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HomeMy WebLinkAboutBethal Coal Fired Gen Plant Feasibility Study 2003BETHEL COAL-FIRED POWER GENERATION PLANT FEASIBILITY STUDY FOR NUVISTA LIGHT AND POWER September 12,2003 Prepared By: Precision Energy Services,Inc. Project Development Division PRECISION ERERGY SEAVICES INC. P.O.Box 1004 e Hayden,Idaho 83835 (208)772-4457 www.pes-world.com 2002 CALISTA REGION ENERGY NEEDS STUDY Introduction ; : Nuvista Light &Power Company,a non-profit corporation formed by Calista Corporation,has conducted the "Calista Region Energy Needs Study,”to identify and investigate alternatives that demonstrate the potential for lowering energy costs in the Calista region.Nuvista Light &Power Company will function as a regional Generation and Transmission (G&T)utilitytodevelop,construct,own and operate any regional generation and transmission'facilities. Nuvista will sell power directly to the Donlin Creek gold mine project and wholesale power to existing utilities for resale to their existing customers.The mine project is presently under exploration.If it is found to be feasible,Stage 1 of the mine will require approximately 25 megawatts of power.Stage 2 of the project,estimated to begin in 2011-2012,will increase power demand to between 40-50 megawatts.The final stage,estimated to commence in 2015-2016, would iicrease power demand to between 60-80 megawatts. The study has concluded that coal-fired generation at Bethel,wind turbines along the coast,and a region-wide transmission grid will provide the lowest power cost in the region.A coal plant being built today will burn as clean as current natural gas plant technology.This regional grid would consist of SWGR transmission lines to provide power to the regional villages and a three-phase 138 kV transmission line to provide power to the Donlin Creek gold mine.The transmission system would utilize a conductor that contains a fiber optic bundle.This will provide Nuvista with the ability to readily monitor and control the entire transmission and generation system as well as provide the region with access to high quality and high-speed telecommunications. Preferred Alternative Absent Development of Donlin Creek Mine Project (15 MW Coal Plant +SWGR Transmission System +Wind Generation): Phase 1:10 megawatts of combined-cycle turbine generation at Bethel and construct SWGER transmission lines to interconnect villages near Bethel to the combined- cycle plant. Phase 2:15 MW coal-fired plant at Bethel and continue with build-out of 859 miles of Single Wire Ground Return (SWGR)transmission power lines to villages. Increase capacity of slow-speed diesel or combustion turbine generation to 20 megawatts if construction of coal plant is significantly delayed.Construct 1.5 MW wind turbine farms at coastal villages as SWGR transmission system is expanded to these areas.Increase wind turbine generation to total of 10.5 megawatts. e Capture waste heat from the centralized power plant located in Bethel and distribute waste heat throughout the community via a district heating system. Preferred Alternative if Donlin Creek Mine Project is developed (Bethel +Mine Site +18 . MW Wind Generation Alternative): Stage I:30 megawatts of slow-speed diesel or combined-cycle combustion turbine generation at or near mine site to supply initial mine load.Construct 10 megawatts of generation at Bethel and construct SWGR transmission lines to interconnect villages near Bethel to the.combined-cycle plant.Continue with build-out of SWGR system.Construct 1.5 MW wind turbine farms at coastal villages as SWGR transmission system is expanded to these areas. Summary -Calista Region Energy Needs Study =1 . Stage 2:In addition to generation outlined in Stage 1,construct 40-50 megawatts of coal- fired generation at Bethel to provide base load power for mine site and regional villages.Construct 138 kV transmission line from Bethel to the mine site. Increase capacity of wind turbine farms at coastal villages to 6 MWs. Stage 3:Increase coal-fired generation at Bethel to 60-80 megawaits. e Capture waste heat from the centralized power plant located in Bethel and distribute waste heat throughout the community via a district heating system,all stages. Single Wire Ground Return Transmission System Single Wire Ground Return (SWGR)transmission can best be described as single phase - single wire transmission of alternating current electricity that uses the earth as the return conductor.The SWGR system suggested for construction in the Calista region would operate at a proposed voltage of 80,000 volts-to-ground,which is the line-to-ground voltage of a standard 138,000-volt transmission line.This voltage was selected because it provides satisfactory electrical performance and off-the-shelf equipment is readily available.The preliminary conductor selected for use on the SWGR transmission