HomeMy WebLinkAboutShungnak Heat Recovery Project Feasibility Study - Sep 2016 - REF Grant 7013011HEAT RECOVERY FEASIBILITY STUDY
SHUNGNAK, ALASKA
PREPARED BY:
Alaska Native Tribal Health Consortium
Division of Environmental Health and Engineering
4500 Diplomacy Drive, Suite 454, Anchorage AK 99508
Phone (907) 729-3600 / Fax (907) 729-4090
September 16, 2016
36
1.0 EXECUTIVE SUMMARY .............................................................................................. 1
2.0 INTRODUCTION .......................................................................................................... 1
2.1 Existing Heat recovery System: ................................................................................ 1
2.2 Proposed heat recovery system: .............................................................................. 2
3.0 OVERVIEW .................................................................................................................. 3
4.0 ESTIMATED RECOVERED HEAT UTILIZATION ....................................................... 3
5.0 HEAT RECOVERY SYSTEM DESCRIPTION AND OPERATION: ............................. 4
5.1 Avec Plant Tie-In....................................................................................................... 4
5.2 Arctic Piping (Recovered Heat Loop) ....................................................................... 5
5.3 Community Buildings Tie-In ...................................................................................... 5
5.4 Community Store Tie-In ............................................................................................ 5
5.5 Rights-Of-Way Issues ............................................................................................... 6
5.6 Potential Risks and Unknowns ................................................................................. 6
6.0 ASSUMPTIONS ........................................................................................................... 6
7.0 PRELIMINARY EQUIPMENT SELECTIONS ............................................................... 6
7.1 Heat Exchangers ...................................................................................................... 6
7.2 Arctic Piping .............................................................................................................. 7
7.3 Circulating Pumps ..................................................................................................... 7
7.4 Expansion Tanks ...................................................................................................... 8
7.5 Glycol Makeup .......................................................................................................... 9
7.6 Controls ..................................................................................................................... 9
8.0 CONCLUSIONS AND RECOMMENDATIONS .......................................................... 10
APPENDIX – A: Conceptual Design ..................................................................................... 12
APPENDIX – B: Graphs ....................................................................................................... 18
APPENDIX – C: Calculation ................................................................................................. 21
APPENDIX – D: Cost Estimation .......................................................................................... 27
37
1
1.0 EXECUTIVE SUMMARY
The existing Shungnak power plant is planning on installing new CAT® SR4B generator with
CAT 3456 engine with marine manifold to replace their outdated generators. At present
power plant provides recovered heat to water treatment plant (WTP) and City office. Once
new generator is installed there will be excess recovered heat to be utilized. The Clinic,
Village Public Safety Officer (VPSO) Housing, New Cookhouse, Community Store, and
School were evaluated for excess heat recovery potential.
Two options were considered for the analysis. At present due to leaks in buried heat recovery
pipe to City office, City office has not be able to fully benefit from existing heat recovery
system. Total project cost for both option include cost to provide new supply and return pipe
to city office. Old heat recovery line will be abandoned and glycol in old lines will be salvaged.
Option 1 - Supplying excess recovered heat to Clinic, Cookhouse, VPSO housing
Community store, and city office. The total estimated annual heating fuel consumption is
estimated to be approximately 14,618 gallons. Heat recovery system is expected to reduce
the fuel consumed by 14,036 gallons. The expected annual savings is $ 126,323.
The payback is based on a 2015 average fuel price of $9/gallon and an estimated 2016
project cost of $ 1,218,132. Assuming construction of the heat recovery system begins in
2016, the design and construction cost with 2 years of 3% escalation is $ 1,292,316. The
simple payback time is 10.23 years
Option 2 - Supplying excess recovered heat to school and city office. The total estimated
annual heating fuel consumption is estimated to be approximately 26,666 gallons. Heat
recovery is expected to reduce the fuel consumed by 19,518 gallons. The expected annual
savings is $ 70,656.
The payback is based on a 2015 average fuel price of $3.62/gallon and an estimated 2016
project cost of $ 865,046. Assuming construction of the heat recovery system begins in 2016,
the design and construction cost with 2 years of 3% escalation is $ 917,727. The simple
payback time is 12.99 years.
2.0 INTRODUCTION
The National Renewable Energy Laboratory (NREL) has collaborated with the Alaska Native
Tribal Health Consortium (ANTHC) to review the feasibility of providing excess recovered
heat from the existing Shungnak power plant to the existing School, Clinic, Community Store,
VPSO Housing, and new Cookhouse in Shungnak. ANTHC also developed a budgetary
project cost estimate based on Force Account Construction, including Engineering and
Construction Administration.
2.1 Existing Heat recovery System:
Since 2013 Shungnak power plant is providing recovered heat to WTP and City office. WTP is
seeing the fullest benefit of recovered heat as it hardly burn any fuel oil for heating.
Recovered heat covers City office’s 60-80% of space heat demand.
38
2
2.2 Proposed heat recovery system:
Alaska Village Electric Cooperative (AVEC) is planning on installing new CAT® SR4B
generator with CAT 3456 engine with marine manifold to replace their outdated generators.
This will be the biggest generator in the power plant. Once the new generator is installed,
there will be excess recovered heat that can be utilized to heat community building and
reduce diesel fuel consumption. The estimated cost of installation of this new generator is
estimated at $429,200 according to AVEC. This cost is not included as part of this feasibility
study.
Two options have been analyzed to utilized excess recovered heat. Heat demand is based on
energy audits conducted by Jim Fowler, Energy Audits of Alaska.
Option 1 – Supply excess heat to Clinic, Community store, VPSO housing, New
Cookhouse.
Existing Clinic currently is hydronically heated with fuel fired boilers. The total heating
demand for clinic is around 200 MBH. Excess recovered heat can cover entire heating
demand of the clinic.
Existing VPSO building is also heated hydronically with fuel fired boiler. The total heating
demand is around 80 MBH. Excess recovered heat will cover entire heat demand of this
building
New Cook house is a community gathering center. This facilities is currently under
construction. It is assumed that this building will be heated hydronically with fuel fired boiler
and estimated heating demand for this building will around 100 MBH.
Any remaining heat will be used by existing Community store. A hydronic unit heater will be
installed in store. This unit heater will be supplementary heat source to currently installed fuel
fired Toyo stove. Store has around 50 MBH heating load
Option 2 – School
Calculated fuel consumption of existing school is approximately 25,852 gal / year and is
hydronically heated with oil fired boilers. Sensible heating from any or all electrical equipment
and lighting fixture is excluded from calculation. A site investigation of the facility has not been
done at this time, but it is anticipated that space can be found for a heat recovery heat
exchanger, associated pumps and controls.
At present due to leaks in buried heat recovery pipe to City office, City office has not be able
to fully benefit from existing heat recovery system. Location of leak is unknown thus digging
out buried pipe to repair will be expensive. Since both option considered to new heat recovery
system will have heating pipe passing nearby City Office, It was concluded that installing new
branch pipe to provide new connection to City office will be cheaper option than repairing the
existing pipes. Total project cost for both option include cost to provide new supply and return
pipe to city office. Old heat recovery line will be abandoned and glycol in old lines will be
salvaged.
