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HomeMy WebLinkAboutScammon Bay Heat Recovery Feasibility Study - Aug 2014 - REF Grant 7081143SCAMMON BAY, ALASKA HEAT RECOVERY STUDY PREPARED BY: Alaska Native Tribal Health Consortium Division of Environmental Health and Engineering 3900 Ambassador Dr., Suite 301, Anchorage AK 99508 Phone (907) 729-3600 / Fax (907) 729-4046 August 29, 2014 EXECUTIVE SUMMARY The Scammon Bay power plant, three adjacent buildings (City Office, Old Clinic and proposed Community Hall) and water distribution loop were evaluated for heat recovery potential. The total annual heating fuel used by the end users is estimated to be approximately 11,578 gallons of diesel per year. The estimated fuel savings realized by implementing a heat recovery system is approximately 11,578 gallons. The estimated cost for the heat recovery project is $571,548. The simple payback based on a fuel cost of $7.40/gallon is 7.06 years. The payback is based on a 2014 fuel price of $7.40 gallon and an estimated 2014 project cost of $571,548. Assuming construction in 2016, the design and construction cost plus 2 years of a 3% escalation rate is $606,355. 1.0 INTRODUCTION The Alaska Native Tribal Health Consortium (ANTHC) reviewed the feasibility of providing recovered heat from the existing AVEC power plant to three adjacent buildings (City Office, Old Clinic and proposed Community Hall) owned by the City of Scammon Bay, and the water distribution loop. ANTHC also developed a budgetary project cost estimate based on Force Account Construction, including Engineering and Construction Administration. The existing two buildings (City Office and Old Clinic) are hydronically heated. They were served by the heat recovery system, but the existing heat recovery system has not been utilized for a long time. ANTHC evaluated the existing heat recovery system and decided to replace them with the new system. The thermal analysis of the proposed Community Hall was performed based on the Community Hall floor plan in Pilot Station because of the similarity in two buildings. The new system serving three buildings in addition to the water distribution loop will require controls and installation of new heat transfer equipment, including a new heat exchanger and new circulating pumps. The water treatment plant can not be directly tied into the heat recovery system because of its distance from the power plant (over 1,000 feet). However, it is possible to add heat to the city water circulation loop that runs near the power plant. This new heat adding system will require controls and installation of new heat transfer equipment, including a new heat exchanger and two new circulating pumps. Raw water is usually heated up to 40 degree F prior to injecting the chemicals and consequently to store in WST. But the new WST heat adding system allows raw water to be pumped into WST without additional heat and then water in WST is heated up to 40 degree F through the new WST heat exchanger in series with the existing. Significant work will be required at the power plant, including installation of a heat exchanger, two circulation pumps (Grundfos Magna3). insulating existing piping and new controls. This is included in the cost estimate. In addition, AVEC requires a heat sales agreement which will result in approximately 30% of the fuel savings to be paid to AVEC. Additional assumptions and brief analysis 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. However, refinements in arctic pipe size and routing, pump and heat exchanger sizing, and other design elements will be re-evaluated as the project progresses to final design. Available information was obtained from AVEC regarding the 2013 power plant electrical IoadsMTP annual fuel use was obtained from a variety of sources, including the City, and engineering estimates including the future water distribution system. Reported fuel consumption and engineering estimates were used to validate this feasibility study. 