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Tununak District Heat Report & Concept Level Design 1991
Tununak 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 NS polarconsult alaska, inc. AL ENGINEERS e SURVEYORS ¢ ENERGY CONSULTANTS ® » 1503 WEST 33RD AVE.* ANCHCRAGE, ALASKA 99503 aN PHONE: (907) 258-2420 FAX: (907) 258-2419 This study was prepared under contract with the Alaska Energy Authority by: Polarconsult Alaska, Inc. 1503 West 33rd Avenue Anchorage, Alaska 99503 The accepted conclusions are: Ls A potential for waste heat recovery has been identified in the community of Tununak. Ze Based on the proposed design and project cost estimate, the project is not economically feasible and does not appear to justify conventional financing. Alternate funding sources and/or revisions to the project scope will need to be evaluated. 3. The designs presented herein are schematic in nature and should not be construed as being complete in design or function. A thorough review of content and correctness should be performed prior to use in the development of construction documents. The concept-level project cost estimate for Scenario #1 is $286,072. Final review comments and responses which were not incorporated into the report have been included in Appendix A. Accepted: ZS. : : Az2t [Fz Brian C. Gray Date Project Manager LLL 2- Date Accepted: Manager of Rural Projects polarconsult Tununak District Heating Executive Summary Tununak is a remote community with a population of 350, located in Western Alaska on Nelson Island at the confluence of the Tununak River and the Bering Sea. Tununak obtains its electricity from a Alaska Village Electrical Cooperative (AVEC) diesel plant. There is potential to recover heat from these diesels. This report was commissioned by the Alaska Energy Authority (AEA) to determine whether introduction of a district heating system, which would recover this heat, would save the community money. With the 1990 cost of heating oil varying between &1.06 and $1.88 per gallon, substantial sums are expended to heat community buildings. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which transfers heat to water, and a pump to circulate the water through the baseboard heaters. At the heaters, the heat is transferred to the air which heats the building. A district heating system works in a similar manner as the engine heats the water, but it utilizes waste heat instead of burning fuel. This report discusses how this heat may be used in Tununak, and what results may be expected. The water system and school buildings were studied as likely candidates to be served by a district heating system in Tununak. The most economical district heating system connection would be the water treatment plant. This combination would utilize half (50%) of the heat available at the power plant during the winter months and would be the most cost effective system. Project cost, annual amount of fuel saved and fuel cost savings for Concept 1 are as follows: Project Cost $286,072 Amount of Fuel Saved per Year 11,001 Annual Savings $20,682 Straight Pay Back in Years 13.8 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 polarconsult Tununak District Heating system, construction of a hot water transmission line and renovations to the water treatment plant heating system. 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 $1,184 per year to repair actual failures in the district heating system. Routine maintenance will be performed during three trips to Tununak 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 13.8 years. The project could be made more attractive economically by reducing its scale through minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Western Alaska communities to reduce Tununak's share of the high mobilization, shipping, travel, and supervision costs required. ad. polarconsult Tununak District Heating CONTENTS Executive Summary List of Figures List of Tables I. Introduction A. Objective B. District Heating System C. Methodology D. Community Description E. Projected Load Changes IL. Site Visit C. Building Heat D. Proposed District Heating Connection IV. Potential District Heating Users A. School 3. Heat Use 4, District Heating Connection B. Water Treatment Building 3. Heat Use 4, District Heating Connection V. Concept Design Drawings VI. Failure Analysis A. Introduction B. Failure Analysis of District Heating System 1. Power Plant 2. Distribution System 3. User Connections polarconsult Tununak District Heating C. Failure Frequency and Cost D. Design Decisions to Minimize Failure VIL. Project Specifications A. Codes and Regulations B. DIVISION 01 - General Requirements C. DIVISION 02 - Sitework D. DIVISION 13 - Special Construction E. DIVISION 15 - Mechanical Outline Specification F. DIVISION 16 - Electrical Outline Specification VIII. Project Cost Estimate A. Power Plant Heat Recovery System B. District Heating Distribution System C. Operation and Maintenance Costs D. Project Cost Summary IX. Conclusions A. Heat Availability & Fuel Consumption B. Project Cost Summary X. Recommendations Calculations Field Trip Notes polarconsult Tununak District Heating List of Figures Il-1 AVEC Plant, Water Treatment Plant, & School... .. 2.0... 0002 ee eee az I-2 AVEC Plant, Remote Radiator, & Proposed District Heating Module Location . 7 I-3 Unit #1, Cummins LTA 10 with Remote Radiator .............00005 8 I-4 Unit #2, Allis Chalmers 6851 with Skid Mounted Radiator ............. 8 IV-1 Proposed Location of District Heating Equipment in School ........... 13 IV-2 Proposed District Heating Connection to School Boiler Return Header ..... 13 IV-3 Proposed District Heating Pipeline to Water Treatment Plant & School ..... 16 IV-4 Proposed District Heating Connection to Boilers... ........ 000 eae 16 V-1 Site Plan & Proposed District Heating System Distribution ............ 17 V-2 Proposed System Schematic»... . eee ee eee eee 18 V-3 Detail of Revisions to Existing Power Plant & District Heating Connection .. 19 V-4 Water Treatment Plant Piping Connection Schematic & Floor Plan....... 20 V-5 School Piping Connection Schematic & Floor Plan. ...... 0.0.00 eee 21 IX-1 Heat Available vs Heat Required ....... 00... cee eee ee ees 45 IX-2 Gallons of Heating Oil Displaced... 2... ee ee 45 List of Tables I-A Concept Alternative Summary... .... ee eee 3 DED ASEM UT VAC sets g cee ese vole ete to ee Pior ceie tom Ete estat eee vateeIs ge aves eets 3 I-B Monthly Power Generation & Available Heat... ....... cece eee 6 IV-A_ Estimated Distribution of Fuel Oil Use atSchool ..............0005 12 IV-B_ Estimated Distribution of Fuel Oil Use at Water Treatment Building ...... 15 VI-A System Component Failure Rates 1... ee ee es 31 VI-B Annual Hours System Components Off Line... .............00 0s 32 VIM-A Summary of Alternative Project Costs... .... cece ee ee 43 IX-A Annual Heating Fuel Displacement & Pipeline Heat Losses ............ 44 13 Jae) oh (wef gett 9 Zereer eee wpa =cieO= CSCS SO =CEO= Ce CIO sO =t=C s0= eran = OSPR EPET=C=TETET 46 polarconsult Tununak District Heating 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 an 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 Tununak District Heating I. Introduction A. Objective The objective of this report is to determine the feasibility of recovering and using the waste heat from the Alaska Village Electric Cooperative (AVEC) power plant generators in Tununak. In view of the present cost of heating oil at over $1.88 per gallon, and the amount of heat presently being wasted to the outdoors through the engine radiators, the Alaska Energy Authority (AEA) determined that utilization of waste heat showed potential savings in heating costs. The scope of this report is to determine if a district heating system is feasible, identify optimal applications, and estimate the cost of constructing this system in Tununak. B. District Heating System A district heating system takes energy that would otherwise be wasted and converts it to beneficial use as space heat. A brief description of a district heating system follows. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which burns fuel, usually oil, and transfers the heat to water, which is circulated by a pump through pipes to radiators. At the radiator the heat is transferred to the air within the building. A district heating system works similarly, with the water heated by diesel engines 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 and distributed in pipes to buildings instead of being rejected to the atmosphere. This report discusses how waste heat can be used in Tununak, and the likely results. C. Methodology The feasibility of waste heat use in Tununak 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 polarconsult Tununak District Heating and identification of potential user facilities. The field trip was coordinated with village officials and AVEC operators. 2. Field Trip: The site visit was made to discuss the project with the Village Council and interested persons, to survey potential user buildings and determine possible distribution pipe routes. Criteria for potential user facilities included public ownership, substantial heat use and proximity to the AVEC power plant. The manager or operator of each candidate building was interviewed. Information was gathered concerning: Rights-of-way; Amount, type and quality of construction equipment available in the village and the rental rates; o Availability of village-supplied labor during, the probable construction period; 0 Specific weather problems such as drifting snow; and Soils information. Field trip notes are shown in Appendix B. 3. Analysis: Field trip notes, photographs, general information and additional Site-specific features of the village were analyzed. Historical power production, weather information, and fuel usage records obtained during the field trip were entered into a computer model to determine the quantity of waste heat available to each potential user facility. On the basis of economics, several potential user facilities were eliminated. Specific details for hook-ups to the district heating system, including distribution pipe routing and location of user heat exchangers, were considered and included in the report. (See Figure V-1, "Site Plan and Proposed District Heating System Distribution," on page 18.) The following table summarizes the concepts which were investigated and the buildings involved with each concept: polarconsult Tununak District Heating TABLE TA Concept Alternative Summary Concept Building 1 Water Treatment Plant 2 School Building 3 Water Treatment Plant & School Building 4. Initial Submittal: A preliminary report on the project was written and distributed to the Alaska Energy Authority staff for comment. 5. Final Submittal: The final report will include all comments received from AEA and other interested parties who have reviewed the interim report. D. Community Description Tununak is located in Western Alaska on the northeast coast of Nelson Island at the confluence of the Tununak River and the Bering Sea. It is 519 miles northwest of Anchorage and 115 miles northwest of Bethel. The population is made up mostly of Eskimos, and the economy is based mainly on commercial fishing and subsistence hunting. The school district is the largest employer. Tununak states it has a population of 337. The community has a water distribution system originating from the water treatment plant / washeteria. Expansion of the water distribution system to the entire community is planned. The city has a large backhoe, UHO-82, which is only a year old, a JD350C equipped with a backhoe, a 545B front end loader, and a dump truck which may not be operational. This equipment will be available for construction of a district heating system. Local labor is available most of the summer, although a majority of the residents participate in commercial fisheries. E. Projected Load Changes The community states 11 new homes will be added this summer and they are projecting an increase in population. As a result there will be a unquantifiable increase in electrical requirements; which will increase the amount of waste heat produced at the power plant. Since the school complex is not scheduled for expansion, their heat requirements should remain constant. The heat requirements polarconsult Tununak District Heating of the water treatment system will grow with the community, and expansion of the water distribution system. AVEC projects an increase of 1% in the community's energy needs over the next three years with an increase of 9% over the following four years, according to its Power Requirements Study and 10-Year Plan. This increased requirement will proportionally increase the amount of heat available for use. Il. Site Visit The site visit was conducted during February of 1990 to discuss the project with the Village Council and interested persons, survey potential user buildings and determine possible routes for district heating distribution pipe. The