HomeMy WebLinkAboutRural Energy Waste Heat Program-Final Report Volume I 1983WAS
007
Vol, 1
RURAL E
WASTE HEAT PROGRAM
electrical
power
water jacket
Waste Heat Management Contract No. CC 08-3007
FINAL REPORT
Volume |
PROJECT SUMMARY
FOR THE VILLAGES OF
Kiana, Ambler, Shungnak, Savoonga, Elim,
Kaltag, Grayling, Goodnews Bay and Angoon
St. Mary’s and Unalakleet
ANCHORAGE ALASKA
DECEMBER 1983 _———"—ALASKA POWER AUTHORITY
polarconsuit alaska, inc CONSULTING ENGINEERS AND PLANNERS
polarconsult
ALASKA POWER AUTHORITY RURAL WASTE HEAT PROGRAM FOR THE VILLAGES OF AMBLER, ANGOON, ELIM, GOODNEWS BAY, GRAYLING, KALTAG, KIANA, SAVOONGA, SHUNGNAK, ST. MARY'S, AND UNALAKLEET
FINAL REPORT - VOLUME I
December 30, 1983
POLARCONSULT ALASKA, INC.
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TABLE OF CONTENTS
Description Page
VOLUME I - PROJECT SUMMARY
SUMMAGY sac kee eS NRE SEE 1
DISCUSSION asneneanens HMPRE TEN MRSS TAMER RE SSS eannas oneemn 3
Construction Management Services Contract Status ........ 6
(Contract No. CC 08-3007)
Construction Management Services Work Accomplished ...... 7
Const ructfon Contract Status scsseas DUKE RS TRB DAV TH Hse ee we 12
Contractor Funding Status ..... eee oe oe ee ee se dead s ues o ~. 17
Suggestions for Future Contracts scsissacse ses sets tae sees 20
VOLUME II
Appendix
Appendix
Appendix
Appendix
Appendix
VOLUME III
A
Appendix F
APPENDIX A THRU E
Contractor Schedule Summa
Construction Contract Mod
Waste Heat Recovery Econo
List of Village, School,
Trip Reports
APPENDIX F
Progress Photographs
ry
ification Status
mics
and Utility Contacts
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SUMMARY
A Professional 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 CMS was
December 1, 1982 through December 31, 1983.
Polarconsult represented the Alaska Power Authority on the
following work:
° Review of the Design Engineers' work under two separate
design contracts (Raj Bhargava for nine villages and
CMH/VITRO for four villages).
° Preparation and advertisement of bid documents.
° Review of bids and preparation of contract documents.
° Overseeing the award of four construction contracts for
eleven villages:
1) Washington Mechanical for the village of Angoon
CContract 045A).
29) Rockford Corporation for the villages of Kiana,
Ambler, Shungnak, Savoonga, Elim, Kaltag,
Grayling, and Goodnews Bay (Contract 045B).
3) Wick Construction for the village of Unalakleet
CContract 046A).
4) J.B. Mechanical for the village of St. Mary's
CContract O046B).
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° Construction monitoring CCMS) for
contracts including such work as:
1)
2)
3)
4)
5D
Shop drawing approvals.
Field inspections.
Contract modification processing.
Project start-up monitoring.
Reporting to APA.
all construction
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DISCUSSION
Polarconsult received Notice to Proceed (NTP) with Contract work
on January 21, 1983. The delay in receipt of Notice to Proceed
of approximately 50 days affected the planned schedule for
Contract bid advertisements, evaluations, and awards. While all
Contract work was completed by the various contract completion
dates, the noted delay, most likely, had some adverse effects on
project cost.
The CMS Contract is broken down into three (3) phases:
° Phase I - Preconstruction.
° Phase II - General Construction.
° Phase III - Post Construction, Waste Heat Recovery
System start-up.
Within these three phases, there are five (5) major tasks which
have thirty-six (36) separate work items. The major tasks are
broken down as:
° Design Review and Cost Estimating (Phases I and II).
° Scheduling (Phases I, II, and III).
° Contract Administration for Construction and Procure-
ment Contracts, CPhases I and II).
° Administration of General Construction (Phases I, II
and ITI).
° Field Inspection, Start-up and Training (Phases II
and III).
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Preconstruction consisted of design reviews of Raj Bhargava and
CMH/VITRO work, government cost estimates for construction;
preparation of bid documents excluding technical plans, adver-
tisement of nine (9) and four C4) villages Creduced to three by
addendum); two separate bid openings, from which four contractors
were judged to meet the Alaska Power Authority's Bid require-
ments; evaluation of Contractor Bids and recommendations of award
to Alaska Power Authority; and Preconstruction Conferences.
Following Contract award, shop drawing approvals and mobilization
were critical activities in order for the Contractors to meet
last barge shipments to Alaska. In some cases Contract award
came too late and shipments had to be by air.