2.0 OVERVIEW The purpose of this study is to provide an estimate of the heat that can be recovered from the AVEC power plant diesel engines and used to offset heating oil consumption at the existing WTP and three end user buildings. Useable recovered heat is quantified in gallons of heating fuel saved using a gross heating value of 134,000 BTU per gallon of #1 arctic diesel fuel and an overall boiler efficiency of 75% for a net heating value of 100,000 BTU per gallon. The WTP building eligible for heat recovery are located at long distance from the AVEC power plant. Therefore, WTP cannot be utilized by recovered heat directly from the AVEC power plant. This analysis evaluates the potential to provide recovered heat to the water system and three adjacent end user buildings. The estimated average annual heating fuel consumption for them will be 11,578 gallons. 3.0 ESTIMATED RECOVERED HEAT UTILIZATION A heat recovery utilization spreadsheet has been developed to estimate the recoverable heat based on monthly total electric power production, engine heat rates, building heating demand, heating degree days, passive losses for power plant heat and piping, and arctic piping losses. The spreadsheet utilizes assumed time -of -day variations for electric power production and heat demand. Power generation data from AVEC for fiscal year 2013 is used in the spreadsheet. The estimated heat rejection rate was estimated with the average values of two power plant gensets, a Cummins QSX15 G9 and a Detroit Diesel S60, because they were equally operated during the winter. Heating degree-days for Emmonak were utilized for this site. All arctic piping is assumed to be routed above grade. The spreadsheet uses monthly heating degree-days to distribute annual fuel consumption by month. The end -user hourly heat load is compared to the hourly available heat from the power plant, less power plant heating loads and parasitic piping losses, and the net delivered heat to the end -user is determined. Following is a summary of annual fuel use and estimated fuel saving in equivalent gallons of fuel for water system: Facility Estimated Annual Fuel Use for water system _(Gallons) Water System Heating 5,878 City Office Building Heating: 1,140 Old Clinic Building Heating: 731 New Community Hall Heating: 3,848 Total Fuel Savings: 11,578 Estimated Fuel saving for water system (Gallons) 5,878 1,140 731 3,848 11,578 4.0 HEAT RECOVERY SYSTEM DESCRIPTION AND OPERATION: The heat recovery system captures jacket water heat generated by the AVEC power plant that is typically rejected to the atmosphere by the radiators. The recovered heat is transferred via above -grade arctic piping to the end users. The objective is to reduce the consumption of expensive heating fuel by utilizing available recovered heat. Although heat recovery is an excellent method of reducing heating fuel costs, recovered heat is a supplementary heat source. 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 sub -cooling of the generator engines and reducing electric power production efficiency. The recovered heat fluid is pumped through buried insulated pipe to the adjacent water distribution loop. 4.1 AVEC PLANT TIE-IN All generator cooling piping will be insulated with a minimum of 3-in rubber foam insulation and have an aluminum jacket where exposed to the weather. All valves will be either bronze ball valves or lug style butterfly valves with seals compatible with 50/50 glycol/water mixtures at 200F. Air vents, thermometers, pressure gauges, drain valves, and pressure relief valves will also be provided. Additional controls will be added, including a BTU meter and motorized bypass valve for coolant temperature control. 