Loading...
HomeMy WebLinkAboutManokotak Waste Heat Status Reports, Trip Reports 1991TRIP REPORT - MANOKOTAK POWER PLANT/WASTE HEAT OCTOBER 29-30, 1991 Date: November 1, 1991 To: Project Files Thru: Brian Gray TH Be From: Joel G. St. Aubin ‘A Re: Trouble shooting visit for the power plant/waste heat recovery system TRIP REPORT Tuesday, October 29, 1991 We departed Anchorage at 10:15 am and arrived in Manokotak at 1:45 pm to investigate reported problems with the waste heat system which were causing the generators to overheat when the waste heat recovery was off-line. We spoke with Nels Franklin, president of the Manokotak Natives Limited Corporation (owner of the power house) and Albert, power house Operator, to obtain information concerning the daily operation of the power house. Later in the day, the maintenance man for the Southwest Region School District (SWRSD) was questioned as to his knowledge of the power plant's operation. Wednesday, October 30, 1991 We surveyed the power house to gather first hand information on the operation of the plant. We departed Manokotak at 5:30 pm and arrived in Anchorage at 10:00 pm. Manokotak Power Plant/Waste Heat Recovery System Nels Franklin and Albert reported that they were having problems keeping the two radiator fan motors operating when the waste heat recovery system was Off-line, which would cause the generators to overheat and shut down. They explained that the overloads on the motor starters were constantly tripping and that the motor starter for the Young radiator (Rad 2) was currently burned. They also believed that Rad 2, a two Pass radiator, was incorrectly piped. Brian attempted to explain that it was configured Properly for a two pass radiator; however, they reported that in the summer if both motors are running, hot air is discharged from Rad 1 but cold air is discharged from Rad 2. The SWRSD maintenance man confirmed this phenomena and reported that a warm air flow could be felt near the bottom of Rad 2, but farther up the radiator face the air flow was cool. Brian noticed that the 3/4" Amot valve bypass was closed and the 3" heat exchanger bypass was open. He explained to Nels & Albert that they should be in the opposite positions and then reset the valves properly. Upon closing the heat exchanger bypass, the waste heat supply to the school increased from 175°F to 180°F. The waste heat supply at the school was 178°F. The school staff stated that they had to activate the waste heat system and open the doors and windows to keep the power plant operating. The radiator aquastats were both set at 170°F but the Amot valve has an 180°F element. The aquastat for Rad 1 was reset to 180°F and the aquastat for Rad 2 to 190°F. Brian reset the starter for Rad 1 and it appeared to operate fine and was rejecting heat. Rad 2 could not be operated because the coil in the motor started was burned. The local crew had removed generator #3 (Cat 3306) because the engine had failed and had placed anew Cummins NT-855-G4 in its position. The coolant and fuel piping are on the opposite side and will require repiping. A sketch of the current status of the piping arrangement was prepared. The exhaust is in a different location and will require a new roof penetration. No electrical connections had been made to date. On the morning of the 30th, the waste heat supply to the school was down to 143°F and the pressure gauge read 0 psig on the supply; however, the expansion tank, located 5' above gauge level, was showing 1/2 full in the sight glass. The tank may need to be charged with compressed air to allow proper operation. Generator #2 (Mitsubishi) was the only unit operating during our visit. It was producing 150°F supply to the heat exchanger during the early morning. The Amot valve was fully closed and 3/4" bypass was fully open. Rad 1 was warm but Rad 2 was at ambient and did not appear to be getting any of the bypass flow. Brian isolated Rad 1 and that caused Rad 2 to begin to warm very slowly and only near the inlet. Rad 2 appears to have a much greater resistance to flow than Rad 1, which may be the cause of its apparent non- function. The heat exchanger was then isolated and the bypass opened. The Amot valve opened at 180°F and diverted flow through