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HomeMy WebLinkAboutRural Energy Waste Heat Program- Final Report 1984RURAL ENERGY WASTE HEAT PROGRAM electrical Waste Heat Management Contract No. CC 08-3007 FINAL REPORT WASTE HEAT RECOVERY SYSTEM OPERATIONS FOR THE VILLAGES OF Kiana, Ambler, Shungnak, Savoonga, Elim, Kaltag, Grayling, Goodnews Bay and Angoon St. Mary’s and Unalakleet ANCHORAGE ALASKA DECEMBER 1984 ALASKA POWER AUTHORITY polarconsult alaska, inc CONSULTING ENGINEERS AND PLANNERS polarconsult alaska, inc. ENGINEERS * ARCHITECTS * ENERGY CONSULTANTS December 28, 1984 Alaska Power Authority 334 West Fifth Avenue Second Floor Anchorage, Alaska 99501 Attention: Mr. Jerry Larson Reference: o Waste Heat Management, Contract CC 08-3007, with Amendment No. 1, dated February 14, 1984. o Final Report; Volume I, II & III; Project Summary for the Villages of Kiana, Ambler, Shungnak, Savoonga, Elim, Kaltag, Grayling, Goodnews Bay, Angoon, St. Mary's, and Unalakleet, December, 1983. o Status Report of Waste Heat Recovery Systems, dated September 10, 1984. Subject: Final Report - Monitoring Eleven (11) Village Waste Heat Systems, Constructed In 1983. Serfal Letter: 3007 APA-54 Dear Mr. Larson: Enclosed is our Final Report dealing with the 1984 monitoring of eleven village waste heat recovery systems constructed for Alaska Power Authority by four Contractors In 1983. This report should be considered with the previous two reports previously sent to your office, as referenced above. This report concluded our specific work efforts of assisting and representing the Alaska Power Authority as Its Construction Managers and Engineer on the various Waste Heat systems. It has been a distinct pleasure to have worked for the Alaska Power Authority. We are ever greatful for the opportunity to assist the Alaska Power Authority. We believe our work for you has been timely, responsive, of high quality and economically performed. 2735 EAST TUDOR ROAD ¢ SUITE 201 * ANCHORAGE, ALASKA 99507 © PHONE (907) 561-1933 © TELEX: 26708 PCA AHG polarconsult Alaska Power Authority 3007 APA-54 December 28, 1984 Page 2 Again, thank you for the opportunity to have once again worked for you on these most Interesting projects. Sincerely yours, POLARCONSULT ALASKA, INC. er / Ge wer i C J®orris un Tunnens) Rob. 4 Project Manager /jkb APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX TABLE OF CONTENTS SUMMARY A wceceeeeeeeee LISt of Fleld Trip Reports, GB ceweweceweasa Fleld Trip Reports, 1984 C wecccccccccce Operation Problems DD) lekeieyel'e Wee sielas s Ambler Piping Problems || loiter e-e'l siete se telleie 6 Punch List mel Remaltning 1984 polarconsult SUMMARY A Professtonal Services Contract for Construction Management Services (CMS) for the construction of waste heat systems In rural Alaska was awarded to Polarconsult Alaska, Inc. under the Alaska Power Authority (CAPA) Contract No. CC 08-3007. This program Is commonly referred to as the "RURAL ENERGY WASTE HEAT PROGRAM" CREWHP). Period of performance for the Contract Amendment was January, 1984 through December 31, 1984. Our work efforts under this Contract Amendment have been associated with: o Working with the Utilities on the waste heat’ system operations from thelr power generation. o Performing routine visits to the project sites to: 1) Monitor system operations, 2) Inspect remedial work done by the Contractor on old and new system punch list items, and 3) Maintain liaison with heat recovery users. o Evaluating piping fallure problems at Ambler with the Contractors field personnel, Contractors management, material supplier, APA system designer, and APA (Csee Appendix D). o Working on Design Deficiency questions. o Maintalning lfaison with the Alaska Power Authority on the above work efforts. polarconsult As of this date, we have completed all Contract work assoclated with monitoring the waste heat recovery systems in the villages/ cIties of Klana, Ambler, Shungnak, Savoonga, Elim, Kaltag, Grayling, Goodnews Bay, Angoon, St. Mary's, and Unalakleet. Most of the work accomplished under this Amendment by our firm for APA was outlined tn some detail in our Status Report to you of September 10, 1984. Subsequent to that, visits to all sites were again made with the exception of Angoon, Coples of these field reports CAppendix B) are enclosed herew!th for ready information. Appendix A provides a summary list of all site visits during 1984. Noteworthy Items included or otherwise referenced to are: o Piping repair report on Ambler CAppendix D). It should be noted that the Contractor repaired 20 facility solder joints In the burted waste heat piping system. o The Contractors (Rockford Corporation and J.B. Mechanical) performed punch list and/or warranty items of work through the one year guarantee period. The Contractors CWashington Mechanical and Wick Construction) had previously completed all their contract work. © Polarconsult accompanied the Alaska Power Authority on a tour of most villages on November 26 and 27, 1984. An AVEC representative (Mr. George Rooney) also was a member of that Party. o After meeting with Rockford Corporation, Raj Bhargava, APA, and Polarconsult, it was decided a manufacturer and/or design deficiency existed on the specified Btu meters for monitoring the systems. This meeting lead to concurrence with Rockford that they had met all Contract provisions In this regard. polarconsult o There are certain system design and/or operating problems which are herein summarltzed and which are covered In more detall In Appendix C, f.e.: 1) Many of the systems are operating low on pressure on the District Heating side. 2) Problems exist with all remote radiator systems, except Unalakleet. 