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Home My WebLink AboutCity of Unalaska Waste Heat to Energy Part 1 - 2012 REF Grant 2195449City of Unalaska Powerhouse Exhaust Gas Waste Heat to Energy Project Final Report EPS Project No. 10-0159 October 22, 2012 Prepared by: Robert W. Whealy, PE Warren Taylor, PE Earl George, PE Electric Power Systems, Inc. Powerhouse Waste Heat to Energy Project Final Report Summary of Changes Revision Number Revision Date Revision Description 1 October 22, 2012 Initial Release Powerhouse Waste Heat to Energy Project Final Report WWW.EPSINC.COM PHONE (907) 522-1953 3305 ARCTIC BLVD., SUITE 201, ANCHORAGE, ALASKA 99503 FAX (907) 522-1182 PHONE (907) 789-2474 2213 JORDAN AVE, JUNEAU, ALASKA 99803 FAX (907) 789-4939 PHONE (425) 883-2833 3938 150 AVE. N.E., REDMOND, WASHINGTON 98052 FAX (425) 883-8492 TABLE OF CONTENTS 1. Summary ........................................................................................................................... 1-4 2. Facility Evaluation ............................................................................................................ 2-7 2.1 Existing Powerhouse Concrete (Old) and Steel (New)........................................... 2-7 3. ORC Evaluation .............................................................................................................. 3-10 3.1 Electratherm Green Machine .................................................................................. 3-10 3.2 Turbo Thermal LLC ................................................................................................. 3-11 3.3 GE Clean Cycle ........................................................................................................ 3-12 4. Exhaust Gas Boiler Evaluation and Integration at Powerhouse ............................... 4-12 5. Conclusion and Recommendations ............................................................................. 5-13 6. Appendices ..................................................................................................................... 6-15 6.1 Schematics & Plans ................................................................................................ 6-15 6.2 Engine Data .............................................................................................................. 6-16 6.3 Cost Estimate ........................................................................................................... 6-17 6.4 Cutsheets, Quotes, Resumes ................................................................................. 6-18 Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 1-4 1. Summary The City of Unalaska has requested that Electric Power Systems, Inc. (EPSI) provide feasibility design services for the installation of an exhaust gas waste heat to electric energy reclamation project. This report explores the feasibility for the various economic and technical solutions available for implementation. Upon investigation, EPSI found that the exhaust gas waste heat reclamation system will require an additional waste heat line between the old and new power plants, three exhaust stack boiler units (one on each exhaust stack), necessary higher temperature ORC units, associated seawater cooling and heat exchanging system, supplemental radiator system, associated valving and instrumentation package, one 480V 3 phase feeder stepped up to 4160V and connect into existing Unit 8 and 9 (after Unit 8/9 removal) power lines, and a remote monitoring SCADA interface. The exhaust gas waste heat project is economically feasible once Unalaska town loads reach minimum continuous year round base loads of 7.5 to 8 MW. Economic feasibility may also become a reality if fuel prices sustain an average price of over $4/gallon. As any one of these factors increase over time the economic feasibility will become more compelling. This conclusion is based on the current available boiler and ORC manufacture data being accurate, conformance to all current and future environmental constraints, and all technical/design issues being appropriately addressed. The environmental constraints that this report’s conclusions are bounded by concern both air and seawater. It is understood that the current ADEC air permit temperature constraints have been relaxed to allow for the use of exhaust gas stack boiler units such that final stack outlet temperatures to atmosphere do not drop below 350F. However, it should be noted that current ADEC/EPA permitting increases to seawater outlet temperatures have not been permitted to be raised to adequate levels. To support the needs of an exhaust gas waste heat project the ADEC/EPA would need to review and permit elevated seawater outlet temperatures before the project could be considered viable. If such permitting cannot be achieved then a costly supplemental radiator system will need to be implemented. For the purposes of this report the cost of supplemental radiators was included. Performance data, prices, drawings, parts, service, warranty, and lead time information was collected from ORC and exhaust gas boiler unit manufacturers. Below are the manufacturers that have been contacted, equipment reviewed, and evaluated for this report. Below each manufacturer listed is a brief synopsis of their equipment. A more detailed discussion follows further within this report. This report does not focus on ranking and comparing various ORC manufacturers for selection purposes but only gives a cursory review of likely vs unlikely candidates for further investigation. This report will tend to focus on the exhaust gas boiler manufacturer’s pros/cons of each and base pricing upon a select manufacturer solely for the purpose of cost to benefit evaluation. o Electratherm (ET) Green Machine This ORC manufacturer produces 50 to 65 kW units. These units were tested at the University of Alaska Fairbanks Mechanical Engineering Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 1-5 Department and yielded 5.5%, 7%, and 7.5% total net efficiencies at operating temperatures of 155F, 195F, and 215F, at various flow rates, respectively. Given the flows, temperature differentials, and total available BTUs for the jacket water system at Unalaska it is expected that each Wartsila or Cat will operate two 50 kW machines (plumbed in parallel) at a net output of 39 kW each. This expected net output has been confirmed both by UAF testing and Electratherm trials and calculations. Temperature differentials are not sufficiently high enough to justify the installation of the more expensive 65 kW machines. o United Technologies Corp (Carrier) (UTC/Pratt Whitney) This ORC manufacturer primarily focuses on 1 MW unit sizes and larger. However, they do make a 250 kW unit that has only become readily available in the last 5 years. Its optimal operating temperatures are also found to be higher than the 195F that Unalaska can deliver. However, the unit can operate to a limited degree at these lower temperatures. Furthermore, Pratt/Whitney is only willing to sell the 250 kW unit size in lots of ten which is well outside of the scope and budget of this project. o Infinity Turbine LLC This ORC manufacturer offers promise in the 200 to 300 kW unit sizes but also has difficulty working with the temperatures. Additionally, they require a money down payment before they will divulge any necessary design information to determine feasibility. AEA grant funding restrictions generally do not allow such payments without proper feasibility reviews. o Ormat This exhaust gas and ORC manufacturer produces units that operate at 1000F+ temperatures and utilizes unit sizes much larger in scale than Unalaska would necessitate. o Ener-G-Rotors This ORC manufacturer is currently beta testing their 35 to 60 kW units that use a special ORC refrigerant that produces highest efficiencies at lower temperatures around 185F. They do not expect a fully functional unit for sale until the end of 2013. o GE GE currently makes a higher temperature ORC unit that grosses 125 kW output. The technology utilizes a hermetically sealed 125 kW high-speed generator and turbine in a single package. It has no external rotating seals and no gearbox. It also uses magnetic bearing technology that creates nearly zero friction losses and minimizes maintenance. It utilizes power electronics to convert high frequency to DC power which is then reconditioned to 60 Hz usable power output. This unit may have application for the exhaust gas waste heat reclamation project. The minimum operating evaporator temperatures require 300+F which can be achieved from the exhaust gas boilers reviewed in this report. Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 1-6 o TAS This ORC manufacturer produces their smallest units at 800 kW which is of a much higher scale and output than Dutch Harbor can support. o Turbo Thermal LLC This ORC manufacturer produces units in the 80 kW size and can bundle 3 or 4 units together in a modular package for a total maximum net output (after pump load is subtracted) of 225 to 300 kW. The R123 refrigerant they use in their units yield a theoretically calculated 7.6% and 11% efficiencies based on the total available jacket water heat and exhaust gas heat sources @ 195F and 300F, respectively. This ORC manufacturer appears to have the most comprehensive calculation foundation upon which their efficiency numbers are based. These efficiencies are also in agreement with Electratherm’s actual tested performance values. o Echogen This ORC manufacturer produces 200 to 300 kW units that operate in the 450F to 1000F operating temperatures. This will not work for this project as 300F temperatures are the maximum available temperatures that can be delivered at Dutch Harbor. o Calinetix This ORC manufacturer is no longer in business having been recently purchased by GE. Some of the Calinetix technology may have been adopted by GE. o Cain Industries, Inc. This exhaust gas boiler unit manufacturer produces a unit than can provide hot water temperatures in the 215F to 230F range where most ORC manufacturers prefer to operate. The Cain is least expensive and largest of the exhaust gas boiler units evaluated. It has several advantages that make it the most affordable of all units throughout its life. Cain provides a complete self-monitoring and self-cleaning low maintenance product that would suit the needs of the project. The controls package monitors in/out exhaust gas temperatures to avoid condensation of sulfuric acid. It also monitors exhaust gas back pressure (to avoid compromising engine efficiency) and provides regular self- cleaning cycles utilizing either steam or compressed air. Maintenance access points are readily available, includes integral exhaust bypass valve and valve controls, and there is good relatively local support of this product. Approximate material cost (not including installation labor) per boiler with all controls included is $235,000. o Maxim This exhaust gas boiler unit manufacturer produces a unit that can provide hot water temperatures in the 215F to 230F range where most ORC manufacturers prefer to operate. They do not offer the same built-in ready-to-go self-monitoring package that Cain does and would thus require additional cost to integrate a controls package to be comparable Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 2-7 to the Cain unit. Furthermore, maintenance service for this unit is very difficult as maintenance access is only available with major disassembly, cleaning, and reassembly of the unit. This would also require crane time and coordination. Support, however, is available relatively locally. o Aalborg This exhaust gas boiler unit manufacturer produces a unit that can provide hot water temperatures that would be needed for this project. Aalborg makes a low weight, compact, easy to maintain, highly efficient, proven design, tailor-made for specific requirements, designed for diesel applications, vibration resistant units. They can provide many references for similar installations. However, Aalborg does not offer an integral exhaust bypass valve and check valve for use with existing exhaust systems. Also, a third party controls/monitoring instrumentation package would need to be developed and integrated into this boiler unit adding further cost and complexity. Approximate material cost only per boiler plus third party controls is $320,000. 2. Facility Evaluation EPSI looked at each of the existing generator units at each powerhouse to determine if the individual heat inputs to the “system” would be viable sources to size the ORC units to be as large as possible. There are two heat sources from which the waste heat project is being developed 1) Engine jacket 2) Exhaust Gas. Both heat sources will require the use of ORC units. While there is much more heat energy to reclaim through the exhaust gas than engine jacket the exhaust gas system will require additional equipment over the engine jacket system. Currently, Units 10, 11, and 13 (new plant) are connected through common engine jacket water waste heat lines and are available for electric conversion according to the BTU amounts shown below in this section of the report. In the old powerhouse building, Units 1 through 6 have been decommissioned and removed. Units 8 and 9 in the old powerhouse and Units 10, 11, and 13 in the new powerhouse are currently in service. All are of a size to provide sources for the ORC units to a certain degree especially with the addition of an exhaust heat recovery system. However, units 8 and 9 are not connected to the existing engine jacket waste heat lines and are expected to be decommissioned and removed in the near future. Therefore, units 8 and 9 are not evaluated for waste heat reclamation potential within this report. Currently, units 10 or 11 are typically base load units, with Units 8 or 9 supporting the remaining loads. Therefore only Units 10 and 11 are considered for exhaust gas waste heat evaluation within this report. In the future, it may be further beneficial to expand the exhaust waste heat system to include additional units as they are run on a more regular basis. Town loads need to be consistently around 7 MW minimum before unit 13 with unit 10 or 11 OR both Wartsila’s would need to be regularly dispatched. Current loading still remains between 5 MW to 7.5 MW where 7.5 MW is rarely approached. Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 2-8 The actual building heating loads for the concrete and steel powerhouses currently extract up to 500,000 BTU/hr from the engine jacket water waste heat system. EPSI recommends continuing to serve the building heating loads from the existing jacket water waste heat system. EPSI, through facility personnel and manufacturers data, was able to determine normal operating conditions for the following units. All evaluation calculations will be based upon 75% unit loading. Units 8 and 9 are not included in this evaluation but are factored into the unit dispatch schedule to support the town loads such that Units 10, 11, 13 only turn on when 75% loading on these units can be expected. Unit 10 – Wartsilla 12V32 Hours per year operation: 4,380 Typical operating load: 75% - 4 MW Heat Rejected to Jacket Water @ 75% loading: 3,586,000 BTU/hr Jacket Water peak temperature and flow at ORC: 195F @ 440 GPM Heat Rejected to Exhaust Gas @ 75% loading: 5,775,000 BTU/hr Exhaust Gas peak temperature and flow at ORC: 300F @ 221 GPM Unit 11 – Wartsilla 12V32 Hours per year operation: 4,380 Typical operating load: 75% - 4 MW Heat Rejected to Jacket Water @ 75% loading: 3,586,000 BTU/hr Jacket Water peak temperature and flow at ORC: 195F @ 440 GPM Heat Rejected to Exhaust Gas @ 75% loading: 5,775,000 BTU/hr Exhaust Gas peak temperature and flow at ORC: 300F @ 221 GPM Unit 13 – Cat C280 Hours per year operation: 1,000 Typical operating load: 75% - 3.3 MW Heat Rejected to Jacket Water @ 75% loading: 2,798,000 BTU/hrJacket Jacket Water peak temperature and flow at ORC: 195F @ 440 GPM Heat Rejected to Exhaust Gas @ 75% loading: 5,789,000 BTU/hr Exhaust Gas peak temperature and flow at ORC: 300F @ 221 GPM Total plant operating heat capacity (all units jacket water + all units exhaust gas @ 75% loading): 27,309,000 BTU/hr Total plant heat capacity (Total plant operating heat capacity minus building heat load) for ORC: 26,809,000 BTU/hr. Actual current available heat (based on today’s town system electrical loads = one Wartsila jacket water plus one Wartsila exhaust gas minus building heat loads) for ORC: 8,861,000 BTU/hr. Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 2-9 Actual current available heat only from Wartsila or Cat exhaust gas energy conversion at the gas boiler 5,775,000 or 5,789,000 BTU/hr, respectively (building heat to be supported on jacket water system). Exhaust gas boiler is conservatively estimated at 90% efficient. This means that 5,197,500 BTU/hr of waste heat energy can be expected to be delivered to the ORC units from each Wartsila and 5,210,100 BTU/hr from the Cat. Current energy production reports reveal that Unalaska is produces 15.5 to 16 kWh per gallon of fuel consumed. This report will use 16 kWh/gal for evaluation purposes. From correspondence with Electratherm and Turbo Thermal LLC technical representatives for Units 10, 11, and 13 it appears that at most the following waste heat energy could be reclaimed from each of the indicated units: Wartsila or Cat C280 jacket water only: Expected ORC output 78 kW after building heat is served (39 kW on each of two separate Green Machines) Wartsila or Cat C280 generator exhaust via exhaust stack boiler: 167 kW per unit (11% ORC efficiency and 90% boiler efficiency). Recommended plant operating Temperatures: Exhaust boiler supply temperature (hot): 300 degrees F Exhuast boiler return temperature (cold): 250 degrees F or as recommended by boiler manufacturer Waste heat System operating: To ORC: 300 degrees F Building Heat: 250 Degrees F Concrete powerhouse building structural Generator units 1 through 6 have been removed from the first floor back room of the old power plant building, leaving space for installation of the new ORC units on this concrete slab-on- grade floor, making structural analysis unnecessary. Additionally, construction on the first floor will be the least expensive as all hot water, cold water, and electrical connection points are located on the first floor. Preliminary evaluation has shown that the second floor can bear up to 100 lbs/sq. ft. Detailed structural design will be needed to determine and avoid compromising the rebar. The UTC 250 kW unit weights appear to fall below this weight restriction and can be therefore safely assumed that most any manufacturer of this size unit will also meet the weight restrictions. For the purposes of this report costs will be focused only on the first floor construction. Electrical Integration of either ORC Unit(s) The electrical modifications required for the installation of the ORC units are rather limited in scope as they do not require many modifications to the existing facilities. The ET Green Machine may be custom ordered to generate at various voltage ratings. The intent will be to order the ORC in the standard 480V 3-phase configuration and connect it to the existing 480V building service in the concrete power plant. This will allow the ORCs to serve all Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 3-10 480V loads in the steel and concrete power plant buildings as well as export any surplus to the 4160V new plant generation bus for delivery to the distribution system. The maximum allowable power that can be exported to the steel building is 332 kW via the available 400A 3 phase 480V plant-to-plant station service feeder between each MDP. Refer to electrical one-line in Appendix A. Should the need arise for more than this amount then the existing 4160V concrete plant system would need to be upgraded or Units 8 or 9 be removed to accommodate. Calculations show that when all units sustain 75% loading (utilizing exhaust gas and jacket water less building heat) approximately 600 to 650 kW of ORC power could become available. This level of loading would require sustained electrical town loads of 11 MW which is over 100% of current day town loading. 3. ORC Evaluation Given the many technical design constraints EPSI has determined that both waste heat systems (engine jacket and exhaust gas) are ideally suited (both electrically and physically) for ORC units in the 40 kW to 80 kW range and would be capable of operating around 190F to 300F continuously. This restricts the selection process to only a very few ORC manufacturers today which include Ener-G-Rotors, Electratherm, Turbo Thermal LLC, and GE. Many other manufacturers were considered but were eliminated from the “potential candidates” list for this project because of lack of interest, operating temperature problems, or unit size scaling issues. Ener-G-Rotors is still currently in beta testing mode and does not expect to produce a commercially available 35 kW to 50 kW unit until December 2013. Electratherm produces the commercially available Green Machine Series 4000 unit that is a 50 kW unit which is ideally suited for use on the jacket water system and/or exhaust gas heat system. Turbo Thermal LLC produces a 240 kW or 320 kW ORC unit that can be broken down into three or four 80 kW units which appear to be more ideally suited for the exhaust gas system. GE Clean Cycle units are 125 kW units that may also work in leau of the Turbo Thermal units on the exhaust gas system. The engine jacket water waste heat to energy project was evaluated in the EPSI 2008 report. During the 2011 Request for Qualifications process only Pratt/Whitney UTC responded. Unfortunately, Pratt/Whitney UTC will now only sell a minimum lot of ten units per order which eliminates them from the “potential candidates” list for this project. Below is a brief description of the Electratherm and Turbo Thermal ORC units and the rationale for their further consideration. The summary of this report lists each of the other manufacturers not mentioned within this section. The reasons for their elimination from the “potential candidates” list are briefly outlined in the summary of this report. The Electratherm (ET) units are more customizable than any other ORC vendor information to date. ET, through their website and communication with the ET representative, has two standard models which fit a variety of applications and unit (heat source) sizes. The electrical output range is also ideally suited to run two 50 kW units for each engine jacket. The ET Green Machine 4000 is a 50 kW unit that consists of a 480V 3 phase 100 HP screw compressor operating in reverse process. The generator consists of a Marathon 50 kW Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 3-11 induction motor run in reverse operation. The induction motor makes for an inherently safe concept such that no export of power is possible should there be loss of AC power on the prime power source side. Additionally, this eliminates the need of synchronization equipment. The entire assembly (including control panel) sits on one skid and has a physical footprint size of approximately 6’ x 8’ x 8’. The first floor space, where recently retired units 1 through 6 resided, is physically restricted to only accommodate units of this size or smaller. Up to three separate units can fit within this existing space. Room for a fourth unit may be provided if the old operator’s office becomes available for renovation to accommodate. Electratherm is willing to customize any of its units to meet the needs of the facility. For this reason information concerning the “base” units has been provided. Customization of the units to optimize the recovery would cause the price to adjust accordingly. Titanium or cupro-nickle in shell and tube configuration heat exchangers are options for use with the sea water cooling system at additional cost. The ET ORC has three moving parts which require maintenance. In general, ET recommends that the turbine drive belt, should be changed annually even though it is rated for over 20,000 hours of operation. The cost of the drive belt is $300. ET has determined that each unit would require 1.5 cents per kW-hr for maintenance over a one year period. This cost would include periodic inspection of the unit (lubrication, seals, performance) and cleaning of the units’ sea water heat exchanger and replacement of the drive belt. ET is a new company/manufacturer and unfortunately does not have years of previous ORC experience to be able to adequately predict the longevity of their units. But, from a design perspective, their unit has 3 moving parts. Based on this fact alone, we would anticipate that the unit should have well over a 20 year life expectancy. This ORC manufacturer makes two different sizes of units that could work well for this project. The first size is a 240 kW unit which consists of 3 (three) 480V 3 phase 80 kW rated expander/generators working in unison. The second size is a 320 kW unit which consists of 4 (four) 480V 3 phase 80 kW rate expander/generators working in unison. The optimal operating temperatures are at 300F but can also run at the expected 230F temperatures at the expense of efficiency as mentioned below. Both units (240 kW and 320 kW) each fit within a 20 foot shipping container and can be broken down and refitted to most any space. The largest pieces of gear consist of three major components: 1) Three or Four expander/Generator skids each @ 30”W x 30”H x 72”L; 2) One common surge tank @ 72”H x 48” diameter; 3) One common control panel @ 72”H x 48”W x 30”D (double door). Approximately every 25F above 230F up to 300F an extra percentage point of efficiency is achieved. For example, at 225F output to the Turbo Thermal ORCs one can expect 8% efficiency. At 250F one can expect 9% efficiency, 10% efficient @ 275F, and 11% efficient @ 300F. For this analysis it is assumed that the exhaust gas boilers can be turned up to 300F output to the ORC units to achieve 11% efficiency from the Turbo Thermal ORC units. Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 4-12 All generators are Westinghouse Premium efficiency (SF = 1.15) 480V 3 phase 100 HP induction motors. This makes for simplification of controls and a safe electrical system. Turbo Thermal has determined that each unit would require 1.0 cents per kW-hr for maintenance over a one year period. This cost would include periodic inspection of the unit (lubrications, seals, performance) and cleaning of the units’ sea water heat exchanger and replacement of the drive belt. These higher temperature ORC units are compact, relatively light weight, and can be broken down and rebuilt to allow for installation in smaller spaces. However, the evaporator and condenser components would have to be provided by the customer at additional cost. The estimated efficiencies are between 9.5% and 10.5% at 300F/55F hot/cold for the given flows and waste heat energy available from each of the Wartsila and Cat exhaust gas stacks. It’s estimated that each Wartsila @ 75% loading can energize 1.1 (137.5 kW) ORCs. It’s also estimated that the Cat @ 75% loading can energize 1.4 (175 kW) ORCs. 4. Exhaust Gas Boiler Evaluation and Integration at Powerhouse Below are the design and construction constraints that should be considered when implementing the exhaust gas waste heat reclamation project. 1. The existing waste heat system, as designed, is connected and in common to the engine jacket water systems for Units 10, 11, and 13, and currently provides up to 195F water temperature. This temperature is too low for many ORC units to operate effectively, some manufacturers’ such as Electrotherm and potentially Ener-G-Rotors, can operate at reasonable efficiencies that can still economically justify the project. Modifications to the system flow rates will need to be implemented such that the waste heat peak temperature could be raised to 195F where these ORCs can be operate at better efficiencies. This modification could be implemented at any time at little to no cost. 2. During construction of the steel powerhouse new 8-inch waste heat transfer piping was installed between the steel powerhouse and the concrete powerhouse to allow for transfer of waste heat to the seawater heat exchanger and the then-future ORC units. However, higher temperature waste heat from the exhaust stack boiler may require the installation of new heat transfer piping from the exhaust gas boilers to the ORCs, which are to be installed on the first and/or second floor of the concrete powerhouse building. 3. Since the exhaust gas boiler lines could operate at much hotter temperatures (around 230 - 300F) than the engine jackets could handle it further suggests that a separate exhaust gas waste heat line be installed. 4. It was considered that the existing jacket water waste heat lines be cut, intercepted, and rerouted to the new gas boilers to save cost. However, after reviewing available BTU outputs from each heat source it was clear that removing the engine jacket waste heat lines would severely limit the availability of waste heat extraction as a whole. Therefore, since a substantial amount of the entire waste heat project centers around the engine jacket system it is critical to leave it intact and develop new higher temperature waste heat lines for the exhaust gas system. Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 5-13 5. As part of the detailed design for the ORC’s a revision to the facility sea water cooling permit may be required to allow for a more elevated discharge seawater temperature than originally permitted. Preliminary data from the ORC vendors indicates a sea water temperature increase of 20F. No sea water temperature restriction was provided to the ORC vendors. Something to consider is that as waste heat is converted to electricity the amount of waste heat/cooling water which requires cooling will be reduced. When the ORC’s are operating at their peak output, the sea water discharge temperature could decrease. If the sea water permit cannot be successfully modified then a supplemental radiator will be needed to remove excess heat prior to dumping remaining heat back into the seawater. 6. According to Wartsila 12V32 design information (from original 2005-2007 design effort) the units are designed to allow a total exhaust restriction of 12 inches of water column. It’s currently estimated that the total system back pressure with the exhaust gas boiler will be 11.35 inches of water column. This is a worst case operating point without detailed design. As such the gas boiler control package should include differential pressure monitoring and alarming. 7.One or two motor operated valves to control sea water flow to the heat exchangers and the bypass around the heat exchangers will be required. This is only a preliminary look at the system, during the detailed design; this strategy would have to be verified. 8. The ORCs operate best at steady state conditions and are not suited for operation on a peak-shaving or back-up unit. This would best be provided by the Wärtsilä units as the base loaded machines. Currently, only one Wartsila or the other is used on a nearly 24/7/365 basis. Eventually, as the town loads increase the Cat C280 will be utilized in a similar fashion at which point another exhaust gas stack boiler could be implemented. 9. It’s suggested that a 50/50 Dowfrost HD/Water solution be used to transport the 300F exhaust gas boiler outlet temperatures expected. This will provide the optimal heat transfer, eliminate chemical breakdown, satisfy environmental requirements, and contain the needed corrosion inhibitors. 