4.2 PRE -INSULATED FLEXIBLE PEX PIPING The proposed pre -insulated flexible pex piping is based on ANTHC's standard pipe design for heat recovery project with a 2-in pex carrier pipe (NSF 61 certified) with the minimum 3" polyurethane insulation. The piping will be buried and run from the power plant to the adjacent water distribution loop (WDL). The estimated length of the pipe is approximately 600 ft. The piping running from the power plant to three buildings will be partially buried and partially above -grounded. The estimated length of this pipe is approximately 400 ft. Circulation pumps located at the AVEC building will circulate heated domestic water from the AVEC facility to WDL. 4.3 RAW WATER and WATER STORAGE HEAT ADD TIE-IN AT WTP Water storage heat add tie-in at the WTP building consist of brazed plate heat exchanger (for potable water application) with two pumps. One is a heat injection pump for WST water to be heated by the recovered heat and the other is a WST water circulation pump through the heat exchanger. When there is insufficient recovered heat to meet the WST heating load, the building heating system (boiler or heater) will fire and add heat to WST. The heat exchanger control will be locked out the recovered heat system when there is insufficient recovered heat available. Typical indoor piping will be type L copper tube with solder joints. Isolation valves will be solder end bronze ball valves or flanged butterfly valves. All piping will be insulated with a minimum of 1-in insulation with an all -service jacket. Flexibility will be provided where required for thermal expansion and differential movement. Air vents, thermometers, pressure gauges, drain valves, and pressure relief valves will also be provided. 4.4 END USER BUILDINGS Each end user building's heat add system consists of brazed plate heat exchanger with a pump for the end user building to be heated by the recovered heat. When there is insufficient recovered heat to meet each end user's the heating load, each building heating system (boiler or heater) will fire and add heat to its own. The heat exchanger control will be locked out the recovered heat system when there is insufficient recovered heat available. 4.5 RIGHTS -OF -WAY ISSUES There'are no apparent conflicts with rights -of -ways for the arctic piping between the power plant and the end -user buildings, as the route is entirely within existing road rights -of -ways on city and AVEC property. 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. 5.0 PRELIMINARY EQUIPMENT SELECTIONS The following initial equipment selections are sized and selected based on preliminary data and will require minor modifications to reflect final design. 5.1 Heat Exchangers Doucette double -wall heat exchanger is selected for AVEC building to dump recovered heat to the water distribution loop. The heat exchangers are selected for the heat add systems. Initial heat exchanger selections are as follows. HX-1: 400 MBH capacity, Installed at AVEC building. Primary: 45 GPM 190F EGT (50% ethylene glycol), 1.0 PSI max WPD Secondary: 60 GPM xx F LWT (50% propylene glycol) 1.0 PSI max WPD HX-2,: 150 MBH capacity, Installed at AVEC WHR Module. Primary: 17 GPM xx F EWT (50% propylene glycol), 1.0 PSI max WPD Secondary: 15 GPM xx F LWT (WDL water) 1.0 PSI max WPD HX-3,: 150 MBH capacity, Installed at AVEC WHIR Module. Primary: 30 GPM xx F EWT (potable water), 1.0 PSI max WPD Secondary: 15 GPM xx F LWT (WST water) 1.0 PSI max WPD HX-4,: 100 MBH capacity, Installed at City Office Building. Primary: 7 GPM xx F EWT (50% propylene glycol), 1.0 PSI max WPD Secondary: 7 GPM xx F LWT (50% propylene glycol) 1.0 PSI max WPD HX-5,: 100 MBH capacity, Installed at Old Clinic Building. Primary: 7 GPM xx F EWT (50% propylene glycol), 1.0 PSI max WPD Secondary: 7 GPM xx F LWT (50% propylene glycol) 1.0 PSI max WPD HX-6,: 100 MBH capacity, Installed at Proposed Community Hall. Primary: 7 GPM xx F EWT (50% propylene glycol), 1.0 PSI max WPD Secondary: 7 GPM xx F LWT (50% propylene glycol) 1.0 PSI max WPD 5.2 Pre -insulated Flexible Pex Piping The length of heat recovery loop piping between the power plant and adjacent water distribution loop is approximately 600ft in round trip while the length of heat recovery loop piping between the power plant and adjacent end user buildings is approximately less than 400ft in round trip. The arctic piping utilizes 2-in carrier pipe to minimize pressure drop and reduce pumping energy. The pipe itself consists of a 2-in pex carrier pipe, 3" of polyurethane insulation and an corrugated seamless polyethylene outer jacket. 