3) Copper piping with solder joints have been a problem in comparlson to steel pipe with welded joints. 4) Problems exist with the design and size of the cooling fans in the module. 5) Btu meters generally don't work. 6) Thermometers are problems, because of high temperatures near certain pieces of equipment. 7 Waste Heat Recovery Modules are generally too small. 8) Victaulic fittings have proven problems and we recommend welded flanges in future AVEC’ generation modules. 9) Operating/design problems: a. Excluding the Ambler piping system failure and damaged to the above ground piping at Kiana by the Public Health Service, all systems operated well through the winter season of 1983-1984. Be Excluding the noted design problems, the systems are not without operating problems. It appears to us, the main operating problems deal with the polarconsult Inability of the Uttlity company operators to be able to balance the systems. Most systems have expansion tanks. For example, on the generator side with each roof mounted radiator, there Is an expansion tank on the Heat Recovery Module roof. Unless they keep these systems’ balanced, the glycol will be spilled from one tank when: (1) The other tank Is low and has air in the system, or (2) The system ts filled up cold and over heated exposure takes place and glycol is lost. The expansion tank on the district heating side also is a problem, these problems are generally associated with possible small leaks In the system and operators failing to keep system pressures up. When accepted from the Contractor, the systems had been balanced and were all operating properly. o As-bullt drawings have been completed and delivered to APA and the respective utilities. o Extra copies of catalog cuts; Operation and Maintenance Manuals, et. al.; have been delivered to the various Utilities and APA. o Appendix E tIncludes copies of letters recently sent to Rockford Corporation and J.B. Mechanical pertaining to outstanding punch list items of work which should yet be done under the guarantee provisions of their respective Contracts. This report concluded our specific work efforts of assisting and representing the Alaska Power Authority as Its Construction Managers and Engineer on the various Waste Heat systems constructed in 1983. FIELD TRIP REPORTS, 1984 WHM-IT JANUARY: Peter N. Hansen Training Session 1- 4 - 84 for AVEC Roland DeBoer, Ambler 1 - 25 - 84 Ivan Solhelm and Peter N. Hansen Roland DeBoer, Kiana 1 - 26 - 84 Ivan Solheim and Peter N. Hansen FEBRUARY: Peter N. Hansen St. Mary's 2 - 16 - 84 MARCH: Peter N. Hansen Ambler 3- 5 - 84 Peter N. Hansen St. Mary's 3 - 8 - 84 Peter N. Hansen Goodnews 3- 9 - 84 APRIL: Peter N. Hansen Kaltag 4 - 26 - 84 Peter N. Hansen Grayling 4 - 26 - 84 Peter N. Hansen Elim 4 - 26 - 84 Peter N. Hansen Unalakleet 4 - 26 - 84 MAY: Peter N. Hansen Savoonga 5 - 15 - 84 Peter N. Hansen St. Mary's 5 - 18 - 84 JUNE Duane Carson and Kaltag 6 - 30 - 84 Peter N. Hansen WHM-IT Duane Carson and Peter N. Hansen Duane Carson and Peter N. Hansen Duane Carson and Peter N. Hansen JULY: Duane Carson and Peter N. Hansen Duane Carson and Peter N. Hansen Duane Carson and Peter N. Hansen AUGUST: Jack Turner Jack Turner Jack Turner Peter N. Hansen SEPTEMBER: Duane Carson Duane Carson Jack Turner OCTOBER: Jack Turner Jack Turner Shungnak Ambler Klana Elim Grayling Unalakleet Ambler Kiana Shugnak Angoon Grayling, Kaltag and Elim Ambler St. Mary's St. Mary's Goodnews Bay 10 10 30 30 30 25 12 19 18 84 84 84 Bu 84 84 84 84 84 84 84 84 84 84 8h WHM-IT NOVEMBER: Peter N. Hansen DECEMBER: Duane Carson Shungnak, Ambler, Klana, Ellm, Savoonga, Grayling and Unalakleet St. Mary's Kaltag, 11 11 12 = 6 = 27 10° 84 & 84 84 polarconsult ‘ FIELD TRIP REPORT Goodnews Bay October 18, 1984 Mr. Turner of Polarconsult Alaska, Inc. conducted a fleld visit to this site. The purpose of this trip was to Inspect the operation of the Waste Heat System Installed by Rockford Corporation, to determine If punch list Items had been completed, and to vlew the overall system operations. This visit Is the last of a serles of visits by Polarconsult to this particular village. The punch list Items whIch had remalned on the constructlion phase of the work have all been completed. During my visIt to Goodnews Bay, I contacted the school maltnte- nance person and Albert Bright, the AVEC Operator. I Inspected the Waste Heat System In the AVEC powerplant, the Heat Recovery Module and the school Boller Room. Of particular