The majority of the field construction work was scheduled to be
completed during August, September, and October, 1983. As usual,
those villages with the best contractor superintendents were
completed ahead of schedule, with excellent workmanship, and
outstanding community relations.
It should be noted that while contracts were not able to be
awarded until the construction season was upon them, the
construction contractors were able to perform within very tight
logistical and environmental Cweather) constraints. They
completed their work on schedule with few change orders.
Overall, they are to be commended for their work efforts under
difficult circumstances.
Start-up took place over a two month period with Angoon being the
first project on line and St. Mary's the last. It was estimated
that the Construction Manager (CCM) would make 48 site visits,
in actuality 102 have been made to date. Generally, the CM tried
to make a field inspection trip to each village once a week when
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work was In progress. The estimated average of four trips per
village, compared to the actual nine per village would have been
Insufficient to adequately cover the project work. Increased
coverage of each village was made possible due to the savings the
CM was able to make in travel to and from the work sites. With
adequate office and field coverage by the CM, claims and change
orders were minimized.
Additional information on this discussion is covered in more
detail in the various sections of this report.
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CONSTRUCTION MANAGEMENT SERVICES CONTRACT STATUS
CCONTRACT NO. CC 08-3007)
Polarconsult was able to respond to the project needs as
stipulated or required. The significant work efforts by the
Construction Manager included:
° Review and re-review of designer's technical plans and
specifications.
° Preparation of Invitation for Bid CIFB) documents,
advertisement, control, addendums, and Bid openings.
° Review of Contractor's shop drawings and work plans a ¥
and schedules.
° General contract Administration.
° Numerous field inspections of construction work at each
village.
fo} Preparation of separate field trip reports to the
various villages. Copies of these are included in
Volume II as Appendix E.
° Final Inspections and project start-up at each village
with representation from the Utility Owners, Village
Leaders, School District personnel, Designer, Alaska
Power Authority, Contractor and Construction Manager.
° Liaison between the villages, the utilities, APA, and
the Contractors.
While the Construction Management Service contract has overrun
budget items in some tasks, others have underrun. From an
overall cost and schedule standpoint, the Construction Management
Service contract will be completed within the specified contract
limits.
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CONSTRUCTION MANAGEMENT SERVICE WORK ACCOMPLISHED
As of this Final Report, the following tasks were contracted for
and have been completed, except where noted (*):
Task 1
Task 2
Task 3
Task 4
Design Review and Cost Estimating
a) Review designs for constructability.
b) Prepare funding forecasts for fixed price
Contracts.
c) Review Architectural/Engineering Gost
estimates.
d)* Cost Estimates for Contract Modifications.
Scheduling
a) Prepare overall Construction Schedule during
preconstruction phase.
b) Monitor and maintain Schedules.
oe) Prepare Start-up Schedule.
Contract Administration
a) Recommend Contract packaging.
b) Prepare Invitation For Bid (Call contracts).
ep Assist in advertising for Bidding.
d) Assist in evaluating Bids received and
recommend award.
e)* Administer Contracts.
General Construction Administration
a) Procure and Manage long lead items.
b) Monitor Contractor submitals / keep records.
eo) Provide quality assurance.
d) Review and forward invoices.
e) Provide and enforce safety program.
fe) Cost control and reporting.
g)* Maintain drawings / prepare As-Built's.
h) Enforce environmental requirements
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Task
Constructi
i) Permitting.
J) Photographic project coverage.
k) Geotechnical services.
1) Final project report.
5 Field Inspection, Start-up, and Training
a) 4 trips to 14 sites.
b) Typing Field Reports.
ce) Airfare
d) Per diem.
Minor amount of work remains in these items in closing out the
on Contracts which will not be fully accomplished until
the end of January 1984.
Major milestones of work accomplished were:
° Maintained close coordination and liaison with the
design firm of Raj Bhargava for the nine villages CIFB
045) and Crews MacInnes Hoffman/VITRO for the two
villages CIFB 046).
Preparation of two separate IFB documents, including
designs and technical specifications and plans.
Preparation of government cost estimate for four C4)
villages and review of Architectural/Engineering costs
estimates for nine (9) villages.
Reproduction and issuing of plans and specifications to
Contractors and suppliers, Including mailing and
refunding (where applicable) and cost accounting for
all documents issued.
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Two Invitations for Bids CIFB):
1) APA-83-R-045 Cwith three addendums)
- Date of issue, March 7, 1983
- Bid opening, April 14, 1983
- For the 9 villages of Kiana, Ambler, Shungnak,
Savoonga, Elim, Kaltag, Grayling, Goodnews Bay,
and Angoon
- 75 sets of plans and specifications were issued
2) APA-83-R-046 Cwith one addendum)
- Date of issue, April 13, 1983
- Bid opening, May 10, 1983
- For the 4 villages of Hooper Bay, St. Mary's,
Tanana Cdeleted by Addendum #1), and Unalakleet
- 55 sets of plans and specifications were issued
Pre-Bid conference held for IFB APA-83-R-045 on March
16, 1983.
