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Home My WebLink AboutNome Joint Utility System Diesel Efficiency Enhancement Final Report - U.S. Department of Energy - AEA Grant 2195273 - Jul 2008 NEWNOMEPOWERGENERATIONFACILITY FINALCONSTRUCTIONREPORT FOR NOMEDIESELEFFICIENCYENHANCEMENTPROJECT ALASKAENERGYAUTHORITY GRANTAGREEMENT#2195273 U.S.DEPARTMENTOFENERGY INSTRUMENTNO.DEͲFG07Ͳ06ID14790 July2008 1 Theprojectreplacedtheexisting40+yearoldprimary(andonly)powergenerationfacilityfor thecommunityofNome,Alaska,population3,500,withanewplantandmoreefficientdiesel generatingequipment.Thepopulationofthecommunityconsistsof58.7%AlaskaNativeor partNative.Discoveryofgoldin1898broughtthousandsofminerstoNome.Peakingatover 20,000inhabitants,thegradualdepletionofgold,amajorinfluenzaepidemicin1918,the depression,andfinallyWorldWarII,eachinfluencedNome’spopulation.Adisastrousfirein 1934destroyedmostoftheCity.ThepopulationofNometodayisamixtureofInupiatEskimos andnonͲNatives.Althoughmanyemploymentopportunitiesareavailable,subsistenceactivities areprevalentinthecommunity.Nomeisthesupply,serviceandtransportationcenterofthe BeringStraitregion.Governmentservicesandgoldminingprovidethemajorityofemployment. Nomeisaregionalcenteroftransportationforsurroundingvillages. History Nome’sexistingPowerPlantisover40yearsold.ItislocatedonthebanksoftheSnakeRiver. Pastfloodingeventshaveresultedinthesuspensionofpowergenerationtothecommunity andspringbreakupisatenseperiodeachyear.Inaddition,EPAandAlaskaDepartmentof EnvironmentalConservation(ADEC)Ͳmandatedinfrastructuretocomplywithairquality regulationsextendedexhauststacksintotheairport’sprotectedairspace.Theexistingfacilityis locatedwithintheNomeAirportRunwayProtectionZone(RPZ)fortheprimary(andonlyILSͲ equipped)runway.Theairportoperator–AlaskaDepartmentofTransportation&Public Facilities(ADOT/PF)–iscurrentlyundertakingprojectstoclearhazardstonavigationfromthe airportapproachestobringtheairportintocompliancewithFAAstandards.Whiletheexisting plantwasinitiallylocatedwelloutsideofdevelopment,communitygrowthandotherrequired infrastructurehavebeenconstructedaroundtheplantandthereisnofurtheropportunityto expandtheplantatthecurrentlocationtomeetthecommunity’severͲincreasingenergy demands.Emergencybackuppowerpreviouslyavailablefromprivateenterprisehas subsequentlybeendismantled. TheUtilityhascontinuedtooperate,maintainandupgradethefacility,butagingequipment mustbereplacedtoinsurecontinuedreliability.Theinstallationofadditionalequipmentatthe existinglocationisnotpossible.Olderunits,physicallylocatedinthemiddleofthefacility, cannotberemovedbecauseothersurroundingpowercontrolsystems,distributionlinesand communitywaterdistributioncomponentshavebeenbuiltaroundthemsotheyarenow physicallyentombedwithinthebuilding.Despiteenjoyingoneofthebestgenerationefficiency factors–approaching16kilowattspergallonofdieselconsumed,generatorandfacility maintenancecostscontinuetoincreaseannually.Existingcontrolsystemshavebeenmodified asnewerequipmenthasbeenadded,butagemakescontinuedoperationoftheseobsolete systemsdifficult.Technologyadvancesnowavailablewoulddecreaseoperatingcostsand improvereliability. TheUtilityhasexperiencedcatastrophicmechanicalfailureswithbothprimaryandolder standbyunits.In1997,theUtilitywasunabletoprovidefullpowertotheentirecommunity andwasforcedtoalternateareasofserviceinanattempttopreventthefreezeupof residences,facilitiesandthemunicipalwaterandsewerdistributionandcollectionsystem.The Utilitywasabletorepairallgenerators,exceptoneduetoageandnonͲavailabilityofparts,to 2 operationalorstandbystatus.In2002,theUtilityissuedapowerconservationalertand requestedfacilitieswithstandbygenerationcapacitytoshedtheirloadfromthecitysystem. Thiswasnecessitatedbyrapid,sequentialfailureofmaingeneratorsand,subsequently, emergencystandbygeneratorswhichhadbeenplacedintoservice. In2003,fireengulfedtheprimarygeneratorlocatedinasatellitebuilding.Capitalizingonthe ChristmasDay1989experiencewhenfiredestroyedthemaingenerator,itsreplacementwas equippedwithfiresuppressionequipment,minimizingdamagethatcouldhavebeen catastrophic.Theplantbuildingcontainingbackupunitsandallgenerationanddistribution controlsystemshasminimalprotection(handextinguishers)duetoageanddesignthatdoes notlenditselftoinstallationoruseofautomatedfirefightingchemicaldispersants. Theavailabilityofreliablepowerisnecessarytopromotenewbusinessandeconomic developmentandresultingjobopportunitiesinthecommunity. Process ThedifficultyinacquiringrepairpartsforolderunitsintensifiedtheUtilityBoard’sbeliefthat thecurrentplantwasoperatingonborrowedtimeandrequiredimmediateactiontoupdate generationanddistributionequipment.Inadditiontopastfloodingthatforcedtheplantto ceasegenerationforaperiodoftime,andwhichcouldoccuragain,theareacontinuestobe erodedbytheSnakeRiver.Intheunlikelyeventofaruptureofafuellineorstoragetank, contaminationoftheSnakeRiverandaquaticlifecouldresult.InallprobabilitytheCitywould notbeabletoreceiveadditionalpermitsfornecessaryexpansioninthelocation,evenifland wereavailable. Designengineerswereselectedtobegindevelopmentofanewpowerplant.AConceptual DesignReport(“CDR”)evaluatedfivesitelocationoptionsforthenewpowergeneration facility,optionsforuseofwasteheatateachlocation,plantconfigurations(singleplantand main/remoteoptions),engineandgeneratoralternatives,incorporationoftheKalinaCycle Turbineintotheplantasadditionaldieselefficiencytechnology,andconstructioncost estimatesforeachalternative.Possiblesitesonwhichtorelocatethepowerplantwere reviewedandarightofentrywasgrantedtootheradjacentstateͲownedproperties,outside therunwayprotectionzone.NJUSperformedapreliminaryenvironmentalassessmentand soilsinvestigationonthesiteandfounditacceptable.Afterconsiderablepublicinputand extensiveanalysisofalternatives,theUtilityBoardandCityCouncilselectedthesiteupon whichthenewfacilitywasconstructed. Priortodeterminingitwasinthebestinterestofthecommunitytoproceedwiththe constructionofanewfacility,NomehadbeensuccessfulinreceivingfundingfromtheUS DepartmentofEnergyfortheDieselEfficiencyEnhancementProject.Theinitialfocusand intentwastoinstalltechnologyonanexistinggeneratorusingtheKalinaCycletoconvertwaste heatintoelectricity.Thetechnologywasbeingdemonstratedonalargescalebasisonagas turbineataDOEfacility.Determiningwhetherthistechnologycouldbeeffectivelyand