line would contain a fiber optic bundle. The use of a conductor containing a fiber optic bundle has the potential to provide the villages with access to high quality and high-speed telecommunications at lower costs. The primary advantage of a SWGR transmission system is that it can provide good electrical performance at a substantially lower initial capital cost than a conventional electric Figure 1.2 Calista Region Boundary °Village -SWSR Transmission Line Routing with Approximate Line Miles =o 438 kV 3-Phase Transmission Line Calista Region is locatedin southwesternAlaskaintheYukon-Kuskokwim area,and encompasses 56,000 square miles. ional Transmission System with Donlin Mine Developmentand18MWWindTurbineGeneration transmission/distribution system.Typically,in Alaska,an SWGR can be built for about one-third the cost of a conventional three-phase power line that can provide the equivalent electrical performance.In southern Africa SWER power lines are being built for approximately one-sixth Summary -Calista Region Energy Needs Study 2 the cost of three-phase power lines.A secondary advantage is that SWGR power lines can be constructed with minimum impact to the environment. A SWGR transmission line demonstration project,operating at a voltage of 14,400 volts- to-ground and was constructed in 1981 in western Alaska to connect the village of Napakiak with Bethel.The 8.5 miles of line interconnecting the two communities extends over tundra-covered terrain,which is underlain with permafrost,and dotted by numerous small lakes.This project has operated for over 20 years and has demonstrated that SWGR technology is technically feasible for use in permafrost regions of Alaska.There is unfortunate much misinformation that has been spread concerning the Napakiak to Bethel SWGR demonstration project. The Napakiak SWGR project was built as demonstration project with an expected useful live of ten years.Yet it is still operating 21 years after it was constructed,with only minimal maintenance.This is not to say the SWGR power line has not experienced some problems.A few structures have been blown over in high winds and several anchors have failed.However, these problems are easily corrected by designing new SWGR lines to withstand higher wind speeds and by using new anchoring techniques. When the SWGR line was built to serve Napakiak the village peak electric load was approximately 90 kilowatts and line losses averaged about five percent,which is very acceptable. Since then the village load has almost doubled and line losses have predictably increased to about twenty percent,which is unacceptable.However,if the existing SWGR power line is replaced with an SWGR power line built to the new standards suggested in the study,line losses would drop to less than one percent. The vast majority of any electrical company's consumers use single-phase power. Typically in a village only the school and maybe the village water system require three-phase power.It is relatively simple to convert single-phase power to three-phase to serve these type loads.Equipment to do this economically has been in existence for many years.The SWGR system proposed by the study would not be less safe than any "conventional”transmission system now in use throughout Alaska.There are no reported safety incidents involving the Bethel to Napakiak SWGR power line. The estimated cost for constructing a SWGR power line is $100,000 per mile.A three- phase power line that would provide the same electrical performance as the SWGR power line would cost about $300,000 per mile.These costs include the cost of construction,engineering, surveying,project management,right-of-way clearing,and permitting.It is simply not possible to built a three-phase power line for anywhere near the cost of a SWGR power line.There is also no advantage of building a conventional single-phase power line instead of SWGR power line.A conventional single-phase line would cost twice as much to build as a SWGR power line and would not provide as good of electrical performance as a SWGR power line. Additional Studies Nuvista is presently moving forward with two additional studies to further investigate the feasibility of building power plants in the Calista region to supply power requirements of the proposed Donlin Creek Gold mine and the region.Nuvista will also continue to examine the feasibility of importing power from the "railbelt”as an alternative to constructing a large coal- fired plant at Bethel. Summary -Calista Region Energy Needs Study 3 eat teen,he bon °<i*.Peenee* CALISTA CORPORATION 301 Calista Court,Suite A Anchorage,AK 99518-3028 Phone:(907)279-5516 Fax:(907)272-5060 Calista Power Generation Calista Inter-tie Analysis $250,000 Calista Corporation is conducting a feasibility analysis of providing electrical power to the proposed Donlin Creek mine currently under exploration,and