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HomeMy WebLinkAboutRural Energy Waste Heat Program-Volume II 1983WAS 007 vol, 2 | Anchorags, Alaska 9 _ RURAL ENERGY WASTE HEAT PROGRAM electrical power Waste Heat Management Contract No. CC 08-3007 FINAL REPORT Volume Il APPENDIX A thru E FOR THE VILLAGES OF Kiana, Ambler, Shungnak, Savoonga, Elim, Kaltag, Grayling, Goodnews Bay and Angoon St. Mary’s and Unalakleet ANCHORAGE ALASKA DECEMBER 1983 ecasite Se c LL LALASKA POWER AUTHORITY polarconsult alaska, inc CONSULTING ENGINEERS AND PLANNERS 2 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 II December 30, 1983 POLARCONSULT ALASKA, INC. polarconsult TABLE OF CONTENTS Description Page VOLUME II -— APPENDIX A THRU E Appendix A - Contractor Schedule Summary Appendix B - Construction Contract Modification Status Appendix C - Waste Heat Recovery Economics Appendix D - List of Village, School, and Utility Contacts Appendix E - Trip Reports RURAL ENERGY WASTE HEAT REVISION .#3 SEPTEMBER 30, 1983 ay ; May 28 |June 4 | uut. 3 | octslost22 Oct29 |Nov. 5 _|Nov.12 |Nov. 19 | Nov.26 EARTHWORK AMBLER’ ANGOON EUM ee S | GOODNEWS BAY __ nici GRAYLING © © : : KALTAG KIANA ST. MARY'S ; SAVOONGA : : ; SHUNGNAK UNALAKLEET es | OUTSIDE PIPING | | AMBLER | See ee ANGOON | ELIM GOODNEWS BAY SRAYLING Se = KALTAG KIANA : Se | | q { < { { ST. MARY'S SAVOONGA SHUNGNAK oa UNALAKLEET Su a8) INSIDE PIPING and TIE- Ue AMBLER” 3 3 ANGOON SELIM = GOODNEWS BAY GRAYLING KALTAG KIANA ST MARY'S SAVYOONGA SHUNGNAK pee oe INSULATION AMBLER Soo ANGOON ELIM GOODNEWS BAY GRAYLING KALTAG KIANA : ST. MARY'S “ SAVOONGA ” ‘SHUNGNAK UNALAKLEET ELECTRICAL | AMBLER © i il — ei Si, Ebes ANGOON ELIM. GOODNEWS BAY GRAYLING KALTAG KIANA © | ‘ST. MARY'S © SAVGONGA SHUNGNAK UNALAKEEET DE MOBILIZE) ON and CLEAN- UP AMBLER | ;. ANGOON ELIM- GOODNEWS BAY GRAYLING = 8 KALTAG SAVOONGA SHUNGNAK b UNALAKLEET foie kif ae—s sttsesenes WORK AS ORIGINALLY SCHEDULED * WORK COMPLETED polarconsult APPENDIX A CONTRACTOR SCHEDULE SUMMARY polarconsult APPENDIX B CONSTRUCTION CONTRACT MODIFICATION STATUS Necessary Contract modifications due to design changes or field changed conditions have been few. While three potential claims remain unresolved as of this report date, we do not expect these to be significant, cost wise. Both approved and potential changes are addressed herein for general information. The following modifications have been processed and approved to date: ° Change Orders 045A-1, A-2 and A-3 were issued to Washington Mechanical. A time extension adjustment of fourteen (14) days was-~ allowed. Price adjustment of $1,132.93 was allowable because of electrical design change. Cont Fact amount now stands at $191,113.93. ° Change Orders 045B-1, B-2, B-3, B-4, B-5 and B-6 have been issued to Rockford Corporation to date in the amount of $47,053.58 which raised their contract amount from $2,154,000.00 to $2,201,053.58. Additionally, time extensions of one (1) day at Shungnak and six (6) days at Kiana were allowed. Changes were necessitated because of design, village and AVEC’ concerns. The biggest price adjustments dealt with village concerns of elevated pipe. These concerns were alleviated through use of culverts and ramps over the waste heat pipe. ° Change Order 0O046A-1 and A-2 have been issued to Wick Construction Company. Contract amount was increased by $1,997.00 because of field changed conditions. This raised the Contract amount from $621,400.00 to $623,397.00. One day additional time was also authorized. polarconsult ° Change Orders O46B-1, B-2 and B-3 were issued to J.B. Mechanical Contractors, Inc. Change Order No. 1 provided a two week time extension because of barge shipping and soil problems that were encountered. Change Order No. 2 was a design change that was Known at the time of Contract award. The price adjustment was $4,438.03 for a larger heat exchanger unit. Field design related Change Order No. 3 was issued to reroute piping in the Mission Building at a cost increase of $1,839.03. Current contract amount now stands at $438,348.03, original contract price was $432,011.02. There are three outstanding known claims yet to be processed. Contractor back-up data for claim justification has either not been received or it has been sent back by the CM for additional information. These claims are: ° Contract 0O45B: Contractor - Rockford Corporation lee Transformer change from 9kVA to 45kVA. CEstimated cost not to exceed $4,000.00) ° Contract O46B: Contractor - J.B. Mechanical Contractors, Inc. be Claims for modification to AVEC building for purpose of hanging pipe. Estimated cost of $2,000.00. 23 Claims for water problems encountered during excavation for buried waste heat piping. Estimated cost of $50,000.00. Three claims by J.B. Mechanical against Alaska Power Authority were rejected since they did not meet the contracted requirements, i.e. not approved in advance by the CM. These denied claims were for an accumulated price adjustment of $5,965.00. polarconsult APPENDIX C WASTE HEAT RECOVERY ECONOMICS (Con an individual village basis): Note: Annual savings are calculated based on current 1983 fuel ofl prices. VILLAGE Ambler UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) CONSUMERS State of Alaska Elementary School CN.W. Arctic-REAA) U.S. Public High School system Fuel Cost $1.70 per gallon Fuel Displaced 17,444 gallons Annual Savings $29,655 Construction Cost $299,700 VILLAGE Angoon ULL Ly. Tlingit-Haida Regional Electric Authority CTHREA) CONSUMERS Sewage Treatment Plant State of Alaska Elementary School CChatam School District) High School Gym Teachers quarters Fuel Cost $1.98 per gallon Fuel Displaced 14,649 gallons Annual Savings Construction Cost $29,005 $189,981 polarconsult _ VILLAGE Elim UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) CONSUMERS State of Alaska High School Bureau of Indian Affairs CBIA) Elementary School (Bering Strait REAA) Fuel Cost $1.60 per gallon Fuel Displaced 16,121 gallons Annual Savings $25,794 Construction Cost $216,500 VILLAGE Hooper Bay UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) CONSUMERS State of Alaska Elementary School (CLower Yukon REAA) Teachers quarters Triplex Fuel Cost $1.58 per gallon Fuel Displaced 37,000 gallons Annual Savings $58,460 Construction Cost 3352417 polarconsult VILLAGE UTILITY CONSUMERS Fuel Cost Fuel Displaced Annual Savings Construction Cost St. Mary's Alaska CAVEC) Mission School Village Electric Co-operative, Inc. Complex CCatholic Parochial) U.S. Public High School water supply City cold storage building $1.68 per gallon 60,000 gallons $100,800 $432,011 VILLAGE Unalakleet UTE Ty Matanuska Electric Association CUnalakleet Valley Electric Co-op or UVEC) CONSUMERS State of Alaska High School (Bering Straits REAA) Fuel Cost $1.65 per gallon Fuel Displaced 85,000 gallons Annual Savings $140,250 Construction Cost $621,400 VILLAGE Kiana UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) CONSUMERS State of Alaska Elementary School (N.W. Arctic REAA) U.S. Public High School system Fuel Cost $1.63 per gallon Fuel Displaced Annual Savings Construction Cost 31,029 gallons S50,577 $279,600 polarconsult_ VILLAGE Savoonga UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) CONSUMERS State of Alaska High School (N.W. Arctic REAA) BIA Elementary School Fuel Cost $1.56 per gallon Fuel Displaced 31,029 gallons Annual Savings $48,405 Construction Cost $248,200 VILLAGE Shungnak UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) CONSUMERS State of Alaska High School (N.W. Arctic REAA) U.S. Public High School water system Fuel Cost $1.77 per gallon Fuel Displaced 30,685 gallons Annual Savings $54,512 Construction Cost $438,500 VILLAGE Goodnews Bay Ul TE Ty. Alaska Village Electric Co-operative, Inc. CAVEC) CONSUMERS BIA Elementary School CLower Kuskokwim REAA) Fuel Cost $1.58 per gallon Fuel Displaced Annual Savings Construction Cost 12,699 gallons $20,064 $189,200 polarconsult - VILLAGE UTILITY CONSUMERS Fuel Cost Fuel Displaced Grayling Alaska Village CAVEC) State of Alaska High School CIditarod REAA) U.S. Public High School system Electric Co-operative, Inc. $1.73 per gallon 19,861 gallons Annual Savings $34,360 Construction Cost $223,000 VILLAGE Kaltag UTED EY: Alaska Village Electric Co-operative, Ine. CAVEC) CONSUMERS State of Alaska Elementary/High School CYukon - Koyukuk REAA) Fuel Cost $1.65 per gallon Fuel Displaced Annual Savings Construction Cost 17,859 gallons $29,467 $369,000 Construction costs are original bid prices and not necessarily as constructed costs (see also Appendix B for As Constructed Costs On) a Contract basis). polarconsult APPENDIX D LIST OF VILLAGES, SCHOOLS, AND UTILITY CONTACTS VILLAGE Ambler SCHOOL Northwest Arctic Schools P.O. Box 51 Kotzebue, Alaska 99572 Telephone: 442-3472 John Rogers MAYOR John Blower General Delivery Ambler, Alaska 99786 UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telephone: 277-6632 Loyd Hodson, General Manager AIR CHARTER VILLAGE Angoon SCHOOL Chatam School District P.O. Box 109 Angoon, Alaska 99820 Telephone: 788-3302 or 788-3682 Darrel Moore MAYOR Wally R. Frank, Sr. P.O), | Box!) /139 Angoon, Alaska 99820 UL: Tlingit-Haida Regional Electric Authority ‘ P.O. Box 2517 Juneau, Alaska 99803 Telephone: 789-3916 Bill Chabot, Loren Karro AIR CHARTER Channel Air CJuneau) polarconsult CITY Elim SCHOOL Bureau of Indian Affairs P.O. Box 1108 Nome, Alaska 99762 Telephone: 443-2284 George Walters UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telephone: 277-6632 Loyd Hodson MAYOR Joseph Murray, ur. City of Elim General Delivery Elim, Alaska 99739 AIR CHARTER Bering Air CNome) Ryan Air CUnalakleet) Telephone: 624-3200 Ghiiy, Goodnews Bay SCHOOL Lower Kuskokwim Schools P.O. Box 305 Bethel, Alaska 99559 Telephone: 543-3611 Jim Kass, Carl Peterson CSuperintendent) UPRTEDTY Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telephone: 277-6632 Loyd Hodson MAYOR Maggie Scholtz : City of Goodnews Bay General Delivery Goodnews Bay, Alaska 99589 AIR CHARTER Yute Air CCharter) Telephone: 842-5333 polarconsult Ciiy: Grayling SCHOOL Iditarod Area Schools P.O. Box 105 McGrath, Alaska 99627 Telephone: 524-3599 Darrie Rempel, Dave Shelborn UTLEY, Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telephone: 277-6632 Loyd Hodson MAYOR Fredie Howard City of Grayling General Delivery Grayling, Alaska 99590 Telephone: 453-5143 AIR CHARTER CH, Kaltag SCHOOL Yukon Koyukuk Schools P.O. Box 00309 Nenana, Alaska 99760 Telephone: 832-5594 Mike McCarty UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telehone: 277-6632 Loyd Hodson MAYOR Fred Alexie General Delivery Kaltag, Alaska 99748 Telephone: 534-9219 AIR CHARTER Ryan Air CUnalakleet) Telephone: 624-3200 polarconsult GITY. Kiana SCHOOL Northwest Arctic Schools P. O75) Box) 51 Kotzebue, Alaska 99752 Telephone: 442-3472 John Rogers MAYOR James Gooden City of Kiana General Delivery Kiana, Alaska 99749 Um INET y, Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telephone: 277-6632 Loyd Hodson AIR CHARTER CLiTY. Savoonga SCHOOL Bureau of Indian Affairs 1108 Nome, Alaska 99762 Telephone: 443-2284 George Walters Ui hy: Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telephone: 277-6632 Loyd Hodson MAYOR Carl Pelowook, Sr. City of Savoonga PaO) Box) Lat Savonnga, Alaska 99769 AIR CHARTER Northern Aviation CNome) Telephone: 443-2622 polarconsult CL TY. Shungnak SCHOOL Northwest Arctic Schools P.O. Box 51 Kotzebue, Alaska 99752 Telephone: 442-3472 John Rogers UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telephone: 277-6632 Loyd Hodson MAYOR Robert Mulluk, ur. City of Shungnak General Delivery Shungnak, Alaska 99773 AIR CHARTE CITY St. Mary's SCHOOL UTILITY Alaska Village Electric Co-operative, Inc. CAVEC) 4831 Eagle Street Anchorage, Alaska 99503 Telephone: 277-6632 Loyd Hodson MAYOR Moses Paukan, Sr. P.O. Box 163 St. Mary's, Alaska 99658 AIR CHARTER Wien polarconsult VILLAGE Unalakleet SCHOOL Bering Straits School District P.O. Box 225 ‘ Unalakleet, Alaska 99684 Wa CTY. Unalakleet Valley Electric Co-operative P70 BOX Unalakleet, Alaska 99684 MAYOR Wilfred P. Ryan, ur. P.O. Box 20 Unalakleet, Alaska 99684 AIR CHARTER Wien and Ryan Air CUnalakleet) Telephone: 624-3200 polarconsult APPENDIX E TRIP REPORTS The following is a complete listing of all Polarconsult Alaska, contract period. Jack Turner, James Barkshire Jack Turner Peter N. Hansen Jack Turner, Peter N. Hansen William Davis Jack Turner Jack Turner Peter N. Hansen Peter N. Hansen Peter N. Hansen Peter N. Hansen Peter -N. Hansen Peter N. Hansen William R. Davis James Barkshire, Peter N. Hansen Duane Carson Tner Grayling, Unalakleet, Elim, Kaltag, Nome Kaltag Angoon Kiana, Ambler, Shungnak Kaltag, Unalakleet Seattle, Washington Perma-Pipe, Stanford University, Palo Alto California Unalakleet, Kaltag, SteeMary's Nashville and Chicago Ambler, Shungnak Rockford Yard Angoon Angoon Goodnews Bay Ambler, Shungnak Angoon personnel for the field trips made by duration of this June June June June June June June July July July Copies of these reports enclosed herein. 14 - 16, 1983 2251983 235 1983 27, 1983 25 - 27, 1983 28 & 29, 1983 30, 1983 4 - 6, 1983 Iie 12, 1983 28 &€ 29, 1983 August 3, 1983 August 3 - 5, 1983 August 8 - 10, 1983 August 10, 1983 August 11 € 12, 1983 August 17 - 19, 1983 polarconsult TRIP REPORTS CCont.) William R. Davis James Barkshire, William R. Davis, Peter N. Hansen James Barkshire, William R. Davis James Barkshire, William R. Davis, Peter N. Hansen Peter N. Hansen, Duane Carson Peter N. Hansen, Duane Carson Peter N. Duane Hansen, Carson Peter N. Hansen, Duane Carson Peter N. Hansen, Duane Carson Peter N. Hansen, Duane Carson Peter N. Hansen, Duane Carson Peter N. Hansen, Duane Carson Phil Kaluza, Peter N. Hansen Phil Kaluza, Peter N. Hansen Duane Carson, Morris J. Turner Duane Carson Goodnews Bay Unalakleet Elim Kaltag, Grayling St. Mary's Elim Unalakleet Kiana, Ambler, Shungnak Elim, St. Mary's, Unalakleet, Grayling Savoonga Goodnews Bay St. Mary's Unalakleet Kaltag, Elim Grayling, Ktlana, Ambler, Shungnak St. Mary's August 1983 August 1983 August August August August August August 1983 August 1983 16 17 18, 18, 24, 24, 24, 25 30 September September 2, September September September September September € 17, & 18, 1983 1983 1983 1983. 1983 & 26, & 31, 1, 1983 E983 2, 1983 8, 1983 8, 1983 8, 1983 10, 1983 polarconsult TRIP REPORTS CCont.) Phil Kaluza, Savoonga September 12, 1983 Peter N. Hansen Duane Carson St. Mary's September 15, 1983 Peter N. Hansen Shungnak September 15, 1983 Peter N. Hansen Ambler September 15, 1983 Peter N. Hansen Kiana September 15 & 16, 1983 Duane Carson, Unalakleet, Kaltag September 16, 1983 Loren Carlander Grayling, St. Mary's Phil Kaluza, Savoonga September 21, 1983 Peter N. Hansen Morris J. Turner, Kaltag, Grayling September 21 & 22, Loren Carlander Unalakleet, 1983 St. Mary's Duane Carson, Shungnak, Ambler, September 22, 1983 James A. Barkshire Kiana Morris J. Turner, Angoon September 26, 1983 Thomas Longstaff, Peter N. Hansen Peter N. Hansen St. Mary's September 28, 1983 Duane Carson Kiana September 28, 1983 Peter N. Hansen Goodnews Bay October 11, 1983 Peter N. Hansen, St. Mary's October 13, 1983 Loren Carlander Thomas Longstaff, Goodnews Bay October 14, 1983 Peter N. Hansen Morris J. Turner, Kiana October 20, 1983 Thomas Longstaff, Peter N. Hansen Morris uJ. Turner, Shungnak October 20, 1983 Thomas Longstaff, Peter N. Hansen polarconsult TRIP REPORTS CCont.) Morris J. Turner, Ambler October 20, 1983 Thomas Longstaff, Peter N. Hansen Bill McDonald, Unalakleet, Grayling October 21, 1983 Duane Carson Kaltag, Elim Duane Carson St. Mary's October 24, 1983 Morris J. Turner, Savoonga October 26, 1983 Jerry Larson, Peter N. Hansen Morris J. Turner, Shungnak October 27, 1983 Peter N. Hansen Morris J. Turner, Ambler October 27, 1983 Peter N. Hansen Morris J. Turner, Kiana October 27, 1983 Peter N. Hansen Jerry Larson, Goodnews Bay November 1, 1983 Don Bassler, Joe Schneider, Morris J. Turner, Peter N. Hansen Morris J. Turner, St. Mary's November 1, 1983 Peter N. Hansen Tom Hebnes, Grayling November 2, 1983 Jerry Larson, Don Bassler, Art Ronimus, Joe Schneider, Carol Scibel, Morris J. Turner, Peter N. Hansen Tom Hebnes, Kaltag November 2, 1983 Jerry Larson, Don Bassler, Art Ronimus, Joe Schneider, Carol Seibel), Morris J. Turner, Peter N. Hansen polarconsult TRIP REPORTS CCont.) Tom Hebnes, Jerry Larson, Don Bassler, Art Ronimus, Joe Schneider, Carol Morris J. Peter Scibel, N. Hansen Tom Hebnes, Jerry Larson, Art Ronimus, Joe Schneider, Carol Morris J. Peter Peter Duane Peter Duane Peter Duane Peter Duane Duane Scibel, N. Hansen N. Hansen, Carson N. Hansen, Carson N. Hansen, Carson N. Hansen, Carson Carson, Tom Longstaff Joe Schneider, Jerry Peter Peter Peter Larson, IN. Hansen N. Hansen N. Hansen Turner, Turner, Elim Unalakleet St. Mary's Grayling Kaltag Unalakleet St. Mary's St. Marys Unalakleet St. Mary's November November November November November November November December December December LT; 1, 12, 135, 1983 1983 1983 1983 1983 1983 1983 1983 1983 1983 polarconsult Messrs. conducted FIELD INSPECTION TRIP REPORT Kaltag, Grayling, Unalakleet, Elim June 14, 15, and 16, 1983 Barkshire and Turner, of Polarconsult Alaska, Inc., a routine inspection visit of the above named villages. The purpose of these site visits were three fold: @) @2) ¢3) At Kaltag to fleld survey the new property lease of the Alaska Power Authority for the Waste Heat Recovery system for the relocation of the AVEC fuel tanks, the generator module, storage shed, and miscellaneous parts; At Grayling to look at the change which will be required because of a new community center’ being constructed, which will Interfere with the previous location of the heat recovery piping; and General familiarization with planned waste heat recovery systems CWHR) in each village. The followIng points are noteworthy: 1s KALTAG. At Kaltag, we met with Mayor Fred Alexi, and Dale Akell, the AVEC generator operator. We told them the purpose of our visit, and inspected the existing AVEC site as well as the new site to which the AVEC property will be relocated and the heat recovery system installed. We then field surveyed the site, noted the various buildings which will impact the AVEC property being relocated. CIn some cases, these buildings were within the property lines of that area being dedicated to the Alaska Power Authority.) We laid out a tenta- tive plan in the fleld. GRAYLING. We met with Mayor Fred Howard, and went over the WHR distribution system. A small change In align- ment will be necessary to miss the new community center. Mr. Howard was most cooperative and indicated their desires to put a T-section into the heat recovery line, which would allow them to utilize some of the waste heat for heating the community center. (This subject was further discussed with Rockford Corporation on June 20, 1983. Rockford has been directed to provide this T-section in the heat recovery line.) Additionally, there will be a slight modification of the piping, probably requiring not over 10 additional feet of piping as an adjustment to bypass the community center... polarconsult Bia UNALAKLEET. At Unalakleet, we viewed the proposed routing of the heat recovery system piping within the village of Unalakleet. Most of this fs in the city's streets and in a burial configuration. COn June 20, 1983, during a construction conference with Wick Construction and their subcontractor, Melin &€ Sons, we discussed this routing at some length. Mr. Melin suggested some changes which appeared to us to have merit. We asked that Wick give these to us In writing and stated that, if there was no problem with easements or costs, we most lfkely would be amenable to the changes noted.) 4, ELIM. We visited Elim, made a routine inspection of the line routing, including the limestone rock outcrop near the AVEC module. We met with Henry Shaccheus, the AVEC operator, and discussed the purpose of our visit. Sis NOME. At Nome, we met with Mr. Jerry Larson, of the Alaska Power Authority, and reviewed the- proposed changes at Kaltag. The reason we felt that we should stay with the system as designed with a few minor changes. Mr. Larson agreed to this. CThis plan has been drawn up and was given to Rockford on June 17, 1983, and to one of their electrical subcontractor's representative, Doug Sweat, on June 20, 1983.) Additionally, Mr. BarkshIre Cbased on [information from Rockford Corporation) went to the field on June 20, 1983, to meet with Rockford Corporation and their subcontractor, Union Electric; as well as Merlin Johnson, from Unalakleet, who will be doing the moving of the bullding. However, these people were not yet there. Consequently, Mr. Barkshire returned without accomplish- ing anything. It should be noted that, in this particular case, the delays In reference to the work at Kaltag due to Rockford Corporation have not caused any significant problems as to the overall work schedule. However, these delays have Impacted our overall costs as it Is necessary for us to be at the site when this work is started and the move of AVEC property started. We have yet been unable to confirms when the Contractor's people will actually be tn | ‘ehe) | field. Over a pertod of two weeks, we have spent considerable time on the Kaltag site change. Little has been accomplished except our field work on June 15, 1983. Morris) Turner, (Pcie. Project Manager /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kaltag June 22, 1983 Based on our fleld trip to Kaltag of June 15, 1983; a meeting with Jerry Larson on June 16; and discussions with Tom Hebnes, of Rockford Corporation on June 17, the undersigned went to Kaltag to meet with the contractor and his subcontractors based on the minor changes of location of facilities at Kaltag to ensure that all parties understood the changes and that the work was being accomplished as specified. At the job site, I met with Messrs. Doug Sweat, of Union Electric; and Merlin Johnson, from Unalakleet, who was. the sub-contractor for Rockford Corporation to do the earthwork and move the tankages, modules, and miscellaneous equIpment for AVEC. I went over In some detail with Messrs. Sweat and Johnson the changes to the plans pointing out the leased area of the Alaska Power Authority CAPA), and discussed the ensuing work, If.e.: iS Use of the geofabric; ne The dikes for the tankage; Ja Tank tolerances once moved; Es Moving the tankages empty; and Si New location for the AVEC generator plant, AVEC storage module, and miscellaneous equIpment. It also should be noted that at the site there was no Rockford superintendent, which disturbed me. This was subsequently brought to the attention of Tom Hebnes, of Rockford Corporation, polnting out their responsibility as a prime contractor for quality control. Morris J. Turner, P.E. Project Manager /pf cc: Mr. Jerry Larson, Alaska Power Authority Mr. Tom Holmes, Rockford Corporation - polarconsult Purpose of Trip Date Time 6/21/83 3:30 6/22/83 52010 11:00 9:00 10530 11:00 pm pm pm am am am am am pm pm pm pm pm TRIP REPORT NO. 2 Angoon June 21-22, 1983 Site verification of drawings and alteration to coolant piping system as_ requested by contractor. Left office to go to airport. Departed alrport on Western Airlines bound for Juneau. Checked in at Breakwater Hotel. Checked out Breakwater Hotel. Checked in at Channel Flying CCharter to Angoon). Arrived Angoon. Arrived Angoon Power Plant. Met with Rodney Hunter, Power Plant Operator, who was very cooperative. Performed numerous meaSurements at the power plant and took several photographs. Especially the cooling system piping was Investigated as there seems to be some deviance between drawings and actual conditions. Inspected the areas that will be affected by the pipe runs. Due to solls conditions and logistics, trenching could be somewhat difficult. Met with Mr. Darrel Moore, Chatam School DIStrice. Inspected boiler rooms and reviewed plants. Boiler rooms are not expected to present any problems. Mr. Moore was very cooperative and knows Robert Swenson of WashIngton Mechanical personally. Went to Angoon float plane dock to await arrival of Channel FlytIng. (CSeat fare ona charter.) Arrtved Juneau and spent one hour reviewing the Information gathered in Angoon. Boarded Western Airlines to go to Anchorage. Arrtved Anchorage and went to office to do miscellaneous work. Left office to go home. All times are Anchorage times. Peter N. Hansen polarconsult FIELD TRIP REPORT Kaltag June 22, 1983 Based on our field trip to Kaltag of June 15, 1983; a meeting with Jerry Larson on June 16; and discussions with Tom Hebnes, of Rockford Corporation on June 17, the undersigned went to Kaltag to meet with the contractor and his subcontractors based on the minor changes of location of facilities at Kaltag to ensure that all parties understood the changes and that the work was being accomplished as specified. At the job site, I met with Messrs. Doug Sweat, of Union Electric; and Merlin Johnson, from Unalakleet, who was. the sub-contractor for Rockford Corporation to do the earthwork and move the tankages, modules, and miscellaneous equipment for AVEC. I went over in some detail with Messrs. Sweat and Johnson the changes to the plans pointing out the leased area of the Alaska Power Authority CAPA), and discussed the ensuing work, i.e.: I Use of the geofabric; ae The dikes for the tankage; Bre Tank tolerances once moved; es Moving the tankages empty; and Bie New location for the AVEC generator plant, AVEC storage module, and miscellaneous equipment. It also should be noted that at the site there was no Rockford superintendent, which disturbed me. This was subsequently brought to the attention of Tom Hebnes, of Rockford Corporation, pointing out their responsibility as a prime contractor for quality control. MoiiriliSmU ear Uisine Iript lee) Eve Project Manager /pf cc: Mr. Jerry Larson, Alaska Power Authority Mr. Tom Holmes, Rockford Corporation polarconsult FIELD TRIP REPORT Angoon June 22, 1983 Because of the potential piping changes and questions dealing with how to plumb the dual header generator at Angoon, the undersigned visited Angoon and met with Mr. Darrel Moore, of the Chatham School District, and Mr. Rodney Hunter, of the Angoon Power Plant. I went over the site and not only were the objectives of the trip accomplished, it was also noted that we had some areas of problems form the pipe routing as shown on the contract documents to the situation which exists in the field. Subsequently, the piping changes, including the question of the dual header, has been discussed with Mr. Swenson, of Washington Mechanical, with the information being furnished to him in writing. Additionally, we have discussed, on June 28, 1983, with Mr. Larson of the APA, potential fuel routing piping changes, and these are subsequently being addressed to Washington Mechanical for corrective action. As to the later case, there should be no requirements for a change order on the pipe routing. However, on the situation of piping changes in plumbing to the generator module, Washington Mechanical is being directed, by letter, to furnish a price change for this work. Peter N. Hansen Mechanical Engineer /1h cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD) TRIP’ (REPORT Kiana, Ambler, Shungnak June 27, 1983 Site visits were accomplished to the three noted villages, to view: 1. The problem with the elevated pipe at Kiana, as related to us by Rockford Corporation. 