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Kivalina District Heat Report & Concept Level Design 1990
Kivalina District Heat Report & Concept Level Design PREPARED FOR State of Alaska Alaska Energy Authority 701 East Tudor Road PO. Box 190869 Anchorage, Alaska 99519-0869 ARcTiC OCEAN Fh See al May 1990 % ite \ rhe { ye S\ OGRimG BEA U ere. See io cae ie a he ee polarconsult alaska, inc. ge we PS y ENGINEERS « SURVEYORS e ENERGY CONSULTANTS oe pe: #% >) 1503 WEST 33RD AVE.* ANCHORAGE, ALASKA 99503 aya PHONE: (907) 258-2420 FAX: (907) 258-2419 polarconsult Kivalina District Heat Executive Summary Kivalina is a bush community with a population of 300, located in Northwest Alaska at the tip of a 700-foot-wide by eight mile long barrier beach between the Chukchi Sea and Kivalina Lagoon. This report was commissioned by the Alaska Energy Authority (AEA) to determine whether introduction of a district heating system would save money for the community. The district heating system would recover energy from the Alaska Village Electrical Cooperative (AVEC) power plant that would otherwise be wasted, and convert the waste heat to beneficial use for the community. With the 1990 cost of heating oil at $1.10 per gallon for the School District and $1.75 per gallon for the City, a considerable amount of money is expended to heat community buildings. A district heating system is not complicated. Our familiar baseboard-heated buildings have a boiler which transfers heat to water, and a pump to circulate the water to baseboard radiators. At the radiator the heat is transferred to the air in the building. A district heating system works in the same manner, with the water circulating around a diesel generator which acts as the boiler. This report discusses how this heat may be used in Kivalina, and what results may be expected. Six buildings were studied as likely candidates to be connected to a district heating system in Kivalina. The most economical choice would be the school complex which would utilize 100% of the heat available at the power plant during the winter months. Project cost, annual amount of fuel saved and fuel cost savings for the school complex are as follows: Project Cost $391,769 Amount of Fuel Saved per Year 18,583 Annual Savings $20,442 Straight Pay Back in Years 19.2 The other buildings studied include the city's two community center buildings next to the power plant, the water treatment plant and the clinic across the road, and the city hall and jail located down the road. polarconsult Kivalina District Heat Total project cost includes design, supervision, inspection, administration and construction. The project includes construction of a new module at the power plant to house the district heating equipment, renovations to the AVEC power plant cooling system and the school-complex heating system, and construction of a hot water transmission line. The life of a district heating project is a function of availability of waste heat from the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance costs. In this case the requirement for electricity and space heat in the community imply an infinite project life. With proper maintenance the life of the district heating system will exceed 25 years. It is estimated that it will cost an average of $1,000 per year to repair actual failures in the district heating system. Routine maintenance will be performed during three trips to Kivalina by a skilled crew each year. Operation will be by a local person who will monitor the system. Because annual operational and maintenance costs and economic decisions will be made by AEA, final economic conclusions are not presented in this report. The straight pay- back time for the best alternative, Concept 1, is 19 years. The project could be made more attractive economically by reducing its scale through minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Northwest Alaska communities to reduce Kivalina’s share of the high mobilization, shipping, travel, and supervision costs required. ae polarconsult Kivalina District Heat INDEX EXCCULLVS)/SUMIMALY, reeieierei ay ate tel sliaitatiolieiiettatioyairslattotetvaprattertatvettoptctiotettstMerre te} sis i Listombipures Meee elec: elcienelaehe sree leledelelevole kell fel te] ite Vv Kistoflables we pee or enene ode sueel enone ne ue Men ee ced eels elas v Glossanyseyrisereirisneyeatet etal citetiet tetterretiel stone tetatcsit etter ety emvepteyr mere eteatietter?stoitatr att od eit vi I. Introduction ASObiectiveltsr siete cists ereelisl sieiertel erations straits iteirersitetistretieassike ter st stattayt straits 1 Be DistrictheatingSystemimer isch oe erecta alee elle siels 1 UME TEC eo ee er em sirele wea all aed Mah Oo a ae eee sag i} IDACommunity/Descriplonernine Mane ec ener tna 5 BYProjected!oadiChanges Py eee dame teed cleo ee sie avbais valet Nees Pai 3 MEFSige Visite epersnete irene tsieter saetieh apeitelpenisitertantest sicettelieystreterteht et srretietetter eens tele a 4 Ill. Power Plant Gene Eee eee eevee eet ie ears nee ies se le alty 3 B. Available Load Information & Available Heat. ..........000e eee 3 Building Heat nee Peele ese pe Serpe el ora pense ie Tea 7 IDs Proposed: District Heatin giConnection ay ana a 9 IV. Potential District Heating Users A. School EM Genera|Hiieisininiinersiianent ati iiibariaavraiiet wiratiati nHHnneUIAr HRCA 12} Ze Cocation neat Nei ale Peete ia iene paey ten tarmac eee re beds 12 SWHCACUSE HAL te abet Wem oe MeMeseealayen eS ELEM WU Le Po UL 13 4s District Heating Connections rei icine iia 13 B. Old & New Community Hall Buildings PiGencraliemceneniie keene ieee eels 16 2eWOCATOM Un (aia Mele ste Melee el ealeteavel ea fae] eM oy eg ea ea ea Pa 16 Seat USE raiaeweratatstteltatrete ou AneMM aa oe LEAL A 16 4s District Heating|Connechonterrrr emirate tee ainiciets is C. Water Treatment Plant & Clinic LS Generalieenitrnrneetara et etaitatete terete te there Tear eta eee 19 ZOO atOonn ere ene ale ee eae ea ee agen co ene ee 19 BUHeat User Leet La ete Le Le ALD COND DC AC 19 AsDistrict Heating: Connectiony yrs e sar sera at eater atest 20 D. City Hall and Jail LGeneralienrareneneainieheiaetietatetelic tetera datetate telereaiotetoteterete 22 La polarconsult Kivalina District Heat Z.Location ... cc ee et ee we ewe eee eee teeta eeee 22 3.,Heat USE nels eles wa sls cigwie lla anee eae Bl nae ewe os 22 4, District Heating Connection... .... ee es 23 V. Concept Design Drawings ©... cee ee ees 24 VI. Failure Analysis Av Introduction... ee ee ee eee 32 B. Failure Analysis of District Heating System ......... 0... e eee 33 1. Power, Plant! |. a |e sees le a Sls le sls elma sin cule ele we om elm al 5 34 2. Distribution System 1.0... es 37 3, User COMNECHON ... ccc wee Ree ee Hea aes Bee wel 38 C. Failure Frequency and Cost... ee ce eens 40 D. Design Decisions to Minimize Failure... 1... cee ee eee 42 VII. Project Specifications A. Codes and Regulations»... . eee eee eee 43 B. DIVISION 01 - General Requirements .......... 0.000 eeeueee 43 C. DIVISION 02 - Sitework 2... es 43 D. DIVISION 13 - Special Construction .. 1... . eee ee ee 44 E. DIVISION 15 - Mechanical Outline Specification .............0005 45 F. DIVISION 16 - Electrical Outline Specification .. 2... . eee eee 48 VIII. Project Cost Estimate A. Power Plant Heat Recovery System ....... 0. cece ee ee 51 B. District Heating Distribution System... .... ee eee 51 C. Operation and Maintenance Costs»... . eee ee 51 BD: Projéct Cost Summaty : 62: se8 dees aes eee wT ew 52 IX. Conclusions A. Available Heat & Fuel Consumption ..... 0... 0.0000 eee eee 53 B. Project:Cost Summaty’: s caa soe wseew a news nee eas oo 55 C. ProjectSummary ...... ee 55 X. Recommendations ...,....0008 soe a HTT ee eee ee RD RHE 56 Calculations 5 454i ese ee eels sees we et oles eles mle ole eo Appendix A Field Trip|NoOtes |.\e:u| ol ule tes a6) se ee me wl ole ow a rata lat 6) Appendix B Cost Estimate)! =| cl te ls: acl sole a milter ce lm tate oe lalt tole mf ah af alas [ot Wiley fe ot folate Appendix C iv polarconsult List of Figures Kivalina District Heat I-1 1-2 1-3 1-4 1-5 1-6 IV-1 Iv-3 Iv-4 IV-5 IV-6 V-1 V-2 v-4 v-5 V-7 V-8 IX-1 IX-2 Proposed District Heating Module & Remote Radiator Locations ........ Exhaust Stack & Cooling Air Louvers, Remote Radiator Locations ....... Unit #1 Exhaust & Enclosed Skid-Mounted Radiator & Cooling Air Louvers . Unit #3/& Building Unit Heater ny sayeire ie) dleietie tol sie els! ol nie iekel ol aj lo feliel \loite Module Radiator Piping from Unit #4, Heat Exchanger ...........0-. Module Station Service Panel, Expansion Tanks & Module Unit Heater... . Proposed District Heating Pipe Connection to School ..........00005 Proposed Location of Secondary Heat Exchanger in School ............ Existing Boiler, Circ. Pumps & Proposed Location of District Heating Conn. . Existing Circ. Pumps & Proposed Location of District Heating Connections . . Proposed Location of District Heating Equipment in New Community Bldg. . Proposed Pipe Alignment to Water Treatment Plant & Clinic, off Distribution! Line|to School AEs wolels tolsolelelisteilleleleltstieitel staltolieli« Water Treatment Plant Boilers & Proposed District Heating Connection ... . Site Plan & District Heating Distribution ........... 20. cece ee eee Proposed|System' Schematic neq-eoieredoder si aieuedsreteasnencnopsieuci ol oeetienole Detail Showing Revisions to Existing Power Plant & District Heating Piping . School Piping Connection Schematic & Floor Plan. ............0005 Old Community Hall Building Schematic & Floor Plan New Community Hall Building Schematic & Floor Plan Water Treatment Building Schematic & Floor Plan... ..... 0.000 eee Clinic !Schematic?& Floor Plan |i avcelts aiel si feleel lol fo fel of ei lolieitellst Alois olfel elo Heat Available vsiHeat/ Required oe ee alle Gallons of Heat Displaced\)))/3)/5) 2s Wlais eisl sae ella ieleaisiaie eines clei I-A II-B IV-A IV-B IV-C IV-D VI0-A Summary of Alternative Project Costs IX-A IX-B Engine Data yee) sili lelisiie lel she kelre) silo e's) sills hs] «| ls) felted oat elie fail aelis) [a sf =) fete Monthly Power Generation & Available Heat... ........ 0000s eee Estimated Distribution of Fuel Oil Use at School... ..........00005 Estimated Distribution of Fuel Oil Use at Community Buildings ......... Estimated Distribution of Fuel Oil Use at Water Treatment Plant & Clinic ... Estimated Distribution of Fuel Oil Use at City Hall & Jail Annual Heating Fuel Displacement & Distribution Pipeline Heat Losses ... . Project CostiSummany, jyiejey er aioe) ele) or oped ee ctor tertedobtertor stfey on erie terteyi er spicier ets polarconsult Kivalina District Heat Glossary AEA: Alaska Energy Authority, the State agency which commissioned the report. AVEC: Alaska Village Electric Cooperative, the electric utility providing electric power to the community. APUC: Alaska Public Utilities Commission, the body which regulates most utilities throughout the State of Alaska. Capital Cost: Total cost to construct the project, including actual costs as well as design, management, contractor's overhead, risk and profit. Operating Cost: Cost to keep the project operational, computed on an annual basis over the life of the project. District Heating: Concept of recovering engine waste heat which would otherwise be lost through radiators to the air. This heat is circulated in pipes as hot water to heat buildings. Present Worth: The value of a future or past sum of money at a given time, usually the present, taking into account the time value of money, using some interest rate. Net Present Worth: The value of a project where costs and income have been converted to a common time and combined. vi polarconsult Kivalina District Heat I. Introduction A. Objective The objective of this report is to determine the feasibility of recovering and using the waste heat from the Alaska Village Electric Cooperative (AVEC) power plant generators in Kivalina. In view of the present costs for heating oil of $1.10 and $1.75 per gallon respectively for the School District and the City, and the amount of heat presently being wasted to the outdoors through the engine radiators, the Alaska Energy Authority (AEA) determined that utilization of waste heat showed potential savings in heating costs. The scope of this report is to determine if a district heating system is feasible, identify optimal applications, and estimate the cost of constructing this system in Kivalina. B. District Heating S A district heating system takes energy that would otherwise be wasted away and converts it to beneficial use as space heat. A brief description of a district heating system follows. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which burns fuel, usually oil, and transfers the heat to water, and a pump to circulate the heated water through pipes to radiators. At the radiator the heat is transferred to the air in the building. A district heating system works similarly, with the water heated by diesel generators in the AVEC power plant instead of being heated by a boiler. The water heated by the engines is normally cooled by the radiators at the plant. In a district heating system, this heat is recovered for beneficial use instead of being rejected to the atmosphere. This report discusses how waste heat can be used in Kivalina, and the likely results. C. Methodology The feasibility of waste heat use in Kivalina has been investigated in the following manner: 1. Information Gathering: Prior to the site visit all pertinent and available information was gathered, including estimates of the amount of heat available and identification of potential user facilities. The field trip was coordinated with village officials and AVEC operators. polarconsult Kivalina District Heat 2. Field Trip: The site visit was made to discuss the project with the Village Council and interested persons, to survey potential user buildings and determine possible distribution pipe routes. Criteria for potential user facilities included public ownership, substantial heat use and proximity to the AVEC power plant. The manager or operator of each candidate building was interviewed. Information was gathered concerning: 0 Rights-of-way; o Amount, type and quality of construction equipment available in the village and the rental rates; o Availability of village-supplied labor during the probable construction period; Specific weather problems such as drifting snow; and 0 Soils information. Field trip notes are shown in Appendix B. 3. Analysis: Field trip notes, photographs, general information and site-specific features of the village were analyzed. Historical power production, weather information, and fuel usage records obtained during the field trip were entered into a computer model to determine the quantity of waste heat available to each potential user facility. On the basis of economics, several potential user facilities were eliminated. Specific details for hook-ups to the district heating system, including distribution pipe routing and location of user heat exchangers, were considered and included in the report. (See Figure V-1, "Kivalina Site Plan and District Heating System," on Page 24.) 4. Initial Submittal: A preliminary report on the project was written and distributed to the Alaska Energy Authority staff for comment. 