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HomeMy WebLinkAboutGambell Waste Heat Recovery Report & Concept Design 1990GAMBELL WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 1, 1990 TABLE OF CONTENTS 1.0 EXECUTIVE SUMMARY 1 2.0 INTRODUCTION 2 3.0 DESCRIPTION OF SITE VISIT 4 4.0 POWER PLANT DESCRIPTION 5 5.0 POTENTIAL WASTE HEAT USER BUILDING DESCRIPTIONS 10 6.0 —RIGHT-OF-WAY/EASEMENT 23 7.0 | CONCEPT DESIGN 24 8.0 ECONOMIC DATA 46 9.0 — FAILURE ANALYSIS 48 10.0 CONCLUSIONS AND RECOMMENDATIONS 58 APPENDICES ys Calculations 2. Contact Names 3. Cost Estimates 4. Raw Data LIST OF FIGURES, TABLES AND GRAPHS Gambell Power Generation - 1988 Power Plant Photographs Gambell High School Fuel Oil Use Gambell High School Photographs Washeteria Fuel Oil Use Washeteria Building Photographs City Office Building Fuel Oil Use City Office Building Photographs Figure 1 - Drawing Legend Figure 2 - System Schematic Figure 3 - System Site Plan Figure 4 - AVEC Module Plan Figure § - AVEC Module Schematic Figure 6 - High School First Floor Plan Figure 7 - High School Second Floor Plan Figure 8 - High School Schematic Figure 9 - Washeteria Plan Figure 10 - Washeteria Schematic Figure 11 - City Office Building First Floor Figure 12 - City Office Building Schematic Figure 13 - Arctic Pipe/Trench Cross Section Heat Available vs. Heat Required Graph GAMBELL WASTE HEAT RECOVERY REPORT AND CONCEPT DESIGN MAY 1, 1990 Waste Heat Recovery Fuel Oil Displaced Graph, Base Bid & Altemate #1 Waste Heat Recovery Fuel Oil Displaced Graph, Alternate #1,2 & 3 1.0 EXECUTIVE SUMMARY A potential for waste heat recovery exists at the community of Gambell. Gambell is lo- cated on the Northwest Cape of St. Lawrence Island, approximately 700 air miles west of Anchorage. The heat energy could be recovered from the diesel engine-generator sets operated by AVEC and circulated to user buildings in the community. Several waste heat users have been Identified. The primary candidates include: the high school, the City Office building, and the Washeteria. lt appears as if the most economical system will provide heat only to the high school since it is closest to the power plant. Adding insulation to the AVEC generator modules improves the economic performance of the waste heat recovery system. If the alterna- tive #1 system Is Installed insulating the AVEC generator modules and connecting waste heat to the high school, the following are the estimated results: Total Construction Costs $361,500 Total Fuel Oll Savings 1170 gallons Total Annual Dollar Savings $ 10,700 Page 1 2.0 INTRODUCTION 2.1 2.2 2.3 Objective The objective of the field investigation and report Is to ascertain the viability of waste heat recovery and use In the community of Gambell. It has been estab- lished that there is a potential source and use for the heat energy, and that the community is interested in pursuing the matter. Methodology Tne approach for investigation and analysis has been as follows: 1. Pre-site visit information gathering: this has consisted of contact with the community officials, owners/operators of potential user buildings, and contact with the local utility. Community data was secured, and previous site studies were reviewed. The site visit was coordinated with the local utility plant operator. Field Investigation: a visit was made to the community to view the site. Photographs of the potential user buildings were taken as well as of the electrical generation buildings and equipment. Sketches were made of the equipment and piping connections. Fuel use records and user build- ing data was gathered. The project was discussed with community offi- clals, building owners/operators, the utility plant operator and interested community members. Office Analysis: additional information was collected regarding weather and historical electrical energy production. This was used in a model to predict the system performance and the amount of energy recovered. Report Preparation: a draft version report was prepared for the expected audience - users and agencies with an interest. Community Description Gambell ls a community of some 450 persons located on the Northwest Cape of St. Lawrence Island in the Bering Sea. The community is 200 miles southwest of Nome. The community is located on a low lying gravel spit. See Figure 3 in Sec- tion 7 for a partial community site plan. Page 2 2.4 Applicable Codes and Regulations The most recently State of Alaska-adopted editions (1985 for all except as noted) of the following codes and regulations have been used in the preparation of the concept design. These are listed below: Uniform Plumbing Code (UPC - 1979) Uniform Mechanical Code (UMC) Uniform Building Code (UBC) Uniform Fire Code (UFC) National Electrical Code (NEC - 1987) National Fire Protection Association (NFPA) Codes Page 3 3.0 DESCRIPTION OF SITE VISIT 3.1 3.2 3.3 Field Notes Contact names are included as part of the Appendix at the end of this report. They include both field contacts and contacts made by phone. Field Contacts The following people were contacted In the field: Branson Tonglyan, City Mayor Franklin Kaningok, AVEC plant operator Nancy Byers, High School Principal Shirley Antoghame, City Clerk Jessie Lowery, Slvuqaq Corporation Clerk Aaron lworrigan, Community AVEC delegate Merlin Kanoonak, BSSD Maintenance Foreman Herbert Apaffingok, Postmaster Gerard Kanoonak, G&E Enterprises Owner Veronica James, Village Public Safety Officer Mike Apatiki, National Guard Armory Tim Stwooko, City Council Member, Education Advisory Council, Fire Chief Community Meeting During the site visit, the annual Community AVEC meeting was held. A brief presentation of the waste heat recovery project was given and questions were addressed. There is a high level of interest in waste heat recovery projects. Page 4 4.0 POWER PLANT DESCRIPTION 41 Narrative Description The original AVEC powerplant was destroyed by fire in 1985. The replacement powerplant is located at the extreme east end of the community, approximately 500 feet east of the high school. The site consists of a series of modules and a fuel tank farm. One module contains switchgear, generator controls, fuel oil day tank and fuel-oil transfer equipment. There are two prime power modules and a standby power module. There Is an unheated storage module. The modules are prefabricated units of steel construction. The modules are skid mounted, some leveled with cribbing. The prime power generators are equipped with duplex remote radiators mounted in a semi-enclosed unheated portion of the module. The remote radiators have variable speed fans. Each generator is equipped with a shell and tube heat exchanger. Waste heat is utilized for module heating and engine block heating. Circulating pumps are located in each prime power module. Each module has unit heaters for space heating. The prime power modules have automatically controlled duplex 2-speed exhaust fans and outside air intakes for space cooling. The standby generator is equipped with a conventional skid-mounted radiator. The radiator discharge is ducted. Exhaust and return air control dampers and outside air intakes with control dampers allow for space cooling and tempera- ture control. The generator is equipped with a shell and tube heat exchanger, interconnected with the prime power waste heat recovery system. All modules are protected with halon fire protection systems. The prime power generators are Cummins KTA19-G2, rated at 350 KW. The standby generator is a Caterpillar 3406DT rated at 350 KW. The generators can be paralleled, however it is not necessary under normal operating conditions as the peak load does not exceed the capacity of a single generator. The prime power units #1 and 2 are altemated. The standby unit, #3, Is rarely used. Page 5 4.2 43 44 The installation is in good condition, although exposed equipment, primarily the prime power unit remote radiators, are showing signs of deterioration from corro- sion. Primary operational problems include: a. Heavy snow drifting around modules, sometimes blocking access. b. The control module and standby module are not insulated. Door seals are poor and pipe penetrations are not tightly sealed. Wind and snow in- filtration are a problem on the interior, while icing is a problem on the ex- terior. Gc The intermodule waste heat recovery system Is not piped in the most ef- fective manner. Module #3 Is always cold. Performance Is satisfactory when unit #2 Is operating, marginal with unit #1 Is operating, and all modules are cold when unit #3 Is operating. A modification is planned for summer, 1990. There is a plan to extend waste heat and power to the storage module in the near future. Floor Plan and Schematics See the Figures 4 and 5 for a typical floor plan and schematic of the system (located in Section 7). Photographs See the attached copies of the original color photographs. Available Load Information Refer to the attached Table indicating historical power production. This informa- tion is from AVEC for the year 1987 and 1998. Figures for other years are also available from AVEC. Page 6 TABLE 1 GAMBELL POWER GENERATION 1987 MONTH hig ings HOURS/ | AVG. LOAD MONTH 110,320 153 FEB 99,520 696 143 MAR 102,240 744 137 APR 89,920 720 125 MAY 81,920 744 110 JUNE 56,560 720 79 JULY 52,560 744 71 AUG 71,920 744 97 SEP 82,000 720 114 OCT 91,040 744 122 NOV 94,720 720 132 DEC 103,600 744 139 ANNUAL 1,036,320 8760 118 PRODUCTION AVG. LOAD KWH JAN 101,040 720 140 FEB 96,880 696 139 MAR 96,880 744 130 APR 84,320 720 117 MAY 75,840 744 102 JUNE 64,240 720 89 JULY 61,040 744 82 AUG 73,280 744 98 SEP 81,520 720 113 OCT 92,320 744 124 NOV 98,240 720 136 DEC 98,720 744 133 ANNUAL 1,024,320 8760 117 Page 7 PHOTO 1: POWER PLANT SITE Prime Power Modules and Control Module PHOTO 2: POWER PLANT SITE Typical Prime Power Module Waste Heat Heat Exchanger Page 8 PHOTO 3: POWER PLANT Typical Prime Power Module View PHOTO 4: POWER PLANT Typical Prime Power Module View Page 9 5.0 POTENTIAL WASTE HEAT USER BUILDING DESCRIPTIONS 5.1 General Several buildings were Identified as potential user building candidates. They are listed following In order of increasing distance from the power plant: High School Washeteria City Office Building Clinic Post Office G&E Enterprise Store Ubrary Teen Center Community Building Armory Telephone Utility Building Public Safety Building Native Store Elementary School Residences and other private buildings were not considered. Preliminary analysis indicated the high school, washeteria, and city office build- ing would utilize In excess of 90% of available waste heat. The three buildings are within 1,100 feet of the power plant. The buildings are generally oriented in a line extending from the power plant. To utilize the remaining increment of available waste heat would require extension of the waste heat arctic pipeline an addi- tional 750 feet to the post office or clinic. The extension would not be cost effec- tive. The final analysis concentrated on the high school, washeteria, and city of- fice building. Photographs accompany each building description. Plans and schematics can be found in Section 7. Page 10 5.2 Gambell High School General The building Is a wood frame structure with a crawl space and conventional spread footing foundation. The building Is two stories in height and encloses ap- proximately 14,000 square feet of conditioned space. The building is used primarily for educational purposes. It is often open in the school year evenings for recreational and community activities. The building appears to be in good con- dition. No programmed future changes were identified. Heating Energy Use The gymnasium, locker rooms, shop, and classrooms are served by three con- stant volume, variable temperature air handling units. Heat generation Is provided by indirect fuel-oil fired furnaces located on the discharge side of each air handling unit. A single mixed air plenum with manually controlled outside air and return air dampers serves all three air handling units. Heat recovery Is provided for the locker room exhaust. The air handling units and locker room ex- haust heat recovery are located In the mixed air plenum on the second floor. The furnaces are located in the mechanical room adjacent to the plenum. An oll-fire storage type domestic hot water heater Is also located in this space. The home-ec/science classroom and kitchen located on the north side of the gym were originally served by the gym air handling system. The spaces could not be appropriately heated and they are now served Independently with a single indirect oil-fired furnace located in the second floor mechanical room above the gym storage room. The furnace has a built-up filter mixing box with manual out- side air and return air control dampers. Also Installed was an indirect oil-fired warm air furnace operating at 100% outside air to serve as a kitchen hood make-up air unit. A perimeter hydronic heating loop with fin-tube radiation was originally installed In the crawl space and connected to the domestic hot water system. The hydronic loop has been abandoned. The equipment appears to be in good condition, although the plenum control dampers were in a deteriorated condition and the heat recovery system ap- peared to need cleaning. The temperature control system incorporates night setback. See the attached Table showing the fuel use for 1989. The fuel use shown is from school records of the current fuel oil inventory. Data for other years are also available. Page 11 TABLE 2 BUILDING FUEL OIL USE - 1989 BUILDING: HIGH SCHOOL YEARLY FUEL USE: 13,593 DHW USE: 10% HEATING DOM. WATER |NETHEATING /|TOTAL USE DEGREE DAYS i USE (GALLONS) |(GALLONS) JAN 2266 FEB 1268 MAR 1565 APR 1287 MAY 1008 JUNE 527 JULY 0 AUG 0 SEP 637 OCT 954 NOV 1537 DEC 2544 13,593 Page 12 PHOTO 5: HIGH SCHOOL View from Power Plant PHOTO 6: HIGH SCHOOL Crawl Space Page 13 PHOTO 7: HIGH SCHOOL Air Handling Units In Mixed Air Plenum PHOTO 8: HIGH SCHOOL Kitchen Hood Make-Up Air Furnace Home-Ec Furnace Similar Page 14 5.2 5.3 Gambell Washeteria General The building is single story wood frame construction with a conventional con- crete slab on grade foundation. The building encloses approximately 2700 square feet of conditioned space. The north side of the building includes a self- serve laundry and restrooms with showers. The south end of the building includes mechanical space, water treatment and pressurization equipment, an office, lab, and work space. The facility is in fair condition. An additional exterior water storage tank was recently added. As well, domestic water was extended to the high school and city offices and connected. There are plans to extend water to some of the closest residences. No other programmed future changes were Identified. Heating Energy Use Space heating Is provided