5. Conclusion and Recommendations EPSI recommends that the engine jacket water waste heat project be fully constructed to completion so as to reap the most immediate and rewarding benefits possible. This should be accomplished through the installation of 4 (four) 50 kW Electratherm Green Machines installed on the lower floor of the concrete plant where units 1, 2, 3, 4, 5, and 6 used to reside. Since plant operating procedure is based on maintaining N-1 unit contingency (plant always allows for one of the largest units to be offline at all times) it is not necessary to evaluate for loading above N-1 plant capacity. As funds become available the project could be expanded to include the use of an exhaust gas waste heat system. EPSI recommends that this be accomplished via the use of two 240 kW Turbo Thermal LLC ORC units (or any equivalently sized units capable of effectively handling 230F to 300F heat transfer fluid) installed on the second floor of the concrete plant building after demolition of units 8 and 9 is accomplished. This will open up the needed floor space for any supplemental radiator system, 480:4160V step-up transformer and 4160V cabling needed while maximizing the use of the available exhaust gas waste heat available for electric conversion. EPSI recommends that one Cain Industries gas boiler unit be installed on each of the three steel plant exhaust stacks (Units 10, 11, and 13). Cain Industries boilers are chosen because Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 5-14 they provide the most complete package including all necessary controls and monitoring that other manufacturer’s do not offer. Furthermore, by comparison the Cain units are much easier to maintain, ensuring long project life. Below are the costs, fuel displacements, and estimated payback periods for both waste heat systems now and into the future. Project Phase I (Engine Jacket Heat Only – 4 x 50 kW Electratherm Green Machines) Initial Cost: $1,889,381 (reduced from previous estimate based on different units and installation moved to first floor from second floor). Annual Cost: $10,000 Total Annual net energy payback @ 8,322 hours = 649,116 kWh Total Annual Fuel Displacement Payback (based on 16 kWh/gallon) = 40,570 gallons Approximate Payback Period with fuel @ $3.80/gallon = 13 years Approximate Payback Period with fuel @ $4.80/gallon = 10.5 years Annual Cost: $20,000 Total Annual net energy payback @ 8,322 hours = 1,298,232 kWh Fuel Displacement Payback (based on 16 kWh/gallon) = 81,140 gallons Approximate Payback Period with fuel @ $3.80/gallon = 6.5 years Approximate Payback Period with fuel @ $4.80/gallon = 5.5 years Project Phase II (Exhaust Gas Heat Only) Initial Cost: $4,948,365 Annual Cost: $21,000 Total Annual net energy payback @ 8,322 hours = 1,389,774 kWh Total Annual Fuel Displacement Payback (based on 16 kWh/gallon) = 86,860 gallons Approximate Payback Period with fuel @ $3.80/gallon = 16 years Approximate Payback Period with fuel @ $4.80/gallon = 12.5 years Annual Cost: $42,000 Total Annual net energy payback @ 8,322 hours = 2,779,548 kWh Fuel Displacement Payback (based on 16 kWh/gallon) = 173,722 gallons Approximate Payback Period with fuel @ $3.80/gallon = 8 years Approximate Payback Period with fuel @ $4.80/gallon = 6 years Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 6-15 6. Appendices Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 6-16 Wartsila - 12V32 Jacket Oil After Exhaust Gas Exhaust Gas Flow Exhaust Stack Water Cooler Cooler Flow Rate @ STD P/T Temperature (BTU/min) (BTU/min) (BTU/min) (ACFM) (SCFM) (°F) % Load 50 27,567 26,833 16,279 22,660 10,241 698 75 59,767 33,200 24,988 32,915 15,362 662 85 72,617 34,283 28,631 36,578 17,127 658 100 92,467 36,167 34,095 42,128 19,597 666 Jacket Oil After Exhaust Gas Exhaust Gas Exhaust Stack Design Water Cooler Cooler Flow Rate Flow Temperature % Load (BTU/min) (BTU/min) (BTU/min) (ACFM) (SCFM) (°F) 70 53,214 31,980 23,235 30,884 14,394 669 Engine Model: Exhaust Properties Exhaust Temperature: 666 °F Fuel Type: Diesel #2 Exhaust Gas Density: 0.03516874 lb/ft3 Exhaust Gas Flow Rate: 42,128 cfm Exhaust Configuration Pipe Size: 36 in Gas Velocity: 6172.001 ft/min Pipe Schedule 10 Total Length of Pipe: 154.00 ft 102.87 ft/sec Turbo Outlet Adapter: 2.5 in-H2O Turbo Exhaust Flex: 1.6 in-H2O Raincap BP: 0 in-H2O Silencer BP: 3.14 in-H2O Silencer + Exhaust Boiler Total Flex BP: 0.6 in-H2O Pipe Fittings No. Short Radius 90° Ells: 1 Equivelant Length: 99.00 ft No. Long Radius 90° Ells: 4 Equivelant Length: 240.00 ft No. 45° Ells: 2 Equivelant Length: 90.00 ft No. Square Ells: 0 Equivelant Length: 0.00 ft Total Fittings: 429.00 ft Total Exhaust Backpressure: 11.35 in-H2O Project Title: City of Unalaska - Powerhouse Renovation Subject: Exhaust Backpressure Calculation - exhaust boiler check By: WBT Checked: Date: 9/11/2012 Sheet ____ of ____ Wartsila 12V32, 5.2MW nominal. Notes: 1. Use 36" schedule 10 pipe as directed by environmental 2. Will have an exhaust gas boiler with 1.6 in wc from cain. 3. Existing Wartsila exhaust silencer documentation indicates silencer has 1.54" wc pressure drop. Ref to wartsila drawing daab464054_-_3es2663.pdf 4. Wartsila exhaust gas maximum backpressure allowed per specifications 12" wc Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 6-17 Electric Power Systems, Inc. 3305 Arctic Blvd. Suite 201 Anchorage, AK 99503 Proposal PHONE: 907-522-1953 FAX 907-522-1182 Email: wtaylor@epsinc.com Description - Materials Quantity Unit Cost Total Building Plumbing 1 lot $0.00 $0.00 Not Used 1 lot $0.00 $0.00 Building HVAC & Plumbing Materials $0.00 Mechanical System 1 lot $1,273,583.34 $1,273,583.34 Electrical System Installation 1 lot $57,074.50 $57,074.50 Not Used 1 lot $0.00 $0.00 Not Used 1 lot $0.00 $0.00 Not Used 1 lot $0.00 $0.00 Not used 1 lot $0.00 $0.00 Not Used 1 lot $0.00 $0.00 Not Used 1 lot $0.00 $0.00 Not Used 1 lot $0.00 $0.00 Generation Mechanical Materials: $1,330,657.84 Materials Subtotal: $1,330,657.84 Description - Labor Quantity Unit Total Building Plumbing 0 Hours $0.00 Not Used 0 Hours $0.00 Building HVAC & Plumbing Labor 0 Hours $0.00 Mechanical System 1669 Hours $241,733.38 Electrical System Installation 387 Hours $71,653.05 Not Used 0 Hours $0.00 Not Used 0 Hours $0.00 Not Used 0 Hours $0.00 Not used 0 Hours $0.00 Not Used 0 Hours $0.00 Not Used 0 Hours $0.00 Not Used 0 Hours $0.00 Mechanical Labor Sub total 2056 Hours $313,386.43 Labor Hours Total:2056 Labor Cost Total: $313,386.43 Incidental Items to Project Material procurement & consolidation (3%) $39,919.74 Insurance (1%) $13,306.58 Bond (3%) $49,321.33 Contingency (33%) Certified Payroll (1%) $3,133.86 Profit (10%) Overhead (18%) Equipment 1 Lot -$ $0.00 Tools 1 Lot -$ $0.00 Freight 1 $/lb 58,636 $75,053.75 Startup, Commissioning, Testing 1 Lot -$ $0.00 Submittal/O&M Manuals - Eng 1 Lot $0.00 As-built - Eng 1 Lot $0.00 HVAC/Plumbing Per Diem 0 Day 245.00$ $0.00 Mechanical Per Diem (10hr/day) 206 Day 245.00$ $64,601.60 Engineering (Design/Construction) Subtotal $245,336.85 Total incidental items $245,336.85 Total materials $1,330,657.84 Labor Hours $313,386.43 Owner Furnished Materials Owner Furnished Equipment & Fuel Total $1,889,381.12 $0.00 Percent of Material & Labor Subtotal Percent of Material & Labor Subtotal Percent of Labor Subtotal Percent of Material & Labor Subtotal Percent of Material Subtotal Percent of Material Subtotal Percent of Material & Labor 10/19/20122:38 PM Copy of dhpp_orc_estimate_update_2012.xlsBase Bid Item Description QuantityCom. TypeMaterial Unit CostLabor (Hr)Unit WeightLabor Cost (per hour)Material Total Labor HoursLabor Total Sub Total Pofit Materials Overhead MaterialsContingency MaterialMaterial Loaded Sub TotalProfit Labor Overhead LaborContingency LaborLabor Loaded Sub TotalConstruction Sub TotalMechanical System10% 18% 33% 10% 18% 33%1 Electratherm (50kW each,at 100 lbs per kW) 3 ea. 212,816.00$40500089.99$ 638,448.00$12010,798.56$ 649,246.56$ 63,844.80$ 114,920.64$ 210,687.84$ 1,027,901.28$1,079.86$ 1,943.74$3,563.52$ 17,385.68$ 1,045,286.96$2 4" piping (CS ASTM A53, std sch) 400 ft 31.84$ 11089.99$ 12,736.00$ 40035,995.20$ 48,731.20$ 1,273.60$ 2,292.48$ 4,202.88$ 20,504.96$ 3,599.52$ 6,479.14$ 11,878.41$ 57,952.26$ 78,457.22$ 3 4" flexible connector (Teguflex W/ Vanstone Flanges) Jacket Water 6 ea. 337.78$ 110.7989.99$ 2,026.68$ 6539.93$ 2,566.61$ 202.67$364.80$ 668.80$ 3,262.95$ 53.99$ 97.19$178.18$ 869.28$ 4,132.24$ 4 4" ANSI class 150 RF WN Flange 30 ea. 37.00$ 3789.99$ 1,110.00$ 908,098.92$ 9,208.92$ 111.00$199.80$ 366.30$ 1,787.10$ 809.89$ 1,457.81$ 2,672.64$ 13,039.26$ 14,826.36$ 5 4" Bolt & Gasket set 30 ea. 9.34$ 0.5489.99$ 280.05$ 151,349.82$ 1,629.87$ 28.01$ 50.41$ 92.42$ 450.88$ 134.98$242.97$445.44$ 2,173.21$ 2,624.09$ 6 4" 90 Deg Ell (CS, butt weld, std sch, long radius) 34 ea. 30.00$ 4589.99$ 1,020.00$ 13612,238.37$ 13,258.37$ 102.00$ 183.60$ 336.60$ 1,642.20$ 1,223.84$ 2,202.91$ 4,038.66$ 19,703.77$ 21,345.97$ 7 4" butterfly valve (lugged, end service, ANSI 150, Buna N) 8 ea. 225.30$ 1.51089.99$ 1,802.40$ 121,079.86$ 2,882.26$ 180.24$324.43$ 594.79$ 2,901.86$107.99$ 194.37$ 356.35$ 1,738.57$ 4,640.43$ 8 Glycol: Ethylene (Straight) 4 55gal 623.15$ 144089.99$ 2,492.60$ 4359.95$ 2,852.55$ 249.26$ 448.67$ 822.56$ 4,013.09$ 36.00$ 64.79$ 118.78$ 579.52$ 4,592.61$ 9Grout1 lot 1,000.00$ 24100089.99$ 1,000.00$ 242,159.71$ 3,159.71$ 100.00$ 180.00$330.00$ 1,610.00$ 215.97$ 388.75$ 712.70$ 3,477.14$ 5,087.14$ 10 6"x4" Tee (CS, butt weld, std sch) 8 ea. 90.00$ 6889.99$ 720.00$ 484,319.42$ 5,039.42$ 72.00$ 129.60$237.60$ 1,159.20$ 431.94$ 777.50$ 1,425.41$ 6,954.27$ 8,113.47$ 11 Pipe Support 1 lot 15,000.00$1503589.99$ 15,000.00$ 15013,498.20$ 28,498.20$ 1,500.00$2,700.00$4,950.00$ 24,150.00$ 1,349.82$ 2,429.68$4,454.41$ 21,732.10$ 45,882.10$ 12 6" AMOT Control Valve 1 ea. 8,000.00$ 625089.99$ 8,000.00$ 6539.93$ 8,539.93$ 800.00$ 1,440.00$ 2,640.00$ 12,880.00$ 53.99$ 97.19$ 178.18$ 869.28$ 13,749.28$ 13 6" piping (CS ASTM A53, std sch) 30 lf 95.00$ 13589.99$ 2,850.00$ 302,699.64$ 5,549.64$ 285.00$513.00$ 940.50$ 4,588.50$ 269.96$485.94$890.88$ 4,346.42$ 8,934.92$ 14 6" ANSI class 150 RF WN Flange 20 ea. 65.00$ 3489.99$ 1,300.00$ 605,399.28$ 6,699.28$ 130.00$234.00$ 429.00$ 2,093.00$ 539.93$971.87$ 1,781.76$ 8,692.84$ 10,785.84$ 15 6" Bolt & Gasket set (CS) 24 ea. 5.50$ 0.5489.99$ 132.00$ 121,079.86$1,211.86$ 13.20$ 23.76$ 43.56$ 212.52$ 107.99$ 194.37$356.35$ 1,738.57$ 1,951.09$ 16 6" 90 Deg Ell (CS, butt weld, std sch, long radius) 10 ea. 54.00$ 4289.99$ 540.00$ 403,599.52$ 4,139.52$ 54.00$ 97.20$ 178.20$ 869.40$ 359.95$ 647.91$ 1,187.84$ 5,795.23$ 6,664.63$ 17 6" butterfly valve (lugged, end service, ANSI 150, Buna N) 3 ea. 220.00$ 1.5289.99$ 660.00$ 5404.95$ 1,064.95$ 66.00$118.80$ 217.80$ 1,062.60$ 40.49$ 72.89$133.63$ 651.96$ 1,714.56$ 18 6" HDPE Pipe 250 lf 6.81$ 0.5189.99$ 1,702.50$ 12511,248.50$ 12,951.00$ 170.25$ 306.45$561.83$ 2,741.03$ 1,124.85$ 2,024.73$ 3,712.00$ 18,110.08$ 20,851.11$ 19 6" HDPE 90 Deg Ell 20 ea. 39.46$ 340089.99$789.20$605,399.28$6,188.48$ 78.92$142.06$260.44$ 1,270.61$ 539.93$971.87$ 1,781.76$ 8,692.84$ 9,963.45$ 20 6" HDPE Flange 32 ea. 63.88$ 1589.99$ 2,044.16$ 322,879.62$ 4,923.78$ 204.42$367.95$ 674.57$ 3,291.10$ 287.96$518.33$950.27$ 4,636.18$ 7,927.28$ 21 6" HDPE Butterfly Valve 8 ea. 843.00$ 22589.99$ 6,744.00$ 161,439.81$ 8,183.81$ 674.40$ 1,213.92$ 2,225.52$ 10,857.84$ 143.98$ 259.17$475.14$ 2,318.09$ 13,175.93$ 22 6" Bolt & Gasket set (HDPE) 20 ea. 10.00$ 0.5489.99$ 200.00$ 10899.88$ 1,099.88$ 20.00$ 36.00$ 66.00$ 322.00$ 89.99$ 161.98$296.96$ 1,448.81$ 1,770.81$23Airfare 12 ea. 1,100.00$ 05089.99$13,200.00$ 0-$ 13,200.00$ 1,320.00$ 2,376.00$ 4,356.00$ 21,252.00$ -$ -$ -$ -$ 21,252.00$ 24 insulation 1 lot 12,000.00$60100089.99$ 12,000.00$ 605,399.28$ 17,399.28$ 1,200.00$ 2,160.00$ 3,960.00$ 19,320.00$ 539.93$971.87$ 1,781.76$ 8,692.84$ 28,012.84$ 25 8" HDPE Pipe 200 ea. 10.29$ 0.5589.99$ 2,058.00$ 1008,998.80$ 11,056.80$ 205.80$370.44$679.14$ 3,313.38$ 899.88$ 1,619.78$2,969.60$ 14,488.07$ 17,801.45$ 26 8" HDPE 90 Deg Ell 20 ea. 53.74$ 32089.99$ 1,074.80$ 605,399.28$ 6,474.08$ 107.48$193.46$354.68$ 1,730.43$ 539.93$971.87$ 1,781.76$ 8,692.84$ 10,423.27$ 27 8" HDPE Flange 10 ea. 90.00$1.52089.99$ 900.00$ 151,349.82$ 2,249.82$ 90.00$162.00$297.00$ 1,449.00$ 134.98$242.97$ 445.44$ 2,173.21$ 3,622.21$ 28 8" HDPE Butterfly Valve 4 ea. 843.00$ 24089.99$ 3,372.00$ 8719.90$ 4,091.90$ 337.20$606.96$ 1,112.76$ 5,428.92$ 71.99$ 129.58$237.57$ 1,159.05$ 6,587.97$ 29 8" Bolt & Gasket set (HDPE) 10 ea. 15.00$ 0.5489.99$ 150.00$ 5449.94$ 599.94$ 15.00$ 27.00$ 49.50$ 241.50$ 44.99$ 80.99$148.48$ 724.40$ 965.90$ 30 Consumables 1 lot 10,000.00$20500089.99$ 10,000.00$ 201,799.76$ 11,799.76$ 1,000.00$ 1,800.00$ 3,300.00$ 16,100.00$ 179.98$ 323.96$593.92$ 2,897.61$ 18,997.61$ 31 Crane1 months 8,000.00$ 01600089.99$ 8,000.00$ 0-$ 8,000.00$ 800.00$ 1,440.00$ 2,640.00$ 12,880.00$ -$ -$ -$ -$ 12,880.00$ 32 Camp Days (4 man crew, 10 hours per day) 179.135 days 216.00$ 0 89.99$ 38,693.16$ 0-$ 38,693.16$ 3,869.32$ 6,964.77$ 12,768.74$ 62,295.99$ -$ -$ -$ -$ 62,295.99$ 3389.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 3489.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 3589.99$-$0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 3689.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 3789.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 3889.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 3989.99$-$ 0-$ -$ -$ -$-$-$ -$ -$ -$ -$ -$ 4089.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 4189.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 4289.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 43-$ 0 -$ -$ -$ -$ Section Totals:791,045.55$1,669 150,144.96$ 941,190.51$ 79,104.56$ 142,388.20$ 261,045.03$ 1,273,583.34$15,014.50$ 27,026.09$ 49,547.84$ 241,733.38$ 1,515,316.72$Electrical System Installation1 Power cable, 350 MCM CU, XHHW-2, 3 conductor w/ground, Corrugated200 ft. 30.00$ 0.54.8115.00$ 6,000.00$ 10011,500.00$ 17,500.00$ 600.00$ 1,080.00$ 1,980.00$ 9,660.00$ 1,150.00$ 2,070.00$ 3,795.00$ 18,515.00$ 28,175.00$ 2 Cable Tray System (includes support system and tray) 1 ea. 3,000.00$ 32150115.00$ 3,000.00$ 323,680.00$ 6,680.00$ 300.00$540.00$ 990.00$ 4,830.00$ 368.00$662.40$ 1,214.40$ 5,924.80$ 10,754.80$ 3 Core Drilling Through Floor and Wall 2 ea. -$ 20115.00$ -$ 4460.00$ 460.00$ -$ -$ -$ -$ 46.00$ 82.80$151.80$ 740.60$ 740.60$ 4 Terminating Cable Ends 6 ea. 50.00$ 13.33333115.00$ 300.00$ 6690.00$ 990.00$ 30.00$ 54.00$ 99.00$ 483.00$ 69.00$ 124.20$ 227.70$ 1,110.90$ 1,593.90$ 5 Conduit System (bushings, seal-tite, floor/wall sleeves, fire stopping, etc.)1 ea. 2,000.00$ 24400115.00$ 2,000.00$ 242,760.00$ 4,760.00$ 200.00$ 360.00$660.00$ 3,220.00$ 276.00$496.80$910.80$ 4,443.60$ 7,663.60$ 6 Grounding (bonding jumpers, ground grid connections) 1 ea. 150.00$ 1210115.00$ 150.00$ 121,380.00$ 1,530.00$ 15.00$ 27.00$ 49.50$ 241.50$ 138.00$248.40$455.40$ 2,221.80$ 2,463.30$ 7 Demolition of Unit #2 1 ea. -$ 800115.00$ -$ 809,200.00$ 9,200.00$ -$ -$ -$ -$ 920.00$ 1,656.00$ 3,036.00$ 14,812.00$ 14,812.00$ 8 Mob/Demob 1 ea. 15,000.00$1200115.00$ 15,000.00$ 12013,800.00$ 28,800.00$ 1,500.00$ 2,700.00$ 4,950.00$ 24,150.00$ 1,380.00$ 2,484.00$ 4,554.00$ 22,218.00$ 46,368.00$ 9 Per Diem (lodging, meals, incidentals) 3 ea. 3,000.00$ 30115.00$ 9,000.00$ 91,035.00$ 10,035.00$ 900.00$ 1,620.00$ 2,970.00$ 14,490.00$ 103.50$186.30$ 341.55$ 1,666.35$ 16,156.35$ 10115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 11115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 12115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 13115.00$ -$0-$-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 14115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 15115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 16115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 17115.00$ -$ 0-$ -$ -$ -$ -$ -$-$-$ -$ -$ -$ 18115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 19115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 20115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 21115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$22115.00$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ Section Total:35,450.00$ 387 44,505.00$ 79,955.00$ 3,545.00$ 6,381.00$ 11,698.50$ 57,074.50$ 4,450.50$ 8,010.90$ 14,686.65$ 71,653.05$ 128,727.55$ Not Used1ea.189.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 2ea.1.5 89.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 3ea 86.00$ 0.50.589.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 4ea. 7.00$ 0.50.2589.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$-$5ea 22.00$ 0.50.2589.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 6ft 2.27$ 0.050.289.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 7ft 1.95$ 0.251.6889.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 8ea. 40.00$ 0.5289.99$ -$ 0-$ -$ -$ -$ -$-$-$ -$ -$ -$ -$ 9ea. 75.00$ 1489.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 10ea. 8.00$ 1.25389.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 11ea. 6.00$ 1289.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 12ea. 32.00$ 1289.99$ -$ 0-$-$-$ -$ -$ -$ -$ -$ -$ -$ -$ 13ft 3.05$ 0.252.7289.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 14ea. 50.00$ 589.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 15ea. 40.00$ 0.5389.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 16ea. 82.00$ 0.5389.99$-$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 17ea. 33.00$ 0.5289.