Bid openings held on April 14, for nine (€9) villages;
and May 10, 1983, for four (4) villages.
Bid evaluations and Contract award recommendations on
April 14 and 15, for IFB 045 and on May 10 and 11, for
IFB 046.
1) Seven (7) Bidders responded to four (4) separate
schedules of IFB 045. Successful Bidders were:
- Rockford Corporation of Anchorage, Alaska for
the eight (8) villages of Kiana, Ambler,
Shungnak, Savoonga, Elim, Kaltag, Grayling, and
Goodnews Bay with a Bid of $2,264,000.00 (7%
less than the government estimate).
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- Washington Mechanical of Seattle, Washington for
the village of Angoon with a Bid of $189,981.00
(7% more than the government estimate).
2) Four (4) Bidders responded to two (2) separate
schedules of IFB 046. Successful Bidders were:
- Wick Construction Company of Anchorage, Alaska
and Seattle, Washington with a Bid of
$621,000.00 (30% more than the government
estimate, but within 4% of the next lowest
Bidder).
- J.B. Mechanical of Kirkland, Washington for the
villages of St. Mary's and Hooper Bay with a Bid
of $784,428.00 (13% less than the government
estimate).
° Preconstruction conference for nine (€9) villages CIFB
045) held on May 18, 1983, for Rockford Corporation and
Washington Mechanical.
° Preconstruction conferences for three (3) villages CIFB
046) held on June 20, 1983, for Wick Construction and
on July 13, 1983 for J.B. Mechanical.
° Assistance to the Alaska Power Authority in securing
Rights of Entry permits from the various villages.
° Forwarding of letters and Progress Reports to village
leaders, local utility companies, school districts, and
political representatives to inform them of the ongoing
waste heat recovery work in these villages and point of
contact, should they have any questions.
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Notification to the Department of Labor of two Contract
awards Ci.e., nine (€9) villages with Rockford and
Washington Mechanical).
Monitoring of field construction.
Monitoring of local hires versus non-residents.
Contract administration.
Prefinal and final inspection of the construction and
system operations of each village waste heat system.
Operator training.
Contract close-out.
Final Report to Alaska Power Authority.
LL
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CONSTRUCTION CONTRACT STATUS
All construction Contracts are substantially complete. The first
village system, Angoon, was judged operational on September 26,
1983 and the last, St. Mary's, on November 30, 1983. While some
known minor problems exist, they will be handled under the
guarantee provisions of the Contract rather than holding the
Contracts open.
Wick Construction CContract 046A - Unalakleet) has completed all
work and the Construction Manager recommended to Alaska Power
Authority that their Contract be closed out on December 8, 1983.
Washington Mechanical CContract 045A - Angoon) is complete with
the exception of final paper work, i.e. lean release, guarantee,
operation manual and revision to the plans Cas-built drawing
mark-up). It is estimated this should all be completed by mid
January, 1984.
Rockford Corporation CContract 045B - Kiana, Ambler, Shungnak,
Savoonga, Elim, Kaltag, Grayling, and Goodnews Bay) is complete
with all field work. They have yet to complete processing of one
authorized change order. Additionally, they have not-~ yet
forwarded to the Construction Manager any project close-out data.
We estimate, this work should all be completed by January 31,
1984 -provided they can get the system BTU” meters fully
functional.
J.B. Mechanical (CContract 046B - St. Mary's) work Is substan-
tially complete. They have indicated possible claims In two
areas which the Construction Manager has not yet received.
As with Rockford Corporation, there remain only field punch list
items of work. However, the Construction Manager has- not
received any Contract close-out data from J.B. Mechanical. It is
estimated that close-out of this Contract will also take place by
January 31, 1984.
xe
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It should be noted that each Contractor must guarantee their work
for a period of one year. This Is the same period the respective
utilities will be evaluating the system. Even though the systems
are operational, Alaska Power Authority can expect’ various
exchanges between the consumer, the utilities, and the Contractor
during this period.
Photos depicting typical heat recovery module, interior piping
and exterior piping are included herein for general information.
Additional project photos are included in Volume III, Appendix F.
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Typical Heat Recovery Module at an AVEC Village.
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Typical Interior Piping Connecting Utility Generators
to the Waste Heat System.
15)
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Exterior Waste Heat Piping from the Utility to the Consumer.