principal of the school complex and operators of the water treatment building 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. Mike Franks of the Lower Kuskokwim School District was contacted about fuel usage of the schools. The school complex uses an average of 23,791 gallons of fuel per year. Field notes including a list of people contacted in the field, are shown in Appendix B. polarconsult Tununak District Heating II. Power Plant A. General The power plant is a standard AVEC Butler type structure. (See Figure III-1.) It now houses a new Cummins LTA 10 in addition to two Allis Chalmers. The Cummins, in position number one is the primary operating unit and is equipped with an individual remote radiator. (See Figures III-2 & III-3.) The other two engines are equipped with skid mounted radiators. (See Figure III-4.) Equipment with the characteristics given in Table III-A is installed in Tununak. Table I-A Engine Data Position/Unit 1 2 3 Engine Cummins Allis Chalmers Allis Chalmers Model LTA 10 6851 3500 Speed (rpm) 1800 1800 1800 Rating, Engine (kw)* 115 186 118 Heat Rejection** To Coolant (Btu/min) 4,100 7,000 5,088 To Stack (Btu/min) 4,600 -- --- To Ambient (Btu/min) 1,060 2,160 — Water Flow (gpm) 60 Ti 64 Intake Air Flow (CFM) 305 520 -_ * Engine rating at shaft. ** Rating at full load. B. Available Load Information & Available Heat Monthly power production figures for Tununak 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 Tununak District Heating 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 ----- 59,040 73,920 73,900 2,472 Feb 2 ==> 56,320 60,480 60,500 2,144 Mar === 58,480 63,360 63,400 2,339 Apr w= 60,480 60,000 60,000 2,215 May a---- 51,840 54,080 54,100 2,242 June ne-- 39,200 42,560 42,600 1,783 July 36,960 39,040 41,120 41,100 1,721 Aug 40,800 43,840 47,040 47,000 1,968 Sept 45,600 48,960 45,760 45,800 1,913 Oct 52,800 58,080 = ----- 62,0002 2,366 Nov 48,160 61,613 —----- 65,8002 2,361 Dec 72,320 70,240 ----- 75,0002 2,527 Annual 596,5873 647,133 691,1813 691,200 26,051 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 11.4% 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 Tununak District Heating WATER PLANT SCHOOL 4 Be FUEL TANKS | ee POWER PLANT Figure IlIl-1 AVEC Plant, Water Treatment Plant, & School = DISTRICT HEATING MODULE LOCATION Figure IlI-2 AVEC Plant, Remote Radiator, & Proposed District Heating Module Location polarconsult Tununak District Heating Figure III-3 Unit #1, Cummins LTA 10 with Remote Radiator . Figure Ill-4 Unit #2, Allis Chalmers 6851 with Skid Mounted Radiator polarconsult Tununak District Heating C. Building Heat The Butler building power plant is a metal frame building with 2 inch insulation in the walls and roof. The building has an uninsulated wooden floor covered with steel plate. Intake air comes from two ventilation louvers by the door. (See Figure Il-1.) Cooling air from the two skid mounted radiators are exhausted through motor-controlled dampers behind the radiators. (See Figures III-2 & III-4.) A schematic of the power plant showing the generators and radiators is shown in Figure V-3 on page 19. Heat losses from the building will reduce heat Availability for distribution by the waste heat recovery system. Heat given off by the engine and generator is usually sufficient to heat the structure in which the equipment is operating. Calculations show a quantity of heat equivalent to 394 gallons of oil per year would be required to keep the Butler building at 65°F with an operating engine. Insulating the floor will reduce this quantity to 95 gallons per year. Calculations are conservative as only the Cummins LTA 10 was assumed to be operating and floors were assumed to be insulated. When unoccupied, the temperature can be lowered, which will reduce losses even further. The engines are to be kept warm by circulating heated coolant from the operating engine through their blocks. The quantity of heat required to heat the engine block is less than that required to heat the module during cold weather. This means that the minimum heat requirement is that required to heat the engine block and that the values used are conservative. D. Proposed District Heating Connection The proposed district heating system schematic is shown in Figure V-2 (page 18) and the connection to the power plant is shown in Figure V-3 (page 19). Interconnections between the existing remote radiator and the proposed new remote radiator as well as the necessary interconnections between the remote radiators and existing engine\generator units 2 & 3 are included. (See Figure V-3.) Per AVEC, a single remote radiator will be sufficient to meet the engine demands, and will allow for any generator to be run off any one of two remote radiators. Building unit heaters and engine warming system connections are also included in the new piping, as is insulation in the floor of the Butler building. polarconsult Tununak District Heating The primary heat exchanger for the district heating system will be located in a small housing module on the back of the Butler building. (See Figure II-2). The expansion tank(s) and district heating pumps will be located at the user ends of the system. The district heat module will use 2x4 standard wood frame construction. The module will be supported on a cantilevered frame off the pile supported Butler building. The module will be insulated with fiberglass batt insulation and covered with metal siding on the exterior and plywood on the interior. Heat exchangers will be stainless steel plate type units. The primary side piping will run from the heat exchanger, under the floor of the butler building, and connect to the three engines. (See Figures II-3 & II-4). The piping will be black welded steel pipe with flanges for valves and other removable fittings. The outside piping between the structures will be insulated. The district heating electrical systems for the new heat exchanger module involving a light and receptacles, 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 VII, Project Cost Estimate. 10 polarconsult Tununak District Heating IV. Potential District Heating Users A. School 1. General The school, which is operated by the Lower Kuskokwim School District, based in Bethel, has an enrollment of 90 students in grades K through 12. The preschool has an enrollment of 30 pupils. One building houses elementary through high school. Other buildings include teacher housing in the converted BIA school. The main school building consists of a new section heated by a boiler and hydronic system, and the old section heated with a forced air furnace. The entire building is estimated to use approximately 16,000 gallons of oil per year. 2. Location The pipeline will extend about 630 feet from the power plant to the school. (See Figure Il-1 & V-1.) "Arctic" distribution pipe, 2.5 inches in diameter, will be buried throughout the first 250 foot long section to the tee off to the water plant. From this point, 2 inch diameter pipe will traverse a distance of 380 feet to the school. (See Figure V-1) The pipeline can be buried or placed adjacent to the existing above-ground water and sewer lines serving the school. The pipeline will cross areas of gravel, rock and permafrost. It is likely private easements will not be required, although easements may be required where the pipeline route is on AVEC, City, Corporation, or school property. 3. Heat Use Fuel records for the school facility in Tununak were obtained from Mr. Mike Franks of the Lower Kuskokwim School District in Bethel. The entire complex used 23,791 gallons of oil in FY 1989 with approximately 16,000 of this amount used in the main school building. The balance was used at the teachers housing which is a converted BIA school. A monthly breakdown of fuel consumed by the school complex was not available. Monthly fuel use was estimated by distributing the average annual fuel consumption based on the number of heating degree days per month. 11 polarconsult Tununak District Heating Table IV-A Estimated Distribution of Fuel Oil Use at School Month Heating School Degree Days (Gal. Oil) January 1,769 2,214 February 1,759 2,202 March 1,406 1,760 April 1,285 1,608 May 1,263 1,581 June 540 676 July 0 0 August 591 740 September 677 847 October 1,006 1,259 November 1,153 1,443 December 1,334 1,670 Annual 12,783 16,000 Purchase Cost / gal $1.055 4, District Heating Connection The buried district heating pipe will emerge under the school, enter the new school section in the shop room, below the second floor boiler room, and extend up into the new section boiler room. The heat exchanger, pumps and expansion tank will be located in this boiler room. (See Figure IV-1.) The secondary side of the heat exchanger will connect to the boiler return lines and the warm air furnace in the adjacent old section mechanical room. (See Figures [V-1 & V-5.) This connection will supply district heating to the old school forced air system and the new school hydronic system. The cost of connecting the school building to the district heating system is covered in Section VIII. 12 = polarconsult Tununak District Heating Figure IV-1 Proposed Location of District Heating Equipment in School - Figure IV-2 = Proposed District Heating _ Connection to School Boiler -_ Return Header LS oi polarconsult Tununak District Heating B. Water Treatment Building 1. General The water treatment building is owned and operated by the City of Tununak. Technical assistance is provided by the U.S. Public Health Service. The facility includes a 50,000 gallon insulated storage tank, water treatment equipment and boilers to heat the water. In addition the building contains a washeteria and watering point for people who haul their water. There are several insulated water distribution loops through the community. With the exception of the line to the school, all of the water lines are below ground. 2. Location The water treatment building is located 250 feet from the power plant. (See Figures II]-1 & V-1.) The district heating distribution pipe from the power plant to the treatment facility will be buried "Arctic" pipe. Service to the water treatment facility will be a 40 foot long, 1.5 inch diameter branch off the main line to the school. (See Figures IV-3 & V-1.) 3. Heat Use The water treatment building's two boilers supply heat to the water treatment building, the water storage tank, the circulating water in the distribution lines, the washeteria dryers, and bathing facilities. Fuel records for the water treatment building were obtained from the City of Tununak. Monthly fuel use was estimated by distributing this fuel consumption, using the number of heating degree days per month. (See Appendix A for sample calculation.) 14 polarconsult Tununak District Heating Table IV-B Estimated Distribution of Fuel Oil Use at Water Treatment Building Month Net Fuel Heating Oil Use Degree Days (Gal.) (HDD) January 1,216 1,769 February 1211 1,759 March 1,052 1,406 April 997 1,285 May 987 1,263 June 661 540 July 643 500 August 684 591 September 722 677 October 871 1,006 November 937 15153 December 1,019 1,334 Annual 11,000 13,283 Purchase cost / gal. $1.88 Note: Oil distribution is based on 5,000 gallons of oil being uniformly distributed over a year with the balance of 6,000 gallons being distributed in accordance with degree-days. 4. District Heating Connection The district heating pipe will be buried and emerge outside the water treatment building and enter through the wall next to the district heating equipment in the Northwest corner of the building. The heat exchanger, pumps and expansion tank will be located in this room, and connection will be made to the boilers in the adjacent room. (See Figure IV-4.) The secondary side of the heat exchanger will connect to the boiler return lines. (See Figure V-7.) The cost of connecting the water treatment plant to the district heating system is covered in Section VII. TS polarconsult Gm, Eg ote ? enon D Tununak District Heating Figure IV-3 Proposed District Heating Pipeline to Water Treatment Plant & School Figure IV-4 Proposed District Heating Connection to Boilers 16 polarconsult Tununak District Heating V. Concept Design Drawings TUNUNAK SITE PLAN & PROPOSED DISTRICT HEATING SYSTEM ne \, ABOVE GROUND WATER & SEWER \ \ \ » » x LEGEND VZZ] PROPOSED WASTE HEAT USER PROPOSED WASTE HEAT LINE —---- EXISTING SEWER LINE ++ EASEMENT REQUIRED EXST. UG POWER LINE —-£-- EXISTING FUEL LINE © EXISTING POWER POLE FIGURE : V-l Li? polarconsult Tununak District Heating TUNUNAK — PROPOSED SYSTEM SCHEMATIC SCHOOL (SEE FIG. V-5> TITAN te | | | | CONNECT | TO USERUSER | SYSTEM HEAT r EINER CONCEPT 3 | | | 290° - .2:5°8 ST 380’ - 2°68 Ti, mk 40° - 15°28 WATER TREATMENT BUILDING (SEE FIG, V-4) ARCTIC PIPE | | CONNECT | USER TO USER | HEAT SYSTEM | EXCHANGER. en I) es oe pa | | | | | | | BURIED | | | | | | | Ito ENGINE eo +} | COOLING system | | ad | | PRIMARY HEAT tl 4d EXCHANGER BUTLER BUILDING DISTRICT HEAT MODULE (SEE FIGURE V-3) CSEE FIG. V-3) Dx] ISOLATION VALVE FN