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 18ea. 30.00$ 0.5189.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 19ft. 1.35$ 0.251.1389.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$-$ 20ea. 45.00$ 0.5489.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 2189.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 22ea. 38.00$ 1989.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 23ea6 89.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$-$ 2489.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 2589.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 26ea. 1,152.00$ 6 89.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 27ea. 2,000.00$ 1.5 89.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 28ea 82.00$0.5389.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 29ea6 89.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 30ea.689.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ Section Total:-$ 0 -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ Not Used1ea0.5 89.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ 2ea 49.00$ 1.751389.99$ -$ 0-$ -$ -$ -$ -$ -$ -$ -$ -$ -$ -$ wage class JW FM GEN FM JW FM GEN FMJM FM Gen FM35.58 40.03 44.0340hr week (ST)73.08$ 80.05$ 86.32$ JW$36.65 $41.23 $45.35 $54.97 $61.85 $68.03 50hr week (1.5)77.20$ 84.69$ 91.42$ H&W$7.72 $7.72 $7.72 $7.72 $7.72 $7.72 60hr week (1.5)79.95$ 87.78$ 94.82$ AK Pension$6.80 $6.80 $6.80 $6.80 $6.80 $6.80 70hr week (1.5)81.91$ 89.99$ 97.25$ National Pension$0.85 $0.85 $0.85 $0.85 $0.85 $0.85Profit10%Overhead18%367 Supp 401K$0.25 $0.25 $0.25 $0.25 $0.25 $0.25 40hr week (ST) + O & P 93.54$ 102.47$ 110.49$Training Fund$1.50 $1.50 $1.50 $1.50 $1.50 $1.50 50hr week (1.5)+ O & P 98.82$ 108.40$ 117.02$Contract Admin$0.20 $0.20 $0.20 $0.20 $0.20 $0.20 60hr week (1.5)+ O & P 102.33$ 112.36$ 121.37$Total APTL 367 Contract Costs $53.97$58.55 $62.67$72.29 $79.17$85.3570hr week (1.5)+ O & P 104.84$ 115.18$ 124.48$SS 6.20%$2.27 $2.56 $2.81 $3.41 $3.83 $4.22Medicare 1.45%$0.53 $0.60 $0.66 $0.80 $0.90 $0.99 JM 3FUTA 0.80%$0.29 $0.33 $0.36 $0.44 $0.49 $0.54 FM 4SUTA 4.00%$1.47 $1.65 $1.81 $2.20 $2.47 $2.72 Gen FM 5Worker's Comp 13.57%$4.97 $5.60 $6.15 $4.97 $5.60 $6.15Liability 3.13%$1.15 $1.29 $1.42 $1.15 $1.29 $1.42Hiring Hall Dues 5.00%$1.83 $2.06 $2.27 $1.83 $2.06 $2.27Travel 5.00%$1.83 $2.06 $2.27 $1.83 $2.06 $2.27Fuel 3.00%$1.10 $1.24 $1.36 $1.10 $1.24 $1.36Small Tools 10.00%$3.66 $4.12 $4.54 $3.66 $4.12 $4.54$19.11 $21.50 $23.65 $21.39 $24.07 $26.471.5OvertimeStraightTotal indirect Costs Powerhouse Waste Heat to Energy Project Final Report 10/22/2012 Page | 6-18 High and consistent performanceComprehensive design and engineeringknow-how – reinforced by advancedproduction technology and ISO 9001quality assurance systems – guaranteethe high quality of our products andreliable, short delivery times.More than 75 years of know-how indevelopment, production and world-wide marketing and support of advan-ced steam systems make AalborgIndustries one of the leading suppliersof waste heat recovery systems in theworld.For further information please contactany local Aalborg Industries subsidiary.Visit our Internet web site:www.aalborg-industries.comDiesel Engine Exhaust Gas BoilerAV-6N is a robust, highly efficientwater tube boiler, designed to improve your plant’s total efficiencyby recovering the heat from theexhaust gas of diesel engines. TheAV-6N boiler is flexible and easy toinstall - even in existing facilities.In addition to traditional forced circulation AV-6N exhaust gas boiler isavailable also as a natural circulationmodel.AV-6NHalskov & Halskov 06/00 · Printed by Formula TryxagerProduct Centre:Aalborg Industries OyP. O. Box 9,FIN-26101 Rauma, FinlandTel. +358 2 838 3100Fax +358 2 823 1133E-mail: rau@aalborg-industries.fihttp://www.aalborg-industries.comYour contacts:■Indonesia: Tel. +62 21 461 0569 ■UK: Tel. +44 1904 557640■Turkey: Tel. +90 212 265 7674■Brazil: Tel. +55 11 3872 8400■Denmark: Tel. +45 99 30 40 00 ■Hong Kong: Tel. +852 2836 3826■Japan: Tel. +81 78 271 5720■Singapore: Tel. +65 261 9898■USA: Tel. +1 814 897 7000 Gas amount: No limitsGas temperature:Norm. < 400°C. Up to 530°C in standard executionPinch point:Norm. 15-20°C. Min. 5°C, limited by feasibility onlyDesign pressure:Norm. < 25barg. Max. 80barg in standard executionSteam temperature:Up to 400°C in standard executionCirculation:Forced or naturalTubes:Double gilled fin tubesTechnical data for AV-6NAV-6NReliable and cost-effective operationWaste heat recovery AV-6N is the optimum solution for high-performance heat recovery systems.Designed with extended heating surface, the AV-6N is compact and cost-effective. The possibility of cleaningduring operation minimises the needfor engine shutdowns and increasesoverall plant availability.Unique boiler construction by Aalborg IndustriesA unique supporting arrangement without end plates - enhanced by computerised analyses - ensures a vibration- and themal stress-free boilerconstruction.Natural circulationIn addition to traditional forced circula-tion boilers, Aalborg Industries offers areliable natural circulation solution. Natural circulation without circulationwater pumps gives the followingadvantages:■Reliability■Less power consumption■Cost effectiveness■Fast site installation■Reduced foundation work and minimised piping and cabling■Minimal foot printEasy to cleanThe tube arrangement of the AV-6Nboiler’s heating surface ensures easymaintenance and service. AV-6N boilerscan be cleaned during operation, reducing the need for engine shut-down. In addition to standard steamsoot blowers, water and air can also be applied.Suitable for all applicationsYears of experienceAalborg Industries has along experience withwaste heat recovery, and devotes constantattention to developmentand innovation within this area. We have installed a largenumber of boilers andheat exchangers, and wehave a large team ofexperienced serviceexperts who will providequick response on anyrequest.MUSD/year150200300Cost saving at various oil prices (USD/m3)3.002.502.001.501.000.500.00510Steam capacity (t/h)15Customer benefits with AV-6N:■Compact heating surface, speciallydesigned for diesel applications ■Vibration resistant■Shop assembled■Easy to clean on flue gas side due toin-line configuration and parallel fins■Short delivery time■High efficiency■Natural or forced circulation■Proven design■Many references■Tailor-made for specific requirements■Small foot print■Low weightSuitable for all applicationsThere are no restrictionsneither on pressure nor oncapacity in practical dieselpower plant applications.Small water volume insidethe boiler allows it torespond quickly to loadchanges.AV-6N can handle largecapacities and is applica-ble in all types of plant.Typical examples of AV-6N boilers for Natural circulation and Forced circulation Alfa Laval Aalborg Jan ary 2012 Terms & Conditions 1.0 Validity of these Terms and Conditions 1.1 An order for delivery of work, i.e. prod- ucts, materials, services, equipment, tools, personnel, etc., from a company within the Alfa Laval group of companies, hereinafter referred to as AL, presupposes acceptance by the Buyer of these Terms and Conditions, regard- less of the form in which the order is given. These Terms and Conditions are valid until otherwise notified to the Buyer by AL. 1.2 Price lists for service assistance, tools, etc. are subject to special terms and shall be enclosed with and form an integral part of these Terms and Conditions. In case of discrepancy between them, the price lists shall prevail. 1.3 These Terms and Conditions are divided into two main sections: I GENERAL CONDITIONS, articles 2-8 II TERMS FOR ASSISTANCE BY AL’S PERSONNEL, articles 9-15 I GENERAL CONDITIONS 2.0 Invoicing 2.1 The invoice for the work will be for- warded as soon as possible after completion of AL’s work and shall be paid by the Buyer within 30 days of the date of invoice. 2.2 Work or products delivered by AL shall remain the property of AL until paid for in full to the extent that the applicable law permits such retention of property. 2.3 If payment is not received on the due date, interest will be charged from that date until payment is effected. Interest shall be added to the invoiced amount on the basis of LIBOR for USD plus 6% p.a. 2.4 If the Buyer wishes to transfer the order to a third party, such transfer requires AL’s prior acceptance. In this situation, the Buyer shall remain liable for payment to AL. 3.0 Delays 3.1 If AL is delayed in delivery or in the work for reasons caused solely or partly by the Buyer or any of his representatives, employ- ees, officers, subcontractors, or agents, AL shall not only be allowed the necessary extra time but also compensation for extra costs that AL may incur. 3.2 If AL is delayed in delivery or in the work by its own fault, AL shall be liable for compensation or liquidated damages only if such written agreement has been stipulated directly in the Contract entered between AL and the Buyer. Liability for damages does not include consequential or indirect damages, irrespective of the nature of such damages. In no event shall the indemnity exceed 7.5% of the contract sum. The Buyer is not entitled to any other remedies and may not cancel the contract due to delays on the part of AL. 4.0 Liability against defects 4.1 All agreements shall be made on the basis of the limited liability provisions set forth herein. Other or more extensive liability, including the right to cancel a contract or claim damages beyond the extent stated herein, shall be valid only if a written agreement stating the nature and extent thereof has been entered before acceptance of delivery of the work and if the price is adjusted to include the costs of appropriate additional insurance or additional exposure. 4.2 AL’s liability for defects in materials deliv- ered shall be limited to procuring and supplying replacement materials free of charge. 4.3 For repair work and other work, AL’s liability for defects shall be limited to repair of the defect in question. AL shall cover only the direct costs of labour and materials for such repair. AL disclaims any other cost, whether direct, indirect, consequential, or otherwise. Payment for travelling time, waiting time, trav- elling expenses, hotel, and meals shall be for the account of the Buyer and shall be invoiced accordingly. 4.4 AL shall be liable for damage only if caused by gross negligence or intent on the part of AL’s personnel. AL’s liability shall be limited to repair of the direct damage and shall cover neither consequential costs nor indirect loss, irrespective of the nature of such loss. In no event shall AL’s aggregate liability arising out of a contract exceed the total value of the contract or the equivalent amount in local cur- rency. In no event can the amount exceed the amount of the contract, the maximum being DKK 10 million. The Buyer agrees to indemnify AL with respect to any liability in excess of this amount. 4.5 AL shall make its best effort to pass on to the Buyer all manufacturers’ warranties for machinery and equipment procured by AL for the work. In no event shall AL’s warranties/ liability for machinery and equipment procured by AL be more extensive than the manufac- turer’s warranties. 4.6 Where ALA has merely supervised the commissioning of the equipment and has not carried out the installation/repair, ALA shall incur no liability in respect of damage caused by defects in connection with such installa- tion/repair. ALA shall be liable only for damage directly related to gross negligence or intent on the part of ALA’s personnel with a view to improper commissioning procedures. 4.7 AL assumes no liability for defective materials or workmanship, loss, or damage once the work has been accepted by the representative of the classification society or the Buyer. In no event shall ALA be liable unless the defective materials or workmanship are detected and presented to ALA in writing within thirty (30) days of the Buyer’s detecting the defects, or the work has ceased for what- ever reason, or products have been returned to ALA, whichever occurs first. 5.0 Force majeure 5.1 In case AL is hindered by an event of force majeure from carrying out the agreed work within the agreed time, then AL shall be allowed the necessary extra time from the point in time when the event of force majeure ceases. AL shall not be liable for loss, damage, or delay caused by an event of force majeure. 5.2 Force majeure shall be taken to include, but not be limited to, acts of God, strikes, lockouts, general disturbance, major traffic disturbance in international transportation, inclement weather conditions, and other circumstances beyond AL’s control. 6.0 Product liability 6.1 Unless other statutory provisions apply, the following shall govern AL’s product liability: 6.2 AL shall be liable for personal injury only if it is proved that such injury was caused by negligence on the part of AL or others for whom AL was responsible. 6.3 AL shall not be liable for damage to property occurring whilst AL’s products are in the Buyer’s possession. Nor shall AL be liable for damage to products manufactured by the Buyer or to products or services of which the Buyer’s products form a part. 6.4 In no event shall AL be liable for loss of production, loss of profit, or any other conse- quential damages or indirect loss. 6.5 In no event shall AL’s liability exceed DKK 10 million. 6.6 To the extent that AL incurs product liability to a third party, the Buyer shall indem- nify AL as far as AL’s liability has been limited by the four preceding paragraphs. 6.7 The above limitations in AL’s liability shall not apply where AL has been guilty of gross misconduct. 6.8 If a claim for damages as described in this clause is lodged by a third party against AL or the Buyer, that party shall forthwith inform the other party thereof in writing. 6.9 AL and the Buyer shall be obliged to let themselves be summoned to the court or arbitration tribunal that examines claims for damages lodged against one of them on the basis of damage allegedly caused by AL’s work or products. 7.0 Disclaimer 7.1 AL disclaims any liability that is not cov- ered by these Terms and Conditions. AL spe- cifically disclaims all warranties of merchant- ability and fitness of AL’s work or products for a particular purpose. 8.0 Venue and applicable law 8.1 All deliveries from AL shall be subject to CISG. Any dispute between the parties regarding a situation arising out of or in con- nection with an agreement governed by these Terms and Conditions shall be subject to the law of the country in which the contracting AL company is domiciled without giving effect to the principle of conflict of the laws thereof. Any dispute shall be settled by the commercial court of the country in which the contracting AL company is domiciled. II TERMS FOR ASSISTANCE BY AL’S PERSONNEL 9.0 Working hours – time sheets 9.1 A normal week comprises 5 working days and 2 weekend days. A normal working day comprises 8 working hours, and hours exceeding 8 working hours shall be consid- ered as overtime hours. 9.2 All working hours on weekend days and AL personnel’s national holidays shall be con- sidered as overtime hours. 9.3 AL personnel can only undertake work- ing hours exceeding 12 hours per day or work on Sundays against the Buyer’s representa- tive’s written approval. Reasons for overtime hours exceeding 12 hours per day and written approval shall be given on the time sheet. 9.4 The Buyer or his authorised representa- tive is requested to follow the progress of the work closely. 9.5 Time sheets showing the time during which AL’s personnel have carried out work for the Buyer shall be filled in daily and shall be countersigned by the chief engineer/work foreman or any other authorised representa- tive of the Buyer. 9.6 If the Buyer’s representative fails to countersign the time sheets, or if the repre- sentative does not approve of the time sheets that have been filled in by AL’s personnel, the Buyer’s representative or the Buyer himself shall immediately inform the AL company responsible for the job by telefax or E-mail of the reason for the refusal. If a time sheet has not been countersigned in accordance with this article, or if the Buyer has not given due notice of the unapproved time sheets to the relevant AL company, then AL shall be entitled to reject any objections regarding invoices based upon time charged to the Buyer. 