2s To view the area of Interference at Kiana with the sawmill. 3. Note the potential changes at Shungnak, based on two new AVEC generators being installed in separate con- tainer modules. 4. General ‘faniliarization with the sites, to compare the contract documents with the existing conditions. The following points, by villages, are noteworthy: Kiana: We met with the mayor, Leonard Hasting, and went over the routing of the piping trom the AVEC gen2rator module to the pump house and to the school. We told him of our concern for a hot pipe being buried In the ice-rich, permafrost area of Kiana, and we suggested that the line be left elevated, but that we would install the above ground piping Cwhich is a different piping system than for a buried pipeline) in areas of concern in a culvert, thereby allowing a free access just between the pump house road and the school, and at the school near the playground. This change will entail about 180 feet of 24" culvert, and will also require the prime contractor to mound up over the pipe. Since the ground is relatively level, a ten percent slope on each side will be maintained. A letter is being sent to Rockford asking for prices for this additional work. It was also noted that the oil piping and electrical dis- tribution lines are different than are shown on the drawing. These will be corrected on the drawing issued to Rockford. No costs would be involved. It was also noted that a new AVEC module and tankage was being installed at Kiana. Additionally, there is chain link fence material and we will be reviewing this with the AVEC Anchorage office to see if there are any changes in the work at Kiana. polarconsult Ambler: We met with John Blower, the mayor, and went over the site conditions as shown on the contract documents are satisfac- tory. No changes or additions to the work were noted. Shungnak: At Shungnak we met with John Douglas, the mayor, and went over the site, and then noted the following: line Potential piping problems exist between the existing AVEC module and the tank farm. This isa high traffic area; pipe is to be elevated in this particular area. We may require the pipe to be put up close to the AVEC dike and a foot bridge built over the pipe in the travel area. Ze Two additional generator modules are being added to Shungnak. Piping tests ae being provided by this contract. 3. Across the street from the AVEC fuel storage, a new village office building is being constructed, and the mayor requested that a tee be installed so that potential waste heat could be used in heating the structure. This will be directed to Rockford for a price quote. ne It was noted that the current routing between the AVEC modules and where the line makes a 90 degree turn to the school along the old, existing sewage lagoon, that the piping is in trafficed areas. Since the pipe in this area is above ground on cripping, it will be moved to the outboard side of the electrical and sewer lines, thereby taking it out of the traffic area. No contract changes envisioned. At Kiana and Shungnak, the mayors noted to us _ potential places where the contractor would be able to house his crews. This information has subsequently been passed on to Rockford for their information and action. Morris J. Turner, P.E. Project Manager /\f cc: Mr. Jerry Larson, Alaska Power Authority Mr. Tom Hebnes, Rockford Corporation polarconsult FIELD TRIP REPORT Unalakleet, Kaltag, Nome June 25-27, 1983 In Unalakleet, visual Inspection was made on various sites and areas of future construction by Wick Construction. Notes are In my file. In Kaltag I met with Messrs. Doug Sweat and Tom Brown. Mr. Sweat is the electrical technician. While touring the site, Mr. Sweat pointed out his plan of action and various problems encountered. Notes taken are as follows: ie Transformer pedestals to be elevated out of frost susceptible soil to 18 inches below top or backfill gravel. 26 Repair O/H power from school generator disconnect and weatherhead to school weatherhead and meter section. Accidental removal by equipment operator. ae Tank Farm Berm/Containment Dyke 60 percent complete. Relocation seems to be as planned. Distances according to marked up plan walked off and checked against plan. Liner (membrane) In place with 3 inch gravel on top. Needs grooming. (See photos.) 4, Abandoned cables may be used for future, providing they are rechecked for continuity, load and marked by phase. 5c H20 treatment plant has 3-10KVA 1 phase transformer with the 1 phases routed in different directions thru adjacent splice box. As Mr. Sweat, the phasing is as follows: Phases to school and airport. Phase B H20 Treatment plant? Phase C picks up remote 37.5 KVA transformer near exist power plant. Phase C needs to be balanced. 6. AVEC personnel have removed one generator complete from existing building to lighten building for moving. Dent in generator end (see photo). Visible damage limited to shroud, Ts Inspected transformers at east generator building. 3-100 KVA 1 phase transformer. 1 short circuit damage; (2) usable. 3-75 KVA 1 phase transformer. 1 short circuit damage; (2) usable. Transformers should be checked visually and electron- ically before installation. polarconsult 8. Mr. Sweat asked if I knew when the general contractor CRockford Corporation) would have a representative on the job site. I said I didn't know. Sr The diesel fuel tanks were being emptied and skids were being assembled for tank relocation. CSee photos.) 10. The existing generator building timbers were inspected and are in good condition. No splits or dry rot. In some cases they have diesel fuel coating. Synopsis Overall progress seems to be on schedule. Communication from AVEC could stand improving. Local labor is not a problem with exception of heavy equipment use. Competent operator for gravel hauling equipment is on site. Mr. Sweat is showing expertise In his performance of duties. Upon returning to Anchorage contact: AVEC Union Electrician APA William R. Davis Project Manager 7ih cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Seattle, Washington and Palo Alto, California June 28-29, 1983 The undersigned went to Seattle, Washington on June 28, 1983, where I met with Mr. Kenny of Kenny Steel, and John Barringer of J.B. Mechanical. In discussions with Mr. Kenny, it was determined that the fab- rication work was being done not in the Kirkland plant, but in Seattle by Pacific Panels at 3530 Rainier Avenue South, Seattle, Washington. Phone number 723-1997, a Mr. Eric Pim in charge. Additionally, Pacific Testing Laboratories at 3220 17th West, Seattle, Washington, 98119, will be the testing laboratory for the specification requirements. The Pacific Panel Company that is making the polyurethane insulated metal skinned panels, has done considerable work in this field. Subsequently met with John Barringer of J.B. Mechanical. He requested that when we go to Saint Mary's, if we could get information on the existing motors which are to be replaced and provide it to him, he'd be most appreciative. Apparently there was some question as to the type motors that exist versus what was shown, since he's going to be providing new two speed motors. Peter Hansen will get this data for him on his trip to Saint Mary's next week. Additionally, Mr. Barringer indicated that he was going to Stanford campus in Palo Alto for a demonstration on field joint- ing of the permapipe and invited me to attend. Inasmuch as this has been a major area of concern on our part, and since this was a substitution from what was specified (this was agreed to by Crews MacInnes Hoffman/VIRTO, the designer, as well), arrange- ments were made to join Mr. Barringer with the Perma-Pipe people on the evening of June 29, 1983, and for the demonstration on June 30, 1983. I then proceeded to locate the Maltby Tank and Barge Company for the shop inspection to be conducted on the morning on June 29, 1983. On June 29, 1983, I met with Mr. Gregory Taylor from Maltby. Went into the shop area, saw the structural members being fabricated, panels being cut, insulation being cut; and also had a chance to observe the area where they apply the epoxy glue resin to the sheet’ metal panels for gluing the Dow styrofoam. I also got to see a number of the panels being constructed for ARCO at Prudhoe Bay, in various stages of fab- rication as well as completed panels. The system looks quite polarconsult good. Northwest Laboratories in Seattle will be the testing laboratory Csee enclosed typical report done for ARCO work). Morris J. Turner, P.E. Project Manager /\h cc: Mr. Jerry Larson, Alaska Power Authority Pacific Testing polarconsult FIELD TRIP REPORT June 30, 1983 Reference: Perma-Pipe Field Test, Stanford University, Palo Alto, California With Mr. John Barringer of J.B. Mechanical, the undersigned attended the field demonstration at Stanford. Six Perma-Pipe people were there, plus personnel from Stanford, where’ the fiberglass jacket was being used to encase high pressure steam- lines. From the standpoint of the field jointing, with the exception of the polyurethane foam around the pipe, the basic fiberglass joint is similar, and consequently the purpose of the trip to observe the trip was appropriate. Personnel conducting the test for Perma-Pipe were Robert Sershon, Mr. Frank Weiss, and Mr. Dwight Knechtl. Enclosed herewith are the installation instructions for Perma-Pipe Drescon-A System, which is the system without the styrofoam. The instructions and details are enclosed as enclosure 1. Enclosure 2 is the in- structions for St. Mary's, number PT7816, included herewith as enclosure number 2. Enclosure number 3 is typical photographs of field work in process. After the field demonstration, we sat down and discussed with the Perma-Pipe people the work to be accomplished at St. Mary's and all. Of significance the following points are noted: I Pipe must be cleaned by sandblasting, or grinding, or wire brushing prior to the application of the resin and fiberglass. ie Temperature controls are critical. Installation should be done between 60 and 80 degrees Fahrenheit. Bye Again critical is the storage of the material, which should be also be done between 60 and 80 degrees Fahrenheit. 4a, The utilization of the resin and fiberglass has a very short life, especially during warm temperatures, 30 minutes maximum. At the Stanford test, they had to mix up two batches; one set up within about 12 minutes. No problem, however, in getting the proper joint, they had to let the thing set up and start over from scratch by re-roughing up the surfaces and mixing a new batch, etic. 5. At St. Mary's Cand also Unalakleet) tents will be required over the field joints when the work is being done to maintain a controlled environment. Heat will have to be applied. Again, there is a safety concern of applying direct flame close to acidtone and some of the various agents to be used. polarconsult Morris J. 6. It is extremely important that procedures be followed to the letter, and air bubbles removed by using the rollers provided by Perma-Pipe. People who are going to be working with this system must be school trained. The Perma-Pipe people have a video tape of typical field installations which we requested be sent. Not only can the contractor utilize the video, but also we could use it in training our inspection force. Turner, Pac. Project Manager JUG cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Unalakleet, Kaltag, St. Mary's July 4, 5, 6, 1983 Mr. Peter N. Hansen of Polarconsult Alaska, Inc., conducted a routine inspection visit to the above mentioned villages. The purpose of the site visits were: 1. Unalakleet - to investigate the pipe routing changes proposed by the Contractor, Wick Construction. 2. Kaltag - to inspect work progress and to monitor the moving of the power plant to its new location. Accord- ing to Contractor, Rockford Corporation; this was to take place July 4-5, 1983. Be St.Mary's - to obtain data necessary for design clarification. a, General familiarization with planned waste heat recov- ery CWHR) systems in Unalakleet and St. Mary's. The following points are noteworthy: Ie Unalakleet: The piping changes proposed by the Con- tractor appeared to be acceptable. I was, however, somewhat concerned over the use of 45° expansion elbows and decided not to submit an approval of the changes until I had an opportunity to discuss the matter with the pipe manufacturer's engineers. Ze Kaltag: At Kaltag, work had not progressed as far as expected. Only three tanks had been moved and Contrac- tor was told to improve tank foundation. Tanks were not level and were not uniformly supported. I was informed by Contractor that geofabric under tank farm was in place. Contractor was requested to improve tank dikes and to repair damage done to fence around existing tank farm. Also, Contractor was told that damage done to existing school emergency generator building was to be repaired as soon as possible. Various piping changes were discussed with the Contrac- tor, and a number of changes were approved. These changes do not require a change order, as they will be beneficial to both the owner and the Contractor. The moving of the power plant was delayed and was not performed until July 7, 1983. polarconsult 3a St. Mary's: At St. Mary's, the power plant and the boiler rooms involved were visited and the piping lay out was inspected. Detailed information concerning power plant radiator fan motors was obtained. Peter N. Hansen Mechanical Engineer /1h cc: Jerry Larson, Alaska Power Authority polarconsult Mr. Peter FIELD TRIP REPORT Nashville and Chicago July 11-12, 1983 N. Hansen of Polarconsult Alaska, Inc. conducted a visit to the above mentioned cities. The purpose of these visits was to inspect the production methods and the quality control procedures for Perma-Pipe, which will be used In the Villages of Unalakleet and St. Mary's. The following points are noteworthy: Le Enroute to Nashville, information was given by Perma- Pipe that inspection of the manufacturing facility in Nashville, Tennessee would not be possible after all. This last minute decision was based on concerns over possible spreading of proprietary information. As it was too late to change reservations on my ticket Csuper saver fare), time was spent visiting the non- proprietary sections of the facility. At Perma-Pipe's facilities in Chicago, comprehensive product information was given, and the joining process was demonstrated. The complications of the joining process were very well demonstrated by the fact that the first joint demon- stration was a total failure and the second demon- stration was not quite acceptable. There is, however, reason to believe that a conscien- tious contractor will be able to produce high quality joints. This impression was shared by Jerry Melin of Melin and Sons of Palmer, Alaska. As a representative for the mechanical sub-contractor for the project in Unalakleet, Jerry Melin also attended the session at the Perma-Pipe facility in Chicago. The piping changes proposed by the contractor (Melin and Sons) for Unalakleet were discussed with Perma-Pipe engineers. Based on these discussions, the proposed changes were approved. polarconsult Perma-Pipe was instructed to be more careful with packing and shipping aS a majority of references provided by Perma-Pipe complained about receiving damaged merchandise. Peter N. Hansen Mechanical Engineer /1h cc: Jerry Larson, Alaska Power Authority polarconsult - FIELD TRIP REPORT Ambler and Shungnak July 28-29, 1983 Mr. Hansen, of Polarconsult Alaska, Inc., conducted a routine inspection visit to the above-named villages. The purpose of these visits were: ills 2. Die To inspect general work progress in Ambler. To answer various questions from the Contractor. At Shungnak to work out a solution to a request made by the school maintenance personnel to relocate the heat exchanger. At Shungnak to inspect the proposed changes to wall penetrations in the pump house. To discuss Change Orders with the Contractor. The following points are noteworthy: ‘Lys y At Ambler, a relief valve was mounted on the wrong side of the shut off valve on a heat exchanger. Also at Ambler, all steel strainers were used in connection with copper lines without the dielectric fittings. This was done in all boiler rooms, as well as in the power plant and the heat recovery module. The Contractor was notified of this. In Ambler, the design calls for 5-foot offsets in piping between the various modules in the power plant. In Ambler, these offsets will be made with flexible connectors, and this has been discussed with Tom Hebnes. Also in Ambler, the supplier's shopdrawings show expan- sion loops in the middle of the streets, where the pipe is supposed to be inside culverts. This is not possi- ble, and expansion loops and anchors were relocated accordingly. Finally, it was noted in Ambler that the 2-foot dirt cover over the pipe can only be obtained in certain areas. In other areas, only one and one-half feet of cover can be obtained due to an abandoned PHS pipe. At Shungnak, the following points are noteworthy: ls The pump house wall penetration will be made somewhat differently in order to avoid outside crossings of existing electric utilities and water pipes. polarconsult as The heat recovery module will be turned 90 degrees to avoid a conflict between the ladder and the existing tank dike. The pipe run from the tank dike to the school goes over swampy ground, and additional cripping will be re- quired. It was agreed with school maintenance personnel, that the heat exchanger will be relocated in the far right corner of the boiler room, next to the ladder. This change was made to ease future boiler maintenance, and it will most likely not require a Change Order. The following general observations were made: Ls The Rovanco preinsulated pipe, delivered to Ambler, did not meet specifications. During the submittal review process the manufacturer was told to deliver one piece jackets for the expansion loops. The expansion loops delivered to Ambler consisted of mitered outer casings, caulked with an unknown caulking substance in_ the corners. This design had cracked already, and was obviously not watertight, as the foam could be seen in various places. Due to delivery time, etc., it will now be too late to do anything about this problem. The Contractor was instructed to do his best to seal up cracks with caulking material, or hot glue, whatever would be the best solution. Also on the 20 foot pipe sections, as delivered by Rovanco, the jackets were, at various points, joined with a shrink sleeve and some caulking material. This procedure was, at no time, approved. Also, some delays in underground piping work at Ambler can be anticipated due to errors made in the delivery process. Living facilities seem adequate at Ambler, and as the same camp will be used for the crew working in Shungnak, no problems can be anticipated there, either. The crew is shuttling back and forth between Ambler and Shungnak in company airplanes. Locally, one laborer has been hired. No local pipe- fitters have been hired, since none were available to the contractor... Peter N. Hansen Mechanical Engineer /\h cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT ROCKFORD YARD August 3, 1983 Mr. Peter N. Hansen, of Polarconsult Alaska, Inc., conducted a routine inspection visit to this. site. The purpose of this inspection visit was: The To Inspect general progress. aie To inspect materials as supplied to Rockford Corpo- ration. Se To discuss and clarify designs with Tom Hebnes_ of Rockford Corporation. The following points are noteworthy: ie As is mentioned in an earlier trip report from Rockford's yard, various items on the skids extend over the side of the skid. This was caused by the fact that the heat exchanger is somewhat larger than anticipated. This problem could have been- solved if the heat exchanger carrying bar had been shortened at an earlier time. At this time it is no longer possible to solve the problem, and if proper care is taken during trans- portation, no impact should be experienced. 2a The heat recovery modules as produced in Rockford's yard, generally look good, and the quality of the workmanship leaves nothing to be desired. Bic Miscellaneous items were inspected in the Rockford Yard. These items included: above-ground Rovanco pipe, below-ground Rovanco pipe, miscellaneous fittings, air tanks, heat exchangers, pumps, valves, etc. None of the inspected items gave any reason for comments. 