39
3
3.0 OVERVIEW
The purpose of this study is to provide an estimate of the excess heat that can be recovered
from the AVEC power plant diesel engines and used to offset heating oil consumption at the
nearby community buildings. Useable recovered heat is quantified in gallons of heating fuel
saved using a gross heating value of 134,000 BTU per gallon of #1 arctic diesel fuel and an
overall boiler efficiency of 70% for a net heating value of 107,000 BTU per gallon.
The public buildings eligible for heat recovery are located within 800-feet radius of the AVEC
power plant. This analysis evaluates the potential to provide recovered heat to the nearby
public buildings. The estimated average annual heating fuel consumption for the nearby
public buildings is in range of 14,000-25,000 gallons. Existing roadways were utilized for heat
recovery pipe routing in order to minimize ground disturbance, avoid additional environmental
impacts, utilize existing right of ways.
4.0 ESTIMATED RECOVERED HEAT UTILIZATION
A heat recovery utilization spreadsheet has been developed to estimate the recoverable heat
based on monthly total electric power production, engine heat rates, building heating
demands, heating degree days, passive losses for power plant heat and piping, and arctic
piping losses. Power generation data from AVEC for fiscal year 2015 is used in the
spreadsheet.
At present Shungnak Power plant has 4 generators (John Deer JD 6619, Caterpillar
CAT3406B, Detroit Diesel S60 and Cummins and Cummins CMS K19G2). Generator-1 (JD
6619) and Generator-2(CAT 3406) hardly runs. Generator-4(DD S60) and Generator-5 (CMS
K19G2) are primary generator. Generators 4 and 5 run one at a time, while the other acts as
stand by.
AVEC is working on securing funds to install new CAT® SR4B generator with CAT 3456
engine with marine manifold to replace their outdated generator (JD 6619 and CAT3406B).
Existing heat recovery system supplies heat to WTP and City Office. Once this new generator
is installed there will be excess recovered heat beyond supplying heat to WTP and City office.
Per Mr. Forest, AVEC, this new generator will be primary generator even if it runs at 30-40%
of its peak capacity.
This analysis assumes AVEC will install part or heat recovery heat exchanger and pump on
their side of heat exchanger and provides two flanges to connect to existing heat recovery
system.
The estimated heat rejection rate for the power plant generator and run time was used to
estimate available recovered heat. For this feasibly study Heating degree-days for the nearby
community of Kobuk were utilized for this site. Part of the heat recovery arctic pipe will be
buried and part is assumed to be routed above grade for connection into existing facilities. All
power plant hydronic piping will be insulated with minimum of 2-inches of insulation. Past
experience was used for estimating the heating load for the power plant, which includes the
power house, an insulated storage module, and one living quarter’s module.
40
4
The heat recovery calculations spreadsheet uses monthly heating degree-days to distribute
annual fuel consumption by month. The end-user hourly heat load is compared to the hourly
available heat from the power plant, less power plant heating loads and parasitic piping
losses, and the net delivered heat to the end-user is determined.
Following is a summary of annual fuel use and estimated heat utilization in equivalent gallons
of fuel for the water plant:
Facility Estimated
Annual Fuel Use
(Gallons)
Estimated Heat
Delivered W/ Intertie
(Gallons)
Option #1
Clinic 7,339 7,339
Cook house 3,280 3,280
VPSO Housing 2,461 2,461
Community Store 1,538 956
Option #2
School 25,852 19,518
5.0 HEAT RECOVERY SYSTEM DESCRIPTION AND OPERATION:
The heat recovery system captures jacket water heat generated by the AVEC power plant
that is typically rejected to the atmosphere by the radiators. The recovered heat is transferred
via below-grade arctic piping to the end user. The objective is to reduce the consumption of
expensive heating fuel by utilizing available recovered heat.
Although heat recovery is an excellent method of reducing heating fuel costs,
recovered heat is a supplementary heat source and it is imperative that the end-user
facility heating systems are operational at all times.
Hot engine coolant is piped through a plate heat exchanger located at the power plant. Heat is
transferred from the engine coolant to the recovered heat loop without mixing the fluids.
Controls at the power plant are used to prevent subcooling of the generator engines which
would reduce electric power production efficiency. The recovered heat fluid is pumped
through buried insulated pipe to the end-user, and is tied into the end-user heating system
using a plate heat exchanger.
5.1 Avec Plant Tie-In
The AVEC plant cooling system will be separated from the recovered heat system with an
injection pump, heat exchanger and controls designed to maintain minimum generator
operating temperature and provide physical isolation of the two systems. The methodology
will follow the standard approach favored by AVEC.
All heat recovery piping at the AVEC facility will be insulated with a minimum of 2-in insulation
and have an aluminum jacket where exposed to the weather. All valves will be either bronze
41
5
ball valves or lug style butterfly valves with seals compatible with 50/50 glycol/water mixtures
at 200F. Air vents, thermometers, pressure gauges, drain valves, and pressure relief valves
will also be provided.
5.2 Arctic Piping (Recovered Heat Loop)
The proposed arctic piping is based on a manufactured pre-insulated Polypropylene Random
Crystallinity Temperature (PP-RCT) pipe system with minimum of 2-in polyurethane foam
insulation and HDPE outer jacket. The piping will be buried approximately 3 ft deep. Heat
recovery pipe will run from the AVEC plant within existing rights-of-way to the end-user
community facilities. An attached drawing (Appendix-A) identifies proposed routing and burial
method. .
The recovered heat fluid will be a 50/50 Propylene Glycol/Water solution to provide freeze
protection to the piping.
5.3 Community Buildings Tie-In
The typical building tie in will consist of a VFD circulation pump to move heat from the power
plant to the respective buildings, a brazed plate heat exchanger and a separate pump to inject
heat into the building’s hydronic heating system designed to avoid introducing excessive
pressure drop in the building heating system. The maximum anticipated delivered recovered
heat supply temperature is about 180F. When there is insufficient recovered heat to meet the
building heating load, the building heating system (boiler or heater) will fire and add heat. Off
the shelf controls will lock out the recovered heat system when there is insufficient recovered
heat available.
Typical indoor piping will be type L copper tube with solder joints. Isolation valves will be
solder end bronze ball valves or flanged butterfly valves. All piping will be insulated with a
minimum of 2-in insulation with an all-service jacket. Flexibility will be provided where
required for thermal expansion and differential movement. Air vents, thermometers, pressure
gauges, drain valves, and pressure relief valves will also be provided.
Each facility will also receive a BTU meter to provide recovered heat use totalization and
instantaneous use.
5.4 Community Store Tie-In
The Community Store tie in will consist of a unit heater and circulation pump to move heat
from the power plant to the Store. The maximum anticipated delivered recovered heat supply
temperature is about 180F. When there is insufficient recovered heat to meet the building
heating load, the building heating system (toyo stove) will fire and add heat. Off the shelf
controls will lock out the recovered heat system when there is insufficient recovered heat
available.