9.7 The effective working time is defined as the time from the commencement of work by AL’s personnel until they leave the job, less the time spent on meal breaks. 9.8 If AL’s personnel are not provided accommodations on board a ship where they are carrying out a job, the working time starts at the time AL’s personnel leave their hotel and ends at their return to the hotel. 10.0 Waiting time 10.1 Waiting time caused by lack of work due to circumstances beyond the control of AL’s personnel shall be invoiced at the rate valid for normal working hours. AL’s personnel are prepared to undertake other kinds of work than originally intended in order to compensate for waiting time. 10.2 Waiting time shall be charged daily between 8 a.m. and 8 p.m. A maximum of 10 hours of waiting time can be charged per day. 11.0 Allowances and travelling and trans- port expenses 11.1 Travelling, hotel, allowances, and other expenses paid by AL, including telephone calls, telefaxes, etc. shall be invoiced to the Buyer at cost plus 15% overhead charges. 11.2 Travelling time shall be invoiced at the rates for normal working hours with max. 12 hours/day. 11.3 Accommodation shall be of a reasonable standard. 12.0 Conditions when staying on board a ship, at a building site, or similar 12.1 Accommodation shall be of a reasona- ble standard. AL’s personnel shall have access to shower with hot and cold water. 12.2 AL’s personnel shall have purchasing facilities for daily requirements such as food, beverages, etc. AL’s personnel shall have access to a refrigerator. 12.3 Payment for beverages etc. bought on board the ship or at the site should preferably be settled with AL’s personnel before they leave. 13.0 Permits, licences, and certificates 13.1 It is the sole responsibility of the Buyer to advise and, whenever necessary, to obtain permissions, permits, passes, licences, or certificates from the appropriate authorities or classification societies for work to be carried out by AL. 14.0 Tools and equipment 14.1 If requested, AL shall supply tools and equipment, subject to a separate agreement. 14.2 Rental of tools from an AL company shall be charged from the day that the tools leave that company until they are received back at the same company. 14.3 After use, AL’s tools shall be packed in AL’s tool box(es) under the supervision of the Buyer or his representative. Any shortages, damage, etc. shall be noted and the tool box(es) locked. 14.4 The Buyer shall arrange for transporta- tion of the tool box(es) to their point of origin. The Buyer shall arrange for insurance against loss or damage. 14.5 The tools shall be received by AL no later than 90 days after termination of the work. If the tools are not received within this time, they shall be considered lost and shall be charged to the Buyer. Damaged tools shall also be charged to the Buyer. 14.6 Upon request AL shall supply industrial gases at the Buyer’s expense. If the Buyer does not specifically request AL to supply such gases, the Buyer shall be expected to supply them. 14.7 Provided no other arrangements are made, the following supplies and services are not included in AL’s work and shall be made available to AL’s personnel: - Assistance for transport of materials to and from the work site. - Necessary scaffolding. - Overhead cranes, blocks, fall wires, and shackles. - General assistance for cleaning, etc. - Supplies of electricity, compressed air for working and personnel protection equipment, water and fuel, and necessary lighting. 15.0 The Buyer’s liability and insurance 15.1 The Buyer shall pay compensation and indemnify AL in case of damage to AL’s property or injury or death of personnel employed by AL or any third party when and to the extent that such injury or death is caused by the Buyer’s negligence, whether direct or indirect. Such negligence may be constituted by lack of neces- sary instructions concerning the work to be carried out by AL’s personnel. 15.2 The Buyer is obliged to inform AL on any material containing asbestos. AL cannot in any way, whatsoever, be held liable for the contents of any such material, including for any financial consequences thereof or con- sequences of safety or as regards time. The Buyer undertakes to indemnify AL for all costs, expenses and consequences caused by any such contents of asbestos. Heat Recovery Silencer Radial Series – HRSR U-Tube Heat Recovery Series – UTR Exhaust Steam Generator Series – ESG1 Heat Recovery Silencer Axial Series – HRSA 3 exhaust heat recovery SYSTEM FUNCTION Btu is transferred from the exhaust stream to heat sinks such as water, glycol, therminol fluids, or steam production. Suitable fuel types for combustion sources include natural gas, propane, digester gas, diesel fuel, and light to heavy fuel oils. PROPOSAL CONSIDERATIONS • Large or irregular exhaust connections • High or varying exhaust temperatures • Particular pinch point requirements • Exhaust or liquid control • Special heat sink requirements • Special heat transfer metallurgy requirements • Specific maintenance concerns • Optional equipment requirements • Installation space and weight concerns • Package system requirements ANTICIPATED RESULTS • Tremendous fuel savings typically pay for equipment and installation within 1 to 3 years of average use. • Pollution reduction due to lowered annual fuel usage. • Lower exhaust temperatures and significantly reduced sound output levels (final sound attenuation is typically 15 - 25 dBA). INTRODUCTION This catalog covers the Cain Industries Product lines for the gas and diesel engines, gas turbines, and micro turbine generator retrofit applications. For these applications, we offer over 500 standard products to choose from, and can typically provide a comprehensive analysis and quotation to fit your exact needs within 24 hours. Our equipment can be adapted and assembled to fit any application or complete installation. COGEN APPLICATIONS • Hospitals • Manufacturing Plants • Schools • Office Buildings • Shopping Malls • Drilling Platforms • Oil & Gas Plants • Marine EQUIPMENT VARIETY • Exhaust steam generators • Large exhaust recovery silencers • Smaller specialized exhaust recovery silencers • Special heat transfer configurations • Recirculating engine jacket water boilers EXHAUST STEAM GENERATOR The fully packaged ESG1 is selected from 48 pre-engineered standard models with output capabilities of 20 to 500 boiler hp and operating steam pressures from 3 to 450 psig. The ESG1 is shipped complete, ready for operating as either a primary or supplementary steam source. The ESG1 package is made up of three basic sections: • finned tube heat transfer section • steam flash circulating drum assembly • modulating full port exhaust bypass system OPERATION & CONTROL The integral forced circulating water pump continually circulates high temperature water from the steam flash drum assembly to the heat transfer core assembly. Btu is transferred from the exhaust to a high flow superheated water/steam mixture. The super-heated water is returned to the steam drum which contains dry pipe, baffles, and lance assemblies, where it flashes into 99% dry stream as its exits out to the system. As the water is generated into steam and exits the boiler, the modulating boiler feedwater system controls continuous feedwater flow for constant drum water level control. Fail safe controls are built in for full exhaust bypass in the event of electrical or pneumatic loss. The steam pressure controller maintains the operating steam pressure as it con- trols the modulating exhaust bypass assembly. This provides solid operating steam pressure under various operating steam load demands. QUALITY CONTROL The ESG1 is manufactured, tested, and stamped in accordance with the requirements of Section I of the ASME Boiler and Pressure Vessel Code, and National Board. Boiler trim includes all safety controls and alarms to meet state and federal codes. Final assembly, electrical wiring, and factory adjustments are completed under a strict set of guide lines. 4 Full operating steam pressure from a cold start in less than 10 minutes. ESG1 OPTIONAL COMPONENTS Hinged Access Door for full heating surface inspection Hinged access doors are considered when firing with fuel oil and/or incomplete combustion requiring full access on a regular basis for manual cleaning. A hinged access door can be incorporated for 100% finned tube viewing and attention. Engine Exhaust Application • Capacity: 400kW – 7MW • Entering gas temps: 600 – 1,600°F • Heat sink types: Supplemental steam demand and/or primary steam source for steam heating or process steam. Continuous Blowdown with Intermittent Conductivity Sampling Assembly Maximize boiler efficiency by periodically sampling surface blowdown water and controlling total dissolved solids. Maintaining optimal levels of concentrations will control the costs of water, energy, and chemicals. Assembly includes: motorized valve, probe, and piping assembly. Automatic Sootblower Sootblowers are available either as a manual push button start or fully automatic with timed sequencing. Sootblowers are considered when firing with fuel oil and/or incomplete combus- tion. Sootblowers are also considered when manual cleanings are not feasible in order to maintain peak performance. WATER PURIFICATION PLANT,Burlington, Ontario Model ESG1-A12D18CSS Recovering Btu from a Caterpillar 3516, 800kW natural gas engine. Reducing 2,382 SCFM from 770°F to 344°F. Delivering 1,277 pph steam @130 PSI operating (150 PSIG design). HOSPITAL,Chicago, Illinois (3) Model ESG1-616B18CSS. Recovering Btu from (3) Waukesha 3516, 1,100kW natural gas engines. Reducing each 2,392 SCFM from 1,135°F to 438°F. Delivering 2,173 pph steam @130 PSI operating (150 PSIG design). 5 HOSPITAL,Renton, Washington (4) Model ESG1-616B19CSS Recovering Btu from (4) Jenbacher JMS-320, 900kW natural gas engines. Reducing each 2,498 SCFM from 977°F to 392°F. Delivering 1,863 pph steam @ 90 PSI operating (150 PSIG design). exhaust heat recovery FEATURES The ESG1 is an easy choice when compared to the “old technology” of a conventional firetube boiler: • Completely self-contained “package” design reduces engineering, installation and maintenance costs. • Size requires only 1/2 the floor space and 1/2 the weight of conventional boilers, which reduces build- ing size, structural support costs, and shipping costs. • Ease of tube replacement requires no overhead cranes, special rigging, special crews, or extra roof height above the unit, while reducing down time. • Many shapes and sizes are available to fit limited space and maintain performance requirements. • Produces greater than 99% dry steam. • Provides 100% turndown capability. • 5–10 minute time from startup to full output. • Integrated exhaust modulating bypass for safe auto- matic steam control. • Explosion-proof heat transfer exchanger. • Low friction loss for minimum static exhaust back pressure. • High circulating flow to minimize scale buildup. • No thermal expansion concerns with cold boiler feedwater. • Performance aimed at the lowest pinch point in the industry, (final leaving exhaust temperature minus operating steam temperature) for maximum thermal efficiency. MINIMUM CONNECTIONS The ESG1 requires only the following connections for a cost effective installation: • steam outlet • exhaust flange inlet and outlet • single main power • single main blowdown • feedwater inlet • pneumatic control air • cooling water inlet and outlet ASME & National Board stamped – Section 1 EXHAUST FLOW: FULL BYPASS POSITION EXHAUST FLOW: FULL OPERATING POSITION ASME Steam safety valve Modulating exhaust bypass 10Ga. carbon steel exterior Lifting eye Finned tube heat transfer section (removable finned tube rack assy) High temperature insulation block Structural steel base Steam outlet flange Steam flash drum assembly (insulated) Water level controller with low & high water cutout Continuous surface blowdown Modulating feedwater valve Main blowdown valve assembly Excess steam pressure switch Steam pressure controller Tube removal access door Circulating pump assembly Pneumatic modulating damper actuator Main inspection door NEMA 12 control panel: Fuse disconnect, Magnetic starter, Stepdown transformer, Alarm lights Localized piping connections: - Feedwater - blowdown manifold - 100psig control air - circulating pump cooling water Water level blowdown ESG1 SERIES FOR: THE COMPLETE STEAM GENERATION PACKAGE 6 ESG1 Front ViewDoor View Header View Back View ESG1: SPECIFICATION The following is a general specification, shown as a guide for design and construction. 1.0 General Design: 1.1 The ESG1 shall be a packaged forced circulation coil design, manufactured and tested in accordance with the requirements of Section 1, of the ASME Boiler and Pressure Vessel Code, and stamped at 150 PSIG (15 to 450 PSIG available) to the appropriate Section. The operating pressure shall be ______PSIG. 1.2 The ESG1 shall have the capacity to operate automatically as a supplemental or primary steam generator. It shall be designed to produce full steam output in approximately 10 minutes from a cold start and to operate fully automatic under fluctuating steam loads and/or exhaust volumes. 2.0 General Construction: 2.1 The design shall be made up of three basic sections mounted on a structural steel skid, pre-piped, wired for ease of installation, requiring no field assembly. 2.2 The sections shall include a finned tube heating surface, modulating full port exhaust bypass, and steam flash drum assembly, as standard components. 2.3 An integral circulating pump shall also serve to circulate water from the heat transfer section back to the steam flash drum assembly. 2.4 All water, air, and blowdown connections shall be localized within a common manifold assembly for ease of the piping installation. 2.5 Exhaust volume connections shall be located at the top of the ESG1 to serve ease of the exhaust piping installation. 3.0 Heat Exchanger Section: 3.1 Explosion-proof heating surface to be nickel brazed/welded fin to tube, for high heat transfer and corrosion protection (.109 wall thickness x .030 minimum fin thickness). 3.2 The finned tubing shall be designed in multiple sections for ease of replacement. 3.3 The heat exchanger section shall contain a main inspection door for tube removal and a main inspection access port for cleaning and/or inspection. 3.4 The reinforced enclosure shall contain 304 stainless steel baffles with 4” minimum thickness thermal insulation. The enclosure shall be designed to operate with exhaust temperatures entering @ 1,250°F maximum (1600°F design available) and shall have a gas tight seal with continuously welded 10ga. carbon steel exterior: Design Pressure (exhaust side): 10 inches water column, primed/painted with high temp. metallic paint. 4.0 Modulating Bypass Assembly: 4.1 The modulating bypass assembly shall be constructed of minimum .25” thickness plate steel (stainless steel available) and the exhaust connections shall be 150 lb. design SA105 exhaust flanges when applicable. The bypass assembly shall be bolted to the heat exchanger section for ease of maintenance. Insulation shall be provided by others as needed. 4.2 The bypass shall be controlled by a modulating pneumatic positioning actuator and steam pressure dial controller, for controlling the volume of waste heat exhaust as dependent on steam pressure. 4.3 The reinforced damper assembly shall be constructed of 304 stainless steel and designed for tight seal during the full bypass. 4.4 The 304 stainless steel damper shaft shall contain high temperature bearings and packing glands to seal exhaust leakage. 4.5 In the event of an air pressure or electrical failure to the ESG1, the modulating bypass assembly shall contain a alarm fail safe operating mode, whereby the damper assembly shall automatically move to the full exhaust bypass position. 5.0 Steam Flash Drum & Control Assembly: 5.1 The steam flash drum assembly shall contain internal baffles and dry pipes for 99% dry steam output, and 1” thick thermal insulation with minimum 16ga. carbon steel exterior and shall include the following: 5.1.1 The ANSI standard configured circulating pump and TEFC motor shall be incorpor- ated to maintain high water flow turbulence for minimum fouling. 