4. Mr. Tom Hebnes of Rockford Corporation addressed the designs at Elim and Goodnews Bay in reference to the location of the boiler bypass lines. The connection of the boiler bypass lines to the boiler return lines, will probably have to be altered. This will be ad- dressed later. polarconsult 5. Also, Tom Hebnes asked that the suitability of flow meters, as they have been supplied to Rockford Corpo- ration, be checked. It appears that these flow meters are probably too small as the connections are somewhat smaller than the surrounding piping in the various locations. A fast response was promised to. this request. Peter N. Hansen Mechanical /1h Engineer CG% Jerry Larson, Alaska Power Authority 1.1 polarconsult FIELD TRIP REPORT Angoon August 3-5, 1983 Mr. Peter Hansen, of Polarconsult Alaska, Inc., conducted a routine inspection visit to the above named village. The purposes of this site visit were: nes To try to solve the conflict that has erupted between the local power plant operator and the contractor's representative at the site. Lie To inspect the materials as received on site. is To inspect general work progress and quality. The following points are noteworthy: lr A rather serious conflict erupted between the local power plant operator, Mr. Rodney Hunter, and the con- tractor representatives on the site. This conflict erupted because the contractor did not look for the person with a key for the power plant when he arrived on Friday, July 29, 1983. On Saturday, July 30, 1983, the contractor broke into the power plant by removing the mosquito screen from the window and crawling through the window. When Mr. Rodney Hunter’ tater arrived at the power plant, the contractor was in progress of moving the operator's stuff around, and making room for the components which were to be stored in the power plant. No damage was done. According to Mr. Rodney Hunter, he is responsible for the power plant, and he is not going to allow anybody to work inside the power plant without an instruction from Tlingit-Haida Regional Electrical Authority in Juneau. Mr. Rodney Hunter had not received such a clearance, and as he also keeps a lot of personal belongings inside the power plant, he was extremely unhappy with the contractor breaking into the power plant. Mr. Hunter contacted Mrs. Loren Karro with Tlingit-Haida Regional Electrical Authority in Juneau, had reported the incident. The word back from Mrs. Karro was that nothing was to be installed inside the power plant until Tlingit-Haida Regional Electrical Authority had approved the install- ation, and this would not happen until the installation had been discussed with APA's representative CPolarconsult Alaska, Inc.). Mr. Hunter asked Mrs. Karro that a mechanic from Tlingit-Haida Electric Corporation was sent to Angoon and this mechanic, Mr. Keith Berggren, arrived in Angoon on August 5, 1983. polarconsult Field Trip Report Angoon August 3-5, 1983 Mr. Berggren had several comments on the design, and asked that several changes be made. The requested changes were: Le Relocation of heat exchangers and pumps to the far left corner of the power plant. 2 That generator number 3 was not to be hooked up. Bie That the system was redesigned so that a leak in the cooling system would not cause the power plant to go down. Mr. Berggren wanted assurance that the airlock problems had been taken care of, and that no total drainage of the cooling system could take place. He asked that manual valves’ be provided in order to separate one cooling system from another. Also, he asked that the proposed step controller not be installed. He added that each existing radiater had a two speed motor, and the controls were installed. However, the wiring had not been completed. He promised that this would be done before this project was put in operation. After discussing these points with Mr. Berggren, we both left on a charter plane to Juneau to see Mrs. Karro of the Tlingit-Haida Regional Electrical Authority. Mrs. Karro made it clear that they had signed the necessary agreements with the Alaska Power Authority and that they were very interested in getting the project installed. However, she also made it clear that their mechanics should be in total agreement with the project before it was installed, and that the design changes proposed by Mr. Berggren would have to be made. Mrs. Karro relayed this message to Mr. Joe Perkins of Alaska Power Authority, and a contact was established between Mr. Perkins of Alaska Power Authority and Mr. Jack Turner of Polarconsult Alaska, Inc. It was agreed that since time is of the essence, and since very major design changes had to be made, Polarconsult Alaska, Inc. should do these changes over the weekend of August 6 and 7, 1983. A meeting with Mrs. Karro, Mr. Berggren, and Mr. Hansen was scheduled for August 8, to clarify the design and to get the final go ahead from the electrical corporation. Also, a meeting was scheduled between the construction manager, Polarconsult Alaska, Inc., represented by Peter Hansen, and the contractor, Washington Mechanical, as represented by Mr. Bob Swenson, for August 9, 1983, in Angoon. The purpose of this meeting was to discuss the final change orders. polarconsult Field Trip Report Angoon August 3-5, 1983 The materials delivered to Angoon were inspected, and it was found that the quality of Rovanco preinsulated pipe left a lot to be desired. As it was found in other villages, the PVC weldings to the expansion loops were not in satisfactory condition. The endseals did not have sufficient overlap over the oversized casing, and finally the 20 foot preinsulated piping sections had been joined with shrink sleeves. This procedure had not been approved. The findings were reported to Mr. Bob Swenson of Washington Mechanical and according to Mr. Swenson, he would attempt to make the necessary repairs on Tuesday, August 9, 1983. It was made clear that no piping could be backfilled until approved by Polarconsult. No other faulty materials were found. Work progress was limited as the contractors had just arrived on site. Living conditions seemed adequate, and it was noted that no locals had been hired by the contractor. Peter N. Hansen Mechanical Engineer /1h CC Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Juneau and Angoon August 8, 9, and 10, 1983 Mr. Peter N. Hansen, of Polarconsult Alaska, Inc., conducted a visit to Juneau and Angoon in order to: 1) obtain final approval for the proposed design changes from Tlingit-Haida Regional Electrical Authority in Juneau; 2) inspect general work progress in Angoon; 3) negotiate and brief on change order’ with Contractor; and 4) witness pressure test of a section of the underground piping. The following should be noted: In Juneau, Mr. Hansen met with Mr. Harry Brown, of Tlingit-Haida Regional Electrical Authority; and Mr. Keith Berggren, also of Tlingit-Haida Regional Electrical Authority. The proposed design changes were discussed. Messrs. Brown and Berggren agreed that the proposed design would satisfy their demand for a failsafe system, and still be compacted enough to fit inside the power plant. Messrs. Brown and Berggren agreed to relay this message to the Alaska Power Authority, and to relay the message to Mr. Rodney Hunter, the local power plant operator at Angoon. As Tlingit-Haida Regional Electrical Authority had signed easements and rights-of-ways on May 11 of this year, no additional written agreements were necessary. Also, in Juneau, Mr. Hansen met with Mr. Bob Swenson, of Washington Mechanical Contractors in Seattle. The proposed design changes were discussed, and Mr. Swenson seemed to agree that the design was constructible and more simple than the previous design. On August 9, Messrs. Swenson and Hansen flew to Angoon to discuss the proposed design changes on site. It was verified that the new design was no more complex and costly than the old design. No agreements were made concerning additional funding for a change order. It was made clear to Mr. Bob Swenson that Polarconsult Alaska, Inc. did not feel that the new design should add any costs. The faulty pipe sections in Angoon had not yet been repaired in respect to correct PVC weldings. However, Mr. Bob Swenson, of Washington Mechanical, agreed that this had to be done. Portions of undamaged pipe had been installed, and a first section of this pipe was pressure tested on August 10 with no comments. In general, the work quality seemed good. The next pressure test was scheduled for August 16, 1983. It appeared that Washington Mechanical had certain problems concerning supplies, and that these problems were caused by poor planning. As Washington Mechanical has requested a time extension, this fact should be taken into consideration. polarconsult Field Trip Report Juneau and Angoon August 8, 9, and 10, 1983 No local labor had been hired, and present working facilities and accommodations seemed adequate. Peter N. Hansen Mechanical Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Goodnews Bay August 10, 1983 Upon” arrival at job site, I met with Mr. Ivan Solhiem, Superintendent for Rockford Corporation, and proceeded to view the following: 1. Power plant. Es Boiler room. ae Heat recovery unit housing. 4a, Proposed underground piping route. Mr. Solhiem pointed out that the existing configuration of the bypass and control valve lines for the school heat would not work with the new heat exchanger piping. I asked Ivan to make a recommendation to his employer (CRockford Corporation) and have them pass it on to the Construction Manager. Ivan agreed. Also, there was some concern of a s/a fan mounted adjacent to the door of the power house. The fan would be an obstruction to moving generators in and out. In addition, the shroud intake would be approximately eighteen inches above the platform. Any accumulation of snow and ice may plug the opening. Results could be serious. The fan is designed to go into the existing louver near the door. Other than the aforementioned, the project seems to be progressing as planned. William R. Davis Electrical Engineer /1h cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Ambler and Shungnak August 11 and 12, 1983 Messrs. Barkshire and Hansen, of Polarconsult Alaska, Inc., conducted routine field visits to the above mentioned sites. The purpose of this trip was to inspect general work progress and to guide the Contractor in areas where this was needed. The findings were as follows: Ambler: In Ambler, connections in the pump house were generally complete and were satisfactory. Building penetrations to the pump house were made somewhat differently, and polyethylene pipe had been used as risers. This was not as approved. However, the Contractor proposed to make plywood cover boxes filled with foam. This solution seemed satisfactory. The Contractor was told to alter building penetrations slightly to allow for expansion. At one pump riser, sufficient shrink sleeve overlap would not be possible. However, the contractor was aware of the problem, and will solve it. The problem was not critical. Where arctic pipe went under the school, less than one foot (1') dirt cover was possible, partly due to conduit with high voltage wires crossing across the pipe trench. The Contractor was told that this would have to be corrected. The Contractor was, however, concerned about the very labor intensive digging underneath the school. Expansion details underneath the school had been changed, partly due to delivery of faulty materials. School boiler room No. 1 was inspected with no comments. General underground piping was inspected with no comments. The Contractor was aware that no backfilling could be completed until pressure testing had been done, and until outer casing problems with expansion loops had been solved. Also, arctic pipe could not yet be completed, as one expansion loop had not yet been delivered to the site. The heat recovery modules seemed to have a severe problem with water leakage. The design relies on caulking for sealing, and since site applied caulking was not perfect, all the panels had been filled with water. Water was dripping from the ceiling. Underneath the heat recovery module, it was obvious that all the wood in the construction was filled with water. The Contractor advised apply!Ing a membrane to the roof of the structure, and was informed that it would be taken under consideration. Remote radiators were in place on top of the module. However, they were not hooked up, and the motors were not yet installed. Inside the module, most electrical equipment was in place and the pump was being installed. The module was not yet hooked up to the power plant. The generator pipe was not yet complete, and flexible connections between generator modules had not yet been polarconsult Field Trip Notes Ambler and Shungnak August 11 and 12, 1983 installed in the steel pipe. It was discovered that copper tubing was run through steel sleeves in the power plant. This did not, however, seem to present a problem, as it was possible to pack the sleeves with flexible insulation and sealing material in order to prevent the copper tubing from contacting the steel sleeves. In Ambler, it was noted that the Contractor had hired three local people: one laborer, one pipe fitter, and one operator. These three locals were being utilized tn Ambler and in Shungnak. Also, it was noted that work and housing facilities were adequate. Shungnak: At Shungnak, the heat recovery module is being erected at this time. Cribbing was being laid, and the crew was starting to put together the panels on August 11, 1983. The panels had arrived at the site, and apparently a few spots of rust had already developed, as they had been left uncovered under rain conditions. The arctic pipe had arrived on site, and seemed mainly undamaged. Arctic pipe building penetration had been made to the pump house, and the first few pipe runs had been made in the direction of the power plant. Cribbing underneath the arctic pipe at the pump house was not satisfactory. This was mentioned to the Contractor. Tie-ins Inside the pump house had been completed at this time. No comments made. The heat recovery skid with equipment mounted had arrived on site. Everything looked satisfactory. In the school boiler’ room, the heat exchanger was. being installed. This work was not yet complete. We met with Mayor Leonard Douglass in Shungnak. He told us that so far the City had not issued any right-of-way for the line going from the power plant to the school. This will have to be addressed. He suggested that the Alaska Power Authority send the City a letter requesting a right-of-way, and this would then be issued. We inspected the school boiler room. There were no problems there. The school maintenance person asked if it would be possible to make a small change order to make the school's heating system more suitable for the waste heat recapture project. Also, he wanted a couple of "T"s on the glycol lines in polarconsult Field Trip Notes Ambler and Shungnak August 11 and 12, 1983 order to facilitate future installation of waste heat equipment for hot water heating. Peter N. Hansen Mechanical Engineer /pf cc: Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Angoon August 17 - 19, 1983 Mr. Duane Carson, of Polarconsult Alaska, Inc., conducted a routine inspection visit to the above named village. The purpose of this trip was: re To inspect the PVC welding. 2 To inspect general work progress and quality. ois To observe pressure test if Contractor was ready. A. The PVC welds: Original field welds were removed and new welds made by the Contractor with the aid of a factory representative. The welds inspected were on the loops and the one tee which had a leak in a factory solder joint. The new welds looked good and could not be pulled off. Welds were acceptable at the time of inspection. Bre Contractor had backfilled and graded the area of the line by the school. The section of line along the teacher's quarters had been layed and the ditch left open. The section of ditch from the south of the teacher's quarters to the treatment plant contains large rocks, some as large as 1,000# Cestimated). Also, there is a buried 4 wire, 440 volt power line that crosses the ditch south of the teacher's quarters into the fenced area, then parallels the building on the east side. The Contractor broke one wire Wednesday night, then broke two wires Thursday morning as he was digging the trench to the building. Tlingit-Haida Regional Power Authority had to be called twice to splice the lines. Contractor will have to provide backfill and spoil the large rocks. Gr Bue to the rocks, electrical Cburied) lines and bad weather, it appears as though the Contractor may be ready to test Saturday or Monday. Delays for digging the ditch about one day. May be additional changes for having the electrical wires spliced. Di It was noted that no locals were working for the Contractor at the time of inspection. Contractor had hired two locals, but they only worked three days and then quit. Duane E. Carson, P.E. Civil CStructural) Engineer /1h cc: Mr. Jerry Larson, Alaska Power Authority it polarconsult FIELD TRIP REPORT Goodnews Bay August 16 - 17, 1983 Mr. William R. Davis of Polarconsult Alaska, Inc., made a routine visit to the above named site. The purpose of this visit was to inspect general progress and construction. The following points are noteworthy: 1. The Rockford crew was working on heat exchanger fans on top on the module, and in the school basement on the heat exchanger. The prime power generators were shut down, and the AVEC crew had just arrived and started repair work. 23 I surveyed the job site, and found the power conductors to the school had been cut and spliced. I checked the heat exchanger module for water damage in the roof and walls and found none. 316 The piping from the module to the school was installed in the trench, with the insulation on except for the joints. The arctic pipe and joints were in good shape. hh, On August 17, I worked with Mr. Ivan Solheim Cthe foreman of the Rockford crew) on trying to resolve the Johnson mixing valve problem and design changes in the arctic pipe routing. The existing piping schematic shows no circulation between the heat exchanger and the school. 5. The pressure test was scheduled for August 17, but the pump for the 75-pound pressure test was not on the job site. Overall, the project seems to be in good shape. Problems resolved via telephone calls to the Rockford shop. William R. Davis Electrical Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Unalakleet August 17 - 18, 1983 Messrs. Barkshire, Davis, and Hansen conducted a routine field inspection visit to Unalakleet on these dates. The purpose was to inspect general progress and verify various items with the Contractor. Contact was made with Messrs. Lynn Rayburn and Jerry Melin concerning certain trenching problems. The Contractor asked whether it would be possible to decrease the dirt cover in front of the elementary school, and it was agreed that a 2-foot dirt cover would be sufficient at the point of entry. Damage done to electrical lines and miscellaneous piping was inspected. Lt appeared that damage had been repaired Satisfactori ly. One section of pipe was in the ground, and the trenching was going well. No tie-in work had been done yet in the schools or in the power plant. Welding seemed to be of good quality, and generally work quality was satisfactory. The Contractor was told to provide a separation between existing pipes in the ground and the new district heating piping in order to avoid the new district heating piping resting directly on the existing steel pipes. No electrical work had been performed so falta. A few sections of the Perma-Pipe had been slightly damaged in transportation. However, the damage seemed repairable. One one problem concerning Perma-Pipe was possible insufficient overlap of mats in the joints right next to expansion loops. The Contractor was told that capped off ball valves did not need to extend 18 feet as shown on the drawings. This would take capped off ball valves under the existing fuel tank, and this did not seem practical. Capped off ball valves would be approximately ten feet from existing lines. Inside the BIA school, a slight piping change was approved in connection to the boilers. The Contractor felt that the heat exchanger was somewhat small and asked that the size of it be checked. The Contractor was told to keep the capped off ball valves away from the roads next to the 14 plex. The utility wants to run a cable in the trench that is open from approximately the street next to the administration building into the high school. I see no problem with that. We will check with Art Ronitmus just as a courtesy on an okay for this item. polarconsult Field Trip Report Unalakeet August 17 - 18, 1983 A pressure test on one pipe section was satisfactorily completed on the night of August 18, 1983. Peter N. Hansen Mechanical Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority. polarconsult Mr. Inc., FIELD TRIP REPORT Elim August 18, 1983 James Barkshire and Mr. Bill Davis of Polarconsult Alaska, conducted a routine inspection visit to the above named village. The purpose of the site visit was to inspect materials as received on site and to inspect the general work progress and quality. The following was noted: Te Very little work has been done in Elim. Most of the major materials appear to be on site. The heat recovery module is not constructed, no exterior piping has been laid, nor any trenching done. No work has been done inside of the generator plant itself. The interior piping has not been done at the BIA School. The only visible work was the heat exchanger installation and_ piping in the high = school. School begins on Monday, August 22, 1983, in Elim at the high school. The Contractor has assured the principal of the school that they will be finished and out of school at that date. The BIA School will begin on the Monday after. Again, the Contractor has assured those people that he will be out by that time. Work inside of the high school appears satisfactory. Upon inspection of the piping, it was found that two of the underground elbows of PVC jackets had insufficient sealed joints, on two of the 90° corners. The rest of the underground pipe appeared to be in better condition than that found at other sites. One of the above ground pipes was crushed at the steel exterior casing; however, it does not appear to affect the watertightness of this pipe. On that same piece of pipe, the interior carrier pipe was crushed at the end, about one inch back from the end. However, they can probably cut this small section off and use the pipe without any problem. The heat recovery skid is sitting half in the street and uncovered by visqueen or any other covering. One of the radiators to be mounted on top of the heat recovery module is over on its side and partially in the street. The damage is minor enough that it won't affect its operation. There is a large group of materials, which looks like it has just recently arrived, sitting in the open on the wood basketball court, halfway between the generator plant and the high school. Inspection of the PVC elbows showed no damage there. The above ground elbows in the steel casing show that the mitre joints are a little bit thin in caulking material, although there did not appear to be any leakage. This material should be moved and stored as local children were playing with one of the fans and pulling on the rubber belts, etc. polarconsult Field Trip Report Elim August 18, 1983 Talked briefly with the pipe fitters in the high school boiler room. We attempted to contact Dick Walls, however, he was unavailable and the pipe fitters had been waiting for some time for him to return to the job site. As we were holding a charter on the ground, and there did not appear to be enough work done to really have much discussion with him, we concluded the inspection and left the job site. James Barkshire Assistant Project Manager /1h cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kaltag and Grayling August 18 - 19, 1983 Mr. Barkshire, Mr. Davis, and Mr. Hansen, of Polarconsult Alaska, Inc., conducted a routine field visit to the above mentioned sites. The purpose of this trip was to inspect general work progress and quality, and to inspect damage done to_ school property. Kaltag: In Kaltag's school, it was noted that the floor in the kitchen area had about 25 feet of burn marks from the electrical work; the floor material is vinyl, and it appears that the whole kitchen floor has to be replaced if total repair is to be made. Also, it was noted that about half of the floor area in the freezer room was damaged. Piping inside the gym at Kaltag was completed. However, the unit heater in the library was not yet in place. Electrical work was not yet completed, as the thermostats were not in place. In the boiler rooms, the piping was in place; however, the heating coils had not yet been installed. The generator in the relocated AVEC generator building is in and operating. The heat recovery module is not yet constructed. The skid is sitting outside the generator building, very loosely covered by a sheet of visqueen. The heat recovery module