by a perimeter hydronic heating system. Heat gener- ation is provided by three oil-fired hydronic heating boilers. The hydronic boilers also serve process loads including water storage tank heating, utilidor heating, and domestic hot water heating through a series of heat exchangers. Water is used as the heat transfer medium. The restrooms and dryers are provided with exhaust systems. No make-up air sys- tem was evident. The systems appeared to be in fair condition. See the attached Table outlining the fuel use for the building and systems. The figures shown were provided by the city office in terms of yearly fuel use. The monthly use was calculated based on the heating degree days for the area. Gambell City Office Building General The building Is of wood frame construction. A post and pad foundation system Is employed. The floor is insulated. The crawl space is skirted, unheated and uninsu- lated. The building Is of two story configuration, enclosing approximately 3600 square feet of conditioned space. The first floor houses the lvory Coop offices, and the local head start program. City and Sivuqagq corporation offices are lo- cated on the second floor along with the Magistrates office. The facility was recently constructed and is in good condition. No programmed future changes were Identified. Page 15 TABLE 3 BUILDING FUEL OIL USE - 1989 BUILDING: WASHETERIA YEARLY FUEL USE: 5,680 DHW USE: 20% HEATING DOM. WATER |NETHEATING |TOTALUSE DEGREE DAYS|HEATING USE (GALLONS) (GALLONS) ALLO! JAN 1906 95 582 676 FEB 1742 95 532 626 MAR 1862 95 568 663 APR 441 536 MAY 295 390 JUNE 186 281 JULY 146 240 AUG 154 249 SEP 313 OCT 359 453 NOV 468 563 DEC 690 4,544 5,680 Page 16 PHOTO 9: WASHETERIA East Elevation PHOTO 10: WASHETERIA Interior View of Laundry Page 17 PHOTO 11: WASHETERIA Boller Piping PHOTO 12: WASHETERIA Boiler Piping Page 18 Heating Energy Use Space heating Is provided by a perimeter hydronic heating system. Heat gener- ation is provided by a single oil-fired hydronic heating boiler located in the mechanical room on the first floor. The boiler incorporates a tankless heater for domestic hot water heating. Water Is used as the heat transfer medium. No alr distribution systems were identified. The systems appeared to be in good condition. See the attached Table outlining the fuel use for the building and systems. The figures shown were provided by the city office in terms of yearly fuel use. The monthly use was calculated based on the heating degree days for the area. Page 19 JUNE JULY AUG SEP OCT NOV TABLE 4 BUILDING FUEL OIL USE - 1989 BUILDING: YEARLY FUEL USE: DHW USE: HEATING DEGREE DAYS 1906 1742 1862 1445 611 477 715 1176 1534 1951 14,893 DOM. WATER HEATING ZALLO DAA MAMAAAAAD ~I a CITY OFFICE BUILDING 1,500 5% NETHEATING |TOTAL USE USE (GALLONS) |(GALLONS) 182 189 167 173 178 184 138 145 93 99 58 65 46 52 48 55 68 75 113 119 147 153 187 193 1,425 1,500 Page 20 PHOTO 13: CITY OFFICE BUILDING East Elevation PHOTO 14: CITY OFFICE BUILDING View of City Office, Washeteria and High School, Looking West Page 21 PHOTO 15: CITY OFFICE BUILDING Boiler Piping Page 22 6.0 RIGHT-OF-WAY/EASEMENT 6.1 Narrative Description The Issue of right-of-ways and easements were not addressed as part of this report. Page 23 7.0 CONCEPT DESIGN 71 System Narrative General guidelines recommended by the Alaska Energy Authority for the design of waste heat recovery systems Includes the following: 1 Use flat plate heat exchangers. Consider multiple circuits, one circuit for each of the generators that may be used. 2. System design should be for at least a 15 degree F temperature drop to keep flow rates as low as possible. The application of waste heat recovery systems to the power generation system was discussed with the operating utility company, AVEC. AVEC personnel offered the following recommendations: Vk Waste heat recovery systems should not reduce the reliability of the power generation system. 2: Existing waste heat recovery systems used for power plant facility heating and generator block heating should be separate and Independent of user building waste heat recovery system. 3. Waste heat recovery equipment and systems should not restrict main- tenance access space to power generation equipment. 4, Waste heat recovery equipment should be located in separate modules, or preferably user buildings rather than in the power plant facility. Electri- cal power for waste heat recovery equipment should not be furnished by the power plant building's electrical distribution system. 5. The requirement for boost pumps on the generator cooling system should be avoided. If boost pumps are required, they should be duplex for maxi- mum reliability. In keeping with the above recommendations, the current concept design in- cludes a single three circuit flat plate heat exchanger at the AVEC module. There Is one circuit for each of the two normally used engine/generator sets and a third circuit for the waste heat recovery loop. The heat exchanger is located in a new insulated enclosure attached to one of the respective generator modules to minimize first cost and impact to maintenance access space. The new waste heat recovery heat exchanger is independent from the existing power plant facility waste heat recovery heat exchangers. Due to the additional Page 24 ©es¢changer pressure drop, boost pumps are required on the generator cooling sys- tem. However, the heat exchanger will be connected in a secondary loop con- figuration such that operation of the boost pumps will not be critical for proper operation of the basic generator cooling system. Heat recovery side flow will be provided by a main circulation pump located in the primary user building, the high school. The pump will be designed for the pressure drop of the furthest connected building. In addition, an air separator, expansion tank, and a glycol make-up system Is required. The pump’s design flow rate will be for the maximum heat available at a 20 degree temperature drop. The electrical energy required to operate the circulation pump will be provided by the high school. Other facilities which may be connected to the waste heat recovery system will not experience a similar cost. As such, waste heat sales agreements should incorporate some form of cost equalization for the pumping energy. The piping between the two generator modules, the high school, and to each other connected buildings will be through arctic pipe buried underground to protect it from damage from passage of three-wheelers, snow machines, and other vehicles. Two separate arctic pipes are envisioned, one for supply to the buildings, and one for return to the AVEC plant. See the attached Figure 2 for the system schematic. The waste heat recovery circulation pump and related components shall be lo- cated in the high school second floor mechanical room above the gym storage. Heat recovery implementation in the high school will consist of waste heat recovery colls installed in each furnace and air handling unit. For air handling units, the coil will be installed in the existing cabinet coil space. For the furnace serving the home-ec room, the coll will be installed in a modified mixing box. For the kitchen hood make-up air fumace, the coil will be installed in the outside air duct. Coil design will be for a single row coil with wide fin spacing to minimize the air pressure drop and its effect on air flow to the spaces. Primary pipe routing will be in the crawl space. The existing control system will be modified to modu- late coils to maintain space setpoints prior to cycling furnace bumers. Page 25 BALANCE VALVE GATE VALVE 2-WAY CONTROL VALVE CHECK VALVE UNION CIRCULATING PUMP a) bd oe oe 3—-WAY CONTROL VALVE N ' 0 l THERMOMETER — i AIR SEPARATOR — PRESSURE REDUCING VALVE FLOW ARROW PIPE DOWN PIPE UP NEW RETURN LINE NEW SUPPLY LINE EXISTING RETURN LINE EXISTING SUPPLY LINE NEW EQUIPMENT/VALVES IN THIS COLOR EXISTING EQUIPMENT/VALVES IN THIS COLOR SYSTEM SCHEMATIC USES ADDITIONAL COLORS TO DEFINE SYSTEMS SYMBOL LEGEND FRYER/PRESSLEY ENGINEERING 660 EAST 34th AVENUE SUITE 300 ANCHORAGE, ALASKA 99503 (907)561-1666 Page 26 22 e6eg VASVIV ‘S9VEOHONY JNIMHANIONG ATISSAd/ UaAua * 999T—199(206) Tivo Lsva 099 OILVWSHOS W3LSAS AYSAOIFY LVSH ALSVM TISEWV9 dj GENERATOR MODULE \ 1 HEAT RECOVERY HEAT | | EXCHANGER CIRCULATING PUMP —{__) GENERATOR MODULE HEAT RECOVERY ENCLOSURE EXTENSION pp AG t— | T) BE COOLING SYSTEM HEAT RECOVERY HEAT EXCHANGER HEAT RECOVERY HEAT EXCHANGER CIRCULATING PUMP ee GENERATOR 2 GENERATOR MODULE —- [TT | ns rns WASHETERIA ALL PIPING SHOWN RUN OUTSIDE BUILDING IS IN ARCTIC PIPE. BOILER GENERATOR SYSTEM DISTRIBUTION SYSTEM BUILDING SYSTEM FURNACE/AIR HANDLING TO OTHER —_—UNIT (TYP.) | Wey DJ iC |] | maa | | - toe | [Hic SCHOOL i=l [CITY OFFICE BUILDING | 7.2 7.3 74 The connections to the Washeteria and the City Office building will be with flat plate heat exchangers located in the respective mechanical rooms. The heat exchangers will reduce the potential problems with building system overpres- surization and loss of heating fluid in the event of a pipe leak. The piping will be connected into the retum lines of the boilers and circulated with the existing in- line circulating pumps. Precautions must be taken to prevent overcooling of the generator jacket water and to prevent building system boilers from heating the waste heat distribution system. The generator engine thermostat generally minimizes any potential for Jacket water overcooling. Reverse operation of the waste heat recovery system can be most easily prevented by proper selection of building system operating temperatures. No problem exists at the high school with the use of independent duct coils. Boiler operating temperatures observed at the washeteria and city offices are compatible with anticipated waste heat recovery system tempera- tures. Site Plan/Routing The routing will be as shown on the attached plan. Essentially, a direct line-of- sight connection is envisioned first from the AVEC plant to the high school, then from the high school to the washeteria, and then to the city office building. There are no established roads for heavy vehicle use. Direct bury to accommodate three-wheeler and snow machine use Is planned. Coordination will be required with the existing buried electrical distrioution system, and water and sewer piping between the high school, city office building and the washeteria. The routing should give consideration to the proposed water and sanitary sewer system to serve adjacent residential buildings. The routing is shown on Figure 3. Generator Module Plans/Schematics See the attached Figures 4 and 5 for the design concept for changes to the AVEC modules. Tne AVEC modules are poorly insulated. Insulating the modules to reduce heat loss will improve the overall performance of the heat recovery system. Adding Insulation to the modules has been considered as an alternative. User Building Plan/Schematics See the attached Figures 6 through 12 for proposed changes to each of the potential user buildings. Page 28 rocommy 7 QOQ4 2 CITY OFFICE BUILDING SEPTIC TANK WASHETERIA i Pail AND LEACH FIELD ALTERNATIVE #3: 1-1/4" RESIDENCE WATER STORAGE ALTERNATIVE 2 & 3: 2” SEPTIC TANK AND LEACH eh HIGH SCHOOL AVEC POWER PLANT BASE BID 3” F P SITE PLAN/PIPE ROUTING rl FRYER /PRESSLEY ENGINEERING ANCHORAGE, ALASKA 99603 (907)561-1666 Page 29 ELECTRICAL AND CONTROL EQUIPMENT EXISTING HEAT RECOVERY HEAT EXCHANGER +s \ EXHAUST FAN, (TYP.) HEAT RECOVERY HEAT EXCHANGER CIRCULATION PUMP ELECTRICAL AND CONTROL EQUIPMENT GENERATOR p—— MOVEABLE STORAGE | | | 4 HEAT EXCHANGER MODULE ADDITION OUTSIDE AIR HOOD TYPICAL POWER PLANT MODULE FIP Ftoor Pian A FRYER /PRESSLEY ENGINEERING ANCHORAGE, ALASKA 996503 (907)561-1666 Page 30 te e6eg £0966 VXSVIV ‘SDVHOHONY 00€ ZLINS ZNANZAY Nive Lsva 099 DNIMAANIDNG AWISSHUNd/ AANA 9991-199(206) JILVWAHOS W4ALSAS SNIN009 dj YOLVYSNID LNW1d Y3MOd HEAT RECOVERY HEAT RECOVERY HEAT EXCHANGER BOOST PUMP 3—CHAMBERED HEAT RECOVERY HEAT EXCHANGER aaa WASTE HEAT SUPPLY AND RETURN TO MODULES HEAT RECOVERY HEAT EXCHANGER HEAT RECOVERY HEAT EXCHANGER BOOST PUMP WASTE HEAT SUPPLY AND RETURN TO MODULES J OO Ss, :.. 8 — ea a SS oe 4 WOOY TWOINYHOSN { WOOY 43x07 SAO8 de y3x007 WOLF (907)561-1666 YOLVYINI9 AGONVLS FIRST FLOOR PLAN ANCHORAGE, ALASKA 99603 HIGH SCHOOL 660 EAST 34th mL souW40 be oe ee ee oe Be osy YOO / t FRYER /PRESSLEY ENGINEERING FP Page 32 aad NEW HEAT RECOVERY EQUIPMENT LOCATION \ ACCESS HATCH ———— 2ND FLOOR MECHANICAL ROOM — MECHANICAL ROOM ECHANICAL PLENUM p HIGH SCHOOL F|P 2no Floor PLAN . FRYER/PRESSLEY ENGINEERING ANCHORAGE, ALASKA 99503 (907)561-1666 Page 33 ve ebeg s/A TO LOCKER ROOMS djl S/A TO MAKE-UP HOME EC. AIR TO & KITCHEN KITCHEN S/A TO GYMNASIUM VASVIV ‘EDVHOHONY OO€ ZLINS ZONZAY Tite Lsva 099 ONIMAANIONA AMISSHNd/YaAA ‘OOHOS HOIH OIL—FIRED HEAT RECOVERY FURNACE COIL IN EXISTING OUTSIDE AIR DUCT JILVWAHOS W3LSAS HEAT RECOVERY COIL IN EXISTING BUILT-UP S/A TO MIXING BOX. CLASSROOMS - 2-1/2" HEAT RECOVERY COIL EXPANSION TANK a IN EXISTING AIR HANDLING UNIT COIL SPACE, TYP. OF 3. AIR SEPARATOR GLYCOL MAKE-UP IN ARCTIC PIPE FROM POWER PLANT IN ARCTIC PIPE TO ADDITIONAL USER BLOGS. (ALT #2 & ALT #3) g : 3 SPAC ——— VARIOUS SUPPORT ES WASTE HEAT MECHANICAL 'ROOM RECOVERY SERVICE AND WATER TREATMENT EXISTING ENTRY rq OO | | a BOILERS NEW HEAT RECO EQUIPMENT —_] VERY mo LAUNDROMAT ——| WASHETERIA FIP Fioor Pian . ERYER PRESSLEY ENGINEERING (907)561-1666 Page 35 3did DLOYV woud/OL AINO YF1I08 JNO S3NOZ WOU ua0V3H MMH “ANVL NOISNVdX3 u30V3H YSONVHOXS LV3H SdNd YaLVM LOH OUS3WOG AVIS i ? ws108 ; U itt S3NOZ OL y30V3H SMH u30V3H NUNLZY OL NYNLZY OLY SdWNd 3NOZ AYVGNOD3S SYSTEM SCHEMATIC WASHETERIA F|P VENUE SUITE 300 ANCHORAGE, ALASKA 99603 (907)561-1666 7 FRYER /PRESSLEY ENGINEERING Page 36 KITCHEN ASSEMBLY ROOM sseMe \—— WASTE HEAT RECOVERY SERVICE ENTRY NEW HEAT RECOVERY — | EQUIPMENT STORAGE BOILER (TYP.) ARCTIC il ENTRY 4 DYN BY: McD CKD BY: ST DATE: 2/13/90 CITY OFFICES FP First FLoor PLAN . ERYER/PRESSLEY ENGINEERING ANCHORAGE, ALASKA 99603 (907)561-1666 Page 37 FROM ZONES HEAT EXCHANGER NEW WORK EXPANSION TANK DOMESTIC HOT WATER HEAT EXCHANGER CITY OFFICES FIP system scHematic . apa ENGINEERING 660 EAST ee eee ate (907)561-1666 Page 38 WASTE HEAT SUPPLY AND RETURN PIPING. RO i hstareraveres ARCTIC PIPE LLERYH? P. cross SECTION FRYER/PRESSLEY ENGINEERING 660 EAST 34th AVENUE SUITE 300 ANCHORAGE, ALASKA BACKFILL, COMPACT X29 > OOOrw - - SERRE. ~e ZRLRB RXPRED ERE ROS ho x) - RS5 (907)561-1666 Page 39 BEDDING, COMPACT TO 95% 6” MIN. BEDDING. 75 76 Arctic Pipe/Utilidor Section A cross section of the anticipated trench and arctic pipe configuration Is shown In the Figure 13. Outline Specifications The outline specifications for the major components of the system are shown below. 