Typical indoor piping will be type L copper tube with solder joints. Isolation valves will be
solder end bronze ball valves or flanged butterfly valves. All piping will be insulated with a
minimum of 2-inche insulation with an all-service jacket. Flexibility will be provided where
required for thermal expansion and differential movement. Air vents, thermometers, pressure
gauges, drain valves, and pressure relief valves will also be provided.
42
6
Each facility will also receive a BTU meter to provide recovered heat use totalization and
instantaneous use.
5.5 Rights-Of-Way Issues
There are no apparent conflicts with rights-of-ways for the arctic piping between the power
plant and the community building selected for this project, as the route is entirely within
existing road rights-of-ways and on city and AVEC property. All the right-of-way issues, if
found, shall be resolved before installation of arctic pipes
A Heat Sales/Right-of-Entry Agreement will be required between AVEC and the end users to
define the parties’ responsibilities, detail the cost of recovered heat, and authorize the
connection to the power plant heat recovery equipment.
5.6 Potential Risks and Unknowns
Existing survey drawing shows buried fuel, water and sewer pipes. Identifying the routing of
these pipes is important before any dirt work is initiated. It is assumed that new generator,
even when running at 30-40% of its peak capacity, will run as primary generator.
6.0 ASSUMPTIONS
This report assumes that space for heat recovery equipment at the power plant will be
available, with necessary controls, pumps and heat exchangers added as part of
modifications to the existing building.
Additional assumptions have been made in the development of this report, including, but not
limited to, the proposed arctic piping route, building heating loads and flow rates and pressure
drops of the power plant heat recovery system. It is anticipated that refinements in arctic pipe
size and routing, pump and heat exchanger sizing, and other design elements will be required
as the project progresses to final design.
Available as-built information of the power plant was obtained from AVEC. Recovered heat
availability is based on the 2015 power plant electrical loads. End-user annual fuel use was
obtained from a variety of sources, including the City, and engineering estimates. Where
possible, reported fuel consumption was used to validate engineering estimates.
7.0 PRELIMINARY EQUIPMENT SELECTIONS
The following initial equipment selections are sized and selected based on preliminary data
and will require minor modifications to reflect final design.
7.1 Heat Exchangers
Based on initial selected flow rates, brazed plate heat exchangers appear to be adequate for
all locations. Initial heat exchanger selections are as follows.
HX-1: (Power Plant). 575 MBH capacity
43
7
Primary: 63 GPM 185F EWT (50% ethylene glycol), 2.0 PSI max WPD
Secondary: 63 GPM 180F LWT (50% propylene glycol) 2.0 PSI max WPD
Option #1:
HX-2: (Clinic). 130 MBH capacity
Primary: 14 GPM 180F EWT (50% ethylene glycol), 2.0 PSI max WPD
Secondary: 14 GPM 175F LWT (50% propylene glycol) 2.0 PSI max WPD
HX-3: (Cookhouse). 70 MBH capacity
Primary: 7 GPM 180F EWT (50% ethylene glycol), 2.0 PSI max WPD
Secondary: 7 GPM 175F LWT (50% propylene glycol) 2.0 PSI max WPD
HX-4: (VPSO Housing). 60 MBH capacity
Primary: 6.6 GPM 180F EWT (50% ethylene glycol), 2.0 PSI max WPD
Secondary: 6.6 GPM 175F LWT (50% propylene glycol) 2.0 PSI max WPD
UH-1: (Community Store). 40 MBH capacity.
Primary: 4.4 GPM 180F EWT (50% propylene glycol), 1.0 PSI max WPD
Secondary: 4.4 GPM 175F LWT (50% propylene glycol) 1.5 PSI max WPD
Option #2:
HX-2: (School). 300 MBH capacity
Primary: 33.33 GPM 180F EWT (50% ethylene glycol), 2.0 PSI max WPD
Secondary: 33.33 GPM 175F LWT (50% propylene glycol) 2.0 PSI max WPD
7.2 Arctic Piping
The round trip length of heat recovery loop piping between the power plant and community
buildings is approximately 1800 feet for both options. The pipe consists of a 2-in PP-RCT
carrier pipe with minimum of 2-in polyurethane foam insulation and an HDPE outer jacket.
The specified product is durable enough for direct bury. The piping and excavated soil will be
will be wrapped in geotextile fabric to hold the pipe in the ground in the event of flooding.
7.3 Circulating Pumps
Option #1:
HP-1A: Clinic (power plant side of HX-2)
Flow = 14 GPM, Head = 20 ft (approximate)
Initial Selection: Grundfos Magna series with integrated VFD and 4-20 mA controller.
Approximately 600W
44
8
HP-1B: Clinic (Clinic side of HX-2)
Flow = 14 GPM, Head = 10 ft (approximate)
Initial Selection: Grundfos Magna series with integrated VFD and 4-20 mA controller.
Approximately 600W
HP-2A: Cookhouse (power plant side of HX-3)
Flow = 7 GPM, Head = 15 ft (approximate)
Initial Selection: Grundfos UPS 26-99F. Approximately 400W
HP-2B: Cookhouse (Cook house side of HX-3)
Flow = 7 GPM, Head = 10 ft (approximate)
Initial Selection: Grundfos UPS 26-99F. Approximately 400W
HP-3A: VPSO Housing (power plant Side of HX-4)
Flow = 6.6 GPM, Head = 15 ft (approximate)
Initial Selection: Grundfos UPS 26-99F. Approximately 400W
HP-3B: VPSO Housing (VPSO side of HX-4)
Flow = 6.6 GPM, Head = 10 ft (approximate)
Initial Selection: Grundfos UPS 26-99F. Approximately 400W
HP-4: Community Store
Flow = 4.4 GPM, Head = 10 ft (approximate)
Initial Selection: Grundfos UPS 26-99F. Approximately 400W
Option #2:
HP-1A: School (power plant side of HX-2)
Flow = 33.33 GPM, Head = 55 ft (approximate)
Initial Selection: Grundfos Magna series with integrated VFD and 4-20 mA controller.
Approximately 600W
HP-1B: Clinic (Clinic side of HX-2)
Flow = 33.33 GPM, Head = 10 ft (approximate)
Initial Selection: Grundfos Magna series with integrated VFD and 4-20 mA controller.
Approximately 600W
7.4 Expansion Tanks
Total heat recovery loop volume is approximately 350 gallons for both options. Pressure relief
at the power plant heat exchanger will be 45 PSIG and the maximum normal operating
pressure will be 30 PSIG.
Option #1
ET-1(Clinic): System requirements: 15 gallon tank and 7 gallon acceptance.
45
9
ET-1(Cookhouse): System requirements: 15 gallon tank and 7 gallon acceptance.
ET-1(VPSO Housing): System requirements: 4 gallon tank and 2 gallon acceptance.
ET-1(Community Store): System requirements: 4 gallon tank and 2 gallon acceptance.
Option #2
ET-1(School): System requirements: 63 gallon tank and 25 gallon acceptance.
7.5 Glycol Makeup
A glycol make-up system at the WTP will be provided to accommodate filling the system and
adding additional glycol.