CHECK VALVE — -— EXISTING NEW DISTRIBUTION NEW @ USER NEW @ PLANT €) USER PRIMARY DISTRIBUTION PUMPS FIGURE V-2 NTS 18 polarconsult fO DISTRICT HEAT SYSTEM ye FIGURE V-I Tununak District Heating TUNUNAK DETAIL SHOWING REVISIONS TO POWER PLANT AND DISTRICT HEAT CONNECTION EXISTING NEW RADIATOR RADIATOR NOTE “7 / Se y/ PP <y™ - | | ro oe @Hih PRIMARY HEAT EXCHANGER | i | DISTRICT HEAT MODULE (NEW) Il -— | + ll} ch 4} +] —_ #1 ENGINE #2 ENGINE #3 UNIT HEATER EQUIPMENT SCHEDULE HEAT EXCHANGER — 400,000 BTU/HR RADIATORS YOUNG, SERIES 22 PLANT PIPING 3"_STEEL, WELDED UNIT HEATER 60,000 BTU/HR 1” CU LEGEND \l BUTTERFLY VALVE SS) AMOT VALVE PX) CHECK VALVE jij += FLEX CONNECTOR EXISTING NEW DISTRICT HEAT SYSTEM NEW PRIMARY PIPING &D «]) PUMP SCALE: NTS EXISTING POWER PLANT OTES: . LOCATION OF POSSIBLE BOOSTER PUMP . PUMPED ENGINE WARM SYSTEMS FOR ENGINES 1 AND 2, AND EXP. TANKS NOT SHOWN. . EXISTING SYSTEM COMPRISES ONE ENGINE WITH REMOTE MOUNTED RADIATOR AND ENGINE #2, & #3 WITH SKID MOUNTED RADIATORS. FIGURE V-3 19 polarconsult Tununak District Heating TUNUNAK — WATER TREATMENT BUILDING (USER HOOK-UP) EQUIPMENT SCHEDULE A suPPLies HEAT EXCHANGER 200,000 BTU/HR t ZONE PUMPS GRUNDFOS, SERIES 200, LIMC 65-80 EXPANSION TANK NOT REQUIRED PIPING: SUPPLY SIDE 1.5” STEEL, WELDED ZONE RETURNS BOILER SIDE 1.5” CU Tinea J | 10 DISTRICT “HEAT SYSTEM FROM DISTRICT HEAT EXCHANGER tC— “HEAT SYSTEM AIR SEPARATOR SYSTEM SCHEMATIC ES TANK a DISTRICT HEATING SYSTEM TT SPACE PUMP § yy, ~ FOR USER ees EQUIPMENT] LEGEND % “ rane 7 GATE VALVE - VY BAL. VALVE EURNAG CD. PUMP CHECK VALVE EXISTING BUILDING WASHETERIA NEW @ USER EXISTING Yd NEW DISTRIBUTION STRAINER TEMP CONTROL VALVE FLOOR PLAN SCALE: 1’ = 15’ FIGURE v—4 20 polarconsult Tununak District Heating TUNUNAK — ELEMENTARY & HIGH SCHOOL BUILDING (USER HOOK-UP) EQUIPMENT SCHEDULE HEAT EXCHANGER 350,000 BTU/HR PUMPS GRUNDFOS, SERIES 200, UMC 65—80 EXPANSION TANK 26 GAL. PIPING: = r SSS r = Ss SUPPLY SIDE 2’ STEEL, WELDED = en exes BOILER SIDE 1-1/2” CU caw Aw Xp © pO Nees zone | LL — — -w +5 SUPPLIES . ZONE —wa-5 RETURNS g10 STRICT Seay Sy STEM EXPANSION TANK _i . gGbyYCOL Fae - -FROM DISTRICT HEAT EXCHANGER “HEAT SYSTEM AIR SEPARATOR SYSTEM SCHEMATIC - (ams! = NEW HEATING COIL ———— IN OLD SCHOOL I Fe - HOT AIR FURNACE pistrict, _ | x HEATING S SYSTEM © - FOR USER EQUIPMENT @ND FLOOR MECHANICAL . LEGEND GATE VALVE - BAL. VALVE PUMP CHECK VALVE = EXISTING BUILDING J NEW @ USER CATWALK - EXISTING , NEW DISTRIBUTION _ I STRAINER TEMP CONTROL VALVE . eT FLOOR PLAN FIGURE 2 ~ SCALE: 1° = 10’ V-5 fail 4 polarconsult Tununak District Heating VI. Failure Analysis A. Introduction Failure analysis is the process of predicting the operational reliability of a system. It provides information on the probable type and frequency of failures, and indicates how the system should be designed and maintained for optimal reliability. Reliability (R) is defined as that portion of time a system is functional. Unreliability (UR) is defined as (1 - R). Reliability is determined using the total time of operation (Total Period), mean time between failures (MTBF), and mean time to repair (MTTR). A district heating system depends on a number of components to provide heat to the user. The total unreliability of the system is the sum of the unreliabilities of these components. For example, if a pipe had an MTBF (mean time between failure) of 8,760 hours, and an MTTR (mean time to repair) of 8.77 hours, the reliability would be 1 - (8.77 / 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 will require an entire day to repair. The system will be unable to deliver heat if both 22 polarconsult Tununak District Heating units are unable to pump. Assuming both pumps fail at the same time, system reliability would average only 0.07 hours per year, as compared to a average of 24 hours per year with a single pump installed. Expressed in percentage of the year not serviceable, the value is 0.000751% for the two-pump system. The preceding example, comparing the failure rate of one versus two pumps, illustrates how important and powerful it is to provide redundant equipment for failure-prone items. This is economically feasible only where the costs of duplication are not great. All reliability analysis has limitations. The limitations of this study are as follows: First, it is based on historical data acquired from military, nuclear, and electrical industries, and is limited to the equipment used and the specific application conditions. Because the equipment and conditions will be different for this project, the outcome will be different. Second, the analysis is based on average conditions, and it is probable that for each individual system there will be a greater or lesser number of failures than predicted. Third, actual failure rates for a large number of plants will be closer to the calculated values, on average, than results from a smaller number of plants. Although the values derived by mathematical failure analysis for these systems cannot be exact for the individual installation, because the results are average values, they do provide important information. First, performing the analysis requires the designer and builder determine what causes system failures and take measures to avoid them. Second. the analysis provides the basis to determine which functions need added emphasis during maintenance programs. Third, some degree of scale is provided on how failure affects project income. B. Eailure Analysis of District Heating System A description of major system components, their failure modes, and impacts of failure on the system is presented below. The description starts at the power plant and works toward the served structure(s). 1, Power Plant a. Components 23) polarconsult Tununak District Heating 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, Tununak will have three. In general, the plants are sized so that a single engine can serve the entire community. The reported down time for AVEC generation systems during 1989 was 33 hours total. 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 the primary heat exchanger and two external radiators. One remote radiators is installed at present in Tununak. The primary generation system failure modes are: 1. Failure or shutdown of the engines; Failure of the radiators due to leakage; Failure of the hoses, valves and piping system; Failure of the engine block itself, and Su et Failure of the primary heat exchanger, piping, pumps and valves associated with the engine. Generation plant: Full failure of the generation plant, due to shut down, will stop heat production and disable the district heating system. AVEC reports that these occurrences average 33 hours per year, out of the 8,760 hours in a year. Radiator failure: Radiators usually fail by leaking from cracks 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 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 24 polarconsult Tununak District Heating prior to automatic shut-down. This allows the operator to isolate the leak, repair it, by-pass the leak, add additional glycol, or shut down the plant, as appropriate. The primary environmental problem associated with engine radiator failure is discharge of glycol onto the ground. Impacts on the environment from glycol leakage include thawing of permafrost, glycol contamination of groundwater, and glycol contamination of adjacent surface water bodies. Leaked glycol is difficult to recover because volumes are small, the terrain is usually rough, glycol mixes with water and ice, and it will disperse rapidly in water unless it is confined to a catchment basin. The above analysis applies to the existing system and the proposed district heating system upgrade. The only changes will be an increased potential volume of lost glycol, a slightly less reliable system as all equipment is connected to a single cooling system manifold, and a slight decrease in reliability caused by the addition of a heat exchanger. Primary heat exchanger: This component is composed of a series of formed stainless steel plates which are separated and sealed by rubber gaskets. The plates are bolted together within a steel frame to compress the gaskets and hold the plates together. The primary heat exchanger is used to transfer heat from the engine cooling fluid to the fluid circulated in the distribution pipes supplying the user's heat exchanger, thus serving to isolate the power plant ‘rom 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; Broken frame; Valve failure and stem leaks; 2 3 4. Cracking or corrosion of plates; 5. Connecting piping system failure; 6 Fouling; 25 polarconsult Tununak District Heating 7. Freezing while generation system is down, if water is used as coolant instead of glycol, and 8. Structural damage to exchanger supports due to fire or other events. Generation plant operational impact: 1. A large, sudden loss of coolant on the engine, or primary, side of the heat exchanger will shut down the engines. 2. 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. 2. 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 and weakening structural supports, and enter groundwater and surface water bodies. Required immediate actions: Determine cause of failure, isolate heat exchanger at valves or add additional glycol as required by procedures. Catch dripping glycol in 26 polarconsult 2. e. Tununak District Heating pans and recover spilled glycol. Call maintenance office if extra help is required. Distribution m Components: Transmission pipe will be mostly 2.5 and 2 inch diameter insulated pipe. Each 2.5 inch pipe will be made up of a steel carrier pipe 2.500 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 plated copper wires. These wires will provide a method to determine if water or glycol has leaked into the insulation. Covering the insulation will be a high molecular weight polyethylene jacket with an outside diameter of 6.30 inches. The pipe will be buried about 2 feet deep in the ground for the run to the water plant and can be buried or elevated along with the existing water lines which serve the school. 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; 4. Failure of pipe welds; and 5. Mechanical failure caused by frost heave or thaw settlement. Generation plant operational impact: None District heating operational impact: 1. No operational impact from minor leaks in jacket or pipe which are detected and corrected by the maintenance crew during routine inspections. 2. Larger leaks which cause a measurable loss of glycol will require shutdown of the line with isolation valves, and pipe repair to put system back on line. Environmental impact: 27 | 7 polarconsult Tununak District Heating 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. er Connections Components: Each system is composed of a heat exchanger similar to the one at the power plant, two circulation pumps, an expansion tank, provisions for adding glycol coolant, a btu meter, piping, and valves. Failure modes of the heat exchanger are: Blown or leaking gaskets; Broken frame; Valve failure and stem leaks; Cracking or corrosion of the plates; Connecting piping system failure; Fouling; PaAYVS YP Yr 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: Pump body failure; and 1. Failure of electrical circuit; 2. Seal failure; 3. Motor failure; 4. Impeller cavitation; 5: 6. Connection leakage. 28 polarconsult Tununak District Heating Failure modes of the expansion tank are: 1. Water logging or bladder failure; 2. Corrosion; and 3. Broken sight glass. Failure modes of the piping system are: 1. Leakage of valve stems; 2. Failure of valves to open or close; 3. Failures due to corrosion; and 4. Failures due to materials or installation defects. Failure modes of each of the school connections are: 1. Failure of the school system to hold fluid; and 2. Failure of the school's circulation pumps. 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: Ifa pump fails the system will be off until the failure is detected and the standby pump is put into service. If two pumps fail the system will be down until one can be repaired. Expansion tank: An expansion tank failure could be caused by the sight gage breaking, which will require system shut down until it is repaired. Corrosion is not a likely form of failure for an ASME 125 psi rated tank. Piping: Failure of the piping will generally occur at valve stems and where there are gaskets or joints. Slow leaks from these causes and from corrosion will not require shutting the system down. Shut-down of the system could be caused by a valve stem being twisted off or by a broken 29 polarconsult Tununak District Heating casting; repairs will be required before the system is returned to operation. e. 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. f. 