15010 GENERAL CONDITIONS The system shall be balanced by the Contractor to the flow specified in the construction documents. 15050 BASIC MATERIALS AND METHODS Valves: Valves for isolation use shall be gate type rated for 150 psig. Speciatties: Vibration isolation, flexible connections, automatic air vents, drains, pressure gages and thermometers, balance valves and other speciatties shall be provided. Devices shall be rated for system conditions. Piping: Piping within the generator modules shall be welded steel. Piping Inside buildings shall be type "L" copper with dielectric unions at connec- tion points of dissimilar metals. 15120 ARCTIC PIPE Arctic Pipe: Carrier pipe shall be schedule 40 welded steel. Insulation shall be foamed polyurethane with no voids. Thickness of insulation to be minimum of 2 Inches. Jacket pipe shall be steel or high density polyethylene. Arctic pipe system shall include kits or fittings for take-off connections to main loop that provide water-tight seal. 15250 MECHANICAL INSULATION Piping insulation: Pipe insulation shall be fiberglass with an all-service Jacket. Minimum insulation thickness shall be 1 inche> Page 40 15750 HEAT TRANSFER Heat Exchangers: Heat exchangers shall be plate and frame type with minimum 20 gage stainless steel plates, painted steel frame with head and end support, top carrying bar, and bottom guiding bar. Ports shall be International pipe thread. Acceptable manufacturers are Bell & Gos- sett, APV, Tranter, and Alfa Laval. Heat Exchanger Capacities: Generator module heat exchanger: 819 MBH; generator side: 189 GPM, 200 EWT (typical of two circuits); heat recovery side: 95 GPM, 195 LWT. Washeteria heat exchanger: 245 MBH; heat recovery side: 28 GPM, 195 EWT; heating system side: 28 GPM, 190 LWT. City Office building heat exchanger: 60 MBH; heat recovery side: 7 GPM, 195 EWT; heating system side: 7 GPM, 190 LWT. Hydronic Coils: Coils shall be copper tube coils with aluminum fins, one tow deep, and 8 fins per inch. Coils shall be designed for the required capacity, 190 EWT, 70 EAT, maximum 0.05 inches water column air pres- sure drop, 20 degree water temperature drop, and a maximum water pressure drop of 3 feet or less. Coil Capacities: AHU-1, gym air handling unit: 8300 CFM, 210 MBH, 24 GPM. AHU-2, locker room and classroom air handling unit: 3100 CFM, 110 MBH, 13 GPM. AHU-3, shop and classroom air handling unit: 3100 CFM, 110 MBH, 13 GPM. Home-ec furnace: 2400 CFM, 200 MBH, 23 GPM. Kitchen hood make-up air furnace: 2000 CFM, 200 MBH, 23 GPM. Page 41 15900 16010 Circulation Pumps: The heat recovery side circulation pump shall be a base-mounted centrifugal pump capable of 95 GPM at 127 feet of head. The generator side heat recovery boost pump shall be a base-mounted centrifugal pumps capable of 189 GPM at 10 feet of head. All pumps shall be compatible with a glycol heating fluid. CONTROLS Sequence of Operation: All of the pumps shall be manually switched. At the high school, the existing control system shall be modified such that each air handling unit or furnace space thermostat shall modulate the new heat recovery coil control valve. The respective fumace shall cycle when the control vaive is full open. In the night setback mode, the heat recovery coil control valve shall be full open and the space thermostat shall cycle the fan and furnace In sequence. No other controls are ex- pected to be necessary. GENERAL This Section of the Division 16 Specifications will include the following sub- headings with appropriate explanations of the requirements covered in each. GENERAL AND SPECIAL CONDITIONS Refers the Contractor to the Project Specifications’ General and Special Conditions. DRAWINGS Explains the nature of the Drawings and how the information depicted on the Drawings should be used and interpreted when viewed in the context of the entire set of Contract Documents. DEFINITIONS Defines some of the major terms used in writing the Specifications. SUBMITTALS AND APPROVALS Defines the acceptable information considered to constitute the material submittals required for verifying the actual equipment and materials proposed for use in the Project's electrical systems. Page 42 16020 16021 PRODUCT DELIVERY, STORAGE AND HANDLING Directs caution in the storage and handling of materials to ameliorate their possible damage prior to their installation. JOB CONDITIONS Advises the Contractor to visit the site to acquaint himself with the actual conditions at this Project’s location. PRODUCTS Establishes general criteria and standards of quality for the Project which apply to all of the materials proposed for the Project. This sub-section also requires all electrical materials to be labeled for their intended use and environment by UL. CLEANING The Contractor is required to clean all surfaces of equipment and remove debris and unused materials in this sub-section. WORK INCLUDED This area of the Division 16 Specification lays out the generalized descrip- tions of the electrical systems and work required in this Project. It also covers which area of the Specifications will define the requirements for equipment or installations which must be coordinated with other building trades. WORK NOT INCLUDED This Section deals with those items which will definitely be provided within other areas of the Project’s various disciplines. An example of such an Item would be the motors provided on a fan unit (obviously specified in Division 15) which Is specified complete with a motor starter, disconnect or other accessories normally found in Division 16. Page 43 16032 16111 16120 16131 16147 16155 MANUALS AND AS-BUILT DRAWINGS Sub-paragraphs describing the required contents of the Operation and Maintenance Manuals, defining the periods of instruction for the Owner's designated personnel and the updating of Information necessary to prepare record drawings of this Project’s final configuration are con- tained in this Section. CONDUIT All types of raceways and their associated appurtenances will be covered in this Section of Division 16. Galvanized rigid steel conduit, PVC-coated galvanized rigid steel conduit, intermediate metallic con- duit, electrical metallic tubing, flexible metal conduit and liquid-tight flexible conduit will be specified. Fittings, couplings, grounding and where each type of raceway may be used will be specified. WIRES AND CABLES Building wires and cables for the distribution, feeders and branch circuits required for this Project are defined in this Section. This Section typically covers only wire with voltage ratings below 600 V. PULL BOXES AND JUNCTION BOXES The various types of pull boxes and junction boxes which will be allowed and/or required for installing the systems defined within Division 16 are specified in this Section. DEVICE PLATES AND COVERS Surface mounted boxes shall be galvanized steel plates. Weatherproof installations will have gasketed metal plates. MOTOR STARTERS This Section will specify the motor contactors and controllers required by mechanical equipment. All controllers will be specified to have integral thermal overloads for motor overload protection. Combination starters utilizing circuit breakers or motor circuit protectors and that are UL listed for the application, will be acceptable. Combination starters utilizing fuses will not be allowed. Page 44 16161 16164 16170 16190 GROUNDING This Section expands on the National Electrical Code requirements. BRANCH CIRCUIT PANELBOARDS Branch circuit breakers required to connect new equipment to existing panelboards will be specified in this Section. All circuit breakers will be bolt-on molded case circuit breakers of the rating and configuration necessary to serve general branch circuits and other defined loads. MOTOR AND CIRCUIT DISCONNECTS Unfused switches will be specified. Disconnects for motor applications will be required to be horsepower rated. Other disconnects will be specified to have ratings as necessary for the application. Enclosures will be NEMA 1 except where otherwise required. SUPPORTING DEVICES This Section will contain the requirements for hardware, anchors and fas- teners used to support raceways, equipment and any other electrical apparatus. Page 45 ECONOMIC DATA 8.1 8.2 8.3 Current Fuel Oll Costs Fuel oil costs for the high school were $.9183/gallon for fuel purchased in 1988/1989. The fuel Is purchased In bulk by the Bering Straits School District and Is lower In price than what Is available to other consumers in the community. Fuel oil costs for the community of Gambell for both the Washeteria and City Of- fice building were $1.32/gallon for fuel purchased in 1988/1989. The City pur- chases fuel in bulk in conjunction with BIA. Displaced Costs Due to Heat Recovery The calculations that model the waste heat system are shown in the Appendix at the end of this report. These calculations essentially make comparisons of the waste heat available to the waste heat demand of the connected buildings. These comparisons are made for each hour of an average day of each month of the year. Since It may not be economically feasible to connect all of the potential build- ings, the calculations were made in a logical order of building connections, that ls, the nearest building was modeled as being connected first. Further, the im- pact of adding insulation to the AVEC generator modules was considered. Once the high school is connected it is more cost effective to add insulation prior to connecting additional buildings. In this proposed order, the high school was connected first, then the generator modules were insulated, then the washeteria was connected, and finally the city office building was connected. The results of the calculations based on the most recent fuel oil costs were as fol- lows: High School only (base) 9,740 gallons saved ($ 8,940) H.S. w/Module insulation (Alt. #1) 11,672 gallons saved ($10,718) H.S. & Washeteria (Alt. #2) 15,130 gallons saved ($15,280) All three buildings (Alt. #3) 15,600 gallons saved ($15,900) Summary Cost Estimate The assumptions for the cost estimate was that bidding would take place in April of 1990. Prevailing local wages as defined by the Department of Labor were used. The cost estimate is presented with costs identified for the total project, but broken out separately to show the component costs for the work at the AVEC plant, for the arctic pipe, and for each of the connected buildings. Page 46 8.4 The cost estimate is organized in an additive alternate form. The base estimate assumes connection to just the High School and the additional cost to insulate the generator modules and for connection to the Washeteria and City Office building are shown separately. Energy Authority SIA (Supervision, Inspection, and Administration) and design costs are included in the figures shown below. High school only $308,900 (base bid) H.S. w/Module Insulation $361,500 (alternative #1) H.S. & Washeteria $457,100 (alternative #2) All three buildings $492,400 (altemative #3) Estimated Component Life and Maintenance Costs The following estimates of maintenance cost were made based on the in- cremental cost of a technician who Is already on-site. Assumptions were made for each of the pleces of equipment regarding frequency of inspection and repair. The total yearly maintenance cost will depend on the scope of installa- tion. The costs for both the base condition and altemative #3 are shown. tem Life (yrs) Maint. Cost ($/Y) Heat Exchangers ‘20 $126 (each, 3 total) Circulation pumps 15 $112 (each, 3 total) Arctic Pipe 15 $210 (total) Interior piping 16 - $70 (each location, 5 total) Interior valves 15 $140 (each location, 5 total) Expansion Tank 15 $70 (total) Alr Separator 15 $35 (total) Glycol 15 $180 (total Coils 20 $105 (total) TOTAL (Altemative #3) $2360/year TOTAL (base condition) $1620/year Page 47 9.0 FAILURE ANALYSIS 91 9.2 General The purpose of this section is to analyze the reliability of the various components of the proposed waste heat recovery system. The analysis of the system will help guide the direction of the design to avoid systems with increased failure rates and repair costs and reduced waste heat recovery effectiveness. Identification of Major Components The following components are those whose failure is likely in the normal course of operation and whose failure could affect the operation of the generator or waste heat recovery systems. A brief description of the component follows the Identification. Circulation pump(s): This Is the pump (centrifugal that will be used to cir- culate fluid from the heat exchanger in the power plant to the user build- ings through the arctic pipe. A circulating pump Is also used on the gen- erator side of the system to help overcome the added pressure drop of the heat exchanger. Jacket Water Heat Exchanger: This component is the device used to transfer heat from one liquid to another. In the design presented here, it is a flat plate, or plate and frame type heat exchanger. The device con- sists of vertical plates separated by gaskets with the fluid of one system flowing In altemate plates heating (or cooling) the other fluid. There are no moving parts during operation. Stack Gas Heat Exchanger: This is a device similar in concept to the jacket water heat exchanger with the exception that the fluids being considered include both a liquid (the waste heat recovery transfer medium) and a gas - the exhaust gases from the engine. Although there are no moving parts, the heat exchanger surface is subject to very high temperatures from the exhaust gases (to 1400 degrees F). Radiator(s): These devices are part of the generation system rather than the waste heat recovery portion. They are used to provide cooling for the engines by transferring heat from the engine coolant to the atmos- phere. In conjunction with the waste heat recovery system, they would be used only when cooling is required beyond the cooling that has oc- curred through the use of waste heat by the recovery system. Page 48 9.3 Control Valve(s): Control valves are used to maintain a setpoint tempera- ture at a specific location in a piping system. In the case of the genera- tion system, they often are the self-contained type as manufactured by Amot. The valve operator movement Is based on the expansion of wax in the valve case. Alternatives are an electrically operated valve to serve the same function. Exterior piping (arctic pipe): The arctic pipe is a pipe-within-a-pipe system used for transferring fluid between locations. The center pipe, or carrier pipe Is used for fluld transfer. The carrier pipe Is insulated to reduce heat transfer. Outside the insulation is a second pipe called the jacket. This is used to protect the insulation. Interior piping/valves: This portion of the system Is found at the power plant or at the user buildings. Its purpose Is to transfer and control the fluid to the