Option #1
GMT-1(Clinic): Axiom MF300 mini feeder, 17 Gal.
GMT -1(Cookhouse): Axiom MF300 mini feeder, 17 Gal.
GMT -1(VPSO Housing): Axiom MF200 mini feeder, 6 Gal.
GMT -1(Community Store): Axiom MF200 mini feeder, 6 Gal.
Option #2
GMT-1(School): Axiom SF100, 55 Gal.
7.6 Controls
Heat recovery system in the end user facilities will use an off the shelf differential temperature
controller to start/stop heat injection pump. Additional controller will look at the differential
temperature across the heat exchanger and modulate the heat recovery circulation pump to
minimize energy consumption. Controls will provide load shedding, freeze protection, and
prevent back feeding of boiler heat into heat recovery system. In addition, A BTU meter will be
provided at each facility using recovered, displaying instantaneous temperatures and heat
transfer, as well as totalizing BTUs used.
Differential Controllers: Honeywell 755 differential temperature control and integrated
temperature controller built into variable speed pump.
BTU Meters:
46
10
Option #1
BTU-1(Clinic): KEP BTU meter with 1-1/2” magnetic flow meter and matching temperature
elements.
BTU-1(Cookhouse): KEP BTU meter with 1-1/2” magnetic flow meter and matching
temperature elements.
BTU-1(VPSO): KEP BTU meter with 1” magnetic flow meter and matching temperature
elements.
BTU-1(Community Store): KEP BTU meter with 1” magnetic flow meter and matching
temperature elements.
Option #2
BTU-1(School): KEP BTU meter with 2” magnetic flow meter and matching temperature
elements.
8.0 CONCLUSIONS AND RECOMMENDATIONS
Estimated construction costs were determined based on prior recent heat recovery project
experience, and include materials, equipment, freight, labor, design, construction
management, and startup and testing. All work at the power plant and selected communities
buildings, along with design and construction management/administration for the complete
project, is included in the Base Project cost. (Refer to attached cost estimate).
At present due to leaks in buried heat recovery pipe to City office, City office has not be able
to fully benefit from existing heat recovery system. Total project cost for both option include
cost to provide new supply and return pipe to city office. Old heat recovery line will be
abandoned and glycol in old lines will be salvaged.
Option 1 - Supplying excess recovered heat to Clinic, Cookhouse, VPSO housing
Community store, and city office. The total estimated annual heating fuel consumption is
estimated to be approximately 14,618 gallons. Heat recovery system is expected to reduce
the fuel consumed by 14,036 gallons. The expected annual savings is $ 126,323.
The payback is based on a 2015 average fuel price of $9/gallon and an estimated 2016
project cost of $ 1,218,132. Assuming construction of the heat recovery system begins in
2016, the design and construction cost with 2 years of 3% escalation is $ 1,292,316. The
simple payback time is 10.23 years
Option 2 - Supplying excess recovered heat to school and city office. The total estimated
annual heating fuel consumption is estimated to be approximately 26,666 gallons. Heat
recovery is expected to reduce the fuel consumed by 19,518 gallons. The expected annual
savings is $ 70,656.
47
11
The payback is based on a 2015 average fuel price of $3.62/gallon and an estimated 2016
project cost of $ 865,046. Assuming construction of the heat recovery system begins in 2016,
the design and construction cost with 2 years of 3% escalation is $ 917,727. The simple
payback time is 12.99 years.
48
APPENDIX – A: Conceptual Design
49
4500 Diplomacy Drive
50
4500 Diplomacy Drive
51
4500 Diplomacy Drive
52
4500 Diplomacy Drive
53
4500 Diplomacy Drive
54
4500 Diplomacy Drive
55
APPENDIX – B: Graphs
56
-
100
200
300
400
500
600
Jan Feb March April May June July Aug Sept Oct Nov DecMBTU/HRMONTH
Shungnak Recovered Heat Utilization- Option #1
Community Store heat demand (MBH)
VPSO Housing heat demand (MBH)
Cook House Heat demand (MBH)
Clinic Heat demand (MBH)
Total City Office Heat Demand (MBH)
Total WTP Heat Demand (MBH)
0
500
1,000
1,500
2,000
2,500
3,000
3,500
Jan Feb March April May June July Aug Sept Oct Nov DecGAL
MONTH
Shungnak Recovered Heat Utilization- Option #1
Combined Community buildings Avoided fuel (Gal)Total Available Recovered Heat Benefit after supplying WTP and City Office (Gal)
57
-
100
200
300
400
500
600
700
800
Jan Feb March April May June July Aug Sept Oct Nov DecMBTU/HRMONTH
Shungnak Recovered Heat Utilization - Option #2
School Heat demand (MBH)
Total City Office Heat Demand (MBH)
Total WTP Heat Demand (MBH)
Estimated Available Heat for Recovery after transmission losses (MBH)
0
500
1,000
1,500
2,000
2,500
3,000
3,500
Jan Feb March April May June July Aug Sept Oct Nov DecGAL
MONTH
Shungnak Recovered Heat Utilization - Option #2
School Avoided fuel (Gal)Total Available Recovered Heat Benefit after supplying WTP and City Office (Gal)
58
APPENDIX – C: Calculation
59