5.1.2 The blowdown valving shall include a main drum blowdown valving assembly including quick opening and shut off valves, continuous surface blowdown valve, and water level control blowdown valve all manifolded for a single blowdown connection. 5.1.3 Safety controls to include low/high water cutout, excess steam pressure cutout, low air pressure cutouts (for pneumatic exhaust bypass actuator). 5.1.4 The water level control system shall contain fully modulating boiler feedwater pump level control and valve assembly with boiler feedwater on/off auxiliary switch. 5.1.5 Water level control to contain red line water level sight glass with drain cock. 5.1.6 All required gauges for steam (41/2” dial minimum), feedwater, pump cooling water, and air indication (21/2” dial minimum) shall be provided. 5.1.7 (1) ASME and National Board stamped steam safety relief valve. 5.1.8 All necessary interconnecting piping linkages and valving shall be provided. 5.1.9 All inner connecting piping shall be insulated by others as required. 5.2 Control panel to be NEMA 12 construction to accept a single main power connection with main fuse disconnect and starter, fuse-protected stepdown transformer, power and run indicating lights, fill indicating light, low & high water alarm indicating lights, and low air & excess steam pressure lights. Testing of all components, electrical controls, and hydrostatics as a system, is completed prior to ship- ment, insuring a smooth and efficient field startup. Final inspection, under the strict guidelines of Cain Industries and ASME quality control standards, is conducted for each unit. Complete packaged units are shipped for immediate installation upon arriving on site. Field startup and operator training is realized quickly with factory trained personnel. 7 exhaust heat recovery 8 HRSR HEAT RECOVERY SILENCER RADIAL The HRS Radial waste heat recovery silencer is a module configuration package with 176 standard models avail- able. It packages standard features such as: full exhaust bypass, full heating surface access, factory insulation, hard shell exterior, stainless interior, 3” thickness factory insula- tion, and a variety of finned tube types and fin spacings to fit the proper application. The HRSR is designed to receive the total exhaust and liquid flow from a single source and control exit temperatures to the desired per- formance levels. During full operation, the radial design channels the exhaust flow through an hour glass expansion flow pattern which provides for significant dBA reduction. The full port exhaust bypass is located at the top for convenient installation. Depending on space considera- tions, the unit may be installed in the horizontal position as shown below. The unique configuration of the single row design heating surface allows for reduced fouling poten- tial. The full access to the core with optional hinged doors also allows for fast routine inspection and/or manual cleaning. Finned tube replacement requires no overhead cranes, special rigging, special crews, or extra roof height above the unit. Individual finned tube replacement if required, is fast and easy with minimum down time. OPTIONAL EQUIPMENT: • Liquid temperature indicating control assembly • Hinged inspection doors for immediate access • Timed automatic timed sootblowers • Modulating damper actuator (pneumatic or electric) • Compression fitted tube to header attachment requiring no welding for fin tube replacement AIRPORT, Detroit, Michigan. (3) Model HRSR-472H28CSS Recovering Btu from (3) Wärtsilä 345G, 5.7MW natural gas engines. Reducing each 698°F @ 18,373 SCFM to 320°F. Raising 175 GPM hot water from 250°F to 350°F. OEM PACKAGER, Model HRSR-1I2C26.5ALS Recovering Btu from (1) 75 kW Micro Turbine Generator, natural gas engine. Reducing each 500°F @ 1,198 SCFM to 213°F; Raising 35 GPM hot water from 160°F to 181°F. Engine Exhaust Application • Capacity: 200kW – 6MW • Entering gas temps: to 1,250°F • Heat sink types: Engine jacket water, process water, boiler water, or ethylene glycol FEATURES: • Full exhaust gas bypass assembly • Sound attenuation • Stainless steel interior lining • Internal heating surface expansion design • No joint welds within the heating surface in contact with the exhaust gas stream • 10ga. hard shell seal welded exterior • Single row design for complete and full access • Ease of tube replacement requiring no overhead cranes or special rigging. Fully packaged for micro-cogen applications through the large turbines 9 exhaust heat recovery (2) MOBILE TRAILERS, (2) Model HRSR-216826SSS Recovering Btu from a diesel fueled N14 Cummins engine Reducing each 865°F @ 1,188 SCFM to 465°F. Raising 70 GPM 50% Ethylene Glycol from 70°F to 90°F. HOSPITAL, Ontario (2) Model HRSR-336B28CSS Recovering Btu from (2) Cummins Wärtsilä CW180, natural gas engines. Reducing each 968°F @ 3,666 SCFM to 339°F. Raising 175 GPM hot water from 195°F to 229°F. Premium footprint space is realized with rectangular variety GOLD &SILVER MINE, Eskay Creek, British Columbia. (3) Model HRSR-316A26CSP Recovering Btu from (3) Caterpillar 3512, 900kW diesel engines. Reducing each 870°F @ 2,100 SCFM to 417°F. Raising 265 GPM 50% ethylene glycol from 187°F to 197°F. 10 *Available tube materials: carbon steel, TP316 stainless Available fin type: carbon steel, TP304 stainless, aluminum Methods of attachment: nickel brazed, welded, Al-Fuse Inspection door assembly, for finned tube inspection, clean out, or removal (optional hinged version) Stainless steel damper shaft Lifting lug Exhaust bypass assembly Thermocouple 3/4 NPT vent ASME Stamp (optional) Control panel (used with Automatic Sootlblower Assembly and/or Liquid Temperature Control - optional) Header manifold (low liquid pressure drop) 10ga thickness. exterior Stainless steel interior 3” THKS. insulation 3/4 NPT drain H-Beam support 11/2 NPT cleanout Finned tube*assembly (single row design for complete access to heating surface) Stainless steel bypass damper Modulating actuator (optional pneumatic or electric) Header ViewLeft Side View Top View HRSR SERIES FOR: LARGE ENGINES & FULL FEATURE DESIGN EXHAUST FLOW: FULL BYPASS POSITION EXHAUST FLOW: FULL OPERATING POSITION ASME & National Board stamped – Sec.VIII, Div.1 HRSR Single row tube configuration for easy cleaning and maintenance. TIMED AUTOMATIC SOOTBLOWER (optional) The exclusive Cain Industries Timed Automatic Sootblower design is applied to combustion sources where the sulphur content is high and/or combustion efficiency is poor. When a soot layer accumu- lates on the heating surface to a thickness of 1/8”, fuel consumption is increased by 8.5%. The sootblower is also applied when it is not cost-effective to open inspection doors and clean the exchanger by other means. The sootblower system will continually keep the heating surface at a high performance level and eliminate the day- to-day operator expense and engine down time. The blowdown sequence occurs while the engine is in full operation and is fully adjustable. The special flood-jet type nozzles achieve maximum cleaning velocity using steam or air as discharged through an electric control valve (included). Together they form a `continu- ous knife edge concentrated spray pattern’ surrounding the heating surface. This `ring nozzle assembly’ as attached to a manifolded flexible steel hose assembly, is powered up and down by a pneu- matic drive cylinder. Dual timing relays allow complete control for 30 second cycle duration and intervals specific to each application. Final results are controlled double cleaning action, insuring that the maximum Btu recovery and anticipated savings are achieved. LIQUID TEMPERATURE CONTROL (optional) Operating Sequence: During a cold startup the exhaust bypass will be powered to the normal operating position. As the liquid temper- ature rises and approaches a preset point, the exhaust bypass damper will begin to move to the temperature control position. When the desired temperature is completely satisfied the damper actuator will move to the maximum open position, bypassing 99% of the exhaust flow (100% bypass cannot be attained due to some leakage and residual heat in contact with the fin tubing). Included is a 4-20 mA output controller, thermocouple, thermocouple weld and wire, and modulating bypass actuator installed, wired, and tested, for a single 120 volt, 1ph, 60hz power connection. Pneumatic Drive Cylinder (1/4 NPT air 80 psig connection) Flexible Steam Hose with Actuated Steam Valve (steam or air inlet connection) Traveling Nozzle Ring Assemblies NEMA 12 Control Panel (single 120v. 60hz 1ph power connection) exhaust heat recovery HRSR: SPECIFICATION A general specification, shown as a guide for design & construction. 1.0 General Design: 1.1 Furnish and install a heat recovery silencer radial (HRSR) in the exhaust duct of the engine in accordance with the following speci- fications as designed and manufactured by Cain Industries, Inc. 1.2 The HRSR shall be a light weight design for easier installation, rectangular with counterflow heat transfer design. 1.3 The HRSR shall be designed to include as standard, an external Exhaust By-Pass Assembly to provide for: full emergency by- pass, requiring no additional exhaust piping for controlling either: Turn Down Performance - Excessive flue gas back pressure due to fouling. 1.4 A manual bypass adjusting plate and arm assembly shall be provided to lock the damper assembly in a desired operating position (optional: modulating damper assembly). 1.5 The HRSR shall have removable, gas tight inspection doors, providing complete access to the entire heating surface for inspection, tube removal, and/or cleaning (optional hinged doors available). 1.6 The HRSR must be capable of being drained completely when mounted in the vertical or horizontal position. 1.7 Header manifolds for low liquid flow pressure drop shall be provided and shall have connections, screwed or flanged as specified. Liquid inlet and outlet pipe connections greater than 2" shall be flanged. The liquid header manifolds shall also contain 3/4" NPT connections for venting, draining, and/or safety relief valves as required. 1.8 The design of the vessel itself shall be such that no tube to tube, or tube to header joint welds shall be in contact with the exhaust stream so to minimize potential vessel failure. 1.9 The finned tubing shall be a single row design for ease of cleaning and inspection. 2.0 Construction: 2.1 Design Pressure (water side): 150 PSIG @650 F.; Test Pressure: 225 PSIG; Max. Flue Gas Inlet Temperature: 1250 F.; Design Pressure (exhaust side): 10 inches water column 2.2 Tube: outside diameter: 1.0"; wall thickness: .085"; material: SA178 GrA. ERW 2.3 Fins: 0.030” thks. carbon steel, nickel brazed/welded to the tube 2.4 Headers: thickness: Sch 80; material: SA53 GrB 2.5 3" thickness factory installed, high temperature insulation shall be contained within the exterior less the liquid headers and exhaust bypass assemblies. 2.6 Exterior surfaces shall be 10ga. carbon steel seam welded and the inner casing shall be 304 stainless steel. 2.7 Special codes (optional): design specifications of ASME Code: Section VIII Division I; `UM', `U’, or `S’ symbol; National Board registered; CRN and/or CSA. 11 Flood jet nozzles together form a unique high velocity knifing action to allow full penetration of the complete heating surface. Traveling nozzle rings and concentrated spray provide superior sootblower cleaning 12 UTR1 Engine Exhaust Application • Capacity: 200kW – 10MW • Entering gas temps: to 1,600°F • Heat sink types: Process water, boiler feedwater, ethylene glycol, or thermal transfer fluids U-TUBE RECOVERY 1 The UTR1 is applied primarily where confined area restrictions vs heat transfer requirements must be considered as a priority, secondarily to the features the HRSR. Its compact industri- al design allows for maximum Btu recovery relative to the space allotted for installation. Finned tube spacings range from bare tube heating surface up through 8 fins per inch, depending on the fouling factor requirements. Standard fin to tube attachment using the nickel braze/weld fin-to-tube process allows no fin-to-tube separation to 2,000°F. The UTR1 can be located above the engine or on the floor for convenient installation. With over 170 standard configurations to choose from, the UTR1 can be designed to meet the closest pinch point requirements when installation space is not an issue. Easy access allows for quick removal of finned tube rows or core assemblies without disturbing the exhaust gas connections, and allows for routine inspections and/or cleaning requirements. OPTIONAL EQUIPMENT: • Inspection doors for easy access/cleaning • Exterior exhaust gas bypass and actuator assemblies • Exhaust piping to UTR1 transitions • Rotating Sootblowers (automatic/manual) Inspection door, fin tube removal Lifting lug H-Beam support 11/2 NPT condensate cleanout drain (optional) 3/4 NPT drain Inspection door (optional), heating surface cleaning Factory Insulation (optional): 2” - 6” thickness available Exhaust transition,(optional) ASME stamp (optional) 10ga. carbon steel exterior, seal welded Fin tube Rack Assemblies (spaced for accessible cleaning) -Tube materials: carbon steel, TP316 stainless -Fin materials: carbon steel, TP304, aluminum -Methods of finned tube attachment: nickel brazed, Al-Fuse, welded 3/4 NPT vent UTR1 SERIES FOR: LARGE ENGINE & COMPACT DESIGN Parallel piping flow arrangement for high liquid flow. Series piping flow arrangement MANUFACTURING PLANT,Mansfield, Ohio (3) Model UTR1-812B18SSP. Recovering Btu from (3) 7100 GSI Waukesha 1,150 kW natural gas engines; Reducing each 1,250°F @ 2,388 SCFM to 383°F; Raising 635 GPM engine jacket water from 235°F to 243.6°F Removable finned tube core assembly (spaced for accessible cleaning) -Tube materials: carbon steel, TP316 stainless -Fin materials: carbon steel, TP304 stainless -Methods of attachment: nickel brazed U-TUBE RECOVERY The UTR is applied where both rectangular configuration and heat transfer surface vs. performance is critical. The UTR can be located within the engine to meet crucial space limitations. There are 44 standard models available for selection to fit the most compact of spaces. With flexible exhaust gas connection sizes and locations, the UTR can adapt easily to an OEM packager’s design needs. The capability of removing the core assembly without disturbing the exhaust gas connections, makes cleaning and inspecting the finned tubing efficient. This is especially important when the combustion is a fuel oil type and could foul the heating surfaces. The rugged heat transfer core is made from SA178 boiler tubing and .25” thickness high grade carbon steel heater assemblies. The heat transfer materials can also be constructed of all stainless steel when exhaust temperatures entering exceeds 1250°F or when liquid temperatures entering are below 120°F. OPTIONAL EQUIPMENT: • Exterior exhaust gas bypass and modulating actuator assemblies MOBILE TRAILER,Venice, California Model UTR-630218CSS. Recovering Btu from a 33kW natural gas engine. Reducing 1,282°F @ 76 SCFM to 319°F; Raising 27 GPM 50% ethylene glycol from 190°F to 198°F 13 UTRexhaust heat recovery Carbon steel shell .25” thickness Stainless steel interior Factory insulation: 1,2, or 4” thickness (optional) 1” NPT condensate cleanout drain (optional) UTR SERIES FOR: SMALL ENGINE COMPACT DESIGN & HIGH LIQUID FLOW Exhaust connections: flange, butt, or NPT Engine Exhaust Application • Capacity: 15 – 300 kW • Entering gas temps: 400 to 1,600°F • Heat sink types: Engine jacket water, ethylene glycol, process water, or boiler water Removable core makes cleaning and maintenance easy 14 HRSA Engine Exhaust Application • Capacity: 15–150 kW • Entering gas temps: 400–1,600°F • Heat sink types: Engine jacket water, process water, boiler water, or ethylene glycol HEAT RECOVERY SILENCER AXIAL Specifically designed for small engine sizes, the HRSA waste heat recovery silencers are compact cylindrical heat exchangers designed for either dual or single exhaust small engines. There are 65 standard models available to meet the specific design- performance criteria. In addition to lowered exhaust noise, the unique coil type configuration and optional circulating pump allows for a secondary circulating liquid flow system. 