components of the system. Failure Mode and Impact For each of the components Identified above, the likely mode or modes of failure Is discussed. These failure modes have been surmised based on conversa- tions with equipment manufacturers and based on engineering experience and Judgment. In addition, the impact of failure on the generation and the waste heat recovery system is gaged as is the environmental effects. Recommended immediate actions by the system caretaker are also noted. Circulation pump(s) Failure Mode: The pump assembly can fail by the failure of its individual components. These include shaft seals, shaft bearings, motor, impeller, or casing. Impeller or casing failure is not expected to occur before the economic life of the component has been reached. This life is expected to be 15 years. Generator Operational Impact: Since failure of a booster pump used on the generator side of the system could result in a high-temperature shut- down of the engine, its use is not recommended. The likely reason for addition of a booster pump is to overcome additional pressure drop im- posed by the system by new heat recovery equipment. To avoid the need for the pump, the system should be designed to keep additional pressure drop below the maximum rated pressure drop of the engine mounted pump. Alternatively, the heat exchanger and boost pump Page 49 could be configured in a primary/secondary arrangement such that failure of the boost pump does not affect the jacket water cooling sys- tem. Waste Heat System Operational Impact: Where only a single circulation pump has been installed for heat transfer services, its failure could result in complete suspension of heat recovery. Shaft seal and shaft bearing failures In their early stages would have little effect on operation but could eventually reduce heat recovery to zero after complete failure. When duplex pumps have been installed, the heat recovery will be af- fected only until the standby pump can be put into service which can occur minutes after the failure is noted. Environmental Impact: Minor - a shaft seal failure could result in a slow fluid leak that could reach the ground outside. Required Immediate Actions: If no significant loss of fluid has occurred (due to shaft seal failure), replacement of the pump will restore the sys- tem to service. The pump should be isolated with the valves on either side of the pump, fluid checked and proper fluid level restored as needed, and the back-up pump (if installed) started. Jacket Water Heat Exchanger Failure Mode: Since there are no moving parts, the failure of this com- ponent can occur from failure of the gaskets, or failure on the frame or plates. Since the plates are generally of stainless steel, failure is unlikely during the rated life of the equipment - or approximately 20 years. The frame Is also unlikely to fail during the 20 year life. The only probable failure during the life would be the gaskets, probably exhibited as a slow leak that worsens with time. Generator Operational Impact: If the gaskets failed serving the genera- tor cooling system fluid, enough fluid could leak out to cause a low water shut-down of the engine. Waste Heat System Operational Impact: Similar to the scenarios above, if fluid from the waste heat system were to leak from failed gaskets, the sys- tem could be incapacitated. Environmental Impact: A major loss of the fluid, most likely an ethylene glycol mixture could have some environmental impacts. Ethylene glycol ls toxic. The problem could be reduced by using propylene glycol which Page 50 Is potable. The problem that often results when using propylene glycol is failure of operating or maintenance personnel to use compatible glycol for system make up. Required Immediate Actions: If an engine side gasket has failed, the heat exchanger should be bypassed and manual shut-off valves used on the leaking side. If the leak occurs on the waste heat side, isolation valves should be closed and the circulation pump shut off. Stack Gas Heat Exchanger Failure Mode: Three mechanisms can lead to this component failure. The first Is through operational wear. This wear is caused by the passage of hot exhaust gases over the heat exchanger surface. The failure through this mechanism determines the life of the equipment which Is ap- proximately 5 years. Two other forms of fallure can occur: the first is through thermal shock by passage of relatively cold fluid into the ex- changer which has been heated to the exhaust gas temperature. Sud- den contraction will destroy the heat exchanger. The second type of fallure could occur if the heat exchanger Is kept at too low of a tempera- ture allowing sulfuric and hydrochloric acids to form from the exhaust gases. Rapid corrosion would result in the heat exchanger failure. Generator Operational Impact: If the heat exchanger is located away from the generator, its failure would probably not release glycol onto the engines surface. Since the flow path of the exhaust gases would not be any more restricted after failure, no significant backpressure is expected to develop. If the stack gas heat exchanger Is used to heat fluid after passing through the main jacket water heat exchanger, no loss of engine coolant will occur. However, to avoid pipe contamination, the generator should be shut down. If available or designed. a bypass device that al- lows exhaust gases to follow a path away from the heat exchanger would allow generator operation with a damaged or missing heat ex- changer. Waste Heat System Operational Impact: The waste heat system would be disabled by a sudden stack gas heat exchanger failure. Environmental Impact: The loss of fluid to the environment could repre- sent a problem as outlined in previous discussions. Page 51 Required Immediate Actions: After failure of the stack gas heat ex- changer, the exchanger should be isolated with valves and a bypass mechanism used for the stack gases. Fluid should be added to make up for losses, and lost fluid collected where possible. Radiator(s) Failure Mode: The main component of the radiators is the heat ex- changer for cooling of the liquid. The heat exchanger is expected to last the life of the radiator or 15 years. The other modes of failure are similar to for circulation pumps: shaft bearings or motors, or controls. The controls in this case are assumed to be variable speed controls for the fan motor. Generator Operational Impact: Failure through leakage would drain the fluid and cause a low water shutdown of the generator. Failure of the fan-related hardware would result In Insufficlent cooling and a high- temperature shut down. Waste Heat System Operational Impact: There would be no effect on the waste heat system until generator shut down. At that time of course, no more heat would be available for recovery. Environmental Impact: The only environmental impact would be if a leakage fallure occurred which Is not the highest probability failure. Required Immediate Actions: The radiator should be isolated and an al- temate radiator used for cooling until repairs can be made. Control Vaive(s) Fallure Mode: The valve casing is expected to last the life of the valve or 20 years. The most likely failure before the life is reached Is that of leaking seals or seats, or failure of the operating mechanism. The seal or seat failure will normally result in a low-loss leak of fluid until repaired. The con- trol mechanisms that can be used in this instance include Amot type operators which use the expansion characteristics of wax to operate the valve or electric motor driven operators. Although Amot-type operators fail less frequently than electric motor operators, they have the disad- vantages of less control (which means less heat recovery) and do not in- dicate current control position. Page 52 Generator Operational Impact: Failure of the operators will normally result in loss of control. Often time these failures can occur at a mixing condition which may not immediately cause a system failure. The ex- treme cases would result in overheating. Waste Heat System Operational Impact: As discussed above, a failure in a mixing mode may not cause complete failure, but it is possible. Environmental Impact: Minor - only small leaks normally develop through seal and seat failures. Required Immediate Actions: The valve should be isolated as soon as the seat or seal failure is discovered. If the failure is an electric operator, the valve could be manually positioned to an acceptable position until the operator can be replaced. When an Amot-type valve is used, manual bypass valves can be used. Exterior piping (arctic pipe) Failure Mode: The only failure mode likely to interfere with the system operation would be a fluid leak at a joint. Generator Operational Impact: None. Waste Heat System Operational Impact: A significant leak would shut down the system. Environmental Impact: The leaking fluid could drain the entire piping sys- tem. Required Immediate Actions: The pump would be tumed off, the system drained as much as possible, and the leaking line isolated as close to the leak as possible. : Interior piping/vaives Failure Mode: Interior piping joints will normally last the length of the pipe life - about 20 years - unless physically damaged. The valves may suffer the same failures as mentioned above for control valves. Generator Operational Impact: A fluid leak would generally be small but it is possible that enough fluid would leak until a low water shut down oc- curred. Page 53 9.4 Waste Heat System Operational Impact: Same as for Generation system effect. Environmental Impact: Minor. Required Immediate Actions: Isolate the leaking valve, shut off pump if fluid loss Is significant. Failure Frequency and Cost Frequencies of failure have been estimated based on conversations with manufacturers and on engineering judgment. Assumptions made regarding the repair include: On-site operator's skill are that of a "caretaker." Skilled preventive maintenance Is performed 3 times yearly. Aone day weather delay is included for all winter repair trips. Travel to site for repair is via jet, and then charter. Skilled mechanics are mobilized from Anchorage, Fairbanks, or Juneau as appropriate. Costs are based on $43/hour labor costs. Travel time Is 12 hours round trip. Travel cost is $600 round trip. Subsistence costs are $100 per day. Qron-> sense Circulation pump(s) Most common failure: Shaft seal, shaft bearings, or motor. Frequency of Occurrence: 0.1 per year Repair Cost: $1900/occurrence Estimate of Down Time: 2 days after discovery Effects of System Life on Frequency: Increase in probability only. Jacket Water Heat Exchanger Most common failure: Gasket failure. Frequency of Occurence: 0.1 per year Page 54 Repair Cost: Estimate of Down Time: $1900/occurrence 9 days Effects of System Life on Frequency: Increasing probability. Stack Gas Heat Exchanger Most common failure: Frequency of Occurrence: Repair Cost: Estimate of Down Time: Operator error - damage to heat exchanger 1 per year $6600/occurrence 30 days Effects of System Life on Frequency: No effect due to frequent expected replacement. Radiator(s) Most common failure: Frequency of Occurrence: Repair Cost: Estimate of Down Time: Motor failure 0.1 per year $1800/occurrence 5 days Effects of System Life on Frequency: Increased probability. Control Vaive(s) Most common failure: Frequency of Occurrence: Repair Cost: Estimate of Down Time: Electric operator (seal for Amot valve) 0.33/year (0.1 for Amot valve) $1800/occurrence 3 days “Page 55 95 Effects of System Life on Frequency: Increasing likelinood due to wear. Exterior piping (arctic pipe) Most common failure: Accidental damage Frequency of Occurrence: 0.1 per year Repair Cost: $1800/occurrence Estimate of Down Time: 21 days Effects of System Life on Frequency: None. Interior piping/valves Most common failure: Valve seat/seal failure Frequency of Occurrence: 0.25 per year Repair Cost: $1800/occurrence Estimate of Down Time: 2 days Effects of System Life on Frequency: Increased likelinood due to wear. Design Decisions Impact on current concept design from the above failure analysis includes the recommendation that stack gas heat exchangers not be used in a location where there Is not a skilled operator on duty at all times. This recommendation Is due to the sensitivity of the equipment to operator error and the delay that could be encountered in retuming the system to service. Other recommendations in- clude design of duplex pumps so that damaged pumps will not halt service for any length of time. This type of approach can also be extended to spare parts stock so that some failures may be attended to during the preventive main- tenance visits to reduce costs. Although the electric motor operators on control valves improve control and heat recovery efficiency, their failure rate is higher than for self-contained Amot- type valves, and may not be cost effective. Page 56 To keep an increased level of reliability of building heating systems, it is also recommended that any building employing a hydronic heating system con- nected the waste heat recovery system use a heat exchanger. In the event of a distribution piping failure, the building’s heating system would continue to operate without Interruption. Page 57 10.0 CONCLUSIONS AND RECOMMENDATIONS The final economics will be completed by the Alaska Energy Authority so a definitive conclusion Is not made at this time conceming the feasibility of a waste heat installation at Gambell. Some conclusions that can be made are that the project Is technically feasible, that the people and agencies in the community seem quite enthusiastic about the project, and that if the economics prove acceptable, a waste heat system for the community can be recommended. Three graphs follow this page that illustrate the current waste heat situation in Gambell. The first graph entitled "Heat Avallable Vs. Heat Required" shows the relationship be- tween these two quantities for each month of a year. One line represents the heat avail- able from the power plant In terms of equivalent gallons of fuel oll. Each of the other three lines represent a construction option: the base condition, alternative #2 and alter- native #3. Altemative #1, insulating the AVEC modules is not shown since the heat re- quired by the user buildings for this alternative is the same as the base case. The second graph Is entitled "Fuel Oil Displaced, Base Bid & Alternate #1" and shows the amount of recovered energy in equivalent gallons of fuel oil for the two defined options for the year. Alternate #1, insulating the AVEC modules shows a substantial increase in the heat recovery utilization because insulating the modules makes more waste heat available to be used at the school. The third graph Is entitled “Fuel Oil Displaced, Altemate #1, 