5.3 Circulating Pumps HP-1: Heat recovery loop pump at AVEC building Flow = 60 GPM, Head = 12 ft Initial Selection: Grundfos Magna3 40-120 F with integrated VFD. HP-2: Heat injection pump at AVEC WHIR Modlue. Flow = 17 GPM, Head = 12 ft Initial Selection: Grundfos Magna3 40-80 F with integrated VFD. HP-3: Heat injection pump at WTP. Flow = 17 GPM, Head = 20 ft Initial Selection: Grundfos Magna3 40-120 F with integrated VFD. HP-4: Heat recovery loop pump at WTP. Flow = 30 GPM, Head = 12 ft Initial Selection: Grundfos Magna3 40-80 F with integrated VFD. HP-5: Heat recovery loop pump at WTP. Flow = 15 GPM, Head = 15 ft Initial Selection: Grundfos Magna3 40-80 F with integrated VFD. HP-6: Heat recovery loop pump at City Office. Flow = 7 GPM, Head = 15 ft Initial Selection: Grundfos Magna3 40-80 F with integrated VFD. HP-7: Heat recovery loop pump at City Office. Flow = 7 GPM, Head = 12 ft Initial Selection: Grundfos Magna3 40-80 F with integrated VFD. HP-8: Heat recovery loop pump at Old Clinic. Flow = 7 GPM, Head = 15 ft Initial Selection: Grundfos Magna 32-60 F with integrated VFD. HP-9: Heat recovery loop pump at Old Clinic. Flow = 7 GPM, Head = 12 ft Initial Selection: Grundfos Magna3 40-80 F with integrated VFD. HP-10: Heat recovery loop pump at Proposed Community Hall. Flow = 7 GPM, Head = 15 ft Initial Selection: Grundfos Magna3 40-80 F with integrated VFD. HP-11: Heat recovery loop pump at Proposed Community Hall. Flow = 7 GPM, Head = 12 ft Initial Selection: Grundfos Magna3 40-80 F with integrated VFD. 5.4 CONTROLS Heat recovery system will use an off the shelf differential temperature controller to start/stop a heat injection pump. In addition, A BTU meter will be provided at the AVEC building, displaying instantaneous temperatures and heat transfer, as well as totalizing BTUs used. Differential Controllers: 1 required Honeywell T775 differential temperature control BTU Meters: BTU-1 AVEC Building: KEP BTU meter with 2-1/2" magnetic flow meter and matching temperature elements. 6.0 CONCLUSIONS AND RECOMMENDATIONS Estimated construction costs were determined based on prior recent heat recovery project experience, and include materials, equipment, freight, labor, design, construction management, and startup and testing. All work at the power plant, three end user buildings and WTP, along with design and construction management/administration for the complete project, is included in the Base Project cost. Incremental costs for pre -insulated flexible pipe, the end user building renovations, and overhead and freight are estimated individually (refer to attached cost estimates). The estimated project cost is $571,548 and estimated recovered heat avoided fuel cost is approximately $80,904 based on the fuel saving of 10,933 gallons. According to the heat sales agreement with AVEC, the City of Scammon Bay has to pay the recovered heat charge of $13,966 (equivalent to 30% of the fuel paid by AVEC to produce the recovered heat) to AVEC. Consequently, the net saving to the Scammon Bay community becomes $67,686. However, the simple payback of 7.06 years is estimated based on the ratio of the project cost to the total fuel saving ($80,904) resulted from the recovered heat. But the construction money for this project will be available in two years if this proposal is granted through the State of Alaska Renewable Energy Fund Grant Program in the Round VIII. With a 2 year escalation rate 3%, the estimated project cost in 2016 is $606,355 (refer to attached ANTHC DEHE spreadsheet). APPENDIX 1. CAD Drawings A. Cover Page B. Site Plan C. AVEC WHR Module D. End User Building Heat Add E. Trench Detail 2. Figure 1.Scammon Bay Recovered Heat Utilization. 3. Figure 2. Scammon Bay Recovered Heat. 4. Cost Estimates for Heat Recovery Project. 