HomeMy WebLinkAboutCity of Saint Mary's Heat Recovery Project Feasibility Study - Sep 2013 - REF Grant 7071043ST. MARY'S, ALASKA
HEAT RECOVERY STUDY
PREPARED BY:
Alaska Native Tribal Health Consortium
Division of Environmental Health and Engineering
3900 Ambassador Dr., Ste 301, Anchorage AK 99508
Phone (907) 729-36001 Fax (907) 729-4046
September 6, 2013
EXECUTIVE SUMMARY
The existing heat recovery system was constructed in St. Mary's in 1984 that captures heat
from the AVEC power plant, which was used to reduce heating fuel consumption at the
Mission and City Cold Storage building. In 1995, the heat recovery system was renovated to
provide additional recovered heat to the adjacent City Shop. The existing system is 29
years old, is at or near the end of its useful life. Therefore, ANTHC recommends to build the
new heat recovery system to provide beneficial use for another 30-years.
The St. Mary's power plant, City Shop, water circulation loops, Cold Storage/Hotel and City
Office Buildings were evaluated for heat recovery potential. The total estimated annual
heating fuel used by all three buildings and the water system is approximately 15,918
gallons. The expected annual savings is 15,726 gallons, which is approximately equivalent
to the total heat demand of three buildings plus the water system. In other words, the heat
recovery system provides sufficient heat to operate three buildings plus water
system without consuming fuel for the existing boiler heating system. The simple
payback based on a 2013 fuel cost of $4.60/gallon is 13.32 years. The ratio of NPV benefit
to cost (B/C) was estimated based on the system lifetime of 20 years. The estimated B/C
value is 1.28.
The payback is based on a 2013 fuel price of $4.60 gallon and an estimated 2013 project
cost of $674,185.
Assuming construction in 2015, the design and construction cost plus a 2 year escalation
rate of 3% is $715,243.
1.0 INTRODUCTION
The Alaska Native Tribal Health Consortium (ANTHC) reviewed the feasibility of providing
recovered heat from the AVEC power plant to City Shop, water circulation loops, Cold
Storage/Hotel and City Office Building in St. Mary's. ANTHC also developed a budgetary
project cost estimate based on Force Account Construction, and included Engineering and
Construction Administration.
The existing heat exchanger at the AVEC power plant will be replaced with the new heat
exchanger specified in the equipment selection. The existing heat recovery module located
next to the power plant will be demolished. The new heat recovery piping routed to the Cold
Storage/Hotel and the City Office building will be extended from the existing piping as
shown in the CAD drawing (System Schematic 1).
The City Shop is hydronically heated. The water circulation loop and WST is also heated by
hydronic system. The existing heat recovery system provides heat to the City Shop and to
the water system (water circulation loops and WST) through the heat exchanger installed in
the City Shop boiler room. The existing heat recovery system installed in 1995 will be
renovated with the new heat exchangers, expansion tanks, air separator and pumps.
The Cold Storage/Hotel, which also utilizes the hydronic heating system, has been taken
advantage of recovered heat. The existing Young F-606-EY-2P shell and tube heat
exchanger will be replaced with a brazed plate heat exchanger. The existing piping will be
abandoned. The new buried arctic pipe will be routed from the power plant.
The City Office building is heated by three Toyo stoves (Laser 73) and forced -air heating
system. Two cabinet unit heaters will be installed in the community hall and baseboard
heater will be installed in the office area. Three Toyo stoves and forced -air heating system
will be remained as the primary heating system to the building. The above ground arctic
pipe will be extended along the existing sewer line from the Cold storage/Hotel to the fan
room of City Office building.
The annual fuel use of the facilities currently served by the heat recovery system is
unknown, and was estimated. End -user annual fuel use for the facilities was obtained from
the City or estimated. A site visit was conducted June 17, 2013 to assess the condition of
the system and obtain information from City Office and system operators.
Additional assumptions have been made in the report, including but not limited to the
proposed arctic piping route, building heating loads, and flow rates and pressure drops of
the heat recovery system. It is anticipated that sizing and routing of arctic pipe, selections of
pump and heat exchanger with other design elements will require refinement as the project
progresses.
We obtained available as -built information from AVEC regarding the 2012 power plant
electrical loads. End -user annual fuel use was obtained from a variety of sources, including
the City of St. Mary's, Alaska Rural Utility Cooperative (ARUC), and engineering estimates.
When possible, reported fuel consumption was used to validate engineering estimates.
