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Wales District Heat Report & Concept Level Design 1990
Alaska Energy Authority LIBRARY COPY | Wales | District Heat Report & Concept Level Design PREPARED FOR State of Alaska PN Alaska Energy Authority 701 East Tudor Road PO. Box 190869 Anchorage, Alaska 99519-0869 ARCTIC OCEAN polarconsult alaska, inc. ENGINEERS ¢ SURVEYORS ¢ ENERGY CONSULTANTS 1503 WEST 33RD AVE.e ANCHCRAGE, ALASKA 99503 PHONE: (907) 258-2420 FAX: (907) 268-2419 polarconsult Wales District Heat Executive Summary Wales a bush community with a population of 159, located on the West Coast of Alaska on the Bering Strait is a potential candidate for a district heating system. This report was commissioned by the Alaska Energy Authority (AEA) to determine whether such a system would save the community money. The district heating system would recover energy from the Alaska Village Electrical Cooperative (AVEC) power plant that would otherwise be wasted, and convert it to beneficial use for the community. With the 1990 cost of heating oil at $1.18 per gallon, a considerable amount of money is expended to . heat community buildings. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which transfers heat to water, and a pump to circulate the hot water through the baseboard radiators. At the radiators the heat is transferred to the air which heats the building. A district heating system works in the same manner, with the exception an engine heats the water like a boiler, but instead of using fuel it used heat that would be wasted. This report discusses how this heat may be used in Wales, and what results may be expected. The water treatment building is the best candidate to be connected to the district heating system in Wales as it would use 64% of the available waste heat available from the engines and is close to the power plant. Project cost, annual amount of fuel saved and fuel cost savings for the water treatment building are as follows: Project Cost $308,222 Amount of Fuel Saved per Year 6,470 Annual Savings $7,634 Straight Pay Back in Years 40 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 Wales District Heat system and the water treatment plants heating system, and construction of a hot water transmission line. The life of a district heating project is a function of availability of waste heat from the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance costs. In this case the requirement for continued use of electricity and space heat in the community imply an infinite project life. With proper maintenance the operational and economic life of the district heating system will exceed 25 years. It is estimated that it will cost an average of $800 per year to repair actual failures in the district heating system. Routine maintenance will be performed during three trips to Wales 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, the water treatment building, is 40 years. The project could be made more economically attractive by reducing its scale through minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Northwest Alaska communities to reduce Wales share of the high mobilization, shipping, travel, and supervision costs required. di polarconsult Wales District Heat INDEX Executive Summarys. |j/sacc 5 anaes 9 belts} ot op fe [nisl fel atl mia e am wile) atc i Hist Of Rigureseiele ie rece cies) eeiresionceaiacnsi iene elle nenenemenetel et steneleheneneretentells v Heist Of LADIES Pere ge teyy eked ste eaientel ettoltolieke fe festente tentetovie}i sy evtelteiten enced enter lte ie) ) fers v Glossary) oa ome ei ailaiel im foitel si os) lat evvilre os] o} th ofa) cu faliol c] cro) (ove a1 lit fo (eo) (alla) vi I. Introduction ATOBCCHVER re rents oieie erect el cle fafelioeetetetemelte) eteqichel elisttiaenerelellelis 1 B. DistrictHeating System. cys eelasec + aa aaa neem smiles) 6 1 CiMethodology sae sl a ate to ims © leilelelel ey se leleie iene) st oy elitr) ch elle fei) el a 1 BD: Community Descriptiony, |. |.) sane 6 eae ses sale isis aes os 3 E.. Projected Load'Changes) 3c 5 ss slsisieie ts ers ilycle sls ee sleels 8 MU Site Visite iy eye eos le lelef ele eiled st edies y=) ch syetie eer ey kel hey cliches eters a eeliel cy airs < II. Power Plant ANS Gemierall rare e greys r otf elfotnen steedieionss) ell otictfello) sf lovlefichite}l ol chioll ey ehielieuten stron tents (ell st oie =) B. Available Load Information & Available Heat... ........00000 00s 3 @yBuilding Heat 5 ae late lis) yt co 6 v1 fee [aise fo 19) ol fo fe lel sie ele| otc 3 fa ells | 8 D. Proposed District Heating Connection ............ cee eee eee 8 IV. Potential District Heating Users A. Water Treatment Building 1Generaliy bie aiiei Stes ele alae ae ales) aaa snes hoa Ly Ze LOCAON ame svey iis leicilelicpesichonereetenedlsicneienenchalekeleloehsielch er oe 11 3 Pleat Used ku cists stein 2 0) 3 fe Poh siieile si ate ie lrlolelielis| a ot oe em aye 11 4. District Heating Connection... ... ee ee ee 12 B. Other Buildings De(Generalls jaja lara fo 3) oo olde si leifallicl vol oto! 6) s\feile fo) ol elie er ere @ este) a 12 iV. Concept Design Drawingsryy) joie ee) /e) elke fo) 6 ies) ate ie} ate irate, oh nto tele) eri ehae! (ot a 14 VI. Failure Analysis A;i|Operation and! Maintenance 770 2/5 3 eileliel«) ele ie oie) te) t+) te eel lo te 6) 6) oe 18 B. Failure Analysis of District Heating System .. 1... .. ee eee ee 19 1 Power Plant ppatnocnelsreclelened eke ichelie ty alder eteneiicneireneitel ai oir 20 25 Distribution’ System) 5) = 46s an mile ls) ae 6 silo ce aslo e) i001) ol) = ise, 015) 23) 3 User Connection) eye raeienelelaleelelericleneleielicneneiic re eiricle 24 GC) Eailure Frequencyand\ Cost.) oe icla sein ae clase era so ie els 81% fe 26 D. Design Decisions Made to Minimize Failure Rate and Impacts ......... 28 4a polarconsult Wales District Heat VII. Project Specifications Ax Codesjand Regulations)-n-:-w-n-iemk too k-Nel MN oket NNR atone oie 29 B. DIVISION 01 - General Requirements. ...... 27... 0c ee eee eee 29 CIDIVISION, 02) = |Site WOT oo pio se ce) oyiestones sonics, susontenssi osrse to) oie foisy see 29 D. DIVISION 13 - Special Construction... 1... . eee ee ee 30 E. DIVISION 15 - Mechanical Outline Specification... ...........00- ol F. DIVISION 16 - Electrical Outline Specification. ...........000 eee 34 VIII. Project Cost Estimate , A. Power Plant Heat Recovery System... 1... ee ee es 37 B. District Heating Distribution System... . 1... . eee ee 37 Operation and: Maintenance Costs) <5 -y.yeyapiene ei -lteen-)i- eel elo) eiieeyio | Oe 37 D Project Cost'Summaty! jaye -iaw eter ei cin cies alieifor siieteivel'e (eflecleliey sols) rel 38 IX. Conclusions A. Heat Available & Fuel Consumption ......... 0.00 e ee eee eee 39 B..ProjectiCost Summiaty 7 sel ete oom) eo oe elo eee) ore) a) elie) ol ee 41 CAPrOjeCctiSUMMALY Mreeeneee seen ete terinenetiotc Ten heriens) ot atte iarfone: a) alte tens erie 41 X. Recommendations. ..... 2... ccc eee eee ee eee eet teens 42 Galculations#) 5 4,,.50 90908 0ee Seer ayer kh yams ee geiek a see Appendix A Shi builiJnn go gguguoODDUDDDOOODDOGOnMoO0Og0DG0UC Appendix B GCost'Estimate o.oo cee dees see seek Mee Aa es Appendix C iv polarconsult Wales District Heat List of Figures Il-1 Building Entrance & Air Intake Louvers... .... . eee eee iv I-2 Exhaust Stack & Cooling Air Louvers, Proposed New Remote Rad. Location . .7 I-3 Unit #1, Remote Radiator Connected & Cooling Air Louver Closed Off .... 10 I-4 Proposed District Heating Pipe Connection to Units #3 & #4 ........... 10 IV-1 Proposed District Heating Pipe & Proposed Boiler Connection .......... 13 IV-2 Proposed District Heating Pipe & Water Tank ........... 0c eee eee 13 V-1 Site Plan and District Heating Distribution ............. 0000 ee eee 14 V-2 Proposed System Schematic ........ eee ee eee 15 V-3 Detail Showing Revisions to Power Plant & District Heating Connection ... .16 V-4 Water Treatment Building Schematic ............ eee eee eee 17 IX-1 Heat Available vs Heat Required ........ eee ee ee ns 40 IX-2 Gallons of Heating OilDisplaced .. 