Interest was the comment by the School Malntenance person that they did not have thelr bollers on during the past winter season or this year, except for one 3-day period last winter when the AVEC generation plant was down. It was also Interesting to note that during that particular period was the only time that the students) and teachers complalned that the school was cold. The malntenance person was quick to pralse the Waste Heat System as a real wonderful tool for the school. Agaln, I would like to highlight that no dlesel fuel was necessary to supplement the Waste Heat System. The Waste Heat System had plenty of capacity for the school and, I suspect, excess capacity. Other Items which are of general Interest to not only this Waste Heat System, but others are: Mr Bright, the AVEC Operator, appears to be doling a good Job In operating the Waste Heat System; both the AVEC plant and the module were clean; It was polarconsult . Fleld Trip Report Goodnews Bay October 18, 1984 Indicated that the hand pump for the glycol system does not work; there have been problems with the Interlor fans for cooling off the Heat Recovery Module, they were on manual rather’ than automatic; and the Btu meters do not work. From the standpolInt of things to look forward to In the future desIgns, as noted above, the fans for the modules, the sIze of the modules, the Btu meters, a system for balancing between one radlator and another could be provided. Addittonally, It Is noted that because of the heat from withIn the AVEC generatton plant, the cases around the thermometers were melting and this needs to be looked at carefully In future designs to Insure that the thermometer cases can withstand the high temperatures that they would be exposed to In the vicinity of these electric generators. Enclosed herewlth Is a copy of the weekly log for the Waste Heat Recovery System that the AVEC villages are usIng. This Is also fllled out for the first three days of the week of the site visit. Agaln, you wlll notice the Btu meters do not work and on the engine side, the pressure was low In comparison with the Heat Recovery Module side which had 15 p.s.i. pressure compared to Just over 1 1b pressure on the engine side. cE | “9 Aa Zs. . a - Co “Morris J. Turner, P.E. Project Manager /Jjkb cc: Mr. Jerry Larson, Alaska Power Authority HEAT RECOVERY SYSTEM LOG FOR WASTE WEEKLY ALASKA VILLAGE ELECTRIC COOPERATIVE, INC, - Month Oc% Year /2¥E During Week Starting MONDAY George. BAY VILLAGE NAME: INSIDE WASTE HEAT MODULE INSIDE POWER PLANT 653 19 MONDAY Date 15_ px | os | ee | an Ire 182 | i TUESDAY 653 - WA7 004> 185" Date 1G WEDNESDAY Date 1s | 192 s THURSDAY Date FRIDAY Date SATURDAY Date SUNDAY Date nside the power plant at ocated RETURN THIS LOG TO AVEC, ALONG WITH THE DAILY OPERATING LOG, EVERY MONDAY MORNING, polarconsult FIELD TRIP REPORT Shungnak, Ambler, Klana, Elim, Savoonga, Kaltag, Grayling, and Unalakleet November 26 & 27, 1984 Mr. Hansen of Polarconsult Alaska, Inc. conducted a field visit to these sites. The purpose of the visits was to conduct final Inspection before these systems are turned over to Alaska Village Electric Corporation and Matanuska Electrical Association. Shungnak: It was noted that there is a leak by an elbow on the above ground district heating line close to the school. The system fs low on pressure (O ps!) and does not seem to be functioning well. It appears that there might be a leak on the left remote radiator (that is the unit furthest to the North). While the tank is dry Inside and outside, the radiator core itself was wet with glycol on the outside, this could Indicate a leak. The replacement transformer for the transformer that was burned out earlier this summer was still mounted outside [In a _ non- permanent manner. Ambler: Insitde the heat recovery module, there is a small leak above the floor penetration on the outgoing line. The system is down to 4 psi static pressure and Is not operating well. It seems like the pumps are surging due to air In the lines. The radiator controls are broken as the step controller no longer works. This means that the radiators cannot cycle and a non- permanent solution has been made which makes the one radiator run at low speed at all times. polarconsult Field Trip Report 8 Villages November 26 & 27, 1984 Klana: The radiator cap on the west remote radiator does not seem to be sealing tightly as glycol Is over-flowing, even when there is no pressure in the system. The system Is, however, in operation and seems to be operating as intended. Elim: The system is operating as intended, however, the static pressure In the system is only 8 psi, and the pumps are surging due to alr In the lines. Savoonga: There Is a leak on the above ground district heating lIne at the elbow right outside the school boller room. There Is also a leak Inside the school boiler room above the floor penetration. The system Is down to 8 psi static pressure and should be recharged at the same time the leak is repaired. Kaltag: The static pressure of the system Is down to 4 psi and the pumps are somewhat noisy because