2.0 OVERVIEW
The purpose of this study is to provide an estimate of the heat that can be recovered from
the AVEC power plant diesel engines and used to offset heating oil consumption at the
nearby public buildings. 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 public buildings eligible for heat recovery are located within 200-foot radius of the
AVEC power plant. This analysis evaluates the potential to provide recovered heat to the
nearby public buildings. The estimated average annual heating fuel consumption for the
nearby public buildings is 15,726 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 generation data from AVEC for fiscal year 2011 is
used in the spreadsheet. The estimated heat rejection rate for the power plant genset (most
frequently operated Cummins QSX15 G9) was used to estimate available recovered heat.
The data for heating degree-days of St. Mary's were available and utilized for this site. All
arctic piping is assumed to be routed below grade. All power plant hydronic piping is
assumed to be insulated with 2 in of insulation. The proposed conceptual generator plant
modification was used to estimate the heating load for the power plant, which includes the
power house..
The spreadsheet uses monthly heating degree-days to distribute annual fuel consumption
by month. 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
City Shop
Water Circulation Loops
Cold Storage/Hotel:
City Office Building:
Estimated
Annual Fuel Use
(Gallons)
5,270
4,294
3,529
2,823
Estimated Annual
Fuel Avoided
(Gallons)
5,078
4,294
3,529
2,823
Total 15,918 15,726
4.0 HEAT RECOVERY SYSTEM DESCRIPTION AND OPERATION:
The heat recovery system captures jacket water heat generated by the AVEC power plant
that is typically rejected to the atmosphere by the radiators. The recovered heat is
transferred via below -grade arctic piping to the end users. 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.
Controls at the power plant are used to prevent subcooling of the generator engines and
reducing electric power production efficiency. The recovered heat fluid is pumped through
buried insulated pipe to the end -user facilities, and is typically tied into the end -user heating
system using a plate heat exchanger.
4.1 AVEC PLANT TIE-IN
Because the AVEC plant was designed for recovered heat, no modifications to the AVEC
power plant cooling system are included or anticipated, except those required to connect
the arctic piping to the power plant heat exchangers.
All heat recovery piping will be insulated with a minimum of 2-in 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 50/50 glycol/water mixtures at 200F.
Air vents, thermometers, pressure gauges, drain valves, and pressure relief valves will also
be provided.
The recovered heat fluid will be a 50/50 Propylene Glycol/Water solution to provide freeze
protection to the piping.
4.2 END -USER BUILDING TIE-INS
End -user building tie-ins typically consist of brazed plate heat exchangers with motorized
bypass valves to prevent back feeding heat to AVEC or other users. Plate heat exchangers
located in the end -user mechanical rooms will be tied into the boiler return piping to preheat
the boiler water 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 about 190F. When
there is insufficient recovered heat to meet the building heating load, the building heating
system (boiler or heater) will fire and add heat. Off the shelf controls will lock out the
recovered heat system when there is insufficient recovered 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.
One BTU meter will be installed at the power plant to provide recovered heat use
totalization and instantaneous use.
4.3 PRIORITIZATION OF RECOVERED HEAT
Recovered heat prioritization is accomplished by setting the minimum recovered heat
temperature for each user, with successive load shedding as the recovered heat loop
temperature falls. The user with the highest allowable recovered heat temperature will be
removed from the system first. The user with the lowest allowable recovered heat
temperature will be removed from the system last.
The system will also provide freeze protection in the event a user's boiler system
temperature falls below a minimum temperature, typically 50-100 degrees F.
4.4 RIGHTS -OF -WAY ISSUES
There are no apparent conflicts with rights -of -ways for the arctic piping between the power
plant and the end -user buildings, as the route is entirely within existing road rights -of -ways
on city and AVEC properties.
A Heat Sales/Right-of-Entry Agreement will be required between AVEC and the City of St.
Mary's to define the parties' responsibilities, detail the cost of recovered heat, and authorize
the connection to 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.
5.1 Heat Exchangers
Based on initial selected flow rates, brazed plate heat exchangers appear to be adequate
for two locations as shown. Initial heat exchanger selections are as follows.
HX-1: (Power Plant). 600 MBH capacity
Primary: 100 GPM 195F EWT (50% ethylene glycol), 2.0 PSI max WPD
Secondary: 80 GPM 19OF LWT (50% propylene glycol) 2.0 PSI max WPD
HX-2: (City Shop). 300 MBH capacity.
Primary: 45 GPM 185F EWT (50% propylene glycol), 1.0 PSI max WPD
Secondary: 45 GPM 180F LWT (50% propylene glycol) 1.5 PSI max WPD
HX-3: (City Office Building). 150 MBH capacity.
Primary: 15 GPM 185F EWT (50% propylene glycol), 1.0 PSI max WPD
Secondary: 15 GPM 180F LWT (50% propylene glycol) 1.5 PSI max WPD
Based on initial selected flow rates, cabinet unit heaters and baseboard heaters appear to
be adequate for the City Office building. Initial heater selections are as follows.