5. Final Submittal: The final report will include all comments received from AEA and other interested parties who have reviewed the interim report. polarconsult Kivalina District Heat D.C sea Beart Kivalina is located in Northwest Alaska at the tip of a 700-foot-wide by eight mile long barrier beach between the Chukchi Sea and Kivalina Lagoon. The population is made up mostly of Inupiat Eskimos, and the economy is based mainly on subsistence hunting and fishing. Kivalina has a population of 300. The community has a water distribution system from the water treatment plant to the school and the clinic. Problems with disposing of the sewage as well as developing a water source have kept the village from expanding the water distribution. A variety of equipment is available for rent from the city. Local labor is available most of the summer, although a number of the residents participate in commercial fisheries out of Kotzebue. E. Projected Load Changes Since the school building is not scheduled for expansion, according to Northwest Arctic Borough School District officials, its heat requirements should remain constant. The heat requirements for the cities two community buildings should also remain constant as there are no plans for expansion. The heat requirements of the water treatment plant should grow with the community at a rate of 2.3%. AVEC projects an increase of about 9% in power demand over the next five years with a stable power requirement over the following five years, according to its Power Requirements Study and 10-Year Plan. This increased power requirement relates directly to the amount of heat available for use. polarconsult Kivalina District Heat II. Site Visit The site visit was conducted during December of 1989 to discuss the project with the Village Council and interested persons, survey potential user buildings and determine possible routes for district heating distribution pipe. The principal of the school complex, and operators of the water treatment building (washeteria) and the AVEC power plant were interviewed. Information was gathered concerning rights-of-way, soils, specific weather problems, and local availability of construction equipment and labor. Paul Weisner, assistant director of the Northwest Arctic School District, was contacted about fuel usage of the schools. He stated that he was very enthusiastic about waste heat systems. Several times during boiler failures at Kiana, the waste heat recovery system had kept the school in operation. He stated inclement weather during boiler failure requires a charter of an Otter aircraft, costing the district over $2,000 per trip. Field trip notes including a list of people contacted in the field, are shown in Appendix B. polarconsult Kivalina District Heat III. Power Plant A. General The power plant comprises one standard AVEC Butler-type structure and one standard module. The Butler building houses three generators equipped with skid-mounted radiators, switch gear, and a day tank and the module houses one generator equipped with two remote radiators. The following equipment is presently installed in Kivalina. Table III-A Engine Data Position 1 2, 8 4 Engine Cummins A-C A-C Cummins Model LTA 10 6851 3500 LTA 10 Speed (rpm) 1800 1800 1800 1800 Rating, Engine (kw)! 175 186 118 175 Heat Rejection? To Coolant (Btu/min) 5,650 7,000 5,088 5,650 To Stack (Btu/min) 7,000 ---- ---- 7,000 To Ambient (Btu/min) 1,500 2,160 o--- 1,500 Water Flow (gpm) 95 ay 64 95 Intake Air Flow (CFM) 490 520 ---- 490 1 Engine rating at shaft 2 Rating at full load B. Available Load Information & Available Heat Monthly power production figures for Kivalina were obtained from AEA. The 1989 figures were rounded to the nearest 100 kwh for use in this report. The amount of waste heat available off the engines was calculated using these generation values and the engine manufacturer's heat rejection figures listed in Table III-A. System losses were subtracted from the amount of heat available off the engines to arrive at the equivalent number of gallons of fuel oil available for use. System losses include building heat, distribution pipeline heat losses, radiator losses and plant piping heat losses. polarconsult Kivalina District Heat Table II-B Monthly Power Generation & Available Heat Month Power Produced Values Used Heat 1987 1988 1989 in Study! Avail.4 (kwh) (kwh) (kwh) (kwh) (Gal.) Jan ewww 71,160 80,760 80,800 2,505 Feb n---- 65,880 68,520 68,500 25135 Mar nooe- 67,080 72,360 72,400 2,365 Apr a---- 58,800 66,240 66,200 2,193 May = === 66,960 58,680 58,700 2TS June 3) 44,520 38,400 38,400 1,501 July 43,200 42,960 37,440 37,400 1,479 Aug 45,600 51,240 45,480 45,500 1,802 Sept 58,800 60,480 66,480 66,500 2,279 Oct 63,360 68,160 ~—----- 68,8002 2,328 Nov 66,080 68,690 —----- 69,4002 2,267 Dec 72,480 73,800 ----- 74,5002 2,326 Annual 707,7173 739,730 + 747,0603 747,100 25,355 1 Values used in this study were the 1989 kwh production figures rounded to the nearest 100 kwh. - From Jan. to Sept. the load increased 1.0% from 1988 to 1989. This rate of increase was used to project the load from Oct. to Dec. 1989. 3 Annual production for 1987 and 1989 was estimated, as data were not available for all months. 4 Equivalent gallons of heating oil available from District Heating Simulation Work Sheet. polarconsult Kivalina District Heat C. Building Heat The Butler building is a metal frame building with 2 inch insulation in the walls and roof, incorporating a wood floor which is not insulated. Intake air comes from a ventilation louver by the door, and cooling air off the radiators is exhausted through motor-controlled dampers behind the radiators. (See Figures Il-1, M1-3 & I-4.) The motor controls on the dampers are not connected. The module is a prefabricated metal structure with 3 inches of urethane insulation between the interior and exterior metal skin. Intake air comes from a ventilation louver by the door. The remote radiators are mounted external from the module. Cooling air is exhausted through motor-controlled dampers mounted in the wall. The ventilation louvers for the remote radiators were closed off due to the amount of blowing snow coming into the module and Butler building (Figure III-2). The Butler building and the module are heated with unit heaters connected to a shell and tube heat exchanger connected to Unit #4 in the module only. The interior temperature was 70°F in both the Butler building and the module at the time of our visit. The outside temperature was -20°F with a 20-knot wind; Unit #4 was running in the module, and the intake and exhaust louvers were closed in the Butler building and the module. Calculations show that a quantity of heat equivalent to 2,936 gallons of oil per year would be required to keep the Butler building and the module at 65°F year- round, This is to facilitate daily engine maintenance. This calculation assumes that only one engine is running in the module, which is now the case, and combustion air is circulated through the building. Insulating the floors of the Butler building and the module could decrease this figure by 781 gallons a year. Our concept design includes taps for heating engine jacket water on standby units, insulation in the floor of the Module and Butler building, and connections to the building unit heaters. polarconsult Kivalina District Heat Figure IIJ-2. Exhaust Stack & Cooling Air Louvers, Remote Radiator Locations polarconsult Kivalina District Heat DE i District Heating C The proposed district heating system schematic is shown in Figure V-2 (page 25) and the connection to the power plant is shown in Figure V-3 (page 26). Interconnection between the existing remote radiators and the new remote radiators proposed for this project is included. This will allow for any generator to be run off either of the four remote radiators. Building unit heaters and engine warm system connections are also included in the new piping, as is insulation in the floor of the Butler building and the Module. The primary heat exchanger will be located in a housing module mounted on the side of the existing AVEC module (Figures III-1 & V-1). The expansion tank and district heating pumps will be located at the user end of the system. The module will be constructed of a steel frame, mounted on the modules existing skids. It will be insulated with rigid insulation and covered with metal siding on the exterior and plywood on the interior. Heat exchangers will be stainless steel plate type units. The primary side piping will run from the heat exchanger under the floor of the Butler building (Figure III-1), come up through the floor next to the engines (Figure III-4), and connect to each engine. The piping will run through the wall of the module and connect to the single engine there. The piping will be type L hard copper or welded and flanged black sch. 40. The district heating electrical systems will be connected into a new electric panel located in this module. The new panel will be connected, through a meter, to the existing station service panel in the Butler building. The cost estimate for the connection of the heat exchanger, pumps, and module at the power plant is covered in Section VIII, Project Cost Estimate. polarconsult Kivalina District Heat AVEC Butler Building de ||| Figure III-3_ Unit #1 Exhaust & Enclosed Skid-Mounted Radiator & Cooling Air Louvers Figure III-4 Unit #3 & Building Unit Heater polarconsult Kivalina District Heat AVEC Module Figure III-5 Module Radiator Piping from Unit #4, Heat Exchanger Figure III-6 Module Station Service Panel, Expansion Tanks & Module Unit Heater ie polarconsult Kivalina District Heat IV. Potential District Heating Users A. School 1. General The school, which is K-12, has an enrollment of 105 and belongs to the Northwest Arctic Borough School District, based in Kotzebue. The main school building houses all of the classrooms and the gymnasium. This building has a hot water heat system with a separate domestic hot water heater. 2. Location The school is located down Bering Street from the AVEC plant. The distribution pipe will be buried "Arctic" pipe running parallel to the existing underground power line to the school. (See Figure V-1.) This will require an easement to cross the three residential lots, parallel to the existing underground power cable to the school. The district heating line will run 520 feet to the main school buildings utility room. (See Figure IV-1.) 3. Heat Use Fuel records for the school facility in Kivalina were obtained from Paul Weisner of the Arctic Borough School District in Kotzebue. The entire complex used 30,000 gallons in 1989, with 25,000 gallons used by the main school building, and the remaining 5,000 gallons by auxiliary buildings. A monthly breakdown of fuel consumption by the school complex was not available. Monthly fuel use was estimated by distributing the average annual fuel consumption computed using the number of heating degree days per month (See sample calculations in Appendix A). 2; polarconsult Kivalina District Heat Table IV-A Estimated Distribution of Fuel Oil Use at School Month Heating Net Fuel Degree Oil Use Days (Gal. Oil) January 2,181 3,508 February 2,081 3,347 March 1,950 3,136 April 1,617 2,601 May 1,094 1,760 June 816 0 July 402 0 August 425 684 September 728 1,171 October 1,436 2,310 November 1,864 2,998 December 2,166 3,484 Annual 16,760 25,000 Purchase Cost / Gal. $1.10 Domestic hot water for the school is also heated off the boilers. 4. District Heating Connection The district heating pipe will come up through the floor of the utility building next to the existing air intake. The existing mezzanine will be extended to make room for the heat exchanger, expansion tank and district heating pump. (See Figure IV-2.) The district heating connection will be made to the boilers return headers in the existing utility room. (See Figures IV-3 & IV-4.) This will be a series connection. (See Figure V-4.) 13) polarconsult Kivalina District Heat Figure [V-1 Proposed District Heating Pipe Connection to School Figure IV-2 Proposed Location of Secondary Heat Exchanger in School polarconsult Kivalina District Heat ui Figure IV-3__ Existing Boiler, Circulation Pimps & Proposed Location of District Heating Connections Figure IV-4 Existing Circulation Pumps & Proposed Location of District Heating Connections tS polarconsult Kivalina District Heat B. Old & New ity Buildi 1. General The old & new community buildings are owned by the City of Kivalina. Each building is heated with its own warm air furnace. 2. Location The old & new community buildings are located on the lot adjacent to the power plant. The district heating distribution pipe from the power plant to the community buildings will be "Arctic" pipe. This pipe will be buried along a straight line from the plant. (See siteplan, Figure V-1.) The length of the hot-water transmission line to the old & new community buildings will be 120 feet. 3. Heat Use The old & new community buildings furnaces supply building heat only. Annual fuel records for the old & new community buildings were obtained from the City of Kivalina. Monthly fuel use was estimated by distributing the average annual fuel consumption computed using the number of heating degree days per month. (See Appendix A for sample calculation.) 16 polarconsult Kivalina District Heat Table IV-B Estimated Distribution of Fuel Oil Use at Community Buildings Month Net Fuel Oil Use Heating OldComm NewComm Degree Days (Gal.) (Gal.) (HDD) January 143 129 2,181 February 137, 123 2,081 March 128 115 1,950 April 106 96 1,617 May 2 65 1,094 June 54 48 816 July 26 24 402 August 28 25 425 September 48 43 728 October 94 85 1,436 November 122 110 1,864 December 142 128 2,166 Annual 1,100 990 16,760 Purchase cost/gal. $1.75 S175) 4. District Heating Connection The two district heating pipes will be buried and will emerge outside the building and extend under the building to the furnace room. The pipes will come up through the floor in the corner of the new community buildings mechanical room behind the proposed district heating secondary heat exchanger and equipment. (See Figure IV-5.) Coils will be added to the existing forced air furnace. (See Figure IV-5.) The proposed pipe penetration, layout and furnace modifications would be the same for the old community building. The cost of connecting the school to the district heating system is covered in Section VII-B. 7 polarconsult Old & New Community Building Figure IV-5 Proposed Location of District Heating Equipment in new community buildings Kivalina District Heat polarconsult Kivalina District Heat C. Water Treatment Plant & Clinic 1. General The water treatment plant is owned by the City of Kivalina and operated under the direction of the U. S. Public Health Service. Heat is provided to the building, the water storage tank, and the domestic hot water off these two boilers. The Clinic is located next to the water treatment plant and is also owned by the city. Heat in the clinic is from a single forced air furnace. Domestic hot water is supplied from a hot water heater. 2. Location The water treatment plant and clinic are located across Bering Street from the power plant. The district heating distribution pipe to the water treatment plant and the clinic will be buried "Arctic" pipe. This line would branch off the main distribution pipe to the school at Chukchi Street. (See siteplan, Figure V-1 & Figure IV-6). The length of the hot- water transmission line to the water treatment plant and the clinic will be 300 feet from the branch off the main line to the School. 