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Rural Energy Waste Heat Program-Final Report For The City Of Tanana 1985
eae 3 WAS ORA = polarconsult alaska, inc. ENGINEERS ARCHITECTS * ENERGY CONSULTANTS March 29, 1985 Alaska Power Authority 334 West 5th Avenue Second Floor Anchorage, Alaska 99501 Attention: Mr. Jerry Larson Reference: o Contract APA-84-C-034 with Amendments 2 and 3 o Our Tanana Progress Report to your office of October 22, 1984 Subject: Final Report - Tanana Waste Heat Recovery Project Serial Letter: 3007 APA-60 Dear Mr. Larson: Based on the joint final Inspection on February 28, 1985 with your office, Rockford Corporation, and the power plant owner, this communication constitutes the completion of our work under the referenced Contract Amendments 2 and 3. Basically, our referenced Tanana Progress Report of October, 1984 covers the work accomplished by our firm as your agent with the final field reports as a supplement’ thereto. We are enclosing herewith additional copies of these final field reports for your ready reference. They depict our field activities subsequent to the October, 1984 report. Also being forwarded separately are: ° Working files for the Tanana project which supplements those files previously transmitted to your office for the basic Contract and Amendment No. 1 thereto, f.e. the Tanana files generated between our offices, Rockford, et. al. during the Contract work under Amendments 2 and 3. ° Rockford's serial letter on March 26, 1985 provided data and responses to our serial letter 034 APA-26 to them of December 5, 1984 which outlined the various Contract completion requirements. Their referenced response to this communication provided the as-built drawings, Contract release certificate, operation manuals, and et. al as requested. 2735 EAST TUDOR ROAD ¢ SUITE 201 * ANCHORAGE, ALASKA 99507 * PHONE (907) 561-1933 ¢ TELEX: 26708 PCA AHG polarconsult Alaska Power Authority 3007 APA-60 March 29, 1985 Page 2 ° Rockford's final payment estimate including thelr Interest calculation on retained percentages. Outstanding work items remaining which should be handled under the warranty provision of this guarantee clause of the Contract are: ° Outstanding problem of damaged (mixed) roadway surface material. ° Compaction of the trench that was excavated as well as bell hole (Cfor welding the E-muffs) which were subsequently backfilled with frozen material and final grading of the roadway surfaces. ° The flow meter is different from the approved flow meter. Rockford has submitted a new one for your consideration. We suggest this decision should be now made by APA Cyour Mr. Peter Hansen concurred with this work item). ° Demobi lization from the job site by Rockford. ° As-built drawings and operation manuals have not yet been provided to the Tanana Power Authority. We suggest this can now best be accomplished by the Alaska Power Authority, and are included herewith. The original drawings are included Tn the package being forwarded separately. Rockford marked-up as-builts have not yet been transferred to the ortginal drawings and should be done before the as-built drawings are furnished to Cliff Elher. I Believe this summarizes the noteworthy outstanding questionable areas for your action as you deem appropriate. We believe our redesign of the Tanana system using the steel welded pipe, minimizing the numbers of pumps and type of heating equipment, eliminating Btu meters, et. al. have been instrumental in providing a system which should prove to be reasonably matn- tenance free. Additionally tncluded herewith is the redesign (specifications) for the Hoopers Bay Waste Heat project, (Cspecification word processor IBM diskettes are also enclosed). Your Mr. Peter Hansen has the Hooper Bay plans. polarconsult Alaska Power Authority 3007 APA-60 March 29, 1985 Page 3 Should you have any questions on our work or outstanding work items by Rockford, please feel free to contact this office. It has indeed been a privilege and a pleasure to work with the Alaska Power Authority on this project and we look forward to serving you again in the future. Sincerely yours, POLARCONSULT ALASKA, INC. lee Jo Gena Cres de J. Turner, « Project Manager /jkb enclosure FIELD TRIP REPORTS polarconsult TANANA RELATED FIELD TRIP REPORTS, 1984-1985 WHM-ITI MAY, 1984: Jack Turner and Tanana 5 - 8 - 84 Peter N. Hansen JULY, 1984: Peter N. Hansen Denmark 7 - 20 - 84 AUGUST, 1984: Duane Carson and Tanana 8 - 29 - 84 Jack Turner Earle Ausman Tanana 8 - 30 - 84 SEPTEMBER, 1984: Peter N. Hansen Tanana 9- 1- 84 Earle Ausman Tanana 9- 5 - 84 Jack Turner and Tanana 9- 8 - 84 Peter N. Hansen Paul Bigum and Tanana 9 - 11 - 84 Peter N. Hansen Earle Ausman Tanana 9-11 - 84 Earle Ausman Tanana 9 - 21 - 84 Jack Turner Tanana 9 - 24 - 84 OCTOBER, 1984: Jack Turner Tanana 10 - 5 - 84 Earle Ausman Tanana 10 - 10 - 84 Peter N. Hansen Tanana 10 - 28 - 84 polarconsult WHM-ITI Page 2 NOVEMBER, 1984: Jack Turner and Peter N. Hansen Jack Turner and Peter N. Hansen JANUARY, 1985: Earle Ausman FEBRUARY, 1985: Jack Turner Tanana Tanana Tanana Tanana 11 11 14 28 84 84 85 85 polarconsult FIELD TRIP REPORT Tanana February 28, 1985 Mr. Jack Turner of Polarconsult Alaska, Inc., and Messrs Peter Hansen and Jerry Larson of Alaska Power Authority conducted a field visit to this site. The purpose of this visit was to perform the final Inspection on the Tanana Waste Heat System. When we arrived, we met with Rockford Representative Mr. Ivan Solheim and he indicated that most problems were now taken care Of. They were still working on the control system which was not quite operational yet due to a burnt relay. In the Day Care Center, it was noted that all punch ltfst items seemed to have been taken care of. The bofler was set suffi- ciently low that efficient utilization of waste heat was possible. No leaks were seen anywhere. In the City Hall Building, it was noted that punch list Items have been taken care of. There is a small problem in here with the control system, as the fan won't come on until the furnace has heated up the fire box. The controls will either have to be circumvented or altered slightly. The city has action on this item. Temperature readings in the Power Plant were as follows: o Heat exchanger, primary sides, in-going 193° out-going 183° o Heat exchanger, secondary sides, in-going 170° out-going 178° With one pump on line, the temperature's were stabilized as follows: o Heat exchanger, primary sides - in-going 194° out-going 184° Pressure drop over primary sides - 4.5 minus 2.25 1 polarconsult Field Trip Report Tanana February 28, 1985 o Heat exchanger, secondary sides - in-going 170° out-going 180° Pressure drop over heat exchanger - 29.5 minus 26.25 The flow is approximately 170 gallons per minute on the secondary sides. The flow meter installed does not seem to be the right type, as there is no connection for the Btu meter. The brand is Thatcher/Padder, Model TR, Part No. 58000-99706 and it is a paddle meter. That does not seem to be the right one - check the specifications. Upon further inspection, it was noted that pump control system was not hooked up correctly. The pumps were not sequencing as intended and it was noted that the two pump control systems were hooked up in parallel where they should have been in series. Mr. Solheim from Rockford Corporation told us that It was easy to change this around and they were in progress of doing this at the time that we left. The system was using all the heat available from the generator as the radiator fans stayed off. Mr. Moore from the City of Tanana had a question concerning a culvert that apparently need to be extended somewhat, and also about the roads which may have to be either graded or repaired as spring comes. The road question {fs an outstanding problem for Rockford next spring. Obviously the system has got plenty of capacity as one pump will deliver about 170 gallons per minute and a temperature drop of 10° with approximately 300kW loads. This means that even with three times the current load, the system will still be able to handle all the necessary heat transfer. polarconsult Field Trip Report Tanana February 28, 1985 The pump sequencing was described to the power plant operator from Tanana Light and Power. He seemed to understand how the pump sequencing Is supposed to work. According