1” NPT interconnecting piping, to and from a main liquid flow loop, provides for simple and less costly special piping modification changes. The required heat transfer surface coupled with a small water flow diversion from the main flow, adequately recovers desired Btu/hr performance and controlled outlet exhaust temperatures as required. An optional internal or external stainless steel exhaust bypass can also allow tempering or full control of the exit temperature when required. Stainless or carbon steel fin tube coil: (optional fixed or removable, ASME stamping) Condensate drain (vertical or horizontal position) Exhaust connections: flange, butt, or NPT Mounting brackets for vertical or horizontal operation Carbon steel shell, .13” thick- ness. (optional stainless and/or factory insulation) Stainless steel diverter drum (optional internal exhaust bypass) HRSA SERIES FOR: COMPACT CYLINDRICAL DESIGN The HRSA design utilizes full counter flow heat transfer for achieving very low outlet exhaust gas temperatures. All stainless steel construction for specific condensing applications is available. The HRSA can be mounted vertically or horizontally as required. The HRSA with its light weight construction and cylindrical configuration low- ers the exhaust from 1000°F to 300°F with a 25 dBA reduction while operating with natural gas or diesel fuel oil. The HRSA waste heat recovery silencers shown with the smaller engines such as a 460 cu.in. V8 shown above or a smaller Caterpillar engine shown below. 15 optional system equipment Cain Industries’ engineering team is available to propose the proper system components at competitive pricing. Upon review of your application, you can expect our proposal within 24 hours. It will include professionally engineered details showing equipment costs, savings analysis, computer generated economizer performance, CAD dimensional drawings, flow schematics, warranty, and a performance guarantee. No matter how small the micro-turbine or how large the engine, Cain Industries has the heat transfer equipment, optional components, and years of experience to provide the best solution. COMPONENTS FOR COMPLETE SYSTEMS: • Remote digital indicators and control packages • Pre-piped skid mounted circulation pump system packages • Boiler blowdown assemblies • Valves: shut off, relief, vent, drain, check • Steam stop and check valves • Pressure or temperature control valves • Bi-metallic or mercury thermometers • Expansion joints • Explosion hatch relief ports • Tanks: storage or expansion • Bypass damper actuators: pneumatic or electric, on/off or modulating, air or spring failsafe return EBULLIENT STEAM GENERATORS FROM ENGINE JACKET WATER The Exhaust Cooling Steam Generator (ECSG) as designed to produce low pressure steam (15 PSIG and under) from engine jacket water via natural circulation. They are available in a variety of tank sizes for horizontal or vertical installations. Standard design includes: ASME stamped steam flash tank built in accordance with Sec.VIII Div.I; shipped as a packaged unit including continuous water level feed control with low water cutoff, auxiliary low water cutoff, excess steam pressure switch, gauge glass assembly, surface and main blowdown assembly, vent valve, steam safety valve, steam pressure gauge, wall or floor mount. Basic customer connections for ease of installa- tion include: 150# steam outlet, 150# water outlet, 150# water/steam inlet, NPT Blowdown, & NPT Boiler feedwater. The unit shall be pre-piped and wired for a single 120v 1ph 60hz customer power connection. BOILER FEEDWATER TANK ASSEMBLY Cain Boiler feedwater systems are available in a variety of tank sizes, feedwater pump configurations, and optional water treatment assemblies. Packaged assemblies include: heavy wall tank as mounted on a 5' high rectangular tube structural steel stand with water level controls and low water cutout, gauge glass and thermometer, magnesium anode; (2) 2" NPT vents; 2" NPT condensate return; 1" NPT drain with shut off valve; Duplex or Triplex Boiler Feedwater Pump System; electrical control panel fully pre-wired with fused disconnect switches, magnetic starters, manual start-stop switches and indicating run lights for feedwater pumps and alarms; all interconnecting wiring from electrical control panel to each component, optional chemical feed system, and/or automatic water softening system; all interconnecting bypass piping, valves, gauges, fittings, etc. Primed, painted, and tested package is a complete, properly functioning assembly, ready for the customer’s primary connections of water, condensate return, and electricity. OUR UNIQUELY DESIGNED EXHAUST GAS BYPASS VALVES Cain Industries offers total exhaust gas control with high temperature modulating bypass and shut off valves. The valve assemblies offer precise exhaust temperature control and/or the design capability for exhaust isolation. Sizes ranging from 4” to 40” diameter are available in carbon steel and stainless steel for all engine temperatures. All valves are available with either electric or pneumatic control actuation, and emergency fail safe features. Four examples of typical combustion source types, and the results with a Cain Industries heat recovery system applied. ©2000, Cain Industries. All rights reserved.Printed in USA #90180 Your Authorized Cain Representative PO Box 189 W194 N11826 McCormick Dr. Germantown, WI 53022 262-251-0051 800-558-8690 sales@cainind.com www.cainind.com DATA without a Cain System Combustion Source: Hot Water Boiler Heat Sink ........................ Return Water Waste Exhaust Temp .................. 510°F Water Temp. Inlet ...................... 130°F Btu/hr Burner Input ............. 6,437,000 Fuel Type ......................... Natural Gas O2 Content .................................. 10% Excess Air ................................... 82% Combustion Efficiency ................... 75% Fuel Cost Per Therm ..................... $.60 Annual Operating Hours ............ 6,000 PERFORMANCE with a Cain System Model Selection ........................... C700 Circulating Water Flow .............. 20 gpm Final Exhaust Temp. ......................250°F Water Temp. Outlet ...................... 186°F Pressure Drop, Water ............... 5.0 psig Pressure Drop, Exhaust ........... 0.10” WC Btu/hr recovered .................... 560,900 Btu/hr saved ........................... 747,900 Total Cost Installed ....................$12,400 Payback ........................... 5.5 mo. Annual Return on Investment 217% Annual Savings ............... $26,880 DATA without a Cain System Combustion Source: 800 BHP Steam Boiler Heat Sink .................. Boiler Feed Water Waste Exhaust Temp. .................. 470°F Water Temp. Inlet ........................ 210°F Btu/hr Burner Input ............ 33,580,000 Fuel Type ........................... Natural Gas O2 Content ..................................... 6% Excess Air .....................................36% Combustion Efficiency ................. 78.9% Fuel Cost Per Therm ...................... $.60 Annual Operating Hours ............. 6,000 PERFORMANCE with a Cain System Model Selection ............ RTR-142H26ALS Boiler Feed Water Flow ...........55.2 gpm Final Exhaust Temp. ...................... 319°F Water Temp. Outlet ................... 263.3°F Pressure Drop, Water ................ 2.0 psig Pressure Drop, Exhaust ........... 0.47” WC Btu/hr recovered .................. 1,417,000 Btu/hr saved ........................ 1,776,000 Total Cost Installed ................... $37,700 Payback ........................... 7.1 mo. Annual Return on Investment 170% Annual Savings .............. $ 63,936 DATA without a Cain System Combustion Source:1,250 kW Engine Heat Sink ............. 50% Ethylene Glycol Waste Exhaust Temp. ................. 968°F Water Temp. Inlet .......................195°F SCFM .......................................3,667 Fuel Type ......................... Natural Gas O2 Content ................................. N/A Excess Air .................................. N/A Combustion Efficiency (relative) ..... 78% Fuel Cost Per Therm ..................... $.60 Annual Operating Hours ............ 6,000 PERFORMANCE with a Cain System Model Selection ..........HRSR-336B28CSS Circulating Liquid Flow ............ 175 gpm Final Exhaust Temp. ......................330°F Water Temp. Outlet ...................... 232°F Pressure Drop, Water ............... 8.3 psig Pressure Drop, Exhaust ...........1.75” WC Btu/hr recovered .................. 2,863,000 Btu/hr saved ........................ 3,670,000 Total Cost Installed ................. $ 57,960 Payback ........................... 5.3 mo. Annual Return on Investment 228% Annual Savings ............ $ 132,120 DATA without a Cain System Combustion Source:1,700 kW Engine Heat Sink ....................... Process Steam Water Exhaust Temp. .................. 783°F Water Temp. Inlet ......................... N/A SCFM ....................................... 5,222 Fuel Type .......................... Natural Gas O2 Content ...................................N/A Excess Air ................................... N/A Combustion Efficiency (relative) ...... 78% Fuel Cost Per Therm ..................... $.60 Annual Operating Hours ............ 6,000 PERFORMANCE with a Cain System Model Selection ........ ESG1-620D18CSS Operating Steam Pressure ........150 PSIG Final Exhaust Temp ...................... 428°F Boiler Horsepower ..................... 68 BHP Equivalent Evaporation .......... 2,339 pph Pressure Drop, Exhaust .......... 1.55” WC Btu/hr recovered .................. 2,269,000 Btu/hr saved ........................2,908,000 Total Cost Installed .................$113,600 Payback ......................... 13.0 mo. Annual Return on Investment 92% Annual Savings ............. $104,688 Savings comparison data is based on a conservative fuel cost per therm (100,000 Btu), and approximate annual operating hours. Your results may vary. Total Cost Installed includes: Equipment, shipping, and complete installation. Contact Cain Industries for your FREE savings analysis proposal. Quotation S12-0479 TRANSMITTAL COVER SHEET Date: 9/28/2012 # of Pages: 9 (including cover sheet) To: Company: Electric Power Systems Attn: Bob Whealy Phone: (907) 646-5132 Fax: Email: bwhealy@epsinc.com From: Submitted by: David Siedenburg Subject: Electric Power Systems – Dutch Harbor Power Plant Ref #: 56370 Message: As requested, please find your proposal attached for a different model for the new conditions. The Stack Corrosion Control Assembly (SCCA) has been added because of the customer’s exhaust gas temperature concerns. Please see the “System Descriptions” section of the proposal. Cain recommends that they use the exhaust gas bypass to control the exhaust gas temperature of the HRSR, and not attempt to control it by varying liquid flow rtes. We recommend this method in order to reduce the possibility of localized boiling, over heating of the liquid, and deposits on the inside of tubes that can be the result of too small of a liquid flow rate. The quoted price is for (1) unit, F.O.B. Cain Industries. Shipment is typically in approximately 10-12 weeks after submittal approval for 1 unit. The terms of sale, Bulletin #25500 form part of this proposal. See this bulletin for payment terms. X INQUIRY: web e-mail phone OUT: fax X fax mail overnight e-mail file other PO Box 189 •W194 N11826 McCormick Dr. •Germantown, WI 53022 •USA •262-251-0051 •800-558-8690 •FAX: 262-251-0118 •sales@cainind.com •www.cainind.com “Manufacturing Waste Heat Transfer Products To Save Energy” Boiler Economizer Systems •Gas & Diesel Cogeneration Systems •Fume Incineration Systems Exhaust Steam Generators •Finned Tubing 12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery Glycol/Water Loop Heater Ref: 56370 Date: 9/26/2012 Rep: 999 Page: 1 Rev: 0 Dehn Engineering Sales Co. P.O. Box 68183 Seattle, WA 98168 Attn:David Siedenburg Ph:(206)243-3123 Fax:(206)243-3124 Engineered For:Engineered For:Engineered For:Engineered For: Electric Power Systems 3305 Arctic Blvd., Suite 201 Anchorage, A 99503-4575 Attn:Bob Whealy Ph:(907)646-5132 Dutch Harbor Power Plant nalaska, A End User:End User:End User:End User: Cain Industries is pleased to propose the following HRSR model exhaust heat recovery unit to recover exhaust heat from a diesel fired, Wartsila 12 32 engine. The recovered heat will be transferred to a 60/40 ethylene glycol/water loop . The HRSR heat recovery unit features: a full port exhaust gas bypass individually removable, type 316 stainless steel tubes with 304 stainless steel fins a stainless steel interior shell 3 of factory insulation (less liquid header assemblies) a 10 gauge carbon steel exterior shell and a hinged full face access door(s) for inspecting and/or cleaning the finned tubes. The finned tubes are compression fitted to the liquid headers. Tube replacement does not require welding. The exhaust gas bypass is stainless steel with stainless steel flanges. The heat exchanger section has 3 thickness factory insulation. The exhaust gas bypass will have 3 thickness blanket wrap insulation. The liquid headers are not insulated and field insulating is recommmended. The iquid Temperature Control Assembly ( TCA) automatically modulates the exhaust gas bypass to control the temperature of the heated glycol/water leaving the heat exchanger. A desired maximum temperature is entered on the digital indicating controller. The controller has a continuous temperature display, and ODB S communications which will allow remote monitoring of the process variable and control of the set point. The controller will be dual input and will switch to exhaust gas temperature control if the exhaust System Description:System Description:System Description:System Description: PO Box 189 •W194 N11826 McCormick Dr. •Germantown, WI 53022 •USA •262-251-0051 •800-558-8690 •FAX: 262-251-0118 •sales@cainind.com •www.cainind.com “Manufacturing Waste Heat Transfer Products To Save Energy” Boiler Economizer Systems •Gas & Diesel Cogeneration Systems •Fume Incineration Systems Exhaust Steam Generators •Finned Tubing 12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery Glycol/Water Loop Heater Ref: 56370 Date: 9/26/2012 Rep: 999 Page: 2 Rev: 0 System Description: (cont)System Description: (cont)System Description: (cont)System Description: (cont) gas temperature falls below a preset minimum temperature (355F). Either process variable, maximum liquid temperature out or minimum exhaust gas temperature out, can be set remotely.Contacts will be provided to remotely drive the exhaust gas bypass to the bypass position. The panel is approved. The Cain Timed Automatic Sootblower has ring nozzle assemblies that travels the length of the heat exchanger while jetting steam or air at the finned tubes. The travelling action of the sootblower, along with the single row arrangement of the finned tubes, ensure coverage of the finned tubes by the steam/air jets. The condensate drain connection will be piped from the center to the side of the unit. The access door will be divided into (2) doors in order to reduce the door swing clearance. A blind flange to manually separate the exhaust gas bypass section from the heat exchanger section is included. The annual operating hours and the cost per 100,000 Btu of diesel fuel were assumed. The exhaust pipe diameter was assumed. PO Box 189 •W194 N11826 McCormick Dr. •Germantown, WI 53022 •USA •262-251-0051 •800-558-8690 •FAX: 262-251-0118 •sales@cainind.com •www.cainind.com “Manufacturing Waste Heat Transfer Products To Save Energy” Boiler Economizer Systems •Gas & Diesel Cogeneration Systems •Fume Incineration Systems Exhaust Steam Generators •Finned Tubing 12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery Glycol/Water Loop Heater Ref: 56370 Date: 9/26/2012 Rep: 999 Page: 3 Rev: 0 Quotation:Quotation:Quotation:Quotation: Qty Part #U/M Description 1 EACH HRSR-472J24SSS -INCLUDING: Full Port Exhaust Gas Bypass Sound Attenuation Stainless Inner Wall 10ga. Carbon Steel Exterior Single Fintube Row Design 3"Thickness Factory Insulation -SYSTEM COMPONENTS: 1 912055 EACH HRSR Hinged Access Door Assy. 1 962020 EACH ASME Stamp-SEC.VIII;DIV.I(`U') 1 971240 EACH Timed Auto Stblwr.: HRSR-472H 112 912100 EACH C.F.T.: Price x Tube Qty. 1 966040 EACH Liq. Temp. Ctrl. Assy. Elec. 1 430602 EACH 1" NPT ASME Relief Val:150 PSI 2 467205 EACH T-METER,5"Dial 200-1000'F 2 480190 EACH 3"Dial, bimetal 50-300 w/well ------------- TOTAL PRICE (USD) $247,277 ANNUAL RETURN ON INVESTMENT 235% 5 YEAR SAVINGS $2,905,760 10 YEAR SAVINGS $5,811,520 PAYBACK PERIOD, MONTHS 5.1 Terms of Sale:Terms of Sale:Terms of Sale:Terms of Sale: * Estimated Shipping: 10-12 weeks after submittal approval * Payment Terms: See Bul. #25500 * See Bulletin 25500 including 'Warranty and Performance Guarantee'. 