3. Heat Use The water treatment plant's two boilers supply heat to the building, the water tank, and the circulating water in the distribution lines. The water tank is insulated with 2 inches of rigid insulation, and heated to about 40°F in the winter. The clinic is heated with a forced air furnace and has a hot water heater for domestic hot water. Fuel records for the water treatment plant and the clinic were obtained from the City of Kivalina. Monthly fuel use for the water treatment plant was estimated by distributing the average annual fuel consumption using the number of heating degree days per month. Monthly fuel use for the clinic was estimated by distributing the average annual fuel consumption, minus a 5 gallon per month use by the hot water heater, computed using polarconsult Kivalina District Heat the number of heating degree days per month. (See Appendix A for sample calculation.) Table IV-C Estimated Distribution of Fuel Oil Use at Water Treatment Plant & Clinic Month Net Fuel Oil Use Heating Water Plant Clinic Deg. Days (Gal.) (Gal.) (HDD) January 90 150 2,181 February 88 143 2,081 March 84 134 1,950 April 76 111 1,617 May 62 15 1,094 June a5 56 816 July 44 28 402 August 44 29 425 September ae 50 728 October 71 99 1,436 November 82 128 1,864 December 90 149 2,166 Annual 839 1,155 16,760 Purchase cost/ gal. $1.75 $1.75 4, District Heating Connection The two district heating pipes will be buried and emerge outside the water treatment building, extend under the building and come up in the proposed new addition to the water treatment building housing the district heating secondary heat exchanger and equipment. (See Figures IV-6 & V-8.) The connection will be made to the return header of the existing boilers. (See Figure IV-7.) The buried pipe to the clinic emerges under the proposed new addition to the clinic housing the proposed district heating secondary heat exchanger. A heating coil will be added to the existing furnace. The cost of connecting the water treatment plant and the clinic to the district heating system is covered in Section VIII-B. 20 polarconsult Kivalina District Heat Figure IV-6 Proposed Pipe Alignment to Water Treatment Plant & Clinic, off Distribution Line to School Figure IV-7 Water treatment plant boilers, Proposed Connection of District Heating System polarconsult Kivalina District Heat D. City Hall & Jail 1. General The city hall houses the City of Kivalina offices and the city jail is located next door. Heat is provided to the buildings from a forced air furnace located in each building. 2. Location The city hall & jail are located down Bering Street from the power plant. The district heating distribution pipe to the city hall & jail will be buried "Arctic" pipe. The line would branch off the main distribution line to the old and new community hall. (See siteplan, Figure V-1.) The length of the hot-water transmission line to the city hall & jail will be 440 feet from the branch off the main line to the old & new community hall. 3. Heat Use The city hall and jail have their own furnaces for building heat and hot water heaters for domestic hot water. Fuel records for the city hall & jail were obtained from the City of Kivalina. Monthly fuel use was estimated by distributing the average annual fuel consumption, computed using the number of heating degree days per month. (See Appendix A for sample calculation.) ae polarconsult Kivalina District Heat Table IV-D Estimated Distribution of Fuel Oil Use at City Hall & Jail Month Net Fuel Oil Use Heating City Hall Jail Deg. Days (Gal.) (Gal.) (HDD) January 178 50 2,181 February 171 48 2,081 March 160 45 1,950 April 133 37 1,617 May 90 25 1,094 June 67 19 816 July 33) 9 402 August 35) 10 425 September 60 17 728 October 118 33 1,436 November 153 43 1,864 December V7 49 2,166 Annual 1375 385 16,760 Purchase cost/ gal. $1.75 $1.75 4. District Heating Connection There is presently not enough heat to support all of the buildings investigated. The city hall and jail are the furthest away, making them the most expensive of the city buildings to connect. Heating coils would need to be added to the existing furnaces if they were connected. 23 polarconsult Kivalina District Heat V. Concept Design Drawings KIVALINA SITE PLAN PROPOSED DISTRICT HEATING SYSTEM / NEW Le WY ts | ONCEPT 1 560’-2.5°9 (G i k pineal STREET He | S OU ) Ne CHUKCHI KIVALINA LAGOON NEW DISTRICT OLD HEAT MODULE COMMUNI J —_ _ TN ss laa CINCEPT 2, Seer 212'=1" EWS sn 88 NEW | COMMUNTR 4 SAVEC PLANT SL SNe Eas ne TRANSFORMERS {—______ OWER PEDESTAL POST OFFICE Zz] PROPOSED WASTE HEAT USER PROPOSED WASTE HEAT LINE 44 EASEMENT REQUIRED | OFFICE —F— EXISTING FUEL LINE f WAREHOUSE —S— EXISTING SEWER LINE BERING STREBT — — EXISTING UG POWER LINE Ny city JAIL BERRY STREET FIGURE Gi TT =| 24 Oo EXISTING POWER POLE polarconsult KIVALINA — Kivalina District Heat PROPOSED SYSTEM SCHEMATIC | PRIMARY HE EXCHANGER CLINIC WATER TREATMENT (SEE FIG. V-7> (SEE FIG. V-8) Fama nal ATAMNTin | Goalie | CONNECT | | | TO USER NEW COMM BLDG. (SEE FIG. V-5> | SYSTEM |) ||| ))| | ena ae |e teem ce |) Se | Pome USER USER | | Pea a8 EAT SYSTEM HEAT | USER. X CHANGER! WW qr SS | HEAT CONNEC'T | tat TD LSERcER | XCHANGER TO USE| alle S AU UE "y STEM oe | SYSTE | EXCHANGE! | | | iE =F I A y OLD COMM BLDG. (SEE FIG. V-6) pee concept 2 || BURIED 340'-1'8 aie’-1'g «| } ARCTIC PIPE SCHOOL UTILITY BLDG. (SEE FIG. V-4) TUTTI NTN i | LW CONNECT, | eS TO USER Yuser | SN SYSTEM HH) HEAT | 0 c--SS 7 il | lle [EXCHANGER | +o a } | BUTLER BUILDING | ie | | L—lS——4d | G see il CONCEPT L@ 23 URENGINE =e oN AIT Sen'-25"y fy (SEE FIGURE V- LEGEND P<] FX CHECK VALVE — — EXISTING —— NEW @ USER g ISOLATION VALVE NEW DISTRIBUTION 3 SER PRIMARY DISTRIBUTION PUMPS SCALE: NTIS DISTRICT HEAT MODULE SSBB) (Pallas NEW @ PLANT veo) FIGURE V -2 Zo polarconsult EQUIPMENT SCHEDULE HEAT EXCHANGER 400,000 BTU/HR RADIATORS YOUNG, SERIES 22 PLANT PIPING 3" STEEL, WELDED UNIT HEATER EXISTING Kivalina District Heat KIVALINA DETAIL SHOWING REVISIONS TO POWER PLANT AND DISTRICT HEAT CONNECTION NEW NEW RADIATOR RADIATOR TO DISTRICT HEAT SYSTEM SEE FIGURE VI-1 & NOTE 4, DISTRICT HEAT MODULE new) PRIMARY HEAT , EXCHANGER [i J (Ho cy Mn NOTE 1-7 £ f= = ine | ENGINE | {ENGINE ae HA Gyr HEATER tH EXISTING POWER PLANT f at — E TING | PALIATOR) ExIs bi i= i! =i L BUTLER BUILDING G > = Sgr [EXISTIN RADIATOR EXISTING POWER PLANT MODULE BUTTERFLY VALVE AMOT VALVE CHECK VALVE FLEX CONNECTOR NEW PRIMARY PIPING PUMP — — EXISTING NEW DISTRICT HEAT PIPING SCALE: NTS ERS . LOCATION OF POSSIBLE BOOSTER PUMP 2. PUMPED ENGINE WARM SYSTEMS FOR ENGINES 1, 2, 3 AND EXP. TANKS NOT SHOWN. 3. EXISTING SYSTEM COMPRISES THREE ENGINES IN BUTLER BLDG, EACH WITH SKID MOUNTED RADIATORS, & ONE ENGINE WITH. TWO REMOTE RADIATORS IN MODULE. SKID MTD RADS WILL BE REMOVED. 26 LS LEGEND EQUIPMENT SCHEDULE th] GATE VALVE pH BAL. VALVE €) PUMP A CHECK VALVE NEW @ USER EXISTING BUILDING EXISTING NEW DISTRICT HEAT PIPE STRAINER TEMP CONTROL VALVE DISTRICT HEATING NEW PLATFORM | TH 6'-6" AFF FOR USER EQUIP, = — ELECTRIC PANELS roo BOILER #1|> =! roo 4 BOWLER #2\> Lod STARTERS EXIS STING SCHOOL MECHANICAL ROOM HEAT EXCHANGER 400,000 BTU/HR PUMPS GRUNDF , 200, UPC50— ‘| 60 66 GAL. EXPANSION TANI PIPING: SUPPLY SIDE " STEEL, WELDED BOILER SIDE " CU ead | | | || IBOILER w) | ——" | | . ZONE é RETURNS —4 | | BOILER nd ZONE al naa + TO DISTRICT eS ¥ SHEAT SYSTEM —— SUPPLIES EXPANSION TANK y - GLYCOL FILL L . FROM DISTRICT HEAT EXCHANGER pre] G HEAT SYSTEM EM SCHEMATIC AIR SEPARATOR ynsuoorejod IaH IOMNSIC VUTTBATY 82 LEGEND EQUIPMENT SCHEDULE GATE VALVE — EXISTING BUILDING HEAT EXCHANGER 100,000 _BTU/HR BAL. VALVE EXISTING PUMPS GRUNDFOSS, SERIES z PUMP NEW DISTRIBUTION 200, UPC50—40 CHECK VALVE “4 STRAINER EXPAN: NEW @ USER t TEMP CONTROL VALVE PIPING SION TANK 8 GAL. SUPPLY SIDE ” STEEL, WELDED BOILER SIDE eGU COMMUNITY ROOM EXISTING MECHANICAL | af | 3o¥NaN4 a SPACE FOR / \ \ DISTRICT USER EQUIPMENT- ry HT SYSTE FLOOR PLAN SCALE: 1’=10° | a NEW DUCT COIL INSTALLED | IN RETURN AIR DUCT S 1 RETURN GRILLE IN | elt COMMUNITY ROOM 7 es az = > oO m TO DISTRICT HEAT SYSTEM yOL¥1N3aI9 aC EXPANSI HEAT EXCHANGER SYSTEM SCHEMATIC AIR SEPARATOR YNIWAIY (dN-YOOH wasn) ALINAWWOS MAN ON TANK ‘ gGLYCoL FILL FROM DISTRICT HEAT SYSTEM ynsuoorejod yeoR] IOLNSIC] BUTTBATY 62 LEGEND GATE VALVE BAL. VALVE PUMP CHECK VALVE NEW @ USER EXISTING BUILDING EXISTING NEW DISTRIBUTION STRAINER TEMP CONTROL VALVE DISTRICT & & HEATING \ STEM EQUIPMENT SCHEDULE HEAT EXCHANGER PUMPS 100,000 BTU/HR GRUNDFOSS, SERIES 200, UPC50-—40 EXPANSION TANK 8 GAL PIPING: SUPPLY SIDE BOILER SIDE PSPACE FOR USER EQUIPMENT | 3O¥NSNS | T ~— 7 EXISTING MECHANICAL COMMUNIT ¥ ROOM FLOOR PLAN + 1’=10' | 1" STEEL, WELDED 1” CU NEW DUCT COIL / ATTACHED TO FURNACE / 3ovNanN4 = | | | | i | ai ws Ne yoLv1n3al Pon A Ls = AULT NN Ne © TO DISTRICT HEAT SYSTEM a, 3 SYSTEM SCHEMATIC YNIWAMM (dN-YOOH 43S qo - 9 ALINOQWWO EXPANSION TANK t ,GLYCOL Fue FROM DISTRICT HEAT SYSTEM b= AIR SEPARATOR ynsuoosejod AT Insiq 8 yeoy 39 O€ LEGEND EQUIPMENT SCHEDULE GATE VALVE BAL. VALVE PUMP CHECK VALVE NEW @ USER EXISTING BUILDING HEAT EXCHANGER 100,000 BTU/HR EXISTING PUMPS GRUNDFOSS, SERIES NEW DISTRIBUTION 200, UPC50-40 STRAINER EXPANSION TANK 9 GAL. TEMP CONTROL VALVE PIPING: SUPPLY SIDE " STEEL, WELDED BOILER SIDE " CU COMMUNITY ROOM ~ 7 NEW DUCT COIL | Vi ATTACHED TO FURNACE et SOVNaN4 EXISTING MECHANICAL = | | | | | = ernie |SO¥NaN4 | bisee wees teal TO DISTRICT NEw 4’x67 | N ENTRY ROOM FOR USER EQUIP. HEAT SYSTEM ¥0197N3a19 \ | \ \ . SS HEAT EXCHANGER \ \ WDISTRICT HEATING SYSTEM FLOOR PLAN TEM SCHEMATIC SCALE: 1*=10' YNEIWAI ) (dN-YOOH waSN) SINK] EXPANSION TANK t qakycoL BILE FROM DISTRICT HEAT SYSTEM }-s AIR SEPARATOR ynsuoorejod OR] IOLNSIC( BUTTRATY Le LEGEND EQUIPMENT SCHEDULE VALVE GATE BAL. VALVE PUMP CHECK VALVE NEW @ USER NEW MODULE 8x6’ FOR USER EQUIP. DISTRICT YO HEATING SYSTEM EXISTING EXISTING NEW DISTRIBUTION STRAINER TEMP. CONTROL r--- | | | | | L FLOOR PLAN SCALE: 1’=10’ FILTER EQUIP. EBLEG, EQUIP. BUILDING VALVE HEAT EXCHANGER PUMPS 100,000 BTU/HR GRUNDFOSS, SERIES 200, UPC50-40 EXPANSION TANK 9 GAL. PIPING: SUPPLY SIDE BOILER SIDE 1” STEEL, WELDED 1 CU SSS aa | | a | 1 | | | I | BOILER ai! IPOILER #2 I II a sn = ‘S m—-5 ZONE pe— 5 SUPPLIES es ZONE Of Sa ge ——a —-5 RETURNS HEAT Eaece = TO DISTRICT fH —SHEAT SYSTEM EXPANSI AIR SEPARATOR n | YNIIVADY dN-™MOOH a3 ( ONITIING LNAWLV4SYL YALVM ON TANK fi jG YCOL FILL fe reels FROM DISTRICT HEAT SYSTEM ynsuoorejod AT eopy IOLNSI B polarconsult Kivalina District Heat VI. Failure Analysis A. Introduction Failure analysis is the process of predicting the operational reliability of a system. It provides information on the probable type and frequency of failures, and indicates how the system should be designed and maintained for optimal reliability. Reliability (R) is defined as that portion of time a system is functional. Unreliability (UR) is defined as (1 - R). Reliability is determined using the total time of operation (Total Period), mean time between failures (MTBF), and mean time to repair (MTTR). A district heating system depends on a number of components to provide heat to the user. The total unreliability of the system is the sum of the unreliabilities of these components. For example, if a pipe had an MTBF (mean time between failure) of 8,760 hours, and an MTTR (mean time to repair) of 8.77 hours, the reliability would be 1-(8.76/8760) = 1-0.001 = 0.999. This means that the pipe will be operating 99.9% of the time. If there were a heat exchanger that could also fail, and it had the same reliability as the pipe, the reliability of the combined items would be 1 - (8.76 + 8.76) / 8760 = 1 - 0.002 = 0.998. This means that both the pipe and the heat exchanger would be operating 99.8% of the time and unable to deliver heat for 0.2% of the time. The system would then be out of service 0.002 x (8760 hours / year) = 17.52 hours per year. Equipment with moving parts, such as pumps, are generally less reliable than static equipment, such as pipes. It is typical practice to install two pumps for this reason, with the second acting as a stand-by. The following illustrates how reliability is calculated for a system with two or more components of which either can perform the task. The system must be such that more than one piece of equipment can perform the same function, and failure of each piece of equipment is independent, that is, it does not affect the performance of other equipment. Two circulating pumps, each capable of pumping all the necessary fluid, is a common situation that will be used as an example. Assume that one of these pumps will fail once per year and polarconsult Kivalina District Heat will require an entire day to repair. The system will be unable to deliver heat if both units are unable to pump. Assuming both pumps fail at the same time, system unreliability would be only 0.07 hours per year, as compared to 24 hours per year with a single pump installed. Expressed in percentage of the year not serviceable, the value is 0.000751% for the two-pump system. The preceding example, comparing the failure rate of one versus two pumps, illustrates how important and powerful it is to provide redundant equipment for failure-prone items. This is economically feasible only where the costs of duplication are not great. All reliability analysis has limitations. The limitations of this study are as follows: First, it is based on historical data acquired from military, nuclear, and electrical industries, and is limited to the equipment used and the specific application conditions. Because the equipment and conditions will be different for this project, the outcome will be different. Second, the analysis is based on average conditions, and it is probable that for each individual system there will be a greater or lesser number of failures than predicted. Third, actual failure rates for a large number of plants will be closer to the calculated values, on average, than results from a smaller number of plants. Although the values derived by mathematical failure analysis for these systems cannot be exact for the individual installation, because the results are average values, they do provide important information. First, performing the analysis requires that designer and builder determine what causes system failures and take measures to avoid them. Second, the analysis provides the basis to determine which functions need emphasis during maintenance programs. Third, some degree of scale is provided on how failure affects project income. f Di A description of major system components, their failure modes, and impacts of failure on the system is presented below. The description starts at the power plant and works toward the served structure(s). 