of air in the lines. The system should be recharged. The Indicator lights on the circulation pump controls are burned out. Grayling: The fan motor on the right radiator is burned out and will have to be replaced. polarconsult Fleld Trip Report 8 Villages November 26 & 27, 1984 The static pressure of the system Is down to 5 psi and the pumps are noisy due to alr in the lines. The site glass on the right radiator Is loose and Is causing some leakage. Unalakleet: The system Is operating as intended. General Notes: On all systems, except Unalakleet, problems exist In connection with the remote radiators. These radiators are connected In series where they should have been connected In parallel. This, combIned with a possibly marginal capacity of the expanston tanks on the radiators, causes substantial losses of glycol. This ts caused by the fact that the operators fi11 both tanks until the site glasses Indicate full, then after the system heats up, or after flow is sent through the radiators, glycol is released by the pressure release caps. According to operators, glycol will have to be added every week In order to avoid low water alarms. This is a design deficiency that should be corrected. This can be done by either moving both expanston tanks to one radiator and mounting an alr vent on the other radiator or by repiping the system so that the radiators are in parallel. Also, the low water cut-off, that is the murphy switch gauges should be mounted in such a way that they will not provide an alarm until the tank Is completely empty. As they are mounted now, an alarm Is given when the tank Is about one third full. polarconsult Fleld Trip Report 8 Villages November 26 & 27, 1984 All systems, except Unalakleet and Kiana, are low on pressure. The system should be charged and the pressure should be monitored in order to see whether leaks are present In the systems. In Ambler, Elim, and Grayling, a leak would be hard to detect due to the nature of the system with underground lftnes. However, the system should be charged and it should be made certain that no leaks exist before the systems are turned over to AVEC. It should be noted that these systems are designed In such a way that they are basically low on glycol whenever the pressure gets under 12 psi. 12 psi fis the charge pressure of the expansion tank and any static pressure lower than that Indicates that glycol has been lost somewhere In the system. It seems like the operators In the various villages have not been Instructed to maintain system pressure. It also seems like no Operation & Malntenance Manuals have been delivered to_ the villages, which again means that all operators are_ lacking understanding of the systems. Lh 6 Nean~ Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Mary's December 10, 1984 Duane Carson and Mark Newell of Polarconsult Alaska, Inc. went to St. Mary's to make a final Inspection of the waste heat recovery system Installed by J.B. Mechanical. At St. Mary's, we met with Mark Jordan and Emanuel Worble of the St. Mary's Mission School and Tim Troll of the City of St. Mary's. The system Is working due to the fact that Emanuel Worble ts doing the malntenance on the system; keeping the system filled with glycol and the pressure up. This service by the Mission Is to thelr benefit by lowering their fuel consumption. Everything appeared to be working at the Main Bullding and Gymnasium Boiler Room. At the Cold Storage Building, there Is a leak In the supply line to the heat exchanger causing a puddle of glycol on the floor. There is also some loose insulation around the supply lines. The pressure on the supply line was 21 psi and the return line was 11 psi. The 10 psi pressure drop appears to be on the high side for the amount of heat being used. Also, the thermometers showed 103°F on the supply line and 121°F on the return. The Btu meter was inoperative at the time of inspection. In the Power Plant, everything appeared to be working. The jacket temperature of the generating unit was being operated at L7G*F,. In speaking with Emanuel, the heat exchanger in the Water Treatment Plant takes a large amount of the available heat when it is In operation. The City water temperature at the plant is polarconsult Fleld Trip Report St. Mary's December 10, 1984 as high as 72°F when It Its left flowing through the exchanger. The automatic heat control, If installed properly, would make more heat available to either the Cold Storage Bullding or the Mission. It was noted that the temperature In the Cold Storage Plant was just above freezing at the time of inspection. The outside temperature was in the teens and brisk wind was blowing. aes Duane Carson Civil Structural Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult OPERATIONAL / DESIGN CONCERNS Based on Polarconsult's system evaluations Cwhich also Includes discussion and opinion of the plant operators, Utility key personnel, designers, and the Contractors) we note the following operational concerns: 1. No rubber hose connections should be used on the engines. Ze Provistons should be made to equalize expansion tank levels on the two radiators. 