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 the user building does not require heat. For a school this would be in the summer. Therefore, the potential effects of loss of energy sales during routine maintenance are not included in the calculations. AVEC generation: The most common form of failure is engine failure. Frequency is variable but outage time is estimated at less than 33 hours per year as four generators will be available. Repair cost to system is $0 as it is not related to district heating system. 30 polarconsult Tununak District Heating 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 7.9 years. Down time is 48 hours, repair cost is $2,000. There are no measurable effects on system life from repairs. User connections at school: The most common form of failure is the heat exchanger. Frequency of system failure for each system is estimated to be 4.3 years. The combined school system frequency of failure of one of the units is once each 1.4 years. Down time ranges from 24 to 72 hours depending on which item fails. Repair cost is $2,000. There will be no measurable effects on system life from repairs. User connection at water plant: The most common form of failure is the heat exchanger. Frequency of system failure for each system is estimated to be 4.3 years. Down time ranges from 24 to 72 hours depending on which item fails. Repair cost is $2,000. There will be no measurable effects on system life from repairs. Total system: Failure frequency of the total district heating recovery system is summarized in the following table. Figure VI-A System Component Failure Rates Item Failure Rate Heat recovery, power plant 0.000507 Transmission pipe* 0.00104 Water heating assembly 0.000747 hool heat assembly. 4 Total 0.003041 31 polarconsult Tununak District Heating *Note: This is the total length of pipe which includes common pipe plus the branches to the water heating and School. To make the above figures of value the subsequent table has been prepared which shows the effect of outages on the production or sale of heat. Figure VI-B_ Annual Hours System Components Off Line Item Failure Oil used Oil Lost Hours/yr % total Eq. hrs/yr Heat Recovery Power Plant 4.4 100.0 4.44 Transmission Pipe 3.4 100.0 3.40 Trans pipe Water 0.5 41.0 0.21 Water Treatment 6.5 41.0 2.66 Trans pipe School D2) 59.0 3.06 School 6.5 59.0 3.83 Sum (Equiv. Hours/yr) 26.5 17.60 The weighted value can be derived by multiplying the systems savings of 13,171 gallons of oil per year x 17.60 / 8,760 which is 26 gallons of oil based on equivalent heat which is not delivered because of failures. The number of maintenance outages which are paid for by AEA will be 0.59 per year at 2,000 each for a total cost of $1,184 per year. *Note: Outage of one of the users means that only that unit's fraction of the heat is lost. This assumes that the isolation valves function. In a case where only a small amount of heat is being lost, maintenance may be performed on a scheduled basis rather than on an emergency basis. In that case the repair costs are considerably reduced. A portion of the annual 33 hours of generation plant outage should be added to the total waste heat recovery system outage time. The proper number should be 25 hours per year (33 total hours minus the 8 hours of scheduled outage which occur during the summer.) The 25 hours would be distributed randomly. The total time the system would be unable to deliver heat based on 32 D. polarconsult Tununak District Heating outage of the engines, heat exchanger and the transmission pipe, would be about 38.5 hours per year, which is 0.44% of the time. The time that the two user facilities are out would be approximately 6 hours per year of total equivalent outage. In terms of the delivery of salable heat, the outage time where some part of the system would not be operable, would be about 51.5 hours per year. 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. 33 polarconsult Tununak District Heating - VII. Project Specifications = A. Codes and Regulations The listed versions of the following codes and regulations were used in the preparation of this report: Uniform Building Code (1988) Uniform Mechanical Code (1988) Uniform Plumbing Code (1988) Uniform Fire Code (1988) National Electric Safety Code (1987) J oo 07 07 oO B. DIVISION 01 - General Requirements This is a general information section covering the coordination of work, | description of the work required for this project, regulatory requirements, — definitions, payment procedure, submittals, quality control, materials and equipment, starting, testing, contract closeout and maintenance. C. DIVISION 02 - Sitework A. Support for the District Heating Module will consist of a cantilever in the back of the Butler building connected to the building floor joists. B. Module floor will be of wood frame construction insulated with fiberglass = batt insulation, and covered with plywood on the top and bottom. 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. t 4 polarconsult Tununak District Heating B. Distribution will be buried "Arctic" pipe with a steel carrier pipe, polyurethane insulation and a high density polyethylene jacket. The pipe shall be IC. Moller Plus pipe, or equal and approved. D.D 13 - Special Con i SECTION 13120 - Pre-Engineered Structures A. This section includes specific requirements, products and methods of construction relating to the district heating module for the project. The foundation is specified elsewhere. B. District Heating Module will be of wood frame construction insulated with fiberglass batt insulation, metal siding on exterior and plywood on the interior. 35 polarconsult Tununak District Heating E. DIVISI - Mechanical line Specifi SECTION 15010 - GENERAL PROVISIONS This is a general information section correlating mechanical work to other divisions of the specifications, defining terms, referencing codes and standards, itemizing submittal requirements, and defining submittals and information required for operation and maintenance manuals. SECTION 15050 - BASIC MATERIALS AND METHODS A. This section includes a description of specific requirements, products, and methods of execution which are typical throughout the mechanical work for this project. Additional requirements for the specific systems will be found in the sections specifying those systems, and supersede other requirements. B. Piping inside the buildings shall be type L hard copper or black sch. 40. Steel piping shall be welded and flanged. Valves shall be 150 psig. butterfly or gate for isolation, plug type for balancing. SECTION 15160 - NOISE AND VIBRATION CONTROL A. This section lists specific requirements, products, and methods of execution which relate to the isolation of all mechanical systems for limitation of transmission of vibration and sound to acceptable levels. B. All connections to engines and radiators, and between the power plant and the district heating module, shall be stainless steel flexible type. SECTION 15180 - INSULATION A. This section describes specific requirements, products, and methods of execution which relate to the insulation of ducts, pipes, and other surfaces of the mechanical installation. B. Insulation is provided for the following purposes: 36 polarconsult Tununak District Heating Energy conservation; Control of condensation; and Safety of operating personnel. Piping inside the power plant shall be uninsulated. Piping inside the district heating module and user buildings shall be insulated 1" thick rigid F/G, with all-service jacket. Piping outside and between the Butler building and/or the engine-modules which connects to the heat exchanger will consist of i.c. Moller or equal "Arctic" insulated steel pipe. SECTION 15191 - OUTSIDE TRENCH EXCAVATION, BACKFILL, COMPACTION This section describes general requirements, products, and methods of execution relating to excavation, backfill, and compaction of utility trenches outside of buildings. SECTION 15600 - HEAT GENERATION A. This is a description of specific requirements, products, and methods of execution for interrelated systems, necessary for the generation of heat which will be distributed to the locations shown. The method of distribution of this heat is specified elsewhere. 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 37 polarconsult Tununak District Heating transfer of excess heat from the locations shown, including the furnishing of interface apparatus and controls and the connection at interfaces with other mechanical systems. B. Generator cooling systems will consist of existing Young horizontal radiators, controlled by Volkman variable speed controllers. SECTION 15850 - BALANCING AND TESTING This section covers general requirements and methods of execution relating to the testing and balancing of the mechanical systems provided on this project. SECTION 15900 - CONTROLS AND INSTRUMENTATION This section describes specific requirements, products, and methods of execution relating to the system of temperature controls and instrumentation for the project. 38 polarconsult Tununak District Heating F, DIVISION 16 - Electrical Outline Specification SECTION 16010 - GENERAL PROVISIONS This is a general information section correlating electrical work with other divisions of the specifications, defining terms and indexing the various Division 16 sections, referencing codes and differences from Division 01 requirements, and defining submittals and information required for operation and maintenance manuals. SECTION 16031 - DEMONSTRATION OF ELECTRICAL SYSTEMS This section includes procedures to be used during final inspection, instruction of operating personnel, and a certificate of completion for the convenience of the Contractor and Owner to determine whether each item has been completed. SECTION 16040 - IDENTIFICATION This section covers labels and name plates for equipment, branch circuit panel board directories, and other identification needed for electrical equipment. SECTION 16050 - BASIC MATERIALS AND METHODS A. A major part of the electrical specification, this section covers the workmanship, coordination, and standards necessary for the electrical work. The products covered include raceways, conductors, and connectors. Installation techniques to cover various construction methods are noted so that fireproofing is maintained, water penetration and moisture migration through raceway systems are prevented, and the proper connectors are used for various conductor terminations and splices. B. Only copper wires and cables shall be used. Raceways shall be rigid galvanized, sherardized steel conduit or electrical metallic tubing with compression or set screw type fittings, for all conduits concealed in the walls, above the ceilings or exposed in work areas. 39 polarconsult Tununak District Heating SECTION 16130 - BOXES, CABINETS, AND PANEL BOARDS A. This is a general section that outlines various standards to follow in the construction of these items, with specific notation on certain types of cabinets to suit various systems. Mounting heights for outlets and cabinets are covered in this section. B. Panel boards shall have copper busing with bolt-on type circuit breakers. SECTION 16140 - WIRING DEVICES A. Receptacles, switches, device plates, and special purpose outlets are covered in this section. B. All outlet devices shall be specification grade or better. SECTION 16150 - MOTORS AND CONNECTIONS Motor specifications regarding voltage, phase, and temperature rise are covered in this section. Distinctions between which motors and control items are included in Divisions 15 vs. contract or responsibilities are also shown. Appliance and miscellaneous equipment connections, whether owner-furnished or contractor-furnished, are covered to provide suitable connection techniques. SECTION 16160 - MOTOR STARTERS AND DISCONNECTS Specific requirements for overload and phase failure protection to be included in motor starters are covered. Also included is a listing of various devices suitable for use as equipment disconnects. SECTION 16180 - OVERCURRENT PROTECTIVE DEVICES This section contains a general listing of various devices suitable for overcurrent protection, such as circuit breakers, fuses, and current limiters. 40 polarconsult Tununak District Heating SECTION 16190 - SUPPORTING DEVICES This section covers, in a general way, the various supporting, fastening, hanging, and securing techniques approved for use by the contractor in the installation of the electrical work. SECTION 16450 - GROUNDING This section itemizes complete grounding requirements and techniques for connections. SECTION 16480 - BRANCH AND FEEDER CIRCUITS This section clarifies drawing preparation technique as being diagrammatic rather than "as-built" and gives the contractor flexibility in conduit routing and circuiting, as may be determined by job site conditions. SECTION 16500 - LIGHTING A. Light fixture construction for both interior and exterior fixtures, lamps, and ballasts are covered in this section. B. Interior light fixtures shall be fluorescent, of industrial design. Exterior fixtures shall be high pressure sodium wall packs controlled by photocell. 