1... . ee es 40 List of Tables I-A Engine Data. oe os om me eet HOR HS se ne ee 5 I-B Monthly Power Generation & Available Heat... 2.0... .. eee eee eee 6 IV-A Deliveries & Estimated Distribution of Fuel Use at Water Treatment Bldg... 12 VI0I-C Summary of Project Costs IX-A Annual Heating Fuel Displaced & Pipeline Heat Losses PXEB Project’ Summary #7 pep ener menos crete cnemertoustemettel cieemouetatictieloyrat cite ma 41 polarconsult Wales District Heat Glossary AEA: Alaska Energy Authority, the State agency which commissioned the report. AVEC: Alaska Village Electric Cooperative, the electric utility providing electric power to the community. APUC: Alaska Public Utilities Commission, the body which regulates most utilities throughout the State of Alaska. Capital Cost: Total cost to construct the project, including direct construction 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 Wales District Heating I. Introduction A jectiv 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 Wales. In view of the present cost of heating oil at over $1 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 Wales. B. District Heatin m A district heating system takes energy that would otherwise be wasted and converts it to beneficial use as space heat. A brief description of a district heating system follows. A district heating system is not complicated. Typical baseboard-heated buildings have a boiler which burns fuel, usually oil, and transfers the heat to water, and a pump to circulate the heated water through pipes to radiators. At the radiator the heat is transferred to the air in the building. A district heating system works similarly, with the water heated by diesel generators in the AVEC power plant instead of being heated by a boiler. The water heated by the engines is normally cooled by the radiators at the plant. In a district heating system, this heat is recovered for beneficial use instead of being rejected to the atmosphere. This report discusses how waste heat can be used in Wales, and the likely results. C. Methodology The feasibility of waste heat use in Wales has been investigated in the following manner: 1. Information Gathering: Prior to the site visit all pertinent and available information was gathered, including estimates of the amount of heat available and identification of potential user facilities. The field trip was coordinated polarconsult Wales District Heating with village officials and AVEC operators. 2. Field Trip: The site visit was made to discuss the project with the Village Council and interested persons, to survey potential user buildings and determine possible distribution pipe routes. Criteria for potential user facilities included public ownership, substantial heat use and proximity to the AVEC power plant. The manager or operator of each candidate building was interviewed. Information was gathered concerning: Rights-of-way; Amount, type and quality of construction equipment available in the village and the rental rates; o Availability of village-supplied labor during the probable construction period; Specific weather problems such as drifting snow; and Soils information. Field trip notes are shown in Appendix B. 3. Analysis: Field trip notes, photographs, general information and additional site-specific features of the village were analyzed. The 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, "Wales Site Plan and Proposed District Heating Distribution," on Page 15.) 4. Initial Submittal: A preliminary report on the project was written and distributed to the Alaska Energy Authority staff for comment. 5. Final Submittal: The final report will include all comments received from AEA and other interested parties who have reviewed the interim report. polarconsult Wales District Heating D nity Description Wales is located on the West Coast of Alaska on the Bering Strait. The population is made up mostly of Inupiat Eskimos, and the economy is based mainly on commercial fishing and subsistence hunting. Wales has a population of 159. The community has a central washeteria in the water treatment building next to the power plant. There is a year-round water distribution loop which connects to the community center and the school. The sewage from the washeteria goes into a septic field behind the water treatment building. A variety of equipment is available for rent from the city. Local labor is available most of the summer, although a majority of the residents participate in the commercial fisheries. E. Proj han: The heat requirements of the water treatment plant should grow as the community expands or as more buildings are connected to the existing water distribution system. AVEC projects a stable power requirement over the next five years with an increase of about 12% over the following five years, according to its Power Requirements Study and 10-Year Plan. This increased power requirement relates directly to the amount of heat available for use. polarconsult Wales District Heating I. Site Visit The site visit was conducted during December of 1989 to discuss the project with the Village Council and interested persons, survey potential user buildings and determine possible routes for district heating distribution pipe. The principal of the school complex, and operators of the water treatment building (washeteria) and the AVEC power plant were interviewed. Information was gathered concerning rights-of-way, soils, specific weather problems, and local availability of construction equipment and labor. The community was very interested and anxious to participate in the project. Richard Ried, the Maintenance Foreman for Bering Strait School District, was also enthusiastic. Field trip notes, including a list of persons contacted in the field, are shown in Appendix B. polarconsult Wales District Heating Ill. Power Plant A. General The power plant is a standard AVEC Butler type structure. It houses 3 generators, switch gear, and a day tank. Unit #1 is equipped with a remote radiator and Unit #2 & #3 are equipped with skid-mounted radiators. Diamond plate has been added over the original plywood floor in the building. The following equipment is presently installed in Wales. Table I-A Engine Data Position 1 2 3 Engine Cummins Allis Chalmers GMC Model LTA10 3500 4-71 Speed (rpm) 1200 1800 1200 Rating, Engine (kw) 115 118 #255 Heat Rejection* To Coolant (Btu/Min) 4,100 5,088 **3,100 To Stack (Btu/Min) 4,600 ---- ---- To Ambient (Btu/Min) 1,060 2,160 ---- Water Flow (gpm) 60 64 *#30 Intake Air Flow (CFM) 305 --—- — * Rating at full load ** No values for 1200 rpm machine available, values extrapolated from 1500 & 1800 rpm machine data. B. Availabl I ion ilable H Monthly power production figures for Wales 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 Wales 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 wee 40,320 44,520 44,500 1,023 Feb o---- 38,640 38,040 38,000 886 Mar ===== 39,840 41,040 41,000 978 Apr ----- 32,640 38,520 38,500 937 May = 27,960 33,480 33,500 886 June o---- 23,520 25,200 25,200 669 July 16,480 28,320 23,200 23,200 622 Aug 24,160 27,120 27,600 27,600 745 Sept 24,925 30,240 30,480 30,500 819 Oct 27,186 35,520 ----- 37,2002 981 Nov 33,800 36,769 ----- 38,5002 945 Dec 33,000 41,640 ----- 43,6002 1,021 Annual 321,7503 362,209 +=421,3803 = 421,300 10,511 1 Values used in this study were the 1989 kwh production figures rounded to the nearest 100 kwh. 2 From Jan. to Sept. the load increased 4.7% from 1988 to 1989. This rate of increase was used to project the load from Oct. to Dec. 1989. Annual production for 1987 and 1989 were estimated, as data were not available for all months. Equivalent gallons of heating oil available from District Heating Simulation Work Sheet. polarconsult Wales District Heating AVEC Butler Building Figure II-1 Building Entrance & Air Intake Louvers Figure II-2 Exhaust Stack & Cooling Air Louvers, Proposed New Remote Radiator Location polarconsult Wales District Heating C. Building Heat The power plant is a metal frame building with 2 inch insulation in the walls and roof. The building has an uninsulated wooden floor covered with steel plate. Intake air comes from two ventilation louvers by the door and cooling air off the skid mounted radiators, for Unit #2 and #3, is exhausted through motor-controlled dampers behind the radiators. (See Figures II-2 & III-4.) The motor controls on the dampers are not connected. The remote radiator is connected to Unit #1 and the exhaust louver behind this unit has been covered over. (See Figure III-3.) The remote radiator has had problems with blowing snow melting and freezing onto the fan blades. The installation is also subject to drifting as well. It is projected that 1,106 gallons of fuel will be required to heat the power plant building to 65°F year-round. This is to facilitate daily engine maintenance during the cold winter months. This calculation assumes that only one engine is running at a time, which is now the case, and combustion air is circulated through the building. Insulating the floor could decrease this figure by 618 gallons a year. Our concept design includes unit heaters to provide heat to the power