3. The murphy switch gauge should be lowered. 4. Heat Recovery Modules, as specified, are too small, too expensive and hard to fleld erect. Believe can do better (more room and less cost) with more conventional metal bulldings. 5. More welded connections should be used. 6. Due to slow reaction of AMOT valve, the radiators should not be kept warm at all times. 7. More vents and drains should be added. 8. Engines not In use should be kept warm with a small by-pass line. 9. New fans In power plant should be exhaust fans. LG. Pipe makings/Identifications should be more tnformative. 11. All Btu meters should be hard-wired and tamper proof. polarconsult 12. Sis 14. 15. 16. Booster pumps Installed should be capable of boosting any generator Installed. Btu meters generally don't work. It Is suggested that flow meters be used In the future In lieu of Btu meters. Problems have been experienced with size of transformers specifled. Larger units should be called for. Systems operate well where the operators understand and work with the systems; otherwise only marginal results are being obtained; for example: o The local plant operators or new operators should be given more guidance or perhaps a point of contact when problems arise, I.e. the operator at Goodnews’ Bay switched the pumps to manual after they shut off on automatic due to a pressure drop. In this case the pressure drop was due to a very minor leak at a union, but it could have been a major problem. No action was taken to determine a problem before switchover. It also appears the pumps are being lubed without removing the overflow plugs. o The damper actuators appear to be breaking due to the dampers’ freezing’ shut. This problem Is due to continue. It is suggested that these items be shut off and disconnected, i.e. block full open In summer, and partial open In winter. Radiators on top of the Waste Heat Recovery Module to have one common filler pipe to do as follows: as Keep the liquid level approximately even in both sight tubes. polarconsult 17. 18. 19. 20. 21. 22. 23. 24. b. Ensure any excess glycol fluld once heated up Cexpanded) will not be wasted but kept within the expansion tanks. Install larger cooling fans and a different type of dampers in the Waste Heat Recovery Module. Design the systems so that equipment In the Waste Heat Recovery Module is Installed so that the equipment can be maintained (e.g. put pumps so the mechanics have ready access to them for maintenance). In regions of salt air environment, such as Savoonga, a different type of radiator fan motor should be installed, or the ones installed should be operated briefly every few months. This Is to prevent corrosion of the motor shafts. Design systems to be self balancing. Provide radiator site tubes at eye level of operators where glycol make-up drums are located. Specify leak detection systems. Use only one pipe per jacket Cproblems with manufacturer's quality control with two pipes In one jacket). Use flex connectors at wall penetrators to underground piping systems. Building (Csuch as Waste Heat Recovery Module on cribbing) frost jack and put stress on piping. polarconsult alaska, inc. ENGINEERS ¢ ARCHITECTS * ENERGY CONSULTANTS October 11, 1984 Alaska Power Authority 334 West 5th Avenue Second Floor Anchorage, Alaska 99501 Attention: Mr. Jerry Larson Reference: Ambler PipIng Problems Serial Letter: 3007 APA-51 Dear Mr. Larson: Based on the statement of a possible claim for a design defl- clency at Ambler, by Mr. Dexter Smith of Rockford Corporation, Polarconsult dispatched our Mr. Duane Carson to Ambler to be on site during all work assoclated with uncovering and redoing the plpe Joints on September 12, 1984. Rockford's personnel arrived on September 13, 1984 to start the repairs to the system and completed repairs on September 25, 1984. In testing and exposing the JolInts, It was found that 16 of the fleld soldered Joltnts and 4 factory made JolInts had leaks for a total of 20. In most cases, the leaks were due to lack of solder between the plIpe and the couplings or physical damage to the carrier pipe. Enclosed Is the report of the findings with photos. Should you have any questions, please feel free to contact this office. Sincerely yours, POLARCONSULT ALASKA, INC. Aisa J. eae Pee; ProJect Manager DC/Jjkb enclosure 2735 EAST TUDOR ROAD ¢ SUITE 201 * ANCHORAGE, ALASKA 99507 © PHONE (907) 561-1933 © TELEX: 26708 PCA AHG polarconsult FIELD TRIP REPORT Ambler September 12 - 25, 1984 A trip was made to Ambler, Alaska by Duane Carson of Polarconsult Alaska, Inc. to record the condition of the waste heat recovery system underground piping. The system piping Is 3 Inch dlameter copper carrler plIpes (2) In urethane foam Inside an outer Jacket of polyethylene. Factory made elbows and expanston loops have outer Jackets of P.V.C. The pipes standard lengths are 20 feet and put together wlth couplings and solder then foamed and shrink sleeves Installed. The Jolnts were numbered from the heat recovery module to the school. No. 1 Jolnt was the vertical Joint Just under the module at the AVEC Power Plant and No. 60 at the School the other end of the system. JolInt No.: 1. Tested at 100 p.s.I. - not opened. 2. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. 3. Tested at 100 p.s.I. - Joint opened and couplings exposed, no leaks. 4. Jolnt at the anchor, not opened but tested to 100 p.s.l. 5. Tested at 100 p.s.I. - not opened. 6. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. 7. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. 8. Top plpe had pulled at the coupling approximately 3/16 Inch. When bottom pipe was cut there was a 1/2 Inch misalignment. New flex couplings Installed In top and bottom plpes. polarconsult Fleld Trip Report Ambler September 9. 10. ive 12. L3< 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 12 - 25, 1984 Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100- p.s.I. - Jolnt opened and coup!Ings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Joint opened and couplings exposed, no leaks. JoInt opened and cut to repair leak In factory 90° elbow In expanston loop. Leak In bottom plpe. Flex couplings Installed. JoInt opened and cut to test 90° elbows In factory expanslion loop. Flex couplings Installed. JoInt was good. JotInt opened and cut to repalr factory 90° elbow In the expansion loop. vJolnt was good. JolInt had been opened and the top plpe cut. Tested at 100 p.s.I. - Jotnt opened and couplings exposed, no leaks. Tested at 100 p.s.JI. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. JolInt opened and leak In bottom plIpe when tested. JolInt had been opened and pipe cut. Joint Is at an anchor and had a leak In the top pipe. Coupling and pipe re-soldered and tested at 100 p.s.I. polarconsult Fleld Trip Report Ambler September 25. 26. 21k 28. Pipe In a 12 - 25, 1984 JoInt Is at an anchor was opened and couplings exposed, no leaks. JoInt was opened and the top pipe was found to be pulled 1/4 Inch. JoInt was opened and a leak was In the bottom plIpe. There was a dent In the plpe next to the coupling. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. sectlon between 28. and 29. Is 83 feet In length and Is culvert under the main road to the village. This sectlon was tested at 100 p.s.I. alr and found to have no leaks. 29. 30. 31. 32. 33. 34. JKe 36. JoInt had been opened and the top pipe cut earller. Bottom plIpe was cut to test the expanslIon loop. Leak was found In the factory 90° elbow In the top pipe. JoInt opened and couplings exposed. Top pipe cut to test expansion loop. Leak was found In 90° elbow next to Joint No. 29. Flex coupling was Installed. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. JoInt opened and couplings exposed. The bottom pipe and coupling has pulled 1/2 Inch. There was very little solder In the connection. Tested at 100 p.s.I. - Jolnt opened and couplings exposed. No leaks, but top plipe cut to allow for testIng of expansion loop. Flex coupling Installed. Joint at an anchor and not exposed, tested at 100 p.s.1. dJolnt was good. JoInt at an anchor and not exposed, tested at 100 p.s.1. dJolnt was good. polarconsult Fleld Trip Report Ambler September 37. 38. 39. 40. 41. 42. 43. bl 45. 46. 47. 48. 49. 50. Se by 26 53. 54. 12 - 25, 1984 JoInt opened and pipe cut to allow for testing. Flex coupling Installed. Tested at 100 p.s.I. - JolInt not opened. Tested at 100 p.s.I. - Jolnt opened and couplings exposed,-no leaks. 90° elbow which had been cut earller. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Jotnt had been opened and both plpes had been cut. Flex couplings Installed. JolInt had been opened and both plIpes had been cut. Flex couplings Installed. Joint Is at the factory 33° bend and not opened. Tested at 100 p.s.I., no leaks. JoInt between factory 33° bend and an anchor. Tested at 100 p.s.I., no leaks. Tested at 100 p.s.I. - Jolnt not opened, no leaks. Tested at 100 p.s.I. - joint opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. Tested at 100 p.s.I. - Jolnt opened and couplings exposed, no leaks. polarconsult Fleld Trip Report Ambler September 12 - 25, 1984 55. Jolnt opened and leak In the bottom plIpe and coupling. Flex coupling Installed bottom plIpe. 56. Joint opened and both pipes had pulled out of the couplings 1/2 Inch. Very little solder was noted and after the sleeves had been cut out, the pipe sections. were pulled out of the couplings by hand. Flex couplings Installed. 57. Jolnt at anchor, not opened. Tested at 100 p.s.I., no leaks. 58. Jolnt at anchor, not opened. Tested at 100 p.s.I., no leaks. 59. Tested at 100 p.s.JI. - Jolnt opened and couplings exposed, no leaks. 