41 polarconsult Tununak District Heating VII. Project Cost Estimate A. Power Plant Heat Recovery System The first cost component is construction of the building to house the district heating system. This includes the mechanical and electrical equipment inside the module and the connection to the modified AVEC power plant as shown in Figure V-3 on page 19. The second cost component is the modification of the existing power plant system. This includes the connections of Unit #1, Unit #2 and #3 to a common manifold and to the heat exchanger as shown in Figure V-3 on page 19. B. District Heating Distribution System The connection of the school complex to the district heating system includes installation of piping from the face of the district heating module to the school, and all equipment and connections within the schools mechanical room, as shown in Figures V-5 on page 21. The connection of the water treatment building to the district heating system includes installation of the piping teeing off from the main line to the school to the water treatment building, and all equipment and connections within the building as shown in Figure V-4 on page 20. C. Operation and Maintenance Costs Annual operation and maintenance costs are determined by the regular system maintenance required as well as the number of failures. Regular maintenance will be performed three times per year by a skilled maintenance crew. Day to day operation will be by a local person who will monitor the system and notify the maintenance department of any failures or problems. Repair of these failures will result in an additional 0.59 trips per year to Tununak by a skilled repairman. With a cost of $2,000 per incident the result is an average cost of $1,184 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. 42 polarconsult Tununak District Heating 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 Z 3 Water School Water & School Module Construction $67,193 $60,012 $68,966 Plant Piping Revisions $22,500 $17,977 $22,482 Water Treatment Connection $196,379 --- $130,258 School Connection --- $289,611 $283,624 Total Project Cost $286,072 $367,600 $505,330 Total project cost includes design, supervision, inspection, administration and construction. The complete cost estimate is included in Appendix C of this report. polarconsult Tununak District Heating IX. Conclusions A. Heat Availability & Fuel Consumption There are presently over 26,000 gallons of equivalent fuel oil per year available as waste heat at the Tununak power plant. The district heating system can displace the following amounts of the proposed user heat requirements: Table IX-A Annual Heating Fuel Displacement & Pipeline Heat Losses Concept 1 2 3 Water School Water & School Heat off Engines 26,051 26,051 26,051 Annual Heat Loss in Dist. Pipes 938 2,211 2,515 Heat Available to User 255113 23,780 23,536 Bldg. Heating Fuel Required 11,000 16,000 27,000 Amount of Fuel Displaced by District Heating System 11,001 15,244 20,795 Percent of Available Heat Used 44% 64% 88% During all but four months in the summer, the two buildings connected would use all of the heat available, as can be seen in Figure IX-1 on the next page. 44 polarconsult Tununak District Heating 3000 2500 3 & 2000 a, ° is c 2 S 5 1500 ; i —e vo é 1000 500 | OSS oo ERLE KKK OOS ae PSeeses Neo TK IGS FOLEY 0 BERR RRR RR KOON SOEKKRRRKKR REC KRRKKG Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Month of the Year o ; BS Native store ZATRCStore (SI Water Plant ZAschool —a- Available Figure IX-1 Heat Available vs Heat Required Equivelent Gallons of Fuel Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Month of the Year Concept 1, Water Plant KS Concept 3, Water + School —a- Available Figure IX-2 Gallons of Heating Oil Displaced 45 polarconsult Tununak District Heating B. Project Cost Summary The school paid $1.055 per gallon, and the city paid $1.88 per gallon for heating fuel during 1989. The annual savings is computed using these costs for heating fuel. The project is summarized in the following table. Table IX-B Project Summary Concept 1 2, 3 Water School Water & School Amount of Fuel Saved 11,001 15,244 20,795 Annual Savings $20,682 $16,082 $31,014 Total Project Cost $286,072 $367,600 $505,330 Straight Pay Back (yrs) 13.8 22.9 16.3 C. Project Summary The life of a district heating project is a function of availability of waste heat off the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance. The requirement for electricity and the need for space heat in the community imply an infinite project life. With proper maintenance the life of the district heating system will exceed 25 years. Because annual operational and maintenance costs and economic decisions will be made by AEA, final economic conclusions are not presented in this report. The straight payback time for the best alternative, Concept 1, is 13.8 years. \ 46 polarconsult Tununak District Heating X. Recommendations One way to make the project more economically attractive is to reduce its scale by minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Western Alaska communities to reduce Tununak's share of the high mobilization, shipping, travel, and supervision costs required. 47 polarconsult Tununak District Heating APPENDIX A Calculations polarconsult alaska, inc. ENGINEERS ¢ SURVEYORS ¢ ENERGY CONSULTANTS Alaska Energy Authority February 5, 1992 P.O. Box 19086 Anchorage, Ak. 99519-0869 Atm.: Brian Gray Rural Systems Engineer Re: Waste Heat Reports for nine Villages. Dear Brian: We are transmitting this letter as requested in response to your technical questions on the nine waste heat recovery reports prepare for AEA. The questions are from the second review of these reports by Steven Stassel of AEA. Copies of the review comments are included with this letter. There were a number of basic assumptions made during the progress of these reports. As the projects are to be constructed in AVEC power plants, the modifications and connections within the plant were to meet with their requirements. We feel that there are a number of ways to decrease the cost of these projects without major impact on the reliability of the power plants by revising the piping connection schematics. Electric demand at the plants varies both hourly and seasonally. As the use of engines is entirely up to the local operator, it is difficult to determine which single engine, or which combination of engines, will be running at any one time. AVEC is also in the process of replacing aging or failed engines, and increasing the size of some plants due to demand as part of their normal maintenance. New engines are mostly Cummins engines that are more efficient. These engines produce less waste heat than the older engines they are replacing. These two factors have a major impact on the amount of waste heat available. Our analysis assumed that the most efficient engine at each plant would run continuously. Station heat requirements were based on having the engine requiring the greatest amount of supplementary waste heat to keep the buildings warm, running continuously as shown in the builling summary sheets in Appendix A. 1503 WEST 33RD AVENUE ¢ SUITE 310 * ANCHORAGE, ALASKA 99503 PHONE (907) 258-2420 * TELEFAX (907) 258-2419 polarconsult alaska, inc. February 5, 1992 District Heat Report Engine manufacturer's specification data is listed in Table III-A. Waste heat utilization simulation work sheets used more detailed heat rejection information at various loads, supplied by the engine manufacturer's. Heat loss figures input into the station heat loss section of the waste heat utilization simulation work sheets were for the engine requiring the most waste heat to keep all the AVEC buildings at 65°F. Heat content of 96,000 BTU for a gallon of heating oil was used for this report. This value was arrived at by using a gross heating value of 132,000 BTU for arctic grade diesel times an estimated efficiency of 73% for boilers. Since the report conclusions are entirely in gallons of oil saved, these assumptions are critical. The BTU content of oil varies depending on the source, blending and grades used, so results can vary plus or minus 5% due to variations in heat content. Further, oil fired equipment efficiencies vary greatly which introduces another plus or minus 5% possible variation in the results. All reports assumed that three trips would be made to each village by a skilled crew each year, to perform routine maintenance. Follows are answers to review comments for each report, as well as copies of the review comments. Sincerely Yours Earle V. Ausman wh9; WHILO9GB.DOC tees Alaska Energy Authority A Public Corporation January 24, 1992 Mr. Earl Ausman Polarconsult Alaska, Inc. 1503 West 33rd Avenue Anchorage, Alaska 99503 Subject: Nunapitchuk and Tununak Waste Heat Recovery Pre-Final Reports Dear Mr. Ausman: Per our letter of understanding dated June 12, 1991, please provide responses to the following questions regarding the Nunapitchuk Waste Heat Report. Also, please rovide the assumed GPM and head-loss data for all circulating pumps for both the unapitchuk and Tununak reports. There are no questions or comments on the Tununak report. I look forward to receiving this information, and the corresponding information outlined in our letter of understanding for the other four reports, at your earliest convenience so that we may finalize the reports and process any outstanding invoices. Nunapitchuk Waste Heat Section 4.A.4 Include information on connection of the waste heat system to the high school heating system. Figure V-3. A. Please explain intended operation of cooling system connection between Butler Building, EMI module, and Module. Some of the flow arrows appear reversed and the amot valve at the butler building is short circuited. Are the amot valves installed in a "mixing" or "bypass" mode? B. Note three, indicates a "skid mounted" radiator. Is this correct? Figure V-2,4,5,6 | V-2 shows 2.5" pipe to the elementary school, high school, and generator building. This does not agree with figure's V-4, 5 & 6 supply side piping. Please explain. Section VI, B.2.a (page 41) Please correlate Arctic pipe diameters with piping runs to high school, elementary school and generator building. Sincerely, Steve Stassel ~ Remote Systems Engineer II SS:jd O PO. Box 110809 Juneau, Alaska 99811-0809 (907) 465-3575 PO. Box 190869 704 EastTudor Road =Anchorage, Alaska 99519-0869 (907) 561-7877 92Q1D2351(1) polarconsult Tununak District Heating Power Plant Heat The amount of heat required to keep the power plant building at 65°F was calculated. The number of air changes in the building was assumed to be equal to the amount of combustion air required by the engines plus 2. This added up to 24 air changes per hour in the Tununak power plant. The conduction heat loss was then added to the infiltration heat loss and the amount of heat rejected to the ambient air off the engine subtracted to come up with the hourly heat requirements for the building. User's Monthly Fuel Oil Usage The annual fuel oil usage, as obtained from the users, was distributed over 12 months using the number of heating degree days (HDD) as follows: School (Monthly HDD) x (Annual Fuel Consumption) Monthly fuel oilusage = == —---~~~~~~~~-~-=-=---------------- ( Annual HDD ) Water Treatment Building (Monthly HDD) x (Annual Fuel Cons. - 12 x 417) Monthly fuel oilusage = 417 = ==—= =e ease sae ( Annual HDD ) Available Waste Heat & User Heat Displaced The amount of waste heat available at the power plant and the amount of heat required by the user were calculated using a computer model with the following input and assumptions: 1. Historical monthly power generation data for the power plant, annual users’ heating oil consumption, and monthly heating degree days were input. 2. The amount of heat available off the engines versus power production, from the engine manufacturer's data, was input. 3. The heat losses for the proposed piping system, plant heat, etc. were input. 