2 and 3", and shows the amount of recovered energy In equivalent gallons of fuel oll for the three defined op- tions. Alternatives #1 and 2 show effective waste heat recovery utilization. The in- cremental utilization achieved with alternative #3 is minor. Page 58 6s ebeg GAMBELL WASTE HEAT RECOVERY HEAT AVAILABLE VS. HEAT REQUIRED FUEL OIL EQUIVALENT (GALLONS) 3,500 3,000% 2,500 |° 2,000 1,500 1,000 500 0 JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC MONTH OF THE YEAR LEGEND —— HEAT AVAILABLE —— HEAT REQ. - BASE —*— HEAT REQ. - BASE + 2 —&— HEAT REQ. - BASE + 3 5/01/90 09 e6dd GAMBELL WASTE HEAT RECOVERY FUEL OIL DISPLACED FUEL OIL EQUIVALENT (GALLONS) 5/01/90 JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC MONTH OF THE YEAR LEGEND MMM Base AAZAtt.1 19 eBDd 2,500 5/01/90 GAMBELL WASTE HEAT RECOVERY FUEL OIL DISPLACED FUEL OIL EQUIVALENT (GALLONS) JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC MONTH OF THE YEAR LEGEND MM ait. 1 Alt. 2 Alt. 3 APPENDIX 1 Calculations 2. Contact Names 3. Cost Estimates 4. Raw Data CALCULATIONS WASTE HEAT RECOVERY CALCULATION METHOD Input Before the calculation of recovered waste heat can take place, the user must input information about power production, fuel use, and system heat loss. The In- formation is for each month of a year. The year is assumed to be either an average year or a representative year. The power production information must Include the amount of power produced for each month of a year and the amount of heat rejected to the jacket water for each KWH of power produced. The power production is from historical records and the heat rejection data is from the manufacturer of the engine/generators being used for power production. The fuel use data Is for each of the potential waste heat user buildings. It Is fuel oll use for each month of the “average” year. It Is also assumed that the fuel oll use reported here Is only for heating energy that can be displaced by waste heat recovery. It would not include fuel oil used by a separate fuel oil-fired water heater. The information ideally should be based on historical information but can also be estimated on a monthly basis for yearly fuel oil use. The system heat loss is a number that represents the energy that Is rejected to the Jacket water, but Is lost or used before it can be used by the end user buildings. Examples of this system Joss can Include: heat loss of the generator cooling sys- tem piping, heat loss from the arctic pipe, and heat recovery in the power plant for space heating or engine block. This figure must be estimated based on avail- able information. Assumptions The most important assumptions made in this model are the diurnal variation of the heat demand, and the power production. The figures shown in the calcula- tions represent a ‘typical’ pattem for rural environments. The heating demand follows an approximate sine curve with minimum demand at solar noon, and maximum demand at solar midnight. The diurnal variation for power plant production Is less regular. The variation assumed has peaks in the morning (around 8:00) and near noon and at 6:00 pm. The lowest power production oc- curs near midnight. When calculating the energy demand for the buildings based on their fuel oil use, it is assumed that each gallon of fuel oll comesponds to 100,000 BTU. This rep- resents approximately a 71% efficient boiler or fumace. Actual efficiencies will vary. Calculations The heat available is calculated by dividing the monthly power production by the number of days in the month - yielding the power production on an average day, then by multiplying that figure by the hourly power production variation for each hour. This is the power produced for each hour of the average day of the month. This figure is multiplied by the manufacturer's factor for heat rejected to the Jacket water. The result is the gross heat available at the power plant on an hourly basis. The system heat loss is subtracted from the gross amount, leaving the amount available for building use. The heat required by the buildings is accomplished in a similar manner. The sum of all the buildings fuel use is multiplied by 100,000 BTU/gallon and adjusted to yield the hourly heat demand for the average day of the month. The heat recovered Is Just the smaller number of the heat available and the heat demand; if the heat available Is larger than the heat demand, all of the heat available will be used. If the reverse is true and much more heat Is available, then all of the building heat demand requirements will be met. The number of gallons displaced also assumes that each 100,000 BTU corresponds to one gallon of fuel oil. GAMBELL WASTE HEAT RECOVERY ESTIMATION PAGE 1 BASE CONDITION WASTE HEAT UTILIZATION SIMULATION WORK SHEET. Location: GAMBELL Date: February 5, 1998 Heat rate: 2340 Btu/kwh produced System loss: 133,708 Btu/hour Total Gen.: 1,038,328 kwh/year ANNUAL Local degree days: 1986.8 1742.8 1862.0 1445.0 968.8 611.0 477.6 506.8 715.8 1176.8 1534.8 1951.0 14,893 Assumed diurnal heat Power plant monthly generation: demand variation: wornnneneecenenne Monthly JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC CHECKSUM Fraction:6.18257 8.89531 8.09663 6.08456 8.07656 8.05862 0.05513 0.07046 6.07935 0.68898 9.09364 0.09818 1 Winter Summer Hour Kwh: 105,688 98,208 99,568 87,120 78,880 60,400 56,800 72,608 81,768 91,680 96,488 101,168 1,030,320 Diurnal 6.0494 8.0494 1 variation 8.038 8.038 8.038 8.038 8.045 8.045 6.045 0.045 0.045 6.045 6.038 6.038 0.0477 6.0477 2 9.036 8.036 0.036 0.036 0.040 0.040 0.040 6.040 0.040 0.040 0.036 6.036 8.0468 9.0468 3 8.034 0.034 8.034 8.034 6.036 0.036 6.036 8.036 6.036 0.036 0.034 6.034 9.0443 8.0443 4 6.034 0.034 6.034 6.034 8.035 8.035 6.035 8.035 8.035 0.035 6.034 6.034 8.0428 9.0428 5 8.033 0.033 6.033 68.033 8.035 8.035 0.035 6.035 0.035 6.035 8.033 6.033 8.0414 6.0414 6 6.034 8.034 6.034 0.034 6.038 9.038 8.038 6.038 0.038 0.038 6.034 9.034 6.0401 6.0461 a7 0.038 8.038 6.038 8.058 6.038 6.038 9.038 8.038 0.038 0.038 6.038 9.038 0.0398 9.0390 8 6.042 8.042 6.042 0.042 6.040 6.040 0.040 6.040 8.040 0.040 6.042 8.042 6.0381 6.0381 9 6.042 8.042 6.042 6.042 0.045 0.045 6.045 6.045 6.045 0.045 6.042 6.042 6.0374 8.0374 10 9.047 6.047 6.047 6.047 6.047 8.047 6.047 6.047 6.047 0.047 6.047 9.047 6.0378 6.0376 "1 6.048 8.048 6.048 0.048 6.040 8.040 0.040 0.040 0.040 0.040 6.048 0.048 6.0367 8.0367 12 6.047 8.047 0.047 6.047 6.048 6.048 0.048 6.048 6.048 6.048 6.047 9.047 6.0367 8.0367 13 6.045 8.045 0.045 6.045 6.050 8.058 0.050 0.050 8.050 0.050 6.045 0.045 0.0378 6.0370 14 6.047 8.047 6.047 6.047 6.052 8.052 0.052 6.052 6.052 6.052 6.047 6.047 6.0374 6.0374 15 6.048 8.048 6.048 0.048 6.058 8.050 0.056 0.050 0.050 0.050 0.048 6.048 6.0381 6.0381 16 6.048 0.048 0.048 6.048 6.050 8.050 0.058 6.050 0.050 0.050 6.048 6.048 6.0398 6.03968 17 6.049 8.049 6.049 8.049 0.045 8.045 8.045 6.045 0.045 6.045 0.049 6.049 6.0401 6.0401 18 8.046 8.046 6.046 6.046 6.047 6.047 0.047 6.047 6.047 6.047 6.046 6.046 6.0414 8.0414 19 6.043 8.043 6.043 0.043 6.050 9.058 0.050 6.050 0.050 0.050 9.043 6.043 6.0428 6.0428 20 6.038 8.038 8.038 6.038 6.045 68.045 8.045 6.045 0.045 0.045 6.038 9.038 9.0443 8.0443 21 6.038 8.038 6.038 6.038 6.041 8.041 6.041 6.041 6.041 6.041 6.038 0.038 9.0468 6.0460 22 6.041 9.041 6.041 6.041 6.041 6.041 6.041 0.041 6.041 6.041 6.041 6.041 8.0477 6.0477 23 6.045 0.045 0.045 6.045 6.041 8.041 6.041 0.041 8.041 6.041 6.045 8.045 8.0494 6.0494 24 6.048 8.046 0.048 06.040 8.043 8.043 0.043 06.043 0.043 0.043 6.048 6.040 Building use per month, gallons of fuel oil BUILDING 1 HIGH SCHOOL 1 2115 1117 1414 1136 857 527 6 6 486 803 1386 =. 2393 12,234 BUILDING 2 6 6 6 6 8 6 a 6 8 8 6 6 6 BUILDING 3 6 6 6 6 6 8 g 8 6 6 4 6 a BUILDING 4 8 8 6 6 8 6 a 8 8 6 a 6 8 BUILDING 5 6 8 6 a 8 8 8 8 8 8 8 a 6 BUILDING 6 6 8 6 a 8 8 8 8 6 a 6 6 8 GAMBELL WASTE HEAT RECOVERY ESTIMATION BUILDING 7 "WILDING 8 BUILDING 9 tOTAL wCornrnueun = oe ieee a aa ole PRBRRSSIABEAS=AS eoryrauwneun = af] 12 13 14 2115 1117 PAGE 2 a 6 0 0 8 0 6 6 6 8 6 6 8 6 6 6 6 6 8 6 6 8 0 6 1414 «1136 = 857527 8 0 Heat available per hour by month (BTU) JAN 175211 158952 142694 142694 134565, 142694 175211 207728 207728 248374 2565083 248374 232115 248374 256503 2565083 264632 240245 215857 175211 175211 199598 232115 191469 FEB 153346 138238 123131 123131 115577 123131 153346 183562 183562 221331 228885 221331 206223 221331 228885 228885 236438 213777 191115 153346 153346 176008 286223 168454 MAR APR MAY JUN JUL AUG 157322 120958 139346 75376.9 62915.4 117668 142005 167555 189008 52146.2 4169.2 89684.6 126688 94152.3 84736.9 33561.5 23592.3 67346.2 126688 94152.3 78669.2 28915.4 19223.1 61761.5 119829 87458.8 78669.2 28915.4 19223.1 61761.5 126688 94152.3 96872.3 42853.8 32330.8 78515.4 157322 120958 96872.3 42853.8 32330.8 78515.4 187955 147765 189888 52146.2 41069.2 89684.6 187955 147765 139346 75376.9 62915.4 117688 226248 181272 151482 84669.2 71653.8 128777 233986 187974 109888 52146.2 41869.2 89684.6 226248 181272 157549 89315.4 76623.1 134362 218931 167869 169685 98607.7 84761.5 145531 226248 181272 181828 187988 93586 156768 233986 187974 169685 98667.7 84761.5 145531 233906 187974 169685 98687.7 84761.5 145531 241565 194675 139346 75376.9 62915.4 117668 218589 174571 151482 84669.2 71653.8 128777 195614 154466 169685 98607.7 84761.5 145531 157322 128958 139346 75376.9 62915.4 117608 157322 128958 115675 56792.3 45438.5 95269.2 188297 141863 115875 56792.3 45438.5 95269.2 218931 167869 115875 56792.3 45438.5 95269.2 172638 134362 127211 66084.6 54176.9 186438 486 SEP 149315 117869 92712.3 86423.1 86423.1 105291 105291 117869 149315 161894 117869 168183 188762 193348 186762 186762 149315 161894 186762 149315 124158 124158 124158 136737 803 ocT 183654 148392 120183 113131 113131 134288 134288 148392 183654 197758 148392 264811 218915 233626 218915 218915 183654 197758 218915 183654 155445 155445 155445 169549 1386 NOV 148318 133475 118632 118632 111211 118632 148318 178805 178885 215112 222534 215112 266269 215112 222534 222534 229955 207691 185426 148318 148318 170583 206269 163162 4928568 43526008 4457320 3499448 3113735 1632492 1343938 2618369 3344578 4139785 4220168 Heat demand by hour by month (BTU) JAN 343569 331526 319787 308333 297615 287754 278931 271314 265041 260232 256976 255332 255332 256976 FEB 181458 175898 168848 162841 157188 151972 147313 143289 139977 137437 135717 134849 134849 135717 MAR APR MAY JUN JUL AUG 229696 184536 139215 85688 6 6 221644 178868 134335 82687.2 6 6 213743 171728 129546 79662.3 6 6 206139 165611 124937 76828.2 8 6 198973 159854 120594 74157.6 6 8 192388 154557 116598 71700.3 6 6 186482 149819 113823 6952.1 6 6 181389 145727 189936 67603.9 8 6 177196 142358 187395 66041.1 6 6 173988 139775 105446 64842.8 8 171883 138826 184127 64831.3 6 170784 137143 103461 63621.7 6 6 176784 137143 183461 63621.7 a 6 171883 138626 164127 64631.3 6 SEP 78947.8 76188.5 73464.7 70851 68388.2 66122.1 64694.9 62344.4 60983.2 ocT 130443 125878 121383 117665 112995 189251 105962 103089 106628 6 59798.1 98882.2 6 59849.7 97565.7 58672 96941.6 58672 96941.6 6 59849.7 97565.7 Nov 225148 217255 209518 202057 195833 188578 182789 177797 173687 170535 168481 167324 167324 168401 BASE CONDITION 2393 DEC 161998 146435 136872 136872 123691 138872 161998 193125 193125 232032 239814 232032 216469 232032 239814 239814 247595 224251 200906 161998 161998 185343 216469 177562 4580520 DEC 388729 375103 3617368 348861 336735 325576 315595 306976 299879 294438 298753 288893 288893 298753 12,234 ANNUAL 1.284E+89 GAMBELL WASTE HEAT RECOVERY ESTIMATION PAGE 3 BASE CONDITION 15 268232 137437 173988 139775 105446 64842.8 16 265842 139977 177196 142358 1087395 66041.1 17 271314 143289 181389 145727 189936 67603.9 18 278932 147313 186482 149819 113023 69502.1 19 287754 151972 192388 154557 116598 71700.3 26 297615 157188 198973 159854 128594 74157.6 21 388333 162841 286139 165611 124937 76828.2 22 319787 168848 213743 171728 129546 79662.3 23° 331526 175098 221644 178868 134335 82607.2 24 343569 181458 229696 184536 139215 85688 6952663 3671926 4648258 3734385 2817226 1732413 6 59798.1 98882.2 178535 294438 6 60983.2 186628 173687 299879 6 62344.4 103009 177797 386976 6 64094.9 105962 182789 315595 8 66122.1 189251 188578 325577 ® 68388.2 112995 195833 336735 6 76851 117865 262057 348861 6 73464.7 121383 209518 361730 6 76188.5 125878 217255 375103 6 78947.8 130443 225148 388729 ANNUAL ® 1597633 2639711 4556213 7866535 1.223E+09 Heat delivered by hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 1 175211 153346 157322 128958 139215 75376.9 6 6 78947.8 130443 148318 161998 2 158952 138238 142605 107555 109888 52146.2 6 6 76188.5 125878 133475 146435 3 142694 123131 126688 94152.3 84736.9 33561.5 8 6 73464.7 128183 118632 138872 4 142694 123131 126688 94152.3 78669.2 28915.4 6 6 70851 113131 118632 130872 5 134565 115577 119829 8745.8 78669.2 28915.4 6 @ 68388.2 112995 111211 123091 6 142694 123131 126688 94152.3 96872.3 42853.8 8 6 66122.1 189251 118632 130872 7 «175211 147313 157322 126958 96872.3 42853.8 6 6 64094.9 105982 148318 161998 8 207728 143289 181389 145727 199888 52146.2 6 6 62344.4 103689 177797 193125 9 207728 139977 177196 142358 187395 66041.1 8 8 60903.2 108628 173687 193125 18 248374 137437 173988 139775 105446 64842.8 8 6 59798.1 9882.2 178535 232032 11 256503 135717 171883 138826 104127 52146.2 6 6 59849.7 97565.7 168401 239814 12 248374 134849 178784 137143 103461 63621.7 6 6 58672 96941.6 167324 232032 13 232115 134849 178784 137143 103461 63621.7 6 B 58672 96941.6 167324 216469 14 248374 135717 171883 138826 104127 64831.3 6 8 59049.7 97565.7 168481 232032 15 256583 137437 173988 139775 105446 64842.8 6 6 59798.1 98882.2 178535 239814 16 256583 139977 177196 142358 107395 66041.1 6 6 60903.2 108628 173687 239814 17 264632 143289 181389 145727 189936 67603.9 6 6 62344.4 183689 177797 247595 18 248245 147313 186482 149819 113823 69582.1 6 6 64094.9 105982 182789 224251 19 215857 151972 192388 154466 116598 71708.3 6 8 66122.1 189251 185426 200986 28 175211 153346 157322 128958 128594 74157.6 8 8 68388.2 112995 148318 161998 21 175211 153346 157322 128958 115875 56792.3 6 6 76851 117865 148318 161998 22 199598 168848 188297 141863 115875 56792.3 6 6 73464.7 121383 178583 185343 23 232115 175898 218931 167869 115875 56792.3 8 6 76188.5 125878 208269 216469 24 191469 168454 172638 134362 127211 66084.6 6 6 78947.8 138443 163162 177562 ANNUAL 4928568 3424775 3963255 3114932 2566497 1381383 8 8 1597633 2634577 3811574 4588528 973552693 FUEL OIL CONSUMPTION DISPLACED (GALLONS) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC ANNUAL 1499 1042 1206 948 781 426 6 6 486 861 1159 1393 9,736 GAMBELL WASTE HEAT RECOVERY ESTIMATION PAGE 1 ALTERNATIVE 1 WASTE HEAT UTILIZATION SIMULATION WORK SHEET. Location: GAMBELL Date: February 5, 1998 Heat rate: 2340 Btu/kwh produced System loss: 37,606 Btu/hour Total Gen.: 1,030,326 kwh/year Local degree days: 1986.8 1742.8 1862.0 1445.0 968.8 611.8 477.6 506.0 715.8 1176.8 1534.8 1951.0 Assumed diurnal heat Power plant monthly generation: demand variation: ----------------- Monthly JAN FEB MAR APR MAY JUN JUL AUG SEP oct NOV DEC Fraction:#.18257 8.69531 8.09663 6.08456 8.07656 8.05862 8.05513 6.07046 8.07935 6.08898 0.09364 0.09818 Winter Summer Hour Kwh: 105,688 98,208 99,568 87,128 78,880 60,400 56,888 72,608 81,760 91,680 96,480 101,160 Diurnal 8.0494 9.0494 1 variation 6.038 6.038 8.038 98.038 8.045 0.045 0.045 0.045 0.045 08.045 6.038 0.038 8.6477 6.0477 2 8.036 8.036 0.036 0.036 6.040 0.040 0.046 6.040 0.040 0.040 8.036 0.036 6.0468 6.0468 s 6.034 8.034 0.034 6.034 6.036 8.036 0.036 0.036 6.036 0.036 6.034 06.034 0.0443 8.0443 4 9.034 0.034 6.034 6.034 6.035 0.035 6.035 8.035 6.035 0.035 0.034 6.034 6.0428 6.0428 5 6.033 0.035 0.033 6.033 6.035 8.035 6.035 8.035 0.035 0.035 0.033 6.033 6.0414 6.0414 6 6.034 0.034 6.034 6.034 6.038 0.038 6.038 6.038 0.038 6.038 0.034 6.034 6.0401 0.0401 7 6.038 8.038 6.038 6.038 6.038 6.038 8.038 8.038 6.038 6.038 9.038 9.038 6.0398 8.0390 8 6.042 0.042 8.042 6.042 8.040 0.040 0.040 8.040 6.040 0.040 0.042 6.042 6.0381 9.0381 9 6.042 8.042 6.042 6.042 6.045 8.045 0.045 6.045 0.045 0.045 6.042 0.042 6.0374 6.0374 16 6.047 8.047 0.047 6.047 6.047 6.047 0.647 6.047 6.047 6.047 6.047 0.047 6.0378 6.0376 ab 6.048 8.048 0.048 0.048 6.040 6.040 0.040 6.040 0.040 6.040 8.048 0.048 9.0367 6.6367 12 6.047 0.047 6.047 6.047 6.048 6.048 0.048 6.048 0.048 6.048 0.047 6.047 6.0367 6.0367 13 6.045 8.045 0.045 6.045 6.050 8.058 0.050 6.050 8.050 6.050 6.045 0.045 6.0378 6.0370 14 6.047 0.047 6.047 6.047 6.052 8.052 6.052 6.052 0.052 6.052 6.047 6.047 9.0374 6.0374 15 6.048 8.048 6.048 6.048 6.058 8.058 8.058 6.050 0.050 6.050 6.048 6.048 6.0381 6.0381 16 9.048 0.048 6.048 6.048 6.058 0.050 6.050 8.0580 0.058 0.050 6.048 0.048 6.0398 6.0398 17 8.049 6.049 8.049 0.049 8.045 0.045 6.045 6.045 6.045 0.045 8.049 0.049 8.0401 6.0401 18 8.046 8.046 6.046 8.046 6.047 8.047 6.047 6.047 6.047 0.047 0.046 8.046 6.0414 8.0414 19 6.043 8.045 6.043 6.043 6.058 8.050 6.050 8.050 8.058 6.050 6.043 0.043 6.0428 6.6428 26 6.038 6.038 6.038 6.038 6.045 8.045 6.045 6.045 8.045 6.045 06.038 6.038 6.0443 6.0443 21 6.038 8.038 6.038 6.058 6.041 6.041 6.041 6.041 0.041 8.041 6.038 0.038 6.0468 6.0460 22 6.041 8.041 6.041 0.041 6.041 8.041 6.041 6.041 0.041 6.041 6.041 6.041 6.0477 6.0477 23 0.045 0.045 6.045 8.045 0.041 8.041 6.041 6.041 6.041 6.041 6.045 0.045 8.0494 6.0494 24 9.048 0.048 6.048 0.040 6.043 8.043 0.043 6.043 6.043 0.043 8.040 0.040 Building use per month, gallons of fuel oil BUILDING 1 HIGH SCHOOL 1 21150 1117, 1414 1136 857 527 6 6 486 803 = 1386 )=— 2393 BUILDING 2 6 6 6 6 6 6 6 6 8 6 6 6 BUILDING 3 6 6 8 6 6 6 6 6 6 6 6 8 BUILDING 4 6 6 8 6 8 8 6 6 8 6 6 8 BUILDING 5 6 6 6 6 6 6 6 6 6 6 6 8 BUILDING 6 6 6 6 6 6 6 6 6 8 6 6 8 ANNUAL 14,893 CHECKSUM 1 1,038,326 12,234 GAMBELL WASTE HEAT RECOVERY ESTIMATION PAGE 2 ALTERNATIVE 1 ~ BUILDING 7 8 a 6 8 6 6 6 6 6 8 8 6 6 BUILDING 8 a 8 6 8 6 8 a 6 a 6 6 6 6 BUILDING 9 a 6 6 8 8 8 a 6 6 6 6 8 6 8 6 8 8 6 4 4 8 8 6 a 6 8 TOTAL 2115 1117, 14141136 857 527 6 6 486 803 1386 = 2393 12,234 Heat available per hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 271311 249446 253422 217058 235446 171477 159815 213788 245415 279754 244418 258098 255052 234338 238105 203655 205188 148246 137169 185785 213969 244492 229575 242535 238794 219231 222788 196252 186837 129662 119692 163446 188812 216283 214732 226972 238794 219231 222788 198252 174769 125815 115323 157862 182523 289231 214732 226972 238665 211677 215129 183551 174769 125815 115323 157862 182523 289231 267311 219191 238794 219231 222788 198252 192972 138954 128431 174615 261391 238388 214732 226972 271311 249446 253422 217858 192972 138954 128431 174615 261391 238388 244418 258098 303828 279662 284055 243865 205108 148246 137169 185785 213969 244492 274105 289225 303828 279662 284055 243865 235446 171477 159815 213788 245415 279754 274105 289225 344474 317431 322348 277372 «247582 188769 167754 224877 257994 293858 311212 328132 352603 324985 330006 284874 205188 148246 137169 185785 213969 244492 318634 335914 344474 317431 322348 277372 253649 185415 172123 230462 264283 300911 311212 328132 328215 382323 387831 263969 265785 194788 186862 241631 276862 315815 296369 312569 344474 317431 322348 277372 277928 204008 189608 252808 289448 329128 311212 328132 352603 324985 330006 284874 265785 194768 188862 241631 276862 315015 318634 335914 352603 324985 330006 284074 265785 194788 180862 241631 276862 315015 318634 335914 360732 332538 337665 298775 235446 171477 159815 213788 245415 279754 326055 343695 336345 309877 314689 270671 247582 180769 167754 224877 257994 293858 303791 320351 311957 287215 291714 258566 265785 194788 188862 241631 276862 315815 281526 297086 271311 249446 253422 217858 235446 171477 159815 213768 245415 279754 244418 258098 271311 249446 253422 217858 211175 152892 141538 191369 228258 251545 244418 258098 295698 272108 276397 237163 211175 152892 141538 191369 228258 251545 266683 281443 328215 382323 367831 263969 211175 152892 141538 191369 228258 251545 296369 312569 287569 264554 268738 230462 223311 162185 156277 202538 232837 265649 259262 273662 ANNUAL 7234968 6659008 6763728 5805848 5420135 3938892 3650338 4916769 5650978 6446105 6526560 6886928 2.126E+09 warn anueun = RPRBXRBSSIRBFAUStS Heat demand by hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 343569 181458 229696 184536 139215 85608 8 78947.8 138443 225148 388729 331526 175098 221644 178868 134335 82607.2 6 76188.5 125878 217255 375183 319787 168848 213743 171726 129546 79662.3 6 73464.7 121383 269518 361738 308333 162841 206139 165611 124937 76828.2 6 70851 117865 282057 348861 297615 157188 198973 159854 120594 74157.6 8 68388.2 112995 195833 336735 287754 151972 192388 154557 116598 71708.3 6 66122.1 189251 188576 325576 278931 147313 186482 149819 113823 69582.1 6 64894.9 185982 182789 315595 271314 143289 181389 145727 169936 67683.9 6 62344.4 183889 177797 386976 265641 139977 177196 142358 187395 66041.1 6 60983.2 188628 173687 299879 16 260232 137437 173988 139775 105446 64842.8 6 59798.1 98882.2 170535 294438 11 256976 135717 171883 138626 104127 64031.3 6 59849.7 97565.7 168481 296753 12 255332 134849 178784 137143 183461 63621.7 8 58672 96941.6 167324 288893 13 255332 134849 178784 137143 183461 63621.7 8 58672 96941.6 167324 288893 14 256976 135717 171883 138626 104127 64031.3 8 59849.7 97565.7 168481 298753 we arynanuerun = GAMBELL WASTE HEAT RECOVERY ESTIMATION PAGE 3 ALTERNATIVE 1 15 268232 137437 173988 139775 105446 64842.8 16 265842 139977 177196 142358 187395 66041.1 17 271314 143289 181389 145727 189936 67603.9 18 278932 147313 186482 149819 113823 69582.1 19 287754 151972 192388 154557 116598 71708.3 26 297615 157188 198973 159854 128594 74157.6 21 388333 162841 206139 165611 124937 76828.2 22° 319787 168848 213743 171728 129546 79662.3 23 331526 175098 221644 178868 134335 82607.2 24 343569 181458 229696 184536 139215 85608 6952663 3671926 4648258 3734385 2817226 1732413 6 59798.1 98802.2 178535 294438 6 60983.2 188628 173687 299879 ® 62344.4 1083089 177797 366976 6 64094.9 105982 182789 315595 6 66122.1 189251 188578 325577 8 68388.2 112995 195833 336735 8 70851 117065 202057 348861 6 73464.7 121383 209518 361730 ® 76188.5 125878 217255 375103 6 78947.8 130443 225148 388729 ANNUAL ® 1597633 2639711 4556213 7866535 1.223E+09 Heat delivered by hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 1 271311 181458 229696 184536 139215 85608 6 78947.8 130443 225148 258098 2 255052 175098 221644 178868 134335 82607.2 6 76188.5 125878 217255 242535 3 238794 168848 213743 171728 129546 79662.3 6 73464.7 121383 269516 226972 4 238794 162841 286139 165611 124937 76828.2 6 76851 117865 282857 226972 5 230665 157186 198973 159854 128594 74157.6 6 68388.2 112995 195833 219191 6 238794 151972 192388 154557 116598 71768.3 6 66122.1 189251 188578 226972 7 271311 147313 186482 149819 113823 69582.1 6 64094.9 185982 182789 258898 8 271314 143289 181389 145727 169936 67603.9 8 62344.4 103089 177797 289225 9 265041 139977 177196 142358 1087395 66041.1 6 60903.2 108628 173687 289225 18 268232 137437 173988 139775 185446 64842.8 6 59798.1 98802.2 178535 294438 256976 135717 171883 138826 184127 64031.3 8 59849.7 97565.7 168481 290753 12 255332 134849 176784 137143 163461 63621.7 6. 58672 96941.6 167324 288893 13 255332 134849 176784 137143 103461 63621.7 6 58672 96941.6 167324 288893 14 256976 135717 171883 138826 184127 64031.3 ® 59849.7 97565.7 168481 298753 15 260232 137437 173988 139775 105446 64842.8 6 59798.1 98802.2 170535 294438 16 265042 139977 177196 142358 167395 66041.1 8 60983.2 108628 173687 299879 17 271314 143289 181389 145727 189936 67603.9 8 62344.4 183089 177797 386976 18 278932 147313 186482 149819 113823 69502.1 6 64094.9 185982 182789 315595 19 287754 151972 192388 154557 116598 71760.3 6 66122.1 189251 188576 297086 26 271311 157188 198973 159854 120594 74157.6 6 68388.2 112995 195833 258098 21 271311 162841 286139 165611 124937 76828.2 6 76851 117865 282057 258898 22 295698 168848 213743 171728 129546 79662.3 6 73464.7 121383 269518 281443 23 328215 175698 221644 178868 134335 82607.2 6 76188.5 125878 217255 312569 nD = 287569 181458 229696 184536 139215 985608 6383299 3671926 4648258 3734385 2817226 1732413 6 78947.8 130443 225148 273662 ANNUAL 8 1597633 2639711 4556213 6588784 1.167E+09 FUEL OIL CONSUMPTION DISPLACED (GALLONS) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC ANNUAL 1942 117 1414 1136 857 527 6 6 486 803 1386 = - 2004 11,672 GAMBELL HEAT RECOVERY ESTIMATION PAGE 1 ALTERNATIVE 2 WASTE HEAT UTILIZATION SIMULATION WORK SHEET. Location: GAMBELL Date: February 5, 1998 Heat rate: 2340 Btu/kwh produced System loss: 57,606 Btu/hour Total Gen.: 1,036,326 kwh/year Local degree days: 1986.8 1742.6 1862.0 1445.0 968.8 611.6 477.6 506.8 715.8 1176.8 1534.6 1951.8 Assumed diurnal heat Power plant monthly generation: demand variation: Lae Monthly JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC Fraction:.18257 8.09531 8.69663 6.08456 8.07656 8.05862 8.05513 6.07046 6.087935 8.08898 8.09364 0.09818 Winter Summer Hour Kwh: 105,688 98,208 99,568 87,128 78,880 60,408 56,800 72,600 81,768 91,680 96,488 101,168 Diurnal 6.0494 6.0494 1 variation 6.038 8.038 6.038 6.038 6.045 8.045 8.045 0.045 0.045 6.045 0.038 0.038 6.0477 6.6477 2 6.036 8.036 6.036 6.036 6.040 6.048 0.040 6.040 8.040 0.040 6.036 9.036 8.0468 6.0460 3 6.034 0.034 6.034 8.034 0.036 6.036 8.036 6.036 0.036 6.036 0.034 6.034 6.0443 8.0443 4 6.034 8.034 6.034 6.034 68.035 6.035 0.035 6.035 8.035 6.035 6.034 6.034 6.0428 6.0428 2 6.035 8.033 6.033 8.033 0.035 6.035 8.035 0.035 8.035 8.035 6.033 9.033 6.0414 6.0414 6 6.034 8.034 8.034 6.034 6.038 6.038 8.038 6.038 9.038 6.038 6.034 9.034 6.0401 6.0401 7 6.038 8.038 6.038 6.038 6.038 9.038 6.038 0.038 6.038 8.038 6.838 9.038 8.0398 8.0398 8 6.042 8.042 6.042 6.042 6.040 6.040 0.040 6.040 0.040 0.040 6.042 9.042 6.0381 6.0381 9 6.042 6.042 6.042 8.042 6.045 6.045 0.045 8.045 0.045 6.045 6.042 8.042 6.0374 6.0374 18 6.047 6.047 6.047 6.047 6.047 8.047 6.047 6.047 0.047 8.047 0.047 0.047 6.0376 6.0378 " 6.048 0.048 6.048 6.048 6.040 0.040 6.040 0.040 6.040 6.040 6.048 0.048 6.0367 6.0367 12 6.047 6.047 6.047 0.047 6.048 6.048 0.048 0.048 0.048 6.048 0.047 9.047 6.0367 6.0367 13 6.045 8.045 6.045 6.045 6.058 8.058 0.050 6.050 6.050 6.058 0.045 9.045 6.0376 6.0376 14 6.047 6.047 6.647 8.047 8.052 6.052 6.052 6.052 6.052 6.052 6.047 0.047 6.0374 8.0374 15 6.048 8.048 6.648 6.048 6.050 8.058 6.056 6.050 6.056 8.058 6.048 9.048 8.0381 9.0381 16 9.048 6.048 6.048 6.048 6.058 8.050 0.050 6.050 0.056 8.050 6.048 9.048 6.0398 9.0398 17 6.049 8.649 6.049 8.049 8.045 8.045 0.045 6.045 6.045 6.045 6.049 8.049 6.0401 8.0401 18 0.046 0.046 6.046 8.046 0.047 8.047 0.047 06.047 0.047 6.047 6.046 9.046 8.0414 6.0414 19 8.045 6.043 6.043 6.043 6.058 9.058 8.050 0.050 6.058 8.050 6.043 9.043 6.0428 6.0428 26 6.038 8.038 6.038 6.038 6.045 6.045 6.045 6.045 6.045 6.045 6.038 8.938 8.0443 6.0443 21 6.038 6.038 6.038 6.038 6.041 6.041 0.041 6.041 6.041 6.041 6.038 8.938 6.0466 6.04608 22 6.041 8.041 8.041 6.041 6.041 8.041 6.041 6.041 6.041 8.041 6.041 6.041 6.0477 6.0477 23 6.045 8.045 8.045 6.045 6.041 6.041 0.041 6.041 6.041 0.041 6.045 8.045 8.0494 8.0494 24 6.040 0.048 6.048 8.048 6.043 6.043 6.043 6.043 06.043 6.043 6.040 6.040 Building use per month, gallons of fuel oil BUILDING 1 HIGH SCHOOL 1 21501117 1414 1136 857 527 6 6 486 883 = 1386 = 2393 BUILDING 2 WASHETERIA 2 676 626 663 536 398 281 248 249 313 453 563 698 BUILDING 3 6 6 6 6 6 6 6 6 6 6 6 6 BUILDING 4 6 6 6 6 6 6 6 6 6 6 6 6 BUILDING 5 6 6 6 6 6 6 6 6 6 6 6 6 BUILDING 6 6 6 6 6 6 6 6 6 6 6 6 6 ANNUAL 14,893 CHECKSUM 1 1,038,328 12,234 5,688 GAMBELL HEAT RECOVERY ESTIMATION PAGE 2 ALTERNATIVE 2 ~ BUILDING 7 QUILDING 8 JUILDING 9 aoa as eae as aeoaaes sans sada aeoseans aeoas eoas eoeas aeoeas eaeoas aa as aosaan ‘OTAL 2791 1743-2877 1672 1247 808 248 249 799 1256 1949 3083 17,914 Heat available per hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 251311 229446 233422 197058 215446 151477 139815 193788 225415 259754 224418 238098 235052 214338 218105 183655 185168 128246 117169 165785 193969 224492 209575 222535 218794 199231 282788 178252 160837 189662 99692.3 143446 168812 196283 194732 206972 218794 199231 262788 178252 154769 185815 95323.1 137862 162523 189231 194732 266972 218665 191677 195129 163551 154769 185815 95323.1 137862 162523 189231 187311 199191 218794 199231 282788 178252 172972 118954 188431 154615 181391 218388 194732 286972 251311 229446 233422 197858 172972 118954 188431 154615 181391 210388 224418 238098 283828 259662 264055 223865 185108 128246 117169 165785 193969 224492 254105 269225 283828 259662 264055 223865 215446 151477 139815 193788 225415 259754 254105 269225 324474 297431 382348 257372 227582 160769 147754 204877 237994 273858 291212 388132 332603 304985 310006 264074 185108 128246 117169 165785 193969 224492 298634 315914 324474 297431 302348 257372 233649 165415 152123 210462 244283 280911 291212 368132 308215 282323 287031 243969 245785 174788 168862 221631 256862 295015 276369 292569 324474 297431 302348 257372 257928 184008 169688 232808 269448 389128 291212 308132 332603 304985 310006 264074 245785 174708 160862 221631 256862 295015 298634 315914 332603 304985 310006 264074 245785 174708 160862 221631 256862 295815 298634 315914 348732 312538 317665 278775 215446 151477 139815 193788 225415 259754 306055 323695 316345 289877 294689 258671 227582 160769 147754 204877 237994 273858 283791 300351 291957 267215 271714 230566 245785 174768 