ANTHC DEHE4500 Ambassador dr, Ste 454Project Name:Shungnak Heat Recovery ProjectANCHORAGE, AK 99503Project Number:TBD(907) 729-4083Engineer:PKCChecked:________FAX (907) 729-3729Revision Date:Print:File: Z:\Secure\Project\Energy Project\Shungnak\[Copy of Shungnak Heat Recovery Calcs (Dixon Edits).xlsx]WHR CalcFind:Feasibility of Heat Recovery from Shungnak's AVEC's Power plant to existing Utility BuildingGiven:Monthly KWH produced by existing Shungnak generator plant in 2015Heating Degree Days for Kobuk is used for this calculationCity office/post office heating load150,000BTU/Hr size of the boiler installed in 2011-12, this building has 100MBH heat recovery heat exchanger.80,000BTU/Hr This heat exchanger was down sized in 2011-12. Original design call for 160MBH 30,000BTU/Hr ( source AN-02-Q78)80,000BTU/Hr ( source AN-02-Q78)115,000BTU/Hr ( source AN-02-Q78)200,000BTU/Hr ( Source - Mr. Jim Fowler, Energy Audit of Alaska)80,000BTU/Hr ( Source - Mr. Jim Fowler, Energy Audit of Alaska)100,000BTU/Hr ( Source - Mr. Jim Fowler, Energy Audit of Alaska)50,000BTU/Hr ( Source - Mr. Jim Fowler, Energy Audit of Alaska)747,706BTU/Hr ( Source - Mr. Jim Fowler, Energy Audit of Alaska)OPTION #2 - Supply suppliment heat to SchoolThis analysis is based on power production rate of 2015 but with Genset 6 (with CAT 3456 engine) that will be installed in near futureWhen Genset 6 is running , Generator 4 and 5 will be backup generator. Generator 1 and 2 are old and shut down. Only used to exercise the generatorPer Forest Button, Manager, Project Development & Key Accounts , AVEC once genset 6 is installed, only this generator will run all the time even if it runs at 30-40 % load capacityAssumptions:Design Air Temperature:-50Deg FDesign Water Temperature40Deg FDesign Glycol Heat Trace Temperature75Deg FWTP buidling Space temperature65Deg FHeat Recovery Operating Temperature180Deg FObserved Sewer Temperature40Deg F Community Facility Fuel Price $9.00 (START Report, Fowler)Occupied office room temperature70Deg F School Fuel Price 3.62 (START Report, Fowler) BTU to radiators / KW Power Generated 1394(BTU/Hr)/KW Estimated Boiler AFUE:70%1400(BTU/Hr)/KW Community Estimated Fuel Price:$10.50per gal ( fuel price 2015)1400(BTU/Hr)/KW AVEC Estimated Fuel Price$5.60per gal (2015 PCE report)1400(BTU/Hr)/KW AVEC Heat Sales Agreement:30%Avoided fuel cost at AVEC's Price2984(BTU/Hr)/KW AVEC Heat Sales Agreement for school:50%Avoided fuel cost at AVEC's PriceAbove Ground Heat Recovery System in Arctic Pipe with atleast 10" of snow cover Frozen Soil Conductivity0.12 (Between 0.05 & 0.15 BTUH/Ft)Electricity cost0.76$/kW-HrCalculations:WTP Building Heat Loss: City Office / Post Office Heat Loss:Building design heating loss:80,000BTU/H Building design heating loss:150,000BTU/HHeat loss / degree of OSA temp695.7BTH/H* F Heat loss / degree of OSA temp1,250.0BTH/H* FSensible heating from any or all electrical and electronic equipment as well as lighting fixture is excluded from calculation.Water storage tank heating load (HE-2)water treatment plant space heating load Water distribution loop heating load ( HE-3, HE-4, and HE-5)08-Aug-1619-Sep-16Raw water heat add (HE-1)Clinic heating demandVPSO housing heating demandProposed new Cook house heating demandGrossary storeSchool Space heating demand OPTION #1 - Supply suppliment heat to Clinic, Cook house and VPSO HoGenerator 1: Recoverable Heat per KW(JD 6619AF, 202kW )Generator 2: Recoverable Heat per KW(CAT 3406B, 335 KW)Generator 4: Recoverable Heat per KW(DD S60K4c 1800, 324KW)Generator 5: Recoverable Heat per KW(CMS K19G2 1800, 397KW)Generator 6: Recoverable Heat per KW(CAT 3456, 505 KW)60
ANTHC DEHE4500 Ambassador dr, Ste 454Project Name:Shungnak Heat Recovery ProjectANCHORAGE, AK 99503Project Number:TBD(907) 729-4083Engineer:PKCChecked:________FAX (907) 729-3729Revision Date:Print:File: Z:\Secure\Project\Energy Project\Shungnak\[Copy of Shungnak Heat Recovery Calcs (Dixon Edits).xlsx]WHR Calc08-Aug-1619-Sep-16Calculations (Continued)Parasitic Generator Cooling System LossesGenerator Module Heat LoadsDesign Air Temperature:-50Deg FAMOT valve leak Rate (average)0.5GPM Power plant space heating ( 20 MBH per module)60000BTU/HrHot CoolantTemperature180Deg F power plant engine heat(15 MBH per Enginer)45000BTU/HrDesign Heat Loss:51750BTU/Hr Storage modules Heat Loss BTU/HrHeat loss / Degree of OSA temp:225.0BTU/HrTotal105000BTU/HrStorage Tank Heat Loss: Treated water onlyHeat loss / degree of OSA temp:808BTU/Hr* deg FDesign heating loss:30,000BTU/HHeat loss / degree of OSA temp333.3BTH/H* Deg FWasheteria Washer Load: Dryer plenum Load:Design heating loss:-MBH/Month design heating loss:-MBH/MonthDryer Plenum Usage ( only when dryer is on)100%Heat Loss / degree of OSA temp:0BTU/H* Deg FWasheteria Dryer Load: water distributing loop heating loadDesign heating loss:-MBH/Month Building design heating loss:115,000BTU/HHeat loss / degree of OSA temp1,277.8BTH/H* Deg FAbove Ground Heat Recovery Pipe Heat Loss: Raw water Heating LoadDesign heating loss:80,000BTU/HDesign Heat Recovery loop Temperature180Degrees F Heat loss / degree of OSA temp888.9BTH/H* Deg FDesign Air Temperature:-50Degrees FInsulation:3Inch foam ins.Buried Heat Recovery Pipe Heat Loss: power plant Pipe:2.375Pipe OD (Inches) Design Air Temperature-50Degrees FInsulation K value0.2BTU x in / (ft^2 x hr x Deg F) Design Ground Surface Temperature-10Degrees FR value = 12.035 Ft x hr x Deg F Insulation:3Inch foam ins.Length of Above ground Pipe0Ft Carrier Pipe:2.5Pipe OD (Inches)Design Heat Loss: - BTU/hr Insulation K value0.017BTUH / (ft x Deg F)#DIV/0! BTUH/ft Ground K value0.12BTUH / (ft x Deg F)Heat Loss / Degree OSA temp 0.0 Pipe R value =11Ft x hr x Deg F Depth of Bury =2.0feetBuried Heat Recovery Pipe Heat Loss: Power plant to WTPSoil R value = 3Ft x hr x Deg F Design Air Temperature-50Degrees F Buried Pipe600FtDesign Ground Surface Temperature-10Degrees F Design Heat Loss:409BTU/hrInsulation:3Inch foam ins. Heat Loss / Foot1BTU/hrCarrier Pipe:3Pipe OD (Inches) Heat Loss / Degree OSA temp8BTU/Hr* deg FInsulation K value0.017BTUH / (ft x Deg F) ( Note : this sytem has two 2.5" pex pipe in arctic pipe. surface area of two 2.5" = one 3.5" pex pipe) Ground K value0.12BTUH / (ft x Deg F)Pipe R value =10Ft x hr x Deg F Depth of Bury =2.0feetSoil R value = 3Ft x hr x Deg F Buried Pipe150FtBuried Heat Recovery Pipe Heat Loss: power plant to City officeDesign Heat Loss:2125BTU/hr Design Air Temperature-50Degrees FHeat Loss / Foot14BTU/hr Design Ground Surface Temperature-10Degrees FHeat Loss / Degree OSA temp9BTU/Hr* deg F Insulation:3Inch foam ins.