for providing low cost power through a central power plant at Bethel,Alaska.This work is being administered through an affiliated non-profit,Nuvista Light and Power Company.This analysis will also examine both Single Wire Ground Return as well as three-phase transmission systems.These feasibility analysis projects are funded through $500,000 in grants provided by the 2002 Alaska Legislature. Additional work is necessary to determine the feasibility of inter-ties with power provided from the railbelt to supply low-cost power to the Calista region.This will provide the mine exploration and regional power generation projects with the necessary data to assist in the determination of feasibility for the Donlin Creek mine and for providing low cost power to the region.The mine exploration project has extended its drilling program to the end of 2002 to more accurately define the high-grade resource.Pre-feasibility of the mine is underway and will commence throughout the next 18 months.An inter-tie analysis will outline proposed routing,inter-tie structures and wiring,sub-stations,outline the cost of construction and materials,and the cost of providing power to the mine project and to the region.There are three power source options available for inter-tie analysis.These include the interior region near Nenana,the Cook Inlet area near Beluga Point,and the Matanuska Valley.Golden Valley Electric Association,Matanuska Electric Association,and Chugach Electric Association are the three utilities that would be involved with this analysis.This part of the feasibility work is needed to assist in determining a viable option for providing power to the mine and the region.It is estimated that this work would cost $250,000 to prepare a feasibility analysis. Single Wire Ground Return (SWGR)Demonstration Project $4,500,000 Statement of Problem:There are 47 year round villages in the Calista region,in addition to Bethel.Electric power in the region is generated by relatively small diesel power plants located in 40 regional villages and Bethel.Only a few of the villages are interconnected to each other or Bethel by power lines.Power costs using diesel generation have continued to slowly increase over the past several decades and will continue to do so in the future.Residential rates in many of the villages exceed 50 cents per kilowatt-hour as compared to 10 cents per kWh in Anchorage and 16 cents per kwh in Bethel.The high cost of power is somewhat offset by the state-funded Power Cost Equalization (PCE)program.However,even when heavily subsidized through the PCE program,residential rates in the villages are 3 times the cost of electricity in Anchorage and twice the cost in Bethel.Few families and businesses can afford such exorbitant energy rates. Calista Power Generat Page 2 Solution:Calista Corporation is currently involved in an energy study through an affiliated non- profit,Nuvista Light &Power Company.The study examined options for providing energy needs for the region.The study has identified the construction of centralized coal-fired plant located at Bethel,Alaska integrated with wind turbine farms on the coast,along with the construction of 860 miles of SWGR transmissions lines to interconnect the regional villages to the centralized power plant and the wind turbine farms as the least cost alternative for providing electric power to the region.It is estimated that SWGR transmission line can be built for less than $100,000 per mile inclusive of all costs including permitting which is less than 1/3 the cost of a conventional power line capable of delivering the same electrical performance.This estimate is based on using gravity stabilized A-frame wood pole structures similar to those used to construct an 8.5 mile SWGR line in 1981 to interconnect the village of Napakiak to Bethel.This SWGR line remains in operation.These structures weight approximately 950 pounds and were transported and erected by helicopter.To further reduce construction costs Nuvista desires to proceed with research, development,and identification of materials,equipment and construction methods that will allow construction using light weight materials &equipment transported by snow machine.This would include but would not be limited to the development of light-weight gravity-stabilized aluminum or fiberglass structures,development of low cost and easily installed foundations and anchors, development of conductor installation and structure erection techniques,selection/modification of appropriate construction equipment.The power line conductor would contain a fiber-optic cable to provide high speed/quality telecommunications capabilities.Following the development phase, Nuvista desires to proceed with final design and construction of a 30 mile long SWGR demonstration project that will connect the villages of Atmautluak,Nunapitchuk and Kasigluk,to