panels are stacked next to the. skid. Most of them are covered by visqueen, although a couple of floor panels are exposed on top. There does not appear to be any rusting on the exposed panels at all. The wood cribbing to support the heat recovery module is partially in place. Radfators are also sitting out back, minus the motors, and the above-ground pipe is also sitting outside. They appear, for the most part, to be undamaged. The tank farm does not comply with contract documents. The fence that was damaged during installation of the new tank farm on the right side has been partially fixed, but it is in terrible shape. The tanks are not level. The one on the right side front is a good 4- to 6-inches below the adjacent one. Throughout the farm, there is quite a bit of difference In elevation of each tank. I would say about half of these tanks are not plumb; they are not sitting level. Almost every elbow and connection at the valve into the tanks I have seen is’ leaking. Fuel oil in small quanities is leaking onto the gravel below. The pipe between tanks is being supported on a mish-mash of blocks and planks strung between the skids that the tanks themselves are on, and fuel is leaking from both valves and running joints. The dyke itself around the farm is, on the average, about 3-foot high. It is not dressed at all. The top of it is up and down all the way aliong tits. Much of the dyke liner is exposed at the outside, and polarconsult FIELD TRIP REPORT Kaltag and Grayling August 18 - 19, 1983 Mr. Barkshire, Mr. Davis, and Mr. Hansen, of Polarconsult Alaska, Inc., conducted a routine field visit to the above mentioned sites. The purpose of this trip was to inspect general work progress and quality, and to inspect damage done to_ school property. Kaltag: In Kaltag's school, it was noted that the floor in the kitchen area had about 25 feet of burn marks from the electrical work; the floor material is vinyl, and it appears that the whole kitchen floor has to be replaced if total repair is to be made. Also, it was noted that about half of the floor area in the freezer room was damaged. Piping inside the gym at Kaltag was completed. However, the unit heater in the library was not yet in place. Electrical work was not yet completed, as the thermostats were not in place. In the boiler rooms, the piping was in place; however, the heating coils had not yet been installed. The generator in the relocated AVEC generator building is in and operating. The heat recovery module is not yet constructed. The skid is sitting outside the generator building, very loosely covered by a sheet of visqueen. The heat recovery module panels are stacked next to the = skid. Most of them are covered by visqueen, although a couple of floor panels are exposed on top. There does not appear to be any rusting on the exposed panels at all. The wood cribbing to support the heat recovery module is partially in place. Radiators are also sitting out back, minus the motors, and the above-ground pipe is also sitting outside. They appear, for the most part, to be undamaged. The tank farm does not comply with contract documents. The fence that was damaged during installation of the new tank farm on the right side has been partially fixed, but it is in terrible shape. The tanks are not level. The one on the right side front is a good 4- to 6-inches below the adjacent one. Throughout the farm, there is quite a bit of difference in elevation of each tank. I would say about half of these tanks are not plumb; they are not sitting level. Almost every elbow and connection at the valve into the tanks I have seen is’ leaking. Fuel oil in = small quanities is leaking onto the gravel below. The pipe between tanks is being supported on a mish-mash of blocks and planks strung between the skids that the tanks themselves are on, and fuel is leaking from both valves and running joints. The dyke itself around the farm is, on the average, about 3-foot high. Tt is not dressed at all. The top of it is up and down all the way along it. Much of the dyke liner is exposed at the outside, and polarconsult Field Trip Report Kaltag and Grayling August 18 - 19, 1983 it is also visible on the inside of the dyke itself. The dyke is extremely irregular. It does not follow any sort of pattern that would be close to square or rectangle around the farm. At the back side of the farm, the grade level is just about as high as the top of the dyke on the front side; there is a slope down to the front. The transformers that are sitting outside the dyke and in front of where the heat recovery module will be are all cock-eyed. None of them are level or plumb at all. Inside the power plant, part of the piping is completed. However, no generators have yet been hooked up. Apparently, the heating coils have not yet arrived at the site. General clean-up in the old power plant area was satisfactory. Grayling: In Grayling, not much progress could be inspected. The Rovanco underground elbows and expansion loops showed the same deficiencies as at other sites. PVC weldings were not Satisfactory. Foam had penetrated the weldings in several places, and expansion loops were the same type patchwork as seen at other sites. On the skids as delivered to Grayling, one relief valve was located on the wrong side of a shut-off valve on the heat exchanger. Some generator piping had been put in; however, no generators were yet hooked up to the system. No underground piping had been completed so far. No underground pipe had arrived at the site; only fittings and expansions loops were on site. The heat exchanger had been placed in the school boiler room; however, piping was not yet completed. In the pump house, the heat exchanger was in place, and hook-ups had been completed. Only the final connection to the glycol return and supply lines had not been made yet, as_ these underground lines were not in place. polarconsult Field Trip Report Kaltag and Grayling August 18 - 19, 1983 General work quality inside the pumphouse seemed satisfactory. James Barkshire Assistant Project Manager /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD | TRIP) REPORT St.) |Many! s August 24, 1983 Mr. Duane E. Carson of Polarconsult Alaska, Inc., conducted a routine inspection visit to the above village. The purpose of the site visit was to inspect work progress. The Contractor has approximately half of the ditch dug. Mhasi) es being done by the city's backhoe and a native Operator. The pipe is laid along the ditch between the Main School Building and Gym. Also from the AVEC building to In front of the post office. Welders were working at the Main Building welding the 5" pipe and the 3" pipe by the AVEC building and the post office building. Six people were on the _ job. One Welder and a helper’ from Anchorage, Alaska. Two from Seattle, Washington and two local natives working as laborers. Duane) |E.) ‘Carson, |P\. iE. Civil CStructural) Engineer DEt J kb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Elim August 24, 1983 Messrs. Carson and Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of this trip was to inspect general work progress and to assist the Contractor in design clarifications. The following points are noteworthy: A major part of the underground pipe had been installed and it was noted that the backfill contained quite a large number of big rocks. The Contractor was told to use the best backfill avail- able in order to avoid pipe damage. Also, it was noted that a few pieces of Rovanco pipe had suffered minor transportation damage. In the Elementary School boiler room, it was noted that the boiler bypass would have to be moved. In the original design this had not been taken into consider- ation. However, the Contractor was willing to do the change with no paperwork involved. Also in the Elementary School boiler room it was noted that an undersized flow meter had been installed. This will have to be corrected in order for the installation to meet specifications. In the High School boiler room it was noted that the heat exchanger was installed backwards. The heat exchanger was in parallel flow and also the flow was in the opposite direction as desired. The Contractor was told to alter this installation. Also in the High School boiler room the flow meter was of incorrect size and again this will have to be corrected. The flow meter sizes have earlier been addressed to Mr. Tom Hebnes of Rockford, Inc., and it has been made clear that the design calls for certain sizes of flow meters and this cannot be changed. Peter N. Hansen Mechanical Engineer PNH: jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Unalakleet, Alaska August 24, 1983 Messrs. Carson and Hansen of Polarconsult Alaska, Inc. conducted a routine field trip to Unalakleet on this date. The purpose of this trip was: le To inspect general progress. 2a To aid the Contractor with design clarifications. ie To inspect quality of Perma-pipe field joints. The following points are noteworthy: General work progress seemed good as substantial progress could be noted from last visit. Work was in progress in the Gym and in the Elementary School boiler room and was under preparation in the 14 plex boiler room. Two design clarifications on boiler room tie-in's and heat exchange connections were provided to the Contractor and minor piping changes were agreed on in the 14 plex boiler room. A section of the underground Perma-pipe was pressure tested satisfactorily and was cleared for foaming, joining and back filling. The first section of Perma-pipe had been foamed and joined and the joints seemed to be of satisfactory quality. The Contractor had hired an experienced glass fiber worker for this portion of the Contract, and the results were satisfactory. The Contractor agreed to temporarily leave a section of the pipe exposed for further’ inspection. This section of the pipe included an elbow, aT, a set of ball valves, and an anchor. Peter N. Hansen Mechanical Engineer PNH: jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kiana, Ambler, and Shungnak August 25 - 26, 1983 Messrs. Carson and Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to these sites. The purpose of these visits were: ls To inspect general work progress. Le To inspect field repair of Rovanco pipe. ar To witness pressure tests. 4, To clarify design for the Contractor. The following points are noteworthy: Kiana: le In Kiana a small problem had evolved concerning the tie-in to the pump house boiler’ room. PHS was in progress of making repairs and additions to the pump house and the Contractor had been told that he could not start working in the pump house until September 6. This could cause a delay for the finishing of the Contract. However, contact was made with Mr. Kenn Wiehoff of PHS. Mr. Wiehoff is in charge of the work being done to the PHS pump house and Mr. Wiehoff agreed to letting the Contractor start working in the pump house at this time. As the interior design of the pump house had changed considerably since the design of this project, the tie-in to the boiler room would have to be altered accordingly. Mr. Wiehof f agreed that the penetration into the pump house should have been made next to the existing wall penetration. The heat exchanger be located behind the existing water tank inside the room. It was agreed that all plumbing except for the tie-ins could be completed any time the Contractor to. should boiler boiler wanted Also in Kiana it was noted that the module had been moved slightly to allow for access to the gate in the fence surrounding the power plant. The Contractor suggested that the new air intake to the AVEC Power Plant be relocated to the other side of the building. This was caused by concern of future access to the power plant. In the original design the new air in-take is located next to the door where the existing louvers are located. However, these louvers are frequently removed to allow access to the power plant. This doubles the width of the door and thus allows for removal of complete engines. It was agreed that the possible relo- cation of the air in-take would have to be negotiated with AVEC in Anchorage. polarconsult Field Trip Report Kiana, Ambler, and Shungnak August 25 - 26, 1983 It was also noted that heat exchanger H2 was’ plumbed backwards. However the Contractor was told not to alter this installation until further notice was given as it was deemed possible that this installation would work. Mr. Hansen promised to check this problem with the APV factory in Tonawanda, New York. The Contractor will have to modify the wooden walkway from the living quarters to allow the pipe to pass over the wooden electrical utilidor and under the walkway. This will require the existing walkway to be cut, then install three steps up, a platform, then three steps down. Ambler: Qe In Ambler a factory representative from Rovanco was working on improving the quality of the pipe that had been delivered to) the site. PVC Welding now seems satisfactory and the factory representative was in the process of making minor design changes to the underground piping. Minor changes to the expansion compensation system were proposed; however, the factory representative was told that no change could be approved on site, a new set of shop drawing would have to be submitted, and the factory representative agreed to do this. It was noted that heat exchangers H2A and H3 were installed backwards. However the Contractor was told not to alter this installation until further notice was given. Shungnak: 3. In Shungnak, the heat recovery module was being erected, and general work quality seemed adequate. The below ground district heating pipe had been pressure tested and the Contractor was allowed to start foaming and joining the jacket. It was noted that cribbing under the pipe was not yet complete and the Contractor was aware that adjustments had to be made. Also the Contractor was told to provide cribbing inside culverts in order to allow for drainage. It was noted that heat exchangers H2 and H3 were plumbed backwards, however the Contractor was told not to alter this installation until further notice was given. polarconsult Field Trip Report Kiana, Ambler, and Shungnak August 25 - 26, 1983 En route back to Anchorage, contact was made with Sandy Oliviera, of APV Heat Exchangers in New York. The problem with the heat exchangers that were installed backwards was explained, and Mrs. Oliviera of APV Heat Exchangers suggested that installations be left the way they were originally done. She explained that on the heat exchangers supplied to Kiana, Ambler and Shungnak, the two loops were identical and thus it did not make any difference that they were plumbed backwards. This message was relayed to the Site Superintendent in Ambler on August 26. Peter N. Hansen Mechanical Engineer PNH: jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Marys August 30, 1983 Messrs. Carson and Hansen, of Polarconsult Alaska, Inc. conducted a routine field visit to St. Mary's on this date. The purpose of the trip was to inspect general work progress, and aid the Contractor in miscellaneous design clarifications. The following points are noteworthy: lee The Perma-Pipe from the cold storage plant to the power plant was welded and had been pressure tested. According to the Contractor, this pressure test was satisfactory. The Contractor was told to start foaming and glass fibering this section of the pipe. The foaming and glass fiber work would be done while the pipe was still on sleepers over the trench. After this was completed, the pipe would be lowered tn) to the trench: It was noted that the elbow overlap was not as submitted by Perma-Pipe. 2-6 Part of the module had been erected. However, no equipment had yet been installed. Sie The trenching was completed all the way from the power plant to the mission. However, due to poor soil conditions, parts of the trench had collapsed. The Contractor foresaw some problems with laying the pipe in this type soil. Bad weather had disturbed the work the last couple of days; however, the Contractor was confident that once dry weather returned it would be possible to finish up the outside work rather quickly. 4, The wall penetration to the boiler room as shown on Drawing M-3, Detail E could not be made as shown. This would due to the fact that the piping would go straight through the exhaust stack. The Contractor proposed to stay in the hallway and go across the boiler room approximately over the first boiler. He was given approval on this. The necessary changes would involve a few feet of 4-inch copper line and some extra elbows. The Contractor will request a Change Order. At this time, it was not clear what the size of the Change Order would be. Sie On August 31, the pipe section from the cold storage plant to the power plant was pressure tested at 200 pounds for four (4) hours. This test was satisfactory. 60 At the cold storage, two risers had been made using elbows Type S-5. These elbows should have been Type S-2. At the heat recovery module, two (2) Type S-2s had been used as expansion elbows. These should have been Type S-5. The Contractor was made aware of this, and it will be corrected. polarconsult Field Trip Report St. Marys August 30 Te Elbows Type S-21 and S-32 had been switched around. Tt wilt have to be checked with the factory whether this can be done. According to the Contractor, some of the soils conditions were not as indicated in the Specifications. Around the mission, an area with plastic type soils was found, and the trenches kept caving in. The Contractor estimated that it would be necessary to excavate a larger area using a D-9 dozer or equal. General work quality seemed adequate, and living conditions were adequate also. Peter N. Hansen Mechanical Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Grayling August 31, 1983 Messrs. Carson and_ Hansen, of Polarconsult Alaska, Ine, conducted a routine field visit to this site. The purpose of this field visit was to inspect general work progress, and to inspect the PVC repairs as done by the Rovanco factory representative. On August 30, Polarconsult Alaska, Inc. had been informed that the factory representative would be in Grayling late on August 30. However, upon arrival in Grayling, it was obvious that the factory representative had not yet arrived, as nothing had been touched since the last time Polarconsult was there. The message was later received that the factory representative had made last minute travel plan changes due to health problems. Peter N. Hansen Mechanical Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP) REPORT Unalakleet August 31, 1983 Messrs. Carson and_ Hansen, of Polarconsult Alaska, Inc., conducted a routine field visit to this site. The purpose of the trip was to inspect general work progress, and to inspect glass fiber joints as produced by the Contractor. The following points were noteworthy: 1. The first section of the pipe from the elementary school to the BIA building had been backfilled. A section of the pipe had been left exposed as had been agreed. This’ section Includes an expansion elbow, a set of "T's, and an anchor. A number of joints were inspected on the Perma-Pipe, and the Contractor was told to make sure that no air bubbles were left in the glass fiber resin before it set up. A few air bubbles were found, and the Contractor was told to repair these. In the school district building, the heat exchanger location had been changed slightly after agreement with Mr. Mike Rohn, who is the chief of the school maintenance. The heat exchanger piping was partially complete. Installation of the heat exchanger in the gym was partially complete; however only the Contractor had not yet been told whether a pump would be necessary due to the fact that 2-inch line was delivered from Perma-Pipe instead of the 3-inch line speci- fied. The Contractor was told that the 2-inch pipe from the "T"s to the elementary school gym could be foamed, glass fibered, and then backfilled. The Contractor was told that the portion of the pipe that had been previously left exposed for further inspection could not be backfilled. The Contractor asked that it be clarified which piping had to be insulated inside the power plant, and whether the heat exchanger had to be insulated. Also, the Contractor wanted to know whether the painting scheme inside the power plant had to be followed on the new piping. The Contractor was told that these points would be clarified as soon as possible. The Contractor asked that another inspection visit be scheduled for approximately the middle of next week, as the Contractor wanted to backfill as soon as possible. Peter N. Hansen Mechanical Engineer ADE ccs Mr. Jerry Larson, Alaska Power Authority al polarconsult FIELD TRIP REPORT Elim August 31, 1983 Messrs. Carson and_ Hansen, of Polarconsult Alaska, Ines > conducted a routine field visit to this site. The purpose of the visit was to inspect general work progress, and to inspect repair done to Rovanco pipe by a Rovanco factory representative. The following points are noteworthy: i It was found that the heat recovery module was being erected at this time, and that all underground piping was in place. Foaming was in progress, and the Contractor was in the process of installing shrink sleeves on the foamed joints. Some of the shrink sleeves were found to not have a satis- factory bond, and the Contractor was told to make sure that the shrink sleeves were of satisfactory quality. Ze In the elementary school boiler room, it was noted that the boiler bypass line had been moved to the correct location. Also, it was noted that the heat exchanger was plugged in correctly. An undersized flow meter was still installed. 315 In the high school heat exchanger room, {it was noted that the heat exchanger was now installed correctly. It was noted that an undersized flow meter was installed. 