375.00 31,000 29,700 8,250 5,933 26,960 WASTE HEAT RECOVERY SYSTEM NOATAK, ALASKA CONSTRUCTION COST ESTIMATE CONCEPT #3 02 - SITEWORK QUANTITY UNIT UNIT RATE PAGE 33 NOVEMBER 29, 1990 ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 3" diameter Schedule 40 pipe with insulation and arctic pipe protection 3" bend 3" tee 870 1,740 18 LF LF EA EA 12.50 Sole 1D. 215.25 248.50 10,875 95,961 3,875 497 WASTE HEAT RECOVERY SYSTEM PAGE 34 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 05 —- METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1.00 1,220 WASTE HEAT RECOVERY SYSTEM PAGE 35 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 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 36 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 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 2500.00 2,500 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 WASTE HEAT RECOVERY SYSTEM PAGE 37 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 15 —- MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 12.50 145 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 80 LF 26.22 2,098 Fittings 16 EA 46.35 742 Butterfly valves 3 EA 325.00 975 Insulation to pipe, 3" diameter 80 LF 7.10 568 Booster pump 1 EA 1450.00 1,450 Heat exchanger, 300,000 BTUH 1 EA 3590.00 3,590 WASTE HEAT RECOVERY SYSTEM PAGE 38 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 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 including fittings 120 LF qT 97, 2,156 WASTE HEAT RECOVERY SYSTEM PAGE 39 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Gate valves 9 EA 260.00 2,340 Check valves 2 EA 260.00 520 Strainer 2 EA 58.00 116 Balancing valve 3 EA 53.00 159 Temperature control valve 1 EA 225.00 225 Insulation 120 LF 5.83 700 Heat exchanger, 100,000 BTUH 1 EA 3175.00 3175 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 WASTE HEAT RECOVERY SYSTEM PAGE 40 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Form hole through existing wall for heating pipes 2 EA 195.00 390 2" diameter black steel piping including fittings 120 LF 17.97 2,156 Gate valves 8 EA 260.00 2,080 Check valves 2 EA 260.00 520 Strainer 2 EA 50.00 100 Balance valve 3 EA 52.00 156 Temperature control valve 1 EA 225.00 225 Insulation, 2" diameter pipe 120 LF 5.83 700 Heat exchanger, 200,000 BTUH 1 EA 3440.00 3,440 WASTE HEAT RECOVERY SYSTEM PAGE 41 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Expansion tank, 66 gallon 1 EA 1535.00 1,535 Air separator 1 EA 495.00 495 Circulation pump, 2" diameter 1 EA 680.00 680 Connection to existing piping system 4 EA 72.50 290 Make-up glycol system connection, including tank 2 EA 610.00 1,220 Glycol 220 GAL 8.80 1,936 Test and balance system 48 HRS 75.00 3,600 Controls and Instrumentation Generator building and new module 1 LOT 2,000 Hook-up inter ties 2 LOTS 1500.00 3,000 WASTE HEAT RECOVERY SYSTEM PAGE 42 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 1 EA 175.00 175 Disconnect switch 1 EA 330.00 330 3/4" EMT conduit 20 LF 3.10 62 #8 copper 80 LF -78 62 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EFA 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 43 NOATAK, ALASKA CONSTRUCTION COST ESTIMATE NOVEMBER 29, 1990 CONCEPT #3 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 115.00 115 1/2" conduit 70 LF 2.80 196 #12 copper 210 LF 52 109 Hook-Up Breaker in existing panel 2 EA 175.00 350 Connection to motor 4 EA 115.00 460 Disconnect switch 4 EA 330.00 1,320 3/4" EMT conduit 240 LF 3.10 744 #8 copper 720 LF 78 562