Rad 2. Rad 2 warmed in the following pattern: bottom inlet - inlet side to top - top to outlet side - down outlet side. The waste heat system and Rad 1 were then reactivated and the system was returned to normal operating mode. Rad 2 may need to be reconfigured to single pass flow in order to allow for balanced flow between both radiators. The nameplate data for the radiators, motors, motor starters and the new generator were then recorded. One obvious problem with the installation was the lack of proper labeling. Aquastats and motor starters should be labeled to indicate which radiator they serve (to eliminate trial and error). The heat exchanger bypass should also be tagged "Normally Closed" and the 3/4" Amot bypass should be tagged "Normally Open". Also, a line-size (3") Amot bypass should be included in addition to the 3/4" bypass in the future. The wire gauge for the motor starters was checked and found to be adequate. TRIP REPORT TO: File THRU: Gary Smith FROM: John R. Bulkow je SUBJECT: Trip Report, Manokotak DATE: November 21, 1990 PURPOSE This trip was made to oversee the start-up of the waste heat recovery system in Manokotak. Unfortunately, the piping in the power plant had not been completed so only the secondary goals of collecting as-built information and coordinating with the School District were accomplished. MANOKOTAK I travelled to Dillingham on the morning of 24 Oct 90. There I met with Don Ford of the Southwest Region School District and we proceeded directly to Manokotak. In Manokotak we first inspected the school end of the waste heat recovery system. The 3-way valve and temperature sensors needed to protect against heating the waste heat system had not yet been installed, an additional air vent needed to be installed, and only temporary wiring for the circulating pumps had been installed. This school portion of the system, however, was capable of being operated in its present condition and had in fact been operated backwards (using the school boilers to heat the arctic piping loop) to bring the arctic piping up to operating temperature so that the E-joints could be welded in place and buried. As-built information and photographs were taken. We next proceeded to the powerhouse. There we discovered that the one operating generator had yet to be connected into the primary loop of the waste heat recovery system. Photographs were taken and as-built information was collected on the portion of the system that was complete. We located Dan Johnson, who was in Manokotak working on the system at that time. Dan indicated that the last generator had not been connected to the primary loop yet because he was concerned about cutting off power to the community while doing the work and he was waiting for assistance, which would arrive on 26 Oct 90, in removing the radiator. I returned to Anchorage on the evening of the same day. CONTINUOUS PRINTING OF ALASKA (907) 562-0446. RAVEL AUTHORIZATION NO. DATE stare oF ataska ina, lun ccunl ect aaae a ck O BO - 14-954 WARRANT MAILING ADORESS CITY v ys AO STATE “ DIVISION [ananns UNIT] WORK STATION | mn £8 AEA EBA PURPOSE OFTRIP OOemsee START up of Manokotak W-H. Susie ZIP CODE PER DIEM OTHER TOTAL $ $ $ enany “iolauiio | ehial pO Lb lofay[49o | kotodc - 29-90 | Civ ] 0 DEPARTMENT DATE GOV. (OUT-OF-STATE ONLY) [DATE javenovas HUT calf tte | yz ———e—— ng he en ee FINANCIAL CODING esTasaten j RANSPORTATION O'SACIO) | costs | § PQA 4116 A Qe fi? 3. SO CLAIMANT'S CERTIFICATION: The facts stated herein or on supporting documents are SUBTOTALS correct and in accordance with established trave} regulations, returned. ig) THIS PAGE (CO 00 . TO pd yf % TOTAL ALL CLAIMANTS SIGNATURE: 7 iS reaeN crn Boge PAGE 1 OF PAGES | PAGES $ ee ee $ 2 ee en a eee ee —— OLCcC om Ss a 13 [eo VFulkKor SCSwdSSC“(i*é‘*;™Cd*dC pp rR dH... pee | eee eee rot amoumr fey] ce Sar eee ee ee ee pa fT BOR OOd | IGT ABSA tT CSSCirStSCtCSY Se Pp ss Pe pt CERTIFICATION: ‘certify thatthe facts herein and on supporting documents are correct that this voucher constitutes a legal charge against funds and appropriations cited that sufficient funds are encumbered to pay this obligation or that there is a sufficient unencumbered balance in the appropriation cited to cover this