HomeMy WebLinkAboutCity of Russian Mission Heat Recovery Project Feasibility Study - Jul 2011 - REF Grant 7050844RUSSIAN MISSION, ALASKA
HEAT RECOVERY STUDY
PREPARED FOR:
ALASKA NATIVE TRIBAL HEALTH CONSORTIUM
Project ANTHC-09-P52187
PREPARED BY:
Alaska Energy and Engineering, Inc.
Mailing Address - P.O. Box 111405
Anchorage, AK 99511-1405
(907) 349-0100, 349-8001 FAX
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July 25, 2011
ANTHC-Russian Mission Heat Recovery Analysis July 25, 2011
Alaska Energy and Engineering
EXECUTIVE SUMMARY
The Water Treatment Plant (WTP) in Russian Mission was evaluated for heat recovery
potential. Total estimated annual heating fuel provided by ANTHC is approximately
2,200-gallons. Estimated fuel savings realized by implementing a heat recovery
system is 2,200-gallons. The estimated cost for the heat recovery project is $351,929.
The AVEC power plant is capable of providing nearly double the amount of recovered
heat the Water Treatment Plant requires. Additional facilities near AVEC or the Water
Treatment Plant should be evaluated for potential to receive recovered heat to better
utilize the available resource.
1.0 INTRODUCTION
Alaska Energy and Engineering, Inc. was retained by the Alaska Native Tribal Health
Consortium (ANTHC) to review the feasibility of providing available recovered heat
from the existing AVEC power plant to the existing water plant in Russian Mission, and
provide a budgetary project cost estimate based on Force Account Construction,
including Design Engineering and Construction Administration.
Additional assumptions have been made in the development of this report including
but not limited to the proposed arctic piping routes, building heating loads, and flow
rates and pressure drops of the existing power plant cooling system and WTP heating
system. It is anticipated that refinements in pipe size and routing, pump and heat
exchanger sizing, and other design elements will be required as the project progresses
to final design.
Available information was obtained from the Alaska Village Electric Cooperative
(AVEC) regarding the existing generation equipment. End -user annual fuel use was
provided by ANTHC. No site visits were made to confirm accuracy of information
obtained.
2.0 OVERVIEW
The purpose of this study is to provide an estimate of the heat that can be recovered
from the jacket water of the AVEC power plant diesel engines and used to offset
heating oil consumption at the WTP. Useable recovered heat is quantified in gallons
of heating fuel saved using a gross heating value of 134,000 BTU per gallon of #1
arctic diesel fuel and an overall boiler efficiency of 75% for a net heating value of
100,000 BTU per gallon.
The Water Treatment Plant is located 600-feet east of the AVEC power plant. This
analysis evaluates the estimated recovered heat available to the Water Treatment
Plant. The estimated average annual heating fuel consumption for the WTP is 2200-
gallons.
3.0 ESTIMATED RECOVERED HEAT UTILIZATION
A heat recovery utilization spreadsheet has been developed to estimate the
recoverable heat based on monthly total electric power production, engine heat rates,
building heating demand, heating degree days, passive losses for power plant heat
and piping, and arctic piping losses. The spreadsheet utilizes assumed time -of -day
variations for electric power production and heat demand. Power Cost Equalization
data for fiscal year 2009 was used in the spreadsheet. The estimated heat rejection
rate for the lead power plant genset, a Detroit Diesel Series 60 DDEC4 1800 rpm
genset installed summer of 2010, is used to estimate available recovered heat.
Heating degree-days for Russian Mission were used for this site. All exterior power
ANTHC-Russian Mission Heat Recovery Analysis July 25, 2011
_ Alaska Energy and Engineering
plant hydronic piping is assumed to be 3" pipe with 1" of fiberglass insulation and
installed above grade. The AVEC power plant consists of six uninsulated 20-foot
connexes arranged in two rows of 3 with a deck between. One row contains the
generator module. It is assumed that the radiant heat from the online generator is
sufficient to maintain space temperature in the generation module. The other row
contains the crew quarters, storage/shop and switchgear controls. This module is
heated using recovered heat from the online generator. The heat load of these three
uninsulated connexes exceeds the power plant available recovered heat during cold
winter months, therefore; to provide useable recovered heat to the water plant, the
storage/control/quarters module needs to be insulated.
The spreadsheet uses monthly heating degree-days to distribute annual fuel
consumption by month. The monthly heat load is then allocated by hour of day using
an estimated daily temperature variation (diurnal cycle). The end -user hourly heat
load is compared to the hourly available heat from the power plant, less power plant
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 each building:
Facility Estimated Annual Estimated Heat *
Fuel Use Gallons Delivered Gallons
Water Plant 2200 2200
Total 2200 2200
Does not account for peak DHW loads
4.0 HEAT RECOVERY SYSTEM DESCRIPTION AND OPERATION:
The heat recovery system captures jacket water heat generated by the AVEC power
plant that is currently rejected to the atmosphere by the radiators. Recovered heat is
transferred via below grade arctic piping to the Water Plant. The objective is to reduce
the consumption of expensive heating fuel by utilizing available recovered heat.
Although heat recovery is an excellent method of reducing heating fuel costs,
recovered heat is a supplementary heat source and it is imperative that the end -
user facility heating systems are operational at all times.
Hot engine coolant is piped through a plate heat exchanger located at the power plant.
Heat is transferred from the engine coolant to the recovered heat loop without mixing
the fluids. The recovered heat fluid is pumped through arctic pipe to the water plant
and is tied into the heating system using a plate heat exchanger.
AVEC PLANT TIE-IN:
No modifications to the AVEC power plant cooling system are included, except those
required to tie a new heat exchanger into the plant hydronic system, provide circulating
pumps, and install instrumentation.
