HomeMy WebLinkAboutak energy grant design misc.New Stuyahok Heat Recovery Design nq Analysis
INTRODUCTION:
The purpose of this analysis is to approximate the amount of recoverable heat produced by the
new AVEC power plant in New Stuyahok, Alaska and to explore the feasibility of delivering jacket
water heat to an end user.
As part of the analysis we explored the option of delivering heat to the New Stuyahok School
currently under construction. The new school was chosen as a viable end user due to its size and
close proximity to the new AVEC power plant.
In order to determine the recoverable heat produced by the generators that could be delivered to
an end user (New Stuyahok School) we had to approximate the following:
1. The amount of jacket water heat produced by the generators
2. The heat consumed by the power plant (since the generator jacket water is used to heat
the generator module living quarters, storage, etc.)
3. The amount of heat lost in a recovered heat distribution system
4. The end user's (New Stuyahok School) heating demand
ANALYSIS AND CALCULATIONS PERFORMED:
The generators jacket water heat generated was approximated using historical electric generation
data (monthly power production and daily instantaneous power production) provided by AVEC.
Using published data on the generators we were able to convert the historical power production
data to jacket water heat production with 35% of the generator input energy being converted to
power and 18% converted to jacket water heat (The remaining 47% of input energy is lost to
exhaust heat, radiated heat, and alternator inefficiencies). Instantaneous power data was used to
approximate an hourly jacket water heat production variation for an average day which is shown
in Table 1. We used Table 1 along with the historical monthly power production data Table I to
come up with Table 2 which shows the generator jacket heat production on an hourly basis for an
average day each month.
Generator Model Assumptions Used in Calculations:
Position 1 - 1200 rpm Cummins KTA1150, 410hp, 271 kw
Position 2 - 1800 rpm CAT 764hp, 500kW
Position 3: Cummins DFEK (QSX15 engine) 755hp, 499kW
The power plant heat consumption was determined by performing a heat loss calculation for the
facility using building construction and operation data/information provided by AVEC along with
historical weather data. For our calculations we used historical weather data for King Salmon,
Alaska as good historical data is not available for New Stuyahok and King Salmon is located
close to New Stuyahok. Table 4 shows the temperature variation for an average day each month
and was derived from historical weather data. An overall thermal conductivity and surface area
value was approximated for the power plant using building construction data provided by AVEC.
We used the overall thermal conductivity and surface area value along with the average daily
temperature variation data in Table 4 to come up with the hourly heat consumption of the power
plant for an average day each month shown in Table 7.
Module Interior Temperature Assumptions Used in Calculations Were as Follows:
Generator Module Position 1 — 70 deg F
Generator Module Position 2 — 70 deg F
Generator Module Position 3 — 70 deg F
Control Module — 65 deg F
Living Quarters — 75 deg F
Warm Storage — 70 deg F
Oil Storage — 60 deg F
Cold Storage — 50 deg F
The heat recovery system losses were approximated by assuming a system similar to Kasigluk
and Toksook Bay would be installed in New Stuyahok. The system heating losses inside the
power plant and school were found negligible as the piping will be insulated and the spaces are
heated. However the heat loss in the recovered heat system distribution piping located outside
was considered for this calculation along with inefficiencies in the heat transmission through a
heat exchanger located in the AVEC heat recovery module and a heat exchanger located in the
school. Using the average temperature variation data in Table 4, along with an assumed total
length of piping and a thermal resistance value (R-value = 18) for the insulation on the piping,
heat exchanger radiated heat losses of 8%, and a generator radiator heat loss of 12% (without
cooling fan operating) we were able to come up with approximate piping system heat loss data
shown in Table 8.
The available heat for delivery to an end user was derived by taking the generator jacket water
heat production data in Table 2 and subtracting the power plant heat consumption data in Table 7
and system losses data in Table 8. The available deliverable heat data is shown in Table 9.
The New Stuyahok School heating demand was approximated using historical weather data and
peak heating load calculations provided by USKH for the school. An average thermal conductivity
and surface area value was derived from the previous calculations performed by USKH. The
approximate thermal conductivity and surface area value for the school was used along with the
hourly temperature variation data in Table 4 to come up with the School's hourly heating demand
for an average day each month. This data is shown in Table 6.