to Ivan Solheim, no glycol loss had been experienced since the system was put Into operation. Three other minor points that are brought to the attention of Rockford's Superintendent, Ivan, were as follows: o Electrical cover missing in the Teen Center above the unit heaters. o A valve handle needs to be secured on the control valve in the stand-by generator room at the School. o Cables need to be retensioned holding up the pipe between the temporary generator unit and the Vocational Education Building. In the Vocational Education Building, the unit heaters gather the saw dust and need to be cleaned periodically in order to function better. Eo | fon Morris J. Turner Project Manager /jkb cc: Mr. Jerry Larson, Alaska Power Authority Waste Heat Controls Flow Meter Generator Radiator Remotely Mounted Piping to Remotely Mounted Generator Vocational Shop Heater Main Workshop Vocational Shop Heater Welding Workshop Piping and Valves Future Generator Piping Header polarconsult FIELD TRIP REPORT TANANA January 3 and 4, 1985 Cont racito r ¢ Rockford Corporation Personnel: Ivan Solheim - Rockford Corporation Jaques Klotz - Energy Management Systems Earl Ausman - Polarconsult Alaska, Inc. Flew by Cessna 206 from Anchorage to Fairbanks where picked up control man in Fairbanks and continued to Tanana. While control man reviewed control system, took the following temperature measurements: Engine Temperature at Exchanger, In - 187°F Engine Temperature at Exchanger, out - 167°F District Heating Temperature at Exchanger, In -—- 175°F District Heating Temperature at Exchanger, out - 174°F 36 pst district heating, 31 psi hot side exchanger, 48 psi high side pump with one pump running. Water was circulating through radiator and fans were running. The next day, the control man started tracing controls. The step controller was not wired to the pump magnetic motor switches. The control man wired In the differential temperature transmitter. This was not wired to the motor switches. The low fluid level cut off switch was not installed so was not wired in. The strobe Calarm) relay was In and functioning but the strobe was not wired in. The flow switch was not functioning as was wired backwards. However, the flow switch will not work as a paddle type is required in the main pipeline. He set the two pressure switches to specifications. polarconsult The control man's function was to set up the instrumentation to the correct set points. This he was unable to do as the equip- ment had not been wired. The glycol make-up barrel was not in place and the hose was just laying on the floor. The powerplant people apparently used the glycol for their engines. Neither Cliff Eller nor his operator were in town. It was apparent from the readings on the system that heat was not betng transferred from the engine to the District Heating System. Ivan looked at the boilers in the buildings and heat was being transferred out of the school and around the system. The reason for this is the engine temperature was not high enough to cause the AMOT valve to circulate fluid through the engine side of the exchanger. An experiment was tried. Turning off the fan on the radiator and partially opening the valve to the radiator resulted in increased temperatures on the District Heating side. A schematic is attached as well as a table of measurements versus time. This clearly shows that the radiator is cooling the system to the point where the AMOT valve does not allow circulation through the exchanger. Therefore, an aquastat is needed to turn off the radiator fans. The radiator has dampers which do not function as they remain open when the fan is off. The test showed that the engine temperature continued to climb and the indicator on the engine showed it was running In the hot zone Cred) near 212°F. The differential temperature across the exchanger on the engine side was 15°F if the thermometers are correct. The differential temperature on the district heating side was 9°F with only one pump on. The difference in these temperatures are high and the high differential for the engine indicates that a higher coolant flow rate would be helpful. At the time the measurements were made, the engine, D399 rated for 800 kW, was producing 67, 60 and 40 amps at 2.5 kV or roughly 240 kW. polarconsult As the engine temperature was slowly climbing after an hour the test was terminated. Even had the temperature not climbed, the radiator fans could not have been left off as the only line of defense for the engine would have been the over temperature shut down. Discussion with N.C. Cat disclose the HT shut down for the engine is factory set for 205°F to 210°F and is not adjustable. The engine thermostat is set at 185°F. Most systems on the slope are provided with boster pumps. Pressure at the exchanger was 4 psi both in and out at a temperature of 182°F. When the temperature increased, the pressure went to 8 psi. I did not see an expansion tank In the engine side of the system. As the system is currently constituted, it will not function. The following needs to be done: An AMOT valve needs to be installed so as to not bypass fluid through the radiator unless the return temperature is over 185°F to 190°F. The AMOT valve which is to protect the engine from cold water should be set lower so it begins to function at a lower temperature. It required a 194°F engine temperature before the valve shut off the bypass flow around the exchanger. A lower temperature at this valve fs not critical. A booster pump is needed to reduce the differential temperature on the engine side of the exchanger. The engine, even at a reduced output, will run to hot when the district heating loops temperature increases. Further, when the engine is loaded, the exchanger will not be able to remove sufficient heat without bypassing to the radiator. The radiator fan needs an aquastat and the louvers need to be set up to close on fan shut down. polarconsult Thermometer for engine return needs to be replaced with one of a high top temperature. The current thermometer only goes to 180°F which was exceeded during testing. An expanston tank needs to be installed. A permanent glycol tank with glycol solution is needed on the district heating side. Controls need wiring and a low water level shut down is required. The control, logic, and diagram, being used by Rockford, will not function in both the differential and 190° mode simultaneously. When the outgoing fluid temperature rises, additional pumps will operate causing a higher flow rate and a reduced incoming temper- ature and a reduced temperature difference between the incoming and outgoing fluid temperatures. The controls have a setable switch to turn on pumps 2 through 4 on rising temperature and a differential temperature device which will turn on additional pumps as the temperature difference increases. Depending on the control set points, either the temperature or temperature difference controllers will dominate but both functions will not operate Independently. A meeting is required to list remaining deficiencies so they may be corrected before an additional attempt is made to set the controls. Cie (ame Earle Ausman Chief Energy Engineer /jkb Attachment: Exchanger / Engine Schematic Exchanger / District Heating Schematic Table of Temperature Photographs Pressure DH Out After Exchange | 31 | 28 Jan. 3 | Jan. 4 Jan. 4 Trials Over Approximately 1+ Hour pm am Radiator Vaive Partially Open - Radiator Fans Off | Teo? Temp. Engine Out 187 | 192 193 194 | 194 | 195 Tey» Temp. Exchange Out 160 | 162 | 168 174 180 Taoyt? Temp. AMOT Out 182 182 | 182 184 186 | Tern’ Temp. Engine In 167 | 182 184 Temp. Dist. H. Out 174 | 174 176 181 Temp. Dist. H. Return 175 172 Pressure Engine In Exchange 4 Pressure Engine out Exchange 4 4 Pressure DH Return 36 38 Pressure DH After Pumps 48 | } Recorded Temperatures In Fahrenheit Degrees Recorded Pressures In PSI, gauge x g / F K x Tek eut Coon MTT fubwe Po wally open v Vo Awnot- vol é N ve ch Cqine Scola Exchaunqer —2epoi Pe YAS polarconsult January 3 and 4, 1985 Radiator outside building is not equipped with fan temperature COnNtrel . polarconsult Piping connections - engine side of exchanger. Close up of piping - engine side of exchanger. polarconsult Make up container for glycol mixture not in place. Control panel not yet wired. polarconsult