HomeMy WebLinkAboutGulkana Water Treatment Plant Biomass Feasibility Study Aug 2018GULKANA, ALASKA WATER TREATMENT
PLANT BIOMASS FEASIBILITY STUDY
PREPARED BY:
Alaska Native Tribal Health Consortium
Division of Environmental Health and Engineering
4500 Diplomacy Dr., Ste 454, Anchorage AK 99508
Phone (907) 729-3600 / Fax (907) 729-4046
August 24, 2018
EXECUTIVE SUMMARY
The Gulkana water treatment plant (WTP) was evaluated for biomass potential, including a
comparison of cordwood and pellet boiler systems. The total estimated annual heating fuel
used by the water treatment plant is approximately 4,277 gallons. The expected annual
savings for a cordwood system is 4,277 gallons and for a pellet system is 3,995. The simple
payback based on a 2018 fuel cost of $3.07 per gallon is 14.98 years for a log heating system
and 13.71 years for a pellet heating system.
The payback is based on a 2017 fuel price of $3.07 per gallon and an estimated 2018 project
cost of $289,149 for a cordwood system and $306,387 for a pellet system. This assumes
construction in 2019. The cost of logs per cord was assumed to be $150 per cord and the
cost of pellets per ton was assumed to be $125 per ton.
1.0 INTRODUCTION
The Alaska Native Tribal Health Consortium (ANTHC) performed the feasibility study to install
a biomass boiler in the water treatment plant in Gulkana. The study reviewed alternatives
related to cordwood and pellet boiler systems. ANTHC also developed a budgetary project
cost estimate based on force account construction, including engineering and construction
administration.
The existing hydronic heating system provides heat to the WTP. The water storage tank
(WST) is located on the site near the WTP building. The system was not designed for biomass
and will require installation of new controls and new heat transfer equipment that includes
heat exchangers, pumps, pipes, and accessories.
This report assumes that the space on the water treatment plant property will be sufficient for
the necessary biomass boiler facilities, equipment, and controls. Additional assumptions
have been made in the report, including but not limited to the proposed arctic piping route,
building heating loads, permafrost effects, and flow rates and pressure drops of the biomass
system. It is anticipated that arctic pipe sizing and routing, pump and heat exchanger
selections, and other design elements will require refinement as the project progresses. Price
information on the cost of produced wood was obtained from the Gulkana Village Council.
End-user annual fuel use was obtained from an energy audit recently conducted by ANTHC
as well as village and engineering estimates. When possible, reported fuel consumption was
used to validate engineering estimates.
2.0 OVERVIEW
The purpose of this study is to estimate the heat that can be produced from the biomass
boilers to offset heating oil consumption at the water treatment plant. Wood consumption is
quantified in gallons of heating fuel saved using a gross heating value of 18,000,000 BTU’s
per cord of wood and an overall boiler efficiency of 80%.
The analysis evaluates the potential to provide biomass heat to the WTP building. The
estimated annual heating fuel consumption for the WTP building, confirmed by comparison
to 2017 heat demand, is 4,277 gallons.
3.0 ESTIMATED BIOMASS HEAT UTILIZATION
A biomass utilization spreadsheet has been developed to estimate the biomass heat based
on monthly total wood production from the biomass production plant in the community,
building heating demand, heating degree days, passive losses for biomass heat and piping,
and arctic piping losses. The spreadsheet uses assumed time-of-day variations for and heat
demand. Fuel use data for the water plant is calculated in the spreadsheet, but compared to
2017 fuel usage to confirm the assumptions. Heating degree-days for Gulkana were used
for this site. All arctic piping is assumed to be shallow buried, no more than 6 inches below
ground. All hydronic piping is assumed to be insulated with 2 in. of foam insulation. The
2017 energy audit was used to help with calculating the heating loads for the water plant.
The spreadsheet uses monthly heating degree-days to distribute annual fuel consumption by
month. The end-user heat load is compared to the available heat from the biomass boiler,
less biomass boiler facility heating loads and parasitic piping losses, and the net delivered
heat to the end-user is determined.