plant building and taps for heating engine jacket water in standby units. D. Proposed District Heating Connection The proposed district heating system schematic is shown in Figure V-2 (page 16) and the connection to the power plant is shown in Figure V-3 (page 17). Interconnection between the existing remote radiator and the new remote radiator to be installed this project is included. This will allow for any generator to be run off either of the two remote radiators. Building unit heaters and engine warm system connections are also included in the new piping. The primary heat exchanger will be located in a housing module next to the AVEC Butler building (Figure II-2). The expansion tank and district heat pumps will be located at the user end of the system. The module will be 2x4 standard wood frame construction on piles. It will be insulated with fiberglass batt insulation and covered with metal siding on the exterior and plywood on the interior. polarconsult Wales District Heating 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, come up through the floor next to the engines and connect to each engine. (See Figure IlI-4.) The piping will be type L hard copper or welded and flanged black sch. 40. The piping will be insulated outside of the structures to prevent excessive heat loss. The district heat electrical systems will be connected into a new electric panel located in this module. The new panel will be connected through a meter to the existing station service panel in the Butler building. The cost estimate for the connection of the heat exchanger, pumps, and module at the power plant is covered in Section VIII, Project Cost Estimate. polarconsult Wales District Heating AVEC Butler Building Figure II]-4 — Proposed District Heating Piping Connections to Units #2 & #3 10 polarconsult Wales District Heating IV. Potential District Heating Users A 1 Tr nt Buildi 1. General The water treatment building is owned by the City and operated under the direction of the U. S. Public Health Service. The facility includes a water storage tank, water treatment equipment, boilers to heat the water, a washeteria, shop building and 2 apartments. The boilers provide heat to the building, water storage tank and domestic hot water. 2. Location The water treatment building is located next to the AVEC plant. The district heating distribution pipe from the power plant to the treatment facility will be buried "Arctic" pipe. This pipe will be buried on AVEC and City property. (See Figures IV-2 & V-1.) The length of the hot-water transmission line to the water treatment building is 160 feet. 3. Heat Use The water treatment building's two boilers supply heat to the building, water tank, cloths dryers, and the circulating water in the distribution lines. Domestic hot water for the washers, public showers and apartments is also heated off these boilers. Fuel records for the water treatment building were obtained from the City of Wales. (See Table IV-A.) The City paid $1.18 / gal for their fuel last year. Monthly fuel use was estimated by distributing the average annual fuel consumption, from Table IV-A, computed using the number of heating degree days per month with a base usage of 300 gallons per month. (See Appendix A for sample calculation.) polarconsult Wales District Heating Table IV-A_ Fuel Deliveries & Estimated Distribution of Fuel Oil Use Month Heating Fuel Oil Deliveries Net Fuel Degree 1988 1989 Oil Use Days (Gal.) (Gal.) (Gal. Oil) January 1,968 646 676 February 1,802 509 683 March 1,833 802 696 April 1,405 300 611 May 877 601 502 June 438 400 423 July 332 700 375 August 398 300 374 September 663 460 409 October 1,207 501 494 November 1,566 500 563 r 2. 4 Annual 14,522 6,469 6,470 4. District Heating Connection The two district heating pipes will be buried and will emerge in the crawl space, under the corridor to the water tank, next to the water distribution line to the community center (Figure V-4). The pipe will come up through the floor and travel along the wall to the heat exchanger and equipment. The district heating connection will be made to the return header on the boilers. (See Figure IV-1.) This will be a series connection. (See Figure V-4.) B, Other Buildings 1. General Other buildings investigated included the Community Center, and Coop. These buildins were not feasible due to the distance from the power plant. 12 polarconsult Wales District Heating Water Treatment Buildin g FigureIV-1 Proposed District Heating Pipeline & Proposed Figure IV-2 Proposed District Heating Pipe & Water Tank Ls polarconsult V. Concept Design Drawings ° SEPTIC TANK DRAINFIELD , LEGEND (ZZ) PROPOSED WASTE HEAT USER PROPOSED WASTE HEAT LINE tte EASEMENT REQUIRED —w— — EXISTING WATER LINE —Ff— — EXISTING FUEL LINE — — — UNDERGROUND POWER LINE ° POWER POLE POWER PEDESTAL —==== PROPERTY LINE SCALE: 1” = 80’ Wales District Heating WALES SITE PLAN & PROPOSED FIGURE v=] 14 polarconsult Wales District Heating WALES — PROPOSED SYSTEM SCHEMATIC CONNECT TO USER system USER HEAT pe EXCHANGER ap — L, elg | WASHETERIA (SFE -FIGiV=45 160’ - 15°A BURIED ARCTIC PIPE 5 TO ENGINE COOLING SYSTEM 2 s PRIMARY HEAT EXCHANGER RICT HEAT MOD EXISTING POWER PLANT Oa ie Fi an (SEE FIG. VI-3> LEGEND D<] ISOLATION VALVE fN CHECK =VALVE — — EXISTING NEW @ USER NEW @ PLANT € USER PRIMARY DISTRIBUTION PUMPS FIGURE LS polarconsult Wales District Heating WALES DETAIL SHOWING REVISIONS TO POWER PLANT AND DISTRICT HEAT CONNECTION EQUIPMENT SCHEDULE HEAT EXCHANGER 150,000 BTU/HR RADIATORS. YOUNG, SERIES 22 PLANT PIPING 3” STEEL, WELDED UNIT HEATER 1" CU 60,000 BTU/HR TO DISTRICT HEAT SYSTEM SEE FIGURE V -1 NOTE ~ 1 =r [EXISTING NEW £ [—|_ RADIATOR ee RADIATOR i i—— Pe | PRIMARY HEAT ae wee eee | DISTRICT HEAT MODULE <NEW) LEGEND |] BUTTERFLY VALVE 4 AMOT VALVE RN CHECK =VALVE \il] = FLEX CONNECTOR — — EXISTING NEW PRIMARY PIPING — NEW DISTRICT HEAT PIPING NTS 34 ‘tl o| o ta [ENGINE =| | PENGINE: nc! [ENGINE | | l | l J ih | UNIT HEATER EXISTING POWER PLANT NOTES: 1, LOCATION OF POSSIBLE BOOSTER PUMP 2. PUMPED ENGINE WARM SYSTEMS FOR ENGINES 1, 2, 3 AND EXP. TANKS NOT SHOWM . EXISTING SYSTEM COMPRISES TWO ENGINES EACH WITH SKID MOUNTED RADIATORS AND ENGINE #1 CONNECTED TO AN EXISTING REMOTE RADIATOR. SKID MOUNTED RADIATORS WILL BE REMOVED. FIGURE V-3 . ALL PIPING TO EXISTING REMOTE RAD NOT SHOWN WILL BE REMOVED, 16 istrict Heating Wales WASHETERIA SIN SJILYWAHIS WALSAS aolvavdas WALSAS aIv 4LV3H LOIALSIC WwOa4 V4 q W09A719 ANVL NOISNVdX3 W3ALSAS LV3H LOISLSIG OL Qo YBONVHOXI LVAH mesa mmy _achy al r TAA | Nd ‘f | | | 14 437104) ; | | | PF" naniaa | waz WHLSAS i i ~T TI Won td ANVL SALVA WALSAS aqig3 ad4 ‘HOX3 L3H Nd Gb G3013M ‘1331S SL W3LSAS ONILV3H | _—e SAIVLY 201 = 41 '31W9S N¥ld so014 Jails YFN08 30IS AlddNS *ONIdid “WO tL ANVL NOISNWdx3 094-0S9dN ‘00z S3I¥aS ‘SSOJGNNYD SdWNd YH/NLE O00'0SL YSONWHOXS LVGH sy He are 4 WOOS LNAWLV3aL aad aan _ Was” a | | o-\7 OO YBONvHOXa lvaH aasryyos 3gvas so N39 aovnana! | feast ILE BAVA TONLNOD dW3L MSNIVALS kG ANWA AO3HO NOLLNBIMLSIG. MIN. —— ONIidld ONUSIXI -—- ONIGTING ONILSIXZ. —— VIASLAHSYA OL = b ‘FWOS Y3aSN ® MIN dWnid SANWA “WW SNWA 3lvS L7 polarconsult (USER HOOK-UP) WALES FINGSHOS LNAWdINOS QN3937 polarconsult Wales District Heating VI. Failure Analysis A. Introduction Failure analysis is the process of predicting the operational reliability of a system. It provides information on the probable type and frequency of failures, and indicates how the system should be designed and maintained for optimal reliability. Reliability (R) is defined as that portion of time a system is functional. Unreliability (UR) is defined as (1 - R). Reliability is determined using the total time of operation (Total Period), mean time between failures (MTBF), and mean time to repair (MTTR). A district heating system depends on a number of components to provide heat to the user. The total unreliability of the system is the sum of the unreliabilities of these components. For example, if a pipe had an MTBF (mean time between failure) of 8,760 hours, and an MTTR (mean time to repair) of 8.77 hours, the reliability would be 1-(8.76/8760) = 1-0.001 = 0.999. This means that the pipe will be operating 99.9% of the time. If there were a heat exchanger that could also fail, and it had the same reliability as the pipe, the reliability of the combined items would be 1 - (8.76 + 8.76) / 8760 = 1 - 0.002 = 0.998. This means that both the pipe and the heat exchanger would be operating 99.8% of the time and unable to deliver heat for 0.2% of the time. The system would then be out of service 0.002 x (8760 hours / year) = 17.52 hours