HomeMy WebLinkAboutNative Village of Quinhagak Heat Recovery Study - Jul 2012 - REF Grant 7060937QUINHAGAK, ALASKA HEAT RECOVERY
STUDY
PREPARED BY:
Alaska Native Tribal Health Consortium
Division of Environmental Health and Engineering
1901 Bragaw St, Ste 200, Anchorage AK 99508
Phone (907) 729-3600 / Fax (907) 729-4090
July 18, 2012
EXECUTIVE SUMMARY
The Quinhagak power house, washeteria and combined utility building were evaluated for
heat recovery potential. The total annual heating fuel used by both buildings is verified by the
community as approximately 20,000 gallons. An additional 3000 gallons of fuel consumption
is expected with expansion of the existing water and sewer system (currently under
construction). The estimated fuel savings realized by implementing a heat recovery system is
approximately 14,200 gallons. The estimated cost for the heat recovery project is $630,000.
The simple payback based on a fuel cost of $4.50/gallon is 9.8 years.
Assuming construction begins in summer of 2014, project cost with 2 years of 3% escalation
is $668,300,
1.0 INTRODUCTION
The Alaska Native Tribal Health Consortium (ANTHC) reviewed the feasibility of providing
recovered heat from the existing AVEC power plant to the existing combined utility building
and adjacent washeteria building in Quinhagak. ANTHC also developed a budgetary project
cost estimate based on Force Account Construction, including Engineering and Construction
Administration.
The existing combined utility building provides heat to the circulating water lines and heat to
one of the WSTs. The system was not designed for waste heat and will require controls and
installation of new heat transfer equipment, including a new heat exchanger and new
circulating pumps. This building is estimated to consume approximately 7,300 gallons of
diesel per year, with expansions currently under construction that will increase fuel
consumption to approximately 10,000 gal per year.
The existing washeteria building is hydronically heated. The city reports fuel consumption of
13,000 gallons/year and importantly, much of this load is present in the summer as well as
winter. New equipment will include a large brazed plate heat exchanger, a new circulator
pump, and controls to prevent back feeding of heat to the generator facility.
Some work will be required at the power plant, including adding marine jackets to the
engines, insulating existing piping, reworking of the AMOT temperature control valve 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 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 information was obtained from AVEC regarding the 2011 power plant electrical
loads. End -user annual fuel use was obtained from a variety of sources, including the City,
Alaska Rural Utility Cooperative (ARUC), and engineering estimates. Where possible,
reported fuel consumption was used to validate engineering estimates. Site visits were made
to the existing WTP and washeteria to confirm accuracy of information obtained.
2.0 OVERVIEW
The purpose of this study is to provide an estimate of the heat that can be recovered from the
AVEC power plant diesel engines and used to offset heating oil consumption at the nearby
public buildings. Useable recovered heat is quantified in gallons of heating fuel saved using a
gross heating value of 134,000 BTU per gallon of #1 arctic diesel fuel and an overall boiler
efficiency of 70% for a net heating value of 93,800 BTU per gallon.
The public buildings eligible for heat recovery are located within 1000-foot radius of the AVEC
power plant. This analysis evaluates the potential to provide recovered heat to the nearby
public buildings. The estimated average annual heating fuel consumption for the nearby
public buildings is 20,000 gallons at present with an additional 3000 gallons expected with the
expansion of the above ground water and sewer system (currently under construction).
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, washeteria loads, heating degree days, passive losses for power plant heat and
piping, and arctic piping losses. The spreadsheet utilizes assumed time -of -day variations for
electric power production and heat demand. Power generation data from AVEC for fiscal year
2011 is used in the spreadsheet. The estimated heat rejection rate for the lead power plant
genset, a Detroit Diesel Series 60 DDEC4, is used to estimate available recovered heat.
Heating degree-days for Quinhagak were utilized for this site. All arctic piping is assumed to
be routed above grade. All exterior power plant hydronic piping is 3- or 4-in pipe. The
analysis includes 1-1/2" of insulation to be installed as part of this project.