Alarm Panel. Meter readings at test time. polarconsult Switch gear single unit. FIELD TRIP REPORT Tanana November 3, 1984 Mr. Turner and Mr. Hansen of Polarconsult Alaska, Inc. conducted a fleld visit. to this site. The purpose of the visit was to discuss punch list items with the Contractor, Rockford Corporation, represented by thelr Superintendent, Mr. Dave Marks. In the power plant, the Contractor agreed to provide a pressure relief valve on the generator side of the heat exchanger. Also, he will provide a drain valve on the stratner. The heat exchanger had been fastened to the floor as _ requested. The Contractor agreed to provide air vents and unions on the lines gotIng to the City Maintenance Building. He also would turn pumps P-1 and P-2 90 degrees and provide correct valves on the suction side. He also agreed to replace a non-glycol rated valve on the glycol filled line. The Contractor agreed to provide pipe supports where ever needed, i.e. under pump flanges and under piping adjacent to the heat exchanger and the AMOT valve. Inside the City Maintenance Building, the Contractor is going to provide line sized valves and move thermo sensors, thermometers and air vents around as requested. The pipe hangers Inside the City Maintenance Bullding were allright. The Contractor was requested to finish the insulation ends with cement. Inside the Washeteria Boller Room, the Contractor agreed to Improve the pipe hangers. Also, he would Install a safety relief valve on the primary side. He also agreed to Install an extra valve next to the circulation pump. However, It was decided not to require the Contractor to install all the valves shown on the details. At this potnt in time it will not be worth the trouble to require all these valves fInstalled. However, It should be considered whether a credit should be requested from the Contractor for all the valves that have not been Installed. The Fleld Trip Report Tanana November 3, 1984 Contractor also agreed to install a drain valve on the strainer and to improve the wall penetration with sleeves. It was decided at this point In time not to request the Contractor to Install sleeves in the walls where these had not been installed. It will not be justified considering the amount of work it will take. However, it should be considered to ask for a credit on it. Also, the Contractor agreed to provide extra hangers around the heat exchanger. Inside the Day Care Center, the Contractor agreed to finish up the Insulatton ends and to fnstall a safety relief valve where the leaking air vent on the district heating supply was Installed. Inside the Fire Station most of the items had been cleaned up. The drain valve had been provided on the strainer and miscel- laneous thermometers had been moved around. Also, additional air vents had been provided and the correct metals had been In contact with each other, i.e. no copper was any longer screwed into cast Iron flanges, etc. Also, an additional relief valve had been provided. It was decided not to require the Contractor to install the air vent at the wall penetration as this didn't seem to provide any problems. Inside the School Generator Building the Contractor is not going to Install a thermometer as it [Is not needed. The air vent will be moved to the location where the return from the unit heater joins the main from the Vocational Education Building crossing through this building. At the lower connection on unit heater, the nipple will be replaced. Also, piping will be straightened out and a hanger will be provided on the mains. The sensor from the thermostatic valve will be mounted with a clamp behind the Fleld Trip Report Tanana November 3, 1984 unit heater. Also, the Contractor was going to support the piping between the Generator Bullding and the Vocation Education Bullding with wires. Inside the Vocation Educatton Bullding the Contractor is going to support the piping, install sleeves In the walls and provide flashings, etc. Also, 3-cone defusers will be installed. In the wood section, the unit heater would be moved to the post and piping would be run horizontally from the present location In a nice, straight manner. Inside the heat exchanger room in the school, the Contractor Is going to provide a 1 inch bypass line and improve the hangers somewhat. Also, he fs going to put a blow off valve on the strainer. It was decided here also not to require the Contractor to provide the specified valves as at this point. In the School Generator Building the Contractor was asked to provide additional support for some of the piping. Also, the Contractor was asked to make sure that the low water cut-off was provided in the power house for protection of the pump. The Contract was told that he could leave out the extra valve required around the pump. The system is based on water and the valve is not strictly necessary. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority FIELD TRIP REPORT Tanana November 14, 1984 Mr. Turner and Mr. Hansen of Polarconsult Alaska, Inc. conducted a field visit to this site. The purpose of the visit was to conduct a final Inspection. Inside the Wood Shop, It was noted that the heat exchanger had been moved as requested and the insulation was basically complete except for painting the exposed piping. Instde the Metal Shop, the unit heater had been installed as requested and the Installation looked nice. Here also, painting of exposed piping was still misstng and the thermostat was not yet Installed. It was noted that exterior polyethylene piping had not been covered with metal siding yet. The pipes between the Vocational Education Building and the School Generator Bullding had been supported with wires. Installation looked ok. Inside the School Generator Building, the Installation had been cleaned up and looked nicer. Exposed piping was not palnted, however, Insulation had been fixed up. Inside the Gymnasium, the district heating pipe had been covered with aluminum and looked very nice. Inside the Heat Exchanger Room, next to the boller room in the school, the 1" bypass line had been installed. Some wall finishing was needed In this room. Instde the City Building, it was noted that the heating coll had been Installed. Piping Insulation was still needed, however, the Installation looked nice. Insulation was also needed on duct work. Fleld Trip Report Tanana November 14, 1984 Inside the Fire Station, only a little bit of insulation work needs to be cleaned up. Outside the Fire Station, ft was noted that the pipe had not been covered yet and the wall penetrations were not complete. However, the Contractor Intended to maybe walt until the summer before he did that. Instde the IRA Building, it was noted that insulation was not completed yet. Also, wall penetrations had to be fixed up a bit. The Sterling cabinet unit heater had been mounted vertically where It should be horizontally mounted. Also, one of the two fans In the cabInet unit heater fs not working. Inside the Day Care Center, some Insulation still needed to be replaced, otherwise the hook-up seemed correct. It was also noted that no drain valve had been installed on the strainer. Inside the City Maintenance Building, the system had been altered as requested and it now looks satisfactory. A Tittle_bit- of Insulatlon clean-up work still needed to be done. Inside the Power Plant, it was noted that the pumps had been turned 90 degrees to allow for a horizontal pump backsIs. Also, it was noted that the piping had been cleaned up somewhat. The expanston tank had been installed and some of the sensors had been installed, however, the installation was not yet complete. The Btu meter had not been completed yet as no flow meter was Installed and some of the wires were just not yet installed in conduit. No piping had been painted inside the Power Plant yet. That Is to be done. Also, part of the control system was not finished yet. Fleld Trip Report Tanana November 14, 1984 Instde the Washeteria a little installation clean-up still needed to be performed. Generally, most Items from the October 28 punch list have been taken care of and the Installation looks good. All major Items had been completed and most of the remaining items pertained to clean-up, etc. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority FIELD TRIP REPORT Tanana October 28, 1984 Mr. Hansen of Polarconsult Alaska, Inc. conducted a field visit to this siIte. The purpose of the visit was to inspect progress and prepare for final tnspection. Inside the City Hall Bullding, It was noted that the district heating pipes had just been stubbed through the wall as can be seen from the picture. No hook-up had been made yet. I met with Mr. Pat Moore, Mayor of Tanana, and Mr. Moore expressed concern that the school was using energy keeping the lines warm. I explained to Mr. Moore that this would be beneficial as long as the power plant was not on line. However, if the power plant would not come on line this fall, it should be considered to let the lines cool off. The lines are kept warm in order to avoid too many thermal cycles, which In the long run could hurt the lines. The following items were noted that will have to be changed: 1. Fire Station: ° An air vent was missing on the supply line where it penetrates the wall and goes’ down. According to specifications, an air vent will have to be provided where ever there is a downward shift in direction as It Is the case at the wall penetration. ° The thermometer on the supply IIine to the heat exchanger wlll have to be installed differently. The thermometer Is not supposed to be installed at the end of a dead end line as it is done here. The same situation appears- on the return from the heat exchanger. These thermometers will have to be placed differently. Field Trip Report Tanana October 28, 1984 The air vent on the line from the heat exchanger to the boiler is installed with a piece of black iron In a copper fitting. This will have to be changed. This plece of black steel nipple will have to be a bronze nipple. An air vent its missing on the supply line from the heat exchanger to the boiler in this boiler room. The new Grundfos pump type UP4375F has been installed Incorrectly as a copper fitting is used directly Into a cast iron flange. This will have to be changed for corrosion reasons. A gate valve is missing on the supply line from the heat exchanger to the boiler. The air vent provided on the return line from the boller to the heat exchanger Is not positioned correctly. It should be positioned at the elbow after the wall penetration from the boiler room out Into the Fire Stattlon. In general, the insulation job does not look finished as the ends of the Insulation fs not finished with any kind of material. In general here, all thermometers will have to be mounted differently. Also a small leak exists on a gate valve by the district heating supply to the heat exchanger. 9. On the strainer on the district heat supply line no gate valve has been provided for blowing off the strainer. Field Trip Report Tanana October 28, 1984 OTHER ITEMS: 10. ll. 12K 13. 14. ore Outside the Teen Center, it was noted that the district heating risers had not been covered with aluminum skin the way they were supposed to be. This will have to be taken care of, Outside the Day Care Center, it was noted that the risers had not been covered with aluminum skin. The same applies to the risers outside the City Building and the Fire Station. Inside the Day Care Center, It was noted that there was a leak on the air vent on the district heating supply line. This had ruined the Insulation, which will have to be replaced. It was noted that no blow-off valve was provided on the strainer. The thermometer on the boiler supply line was not installed correctly. This will have to be changed. Also, the thermometer on the district heating return Is questionable. On all thermometers it seems like the well is not inserted Into the flow the way It is supposed to be. The heat exchanger in this location is installed backwards, however, it has been reversed twice and the net result Is that the installation will work. Fleld Trip Report Tanana October 28, 1984 16; 17. 18. 19. 20. 21. 22. 23. Instde the power plant, the following was noted: ° An air vent was missing on the return line and the supply line to the City Maintenance Building. ° The pumps were probably not vented correctly as there was some noise from either dirt or air tn the pumps as they were running. ° The wall penetrations and the end caps on the district heating pipes were not the way they were supposed to be. Foam was exposed. There was a small leak on an alr vent on the district heating supply line. No valve had been provided on the strainer on the district heating side. The Btu meter, flow meter, and sensors were not installed yet. A couple of minor leaks were noted on the pump plugs. The air vent on top of the heat exchanger on the generator supply should be modified somewhat for neater installation. The key on the butterfly valve can be turned In such a way that all the fittings on the air vent become unnecessary. The heat exchanger should be bolted to the floor, ft.e. that Is If that has been specified. Pumps No. 3 and 4 were not yet hooked up electrically. Fleld Trip Report Tanana October 28, 1984 24, 25. 26. 27. 28. 29. 30. The supports for the piping and the pumps at this time consist of a piece of lumber. That should be changed into a permanent solution with steel supports. The butterfly valves on the pumps wlll have to be mounted differently. These butterfly valves should be with threaded bodies so that the pump can be removed. That is the whole purpose of the butterfly valve. In the present Installa- tion, the pump cannot be removed without shutting down the system. It seems that two valves are undersized, that should be checked. The valves on the pump look ltke 3 tnch valves and they should be 4 Inch valves. The pumps were installed in such a way that the axis Is vertical. It should be checked whether this Is according to manufacturer recommendations to the Contractor. A small ptnhole leak was found on the return line from the City Maintenance Building. The drain valve installed on the filler line is not a glycol approved valve and will have to be replaced. It seems like either the check valve or the filler pump ts leaking. The AMOT valve or the piping around it will have to be supported as this much weight might damage the _ heat exchanger nozzles. Fleld Trip Report Tanana October 28, 1984 Bilis CITY 5i2'6 33. 34. 35. 36. The connection to the district heating lines to the City Maintenance shop has been made with only untons In one end. If, for Instance, a leak develops right on top of the floor penetrations, it will be difficult to fix this’ leak. A union should be installed in both ends. MAINTENANCE SHOP: It was noted that the wall penetrations tInto the City Maintenance Building had not been covered with metal skin the way they were supposed to be. It looks like one of the flexible connectors might have been twisted, as glycol appears on the outside of it. It Is recommended that the sensor pockets be installed In the tee where currently the alr vents are Installed, and that the air vents are installed where currently the sensors are installed. Also, the sensor should be as close to the unit heater as possible. The shut-off valves on the return lines are only 3/4 Inch valves. This fs not according to specifications. These valves are supposed to be full ltIne size. Also, the 3/4 Inch shut-off valve is on the wrong side of the thermostatic valve. It Is supposed to be on the district heating side and not on the unit heater side. The piping around the unit heaters Is crooked. A small leak appears on the supply line on the unit heater closest to the door in the City Maintenance Bullding. Field Trip Report Tanana October 28, 1984 Bilaw The reducers, in connection with the unit heaters and the thermostatic valve, are made with bushings, that fs not according to specifications. They are supposed to provide reducers and not just bushings. SCHOOL COMPLEX: 38. 49, 40. 41. 42. The lines that are run between the School Generator Bullding and the Vocational Education Building should be covered with aluminum, and also they should be supported. Inside the School Generator Bullding, it was noted that there are a couple of small leaks around the unit heater. It was also noted that the installation In general is somewhat messy. For Instance, the piping will have to be supported better. The foam is exposed and this will have to be taken care of. The air vent on the return line is not positioned correctly as It fs in a low spot. The sensor should be fastened behind the unit heater, not with a piece of tape as it has been done now but with a clamp. Risers outside on the School Generator Building will have to be clad with aluminum. The risers on the Gymnasium will have to be clad with aluminum to protect from ultraviolet light. Inside the Storage Room where the heat exchanger is located, it was noted that there is a leak next to the thermostatic valve. Also, it was noted that the 1 Inch bypass line around this valve is missing. Field Trip Report Tanana October 28, 1984 43. 