per year. Equipment with moving parts, such as pumps, are generally less reliable than static equipment, such as pipes. It is typical practice to install two pumps for this reason, with the second acting as a stand-by. The following illustrates how reliability is calculated for a system with two or more components of which either can perform the task. The system must be such that more than one piece of equipment can perform the same function, and failure of each piece of equipment is independent, that is, it does not affect the performance of other equipment. Two circulating pumps, each capable of pumping all the necessary fluid, is a common situation that will be used as an example. Assume that one of these pumps will fail once per year and polarconsult Wales District Heating will require an entire day to repair. The system will be unable to deliver heat if neither of the two units are able to pump. Assuming failure of both pumps at the same time, system unreliability would average only 0.07 hours per year, as compared to a unreliability 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 tequires that the designer and builder determine the causes of system failures and suggests measures to avoid them. Second, the analysis provides the basis to determine which functions need emphasis during maintenance programs. Third, some degree of scale is provided on how failure affects project income. B. i is of Distri in 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. polarconsult Wales District Heating 1. Power Plant a. Components Engines: The engines are the source of heat; if they are not running, heat is not available to be delivered. Wales has three engines as do most AVEC plants. In general, the plants are designed and operated so that a single engine serves the entire communities load. The reported down time for AVEC generation systems during 1989 was 33 hours total. This quantity was determined by adding 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 together. 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 or more radiators. As radiators are unreliable components, two will be used at Wales to reduce failure probabilities. 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 Sa Failure of the heat exch., piping, & valves assoc. 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. 20 polarconsult Wales District Heating Controls are installed to shut down the plant in the event that coolant levels fall to a dangerous level. Alarms are installed to alert the operator prior to automatic shut-down. This allows the operator to isolate the leak, repair it, by-pass the leak, add additional glycol, or shut down the plant, as appropriate. The primary environmental problem associated with engine radiator failure is discharge of glycol onto the ground. Impacts on the environment from glycol leakage include thawing of permafrost, glycol contamination of groundwater, and glycol contamination of adjacent surface water bodies. Leaked glycol is difficult to recover because volumes are small, the terrain is usually rough, glycol mixes with water and ice, and it will disperse rapidly in water unless it is confined to a catchment basin. The above analysis applies to the existing system and the proposed district heating system upgrade. The only changes will be an increased potential volume of lost glycol, a slightly less reliable system as all equipment is connected to a single cooling system manifold, and a slight decrease in reliability caused by the addition of a heat exchanger. Engine heat exchanger: This component is composed of a series of formed stainless steel plates which are separated and sealed by rubber gaskets. The plates are bolted together within a steel frame to compress the gaskets and hold the plates together. The heat exchanger is used to transfer heat from the engine cooling fluid to the fluid circulated in the distribution pipes supplying the user's heat exchanger. The engine heat exchanger thus serves to isolate the power plant from the distribution system. This isolation means that failures in the distribution piping or at the user facility will not affect the power generation system. Failure modes of the engine heat exchanger are: 1. Blown or leaking gaskets; 2. Broken frame; 3. Valve failure and stem leaks; 4. Cracking or corrosion of plates; 21 polarconsult Wales District Heating 5. Connecting piping system failure; 6. Fouling; 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: i, A large, sudden loss of coolant on the engine, or primary, side of the heat exchanger will shut down the engines. A slower leak on the primary side can shut down the plant as a result of low coolant levels in the engines. If found in time, the failed exchanger can be isolated with valves. It is unlikely that valves will not work during a heat exchanger failure. District heating system operational impact: 1, Small leak: Operation of system will continue. According to maintenance procedures the bolts will need to be tightened, valve packings tightened, new glycol added to the coolant system, and spilled glycol recovered. Large leak: If on the primary (engine) 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. 22 polarconsult Wales District Heating Required immediate actions: Determine cause of failure, isolate heat exchanger at valves or add additional glycol as required by procedures. Catch dripping glycol in pans and recover spilled glycol. Call maintenance office if extra help is required. istribution m Components: Transmission pipe will be 1.5 inch diameter insulated pipe. Each pipe will be made up of a steel carrier pipe 1.902 inches in diameter with a 0.102 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 4.33 inches. The pipe will run from the district heating module, which houses only the heat exchanger, 160 feet to the water plant. The pipe will be buried about 2 feet deep in the ground. Failure modes of the district heating transmission system are: 1. External or internal corrosion of the carrier pipe; 2. Mechanical damage to the pipe from equipment or digging into the pipe; 3. Failure of the pipe; 4. Failure of pipe welds; and 5. Mechanical failure caused by frost heave or thaw settlement. Generation plant operational impact: None d. District heating operational impact: 1. No operational impact from minor leaks in jacket or pipe which are detected and corrected by the maintenance crew during routine inspections. 2. Larger leaks which cause a measurable loss of glycol will require 23 polarconsult Wales District Heating shutdown of the line with isolation valves, and pipe repair to put system back on line. Environmental impact: Glycol spilled on the ground is the environmental impact of a pipeline failure. Glycol can escape into the ground, thawing permafrost and weakening building supports, and also enter groundwater and drain into surface water bodies. Required immediate actions: Determine cause of failure, isolate pipeline at valves or add additional glycol as required by procedures. Catch dripping glycol in pans and recover spilled glycol. Call maintenance office if extra help is required. 1 Connection Components: The 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; SO = SAN, Freezing while generation system is down, if water is used as coolant instead of glycol; and 8. Structural damage to the exchanger supports due to fire or other events. Failure modes of the pumps are: 1. Failure of electrical circuit; 2. Seal failure; polarconsult Wales District Heating Motor failure; Impeller cavitation; Pump body failure; and De Connection leakage. Failure modes of the expansion tank are: 1. Water logging or bladder failure; 2. Corrosion; and 3. Broken sight glass. Failure modes of the piping system are: 1. Leakage of valve stems; 2. Failure of valves to open or close; 3. Failures due to corrosion; and 4. Failures due to materials or installation defects. Failure modes of each of the school connections are: 1. Failure of the school system to hold fluid; and 2. Failure of the school's circulation pumps. Generator operational impact: Failure of the above items will not affect the generation plant. District heating system operational impact: Heat exchanger: As described for the power plant, minor leaks from the heat exchanger will be corrected by catching and returning leaking glycol, tightening bolts, and scheduling the unit for gasket replacement. Major leaks of the heat exchanger will require the system to be isolated with the valves until it is repaired. Pumps: If a pump fails the system will be off until the failure is detected and the standby pump is put into service. If two pumps fail the system will be down until one can be repaired. Expansion tank: An expansion tank failure could be caused by the sight gage breaking, which will require system shut down until it is repaired. 