33 polarconsult Kivalina District Heat 1. Power Plant a. Components Engines: The engines are the source of heat; if they are not running, heat is not available to be delivered. Most AVEC plants have three engines, Kivalina has four. In general, the plants are operated so that a single engine can serve the entire community. The reported average down time for AVEC generation systems during 1989 was a total of 33 hours per year at each plant. This quantity was from 12 hours forced outage of generators, 3 hours power line outages caused by storms, 8 hours planned maintenance outages, and 9 hours all other outages. Based on these values, the system will not generate heat 0.377% of the time. Cooling system: The power plant cooling system associated with the district heating system requires connecting the engines to a common manifold which, in turn, connects to the primary heat exchanger and two or more radiators. As radiators are unreliable components, four will be used at Kivalina to reduce failure probabilities. The primary generation system failure modes are: 1. Failure or shutdown of the engines; 2. Failure of the radiators due to leakage; 3. Failure of the hoses, valves and piping system; 4. Failure of the engine block itself, and 5. Failure of the heat exchanger, piping, and valves associated with the engine. Generation plant: Full failure of the generation plant, due to shut down, will stop heat production and disable the district heating system. AVEC reports that these occurrences average 33 hours per year, out of the 8,760 hours in a year. Radiator failure: Radiators usually fail by coolant leakage from cracks which are caused by rapid and extreme temperature changes. Usually radiator failures do not result in total plant shut-down but do require isolating the leaking radiator and running the system off the standby. If a radiator or engine connection hose breaks it can drain glycol coolant at 34 polarconsult Kivalina District Heat a rapid rate, requiring plant shut-down. Controls are installed to shut down the plant in the event that coolant levels fall to a dangerous level. Alarms are installed to alert the operator prior to automatic shut-down. This allows the operator to isolate the leak, repair it, by-pass the leak, add additional glycol, or shut down the plant, as appropriate. The primary environmental problem associated with engine radiator failure is discharge of glycol onto the ground. Impacts on the environment from glycol leakage include thawing of permafrost, glycol contamination of groundwater, and glycol contamination of adjacent surface water bodies. Leaked glycol is difficult to recover because volumes are small, the terrain is usually rough, glycol mixes with water and ice, and it will disperse rapidly in water unless it is confined to a catchment basin. The above analysis applies to the existing system and the proposed district heating system upgrade. The only changes will be an increased potential volume of lost glycol, a slightly less reliable system as all equipment is connected to a single cooling system manifold, and a slight decrease in reliability caused by the addition of a heat exchanger. Engine heat exchanger: This component is composed of a series of formed stainless steel plates which are separated and sealed by rubber gaskets. The plates are bolted together within a steel frame to compress the gaskets and hold the plates together. The heat exchanger is used to transfer heat from the engine cooling fluid to the fluid circulated in the distribution pipes supplying the user's heat exchanger. The engine heat exchanger thus serves to isolate the power plant from the distribution system. This isolation means that failures in the distribution piping or at the user facility will not affect the power generation system. Failure modes of the engine heat exchanger are: 1. Blown or leaking gaskets; 2. Broken frame; 35 polarconsult Kivalina District Heat Valve failure and stem leaks; Cracking or corrosion of plates; Connecting piping system failure; Fouling; 2 oP Freezing while generation system is down, if water is used as coolant instead of glycol, and 8. Structural damage to exchanger supports due to fire or other events. Generation plant operational impact: i A large, sudden loss of coolant on the engine, or primary, side of the heat exchanger will shut down the engines. A slower leak on the primary side can shut down the plant as a result of low coolant levels in the engines. If found in time, the failed exchanger can be isolated with valves. It is unlikely that valves will not work during a heat exchanger failure. District heating system operational impact: 1: Small leak: Operation of system will continue. According to maintenance procedures the bolts will need to be tightened, valve packings tightened, new glycol added to the coolant system, and spilled glycol recovered. Large leak: If on the primary side and if too much fluid is lost before the shut-off valves can be closed, the engines will shut down under low water level control. If on the secondary side: Without fluid, the district heating system will be out of operation until repaired. Pipeline will be drained of fluid and operator will notify main maintenance office. Environmental Impact: Glycol spilled on the ground is the environmental impact of an exchanger failure. Glycol can escape into the ground, thawing permafrost which can weaken structural supports, and enter groundwater 36 polarconsult a. b. Cc. Kivalina District Heat and surface water bodies. Required immediate actions: Determine cause of failure, isolate heat exchanger at valves or add additional glycol as required by procedures. Catch dripping glycol in pans and recover spilled glycol. Call maintenance office if extra help is required. Components: Transmission pipe will be mostly 2 inch diameter insulated pipe. Each pipe will be made up of a steel carrier pipe 2.374 inches in diameter with a 0.114 inch thick wall. The carrier pipe will be covered with high density urethane foam. Encapsulated in the foam will be two tin plate copper wires. These wires will provide a method to determine if water or glycol has leaked into the insulation. Covering the insulation will be a high molecular weight polyethylene jacket with an outside diameter of 5.51 inches. The pipe will run from the district heating module, which houses only the heat exchanger, 560 feet to the School. The pipe will be buried about 2 feet in the ground. Failure modes of the district heating transmission system are: 1. External or internal corrosion of the carrier pipe; 2. Mechanical damage to the pipe from equipment or digging into the pipe; 3. Failure of the pipe; Failure of pipe welds; and 5. Mechanical failure caused by frost heave or thaw settlement. Generation plant operational impact: None d. District heating operational impact: 1. No operational impact from minor leaks in jacket or pipe which are detected and corrected by the maintenance crew during routine inspections. Si polarconsult Kivalina District Heat 2. Larger leaks which cause a measurable loss of glycol will require shutdown of the line with isolation valves, and pipe repair to put system back on line. Environmental impact: Glycol spilled on the ground is the environmental impact of a pipeline failure. Glycol can escape into the ground, thawing permafrost and weakening building supports, and also enter groundwater and drain into surface water bodies. Required immediate actions: Determine cause of failure, isolate pipeline at valves or add additional glycol as required by procedures. Catch dripping glycol in pans and recover spilled glycol. Call maintenance office if extra help is required. User Connection Components: This system is comprised of a heat exchanger similar to the one at the power plant, two circulation pumps, an expansion tank, provisions for adding glycol coolant, a btu meter, piping, and valves. Failure modes of the heat exchanger are: Blown or leaking gaskets; Broken frame; Valve failure and stem leaks; Cracking or corrosion of the plates; Connecting piping system failure; Fouling; Oe Se Freezing while generation system is down, if water is used as coolant instead of glycol; and 8. Structural damage to the exchanger supports due to fire or other events. Failure modes of the pumps are: 1. Failure of electrical circuit; polarconsult Kivalina District Heat Seal failure; Motor failure; Impeller cavitation; Pump body failure; and Das ews Connection leakage. Failure modes of the expansion tank are: 1. Water logging or bladder failure; 2. Corrosion; and 3. Broken sight glass. Failure modes of the piping system are: 1. Leakage of valve stems; 2. Failure of valves to open or close; 3. Failures due to corrosion; and 4. Failures due to materials or installation defects. Failure modes of the school are: 1. Failure of the school system to hold fluid; and 2. Failure of the school's circulation pumps. Generator operational impact: Failure of the above items will not affect the generation plant. District heating system operational impact: Heat exchanger: As described for the power plant, minor leaks from the heat exchanger will be corrected by catching and returning leaking glycol, tightening bolts, and scheduling the unit for gasket replacement. Major leaks of the heat exchanger will require the system to be isolated with the valves until it is repaired. Pumps: If a pump fails the system will be off until the failure is detected and the standby pump is put into service. If two pumps fail the system will be down until one can be repaired. Expansion tank: An expansion tank failure could be caused by the sight 39) polarconsult Kivalina District Heat gage breaking, which will require system shut down until it is repaired. Corrosion is not a likely form of failure for an ASME 125 psi rated tank. Piping: Failure of the piping will generally occur at valve stems and where there are gaskets or joints. Slow leaks from these causes and from corrosion will not require shutting the system down. Shut-down of the system could be caused by a valve stem being twisted off or by a broken casting; repairs will be required before the system is returned to operation. Environmental Impact: The environmental impact will relate to glycol spillage. A large, rapid leak might enter the ground, where it could lead to thawing and structural failure. There is potential for groundwater and surface contamination. Small leaks are likely to stay in the building, but will require immediate and complete cleanup. Required Immediate Actions: For a slow leak, pans will be placed to catch leaking glycol, packings and joints will be tightened if appropriate, and fluid replaced. For a large leak, isolation valves will be closed to reduce loss of fluid. Repairs and replacements will be made, or maintenance crew notified, as required by procedures. For a pump failure, the failed pump's valves will be closed, the standby pump's valves opened, and the motor energized. If both pumps fail, one or both will require repairs. If an expansion tank fails, the tank will require recharging or repairs. For extensive repairs or replacement the maintenance crew must be notified. C. Failure Frequency and Cost The most common modes of failure are listed below, along with the associated frequency of occurrence, repair cost per occurrence, amount of down time, and a description of the effects on system life. Failure rates are calculated using the method shown in the Introduction. It should be noted that maintenance of certain items will require that the system be removed from service. This maintenance can be scheduled during a period when the power plant is out of service or when 40 polarconsult Kivalina District Heat the user building does not require heat. For a school this would be in the summer. Therefore, the potential effects of loss of energy sales during routine maintenance are not included in the calculations. AVEC generation: The most common form of failure is engine failure. Frequency is variable but outage time is estimated at 33 hours per year. Repair cost to system is $0 as it is not related to district heating system. Heat exchanger at power plant: The most common form of failure is failure of seals. Frequency of occurrence is 10.6 years. Down time is 72 hours, repair cost is $2,000. There will be no measurable effects on system life from repairs. District heating pipe: The most common form of failure is from poor installation. Frequency of occurrence is 9.5 years. Down time is 48 hours, repair cost is $2,000. There are no measurable effects on system life from repairs. User connection at school: The most common form of failure is the heat exchanger. Frequency of system failure is estimated to be 4.3 years. Down time ranges from 24 to 72 hours depending on which item fails. Repair cost is $2,000. There will be no measurable effects on system life from repairs. Total system: Failure frequency of the total district heating recovery system is summarized in the following table. Item Failure Rate Heat recovery at power plant 0.000507 Transmission pipe to school 0.000869 School heating assembly 0.000747 Total 0.002123 Average outage rate 18.6 hours/yr A portion of the annual 33 hours of generation plant outage should be added to this. The proper number should be 25 hours per year (33 total hours minus the 8 hours of scheduled outage which occur during the summer.) The 25 41 polarconsult Kivalina District Heat hours would be distributed randomly. The total time the system would be unable to deliver heat would be about 43.6 hours per year, which is 0.50% of the time. D. Design Decisions Made to Minimize Failure Rate and Impacts Some of the design decisions that will be made to assure long life and reliability are the selection of corrosion resistant materials, the use of duplex pumps, and the use of isolation valves so a failure on one leg will not necessarily shut down the entire project. Where possible, flanges will be used for valves and all interior plant pipe will be welded to improve system reliability. Items which the reliability analysis shows are of critical importance will be duplicated if economically feasible. All connections to the district heating system are separated from the power plant by isolation valves and a heat exchanger to minimize the consequences of a failure. User building heat will not be interrupted by a failure of the main district heating system, or by the failure of another user's system. The design includes the use of "Arctic" pipe which includes a steel carrier pipe butt-welded together and from 1 to 2 inches of insulation covered with a non- corrosive jacket. Two tin-plated copper wires are carried in the insulation to indicate the presence of moisture as an alarm. These alarm wires are read by a $1,500 alarm device which can connect to as many as four individual pipe loops. These devices allow for failures to be detected before they have time to become a major problem. They also minimize the time required to locate the failure and reduce excavation costs. At this time we know of no failures of this piping system in Alaska. polarconsult Kivalina District Heat VII. Project Specifications A. Codes and Regulations The listed versions of the following codes and regulations were used in the preparation of this report: © Uniform Building Code (1988) o Uniform Mechanical Code (1988) o Uniform Plumbing Code (1988) o Uniform Fire Code (1988) o National Electric Safety Code (1987) B. DIVISI 1- ral i This is a general information section covering the coordination of work, description of the work required for this project, regulatory requirements, definitions, payment procedure, submittals, quality control, materials and equipment, starting, testing, contract closeout and maintenance. C. DIVISION 02 - Sitework SECTION 02700 - PIPED UTILITIES A. This section covers specific requirements, products and methods of execution relating to the water distribution system for the project. The interior piping is specified elsewhere. B. Distribution will be buried "Arctic" pipe with a steel carrier pipe, polyurethane insulation and a High Density Polyethylene Jacket. The pipe shall be ILC. Moller Plus pipe, or equal and approved. 43 polarconsult Kivalina District Heat D. DIVISION 13 - Special Construction SECTION 13120 - Pre-Engineered Structures A. This section includes specific requirements, products and methods of construction relating to the district heating module for the project. The structure will be cantilevered off the side of the existing power plant module's frame. B. District Heating Module will be of steel frame construction insulated with rigid insulation, metal siding on exterior and plywood on the interior. 44 polarconsult Kivalina District Heat E. ISION 15 - ical i ificati SECTION 15010 - GENERAL PROVISIONS This is a general information section correlating mechanical work to other divisions of the specifications, defining terms, referencing codes and standards, itemizing submittal requirements, and defining submittals and information required for operation and maintenance manuals. SECTION 15050 - BASIC MATERIALS AND METHODS A. This section includes a description of specific requirements, products, and methods of execution which are typical throughout the mechanical work for this project. Additional requirements for the specific systems will be found in the sections specifying those systems, and supersede other requirements. Piping inside the buildings shall be type L hard copper or black sch. 40. Steel piping shall be welded and flanged. Valves shall be 150 psig. butterfly or gate for isolation, plug type for balancing. SECTION 15160 - NOISE AND VIBRATION CONTROL A. This section lists specific requirements, products, and methods of execution which relate to the isolation of all mechanical systems for limitation of transmission of vibration and sound to acceptable levels. All connections to engines and radiators, and between the power plant and the district heating module, shall be stainless steel flexible type. SECTION 15180 - INSULATION A. This section describes specific requirements, products, and methods of execution which relate to the insulation of ducts, pipes, and other surfaces of the mechanical installation. 