CUH-1 & CUH-2: (City Office building). 40 MBH capacity each.
Primary: 8 GPM 185F EWT (50% propylene glycol), 1.0 PSI max WPD
BB-1 & BB-2: (City Office building). 20 MBH capacity for office area.
Primary: 2 GPM 185E EWT (50% propylene glycol), 1.0 PSI max WPD
5.2 Arctic Piping
The round trip length of heat recovery loop piping between the power plant and most distant
facility is approximately 1600 ft. The proposed arctic piping consists of a 2-1/2 inch
polypropylene (buried) and 1-1/2 inch polypropylene (above ground), and fiberglass
composite carrier pipe (Aquatherm Climatherm phaser composite) insulated with 3.5" of
polyurethane foam insulation, and HDPE outer jacket. The specified product is durable
enough for direct bury. The piping and excavated soil will be will be wrapped in geotextile
fabric to hold the pipe in the ground in the event of flooding. The arctic pipe will be buried
approximately 2 ft deep and run from the AVEC plant within existing rights -of -way to the
Cold Storage/Hotel building, and also the pipe will be above ground from the Cold
Storage/Hotel building to the City Office building.
5.3 Circulating Pumps
P-HR1: Heat injection loop in City Shop
Flow = 45 GPM, Head = 16 ft
Initial Selection: Grundfos Magna 65-60 (max. 450 W).
P-HR2: Boiler return loop in City Shop
Flow = 23 GPM, Head = 10 ft
Initial Selection: Grundfos Magna 32-60 (max. 180 W).
P-HR3: Heat injection loop in Cold Storage/Hotel
Flow = 15 GPM, Head = 21 ft
Initial Selection: Grundfos Magna 32-100 (max. 180 W).
P-HR4: Boiler return loop in Cold Storage/Hotel
Flow = 8 GPM, Head = 10 ft
Initial Selection: Grundfos Alpha (max. 45 W).
P-HR5: Heat injection loop in City Office building
Flow = 15 GPM, Head = 41.5 ft
Initial Selection: Grundfos Magna 40-120 (max. 450 W).
5.4 Expansion Tanks
Total heat recovery loop volume is approximately 500 gallons. Pressure relief at the power
plant heat exchanger will be 45 PSIG and the maximum normal operating pressure will be
40 PSIG. Two existing expansion tanks located at the City Shop will be replace with the
tank described below.
ET-1 & ET -2: System requirements: Amtrol SX-90V, 44 gallon tank and 34 gallon
acceptance.
5.5 GLYCOL MAKEUP
A glycol make-up system at the City Shop will be provided to accommodate filling the
system and adding additional glycol.
GT-1: Select AXIOM SF100 55 Gal Glycol make-up tank.
5.6 CONTROLS
Heat recovery system in each building will use an off the shelf differential temperature
controller to actuate a 3-way valve and start/stop heat injection pump (if used). Control will
provide load shedding, freeze protection, and prevent backfeeding of boiler heat into heat
recovery system. In addition, A BTU meter will be provided at each facility using recovered,
displaying instantaneous temperatures and heat transfer, as well as totalizing BTUs used.
Differential Controllers: 6 required Tekmar Model 155 differential temperature control
Control Valves:
CV-1 : Power Plant: 3" 3-way motorized control valve with 24v Actuator
BTU Meter:
BTU-1, Power Plant,: KEP BTU meter with 2-1/2" magnetic flow meter and matching
temperature elements.
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, three city buildings and
the water system, along with design and construction management/administration for the
complete project, is included in the Base Project cost. Incremental costs for arctic pipe, end -
user building renovations, and overhead and freight are estimated individually for each of
the other end -user buildings (refer to attached cost estimate).
The estimated project cost is $674,185. Estimated annual fuel savings are:
• 15,726 gallons ($50,637) for a simple payback of 13.32 years.
Payback is based on a 2013 fuel price of $4.60/gallon.
The most significant benefit of this feasibility study is that recovered heat can
replace the entire heating demand for three buildings plus the water system.
Funding for design and construction isn't expected until 2013 fall, with construction
occurring 2015 summer. With a 2 year escalation rate of 3%, the estimated 2015 project
cost is $715,243 and the corresponding benefit/capital cost (B/C) ratio is 1.28 (refer to the
attached B/C model spreadsheet).
APPENDIX
1. CAD Drawings
A. Cover Page
B. Site Plan
C. System Schematic I
D. System Schematic 11
E. Detail I
F. Detail11
2. Figure 1. St. Mary's Recovered Heat Utilization.
3. Figure 2. St. Mary's Recovered Heat.
4. Cost Estimates for Heat Recovery Project.
5. Benefits to Capital Costs Ratio.
6. Recovered Heat Utilization Simulation Work Sheet.
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