obligation. | am aware that certifying false, inaccurate or misieading documents constitutes an unswom falsification under AS 11.56.210. Woe. TRIP REPORT O: David Denig-Chakroff Director, Rural Programs FROM: John R. Bulkow 7 Project Manager SUBJECT: Trip Report, Manokotak DATE: August 20, 1990 PURPOSE The Alaska Energy Authority is assisting the Southwest Region School District in the construction of a waste heat system in the community of Manokotak. On July 30th Energy Authority personnel were sent to Manokotak to complete the piping required in the powerhouse. This trip was made to coordinate our efforts with the school district and oversee the construction. DILLINGHAM On the morning of August 3 I travelled to Dillingham via Markair. In Dillingham I met with Don Ford of the Southwest Region School District. He indicated that the radiator and power plant heat exchanger had not arrived yet. He also indicated that the District would just as soon wait until an as-built was made of the system before getting multiple copies of the plans for the system. Don Ford and I then proceeded to Manokotak on Tucker Air using a School District TR. MANOKOTAK On arrival in Manokotak Don Ford and I met with the School District personnel installing the arctic piping for the system and stressed that the piping must be air tested before the joints are covered up. I then proceeded to the power plant where George (Chip) Sterbenz, Gary Thomas, and Noel Cervantes were working on the piping within the power plant. Upon my arrival the radiator had been removed from the Detroit Diesel gen-set, the engine primary outlet piping was partially complete, and the radiator platform was mostly finished. On August 4 the engine primary inlet piping was constructed, the legs were welded to the radiator platform, and the Amot valve was installed. While welding inside the power plant on this day sparks ignited a stain of diesel fuel on the floor. Although the fire was quickly and easily extinguished, it is distressing to note that no fire extinguisher was on hand and the stain came from leaks in fuel piping recently installed by the Alaska Energy Authority. Fire extinguishers were borrowed from the school, the stain was covered with Plywood, and (since fixing the leak required shutting down the generator) a catch pan was used to contain further leakage ona temporary basis. On August 5 engine connections were made to the Detroit and Mitsubishi generator-sets, School District personnel painted the radiator platform, and the site was cleaned up. I located the power plant operator, and he notified the community by radio that the power was about to be shut off and then shut down the system for us. The power remained off for about 20 minutes while we repaired the leaks in the fuel piping, which were mainly in the filter and meter assembly. I and the rest of the Energy Authority personnel then returned to Anchorage via Dillinghan. ADDITIONAL ACTION REQUIRED At the time of the writing of this report the heat exchanger, radiator, and other materials needed to complete the project have arrived in Manokotak and Energy Authority personnel are in route to complete the power plant portion of the system. When the system is complete, I shall make one more trip to assure a smooth start-up and as-built the system. On the subject of fire extinguishers I suggest that our existing stock of extinguishers be inspected and recharged if necessary, addition extinguishers be purchased if needed, and at least Rural Programs (if not the entire Alaska Energy Authority) institute a policy that no cutting torch or welding equipment is ever to be used unless fire fighting equipment is on hand. As part of this policy it should be required that any time a torch or welder is sent to a remote location a fire extinguisher must be sent also. > . @& -_ COUN TINUUUDS FRINGING Ur ALASKA yurp or ww . oN \ v wen TRAVEL AUTHORIZATION NO. { eS STATE OF ALASKA fey 6/4 -)95(,191) (9 (it ragibo P(e Masog "Sap 14 —15: ee Oy a erp ued HO DIVISION -5 < sos IG/UNIT JWVVLALE AK PONG SL Mack PURPOSE OF TRIP = 7 et Widen 2 f 2 tut al af ase Te Suz Aw Safed 0 fe res sO [tgnsronaren . DIEM OTHER TOTAL re GA $ aecniny Nag oh ATU pI | Wine L. , i RN 0) eye 0 iz QEPARTMENT DATE