45 polarconsult Kivalina District Heat B. Insulation is provided for the following purposes: Energy conservation; Control of condensation; and Safety of operating personnel. Piping inside the power plant shall be uninsulated. Piping inside the district heating module and user buildings shall be insulated 1" thick rigid F/G, with all-service jacket. SECTION 15191 - OUTSIDE TRENCH EXCAVATION, BACKFILL, COMPACTION This section describes general requirements, products, and methods of execution relating to excavation, backfill, and compaction of utility trenches outside of buildings. SECTION 15600 - HEAT GENERATION A. This is a description of specific requirements, products, and methods of execution for interrelated systems, necessary for the generation of heat which will be distributed to the locations shown. The method of distribution of this heat is specified elsewhere. B. Heat generation (transfer) will be accomplished with stainless steel plate heat exchangers, as manufactured by Tranter, or equal and approved. Primary heat exchangers will be located in the district heating module and will interface with the power plant. Secondary heat exchangers will be located in the user facility and will interface with the user's heating system. SECTION 15650 - COOLING SYSTEMS A. This section describes specific requirements, products, and methods of execution relating to the cooling systems for the project. The work of this section includes provision of systems and equipment for removal and transfer of excess heat from the locations shown, including the furnishing 46 polarconsult Kivalina District Heat of interface apparatus and controls and the connection at interfaces with other mechanical systems. B. Generator cooling systems will consist of Young horizontal radiators, size 22, controlled by Volkman variable speed controllers. SECTION 15850 - BALANCING AND TESTING This section covers general requirements and methods of execution relating to the testing and balancing of the mechanical systems provided on this project. SECTION 15900 - CONTROLS AND INSTRUMENTATION This section describes specific requirements, products, and methods of execution relating to the system of temperature controls and instrumentation for the project. 47 polarconsult Kivalina District Heat F. DIVISION 16 - Electrical Outline Specificati SECTION 16010 - GENERAL PROVISIONS This is a general information section correlating electrical work with other divisions of the specifications, defining terms and indexing the various Division 16 sections, referencing codes and differences from Division 01 requirements, and defining submittals and information required for operation and maintenance manuals. SECTION 16031 - DEMONSTRATION OF ELECTRICAL SYSTEMS This section includes procedures to be used during final inspection, instruction of operating personnel, and a certificate of completion for the convenience of the Contractor and Owner to determine whether each item has been completed. SECTION 16040 - IDENTIFICATION This section covers labels and name plates for equipment, branch circuit panel board directories, and other identification needed for electrical equipment. SECTION 16050 - BASIC MATERIALS AND METHODS A. A major part of the electrical specification, this section covers the workmanship, coordination, and standards necessary for the electrical work. The products covered include raceways, conductors, and connectors. Installation techniques to cover various construction methods are noted so that fireproofing is maintained, water penetration and moisture migration through raceway systems are prevented, and the proper connectors are used for various conductor terminations and splices. B. Only copper wires and cables shall be used. Raceways shall be rigid galvanized, sherardized steel conduit or electrical metallic tubing with compression or set screw type fittings, for all conduits concealed in the walls, above the ceilings or exposed in work areas. 48 polarconsult Kivalina District Heat SECTION 16130 - BOXES, CABINETS, AND PANEL BOARDS A. This is a general section that outlines various standards to follow in the construction of these items, with specific notation on certain types of cabinets to suit various systems. Mounting heights for outlets and cabinets are covered in this section. B. Panel boards shall have copper busing with bolt-on type circuit breakers. SECTION 16140 - WIRING DEVICES A. Receptacles, switches, device plates, and special purpose outlets are covered in this section. B. All outlet devices shall be specification grade or better. SECTION 16150 - MOTORS AND CONNECTIONS Motor specifications regarding voltage, phase, and temperature rise are covered in this section. Distinctions between which motors and control items are included in Divisions 15 vs. contract or responsibilities are also shown. Appliance and miscellaneous equipment connections, whether owner- furnished or contractor-furnished, are covered to provide suitable connection techniques. SECTION 16160 - MOTOR STARTERS AND DISCONNECTS Specific requirements for overload and phase failure protection to be included in motor starters are covered. Also included is a listing of various devices suitable for use as equipment disconnects. SECTION 16180 - OVERCURRENT PROTECTIVE DEVICES This section contains a general listing of various devices suitable for overcurrent protection, such as circuit breakers, fuses, and current limiters. 49 polarconsult Kivalina District Heat SECTION 16190 - SUPPORTING DEVICES This section covers, in a general way, the various supporting, fastening, hanging, and securing techniques approved for use by the contractor in the installation of the electrical work. SECTION 16450 - GROUNDING This section itemizes complete grounding requirements and techniques for connections. SECTION 16480 - BRANCH AND FEEDER CIRCUITS This section clarifies drawing preparation technique as being diagrammatic rather than "as-built" and gives the contractor flexibility in conduit routing and circuiting, as may be determined by job site conditions. SECTION 16500 - LIGHTING A. Light fixture construction for both interior and exterior fixtures, lamps, and ballasts are covered in this section. B. Interior light fixtures shall be fluorescent, of industrial design. Exterior fixtures shall be high pressure sodium wall packs controlled by photocell. 50 polarconsult Kivalina District Heat VII. Project Cost Estimate A. Power Plant Heat Recovery System The first cost component is the construction of the building to house the district heating system. This includes the mechanical and electrical equipment inside the module and the connection to the modified AVEC power plant as shown in Figure V-3 on page 26. The second cost component is the modification of the existing power plant system. This includes the installation of new remote radiators connected to Units #1, #2 and #3, as shown in Figure V-3 on page 26. B. District Heating Distribution System The connection of the school to the district heating system includes installation of piping from the face of the district heating module to the school, and all equipment and connections within the school, as shown in Figure V-4 on page 27. The cost of building the new mezzanine for the user equipment is included. The connection of the old and new community buildings to the district heating system includes installation of the piping from the face of the district heating module to the two buildings, and all equipment and connections within the mechanical rooms as shown in Figures V-5 & V-6 on pages 28 & 29. The connection of the water treatment plant and the clinic to the district heating system includes installation of the piping from the face of the district heating module to the water treatment plant and clinic, construction of a new addition to both buildings to house the district heating equipment, and all equipment and connections within the mechanical rooms as shown in Figures V-7 & V-8 on pages 30 & 31. C. Operation and Maintenance Costs Annual operation and maintenance costs are determined by the regular system maintenance required as well as the number of failures. Regular maintenance will be performed three times per year by a skilled maintenance crew. Day to day polarconsult Kivalina District Heat operation will be by a local person who will monitor the system and notify the maintenance department of any failures or problems. Repair of these failures will result in an additional 0.5 trips per year to Kivalina by a skilled repairman. With a cost of $2,000 per incidents the result is an average cost of $1,000 per year to repair failures. Cost of the three annual maintenance trips must be added to this failure repair cost to arrive at the total annual operation and maintenance cost. D. Project Cost Summary Total project costs for the three alternative concepts are shown below. Table VII-A Summary of Alternative Project Costs Concept 1 2 3 School Old Comm & Clinic & New Comm Water! Module Construction $75,403 $68,047 $69,000 Plant Piping Revisions $95,779 $87,862 $89,267 School Connection $220,587 $202,459 $204,920 Old & New Comm. Bldg's. $0 $134,980 $0 Water Treatment & Clinic $0 $0 $114,625 Total Project Cost $391,769 $493,428 $477,811 1 Includes connection of the School. Total project cost includes design, supervision, inspection, administration and construction. The complete cost estimate is included in Appendix C of this report. polarconsult IX. Conclusions A. Heat Availability & Fuel C : There are presently over 25,500 gallons of equivalent fuel oil per year available as waste heat at the Kivalina power plant. The district heating system can displace Kivalina District Heat the following amounts of the proposed user heat requirements: Table IX-A Annual Heating Fuel Displacement & Pipeline Heat Losses Concept 1 8 User School Comm Bldgs! Water & Clinic! Heat Available off Engines 25,567 25,567 25,567 Annual Heat Loss in Dist. Pipes 2,204 2,743 3,069 Heat Available to User's 23,363 22,824 22,498 Bldg. Heating Fuel Required 25,000 27,088 26,922 Amount of Fuel Displaced by District Heating System! 18,583 18,672 18,533 Percent of Available Heat Used 79.5% 81.8% 82.4% 1 Includes the school. During the winter months the school would use all of the heat available, as can be seen in Figure IX-1 on the next page. Heat lost from an additional distribution pipe, to the water treatment building, for example, would reduce the total available useful heat. This would make the water treatment building a net loss to the system in the winter, if included, as the distribution line would remain heated but would provide no heat to the water treatment building during the winter. Heat is displaced at the water treatment building during 6 months of the year. 53 polarconsult Kivalina District Heat 4000 g Heat (Gallons of Oil) : 1000 y Vhs 0 LBS AA MAAS SSO Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Month Blcinic+ PHS WCAcomm.Bidg. LZ school —a- Heat Available Figure [X-1, Heat Available vs Heat Required 3 FERS q etatatetetetatatetetaterecerececece, 4 PRR RK KKK ‘S PSO KR KKK 4 ° BOSSI F 4 BD 1500 LBS KKK RRRRKS 4 s RRR K KK KSI XK RRRRKK 4 ° RRKRRKRE KKH BRREKRKRKS = PKR RK KKK ERR RRS GI Bese OL PRN q PSR RRR KKK SRS oO PRKRRKKR KK KSI BXKKRKKKR EEK 4 PRR RK KKK ERRORS 4 3 PSR KR KK Ke fESEEEERRrre § 1000 PSR RRR RK BSR RIND 4 2 PSSSOSIRRRRKRKKEKY BERR RRRRRRRROKK KKK g POSSE FERRO RRR = Pee R KR KKK VT ERR RRRER KR KR KKK KK 3 Bese RRR KR KKH BRR RRR RRR RK KKM PRK RK RKC SOR R RRR RR KR KN o BEKO B55 PRK KR KR KKH RRR RRR KR KKK] BeOS KKK SRR RR RRR KKK KKM POSER KKK SORKIN | S00 LBeSeeeeseeooR ERK Kove RRR RRR RK KR KKK KM PRR RRR KK KG ERR RRR RRR KKK] Bee RRR KKH BRR RRR RRR RRR RK KI RSS SSSR RR KKK KKH OK RRR RRR KKK KKK BRR RK ONY RRR RRR RRR RK KR KK RSS RR KKK KKH Ho ESR RRR RN RN | BRR K KKK HH BRR RRR RRR KKK KY PORK KR KKH HY RRR RRRKRR KKK RK KKK KKK KKK Morecacevenecacececenenececececeetstsee esse «| ESSER oroovrvorevo SRRKKKK KKK oe papperreoreororereee HTT NY 0 LLL CF Jan Feb March April May June July Aug Sept Oct Nov Dec Jan Month of the Year Re ini LC] Z School + Clinic + Water Plant School Lia School + Comm. Bldgs. Figure IX-2, Gallons of Heating Oil Displaced 54 polarconsult Kivalina District Heat B. Project Cost Summary The school paid $1.10 per gallon, and the city paid $1.75 per gallons for heating fuel during 1989. The annual savings is computed using these costs for heating fuel. The three concepts are summarized in the following table. Table IX-B Project Summary Concept 1 2 3 User School Comm Bldgs! Water T B! Amount of Fuel Saved 18,583 18,672 18,533 Annual Savings $20,441 $20,490 $20,386 Total Project Cost $391,769 $493,428 $477,811 Straight Pay Back (yrs) 19.2 24.1 23.4 1 Includes the school connection. C. Project Summary The life of a district heating project is a function of availability of waste heat off the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance. The requirement for electricity and the need for space heat in the community imply an infinite project life. With proper maintenance the life of the district heating system will exceed 25 years. Because annual operational and maintenance costs and economic decisions will be made by AEA, final economic conclusions are not presented in this report. The straight payback time for the best alternative, the school-complex, Concept 1, is 19 years. Do) polarconsult Kivalina District Heat X. Recommendations One way to make the project more economically attractive is to reduce its scale by minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Northwest Alaska communities to reduce Kivalina's share of the high mobilization, shipping, travel, and supervision costs required. 56 polarconsult Kivalina District Heat APPENDIX A Calculations polarconsult Kivalina District Heat Power Plant Heat The amount of heat required to keep the power plant building at 65°F was calculated. The number of air changes in the building was assumed to be equal to the amount of combustion air required by the engines plus 2. This added up to 10.4 air changes per hour in the Kivalina power plant. The conduction heat loss was then added to the infiltration heat loss and the amount of heat rejected to the ambient air off the engine subtracted to come up with the hourly heat requirements for the building. Users Monthly Fuel Oil Usage The annual fuel oil usage, as obtained from the users, was distributed over 12 months using the number of heating degree days (HDD) as follows: (Monthly HDD) x (Annual Fuel Consumption) Monthly fuel oilusage = See ( Annual HDD ) Water treatment plant (Monthly HDD) x (Annual Fuel Cons. - 12 x 30) Monthly fuel oil usage = 30 +: ----------------------------- = ( Annual HDD ) r Disp] The amount of waste heat available at the power plant and the amount of heat required by the users were calculated using a computer model with the following input and assumptions: 1. Historical monthly power generation data for the power plant, annual users’ heating oil consumption, and monthly heating degree days were input. 2. The amount of heat available off the engines versus power production, from the engine manufacturer's data, was input. 3. The heat losses for the proposed piping system, plant heat, etc. were input. 4. The hourly diurnal power generation variation per month and the hourly diurnal heating requirements were input to distribute the power and heat data over a one- year period in the model. 