Following is a summary of annual fuel use and estimated heat utilization in equivalent gallons
of fuel for the water treatment plant:
Facility Estimated
Annual Fuel
Use
(Gallons)
Estimated Annual
Fuel Avoided –
Cordwood
System
(Gallons)
Estimated Annual
Fuel Avoided – Pellet
System
(Gallons)
WTP Heating: 4,277 4,277 3,995
4.0 BIOMASS SYSTEM DESCRIPTION AND OPERATION
The biomass system uses a wood-based fuel to generate heat through combustion in the
biomass boiler. The heat is transferred via hydronic piping to the water treatment plant where
it is received by the building heating system via a heat exchanger. The objective is to reduce
the consumption of heating fuel by utilizing available biomass heat.
Although biomass is an excellent method of reducing heating fuel costs, biomass is a
supplementary heat source and it is imperative that the end-user facility heating
systems are operational at all times.
The community of Gulkana has a wood production plant that sells wood briquettes (useable
in cordwood models), chips, and pellets to customers in the copper river valley region with
wood heating systems. This study assessed the feasibility of wood heating systems using
cordwood and pellet types of wood fuel to determine the most feasible option. Both systems
assume the same building facility on the water treatment plant property. The community also
desires to assess the feasibility of installing both units into the same biomass building. Chip
heating was not considered due to the difficult nature of wood storage.
4.1 LOG HEATING SYSTEM DESCRIPTION
The cordwood boiler is a non-pressurized unit that burns logs in a combustion chamber to
produce heat. The heat is surrounded by a water storage jacket that operates as a heat sink.
The heated water is then circulated through a heat exchanger that ties into the building
hydronic heating loop, where the biomass heat is exchanged into the loop. Wood storage is
necessary for the logs as well as equipment for splitting or cutting wood into lengths in the
event that the commercial mill in the community is not operational.
4.2 PELLET HEATING SYSTEM DESCRIPTION
The pellet boiler is a pressurized unit that burns wood pellets in the combustion chamber and
extracts the heat through the heating chambers in the boiler. In addition to the boiler,
significantly more equipment is required for pellet operation. A pellet storage tank, or hopper,
is required to house the pellets and a feed system is also required to transfer pellets from the
storage tank to the boiler when the boiler fires for operation. This additional equipment
increases the complexity of operation due to sophisticated controls and typically increases
downtime, as moving parts and controls are prone to failure. The boiler uses water as a heat
transfer medium and the heated water is then circulated through a heat exchanger that ties
into the building hydronic heating loop, where the biomass heat is exchanged into the loop.
4.3 WATER TREATMENT PLANT TIE-IN
WTP tie-ins will typically consist of brazed plate heat exchangers with node pumps to prevent
back feeding heat to the biomass boiler unit. A plate heat exchanger located in the WTP
mechanical room will be tied into the boiler return piping to preheat the boiler fluid prior to
entering the boiler. Where required, a heat injection pump will be used to avoid introducing
excessive pressure drop in the building heating system. The maximum anticipated delivered
recovered heat supply temperature is approximately 160F. When there is insufficient biomass
heat to meet the WTP heating load, the building heating system (boiler or heater) will fire and
add heat. Off the shelf controls will lock out the biomass heat system when there is insufficient
heat available.
Typical indoor piping will be type L copper tube with solder joints. Isolation valves will be
solder end bronze ball valves or flanged butterfly valves. All piping will be insulated with a
minimum of 1-in insulation with an all-service jacket. Flexibility will be provided where
required for thermal expansion and differential movement. Air vents, thermometers, pressure
gauges, drain valves, and pressure relief valves will also be provided.
The water treatment plant will also receive a BTU meter that will display critical information
for biomass building monitoring and heat totalization.
4.4 RIGHTS-OF-WAY ISSUES
There are no apparent conflicts with rights-of-ways for the arctic piping between the biomass
building and the water treatment plant as the route is entirely within the water treatment plant
property, which is owned by the Gulkana Village Council.
4.5 POTENTIAL RISKS AND UNKNOWNS
The location of heating pumps and organization of the piping system is dependent on the
desired operations for the water treatment plant by the community. The cost estimate included
in this feasibility study includes costs for either the log heating system or the pellet heating
system.
The feasibility study assumes that the community wood mill will be in full operation over the
lifespan of the biomass project. If the mill were to shut down, wood fuel would have to be
obtained from other sources, likely for higher prices.
5.0 PRELIMINARY EQUIPMENT SELECTIONS
Biomass boiler units were selected for each type of biomass fuel. These units were sized to
match the existing heat loads in the WTP facility. Additional equipment for each type of
biomass fuel have also been included to give more details on each potential heating system.