efficientlyinstalledonsmalldieselturbineswasthefocusofayearͲlongeffort.Priorto enteringintoaPhaseIIagreementwithExergy,athoroughreviewofthePhaseIreport 3 providedwasdonebytheUtilityanditwasdeterminedthecontributiontotheoveralldiesel generationefficiencyprojectbyincludingtheKalinaCycletechnologywouldnotprovide adequatebenefit;projectedcost/benefitdidnotwarrantfurtherconsiderationofapplyingthe technologytotheoverallproject.TheUtilityBoardadoptedtheirfindingsbyResolutionwhich wastransmittedtoExergy.ShortlythereafterExergywasnolongerinbusiness. Thedeterminationwasmadetoproceedwithdesignactivitiesforanewandmoreefficient dieselgenerationplant.Datawassolicitedonengines;criteriaforevaluationincludeddiesel efficiency,utilizationofwasteheat,operatingandmaintenancecosts,repairpartsandtraining availability,andmaintenanceofairqualitystandards.Fourenginemanufacturerspresented technicalandproductdataonsixpotentialengines.UtilityBoardusedthefollowingdecision matrix:cost(capital,operatingandmaintenance),service,performanceandmanufacturer support.Throughtheprocess,twounitswereeliminatedwithfurtherevaluationofthe remainingfour.Wethenworkedwithmanufacturerstocompileairqualitydatawhichwill impactairpermittingrequirementsofvariousengines,surveyedotherusersofsimilar equipmenttoacquireindependentperformanceandreliabilitydata,whilecontinuingtohold publicmeetingsonthestatusofactivities.Ultimately,theUtilityBoardselectedWärtsiläasthe supplierofthenewgeneratorsanddeterminedthe12V32modeltobethemostappropriate. UtilityBoard,managementandstaffmetwiththedesignteamtoreviewfinalfacilityplans; formallyapprovedbyBoardResolutionandtransmittedtofiremarshalforreview. Procurementpackagesforbuilding,mechanical,electricalandfiresuppressionsystems,engine controls,etc.preparedforearly2005release.Board&CityCouncilDirection:packagestobe “sized”toallowmaximumparticipationbylocalcontractorsandbusinesses;uselocalhire wheneverpossibleontheproject. Variousbidpackageswerereleased,andwhenopenedbidpackagesforSteelBuildingSupply& Erection,ConcreteForming&Installation,andHVACsystems,somebidswere“conditional”, notadheringtostatedbidrequirements.Costssubstantiallyaboveengineers’estimates;with excessivecostoverrunsprojectedbasedonbids,Utilitydeterminedtorollprojectbackuptoa fullyforceaccountprojectnotingsignificantpotentialforconstructionclaimsusinga“multiple primecontractor”scenario.UtilityBoarddeterminedbenefittoUtilityandcommunityby servingasitsowngeneralcontractor,givingmoreflexibilitytomakeinevitabledesignchanges withouthavingtonegotiatecostlychangeorders. Followingdeterminationtoconstructunderforceaccount,alocalconstructionsuperintendent washired.TotheextentpossiblelocaldirectͲhirelabor(bothskilledandunskilled)washired, supplementedbyskilledoutͲofͲtownlaborinspecialtytrades(steelerection,pipefitting, electricians). ProjectSuccesses,Challenges,LessonsLearned Thecompletedprojectwillservethecommunitywellformanydecades.Stateoftheart monitoringandcontrolequipmentprovidesforexcellentsystemmonitoringandelectronic control,andintheeventofaproblem–improveddiagnosisandtroubleshooting.Parameter adjustmentutilizingcomputerizedprogrammablelogiccontrollersallowsformorerapid 4 dispatchadjustmentsaspowerdemandincreaseordecreaseresultinginbetterfuelefficiency, conservationandcostcontainment.Priormechanicalequipmentcouldnotberegulatedtothe sameextentandrequiredongoinghumanattentionandintervention.Timesynchronization andrecordationofgenerator,relay,andbreakeroperationorfaultsallowsystemoperatorsand engineerstomonitoroperationsanddiagnoseproblemsorinterruptionsmorerapidly. Thenewfacilityisallowingustotakegreateradvantageofandutilizewasteheatgenerated. Theprimaryuseofavailablewasteheatistoraisethetemperatureofthedomesticwater. Deepwellsprovidethecommunity’sdrinkingwaterwhicharrivesatthepowerplantata temperatureofapproximately37degrees.Afterheatexchange,thedistributiontemperatureis approximately60degrees.Duringwintercirculation,waterreturnsatapproximately45 degrees.Becauseofthewasteheatrecovery,residentsandbusinessesinthecommunitysave asubstantialamountofenergywhichwouldbeotherwiseconsumedbytheirboilersorwater heaterstoheatdomesticwater.Secondaryutilizationistoheatutilitymaintenanceand operationsfacilitiesinproximitytothepowerplant,dramaticallyreducingtheamountof heatingoilthatisconsumed.Additionalopportunitiestoprovidewasteheattootherfacilities inthevicinityareunderinvestigation. Thesuccessoftheprojectcanlargelybeattributedtoourdecisiontoserveasourowngeneral contractoranduselocalforcesintheconstruction.Whiledetailedengineeringplanswere developed,intheconstructionphase,adjustmentstoimproveoperationsflowcouldmore readilybemodifiedwithoutexpensivecontractorchangeorders.Additionally,havinghad operationspersonnelintimatelyinvolvedinallphasesofthedevelopmentandconstruction aidedinthetransitiontoandtheirfamiliarization/trainingwiththeoperationsflowatthenew facility. Becauseofourremotelocation,accessibleonlybyair,orseasonaloceanͲgoingbargesduring summer,redundancyinsystemsisanecessity.Wearenotconnectedtoagridwherewecan obtainpowerintheeventoflossofgeneratingcapability.Thiscanbeextremelycriticalinthe Arcticwherefreezingtemperaturescanrapidlyplungethecommunityintocatastrophe, threateninglives,homes,criticalfacilities,waterdistributionandwastewatercollection infrastructurewithpowerinterruptionofevenashortduration.Weatherconditions(snow blizzards,fog,etc.)canimpactairlineflightschedulesandlandingability,sooutsideassistance andpartsavailabilitycanbe,atbest,adayaway,androutinelyseveraldays.Evenabsent weatherissues,partsavailabilityandexpeditingthemtoruralAlaskacandelayrepairs. Severalfundingpartnerscontributedtothesuccessoftheproject;however,therewere instanceswhenfundingbelievedtohavebeensecureddidnotmaterializeinthetimeframe expected.Asaresulttherewereseveraltimesthatconstructionactivityhadtobesloweddue toincrementalfundinguncertaintyordelays,andwewereonlyabletoproceedwith contractualobligations(suchasmaterialsorderedfortransportationbybarge,whichifnot orderedwouldhaveputtheprojectonholdforlongerperiodsoftime)andminimalbuilding activities(atareducedlevelwhichwasrequiredtoretainlocalemployees).Thiswasthesingle mostchallengingpartofcompletingtheproject,andrequiredextensiveuseoflineofcredit arrangementspendingreceiptofparticipantfunds;interestexpenseofnearly$1.2million added3.4%totheoverallprojectcosts. 