the electric and telephone utility systems in Bethel.Peak KW demand of these 3 villages is expected to exceed 1 MW by the year 2010.The SWGR demonstration will establish the technical and economic feasibility of the SWGR transmission system.The estimated cost of the demonstration project is 4.5 million dollars,which includes the cost of development,design and construction. Impact to Alaska:The benefits of interties are well known.They allow the transfer of low cost energy to high cost areas and consolidate a large enough customer base to make it economically feasible to develop projects,which are capital-intensive to construct by producing lower cost electricity,such as a centralized coal-fired generation plant at Bethel,which in turn would reduce the regions dependency on fuel oil.However,just as important,interties reduce the need for stand-alone generation systems in the villages and the associated requirement to maintain large on-site fuel storage facilities in each village and the associated fuel spill liability.Interconnecting villages in western Alaska to a centralize power plant using low cost power lines would substantially reduce the cost of power in the villages and will minimize if not eliminate the need for government funded PCE payments in the region.By installing fiber-optic cable in the power line conductor,high speed/quality telecommunications capabilities would be provided throughout the region.SWGR systems could be built throughout rural Alaska to provide lower cost power and high speed/quality telecommunications capabilities. Fuel Cost Analysis $125,000 In order to determine the efficiency and effectiveness of alternatives to diesel for electrical power generation in the Calista region,it is necessary to also conduct an analysis of the costs of diesel fuel,and the determinants of costs,particularly the potential impact of changes in these costs over time.Because of the significant investment in diesel fuel systems in the region,and the potential impact that a regional power distribution has on these systems,it is important to provide an Calista Power Generat Page 3 analysis that assists in determining the feasibility of a regional electrical power system.It is estimated that it would cost $125,000 to conduct a fuel cost analysis that is coordinated with current efforts for a regional power system. Wind Generation Study $180,000 The proposed regional electrical power distribution systems suggested in the Calista Corporation's 2002 Regional Energy Study includes incorporating wind generation in areas along the coast.In the study,supplemental wind generation was evaluated in combination with a diesel +waste heat recovery alternative and for the alternative involving the construction of a centralized 15 MW coal plant at Bethel.Wind generation would include those villages where there is sufficient wind resources to justify installation of wind turbines where the Wind Power Class is 4/5 or greater as designated in the Wind Energy Resource Atlas of the United States. Wind turbines used in these villages would likely duplicate the performance of the wind turbines installed by Kotzebue Electric Association.Kotzebue,Alaska is located in a 4/5 wind power class area.Work is necessary to estimate costs for installing wind turbines as part of an integrated regional power system,the potential total installed capacity,the total annual kWhs generated by wind turbines,and to specify the wind power class and annual village energy requirements.This would assist in coming up with resulting annual power costs that includes supplemental wind generation.It is estimated that a wind generation study would cost $180,000. WalistaYE?Corporation 301 Calista Court,Suite A *Anchorage,Alaska 99518-3028*(907)279-5516*Facsimile (907)272-5060*Website:www.calistacorp.com February 4,2002 IE ¢E |VV IE Robert Poe,Jr.FEB 09 2002 Executive Director AIDEA AIDEA/AEA 813 West Northern Lights Blvd. Anchorage,AK 99503 Re:-Regional Energy and Transportation Summit Dear Mr.Poe: This is a request for participation of AIDEA with us to consider a regional plan and strategy for energy and transportation for the Yukon Kuskokwim Delta region.Our first effort in this process is a regional summit on March 19,2002 in Bethel during the AVCP Mid-Year Convention.So far,both Mr.Mike Harper and Mr.Bruce Tiedeman of your staff have agreed to work with us directly and be involved in the summit.Since energy in our region is complex and difficult,addressing this issue will require a great deal of inter-agency coordination.We are hoping that AIDEA can assist us in this process,perhaps as a lead agency for the State of Alaska to help coordinate other state and federal agencies and organizations to arrive at viable energy strategies for our region. We'd like to discuss this issue with you further as we get closer to the upcoming summit. Energy will be