GOV. oe oO . DATE APPROVALS Y ZIG I a MY 4 pores [The gd EAE FACTUAL COSTS EXPLANATION IMILES X RATE] CASH FARE PER DIEM OTHER DATE 1 2/h3/GO | DePArTED ANCHOPAGE 1OSO AT) yy MILEAGE OR a ARALED Dueinenam 1:50 Am _| IOF DEPATTEND O1OINGHAM 41:45pm Arrive.) MAN CKOTAK 2:00 P27 PAID for 2 DiGHTS LODGING | IW SCRooU Housi WG 5 QePATIEO MAN GLOTAK 4:30AM | J Arrui=Q Diteing wam 4. ys PM PDEPATIEO DLLME HAM 6:30 PM Arriv©) AncvorAge Zar pm | F OO} PArknNE FEC AIrRrr B1O3190|} mit eEAce FOF From PoeT i 5/05 190. F AIR 00 Vay of CLAIMANT'S CERTIFICATION: The facts stated herein or on supporting documents are lf . correct and in accordance with established travel regulations, returned. iia IS” g O Ob Q THIS PAGE TOTAL ALL PAGE 1 OF PAGES | PAGES ee ae oe LESS TATE ASTINEE == | 422.00 | Z/o2T9D _|* $ SEE FINAL PAYMENT _——}————}: $ COMMENTS - ——- (Jo CERTIFICATION: | certify that the facts herein and on supporting documents are correct that this voucher constitutes a legal charge against funds and appropriations cited that sufficient funds are encumbered to pay this obligation or that there is a sufficient unencumbered balance in the appropriation cited to cover this obligation. | am aware that certifying false, Inaccurate or misleading documents constitutes an unswom falsification under AS 11.56.210. Han Choe. DATE: TO: FROM: SUBJECT: TJ8797 (1) MEMORANDUM August 6, 1990 File George (Chip) Sterbenz Remote Construction/Maintenance Worker Trip Report - Manokotak July 30, 1990 Departed Anchorage at 10:50 a.m. Arrived in Dillingham at 11:45 a.m. Checked with three local airlines about chartering out to manokotak with 1,800 lbs. of gear. All of the airlines were busy until 9:00 p.m., which is cutoff time for flying. We waited around the airport for a couple of hours to see if a flight might become TJ8797 (2) available, but to no avail. Stayed overnight in Dillingham. July 31, 1990 I sent Noel with the first planeload of gear over to Manokotak. It took three planeloads to get everything over. I finally arrived over at Manokotak at 12:30 p.m. Met up with Noel at the airport. Moved personal gear over to school housing, where we will be staying. Afterwards, Noel and I went over to the plant and unpacked tools and organized parts. Started removal of the remote radiator off of the Detroit Diesel gen-set. August 1, 1990 Finished removing the radiator and~ placed it outside. Started moving material away from alongside of the powerplant, so that we could get behind the plant with some heavy equipment. Gary Thomas showed up late this afternoon. I went over the plans with him to build the remote radiator stand. August 2, 1990 TJ8797 (3) Assisted Gary in building the radiator stand. Moved miscellaneous material from the side of the powerhouse, so that the stand could be set behind the powerhouse with the frontend loader. August 3, 1990 Built engine primary outlet piping. Moved it into place and fastened it to the wall. Stubbed the pipe outside towards where the radiators will be. August 4, 1990 Built engine primary inlet piping. Installed the amot valve. I then built the bottom outlet piping off of the A port of the Amot valve. Stubbed the pipe outside, through the powerplant wall. August 5, 1990 Made up the engine connections for the Detroit and Mitsubishi gen-sets. Used red stripe nitrate house and bolt type band clamps to make final connections. Cleaned up plant site outside and inside. Departed Manokotak at 4:30 p.m. Arrived in Dillingham at 4:45 p.m. Made eee 138797 (4) arrangements to freight tools on MarkAir Cargo back to Anchorage. Departed Dillingham at 6:30 p.m. Arrived in Anchorage at 7:30 p.m. Summar The primary piping is approximately 75% completed. Upon arrival of the second remote radiator and the heat exchanger, the entire system will be completed in 4-5 days. Work needed to be completed is the CAT 3306 generator needs to be tied into the new primary system, and both radiators to be plumbed together. Also the heat exchanger needs to be piped in on both primary and secondary sides. GS:tlj a ace MEMbLES Couns SCHAALEE HULA Riaur ACROSS Fhe STORE LAS TU6BLUEL -— CAML crtO oe hClh TRIP REPORT TO: David Denig-Chakroff Director, Rural Programs FROM: John R. Bulkow Rural Systems Engineer SUBJECT: Trip