5 AnotherunanticipatedandfarͲawayevent,HurricaneKatrina,impactedthescheduleand overallcostoftheproject.Withtheextensivedevastationandreconstructionactivities, materialsbecamescarce,hadlongerleadtimes,andweremorecostly.Withsubstantialworld oilandmetalpriceescalations,costsweremuchhigherthanprojectedforsteel,copperand aluminum,anditemswhosemanufacturingincludeuseofpetroleumproducts. Schedule TheProjectActivitiesSummaryfollowcostssummariesandindicateconstructiontiming/ schedule,activitiesaccomplishedandissuesthatimpactedconstructionactivities. Costs Projectaccountingcapturedcostsbymajorcapitalizationunitsandcomponenttasks. FollowingtableisasummaryofcostsbyProjectID(majorclassificationsforcapitalization): NEWNOMEPOWERGENERATIONFACILITY SUMMARIZEDBYPROJECTID ProjectCost (Finalest) @9/30/08 (000) %of totalProject IDDescription 69Ͳ0000KalinaCycleInvestigation(Exergy) 2750.8% 60Ͳ0099PowerPlantDesign 1,600 60Ͳ0140AirPermitting 225 1,8255.2% 60Ͳ0110PropertyPurchase 180 60Ͳ0120Environmental–EPABrownfields 159 3391.0% 60Ͳ0100Generators 4,800 60Ͳ0101GeneratorElectricalSystems 2,575 60Ͳ0102GeneratorMechanicalSystems 1,675 60Ͳ0130EnvironmentalͲ Other 275 60Ͳ0200SitePreparationandDevelopment 725 60Ͳ0210Foundation 2,522 60Ͳ0211SlabandConcrete 2,008 60Ͳ0220Building 4,890 60Ͳ0221BuildingMechanicalSystems 4,993 60Ͳ0222BuildingElectricalSystems 3,300 60Ͳ0223BuildingSecuritySystems 245 60Ͳ0225BuildingFireSystem 370 60Ͳ0270FuelStorage 320 28,69881.2% 60Ͳ0280DistributionInterconnect/Relocate 1,4004.0% 60Ͳ0205ConstructionManagement 1,6104.6% 60Ͳ0205CapitalizedInterest 1,1903.4% TOTAL 35,337100% 6 FollowingtablesummarizestotalprojectcostsbycomponentortaskID: NEWNOMEPOWERGENERATIONFACILITY SUMMARIZEDBYCOMPONENT(TASK)ID ProjectCost (Finalest)@ 9/30/08 (000) %of totalComponent (Task)IDDescription 00Ͳ0Labor 4,62013.1% 01Ͳ0Materials 8,20023.2% 01Ͳ1Engines&Generators 4,06711.5% 02Ͳ0Freight 1,6004.5% 03Ͳ0Equipmentrental 1,3403.8% 05Ͳ0Services 8,00022.6% 06Ͳ0Legal 260.1% 07Ͳ0Permits 950.3% 08Ͳ0Inspection 1010.3% 09Ͳ0Supplies 6251.8% 10Ͳ0Travel/PerDiem 2010.6% 11Ͳ0EngineeringDesign 2,6217.4% 12Ͳ0EngineeringManagement 7302.1% 15Ͳ0Surveying 160.0% 16Ͳ0ProjectManagement 1,6304.6% 20Ͳ0CapitalizedInterest 1,1903.4% 69Ͳ9KalinaCycleInvestigation(Exergy)2750.8% TOTAL 35,337100% ProjectSuccessMeasure Theultimatesuccessoftheprojectisdemonstratedbyanincreasedefficiencyinoperations. TheUtility’sfuelefficiencyfactorhasimprovedtoanewhighof16.5kilowattͲhourspergallon ofdieselfuel,andonlyinextenuatingcircumstanceswilloldgeneratorsinthe11Ͳ13rangehave tooperateagain.Withtheextremelyhighandincreasingcostsofdieselfuel,atrecordpricesin recentmonths,everyfractionofagallonoffuelthatcanbemoreefficientlyconvertedto electricitybecomesmorevaluable. PostͲscript Inthedesignofthenewfacility,theabilitytointegratealternativeenergytechnology(wind power)wasincorporatedintoswitchgearandcontrolssystems.WhiletheCitycontinuesto pursueitsownadditionofwindgeneration,wearecooperatingwithaconsortiaofthelocal villageandregionalNativeCorporations,andbyDecember2008a1MWwindfarmwillbe operational,whichwillallowthecommunitytoreduceitsdieselconsumptionforpowerbyan estimated12Ͳ18%.Ifthenewmoredieselefficientfacilityhadnotbeenconstructed,the integrationofwindwouldnothavebeenpossibleinsuchashorttimeframe,andtheadditional reductionsinenergycoststothecommunitywouldhavebeenforegone. Photographs Thousandsofphotographsweretakenduringtheprojectdetailingtheentireproject,from planningthroughconstructiontooperations.Asamplingofthesephotosisappendedtothis report. NEWNOMEPOWERGENERATIONFACILITY ProjectActivitiesSummary 1981 x Utilityboardidentifiesneedforadditional,newandimprovedutilityservicefacilities 1990 x Localappropriationforconceptleveldesignforanewpowerplantutilizingawasteheat recoverysystem 1994 x LocalappropriationforConceptualDesignPlanforNewPowerPlant 1995 x NJUSBoardrecognizesneedtoconstructanewpowerplanttoreplacetheexisting, antiquatedplant 1997 x Localappropriationforengineeringstudyfornewpowerplant 1998 x Localappropriationforengineeringstudyfornewpowerplant 1999 x Localappropriationforengineeringstudyfornewpowerplant 2000 x Communitypriority:Seektechnologyfordieselefficiency 2001 8 x UtilityBoardtoCityCouncil:Newpowerplantneeded;Newdieselefficientpowergeneration facilityselectedascommunity’s#1priority x LocalappropriationforNewPowerPlantEngineering/Design 2002 x Communitypriority;localappropriationforNewPowerPlantEngineering/Design x Selecteddesignengineersfornewpowerplant x ConceptualDesignReport(“CDR”)evaluatedfivesitelocationoptionsfornewpower generationfacility,optionsforuseofwasteheatateachlocation,plantconfigurations(single plantandmain/remoteoptions),engineandgeneratoralternatives,incorporationofthe KalinaCycleTurbineintotheplantasadditionaldieselefficiencytechnology,andconstruction costestimatesforeachalternative x UtilityBoardadoptedResolution#02Ͳ26reviewingCDRandselectingalternatives.Adopted #02Ͳ27reviewingKalinaCycleTurbineprojectanddetermineditscontributiontotheoverall dieselgenerationefficiencyprojectwouldnotprovideadequatebenefit;projectedcost/ benefitdidnotwarrantfurtherconsiderationofapplyingthetechnologytotheoverallproject x MeetingswithAIDEA/AEA,theDenaliCommission,USDARuralUtilitiesServiceandAlaska’s congressionaldelegationtoreviewprojectplansandalternatives x Designactivitiesforanewandmoreefficientdieselgenerationplant x Datasolicitedonengines;criteriaforevaluationtoincludedieselefficiency,utilizationof wasteheat,operatingandmaintenancecosts,repairpartsandtrainingavailability,and maintenanceofairqualitystandards x CollectedenvironmentalinformationrequiredforaCommunityDevelopmentBlockGrant (“CDBG”) x PreliminarygeoͲtechnicalandenvironmentalanalysisatpreferredsite(whichwouldallow interconnectiontoexistingancillarysystemsandprovidewasteheattofacilities) 2003 x Communitypriority;localappropriationforNewPowerPlantEngineering/Design,grant matches x Fourenginemanufacturerspresenttechnicalandproductdataonsixpotentialengines. UtilityBoarddecisionmatrix:cost(capital,operatingandmaintenance),service,performance andmanufacturersupport.Eliminatedtwounitswithfurtherevaluationofremainingfour; 9 workwithmanufacturerstocompileairqualitydatawhichwillimpactairpermitting