5.1 LOG WOOD HEATING SYSTEM
The log heating biomass boiler selection was made based on the heating demands of the
water treatment plant. The community has experience with the Garn biomass boilers in other
community facilities and will be easily able to operate the boilers. Two Garn biomass boilers
were compared for consideration by the community.
Garn 1000: 180 MBH
980 Gallons Storage
Garn 1500: 250 MBH
1,420 Gallons Storage
5.2 PELLET HEATING SYSTEM
The pellet biomass boiler selection was made based on the heating demands of the water
treatment plant. The community has experience with the Tarm pellet boilers for other heating
applications in the community, though the boilers they have are discontinued models.
Froling P4 Boiler 48/60-163: 164-200 MBH
5.3 HEAT EXCHANGERS
Based on initial selected flow rates, brazed plate heat exchangers appear to be adequate for
the biomass building. The initial heat exchanger selection is as follows.
HX-1 (Biomass Building): 125 MBH
Primary: 17 GPM 160F EWT (water), 0.6 PSI max GPD
Secondary: 16 GPM 155F LGT (50% propylene glycol) 0.7 PSI max GPD
It is assumed that the same heat exchanger can be used for heat from either the Garn 1000
or 1500 unit or the Tarm Multi-Heat 4.0 - 360L unit.
5.4 CIRCULATING PUMPS
HP-1A & HP-1B(Biomass Building): Biomass Circulation Pump
Grundfos Magna3 25-40, 110 Watts, Flow = 17 GPM, Head = 5 ft.
5.5 CONTROLS
The biomass boiler system in the water treatment plant will use an off-the-shelf differential
temperature controller to control the biomass boiler operation in sequence with the existing
fuel-oil boilers. The controller will start the fuel-oil boilers only when the biomass heat is not
capable of covering the full heat load and will prevent back feeding of the boiler heat into the
biomass system. A BTU meter will also be provided in the water treatment plant that will
display instantaneous temperature and heat transfer values as well as the totalized BTU
usage.
Differential Temperature Controllers: Honeywell T775 or Tekmar 156 or similar
BTU Meters: KEP BTU meter or similar with electromagnetic flow meter and matching
temperature sensors.
6.0 LIMITATIONS
The results of this report are impacted by some limitations during the analysis. The wood
heat values are based on estimates from previous wood inventory reports in the region.
Actual wood heating values will vary based on site conditions and annual weather patterns.
Wood production costs based on estimates from the Gulkana Village of future commercial
sales and operation costs of locally owned wood production mill. Wood production costs may
vary as the mill production develops fully. This study did not have access to local soil
conditions to determine the effects of permafrost in the region. The building to house the
biomass boiler used many assumptions in size and construction. Details of this facility will
need to be determined based on the type of biomass boiler unit selected.
7.0 CONCLUSIONS AND RECOMMENDATIONS
Estimated construction costs were based on recent biomass project data.
Estimates include the costs of material, equipment, freight, labor, design, construction
management, and startup and testing. The base project cost includes the biomass building
and WTP, along with design and construction management/administration. Incremental costs
for arctic pipe, end-user building renovations, and overhead and freight are estimated for this
specific project (refer to attached cost estimate).
In the economic analysis, the wood costs are considered as benefits to the community
because the money for this fuel stays within the community and provides income and
employment to community members. Currently, the fuel oil costs leave the community and
provide no economic benefit to the community. The economic benefit of the wood production
is included in the annual savings numbers.
Estimated annual savings are:
Cordwood system: 4,277 gallons (fuel oil savings of $13,131). Payback is based on a
2018 fuel price of $3.07 per gallon.
Pellet system: 3,995 gallons (fuel oil savings of $12,266). Payback is based on a 2018
fuel price of $3.07 per gallon.