( Note : this sytem has two 2" pex pipe in arctic pipe. surface area of two 2" = one 3" pex pipe) Carrier Pipe:2Pipe OD (Inches)Insulation K value0.017BTUH / (ft x Deg F)Heat TapeGround K value0.12BTUH / (ft x Deg F)Electric heat demand0.0KW Pipe R value =13Ft x hr x Deg F kwh/month0.0kW-Hr Depth of Bury =2.0feetSoil R value = 3Ft x hr x Deg F Heat tapeBuried Pipe300FtHeat tape amperage amp Design Heat Loss:3504BTU/hrVoltage240V Heat Loss / Foot12BTU/hrkwh/month0.0kW-Hr/month Heat Loss / Degree OSA temp15BTU/Hr* deg F( Note : this sytem has two 1.5" pex pipe in arctic pipe. surface area of two 1.5" = one 2" pex pipe) 61
ANTHC DEHE4500 Ambassador dr, Ste 454Project Name:Shungnak Heat Recovery ProjectANCHORAGE, AK 99503Project Number:TBD(907) 729-4083Engineer:PKCChecked:________FAX (907) 729-3729Revision Date:Print:File: Z:\Secure\Project\Energy Project\Shungnak\[Copy of Shungnak Heat Recovery Calcs (Dixon Edits).xlsx]WHR Calc08-Aug-1619-Sep-16Calculations (Continued)VPSO Building Heat demand: School Building Heat demand:Building design heating loss:80,000BTU/H Building design heating loss:747,706BTU/HHeat loss / degree of OSA temp666.7BTH/H* F Heat loss / degree of OSA temp6,230.9BTH/H* FClinic Heat Demand:Building design heating loss:200,000BTU/HHeat loss / degree of OSA temp1,666.7BTH/H* FCook house Building Heat demand:Building design heating loss:100,000BTU/HHeat loss / degree of OSA temp833.3BTH/H* FCommunity store Heat demand:Building design heating loss:50,000BTU/HHeat loss / degree of OSA temp416.7BTH/H* FBuried Heat Recovery Pipe Heat Loss: power plant to VPSO,cookhouse, clinic and city office Buried Heat Recovery Pipe Heat Loss: power plant to SchoolDesign Air Temperature-50Degrees F Design Air Temperature-50Degrees FDesign Ground Surface Temperature-10Degrees F Design Ground Surface Temperature-10Degrees FInsulation:3Inch foam ins. Insulation:3Inch foam ins.Carrier Pipe:3Pipe OD (Inches) Carrier Pipe:3Pipe OD (Inches)Insulation K value0.017BTUH / (ft x Deg F) Insulation K value0.017BTUH / (ft x Deg F)Ground K value0.12BTUH / (ft x Deg F) Ground K value0.12BTUH / (ft x Deg F)Pipe R value =10Ft x hr x Deg F Pipe R value =10Ft x hr x Deg F Depth of Bury =3.0feet Depth of Bury =3.0feetSoil R value = 4Ft x hr x Deg F Soil R value = 4Ft x hr x Deg F Buried Pipe900Ft Buried Pipe900FtDesign Heat Loss:12251BTU/hr Design Heat Loss:12251BTU/hrHeat Loss / Foot14BTU/hr Heat Loss / Foot14BTU/hrHeat Loss / Degree OSA temp53BTU/Hr* deg F Heat Loss / Degree OSA temp53BTU/Hr* deg F( Note : this sytem has two 2" preinsulated ( e.g. rhinoflex) pex pipe ( Note : this sytem has two 1.5" pex pipe in arctic pipe. surface area of two 1.5" = one 2" pex pipe) Month KWH / Month Days / Month Avg KWHtg Degree Days / Month (40F)Htg Degree Days / Month (65F)Htg Degree Days / Month (70F)Htg Degree Days / Month (180F)% run Engine 4% run Engine 5% run Engine 6Available heat (MBH)Parasitic Cooling System Losses (MBH)Maximum Available heat (MBH)Jan 163406 31220 1,4952,2702,425 5,835 0% 0% 100% 657 42615Feb 143963 29207 1,3902,1152,260 5,450 0% 0% 100% 619 42576March 161106 30224 1,2542,0042,154 5,454 0% 0% 100% 669 41628April 141352 30196 7181,4681,618 4,918 0% 0% 100% 587 37550May 115642 31155 24799954 4,364 0% 0% 100% 465 32433June 98443 30137 -334484 3,784 0% 0% 100% 409 28381July 94038 31126 -240395 3,805 0% 0% 100% 378 28351Aug 90507 31122 -355510 3,920 0% 0% 100% 364 28335Sept 121296 30168 -684834 4,134 0% 0% 100% 504 31473Oct 133291 31179 6251,4001,555 4,965 0% 0% 100% 536 36500Nov 154269 30214 1,0811,8311,981 5,281 0% 0% 100% 641 40601Dec 161623 31217 1,5052,2802,435 5,845 0% 0% 100% 650 4260715,780AVEC Available Recovered Heat EstimateOption #1 - VPSO Housing,Clinic, New Cookhouse, Community Store Option #2 - School only62
ANTHC DEHE4500 Ambassador dr, Ste 454Project Name:Shungnak Heat Recovery ProjectANCHORAGE, AK 99503Project Number:TBD(907) 729-4083Engineer:PKCChecked:________FAX (907) 729-3729Revision Date:Print:File: Z:\Secure\Project\Energy Project\Shungnak\[Copy of Shungnak Heat Recovery Calcs (Dixon Edits).xlsx]WHR Calc08-Aug-1619-Sep-16Calculations (Continued)City Office DemandMonth Building Heat Loss (MBH)WST Heat Loss (MBH)Raw water Heating load ( MBH)water distributing loop heating load (MBH)Total WTP Heat Demand (MBH)Total City Office Heat Demand (MBH)Jan51 16 43 621721360.3398776Feb51 16 43 611711265.5897723March46 14 37 531511158.8390689April34 8 21 3194720.5767517May0 0 1 1215.3538305June0 - - --0.0020155July0 - - --0.00-0Aug0 - - --0.0021163Sept0 - - --0.0035267Oct31 7 18 2682648.9863497Nov42 12 32 461331017.3783634Dec51 16 43 621731368.51987797555.52 