4a 4&5. 46. 47. The wall penetration will have to be fixed up. A blow-off valve should be provided on the strainer. The bypass valve should be left open as the pump Is supposed to take care of any flow through the heat exchanger. Inside the Vocational Education Building, in the welding section, It was noted that the pipe had not yet’ been Insulated. Also, It was noted that no 3-cone diffuser had been mounted on the unit heaters as specified. The plIpe had not been supported the way It was supposed to. It was tied to a plece of conduit with copper wire. It was also noted here on the unit heater that the reduction was done with a bushing from 2 Inch down to 3/4 inch. The unit heater In the wood section had not been installed In the locatton where it was supposed to be installed. Air vents were not installed correctly on this unit as an air lock would and could develop, and the pipe was resting on top of another pipe. Also, the thermostatic valve was Installed incorrectly as the sensor Is on the wrong side of the shut-off valves. Also, on the supply line to this unit heater, an air vent is missing. Generally, all unit heaters must have sufficient air vents on supply and return. Especially when it Is at the very high potnt in the system as Is the case here. The sensor will have to be immersed In the flow and not as it has been done here, at the end of a nipple. The flex connectors at this location have been used to change direction from the angle at which the glue lamps are running to a horizontal direction. This unit heater should have been located about 20 feet further into the building by the next post. Fleld Trip Report Tanana October 28, 1984 48. Inside this building, the wall penetrations will have to be finished up with sleeves and escutcheons In order to retain the fire rating of the walls. IRA_TEEN CENTER: 4g, Inside the IRA Teen Center, it was noted that only the pIpes had been brought in and valved off. The cabinet unit heater was not Installed yet. It could be seen that the wall penetrations were not finished yet. This will have to be done with escutcheons and sleeves, etc. WASHETERIA: 50. The wall penetrations were not finished up neatly, and also, the strainer did not have a blow off valve. Valves had not been provided as specified right next to the main IJine bypass. The circulation pump was not yet installed. It did not seem like the electrical hook-up had been done yet. In general, several valves are missing around pumps, _ heat exchangers, etc. However, only a few of the missing valves wil] have Impact on system performance and each case should be discussed with the Contractor. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson FIELD TRIP REPORT Tanana October 10 & 11, 1984 Contractor: Rockford Personnel: Dave Marks, Foreman JIm Shivers, Welder/Operator Duane Marks, Laborer Ed ,» Unton Electric Machines: 1 - Welder, Truck Mounted 1 - 4 Wheeler Progress Since Last Visit: ° Days were sunny and warm - evenings, 27°. Little frost in ground. Contractor was having problems with the E-Compensators, which are devices to place the 0 stress level of the pipe near the mid point of the operating temperature range. The Contractor's problem was without the hot water from the generator he was unable to close the Compensators to their butted position before welding. He was using the School boiler as a heat source and had the upper limit set. The problem fs on backfill that the water at the boiler return line, after passing through the School, is much cooler than that at the boiler high side which was 210°F with two 2-horsepower Grundfoss pumps operating. The temperatures and pressures were as shown: Field Trip Report Tanana October 10, 1984 Temperature boiler, high - 210°. Temperature at low side of School exchanger - 149°F. Temperature at high side of School exchanger - 153°F. Pressure - 38 p.s.l. Pressure outlet of Power House pumps - 42 p.s.i. Temperature outlet of Power House pumps - 146°F. Pressure at incoming side of exchanger at Power House - 19 p.s.l. Temperature in at exchanger at Power House - 148°F o Temperature constant at Power House. It should be noted there was air in the line in the high leg of the Gymnasium, Contractor states will add air bleeds In attic above School exchanger. o The Contractor had ground out the tack welds on the Compen- sators and reported the pipe broke the remaining weld and slid over the weld material. The Compensators all were at different positions. Generally, ft was understood all Compensators were welded at 0.14 feet or 1.68 Inches. This was not verifiable except in some cases as the pipe had expanded. © Suggested that the Contractor use bolts and steel plates to draw up compensators. Rough calculation Indicated 12,000 pounds would be sufficient. See remark under "Individual Compensators" for actual problems with this technique. The Contractor cut slot in two heavy flanges to fit them over the pipe. Four 5/8 all thread bolts were used to draw up the E-Compensators. Force used In cases was sufficient to stretch bolts and bend flanges. See photographs. Field Trip Report Tanana October 10, 1984 COMPENSATOR LOCATION 3rd Ave. First West Safewater First West Safewater Second West Safewater Second West Safewater 3rd Ave. First West Mills Street First West MI1I1s Street Second West Mills Street Second West Millis Street School Street School Street Maintenance Bullding Leg Matntenance Building Leg City Hall Leg City Hall Leg PIPE SIZE Out 114.3 Ret. 114.3 Out 114.3 Ret. 114.3 Out 114.3 Ret. 114.3 Out 114.3 Ret. 114.3 Out 114.3 Ret. 114.3 Out 48.3 Ret. 48.3 Out 60.3 Ret. 60.3 mm mm mm mm mm mm mm mm mm mm mm mm mm mm MEASURED 0.59 0.59 0.411 0.37 1.06 0.98 SET INCHES — . . al ND ial — a on —) 0.55 0.39 0.13 0.09 REMARKS (See No. Below) 1. 2. 3. Pulled In Welded Before Fleld Trip Report Tanana October 10, 1984 Remarks: 1. Tack welds held up Compensator, stretched bolts, force far exceeded amount needed to stretch pipe. Welded before developed pulling device, temperature near that of return at 148°-150°F. Welded before developed pulling device. Pulled until all bolts stretched, hit with hammer, maximum pull possible, far exceeded force to stretch pipe, probably hung up on weld. These Compensators were free. Pulled to maximum. Compensator near anchor. Compensator was set for too much compensation as anchor near and only pulling one leg. Welded when wasn't there, Compensator was set too low, temperature closed it. Pulled two bolts tight, sufficient for this pipe. Watched Compensators move freely as tack welds cut before heating. Field Trip Report Tanana October 10, 1984 o The Contractor is unable to complete installation of the unit heater at the City Hall and the Teen Center as this equipment had not arrived. o The School's main heat system was Installed. The School Generator Bullding was installed Incorrectly as the Danfoss valve's probe was to be In free air. He was instructed to change it. This was done. Both of the heaters in the shop were installed and one was plumbed. Contractor reports fan blast Is so great as to blow sawdust off of benches. Some form of speed control could be needed. o The Safewater Building has been completed, except for the installation of the pump which has been ordered for 240v 3-phase. The dresser coupling on the Incoming water let loose. It was fixed and held together with chains. o The Day Care Center, Fire Hall and Maintenance Building are complete. o The Generator Building ts also complete. The electrical Contractor was only able to install the 4 motor controllers as the generator switch gear fs not In place. Pumps are powered by 480v 3-phase temporary power. The Contractor ts unable to work on controls as schematic and parts are not there. o Called John Roe C456-8000) In Fairbanks and explained the control philosophy. That 