Using the hourly available heat data shown in Table 9 along with the hourly heating demand data
in Table 6 we were able to approximate the actual amount of heat that could be delivered on
average to the New Stuyahok School shown in Table 10.
Using a school boiler efficiency of 75% we were able to convert the deliverable heat values in
Table 10 to annual school fuel savings. The fuel that could potentially be displaced is shown in
Table 11.
Other supporting recovered heat analysis documents:
Please see the attached spreadsheets for all data used, other assumptions made, and
calculations performed for the recoverable heat analysis.
�Y�1i<fuili'i
The analysis results in Table 11 shows that delivering the recoverable generator heat to
the New Stuyahok School on an average year could displace up to 11,000 gallons of fuel oil per
year. The Cost Savings Summary Table on the following page provides a break down of
projected savings associated with the 11,000 gallon annual fuel savings.
COST SAVINGS SUMMARY TABLE
Delivered Fuel
Costs $/gallon
Annual cost
savings to
customer
Allowable Investment
for Capital Equipment 2
Estimated savings to
customer over
lifespan of project 3
$1.70
$9.921.71
$116,147.34
$355,317.64
$1.80
$10,505.34
$122,979.53
$376,218.68
$1.90
$11,088.97
$129,811.73
$397,119.72
$2.00
$11,672.60
$136,643.92
$418,020.76
$2.10
$12,256.23
$143,476.12
$438,921.80
$2.20
$12,839.86
$150,308.32
$459,822.83
$2.30
$13,423.49
$157,140.51
$480,723.87
$2.40
$14,007.12
$163,972.71
$501,624.91
$2.50
$14,590.75
$170,804.91
$522,525.95
$2.60
$15,174.38
$177,637.10
$543,426.98
$2.70
$15,758.01
$184.469.30
$564,328.02
$2.80
$16,341.64
$191,301.49
$585,229.06
$2.90
$16,925.27
$198.133.69
$606,130.10
$3.00
$17,508.90
$204,965.89
$627,031.14
$3.10
$18,092.53
$211,798.08
$647,932.17
$3.20
$18,676.16
$218,630.28
$668,833.21
$3.30
$19,259.79
$225,462.48
$689,734.25
$3.40
$19,843.42
$232,294.67
$710,635.29
$3.50
$20,427.05
$239,126.87
$731,536.33
$3.60
$21,010.68
$245,959.06
$752,437.36
$3.70
$21,594.31
$252,791.26
$773,338.40
$3.80
$22,177.94
$259,623.46
$794,239.44
$3.90
$22,761.57
$266,455.65
$815,140.48
$4.00
$23,345.20
$273,287.85
$836,041.51
$4.10
$23,928083
$280,120.05
$856,942.55
$4.20
$24,512.46
$286,952.24
$877,843.59
$4.30
$25,096.09
$293,784.44
$898,744.63
$4.40
$25,679.72
$300,616.63
$919,645.67
$4.50
$26,263.35
$307,448.83
$940,546.70
NOTE 1- Annual cost savings based on 50% of total projected gallons of fuel saved. Fuel
saved is based on heating demand calculated using historical weather data.
NOTE 2 - Investment for capital equipment assumes 5.75% cost of capital, and 20 year life
span of project.
NOTE 3 - Potential long term savings to customer, based on investing annual savings at 4%
over the lifetime of the project.
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New Stuyahok. Alaska May 2007
Bulk Fuel Storaee and Power System Upgrades Draft Conceptual Design Report
capacity is six standard 27,000 gallon tanks for diesel fuel and three standard 27,000 gallon tanks
for gasoline. The tank farm containment will be sized for 20-year expansion which will require
two extra spaces for a future standard diesel fuel tank and gasoline tank.
4.3.4 Southwest Regional School District
SRSD's projected diesel fuel consumption includes capacity for the existing school, existing
teacher housing, the new school, and future teacher housing. At this time it is unknown what the
old school will be used for once the new school is complete. In this report it is assumed that
SRSD will continue to heat the building. The current fuel use reported by SRSD for the existing
school and existing teacher housing is 34,000 gallons per year. The existing school is provided
recovered heat from the existing AVEC power plant. When AVEC constructs the new power
plant as part of this project the existing recovered heat system will be shut down and the existing
school fuel demand will likely increase. It is anticipated that the additional fuel required to
offset the loss of input heat to the existing school will be picked up in fuel savings from the new
recovered heat system that will be providing heat to the new school. On an average year it is
estimated that the new recovered heat system could displace 11,000 gallons of heating diesel fuel
for the new school. Refer to the New Stuyahok Recovered Heat Analysis included in
Appendix F.