The spreadsheet uses monthly heating degree-days to distribute annual fuel consumption by
month. The washeteria commercial heating loads are field verified as approximately 80% of
maximum utilization for 8 hours a day, 5 days a week. The end -user hourly heat load is
compared to the hourly available heat from the power plant, less power plant heating loads
and parasitic piping losses, and the net delivered heat to the end -user is determined.
Following is a summary of annual fuel use and estimated heat utilization in equivalent gallons
of fuel for each building:
Facility
Combined Utilty Building
Washeteria
Total
Estimated
Estimated Heat
Annual Fuel Use
Delivered
(Gallons)
(Gallons)
10,000
10,000
13,000
4,200
23,000
14,200
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 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 sub -cooling of the generator engines and
reducing electric power production efficiency. The recovered heat fluid is pumped through
buried insulated pipe to the end -user facilities, and is typically tied into the end -user heating
system using a plate heat exchanger.
4.1 AVEC PLANT TIE-IN
Marine Jackets will be added to the AVEC Generators to increase the available recovered
heat. If practical, an electric boiler will be added to pick up excess wind capacity when
available. All heat recovery piping will be insulated with a minimum of 1.5-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 ARCTIC PIPING (Recovered Heat Loop)
The proposed arctic piping is based on ANTHC's standard arctic pipe design with a 3-in fiber
reinforced polypropylene carrier pipe (Aquatherm Climatherm SDR11), 4-in polyurethane
foam insulation, and aluminum outer jacket. The piping will be supported on sleepers on the
ground surface or helical piers where the ground isn't sufficiently stable. The heat recovery
piping will run from the power plant alongside the road to the abandoned sewer lagoon to the
end -user buildings.
Because multiple users are connected to the system, circulation pumps located at the
washeteria and combined utility building will circulate heating fluid to each user from the
AVEC facility. When users are not actively consuming recovered heat, their systems will
throttle down heating fluid flow to minimize power consumption.
The recovered heat fluid will be a 50/50 Propylene Glycol/Water solution to provide freeze
protection to the piping.
4.3 END -USER BUILDING TIE-INS
End -user building tie-ins typically consist of brazed plate heat exchangers with motorized
bypass valves or heat injection pumps to prevent back feeding heat to AVEC or other users.
Plate heat exchangers located in the end -user mechanical rooms will be tied into the boiler
return piping to preheat the boiler water prior to entering the boiler. Where required, a heat
injection pump will be used instead of a motorized bypass valve to avoid introducing
excessive pressure drop in the building heating system. The maximum anticipated delivered
recovered heat supply temperature is about 190F. When there is insufficient recovered heat
to meet the building heating load, the building heating system (boiler or heater) will fire and
add heat. Off the shelf controls will lock out the recovered heat system when there is
insufficient recovered heat available.
Typical indoor piping will be type L copper tube with solder joints. Isolation valves will be
solder end bronze ball valves or flanged butterfly valves. All piping will be insulated with a
minimum of 1-in insulation with an all -service jacket. Flexibility will be provided where
required for thermal expansion and differential movement. Air vents, thermometers, pressure
gauges, drain valves, and pressure relief valves will also be provided.
Each facility will also receive a BTU meter to provide recovered heat use totalization and
instantaneous use.
4.4 PRIORITIZATION OF RECOVERED HEAT
Recovered heat prioritization is accomplished by setting the minimum recovered heat
temperature for each user, with successive load shedding as the recovered heat loop
temperature falls. The user with the highest allowable recovered heat temperature will be
removed from the system first. The user with the lowest allowable recovered heat
temperature will be removed from the system last.
The system will also provide freeze protection in the event a user's boiler system temperature
falls below a minimum temperature, typically 50-100 degrees F.
4.5 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
and 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
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). 450 MBH capacity
Primary: 50 GPM 195F EWT (50% ethylene glycol), 1.5 PSI max WPD
Secondary: 50 GPM 190F LWT (50% propylene glycol) 1.5 PSI max WPD
HX-2: (Combined Utility Building). 250 MBH capacity.