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CONTRACTOR FUNDING STATUS
The original Contract awards were as follows:
° Washington Mechanical - Village of Angoon, $189,981
° Rockford Corporation - Eight (8) villages, $2,154,000
° Wick Construction - Village of Unalakleet, $621,400
° J.B. Mechanical - Village of St. Mary's, $432,011
INITIAL CONSTRUCTION CONTRACT BIDS TOTALED:
11 villages = $3,397,392.00
Construction change orders have been issued to the Contractors in
the following amounts:
° Washington Mechanical CO4S5A) - $1,132.93
° Rockford Corporation €045B) - $47,045.58
° Wick Construction CO46A) - $1,997.00
° J.B. Mechanical (C046B) - $6,337.00
Construction claims against the Alaska Power Authority have been
denied to:
° J.B. Mechanical (€046B) for four claims in the amount of
$6,154.00
fo} Rockford Corporation for one claim in the amount of
$3,061.00.
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Potential known construction claims outstanding are:
° Rockford Corporation €045B) - $4,000+
° J.B. Mechanical (€046B) - $50,000
Assuming all potential claims are allowable total project
construction costs would be approximately $3,500,000. This
represents only a 2 1/2% cost increase for design and field
condition changes over 11 different areas in Alaska. This is
considered quite remarkable for remote projects of this type.
Volume II, Appendix B provides a summary of all change orders to
date.
The following table provides a current Contract Status Summary
for each of the various construction contracts.
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ALASKA POWER AUTHORITY - RURAL ENERGY WASTE HEAT PROGRAM
CONTRACT STATUS
December 30, 1983
ORIGINAL SPENT APPROVED PENDING ESTIMATE AT = CONTIN- TOTAL
ITEM DESCRIPTION CONTRACT TO DATE CHANGES CHANGES __ COMPLETION GENCY 3 BUDGETED
Construction
Contracts:
1. Rockford 1,2
Corporation $2,154,000 $2,194,226.01 ” $47,053.58 $4,000.00 $2,205,053.58 $102,946.42 $2,304,000
2. Washington 1,2 Mechanical 189,981 170,983.00 ~’ $1,132.93 -0- 191,113.93 15,000.00 204,981
3. Wick 1.2
Construct ion 621,400 623,397.00 ~” 1,997.00 -0- 623,397.00 48,003.00 671,000
4. J.B. 1,2
Mechanical 432,011 385,622.00 ” 6,337.00 54,000.00 492,388.00 30,000.00 462,011
Construction 6
Management 306,000 284,941.10 -0- 306,000.00 -0- 306,000
Engineering 127,000 113,166.30 3 ; - 13,833.70 127,000
Owner Costs 85,008 i“ * 55,000.00 140,008
TOTAL $3,915,400 $3,772,335.41 $56,520.51 $58,000.00 i $264,783.12 $4,215,000
Billed through December 30, 1983.
Includes retained percentage by APA.
Original (to date unknown).
Not known.
APA original.
Billed through November 27, 1983. nou FW NH }JNsuodejod
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SUGGESTIONS FOR FUTURE CONTRACTS
In administration of the Constructlon Management Service Contract
few major problems were encountered.
The following summary depicts those items where improvements may
be possible:
° While the work was completed in one construction
season, we believe lower Contract cost would have been
realized if the design work, including reviews, had
been completed so that Invitation for Bids could have
been issued in early January, 1983.
° Permits, Easements, Rights-of-Way, and operational
agreements between the Utilities and the Consumers
should be in hand before Contracts are signed. We
believe this would promote better understanding of how
projects of this type benefit each community.
° While we recognize the cost implications, upgrading of
some of the Utilities' facilities would be in _ the
economic interest of the community. Possibly the
Utility should have provided some funds for upgrading
so that the entire system would be more compatable.
For example, new support timbers should have been used
in connection with the tank relocations at Kaltag.
° Heat Recovery Modules should have been larger, rather
than 8' x 12' they should be 8' x 16" or 10' x 16.
There was insufficient room for the mechanical and
electrical equipment. Consequently, maintenance will
be difficult and safety becomes a special concern when
working on the electrical panels, since NEC clearance
requirements for panels has not been met.
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Better BTU meters should have been specified. We are
having problems in many of the villages getting what we
believe are realistic readings. Since these will
effect the cost to the consumer and will be used to
judge the operational efficiency, they should be as
accurate and all encompassing as possible.
More use should be made of welded connections and less
of Victaulic Fittings. We believe this would provide
overall a more structurally sound, leak proof system.
Better arctic pipe should have been specified. The
Rovanco Arctic Pipe specified was of inferior quality
for below grade applications. A high quality arctic
pipe from an experienced manufacturer should be
specified. It appears that steel pipe foamed in place
In a polyethylene jacket is a more durable design.
Pipe sections should be welded together and jackets
should be joined using steel muffs Instead of shrink
sleeves.
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