5504Based on WTP operator, WTP hardly uses any fuel after installation of exsiting heat recovery systemCity Office also hardly uses any fuelMonthAVEC Facility Heating load (MBH)Burried Pipe Loss Power plant (PP) (MBH)Buried Pipe Loss PP to WTP (MBH)Buried Pipe Loss PP to City office (MBH)Sum Transmission Losses(MBH) MonthEstimated Available Heat for Recovery after transmission losses (MBH)Total WTP Heat Demand (MBH)Total City Office Heat Demand (MBH)TotalAvailable Recovered Heat Benefit after supplying WTP and City Office (MBH) TotalAvailable Recovered Heat Benefit after supplying WTP and City Office (Gal) Jan59 2 2 365Jan549 172 97.8280 2222Feb59 2 2 365Feb511.46 171 97.4243 1807March54 1 2 360March569 151 89.8328 2517April40 1 2 245April506 94 67.4344 2642May21 1 1 225May408 2 38.5367 2915June- 1 1 24June377 0 20.2356 2735July- 1 1 24July346 0 0.0346 2748Aug- 1 1 24Aug331 0 20.6311 2465Sept- 1 1 25Sept468 0 34.8434 3329Oct36 1 1 242Oct458 82 62.7314 2488Nov49 1 2 355Nov546 133 82.5331 2543Dec59 2 2 366Dec542 173 98.2271 2151Recovered Heat Transmission Losses and avec space heat demand Available Recovered Heat WTP Heating Demand63
ANTHC DEHE4500 Ambassador dr, Ste 454Project Name:Shungnak Heat Recovery ProjectANCHORAGE, AK 99503Project Number:TBD(907) 729-4083Engineer:PKCChecked:________FAX (907) 729-3729Revision Date:Print:File: Z:\Secure\Project\Energy Project\Shungnak\[Copy of Shungnak Heat Recovery Calcs (Dixon Edits).xlsx]WHR Calc08-Aug-1619-Sep-16Calculations (Continued)Option #2MonthClinic Heat demand (MBH)Cook House Heat demand (MBH)VPSO Housing heat demand (MBH) Community Store heat demand (MBH) Total Heat Demand (MBH)Total Heat Demand (Gal)Burried Pipe loss (MHB)School Heat demand (MBH)Total Heat Demand (Gal)Burried Pipe loss for School (MHB)Jan130 65 52 33280 222310487 386610Feb130 65 52 32279 207210486 360310March120 60 48 30257 197510447 343410April90 45 36 22193 14839336 25809May51 26 0 077 6107192 15217June27 0 0 027 20670 00School closed for summerJuly0 0 0 00 070 00School closed for summerAug27 0 0 027 2177103 8137Sept46 0 0 046 3567173 13307Oct84 42 33 21180 14269313 24799Nov110 55 44 28237 18169411 31589Dec131 65 52 33281 223310489 38821014618 101 26666Based on WTP operator, WTP hardly uses any fuel after installation of exsiting heat recovery systemCity Office also hardly uses any fuelTotalCommunity building heat Demand (MBH)Total Recover Heat Available after losses (MBH)Combined Community buildings Avoided fuel (Gal) Avoided Fuel($)Cost of Heat Recovery ($)Net Savings to Community ($)Total School heat Demand (MBH)Total Recover Heat Available after losses (MBH)School Avoided fuel (Gal)Avoided Fuel($)Cost of Heat Recovery ($)Net Savings to Community ($)Jan280 270 2,142 19,280 3,599$15,681.36$Jan487 270 2,142 7,755 5,998$1,756.66$Feb279 233 1,732 15,591 2,910$12,680.83$Feb486 233 1,732 6,271 4,851$1,420.53$March257 318 1,975 17,774 3,318$14,456.14$March447 318 2,442 8,841 6,839$2,002.74$April193 336 1,483 13,351 2,492$10,858.88$April336 336 2,575 9,323 7,211$2,111.87$May77 360 610 5,492 1,025$4,466.92$May192 360 1,521 5,506 4,259$1,247.15$June27 350 206 1,858 347$1,510.82$June0 356 0 0 -$-$July0 340 0 0 -$-$July0 346 0 0 -$-$Aug27 304 217 1,957 365$1,591.98$Aug103 304 813 2,943 2,277$666.72$Sept46 426 356 3,201 597$2,603.36$Sept173 426 1,330 4,813 3,723$1,090.28$Oct180 305 1,426 12,831 2,395$10,436.07$Oct313 305 2,420 8,762 6,777$1,984.74$Nov237 322 1,816 16,346 3,051$13,295.09$Nov411 322 2,471 8,944 6,918$2,025.90$Dec281 261 2,071 18,640 3,480$15,160.90$Dec489 261 2,071 7,498 5,799$1,698.35$14,036 126,323$ 23,580$ 102,742$ 19,518 70,656$ 54,651$ 16,005$Estimated saving (Gal, $) - Option #1 Estimated saving (Gal, $) - Option #2 Option #164
APPENDIX – D: Cost Estimation
65
Shungnak Total Project Estimate - Option #1 1,292,316$
# of Employees Hours/Quantity
Hourly Rate/Unit
Rate Total Cost
Design Performed by Qualified Contractor 99,970.0$
Mechanical Engineer 1 180 140$ 25,200.0$
Civil Engineer 1 120 120$ 14,400.0$
Electrical Engineer 1 80 130$ 10,400.0$
Survey 2 60 110$ 13,200.0$
Autocad support 2 75 110$ 16,500.0$
Travel 5 1 1,250$ 6,250.0$
Cost Estimator 1 40 120$ 4,800.0$
Design Review 4 4 120$ 1,920.0$
Environmental 1 30 110$ 3,300.0$
Project Management 1 40 100$ 4,000.0$
Construction 959,275$
Materials 406,700$
Buried Piping 135,780$
Pre-Insulated 2" PPR-CT Arctic Pipe 1800 60$ 108,000$
Fittings/other 90 17$ 1,530$
Geotextile 900 5$ 4,500$
Clamps/Insulation/Other 90 75$ 6,750$
Glycol 6 1,000$ 6,000$
Insulation 900 10$ 9,000$
Above Ground Piping 13,920$
Pre-Insulated 2" PPR-CT Arctic Pipe 200 60$ 12,000$
Fittings/other 10 17$ 170$
Geotextile 0 5$ -$
Clamps/Insulation/Other 10 75$ 750$
Glycol 1 1,000$ 1,000$
VPSO House Connection 28,500$
Pipe and Fittings 1 10,000$ 10,000$
Heat Exchanger 1 4,000$ 4,000$
Controls 1 7,500$ 7,500$
Insulation 1 1,000$ 1,000$
Expansion Tank 1 1,000$ 1,000$
Pump 2 2,500$ 5,000$
Clinic Connection 32,500$
Pipe and Fittings 1 10,000$ 10,000$
Heat Exchanger 1 6,000$ 6,000$
Controls 1 7,500$ 7,500$
Insulation 1 3,000$ 3,000$
Expansion Tank 1 1,000$ 1,000$
Pump 2 2,500$ 5,000$
66
City Office Connection 10,500$
Pipe and Fittings 1 5,000$ 5,000$
Heat Exchanger 1 -$ -$
Controls 1 -$ -$
Insulation 1 500$ 500$
Expansion Tank 1 -$ -$
Pump 2 2,500$ 5,000$
Cook House Connection 32,500$
Pipe and Fittings 1 10,000$ 10,000$
Heat Exchanger 1 6,000$ 6,000$
Controls 1 7,500$ 7,500$