25 polarconsult Wales District Heating Corrosion is not a likely form of failure for an ASME 125 psi rated tank. Piping: Failure of the piping will generally occur at valve stems and where there are gaskets or joints. Slow leaks from these causes and from corrosion will not require shutting the system down. Shut-down of the system could be caused by a valve stem being twisted off or by a broken casting; repairs will be required before the system is returned to operation. Environmental Impact: The environmental impact will relate to glycol spillage. A large, rapid leak might enter the ground, where it could lead to thawing and structural failure. There is potential for groundwater and surface contamination. Small leaks are likely to stay in the building, but will require immediate and complete cleanup. Required Immediate Actions: For a slow leak, pans will be placed to catch leaking glycol, packings and joints will be tightened if appropriate, and fluid replaced. For a large leak, isolation valves will be closed to reduce loss of fluid. Repairs and replacements will be made, or maintenance crew notified, as required by procedures. For a pump failure, the failed pump's valves will be closed, the standby pump's valves opened, and the motor energized. If both pumps fail, one or both will require repairs. If an expansion tank fails, the tank will require recharging or repairs. For extensive repairs or replacement the maintenance crew must be notified. C. Failure Frequency and Cost The most common modes of failure are listed below, along with the associated frequency of occurrence, repair cost per occurrence, amount of down time, and a description of the effects on system life. Failure rates are calculated using the method shown in the Introduction. It should be noted that maintenance of certain items will require that the system be removed from service. This maintenance can be scheduled during a period when the power plant is out of service or when the user building does not require heat. Therefore, the potential effects of loss of 26 polarconsult Wales District Heating 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 total system outage time is estimated at 33 hours per year. Repair cost to system is $0 as it is not related to district heating system. Heat exchanger at power plant: The most common form of failure is failure of seals. Frequency of occurrence is 10.6 years. Down time is 72 hours, repair cost is $2,000. There will be no measurable effects on system life from repairs. District heating pipe: The most common form of failure is from poor installation. Frequency of occurrence is 33 years. Down time is 48 hours, repair cost is $2,000. There are 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 the 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. Item Failure Rate Heat recovery at power plant 0.000507 Transmission pipe 0.000106 Water heating assembly 0.000597 Total 0.001210 Average outage rate 11 hours/yr 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 Zi polarconsult Wales District Heating outage which occur during the summer.) The 25 hours would be distributed randomly. The total time the system would be unable to deliver heat based on outage of the engines and the transmission pipe, would be about 36 hours per year, which is 0.41% of the time. D. Design Decisions Made to Minimize Failure Rate and Impacts Some of the design decisions that will be made to assure long life and reliability are the selection of corrosion resistant materials, the use of duplex pumps, and the use of isolation valves so a failure on one leg will not necessarily shut down the entire project. Where possible, flanged valves will be used, and all interior plant pipe will be welded to improve system reliability. Items which the reliability analysis shows are of critical importance will be duplicated if economically feasible. All connections to the district heating system are separated from the power plant by isolation valves and a heat exchanger to minimize the consequences of a failure. User building heat will not be interrupted by a failure of the main district heating system, or by the failure of another user's system. The design includes the use of "Arctic" pipe which includes a steel carrier pipe butt-welded together and from 1 to 2 inches of insulation covered with a non- corrosive jacket. Two tin-plated copper wires are carried in the insulation to indicate the presence of moisture as an alarm. These alarm wires are read by a $1,500 alarm device which can connect to as many as four individual pipe loops. These devices allow for failures to be detected before they have time to become a major problem. They also minimize the time required to locate the failure and reduce excavation costs. At this time we know of no failures of this piping system in Alaska. polarconsult Wales District Heating VII. Project Specifications nd Regulation 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) ooo: 08 (8 B. DIVISI 1 - General Requiremen This is a general information section covering the coordination of work, description of the work required for this project, regulatory requirements, definitions, payment procedure, submittals, quality control, materials and equipment, starting, testing, contract closeout and maintenance. C. DIVISION 02 - Sitework SECTION 02350 - PILES A. This section lists specific requirements, products and methods of construction relating to the pile foundation system for the district heating building module. B. Piles will be steel thermal piles. 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 29 polarconsult Wales District Heating interior piping is specified elsewhere. B. Distribution will be buried "Arctic" pipe with a steel carrier pipe, polyurethane insulation and a High Density Polyethylene Jacket. The pipe shall be I.C. Moller Plus pipe, or equal and approved. DIVISION 13 - ial Con 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. 30 polarconsult Wales District Heating DIVISION 15 - Mechanii in ification 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. 31 polarconsult Wales District Heating B. Insulation is provided for the following purposes: Energy conservation; Control of condensation; and Safety of operating personnel. Piping inside the power plant shall be uninsulated. Piping inside the district heating module and user buildings shall be insulated 1" thick rigid F/G, with all-service jacket. SECTION 15191 - OUTSIDE TRENCH EXCAVATION, BACKFILL, COMPACTION This section describes general requirements, products, and methods of execution relating to excavation, backfill, and compaction of utility trenches outside of buildings. SECTION 15600 - HEAT GENERATION A. This is a description of specific requirements, products, and methods of execution for interrelated systems, necessary for the generation of heat which will be distributed to the locations shown. The method of distribution of this heat is specified elsewhere. B. Heat generation (transfer) will be accomplished with stainless steel plate heat exchangers, as manufactured by Tranter, or equal and approved. Primary heat exchangers will be located in the district heating module and will interface with the power plant. Secondary heat exchangers will be located in the user facility and will interface with the user's heating system. SECTION 15650 - COOLING SYSTEMS A. This section describes specific requirements, products, and methods of execution relating to the cooling systems for the project. The work of this section includes provision of systems and equipment for removal and transfer of excess heat from the locations shown, including the furnishing 32 polarconsult Wales District Heating of interface apparatus and controls and the connection at interfaces with other mechanical systems. B. Generator cooling systems will consist of Young horizontal radiators, size 22, controlled by Volkman variable speed controllers. SECTION 15850 - BALANCING AND TESTING This section covers general requirements and methods of execution relating to the testing and balancing of the mechanical systems provided on this project. SECTION 15900 - CONTROLS AND INSTRUMENTATION This section describes specific requirements, products, and methods of execution relating to the system of temperature controls and instrumentation for the project. 33 polarconsult Wales District Heating DIVISION 16 - Electri lin 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. 