17:25:jr PO Box 189 •W194 N11826 McCormick Dr. •Germantown, WI 53022 •USA •262-251-0051 •800-558-8690 •FAX: 262-251-0118 •sales@cainind.com •www.cainind.com “Manufacturing Waste Heat Transfer Products To Save Energy” Boiler Economizer Systems •Gas & Diesel Cogeneration Systems •Fume Incineration Systems Exhaust Steam Generators •Finned Tubing 12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery12V32 Engine Exhaust Heat Recovery Glycol/Water Loop Heater Ref: 56370 Date: 9/26/2012 Rep: 999 Page: 4 Rev: 0 Waste Heat Exhaust:Waste Heat Exhaust:Waste Heat Exhaust:Waste Heat Exhaust: Primary Fuel Type: Diesel Heat Source: Wartsila 12V32 engine Secondary Fuel Type: Exhaust Flow: Horizontal/Vertical Fuel Cost per 100,000 BTU (USD): $2.50 Heat Sink: 50/50 propylene glycol/water loop Model: HRSR-472J24SSSModel: HRSR-472J24SSSModel: HRSR-472J24SSSModel: HRSR-472J24SSS Overall Configuration, inches 104x91 Overall Height, inches 322 Liquid Connection 8 Exhaust Connection 36" Dia. Dry Weight, lbs. 29400 Wet Weight, lbs. 30190 Surface Area, Ft2 3,953 Design Pressure, PSIG 150 Hydrostatic Test Pressure, PSIG 225 @ Design Temperature, °F 550 Maximum Entering Temperature, °F 800 Performance:Performance:Performance:Performance: Load 1Load 1Load 1Load 1 Load 2Load 2Load 2Load 2 Load 3Load 3Load 3Load 3 Load of Maximum Output, %100% 75% 50% Exhaust Entering Temp, °F 723° 626° 669° Exhaust Flow Rate, SCFM 17900 15300 11100 Exhaust Leaving Temp, °F 375° 344° 331° Pressure Drop " W.C. Max 1.54 1.10 0.65 Liquid Entering Temp, °F 250.0° 250.0° 250.0° Liquid Flow Rate, GPM 351.0 221.0 185.0 Liquid Leaving Temp, °F 298.6° 302.6° 304.6° Pressure Drop, PSIG 12.69 5.45 3.95 Heat Recovered, MBTU/Hr 7770 5287 4597 Savings:Savings:Savings:Savings: Heat Saved (x 100 MBTU/Hr)77.697 52.866 45.970 Annual Hours of Operation 219 3504 657 ANNUAL SAVINGS (USD)ANNUAL SAVINGS (USD)ANNUAL SAVINGS (USD)ANNUAL SAVINGS (USD) $581,152$581,152$581,152$581,152 DATE: 9/26/2012 REF#: 56370563705637056370 FOR: Dehn Engineering Sales Co. RE #: 0000 c/o: Cain Industries, Inc. ODE : HRSR-472 24SSS HEAT SO RCE: Wartsila 12 32 engine A. 723 F B. 375 F C. 250 F D. 299 F E. 104x91 F. 322 . 8 CO . H. 36 Dia. CO . 3,953H.S. 29400 # W T 150 PSI 800 TE P. ✔ ✔ ✔ ✔ ✔ ✔ ✔ 19" © 2011 Cain Industries, Inc. Cain Industries, Inc. PO Box 189 Germantown, WI 53022 • USA • 262-251-0051 • 800-558-8690 • 262-251-0118 Fax • sales@cainind.com The terms of the attached Limited Warranty are included in these Terms of Sale and are incorporated by reference herein. The following “Terms of Sale” forms as a part of the Cain Industries equipment proposal as attached herein.All proposed pricing is quoted F.O.B. factory. All pricing is quoted in U.S. currency. QUOTED DELIVERY TIME: Delivery times quoted are appropriate for various product lines, and based on condi- tions at the time of quotation. Cain Industries, Inc. will, in good faith, attempt to deliv- er the equipment within the time quoted. In no case shall Cain Industries, Inc. be liable for incidental or consequential damages resulting from failure to meet requested or quoted delivery schedules. Quoted delivery time is based from the date of receipt of an approved written purchase order including written authorization to proceed with fab- rication and the initial down payment if required, or from date of receipt of submittal drawings when required (less 10 working days). OFFER EXPIRATION: All offers expire 60 days from the quotation date unless otherwise stated and are sub- ject to cancellation by Cain Industries, Inc. at any time prior to the formal acceptance of our offer to furnish equipment quoted. SUBMITTAL DRAWINGS: Submittal drawings are issued 5-10 working days from receipt of written purchase order, when required by either Cain Industries and/or the Buyer, and must be returned (marked “Approved for Production”, signed, and dated) in order to initiate production. Production cannot begin until the approved submittal drawings are returned. SHIPMENT OF GOODS: Unless otherwise specifically agreed, all shipments are made F.O.B. Factory via "best way" and shipped freight collect. Cain Industries, Inc. responsibility ceases upon acceptance by the carrier. SHOULD GOODS BECOME LOST OR DAMAGED IN SHIPMENT, THE PURCHASER OR RECIPIENT OF THE GOODS MUST IMMEDI- ATELY NOTIFY AND PLACE CLAIM WITH THE CARRIER, ADVISE CAIN INDUS- TRIES, INC. OF ANY DAMAGE OR DISCREPANCY, AND OBTAIN AUTHORIZATION FOR RETURN OR REPLACEMENT. As a courtesy, Cain Industries, Inc. will assist in tracing and recovering lost goods and the collection of just claims, but cannot guaran- tee safe delivery. Loss or damage in shipment does not release the purchaser from payment of the total invoice. PAYMENT-ESTABLISHED ACCOUNTS: Payments for established accounts with a credit limit are due on or before the Net 30 days from date of invoice due date, and coinciding with shipment date and/or ‘ready for shipment date’. EXPEDITING: Expediting charges may be issued in order to improve delivery depending on the shorter delivery time required. Contact Cain Industries for pricing for the best possi- ble delivery. STORAGE: When the equipment is ready for shipment, it will be shipped to the ‘ship to’ address noted on the Sales Order, unless other wise indicated. Should there be a request to hold the equipment beyond the ‘ready for shipment date’, Cain will store the equipment for up to 30 days at no cost providing storage space is available. Contact Cain Industries for storage costs when equipment is expected to be stored for more than 30 days. If storage space is unavailable, the buyer agrees to make provisions to receive the equipment when it becomes ready for shipment. MINIMUM BILLING: The minimum order is $100.00, plus shipping costs. CREDIT LIMIT: Accounts over credit limit will be on a "Cash with Order" basis until account is brought to below "Credit Limit" status. Special circumstances may occur where credit limits may be adjusted for companies with past credit history satisfactory to Cain Industries, Inc. TAXE S OR SURCHARGES: Quoted prices do not include sales, use, excise, occupation, processing transportation or other similar taxes which Cain Industries, Inc. may be required to pay or collect with respect to any of the quoted materials. Such taxes which are or may be incurred shall be paid by the purchaser. PAYMENT-NEW ACCOUNTS: An initial purchase order received from a new account shall require a 50% down pay- ment with the order, receipt of the completed credit application for immediate process- ing, and the balance due prior to shipment; or 30% with purchase order and receipt of the completed credit application (order will be held until credit limit has been established) in conjunction with credit limit and/or progress payment schedules. Allow a 3 week pro- cessing period to complete the credit check. PAYMENT-ORDERS OUTSIDE THE UNITED STATES: For purchase orders received wherein the the final installation and/or the Buyer is locat- ed outside the United States, payments shall be made according to the guide lines as set forth herein. It is recommended that a Letter of Credit be created and issued with the purchase order for immediate order processing. All costs associated with interna- tional payments such as but not limited to: proforma invoicing, letter of credit, agents of record processing, currency adjustments, tariffs and special taxes, etc. shall be the responsibility of the purchaser. All payments shall be made in U.S. currency and shall be paid in full prior to shipment outside the United States. SERVICE CHARGE: A 2% per month service charge will be assessed on all past due amounts. PROGRESS PAYMENT SCHEDULES: The following are payment schedules for orders exceeding credit limit: •For purchase orders of $25,000 to $50,000: -30% due with purchase order -30% due at 45 days from receipt of approval drawings -Balance due 30 days from shipment. •Over $50,000 or required for the ESG product orders: -15% due with purchase order -15% due with submittal approval drawings -30% due 45 days from receipt of approved submittal drawings -30% due prior to shipment -Balance due 30 days from shipment. CANCELLATION AND CHANGES: As many Cain Industries, Inc. products are manufactured and/or adjusted "to order", orders accepted and acknowledged by Cain Industries, Inc. are not subject to change or cancellation without prior consent of Cain Industries, Inc. Order quantity reductions or cancellations, if granted, will be subject to cancellation charges consistent with components "restockability versus made to order specifications" percent of production completion, etc. EQUIPMENT STARTUP & SERVICE: Pricing for equipment requiring startup or service: $1100 per day for installations located within the continental United States; $1300 per day for installations located in Canada; all other installation locations are quoted per application. Travel, lodging, and subsistence expenses are in addition. Startup can only be initiated upon receipt of completed Pre-Startup form.ESG & ESG1 boiler startups must be completed by authorized Cain personnel to allow the warranty to become effective, unless otherwise stated in a written agreement issued by Cain Industries to the Buyer. RETURN OF GOODS FOR WARRANTY REPAIR, REPLACEMENT, OR CREDIT: Authorization to return goods for any reason must be obtained from Cain Industries, Inc. prior to the return of the shipment being made. All items returned for repair, replacement or credit shall be returned freight prepaid. Freight collect shipments will not be accept- ed. A 30% "minimum" restocking charge will be made on all items returned for credit. Cancellation and/or restocking charges will apply to the balance of the order pending with a maximum of 90% as determined at the point of cancellation dependent on the work in process. Quantities shipped prior to the point of cancellation shall be issued an additional invoice for the difference in price breaks between the original quantity ordered and the total shipped up to the point of cancellation. PROPRIETARY DATA: All manufacturing drawings, specifications and technical material submitted by Cain Industries, Inc. are the property of Cain Industries, Inc. and are to be considered as con- fidential. Except for its original intent the submittal information supplied herein attached cannot be copied, transferred, or used in any way without the express written authori- zation from Cain Industries, Inc. LIMITATION OF REMEDIES: Cain’s liability is limited exclusively to its obligations under the attached Limited Warranty, the terms of which are incorporated by reference herein. Buyer agrees that in no event will Cain be liable for cost of processing, loss of profits, or any other conse- quential or incidental damages or cost of any kind resulting from the order and or use of its product, whether arising from breach of warranty, non-conformity to order specifica- tions, delay in delivery or any other loss sustained by buyer. TERMS OF SALE Bul. 25500 © 2008 Cain Industries, Inc. Cain Industries, Inc. PO Box 189 Germantown, WI 53022 • 262-251-0051 • 800-558-8690 • 262-251-0118 Fax • sales@cainind.com LIMITED WARRANTY AND PERFORMANCE GUARANTEE Bul. 25500 LIMITED WARRANTY AND PERFORMANCE GUARANTEE Cain Industries, Inc. warrants all products manufactured to be free from defects in material or workmanship under normal use and conditions for a period of one year from the date of startup or 18 months from date of shipment from our factory whichever occurs first. Cain Industries liability under this warranty to the buyer shall be limited to Cain's decision to repair or replace, all its factory items deemed defective after inspection at the factory or in the field. When field service is deemed necessary in order to determine a warranty claim, the costs associated with travel, lodging, etc. shall be the responsibility of the buyer except under prior agree- ment for a field inspection. All warranty claim requests must be initiated with a Material Return Authorization (MRA) number for processing and tracking purposes. The MRA number shall be issued to the buyer upon Cain’s receipt of a purchase order for replacement component(s) required immediately and prior to warranty claim approval and/or a field inspection. No agent or employee of Cain Industries, Inc. has any authority to make verbal representation or warranty of any goods manufactured and sold by Cain Industries, Inc. without written authorization signed by an executive officer of Cain Industries, Inc. Cain Industries, Inc. warrants the equipment designed and fabricated to perform in accordance with the specifications as stated in the propos- al for the equipment, and while the equipment is in new and clean condition and properly operated within the specific design limits for that equipment. Should any piece of equipment designed by Cain Industries, Inc. not meet performance requirements when determined by standard test procedures, Cain will make correc- tions it deems necessary at its option under the limitations of this warranty. Any alterations or repair of Cain equipment by personnel other than those directly employed by Cain shall void this warranty unless otherwise stated under a specific written guideline issued by Cain Industries to the buyer. The ESG1 and ESG boiler startup must be completed by authorized Cain personnel to allow the warranty to take effect unless otherwise stated in a written agreement issued by Cain Industries to the buyer. This warranty does not cover damage resulting from misapplying Cain Industries products and/or improper installation. This warranty does not cover corrosion resulting from the effects of physical or chemical properties of water, steam or the liquids or gases used in the equipment. This warranty does not cover damage resulting from combustion source back- fires or explosions which exceed Cain Industries product specific maximum design pressure and/or when explosion hatches are not properly installed where required. This warranty does not cover damage resulting from excessive vibration resulting from isolating vibration protection not properly installed where required. This warranty does not cover damage resulting from expansion due to expansion joints not properly installed where required. This warranty does not cover damage or lost performance due to combustion source relat- ed deficiency such as soot build up on the heating surface. Cain makes no other warranties of performance or product either expressed or implied which extends beyond the limits contained within this instrument. All acceptance tests shall be conducted at the buyer’s expense. Any such tests shall be made when the equip- ment is new, clean, and before being placed into service, and shall be made within 120 days of delivery. Where field test are required, the following procedures are to be used. The exhaust gas and liquid inlet and outlet temperatures shall be recorded simultaneously and measured at a minimum distance of 6 pipe diam- eters from the equipment. Exhaust gas and liquid volumes shall be determined by actual measurement, if practical, or by calculations if necessary. All factors of O2, CO2, excess air, full input, altitude and the oper- ating efficiency of the primary direct fired unit, shall be incorporated in the final determination and calculation of the volume of the exhaust gas. The expense incurred for such test shall be the responsibility of the buyer and a copy of the test procedures conducted, data accumulated, and calculations used to arrive at the final results shall be submitted to Cain Industries. All workmanship, material and performance requirements shall be deemed to have been met if a contrary report has not been furnished within 120 days of delivery. This “Limited Warranty and Performance Guarantee” forms as a part of the Cain Industries equipment proposal as attached herein. IN NO EVENT SHALL SELLER BE LIABLE FOR CLAIMS (BASED UPON BREACH OF EXPRESS OR IMPLIED WARRANTY, NEGLIGENCE OR OTHERWISE) FOR ANY DAMAGES, WHETHER DIRECT, IMMEDIATE, INCIDENTAL, FORESEEABLE, CONSEQUENTIAL, OR SPECIAL.