Primary: 25 GPM 180F EWT (50% propylene glycol), 1.0 PSI max WPD
Secondary: 25 GPM 175F LWT (50% propylene glycol) 1.5 PSI max WPD
HX-3: (Washeteria). 250 MBH capacity.
Primary: 25 GPM 180F EWT (50% propylene glycol), 1.0 PSI max WPD
Secondary: 25 GPM 175F LWT (50% propylene glycol) 1.5 PSI max WPD
5.2 Arctic Piping
The length of heat recovery loop piping between the power plant and most distant facility is
approximately 1600ft, round trip. The arctic piping utilizes 3-in carrier pipe to minimize
pressure drop and reduce pumping energy. The pipe itself consists of a 3-in fiber reinforced
polypropylene carrier pipe, 4" of polyurethane insulation and an aluminum outer jacket. The
specified product is durable enough for direct exposure to the weather and resistant to
crushing.
5.3 Circulating Pumps
P-HR1: Heat recovery loop pump at combined utility building
Flow = 25 GPM, Head = 35 ft
Initial Selection: Grundfos Magna with integrated VFD.
P-HR2: Heat injection pump in combined utility building.
Flow = 25 GPM, Head = 15 ft
Initial Selection: Grundfos 50-60F.
P-HR3: Heat recovery loop pump at washeteria building
Flow = 25 GPM, Head = 35 ft
Initial Selection: Grundfos Magna with integrated VFD.
P-HR4: Heat injection loop in Washeteria
Flow = 25 GPM, Head = 14 ft
Initial Selection: Grundfos , 50-60F
5.4 Expansion Tank
Total heat recovery loop volume is approximately 900 gallons. Pressure relief at the power
plant heat exchanger will be 45 PSIG and the maximum normal operating pressure will be 40
PSIG.
ET-1: System requirements: 140 gallon tank and 80 gallon acceptance
5.5 GLYCOL MAKEUP
A glycol make-up system at the combined utility building will be provided to accommodate
filling the system and adding additional glycol.
GT-1: Select AXIOM SF100 55 Gal Glycol make-up tank.
5.6 CONTROLS
Heat recovery system in each building will use an off the shelf differential temperature
controller to start/stop a heat injection pump. Control will provide load shedding, freeze
protection, and prevent backfeeding of boiler heat into heat recovery system. In addition, A
BTU meter will be provided at each facility, displaying instantaneous temperatures and heat
transfer, as well as totalizing BTUs used.
Differential Controllers: 2 required Tekmar Model 155 differential temperature control
BTU Meters:
BTU-1 Combined Utility Building: KEP BTU meter with 2" magnetic flow meter and matching
temperature elements.
BTU-2 Washeteria: KEP BTU meter with 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 and WTP, along with
design and construction management/administration for the complete project, is included in
the Base Project cost. Incremental costs for arctic pipe, end -user building renovations, and
overhead and freight are estimated individually for each of the other end -user buildings (refer
to attached cost estimate).
The estimated project cost for is $630,000. Estimated fuel savings are about 14,200 gallons.
Using a 2011 fuel price of $4.50/gallon results in estimated community savings of $64,000 for
a simple payback of 9.8 years.
Funding for design and construction isn't expected before fall 2013, with construction
occurring summer of 2014. With 2 years of escalation at 3% per year, the estimated project
cost in 2014 is $668,300.
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QUINHAGAK, ALASKA
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Sheet List Table
Sheet Number
Sheet Title
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SLEEPER PIPE SUPPORT
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1HELICAL ANCHOR PIPE SUPPORT
Alaska Native QUINHAGAK, AK
Tribal Health Consortium ANTHC RECOVERED HEAT STUDY
Division of Environmental
Health and Engineering DATE: 07-02-2012 LAYOUT: COVER
1901 Brepaw Street, Suite 200
ANCHORAGE, ALASKA, 9950E-3"0 DRAWN BY: TH FILE NAME: KWN-G-STSITE
(907) 7204600
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ANCHORAGE, ALASKA, 09508.3440 DRAWN BY: TH
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