Insulation 1 3,000$ 3,000$
Expansion Tank 1 1,000$ 1,000$
Pump 2 2,500$ 5,000$
Store Connection 21,000$
Pipe and Fittings 1 5,000$ 5,000$
unit heater 1 4,000$ 4,000$
Controls 1 5,000$ 5,000$
Insulation 1 1,000$ 1,000$
Expansion Tank 1 1,000$ 1,000$
Pump 2 2,500$ 5,000$
Power Plant Connection 53,000$
Pipe and Fittings 1 20,000$ 20,000$
Heat Exchanger 1 10,000$ 10,000$
Controls and thermal management panel 1 20,000$ 20,000$
Insulation 1 3,000$ 3,000$
Expansion Tank 0 1,000$ -$
Pump 0 2,500$ -$
BTU Meter Install 46,000$
BTU Meter 5 2,000$ 10,000$
Flow Meters 6 3,500$ 21,000$
AVEC Link 5 3,000$ 15,000$
Other 33,000$
Spare Parts 1 15,000$ 15,000$
Remote monitoring 6 3,000$ 18,000$
Freight 151,675$
AVEC Freight 1 1 13,250$ 13,250$
Preinsulated Pipe Freight 1 1 37,425$ 37,425$
Other Materials Freight 1 1 51,000$ 51,000$
equipment Move in- move out ( Herc)1 1 50,000$ 50,000$
Equipment 29,200$
Rental (excavator , truck, bobcat, 4 wheelers)4 24 200$ 19,200$
Repair 2 1 2,500$ 5,000$
Fuel 2 1 2,500$ 5,000$
67
Labor 361,600$
Construction Management 1 240 120$ 28,800$
Construction Travel 2 4 1,400$ 11,200$
Superintendent 1 390 140$ 54,600$
Superintendent travel 2 1 1,000$ 2,000$
Electrician 1 120 120$ 14,400$
Electrician Travel 1 1 1,000$ 1,000$
Plumber/Foreman Labor 2 250 130$ 65,000$
Plumber Travel 2 1 1,000$ 2,000$
Pipe Installation Local Labor 4 240 50$ 48,000$
Interior Plumbing Local Labor 2 240 50$ 24,000$
AVEC Labor 2 60 120$ 14,400$
AVEC Travel 2 2 1,400$ 5,600$
Shipping and Receiving 3 80 110$ 26,400$
Purchasing 1 100 110$ 11,000$
Contracting 1 40 100$ 4,000$
Safety 1 40 120$ 4,800$
Training ( local labor)1 40 50$ 2,000$
Engineer Labor ( CA support)3 60 130$ 7,800$
Site Travel 3 3 1,400$ 4,200$
Utility Support - training and start up 1 80 100$ 8,000$
Utility Support Travel- training and start up 1 3 1,400$ 4,200$
Utility Support - remote monitoring 1 40 100$ 4,000$
Utility Support Travel - - remote monitoring 1 1 1,400$ 1,400$
Technical Writer 1 60 80$ 4,800$
Project Management 1 80 100$ 8,000$
Other 10,100$
Construction Lodging 1 101 100$ 10,100$
1,059,245$
1,218,132$
2 years escalation @ 3% / year 74,184$
Total 1,292,316$
$126,323
10.23
Labor + Mat + Frgt + Design
All + 15% contingency
Estimated annual fuel savings
Simple Payback ( in Years)
68
Shungnak Total Project Estimate - Option #2 917,727$
# of Employees Hours/Quantity
Hourly Rate/Unit
Rate Total Cost
Design Performed by Qualified Contractor 86,270.0$
Mechanical Engineer 1 140 140$ 19,600.0$
Civil Engineer 1 80 120$ 9,600.0$
Electrical Engineer 1 80 130$ 10,400.0$
Survey 2 60 110$ 13,200.0$
Autocad support 2 60 110$ 13,200.0$
Travel 5 1 1,250$ 6,250.0$
Cost Estimator 1 40 120$ 4,800.0$
Design Review 4 4 120$ 1,920.0$
Environmental 1 30 110$ 3,300.0$
Project Management 1 40 100$ 4,000.0$
Construction 665,944$
Materials 251,835$
Buried Piping 130,780$
Pre-Insulated 2" PPR-CT Arctic Pipe 1800 60$ 108,000$
Fittings/other 90 17$ 1,530$
Geotextile 900 5$ 4,500$
Clamps/Insulation/Other 90 75$ 6,750$
Glycol 1 1,000$ 1,000$
Insulation 900 10$ 9,000$
Above Ground Piping 4,555$
Pre-Insulated 2" PPR-CT Arctic Pipe 50 24$ 1,200$
Fittings/other 2.5 17$ 43$
Geotextile 25 5$ 125$
Clamps/Insulation/Other 2.5 75$ 188$
Glycol 3 1,000$ 3,000$
School House Connection 37,500$
Pipe and Fittings 1 10,000$ 10,000$
Heat Exchanger 1 6,000$ 6,000$
Controls 1 7,500$ 7,500$
Insulation 1 3,000$ 3,000$
Expansion Tank 1 1,000$ 1,000$
Pump 2 5,000$ 10,000$
Power Plant Connection 53,000$
Pipe and Fittings 1 20,000$ 20,000$
Heat Exchanger 1 10,000$ 10,000$
Controls and thermal management panel 1 20,000$ 20,000$
Insulation 1 3,000$ 3,000$
Expansion Tank 0 1,000$ -$
Pump 0 2,500$ -$
69
BTU Meter Install 12,000$
BTU Meter 1 2,000$ 2,000$
Flow Meters 2 3,500$ 7,000$
AVEC Link 1 3,000$ 3,000$
Other 14,000$
Spare Parts 1 5,000$ 5,000$
Remote monitoring 3 3,000$ 9,000$
Freight 112,959$
AVEC Freight 1 1 13,250$ 13,250$
Preinsulated Pipe Freight 1 1 33,834$ 33,834$
Other Materials Freight 1 1 15,875$ 15,875$
equipment Move in- move out ( Herc)1 1 50,000$ 50,000$
Equipment 17,800$
Rental (excavator , truck, bobcat, 4 wheelers)4 16 200$ 12,800$
Repair 1 1 2,500$ 2,500$
Fuel 1 1 2,500$ 2,500$
Labor 276,450$
Construction Management 1 230 120$ 27,600$
Construction Management Travel 1 4 1,250$ 5,000$
Electrician 1 60 120$ 7,200$
Electrician Travel 1 1 1,000$ 1,000$
Superintendent 1 330 140$ 46,200$
Superintendent travel 2 1 1,000$ 2,000$
Plumber Labor 1 300 130$ 39,000$
Plumber Travel 1 1 1,000$ 1,000$
Pipe Installation Local Labor 4 180 50$ 36,000$
Interior Plumbing Local Labor 2 140 50$ 14,000$
AVEC Labor 2 60 120$ 14,400$
AVEC Travel 2 2 1,400$ 5,600$
Shipping and Receiving 4 40 110$ 17,600$
Purchasing 1 100 110$ 11,000$
Contracting 1 40 100$ 4,000$
Safety 1 40 120$ 4,800$
Training (Local Labor)1 40 50$ 2,000$
Engineer Labor 3 60 125$ 7,500$
Site Travel 3 3 1,250$ 3,750$
Utility Support - training and start up 1 70 100$ 7,000$
Utility Support Travel- training and start up 1 3 1,400$ 4,200$
Utility Support - remote monitoring 1 40 100$ 4,000$
Utility Support Travel - - remote monitoring 1 1 1,400$ 1,400$
Technical Writer 1 40 80$ 3,200$
Project Management 1 70 100$ 7,000$
Other 6,900$
Construction Lodging 1 69 100$ 6,900$
70
752,214$
865,046$
2 years escalation @ 3% / year 52,681$
Total 917,727$
$70,656
12.99
Labor + Mat + Frgt + Design
All + contingency
Estimated annual fuel savings
Simple Payback ( in Years)
71