190° incoming water is preeminent and that holding the 30° temperature differential between Fleld Trip Report Tanana October 10, 1984 the hot and cold side is not so important. The differential device as proposed which turns on pumps 2, 3 and 4 as required to hold 30° was approved Cpump 1 Is always on). A cam setable temperature controller with 5 outputs will be used to control interposing relays between the differential temperature controller and each pump motor. This will prioritize the 190°F requirement. This equipment will be assembled in Tanana. o The insulators are due the 12th and the electrician is leaving as are the Rockford personnel. Rockford's people claim they will be gone several weeks. o Cliff Eller, Tanana Power Plant owner, told (Chearsay) the Contractor he did not want the exchanger In the powerhouse Insulated. Am trying to contact him and persuade him not to do this. o Eller also supposedly told the Contractor the damaged 4" condult is allright. I am In disagreement with this. o Throughout the job it has been my observation the Contractor cuts corners to the detriment of quality. As an example, the situation of the backfill, marking tape and compaction. This time he did not test the Muffs with soap until I Instructed htm. One E-Compensator was not drawn up entirely. Infact, he would have welded them all_= short unless a solution was found. He wants to bury the damaged cable which would well go out during the coldest weather. He also mishandles the pipe. Field Trip Report Tanana October 10, 1984 © Quality control in these district heating pipes Ts Important. The pipe Is subject to high cyclical temperature stresses, bending from frost heave, thaw and differential settlement. The jacket Integrity is also extremely Important as the Ingress of water to the pipe will cause degradation of the Insulation, and more importantly, rapid corrosion of the unprotected thin wall steel pipe. In only a few years, Alyeska has had to replace much Insulation and piping at pump stations because of these types of problems. o Collected sample of wall covering In the Gymnasium. o Contacted Jens Madsen Brown-Bovarl in New Jersey, (201) 932-6244, He said the way the factory said to paint pipe was to roughen polyethelene jacket with a soft flame or use adhesive type of the appropriate color. He also suggested Chis idea) sandpaper. He will send us a fault detector permanent for trial. A permanent machine costs $1,200, whereas a portable is $4,000. Permanent device measures approximately 12" x 8" x 4", o Power House floor and walls are palnted In generator area and lights Installed in one bay. o Problems with 3rd Avenue west of Mills Street were discussed with Pat Moore, Mayor. Pat was not concerned with the road extending beyond the 30 foot ROW. He did want loose dirt piles leveled and sticks and roots picked up. Talked to Marks and asked him to do this Friday when the E-Compensator holes were to be filled. Fleld Trip Report Tanana October 10, 1984 o As the engines were not Installed, the Contractor may have lost an estimated 1-2 crew days having to heat the system with boiler water and pull up the Compensators. o Contractor did not follow the specification on cleaning the system as per 7.5.4.1 also 150 p.s.I. test has not been run. He charged the system directly with 50/50 water glycol. He stated he was worried about freeze-up. If the system were as hot as it was or he was on schedule it could be done. Glycol filling was done when no inspection was present. Earle Ausman Chief Energy Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority Photographs included FIELD TRIP REPORT Tanana October 5, 1984 Mr. Turner of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the trip was to inspect the on-golng work at Tanana and to try to resolve a problem which had surfaced at the school, I.e. whether or not the waste heat pipes could be hung inside the Gymnasium on the wall or whether they would have to go across the top of the roof, into the Boller Room. During this visit to Tanana, I met with Pat Moore, Mayor; Ken Lease, School Superintendent; Dave Marks, Rockford Superinten- dent; and discussed on the phone with Jerry Larson of Alaska Power Authority, the problems associated with the piping in the School Gymnasium. After numerous discussions, phone calls, et. al. ft was finally agreed that the piping could be hung on the inside of the Gymnasium wall In as much as a Change Order in the amount of $8,000 would be required to move the piping over the top. To accommodate the school's concerns, the following items will be accomplished: 1. A Change Order will be issued to Rockford to paint the piping to make ft look reasonably compatible with the Gymnasium. 2. Engineers Certificate that the hangers for the piping are adequate to carry the loads improposed by the waste heat system and those possibly anticipated because of students possibly hanging on the piping, etc. The question of where the piping would go, and the _ final solution, was again discussed with Pat Moore and Ken Lease of the school. Fleld Trip Report Tanana October 5, 1984 Rockford is making good progress on the work. The status Is as follows: o All underground and above ground piping exterior of the bulldings Is in. o All other work Is completed, with the following exceptions: 1. Installation of the unit heater in the Teen Recreation Center. 2. Installation of the heater In the City Office Building. 3. Installation of the waste heat piping in the Gymnasium. 4. One of two unit heaters has been installed in the School Workshop. 5. The electrical work has yet to be completed. 6. Insulation of the systems has yet to be done. 7. Heating up the systems and welding the E-Muffs remains. 8. Clean up of the project. 9. Final Inspection and acceptance by the Utility, City, and utility APA. It should be noted that Cliff Eller of Tanana Electric still has not moved the generators over to the generator bullding even though Rockford (Cwith the exception of the electrical and Insulation work) Its finished in the generator bullding. Overall, the progress and work looks good, with the exception of the questions dealing with the road surface material and compaction of the backfill, which has previously been addressed In other Tanana reports. Morris J. Turner, P.E. Project Manager /jkb ACTION REQUIRED by APA ACTION REQUIRED by APA EU GENERAL CONTRACTORS . . PIPELINE CONSTRUCTION . TANK ERECTION P.O. Box 111706 Telex 26622 Phone (907) 344-4551 Anchorage, Alaska 99511 SUMITTAL RURAL ENERGY WASTE HEAT PROGRAM TANANA APA84-C-034 “owre: Mae 25 _ SUBMITTAL FT| Thee (ZS) "CONTROL REGISTER #: Zz _ ITEM DESCRIPTION: Eee dese able tlre. MANUFACTURE AND CATALOG #:. BOTVACK. Per 4 INDUSTRIAL 5 Mood per pm 999004 08 Turbo Meter With Pneumatic / Batching Register ~~ Meter With Pulse Transmitter EPs PIPES, VALVES, FITTINGS, HEATING P.O. Box 3714 @ Seattle, WA 98124 (206) 767-4300 e@ Telex 32-9559 MAGNETIC DRIVE TURBO METERS... HIGH ACCURACY OVER BROAD FLOW RANGE @ Badger’s magnetic drive turbo meters provide industrial pro- cessors with higher accuracy over a broader flow range than traditional turbine meters with vertical rotors. Accuracy of the turbo meter can be maintained within + 1% % over the meter's entire flow range—not just at one point. Repeatability is within Y2 of 1%. The straight-through flow design makes it possible ‘to operate the turbo at a higher continuous flow than a comparable turbine. In addition, the low flow range on most models is extended about 50% below the minimum for vertical-rotor turbines. Because of the magnetic drive design, Badger turbo meters also help to reduce maintenance problems. There are no gears in the flow stream, no packing glands to cause leaks. Badger turbo meters are offered in four different housing mate- tials for measuring liquids up to 250°F. They can handle a wide variety of chemical solutions, paper coating materials, oils, water and food ingredients. WIDE FLOW RANGE METERING CAPABILITY : 0 ONTINUO! OPERATING PRINCIPLE = FLOW:.: ci Badger's turbo meter, with straight-through flow design, is equipped with straightening vanes and a nose cone at the inlet side. These minimize the swirling effect of upstream piping. Liquid flowing through the meter tube strikes the blades of a rotor, causing the rotor to turn. By means of a magnetic coup- ling, this motion is transferred to a vertical spindle and then to gears in the meter's register. *Consult your Badger representative about accuracy performance above and below flow rates shown. SERVICE ~ ta BaF Pf { WITHOUT REMOVAL ~ |. Fi FE Fer easy servicing, the .” <1. f01Qe and ead assem- ¥ 5, ‘bly'in the turbo meter ‘gan be removed without © | disconnecting the me- ter from the line. Just loosen {he head bolts .. ON top of the housing oS and lift out the entire i bration, i bat i bronze hoysiny ite and 3” meterg hs remove the ecing fu and turn the ¥ WIDE CHOICE OF REGISTERS AND ACCESSORIES . AUTOMATIC ELECTRIC PNEUMATIC SIGNAL MANUAL RESET BATCH BATCH REGISTER REGISTER REGISTER REGISTER REGISTER ELECTRIC INCLINED CONTACTING RESET REGISTER REGISTER Choice of Registra: tion in Gallons. Cubic Feet, Pounds, Metric Units, etc ae ee eae RoTMiaata MODELS MS-ER-1 REGISTER AND MS-E1 PULSE TRANSMITTER w@ q mie WITH ADAPTER 37.4" 4 TURBO METER 2°,3".4" OR6” ai MODEL PRC MODEL RBC-210 wl ‘ PULSE RATE-TO-DC REMOTE BATCH CONVERTER CONTROLLER ERIE Gore EOE fy t se MATERIALS OUSINGS 922 sem sistas een .. 