34 polarconsult Wales 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. 35 polarconsult Wales 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. 36 polarconsult Wales District Heating VII. Project Cost Estimate A. Power Plant Heat Ri m The first cost component is the construction of the building to house the district heating system. This includes the mechanical and electrical equipment inside the module and the connection to the modified AVEC power plant as shown in Figure V-3 on page 17. The second cost component is the modification of the existing power plant system. This includes the installation of a new remote radiator, and modifications to the piping to the existing remote radiator connected to Unit #1, as shown in Figure V-3 on page 17. District Heating Distribution The connection of the water treatment building to the district heating system includes installation of piping from the face of the district heating module to the water treatment building, and all equipment and connections within the mechanical rooms as shown in Figure V-4 on page 18. 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 0.4 trips per year to Wales by a skilled repairman. With a cost of $2,000 per incidents the result is an average cost of $800 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. polarconsult D. Project Cost Summary Wales District Heating Total project costs for the three sections of work are shown below. Table VI-C Summary of Project Costs Cost component Cost Module Construction & Connection Plant Piping Revisions Water Treatment Building Connection $143,035 $60,941 $104,246 Total Project Cost $308,222 Total project cost includes design, supervision, inspection, administration and construction. The complete cost estimate is included in Appendix C of this report. 38 polarconsult Wales District Heating IX. Conclusions Heat Availabl nsumption There are presently over 10,500 gallons of equivalent fuel oil per year available as waste heat at the Wales power plant. The district heating system can displace the following amount of the proposed user heat requirements: Table IX-A Annual Heating Fuel Displaced & Pipeline Heat Losses Scheme Concept 1 User Water Treatment Building Heat Available off Engines 10,534 Annual Heat Loss in Dist. Pipes 500 Heat Available to User 10,034 Bldg. Heating Fuel Required 6,470 Amount of Fuel Displaced by District Heating System 6,470 Percent of Available Heat Used 64.4% The water treatment building, which is only 160 feet away distant from the power plant can use 64% of the usable waste heat produced by the power plant. This makes it the best alternative for connection to the district heating system. 39 polarconsult Wales District Heating Heat (Gallons of Oil) Equivelent Gallons of Fuel 1100 1000 83288 500 300 200 100 o <4 “4 <q “J 1% ‘ ‘J So YL KXX KKK KKK Y RSS RRR BRRRRKY BSR RRR KS g BES RRR RRR KR KG J EER PERRY Y p , EORRRRKRS RRR Uy } PISS G e DISS RR RK KING ZEXRRRERRR RM PRR RRR KR KKK KG J EEO] PRR RRR KS J FEN ROS KN Yl RB EEE OEE OOOO 5520 KOO OOOO PRR RRR BERS] BESO RRR RRR RR KK NG J FESS IS PRK RRR KK J GEES OOOO OQ QPP SAS PR QQ QO DOO OOOY OOOO QQ QQ DDD IFS RO OOOO OTD OOOO OP POO? Bo POPP OOO QO” RSS KKK RHI III III III BRR RRR RRR KKK RRR RR III II III IIIS OOOO Qo oo ooo oO OOOO OOO OOO OO OOO OOO] PISS RRR III HHI III III IIS 55559 5 50909 F5 P5990 MK KKK KOKO BESS RRR RRR RRR RRR RHI I III I PESOS KR RII II III HII III] Bess RR III III PRR KR RRR RR HHH IIH] Bess KI IID PSS RRR II IIIT HHI III III] Bess RRR III III ID PSR RRR III HHH HII] BSI HHH HHH HII PRR RRR KKK II POSSI IIHS RSS CR RID SOOO IRI POOR RRR KK KKK RRR RII III II III IIS PSR RRR KR RRR RII III IIH HHH HY PSSST HIICIIIII | RRR RRR RK KKK RRR RRR HHH KRG Jan Feb March April May June July Aug Sept Oct Nov Dec Jan Month BBS) Heat Required @ Washeteria Heat Available from Engines Figure IX-1 Heat Available vs Heat Required 4 s a 0] 0] ~ ° S ) S S S Sy gee a SRR ERY RRR ERKRY SOKRKERR KR RD ESRKRKM RRR KD ERRRRK SRE KRRR KR KRIS ESKRKRRH ROSS EKER SERRE KK SRR KRG KR RRR KRY SKK SERRE RD SSRIS RRR RRR RG ERREKRREKRY SERRE RRR RRR RRR KRG SERRE KRY 4 ROR RRR SRR RR RRS 4 RRR ERE EK KERRI RRR KR KR KRY 4 QoS ooo 855555555 oS RRR ERR EKER KRY BRREKRRRRR ERK SKK KERR ERIN ERR RRR ERRNO Poo oe 5S QO OPO OOOO YOYOTU SSRIS EXER KKK Roe SCSI BERR ERK KKK RH SSOP 55525505 SOS RK OOOO o> OOS ooo OG IO HOMO OSOSSCIKKKKOKY SRR RRR RK KREIS ooo SK OOK MSS Oooo OOK OSS SSS 1550525250505 25 2505055855985 OOK KI | SRR RR KK ORK KKH HHH RIN HII IIIT IIHS KKK KK KKK KKK KN HI HHI HHHH HII HHH HI SKK RK KR KKK KKK KIN HH HHI HR III IHS Yeeros arate tate ete ate te tata te tates te Fe Oe GeGs 4s G40, 0.0.0.0 8 SERRE KKK KKK KKH HHH IIH IHR IIIT OTIS RRR ERK KKK HII HH IIIT RRR KKK RE KKK KKH RH HII IIH IIS KKK INH H I HHI HII IIH III SER KKK KKK KR ERK INH RI HH IIH HII IONS RRR ERR ERK RED SS RRR KY SKK KR KR KKK NII HII III IIH KKK KR KKK KR KHI II HHIOIIHIHIHII SSS SSSI IG SOS SSS SS 555 Soo KF RSS RRR KKK RK RK HH HH HHH HHI HHI SKK KR KR KKK IIH HHH IIH HIN RK ESR KKK RR KKK KKH I HOH IIIT HI SKK KR KKK KKK KKH HHI IIHS Oooo ooo KOK OOK SOS OSS SSF SRR RRR KKK KKK KKK KH RK HHI HII HTH Mererececetatatecerarererereeceereer eer eee eee eeeeseeeesseeceseeseeeie SOS SSSI HICSS OOOO MY COS RR KR KKK KKK RR III IIH SSS SSSI IIPS SSS Sooo KOKO WOOO OOO, 0,0 0,020 WW 0,0,0, 0G 0,0, W, 00,000,040. 4,04. OOO CCC CEOCEOOOOOOS RECESS RK KR KKK KKK KI RR IK HH HH HII RSS RRR KERR RRR RR HHH HHS Jan Feb March April May June July Aug Sept Oct Nov Dec Month of the Year Ra Washeteria Figure IX-2 Gallons of Heating Oil Displaced 40 polarconsult Wales District Heating B. Project Cost Summary The city paid $1.18 per gallons for heating fuel during 1989. The annual savings is computed using these costs for heating fuel. The proposed concept is summarized in the following table. Table IX-B Project Summary Concept 1 User Water Treatment Building Amount of Fuel Saved 6,470 Annual Savings $7,634 Total Project Cost $308,222 C. Project Summary The life of a district heating project is a function of availability of waste heat off the electric generation plant, the requirement for heat at buildings connected to the system, and system maintenance. The requirement for electricity and the need for space heat in the community imply an infinite project life. With proper maintenance the life of the district heating system will exceed 25 years. Because annual operational and maintenance costs and economic decisions will be made by AEA, final economic conclusions are not presented in this report. The straight payback time for the best alternative, the water treatment building, is 40 years. 41 polarconsult Wales District Heating X. Recommendations One way to make the project more economically attractive is to reduce its scale by minimizing new construction and renovations at the power plant. Another approach would be to combine this project with waste-heat projects in other Northwest Alaska communities to reduce Wales share of the high mobilization, shipping, travel, and supervision costs required. 42 polarconsult Wales District Heat APPENDIX A Calculations polarconsult Wales District Heat Power Plant Heat The amount of heat required to keep the power plant building at 65°F was calculated. The number of air changes in the building was assumed to be equal to the amount of combustion air required by the engines plus 2. This added up to 10.4 air changes per hour in the Wales power plant. The conduction heat loss was then added to the infiltration heat loss and the amount of heat rejected to the ambient air off the engine subtracted to come up with the hourly heat requirements for the building. Users Monthly Fuel Oil Usage The annual fuel oil usage, as obtained from the users, was distributed over 12 months using the number of heating degree days (HDD) as follows: Water Treatment Building (Monthly HDD) x (Annual Fuel Cons. - 12 x 250) Monthly; fuel oil sa oe 25 Oi ( Annual HDD ) Domestic hot water is heated off these boilers. Displ 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 Wales District Heat Program Notes: a. The amount of heat available off the engines listed in Table III-B is from the engine manufacturers engine specs. The amount of heat available off the engines used in Appendix A comes from the engine manufacturers test data which they indicated was good to +/,5%. We used 95% of their test data values for use in Appendix A as the heat available off the engines. Appendix A Page z 95% 300 958 Dec 1 1 1 x £ ’ ’ 347 PM ee ae eae eee ee eee Annual 15 04/11/90 02 421 Wale: ddd Dec 903 Nov BIU/HR 1 BTU/HR BTU/HR BTU/HR ddd 6 6 610 610 Nov 7500 43,600 441 Oct lL, ddd TOO MMMM WNOAOOOOCOSCO INNA Oct 7200 38 123 Sept Heat To Heat To 1, coooammmmmm ddd WADA ddiddddd 1,200 RPM Output kw Coolant Ambient 30 Sept 7500 37 734 Aug ddd 600 30. 