The economics for each biomass boiler scenario are:
Log Heating System: Garn 1000 Cost = $289,149; Savings = $19,306; Simple
Payback = 14.98 years; SIR (30 Years) = 2.00
Log Heating System: Garn 1500 Cost = $303,725; Savings = $19,306; Simple
Payback = 15.73 years; SIR (30 Years) = 1.91
Pellet Heating System: Cost = $303.090; Savings = $22,350; Simple Payback =
13.56 years; SIR (30 years) = 2.21
APPENDIX
1. CAD Drawings
A. Cover Page
B. System Schematic I
C. Site Plan
D. Heat Exchange Diagram
2. Equipment Selection Cutsheets
A. Garn 1000 Biomass Boiler
B. Froling P4 Biomass Boiler
C. Kelvion Heat Exchanger
3. Gulkana Biomass Technical Calculations
A. Garn 1000 and Froling P4 Calculations
B. Garn 1500 and Froling P4 Calculations
4. Gulkana Biomass Cost Estimates
A. Garn 1000 Biomass Boiler Cost Estimate
B. Garn 1500 Biomass Boiler Cost Estimate
C. Froling P4 Biomass Boiler Cost Estimate
Kelvion Inc. PHE Division
100 GEA Drive
York, PA 17406 USA
Ph: +717-268-6200
Fax: +717-268-6162
info.geaphena@geagroup.com
Website: www.kelvion.com/us
Liquid to liquid
Customer / Project Gulkana WTP Feasibility Garn HX Selection ID NUN2W2C4P
User name Kevin Ulrich Print date 7/16/2018
Model: FG10X20-50 (2" MPT)
Load (Btu/h) 125,000 Nominal surface (ft²) 63.0
Log mean temp. diff. (°F) 5.0 Dimensions 11.1W x 21.4H x 5.7D
Overall HTC (Btu/h·ft²·°F) 415 Plate construction Single wall
Oversurface percent 4.6 Net weight (lb) 84.0
Model size 10x20
Design Conditions Side A - Liquid Side B - Liquid
Fluid type Water Propylene glycol
Fluid conc. 50
Fluid mass flow rate (lb/min) 139 157
Entering fluid temp. (°F) 160.0 140.0
Leaving fluid temp. (°F) 145.0 155.0
Fluid flow rate (GPM) 17.0 18.6
Fluid fouling factor (h·ft²·°F/Btu) 0.00010 0.00010
Fluid specific heat (Btu/lb·°F) 1.000 0.884
Fluid thermal conductivity (Btu/h·ft·°F) 0.382 0.219
Fluid viscosity (lb/ft·h) 1.021 3.830
Fluid density (lb/ft³) 61.14 63.29
Fluid freezing temp. (°F) 32.0 -28.6
Model Parameters
Number of channels 24 25
Velocity (ft/s) 0.33 0.34
Pressure drop (psi) 0.6 0.7
Heat transfer coef. (Btu/h·ft²·°F) 1,446 659
Internal volume (ft³) 0.247 0.257
Kelvion Inc. PHE Division
100 GEA Drive
York, PA 17406 USA
Ph: +717-268-6200
Fax: +717-268-6162
info.geaphena@geagroup.com
Website: www.kelvion.com/us
Ratings at Varying Conditions
Percent difference -15% -7½% 0% 7½% 15%
Pressure drop (psi) (Side A) 0.4 0.5 0.6 0.6 0.7
Pressure drop (psi) (Side B) 0.6 0.7 0.7 0.8 1.0
Load (Btu/h) 106,250 115,625 125,000 134,375 143,750
Fluid flow rate (GPM) (Side A) 14.4 15.7 17.0 18.3 19.5
Fluid mass flow rate (lb/min) (Side A) 118 129 139 149 160
Fluid flow rate (GPM) (Side B) 15.8 17.2 18.6 20.0 21.3
Fluid mass flow rate (lb/min) (Side B) 133 145 157 169 181
Entering fluid temp. (°F) (Side A) 160.0 160.0 160.0 160.0 160.0
Entering fluid temp. (°F) (Side B) 140.0 140.0 140.0 140.0 140.0
Leaving fluid temp. (°F) (Side A) 145.0 145.0 145.0 145.0 145.0
Leaving fluid temp. (°F) (Side B) 155.0 155.0 155.0 155.0 155.0
Oversurface percent 11.5 7.9 4.6 1.7 -1.0
Disclaimer
This software and the generated calculations provided herein are estimates only and should be treated as such. GEA PHE Systems North America, Inc. always strives to give
complete and accurate information, but cannot provide any guarantees. This software and its output are provided "as is" and any express or implied warranties, including, but
not limited to, the implied warranties of merchantability and fitness for a particular purpose are disclaimed. In no event shall GEA PHE Systems North America, Inc. be liable
for any direct, indirect, incidental, special, exemplary, or consequential damages (including, but not limited to, procurement of substitute goods or services; loss of use, data,
or profits; or business interruption) however caused and on any theory of liability, whether in contract, strict liability, or tort (including negligence or otherwise) arising in any
way out of the use of this software, even if advised of the possibility of such damage.