316 Stainless phat Cast Iron Cast Steel slo bad 4 ie # BY) 25S BREE ep . .Cast Bronze Rotor and Nose Cone whe} Podl slafodal a eegeoesior Sita nk 4S he Kynar Rotor Bearing, Spindle and Endstone. . . . .Ceramic Ceramic ... 316 Stainless .. Thermoplastic 316 Stainless — 2" and 3"' Meters Asbestos/Buna N . .Asbestos/Acid-resisting Binder EPR, Buna N or Viton A Straightening Vanes .. Register Base Bypass Valve Head Gasket... ADDITIONAL ACCESSORY INFORMATION MODEL DESCRIPTION BULLETIN NO. BRE Batch Register, Electric IBR-3010 BRP Batch Register, Pneumatic IBR-3010 MR Batch Register, Manual IBR-3010 AR Automatic Reset Register IAR-3011 SR Signal Register 1AR-3011 ' EC Electric Contacting Register REC-5004 RTS Inclined Reset Register C-230 RBC Remote Batch Controller IRC-3009 MS-ER-1_ Pulse Transmitter XP-6011 MS-E1 Pulse Transmitter XP-6008 PRC Pulse Rate-to-DC Converter IPR-3001 o" 3" POUNDS PRESSURE LOSS ry is SPECIFICATIONS Accuracy — Entire Flow Range............ Repeatability — Constant Flow and Vemperature . cscs 002503 Head Loss — Maximum Flow (PSI) . 3% Maximum Operating Temperature (°F)...... Maximum Operating Pressure (PSI)......... Approx. Weight (Lbs.) with 150 PSI Conn. (Depends on Meter Material Selected). ... Laying Length (Inches) sia's sicic < siois <oss. 5 ose ciose Height — wio Register (Inches) Connection Flanges WHEN ORDERING Specify turbo. meter size (flow range) and type of housing material (for compatibility with liquid). _ When ordering meter with register, specify model of register and unit of measure. If PRE or BAP batch register is required, specify dial capacity. When ordering meter with pulse transmitter, specify pulse/unit-of measure. Please also list RBC-210 remote batch controller, pulse rate-to-dc converter, electric con- lacting register or inclined reset register if required. 2" 41.5% +0.5% 4.5 250 150 Std. 300 Opt. 30-40 10 3" 4" 6" +1.5% +1.5% +1.5% +0.5% +05% +0.5% 6 5.5 5.5 250 250 250 150 Std. 150 Std. 150 Std. 300 Opt. 300 Opt. 300 Opt. 40-50 60-75 100-125 12 14. 18 9 10 12 Round Round Round WARRANTY Badger warrants meters and parts manufactured by it and supplied hereunder to be tree from detects in materials and workmanship for a period of 18 months {rom date of shipment or 12 months trom date of installation, whichever period shall be shorter. If within such period any meters or parts shall be proved to Seller's satistaction to be detective, such meters or parts shall be repaired or replaced at Seller's Option. Seller's obligation hereunder shall be limited to such repair and replacement and shall be con- ditioned upon Seller's receiving written notice of any alleged detect within 10 days after its discovery and, at Seller's option, return of such meters or parts to Seller f.0.b. its factory. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES WHAT- SOEVER INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES (EXCEPT OF TITLE) OF MER- CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Badger shail nol be liable for any deflects attributable to acts of omissions of others alter shipment, nor any consequential, incidental or Contingent Gamage whatsoever. UE GENERAL CONTRACTORS as . PIPELINE CONSTRUCTION . TANK ERECTION P.O. Box 111706 Telex 26622 Phone (907) 344-4551 Anchorage, Alaska 99511 SUMITTAL RURAL ENERGY WASTE HEAT PROGRAM TANANA APA84-C-034 ~~ DATE: Waerh 22S . ~~ SUBMITTAL rT There = CONTROL REGISTER f: ZA ITEM DESCRIPTION: ws Balke’ teledowl neh tee syieh: Metre. MANUFACTURE AND CATALOG #:. BorVanek. pT eet 2 hE YL) Turbo Meter With Pneumatic | y Batching Register ~~ Meter With Pulse Transmitter di yh HIGH | ACCURACY OVER PIPES, VALVES, FITTINGS, HEATING P.O. Box 3714. @ Seattle, WA 98124 (206) 767-4300 e Telex 32-9559 | MAGNETIC DRIVE TURBO METERS... HIGH ACCURACY OVER BROAD FLOW RANGE y Badger's magnetic drive turbo meters provide industrial pro- cessors with higher accuracy over a broader flow range than traditional turbine meters with vertical rotors. Accuracy of the turbo meter can be maintained within + 1%% over the meter’s entire flow range—not just at one point. Repeatability is within “2 of 1%. The straight-through flow design makes it possible ‘to operate the turbo at a higher continuous flow than a comparable turbine. In addition, the low flow range on most models is extended about 50% below the minimum for vertical-rotor turbines. Because of the magnetic drive design, Badger turbo meters also help to reduce maintenance problems. There are no gears in the flow stream, no packing glands to cause leaks. Badger turbo meters are offered in four different housing mate- tials for measuring liquids up to 250°F. They can handle a wide variety of chemical solutions, paper coating materials, oils, water and food ingredients. WIDE FLOW RANGE METERING CAPABILITY INTIN FLOW :-: *Consult your Badger representative about accuracy performance above and below flow rates shown. OPERATING PRINCIPLE Badger’s turbo meter, with straight-through flow design, is equipped with straightening vanes and a nose cone at the inlet side. These minimize the swirling effect of upstream piping. Liquid flowing through the meter tube strikes the blades of a rotor, causing the rotor to turn. By means of a magnetic coup- ling, this motion is transferred to a vertical spindle and then to gears in the meter's register. SERVICE WITHOUT REMOVAL For easy servicing, the foler and head assem- A convenient. bly.In the turbo meter "valve, for ‘pregise “= gan be removed without © & bx bration, is bullt ‘ disconnecting the me- = | bronze hous ter from the line. Just |} "' loosen {he head bolts ;. ON top of the housing “-and lift out the entire _AO108 a ‘V BACKUP PAD Jo- EnOSTONE (CERAMIC) WIDE CHOICE OF REGISTERS AND ACCESSORIES . AUTOMATIC ELECTRIC PNEUMATIC SIGNAL MANUAL RESET BATCH BATCH REGISTER REGISTER REGISTER REGISTER REGISTER ELECTRIC INCLINED a ‘ CONTACTING RESET REGISTER REGISTER Choice of Registra- tion in Galtons. Cubic Feet, Pounds, Metric Units, etc eee a yray eas. Ube MPRERAEARET UUUEOIVOIDENT ES PENUEA | RLACARUAN PIPE PUMUEEGET HOUR IPLLIRORP AUER OY fs ane eee TOTALIZING MODELS MS.ER-1 REGISTER AND MS-E1 [4 eon | t PULSE yagi TRANSMITTER q mie WITH ADAPTER 2°,3".4" ORG" ‘ TURBO METER , Cee eter : HI MODEL PRC MODEL RBC-210 . . PULSE RATE-TO-DC REMOTE BATCH CONVERTER CONTROLLER payee: AY oAADMED ot, “MATERIALS HOUSING stsisxisjise)| balaal Seale Biers eee ..... 316 Stainless Midis oi setae CASE ALON A Ct Cast Steel ee . .Cast Bronze Rotor and Nose Cone VUTULORRT UUM ha ed Ce ee Kynar Rotor Bearing, Spindle and Endstone.. . me . Ceramic Magnelesrsns rears : eer EeEE Ceramic Straightening Vanes .. 316 Stainless Register Base . Thermoplastic BypassiValveseccemeer een 316 Stainless — 2" and 3" Meters Head Gaskel..... ........Asbestos/Buna N " Asbestos/Acid- -resisting Binder SONATA Naa EPR, Buna N or Viton A ADDITIONAL ACCESSORY INFORMATION MODEL DESCRIPTION BULLETIN NO. BRE Batch Register, Electric IBR-3010 BRP Batch Register, Pneumatic IBR-3010 MR Batch Register, Manual IBR-3010 € AR Automatic Reset Register 1AR-3011 SR Signal Register 1AR-3011 EC Electric Contacting Register REC-5004 RTS Inclined Reset Register C-230 RBC Remote Batch Controller IRC-3009 MS-ER-1 Pulse Transmitter XP-6011 MS-E1 Pulse Transmitter XP-6008 PRC Pulse Rate-to-DC Converter IPR-3001 POUNDS PRESSURE LOSS ry SPECIFICATIONS Accuracy — Entire Flow Range............ Repeatability — Constant Flow and Temperature eee Head Loss — Maximum Flow (PSI) . . ore Maximum Operating Temperature (°F)...... Maximum Operating Pressure (PSI)......... Approx. Weight (Lbs.) with 150 PSI Conn. (Depends on Meter Material Selected)... . Laying Length (Inches)...................- Height — wio Register (Inches) ............ Connection Flanges ...........cscessceees Psy WHEN ORDERING Specify turbo. meter size (flow range) and type of housing material (for compatibility with liquid). _ When ordering meter with register, specify model of register and unit of measure. If PRE or BRP batch register is required, specify dial capacity. When ordering meter with pulse transmitter, specify pulse/unit.of measure. Please also tist RBC-210 remote batch controller, pulse rate-to-dc converter, electric con- lacting register or inclined reset register if required. 2" 3" 4a" 6" 41.5% +1.5% +1.5% +1.5% +05% | +0.5% + 0.5% + 0.5% 45 6 5:5 25) 250 250 250 250 150 Std. 150 Std. 150 Std. 150 Std. 300 Opt. 300 Opt. 300 Opt. 300 Opt. 30-40 40-50 60-75 100-125 10 12 ans 18 8 9 10 12 Round Round Round Round Smee ga stg Sipe : WARRANTY Badger warrants meters and paris manufactured by it and supplied hereunder to be free from detects in Materials and workmanship for a period of 18 months trom date of shipment or 12 months trom date of installation, whichever period shall be shorter. If within such period any meters oF parts shall be proved to Setier's satistaction to be detective, such meters or parts shall be repaired or replaced at Seller's Option. Selier's obligation hereunder shall be limited to such repair and replacement and shall be con- ditioned upon Seller's receiving written notice ot any alleged detect within 10 days after its discovery and, at Seller's option, return of such meters or parts to Seller 10.b. its tactory. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES WHAT- SOEVER INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES (EXCEPT OF TITLE) OF MER- CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Badger shail nol be liable for any elects attributable to acts oF omissions of others alter shipment, nor any consequential, incidental or Contingent damage whatsoever Galions z™ 99904608 Turbo Meter With Pneumatic Batching Register Meter With Pulse Transmitter PIPES, VALVES, FITTINGS, HEATING P.O. Box 3714 @ Seattle, WA 98124 (206) 767-4300 @ Telex 32-9559 MAGNETIC DRIVE TURBO METERS... HIGH ACCURACY OVER BROAD FLOW RANGE € Badger's magnetic drive turbo meters provide industrial pro- cessors with higher accuracy over a broader flow range than traditional turbine meters with vertical rotors. Accuracy of the turbo meter can be maintained within + 1% % over the meter's entire flow range—not just at one point. Repeatability is within 2 of 1%. The straight-through flow design makes it possible ‘to operate the turbo at a higher continuous flow than a comparable turbine. In addition, the low flow range on most models is extended about 50% below the minimum for vertical-rotor turbines. Because of the magnetic drive design, Badger turbo meters also help to reduce maintenance problems. There are no gears in the flow stream, no packing glands to cause leaks. Badger turbo meters are offered in four different housing mate- tials for measuring liquids up to 250°F. They can handle a wide variety of chemical solutions, paper coating materials, oils, water and food ingredients. WIDE FLOW RANGE METERING CAPABILITY OPERATING PRINCIPLE Badger's turbo meter, with straight-through flow design, is equipped with straightening vanes and a nose cone at the inlet side. These minimize the swirling effect of upstream piping. Liquid flowing through the meter tube strikes the blades of a rotor, causing the rotor to turn. By means of a magnetic coup- ling, this motion is transferred to a vertical spindle and then to gears in the meter's register. *Consult your Badger representative about accuracy performance above and below flow rates shown. SERVICE WITHOUT REMOVAL F ' ; For gasy servicing, the .: rotor and head assem- + bly.'in the turbo meter - ean be removed without : “disconnecting the me- ter from the line. Just Joogen the head bolts on top of the housing .- and lift out the entire and 3” meterg remove the 20108 Dour rao Jo ENOSTONE (CERAMIC) pay Se WIDE CHOICE OF REGISTERS AND ACCESSORIES . 2 AUTOMATIC ELECTRIC PNEUMATIC SIGNAL - MANUAL RESET BATCH BATCH REGISTER REGISTER REGISTER REGISTER REGISTER * 5 nent Se Staten ELECTRIC INCLINED CONTACTING RESET REGISTER REGISTER Choice of Registra- tion in Gallons, Cubic Feet, Pounds, Metric Units, etc foramina MODELS MS-ER-1 REGISTER AND MS-E1 PULSE TRANSMITTER mie WITH ADAPTER 2°,37.4" OR6* 4 TURBO METER x L---—-—-- 2 a / MODEL PRC MODEL RBC-210 = PULSE RATE-TO-DC REMOTE BATCH CONVERTER CONTROLLER a MATERIALS i Housing Sea ELAINE ehn baad eam ee EU 316 Stainless Wa we LAPS Bibl hls Ebetn fel lolebnin loners pet era tehang conte pee Cast Iron tom genes Ee Cast Steel Cast Bronze .. Kynar Ceramic Ceramic Stdightening Vanes sa). sie vsis'< sre rics) ones oie «is ev 316 Stainless Register Base... bi. is. osx sarees sams Seis toe Thermoplastic Bypass Valve. . . 316 Stainless — 2” and 3"' Meters ead Gaskets asa cys cies tins wie, sone opones oft lors 8g Asbestos/Buna N bc opala ages 2 la Gad Asbestos/Acid-resisting Binder “O" Ring and Tetraseal E hig ieee» ies ois EPR, Buna N or Viton A ADDITIONAL ACCESSORY INFORMATION MODEL DESCRIPTION BULLETIN NO. BRE Batch Register, Electric IBR-3010 BRP Batch Register, Pneumatic IBR-3010 MR Batch Register, Manual IBR-3010 é AR Automatic Reset Register IAR-3011 SR Signal Register 1AR-3011 EC Electric Contacting Register REC-5004 RTS Inclined Reset Register C-230 RBC Remote Batch Controller IRC-3009 MS-ER-1 Pulse Transmitter XP-6011 MS-E1 Pulse Transmitter XP-6008 PRC Pulse Rate-to-DC Converter IPR-3001 ru POUNDS PRESSURE LOSS. ry SPECIFICATIONS Accuracy — Entire Flow Range............ Repeatability — Constant Flow and RGMMPOLSTLG! re Saeco tlkla yates ies erate pelos Head Loss — Maximum Flow (PSI) ......... Maximum Operating Temperature (°F)...... Maximum Operating Pressure (PSI)......... Approx. Weight (Lbs.) with 150 PS! Conn. (Depends on Meter Material Selected). ... Laying Length (Inches).................... Height — wio Register (Inches) ............ Connection FiAnges. «soc iiss sisie duis asin 0: WHEN ORDERING Specify turbo. meter size (flow range) and type of housing material (for compatibility with liquid). _ When ordering meter with register, specify model of register and unit of measure. If PRE or BRP batch register is required, specify dial capacity. When ordering meter with pulse transmitter, specify pulse/unit-of measure. Please also list RBC-210 remote batch controller, pulse rate-to-de converter, electric con- lacing register or inclined reset register if required. 2" 3" 4" 6" + 1.5% +1.5% += 1.5% +15% + 0.5% +0.5% +0.5% +0.5% 45 6 5:5 5:5 250 250 250 250 150 Std. 150 Std. 150 Std. 150 Std. 300 Opt. 300 Opt. 300 Opt. 300 Opt. 30-40 40-50 60-75 100-125 10 12 4. 18 8 9 10 12 Round Round Round Round Sane BOSS Og as | A ae | WARRANTY Badger warrants meters and parts manufactured by it and supplied hereunder to be tree from detects in materials and workmanship tor a period of 18 months {rom date of shipment or 12 months trom date of installation, whichever period shail be shorter. If within such period any meters or parts shall be proved lo Seller's satistaction to be detective, such meters or parts shall be repaired of replaced al Seller's option. Seller's obligation hereunder shall be jimited to such repair and replacement and shall be con- ditioned upon Seller's receiving written notice of any alleged detect within 10 days after its discovery and, at Seller's option, return of such meters or parts to Seller 10.b its factory. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES WHAT- SOEVER INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES (EXCEPT OF TITLE) OF MER- CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Badger shail not be liable tor any detects attributable 10 acts oF omissions of others after shipment, nor any Consequential, incidental or contingent damage whalsoever.