requirementsofvariousengines x FinaldocumentationforCDBGcompletedandawardinplace x ApplicationsubmittedtoUSDA–RuralUtilityHighEnergyCostCommunityGrantProgram x DenaliCommissionpassedresolutionallocating$4millioninFY2003funding.Metwith AIDEA/AEAandDenaliCommission;DenalifundingtoNomethroughAEA x MetwithStateofAlaskatoreviewpreliminaryengineeringdataobtainedfromnewsite investigation.StaterepresentativesspentaweekworkingwithNJUSstafftoaddressthe minorenvironmentalissuespreviouslyidentifiedonthepropertytobeconveyed x Surveyedotherusersofsimilarequipmenttoacquireindependentperformanceand reliabilitydata x Publicmeetingsheldonprogressandstatusofactivities x Boardreviewedengineerreportonpotentialthatselectivecatalyticreduction(SCR)maybe requiredasbestavailablecontroltechnology(BACT)underADECairpermittingprogram. RevisedconfigurationchangedatatoavoidSCRreceived x UtilityBoardResolution#R03Ͳ06selectedWärtsiläassupplierofnewgenerators x NotifiedbyUSEPAfundingtoNomewasapprovedunderBrownfieldsProgram,designated forenvironmentalmonitoringandanyadditionalrestorationactivities x ProtocolssubmittedtoADECforairmodeling;subsequentmeetingtoprovideupdateon design,discusspermitting,airqualitymodeling,meteorologicaldatacollectedandreview timelines;anothermeetingtoreviewTitleVAirQualityConstructionPermitApplication x Bidpackagereleasedfordynamiccompactionofsitesoilsrequiredtomeetseismicdesign codes;contractorhired;workbegunmidͲSeptember,completedfirstweekofOctober. Followingcompletionofdynamiccompactionofsoils,thepropertysitewasfilledin compactedliftstoraisetheelevationabovethe100Ͳyearfloodline x SubmittedTitleVAirQualityConstructionPermitapplicationtoADEC;metwithagencyto reviewcompletenessandprovideadditionalinformationrequiredtoallowprocessing. Additionalinformationgeneratedandsubmittedtostateairpermittingregulatorstoassistin evaluationofselectivecatalyticreductiontechnologyoptions x PropertyRecordofSurveyPlatcompletedandsubmittedtotheStateofAlaskaforapproval; propertyappraisalcompleted.Negotiationsongoingforpropertyacquisition/transfer x October16,2003,afireeruptedinaportionoftheexistinggenerationplantcontainingthe community’sprimarypowergenerator;fuellinefailure.Communityforcedbackintoreliance 10 onoldstandbygenerators.GensetrepairedandreturnedtoserviceonOctober30,2003. Buildingmadestructurallystablewithroofrepairstobecompletedwhenweatherconditions allow x Continuedquestforadditionalfundingpartnerships x Continuedtoward95%designcompletion 2004 x Communitypriority;localappropriationforNewPowerPlantEngineering/Design,grant matches x ContinuedresponsestoADECAirPermittingstaffrequestsforadditionaldetailedinformation toevaluateBACT(bestavailablecontroltechnology)aspects.April14meetingwithair permittingstaff,consultantsandrepresentativesofWärtsilätoprovideadditionaltechnical information.May6–ADECpostedpublicnoticeofintenttoissueAirQualityControl ConstructionPermitforthenewplant.ThirtyͲdaypubliccommentperiodthroughJune6. May17–ADECadvisedofEPArequestthatADECcollectadditionalinformationonfuel switchingtechnology;submitted.ADECevaluatingadditionalinformationandcomments submitted;objectedtoproposaltorequirefuelswitchingduetoexcessiveoperatingand capitalcoststhatwouldberequiredtoaccommodatemultiplegradesoffuel.AirQuality ConstructionPermitissuedNovember5,2004containinglowsulfurfueluserequirement. NJUSunsuccessfulinobtainingbidsfromsupplierstoprovidethisfuelwhichisnotyet commerciallyavailableinAlaska x ApplicationseekingfundingassistancerevisedandresubmittedtoUSDepartmentof AgricultureͲRuralUtilitiesServiceunderHighEnergyCostCommunityprogram.(Prior applicationrankedNomeproject#10outofapproximately50applicationssubmitted;9were fundedduringtheinitialround) x Contractawardedtodemolisholdstateshopbuildingonnewpropertysite;buildingremoved andadditionalgravelfillimportedasrequiredtoelevatethenewbuildingsiteoutofflood plain x MeetingsinWashington,DCwithSenatorStevens,SenatorLisaMurkowski,andCongressman Youngtoupdateonstatusandprogressofthenewpowerplantproject x DeedtransferringpropertytotheCityrecordedbytheStateofAlaska x Buildingdesignandspecificationspackagefinalized x FoundationplanssubmittedtoFireMarshalandapproved 11 x Steelpilingmaterialsorderedandreceived;contractawardedtoinstallpiling.Piledriving contractoronͲsitetobegininstallationatthebeginningofAugust;completedinstallationof all(141)pilingbymonthend x Contractorselectedtoprovideconcretematerialsreadyforplacementtoconstructbuilding gradebeamsandfoundationslabs.Materialstoarriveonlastbarge;contractorbegan processingaggregate x 210tonsofreinforcingsteel(rebarandmesh)orderedtoarriveonlastfallbarge.Electrical andunderͲslabconduitorderedandarrived;substantialportioninstalledduringOctober whiletemperaturesstillallowedforgroundexcavation x SubmittedQAplantoEPAforcleanupworkfundedthroughBrownfields;approved.Soils excavatedandhauledtothemunicipallandfill x FuelpipingandstoragefacilityplansweresubmittedtoADECforreviewandapproval x EnginepurchasecontractwithWärtsiläfinalizedandapprovedbyUtilityBoardResolution #04Ͳ12;enginestoenterproductionforfall2005delivery x UtilityBoard,managementandstaffmetwiththedesignteamtoreviewfinalfacilityplans; formallyapprovedbyBoardResolution#04Ͳ11.Planstransmittedtofiremarshalforreview x Procurementpackagesforbuilding,mechanical,electricalandfiresuppressionsystems, enginecontrols,etc.preparedforearly2005release.Board&CityCouncilDirection: packagestobe“sized”toallowmaximumparticipationbylocalcontractorsandbusinesses; uselocalhirewheneverpossibleonproject x Preparerevisedtimeline;continuematerialsprocurement x ContinuedialoguewithDenaliCommissiononallocationofadditionalfundspreviously authorizedbyCongress 2005 x Communitypriority;localappropriation–grantmatches x Bidpackagespreparedandreleasedtoacquirethemetalbuildingpackage.Additional directionprovidedonseparationofvariousconstructioncomponentsinefforttomaximize localinvolvement.Additionalbidpackagespreparedandreleasedformechanicaland HeatingVentilationAirConditioning(HVAC)systems,concreteformingandinstallation,nonͲ structuralframing,fueloilpiping,exteriorstructuralsteelandfencing x CostͲbenefitanalysisofvariouscathodicprotectionoptionsforfacilitypilingreviewed. Analysisindicatedadditionalcostof$300,000Ͳ$500,000andwouldrequireextensive 12 