60. Tested at 100 p.s.I. - Joltnt opened and couplings exposed, no leaks. On September 24, the entire system was tested from the pump house to the School and to the Module. The return line was tested at 100 p.s.!I. with alr for 4& hours with a 2 p.s.I. pressure drop. This was assumed to be from the coollng of the alr, due to ground temperature. The supply line was tested at 100 p.s.I. for 2 hours with only a slight drop In pressure. Repairs to the system were completed at 7:00 pm, all Jjoltnts foamed, shrink sleeves Installed and the area backfilled. The crew returned to the Job after the evening meal and charged the system with glycol. On the 25th, the alr was removed from the lInes and the system was put Into operation. polarconsult Fleld Trip Report Ambler September 12 - 25, 1984 Observation at the time the Jolnts were opened showed the followlIng: 1. Shrink sleeves for the most part were well bonded to the outer Jacket. One Jotnt where the top section of the shrink sleeve strip was left off and covered by sheet metal and had molsture In the Insulation. 2. $%In the JoInts that had water or glycol between the plIpes and the Insulation, there was very little bond between the two. Where the JolInts were dry, the bond between the plpes and Insulation was good. 3. In some cases, the foam on the Jolnts appeared to have been compressed on the pipe sections and had pulled away. This gap between the factory foamed sections and the fleld foam was as much as one Inch. 4. When the factory 90° elbows at the expansion loops were opened It was noted that the flberglass Insulation had been compressed as much as 2 1/2 Inches on the hot side of the pipe. 5. It was noted that JoInts which were leakIng were In most cases due to lack of solder between the plpe and couplings or there was physical damage to the carrler pipes. In two cases the sections of pipe, after belng cut out the line, was removed from the coupling by tapping the pipe with a wrench, polarconsult Fleld Trip Report Ambler September 12 - 25, 1984 6. Of the 59 Jolnts numbered, there were leaks In the following: 8, 18, 22, 23, 24%, 26, 27, 33, 44, 45, 55, and 56, for a total of 12 made In the fleld. No. 40, which Is a factory 90° elbow and three other factory JolInts leaked for an overall total of 16. In some cases, both of the carrler pipes leaked while In others only one pipe leaked. Total number of leaks at plpe and coupling or 90° elbows was 20. Flex couplings Installed: No. 8 - 2 No. 29 - 2 ea 300 16 - 2 33) a 17-1 34-1 18 - 1 B=) d 22-1 44 - 2 23 - 2 45 - 2 26 - 1 Doll 27) 1 56 - 2 Total flex couplings Installed: 25. Repaired Jolnts: The flex couplings has a loose fIx on the bell end and have an Inside dimension length of 3/4 Inch to fit over the pipe or to fit Into the slip sleeve. The orlgtnal coupling allowed the pipe to slip In 1 11/16 Inch to provide a surface for the solder. What effect this may have on the strength of JoInt Is not known. It would appear to be a weaker Joint, but the coupling wlll allow for some movement in compression and tension. Solder used for the repalrs was 95-5 and some fittings wiped with 50-50. polarconsult Fleld Trip Report Ambler September 12 - 25, 1984 After the flex couplings were Installed they were wrapped wlth flberglass Insulation before the JoInt and were foamed. This was done to keep the foam away from the coupling to allow It to move during heatIng and cooling of the system. The new shrink sleeves Installed are longer than those removed, so when applied there was an overlap of approxli- mately 10 to 12 Inches. The old shrink sleeves were about 3 Inches short and required a narrow strip to close the gap when Installed. QeuwerE Caner~ Duane Carson Civil /Jkb cc: / Structural Engineer Mr. Jerry Larson, Alaska Power Authority 2 18° factory Benes Load Cross “7 ok *G. Misalitemen’ Ve" “ AS OK #4 0& 3 Ok oints tested iia 2 _ 100 P6/- A/F” #8 Top pie pulled Ye' -Alex Couplings installed TOP and Boom pipes BOr - ZOn aie [ 20% a Jon t cut ty dest | Go? Elbows * Alex Coup/ngs sftalled- Leak lh Go E/Low Botem pie — beak in 90° E/bour Fackary fataty— aoe eed z oO’ I Zo / a | g é eo 1G 42 #7 o& 4s o£ Hip 4 OK HB Top ee, Car 7 ok Ok. Bree ee a Ve #. iS cor to ms fall « 1-Aex Coupling installed] [~ 72K Couplings 125telle). Zo' Zo* ZO a #7 a # “28 mee ce —. ah 422 Jonk Lomeeds 422. Leak ih bots, ina ° Berlhar pe “Tabage og Z LB CC p 2-flex Coup! ines tastilled | Pile Couphiig Meshelle! - sod deag~ lia =: Suis “ Lote 2 Eyes epee PA f ea eee IO Ci/ 7 JAB a ee [PAO LG a “Sry 5 JSoL b2—e Lin PPCT 1 €8 | PYGrY buono xe! ——7150 C0] OF PoP at age 7 bufldrog wags by an re af ft Fa: pie, eee hror~ yz 4 peyrd — ue aid “oid Sop W/ Y*3 ig - acd dos Var cugouy by y Vor Lig 79 “ya Le Pile 5% 24, Lae 82, | — ~Oa ,Oe 4? x Ei ? Le Ww py eee ES Caclory a fa! 26 Za! Zo’ #ds # 4p Aya Hs Botte pipas Adee Bath? yee ae rencred ebony Tl LEP USP tiOn-~ § Laplerainspel Lier — QF J) 2-H Cpe p/rgs 2-FVCf ONLOIII9F 458 458 f ¢57 7esxe - “ati 7oops/ QF) LL: oD oO Jeeves os, fib AS Lisp, par el aL ci EEG, ee Cure Joint #8 - Top pipe on the left of photo has pulled out of the coupling approximately 3/16 of an Inch. Leak In bottom pIipe at the 90° elbow In the factory bullt part of the expansion loop. Next to JoInt #15. Leak In bottom pipe at the 90° elbow In the factory bullt part of the expansion loop. Next to Joint #16. Jolnt #18 - Plpe had been cut at an earller Inspection trip. Jolnt #22 - Leak In bottom plIpe. No Indication of the plpe belng pulled out of the sleeve. Joint #23 - Plpes had been cut at an earller Inspection trios Joint #24 - Small leak In the top pipe at the