The escalation used for the SRSD projected fuel consumption was to add 1% per year to the
existing fuel usage reported. The 1 % increment accounts for any losses in heating system
efficiency as the heating systems age. In addition to the 1 % increment, at the final year of
projection an additional month's fuel usage (13-month capacity) was added.
Fuel demand used for the new SRSD school was provided by the designers of the replacement
school. It is estimated that in the coldest year that can be expected, the new school will use
39,000gallons of fuel. An additional 5,000 gallons (15% of the current consumption 34,000
gallons) was added for heating the planned future teacher housing. Since the new power plant
will be located near the replacement school, a new recovered heat system will be constructed to
reduce the overall amount of fuel that is required to heat the new school. The reduction of fuel
demand by using the recovered heat system has not been included in the consumption projection.
13
ACOFFMAN
New Stuyahok. Alaska May 2007
Bulk Fuel Storage and Power System Upgrades Draft Conceptual Design Report
Table 4, New Stuyahok - Fuel Use/ Capacity Summary
13-Month
Required
Required
Actual
Existing
Useable
Current
Future
Future
Future
Number
Future Net
Capacity
Capacity
Use 1
Use 2
Use 3
Capacity °
Of
Capacity 6
Project Participant
Gal
Gal
Gal
Gal
Gal
Gal
Tanks a
Gal
AVEC New Stuyahok Diesel Fuel
108,427
97,584
94,360
113,472
122,550
136,166
6
145,800
AVEC Ekwok Diesel Fue17
34,357
57,202
61,778
168,642
3
72,900
Subtotal AVEC Diesel Fuel:
108,427
97,594
128,717
170,674
184,328
204,809
9
218 700
SRSD Existing Diesel Fuel 9
57,580
51,822
34,000
37,557
40,562
45,069
2
48,600
SRSD New School Diesel Fuels
,000
48,603
52,492
58,324
2
48,600
SRSD Diesel Fuel Intermediate Tank
1
6,800
SRSD Diesel Fuel Dispensing Tank
1
4,250
Subtotal SRSD Diesel Fuel:
57,580
51822
178,000
86160
93,054
103,393
6
108,250
Stuyahok Limited Diesel Fuel
41,000
36,900
100,000
120,245
129,875
144,305
6
145,800
Stuyahok Limited Diesel Fuel
Dispensing
0.5
4,250
Subtotal Stuyahok Limited Diesel
Fuel:
41,000
6 900
100,000
120,245
129,875
144,305
6.5
150 050
Stuyahok Limited Gasoline
20,000
18,000
50,000
60,127
64,937
72,153
3
72,900
Stuyahok Limited Gasoline Dispensing
0.5
250
Subtotal Stuyahok Limited Gasoline:
20,000
18,000
5011000
60127
64,937
72 153
3.5
77150
Total Diesel Fuel:
207,007
186,306
306,717
77 079
407 257
452,507
21.5
477 000
Total Gasoline:
20 000
18,000
50 000 160,127
164,937
72153
3.5
77150
AVEC usage numbers are based on year 2005, projections correspond accordingly. Stuyahok Limited usage numbers are based on year 2005 barge
elivery records including fuel delivered to individual users in the community.
Assumes 1.86% annual growth for New Stuyahok and 523% annual growth for Ekwok - projected 10 years into the future from 2007.
Assumes 13-month period or a factor of 1.08.
Assumes only 90% of tank is useable therefore the 13 month use is divided by 0.9.
This is the Required Future Capacity / 27,000 gallons and rounded up to nearest whole number.
This is the total net capacity; 90% of shell capacity for bulk storage tanks, 85% shell capacity for dispensing tanks.
Ekwok fuel statistics used for intertie purposes, assumes annual growth rate of 5.38% projected in to the future 10 years from 2007.
Based on USKH model of replacement school loads, does not take into consideration any fuel savings realized by the new recovered heat system. An
owance of 5,000 gallons for future teacher housing has also been included. (Ernie Hetrick, 3/05).