maintenanceofanodesbutwouldnotmateriallyextendthelifeofpilingsystem;UtilityBoard unanimouslyrejectedinstallationofcathodicprotection x PetitionfiledwithADECtodefaultairconstructionpermitBACTdeterminationforSO2.Per agreementwithADEC,iftheincrementalcosttouselowsulfurfuelexceeded$0.04/gal, defaultdeterminationwouldbeenacted;projectedincrementalcostbasedonbidsfrom suppliersexceeded$0.10/galwithproductnotcommerciallyavailableinAlaska x OpenedbidpackagesforSteelBuildingSupply&Erection,ConcreteForming&Installation, andHVACsystems;somebids“conditional”,notadheringtostatedbidrequirements.Costs substantiallyaboveengineers’estimates;withexcessivecostoverrunsprojectedbasedon bids,Utilitydeterminedtorollprojectbackuptoafullyforceaccountprojectnoting significantpotentialforconstructionclaimsusinga“multipleprimecontractor”scenario. UtilityBoarddeterminedbenefittoUtilitybyservingasitsowngeneralcontractor,giving moreflexibilitytomakeinevitabledesignchangeswithouthavingtonegotiatecostlychange orders x Localweldingcrewcertifiedandinstalledpilecaps.Additionalrunsofunderslabelectrical conduitinstalled x AssemblyofWärtsilägeneratorscompletedinJune;Utilityandengineeringrepresentatives witnessedoperationaltestsattheFinlandfactoryandacceptedthemforshipment.Arrived NomeSeptember8 x Localconstructioncontractorhiredtosuperviseformingandconcretepouring;formingof gradebeams,generatorspadsandfoundationslabscompletedSeptember20 x Steelbuildingpackageprocured;manufacturingbuildingpackage,metalstairsandoverhead cranescompletedandarrivedonfallbarge.BuildingerectionbeganSeptember24; substantiallycompletetoallowinstallationoffirstwallshellpanelsOctober19;byOctober31 thesecondwallwasnearingcompletion.Continuedwithroof,endwallsandtrim; substantiallycompletebyDecember9.Afewexperiencedpersonnelwerehiredto supplementthelocalworkforce;completedusing1,900lesslaborhoursthanbudget projection x GeneratorsmovedintopermanentpositioninfacilityOctober8 x $4millionUtilityrevenuebondtoprovideadditionallocalfundingtotheprojectwassoldto theAlaskaMunicipalBondBankAuthorityonOctober20,2005 x ApplicationsubmittedtoUSDAforadditionalfundingunderprogramtoprovideassistanceto communitieswithextremelyhighenergycosts;additionalinformationrequestedbyagency. Statusunknown x MetwithStateofAlaskarepresentativestodiscusswasteheatavailabilityandtheir requirementsforstatefacilitieslocatedadjacenttothenewsite 13 x Airhandlingunits,indoorswitchgear,andexteriorsteelforfuelstorageandcontainment, exhaustsystems,andsilencerframes,mechanicalsystem,buildingnonͲstructuralframing materials,boilers,windows,doorsandhardwarewereorderedtomakelastfallbarge.Work continuedsortingandcatalogingmaterials,suppliesandequipmentinanticipationof beginninginsideconstructionafterthefirstoftheyear x MetwithnewDenaliCommissionFederalCoͲChairtobriefonproject 2006 x Communitypriority;localappropriationforgrantmatches x Activitiestargetedinclude: o followupwithUSDAͲRDandtheDenaliCommissiononstatusofadditionalfunds neededtocontinuetheproject o interiorconstructionframing,electricalwiringofbuilding,installfiresuppression, mechanical,andelectricalgenerationanddistributionsystemcomponents o exteriorconstruction,includingerectionofexhaustsystems,placementof transformers,installationofsecurityfence(requiredbyairpermittolimitaccessͲ exposure),erectfuelstoragetanksandcontainment o reroutedistributionfeederstonewplant o installundergroundconduitandpipingbetweenoffͲsiteemergencystandbygenerator andnewplantelectricalbus o commissionnewplantbySeptember15,2006 o begindecommissioninganddismantlingofexistingfacility;completeenvironmental restorationactivities x Funding: o DenaliCommissionawarded$2.75Mofanticipated$5.0MtoNomeProjectatJanuary Commission2006meetingtocovercostsofmaterialsandequipmentreceivedonthe fall2005barge o AlaskaStateLegislatureappropriated$4.0Minstatefunding,availablestartingJuly 2006,toassistwithincreasedprojectcostsforpriceescalationsresultingfromfunding delays,reroutingofdistributionsystemstonewplant,anddecommissioningcostsfor existingplant 14 o 2005fundingassistanceawardof$950KfromUSDeptofEnergyfordieselefficiency finalizedinOctober2006 o USDARuralUtilitiesconsideredrequestforspecialconsiderationunderHighCost EnergyCommunityGrantProgram,awardinganadditional$2.5Massistancein October2006 o Communitypriority;localappropriationforgrantmatches x 2006ActivitiesCompleted: o January -Constructionactivityslowedduetofundinguncertainty;proceededwith contractualobligationsandminimalbuildingactivities(atminimumlevelto retainlocalemployees) -Completedinstallationoffirstengineairhandler -Interiorandspecialsoundwallframing -Firstsheetrockhung -Largeexteriorpaneldoorsinstalled -Begininstallationofsecondengineairhandler o February -Continuedinteriorframing,insulatingandsheetrock -Formedconcretecurbsatwalllocations(necessarytocontainfuelintheevent ofaleak) -Electricalswitchgearmovedintoplace -Domesticplumbinginstallationinitiated o March -Completedinstallationofsecondengineairhandler -Pouredcontainmentcurbs -Continuedwallframing -BeganHVACductwork 15 -Beganlowvoltageelectricalconduitinstallation o April -Beginmechanicalpipefabrication -ContinuedHVACductinstallation -Insulatingofinteriorwalls -Domesticplumbingcompleted o May -Completedinstallationofbuildingairhandlingunitandducting -Installedengineandcontrolbackupbatteryracks -Overheadcraneselectrified,loadtestedandcertified -Generatorsleveledandsetinfinalpositiononspringpads -Beginfabricationofmechanicalpipesupportracks -Exteriorairlouversinstalled -Initiatedesignoffiresuppression,control,accessandsecuritysystems -Exteriorearthwork–fillandgradeareasforinstallationofradiatorsand silencers o June -Summerconstructionseasonbeginsinearnestwiththearrivalofthefirst springbarge,anduponconfirmationoftheStateLegislature’sfunding commitment -HVACcontrolscompleted -Concentratedeffortbeganonweldingofmechanicalsystemspipe -Radiatorstandsweldedintopositionandradiatorsset -Formingoflubeoilcontainment,transformercontainmentforconcretepours -Excavateforplacementofundergroundelectricalvaults 16 -InstallsubͲsurfacegroundingcablenetwork -Waterdistributionmainsextendedandtemporarymanifoldinstalled o July -Begininstallationoffireprotectionsystem -Pressuretesteddomesticplumbing -Firstconcretepoursonlubeoilandtransformercontainment -Continuefabricationandinstallationofmechanicalpiping -Beginformingofundergroundelectricalvault#1 o August -Bargearrivalwithadditionalmaterials -Beginfabricationofpipesupportstands -TieͲinofairhandlerandheatloops -Beginformingoffueltankpads -Preparation,fabrication,andgroundworkforfuelpipinginstallation/tieͲin -Pouredundergroundelectricalvault#1;beginformingofelectricalvault#2 -Pressuretestedfiresystempiping -Installedbuildingunitheatersandsnowmeltcontrols -Continuedformingandpouringoftransformerpads -Completedlubeoilcontainment -Continuedmechanicalpipingfabrication;beginplacementonpipesupports -Wasteheatpipingtowaterdistributionplant -Continuedinstallingsheetrock(onrainydays) o September -Bargearrivalwithadditionalmaterials 17 -Formedtransformercontainmentseparationwalls -Pouredconcretefoundationsforfueltanks -Installedundergroundfuellines,includingcathodeprotection -Installedconduitandwiringforaccess,securityandcontrolsystems -Pouredundergroundelectricalvault#2 -Form/pourconcretedoorentrypadsandapproachaprons -Beginerectingsilencertowers o October -Installundergroundconduitbetweenbuilding,electricalvaultsanddistribution system -Begininstallationofgeneratorpipeskidmodulesandconnectiontofirst generator -Removetemporaryexteriormanifoldandbringwatersystemdistributioninto building -Sitepreparationinadvanceofseasonalfrost -Silencerssetintower -Fabricationofcomponentsforfuelcontainment -Continuemechanicalpipingfabricationandinstallation,includingtoradiators o November -Beginweldinginpositionoffuelcontainmentdike -Erectingsecondstageofsilencertowers -PlaceWärtsilaenginepipingmoduleandfabricateconnections -Completedinstallationofundergroundelectricalconduitandplacementof cabinetsovercabinetrisersinpreparationtopullcable -BlackStartGeneratormovedintopositiononmezzanine 18 -Installationofwiringandconduitforcontrolsystemscompleted -Continuelowvoltageelectricalconduitplacement,sheetrocking,andbegin installationofinsulatedwallpanelstoreduceenginesoundtransfer -Beginfabricationofwaterdistributionmanifolds -Continuemechanicalpipingfabricationandinstallation -Electricaltransformersmovedtosite;placementoncontainmentpadspending o December2006 -FinalizedfundingagreementwithAlDEA/AEAforUSDept.ofEnergygrant ($950K) -Completedfuelcontainmentandsetfueltanksinposition -Completederection/weldingofsilencertowersandsetexhaust“stingers” -FabricatedandinstalledpipingconnectionsbetweenWärtsilägeneratorsand auxiliarysystemsmodule -Completedweldingoffuelcontainmentandanchoredfueltankstopads -Continuedsheetrockinstallation -Continuedfabricationofpipinginwaterroom -Beganwireterminationbetweenswitchgearcubicles -Beganinstallingelectricalandcontrolcabletrays -CompletedwiringofDCbatterysystems o January2007 -Beganinstallationofsoundpaneling;continuesheetrock -Transformerssetinpositionandbeganinstallingwirebetweentransformers andswitchgear -Fabricatedheatrecoverypiping -Beganelectricalcabletray,conduitinstallationandwirepullsbetween generators,switchgear,motorcontrolcenters,fielddevices -Continuepipingfabricationinwaterroom 19 -Prepareelectricalvaultsforwirepulls -Overheadcranesinspected/certified o February -WärtsilämechanicaladvisoronͲsite -Continueconduitinstallationandwirepulls -Structuralexhausttowerscompleted -Completedgeneratormechanicalexhaustpipingtogenerators;exhaust penetrationsthroughbuildingandinstalledspools -Installedfireseparationdoors -Continuedinstallationofsoundpanelingandsheetrock -Fabricatedexpansiontankstands -Continueinstallationofairhandlingcontrols -Completedfabricationandinstallationofheatrecoverylooppiping -Beganinstallationofcommunication/controlconduit -Wirepulledtotransformers -BeganwirepullsbetweenelectricalvaultsanddistributionfeedertieͲin connectionpoints -Completedmechanicalconnectionstofirstgenerator -PlacedWärtsilapipeandancillarymodulesinplaceforsecondgeneratorand beganconnections o March -AgencyͲrequiredrevisionstoAIDEA/AEAagreementforUSDOEfunding submittedandapproved -Continueinteriorfuelsystempipingtoboilers,daytanks,centrifuges -Wärtsiläenginecontrolcablespulledandterminated 20 -Continuesoundpanelingandsheetrock -Continueconduitinstallationandwirepullsforcommunication -Placeexpansiontankstandsandtanksinposition -PLCprogrammersonͲsite;installcomputerserversandbegantestingofcontrol systems -WärtsiläelectricalandPLCadvisorsjoinmechanicaladvisoronsite -CompletedwirepullsbetweenelectricalvaultsandfeedertieͲinpoints;begin wireterminationsandplaceswitchcabinets -Permanentstationserviceconnectionscompleted,commissionedand energized -WärtsiläGenerator#1(NJUSUnit16)turnedovertoWärtsiläadvisorsfor initialcheckout -Beginelectricalinstallationtowaterroomequipmentandcontrolsystems o April -Completedsoundpanelinstallationandmajorityofsheetrock -Continuingconduitinstallationandwirepulls,includingtocommunications andcontrolsystems -Continuingfielddevicewiring -Continuingswitchgearinterconnectionwiring -Airsystemscompleted;compressorstested -Finalcheckstofueldistributionsystembetweenoutsidedaytanksandinternal points -Begininstallationofsecondfuelcentrifugeunit -CompletedfeedertieͲinterminationsandcabinetplacementforCity#1,City #2andNorthdistributionfeeders -Completedmechanicalsystemsinwaterroom -Beganinstallationofceilinggridsandplumbingfixtures 21 o MayͲJune -Completedelectricalandcontrolsystemsinwaterroom;commissionplant -Completedmechanicalcoolantsystems,flushandfill -Completedallwiringandcontrolcommissioningrequiredforgeneratorstartup -Completedcommissioningtestsofgenerators,includinginitialloadtesting -Completedcommissioningoftransformers -Generatorunitsavailabletobeginproducingpower -Completedpaintingandmarkingofpipesinwaterroom -StateLegislatureincludedappropriationof$1.5millioninadditionalfundingin 2007capitalbudget o JulyͲSeptember -Trainedoperatorsonnewsystem -Completedairhandlingsystemcontrolsinstallationandbalanceunits -Completedsheetrockfinishingandpainting,includingdoorsandwindow frames -Completedinterconnectionoffueldaytankstodistributionpipeline -Insulatedradiatorandheatpiping,paintedandmarked o October -PLANTOFFICIALLYOPERATIONAL x Itemscompletedsubsequenttooperations(asweather,timeandfundingpermits): -Wärtsilä50Ͳhourmaintenancecheck 22 -Conduitinstallation,wirepulls,terminationandconnectionofremainingdistribution feeder;retireexistingconnectionfacilities -Paintpipesupports -Finalbuildingtriminstallations -Grading,finishingofexteriorentrancesandyards,apronpaving -Perimeterfenceinstallation -ReͲtorqueroofpanelbolts -RelocateGenerator#14fromexistingplant -ReroutedistributionfeedersunderSnakeRiver -Installmonitoringandsecuritysystems 2008 x Generatorsourcetestingrequiredbyairpermit[rescheduledtoandcompletedin2/08] x StateLegislatureincludedappropriationof$2.5millioninadditionalfundingin2008capital budget 23 BEFORE(OLDPLANT)AFTER(NEWPLANT) a component unit of P.O. Box 70 • Nome, Alaska 99762 • (907) 443-NJUS • Fax (907) 443-6336 NEW POWER GENERATION FACILITY PLANNING AND CONSTRUCTION ACTIVITY AS OF 12/31/2004 PHOTOGRAPHS Aerial view of Nome, Alaska during winter – frozen Bering Sea Existing power plant is located on the bank of the Snake River adjacent to Nome Airport A new site was selected and purchased from the Alaska Department of Transportation & Public Facilities. The new facility will be located outside the Airport Runway Protection Zone (RPZ), away from the Snake River, and is elevated to prevent flooding. Locating in this area will allow continued use of existing bulk fuel storage facilities and power distribution feeders, as well as connection to the community water distribution system. Other facilities in the area can utilize generated waste heat. (approximate new site location boundaries indicated in red) Engineering Team Project Design Meetings Electric Power Systems (EPS) was selected to serve as the principal engineering firm responsible for electrical design and project coordination. Other engineering firms involved in the project include: • Hattenburg, Dilley & Linnell, Inc. (geotechnical) • LCMF, Inc. (architectural, structural and mechanical) • Travis/Peterson Environmental Consulting, Inc. (environmental) • HMH Consulting (air permitting) Regular meetings with Alaska Department of Environmental Conservation personnel in Juneau were necessary to develop and finalize an Air Quality Construction Permit In determining engines to equip the new plant, the Utility Board Vice Chairman, Power Plant Chief Mechanic and Utility’s Chief Operating Officer consulted with operations and maintenance personnel at Cominco’s Red Dog Mine on reliability, operations and maintenance history with similar equipment. The Utility Board held regular work sessions with design engineers throughout the development of the project plans. (L) Mayor Denise Michels reviews plans at a public hearing on the project (R) Jeff Staser of the Denali Commission meets with Nome officials stressing “sustainability” of Projects. Utility Board Chairman Berda Willson and NJUS Manager John Handeland presented the community’s #1 capital priority to the Alaska Congressional Delegation. Senators Stevens and Murkowski are briefed on project progress and funding. Site work begins: • Excavation of petroleum contaminated soils present on site from prior industrial use; funded 50/50 by EPA Brownfields Grant and local match (above) • Core sampling to determine soils/geotechnical characteristics (L) Site being filled to elevation above flood plain. Local equipment and contractors and NJUS force account construction labor were utilized. Soils were densified by dynamic compaction to insure stability of the facility’s foundation. A 35-ton weight is dropped repeatedly to compact the soils. Children on a home school field trip were fascinated by the “moon craters” created in the process. When acquired from the State of Alaska, the site contained a World War II vintage building. The structure was previously used by ADOT/PF for airport equipment storage. It had been condemned and vacated by the State, but remained on the property. NJUS hired a local contractor to demolish the structure and level the site. Over 140 piling, 20” in diameter, were drilled into bedrock to support the facility. An Alaskan contractor from Anchorage performed the installation. In addition to construction inspectors and visits from the general public, a local Muskox dropped by to inspect the piling materials and their installation. Completing the piling installation After completing piling, site was readied for installation of under-slab electrical conduit. Conduit was installed to run electrical cabling to connect generators, switch gear and controls. A fire in the existing power plant caused considerable damage. An October 2004 storm threatened the plant by flooding; a protective dike was constructed. The existing Power Plant on the bank of the Snake River. Located within the Nome Airport Runway Protection Zone (RPZ) and on the bank of the Snake River, the existing 40+ year-old plant has exhausted its useful life. A newer section of the existing plant will remain in warm-start readiness as ancillary backup to the new facility. NEW POWER GENERATION FACILITY 2005 CONSTRUCTION ACTIVITY PHOTOGRAPHS a component unit of P.O. Box 70 • Nome, Alaska 99762 • (907) 443-NJUS • Fax (907) 443-6336 NJUS employees on new site in short sleeves! February 4, 2005; Ambient Temp was –16°F Concrete pouring and forming underway – site photo 7/15/05 Report Date: July 15, 2005 4/24/05 - Days are getting longer; snow is melting rapidly Engine manufacturer provided shirts to NJUS employees – we pose for a photo at the pile location where the concrete pads will be constructed and engines located. A Texan ordered the shirts – with short sleeves! Despite sub- zero ambient air temperature (-16°F), hearty Alaskans took it all in stride... [Perhaps the person ordering looked at one of those common U.S. maps that shows Alaska and Hawaii closer to Mexico? Ha!] 4/29/05 - What a difference a few days makes… We’re getting anxious to start construction! Multiple runs of electrical conduits are being placed prior to forming of concrete and pouring the floor slab. Over a mile of conduit snakes through the site. Grounding wire must also be bonded to each pile. The community’s domestic water and fire fighting supply is distributed from a pump room in the power plant. In addition to utilizing waste for utility and government buildings, additional waste heat from the engine cooling jacket is introduced into the water system, raising the temperature of distributed water thereby reducing the energy cost residents would otherwise have