160862 221631 256862 295015 261526 277006 251311 229446 233422 197858 215446 151477 139815 193768 225415 259754 224418 238098 251311 229446 233422 197858 191175 132892 121538 171369 268258 231545 224418 238098 275698 252188 256397 217163 191175 132892 121538 171369 268258 231545 246683 261443 308215 282323 287031 243969 191175 132892 121538 171369 208258 231545 276369 292569 267569 244554 248738 216462 283311 142185 138277 182538 212837 245649 239262 253662 ANNUAL 6754968 6179808 6283728 5325848 4948135 3458892 3178338 4436769 5176978 5966105 6046560 6406928 1.951E+09 onynnueun = ah Die SSeS Se See RPRQBRPRSSGTRATFAS FSS A Heat demand by hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 453381 283140 337396 271687 282568 131255 38986.6 40448.6 129793 204038 316604 560815 437489 273215 325578 262886 195467 126654 37628 39838.7 125243 196878 305506 483260 421893 263475 313963 252743 188499 122139 36278.9 37639.3 128778 189859 294615 466032 406883 2541082 382793 243751 181793 117793 34988.2 36308.2 116481 183105 284133 449452 392748 245269 292268 235278 175473 113699 33772 35038.4 112432 176748 274256 433829 379726 237142 282584 227482 169659 189931 32652.9 33877.4 188787 178883 265169 419454 368084 229871 273928 220508 164457 186561 31651.8 32838.7 105374 165644 257839 486594 358031 223593 266439 214485 159966 183651 38787.3 31941.9 182496 161128 250819 395489 349755 218424 268288 289527 156268 181255 30875.6 31203.5 108127 157396 244239 386347 343488 214461 255557 205725 153432 99417.4 29529.9 30637.3 98318 154548 239887 379336 339111 211777 252358 285158 151512 98173.2 29168.3 38253.9 97879.7 152686 236886 374589 336941 210422 258744 281851 150543 97545.2 28973.8 30068.3 96458.7 151638 235292 372193 336941 218422 258744 261851 158543 97545.2 28973.8 30068.3 96458.7 151638 235292 372193 339111 211777 252358 203158 151512 98173.2 29168.3 38253.9 97879.7 152606 236886 374589 worn nueun = Fanta GAMBELL HEAT RECOVERY ESTIMATION PAGE 3 ALTERNATIVE 2 15 343408 214461 255557 205725 153432 99417.4 29529.9 30637.3 98318 154548 239887 379336 16 349755 218424 268288 269527 156268 161255 30875.6 31283.5 166127 157396 244239 386347 17 358031 223593 266439 214485 159966 183651 30787.3 31941.9 182496 161128 250019 395489 18 368684 229871 273928 220508 164457 106561 31651.8 32838.7 105374 165644 257839 406594 19 379726 237142 282584 227482 169659 189931 32652.9 33877.4 108787 170883 265169 419454 28 392748 245269 292268 235278 175473 113699 33772 35038.4 112432 176748 274256 433829 21 406883 254162 302793 243751 181793 117794 34988.2 36300.2 116481 183105 284133 449452 22 421893 263475 313963 252743 188499 122139 36278.9 37639.3 128778 189859 294615 466032 23 437489 273215 325578 262086 195467 126654 37628 39030.7 125243 196878 305586 483260 24 453381 283148 337396 271687 282568 131255 38986.6 40448.6 129793 204030 316604 506815 ANNUAL 9174885 5729783 6827745 5496384 4899277 2656147 788955 818548 2626561 4128863 6406969 1E+87 1.791E+09 Heat delivered by hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 251311 229446 233422 197858 282568 131255 38986.6 40448.6 129793 204038 224418 238098 235052 214338 218105 183655 185188 126654 37628 39838.7 125243 196878 209575 222535 218794 199231 262788 176252 168837 189662 36278.9 37639.3 128778 189859 194732 266972 218794 199231 262788 176252 154769 105015 34988.2 36308.2 116481 183105 194732 206972 218665 191677 195129 163551 154769 185815 33772 35038.4 112432 176748 187311 199191 218794 199231 262788 176252 169659 189931 32652.9 33877.4 168767 176883 194732 266972 251311 229446 233422 197058 164457 186561 31651.8 32838.7 105374 165644 224418 238098 283828 223593 264055 214485 159966 103651 30787.3 31941.9 162496 161128 258019 269225 283828 218424 260288 209527 156268 181255 30875.6 31203.5 168127 157396 244239 269225 324474 214461 255557 205725 153432 99417.4 29529.9 38637.3 98318 154548 239887 308132 332603 211777 252358 203158 151512 98173.2 29160.3 36253.9 97679.7 152606 236806 315914 324474 218422 258744 281851 158543 97545.2 28973.8 38868.3 96458.7 151638 235292 368132 308215 218422 258744 261851 158543 97545.2 28973.8 30060.3 96458.7 151638 235292 292569 324474 211777 «252358 283158 151512 98173.2 29168.3 3253.9 97879.7 152606 236866 308132 332603 214461 255557 205725 153432 99417.4 29529.9 30637.3 98318 154548 239807 315914 332603 218424 268288 289527 156268 181255 30875.6 31203.5 108127 157396 244239 315914 348732 223593 266439 214485 159966 183651 38787.3 31941.9 182496 161128 2500619 323695 316345 229871 273928 220508 164457 106561 31651.8 32838.7 105374 165644 257839 3008351 291957 237142 271714 227482 169659 189931 32652.9 33877.4 168787 178883 261526 277006 251311 229446 233422 197058 175473 113699 33772 35038.4 112432 176748 224418 238098 251311 229446 233422 197858 181793 117794 34988.2 36306.2 116481 183105 224418 238098 275698 252188 256397 217163 188499 122139 36278.9 37639.3 128778 189859 246683 261443 308215 273215 287831 243969 191175 126654 37626 39038.7 125243 196878 276369 292569 267569 244554 248738 218462 262568 131255 38986.6 40448.6 129793 204038 239262 253662 ANNUAL 6754968 5315737 5861456 4835257 4089236 2622288 788955 818548 2626561 4128863 5571963 6486928 1.513E+09 wornuer wn — RPRSBRRSaWRGBFUS tS FUEL OIL CONSUMPTION DISPLACED (GALLONS) JAN FEB MAR APR MAY JUN JUL AUG ‘SEP ocT NOV DEC ANNUAL 2055 1617 1783 1471 1228 798 240 249 799 1256 1695 1949 15,131 GAMBELL HEAT RECOVERY ESTIMATION PAGE 1 ALTERNATIVE 3 WASTE HEAT UTILIZATION SIMULATION WORK SHEET. ocation: GAMBELL Date: February 5, 1998 Heat rate: 2340 Btu/kwh produced ystem loss: 62,688 Btu/hour ‘otal Gen.: 1,036,328 kwh/year Local degree days: 1986.8 1742.8 1862.8 1445.0 968.0 611.0 477.6 506.0 715.8 1176.0 1534.8 1951.0 Assumed diurnal heat Power plant monthly generation: demand variation: —a—meneeanenmneneo Monthly JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC Fraction:0.10257 8.69531 0.69663 0.08456 0.07656 8.05862 8.05513 6.07046 8.07935 8.08898 0.09364 4.09818 Winter Summer Hour Kwh: 185,688 98,208 99,560 87,126 78,880 60,400 56,800 72,600 81,768 91,680 96,488 101,168 Diurnal 8.0494 6.0494 1 variation 8.038 9.038 98.038 8.038 8.045 8.045 8.045 0.045 6.045 6.045 8.038 0.038 6.0477 6.0477 2 6.036 0.036 6.036 0.036 6.040 0.040 0.040 06.040 8.040 0.040 0.036 0.036 8.0468 9.0460 3 8.034 8.034 0.034 8.034 0.036 0.036 6.036 6.036 6.036 0.036 6.034 0.034 8.0443 8.0443 4 9.034 0.034 6.034 6.034 8.035 8.035 0.035 6.035 6.035 0.035 9.034 0.034 8.0428 8.0428 5 6.033 8.033 6.033 8.033 08.035 8.035 0.035 6.035 0.035 8.035 6.033 9.033 8.0414 8.0414 6 8.034 8.034 8.034 6.034 8.038 0.038 6.038 6.038 0.038 6.038 6.034 0.034 6.0401 8.0401 7 9.038 6.038 0.038 6.038 6.038 8.038 0.038 6.038 0.038 0.038 6.038 9.038 6.0398 9.0398 8 6.042 8.042 8.042 8.042 0.040 6.040 6.040 6.040 6.040 0.040 6.042 6.042 6.0381 6.0381 9 6.042 6.042 6.042 8.042 6.045 8.045 0.045 6.045 0.045 0.045 6.042 8.042 8.0374 6.0374 16 6.047 0.047 6.047 6.047 6.047 0.047 0.047 6.047 6.047 6.047 6.047 8.047 6.0376 6.0376 1 9.048 6.048 0.048 6.048 6.040 0.040 0.040 0.040 8.040 6.040 6.048 0.048 6.0367 6.0367 12 6.047 0.047 0.047 6.047 6.048 8.048 0.048 0.048 6.048 6.048 6.047 6.047 9.0367 6.0367 13 6.045 0.045 0.045 6.045 6.050 8.058 0.050 0.050 6.050 6.050 6.045 9.045 6.0376 6.0376 14 8.047 6.047 6.047 8.047 6.052 8.052 8.052 6.052 8.052 8.052 6.047 0.047 9.0374 6.0374 15 6.048 6.048 6.048 0.048 0.050 8.058 0.050 0.058 0.050 6.058 0.048 9.048 9.0381 6.0381 16 6.048 0.048 6.048 0.048 0.050 08.058 8.050 6.050 8.050 9.050 0.048 9.048 8.0398 6.0398 17 9.049 8.049 8.049 6.049 6.045 8.045 8.045 6.045 0.045 0.045 6.049 9.049 6.0401 6.0401 18 9.046 8.046 8.046 8.046 6.047 0.047 6.047 6.047 6.047 6.047 6.046 0.046 8.0414 6.0414 19 6.043 8.043 6.043 0.043 6.050 9.058 8.050 0.050 6.050 8.058 6.043 9.043 8.0428 6.0428 28 9.038 8.058 6.038 6.038 6.045 8.045 0.045 6.045 0.045 6.045 6.038 9.038 9.0443 6.0443 21 6.038 0.058 6.038 6.0538 6.041 8.041 0.041 6.041 6.041 6.041 6.038 9.038 8.0468 8.04608 22 8.041 8.041 6.041 0.041 8.041 6.041 6.041 6.041 6.041 8.041 6.041 9.041 6.0477 6.0477 23 0.045 8.045 6.045 8.045 0.041 6.041 0.041 6.041 0.041 0.041 0.045 9.045 8.0494 6.0494 24 9.048 8.048 0.048 06.040 8.043 6.043 0.043 0.043 0.043 0.043 6.040 8.040 Building use per month, gallons of fuel oil SUILDING 1 HIGH SCHOOL 1 2115 1117 1414 1136 857 527 6 8 486 803 1386 2393 BUILDING 2 WASHETERIA 2 676 626 663 536 398 281 240 249 313 453 563 698 SUILDING 3 CITY OFFICE BUILDING 3 189 173 184 145 99 65 52 55 6 119 153 193 SUILDING 4 8 a 6 a 8 8 6 6 6 6 6 6 BUILDING 5 6 a a 6 8 8 6 8 6 6 8 a S3UILDING 6 8 6 6 a 6 8 6 8 6 6 8 a ANNUAL 14,893 CHECKSUM 1 1,038,328 12,234 5,688 1,502 GAMBELL HEAT RECOVERY ESTIMATION PAGE 2 ALTERNATIVE 3 BUILDING 7 6 6 4 6 6 4 a 8 8 6 6 4 6 “UILDING 8 a 4 4 6 6 6 6 6 8 6 6 6 8 UILDING 9 6 4 8 6 8 a 6 6 8 6 8 6 6 a 6 6 4 6 a 8 6 6 0 6 6 4 OTAL 2988 1916 = 2261 1817 1346 873 292 304 874 1375 =. 2182, 33276—:19, 416 Heat available per hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 246311 224446 228422 192058 210446 146477 134815 188768 226415 254754 219418 233098 230052 209338 213105 178655 186188 123246 112169 168785 188969 219492 284575 217535 213794 194231 197788 165252 155837 164662 94692.3 138446 163812 191283 189732 261972 213794 194231 197788 165252 149769 188815 90323.1 132862 157523 184231 189732 261972 205665 186677 198129 158551 149769 100815 90323.1 132862 157523 184231 182311 194191 213794 194231 197788 165252 167972 113954 183431 149615 176391 205388 189732 261972 246311 224446 «228422 192858 167972 113954 183431 149615 176391 205388 219418 233098 278828 254662 259055 218865 188188 123246 112169 168785 188969 219492 249105 264225 278828 254662 259855 218865 218446 146477 134815 188788 228415 254754 249105 264225 319474 292431 297348 252372 222582 155769 142754 199877 232994 268858 286212 303132 327603 299985 305806 259074 188188 123246 112169 168785 188969 219492 293634 310914 319474 292431 297348 252372 228649 160415 147123 205462 239283 275911 286212 383132 303215 277323 282031 238969 248785 169788 155862 216631 251862 290815 271369 287569 319474 292431 297348 252372 252928 179888 164606 227800 264448 304128 286212 303132 327683 299985 305086 259074 248785 169788 155862 216631 251862 290015 293634 310914 327683 299985 305006 259874 240785 169788 155862 216631 251862 290815 293634 316914 335732 307538 312665 265775 210446 146477 134815 188768 226415 254754 361955 318695 311345 284877 289689 245671 222582 155769 142754 199877 232994 268858 278791 295351 286957 262215 266714 225566 248785 169788 155862 216631 251862 298815 256526 272006 246311 224446 228422 192058 210446 146477 134015 188768 228415 254754 219418 233098 246311 224446 228422 192058 186175 127892 116538 166369 195258 226545 219418 233098 270698 247188 251397 212163 186175 127892 116538 166369 195258 226545 241683 256443 303215 277323 282831 238969 186175 127892 116538 166369 195258 226545 271369 287569 262569 239554 243738 205462 198311 137185 125277 177538 267837 240649 234262 248662 ANNUAL 6634968 6059008 6163728 5205848 4826135 3338892 3050338 4316769 5050978 5846105 5926560 6286928 1.907E+09 orynurwUn = eps s= = RPRBRPRSSVIRGAFUSZS wo Heat demand by hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG ‘SEP ocT NOV DEC 484083 311243 367286 295161 218658 141814 47433.7 49383 141976 223361 341457 532167 467115 380333 354412 284815 218985 136843 45771 47652 136999 215531 329488 513513 450463 289626 341777 274661 285464 131964 44139.3 45953.2 132116 207848 317742 495206 434436 279322 329618 264898 196225 127269 42568.9 44318.3 127415 200453 306438 477588 419335 269613 318168 255682 189484 122845 41889.2 42777.8 122986 193485 295786 468987 405446 260679 307617 247216 183128 118775 39727.7 41368.3 118911 187874 285985 445712 393018 252687 298186 259631 177514 115133 38509.7 48892.3 115265 181338 277217 432047 382276 245786 290042 233086 172666 111989 37457.9 38997.3 112117 176386 269646 420247 9 373439 240104 283338 227698 168674 189488 36592 38895.8 189525 172308 263412 410532 18 366663 235747 278196 223566 165614 187415 35928.1 37484.6 187538 169182 258633 403083 11 362874 232797 274715 220768 163541 186071 35478.4 36936.4 106192 167864 255396 398039 12 359758 231388 272958 219356 162495 185392 35251.5 36788.2 105513 165996 253762 395493 13 359758 231308 272958 219356 162495 105392 35251.5 36708.2 105513 165996 253762 395493 14 362074 232797 274715 220768 163541 106071 35478.4 36936.4 186192 167864 255396 398039 oryrnwurun = GAMBELL HEAT RECOVERY ESTIMATION PAGE 3 ALTERNATIVE 3 15 366663 235747 278196 223566 165614 187415 35928.1 37404.6 107538 169182 258633 403083 16 373439 248104 283338 227698 168674 109488 36592 38095.8 109525 172368 263412 410532 17 382276 245786 290842 233086 172666 111989 37457.9 38997.3 112117 176386 269646 428247 18 393818 252687 298186 239631 177514 115133 38509.7 46092.3 115265 181338 277217 432047 19 405448 260679 307617 247218 183128 118775 39727.7 41368.3 118911 187874 285985 445712 28 419335 269613 318168 255682 189404 122846 41089.2 42777.8 122986 193485 295786 460987 21 434436 279322 329618 264898 196225 127269 42568.9 44318.3 127415 200453 306438 477589 22 450463 289626 341777 274661 203464 131964 44139.3 45953.2 132116 207848 317742 495206 23 467115 380333 354412 284815 2108985 136845 45771 47652 136999 215531 329488 513513 24 484883 311243 367286 295161 218658 141814 47433.7 49383 141976 223361 341457 532167 ANNUAL 9796187 6298488 7432610 5973044 4424721 2869822 959895 999343 2873118 4520053 6989928 1.1E+#7 1.942E+09 Heat delivered by hour by month (BTU) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC 246311 224446 228422 192058 210446 141814 47433.7 49383 141976 223361 219418 233098 230052 289338 213105 178655 188168 123246 45771 47652 136999 215531 284575 217535 213794 194231 197788 165252 155837 104662 44139.3 45953.2 132116 191283 189732 201972 213794 194231 197788 165252 149769 160815 42568.9 44318.3 127415 184231 189732 261972 205665 186677 198129 158551 149769 188815 41889.2 42777.8 122986 184231 182311 194191 213794 194231 197788 165252 167972 113954 39727.7 4136.3 118911 187674 189732 261972 246311 224446 228422 192058 167972 113954 38509.7 40092.3 115265 181338 219418 233098 278828 245786 259055 218865 172666 111989 37457.9 38997.3 112117 176386 249185 264225 9 278828 240104 259055 218865 168674 109408 36592 38095.8 189525 172388 249185 264225 18 319474 235747 278196 223566 165614 107415 35928.1 37404.6 187538 169182 258633 303132 11 327683 232797 274715 228768 163541 106871 35478.4 36936.4 186192 167864 255396 316914 12 319474 231388 272958 219356 162495 185392 35251.5 36788.2 105513. 