Based on existing SRSD consumption including existing teacher housing, does not take into consideration any fuel savings realized by the existing
recovered heat system.
5.0 PROPOSED FACILITY DESCRIPTION
The proposed location of the AVEC and SRSD tank farms is adjacent to the new replacement
school and new power plant. Stuyahok Limited's tank farm and dispensing tank will be located
on two of the three lots adjacent to the existing AVEC power plant. Refer to Appendix B for site
locations.
In order to be in close proximity to the replacement school, the power plant will be constructed
near the existing runway, adjacent to the site selected for the replacement school. This will
facilitate construction of a recovered heat system to reduce the overall fuel that is required to
AUEC' � N GIN E E N
14
B,DO, GALLON
INTERuLWTE TANK
PROYIOEO BY SxsO
SCHOOL PROJECT
NEW HEAT RECD&W
RIPPLY AM RETURN
NEW SRSO FUEL- PIPING
f4 DISPENSER
f - NEW SRSO FUEL
NEW SINGLE PRDOUCT - OL SUPPLY
DISPENSING TANK AND \ PIPING
TRANSFER PUNP 157 00
ems.
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38.00
ITE PLAN
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HEAT NODULE
AY TO BE
PROODED BY SRSO
SLIgOL PRO.,FGT
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C�4NCEPTUAL DESIGN 5A
SYMBOL LEGEND
SEWER IVANHOLE
NOT GLYCOL RETURN PIPE (BELOW GROUND)
SEWER VAIN CLEAN OUT
NOT GLYCOL SUPPLY PIPE (BELOW GROUNO)
FIRE HYDRANT
.. URUTY POLE
GUY ANCHOR
TELEPHONE PEDESTAL
SURVEY CONTROL LEGEND
FUEL PIPE
'S 3-1/1• BUY BRASS CAP UONUYENT
. FUEL VALVE
FOUND 2• DIA UM PIPE
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(E) P05T/8IX1ARO
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u FOUND 5/8• ALUM. ROD. W MSS04
1
1
EDGE OF GRAVEI/SHOIADER
I
.. .... - - 5' OWN UNIX FENCE
1
CMN UNK FENCE
1
.. .. WOOD FENCE
I
...
FUEL PIPE (ABODE GROUND)
FUEL PIPE (BEUDYF GROUND)
_.. CAS PIPE (ABOVE GROUND)
,
- frLS PIPE (66IIW GROUND)
1
WATER
-A- FENCE
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FUTURE SRSD F
REPIACEYENT SCNOOLY
FUME WIND TURIMME
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OVERALL
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Southwest Region School purchasing guidelines DRAFT AR 3311
To ensure that full value is received for funds expended, specifications shall be carefully designed and shall describe in detail the
quality, delivery and service required. Purchases can not be split to avoid more stringent guidelines. If actual quotes come in
significantly higher there may be a need to change the documentation submitted with the purchase request. Always submit all
documentation with the purchase request. Always look for viable vendors not ones that will produce a "did not bid" response. Use
Sole Source documentation sparingly.
For purchases up to $5,000, no price comparisons necessary but strongly encouraged and justification may be requested by
superintendent or designee.
Best practice: Search for a minimum of 3 on-line or local vendors for items that satisfy the purchasing need, look at
quality of item, try to spread purchases to as many vendors as possible, complete a purchase requisition and submit to
business office to generate a purchase order. Do the same with services however bring as many details as possible to
business office for determination on whether the service should be run through payroll or on a Memorandum of
Agreement. Write justification if not going with lowest cost on purchase request.
For Purchases from $5,000.01 up to $25,000 requires at least three firms or persons to be contacted for a quotation or
informal proposal. The solicitation and response can be verbal or in writing. The names of the firms or persons contacted will
be included with the purchase request to the business office. Sole source justification can be provided. The award will be
given to the vendor with the "best deal' for the district not necessarily best price.
Best practice: On price comparison form or spreadsheet write down specifications or itemize what is needed, Find a
minimum of 3 vendors that can provide the what is needed, Write down the details, (vendor information and size, item
number, quantity, description(specs), and cost of items, consider best value for district and write justification for not
going with lowest cost. Again bring any service information to the business office for determination on type of contract.