5. The amount of heat usable by the proposed users is summed up for each month to determine the equivalent number of gallons of oil which will be displaced by the district heating system each year. Appendix A Page 1 polarconsult Kivalina District Heat Program Notes: a. The amount of heat available off the engines listed in Table III-B is from the engine manufacturers engine specs. The amount of heat available off the engines used in Appendix A comes from the engine manufacturers test data which they indicated was good to +/,.5%. We used 95% of their test data values for use in Appendix A as the heat available off the engines. Appendix A Page 2 Kivalina 04/23/90 09:32 AM 1,800 RPM 1 School GENERATOR DATA: Cummins LTA 10, Concept Kivalina Apr-90 WASTE HEAT UTILIZATION SIMULATION WORK SHEET Location Date 1 “! a1 4100 41 @0000 at BICoo BIO 1 Siena Sia | SESESSSES58 gi sc giz = S555 Sse 1 as is | SESEESEEEE cel ISS ' ! lmmmmmmmom momo 20 | MOPEMTONArOnNRaDMnoM@aAnNOd v1 awo v 120000 (ite ito oto ote 2 MMMAOVOTGI STC ITT STOTT B1MCO O1@ PRENSA S SSS Aldo! alan als I DDDDDDDDDDD 1 | ors i PERS Reb Rebbe 1 1 as io | amaaaaaaama ! 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S555555555500555 Bios ates a 2 Zico OCCCCCC0CC0C000 21 da BE ie fay C ay 5 ot 1 3 1 HX 3 1 1 Poe a 0 Ql OorerMTonaranNnroanmnomawannd Ql@4Q AaAlnocco 1 sus gun <0 LB DLAMMMMNMGI TTT STG ST SOOT TS OINDO DOIS | ses Sse Oo Bf 1GO0G99058555586555500900 BIO Om Im y << Cha aC CCNA aC Ra NCCT a CC CDE) oe 2 1 33535 3355 <a Bb = 1GBGdd0dddc0GC00000000000 1 ao wi im 1 DODD DoD e 1 “Se 06 | maaan mama 5! ! a | | oncom ovo a RM Fl OwTEMTENAr@rNNeanvmmadNS dOoOm Eldado Ee1m0c0o 1 ORCm haw e BL MMMMOMOGI TT STITT TSO TTS on SIMD OGIO 1 4a a I BB 1SOSGSGSSS5SS5S5585005686 og Brae Aw too a a = 1o0d000c0000000C0000000000 0 1 ao @ IM i oan ° oUt nN 1 “eo oo 5 | ce FO wl i | todas 8 o a6 3} 8 lL damsncrancdamsnenancndams 1 1 Boy eo BS 31 SAA AANA 1 lo stge tha z= ~ ol 1 | baog Ado Ss a =I 1 aves 1 1 € cy Brio 20 9 1 we tee i>as 1 4000 ADA =a > vot tas 1 eas 1 «8 | BONE De Sz 7 oa ot a tans tossed 1 G0 ‘Ow a Qo ow pl ge i 1 Be “O @co Ed |AmomondassrsNTmmmmmmanson 4§ Md e1 0 aie HO, “OD “ ~ Eg lmmnnmnnsvessereuveTTTTTSO OOF Aladd0n Glavsca vague < o ABB 1GOGG00655555565565665655 2 sah BI o0040 Klocoda owed a oy 4 Did} etter eset eee reese sees & fdo Ao” ec Aloggoy aynad gs < 3 EDA l|CocccCCCCCCSCSCSSssssCsS OS 4O4 Hicusdu latseo us4g rard ag hot 4 gon BIOdO46 1 OmnEE Ona 6 < & Bat 6 0 ainozos aid a Ze a aa ant 4 8 8 oO! oa - | BS lnmmmoadmeserinwmmmmmamanon ds Ale o a vo ge yo Sulmmmmnnsssssessssssrsssssm Oud te a ee Za of B” B1GOG0G0S5SS5S5555SS5S5560 rOaGE Z18 a ga 45 Soon 4 DU | crete tet e tee tet eet tte ete esos 1D GI = a OOnO FB EEE ICCCOSSSSSSSGSSSSGSSSSSGSCG 1b Ou0 Blo a wey act Ba Sant OHarD alg 4 Ze Ho OsAG oest SOGCE 10 s aig DS dois 3 aot 09906 aro > o= aa ozus a aa i LHAZO 24,998 PAGE 1 OF 3 0 684 1,171 2,310 2,998 3,484 0 Total Use ~—-3,508 3,347 3,136 2,601 +41,760. 0 0 684 1,171 2,310 2,998 3,484 24,998 Total Use Kivalina 1 School Concept WASTE HEAT UTILIZATION SIMULATION WORK SHEET Annual WN ~(~ O~ DINNO™OVOMHIMNDODodG ID OON ONIN AAA ANHODONATEH INANANANANNNNNN NNN AMANO Dec 228 FIOM AOWNMNAN AMMAN ONAN PS LOLD PND TT OO DDAK~NAAMOM INANNANNNNNNNNNNNNNNNNNN Nov 291 CWPAMMBOTOATNOAODOADOANAAM FONT COCO TNDOM AR RMR TAAAM v o ° INNANNNNNNN NNN NNN MOON ANN Od TH HANTANINNO DOTS OTFODOGDADOTOOTAAAM INANANNNNNANNNNN NANA NAN Sept 249 MA AODONAMOOMLE EE TOOrOMaaN DONA DANDAMIMMANMADDON AAA ANN ANNAN NNN NNN ted Aug 210 WOT COrOGONOOMDrODBOOON SANAMM POR TOADAAAO- AON AAAI tet July 168 TFN OOWM POM TAI AAO AONAAD MMMM GTN ODNAOAOOR DOM NNN] aA tet June 178 ONIN OBOCHDOCTHTTMATORE SAHOONNTROTANTOMLOMK TSO INNANANNNNNNNNNNNNNNANN 275 May AOU TTONOMONNOHNOrLANT OTIOTH MMO CONOR RENTER AND INANNNNNNNNNNNNNNNNNNNNN 277 April I COnOTODNONONOONNNT HOW FOONGATIODOOOODDMOANNAATOM INNANNNNNNANNNNNNNNNNNN March 294 ONAMANOOMAMANANAOrAAMAO JAW MOGOHOAODAOCODOOMMMNAT INANANANANANMNANAMMANNNANNN Feb 232 OMANMNCOON shan ssADrOONNH AMAADANDDANTOAANAMOOHN-OwW AANNANANANAMMMAMMMMMANANNMN per hour by month (1,000 BTU’s) Jan ANMTNOrDACHAMTNwWROAOKGAMS AAA AAA ANNAN Hour Heat available 23,363 2,113 2,160 2,107 2,161 1,302 1,627 1,332 7004 2 2,031 7199 987 2 (1,000 BTU’s) i, 7341 tei 182,761 202,279 186,794 184,367 122,489 119,715 149,629 194,367 198,655 193,757 198,813 2,148,945 Gallons Heat demand by hour by month BTU’s Month Annual WNNONAMWMOd TEN dd TOdKMOTT HNN QDANADAONTNNNNHOHS TTT TIMMS TMNT TESTES Dec C9 AW A DO AF OOMINDMODONOMAD WN FIN NOCCOGOANAAHAANDOOOS MMMM MMM TIPE IIMMMMMMAMOMM Nov 360 MAM AONTAGAMOANE MMR NANA WON OGODAHOCCOAAADAAANDO-O INNANNNNNAMMANNNNNNNNNNN Oct 269 OLN NON - DOKHOM PNM TIO MMMM MTU ININININ BININININININININA a AAA ett Sept 141 DMO AMDOANOOOOroornndd I~ KKK DDDDDAADDDODDMDDHO Aug 80 eccceccoCCCCCCCCCCOCCCOCCO July eccoceoeoeoCCCCCCCCCCCCCO June MOADOAMNCGDAADIMONOMBOINADAN DOAAAGAAANAAMMANAAANNGHOO ANAAANNNNNNNNNNNNNNNNN May WU MIN ADDNDOONWOMNOMNMINMOM JOONCON TTHNHMMN TTT TTT AMAMAMMAMMMMMAMMMAMMMMMAM 313 April MAN AAMOVAADGNWOOMMEMMOT@AMIN IN FINODOCCOHHOCONOOCODArO MMMM OS PGI T TSIM TSIM March 365 INONOMALCAMMBOAMCOLOOMAAAH NAAN ODDARE RRR ons Teves rTeTeserrese TES Feb 431 DOOL OAT MOTTO TIO TO DANO NO NNN GON BN TON IMM AO OOP PAG G AGG TTT Jan 408 400 ANN TNO ONOGAMNTNCrANnOKAMS FAA AAA AAA ANNAN Hour O 62,883 107,714 212,469 275,796 320,480 2,299,582 0 jemand 322,699 307,903 288,520 239,250 161,867 0 0 62,883 107,714 212,469 275,196 320,480 2,299,582 Total Demand May June July Aug Sept Oct Nov Dec Annual April month (1,000 BTU’s) Feb ~ March yy hour by Jan Heat delivered b Hour Heat Delivered ONK-D-ONNoMOwornrIMAwDVMoOvdG NOOONHOANNNAAAK-ANHOOOANTH ST NAAANNANNANNNNANNNM NNN IO HOON ANANNAAAA ION FLOW TN OVI TOMO DOAD-NAADMOM INNNANANN NNN NNNNNN NNN 291 ANMMODTOATNDADDOADWHDONM OI TTPOCGO TNDOK ALE TNT THOR INNNNNNN NNN 246 DIMM ADIN MOK THMNNT4OT AMO ON STUN NINA IN OLN IN INL ANNI NAAT ttt ett te td ie tebeted tet 141 80 Or Or AMDDAROOOrOrearnndo HERR DDDHOAADODHDODODODHDHOO [olololololololololololololololololololololololo} [olololelolololololololololololololololololololo} MODCOAMNCGDADIMONOMBOINA®BAN DOAAADDAAAANMMNANNNANNAHOO AANA AANNNNNNNNNNNNNNNNNNS RewMrnrssoNomennmanorrens ROTTOTHMMOFONLRER HSE AND NANANNNANNNNANNNNNNNNNNNNN TNOOHOTOMNONONMONNMNTT HON A~ GON OAT TOODOGDDDAMINAATON ANANNANANNNANNNNNNNNNNNN NONAMANCOMAMAMANAeOMAIMAO MARL OKMGOAOMNDAOCCOBOMMMAT NANANANNNNNNMNNNM MANNA OMaNMNOCORN Shans syAaroCONNNH DMNADADAADDANAOANAMOOMNNHrOO NAAAANNNNNNMMMMMMMMANANNON ANAM TOF OAOGAMNTNOrODOKAMS AAA AANA O 62,883 107,714 197,039 193,757 198,813 1,709,225 215,318 182,761 202,279 186,794 161,867 0 BTU’s Concept School 18,583 1,171 2,142 2,107 2,161 684 1,987 2,199 2,031 1,760 Maximum Hourly Heat Demand 2,341 Gallons PAGE 2 OF 3 1 Btu/Hr 8 Kw Heat Available Heat Displaced Y ye Maximum Hourly Peak KW Maximum Hour] Maximum Hour] WASTE HEAT UTILIZATION SIMULATION WORK SHEET - Concept 1 School Kivalina ** Main HE ** ** User HE ** * Hot * * Cold * * Hot * * Cold * Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 95.00 41.48 Gpm (Max Heat Demand) /8,000 Calc. 37.53 37.61 48.31 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/f£t*3 Spec Heat 863 0.859 Btu/lb F Ther Cond 33 0.234 Btu/Hr Ft F Viscosity 59 0.819 cP : Pipe Temp. In 190 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 41.48 gpm Length 560 Fe Size 2.5 in 0.20833 feet Heat Loss 20.66 Btu/Hr/Ft Heat Loss 11,568 Btu/Hr 11,570 Used above Velocity 3.21 Ft/Sec Friction Factor 0.0464 From Calc. Below Pipe Head Loss 9.40 Ft Darcy-Weisbach Pipe Head Loss 4.07 psi Calc. PAGE 3 OF 3 37 AM 04/23/90 Kivalina 09 Cummins LTA 10, 1,800 RPM 2 School + Comm. Bldgs. GENERATOR DATA Concept Kivalina Apr-90 WASTE HEAT UTILIZATION SIMULATION WORK SHEET Location Date: ray ! a1 4100 4 at BIOS a ' Sian 3 |sssscsssszs es z |eaeeeeaage | I=: i { = ie ISSN ' , Lemme Om mm moO vice 8 1 OOTIMTONNE OLN DODHOMBDANO 8 i mitmatio oot B10 OI MMAMNOMTS TITTIES TS TOOTS o SSS alba A100! a | BBSDSBSS5555 bas hae TBR B Bobo loa 10 [Ranmaammacs 1s Ovi ' t BE lnnMnagdddddd plows > lmoremvonnronnreaancm@aanno > BL MATOARAAAAR S168 Ol anmananvessessseT TIONS TS 3 gp SCHRITSSSSS Ziso Z 1990099958655555555659585 z 83! a [Socddccddcddddcddddeddcs oul | BE | damnocseees vlow Bl wonserrasoaradaasonr0ooN Pn 5 | DOOTONANANS o1Om OL FAMMMNAMSEMTCNTCT SETS SSS o Ba | Seonmammmen Olas © 18909999985988655585655865 ° 28 | eininicinininicietes 3a 1900096006000606000600060 | I bz lomovarnnene Blow bl wonser nascar adaasonroooN 2 5H | came anoawon a1on Bl SOMMAMIMSTOTTOTT STS TTS a a adcdetetet OTS B189999S698555865555555555 2g 2} |ddddd0dd606c000006d6660 { I ' Ol wonsernacconadaasensc0ooNn o I eP>Pr>>r>eroe> BIyoMNNNNNs OTTO ETTS 2 139999999000 %1G00600005605505550555555 2 TRSBASAB2838 (RRO RIAA Secs ece ce Bj Sceeceeeces 1900000000000800600600006 = lL VUVUVUUUUUUUU ' 1OGGTGGTIITG 1 9100000000000 pl tanger raccanadaas0ons000oN wo > BL AAA actedetetet FLSOMMAMNMSSO STOTT TS ITSS FimssS a H geararinn tea grncd B 1 OO0G000065606605565555565 31° Se 3 [ESS555455555 al | Seca spceninig ce ceiouie ce cocoate Te cosa aioniacess 5 c 5 | ERSSSEELLES Idddddddddddddddddddddccs 2 a ouevvouoony 1 BGCTITGTOTS t © | wongernnaccanadaasonzcooNn @1000 ©! 20000000000 EL SOMMIIMMSTOSTOT TS ICTS TSS EImao Sl oeesovosooy B1S000000056056085555S55S5 51° as S| Sesscccnunn 51 Ble eaeinices Sieh eteit ea teas 5 c PSUS SSE SSS iddddddddddddddddddddddd6 o a Bl vvevvvvvvvoy e | Ol agg gKGKK0R o ot 4199900000000 = A plvansernascanadaaccnscoon paso a BI REEEEE Eee a B Fi sQnaanamssnseHesssssssss S135 ' 3 B B1S99699695865505655555555 oes ' a % — [G90dG0d00080000000000000 aa 4 1 St 6 : > al dloro ot et at diane 2 <3 wR! HITGN 8 a o <I Zi ao § =) ie w ot & oS alow kinoo oO 2 E DIMMING T TTT STITT TOMS SS Simno ff O § WISSSSSSSSSSSSS5555SSSS555 Bias oO a 2 Bloc SoSCCCCCCCCCCCCCCCCC0C0 2 ag o a fas fa fag 5 I 3 1 RM 3 ot | sees “sere el 0 2 ooremronnronnrananomaadno Qleao 4 Tosa 2 B DIMMMANINTS TESTIS TT TTONS TS DINZO | see ses o Af 1G00969955585555556590555 aiVon 3 | s355 535 ot Bb 1000000000000000000000000 ao 4 1 SDDD Doo e | a) | anna mmm 5 4 i | ovos ovo Pl rm BR Fl OOsEMTONAr@rNrea@nwMBadING aOoOM Elado 1 °S°S Ban ey o BI MMAMNAOMTSTSSTTTT TT STON SSS ace Simao 6 1 28 - — a w SISSSSSsssssssssssssssssss 83 Si°ha 4 os ; oe CRORE ROR NICER ORICA IOI % ~. a i oo a a 0! = lodccccdcccdcdccedesdscN6ccG c ao 3 i oan a ° ot Nn o oO | ce fr ™ 1 tae 4 ae 1 3 Bl damencrancdamencrancdams 1 poo Bb g 31 AAA AN lowtee ¢ == o . o1 | GRos eo Ss Zz a = ates 1 2°25 Bao 20 9 1 setae Sas | a00a abe =a > » ot tas sas 9 | Bone Be xm 7 3s | an AR ted 52.0 Os 4 Oo wl a iu «1 BM oO | oc0 Ee dl aommvndmsesensammmmmanon 4 DO @ aiomtte: woo - - EB lommMnmsssrsessTTTTETTTT OOS op Glovsea wave < o AS EBISSG05G55SS5S55S55S55S555 8 say O04 0 Ri Sana shes 6 -° 3 a4 Migieiecscoeieieesreiniccereteiaicceercs bi ee ae Alugaow ung ae < 3 Lal dccccccddddcccccdccccccS 6B O4ON Osu a (gceee aa seg 5 Ae | S383 aida aia 4 Ze a a aw ot 4 0 8 ot oa ~ BS lammmmadnessenemmmammmanon dg Aly o 5 vo > Sulnmomonscssvesevevsesesso 9 s4aU le a em Zu & BB 1900G050655S55S55555S55555 roaGe a3 a ga a3 5 GUS | ccc c coe ccc cee ccc ce ccs ec 28058 ip S = a 3 BEE | Oddddddddddddddddddddddd “Oud Bla a ae aa 4 a3 cuore aig u Z Ho qn aest E8858 16 s Da 3 ao So00 a1o > oO ae a <a 1 arnZo 27,088 3,780 3,607 3,380 2,802 1,896 102 50 737 1,262 2,489 3,231 3,754 PAGE 1 OF 3 Total Use Kivalina Comm. Bldgs. ° = Zz °o w z an Zz 3 g « N at a is] B 1 a ei gt =u Annual NAGAIMANOO TA TOTH TOM LENANMOw AR CONCNAHODADBRORAAR- HANS NANNANNNNNNNNNNN ANNAN Dec DAMIMANOOMOMOMOOLVLrNNMOr WON TNO TT O~O-~ DODOOTDOM: INNANNNNNN ANNAN ANNAN 285 Nov ID ODDAUNVAAMAONNANAAM NEE FMM OOM TN OOM A TIN TODO: INNANNNANNNNNNNANNNNNN Oct 243 241 NAA ANN AMOAMNMININMONMS0O: OSPF POO A COO OLA FAD: INAANNNNANNNNNNANNNNNNNN 1S Sept mMNOOOON WHR ONAN FINA OOM OAL AMIMMOAMODHH: AAA ANN ANNAN ted) Aug 204 ONDOAHONTHOUTO STAT TONNININ FAAAIMM POM FOND OOM OOS <r AAA detected) July 162 DOM DHONI DWININININNTMAMMMA FANAMMTROFDVNONAR DAMNING AN ete June 2 7410 1,287 FONAOOTPAMNTFONODAAMAAGA AW MODANAMOOMANTANCONOST ITH INNA NANNNNNNNNNNNNNNN 153 118 May 269 1,959 NADA ANNODOCO™OOVNTMNANANEO DMAMMMm~NANOOOTOOOMINMR KATO INANNNANNANNNNNNANN ANNA 716 180 s Beeld 272 1,986 AT TO TOAUNOMOMOMMADADDOMA LU TNO FT OO DOOOGTOOMON INAANNNNNNNANNNNANN NNN 288 98,065 182, 2,153 March (1,000 BTU’s) FOO OOTPAHAOMNAOOMNAGOOrND IDOONONINNDAD-DANHODONNT EHS INAANNANNANNNNANNAMNANN Feb 226 1,946 DROIT TANIOHDNAOTITTOOD NOOO AAO AA ANODTTOONI INNANNNANAMMMAMMMAMANNNNNN Jan 244 , 2,295 'y hour by month Hour ANM TNO ONOGAMTINLLADACKAMS AAA Hour a < a0 o4 Da aa a0 Heat available per hour by month (1,000 BTU’ Annual Nov Oct May June July Aug April Feb March Jan Heat demand b: HONMNAMDAOHAAAE OANLANDOT ANNANMNDODDAND-O-DOr-woowm servers sT TTT ETE TSEC QDAD TFA ANNNAANIOAMADROOMRrO D> DONMMIMIMANANNANA ADO MOMS EPS PEPTIC TTT T TIM 388 IATA FONT TONNDONCOBOHMwLA DOM DODO NANA AIONO INANANNMAMMMMMAMMMMAMMMMMAANN 289 NADNDODDACOHMACVMONMDOAKING MITTITANOOR ERE OOOOVBODUOKLOINN et ddttdidtdtdtdtidtdtididtdtdididdtdedtdtdted ANMNOWM Or MN TNMMNN TATOO DODO OI ANN ANA NAAN ANANDA ACO 86 84 COCOOCOBOWOOUN FF OLOOwwwlwwwww AANANANNANS Tee EMSA Ft ttt WON ANOATML NM AdHATOSTNONLN AAAS AO SSP SP TO SST SIS IMMNN INNNNANANNNNNNNNNNNNNNNN 221 OMnOMMANMErOMMANKANaAAONMr ANNAMUE EEE OOP ororroondsm MAMAMAMAMMMAMAMMAMMMMAMMMmAM 337 NMOMANTOOOMM ATO TddONM DOK DOAMM TSF IEICMAIMAMMMAGOD MMMOMNMNTT TTT Te TTS TTT 393 NNTMOMM-COTOrAMLNMAaCWs DMPO OO AGIANNAOTOGHONAEO TIT TTTONNNNNNNNNNONN Sos 464 CHOON AOANNOOANOAWONHDOO FANANMODDAAHNGDOO-MDOroNS Tress TTT TSS ANM TNO OAOAAMNTNLCLADnoIAMS FA tA 67,758 116,065 228,941 297,177 345,325 2,491,828 9,360 4,611 May 000 BTU’s) Al Apr. a aa BO gu es by bY 347,716 331,773 310,888 257,798 174,416 y hour Heat delivered b: Total Demand Heat Delivered AAGAM IANOO TA TOTIHOrONNMOW (~ QON OANA DAD-OAADAMNANTRM INANNNANNNANNNNNNNNNNNAN DWAMIMAINOOMOMOMOOVLLrMNMOor ON TN OPP DO O-~ DDDOTOOMON INAANNNNNNNNNNANANNNNNNN JDODOAVVAAM AON AIMEE EO I~ TMMOC™ TNE OC ORL TNE TODON INANNNNNN NNN NNN NNN JAD NDONDACCAMALVMNDOONAING TITTHNOORR Rr ODwuuowuuuinn AAA AA AAA dette et TOAUMNOMNOCr MN TNMMN eNTOo DODD OA AA AN HAA AA AAA HAO WOOOOCLUF EF OLOowwnwwvwoouww NAAN See SEM TMS TOMA AA ttt teed 12 HOOAAMOTMN sARnOAMOTaANONLA NAQNADAAMN TIEMINTANTINIOINN ANNA ANNNNNNNNNNNNNNNNNN ANNAAIANDMDOCOrOwWOMNTHNANrO RUMMNMMRNNOCOTOOOMMK KATO NANANAANANNNNANNNNNNANNNNNN AT TN TF OAUNOMOMOMMADADD OMA PLDI SPO FT OO DODDOTOOMON INNNNNANNNNANNNNNNNNN NN o. @. ~ TPOOMOOTIAOANAOGOMATOLOENO IDOGNONNNDAD-DAHODONA TOS INNANNNNNNNNNNNNMNNNNNNN PITA OANHVOTITTOOD PRAIA ANOOT TON NNAMMMAANMMMMMNNNNNN ANMTNOROROGAMTNLCrOnOAdAMS ttt td tA AINNNNN 18,672 PAGE 2 OF 3 678 194,599 1,717,410 2,116 , 2,062 737 1,262 2,114 4,611 67,758 116,065 194,441 189 50 9,360 102 1,849 5 Btu/Hr 6 Btu/Hr 6 Btu/Hr 716 170,061 8 Kw , 1,986 $28,41 326,16 326,16 12 2,153 1,946 Heat Demand Heat Available Heat Displaced ve Maximum Hourly Peak KW y y 2,295 BTU’s 211,103 178,955 198,065 182, 604,611 67,758 116,065 194,441 189,678 194,599 1, 717,41 Maximum Hourl Maximum Hourl Maximum Hourl BTU’s BldGallons Concept School + Comm. WASTE HEAT UTILIZATION SIMULATION WORK SHEET —- Concept 2 School + Comm. Bldgs. ** =Main HE ** ** User HE ** * Hot * * Cold * * Hot * * Cold * Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 95.00 4.75 Gpm (Max Heat Demand) /8,000 Calc. 4.30 4.31 3.75 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/ft*3 Spec Heat 0.863 0.859 0.854 1.004 Btu/lb F Ther Cond 0.233 0.234 0.234 0.383 Btu/Hr Ft F Viscosity 0.759 0.819 0.900 0.425 CP Pipe Ground Temp. In 190 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 4.75 Length 312 FE Size 1,0 in 0.08333 feet Heat Loss 13.36 Btu/Hr/Ft Heat Loss 2,832 Btu/Hr 14,402 Used above Velocity 4.54 Ft/Sec Friction Factor 0.0719 From Calc. Below Pipe Head Loss 6.69 Ft Darcy-Weisbach Pipe Head Loss 2.90 psi Calc. PAGE 3 OF 3 95% 0 ° ddiddad 365 16,760 Dec 747,100 09:42 AM Annual 747,100 16,760 Annual Annual 24,998 / 4 / 4 7 4 4 4 / / if ODOTTNTONNr OPN aDnoMaaDdND MONNMNNNNVe Tee TOMS O80000000000000000600000 eoocococecCCCCeCCCCCCCC0G0 0 0 149 ddd BTU/HR) BTU/HR BTU/HR BTU/H BTU/H BTU/H BTU/H BTU/H BTU/H BTU/H Dec 7500 2,166 Nov Dec Dec 31 2,166 7900 Dec 3,484 { Q Q 128 ddd SOTO OMN-DOHOMMDHNO MOMOMTTIT TTT TTT TONS