Contact:
Customer / Project:
Model Nomenclature:
Selection ID:
Dimension Sheet Brazed Plate Heat Exchanger
Technical Data
Allowable Working Pressure and Temperature:
Max pressure Circuit A:
Circuit B:
Max temperature
Min temperature
Standard construction materials:
Braze Alloy:
Connector:
Plate:
Code Approvals:
Note: Code approval applies to heat exchangers only.
Installation Notes:
Pipe in counter flow direction.
Water strainer should be installed in the fluid inlet circuit to protect the heat exchanger from blockage (20-40 mesh).
Thread Connections Use Teflon tape or other sealant on male threaded part of the connection to prevent leakage.
A:
B:
C:
D:
F:
G:
H:
Dimensions - inches (mm): Reference only
Connections Volume per BPHE
Circuit A Circuit B
Position 1 Position 2 Position 3 Position 4
Circuit A Circuit B
Net Weight:
Mounting Bracket
(optional)
NUN2W2C4P
FG10X20-50 (2" MPT)
Copper 99.9%
304 Stainless Steel
316L Stainless Steel
450 psig (31.0 bar ga)
350.0 °F (176.7 °C)
-320.0 °F (-195.6 °C)UL Pending
Kelvion Inc. PHE Division
100 GEA Drive, York, PA 17406
Toll Free: 1-800-774-0474
Phone: 1-717-268-6200
Fax: 1-717-268-6163
www.kelvion.com/us
E-mail: info.geaphena@geagroup.com
Gulkana WTP Feasibility Garn HX
11.06 (280.9)
21.38 (543.1)
7.80 (198.1)
18.11 (460.0)
3.94 (100.1)
5.51 (140.0)
5.65 (143.5)
0.247 ft³ (6.988 L) 0.257 ft³ (7.279 L)
84.0 lb (38.1 kg)2" MPT 2" MPT 2" MPT 2" MPT
450 psig (31.0 bar ga)
Cost Estimate for Biomass Heating Project
Qty Rate 134 126 117 115 127 126 85 108 35 35 35 Labor
Civil 100 8 10.0 15,000$ Site Visit 1 1,100$ 1,100$
Mechanical 150 8 15.0 22,500$ Site Visit 1 1,100$ 1,100$
Electrical 100 8 10.0 15,000$ Site Visit 1 1,100$ 1,100$
CAD 120 8 12.0 12,000$
Survey 24 8 2.4 2,880$ -$
67,380$ 3,300$
Biomass Harvesting Plan -$
Biomass O&M Manual / Business Plan -$
Subtotal 3,300$
70,680$
Total hours >127.5 85.0 0.0 0.0 92.5 110.0 25.0 0.0 320.0 20.0 80.0
Mobilization Man-Days
Equipment Shipping 1.0 1 850$
Takeoffs 3.5 0.75 0.5 0.75 1 0.5 4,147$
Materials Receiving and Inventory 2.0 0.5 0.5 1 2,115$
Set up Materials Storage/Yard 3.0 1 2 2,040$
Housing
Local Rental Lodging Rental *Note
Sitework: Clearing & Pad Prep Equipment Rental 1 -$ -$ -$
GarnPac Placement 3.5 0.5 3 1,720$ Garn 1000 Boiler 1 27,500$ 27,500$ 15,980$ 43,480.00$
Out-building Installation 15.0 5 10 10,200$ Building Package 1 15,000$ 15,000$ 1,500$ 16,500.00$
Arctic Pipe (trench & bury)3.5 0.5 2 1 1,720$ Arctic Pipe/Ftgs 1 5,000$ 5,000$ 1,500$ 6,500.00$
Out-building Biomass Mechanical 6.0 3 3 4,830$ Boiler Accessories 1 2,500$ 2,500$ 500$ 3,000.00$
Out-building Electrical 6.0 3 3 4,860$ Electrical 1 7,500$ 7,500$ 500$ 8,000.00$