Again write justification if not going with the lowest cost.
For purchases from $25,000.01 up to $50,000 requires at least three firms or persons to be contacted for a quotation or
informal proposal. The solicitation can be verbal or in writing with detailed specifications, the responses will be in writing. The
names of the firms or persons contacted will be included with the purchase request to the business office. Sole source
justification can be provided. The award will be given to the vendor with the "best deal' for the district not necessarily best
price.
Best practice: Detailed specifications are important at this level. Get quotes from at least 3 vendors. Sole Source
justifications at this level should be very few and have a very good detailed reason for not going with fair and open
competition. Requests to vendors should be written with the same thing going to every vendor. Any new information
that comes up while acquiring prices should go to all vendors asked to provide prices. The specifications should have
enough details to show vendors what the district is wanting. Many of these purchases may not be lowest price but
vendors should know what is most important to the district. Write what factors went into the decision of why the final
vendor was chosen.
In excess of $50,000 formal bid process when required by law is needed. At least three firms or persons shall be
contacted for a quotation or proposal. The solicitations shall be made in writing and shall include the specifications, the
award criteria, date the responses are due, and date of bid opening. Responses shall be in writing in sealed envelopes
addressed to Director of Administrative Services. Exemptions from the formal bid process, but not competition, are
textbooks, open market equipment, services where no competition exists, and professional or educational services. The
names of the firms or persons contacted will be included with purchase request for exempt purchases.
All purchases over $50,000 need to be approved by the board PRIOR to the purchase. They can be approved in the budget
process with the adopted budget.(BP 3300)
The district cannot enter into agreements for more than one year. We can do a one year contract with up to 5 years
renewal option, with a clause allowing termination at the end of one year. Keep this in mind when making
agreements.
Check requests over $1,000 will not be processed. All purchases for that amount need to have a purchase order in
place before any action is taken. All check requests under $1000 will be required to have justification as to why a
purchase order could not be done. Please include this information with the check request containing proper
signautures.
!' T R I C 0NN
Piping Systems, Inc.
TO: Walter Creasey
Southwest Region School District
P.O. Box 361
2 Technology Blvd.
Canastota, NY 13032
Tel. (31 5) 697-8787
Fax (315) 697-8788
March 26, 2012
Revision 91
Quote No. Job Name Destination Product
PX 11-10188-AK Dillingham, AK
Tricon INSULPEX
Service Pipe: Cross -linked polyethylene (PEX-a) with an EVOH oxygen barrier (NSF approved).
Insulation: 90-95% Closed cell polyurethane foam
Jacket: Extruded, Black, Seamless LDPE.
Fittings: Cast bronze clamp -on style adapters to convert to a threaded end (MPT).
Scope of materials:
Pipe
LDPE
Length
MPT/Copper
Adapters
Sleeves
900 & Kits
End Caps
3.5" OD (90mrn)
6.4"
700 Ft.
4
4
4
4
1.125" OD (1" + 1")
4.40"
150 Ft.
4
4
2
2
TOTAL S51,780.00 FOB Canastota, NY 1 FFA Dillingham, AK
No Taxes Included * Terms: Net 30 Days * Freight Included
Note: Add $5,000.00 for tool rental. Full credit of rental upon return receipt of tool to
Tricon Piping Systems in good working order.
Quotation is valid for a term of 30 days and subject to prior sale. The total pricing above is for
quantities indicated. Any additional footage or accessories required after 30 days will be invoiced at
prevailing prices. Any shortages or deletions may also affect pricing.
Our Products and services are warranted only to the extent that we will replace without charge, products proved to have
manufacturing defects within one year of the date of the delivery thereof and provided we have been given an opportunity to
inspect the product alleged to be defective. No warranty is included against any expense for removal, re -installation or
other consequential damages arising from any defect. Owing to the widely varying conditions under which our products
are installed and utilized we cannot be and are not bound, and no person is authorized to bind us, by any further warranty
whatsoever expressed or implied, statutory or otherwise and the implied warranties of merchantability and fitness for a
particular purpose are expressly disclaimed. Tricon will not accept any purchase orders involving retainage and/or
liquidated damages. Triton's terms are Net 30 Days, I'1z % interest per month on past due invoices.
Prepared By:
Hugh Roszel