coupling. This JjJolnt fis next to first anchor from the Heat Recovery Module. Jolnt #26 - The section of plIpe In the middle of the Joint had out of the coupling on the left approximately 1/4 Inch. Joint #27 - Leak In the bottom pipe. A dent was noted In the pipe next to the coupling. JoInt #29 - Pipe had been cut during an earlier Inspection trip. Leak In top pipe at the 90° elbow In the factory bulit expansion loop, next to Joint #29. JolInt #33 - The bottom pIpe on the left had pulled out of the sleeve approximately 1/2. tnch. The pulled sectlon showed slIigns of very little solder tn the connections. Joint #40 - This Jolnt Is In the factory bulit 90° elbow next to the water treatment bullding. The pipe had been cut during an earller Inspection trip. JoInt #44 - Pipes had been cut during an eariler Inspection trip. *BujLdnos ey 40 4NO pat{nd Bujeq edjd 843 43° SUB{S ON ‘edjd wWo4340q EY UJ yYeaT - SSH AUjON *dj4q uojyoedsuy 4e;[4e8 ue Bujunp 3nD5 ueeq pey sedig - Sh# UulOP Joint #56 - Both pipes have pulled approximately 1/2 Inch out of the couplings. Very little solder was noted In the connections. When sections were cut out the sections of pipe on the right of the coupling were removed from the couplings by topping them with a wrench, JoInt #8 - After the Installation of flex couplings. Joint #29 and factory 90° elbow - Flex couplings and new 90° elbow Installed. Leak was In the 90° elbow, which had been soldered at the factory. JoInt #33 - Flex coupling Installed. Note wood wedges used to separate the two carrier pipes so that the coupling could be Installed. Jolnt #40 - New 90° elbow Installed. JoInts #4 and #5 - Joints were not opened at this anchor. Anchor Is located between Module and the first road crossing. Jolnts at the anchor and the road crossing were tested at 100 p.s.Ii. alr for two hours with no pressure loss. Joint #56 - Flex couplings wrapped with fiberglass before the Joint was foamed. JoInt #28 - Tested at 100 p.s.I. alr, no leaks and the JolInt was dry. Foam Insulation was bonded to the carrler pipes. polarconsult alaska, inc. ENGINEERS ¢ ARCHITECTS * ENERGY CONSULTANTS December 20, 1984 J.B. Mechanical Contractors, Inc. P.O. Box 2549 Kirkland, WashIngton 98033 Attention: Mr. John Barringer Reference: Rural Energy Program, Contract No. APA-83-C-046B Subject: Completion of Punch List Items / Final Inspection Serlal Letter: 046B APA-39 Dear Mr. Barringer: This communtcation confirms our recent discussion stnce I met you at St. Mary's In November. We made a trip on December 10, 1984 to Inspect your work efforts on the final punch list, but we noted that two Items yet remaln. They are: o A Leak in the supply line Instde the Cold Storage Bullding, and o Btu meter In Cold Storage Bullding does not work! Correction of these two Items should complete your work under the guarantee proviston of your Contract. Should you have any further questlons on this subJect, please feel free to contact this office. Sincerely yours, POLARCONSULT ALASKA, INC. orris J. Turner, P.E. | Manager L /jkb cc: Mr. Jerry Larson, Alaska Power Authority 2735 EAST TUDOR ROAD ¢ SUITE 201 ¢ ANCHORAGE, ALASKA 99507 ¢ PHONE (907) 561-1933 e TELEX: 26708 PCA AHG polarconsult alaska, inc. ENGINEERS * ARCHITECTS * ENERGY CONSULTANTS December 6, 1984 Rockford Corporatton P.O. Box 10-1706 Anchorage, Alaska 99511 AttentIon: Tom Hebnes Reference: o Rural Energy Program / Contract APA-83-C-045B. o Our Serlal Letters: 58, dated February 16, 1984; and 65, dated October 16, 1984. Subject: . Punch List Items Serial Letter: 045B APA-66 Dear Mr. Hebnes: This communication confirms some of our recent discusslons on the yet outstanding punch list Items and recent/previous punch list, problems noted during our most recent Inspection, i.e.: ve SHUNGNAK: ° Leak by an elbow on the above ground district heating lIne close to the school. This leak has previously been noted to Rockford for corrective action. 2. AMBLER: ° Inside the heat recovery module, there Is a small leak above the floor penetration on the outgoing line. The system Is down to 4 psi and Is not operating well Cseems like the pumps are surging due to air in the line). ° Radiator controls are broken (step controller no longer works - this Is a long outstanding problem). 3. SAVOONGA: ° There Its a leak on the above ground district heating line at the elbow right outside the school boiler room. ° There Is a leak Inside the school boller room above the floor penetration. 2735 EAST TUDOR ROAD e SUITE 201 *® ANCHORAGE, ALASKA 99507 ¢ PHONE (907) 561-1933 © TELEX: 26708 PCA AHG - polarconsult 045B APA-66 December 6, 1984 Page 2 4q, GRAYLING: ° The fan motor on the right radiator Is burned out. Please let us know when these punch list Items have’ been corrected, since this should complete your responsibility under the Guarantee Provisions of the Contract except for the Ambler piping. Should you have any questlons on the above, please feel free to contact this office. Sincerely yours, POLARCONSULT ALASKA, INC. eae a orris J. Turner, P.E. Project Manager /Jkb cc: Mr. Jerry Larson, Alaska Power Authority