568 Aug 27, July ddd 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 load above Heat rate at kw-load above Heat rate at kw-load above Heat rate at kw-load above 95 gpm July 7200 577 June Cummins LTA 10, k ddd June 25,200 23 794 May ddd oo >> Qo AQ. an U0 ag 60 aint bu 3 eM, ve an oo be aa wa be og ao mx Flow Rate Heat rate at Heat rate at kw- May 7500 160 1, April < a < a % ° gl Z a oO dates April 38,500 33 1,660 March ddd March 7000 2,050 Feb ddd QO Btu/hr. 5,254 Btu/hr. OQ Btu/hr. Feb 7000 41 1,990 Jan 5,254 Btu/hr. mame ttaipind 50 Btu/hr.xF 973 Btu/hr.xF 50 Btu/hr.xF Jan 500 38 958 0.73 QO 44 1 Boiler SeasonalSeasonal Effic. in in 000 e 000 4 ea sses PB. jipini Beings Non- Radiator lo: HDD/Mth: 3, Kwh/Mth P. e iping ace prehi al constant oCCO ine 3,469 ariable losses: Plant he Subsur: Surface Plant En {STEM LOSS DATA: onstant losses To asheteria uilding in use; l=yes, O=no id GENERATION DATA ““EATHER DATA BUILDING DATA: Fuel use, aallons 8 1 OOTTMTONNE Or NE MOAOMBOAND MMMMNNTTIT TTT TTT TONS IODOO00G0000000000000000 OTTO SONA ON DOHOMODHND MOMMMMONTTI TTT TTT INNS OOCSOSGGGGGG0000000000, IOOCCSCDDSDSCSCCOCOCCCOCCC0O DO SPP ADPONM AAIDATONTOOON AAIMNAAAT TOGA FIGS AIS LS DOS SHA ATONEAIAATONTOOON AMMMOMNOTIONT TOTTI TS TS TSS IISO000000000000000000 CCCCCCCCCCCCCCCSCC0CO MOPS ATONMAGAATONTOOON OMMMMMNMTTIMT TOTTI STS ISS OOGOCSSGGG0000000000000, JOOOOSSSGSGOSGC000000000 DOS SAA ATONMAIAATONTOOCON MMMMMMOTINT COT STITT TTsSS IDOOOOGGOGGGG00GG0000000 IOOOSOSDGCOGGCC00000000 DOT SPAS ATONNAGADATONTOOON MMMOMMMMNTIMNGT COST I TT IT ITS IDOOOSOGGGGGG00000000000 IODOOCOCCDDSCSCCCSCCCCCCCCCCO DOGS ATON-AGADATONTOOON MAMMMMMNTIN TCO TT TSK TST SOS0CG00G000000000000, OCOCOSSCCDCCSCCCCCCCCCO OTTO SONA OM NE- DOAOMOOHND MOMMNNONTTI TT TTT TET TONS OOS90S0S00000000000000, OOCCCCCCCCOCCCCCCCCCCO WOTTON FOV OM NE DOAOMODHND MOMMNNOMNTTI TTT TTT TONS SC00S0009000000000000, eooceCCCCCCSCSCCCCCCCCCCO OTTO TF OVA OM IN-DOAOMOOAIND MMMMNMOMTT ITI TTT TTT TOOTS OOCOGSGCGGGG0000000C0, eooCCCCCCCCRCCCCCC00000 OPPO TOV OMI DONOMODHNO OOM MOT TGC IPT TTT ITO TS OCOCCOSGSCGGGGGG000000000, eocceecCCCCCCCCCCCCC0000 Power Plant Production & Hourly Variation ANMTNOFODOFAMTNOrAnOKAMS FAIA Hour: DODDOAAM Se TTMOTMMMMMMANOND MNNNNNTITETE TTT TIM eoocCCDCCCCCCCeCCGGCG000 oeoeceoecoCCCCCCCCCOCCCCO Summer DOWDOOAD AM TTT TOTMMMMMMANOD ONMNNNMVTTIT TITS TTT TIM SO8CCC90CG000000000000000 oeoceeeecCCCCCCC000000000 Winter Assumed Diurnal Heat Demand Variation 375 373 410 494 563 664 6,469 PAGE 1 OF 3 423 611 502 696 683 Oo o a or ° o oO io ” ° 3 re) = > 676 1,958 Gallons of Oil used per month?) Gallons ie , Compound boiler e: cons. easonal cons., gls. Total Use ower year factor ear no. Non~seas. TINO wNUTxXeW TINO unt Kew My xeed ATINOH umUTXeW eTqeTTeAy 3eeH Kk pueweg 3eeH A peoetdstq jeeH ATInoy unuytxew € dO 2 dowd SUOCTTEOTd Juewjeery 1032 €9¢ v6b Op ble SLE €@p zos 119 969 £89 9L9 TIs‘TtS 2Sb‘Sb v99 6909 I adasuoy BLO‘LE SSE‘DE SES‘DE bLB‘BE Z6T‘9D 6b0‘T9 8S0‘S6S RRNVVEBE EERE BWNEPOODIAUSWNH OOS IAU BWI UIROWDDHHMDODHHOOOSHOII IV COSSHIIAIAIOOOOIIN®IGIA 6L Trady (s,La 000‘T) Y3uow Aq znoy Aq pezeatTep 3eeH e WMOOOWOWOWOOOWOOWOOOOODODHHOO MMOD DDMDOWMO OW OOOO NOW IIIIO PUDIOOOBOCONEHHOOUNCOIOCF NIIIOOHHOOOOHHBOOOIIIIII OUDOPEROPPNAWNNNEIWNONNW DAAANAADAAADANADADAN NADA DONGSUUSUL VAAN © JVI DANAAANAA AANA NN PNBBAADAAAANOITIAADWOOOCOH Sooo... ..H.5 UL aon. nnn55 PUGDIBOHDODOOOOOOOBDAWWNWWS LLL ASL SHALL H PALA LASS DD WH DV IDDHIDOOOOOOMDOHAWNNYNWW PANNA NAAN Be CONGSAAALAUTADHUUTIUNSNVOGILOO MNADAADAADADAADAADAADAADA UU VOPNGWWOOOLUDODSAAWOIDUNADAT DAVIIIIIN III IIIS IQAVAGD DONOSUTHUISUNIADAANH IUD IIOOODHOMDOOOOHHOOMOOIIIII VONGUUULAUABIADVDAEH ANS UVAT uec qed yorew en :eq AON 200 ades bow Atng eunc “Tenuuy 98g ~AON~-300.~C*Mdes—sBay ~~ ~<Atapounp PereaTtTed 3eeH euleg TeIOL ile ilstateledeletetel ated BWNPOODIDUSWNHOCOIAUH WN ILDDLODOHMDOOHHHOOMOIIII~ COBLHAINAIAN~T OOOO YIN INIA) - MDOOWOOOOOO OOOO WO OOOO DODO: DOSAAINAIDADOODOOINIAL MH: MHMDMDMDHDOMDMDHO OOOO 0.0 WHO ~I~I~I~J HPOAICOCODOCONFPPPOCUCCIOOF ” 2 © VAS iB Be Be > | PNPLAAHDUIAAAOISIANAWOwWOoOoor | : a g | apnannanennupannannennen | PUDAIDODDOHDODOOWOOOODAWWNWWS I< Speepeeeeeseekecauenenn| |B D\~ JOO OID DOD OOOOODANWNMNMWW IQ g PVT VV 1 Be Bo Be Bo Be Be 1 sunnnerpremmmmesss ses |h =| 9 &| suspannenesnserennnamms| § annem earas | H Zz DIIIIIIIIIIIIIIIIAAAAADN | O WON WUE U1 UII ANOVA UU SIGNI |S |~J'€D GD GD GD 0 00 GD GD GOD 09 09 69 G0 GO. J JJ J ~~ ® snenpnspreminenet saat § 2 c wv E me ) r) ry r 100 INI NYOOHOMOMOOMOOIIIII I QWUDOPEPOPPNSWNNNEIWNONNW DAADAADADAAAADADAADAADAAADUUAUU DONGHUUL UNS UAAUINUIIH © uep 2noH ged Trady yozeW (s,QL@ 000‘T) yauou Aq znoy Aq puewep jeeH Kew eunc “Ken iady. wozem ded. uep anon” yauoW Ss ,NLe suoTTe) p86 b9b ‘06 oss €0L oss, 629, ses 868 8E6 Z9E°ES LLB‘LS PRL‘LL 209‘78 PLz‘98 = BBT‘BL 6LL ‘ ove ‘ ‘ ‘ Tpe‘es PLb‘98 LES‘TL 8b9‘¥9 ine 998 182 ‘06 786 bEO‘OT 268 ‘226 RRNA EEE REE PWNPOCOIDULWNHOODIDULWUH BREE BREE RRB ERE WNRWNRNENWNNANNNNEENEOREEN NODS AWNOOHDODOAHH BORNCONS BERBER BREE HERE Ree NEREROPNNNEEENEWWHOCOCOH WNADADWNWOOONVBOBGOADNONNOy BREE EBB BRB Re RONERORNEERPORHENNEOCOOOF CIGGHSNCBHHIAD@OUNIIWODCCAW BPP EBBBERRR REE HRHEE Be PONEENOPEEROPEENNEOOOOOH SERRE IIOUUWSWUWSSHOSOOSH BERBER Be » DOOVONFONNNNECHOCLLBOOCO BOODOW.HOWOOW INE ONCOPH BUNS INITIO OOOO WOWOWOOIBOIAAHNAD IG CODTS DOLSDOLOWVOHLWOCNNUWS €L AIAAHIOINYOWOOOHN II ANAND PIIIO SONS SOSONOUUEEPADDUW $9 PeRee 2ODOCOWGVOOOOO~O0IIIAA I~ DAPPRPONUONNANTCOUOOUUNDBOWOO PRPRRREBR BE e WOOCOOPOOPHNEHCOOOHHOIIHOO DWVWWHICSIINGEHPOSPUNOOORS BEEBE BEEBE HEHE PEPER ONNWWHWWONNOCOCOCODO DOCONIONIIAIH IONE ENN Lot eet BEEBE PEE be PONPENOPPEROPEENNE OOOOH DANNNOOOAD HUH HDHUIUNOAOOTAN BEBE EERE REE NPWNNENWNNNENNNWWNOCOCOHN WOWNNNHOIISOSISBADNOSLOOUN uer iInoH Aq znoy zed eTqeTTeae jeoH yoIeW ged $,N18 000‘T) yRUOW ady % yTenuuy 06/TT/0 LIIHS WHOM NOILWINWIS NOILWZITIIN LW3H GLSWM T adeou0p - queTd JueujPez, 763eM seoTeM WASTE HEAT UTILIZATION SIMULATION WORK SHEET 04/11/90 ** Main HE ** * Hot * * Cold * ‘emp. In 205 180 ‘emp Out 190 200 a Avg. 197.5 190 Flow 95.00 Calc. 11.31 ‘luid Glycol50Glycol 50 Density 63.34 63.53 Spec Heat 0.863 0.859 Ther Cond 0.233 0.234 'iscosity 0.759 0.819 aemp. In Temp Out T Avg. ‘low vength size Heat Loss Heat Loss 'elocity ‘riction Factor ‘ipe Head Loss ‘ipe Head Loss ° b N w PWOR oO =e 0 PRE ah be DU wo AGI Be mi Oo @HAOIONU GO Mo ** User HE ** * Hot * * Cold * 190 160 170 180 180 170 12.50 11.33 9.85 Glycol 5 Water 63.78 62.40 0.854 1.004 0.234 0.383 0.900 0.425 Ground deg F 30.0 m Ff 830.00 in 0.125 Btu/Hr/Ft Btu/Hr 2,627 Ft/Sec From Cal Ft Darcy-We psi Cale. Concept 1 Gpm (Max Heat Demand) /8,000 Gpm 1b/£t*3 Btu/lb F Btu/Hr Ft F cP deg F feet Used above c. Below isbach Water Treatment Plant PAGE 3 OF 3 Wales Building Heating Summary One Std. Butler Bldg. 7 No insulation in floor. 04/11/90 Fuel Oil: 96,000 BTU/Gal ,Engine: Cummins LTA 10, 1200 RPM . Combustion Air: 305 CFM = = 5.27 Air Ch/Hr Heat to Ambient: 1,060 Btu/Min Heat to Coolant: 4,100 Btu/Min Engine Rating: 115 Kw Generator Eff.: 93.4% Bldg Conduction Heat Loss: 456.1 BTU/Hr/F @65F nfiltration Heat Loss: 98.1 BTU/Hr/F/Air Change Heat to Bldg. Heat to Excess Kwh HDD Coolant Heat Ambient Heat Reqd Jan 44,500 1,958 1,062 476 274 202 Feb 38,000 1,990 907 484 234 250 Mar 41,000 2,050 978 499 253 246 Apr 38,500 1,660 919 404 2571 166 ay 33,500 1,160 199 282 207 716 Jun 25,200 7194 601 193 155 38 Jul 23,200 Sy 553 140 143 i) Aug 27,600 568 658 138 170 0 Se 30,500 734 7128 178 188 0 Oc 37,200 1723 887 213 229 44 Nov 38,500 1,441 919 350 237 3 Dec 43,600 1,903 1,040 463 269 194 421,300 15,955 10,051 3,881 2,599 1,327 Kwh = Historical Records Input HDD = Historical Records Input Heat to Coolant = Heat rejected _to coolant by ee Fags Heat = Heat Loss from building at 65 deg. F. Heat to Ambient = Heat rejected to ambient by engine Heat Reqd. = (Bldg Heat) = (Heat to Ambient) One Std. Butler Bldg.; 6" Insulation added in floor. Bldg Conduction Heat Loss: 270.9 BTU/Hr/F @65F nfiltration Heat Loss: 98.1 BTU/Hr/F/Air Change Bldg. Heat to Excess HDD Heat Ambient Heat Reqd Jan 1,958 385 274 alee Feb 1,990 392 234 SY, Mar 2,050 404 253 LST Apr 1,660 327 2311 89 ay 1,160 228 207 22 Jun 7194 156 SS A Jul Sit 114 143 0 Aug 568 T72 170 0 Se 734 144 188 Q Oc 1,123 221 229 0 Nov 1,441 284 Zoi 46 Dec 1,903 375 269 106 BR oa ~ Oo oO oa Ww s i ry ND ND ~ a io Co) oO) eo WwW polarconsult Wales District Heat APPENDIX B Field Trip Notes polarconsult Wales Field Trip Notes December 23, 1989 Earle Ausman, Leslie Moore, PCA Met with: Ellen Richards, City Clerk 664-3501 Dan Richards, Previous Mayor 664-3501 Don Hasbond, Previous Mayor 664-3501 Jonah Tokienna, Mayor 664-3501 1. Weather: Coastal, high winds, average wind is 22 knots from north. Drifting a problem due to high winds. Population: 159 (41 school enrollment) 2. Utilities: Water: Water tank temperature was at 42°F during our visit. Teachers hook up uses some water. Pipeline to community center and teachers at school. Sewer: To septic tank behind washeteria. Elec: Overhead and Underground Fuel: Pay $1.13 / gallon 3. Right of Way May need easement to cross private lot between power plant and washeteria. 