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 Tununak District Heating Program Notes: a. The amount of heat available off the engines listed in Table III-A is from the engine manufacturer's engine specs. The amount of heat available off the engines used in Appendix A comes from the engine manufacturer's tabulated data which they indicated was good to +/.5%. We used 95% of these tabulated values for use in Appendix A as the heat available off the engines. Appendix A Page 2 Tununak 1 Water Plant Concept: ASTE HEAT UTILIZATION SIMULATION WORK SHEET o t t 1c Alon AMMO WO @1O@ @ 100 ™ DING BIMNN rn ei-s- gto. NN a bam gl Oa ge Lod ci aon woo wo t wo coo ' t H ' ' I a vlos DOT IMTONNE OF N-DOHOMDDAND Vidavso 0 @a10om MMMMMOMTITTT TST TTT a@IMMO ' rae JSdcddddddddddddddddddcd | us 2 2 1 ! ! a oO 1 1 w a Plom OPT MO SFO NA OM NT DOHOMBDDAHNO Plomo a o1on MOMMMOOPPICGC TTT TTT TS oOImMMo w o 14 leleleololelelelolelelelelelelolelelelelelelelo} tf aw u = oO I wo t 0 I ' a ae vIiow DOP PSS ADTPONS VDANNTONTOOON vIawo t eseneesess = -8 188 MRIANMASSASTOSRIS TESTS BImss fo Ba1BeSGHsSSSsSS 6188 B88S985SSSS8SSSSS555SS 81°88 188 | eiciotainindeindeinted lead Sddddccddcodccddccccdds | agi 2 12 I ' 1am wv MODADS ee vylonr DOT PS ADPON DANATONTOOON vlioro " 3. TAM-DDODDODD ator MOMMMMNMTIMTTNOT TTT AaImMro io & Cinaeaacs S186 BOGOOGOSSOSOOSSOSOOOSSS B1°SS : 2 2 ia ' I w - oo oO DIOod DOP IEE ADTONEAAANANTONTOOON Dido oO PPPPPD>E>DDD sion MOMMMOMMMTIMVTTNTT TTT BdImMNoO : e000000000 ciown OAWOODOOCOCOCSCOCSCCSCOCCCCCooscO <i no a QAQDAQQAAAQ i oeeveeevevreeeeeeeeeeee wee 1 i. { 6 DIGDVIDDNVNDG 1S COOOCOSCCCSCSCCCSCCSCCSOSCCCCCCO { c & ci oA VUVUVUUUUUUU ' I a QVUVCVCIVIVDGD ' t oa 0000000000 m>loo DOP PSS ADPONE AAGADNANTONTOOON >laoo a S AA AA AAA A1CoO MOMOMOMMOMMATIMTINOTI TTT CS AImMOooO 14 PTT TTT TTT Blan B8S0SS SOS SOS SSSSSSSSS 31° RS u 5 ESS3333335 See i OM CUCU OO i ee veeee cee eree 51 . f 5 RS MS BM St A eB Se OS oS ee lolelelelelelelelelelele} lololololololo} t a 3 | 3 16 buvevevuon I ' w DUDDVVDGDVNDG ' t a oe ao1co on DIPHNOSIR OE ADTONLADGIADNTONTOOON ol oo OVODOOOHOOD cios an CITMMMMNNMNNsTNVTTMOsINTNTTCTCS ct ié sesssessss | =6sIss OSS 513 51 oe DNNDDHNDNDG a) we 4H HI i a Of Ba ha ha ha Ba ha Ba Ba he ha ss | S om Blvevvvvvvvyyvy 1 cS ' so OL DDHDVDVVDTVNDG 1 oO 1 eo 8188888839000 = mlom ve S Sy w Ss BI ner L Torr Hiow 0 aq S w ! zlan ao 9g = Os: 1a) { fas S83 s a om 1 Isa wy a 1 td) I mw o o ' 1 Vv 1 { > 0 i H dion a+ > tl oogemsonnronnroonoemaaino a sit H 4188 0 Be 2 FI Bisanmosweeeeee seen eeS a eat ' Ties | AS th WISOS8S095SSSSSSS5SSS505S5 a Sut H ques || aa 3 pacaqaaarcess| pons uo eet w aiod oO lolelelelelelelelolelelelele} lelelelelelolele} « Oc ' 18 g e*} i ' { a ' aw wet a s1oo o DOTIMGONNE OF NE DDHOMDDANO a ocl a v01co aw s MOMMMNNNNTT TTT TTT TONS Oo aol a viscsw AD ° lolololololololelolelelelelelelelclelelelolelele} wy wt t gist ag iS BE eee oe aeons 8 ga! ‘ fae a 8 COOCSCSCSCDSSCOSCSCSCSCOOSCSCSCOCC0O = s i a ing Cy Lng I 3 a ' w ee ' oO ' t als 5 Hie Q100 ue 3 OTM GOVE OMNR MMAOMODHINO a 4a) w SEeEkel BY gion o he MOMMMMCIG TTT TTT ITNT o AOI a LoLG San & wom a cr OODOOOCSCOCCSSOCSCCSCSCCCCOO ta Obl a ae SN : © Sa oeeoeeeeweowvreewww eee ee ee . I o saan sag lod oO vy lololololelolololelolelolelolololelololeloleote) wy t a Py pyy oO a c ° ' 1 mannan ann ' 4 a | H onon ono clon a WETOTONAT ORM MODOMMBDAHNS HOGOM « fel a rs non Glow S MMMMMMTIITTT TTT TTITNNTTS cor oO og! H B.S lies Ar a Ee aaah 2 a a an a M4 = lolelolololololololele} OOOCCCSCO ww og t a im ° oO 0 t ! I 2 8 ' ' ge _ ss & ' i cdadoe oe aS I oO o ANMTNOFDAOANMTNOFANOGNMST ! " Ave od bo < 3 SIA aa A 1 1 eA OE Eon z= Oo o - 1 a r200 Aca SS Zz - a o ! o w Ge cv art O £Q wo oO ee ! vow a ADDON ded zQ > v yn t c Oo o AON an Mo a 0 ash t go vo wx AG 0 On a @ sO ol a OH GO a Aw Oo oco 1 me DDDODADNAIM GT GI TOTMMMMMMANOO ums 6! ou oO ao ceive HO “OO os So ~ MMNMNMNMTI STS ST SST SST oT ° . ALD Ady ool Blavocd agua « °o o Ao fololololololelololelelolelelelelelelelelelelele) vy Oh DIGCHOrn oc e£1Ocvwdg OHod & oe - a On .eoveveeee ee eee eee ee eee oO “co AldaAaod oa AlngQonw anas ae < wo 3 EVN |OOODSCOOOOCCOCOOSCCOSCCCCCCCOoO © nod Al AvoVO’ a5 taasco Sane ac & uo ' Ww COd DIaAgoam, a N1OanhE ONAL, a <= S Bd ' oo OIiasznZe a 7 el a Ze a Ss A cd ! uw Oo Q Bee ol oa ~ a as LDNODODDNAMGTITTINITMMMMMMANNOOD 0 . is wiv o Hw oo ov oO PH IMMMNMMNMVTT IETS SSE TIO oO 44nd Oo ic ad em 2a oy S hoME ME Rolololololelelelolelelelelelelslelelelelelelele) PODVGDS 19 1e a 2g ABZ ly S| iGes Si commen poceaaoasocnssesses gags Wve Ie 0 = Q Cl] os Ecco |OOOCOCOCOCOCOOCOCOCCCoOoCoCoooO wu Ondo oo Bia a Ge Add o a S041 OnOLQ ov oI1se wy Zs Hod! OW aA HES! 2UGUCE oa mia a Gig) DoaqaIinwg a no t ovovod } u I bi ola c ca - I PAGE 1 OF 3 ' ! ! ' 41 fom ot 10 HOwnO a! Io ot is Scounn 31 Inq Bt 1@ CQadd g! fas Gf ics as &! jan gt Ia MoMA ' ton 1 Ia sand 1 1 1 10 1 Jae 1 1s is 4 VL AANAMNAOOOTONOTTHAN GAMA INE 0 | HOWOMON TIAN TNVOIAGTON OAD 1 O OOMOM FANN TNVOGAIION OT D | CNOODOGAAAMAAIIMIMTANOCOOE FOTO AIA AAAMMMMMMMAMANMMANNT 10 AA AAANMMMMMMMMMAMMMAING: A LAMMMAMANAMMMMAMAMMANANAN |e Ol ddidddincidicinicictricicticictcictctctetet | AAA eet dette tte ~s Is ' lw ! od ! te ! to ' pS { ' 1 DIL ROMMMORANMANANDANDOAre MAT IAT Pb IMOOBON@TNOCK ONT TTT TAIOWM 11h COMONOTNOLCK ONTO TI TIOW DI OAKKCFOOONONDAGCOODCGOOMAN ISO 0 IP AAG OSA ANANNNNANNAAANNA 1 AOA A ANNAN ZLANAANAMANAANANMIMMANAMMMNM LON 2 fadddddddddtdidtddtcdcicticictctried | 0 AAA A teed eed ted tet ~* 1s ! lon ! 10 ! i ' 10 ja | | | ! 1 BENTMNNOOTAATNDODONAONE 1OO BW FADAMHDOWAMNMNNTNMANONATHAOT | O 2 LADANAOLWANAMSHMANONNTAOS O 1 NON TFOOCDANDORARKAMRAAADG IND 0 | ONDANOO MI HtdddaAdOOOO IN B I ODAADADGO Nt AAOOO: O [MANANAAAMANANAAAMAIMNANG 1 O bt FAA dtttttttttitett bet Ol” Atte ttt s pes 1 ! 1on ! 10 ' ! 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DB LHL AAMTNCMOHOFAMTNLCEOHOdAMS | OH LANMTNOrOHOKAMTNCMAHnOTANS | Ha ost AAA AAA ANNAN OOS AAA AAA | VOUS! AAAI AA AAANNNNN | Si azt iva 221 ig Beet is oO | lea oa I ic oo | 1p gig t to ct 19 po | Ve <aiona it a0 6 1 16 ax ot 10 Gio t ! 5] ! 4 me > Tt ! ! 1a @ o 1 ' Oo I 1 a a 1 1s ! 4 ote t tg 8 is aio | 19 @ 1 10 o =iom 1S mt te = b a o 8 e 3 11,001 1,019 PAGE 2 OF 3 938 871 723 684 643 661 987 997 211 1,052 Maximum Hourly Heat Displaced 1, Heat Available Heat Demand Y y 216 Maximum Hourly Peak KW 1, Maximum Hour] Maximum Hourl Gallons ater Plant WASTE HEAT UTILIZATION SIMULATION WORK SHEET — Concept: 1 Water Plant Tununak ** Main HE ** ** User HE * Hot * * Cold * * Hot * * Cold * emp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 low 95.00 22.18 Gpm (Max Heat Demand) /8,000 Calc. 20.07 20.11 17.48 Gpm -luid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.5 63.78 62.40 lb/ft*3 0.854 1.004 Btu/lb F 0.234 0.383 Btu/Hr Ft F 0.900 3 “pec Heat 0.863 0.859 er Cond 0.233 2-234 iscosity 0.759 oO. 0.425 cP Pipe Ground Temp. In 190 Temp Out 180 Avg. 185 deg F 25.0 deg F low 22.18 gpm ength 290 fe to: Water Plant Size 1.5 in 0.125 feet Heat Loss 16.98 Btu/Hr/Ft eat Loss 4,924 Btu/Hr 4,924 Used above elocity 3.14 Ft/Sec riction Factor 0.0491 From Calc. Below ipe Head Loss 17.35 Fe Darcy-Weisbach Pipe Head Loss 7.52 psi Cale. PAGE 3 OF 3 23 AM 06/23/90 09 Tununak 1,800 RPM Output 3 Water + HS GENERATOR DATA: Cummins LTA 10, Concept: Tununak Jun-90 STE HEAT UTILIZATION SIMULATION WORK SHEET cation te: 365 13,283 691,200 Annual 26,998 OTTO SOV OM ~-DOHOMDOH4iNO MOOMNMMO TT TTT TTT TTT TON TSS OOCOGCGGGOGGG0000000000 folelolololololololololololololololololololelo} 31 PAGE 1 OF 3 Dec 1,334 75,000 v o a BTU/HR 0.038 2,906 STIANTOUNE OPN DOAOMHOHNO MMNNMTT TTS TTT TESTIS S BOOCGGOC0S0G0G0000000 COCCCCCCCC0C0000000000 Nov Nov 30 1,153 2,568 0.038 0.036 DPSS ADTPONMAAGAATONTOOON MOMMMNOMTTMT TOTTI ST TS QOOO0GGG000000000 OOOCOG0CCD000000 WN TFANOOOWO O10 mative ss DOoONTTITTS AMAA 31 1,006 000 65,800 Oct Oct 875 2,293 Heat To Heat To 044 0.039 3 QO OPIS ATPONNAAAATONTOOON MOMMNMNMMNTTCNT TOTS TS SS OCCOSSGGOSSGG0G0000000, IDOOCCOCCGSCCCCOCCCCCCCCCO onovarrenrner TAM DOOODH ddd kw Coolant Ambient Sept 0.044 039 Sept 30 677 800 62 1,680 45, NOTES AAPON-AIGANTONTOOON MMMMMNOMTINTTOTT TITS S forofofololololololololol DOOOCSSC00000 Aug Aug 31 591 0.044 1,101 oo0co DO PSPS ANPONAGANTONTSOOON AMMO MOM P SOTTO STIS TTS TS WOOOOOOGOGOGGGGGGG000000, [olololololololololololalololololololololololo} 95 gpm 31 500 643 > q 3 5 July July 0.044 2 15 661 938 2,27 3 0 QO 0. 0. 0. 0. 0. 0. 0. 0. 0 0 0. 0 0 0. 0 0. 0. 0 0 0. 0 June 30 $40 42,600 41,100 47,000 June Pipe Lobs (Btu/Ft) (GAL/YR) 42, 0 DOP PHS APONMAIGAANTONTOOON MMMM MOMMPFINTCOT TIT ITS ITS IDOOOOSOGGOGGGGGG0000000, OOSCOCCSCC0CCCO! Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above: Heat rate at kw-load above: Flow Rate Heat rate at Heat rate at May Heat Loss 16.98 18.93 May ak 263 10! May 1,880 bE 000 54 1,263 21.34 , , Gallons OTTOTONAE OFM DOAOMDHANO OMNMNNMOTT TTT TT TTT TONS SS OOOOCOGGSS0S00000000000, OCCOCSCCDC00000000000000 April 60,000 54,100 1,285 Pipe Dia. (IN) 2.5 1.5 2.0 April 30 1,285 60, er month April 2,814 uy 6 0 OT TOTOVAE ON OORAOMDHAND MMMNNMNTTT TST S TT TTTONS SS POOOSGSSSS9G0G00000000 SECCCO0CCCC0C0000000000000 (FT) 250 40 380 3 0 0 i 1,05 1,98 , , 3,039 4 4 March March March 1,406 Pipe Dist. 1 3 OTT AOTOUVAOM NM DONOMDOH4NO Onmooo MMMM GTC TIT TT TION TSS OOBWGOGGGG0000000000000, DOOOOSSODCCCCC0C000 Feb Feb Feb 1,21 2,48 7500 63,400 1,759 3,698 Boiler Effic. Q Btu/hr. ipin 26,415 Btu/hr. Q Btu/hr. 26,415 Btu/hr. OTTFMTFOVAOMN-DODAOMMBOHNG cHOOOM oLwnoCco MMMMMNOTT TTT TTT TT TIONS oor OSOOCOGSOSS900000000000, co Sa w/e we erences ye 6-5) cee eee ee ee ~ 30 CCOCCCSCSCCCSCCCCCC000000 nw $0 Btu/hr.xF 1 2 = 1,167 Btu/hr.xF 50 Btu/hr.xF In Jan 1 0 Gallons of Oil used Jan 3,717 1,21 2,50 Power Plant Production & Hourly Variation NM TPFNODAOAAMTNOEOVOGAMS AAA 9 5,000 0 Ein sses: Non- ng SeasonalSeasonal Use ? gy Radiator lo: 1s.: ompound boiler eff.: oa bye z= Ss £Q za som prehea piping iping ace p. Total constant DDODAN AM Ter TW TMMMMMMAINOD OOM PGP IT PGI STITT TTT I TIO OO090000000000000000000 OOCSCSSSCCSCSCCCSCCCC00000 9 6,000 16,000 cons., Total Use 0 0 0 Bldg #6 0 Subsurt Engine Surface Plant heat Building Pipin Water Plant School Native Store TRC Store osse: Plan’ DOOOA AM TT TMOTMMMMMMAUNOD MMMMMGITS CTT ST TST TTS TSO OCOCOSSSGCSS0C00000000, OCCCESCCCCCCCCCCCCC0000 wer year factor sonal cons., gls.: ing iter Plan ar no. n=-seas. iriable losses: shool JILDING DATA: tel use, gallons assumed Diurnal Heat GENERATION DATA Demand Variation WEATHER DATA: ™nilding in use; l=yes, 0=no aveno ! ! ' ! at at im is a! a! 1a ornorre is st a! 1o ONAN Ia a! et is ok as Tis & ! cl Iq AMOMN in ! <I in aan 1c ' ! ic is ! t ps tes is 3 Pi gloneoerovrworoenauucmasa in ncoeroussengecuenanonen [a or Det SPS PTO SII SST IMM Vet 1 AA AA AOS PEPE SPIO ST SIMON | a | a { NANNNNNNNNNNNNNNNNNNNNNN 12 INNNNNNNN NNN ie t t im im ! t in ic 3 i ! 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AAAS AAASIAINNNNN | c pol AAAI AAAANNNNN I VUSI FAA ASIAINNNG aot Imo QO1 1 oo axl Ina =I Io Merl o ! ipa vo tf tc on | at to cl ia Po | at mo 9 1 1E ax ot os ! ! et 1o — >t t oa! ta 2 o ! t vt t a ! ts ' Ia vil te vil to 2 a ! ts so ! Ie a ®@ 1 t g @! to @ = ot ' mt 1a nh 3 a. o 3 c a 15,244 PAGE 2 OF 3 1,887 1,630 1,422 957 418 893 1,814 872 Btu/Hr 361 Btu/Hr 878 Btu/Hr 119 Kw 1,980 1,969 Maximum Hourly Heat Displaced Heat Demand Heat Available y Y 2,272 Maximum Hourly Peak KW Maximum Hourl Maximum Hour] Gallons chool WASTE n +e * Hot * * Cold * * Hot * * Cold * mp. In 205 180 190 160 Temp Out 190 200 170 180 T Avg. 197.5 190 180 170 low 95.00 39.61 Gpm (Max Heat Demand) /8,000 Calc. 35.84 35.92 35.89 Gpm -iuid Glycol50Glycol 50 Glycol 5 Water Density 63.34 63.53 63.78 62.40 lb/f£t*3 “ Jec Heat 0.863 0.859 0.854 1.004 Btu/lb F yer Cond 0.233 0.234 0.234 0.383 Btu/Hr Ft F iscosity 0.759 0.819 0.900 0.425 CP Pipe Ground Temp. In 180 Temp Out 180 Avg. 185 deg F 25.0 deg F Low 39.61 gpm angth 630 to: School Size 2.0 in 0.16667 feet Heat Loss 18.93 Btu/Hr/Ft sat Loss 11,927 Btu/Hr 11,927 Used above rlocity 3.51 Ft/Sec riction Factor 0.0433 From Calc. Below ._ipe Head Loss 31.19 Ft Darcy-Weisbach Pipe Head Loss 13.52 psi Cale. PAGE 3 OF 3 691,200 13,283 15,999 , ) ) ) ' ) ) ) ) ) ’ Annual PAGE 1 OF 3 KWH KWH KWH 1 tRWH KWH KWH KWH KWH KWH 15 { Y BTU/HR) / d/ } VL OOPTNTONANL OLN OMDAOMHHH4ND dl NNNNNNNsG TIS T TT INNS SS A 1900000000000000000000000, IDOCOOSCHGOGSGGGGGC0C00000 BTU/HR) / BTU/HR) / BTU/HR) / BTU/HR) / BTU/HR) / BTU/HR) BTU/HR) BTU/HR: Dec 1,334 1,886 BTU/HR OTTO TON ON DODOMOD Hino > OOOO OOT TT GGT PITT TOOT ST ° 2990990000009690096000000 az lolelololololololololololololololololololole} 517 17 17 17 17 Nov 689 689 (BTU/HR 574 536 520 517 5 5 5 5 800 75,000 153 1,153 1,630 65 a TOMS EHR ATOARAGAATOATOOCON TOONNMNMNNNTINTTOsTTeTITITS SC000CGO00G00000000000000, eccoccoeeCcCCeCeCCCCCCCCO 875 7 1 7 1 4 4 4 4 4 4 Oct Oct 006 1,422 , 62,000 65,800 F Heat To Heat To 62,000 1,006 TOM TION ATONNAGAATOATOOON TONMNNMNNTIMNTTOVTT STITT S kw Coolant Ambient 45 9 3 7 8 8 187 187 187 187 Sept 677 Sept 957 [olelolololololololololololololalalolololole} 1,800 RPM output 45,800 Aug $91 3 3 3 4 4 3 4 4 5 4 4 4 4 4 4 4 4 4 4 Aug 418 47,000 0 WIP PANTONE AAIADATONTOOCON > MMMMOMTTMN TTT TTT c= 5 95 gpm load above 500 WOCSOCOGGGS0GGCGGC00000 JIPCCOCODSSCCCC000000000 Or on 20 33 TAM TENN ATOARAGAATONTOOCON o FONNNNNNTTOTTOTTTSTTTS SS € S80000000000000000000000 2 °. 540 pe Oss 0 BA (Btu/Ft) (GAL/YR) a 1.34 (938. 315 June IDDOCOGHOOSGSGG0000000000 Heat rate at kw-load above: 42,600 41,100 Heat rate at kw-load above Heat rate at kw-load above 2 School Heat rate at kw-. Heat rate at kw-load abov Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above: Heat rate at kw-load above Heat rate at kw-load above Flow Rate May 1,263 893 Heat Loss 63,400 60,000 54,100 1,263 21.34 18.93 GENERATOR DATA: Cummins LTA 10, QOTINTOAUNE OPN DOROMaDANO a MONNNMNNMTT TTT TTT STON TS “4 SB9e000000000000000000000 w « Pipe Dia. (IN) 2.5 2.0 1,817 BOOOOCOSGCGGG000000000 60,000 54,100 1, 1,285 April July Concept TPOTLOANNE OPN DODAOMMHHNO ONNMTT ITT ITT TT TIONS SS90000000000000000000 oeccoeceCceeCCCCCCSCCCCCSCCO e (FT) 0 630 1034 1,406 March 63,400 1,406 Pi Dist March 1,987 QI DOT TM TONANNONNKMMHOMBDAHO 8 lQanANANTeeTTTTITITINNTSS oo Feb 1,759 0.73 0.73 Feb 2,487 Boiler 1, Q Btu/hr. Btu/hr. Effic. 