Pipe & Fittings 1 7,500$ 7,500$ 500$ 8,000.00$
Building Penetrations 4.0 1 2 1 2,390$ Heat Exchanger 2 3,000$ 6,000$ 500$ 6,500.00$
Plumbing 6.5 0.5 3 3 5,500$ Pumps 2 1,500$ 3,000$ 500$ 3,500.00$
Electrical & Controls 6.5 0.5 3 3 5,530$ Controls 1 2,500$ 2,500$ 500$ 3,000.00$
BTU Meter 1 1,500$ 1,500$ 100$ 1,600.00$
Flow meter 1 3,000$ 3,000$ 100$ 3,100.00$
Connection and install 3.5 0.5 1 1 1 2,595$
Programming and interface 1.0 1 1,008$
Glycol 6 1,150$ 6,900$ 1,500$ 8,400.00$
Pressure test/Fill with Glycol 2.0 1 1 1,610$
Startup and Operator Training
System Startup and Labeling 3.5 0.5 2 0.5 0.5 3,951$
Training 1.0 1 1,008$
Job Clean Up/ Final Inspection
Preliminary Clean Up 2.5 0.5 2 1,370$
Final Inspection Punch List 7.0 1 2 1 1 2 6,586$
Final Clean Up / De-mobe 3.0 1 2 2,040$
Financial Close out/ Auditing 1.0 1 1,008$
Record Drawings 1.0 1 1,008$
68,086$
97,800$ 23,680$ 111,580$
179,666$
70,680$
Subtotal =250,346$
12,517$
Contingency @ 10%26,286$
Total 289,149$
Total Construction Phase Labor
Fixed estimate @ 100 /hr.
*Note
Fixed estimate @ 150 /hr.
Assumed complete as part of the
communities existing facilities
Freight Materials
+ Freight
Closeout
Support Activities
Total Cost
Design Total
Design Travel Total
Item No.Cost EaMechanic
Construction
Total Mat
MATERIALS / SUBCONTRACT
Local PlumberFixed estimate @ 150 /hr.
*Note LocalLabor ElectricianLocal Operator*Note
Project Management @ 5%
Gulkana Biomass Cost Estimate
PlumbershippingGulkana Biomass Cost Estimate
Total ItemOperatorProduction
Rate
EngineerDays
(60hr.
Week)Crew LeadSuperLABOR
Design
Assumptions:
- Local accomodations are available and
provided free of charge by community as in
kind match.
- Exterior piping estimated at 100' RT and
run below ground at approxmately 1.5' bed
depth, 6" of cover
- Local equipment is available and provided
free of charge by community as in kind
match.
- Existing pad developed for WTP to be used
for biomass out-building. No
clearing/grubbing necessary
No.Cost Ea Total Cost
BTU Meter install
Design
WTP Integration
ELEMENT
Fixed estimate @ 120 /hr.
Biomass Boiler
Fixed estimate @ 150 /hr.
Design Subtotal
Cost Estimate for Biomass Heating Project
Qty Rate 134 126 117 115 127 126 85 108 35 35 35 Labor
Civil 100 8 10.0 15,000$ Site Visit 1 1,100$ 1,100$
Mechanical 150 8 15.0 22,500$ Site Visit 1 1,100$ 1,100$
Electrical 100 8 10.0 15,000$ Site Visit 1 1,100$ 1,100$
CAD 120 8 12.0 12,000$
Survey 24 8 2.4 2,880$ -$
67,380$ 3,300$
Biomass Harvesting Plan -$
Biomass O&M Manual / Business Plan -$
Subtotal 3,300$
70,680$
Total hours >127.5 85.0 0.0 0.0 92.5 110.0 25.0 0.0 320.0 20.0 80.0
Mobilization Man-Days
Equipment Shipping 1.0 1 850$
Takeoffs 3.5 0.75 0.5 0.75 1 0.5 4,147$