5. Recovered Heat Utilization Simulation Work Sheet. SCAMMON BAY, ALASKA ENERGY FEASIBILITY STUDY CNLM'CW SEA ISLNIC NA4TLiV SObT,e7 St ` N r sew SCAMMON 13A CI Iq ■9P1. wl0� 1[f1/B 6[INOIAq :I BER/AG SEA ARCVC OCEAN OF ALASXA v , BRISIM BAY GjjLF KOgAK e : 5 � II1000O00 15L'NB �� o N �� • O Ri��lll'LRF.ASKA 0 SHEET LIST TABLE SHEET NUMBER SHEET TITLE 1 COVER SHEET 2 SITE PLAN 3 AVEC WHR MODULE 4 END USER BUILDING HEAT ADD 5 BURIED ARCTIC PIPE INSTALLATION Alaska Native SCAMMON BAY, AK Tribal Health Consortium Division of Environmental ENERGY FEASIBILITY STUDY 0rHealthandEngi6.1rg COVER SHEET 6poo Amh1..Aaef 1�q 6u11. 3U1 Anehxap, Alnka 99506 (907) 72W600 PRINTED DATE: 8/8/14 SHEET 1 OF 5 RECOVERED 'HEAT LOOP HEAT RECOVERY MODULE ' WATER u �� 009 DISTRIBUTION 1PROPOSED LOOP n r o 6 5 -=COMMUNITY HALL o Li o AVEC f - p f' I �► d \ "-- CITY OFFICE - r� r ^� OLD CLINIC]<\ 1 +~ 1 q C IIf ` l W- 1 1 0 - WTP ISL _�- - Alaska Native Tribal Health Consortium Division of Environmental Health and Engineering 5800 Amhssaadar Dri s, Suits 501 AnO..0, Alaska 58508 (007) 7284600 0 200' 400' SCAMMON BAY, AK ENERGY FEASIBILITY STUDY SITE PLAN PRINTED DATE: 8/8/14 SHEET 2 OF 5 FROM THREE END USERS r--------- fONTROL PANEL BTU I r METER I 1 � 1 r 1 I t I l 1 I I I 1 1 1 1 1 i!i LJ 1 1 O ; TE TE Z I 1 ( O F- t i i \ J �W t I �2N I 1 0 UN Q T HX-1 T F HX-2 (400 MBH) (150 MBH) �--r TE HP-1 HP-2 HP-3 60 GPM 17 GPM 17 GPM TO THREE END USERS AVEC WHR MODULE Alaska Native SCAMMON BAY, AK Tribal Health Consortium Division of Environmental ENERGY FEASIBILITY STUDY Health 00Ambe ad Engineering AVEC WHR MODULE 3g00 AmWuadw Drive, Sulu 301 Anehaeg., Aluka 09508 (907) 72W000 PRINTED BATE: 8/8/14 SHEET 3 OF 5 r--------- TC---------- -- : , ' TE OceU- HX-4 (100 MBH)^s , HP-6 7 GPM T- ____J HP-7 7 GPM CITY OFFICE BUILDING (SIMILAR IN TWO OTHER END USER BUILDINGS) r--------- TC ----------------- 11 HP-5 T 15 GPM TE O J ; ; 38'F O O i EXISTING HEAT O Ir ' EXCHANGER ' HX-3 (150 MBH) HP-4 30 GPM -'--J HGS/HGR WATER TREATMENT PLANT Alaska Native SCAMMON BAY, AK Tribal Health Consortium Division of Environmental ENERGY FEASIBILITY STUDY HealthandEngineering END USER BUILDING HEAT ADD 3600 Amh�awdm Drlva, Suits 301 Anchw.1p, Alaska 60506 (607) 72"600 PRINTED DATE: 8/8/14 SHEET 4 OF 5 F J \ QZ O p U 2 p 3 W �- o��Q oNO3 3�o~cna>-LLJ m `�W Q~-j N Q Y JEa QQ pNX Yw =p�? a; Ow WJ�Q wamp!-- H =�ZcJ7 oiJ�{n cf O M ma:-jV �U 0 Zm U to U WaDQ� W wZ NW Qxo� Z Np pp aZ J -Lid wo QW U 1i ao caCooz o U—�0oZ zxz 3L o U0 U w = 04 UCL XU- �w nLcla �f�f\ X'/ ss 04 X i� in 1201 24" X Alaska Native SCAMMON BAY, AK Tribal Health Consortium Division of Environmental ENERGY FEASIBILITY STUDY Health 300Amhand Engineering BURIED ARCTIC PIPE INSTALLATION 3g00 AmWs�ador Drive, Bulb 301 Anch..g., Al..k. 805DO (907) 728-3500 PRINTED DATE: 8/8/14 SHEET 5 OF 5 O Z t O a v to Q 00 O 00 OL N I r-I H8W a 7 O Z 4+ Q. 41 N bA 7 Q Q Q t U L 11I � I 1 I I I I I 0 0 0 0 0 0 0 0 l0 N O 00 l0 N r-I ri r-I r-I ld9 W" O o00 o000 000' o0``;O 0 00 O f 0 O. 0, o, o O ` 01 �0 G'O CD O O ` cc ry w Y •� CD, N c;0 O O 0 O o 0 O' 0 0 0 O> 0 0' o• 0 0 0 0 .0 0 N O O W O O N�¢D O O W N Ln CO CD LL M r O r N f I- c) O N C O N d C r2 + r Nil 10 fog .H U) w w 69 69 fR H w w H3 69 V�, VA V7 69,tR M H fA_w) b3 if3 H fA O 10 -0 0 0 0 0 0 •0 0 •0 O O O t O Orr O O 0 N 0 00 r0CD O •O m"NN 0 O 00 O 0 N•N O 00 t o f[ 7 Ol LD LL H 69 64 69 69 EA U9, 69 'F9 d9 . 69 79 Vi fA'Vi N 000 O OOO o0 `'o OOOO 0,00 000 O U O r O O N r _O ' ' r ' } •O N O 0 O •O O 0.0 0 O O O CD O O O �O 0 �0 O 0 O -R O 0 O O 0.0 Iq u1 Q N �'C CV r07 V 4 N r-ncM O •CO N O NiV h Q O 119 69 H 69- H 69 69,0 V3 fA •Ffl 69 fA vi ,vi 69 69 69 69 Vi iV3 69 69 vi l69 H MItA - 0 DO 0 0',w a •o 0 0 0 0 0 0 •o o •o 0 0 0 0 0 �000 r r r oo r N oo•oo•000 0 0 •O O •O f D 0 000 ONO 00o O f 0 0 u� 0 a 7 u 7 N I- -MM OMEN N a V NA H 69 fA �yj as f<i ,e9 69 iEA 69 V! 64 ,» 0H H iVi fie fA tlA rNr rN r r•Nr rCD M.--C c; N i0 C fY N W N_ Xro- y �5 G� - > _W > > > 54 °a p W Q N j o8 w a0 dma> E d0 „`s �Em �Em 3 m q, (.) w0 �� 'a ¢ ciLL inr�n n in LL'ciICL aa'= a'= OOCPoo O O 0 f 00 f 0 00 0 0 r 0 f o M 0o0 0 'r N r 0 0 n 00 O Q N N O f+l fD o N N N N a 1; 0 NV=+ N o o M N N n 'n F J N N H H H M H H H H M ",m 69 H H GO W H M H 61 0. 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