4, Inside the power plant, a minor portion of the piping was complete. It was noted that shims had been used underneath the heat recovery module cribbing, and the Contractor was told that this was not completely satisfactory. The cribbing was only supported in a small area, and there was the risk that the building would shift with time. Ss It was noted that the equipment on the skid inside the heat recovery module was installed opposite of what is shown on the drawings. However, this will most likely not have any effect, as piping will still be rather simple. At this time, it will be quite involved to change this to reflect the original drawing, as the module would have to be taken apart. The Contractor was told that the equipment locations would not necessarily have to be changed; however, tie-ins would have to be made in a neat manner with hangers, etc. The Contractor agreed to this. polarconsult Field Trip Report Elim August 31, 1983 In Elim, living conditions seemed somewhat primitive. Peter N. Hansen Mechanical Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Savoonga September 1, 1983 Messrs. Carson and_ Hansen, of Polarconsult Alaska, Imei conducted a routine field visit to this site. The purpose of the trip was to inspect general progress, and to aid the Contractor in design clarifications if needed. The following points are noteworthy: ie Most materials had arrived on the site, and the heat recovery module foundation was in place. The skid was mounted on the foundation. The exhaust fan had been installed in the power plant, and the heat exchanger had been placed inside the boiler room. So far, no hook-ups had been made. Two sections of culvert had arrived, and apparently would be needed for crossing under the new road that had been put in between the church and the boiler room. The Contractor asked whether he could have the freedom to turn the skid inside the heat recovery module in the best possible direction. This would allow him to put the outside steps where a new road was built. The Contractor was told that he could turn the skid to the most practical way. The Contractor asked whether the pump inside the power plant could be placed between the day tank and the generator instead of, as shown on the drawings, between the day tank and the shelves. The Contractor was told that this would have to be checked with AVEC in Anchorage before this decision could be made. The | |Conthactor | felt) that) the location between the day tank and the generator would give more room for the operator to work inside the power plant. The Contractor asked whether the piping inside the boiler room could be run along the opposite wall over the hot water heater and oil storage tank. The expansion loops would be in the same positions as shown on the drawing; just on the opposite wall. This would facilitate piping considerably, as the pipe route as shown goes through several congested areas, and it is not possible to make it exactly as shown on the drawing. The Contractor was told that this would most likely be possible to change to the proposed routing. However, no piping could be done until the designer had cleared. The Contractor was promised an answer within a few days. polarconsult Field Trip Report Savoonga September 1, 1983 Living conditions seemed somewhat primitive. Peter N. Hansen Mechanical Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Good News Bay September 2, 1983 Messrs. Carson and Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The following points are noteworthy: 1. When we arrived at the site the system was in operation and was being tested. Inside the power plant, one engine was operational and was hooked up to the waste heat system. According to an AVEC mechanic on site, the waste heat system had solved one major problem for the power plant. The generator’ on line did no longer overheat as it did previously. The Contractor was told that PVC shrink sleeve on pipe riser at the school would have to be improved. Inside the heat recovery module it was noted that there was a leakage problem in the panels. The Contractor was told to turn all meters and gauges in such a manner that they could be read from the door area inside the module. Inside the power plant it was noted that no flex connectors had been used between the engines and the system. Inside the power plant, hose connections had been made some what differently. The fan sequencing was demonstrated and on top of the heat recovery module it was noted that two ponds of water had collected. It was apparent that there had been water problems inside the module, however the Contractor told us that’ these problems were now solved. Also it appeared that no bond existed between the sheet metal and the foam in the panels. The flexible hose connection between the power plant and the heat recovery module had not been made as specified. The bell shaped ends were not as_ specified. Inside the heat recovery module, no bell shaped ends were present and also outside the power plant wall no bell shaping had been done. No 18 x 18 inch steel angle support brackets were mounted. In the boiler room, it was noted that the boiler bypass had not been changed. The three way valve was not operating the way it was supposed to. However, the three way valve apparently had been disconnected and it becomes a question as to whether the boiler bypass connection should be polarconsult Field Trip Report Goodnews Bay September 2, 1983 changed. The Contractor had been told that the Elementary School was to be abandoned next year. Peter N. Hansen Mechanical Engineer PNH: jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult ELEED) TRIP) REPORT Sit.) Many's September 2, 1983 Mr. Carson and Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the visit was to inspect general work progress and to inspect Perma-Pipe field connections. Foaming and glass fiber work was in progress and the quality seems rather satisfactory. The Contractor was told that after foaming and glass fibering, the pipe section from the power plant to the cold storage plant could be lowered into the trench and back filled. However the Contractor was told to leave exposed, the anchor and the elbows. Inside the power plant some victaulic piping had been made and the Contractor was in progress of making tie-in's to one generator. The Contractor proposed that a bypass’ line be provided on the heat exchanger so that in case of heat exchanger failure, a glycol could be circulated through the system, and that way prevent freeze up. The Contractor still had some problems with water in the ditch and the sides of the ditches caving in. However, it did seem like the Contractor was able to keep the ditches almost dry with pumping. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Unalakleet September 8, 1983 Mr. Kaluza and Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of this trip was to inspect general work progress. The Contractor had encountered a problem in the area next to the tee branching off to the 14 plex. A water line was running along the trench at such a depth that it would be highly unpractical to go underneath the water line. The water line was not as shown on the plans. The Contractor asked whether he could lead the glycol line over this water line or whether he would have to dig down underneath it. A quick response to this question was promised. Consultation was made with Mr. Mark Newell of Polarconsult Alaska, Inc. and it was decided that it would be safe to let the glycol pipe run over the water pipe. The Contractor was told to make sure that joints in both carriers and both jackets were sound so that no contamination could ever take place. In order for a contamination to take place we would have to have a leak in both carriers, both jackets at the same time and at the same place. And also a pressure loss in the water line greater than the pressure loss in the glycol line. This would be the only way a leak could ever contaminate the water line. Minimal dirt cover over the glycol pipe will be approximately 3-1/2 foot. Trenching was almost complete to the power plant. The pipe was being laid between the city hall and the 14 plex. The Contractor was ready to start installing the heat exchanger in the power plant. The following problem areas were pointed out by the Contractor. Piping the gym was almost complete. The Contractor requested an answer as to whether a pump should be installed in the gym or not. The piping in the elementary school boiler room was not yet complete due to lack of materials. Piping in the school district building boiler room was complete except for the flow meter. In the 14 plex boiler room, the heat exchanger was in place and piping had started. The Contractor should be done with piping in about one week. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kaltag, Grayling, and Elim September 8, 1983 Messrs. Kaluza and Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to these sites. The purpose of these Visits was |to: le Investigate complalnts concerning school heating system in Kaltag; ae To inspect general progress and workmanship; and 35 To Inspect repairs done to Rovanco pipe in Grayling. The following points are noteworthy: Kaltag: Ss In Kaltag, it appeared that the school had been rephased in such a manner that motors were turning backwards, and the electrical meter was turning backwards. 2's The school heating system was not able to provide temperatures necessary for comfort. Bye The Contractor had tools and materials stored in the high school kitchen, and this will have to be taken care of immediately. 4. The tank farm had not yet been improved, and generally very little progress could be seen from the last site visit. Grayling: ils The high school maintenance personnel complained that the Contractor had left the school heating system in such a manner that it could not be operated. Pipes had to be connected and water had to be added before the system was operable, and the Contractor had not taken care of this. Also, a couple of leaks had been made in the school heating system, and this will have to be taken care of. Die The heat exchanger was in place underneath the_ school building. However, it was not yet hooked up. Generally, very little progress could be seen since the last site Visit. 3 The Rovanco PVC pipe jackets had been repaired. However, the job did not seem to be done yet, as several fittings still had unsatisfactory welds. polarconsult FIELD TRIP REPORT Kaltag, Grayling, and Elim September 8, 1983 Elim: i All underground pipe had been backfilled, and work was almost complete in all boiler’ rooms. It appeared that above-ground piping underneath the high school would have to be improved somewhat, as foam was exposed in several places. Work in the power plant and the heat recovery module was not yet complete. General work quality was not impressive. The site superintendent was not on site, and could not be reached for comments. Peter N. Hansen, Mechanical Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kiana, Ambler, and Shungnak September 8, 1983 Messrs. Carson and Turner of Polarconsult Alaska, Inc. conducted a routine field inspection of the above mentioned villages. The purpose of the trip was to inspect the general work progress and to guide the Contractor in areas where needed. The findings were as follows: Shungnak: 1, In Shungnak, the work is progressing very satisfactorily, and the contractor has hopes of starting the system up during the week of September 12 - 18, providing the electricians are able to finish up their work. Basically, all work except electrical is substantially complete, with minor clean-up of the area remaining. Overall quality of the work appears to be satisfactory. Dis In the heat recovery module, weatherstripping of the doors will be required. Additionally, some of the cribbing for the above ground piping needs to be pinned together so that it will be secure from winds, vandalism, etc. Ambler: 5 In Ambler, the piping work is substantially complete, and the electrician was in the process of wiring the waste heat module equipment into the AVEC generators. 4, As in the case of Shungnak, minor clean-up remains as well as the regrading of the buried pipe in the vicinity of the water tank and the school. ee It was noted that the Contractor ran into fce on the run between the AVEC module and the new water tank in the vicinity of the old Public Health Service abandoned water line. This condition was apparently unknown to the designers, and certainly to the Construction Manager. Consequently, this is an area that will require watching to ensure that proper support for the below ground pipe exists should there be any thaw settlement due to the warm pipe, and any ice in the ground. 6. Similar to Shungnak, Ambler should be ready for start-up during the week of September 19 - 25. polarconsult Field Trip Report Kiana, Ambler, and Shungnak September 8, 1983 Kiana: 7. In Kiana, work has not progressed as far as Shungnak or Ambler. The heat recovery module has been set up. We were not able to get into the module during the site visit, but from the equipment in the general vicinity there is obviously piping and electrical yet required, as well as hook-up between the heat recovery module and the AVEC building. The above ground pipe has been laid out, including the culverts, but no earthwork has yet’ been accomplished over the above ground pipe. Since the original design by Raj Bhargava & Associates and the initial field trip by Polarconsult, AVEC has installed a fence around the tank farm and the new generator modules. Additionally, a new water plant and a water tank is being constructed at the Public Health Service for the village. In evaluation of these new facilities Cunknown to us before this time), we conclude that reconsideration of the overall alignment should take place. This is now being pursued with AVEC, Rockford, the Alaska Power Authority, and Raj Bhargava (the designer) to determine if in fact it is in the best interest of the village and all parties to make this relocation. Since the subject of some concern, and special communication to the APA and Rockford will be initiated, no additional in-depth discussion will take place based on this trip report. Morris J. Turner, P.E. Project Manager /pf cc. Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Mary's September 10, 1983 The undersigned made an Inspection visit to St. Mary's on September 10, 1983 to view ongoing work of J. B. Mechanical. The following points are noteworthy: Most of the trench was open with glass fiber reinforced CPerma-Pipe) waste heat pipe strung over much of the ditch. Water and sloughing ditch banks were encountered in many areas, while in others the ditch was dry. A portion of the line had been pressure tested, insulated, and glass fibered. The workmanship was_ good. Backfilling of the ditch had taken place from the cold storage building, thence alongside the post office and to the utility generators building. Duane Carson Civil Engineer /pf cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Savoonga September 12, 1983 Messrs. Kaluza and Hansen of Polarconsult Alaska, Inc. conducted a routine field trip to this site. The purposes of the trip were: 1. To inspect general progress, Qe To clarify design, and Ve To investigate a complaint by AVEC. The following points were noteworthy: Ls Arctic pipe had been installed. Foaming and covering of joints was yet to be done. Inside the boiler room, tie-in to the boiler systems had been done. No piping had been done. An additional culvert had been placed under the road. Remote radiators were in place on top of the heat recovery module. The heat recovery module was in place, however inside piping was not yet complete. We talked with Robert Greeson of AVEC who said that the complaints which had been filed over the Contractor had no significance at all; the Contractor was not to blame for any of the problems. Inside the power plant, some victaulic piping had been done; however, no connections had yet been made to the generators. The Contractor had been told by AVEC personnel that tie-in to the last generator could not be completed before approxi- mately the end of this month. Only one generator was operational, and this could not be shut down. Peter N .Hansen Mechanical Engineer /pft GGr Mr. Jerry Larson, Alaska Power Authority polarconsult . FIELD TRIP REPORT St. Mary's September 15, 1983 Mr. Duane E. Carson of Polarconsult Alaska, Inc. conducted a routine inspection visit to the above village. The purpose of the site visit was to inspect work progress. The following points are noteworthy: The 3" lines from the module to the hotel is in the ditch and back-filled. All elbows have been left uncovered. The 5" lines from the module the the main school building were being filled with water for the hydro test. The insulation foaming and fiberglassing crew is getting 10 to 12 joints per day. The Contractor found that by blowing warm air through the pipe the foaming worked better and used approximately 1/3 less materials. Also, the crew has run out of fiberglass mat material so will use fiberglass cloth for all the layers. The barge arrived the night of September 9th with materials for the job, which included the heat exchangers and parts for the module. Job hours are now 6 days a week, 9 hours per day; so welders quit and left on the 3:15 p.m. flight to Bethel. Duane E. Carson, P.E. Civil (Structural) Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FLED ERIE REPORT, Shungnak September 15, 1983 Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the trip was: lice To inspect general work progress, and if necessary 2h. To aid in design clarifications. Piping instde the heat recovery module was almost complete and electric work was in progress. Routing pipe to the pump house was almost complete, except for a few minor cripping changes. Inside the pump house the piping was complete. The Contractor was told that the banding on arctic pipe around cripping should be improved. Also, the Contractor was told that only pressure treated cripping was to be used. The Contractor was told that inside the school boiler room, an air vent on the district heating side would be needed. Inside the school boiler room, it was noted that two thermometers were placed in the heat exchanger line on the same side of the heat exchanger. Inside the school boiler room, pipe hanger would also have to be improved. Inside the power plant most piping was complete, however no ‘generators were hooked up at this time. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD) TRIP) REPORT Ambler September 15, 1983 Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of this trip was: ie To Inspect general work progress. All underground piping had been backfilled and work quality seemed adequate. No work had been performed in boiler rooms since the last inspection. Inside the pump house boiler room an air vent was needed on the supply side next to the pressure gauge. The module was not yet finished, and hook-up to the power plant had not yet been completed. The power plant piping was not yet complete and the Contractor foresaw a problem with hooking up the operating generator as this was the only generator opera- tional that was large enough to handle the load in the town. However, the Contractor was counting on being able to shut off the school over a weekend and then use the smaller generator to run the rest of the town. This would allow the Contractor to hook-up the waste heat system to the larger operating generator. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kiana September 15 - 16, 1983 Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the trip was: NS To inspect general work progress. 2s To aid the Contract in design clarifications. Bie To discuss various change orders with the Contractor's representatives. The Contractor was going to fix the panel underneath the heat recovery module with sheet metal screws. Sealing would be with silicone caulking. The expansion loop by the basketball court had been turned 180° to give extra room for the basketball court. The extension loop by the school had been placed under the stairs. The panels inside the heat recovery module would be repaired and painted according to the Contractor. The outside piping was complete except for a few foam joints and a few clamped outer jackets. No anchors had been made yet. Steps in board walk had still not been made. Cribbing and banding of outside pipe was also not yet complete. The school boiler room piping was almost complete. The Contractor told that the area along the arctic pipe was not really a road. It was just a track that had been used as a road. It appeared that the wisest decision would be to leave the arctic pipe the way that it was at this time. The fuel oil pipe to the pump house had been placed inside the culverts along the arctic pipe. A total to 220! of culvert had been installed. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult ETEEDSGRTEPCREPORT. Kaltag, Grayling, Unalakleet, St. Mary's September 16, 1983 Messrs. Carson and Carlander of Polarconsult Alaska, Ince conducted a routine Inspection visit of the above named villages. Kailitag:—_ Contractor is not on-site -at=thiis=t imei. We met the AVEC power plant operator Chris Semaken. The number two generator is overheating in the morning and evenings due to the overload. The fresh air fan into the power plant has been removed, which may be adding to the heating problem. The Contractor has taken the fan to Grayling as it is a single phase motor and Grayling has only single phase power. The operator had a small fan in the doorway trying to get some cool air into the building. Also for some reason they cannot run two units at the same time. The operator stated that when the number one generator is turned on line with number two running it trips the circuit breakers. Grayling: Contractor has the ditch dug and pipe in the ditch from the module to the_ school. It was noted and the Contractors' workmen, Don Seek, told that the welding on the expansion loop and the PVC piping had to be re-welded. Insulation could be seen between the joint. Contractor will try to test the system on Friday the 16th. The module has been put together and the skid turned 180° so that the pumps are near the door. Unalakleet: All of the pipe is now in the ditch and the Contractor has twelve (12) welds left to do and he would pressure test on Thursday. The ditches around the schools and to the city hall are backfilled and graded. Contractor hopes to have all ditches backfilled next week. St. Mary's: Contractor has all of the pipe in the ditch and backfilled except for the concrete anchors, and the foaming and fiberglassing of some joints. Gordon Blase was trying to locate the power catalyst for the fiberglass resin. Duane Carson Civil Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Savoonga September 21, 1983 Messrs. Kaluza and Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the visit was as follows: i To investigate change order requests made by the Contractor. 2s To Inspect general progress. Se To investigate the Contractor's questions concerning markings on pipes in the boiler rooms. The following points are noteworthy: ° Only minor work had been done in the power plant and according to AVEC Mechanic, the power plant would be ready for hook-up in two to three days. fo} The heat recovery module was not yet finished as radiators had not been hooked up. Also, electrical work had not been finished yet. fo} The arctic pipe between the heat recovery module and the boiler room was not yet complete. No joints had been foamed and no jacket joints were yet finished. ° Inside the boiler room, the heat exchanger was connected to the district heating system. However, installation was not according to drawings, as only one expansion loop had been installed. It | jis |\/a |) question however whether this second expansion loop is necessary or not. A pressure test had been performed on the district heating loop, however there was a leak inside the boiler room. As discussed with the Contractor, the design had been changed slightly and the pipe is now run on the opposite side of the boiler room. ° On September 19th, the Contractor had made an inquiry concerning markings on existing piping In the boiler room. There appeared to be a conflict between the mounted check valves and the markings on the pipes. Uh the pipe markings were correct the design would have to be changed. If the check valve was installed correctly the waste heat system could be installed as designed. It was determined that the check valve was installed correctly and that the pipe markings had to be wrong. It appeared obvious that the design would not work if the markings on the pipe were not correct. polarconsult Field Trip Report Savoonga September 21, 1983 Peter N. Mechanical Engineer /jkb cc. Mr. It was verified that the Contractor had performed additional work in connection with putting in a gravel pad under the new heat recovery module. This gravel pad was not specified, however soils conditions were so poor that a gravel pad was necessary. Also, it was verified that the culvert had been put in the new road and that this road crossing would be an extra item that was not taken into account in the original design. We met with the high school principal, Mr. Rudy Howard, and he expressed appreciation for the way that the Contractor was installing the project. The Contractor seemed to be very responsive to requests made by the high school and for instance, only a two hour shut down of the heating system was experienced on a weekend when the tie-in to the boiler system had been made. Hansen Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Unalakleet, Kaltag, Grayling, St. Mary's September 21 - 22, 1983 Messrs. Turner and Carlander of Polarconsult Unalakleet: We met with Lynn Rayburn’ and Jerry Moline of Construction and visited the heating plant Alaska, Inc. conducted a routine inspection visit of the above named villages. Wick locations of all heat exchangers. Work is proceeding and is near completion at all locations. Work in the AVEC Power Plant has been started. The Utility has requested the consideration of running our 4" WHR supply and return lines in their trench to the generators. trench appears to be too small to accommodate the The lines. Also, the questions of raising temperatures along side of the fuel line was raised by Wick Construction. Exterior welding and insulation is complete and most of the line has been backfilled. Fiberglassing of the joints should be completed Friday, September 23. Overall workmanship at Unalakleet by Wick Construction excellent. Kaltag: The H.R. Module has been erected and generator building is operating. Material work on the exterior above ground line. is on remaining is the fan on the Audometer readings were taken at the generator building, the teacher residences and, in and outside