to pay to heat their water. Water distribution connections are being brought up to the new power plant building. Through the maze of electrical conduits, plumbers prepare route and insure proper grade for drains and waste disposal lines at the facility. Local welders go through certification process in preparation for cutting of piling and installation of pipe caps. Over 140 pile to support building, generators, transformers, exhaust Systems and fuel storage tanks set in 2004 were cut off to grade and pipe caps welded into place. Upon independent inspection all pipe welds were determined to be Nearly 300 thousand pounds of reinforcing bar will be placed and tied together to form generator pads, grade beams and floor slab. Each generator will sit on a concrete pad situated on top of eight piling. The initial forming activity focused on the area of the four generator pads. Forming and rebar tying activities moved from the generator pads to the building walls and the concrete grade beams that will support the building. A local contractor batches and provides the concrete to the site; the Utility rented a concrete pumper truck to place concrete in forms. Utility force account crews handle concrete placement and finishing. A contract engineering firm takes test cylinders and verifies mix. Generator pads 1-4 have been poured and forms now removed. Two new Wärtsilä 12V32 Diesel Generating Sets will serve as primary power producers in the new plant. The generators were manufactured at the Wärtsilä factory in Vaasa, Finland. John Handeland, Utility Manager, Dan Rogers, EPS Principal Electrical Engineer and Fred Moody, Utility Board Vice Chairman traveled to the factory to inspect the equipment. Engineer takes one final look at operational test data. Engineer, customer, and manufacturer review load test results; all parameters were found to be well within acceptable limits. Vice Chairman Moody signs acceptance documents. Parties point to locations of manufacture and final destination. One of generators is loaded on trailer headed to port. Route will take generators by ship from Europe, through Panama Canal to Seattle, Washington and then by barge to Alaska. Utility Board Member Carl Emmons and Mayor Denise Michels visit the site to check on progress. “Velvet Eyes”, Carl’s pet reindeer is a regular visitor to the construction site. Jennifer Imus, Community Banking President and Jim Lund, Wells Fargo Alaska’s District President drop by to visit with an NJUS employee and to observe construction progress. Mayor Michels grabs the “stinger” to provide some welding assistance. Manager’s instruction to assistant: “Please take some pictures of the new power plant site construction activity.” I’m scared of heights!!!! June 22, 2005 June 29, 2005 July 15, 2005 Happy employees, happy community. One employee commented “actually seeing the construction of the new power plant get underway is better than Christmas!” NEW POWER GENERATION FACILITY 2005 CONSTRUCTION ACTIVITY PHOTOGRAPHS July 16 - December 4, 2005 a component unit of P.O. Box 70 • Nome, Alaska 99762 • (907) 443-NJUS • Fax (907) 443-6336 Report Date: December 5, 2005 It seemed the piles of rebar were never-ending, yet employees remained positive - thankful for a relatively rain-free summer. The final grade beam forms were completed and rebar tied. Additional grade beams being poured. Grade beams poured and stripped on south end of facility; now framed and tied on north end. Frames stripped. Now...more rebar in preparation for the floor slab. After additional compaction, installation of the rebar mat for the slab begins. Dixie studies the activity with great interest from her front seat; Sidewalk Superintendent Velvet Eyes is a little less attentive to the details. September 9, 2005. The long-awaited barge from Seattle carrying the new generators, building package and other construction materials approaches the Nome Port. Building Generators Generators are offloaded from Northland barge and transported by truck to the Port Industrial Pad; each unit weighs over 200,000 pounds Power Plant mechanics take their first look — “WOW!” Barge container vans and materials being delivered to site. In order for construction to proceed on schedule, materials had to be procured for shipment on the fall barge. Northland picked up materials in both Seattle and Anchorage for delivery to Nome. Over 40 vans and flats of construction materials were received. Concrete pours for the floor slabs were begun in September. Because of the volume of concrete, pours had to be completed in several individual sessions. Construction teams watched weather forecasts closely. When it seemed apparent the weather would not cooperate, crews donned rain gear and built tents over the slab. Once started, a section had to be completed - resulting in some all night marathon sessions... While the concrete pour was ongoing, the insulated building panels and steel frame were inventoried, sorted and staged. [Existing power plant in background of lower picture.] The first building column was lifted into position on September 24, 2005. October 5, 2005. Generators moved to permanent position in New Power Generation Facility. South End. Building frame nearing completion. North End. First shell panels installed October 19, 2005. West wall complete October 21. East wall nearing completion October 31. November 3, 2005 Work is progressing nicely on the roof. The building was virtually closed in prior to Thanksgiving. View from southeast corner. View from northeast corner. December 4, 2005 Photos looking at facility location from Port Industrial Pad to the southwest. September 29, 2005 June 29, 2005 New switchgear cabinets Interior view of generators in bay. John Handeland, Nome Utility Manager and Leo Rasmussen, USDA Nome Area Manager with one of signs acknowledging Denali Commission and USDA project assistance. Construction schedule: December 5-17 Complete building trim and installation of exterior doors December 7-9 Complete interior mezzanine concrete pours December 12-16 Position switchgear December 17 Christmas Holiday January 3, 2006 Begin interior work: plumbing, electrical, framing – pending availability of funding October 1, 2006 Commission new plant August 1, 2006