OOCSOSCCGGCCGGGG000000, IOSDCSSCCCCCCCCCCSCCCCCCSCO 655 655 545 509 494 491 491 491 9 9 9 Nov 400 74 Oct Nov 036 034 Nov 30 864 400 74 Nov 998 1,864 0.038 1, yi 2, 0 0 99 daddies DOS P SS ATODNAAGANTONTOOON MMMMOMNMNTINTTHTTITTTSTTS IIDOODOOSGGGCGGGGG00000000, IODGOSCCCCCCCSCCCCCSCCCCC0O 681 8 6 4 8 2 2 2 2 2 2 Oct 8g00 69 Sept Oct Oct 31 436 800 69 Oct 310 , ’ AMNNNNNNANN 1,436 0.044 1 2, ddd DOF IA ATOANNAGAATONTOOCON MMOMMMNOTINTTIOTITTTTs ToS IDODOOSHGOGSGOGGG0000000000, SeoooCoCCCCCCCCCCCC00000 OTAr ree AM co.cc. 00 ddd kw Coolant Ambient 45 Sept 500 68 728 Aug Sept Sept 30 728 66,500 68 Sept 171 0 QO 50 0.044 Output Heat To Heat To 1, 0 0 DOSS ATONNAGAATONTOOCON MOMMMNNMNTIMTTOTITT TTT SSS IPOOOOGOGG0G000000000000, IODOOCSCCOCCCOCCCCCCCCCCO Oddi Aug 500 66 425 July Aug Aug 31 425 Aug 684 29 44 , 0.044 4 2 \, ic | ' load above: load above 9 0 oO 28 DSP ATONE-AGAATONTOOON MMOMMONNTIO TTT S IDOOOOSGSSGGGGGGCGG000G0, OoCCCCCCCCCCCCCCCSCCC0O April July 400 45, i "402 June July 0.044 July 31 402 July 0 DSSS ATONAIAATONTOOCON AOOMOMN TFC TOG TSK GIT OCSOGGGGCGG00000000000 OooCCCCCCCSCCCCCCCSCSC00000 816 May 30 816 June June June June Heat rate at kw-load above 0.044 Heat rate at kw-load above: 0 0 75 WISP TL ATOANAGAATONTOOON MMMOMNMMNTINTTNTTsTTTTISS IODOOOOSSSSSS9G000000000 OoceCCCCCCCCCCCCCSCO Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above Heat rate at kw-load abov Heat rate at kw-. Heat rate at kw-. May 1,094 April May 0.044 0.039 May 31 1,094 May 1,760 QO GENERATOR DATA: Cummins LTA 10, 1,800 RPM Gallons 0 0 111 CIN TONNE OrNrDODAOMAOANO MMMNMVT TIT T TIT TT INNS OoooccooscoccscaGeGecGsGo OOCCCCCCCCOCCCCCCCCCCCO 1,617 0.038 036 April on Ao SS 1,617 2,601 April School March April er month 0 0 134 IPTPOTONNT ONE DOHOMBOH4NO MOMMNMTI TTI TTT S OOCCOSSGSGGGGG0G0000060 IDOCOCSCCCCCCCCCCCCCCCCO 1,950 Feb 31 1,950 March 136 March March 0.038 0.036 March 3, 0 0 143 CIN TONNE OrNrDDHAOMMOANO MMNNMVT TTS TTS TTS STS OOCSCGGSCCS00000000000 CoooeCeCCCCCCCCSCSCCSCCOSO 500 72,400 66,200 58,700 38,400 37 Feb Jan Feb Feb 28 2,081 Feb ’ 2,081 68,500 72,400 66,200 58,700 38,400 37,400 45,500 0.038 0.036 3,347 0 Btu/hr. dpin 32,224 Btu/hr. 0 Btu/hr. 224 Btu/hr. 0 0 150 SIONTONArOMMNEOMHOMMOGNO HOTOM MOONMO GPG IS STG ITT TION TS aor OOSOSGSSGGS0GG000000000 oss ae 5) Wile (eB) Wis lel Telle Br Iv Te "6 Lelecisier6 <O) jeoecoeeoCcosoCCSCCSCCCCCSDO ~ 50 Btu/hr.xF 196 Btu/hr.xF 50 Btu/hr.xF Jan 800 68 2,181 Jan 0.038 0.036 dan 31 2,181 80,800 Gallons of Oil used Jan 3,508 Boiler SeasonalSeasonal Effic. School 32 1, 80, Power Plant Production & Hourly Variation ANMTNCRODCKHAMTNCLAROGAMS AAA AANA Ein tant: Non- Hour PB. s prehea e, al cons Apin ating? Radiator losses Kwh/Mt. HDD/Mth: iping ace gls 1: offs: D HDB kwh DOONAN SPT TOTMMMMMMANOD MOMNOMTTI TTI TTT TIO OCooccocCCCCCCCCCCCCCO IDOPOCCSCCCCCCCCCCCCC0000 ine Summer Subsur. Surface Plant he 0.039 0.038 cons. Building Old Comm. Eni To! Plant Variable losses: ADDDOVDAIM TE TTOTMMMMMMANOD MNNNNM TIT TIVT TESTS SSS9090600000000000000000, eococeccececccCCCCCC00000 , year factor fear no. 25 1 Building in use; l=yes, O=no Winter SYSTEM LOSS DATA: GENERATION DATA: WEATHER DATA: BUILDING DATA: Fuel use, Assumed Diurnal Heat Demand Variation: Seasonal cons., Non-seas. Compound boiler e. Constant losses gallons Old Comm. New Comm. Clinic Washeteria Power x PAGE 1 OF 3 18,533 PAGE 2 OF 3 757 1,274 2,086 2,035 2,088 111 72 1,836 6 Btu/Hr 8 Kw 2,126 1,960 1,921 Heat Available Heat Displaced ~ Maximum Hourly Peak KW 2,267 Maximum Hourly Heat Demand iy Maximum Hour] Maximum Hour] 3 School + Clinic + Gallons ' ' ! ' ' at oat lovo to at ei at Sa is at att od 1S 31 St 21 {fas i gt gt gf lac to Bl Sa 1 SN 1@ { at 1 1o is t Mt 1 ts ts ' Po is “ | 1 VB IDODDNDHNOOKGR ARAL TIMNAAAKN ISO TSATANANTONNNODMNVNDNODOWTAMM 1H BI NDODDNDNOOKE AR ALE TIEMAANA fo DI AR HHH Ae TOOOSOOOAM OAM |B AAAI VOBOABL LLL OOT 1A Ol ARNT N ATT ODOCODOOAN OAS are & | ' ' TAN in ' 1 t 1a iS i i ol 5 [= | t 1 2 INMBDDADNOWOCWOOWCOWOUOMMMANNOOM 1oON DONO FOANNNNIAAMOOWWOMMOWMW I P LNMBDDANDNOWOWOWOWUMMMANNOW! 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' ' a miob | t 1a @ fet ' | a oe ts Iq Biv 1B ow ‘3 2 at a ' tc a Ie oa aio} ig @ 10 @ =ix ' = = te = » a o oO g 6 & WASTE HEAT UTILIZATION SIMULATION WORK SHEET —- Concept 3 School + Clinic + Wash Kivalina ** Main HE ** ** User HE ** * Hot * * Cold * * Hot * * Cold * Temp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 Flow 95.00 4.23 Gpm (Max Heat Demand) /8,000 Calc. 3.83 3.84 3.34 Gpm Fluid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/£t*3 Spec Heat 0.863 0.859 0.854 1.004 Btu/lb F Ther Cond 0.233 0.234 0.234 0.383 Btu/Hr Ft F Viscosity 0.759 0.819 0.900 0.425 CP Pipe Ground Temp. In 186 Temp Out 180 T Avg. 185 deg F 30.0 deg F Flow 4.23 gen Length 340 Size 1,0 in 0.08333 feet Heat Loss 13.36 Btu/Hr/Ft Heat Loss 4,542 Btu/Hr 16,112 Used above Velocity 4.37 Ft/Sec Friction Factor 0.0750 From Calc. Below Pipe Head Loss 8.89 Ft Darcy-Weisbach Pipe Head Loss 3.85 psi Cale. PAGE 3 OF 3 Kivalina Building Heating Summary One Std. Butler Bldg.; Insulation added in floor. 04/23/90 Fuel Oil: 96,000 BTU/Gal Engine: Cate ergs .1ar D342, 1200 RPM Combustion Air: 25 CFM ; Airchanges/Hr: 8.70 with eng. 1.5 without eng. runni Heat to Ambient: 2,894 Btu/Min Heat to Coolant: 9,400 Btu/Min Engine Rating: 160 Kw Genérator Eff.: 93.4% Bldg_Conduction Heat Loss: 270.9 BTU/hr/F Infil. Heat Loss: 98.1 BTU/hr/F/AC Heat to Bldg Heat Heat to Additional Bldg He Kwh HDD Coolant Req’/d Ambient w/ eng w/o eng Jan 80,800 2,181 ST 613 978 0 228 Feb 68,500 2,081 2,693 585 829 0 217 Mar 712,400 17950 2,846 548 876 0 204 Apr 66,200 1,617 2,603 454 801 0 169 ay 58,700 1,094 2,308 307 710 0 114 Jun 38,400 816 T7510 229 465 0 85 Jul 37,400 402 1,470 113 453 0 42 Aug 45,500 425 1,789 119 oil 0 44 Se 66,500 728 2,614 205 805 0 76 Oc 68,800 1,436 2,705 404 833 Q 150 Nov 69,400 1,864 2,728 524 840 0 195 Dec 74,500 2,166 2,929 609 902 0 226 747,100 16,760 29,371 4,710 9,043 0 poe Kwh = Historical Records Input HDD = Historical Records Input Heat to Coolant = Heat rejected. to coolant by engine pugs Heat = Heat Loss from building at 65 deg. with engine running Heat to Ambient = Heat rejected to ambient by engine Additional Heat Required: w/ eng = = ies Heat w/ eng) poet to Ambient) eat to keep peed at 5F_ with one engine running w/o eng = Heat to keep bldg at 65F with no engines running Module with one engine; Insulation added in Floor Engine: Cummins LTA 10, 1800 RPM Combustion Air: 490 CFM . Airchanges/Hr: 14, 73 with eng. 1.0 without eng. runni Heat to Ambient: ,500 Btu/Min Heat to Coolant: 51 e80 Btu/Min Engine Rating: 175 Kw Generator Eff. 93.4% Bldg Conduction Heat Loss: 84.5 BTU/hr/E Infil. Heat Loss: 47.1 BTU/hr/F/AC Heat to Bldg Heat Heat to Additional Bldg H Kwh HDD Coolant eq’d ient w/ eng w/o eng Jan 80,800 2,181 1,746 424 463 0 72 Feb 68,500 2,081 1,480 405 393 12 68 Mar 72,400 1,950 1,564 379 415 0 64 Apr 66,200 LA OLd 1,430 S15 380 8 $3 ay 58,700 1,094 1,268 213 337 36 Jun 38,400 816 830 159 220 0 27 Jul 37,400 402 808 718 215 Q As Aug 45,500 425 983 83 261 0 14 Se 66,500 7128 1,437 142 381 0 24 Oc 68,800 1,436 1,486 279 395 ) 47 Nov 69,400 1,864 1,499 363 398 0 61 Dec 74,500 2,166 1,610 421 427 0 71 747,100 16,760 16,141 3,260 4,285 12 S51 Page 1 of 2 Kivalina Building Heating Summary One Std. Butler Bldg.; No Insulation in floor. Fuel Oil: 96,000 BTU/Gal ,Engine: Cabene ae aS D342, 1200 RPM Combustion Air: 25 CE Airchanges/Hr: 8.70 with eng. aoe) Heat to Ambient: 2,894 Btu/Min Heat to Coolant: 9,400 Btu/Min Engine Rating: 160 Kw Genérator Eff.: 93.4% Bldg_Conduction Heat Loss: 456.1 BTU/hr/E Infil. Heat Loss: 98.1 BTU/hr/F/AC Heat to Bldg Heat Heat to Kwh HDD Coolant Req’ d Ambient Jan 80,800 2,181 Sylvian 714 978 Feb 68,500 2,081 2,693 681 829 Mar 712,400 1,950 2,846 638 876 Apr - 66,200 1,617 2,603 529 801 ay 58,700 1,094 2,308 358 710 Jun 38,400 816 S10) 267 465 Jul 37,400 402 1,470 132 453 Aug 45,500 425 1,789 739 Soi Se 66,500 7128 2,614 238 805 Oc 68,800 1,436 2,105 470 833 Nov 69, 400 1,864 2,728 610 840 Dec 74,500 2,166 2,929 109 902 747,100 16,760 29,371 5,486 9,043 Kwh = Historical Records Input HDD = Historical Records Input Heat to Coolant = Heat rejected. to coolant by engine 04/23/90 without eng. runni Additional Bldg H w/ eng w/o eng RPRNNWW NOPRPADANASOFN SRPIOCOBRPWUIE BBO WNNF Oo i) . on N @ eens Sen = Heat Loss from building at 65 deg. with engine running Heat to Ambient = Heat rejected to ambient by engine Additional Heat Required: w/ eng = (Bldg Heat w/ en - (Heat to Ambient) ) ' = Heat to keep bidg at ©5F with one engine running g w/o eng = Heat to keep bl at 65F with no engines running Module with one engine; No Insulation in Floor Engine: Cummins LTA 10, 1800 RPM Combustion Air: 490 CFM Airchanges/Hr: 14.73 with eng. 1.0 without eng. runni Heat to Ambient: 1,500 Btu/Min Heat to Coolant: 5,650 Btu/Min Engine Rating: 175 Kw Generator Eff.: 93.4% Bldg_Conduction Heat Loss: 358.4 BTU/hr/EF Infil. Heat Loss: 47.1 BTU/hr/EF/AC Heat to mag Heat Heat to Additional Bldg H Kwh HDD Coolant eq’d Ambient w/ eng w/o eng Jan 80,800 2,181 1,746 574 463 110 227 Feb 68,500 2,081 1,480 547 393 154 2A Mar 712,400 1,950 1,564 Sits 415 98 198 Apr 66,200 AK phy 1,430 425 380 46 164 ay 58,700 1,094 1,268 288 Soil 0 ey Jun 38,400 816 830 21:5 220 Q 83 Jul 37,400 402 808 106 25 0 41 Aug 45,500 425 983 12 261 Q 43 Se 66,500 7128 1,437 191 381 0 74 Oc 68, 800 1,436 1,486 378 395 0 146 Nov 69,400 1,864 1,499 490 398 92 189 Dec 74,500 2,166 1,610 570 427 142 220 747,100 16,760 16,141 4,408 4,285 642 1,699 Page 2 of 2 polarconsult Kivalina District Heat APPENDIX B Field Trip Notes polarconsult Kivalina Field Trip Notes January 12, 1990 Earle Ausman, Leslie Moore, PCA Met with: Bob Hawley, Jr Chief Operatorfts 645-2137 Colleen Koenig City Administrator 645-2137 Joe Swan Mayor 645-2137 Victor Adams Water Operator 645-2137 Northwest Arctic Borough School District, Kotzebue Dan Coffey Director Maintenance 442-3472 Paul Weisner Asst. Director 442-3472 1. Construction Wages: Did not know exact figures, $15 highest, $10 is the average wage. If hand digging is involved higher wages would be needed. Power Plant Operator gets $10.60 per hour for extra work like putting in a steel floor or interior walls. The normal salary is about $1,500 per month. Weather: Feb-Mar, north winds, drifts. Coastal, high winds. Module air louver blocked off on both sides due to drifting snow coming in. It would appear that cooling capacity is so great that the air opening is not needed. Soils: Permafrost, active layer 5-6’, electric cables are buried at 3'. They had a power outage and they located the electric cable with a thumper, it took 3-4 days. They thawed the ground with a space heater in a box. Population: 300+ 2. Utilities: Water: 500,000 gallon heated storage tank. Need new tank. Water tank temp was at 40°F based on thermostat setting. Piped to school and clinic. No delivery service from washeteria. Sewer: Elec: Underground Distribution Fuel: City paid $1.75 / gallon. Cable TV installed. Appendix B polarconsult Kivalina Field Trip Notes January 12, 1990 3. Right of Way Property lines shown on the AVEC site plan. 4. Equipment Loui Wesfrey said new Backhoe is broken down, needs repairs. 5. Water Plant, Oil deliveries, water temp 180°F, $96.25 / 55 gallon, equals $1.75 per gallon. January DiS July 0 February 165 August 605 March 165 September 0 April 165 October 0 May 0 November 55 June 0 December 0 1,430 The water plant gets its water from a stream on the other side of Kivalina Lagoon via a pipeline in the summer. The water is stored in a large tank over the winter. There was discussion that a community water system will be installed at Kivalina. Latter discussions with DEC and EPA show that there is not sufficient water and there is no practical way to deal with the sewage. As a result it is likely that the system will not expand greatly. The plant operator did state however, that a additional tank has been requested. If a second tank is installed the amount of oil used for tank heating will increase. A a rough estimate there may be a need for a additional 1,000 gallons of oil per year. 6. School The school is run by the Northwest Arctic Borough School District which has is district offices in Kotzebue. The borough states the school used 30,000 gallons of fuel last year. Of this, 25,000 gallons were used in the High School and 5,000 gallons in other adjacent buildings. Appendix B polarconsult Kivalina Field Trip Notes January 12, 1990 Paul Weisner, borough, says the Kiana waste heat system has saved them money and kept the Kiana school in operation several times when there was a heating plant failure at the school. He was very much in favor of waste heat for Kivalina and Noatak. He said during inclement weather they have to travel by Otter which costs over $2,000. This is because the piston planes will not fly at temperatures below - 30°F. 7. City Office The local residents expressed a desire to connect up the city office. This office is heated by a forced air furnace. If a loop were run to the city office it would be easy to connect the jail as well. The combined use of oil at these facilities last year was 1,696 gallons of oil. The price for the community oil was $1.82 per gallon. So the vae of last years fuel was $3,080. 8. AVEC 1) Caterpillar D342 2) Caterpillar D353 3) JD 6619A 4) Cummins LTA 10 - 1800 rpm Buildings on piling, steel plate on floor. The Butler building portion of the power plant was not operating while at Kivalina as the AVEC roving maintenance man, was there. He stated he liked the waste heat system at Kiana, and it provided positive benefits for the diesel plant. The AVEC field man stated engine 1) was not good and was not likely to be operated much. Appendix B 3 polarconsult Kivalina District Heat APPENDIX C Cost Estimate HMS 9022 CONSTRUCTION COST STUDY WASTE HEAT RECOVERY SYSTEM KIVALINA, ALASKA Cost Consultant Engineer HMS, Inc. Polarconsult Alaska 4103 Minnesota Drive 1503 W. 33rd Street, Suite 310 Anchorage, Alaska 99503 Anchorage, Alaska 99503 (907) 561-1653 May 7, 1990 (907) 562-0420 FAX WASTE HEAT RECOVERY SYSTEM PAGE 1 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from eight (8) 8 1/2"x11" sketches and outline specifications linking five facilities in different configurations at the village, as detailed by Polarconsult. This estimate is a statement of probable construction cost only, and is priced using A.S. Title 36 prevailing labor rates and current materials, freight and equipment prices, and to reflect a competitive bid in Summer 1990. Removal of hazardous material has not been considered in this cost estimate. CONCEPT NO. 1 - School Only $ 391,769 CONCEPT NO. 2 - School and 0Old/New Community Centers $ 493,428 CONCEPT NO. 3 - School and Clinic and Water Treated Building $ 477,811 WASTE HEAT RECOVERY SYSTEM KIVALINA, ALASKA CONSTRUCTION COST STUDY CONSTRUCTION COST 01 General Conditions, Overhead and Profit 02 Sitework 05 Metals 06 Wood and Plastics 13 Special Construction 15 Mechanical 16 Electrical Subtotal Estimate contingency for elements of project not determined at this early level of design Esclation at .33% per month TOTAL CONSTRUCTION COST PROJECT COST Design SIA (Supervision, Inspection and Administration) Project Contingency TOTAL PROJECT COST (10%) ( 1%) (10%) (20%) (10%) PAGE 2 MAY 7, 1990 CONCEPT #1 CONCEPT #2 CONCEPT #3 112,775 125,929 124,658 53,728 78,222 69,593 1,220 1,220 1,220 1,200 1,200 1,200 4,810 4,810 4,810 62,305 84,290 84,335 6,819 10,203 10,378 242,857 305,874 296,194 24,286 30,587 29,619 2,671 3,365 3,258 269 ,814 339 ,826 329,071 26,981 33,983 32,907 59,359 74,762 72,396 35,615 44,857 43,437 391,769 493,428 477,811 WASTE HEAT RECOVERY SYSTEM PAGE 3 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 WASTE HEAT RECOVERY SYSTEM PAGE 4 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 01 - GENERAL CONDITIONS, OVERHEAD AND PROFIT QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,000 Freight 32,000 LBS -40 12,800 Supervision, equipment, utilities clean site, tools and protection 10 WKS 3000.00 30,000 Per diem 260 DAYS 110.00 28,600 Travel costs, including time in travel 6 RT 1250.00 7,500 Bond and insurance 1.75 3 3,797 Protit 10 % 22,078 WASTE HEAT RECOVERY SYSTEM PAGE 5 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 02 - SITEWORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 560 LF 12.50 7,000 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 1,120 LF 39 .90 44,688 Bend 12 EA 170.00 2,040 WASTE HEAT RECOVERY SYSTEM PAGE 6 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1.00 1,220 TOTAL ESTIMATED CO WASTE HEAT RECOVERY SYSTEM PAGE 7 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 06 - WOOD AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200 WASTE HEAT RECOVERY SYSTEM PAGE 8 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 13. - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8'0"x8'0" building module with floor, exterior wall structure and roofing complete 1 EA 2500.00 2,500 Hole through exterior wall for heating pipes 10 EA 110.00 1,100 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 WASTE HEAT RECOVERY SYSTEM PAGE 9 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 72.50 145 Form hole through existing wall for heating pipes 10 EA 195.00 1,950 3" diameter black steel welded piping 120 LF 22.65 2,718 Fittings 30 EA 45.00 1,350 Butterfly valves 5 EA 166.00 830 Control valve 1 EA 89 .00 89 2 1/2" diameter black steel welded piping 30 LF 18.85 566 Fittings 4 EA 37.00 148 Butterfly valve 2 EA 149.00 298 WASTE HEAT RECOVERY SYSTEM PAGE 10 KIVALINA, ALASKA CONSTRUCTION COS'T STUDY MAY 7, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Insulation to pipe, 3" diameter 120 LF 6.65 798 Ditto, 2 1/2" diameter 30 LF 6.15 185 Booster pump 1 EA 1550.00 1,550 Heat exchanger, 400,000 BTUH 1 EA 3750.00 3,750 Unit Heater (3 Each) (2 - Generator Building and 1 - Module Building) Unit heater, 60 BTUH, including thermostat 3 EA 330.00 990 1" diameter piping including fittings 120 LF 9.10 1,092 Gate valves 6 EA 71.00 426 Insulation 120 LF 4.10 492 WASTE HEAT RECOVERY SYSTEM PAGE 11 KIVALINA, ALASKA . CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Radiators Remove all existing radiators including all piping back to generators 1 LOT 1,200 Young series 22 radiator 2 EA 3830.00 7,660 Radiator stand and roof 2 LOTS 3490.00 6,980 3" diameter piping 110 LF 22565 2,492 Fittings 20 EA 45.00 900 Butterfly valves 11 EA 166 .00 1,826 Control valve 1 EA 89 .00 89 Insulation 110 LF 6.65 732 Anti-freeze 150 GALS 7.60 1,140 WASTE HEAT RECOVERY SYSTEM PAGE 12 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up Form hole through existing wall for heating pipes 2 EA 195 .00 390 2 1/2" diameter black steel piping 120 LF 18.85 2,262 Fittings 30 EA 37.00 1,110 Gate valves 10 EA 149.00 1,490 Check valves 2 EA 149.00 298 Strainer 2 EA 58.00 116 Balancing valve 3 EA 58 .00 174 Temperature control valve 1 EA 225.00 225 Insulation 120 LF 6.15 738 Heat exchanger, 400,000 BTUH 1 EA 3750.00 3,750 WASTE HEAT RECOVERY SYSTEM . PAGE 13 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 15 —- MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Expansion tank, 66 gallon capacity 1 EA 1490.00 1,490 Air separator 1 EA 495.00 495 Pumps, circulation Grundfoss 200, 2 1/2" diameter 2 EA 790.00 1,580 Connection to existing piping system 2 EA 72.50 145 Make-up glycol system connection, including tank 1 EA 610.00 610 Glycol - 110 GAL 7.60 836 Test and balance system 36 HRS 75.00 2,700 Controls and Instrumentation Generator building and new module 1 LOT 2,000 Hook-up inter ties 1 LOT 17500 WASTE HEAT RECOVERY SYSTEM PAGE 14 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel a EA 175.00 350 Connection to motor 3 EA 115.00 345 Disconnect switch 1 EA 330.00 330 3/4" EMT conduit 70 LF 3.10 217 #8 copper 280 LF ot 210 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 277 Panel 1 EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light fixtures 6 EA 190.00 1,140 Continued WASTE HEAT RECOVERY SYSTEM PAGE 15 KIVALINA, ALASKA i CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) Switch 1 EA 55.00 55 Duplex outlets a EA 68.00 272 Equipment connection 1 EA 115.00 115 1/2" conduit 70 LF 2.80 196 #12 copper 210 LF -50 105 Hook-Up Breaker in existing panel 1 EA 175.00 175 Connection to motor 2 EA 115.00 230 Disconnect switch 2 EA 330 .00 660 3/4" EMT conduit 120 LF 3.10 372 #8 copper 400 LF «15 300 WASTE HEAT RECOVERY SYSTEM PAGE 16 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 WASTE HEAT RECOVERY SYSTEM PAGE 17 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 01 - GENERAL CONDITIONS, OVERHEAD AND PROFIT QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,000 Freight 37,100 LBS -40 14,840 Supervision, equipment, utilities clean site, tools and protection 10 WKS 3000.00 30,000 Per diem 300 DAYS 110.00 33,000 Travel costs, including time in travel 6 RT 1250.00 7,500 Bond and insurance ie25 % 4,782 Profit : 10 % 27,807 WASTE HEAT RECOVERY SYSTEM PAGE 18 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 02 - SITEWORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 900 LF 12.50 11,250 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 1,120 LF 39.90 44,688 1" ditto 680 LF 27.30 18,564 2 1/2" bend 12 EA 170.00 2,040 2 1/2" tee 2 EA 220.00 440 1" bend 10 EA 100.00 1,000 1" tee . 2 EA 120.00 240 WASTE HEAT RECOVERY SYSTEM PAGE 19 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1.00 1,220 WASTE HEAT RECOVERY SYSTEM PAGE 20 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #1 06 - WOOD AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200 TOTAL ESTIMATED COST WASTE HEAT RECOVERY SYSTEM PAGE 21 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 13. - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8'0"x8'0" building module with floor, exterior wall structure and roofing complete 1 EA 2500.00 2,500 Hole through exterior wall for heating pipes 10 EA 110.00 1,100 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 TOTAL ESTIMATED CO WASTE HEAT RECOVERY SYSTEM PAGE 22 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 15 —- MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 72.50 145 Form hole through existing wall for heating pipes 10 EA 195.00 1,950 3" diameter black steel welded piping 120 LF 22.65 2,718 Fittings 30 EA 45.00 1,350 Butterfly valves 5 EA 166.00 830 Control valve 1 EA 89 .00 89 2 1/2" diameter black steel welded piping 30 LF 18.85 566 Fittings 4 EA 37.00 148 Butterfly valve 2 EA 149 .00 298 WASTE HEAT RECOVERY SYSTEM PAGE 23 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Insulation to pipe, 3" diameter 120 LF 6.65 798 Ditto, 2 1/2" diameter 30 LF 6.15 185 Booster pump 1 EA 1550.00 1,550 Heat exchanger, 400,000 BTUH 1 EA 3750.00 3,750 Unit Heater (3 Each) (2 - Generator Building and 1 - Module Building) Unit heater, 60 BTUH, including thermostat 3 EA 330.00 990 1" diameter piping including fittings 120 LF 9.10 1,092 Gate valves 6 EA 71.00 426 Insulation 120 LF 4.10 492 WASTE HEAT RECOVERY SYSTEM PAGE 24 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Radiators Remove all existing radiators including all piping back to generators 1 LOT 1,200 Young series 22 radiator 2 EA 3830.00 7,660 Radiator stand and roof 2 LOTS 3490.00 6,980 3" diameter piping 110 LF 22.65 2,492 Fittings 20 EA 45.00 900 Butterfly valves 11 EA 166.00 1,826 Control valve 1 EA 89.00 89 Insulation 110 LF 6.65 732 Anti-freeze 150 GALS 7.60 1,140 WASTE HEAT RECOVERY SYSTEM PAGE 25 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up Form hole through existing wall for heating pipes 2 EA 195.00 390 2 1/2" diameter black steel piping 120 LF 18.85 2,262 Fittings 30 EA 37.00 1,110 Gate valves 10 EA 149.00 1,490 Check valves 2 EA 149.00 298 Strainer 2 EA 58.00 116 Balancing valve 3 EA 58.00 174 Temperature control valve 1 EA 225.00 225 Insulation 120 LF 6.15 738 Heat exchanger, 400,000 BTUH 1 EA 3705.00 3,705 WASTE HEAT RECOVERY SYSTEM KIVALINA, ALASKA CONSTRUCTION COST S'TUDY CONCEPT #2 15 —- MECHANICAL Hook-Up (Continued) Expansion tank, 66 gallon capacity Air separator Pumps, circulation Grundfoss 200, 2 1/2" diameter Form hole through existing wall for new heating pipes 1" diameter black steel piping including fittings Gate valves Check valves Strainer Balance valve 240 20 QUANTITY UNIT EA EA EA LF EA EA EA PAGE 26 MAY 7, 1990 UNIT RATE ESTIMATED COST 1490.00 1,490 495.00 495 790.00 1,580 195.00 780 9.10 2,184 71.00 1,420 71.00 284 50.00 200 52.00 Sii2 WASTE HEAT RECOVERY SYSTEM PAGE 27 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) Temperature control valve 2 EA 225.00 450 Insulation 240 LF 4.10 984 Heat exchanger, 100,000 BTUH 2 EA 3075.00 6,150 Expansion tank, 8 gallon 2 EA 495.00 990 Air seperator 2 EA 495.00 990 Circulation pumps, Grundfoss, 1" diameter 2 EA 520.00 1,040 Connection to existing piping system 6 EA 72250 435 Make-up glycol system connection, including tank 3 EA 610.00 1,830 Glycol 220 GAL 7.60 1,672 Test and balance system 48 HRS 75.00 3,600 WASTE HEAT RECOVERY SYSTEM PAGE 28 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Controls and Instrumentation Generator building and new module 1 LOT 2,000 Hook-up inter ties 3 LOTS 1500.00 4,500 WASTE HEAT RECOVERY SYSTEM PAGE 29 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 16 —- ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 2 EA 175.00 350 Connection to motor 3 EA 115.00 345 Disconnect switch 1 EA 330.00 330 3/4" EMT conduit 70 LF 3.10 217 #8 copper 280 LF oir) 210 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 at7 Panel 1 EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light fixtures 6 EA 190.00 1,140 WASTE HEAT RECOVERY SYSTEM PAGE 30 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #2 16 —- ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) Switch 1 EA 55.00 55 Duplex outlets 4 EA 68.00 272 Equipment connection 1 EA 115.00 115 1/2", conduit 70 LF 2.80 196 #12 copper 210 LF -50 105 Hook-Up Breaker in existing panel 3 EA 175 .00 525 Connection to motor 6 EA 115.00 690 Disconnect switch 6 EA 330.00 1,980 3/4" EMT conduit 360 LF 3.10 1,116 #8 copper 1,080 LF tD) 810 WASTE HEAT RECOVERY SYSTEM PAGE 31 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 WASTE HEAT RECOVERY SYSTEM KIVALINA, ALASKA CONSTRUCTION COST STUDY CONCEPT #3 01 - GENERAL CONDITIONS, OVERHEAD AND PROFIT QUANTITY UNIT PAGE 32 MAY 7, 1990 Mobilization Freight Supervision, equipment, utilities clean site, tools and protection Per diem Travel costs, including time in travel Bond and insurance Profit 10 WKS 300 DAYS 6 RT 175 % 10 % UNIT RATE ESTIMATED COST 8,000 -40 14,600 3000 .00 30,000 110.00 33,000 1250.00 7,500 4,631 26,927 124,658 WASTE HEAT RECOVERY SYSTEM PAGE 33 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 02 - SITEWORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backtilling and spread and level surplus 772 LF 12.50 9,650 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 1,120 LF 39 .90 44,688 1" ditto 424 LF 27.30 1157/5 2 1/2" bend 12 EA 170.00 2,040 1" bend 14 EA 100.00 1,400 1" tee 2 EA 120.00 240 WASTE HEAT RECOVERY SYSTEM PAGE 34 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1.00 1,220 WASTE HEAT RECOVERY SYSTEM PAGE 35 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 06 - WOOD AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200 WASTE HEAT RECOVERY SYSTEM PAGE 36 KIVALINA, ALASKA CONSTRUCTION COST STUDY : MAY 7, 1990 CONCEPT #3 13. - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8'0"x8'0" building module with floor, exterior wall structure and roofing complete 1 EA 2500.00 2,500 Hole through exterior wall for heating pipes 10 EA 110.00 1,100 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 WASTE HEAT RECOVERY SYSTEM PAGE 37 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 15 —- MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 72.50 145 Form hole through existing wall for heating pipes 10 EA 195.00 1,950 3" diameter black steel welded piping 120 LF 22.65 2,718 Fittings 30 EA 45.00 1,350 Butterfly valves 5 EA 166.00 830 Control valve 1 EA 89.00 89 2 1/2" diameter black steel welded piping including fittings 30 LF 18.85 566 Fittings 4 EA 37.00 148 2 1/2" butterfly valve 2 EA 149 .00 298 Insulation to pipe, 3" diameter 120 LF 6.65 798 WASTE HEAT RECOVERY SYSTEM PAGE 38 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Ditto 2 1/2" diameter 30 LF 6.15 185 Booster pump 1 EA 1550.00 1,550 Heat exchanger, 400,000 BTUH 1 EA 3750.00 3,750 Unit Heater (3 Each) (2 - Generator Building and 1 - Module Building) Unit heater, 60 BTUH, including thermostat 3 EA 330.00 990 1" diameter piping including fittings 120 LF 9.10 1,092 Gate valves 6 EA 71.00 426 Insulation 120 LF 4.10 492 WASTE HEAT RECOVERY SYSTEM PAGE 39 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Radiators Remove all existing radiators including all piping back to generators 1 LOT 1,200 Young series 22 radiator 2 EA 3830.00 7,660 Radiator stand and roof 2 LOTS 3490.00 6,980 3" diameter piping 110 LF 22.65 2,492 Fittings 20 EA 45.00 900 Butterfly valves i EA 166.00 1,826 Control valve 1 EA 89.00 89 Insulation 110 LF 6.65 732 Anti-freeze 150 GALS 7.60 1,140 WASTE HEAT RECOVERY SYSTEM KIVALINA, ALASKA CONSTRUCTION COST STUDY CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE PAGE 40 MAY 7, 1990 ESTIMATED COST Hook-Up Form hole through existing wall for heating pipes 2 1/2" diameter black steel piping Fittings 2 1/2" gate valves 2 1/2" check valves Strainer 2 1/2" balancing valve Temperature control valve Insulation Heat exchanger, 400,000 BTUH 120 30 10 LF EA EA EA EA EA EA LF 195.00 18.85 37.00 149 .00 149.00 58.00 58.00 225.00 6.15 3750.00 390 2,262 1,110 1,490 298 116 174 225 WASTE HEAT RECOVERY SYSTEM PAGE 41 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 15 —- MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) Expansion tank, 66 gallon capacity 1 EA 1490.00 1,490 Air separator 1 EA 495.00 495 Pumps, circulation Grundfoss 200, 2 1/2" diameter 2 EA 790.00 1,580 Form hole through existing wall for heating pipes 4 EA 195.00 780 1" diameter black steel piping including fittings 240 LF 9.10 2,184 Gate valves 20 EA 71.00 1,420 Check valves 4 EA 71.00 284 Strainer 4 EA 50.00 200 Balance valve 6 EA 52.00 S32 WASTE HEAT RECOVERY SYSTEM PAGE 42 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up (Continued) Temperature control valve 2 EA 225.00 450 Insulation 240 LF 4.10 984 Heat exchanger, 100,000 BTUH 2 EA 3075.00 6,150 Expansion tank, 9 gallon 2 EA 495.00 990 Air separator 2 EA 495.00 990 Circulation pump, 1" diameter 2 EA 520.00 1,040 Connection to existing piping system 6 EA 72.50 435 Make-up glycol system connection, including tank 3 EA 610.00 1,830 Glycol 220 GAL 7.60 1,672 Test and balance system 48 HRS 75.00 3,600 WASTE HEAT RECOVERY SYSTEM PAGE 43 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Controls and Instrumentation Generator building and new module 1 LOT 2,000 Hook-up inter ties 3 LOTS 1500.00 4,500 WASTE HEAT RECOVERY SYSTEM PAGE 44 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 3 EA 175.00 525 Connection to motor 3 EA 115.00 345 Disconnect switch 1 EA 330.00 330 3/4" EMT conduit 70 LF 3.10 217 #8 copper 280 LF at5 210 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 277 Panel 1 EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light tixtures 6 EA 190.00 1,140 TOTAL ESTIMATED COS WASTE HEAT RECOVERY SYSTEM PAGE 45 KIVALINA, ALASKA CONSTRUCTION COST STUDY MAY 7, 1990 CONCEPT #3 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) Switch L EA 55.00 55) Duplex outlets = EA 68.00 272 Equipment connection 1 EA 115.00 1S) 1/2" conduit 70 LF 2.80 196 #12 copper 210 LF -50 105 Hook-Up Breaker in existing panel 3 EA 175.00 525 Connection to motor 6 EA 115.00 690 Disconnect switch 6 EA 330.00 1,980 3/4" EMT conduit 360 LF 3.10 1,116 #8 Copper 1,080 LF 75 810