4. Equipment Backhoe broken down, needs fixing. Don says clean up machine so it will run will cost $2-3,000. A short trench can be excavated by hand. 5. Water treatment plant / washeteria, oil burner, boiler water temp was 180°F Oil Usage in Gallons per month Dec 88 500 May 601 Sept 460 Jan89 646 June 400 Oct 501 Feb 509 July 700 Nov 500 Mar 802 Aug 300 Dec 89 750 Apr 300 Appendix B Page polarconsult Wales Field Trip Notes December 23, 1989 (2) Burnham V-36, output 284,000 Btu/Hr Water Heater SGE Model VG30-6P-2830 Heat Exchanger (Boiler Water to Water Tank) B/G Model WU 43-24 Washeteria heat plant includes City cold water tank, Washeteria hot water, heating, dryers and (3) apartments (part of same building). 6. School Fuel from Rick Ried, Unalakleet, Regional Bearing Straights School District. 7. AVEC 1) Cummins LTA 10 - 1200 rpm with remote radiator. 2) Allis-Chalmers 3500 3) GMC 4-71 Running LTA 10 mostly, new 64 kW @ 420 Amps, 245V, Noon Max; 62 Kw - Night, 95 Kw - Day Summer; 75 Kw, 40-50 Kw night. Building on piling, steel diamond plate on floor. Single Phase Panel, Station service panel full Vokman radiator control at 200°F Appendix B Page 2 polarconsult Wales District Heat APPENDIX C Cost Estimate HMS 9022 CONSTRUCTION COST STUDY WASTE HEAT RECOVERY SYSTEM WALES, ALASKA Cost Consultant Engineer HMS, Inc. Polarconsult Alaska 4103 Minnesota Drive 1503 W. 33rd Street, Suite 310 Anchorage, Alaska 99503 Anchorage, Alaska 99503 (907) 561-1653 March 16, 1990 (907) 562-0420 FAX WASTE HEAT RECOVERY SYSTEM PAGE 1 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 NOTES REGARDING THE PREPARATION OF THIS COST ESTIMATE This study has been prepared from four (4) 8 1/2"x11" sketches and outiine specifications linking one tacility in the village, as detailed by Polarconsult. This estimate is a statement ot probable construction cost only, and is priced using A.S. Title 36 prevailing labor rates and current materials, treight and equipment prices, and to retlect a competitive bid in Spring 1990. Removal of hazardous material has not been considered in this cost estimate. WASTE HEAT RECOVERY SYSTEM WALES, ALASKA CONSTRUCTION COST STUDY TOTAL PROJECT COST $ 308,222 PAGE 2 MARCH 16, 1990 SUMMARY CONSTRUCTION COST 01 General Conditions, Overhead and Profit 99,713 02 Sitework 41,714 06 Wood and Plastics 4,328 13 Special Construction 4,150 15 Mechanical 42,303 16 Electrical 5,954 Subtotal $ 198,162 Estimate contingency for elements of project not determined at this early level of design (10%) 19,816 Esclation at .33% per month ( 1%) 2,180 TOTAL CONSTRUCTION COST $ 220,158 PROJECT COST Design (10%) 22,016 SIA (Supervision, Inspection and Administration) (20%) 44,032 Project Contingency (10%) 22,016 WASTE HEAT RECOVERY SYSTEM PAGE 3 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 01 - GENERAL CONDITIONS, OVERHEAD AND PROFIT QUANTITY UNIT UNIT RATE ESTIMATED COST Mobilization 1 LOT 8,000 Freight 25,000 LBS -40 10,000 Supervision, equipment, utilities clean site, tools and protection 10 WKS 3000.00 30,000 Per diem 210 DAYS 110.00 23,100 Travel costs, including time in travel 6 RT 1250.00 7,500 Bond and insurance 1.75 % 3,098 Profit 10 % 18,015 WASTE HEAT RECOVERY SYSTEM PAGE 4 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 92 - SITEWORK QUANTITY UNIT UNIT RATE ESTIMATED COST Piles Mobilize 1 LOT 8,000 Steel thermal piles 4 EA 2100.00 8,400 Drill pile hole 60 LF 25.00 1,500 Slurry 3 cY 280.00 840 Freeze back - EA 220.00 880 Test and demobilize 1 LOT 3,000 Piped Utilities Excavate trench for arctic pipe, including backfilling and spread and level surplus (hand) 160 LF 49.15 7,864 1 1/2" diameter Schedule 40 pipe with insulation and arctic pipe protection 320 LF 31.50 10,080 Bend 10 EA 115.00 1,150 WASTE HEAT RECOVERY SYSTEM PAGE 5 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 06 - WOOD AND PLASTICS QUANTITY UNIT UNIT RATE ESTIMATED COST Glulam beams to support new module 48 LF 36 .00 1,728 Miscellaneous metals 800 LBS a7S 1,400 Access steps, including handrail and base 1 LOT 1,200 WASTE HEAT RECOVERY SYSTEM PAGE 6 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 13. - SPECIAL CONSTRUCTION QUANTITY UNIT UNIT RATE ESTIMATED COST Pre-engineered 8'0"x8'0" building module with tloor, exterior wall structure and rooting complete 1 EA 2500.00 2,500 Hole through exterior wall for heating pipes 4 EA 110.00 440 Exterior door 1 EA 710.00 710 Louver 1 EA 500.00 500 WASTE HEAT RECOVERY SYSTEM PAGE 7 WALES, ALASKA CONSTRUCTION COST STUDY . MARCH 16, 1990 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COS'T 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 22.65 1,812 Fittings 16 EA 45.00 720 Butterfly valves 3 EA 166.00 498 1 1/2" diameter black steel welded piping including fittings 30 LF W225 368 Butterfly valve 2 EA 97.50 195 Insulation to pipe, 3" diameter 80 LF 6.65 532 Ditto, 1 1/2" diameter 30 LF 4.40 13:2) TOTAL ESTIMATED COST: Continued WASTE HEAT RECOVERY SYSTEM PAGE 8 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Exchanger and Connections (Continued) Booster pump 1 EA 1450.00 1,450 Heat exchanger, 150,000 BTUH 1 EA 3208.00 3,208 Unit Heater (2 Each) (1 - Generator Building and 1 - Module Building) Unit heater, 60 BTUH, including thermostat 2 EA 330.00 660 1" diameter piping including fittings 80 LF 9.10 728 Gate valves 4 EA 71.00 284 Insulation 80 LF 4.10 328 Radiators Remove existing radiator including all piping back to generators 1 LOT 720 Young series 22 radiator 1 EA 3830.00 3,830 TOTAL ESTIMATED COST: Continued WASTE HEAT RECOVERY SYSTEM PAGE 9 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Radiators (Continued) Radiator stand and roof 1 LOT 3,490 3" diameter piping 80 LF 22.65 1,812 Fittings 16 EA 45.00 720 Buttertly valves 8 EA 166.00 1,328 Control valve 1 EA 89.00 89 Insulation 80 LF 6.65 532 Anti-rreeze 150 GALS 7.60 1,140 Hook-up Form hole through existing wall for heating pipes 2 EA 195 .00 390 1 1/2" diameter black steel piping including fittings 120 LF 12225 1,470 WASTE HEAT RECOVERY SYSTEM WALES, ALASKA CONSTRUCTION COST STUDY 15 - MECHANICAL Hook-up (Continued) Gate valves Check valves Strainer Balancing valve Temperature control valve Insulation Heat exchanger, 150,000 BTUH Expansion tank, 7 gallon capacity Air separator Pumps, circulation Grundfoss 200, 1 1/2" diameter QUANTITY UNIT UNIT RATE PAGE 10 MARCH 16, 1990 ESTIMATED COST EA EA EA LF 125.00 125.00 58 .00 49.50 225 .00 4.40 3208 .00 495 .00 495.00 575.00 1,375 250 116 149 225 528 3,208 495 495 TOTAL ESTIMATED COS' WASTE HEAT RECOVERY SYSTEM PAGE 11 WALES, ALASKA 7 CONSTRUCTION COST STUDY MARCH 16, 1990 15 - MECHANICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Hook-up (Continued) Connection to existing piping system 2 EA 72.50 145 Make-up glycol system connection, including tank 1 EA 610.00 610 Glycol 110 GAL 7.60 836 Test and balance system 30 HRS 75.00 2,250 Controls and Instrumentation Generator building and new module 1 LOT 2,000 Hook-up inter ties 1 LOT 1,500 WASTE HEAT RECOVERY SYSTEM PAGE 12 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST Motor Connections Breaker in existing power panel 2 EA 175 .00 350 Connection to motor 5 EA 115.00 575 Disconnect switch 3 EA 330.00 990 3/4" EMT conduit 100 LF 3.10 310 #8 copper 400 LF 75 300 New Module Main feeder and conduit 40 LF 8.50 340 Breaker in existing distribution panel 1 EA 277.00 277 Panel 1 EA 800.00 800 Exterior light fixture 1 EA 330.00 330 Light tixtures 6 EA 190.00 1,140 WASTE HEAT RECOVERY SYSTEM PAGE 13 WALES, ALASKA CONSTRUCTION COST STUDY MARCH 16, 1990 16 - ELECTRICAL QUANTITY UNIT UNIT RATE ESTIMATED COST New Module (Continued) Switch 1 EA 55.00 55) Duplex outlets 4 EA 68.00 272 1/2" conduit 50 LF 2.80 140 #12 copper 150 LF -50 75