165996 253762 303132 13 303215 231388 272958 219356 162495 185392 35251.5 36768.2 105513 165996 253762 287569 14 319474 232797 274715 228768 163541 186871 35478.4 36936.4 106192 167064 255396 303132 15 327683 235747 278196 223566 165614 187415 35928.1 37404.6 187538 169182 258633 318914 16 327603 240184 283338 227698 168674 189408 36592 38095.8 189525 172308 263412 310914 17 335732 245786 290842 233086 172666 111989 37457.9 38997.3 112117 176386 269646 318695 18 311345 252687 289689 239631 177514 115133 38589.7 40892.3 115265 181338 277217 295351 19 286957 268679 266714 225566 183128 118775 39727.7 41368.3 118911 187874 256526 272006 26 246311 224446 228422 192058 189404 122846 41089.2 42777.8 122986 193485 219418 233098 21 246311 224446 228422 192858 186175 127269 42568.9 44318.3 127415 208453 219418 233098 22 278698 247188 251397 212163 186175 127892 44139.3 45953.2 132116 207848 241683 256443 23 303215 277323 282031 238969 186175 127892 45771 47652 136999 215531 271369 287569 24 262569 239554 243738 205462 198511 137185 47433.7 49383 141976 223361 234262 248662 ANNUAL 6634968 5525325 5987881 4948880 4154736 2755187 959895 999343 2873118 4478011 5681664 6286920 1.56E+09 eoryranawneun = FUEL OIL CONSUMPTION DISPLACED (GALLONS) JAN FEB MAR APR MAY JUN JUL AUG SEP ocT NOV DEC ANNUAL 2018 1681 1821 1505 1264 838 292 304 874 1362 1728 1912 15,601 Jos AX Gere So FPE _ consuttine ENGINEERS 560 E. 34th Avenue, Suite 300 SHEET NO: oF 1 . Kk la Ph (607) 961.1666 CALCULATED BY aa DATE 17] po FAX (907) 561-7028 CHECKED BY DATE -. SCALE Steam CceSes* ts aR” Peas Soa al te Jtece fron Auch = Goxe)e + xlo)e et (Sxic)z= S05 + LA ne [tee [Looe = S55 *¥ lle Gos (LR nee ESanens B Ale. OA \nerunenes = (exe Lo Ye Ss) y Lo&s- 14d wo Ub tem=- ASL —> ABO *& 2 Mous= (Aoo Donnie nus (RTE) tne Canina Adase 08499 FPE _ consuttine eNncineers ve 560 E. 34th Avenue, Suite 300 SHEET NO’ oF. Anchoregs. Alaska 99503 Ph. (907) 561-1666 CALCULATED BY DATE FAX 1-71 — CHECKED BY pare. SCALE 20d x tile Whe tee isd = (@exiz) + Qrx'z Zi (raxrrze lose 4 f wer / Rese Ve= 1@30x lo |om 1 Pune. — Snes op Ale. mO r Us Renee « Z2xIZTKA_)U bo UA Tote = 412.3 —> Aro, frees Ro tee lo: fret au |) Hons Ohsec heeus 6 HA, By Foes pene Ussfes | Tore fos A= 22 fpushos Barer Aw Temes 24.2° prot ee Dae = (280 (16 ~ 24-2) = los ood emi — > [lo os Fo, eesomens, ther Leec Fie Lece Rene le" oy wf "erred & IS? Ave ‘ Ro Asst ac Rr DAerAs O= lf soufe. Qrne= I4e lez Ue |to6—= [Too Bot PRON 206.1 ATES) tne Cinton Meee 1471 FPE _ consuttine ENGINEERS ve 560 E. 34th Avenue, Suite 300 SHEET NO: OF Anc! , Alaska 99503 Ph. (907) 561-1666 CALCULATED BY DATE ra oe See CHECKED BY DATE SCALE tras lec Mom feme Ars _ AES Me ZO ru je Rrw Rar —> thou Sctoov thet Sctoeoe — eeerniR § Zox Sor 2 Ze, coo Free Asim sv ChTY CREICES | Zor |@sxee Shop Prue _ Tor pushes SYS UsSS * Perse Coroimonds = (33 Tos Pu Westie = ISB es | Pro OM Fray = \SB) Teo Bos PRODUCT 204-1 (AEBS) Inc., Groton, Mass. 01471. Ase - Conga OB FPE _ consuttine eNciNeers , 560 E. 34th Avenue, Suite 300 == OF pia, or 9) Sellece CALCULATED BY Be DATE z/t/te FAX (907) 561-7028 CHECKED BY DATE — SCALE Pouspuas Hous, As Wome SeouwAuses TO a Etec [Suueno) + WaT SMPAS = ~TO Acthas hushoc Ya. Ale WEL MEMO Luckie /anor/ rice. v= 10 wax fhooe./ Fron Awa” Coane, 4 Sony Mous- B5ovrr= Toot wd Plums eos = loSet+ 264 = [s4que Sio4 He —> Spo a4 Us = (<t0)C3t00)) = Slo TAL pus © Cote f¢ Cay Moaus = (oxexio)z= roo? (SP frums Monts = Czy 2x2) = aice ft" (630 +- —> baa 1? G4e ¥.26 . 1.08: 2b. Tes 5 Conny = 7, Gos Pot lume asthenia = S600 Bit WIT CLM ret = @2 eco Pm Donner on: (RTE) tan Aontnn thane 8498 CONTACT NAMES The following people were contacted In the field: Branson Tongiyan, City Mayor (985-5112) Franklin Kaningok, AVEC plant operator Nancy Byers, High School Principal Shirley Antoghame, City Clerk Jessie Lowery, Sivuqag Corporation Clerk (985-5826) Aaron lworrigan, Community AVEC delegate Merlin Kanoonak, BSSD Maintenance Foreman (985-5140) Herbert Apaffingok, Postmaster Gerard Kanoonak, G&E Enterprises Owner Veronica James, Village Public Safety Officer Mike Apatiki, National Guard Armory In addition, the following people were contacted from Anchorage: John Lyons, Manager, Operations & Maintenance, AVEC - 561-1818 Mark Tietziel, Manager, Engineering, AVEC - 561-1818 David Biegel, Sr. Electrical Engineer, AVEC - 561-1818 Rick Reid, Maintenance Foreman, Bering Strait School District, 624-3611 COST ESTIMATES SIMPLE ECONOMIC SUMMARY COST SUMMARY BASE BID $71,282 ALTERNATIVE 1 $83,423| $361,498 ALTERNATIVE 2 $105,712| $458,084 ALTERNATIVE 3° $113,854| $493,367 FUEL OIL SAVINGS SUMMARY 50 sel $1 ‘0 [- $0.800 I$ SAVINGS BASE BID 9,740 0 $8,944 ALTERNATIVE 1 11,672 0 0 $10,718 ALTERNATIVE 2 11,672 3,458 0 $15,283 ALTERNATIVE 3 11,672 3,928 0 $15,903 SIMPLE PAYBACK SUMMARY SAVINGS SAVINGS PAYBACK BASE BID 34.5 ALTERNATIVE 1 33.7 ALTERNATIVE 2 30.0 ALTERNATIVE 3 31.0 HMS 9011 CONSTRUCTION COST STUDY WASTE HEAT RECOVERY SYSTEM GAMBELL, ALASKA Cost Consultant Engineer HMS, Inc. FPE Consulting Engineers 4103 Minnesota Drive 560 East 34th Avenue Anchorage, Alaska 99503 Anchorage, Alaska 99503 (887) 883-3853 eax Rhee fe 1348 WASTE HEAT RECOVERY SYSTEM PAGE 1 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 NOTES REGARDING THE PREPARATION OF THIS ESTIMATE This study has been prepared from twelve (12) 8 1/2"x11" sketches, photographs, and narratives linking four (4) buildings and provided by FPE. This study is divided into a Basic Bid and four (4) Add Alternates. The estimate is priced using A.S. Title 36 prevailing labor rates and current materials and equipment prices to reflect a competitively bid date of Spring 1990. This is a statement of probable construction cost only and excludes the following costs. A/E fees Administrative costs Cost for any other remodel work Cost of asbestos abatement, if found in existing pipes/equipment. mwWh— o 8 WASTE HEAT RECOVERY SYSTEM PAGE 2 GAMBELL, ALASKA CONSTRUCTION COST STUDY . FEBRUARY 6, 1990 BASIC’BID >. Arctic Pipe AO S08 Power Plant Modifications “ 37,440" 0 ; 0 High School Modifications 43/265 Washeteria Modifications ee 207 \ Insulate Modules * a \0 0 City Offices Modification |” “0 ae Gey as si 0 & ; , 5 Simplify HR in High School y / ee 0” 0 (26,135) \ - Ny E < . weg we SUBTOTAL as 127,063 21,640 “ 39,731 14,514 (26,135) 8. General Conditions, Se: pee fie of Overhead & Profit 70% \ 88,944. NS AS55148 / 27,812 10,160 (18,295) 9. Contingencies 10% 21,601 : “3,679 6,754 2,467 ( 4,443) TOTAL 237,608 40,467 74,297 27,141 (48,873) NOTE: Add Alternate Insulate AVEC Modules Add Alternate HR in Washeteria Add Alternate <BR in- City Halt Add Alternate : Simplify HR in School WASTE HEAT RECOVERY SYSTEM PAGE 3 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 1. ARCTIC PIPE QUANTITY UNIT UNIT RATE ESTIMATED COST BASIC BID Excavate, backfill and dispose surplus 525 LF 12.50 6,563 Arctic pipe comprising 3" schedule 40 steel pipe, 2" polyurethane insulation and 7" Pvc jacket pipe (2) 1,050 LF 32.50 34,125 Ditto 4" diameter with 8" jacket fixed underside soffits between two modules 60 LF 43.50 2,610 3" tee 2 EA 185.00 370 3" bend 4 EA 135.00 540 4" ditto 10 EA 155.00 1,550 Connect arctic pipe to buildings 4 EA 150.00 600 WASTE HEAT RECOVERY SYSTEM PAGE 4 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 1. ARCTIC PIPE QUANTITY UNIT UNIT RATE ESTIMATED COST ADD ALTERNATE #2: Heat Recovery in Washeteria Excavate, backfill and dispose surplus 478 LF 12.50 5,975 2" schedule 40 arctic pipe, 2" insulation and 6" PVC jacket (2) 956 LF 26.40 25,238 2" tee 2 EA 145.00 290 2" bend 2 EA 110.00 220 Connect arctic pipes and buildings 4 EA 120.00 480 WASTE HEAT RECOVERY SYSTEM PAGE 5 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 1. ARCTIC PIPE QUANTITY UNIT UNIT RATE ESTIMATED COST ADD ALTERNATE #3: Heat Recovery in City Hall Excavate, backfill and dispose surplus 160 LF 12.50 2,000 1 1/4" schedule 40 arctic pipe, 2" insulation and 6" PVC jacket 320 LF 22.95 7,344 1 1/4" bend 4 EA 95.00 380 Connect arctic pipes and buildings 4 EA 115.00 460 SUBTOTAL 10,184 WASTE HEAT RECOVERY SYSTEM PAGE 6 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 2. POWER PLANT MODIFICATIONS QUANTITY UNIT UNIT RATE ESTIMATED COST BASIC BID Attach 6'x6'x6' prefabricated insulated module to existing structure (1 EA) 216 SF 27.50 5,940 Extra for 3'x4' outside air louver 1 EA 550.00 550 Cut existing pipes for new equipment 8 EA 110.00 880 819 MB, 20 gauge stainless steel (3) chamber heat exchanger 1 EA 12750.00 12,750 189 GPM, 10' head, 2 HP circulation pump 2 EA 2375.00 4,750 4" insulated schedule 40 steel header 160 LF 42.00 6,720 4" gate valves 6 EA 390.00 2,340 4" check valves 2 EA 370.00 740 4" balance valves 2 EA 225.00 450 4" tees and elbows 14 EA 120.00 1,680 Connections to equipment 8 EA 80.00 640 WASTE HEAT RECOVERY SYSTEM PAGE 7 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 3. HIGH SCHOOL MODIFICATIONS . QUANTITY UNIT UNIT RATE ESTIMATED COST BASIC BID Cut and install new heat recovery coil in existing AHU, 8,300 CFM, 210 MBH, 24 GPM 1 EA 3750.00 3,750 Ditto 3,100 CFM, 110 MBH, 13 GPM 2 EA 1775.00 3,550 Ditto 2,400 CFM, 200 MBH, 23 GPM at Home Ec. furnace 1 EA 1650.00 1,650 Ditto 2,000 CFM, 200 MBH, 23 GPM at kitchen 1 EA 1650.00 1,650 Reconstruct mixing box at kitchen 1 EA 875.00 875 Glycol mix drum 1 EA 320.00 320 Hand pump 1 EA 280.00 280 Glycol mix 80 GAL 6.20 496 Air separator 1 EA 480.00 480 95 GPM, 127' head circulation pump 1 EA 1650.00 1,650 WASTE HEAT RECOVERY SYSTEM PAGE 8 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 3. HIGH SCHOOL MODIFICATIONS QUANTITY UNIT UNIT RATE ESTIMATED COST BASIC BID 40 gallon expansion tank 1 EA 1130.00 1,130 3" insulated pipes 40 LF 30.50 1,220 2, 1725 aitto 250 LF 27.50 6,875 2° (aitto 90 LF 21.30 1,917 1 1/2" ditto 80 LF 17.40 1,392 3/4" cold water pipe 20 LF 9.50 190 3" gate valves 4 EA 285.00 1,140 2" ditto 6 EA 170.00 1,020 t 172° aitto 4 EA 105.00 420 3/4" ditto 1 EA 40.00 40 3" check valve 1 EA 220.00 220 WASTE HEAT RECOVERY SYSTEM PAGE 9 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 ‘3. HIGH SCHOOL MODIFICATIONS QUANTITY UNIT UNIT RATE ESTIMATED COST BASIC BID 3" balance valve 1 EA 185.00 185 2" ditto 3 EA 100.00 300 1 1/2" ditto 2 EA 85.00 170 2" (3) way control valve 3 EA 385.00 1,155 1 17.2" ditto 2 EA 225.00 450 3" to 1 1/2" tees and elbows 26 EA 75.00 1,950 Connect pipe to arctic pipe , 2 EA 110.00 220 Connect to equipment 18 EA 75.00 1,350 Modify controls at AHU 3 LOTS 1750.00 5,250 Ditto at Home Ec./Kitchen 2 LOTS 985.00 1,970 WASTE HEAT RECOVERY SYSTEM PAGE 10 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 4. WASHETERIA MODIFICATIONS QUANTITY UNIT UNIT RATE ESTIMATED COST ADD ALTERNATE #2: Heat Recovery in Washeteria Cut existing pipes for new equipment 2 EA 85.00 170 245 MBH, 28 GPM, 20 gauge stainless steel heat exchanger 1 EA 4250.00 4,250 2" insulated steel header 60 LF 214630 1,278 2" gate valves 3 EA 170.00 510 2" balance valves 2 EA 100.00 200 2" tees and elbows 8 EA 60.00 480 Connect to equipment . 6 EA 70.00 420 Connect to arctic pipe 2 EA 110.00 220 WASTE HEAT RECOVERY SYSTEM PAGE 11 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 5. CITY OFFICES MODIFICATIONS QUANTITY UNIT UNIT RATE ESTIMATED COST ADD ALTERNATE #3: Heat Recovery in City Hall Cut existing pipes for new equipment 2 EA 80.00 160 60 MBH, 7 GPM, 20 gauge stainless steel heat exchanger A EA 1850.00 1,850 1 1/4" insulated steel header 40 LF 16.50 660 1 1/4" gate valves 3 EA 90.00 270 1 1/4" balance valves 2) EA 70.00 140 1 1/4" tees and elbows 8 EA 65.00 520 Connect to equipment 6 EA 100.00 600 Connect to arctic pipe 2 EA 65.00 130 WASTE HEAT RECOVERY SYSTEM GAMBELL, ALASKA CONSTRUCTION COST STUDY 6. INSULATE MODULES QUANTITY UNIT UNIT RATE PAGE 12 FEBRUARY 6, ESTIMATED COST 1990 ADD ALTERNATE #1: Insulate/Weatherstrip Modules Insulate module walls with 4" rigid insulation attached to existing walls and roof with clips and covered with metal siding (2) 1,360 Apply plastic membrane underside floor soffit and apply spray-on urethane insulation and seal 400 Seal all pipe penetrations weather tight 2 SF SF LOTS 12.50 9.70 380.00 17,000 3,880 760 WASTE HEAT RECOVERY SYSTEM PAGE 13 GAMBELL, ALASKA CONSTRUCTION COST STUDY FEBRUARY 6, 1990 7. SIMPLIFY HEAT RECOVERY IN HIGH SCHOOL QUANTITY UNIT UNIT RATE ESTIMATED COST ADD ALTERNATE #4: Simplify Heat Recovery in School OMIT All work at Basic Bid (High School) 1 LOT (43,265) ADD Glycol mix drum 1 EA 300.00 300 Hand pump 1 EA 280.00 280 Glycol mix 50 GALS 6.20 310 95 GPM, 27' head circulation pump J EA 1650.00 1,650 40 gallon expansion tank 1 EA 1130.00 1,130 3" insulated pipes 30 LF 30.50" 915 2 172" ditto 200 LF 27.50 5,500 3/4" cold water pipe 20 LF 9.50 190 WASTE HEAT RECOVERY SYSTEM GAMBELL, ALASKA CONSTRUCTION COST STUDY 7. SIMPLIFY HEAT RECOVERY IN HIGH SCHOOL QUANTITY UNIT UNIT RATE ESTIMATED COST PAGE 14 FEBRUARY 6, 1990 ADD ALTERNATE #4: Simplify Heat Recovery in School ADD 3" gate valves 3" check valve 3" balance valve 2 1/2" gate valves 3" to 2 1/2" tees and elbows Connect pipe to arctic pipe Connection to equipment 8,000 CFM, 400 MBH cabinet fan coil unit heaters in existing mixed air plenum Adjust controls 10 EA EA EFA EA EA EA EA 285.00 220.00 185.00 180.00 75.00 110.00 75.00 3250.00 700.00 570 220 185 360 600 220 750 3,250 700 RAW DATA Raw Data Power Plant Generators: Prime Power: 2 each Cummins KTA19-62 with 350 KW KATO generators Standby: 1 each Catepillar 3406DT with 350 KW KATO generators Radiators: Prime Power: Young, Model not available Standby: Integral skid mounted. Operating Conditions during site visit: Generator #2 running, Load varied engine LWT = 185 degrees engine RWT = 165 degrees. Min. Return Temp to Generator: Amot contorl valve setpoint 175 degrees. Engine Design Flow and Max External Pressure: 189 GPM, 5 PSI. User Buildings High School Air Handling Units and Fumaces: Gym: Pace model #B-15B, 5 HP air handling unit with 2 each Lennox Model #011-168 furnace. CFM: 8300 Furnace Input: 168 MBH each. Locker Room & Classroom: Pace model #A-15B air handling unit with 1 each Lennox model #01 1-168 furnace. CFM: 3100 Furnace Input: 168 MBH Shop & Classroom: Pace model #A-15, 2 HP air handling unit with 1 each Lennox model #01 1-168 furnace. CFM: 3100 Furnace Input: 168 MBH HomeEc: Dravo-Hastings model #P-25-Lo furnace. CFM: 2400 Input: 312.5 MBH Kitchen Hood Make-up Air: Dravo-Havtings model #P-25-Lo furnace. CFM: 2000 Input: 312.5 MBH Washeteria Boilers: 3 each American Standard Model #VP230 Output: 230 MBH each. Boiler Supply Setpoint Temp.: 185 degrees Actual Boiler Return/Supply Temp.: 160 degrees supply. Return not available. Primary Circulating Pumps: 2 each TACO model #120-C12, 1/6 HP. Circulating Pump Pressure: Not available. City Office Boller: Slant Fin model #78-175 Output: 159.1 MBH Boiler Supply Setpoint Temp.: 185 degrees Actual Boller Return/Supply Temp.: 185 degrees supply, 120 degrees retum Circulating Pump: Bell & Gossett Model #L88, 1/12 HP Circulating Pump Pressure: Not available