of the school building. Readings were as follows: Just outside the AVEC plant Cschool side) At the nearest school building corner to generator Inside AVEC Generator Building At exhaust side AVEC Generator Building Caway from school building) Near school workshop Outside teachers quarters Cfar side from school) Inside school location Ckitchen) At teachers quarters Cnear side to school) Inside school entrance, nearest generator building Took reading when dogs in town were 90 67 100 95 7D 60 45 70 50 howling site for at DB DB DB DB DB DB DB DB DB and recorded a reading of 110 DB which was worse than inside school generator module. polarconsult Field Trip Report Unalakleet, Kaltag, Grayling, St. Mary's September 21 - 22, 1983 We met with Kevin LaFever, the Principal, to inquire about school complaints: ° Contractors materials and tools were moved under the school building by the school officials. ° Fencing the generator fuel tanks was agreed to be desirable. ° We also met with Dick Walls of Rockford in Grayling to discuss other problems. Electrical panel covers removed by AVEC and Rockford persons inside and outside school will be replaced September 23, 1983. ° Inspection failed to) turn up reason. for reverse operation of blowers and electricity meter. An underground cable cut by others Cnot Rockford) may have been improperly spliced when recently done by city personnel and could possibly be problem although most likely it was caused by Rockford. In other words problems may not be Rockford caused. Grayling: We met with Dick Walls of Rockford. Work jis progressing in the H.R. module and most of the underground work is completed and final grading of backfill was taking place. The welded p.v.c. joints have been repaired and final thrust block poured. St. Mary's: We met with Gordon Blase and toured the _ heat exchanger sites. Piping routes Inside school are being modified because Of headroom, construction obstacles and plan inconsistencies. Purlins supporting piping in the generating plant are to be reinforced. Contractor ran piping different than shown on Contract drawing. Exterior fiberglass joints are being completed with thrust blocks poured and backfilling should be completed within the couple of weeks. Workmanship poor on latest fiberglass jointing work. polarconsult Field Trip Report Unalakleet, Kaltag, Grayling, St. Mary's September 21 - 22, 1983 Morri Civil /jkb GGi. Contractor requested to be able to plumb on opposite side of pump at the school Creference H/M-3 detail). We told Mr. Blase that we would check this out and let him know if o.k. Our opinion is that it poses no problem and is a good way to do the work, we confirmed to Mr. Blase that this change was o.k. on September 23. There was snow in the air. s J. Turner Engineer Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Shungnak, Ambler, Kiana September 22, 1983 Messrs. Carson and Barkshire of Polarconsult Alaska, Inc. conducted a routine inspection of the above named villages. Shungnak: There is no-one at Shungnak except one laborer, who was at that time painting inside the heat recovery module. However, the system is up and running at Shungnak. Routine inspection showed no observable problems. All available heat at this time is being diverted to the school; no waste heat is being supplied at the pump house. This is due to the fact that there is not enough heat available at present. The following operating temperatures were observed: Heat recovery module, 180°F in - 170°F out. School boiler room heat exchanger, 157°F in - 115°F out. School boiler system, 130°F in - 128°F out. No insulation of piping has been done at Shungnak yet. Also it was observed that the vertical pieces of steel at the anchors on the outdoor pipe should be capped or protected in some way to prevent injury to a passer-by. The BTU meter in the school boiler room has not yet registered a single BTU, although heat is flowing. Unable to determine the exact reason for this while on site. Ambler: Underground piping complete and backfilled. Work currently going on at the pump house and in the heat recovery module / generator building. It was cbserved that the heat recovery module itself has been recaulked and appears to be dry. Contractor estimated that all piping would be complete within four (C4) days. They are awaiting electrician and insulators to arrive on site. Contractor estimated start up at Ambler some time next week. All work and progress seemed satisfactory. Kiana: Work at Kiana is progressing smoothly. All aboveground pipe is complete. Work is currently under way in the pump house and the heat recovery module. Heat recovery piping in the module expected to be completed by the end of this date. Piping will begin next in the generator building itself. Expansion loops at the school building and adjacent to the playground have both been moved as requested by Polarconsult Alaska, Inc. Also, a step over has been built on the wooden walkway school grounds as requested. There is a 20' section of pipe at the playground that is exposed. There are culverts on both sides of this pipe, with built-up dirt crossings over. Why the entire pipe in this area of the polarconsult Field Trip Report Shungnak, Ambler, Kiana September 22, 1983 playground was not placed in culvert and covered with dirt is not’ known. The edges of the culvert and also the vertical steel at the anchor may provide a serious hazard to children playing in the playground area. Other than this concern, all work at Kiana appears to be of very high quality. James Barkshire Assistant Project Manager /jkb cc. Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIE REPORT Angoon September 26, 1983 Mr. Turner, Mr. Longstaff, and Mr. Hansen of Polarconsult Alaska, Ine.| conducted) a field Visit to this, site. The purpose of the trip was to witness start-up, and to do final inspection. Also, Mr. Jerry Larson of Alaska Power Authority was present for the start-up as was Mr. Harry Brown from Thlingit Haida Electrical Authority. The following points are noteworthy: The motor starters for both P-1A and P-1B were located on the wall behind the flat plate heat exchanger. This location did not provide the clear space required to trouble-shoot failures in the motor starters. Minimum working space about electrical equipment of this voltage class (151-600 volts to ground) is defined in NEC Article 110-16 Ca)-Cf). The working space required for these motor starters is 36" from the enclosure front; 30" width, which need not be directly centered on the equipment, but must be a cleared space from floor level to the top of the working space; 64" from the floor level to the top of the working space. The 1/2" EMT conduit, between the pressure switch and the motor starters for P-1A and B, was taped to a pipe hanger strap approximately 3 feet from the pressure switch location. This tape should be removed and replaced with a metal pipe or conduit clamp. NEC Article 348-12 requires that EMT shall be securely fastened in place at least every 10 feet and within 3 feet of each outlet box, junction box, cabinet or fitting. The directories in the circuit breaker panelboards Cin both the generator building and the sewage treatment plant) were hand written instead of typed as required by the specifications. For safety, a legend should be inscribed on the front cover of both Pl motor starters to indicate that control voltage is supplied by circuit breaker 13. Not the disconnect switches, which control the motor voltage supplies. The overload heaters in the motor starters were Square D type B9.10, which are rated at 5.22-5.84 Amp. The motors are rated at 4.5 Amp., with a 1.10 service factor. The Square D Digest 162, pg. 466 indicates that the heaters should be sized at no more than the rated Amps. The proper heater size is indicated in Table 13, pg. 472 as a B 7.70 which is rated at 4.49-4.93 Amp. polarconsult Fleld Trip Report Angoon September 26, 1983 Seeding had not been done to areas where excavating had been done. However, the Contractor told that the city had asked him not to do any seeding. The BTU meters in various locations did not work satisfactory. Also, two minor leaks were found In soldered connections inside the power plant. General workmanship was quite satisfactory. The system functioned as intended and it was noted that the boilers did not come on in the boiler rooms after the system was put Into operation. The system was not balanced as the designer had not provided data necessary for balancing. In the high school gym a problem occurred with the temperatures not being sufficient for the application. The high school has a dishwasher that requires 200° water and naturally, the waste heat system is not capable of providing this temper- ature. Recommendation was made to Mr. Darrell Moore of Chatham School District to have a tank water heater installed that would boost the temperature from the 160° provided to the necessary 200°. Mr. Moore acknowledged that this was the necessary solution. It appeared that the missing air vents had been installed properly and that the system was capable of bleeding itself for ann It did not seem to contain any aftr a short time after it had been put into operation. A hand written draft of operation, start-up, and shut-down procedures were delivered to the power Plant operator and the school maintenance personnel, and it was posted in the proper locations. These procedures will have to be typed and delivered in accordance with specifications. Peter N. Hansen Mechanical Engineer CG: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Mary's September 28, 1983 Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the visit was: 1. To help the Contractor in design clarifications. Ze To investigate complaints by the city of St. Mary's concerning possible lack of sufficient heat for heating the city water system. 3. General inspection. The Contractor asked: ie Whether it was necessary to mount pumps with flexible connectors. He felt that the victaulic piping used provided sufficient flexibility to insulate from sound transmission. Ze Whether it would be allright to use neoprene rubber biscuits Instead of neoprene rubber pads underneath the pumps. Sie Whether pipe from cold storage plant could penetrate the heat recovery module floor instead of the wall. 4, Whether heat exchanger installation could be reversed. The Contractor was promised an answer within a few days after the factory had been consulted. The Contractor had changed pipe supporting system within the power plant to what he felt was SUTTrIGient.. It was discovered that the Contractor had not put in a valve on the line going to the expansion tank. However, the Contractor was told not to correct it until further notice was given as it fs normally considered bad practice to have a valve on a line to an expanston tank. Also, it was discovered that the Contractor had piped the return line from the heat exchanger to generator No. 353 incorrectly. The return pipe from the remote radiators had been connected to the wrong side of an AMOT Valve. The design drawings were very unclear and erroneous. The Contractor might decide to ask for a change order based on this fact. On the design drawings several pipes were missing and the AMOT Valve was not shown at all. It is however the impression of the Engineer that the Contractor should have asked questions before installation was made. It was discovered that existing water heating system is connected in parallel with the new system in such a way that proper function of the old system can be obtained by using existing butterfly valves as balancing valves. However, there is no way of determining when the system works correctly and some kind of improvements might have to be made later on. It appears that with the type of temperature controls that are incorporated into the generators simply balancing the system using butterfly valves will not give a very stable system. polarconsult Field Trip Report St. Mary's September 28, 1983 There appears to be no immediate simple solution to this problem. If the system is balanced as described before, the balance will be valid for only one load size. If the load is less than what it is balanced for, the heat not used in the water heating system will go to the remote radiators where it will be lost. If however the load Is greater than what the system is balanced for, the heat will not be available as this heat is removed in the new heat exchanger and thus the city will not have the _ heating capacity necessary. This all means that in order to provide the city with sufficient heat at all type loads, the system will have to be balanced for the maximum load and whenever the load Is less than the maximum load, the heat will simply be wasted in the radiators. From a heat utilization standpoint this is highly undesirable. One solution seems to be installing a_ thermostatic valve where the tee is connecting the old heat exchanger with the new heat exchanger. This thermostatic valve shall then be controlled by the exit temperature from the old heat exchangers secondary side. However, if the existing heat exchangers are not oversized sufficiently, this again will mean that heat will be wasted in case of a heavy load on the existing heat exchangers. Another option is to install a motorized control valve on the new heat exchanger and let this valve be controlled by the exit temperature from the existing heat exchanger. If this temper- ature gets below a pre-set limit, the motorized control valve will shut off the new heat exchanger. This will allow adequate flow through the old heat exchangers. However, if the existing heat exchanger system allows the exit temperature on the primary side to exceed a certain value the motorized control valve shall open and allow some flow through the new heat exchanger. At that time also, an alarm shall be activated. This situation will occur at a time when the existing heat exchangers are not big enough anymore. Further investigations in the PHS pump house revealed that the heat exchanger for the city water system is grossly undersized. If this is taken care of it should be possible to operate the two systems in parallel with no problems. This system will have to be sized in such a manner that the available temperatures from the power plant can be utilized fully. This will assure that the water heating system will get adequate heat before heat is removed with the new district heating system. Met with Tim Troll of the city of St. Mary's and explained these things to him. Mr. Troll asked that I investigate the necessary size of the heat exchanger and relay the information back to him as soon as possible. The Contractor, J.B. Mechanical, is currently negotiating with the city to do miscellaneous upgrading to some heating systems in the city shop buildings and also_ some upgrading to the water system. If the necessary changes can be polarconsult Field Trip Report Sti.) Marys September 28, 1983 calculated soon enough, these changes can be incorporated to the system before J.B. Mechanical demobilizes. An inspection was performed to a section of the perma-pipe in the area where water problems have occurred. It was evident that the glass fiber work on that section of the pipe was of inferior quality. No tent had been used and water had penetrated the resin. This made the resin milky white and the resin would not set up properly. Also, cleaning of pipe sections to be joined to the glass fiber was not sufficient. Mud was found underneath glass fiber mats and resin and the Contractor was told to remove two 8' sections of glass fiber and redo both sections. Also the Contractor was told that pictures would have to be _ provided showing that these two 8' sections had been removed and cleaned and that new sections of adequate quality had been provided. The Contractor was told to do the work under a tent. Considering the inferiority of quality it might be a good idea that’ these sections are inspected before back-filling. There were large voids in the glass fiber and foam was accessible through these voids. Water would penetrate immediately and destroy the pipe. The Contractor's attention was called to the severity of the bad craftsmanship and Contractor promised to take the necessary actions to avoid repetitions of this. Inside the power plant, the pipe hangers had been’ improved somewhat however, it is to be determined whether the improvements are adequate. The Contractor had had a problem with a plumber walking off the job complaining about insufficient living facilities and bad food. It is not the impression of the engineer that’ these complaints are reasonable. It appears that J.B. Mechanical are providing the best quality of living facilities of all eleven jobs. Peter N. Hansen Mechanical Engineer cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kiana September 28, 1983 Mr. Carson of Polarconsult Alaska, Inc. conducted a_ routine inspection visit to the above named village. Rockford personnel were not on site during the visit. The crew was trying to get to Ambler for the start-up of the system there. Bad weather; 300 foot ceiling and 1/4 mile visible and blowing snow, forced them to return to Kiana. The outside work at Kiana appears to be nearly complete. Some piping work is being done at the utility building, heat recovery module and the pump house. The water utility has asked the Contractor not to connect the heat exchanger to the boilers In the pump house. This connection fis to be made in the spring. Ambler: Due to bad weather at Ambler, I spoke to Dave Marks of Rockford on the telephone. He hopes to start-up the system the first part of next week if the weather will allow the electricians to get to the job site. Shungnak: The pipe insulation crew is on site, work progress could not be checked due to bad weather. Duane E.| Carson, |P. E. Civil CStructural) Engineer /jkb cc: Mr Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Goodnews Bay October 11, 1983 Mr. Hansen of Polarconsult Alaska, Inc. conducted a field visit to ‘this site. The purpose of the trip was to conduct final Inspection. An Electrician was working on installing the BTU meters. The flow meters had been installed. The system was operating and the radiators on top of the heat recovery module were idle as were the boilers in the school boiler room. This indicated that the system was working. In the school boiler room, a leak was found in the return line going to the boilers. The Contractors attention was called to this item. Glycol had penetrated the insulation and the leak obviously had to be fixed. Protective metal shields had been installed on exposed shrink sleeves on the district heating pipe. This item had been criticized earlier. Ponds of water were found on top of the heat recovery module. However, they did not cause any water pene- tration into the module. In the generator building it was found that an air vent was missing on the supply line to the heat recovery module. On generator No. 1 there seems to be no easy way to install drains and air vents. On the hot sides an air vent could be installed where the thermometer is presently installed. This would require a tee, two short nipples and a gate valve; all 3/4 inch. The same vent arrangement could be installed on the cold return. St would then be installed in the tap where the pressure gauge currently is installed. The same materials would be needed. There seems to be no easy way to install a drain. However a drain is installed in the engine block itself. L&) thls) iis; moe sufficient, a saddle type drain could be installed over the horizontal section of the cold return. It is a question as to whether these drains and vents are necessary at all as the engine can be drained by using the existing drain and loosening either the temperature gauges or the pressure gauge and thereby letting air into the system. This solution is however somewhat less convenient. Generator No. 2 is currently not installed. Air vents would here be installed in the same manner as described for generator No. 1. Drainage arrangement should consist of a 3/4 inch gate valve located as low as possible on the cold return. On generator No. 3 air vents could be installed in the same manner as described for generator No. 1. A small drain is presently installed at the bottom of the water pump. This drain should be sufficient. However, if extra drainage capacity is required, this could be attained by removing the existing drain and installing a 1/2 inch nipple 5 inches long and a gate valve. No vent is installed on the generator return header at all, neither automatic or manual. polarconsult Field Trip Report October 11, 1983 Page 2 This should be changed with time. There are two ways of doing this. ee One of the blind flanges can be replaced with a blind flange with a half inch hole in which a nipple and gate valve is mounted. This hole should be off center as much as possible. ine One of the victaulic clamps can be replaced with a victaulic clamp with a tap. In the tap should be mounted a half inch nipple and a gate valve. It does not seem practical to install an automatic air vent on the generator supply header as this automatic air vent would stick up into the insulation. The generator headers should not have been installed as high as they are. However, it does not seem to make sense to change this at this time. It was noted that no valve tags had been installed and that no piping had been painted. Neither inside or outside the heat recovery module or inside the generator module. Inside the heat recovery module a temperature sensor had to be moved to allow for correct operation of the remote radiators. The Contractor was in progress of doing this. It was noted that the base mounted pumps had been welded to the skid. No painting has been done. It seems that according to specs all outside piping will have to be painted. Contractors attention was called on this point. It was noted that no pipes had been marked with hot water supply, hot water return, etc. Neither had any arrows been painted on the piping. No written valve directories, shut down procedures operations manuals had been provided. School maintenance personnel had been instructed on how to operate the system and how to put the heat recovery module into service after power failures, etc. Power Plant Operator had been instructed how to operate system. However, Contractor was not sure that they understood the procedures. An appointment was set up with the Power Plant Operator in order to provide further training. However, he never arrived at the agreed time and place. It seemed quite clear to the Engineer that the Power Plant Operator had not understood the procedures and that he did not have the necessary background to understand them. He had no idea what the system was doing and he had made no attempt to find oOut.; It seems very clear that in Goodnews Bay it will be up to the school maintenance personnel to keep the system running as the Power Plant Operator has no idea about what to do in case something goes wrong within the system. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority . polarconsult FIELD TRIP REPORT St. Mary's October 13, 1983 Messrs. Carlander and Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the trip was to inspect general work progress and aid the Contractor in design clarifications. Inside the heat recovery module not much progress could be _ noted. Inside the power plant, the Contractor was told to improve pipe hangers slightly. Insulation works were in progress between the heat recovery module and the power plant. This work was being done with pre-formed form and metal covers. In the main building boiler room, it was noted that a couple of air vents were missing. However, these air vents did not seem crucial and the Contractor was allowed to leave them out. These air vents should have been on the lines going from the hook up to the existing boilers to the heat exchanger. On the heat exchanger's secondary side no shut off valves had been installed and the Contractor was told to do so. Also, no relief valve was installed and this would have to be corrected. Contractor had made wall penetration into boiler room on the left side of the chimney looking in the direction of the supply line. The Contractor was told that the missing air vents would have to be described in the owner manual in such a manner that operations personnel knew that pumps should be off when system was to be vented. The Contractor mentioned that in the cold. storage building no piping detail had been shown for the heat exchanger. This will have to be provided to the Contractor. In the gym boiler room the mission had requested that’ the Contractor look into possibly replacing the boiler. Polarconsult promised that a small design change would be made so that the boiler could be replaced without the heating system having to be shut down. During the boiler replacement operation the heat “exchanger would take care of the heating load. In the gym boiler room the Contractor was allowed to turn the heat exchanger 90° in order to facilitate piping. Also the Contractor was promised a revised piping schematic in order to incorporate the new boiler bypass line. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Goodnews Bay October 14, 1983 Messrs. Longstaff and Hansen of Polarconsult Alaska, Inc. conducted a field visit to this site. The purpose of the trip was perform electrical final inspection and the check on items to be corrected from the last field visit. The pipes had been painted as required, however it was not a very nice paint job. Valve tags had not been provided so far and no arrows or identifications had been provided on the insulated Pipes. The insulation was not complete inside the heat recovery module and the insulation had not been repaired in the boiler room where a leak was found last time. The leak had been repaired. The BTU meters did not seem to work as the BTU meter in the heat recovery module did no change reading the entire time and the BTU meter in the school changed only 30,000 the entire time we were there. Inside the power plant some insulation was missing on elbows. Inside the school boiler room, the electrical connection to the BTU meter did not meet code as it was not in conduit. Also, it was not marked anywhere which circuit breaker the BTU meter was on, District heating temperature going into the heat exchanger was about 164; going out was about 146. Due to the bad weather conditions, no attempts were made to set up meetings with potential maintenance personnel. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kiana October 20, 1983 Mr. Turner, Mr. Longstaff, and Mr. Hansen of Polarconsult Alaska, Inc. conducted a field visit to this site. The purpose of the visit was to conduct final inspection for the waste heat recovery system. The system was installed and in operation and was basically complete. Inside the heat recovery module, work was basically complete except for electrical panels where covers and miscellaneous items still were missing. Inside the heat recovery module no mechanical deficiencies were found. Insulation was complete, however some pipes still needed to be painted. Also pipe identification and arrows were still missing. The system operated with only slight noise. As in other installations, space was extremely limited inside the heat recovery module. This, however, could not be blamed on the Contractor. On top of the heat recovery module, the radiators were installed as specified. The radiators were hot, and the motors were not running. BTU meter had counted approximately 350,000 BTU's in approximately 16 hours. Inside the power plant, piping was complete and satisfactory. A drain had been installed on the return to the 353. A vent could be installed on the supply by installing a 3/8 inch tee, a nipple 2 Inches long, another nipple 2 inches long, and a 3/8 inch gate valve in the location where the pressure gauge is currently installed. This was the case on both 353 generators. On the Allis Chalmers, a vent could be installed in the same manner as described for the 353. However, this vent would only have little effect as it is quite far from the highest point of the valve. The booster pump had been installed properly. It was noted that there was no way of draining the return header. No drain had been provided at all. The supply header had one drain in the far |right | side. This drain consisted of a gate valve, mounted high. A low drain was located on the water pump, and an extra drain was not deemed necessary. On all three generators quick drainage could be obtained by using the installed drain or the existing drain and dismantling the pressure gauge to let air enter the system. This would also be a safe procedure for bleeding the system on start-up, because a pet cock was provided on each pressure gauge. Inside the power plant, the _ pipe markings and other identifications had been provided in a satis- factory manner. Hand pump and meter for glycol filling had been provided as specified. Radiators had not been packed and crated as required in the specifications. In was noted that the anchors presented a safety hazard as sharp metal corners were exposed. polarconsult Field Trip Report October 20, 1983 Page 2 General workmanship seemed nice. It was noted in the_ school boiler room that there was a valve on only one side of the strainer on the secondary loop. It was noted that on the primary loop, there were valves on both sides of the strainer. One valve was the circuit center. It seemed that the energy meter in the boiler room was functioning properly. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Shungnak October 20, °1983 Mr. Turner, Mr. Longstaff, and Mr. Hansen of Polarconsult Alaska, Inc. conducted a field visit to this site. The purpose of this visit was to conduct final inspection on the waste heat recovery system. Inside the AVEC building, it was noted that on the Emerson generator, a drain was’ installed. A vent would be installed using a 3/4 inch tee, two short 3/4 inch nipples, and a gate valve. However, the system could be vented by dismantling the pressure gauge. In Shungnak, an automatic air-vent was installed on both the supply and the return header. System seemed to be functioning properly. No mechanical deficiencies were found in the generator building. However, the support of the pipe for generator No. 3 was not completely adequate. Pipe markings and identification had not yet been installed. Inside the module, the hose on the supply sides should be supported. Pumps had been bolted to foundation, and this seemed adequate. Pipe had not yet been painted, and markings and identifications were not in place at this time. Insulation with black tape should be improved slightly. Also, where no ends were provided on insulation, this should be provided. Insulation material was exposed. BTU meter in the module seemed to be working. BTU meter was leaking by the union. 4-pound caps have been installed on the radiators. No outside piping had been painted yet, on top of the module. It seemed like the anchor posts were too weak for the purpose. The anchor closest to the heat recovery module, on the long line, had been pulled in direction of the power plant. Underneath arctic pipe, there were still some non-pressure treated cribbing used for support. There was a small leak in the elbow where the line turned 90° to go to the school. Anti-freeze was coming out of the first joints in direction of the school. BTU meter in school boiler room was not working. No markings have been installed yet on pipes in school boiler room. Old radiators had not been crated and packed. The heat recovery system was not being used in the water plant for two reasons. i The school needed all of the heat that it could get, and 2. Boiler temperature in the water treatment plant was so high that no heat could be transferred across the heat exchanger. The school maintenance man, Mr. Paul Weisner, was taking care of the system and had everything under control. When the school had its boiler repaired and did not need all the heat anymore, he would gradually try to decrease the temperature on the water heating system so that heat could be supplied to this building also. polarconsult Field Trip Report October 20, 1983 Page 2 Contractor should be required to report to the Engineer what the full load current of each motor is, and should then also report to the Engineer which size motor heater has been installed. That way it will be possible to check that correct size heaters have been installed. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Ambler October 20, 1983 Mr. Longstaff, Mr. Turner, and Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the trip was to conduct final inspection. Inside the heat recovery module it was noted that some insulation was missing, that no painting had been done so far, that a relief valve was located on the wrong side of a valve, and that voids between the pipe and the steel sleeves were not filled with insulation material. There appeared to be a leak somewhere as there was glycol on the floor. The leak was on the pump where the 1/4 inch copper tube is run. Also, there were small leaks around the three-way valve. The pumps were welded to the floor, however noise was not a problem. The insulation had to be repaired in places where the ends were not neatly finished. Relief valve problem was on primary side. One thermometer would have to be replaced; it was broken. No outside painting had been done so far. Cover pipe was in cover sleeves. Screws on the air intake would have to be tightened. Radiators had not been packed and crated. Inside module No. 2 it was noted that a drain was mounted. Also, it was noted that caps and a block should be provided for the pipes that were not installed to the generator yet. No flexible connections were seen on the steel pipe between the modules. Generator No. 2 was not installed at this time. It would be easy to install drain and vent here. In Module No. 1 there was still insulation materials missing in the sleeves and it was noted that a drain was installed. A vent could be installed by using two 3/8 inch nipples, a 3/8 inch gate valve, and a 3/8 inch tee. The booster pump was operating correctly and pipe supports were adequate. Inside one school boiler room a cover was missing on the flow meter. It seems like the BTU meter in the module does not work. The BTU meter in the school boiler room might work. However, it had only shown that approximately 60 gallons of oil had been delivered. In school boiler room No. 2, also a cover was missing on the flow meter. Here also, the BTU meter did not seem to work. In this boiler room the relief valve on the primary side was located next to the BTU meter, which is incorrect. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIEEDATIRIP "REPORT Unalakleet, Grayling, Kaltag and Elim October 21, 1983 Messrs. McDonald and Carson of Polarconsult Alaska, Inc. conducted a routine field visit to these sites. Unalakleet: Contractor is working in the power plant installing the electrical panels and wiring. Start-up should be later in the week on the first part. of next week. Piping within the power plant is being painted green to match the existing. At the request of the power plant personnel there will be no insulation on the piping in the plant. Mr. McDonald will submit the electrical report under separate cover. Grayling: Contractor is doing pick-up work while he waits for the electrical personnel to do their work. Dick Walls is hoping to start-up the system next week. The area between the power plant and the school was messy, but this appears to be caused by the Contractor, who is building the houses in the village. His staging area is between the power plant and the pump house. Kaltag: No Contractor personnel were on site at the time of the WLS TG The electrical panels were still outside the module in boxes. In the power plant the pipes were insulated and the No. 3 generator is connected to the system. Ealim(s The system is operating, but the following items were noted: Ls The starting heaters for the motors were the wrong iS lZiers Mr. McDonald will furnish an electrical report under separate cover. DE At the BIA school there is a 12 inch gap between the 90° elbow outer pipe and the pipe sleeve at the foundation penetration. This will have to be insulated and an outer sleeve installed. Also there is a space between the concrete and the pipe sleeve that has to be sealed. 55 Pipe insulation work in the furnace room of the BIA school appears to be incomplete. polarconsult FLED. TRIEPSREPORT: October 21, 1983 Page 2 ie In the high school, at the heat exchanger, the tape at the insulation joints is loose and should be redone. Duane: En Garson; PsE. Civil CStructural) Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Mary's October 24, 1983 Mr. Carson of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the trip was to inspect work progress. Inside the power plant the Contractor has added more pipe hangers and supports to the main ridge frames of the building. Contractor has six joints yet to foam and insulate outside. Also, one concrete anchor to pour. Work in the module was going- on during the time of inspection. Electrical panels and the pump have been installed with work being done on the piping. The Contractor was instructed to do the piping on the _ heat exchanger in the cold storage building, the same as detail C on M-3. Work to be done only on the primary side. The two sections of field insulated and fiber glassed pipe have been removed and _ factory insulated and fiber glassed _ pipe installed. Contractor hopes to have all outside work completed this week. Start-up of the system to be late this week or early next week. Duane E. Carson, P.E. Civil CStructural) Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Savoonga October 26, 1983 Mr. Turner, Mr. Larson, and Mr. Hansen, of Polarconsult Alaska, Inc. conducted a field visit to this site. The purpose of this visit was to make final inspection. Inside the power plant, it was noted that the connectors on the cold side of the two large generators were made with hoses and not with approved connectors. It was noted that the radiators were not yet packed and crated. No pipe markings had been provided so far. The leak had been fixed inside the module. Inside the module, the counter had counted 1.572 million BTU. Electrical panels were not yet complete. Fan motor had not been replaced. Anchors had been installed, however, anchor #1 was not deemed sufficient. Only one rod had been welded on, and it was not a straight weld. Also, rod was put in the ground at an angle and not straight down. Anchors #2 and #3 were definitely insufficient. Anchor #4 was also insufficient. It only had one rod. The skirt on the boiler room had _ been installed. Insulation was in progress and looked nice. No pipe markings had been provided yet. One boiler was operating. Temperature out of boiler was 160°. In the boiler room the BTU meter had counted oie. In approximately 72 hours, 1.35 million BTU has been transferred. The serial number is 000365. Delta tee on district side was approximately 10°. Contractor was in progress of providing pipe identification and arrows. Contractor was in progress of putting on valve tags. Edges on anchor plates present a safety hazard. Touch-up paint is needed on the module. Penetrations had been improved. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult PUNCH LIST Savoonga October 26, 1983 Non-electrical Items: 1. Sheet Rock to be repaired in Utility Building ceiling. 2 Insulation to be completed. 3. Pipe connectors in power plant might have to be replaced. Item will be clarified. 4, Anchors to artic pipe will have to be proven sufficient. Contractor must submit proof. 5. General clean-up to be completed. 6. Paint to be touched-up on module. 7. Radiators to be packed and crated. 8. Electrical panels not complete in module. 9. Valve tag and pipe identification to be completed. 10. BTU meter readings are questionable. polarconsult FIELD TRIP REPORT Shungnak October 27, 1983 Mr. Turner and Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the field visit was to perform final inspection. The following points were noted. The BTU meter in the heat recovery module was reading approxi- mately 3.5 million BTU. The serial number was 369. Valve tagging had been performed and pipe identification had been performed. Insulation could be improved in a few spots. Wall panels were not complete yet. BTU meter in water house showed 950,000 BTU's. BTU meter in school boiler room still does not work. Thermometers are hard to read in a lot of locations. Thermometers do not correspond. They should be adjusted. Thermometers next to engines are starting to melt. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult. PUNCH LIST Shungnak October 27, 1983 1. BTU meter does not work. 2. Thermometers should be calibrated. 3. Leak on radiator? 4. Hand pump should be wall mounted. 5. Ambler BTU meters, module one - motor control box should be secured. Hand pump should be wall mounted. 6. Kiana anchor PHS leak on booster. BTU meters leak in school boiler room. In Ambler, apparently, there is no safety disconnect for the booster pump within the module. The safety switch has been located in the heat recovery module. polarconsult FIELD TRIP REPORT Ambler October 27, 1983 Mr. Hansen and Mr. Turner of Polarconsult Alaska, Inc. conducted a field visit to this site. The purpose of this visit was to conduct final inspection. Inside the heat recovery module it was noted that valve tagging and pipe identification had been completed and that the BTU meter did not’ work. In Ambler, thermometers had been calibrated. Also, radiators had been packed. BTU meter in the first school boiler room read 727 x 10,000 BTU. BTU meter in water plant read 2.447 million BTU. This seems to be the only one that works. BTU meter in second boiler room did not work. Number is 000469. Unit heaters in generator modules do not seem to have thermostats. Boiler control box for old radiator in module No. 1 was left open. This should be corrected. There is a leak on top of the heat recovery module in the radiator by the murphy switch gauge in Shungnak. Glycol hand pump should be wall mounted to prevent that. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kiana October 27, 1983 Mr. Turner and Mr. Hansen of Polarconsult Alaska, Inc. conducted a) field visit, ‘to) this site. The purpose of this visit was to conduct final inspection. It was noted that the anchor next to the water house was not hooked up. A leak was noted by the booster pump in the power house. BTU meter in heat recovery module showed 3.144 million BTU's. BTU meter in school boiler room is not working. There is a leak in the school boiler room by the flow meter. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FLELD-TRIP- REPORT Goodnews Bay November 1, 1983 Mr. Jerry Larson of Alaska Power Authority, Mr. Don Bassler of Raj Bhargava and Associates, Mr. Joe Schneider of Alaska Village Electric Corporation, and Messrs. Turner and Hansen of Polarconsult Alaska, Inc. conducted a field visit to this site. The purpose of the trip was to conduct final inspection. Inside the school boiler room it was was noted that the wire for the BTU meter still was not installed in conduit and that some insulation work had to be completed. The BTU meter was still not working. According to the school maintenance personnel, the system was functioning properly and was saving a lot of fuel. The cycling of the outside radiators was tested and seemed to function; however, intervals between steps should be _ longer. Inside the module it was noted that pipe markings and identi- fications had not been completed and that a little bit of insulation work was still to be done. Weather stripping around the door was still not mounted. The Contractor represented by Mr. Dave Marks was given a list of these items. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Mary's November 1, 1983 Mr. Hansen and Mr. Turner of Polarconsult Alaska, Inc. conducted a tield -vistt to this site... The purpose of the trip was to clarify complaints from the Alaska Village Electrical Corporation and to do general inspection. Inside the cold storage plant the heat exchanger was being installed. Outside piping was not yet insulated. Piping from the district heating pipe and into the heat recovery module was not yet complete. Inside the module, plumbing was in progress and some electrical work had been done. Obviously, the motor starters would not meet code the way they were installed. John Barringer of J.B. Mechanical showed us that the transformer that burned out and the welder that caused it. The welder was the property of the Alaska Village Electrical Corporation. However, John Barringer explained that they had been trading equipment back and forth with AVEC in order to get various jobs done. For instance, AVEC had used their boom truck for raising poles, etc. John Barringer explained that the welder had been plugged into the outlet as usual and they had not done any re-wiring. Thus, it should not be their responsibility. Inside the gym boiler room it was noted that the relief valve on the heat exchanger had been put on the primary instead of the secondary side. The extra bypass line that the Contractor had been asked to provide had been installed, however it was noted that the manifold for hooking up to the heat exchanger had not been assembled correctly. Also, it was noticed that by pumps and by miscellaneous fittings, no di-electric unions had been used. In the main building boiler room the Contractor was aware that a relief valve was still missing on the secondary side of the heat exchanger. It was noted that around the newly installed pump, a valve was located on both sides of the pump. A problem exists on the final grading as much of the area was frozen up before work was done. Installation of the seals around the gate valves in the main line is still to be done. The module has not been caulked around all exposed joints. Joe Schneider of Anchorage and one of the field personnel of AVEC, Jerry Larson of Alaska Power Authority, John Barringer of J.B. Mechanical, and Peter Hansen and Jack Turner of Polarconsult met to discuss the question raised by the AVEC maintenance people of 10KVA transformer being blown up. We had been led to believe that the J.B. Mechanical was responsible per the AVEC Anchorage people. Apparently AVEC and J.B. field personnel were trading polarconsult Field Trip Report November 1, 1983 Page 2 off use of equipment with uJU.B. having permission to use the welder. The welder was plugged into a 240 volt circuit. After field discussion of this problem we believe that the use of the welder had really nothing to do with the transformer failing and that J.B. had permission to use the welder. If properly fused, no transformer would have failed. The second point by AVEC was with J.B. using fuel from the day tank. They agreed that some fuel had been used and that this had been authorized by the AVEC man. Any costs for this fuel are between AVEC plant operator and J.B. Mechanical. This was left that John Barringer was going to talk to the AVEC man who in turn was to get back with his maintenance people to resolve this question. In summary, it Is believed that really no problem exists in the field and there appears to be more of a misunderstanding of sequence of events, et. al., by the Anchorage field office of AVEC. Overall, the job is behind schedule. According to Mr. Barringer, he would hope to start filling the line this week. Insulators will be in Thursday or Friday and they still hope to be done in about two weeks. We question this. It appears more like a month. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority Mr. Joe Schneider, AVEC Mr. John Barringer, J.B. Mechanical polarconsult FIELD TRIP REPORT Grayling November 2, 1983 A field trip was conducted to this site by Mr. Tom Hebnes of Rockford Corporation; Mr. Jerry Larson of Alaska Power Authority; Mr. Don Bassler of Raj Bhargava and Associates; Mr. Art Ronimus of Crews MacInnes Hoffman/Vitro; Mr. Joe Schneider and Mrs. Carol Seibel of Alaska Village Electrical Corporation; and Mr. Hansen and Mr. Turner of Polarconsult Alaska, Inc. The purpose of this trip was to conduct final inspection. The following points were note worthy. Additional caulking was needed on the sides of the heat recovery module. Also the door had to be weather stripped. Hose arrangement between _ heat recovery module and power plant had to be improved with supports, etc. The hot water supply from the left generator had to be improved somewhat and made horizontal. A glycol fill tank had to be installed. Radiators were to be packed and crated. A thermo- meter had to be moved inside the PHS house. The thermometer was prone to damage from maintenance crews accidentally hitting it when passing by the heat exchanger. Anchors and identifications on pipes in the boiler room should be improved; they were backwards. The heat exchanger under the high school crawl space had to be plumbed differently. It was plugged in backwards. A wooden step had to be made over the pipe across the floor in the PHS building. Insulation in high school boiler room was not yet complete. Set points on all controls should be displayed. BTU meters did not seem to be working. These items were all pointed out to the Contractor. Peter N. Hansen Mechanical Engineer / jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Kaltag November 2, 1983 A field trip was conducted to this site by Mr. Tom Hebnes of Rockford Corporation; Mr. Jerry Larson of Alaska Power Authority; Mr. Don Bassler of Raj Bhargava and Associates; Mr. Art Ronimus of Crews MacInnes Hoffman/VITRO; Mr. Joe Schneider and Mrs. Carol Seibel of Alaska Village Electrical Corporation; and Mr. Hansen and Mr. Turner of Polarconsult Alaska, Inc. The following points were note worthy. The supports for piping inside the power plant were mounted on the generator skids. This had to be altered so that the skids could be removed without effecting the pipes. The power plant was not’ leveled and especially the southern side had to be raised somewhat. The hoses between the power plant and the heat recovery module had to be supported as specified. The door in the heat recovery module had to be weather stripped. The floor in the high school kitchen was to be repaired. The radiators should be packed and stored. Insulation should be finished where floor penetration was made. Wall penetrations had to be made a bit neater. A few air vents were missing in the cabinet unit heater area. Three-way valve was missing on the fuel line. Insulation in high school boiler room was not yet complete. Set points on all controls should be displayed. BTU meters’ did not seem to be- working. The Contractors attention was called to these points. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Elim November 2, 1983 A field trip was conducted to this site by Mr. Tom Hebnes of Rockford Corporation; Mr. Jerry Larson of Alaska Power Authority; Mr. Don Bassler of Raj Bhargava and Associates; Mr. Art Ronimus of Crews, MacInnes and Hoffman Vetro; Mr. Joe Schneider and Mrs. Carol Seibel of Alaska Village Electrical Corporation; and Mr. Hansen and Mr. Turner of Polarconsult Alaska, Inc. The following points were note worthy. The system did not seem to operate well, as boilers were on in various boiler rooms and the radiators were working. It seemed like adequate flow was missing. It was noted that in the elementary school boiler room, pressure on the district heating side was in excess of 50 pounds per square inch. Valve tags and pipe identifications and arrows were missing. A leak was found on one circulation pump. Fan control should be improved so that both fans did not come on at the same time. Hose arrangements within the power plant should be improved. Safety guard on No. 1 engine was not satisfactory. Insulation inside the power plant was not complete. Pipe hangers in module should be improved somewhat. Set points on all controls should be displayed. BTU meters did not seem to be working. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Unalakleet November 2, 1983 A field trip was conducted to this site by Mr. Tom Hebnes of Rockford Corporation; Mr. Jerry Larson of Alaska Power Authority; Mr. Art Ronimus of Crews MacInnes’~ Hoffman/Vitro; Mr. Joe Schneider and Mrs. Carol Seibel of Alaska Village Electrical Corporation; and Mr. Hansen and Mr. Turner of Polarconsult Alaska, Inc. The following points were note worthy. Pipe risers outside the power plant should be wrapped with stainless steel wrapping. Temperature sensors on the pump header should be moved so that temperature was sensed after the last pump. BTU meters did not seem to be working. A few minor leaks were found in the power plant. Valve tags needed to be provided and pipe markings and identification needed to be made. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Mary's November 8, 1983 Mr. Carson and Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the trip was to conduct inspection. The Contractor was in progress of filling the system with glycol. It was noted that one valve was missing on the out-going line from pumps P7-P8, however, this was not considered significant. Inside the power plant it was noted that one valve had stem vertically downwards. The Contractor was asked to alter this. Inside the power plant it was noticed that on the supply from the generators on the 6 inch line, two 6 inch valves were missing. Also, it was noted that the 6 inch line to the 353 had been substituted by a 3 inch line. Also, here a valve was missing. The 6 inch valves missing had been substituted with other valves that would do the job. Inside the cold storage plant, heat exchanger primary side had been installed. Inside the gym boiler room it was noted that the manifold was not connected correctly. The Contractor will change this. Inside the main building boiler room, no comments were made. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult . FIELD TRIP REPORT Kaltag November 9, 1983 Mr. Carson and Mr. Hansen of Polarconsult Alaska, Inc. conducted a ‘fleld|) visit to this) site. The purpose of the trip was to conduct final inspection. The system was in operation and according to the Contractor it was working well. It had just been balanced. The kitchen floor had been replaced, however the floor in the kitchen storage room had not been replaced yet. Floor penetration had been re-insulated. Inside the gym the unit heaters were working properly. Inside the furnace room no furnaces were running however the fans were running and the school was kept hot without the furnaces. In the first furnace room an air vent had been placed in the unit heater area. However, the air vent was not in the right place. It did not seem however that there were any air problems. There was a small leak on a di-electric union in the second furnace room. Inside the heat recovery module it was noted that there was a leak somewhere; as there was glycol on the floor. It looked like there was a leaking weld underneath the three-way valve. BTU meter in the heat recovery module does not seem to work. The motorized damper in the heat recovery module does not close when the fan is off. The power plant had been raised and according to the Contractor it is now level. However, it was not completely level on the south side. Radiators had been put on pallets. The center of the power plant is still sagging quite a bit. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Unalakleet November 9, 1983 Mr. Carson and Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field visit to this site. The purpose of the trip was to do inspection. Inside the 14 plex boiler room, it was noted that the BTU meter read 5,122 x 100 gallons and 3698 x 10,000 BTU. Delta T was 5 and it read 200,000 BTU per hour. The flow rate was 39. On the heating side it was 160 going in and 170 going out. On the district heating side it was 176 going in and 169 going out. The pressure was at 28 pounds. Riser outside at the power plant had been covered with aluminum skin as requested. In the power plant, on the primary side in-going temperature is now 184° and the out-going temperature is 174°. On the secondary side the in-going temperature is 172° and the out-going temperature is 174°, Temperature sensors had been removed as requested and the leak had been fixed. The power plant had one low pressure warning, however this was probably due to air bleeding out of the system. Glycol had been added and no problems had been encountered since. Delta T at the BTU meter read 2 and it read 500,000 BTU's per hour and a flow rate of 220 gallons per minute. 3.952 million of gallons had been delivered and 208.3 million BTU had been delivered. The electrical punch list items concerning connectors had not been taken care of here. Inside the gym boiler room the BTU meter was reading 694,000 gallons and 37.4 million BTU. Delta-T was 2°, We had 100,000 BTU per hour and a flow rate of 30 gallons per minute. The electrical punch list items in the boiler room had not been taken care of yet. In-going temperature in the boiler room was 175° and the out-going was 172°. There is a small leak in the glycol supply line on the secondary side over the heat exchanger some- where. BTU meter in the elementary school boiler room did not work; dispay nor totalizer. Primary in-going temperature was 175° and the primary out-going temperature was 164°. Boiler meter had counted 296,000 gallons. On the secondary side the in-going temperature was 132° and the out-going temperature was 168°. The boiler temperatures supposedly had not been set low enough yet. The BTU meter had been disconnected by the outlet. Delta T was 14° and it did not show any flow rate or any BTU's per hour. The meter read 61,000 gallons and 99944 x 100,000 BTU. Power supply for the BTU meter did not meet code. It was just a chopped off extension cord and it was not in conduit. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority 1 polarconsult FIEED | TRIP REPORT St. Mary's November 17, 1983 Messrs. Carson of Polarconsult Alaska, Inc. and Longstaff of Longstaff, Inc. conducted a routine field visit to this site. The purpose of the trip was to inspect the electrical and general work progress. Inside the heat recovery module work appeared to be almost complete. One of the main pumps had been disconnected because of a leak. Needs clean-up and some touch-up painting. At the cold storage building there is a small. section of insulation to be installed on the exterior piping. In the power plant all of the insulation was completed except for some of the metal plates at the hangars were missing. The Contractor said he would install them. The heat exchanger has been taken apart and the two leaking plates were removed and the exchangers put together. New plates are to be sent air freight from the factory. The exchanger had 24 psi of pressure and was not leaking at the time of inspection. The area needs to be cleaned up. In the gym boiler room the Contractor has not corrected the piping in back of the boiler. None of the BTU meters have been connected in any of the buildings. Electrical comments will be in a separate letter from Longstaff Engineering. Contractor hopes to start-up the system by the end of the week, or the first part of next week. Duane Carson, P.E. Civil Structural Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Mary's December 1, 1983 Mr. Joe Schneider of Alaska Village Electric Corporation, Mr. Jerry Larson of Alaska Power Authority, and Mr. Peter N. Hansen of Polarconsult Alaska, Inc. conducted a field visit to this site. The purpose of this visit was to conduct final inspection. Inside the heat recovery module, it was noted that some clean-up work had to be done on the insulation and on the hangers as insulation was crushed in places. Also, there were miscellaneous leaks inside the heat recovery module that had to be fixed. The glycol filler pump was not floor mounted as it was supposed to be and this had to be taken care of. A thermometer on the return line was broken. Door handles were not installed yet. Also, some touch up painting had to be done. Where the return line from the mission entered the heat recovery module, a different support system had to be provided. It appeared that numerous electrical items were still missing. The alarm control system was not yet complete. On the outside of the module, on the side facing the power plant, a few screws were missing. The same was the case on the western facade. Inside the module, the flexible conduit had to be fastened to something. Here, a flexible conduit clamp should be used. The door was not yet weather stripped. Sheet metal plates on wall penetration into power plant had to be painted. Hanger for victaulic pipe on the center generator had to be improved somewhat. It was tied with a rope. Also, the hanger for the west generator had to be improved. On generator loop in-going temperature was 176°F., and the out-going temperature was 156°F. On the heat recovery side, in-going temperature was 150°F., and the out-going was 158°F. The heat exchanger had not’ been insulated. Two plates were still missing on the heat exchanger polarconsult Field Trip Report St. Mary's December 1, 1983 as they were being delivered from the factory. They had caused the leak. One pump supplying the hotel had burned and a replace- ment was underway. There had been a leak in the power plant and a spot of glycol could be seen on one of the lines going to the heat recovery module. However, this leak had now been repaired according to the Contractor. In the mezzanine area in the power plant, the new pipe connections to the old 3 inch AMOT valve had been installed. The hanger was not satisfactory. There was, or had been, a glycol leak right around the check valve. Where the first faulty connection had been made, a pipe was only closed with a butterfly valve. Here a cap should be provided. Heat was dissipated in the radiator. In-going temperature to the radiator was 156°F., and the out-going temperature was 112°F. The Contractor was in Progress of putting on valve tags. No pipe markings or identifi- cations had been provided yet. Insulation will have to be finished by the entrance to the cold storage plant. Inside the cold storage plant the BTU meter was not yet hooked up. There seemed to be a leak by the entrance to the gym boiler room. There seemed to be a leak in the supply line in the last elbow before it heads for the heat exchanger. The strainer was leaking at the flange. There was a leak on the return from the heat exchanger before the wall penetration. The primary side in-going temperature was 150°F., and the out-going temperature was 127°F. On the secondary side, the in-going temperature was 130°F., and the out-going temperature was 137°F. Inside the gym boiler room, the mechanical hook-up was still not correct. There was no valve to avoid bypassing the heat exchanger system. The BTU meters in the heat recovery module and in the mission gym boiler room were actually working. Valve polarconsult Field Trip Report St. Mary's December 1, 1983 boxes on outside ball valves had not been provided yet. There was an agreement with the mission to grade the area and install the valve boxes. The Contractor was aware that a document would be needed to show this. A little bit of glass fiber work had to be done by the entrance to the main building. The wall pene- tration had to be improved somewhat. In the main building there was a leak on the heat exchanger. eC seemed like it was a flange on the return primary side. It was probably a sweated connection. In the main building boiler room the BTU meter was not yet hooked up. Apparently there was barely any delta T on the primary side. In the main building boiler room there was a piece of insulation missing right over the new pump. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT Unalakleet December 12, 1983 Mr. Hansen of Polarconsult Alaska, Inc. conducted an operational system trouble shooting visit to the site. The purpose of the trip was to improve system performance and clarify data as collected by the balancing company. It was found that the system was in operation and that the out-going temper- ature from the engines were approximately 185°. In the boiler rooms it was noted that the boilers were working at times and at the same time cooling fans in the power plant were working. A design error was found as balancing valves are placed on bypass lines on drawing M-2 detail A the balancing valves are shown in their correct position while on drawing M-3 detail C_ the balancing valves are shown on the bypass lines. Unfortunately, the Contractor did not pick up the error either. The Contractor used the detail to construct the system and thus all the balancing valves by the end users are located on the bypass line where they have no purpose, i.e. if the bypass is completely closed the pressure drop, according to the heat’ exchangers pressure drop, will be read across the balancing valve and this pressure drop will then be interpreted as a certain flow. If the balancing valve is fully open the most flow possible will go through the balancing valve and the pressure drop forward will be almost zero as the pressure drop will be the same as over the heat exchanger, which in this case will have hardly any flow. Thus, according to the balancing valve, no flow will exist at all. Obviously, this is not the case. The system was then balanced using the flow meters at the end users, and values very close to the design values were obtained. It should be noted that in the gym boiler room, the pump installed to compensate for the smaller line size was shut off polarconsult Field Trip Report Unalakleet December 12, 1983 and this in return gave a flow very close to the design para- meters. If the pump was turned on, flows in other locations were greatly reduced and when using the small pump in the power plant, no flow was obtained in some locations at all. Thus, the following procedures should be used. The pump in the gym boiler room shall be left off completely. Consideration should be given to a change order in which all balance valves are place in the right positions and a gate valve is placed on the bypass valve, as it probably originally intended. Total district heating loop flow in the power plant was measured using the flow meter and flows through the existing tube and shell heat exchanger and the new district heating heat exchanger were measured using balance valves. Before adjustment, the flow in the district heating heat exchanger was approximately 250 gallons per minute, and the flow through the existing tube and shell heat exchanger was 310 gallons per minute. After all balance valves at the end users had been closed, the flows balanced out according to. the balancers report. On the generator side, the balancing valve for the existing tube and shell heat exchanger was partly closed so that a flow of approximately 75 gallons will be obtained in this location when a flow of 250 gallons is obtained in the new heat exchanger. Total system pressure loss on the generator cooling loop was approxi- mately 5 psi in this configuration and this is well within limits. When both new generators were operating, flows were obtalned according to the balances report and system pressure losses did not exceed 8 psi. Again, this is well within limits. Temperatures were now turned up so that engine exit temperature was approximately 196° before the fans came on. This in return caused the fans to stay off as more heat could be utilized in the polarconsult Field Trip Report Unalakleet December 12, 1983 buildings. Pump No. P-2 was turned on instead of pump No. P-3 and this decreased the flow to approximately 105 gallons per minute on the district heating site. A delta T of approximately 16° was then obtained. Out-going temperature was about 190° and the in-going temperature was about 174°. The power. plant personnel were instructed that this procedure should be followed in order to keep delta T's from 10° to 15°. This will save pump energy. Contact was made with the Principal of the elementary school who reported that apparently something has happened to the heating system after the district heating system has been Installed. The elementary school can be kept warm, however there is no longer sufficient hot water in spite of the fact that boiler temper- atures have just barely been changed. This is believed to be caused by the too small heat exchanger being installed in the elementary school. This has probably decreased the total flow rate on the boiler loop site and probably thus disturbed the flow pattern through the hot water heater. The Principal reported that the situation was somewhat acceptable. Also, the Principal asked whether it would be possible to connect the swimming pool boiler located next to the gym and he was told that this would be a very easy task as this boiler temperature is only 110°. He reported that the swimming pool boiler was one of the biggest expenses. In summary, the following problems were encountered in Unalakleet: 1) The heat exchanger in the elementary school has obstructed flow. 2) Flows cannot be balanced as balance valves are! | not) in thelr | correct) || positions. 3) The pump in the gym polarconsult . Field Trip Report Unalakleet December 12, 1983 boiler room should be removed. This will allow for somewhat increased flow in the gym boiler room. 4) A pressure switch located next to the pump manifold in the power house leak badly. 5) Unalakleet Valley Electric Corporation CUVEC) requested that power supply for control panels’ be installed according to drawings. This would mean installing a transformer for the controls. The controls were at this time connected to the power plant system. 6) Pump 2 was slightly overloaded in spite of not giving the flow specified. However, it was within the service factomn. The system seems to be in operable conditions. Another request made by UVEC was that all BTU meters be installed In such a way that they cannot be tampered with. That is, they should not be installed with a wall outlet and a plug. They should be wired in permanently. For instance, to a circuit breaker that also ran a pump. According to Unalakleet personnel, whenever they inspected the boiler room, the BTU meters had been switched off or the plug had been pulled. Peter -N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority polarconsult FIELD TRIP REPORT St. Mary's December 13, 1983 Mr. Hansen of Polarconsult Alaska, Inc. conducted a routine field Visit! to this isite. The purpose of the trip was to reinspect the punch list items to see if they had been taken care of. The following points were noted. ° In the main building the leak had been fixed, however another leak had developed right next to it. This should be fixed today. ° The BTU meter had been re-hooked up after being returned from Seattle, however the BTU meter still did not function properly. ° The system could not be balanced as the flow in the main building was unknown. However, the balance valve on the bypass was fully closed and the delta tee was very slight over the heat exchanger. Outside the gym the leak had been fixed. Inside the gym boiler room the hookup behind the boiler had been corrected. Leaks in the gym boiler room had been fixed. Inside the heat recovery module the glycol pump had been floor mounted as specified. ° A pump motor was still on order, the one initially installed had burned out. ° All controls were now functioning according to the Contractor. ° According to Contractor, the length of the flexible conduit was within code limits and also the length of the pipe going to the power plant was within the pressure vessel code limitations. ° Miscellaneous leaks inside the heat recovery module had been fixed. ° All electrical systems were in place and operating. polarconsult Field Trip Report St. Mary's December 13, 1983 According to the BTU meter in the heat recovery module, we are putting out about 1.2 million BTU per hour and every- thing seemed to be working. In the power plant, the new plates had been added to the heat exchanger. Hangers on generator piping had been improved. The leak in the power plant had been fixed. The fan motors were now off and the power plant had cooled down considerably. It appeared that before, because of the radiators being plugged up with dirt, most of the cooling air was blown back in the power plant and contributed to heating problems there. The pump was shut off, thereby providing no cooling. This caused the fan to come on at the power plant as planned. It remains a real question whether something should be done to the ventilation system inside the power plant. It seems like it is a lot cooler now than it used to be. There were still a few clean up items to be done, like a little cleaning here and and a little insulation there. However, the system was now basically complete and it seemed to be operating well. Peter N. Hansen Mechanical Engineer /jkb cc: Mr. Jerry Larson, Alaska Power Authority