Report Manokotak, Clark’s Point, & Levelock DATE: February 20, 1990 PURPOSE The Alaska Energy Authority has agreements with the Southwest Region School District and the Lake & Peninsula School District to assist in the design and construction of waste heat systems in Manokotak & Clark’s Point and the redesign of the waste heat system in Levelock. This trip was made to obtain the required design information at all three sites. MANOKOTAK I left Anchorage on the morning of February 5 and travelled through Dillingham to Manokotak via Markair & Markair Express. On arrival in Manokotak I went directly to the school where I met with the principal, Kevin Hoyer. Mr. Hoyer indicated that the heating system of the school had recently been rebuilt and was working well. I then spent a few hours photographing and making as-built sketches of the school boiler room and fan room. There is ample room for waste heat recovery equipment in the boiler room. The return header of the school heating system already has valved and capped tees in place for future connection of a waste heat system. Next the power plant operator was contacted. He provided access to the powerhouse but did not have time to discuss connecting a waste heat recovery system. The powerhouse is an approximately 16’x50’ uninsulated wood frame structure with metal siding and a concrete floor. The building contains three 300 KW generators. At the time of my visit only one of the units was operating and one of the units was partially dismantled (presumably for repairs). Each generator set currently has a skid mounted radiator. Connecting a waste heat recovery system would require removing the skid mounted radiators and providing remote radiators, a heat exchanger, & header piping connecting the existing generator units to the new equipment. There is sufficient space inside the powerhouse for a waste heat recovery heat exchanger and space behind the powerhouse for remote radiators. After completing my inspection of the power plant I investigated the area between the school and the powerhouse for possible routes for the waste heat arctic piping. There are two logical routes for the piping to take. One route could follow the existing roadway easements. A more direct route would require obtaining a right-of-way across what appears to be private property. At 4:45 p.m. I took a Markair Express flight back to Dillingham where I spent the night at the Bristol Inn. The next morning I met with Don Ford, the maintenance supervisor for the Southwest Region School District. Mr. Ford took me to the school district maintenance building where I reviewed the Fryer/Pressley design for the Manokotak school heating renovation. Together with one of the school district welders we discussed Southwest Region School District criteria for waste heat recovery systems. In general they like our standard waste heat designs, however, rather than tying the arctic pipe directly to the school heating system as we sometimes do they would prefer to isolate the school heating system from the arctic piping with a heat exchanger. At this meeting they also indicated that they were down to about 400 ft of arctic pipe and completely out of arctic pipe fittings, foam packs, foam pads, etc. CLARK’S POINT At 11:00 a.m. Don Ford & I took a Peninsula Air flight to Clark’s Point. We first checked in with Richard (Dick) Montgomery, the school principal, and then went to the power plant. Sam Clark, the power plant operator, met us there. Don Ford spoke with Sam Clark in the plant office while I photographed and made as-built sketches of the generator cooling system. The plant has three generator sets: a 50 KW, a 60 KW, & a 100 KW. Sam Clark indicated that power is provided almost exclusively by the 60 KW unit. The generator engines at this site have already been connected to a common header and a remote radiator. Three unit heaters for heating the powerhouse are connected directly to the header and a shell & tube type heat exchanger was incorporated into the system for future connection of a waste heat recovery system. The system appears to function adequately despite the fact that in some places the cooling piping reduces in size for no apparent reason. Connecting a waste heat recovery