Materials Receiving and Inventory 2.0 0.5 0.5 1 2,115$
Set up Materials Storage/Yard 3.0 1 2 2,040$
Housing
Local Rental Lodging Rental *Note
Sitework: Clearing & Pad Prep Equipment Rental 1 -$ -$ -$
GarnPac Placement 3.5 0.5 3 1,720$ Garn 1000 Boiler 1 33,000$ 33,000$ 19,200$ 52,200.00$
Out-building Installation 15.0 5 10 10,200$ Building Package 1 18,000$ 18,000$ 1,800$ 19,800.00$
Arctic Pipe (trench & bury)3.5 0.5 2 1 1,720$ Arctic Pipe/Ftgs 1 5,000$ 5,000$ 1,500$ 6,500.00$
Out-building Biomass Mechanical 6.0 3 3 4,830$ Boiler Accessories 1 3,000$ 3,000$ 600$ 3,600.00$
Out-building Electrical 6.0 3 3 4,860$ Electrical 1 7,500$ 7,500$ 500$ 8,000.00$
Pipe & Fittings 1 7,500$ 7,500$ 500$ 8,000.00$
Building Penetrations 4.0 1 2 1 2,390$ Heat Exchanger 2 3,000$ 6,000$ 500$ 6,500.00$
Plumbing 6.5 0.5 3 3 5,500$ Pumps 2 1,500$ 3,000$ 500$ 3,500.00$
Electrical & Controls 6.5 0.5 3 3 5,530$ Controls 1 2,500$ 2,500$ 500$ 3,000.00$
BTU Meter 1 1,500$ 1,500$ 100$ 1,600.00$
Flow meter 1 3,000$ 3,000$ 100$ 3,100.00$
Connection and install 3.5 0.5 1 1 1 2,595$
Programming and interface 1.0 1 1,008$
Glycol 6 1,150$ 6,900$ 1,500$ 8,400.00$
Pressure test/Fill with Glycol 2.0 1 1 1,610$
Startup and Operator Training
System Startup and Labeling 3.5 0.5 2 0.5 0.5 3,951$
Training 1.0 1 1,008$
Job Clean Up/ Final Inspection
Preliminary Clean Up 2.5 0.5 2 1,370$
Final Inspection Punch List 7.0 1 2 1 1 2 6,586$
Final Clean Up / De-mobe 3.0 1 2 2,040$
Financial Close out/ Auditing 1.0 1 1,008$
Record Drawings 1.0 1 1,008$
68,086$
106,800$ 27,300$ 124,200$
192,286$
70,680$
Subtotal =262,966$
13,148$
Contingency @ 10%27,611$
Total 303,725$
Design
Assumptions:
- Local accomodations are available and
provided free of charge by community as in
kind match.
- Exterior piping estimated at 100' RT and
run below ground at approxmately 1.5' bed
depth, 6" of cover
- Local equipment is available and provided
free of charge by community as in kind
match.
- Existing pad developed for WTP to be used
for biomass out-building. No
clearing/grubbing necessary
No.Cost Ea Total Cost
BTU Meter install
Design
WTP Integration
ELEMENT
Fixed estimate @ 120 /hr.
Biomass Boiler
Fixed estimate @ 150 /hr.
Design Subtotal
Project Management @ 5%
Gulkana Biomass Cost Estimate
PlumbershippingGulkana Biomass Cost Estimate
Total ItemOperatorProduction
Rate
EngineerDays
(60hr.
Week)Crew LeadSuperLABOR
MechanicConstruction
Total Mat
MATERIALS / SUBCONTRACT
Local PlumberFixed estimate @ 150 /hr.
*Note LocalLabor ElectricianLocal OperatorCloseout
Support Activities
Total Cost
Design Total
Design Travel Total
Item No.Cost Ea
Total Construction Phase Labor
Fixed estimate @ 100 /hr.
*Note
Fixed estimate @ 150 /hr.