0 1 0 23,853 Btu/hr. DOTIMTFONAL ONE DOHOMBOHNO HOOOM ONMNNNMTTE TESTES TINS 6 $0 Btu/hr.xF 1,167 Btu/hr.xF 50 Btu/hr.xF Jan In 00 Jan 2,501 ox S16 66/6 W010 0 616 8) ele 010 ie ie a) elolelolololololololololololototololololate) 1, 73,900 60,500 Gallons of Oil used per mone Gallons 3,900 60,500 1,769 16 Power Plant Production & Hourly Variation ANMTMORDNOAAMTNOLONOFAMS AAA AAAI ANNI ipin 23,853 Btu/hr. in Non- ° 0 Hour: SeasonalSeasonal Use ? PB. eat. ing: ng iping: ace preh onstant Ba Plant heath Kwh/Mth: HDD/Mth: fei ’ er e@ DWWDMDODAGMT TTT TMMMMMMANOD QNMNAMN TE TISLTTSITISTIITIN 0 E 16,000 IPOONGSG000000000000000 ecocecccccCC0000C0000000000 Summer ° o ea ag ow co oie Tununak Jun-90 School Native Store TRC Store Bldg #6 Total Use Radiator losses cons. Surface ‘i vo co GQ VS 0 DOOD AM TTT TO TMAMMMMANOD MMM GGT GGT TTT CCO000000000000000000 CCCCCCSGDOCC0CC0000000 0.039 0:038 Winter ASTE HEAT UTILIZATION SIMULATION WORK SHEET hool ailding in use; l=yes, O=no ower year factor ear no. easonal cons., gl on-seas. 10 1a 1a 10 1a 1 1a ig 1a 1a 1a 1c ta ariable losses JILDING DATA ael use, gallons Compound boil ocation ate assumed Diurnal Heat ™ SYSTEM LOSS DAT. GENERATION DATA: WEATHER DATA: ™ Piping Demand Variation: Tununak 3 Water + HS - Concept: WASTE HEAT UTILIZATION SIMULATION WORK SHEET TNOWOWVTMNMONONMOR KN sAdTTONA TODO OTK RAO HNOOT TOON NANNAAANANAMMMAMMMMMANNANANN ATH NOM dNNONONOMMANNT HONDO DMN TATE ORO DOANINAAGOO NAANNNANANANANNNANNNANNNNONO CR OMBDAGMOMNAdMAAOMAwWHWNMO OOMANNNOOTOTOROCOTOORE RD ANANNANNMNNANNNANMNAM AN 2 I ROTODOCOMAONMAMRrOAre ss TO QI NAR COBDWMAANMATNONNAMNNCOOT BL NAA AIAN ANNAN NN MMM NNT COrTOrwoowvmownmnas IN ~ OODDANMATMNONNAMANOCOR AAA A ANNAN NN NNN DOMMAADATANOCCOCOCOTMO TITS OTTINMNOGNOOANMANHDONAR EO AAA AA AA AN ANNAN ed AAA AA ANN ANNAN ttt Ode TTONNMONINONNAHNAT TO NODA AANO~NDHDODAO-AOMMM NAGANANNNNNNM ANNAN AN WAAIMAAIMMOWOBOOONTONIAIND! TAMAMOADAANAMIMNNOTOOOOM INNA ANNAN ANNAN NOWDOWDOOWMOTONMDAO- BONS WMAMAMOOONONTNOOONOOOO— IN NANAANM MAAN ANNONA INDRHONNDOOMOMOnK Ms sANNre OPP PTOMME LENE RL OOTODOW ANAANANNNNNANNANNNANNNNN ON I~ AHODO™-MOMOMOOMiINTOMOM NFA MOCO ODONA AIA MMO INANANAAAMMMANMAMMMAANAINN AM TNCHOHOAAM TNO OHOdAM AAA AAA AON Heat available per hour by month (1,000 BTU’s) 164,799 23,536 2,313 Dec 338 Nov 2,154 930 198,151 212,776 2 Oct 2,152 2 1 B.| QNARAOANANANMANANANA TIS a a 7329 156,983 197 1,707 1,754 7654 161 1,507 1,576 June ' 1 1 1 ! 1 ' ' ' i 1 1 1 1 1 1 i ! 1 1 1 ' 1 ! 1 ! ' ! | ' ' ' ' 1 1 1 ! ! 1 i ' ' 1 ! 1 1 ! i ' ' ! ' ' 1 1 1 1 ' t ' ' 144,997 138 April May (1,000 BTU’s) March Jan Feb Hour Heat demand by hour by month JADMAN SF MODDANOGCAMOMMANOW: ANNAN SSP OOrT Orn woos MAMNAMMAMMMAMMAMMMMMMMMMMOM: ADVAN AN TAMOGOWMAMAGOAAAIOO COOKCON TT TTT TMNT TIAMAT MAANCAAMMMMMAMMMAMMMAMMMMMM CHOMOTONNADIMEMMANNMOTM WOON GODAAAHDOAAHDAAAADO~ ANANANNNN NAM MANNA RMNONMMOODOWKAMOMMHCWHN JAA ANNA NNN NANA NNN NMI FAAMMTONTINONNTE OO Dl: 2 INAANAANST TESST SST STI MM a AAA AA et tte ted ted OMNMAM TON TITNMAMAMMAOHNON EREe eRe ODDDDDDDODDMOMOOMAe DOMOLAMDDANOCO@rOoMwMrMnsdn RARER DDDDOADDWODDMDODDODDOr 78 TMANOGANMNNEANOVONNOTO TO AAOAANS ST TPIT TST TOTS TOMA JU NANAAAN NANA ANNA ANS 219 AQOTOMN TONDO TOTTANOOO © MAMAN EE OOrEr orn oosm o” MOTOTOTOMOOAAMBONOOMHwAG DPIPFOPALANADAONDADADO™— Ow MMAAMMMMMMAMMTMMMMMMMMMMe CWOTOTAHCGCOMMENONLOAWONONO ROONMORANAMIMTAAAAAANTOO™ SITET TT TONNNINHNNNNNNNNH SS AMAT HOMO EN Ad OdOOTMOAG ANAND DDOODOK KEKE COTM VV TTT ANMTNOMDAOAAMNTNOLODOGAMS AAA AAA AAA ANN o 37 60,766 5 month (1,000 BTU’s) 'y ur bs Feb 341,900 340,184 279,522 258,843 172,937 y ho Heat delivered b: Total Demand Heat Delivered dvwdo ovann Onn dwuomn Aan Annual MOOOOTMMOMOMONE TAT TON QOOK OPA AA AD AA ANOOT TOON 9 o ALAM NNNNANNMMMAMMMMANNANNN 244 FIOM ANN DN ONMONMNANATAONO PLLA TWINS OPO DOAK NADAAICOO INANANANNNNANANANAANNO NO Nov 291 DOOR MRAM AMMWM WOMANI OA TOTO OOATON- EEO INNA NAAN ANNAN NAAN Oct 267 BIN@o 2.1 QA~OODOANANANMANNNNNNCOCO DO NA SAA AANA ANNAN an DONNER TANMMTONANONAAE OO ANNAN SST TIS TTT TTT TMM Fd tt ddd Aug NMNMAMTONMTTTOMAMAMMADACN REE Ker ODDDDDDDOBOOVOOMA July DDMrOKAMBOANOOMrOwMOrNTAID FRR RRRDODDDDAADDDDODMOOOM June DOTA IT TOMNONAMONOANOTOTA AAOQNA SANT STATS T TINT TIONG 1 1 1 ' 1 1 1 1 1 1 ' 1 ' i ' ' 1 ' ' ' ' ! ' ' ' ' ' ' 1 1 1 1 | | UDTDOooDIN CMB AMOMAIST TTA ' 1 ' 1 1 1 1 1 ! ' i ! ' ' ' ' 1 ! 1 1 1 1 i ' ' ' I ' ' ANNA ANNAN ANA NNNNNANNNNON ACAAMAAIMMOWOMOVLVANTONANOD WIMMAMOAAHNNMNNNHOTOOCOM ANAANANANNNNANNNNNAMNNNN April WOWDODOOVMOTONMACr@MATS WMMAMOCOMONTNOOONOOOATHO JN NANNAMMNNANNNANAMANAN March 268 NNAAONNBBONOCKMORnK Ms TANNED DOTTITOMMEERMOE Lr DOTOOONA ANANANNANNANNANNNNNNNNNO NN Dr ARODOM-MOMAMcOMNToaLoOoON MAME EE MOCOFODOGIAIAATMMOON ANANNNNNNMMMAMMMMANANNNNN Jan ANMTNOFODOdAMTNLOrAnOdAMS AAA AAA AANA Hour 20,795 PAGE 2 OF 3 1,102 1,616 2,116 2,154 2,313 59,104 101,316 148,652 194,604 198,151 212,776 1,912,725 643 60,766 661 2,008 1,848 324,316 Btu/Hr $41,811 Btu/Hr 324,316 Btu/Hr 119 Kw 2,125 1,951 Maximum Hourly Heat Displaced Heat Demand Heat Available 4 y Maximum Hourly Peak KW 2,259 BIU’s 207,744 179,431 195,469 184,725 169,987 60,766 59,104 101,316 148,652 194,604 198,151 212,776 1,912,728 BTU’s Gallons Maximum Hour] Maximum Hour] oncept: ater + HS ASTE HEAT UTILIZATION SIMULATION WORK SHEET -—- Temp. In Temp Out T Avg. Low Calc. Fluid Nensity vec Heat ter Cond -scosity Temp. In “>mp Out Avg. Low wength Size zat Loss zat Loss slocity ** Main HE ** * Hot * * Cold * 205 180 190 200 197.5 190 95.00 36.68 Glycol50Glycol 50 63.34 63.53 0.863 0.859 0.233 0.234 0.759 0.819 siction Factor pipe Head Loss Pipe Head Loss - ° NON au @ wn we OBIoAsBu OF uF ° Ny RBONT = o 7 ae NOMPMOWs ** User HE ** * Hot * * Cold * 190 160 170 180 180 170 40.54 36.76 53.37 Glycol 5 water 63.78 62.40 0.854 1.004 01234 02383 0:900 02425 Ground deg F 25.0 m fe to: Piping in 0.20833 Btu/Hr/Ft Btu/Hr 13,207 Ft/Sec Concept: 3 Water + School Gpm (Max Heat Demand) /8,000 Gpm 1b/£t*3 Btu/lb F Btu/Hr Ft F cP deg F feet Used above From Calc. Below Ft Darcy-Weisbach psi Cale. Ft Total Tununak PAGE 06/29/90 3 OF 3 Tununak - Butler Bld Kwh HDD Hea th 6" of Insulation added to the Building Conduction Heat Loss: Infiltration Heat Loss Bldg. With 6" No insulation in floor. 96,000 BTU/Gal Cummins LTA 10, 490 CFM 1,500 Btu/Min 650 Btu/Min 9° 6i ,Engine: Combustion Air: Heat to Ambient: Heat to Coolant: Engine Rating: Genérator Eff.: Bldg Conduction Heat Loss: Infil. Heat Loss: 1800 oe BTU/hr/F BTU/RE/E/ac Bldg. tO PRAW oct SOO. BUIONONO)~) QUINUASFNPOWOW CWODOPOHPHOHUNWO COCCOCCOCOCOCOOO COOCCOCCOCCCOOO WUIONIW BOWOOUTIOY DAWOCHWOrFNWWUI NNOWOPONDOTOW CNWOWVIDBDOWOO~ I~) WWHRPR PWWLUUI CWOON UD)TRRR WN PONDMOWVUIOWDS) Historical Records Input Historical Records Input Heat to Coolant = Heat rejected to coolant by p.og- Heat = Heat Loss from building at 65 deg ! t nt = Heat rejected to ambient by engine (Heat to Ambient) eat required to keep bldg at 65 deg. F —e o Amb : Heat Reqd. Bldg Heat) -9 BTU/hr/F -l BTU/hr/F/AC Heat to Additional Heat Ambient Heat Reqd WRODW UINNS~]~] WUIONW BOCOUIC) PWOTROOWVUIDWW WNHNFR PWWWAS NOBODE WR BWW DWAIDUOWODVIN A BWWNHNNNWWWWS WIUDIWPR BODN CAIDWODHOP SAD @ OOOODOOCOOCOOU1 ~ ao Ww Ww wo RPM 1225 ‘Aix Ch/7Hs 424 PWWNHNNYNYWWWW WIUID IW SR Boyd CADWOODLOLSH~) 05/02/90 Heat to Additiona Heat Ambient Heat Reqd 92 UWB oY COOCCCCOOr~)0)! polarconsult Tununak District Heating APPENDIX B Field Trip Notes polarconsult Tununak Field Trip Notes February 6, 1989 Leslie Moore, Michael Dahl, PCA Met with the following people in Tununak and discussed the project and their concerns. Mike Albert Pres. Village Counsel 652-6926 Simeon Fairbanks, Jr. Assist. AVEC Operator 652-6626 Andy Patrick Manager Tununak. Native Store 652-6813 Victor Sr. Wash. Operator 652-6626 Tan Parks Principal 652-6827 Tommy Angaiak Manager Vil. Corp. Store 652-6928 Lower Kuskokwim School District (Tununak & Nunapitchuk) Mike Franks Maint. Dir. 543-4800 Earl Rinneo Assistant 543-4800 1. Weather: Coastal weather influence. Considerable drifting from NNE, reaches tops of buildings by April. Population: 337+. During the summer most people commercial fish, although many workers are available and like to work in town. Eleven new homes are to be constructed this next summer. 2. Utilities: Water: Year-round underground distribution and water pick at the water treatment/washeteria. Water treatment plant is located up the hill right next to the school. Use about 11,000 to 12,000 gal/yr of oil for water heating and pumping. Paid $1.88/gal last year. Provides heat to the building, water distribution system, and the washeteria. Last year the city was short of money to buy fuel so it borrowed 2,000 gallons of oil from the school. 2 boilers in plant are both Burnhams, one model No. PF35, 375 Mbh output, Second model No. V-37 342 Mbh output. Water heater is a Chemithom, HP 78248 which was operating with a 184 °F output and a 174 OF input. The water tank heater temperature was 60 OF in and 48 OF out. The exchanger was shell and tube. 3. Equipment (1) UHO 82 backhoe, one year old. Appendix B Page 1 polarconsult Tununak Field Trip Notes February 6, 1989 (1) JD 350C w/ backhoe - operational. (1) 545 B Loader. 4. School: Principle Ian Parks: The structure is comprised of an old section and a newer addition. There are 30 preschool children and from 85 to 90 children in grades 1 through 12. The new section of the school is heated by two boilers as listed below: Boiler 1 2 Manuf. Burnham Burnham Model # Serial # 7587133 7587130 Output 342/370Mbh 342/370Mbh The old school is heated by a single forced air furnace. Water is heated by a single unit as listed below: Storage Tank 1 Manuf. PBI Model # 1.0N85A0 Serial # 771937842 Input 140 Mbh Day Tank 85 gal 5. Village Corporation Store: Tommy Angaiak, Manager: Three year old building uses forced air heating. The building is made of metal with interior plywood walls. No fuel records other than the 409 gallons used in January 1990. Furnace 1 Manuf. Williamson/Cinncinati Tempomatic Model # 1 164-18-1 Serial # DB-529751 #212735 Input 158 Mbh/1.35 gph Appendix B Page 2 polarconsult Tununak Field Trip Notes February 6, 1989 Tununak Native Store: Andy Patrick, Manager: The main building is 30 x 40 feet in dimension with a 14 x 40 foot addition and a 24 x 24 foot warehouse . Mr. Patrick states the fuel oil use is from 1,000 to 1,500 gallons per year and they pay $103.40 for a 55 gallon barrel of oil. He states the peak use with the old stove was a barrel every 4 days, and with the new stove he predicts a rate of 10 gallons per day. Stove was installed the day of the field trip. Furnace 1 Manuf. Lear Siegler Model # CMF-80 70 Serial # L-467803 Input 66.4Mbtu AVEC Plant: Simeon Fairbanks, Jr, assistant operator: The plant is a standard butler building with diamond plate on the floor. There are two working automatic vent dampers. Electrical panel is 120/240 volt 1 phase. Temperature in building was 48 OF inside with -8 °F outside. When the louvers were closed, the temperature inside was 60 OF. At the time of the visit, the plant was generating 122.5 kW at 0.93 power factor, 560 amps and 248 volts. Unit 1: Cummins LTA 10 C, 1800 rpm with remote radiator. Return temperature was 185 OF with 12% fan speed. Unit 2: AC 685 I, 1800 rpm with skid mounted radiator Unit 3: AC 3500, 1800 rpm with skid mounted radiator. Generator was a Kato Sr. No. 83605, 75 kW, single phase, voltage 120/240. Appendix B Page 3 (a # t ) { polarconsult APPENDIX C Cost Estimate Tununak District Heating hl | ea ss i a st HMS 9022 CONSTRUCTION COST ESTIMATE WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA COST CONSULTANT. ENGINEER Polarconsult Alaska 1503 West 33rd Street, Suite 310 Anchorage, Alaska 99503 HMS Inc. 4103 Minnesota Drive Anchorage, Alaska 99503 (907) 561-1653 February 18, 1991 (907) 562-0420 FAX ; on oo 1 | 2 ty ' M@®,.). ' Me hs WASTE HEAT RECOVERY SYSTEM PAGE 1 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from seven (7) 8 1/2"x11" sketches and outline specifications linking two facilities in the village, as detailed by Polarconsult. Unit prices and costs indicated in this estimate are based on current knowledge. The possible effects of current hostilities in the Middle East have not been considered in the preparation of this estimate. This estimate is a statement of probable construction cost only, and is priced using A.S. Title 36 prevailing labor rates and current materials, freight and equipment prices, and to reflect a competitive bid in Spring 1992. Removal of hazardous material has not been considered in this cost estimate. CONCEPT #1 - Water Treatment Building CONCEPT #2 - School CONCEPT #3 - Water Treatment Building asa 's « WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY CONSTRUCTION COST ESTIMATE 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 Escalation at .50% per month to Spring 1992 TOTAL CONSTRUCTION COST: PROJECT COST Design SIA (Supervision, Inspection and Administration) Project Contingency TOTAL PROJECT COST: SUMMARY CONCEPT #1 CONCEPT #2 CONCEPT #3 93,426 106,008 164,912 32,861 62,811 69,965 1,403 1,403 1,403 1,200 1,200 1,200 4,450 4,450 4,450 33,861 39,999 54,775 5,600 6,177 8,538 172,801 222,048 305,243 10.00% 17,280 22,205 30,524 7.50% 14,256 18,319 25,183 204,337 262,572 360,950 10.00% 20,434 26,257 36,095 20.00% 40,867 52,514 72,190 10.00% 20,434 26,257 36,095 286,072 367,600 505,330 PAGE 2 2/18/91 1. J J I bo pe | ' oie: y ‘ { PAGE 3 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #1 iy.) #e ty 7 ‘PF, 4 FF WASTE HEAT RECOVERY SYSTEM po TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #1 01 - GENERAL CONDITIONS QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization al LOT 8,500.00 8,500 Freight 45,000 LBS 0.50 22,500 Supervision, equipment, utilities, clean site, tools and protection 6 WKS 3,500.00 21,000 Per diem 126 DAYS 110.00 13,860 Travel costs, including time in travel 6 RT 1,400.00 8,400 SUBTOTAL 74,260 Bond and insurance 2.25 % 3,457 Profit 10.00 % 15,709 TOTAL ESTIMATED COST: 93,426 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY CONCEPT #1 - WORK QUANTITY Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 290 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 500 1-1/2" ditto 80 2 1/2" bend 1 1/2" bned TOTAL ESTIMATED COST: UNIT LF LF LF EA UNIT RATE 12.50 48.50 37.50 180.50 135.50 PAGE 5 2/18/91 ESTIMATED COST 3,625 24,250 3,000 1,444 542 32,861 | I I | J | i \ 1 { Ll ( } 4 er ‘ { ‘ WASTE HEAT RECOVERY SYSTEM a © TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #1 QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 1115) 1,403 TOTAL ESTIMATED COST: 1,403 me. (Jif o OB ck c/ Pa WASTE HEAT RECOVERY SYSTEM ean TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #1 06 - WOODS AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200.00 1,200 TOTAL ESTIMATED COST: 1,200 aT MM Wot e icicle) ee WASTE HEAT RECOVERY SYS'TEM er TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 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 2,800.00 2,800 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door a EA 710.00 710 Louver 1 EA 500.00 500 TOTAL ESTIMATED COST: 4,450 ', fF, se, ya. re oy ie Ct , WASTE HEAT RECOVERY SYSTEM ae ta TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections Connection to existing piping to cooling system of generators 2 EA 72.50 145 Form hole through existing wall for heating pipes 2 EA 195.00 390 3" diameter black steel welded piping 80 LF 26.22 2,098 Fittings 16 EA 46.35 742 Butterfly valves 4 EA 325.00 1,300 Insulation to pipe, 3" diameter 80 LF TalO 568 Booster pump 1 EA 1,450.00 1,450 Heat exchanger, 400,000 BTUH 1 EA 4,950.00 4,950 Unit heater, 60 MBH including thermostat 1 EA 330.00 330 1" diameter piping including fittings 40 LF 9.70 388 Gate valves 2 EA 77.00 154 Insulation 40 LF 4.30 172 1 1) | | d v4 | \ co 1 WASTE HEAT RECOVERY SYSTEM PAGE 10 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 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 1 1/2" diameter black steel piping including fittings 30 LF 14.75 443 1 1/2" copper piping including fittings 30 LF 14.95 449 Gate valves 10 EA 260.00 2,600 Check valves 2 EA 260.00 520 Strainer 2 EA 58.00 116 Balancing valve 3 EA 53.00 “159 Temperature control valve L EA 225.00 225 Insulation 60 LF 5.83 350 Heat exchanger, 200,000 BTUH a EA 3,550.00 3,550 Air separator 1 EA 495.00 495 Pumps, circulation Grundfoss 200, 2" diameter 2 EA 680.00 1,360 ‘Sw ', fa! Pig |i A -_ Poe Fg! ' WASTE HEAT RECOVERY SYSTEM PAGE 11 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #1 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Connection to existing piping system 2 EA 72.50 145 Glycol 440 GAL 8.80 3,872 Test and balance system 40 HRS 75.00 3,000 Controls and Instrumentation Generator building and new module 1 LOT 2,000.00 2,000 Hook-up inter ties 1 LOT 1,500.00 1,500 TOTAL ESTIMATED COST: 33,861 WASTE HEAT RECOVERY SYSTEM PAGE 22 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-Up Breaker in existing power panel a EA 175.00 175 Connection to motor 4 EA 115.00 460 Disconnect switch 3 EA 330.00 "990 3/4" EMT conduit 80 LF 3.20 256 #8 copper 320 LF 0.85 272 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 277 Panel A EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light fixtures 6 EA 190.00 1,140 Switch 1 EA 55.00 55 Duplex outlets 4 EA 68.00 272 ) J J J I | I J J I ' i) i ‘ ef . WASTE HEAT RECOVERY SYS'TEM = TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #1 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) 1/2" conduit 50 LF 3.00 150 #12 copper 150 LF 0.55 83 TOTAL ESTIMATED COST: 5,600 1 ot 1 | a | | | | | | PAGE 14 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #2 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY PAGE 15 2/18/91 CONCEPT #2 QUANTITY UNIT UNIT RATE ESTIMATED COST 01 - GENERAL CONDITIONS Mobilization Freight Supervision, equipment, utilities, clean site, tools and protection Per diem Travel costs, including time in travel SUBTOTAL Bond and insurance Profit TOTAL ESTIMATED COST: 2.25 10.00 LOT LBS WKS DAYS RT 8,500.00 0.50 3,500.00 110.00 1,400.00 106,008 WASTE HEAT RECOVERY SYSTEM —_ TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #2 QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 630 LF 12.50 7,875 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 500 LF 48.25 24,125 2" ditto 760 LF 37.50 28,500 2 1/2" bend 6 EA 180.50 1,083 2" bend 6 EA 135.50 813 3" tee 2 EA 207.50 415 TOTAL ESTIMATED COST: 62,811 PAGE 17 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #2 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS Tat 1,403 TOTAL ESTIMATED COST: 1,403 WASTE HEAT RECOVERY SYS'TEM a at TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #2 06 - WOODS AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Access steps, including handrail and base 1 LOT 1,200.00 1,200 TOTAL ESTIMATED COST: 1,200 WASTE HEAT RECOVERY SYSTEM pa i TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 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 dL EA 2,800.00 2,800 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 TOTAL ESTIMATED COST: 4,450 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY CONCEPT #2 15 - MECHANICAL Exchanger and Connections Connection to existing piping to cooling system of generators Form hole through existing wall for heating pipes 3" diameter black steel welded piping Fittings Butterfly valves Booster pump Heat exchanger, 400,000 BTUH Unit heater, 60 MBH including thermostat 1" diameter piping including fittings Gate valves Insulation PAGE 20 2/18/91 QUANTITY UNIT UNIT RATE ESTIMATED COST 2 EA 72.50 145 2 EA 195.00 390 80 LF 26.22 2,098 16 EA 46.35 742 4 EA 325.00 1,300 1 EA 1,450.00 1,450 1 EA 4,950.00 4,950 1 EA 330.00 330 40 LF 9.70 388 2 EA 77.00 154 40 LF 4.30 172 WASTE HEAT RECOVERY SYSTEM PAGE 21 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 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 1 1/2" diameter black steel piping including fittings 30 LF 14.575 443 Gate valves a3, EA 260.00 31,3980 Check valves 3 EA 260.00 780 Strainer 2 EA 58.00 116 Balancing valve 3 EA 53.00 . 159 Temperature control valve iL: EA 225.00 225 Insulation 60 LF 5.83 350 Heat exchanger, 350,000 BTUH 1 EA 4,305.00 4,305 Expansion tank, 26 gallon capacity 1 EA 1,245.00 1,245 Air separator 1 EA 495.00 495 Pumps, circulation Grundfoss 200, 2" diameter 3 EA 680.00 2,040 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY PAGE 22 2/18/91 CONCEPT #2 15 - MECHANICAL Hook-up (Continued) New heating coil Connection to existing piping system Make-up glycol system connection, including tank Glycol Test and balance system Controls and Instrumentation Generator building and new module Hook-up inter ties TOTAL ESTIMATED COST: QUANTITY UNIT UNIT RATE 1 EA 2 EA a. EA 440 GAL 66 HRS 1 LOT i. LOT 875.00 72.50 610.00 8.80 75.00 2,000.00 1,500.00 ESTIMATED COST 875 145 610 3,872 4,950 2,000 1,500 39,999 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY CONCEPT #2 16 - ELECTRICAL Hook-Up Breaker in existing power panel Connection to motor Disconnect switch 3/4" EMT conduit #8 copper New Module Main feeder and conduit Breaker in existing distribution panel Panel Exterior light fixture Light fixtures Switch Duplex outlets QUANTITY UNIT UNIT RATE PAGE 23 2/18/91 ESTIMATED COST 100 400 40 EA EA EA LF LF LF EA EA EA EA EA 175.00 115.00 330.00 3.20 8.50 277.00 800.00 330.00 190.00 55.00 68.00 175 575 1,320 320 340 340 277 800 330 1,140 55 272 WASTE HEAT RECOVERY SYSTEM PAGE| 24 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #2 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) 1/2" conduit 50 LF 3.00 150 #12 copper 150 LF 6.85 83 TOTAL ESTIMATED COST: 6,177 PAGE 25 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY CONCEPT #3 QUANTITY UNIT UNIT RATE PAGE 26 2/18/91 ESTIMATED COST 01 - GENERAL CONDITIONS Mobilization Freight Supervision, equipment, utilities, clean site, tools and protection Per diem Travel costs, including time in travel SUBTOTAL Bond and insurance Profit TOTAL ESTIMATED COST: 87,000 12 265 2.25 10.00 LOT LBS WKS DAYS RT 8,500.00 0.50 3,500.00 110.00 1,400.00 8,500 43,500 164,912 WASTE HEAT RECOVERY SYSTEM aE 37 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 QUANTITY UNIT UNIT RATE ESTIMATED COST Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus 670 LF 12.50 87375 2 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 500 LF 48.25 24,125 2% ditto 760 LF 41.50 31,540 1 1/2" ditto 80 LF 37.50 3,000 2 1/2" tee 2 EA 207.50 415 2 1/2" bend 6 EA 180.50 1,083 2" bend 6 EA 147.50 885 1 1/2" bend 4 EA 135.50 542 TOTAL ESTIMATED COST: 69,965 PAGE 28 WASTE HEAT RECOVERY SYS'TEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 05 - METALS QUANTITY UNIT UNIT RATE ESTIMATED COST Structural steel support welded to existing skid 1,220 LBS 615 1,403 TOTAL ESTIMATED COST: 1,403 WASTE HEAT RECOVERY SYSTEM PAGE 29 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 QUANTITY UNIT UNIT RATE ESTIMATED COST 06 - WOODS AND PLASTICS Access steps, including handrail and base 1 LOT 1,200.00 1,200 TOTAL ESTIMATED COST: 1,200 WASTE HEAT RECOVERY SYSTEM naan TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 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 - EA 2,800.00 2,800 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 TOTAL ESTIMATED COST: 4,450 WASTE HEAT RECOVERY SYSTEM eae ie TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 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 2 EA 195.00 390 3" diameter black steel welded piping 80 LF 26.22 2,098 Fittings 16 EA 46.35 742 Butterfly valves 4 EA 325.00 1,300 Insulation to pipe, 3" diameter 80 LF 7.610 568 Booster pump 1 EA 1,450.00 1,450 Heat exchanger, 400,000 BTUH 1 EA 4,950.00 4,950 Unit heater, 60 MBH including thermostat a EA 330.00 330 1" diameter piping including fittings 40 LF 9.70 388 Gate valves 2 EA 77.00 154 Insulation 40 LF 4.30 172 WASTE HEAT RECOVERY SYSTEM aioli TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 15 — MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up Form hole through existing wall for heating pipes 2 EA 195.00 390 1.1/2" diameter black steel piping including fittings 60 LF 14.75 885 1 1/2" copper piping including fittings 60 LF 14.95 897 Gate valves 23 EA 260.00 5,980 Check valves 5 EA 260.00 1,300 Strainer 2 EA 58.00 116 Balancing valve 3 EA 53.00 159 Temperature control valve 2 EA 225.00 450 Insulation 120 LF 5.83 700 Heat exchanger, 350,000 BTUH i EA 4,305.00 4,305 Ditto, 200,000 BTUH 1 EA 3,550.00 2,550 Expansion tank, 26 gallon capacity a EA 1,245.00 1,245 WASTE HEAT RECOVERY SYSTEM PAGE 33 TUNUNAK, ALASKA CONSTRUCTION COST STUDY 2/18/91 CONCEPT #3 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Air separator 2 EA 495.00 990 Pumps, circulation Grundfoss 200, 2" diameter 3 EA 680.00 2,040 New heating coil 1 EA 875.00 875 Connection to existing piping system 4 EA 72.50 290 Make-up glycol system connection, including tank 1 EA 610.00 610 Glycol 495 GAL 8.80 4,356 Test and balance system 106 HRS 75.00 7,950 Controls and Instrumentation Generator building and new module 1 LOT 2,000.00 2,000 Hook-up inter ties 2 Lots 1,500.00 3,000 TOTAL ESTIMATED COST: 54,775 WASTE HEAT RECOVERY SYSTEM TUNUNAK, ALASKA CONSTRUCTION COST STUDY PAGE 34 2/18/91 CONCEPT #3 16 - ELECTRICAL Hook-Up Breaker in existing power panel Connection to motor Disconnect switch 3/4" EMT conduit #8 copper New Module Main feeder and conduit Breaker in existing distribution panel Panel Exterior light fixture Light fixtures Switch Duplex outlets QUANTITY 180 720 40 UNIT UNIT RATE EA EA EA LF LF LF EA EA EA EA EA 175.00 115.00 330.00 3.20 0.85 8.50 277.00 800.00 330.00 190.00 55.00 68.00 ESTIMATED COST 350 1,035 2,310 576 612 340 277 800 330 1,140 55 272