All piping will be insulated with a minimum of 1" insulation and have an aluminum
jacket where exposed to the weather. All valves will be either bronze ball valves, or
lug style butterfly valves with seals compatible with 50150 glycol/water mixtures at
ANTHC-Russian Mission Heat Recovery Analysis July 25, 2011
Alaska Energy and Engineering
200F. Air vents, thermometers, pressure gauges, drain valves and pressure relief
valves will also be provided.
ARCTIC PIPING (Recovered Heat Loop):
The proposed arctic piping is a pre -insulated buried piping system. The piping will be
routed from the AVEC plant within existing rights -of -way to the end -user building.
The arctic piping system is a pre -insulated, bonded PEX piping system. The pipes
consist of Cross -Linked Polyethylene carrier pipe and LDPE outer jacket bonded to
polyurethane foam insulation. The carrier piping uses hydraulically pressed bronze or
steel couplings, similar to those used in high-pressure hydraulic hoses. The system
comes complete with all fittings, tools and accessories required for assembly. The
recovered heat fluid will be a 50/50 Propyiene Glycol/Water solution to provide freeze
protection to the piping.
END -USER BUILDING TIE-INS:
End -user building tie-ins typically consist of either brazed plate heat exchangers or
cabinet unit heaters. Plate heat exchangers located in the end -user mechanical rooms
will be tied into the boiler return piping to pre -heat the boiler water prior to entering the
boiler. Where Toyo-style heaters are used, cabinet unit heaters will be located in the
occupied space. The maximum anticipated delivered recovered heat supply
temperature is about 180F. When there is insufficient recovered heat to meet the
building heating load, the building heating system (boiler or heater) will fire and add
heat.
Typical 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" 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.
RIGHTS -OF -WAY ISSUES:
It appears the arctic piping route between the power plant and the WTP is entirely
within existing road rights -of -ways, and on City and AVEC property.
A Heat Sales / Right -of -Entry Agreement will be required between AVEC and the
Alaska Rural Utilities Collaborative (ARUC) to define the parties' responsibilities, the
cost of recovered heat, and to authorize the renovation of the power plant heat
recovery equipment.
5.0 PRELIMINARY EQUIPMENT SELECTIONS
The following initial equipment selections are sized and selected based on preliminary
data and will require minor modifications to reflect final design.
3
ANTHC-Russian Mission Heat Recovery Analysis July 25, 2011
Alaska Energy and Engineering
5.1 Heat Exchangers
Based on initial selected flow rates, brazed plate heat exchangers appear to be
adequate for all locations. Initial heat exchanger selections are as follows.
HX-1: (Power Plant). 400 MBH capacity (see note)
Primary: 92 GPM 190F EWT (50% ethylene glycol), 2.0 PSI max WPD
Secondary: 60 GPM 18OF LWT (50% propylene glycol) 1.0 PSI max WPD
HX-2: (Water Treatment Plant). 70 MBH capacity.
Primary: 11 GPM 180F EWT (50% propylene glycol), 1.0 PSI max WPD
Secondary: 14 GPM 175F LWT (50% propylene glycol) 1.5 PSI max WPD
Note: the power plant heat exchanger is sized for future system expansion
5.2 Arctic Piping
The length of heat recovery loop piping between the power plant and Water Treatment
Plant is approximately 1200-feet, round trip. The arctic piping utilizes 2" PEX to
minimize pressure drop and reduce pumping energy.
5.3 Circulating Pumps
P-HR1: Heat recovery loop to end -user buildings
Flow = 11 GPM, Head = 27'
Initial Selection: Grundfos UPS 40-16012. 11 GPM at 27' TDH, 1-112 HP
5.4 Expansion Tank
Total heat recovery loop volume is approximately 150-gallons. Pressure relief at the
power plant heat exchanger will be 50 PS1G and the maximum normal operating
pressure will be 90% of maximum (45 PSIG).
ET-1: System requirements: 17.3 gallon tank and 10.6 gallon acceptance
Select: Extrol AX-40V, 21.7 gallon tank and 11.3 gallon acceptance
6.0 CONCLUSIONS AND RECOMMENDATIONS
Estimated construction costs were determined based on prior recent heat recovery
project experience, and include materials, equipment, freight, labor, design,
construction management, and startup and testing. All work at the power plant and
water treatment plant, and design and construction management/administration for the
project is included (refer to attached cost estimate).
The estimated project cost for is $351,929. Estimated fuel savings are about 2,200-
gallons. Using an assumed fuel price of $5.001galion results in estimated savings of
$11,000 for a simple payback of 32-years.
The AVEC power plant has the capability of providing nearly double the amount of
recovered heat the Water Treatment Plant requires. Also, the recently installed 1800-
rpm Detroit Diesel genset is capable of being retrofit with an OEM marine jacket to
capture additional recovered heat. Additional facilities nearby the AVEC or the Water
Treatment Plant should be evaluated for recovered heat potential to better utilize
available fuel savings and to provide a reduced simple payback.
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PROJECT: ANTHC RECOVERED HEAT STUDY
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ALASKA ENERGY & ENGINEERING, INC.
P.O. BOX 111405 ANCHORAGE, ALASKA 99511-1405
oE300 BY, SJS
6QE 12/6/10
RUSSIAN MISSION RECOVERED HEAT
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SHEET OF
SCHEMATIC, DETAIL AND LOCATION ASAP
RUSSiAN.DWG
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PHONE (907) 349-0100
PRWEM ANTHC RECOVERED HEAT STUDY
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ALASKA ENERGY & ENGINEERING, INC.
P.O. BOX 111405 ANCHORAGE, ALASKA 99511-1405
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Om- 12/6/10
"n-F-' RUSSIAN MISSION RECOVERED HEAT
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