Assumed complete as part of the
communities existing facilities
Freight Materials
+ Freight
Cost Estimate for Biomass Heating Project
Qty Rate 134 126 117 115 127 126 85 108 35 35 35 Labor
Civil 100 8 10.0 15,000$ Site Visit 1 1,100$ 1,100$
Mechanical 180 8 18.0 27,000$ Site Visit 1 1,100$ 1,100$
Electrical 140 8 14.0 21,000$ Site Visit 1 1,100$ 1,100$
CAD 120 8 12.0 12,000$
Survey 24 8 2.4 2,880$
77,880$ 3,300$
Biomass Harvesting Plan
Biomass O&M Manual / Business Plan
Subtotal 3,300$
81,180$
Total hours >127.5 85.0 0.0 0.0 102.5 115.0 25.0 0.0 330.0 20.0 85.0
Mobilization Man-Days
Equipment Shipping 1.0 1 850$
Takeoffs 3.5 0.75 0.5 0.75 1 0.5 4,147$
Materials Receiving and Inventory 2.0 0.5 0.5 1 2,115$
Set up Materials Storage/Yard 3.0 1 2 2,040$
Housing
Local Rental Lodging Rental *Note
Sitework: Clearing & Pad Prep 0.0 -$ Equipment Rental 1 -$ -$ -$
TARM Placement 3.5 0.5 3 1,720$ TARM Multi-Heat 4.0 1 20,000$ 20,000$ 17,500$ 37,500.00$
Out-building Installation 15.0 5 10 10,200$ Building Package 1 15,000$ 15,000$ 1,500$ 16,500.00$
Arctic Pipe (trench & bury)3.5 0.5 2 1 1,720$ Arctic Pipe 1 5,000$ 5,000$ 1,500$ 6,500.00$
Out-building Biomass Mechanical 7.0 3.5 3.5 5,635$ Boiler Accessories 1 6,500$ 6,500$ 1,625$ 8,125.00$
Out-building Electrical 8.0 4 4 6,480$ Electrical 1 7,500$ 7,500$ 500$ 8,000.00$
Building Penetrations 4.0 1 2 1 2,390$
Plumbing 6.5 0.5 3 3 5,500$ Pipe & Fittings 1 7,500$ 7,500$ 500$ 8,000.00$
Electrical & Controls 6.5 0.5 3 3 5,530$ Heat Exchanger 2 3,000$ 6,000$ 500$ 6,500.00$
Pumps 2 1,500$ 3,000$ 500$ 3,500.00$
Controls 1 2,500$ 2,500$ 500$ 3,000.00$
Connection and install 3.5 0.5 1 1 1 2,595$ BTU Meter 1 1,500$ 1,500$ 100$ 1,600.00$
Programming and interface 1.0 1 1,008$ Flow meter 1 3,000$ 3,000$ 100$ 3,100.00$
Pressure test/Fill with Glycol 2.0 1 1 1,610$ Glycol 6 1,150$ 6,900$ 1,500$ 8,400.00$
Startup and Operator Training
System Startup and Labeling 3.5 0.5 2 0.5 0.5 3,951$
Training 1.0 1 1,008$
Job Clean Up/ Final Inspection
Preliminary Clean Up 2.5 0.5 2 1,370$
Final Inspection Punch List 7.0 1 2 1 1 2 6,586$
Final Clean Up / De-mobe 3.0 1 2 2,040$
Financial Close out/ Auditing 1.0 1 1,008$
Record Drawings 1.0 1 1,008$
70,511$
94,300$ 26,325$ 110,725$
181,236$
81,180$
262,416$
Project Management @ 5% =13,121$
27,554$
303,090$
Total Construction Phase Labor
Freight Materials
+ Freight
*Note
*Note
Assumed complete as part of
the communities existing
Fixed estimate @ 100 /hr.
Total Cost
Design Total
Design Travel Total
Item No.Cost Ea
Closeout
Construction =
Total Mat
MATERIALS / SUBCONTRACT
Local PlumberSupport Activities
Fixed estimate @ 150 /hr.
*Note LocalLabor ElectricianLocal OperatorGulkana Biomass Cost Estimate
PlumbershippingGulkana Biomass Cost Estimate
Total ItemOperatorProduction
Rate
EngineerDays
(60hr.
Week)Crew LeadSuperLABOR
MechanicNo.Cost Ea Total Cost
BTU Meter install
Design
WTP Integration
ELEMENT
Fixed estimate @ 120 /hr.
Biomass Boiler
Fixed estimate @ 150 /hr.
Design Subtotal
Fixed estimate @ 150 /hr.
Contingency @ 10% =
Subtotal =
Design =
Assumptions:
- Local accomodations are available and
provided free of charge by community as in
kind match.
- Exterior piping estimated at 100' RT and
run below ground at approxmately 1.5' bed
depth, 6" of cover
- Local equipment is available and provided
free of charge by community as in kind
match.
- Existing pad developed for WTP to be used
for biomass out-building. No
clearing/grubbing necessary
- It's assumed that since the pellet set up is
slightly more complex, additional labor for
design and construction will be necessary Total =