system for the school would require a plate & frame type heat exchanger and replacing the undersized piping in the cooling system. After breaking for lunch we next inspected the school boiler room, fan room, and crawl space. The boiler room is congested and has little space available for a waste heat recovery heat exchanger. Capped tees terminating in the crawl space are already installed in the heating system return header for connection of a waste heat recovery system. Unfortunately, one of these tees is incorrectly placed to be utilized. The most viable location for a waste heat recovery heat exchanger is in the fan room located directly above the boiler room. At 4:00 p.m. Don Ford and I returned to Dillingham. LEVELOCK On the morning of February 7 I proceeded to Levelock via Peninsula Air. Chuck Beatie, maintenance supervisor for the Lake & Peninsula School District, met me at the airport and took me to the school. As noted by Peter Hansen on a previous visit to this site, the school boiler room piping is quite complicated. There are certainly more pumps than necessary for this type of system and some of these pumps may be oversized. Chuck Beatie indicated that he would like the system redesign to simplify the piping as much as possible. Chuck Beatie also indicated that he liked the Grundfos series 200 type pump but would rather not use the dual head version of this model. It should be noted that there are two domestic water lines in the boiler room that are insulated with asbestos insulation. The School District is aware of the asbestos problem and has the area posted. Care should be taken, however, to avoid disturbing this piping while working on the heating system piping. The power plant has three generator sets: two 130 KW units and a 50 KW unit. The 50 KW unit and one of the 130 KW units are connected to a common header. The piping of this common header runs through a shell and tube type heat exchanger, an AMOT valve, and then either back to the engines or through a remote radiator and back to the engines (depending on the operating position of the AMOT). Cooling piping for the third generator set is identical to the common header except there are no connections to the 50 KW unit. The two shell and tube heat exchangers capture the waste heat for the school. There are 2-way control valves in the secondary side piping coming from the heat exchangers. It appears that these 2-way valves shut when a temperature switch in the primary piping senses that the supply temperature from the engines has dropped below 145 degrees Fahrenheit. This protects the engines from being overcooled but leaves the waste heat pump trying to pump fluid through a blocked line when the valves close. No controls for the remote radiators were evident, apparently the remote radiator fan of whichever radiator is connected to the running generator set is allowed to run continuously. Work that should be done in the power plant includes replacing the two shell & tube type heat exchangers with a single plate & frame heat exchanger, replacing the 2-way control valves with a 3-way control valve, and providing two speed controllers for the remote radiators. At 5:45 p.m. I returned via Peninsula Air to Dillingham where I took a Markair flight back to Anchorage. MAN ALSTAL 2/5/42 ABS Bt ab suvaedv 2-27? Q3sv|enra PIMORS 7H Wweda estui/ dpe 33 b§ @we9 GS = F-9 Oe 3911335 934 2-20 wea esr / ans 42 54 @we? SS os s2I73s 72d 3 I1-d? ZeEeo Ei —- O1VlL Fired. Ho.H. Or’ Bick Monte 36lE EAP. Wi Bi8 Brews Bteovs GO GAL RATE 3 GR Few Qq cy Teri? : super? 166 °F QO 14°F HWC RMrURNS 3G irene nd = FuRnace WARM Ay ’ Osiz-i8s CAP, FitiniG cAamAuTY 150 MBH 4.35. Grit LéncA Mopper veouwn | 7TevOLLeN 5 SQUARE ETS 5 SQUARE $9 SHEETS 5 SQUARE Rae | Sto 2/sl ic MANS KOTAK Scttooer AlyeADY § (pas Bio “NACVED > o¥eds (ours. 4st. Welle CopPtcsr ren Ligic -rt cleArdt “Bercees StZE 45 BH —-I-S 94S mBH Nor 2ATWe Cusarees Gotan -PIATT RB.T-C-OT =—BuenKseS 4 4 Gl (OE SR: ae Bowers or = |Se ISZ2° FR. peru serte. © times: om vise EXTROU MODEL AY-2UOV EXPANSION TANK COA NG Oy £22. SAO Peg EN Sree. 1s WATBHL Jarv¥oeoe mix Coovitusem °SsB~t ) \ DDC CONTROLS | ASOLT BY SHsTecH cOrmTFOLS FOel Rook BAG Bio AiR Uanteina UPTS~ AL AUT ERO oi eartie¥ og