discussed in the morning of the 19"and transportation is to be addressed in the afternoon.It will be a packed day and we hope that this will be the first of subsequent discussions on these two issues.We are presently working on a draft document (copy enclosed)that includes an agenda and supporting information.We are also planning on outlining some policy recommendations for consideration by those present at the summit and for following meetings and conventions of the participating organizations.Participants will include Calista Corporation,AVCP,AVCP-RHA, YKHC,local tribal representatives,as well as local utility representatives.Bob Charles is the lead coordinator for this project and can be reached here at Calista Corporation for any questions or concerns about the upcoming summit. Sincerely, CALISTA CORPORATION & Matthew Nicolai President/CEO Enclosure Cc w/enclosure:Mike Harper/Brude Tiedeman,AIDEA/AEA Office of the President JEFFREY Y.FOLEY Senior Exploration Geologist tN al iStA Corporation 301 Calista Court,Suite A *Anchorage,Alaska 99518-3028 Phone:(907)279-5516 Direct:(907)868-2419 E-Mail:jfoley@calistacorp.com Facsimile:(907)272-5060 Website:www.calistacorp.com Walter T.Featherly teathoy@ sertontoggs com PATIO N B 0 6 G 5 LLP Facsimile 907-279-7973 ATTORNEYS AT LAW 1031 West Fourth Avenue Suite 504 Anchorage,Alaska 99501 907-277-4900 DRAFT Calista /AVCP /AVCP-RHA/YKHC /56 Tribes Regional Energy and Transportation Summit Bethel,Alaska March 19,2002 "Strategies and plans for achieving low cost energy and viable infrastructure to promote the social and economic well-being of the people of the Calista /AVCP Region.” A collaborative partnership of the regional organizations and tribes. (insert photos /images for cover) Calista (INSERT OTHER LOGOS) Calista -AVCP -AVCPRHA -YKHC -56 Tribes Regional Energy and Transportation Summit Bethel,Alaska-March 2002 (Draft Publication -Regional Summit Promotion) Introductory letter from the Regional CEO's/Board Chairmen: Electricity,home heating,fuel for homes and business,telecommunications,and transportation are basic infrastructure needs for the people of the Calista/AVCP region.The high cost of energy and challenges in transportation have a significant impact on our ability to address the social and economic well-being of the people in the region.Our future depends on establishing plans and strategies directed to achieving low cost energy and viable transportation. Calista Corporation,AVCP,AVCP-RHA,and YKHC are all committed to a regional energy and transportation plan that is prepared and adopted by the regional organizations and the 56 tribes. The goal for this effort is to promote low cost energy and viable transportation projects.To accomplish this,we need a long-term plan outlining how we as a region will work together in a coordinated and unified effort to address these two basic infrastructure issues. We encourage you to participate with us in determining our future in energy and transportation in a Regional Summit on Energy and Transportation during the AVCP Mid-year convention on March 19,2002 in Bethel,Alaska. Sincerely, CALISTA CORPORATION AVCP,INC. YKHC AVCP-RHA 2002 Regional Summit on Energy and Transportation March 19,2002 Draft Agenda AM -Energy (Moderators:Bob Charles,Calista Corporation,Robert Beans,YKHC) PM -Transportation (Moderators:Allen Joseph,AVCP;Mark Charlie,AVCP-RHA) 8:00am -8:30am Registration 8:30am Call to order Welcome Address and Invocation Opening Remarks: Policy Panel addressing Regional Plan and Strategy: AVCP,Art Lake AVCP-RHA,Ron Hoffman Calista Corporation,Matthew Nicolai YKHC,Gene Peltola 9:00am Energy "Considering Energy Resource Alternatives for attaining energy efficiency and providing for energy cost savings for Electricity,Home Heating,Fuel Consumption for Homes and Businesses, and Telecommunications.” Presentations followed by Questions and Answers: Electrical Power Generation and Transmission Nuvista Light and Power Energy Study and Pre-feasibility Analysis Report. Frank Bettine,Nuvista L&P Co. Donlin Creek Overview Rick Van Nieuwenhuyse,NovaGold AIDEA -Alaska Energy Authority Mike Harper/Bruce Tiedeman,AIDEA/AEA Energy Denali Commission Annual Report/Energy Projects -Al Ewing Jeff Staser Energy Policy Recommendations and Discussion Policy Panel with Tribes and Utility Representatives 12:00pm -1:30pm 1:30pm -4:00pm Lunch Break Transportation "Providing for a tribal planning process,promoting economic development opportunities, addressing community infrastructure needs,and reducing the overall cost of transportation of goods and services.” 4:00 -5:00pm Presentations followed by Questions and Answers: YK Regional Transportation Plan and Process: YK Regional Transportation -Mike McKinnon,DOT BIA Roads Planning and Engineering -AVCP,BIA Infrastructure Needs for Housing -AVCP-RHA,AHFC Donlin Creek Road --Calista Corporation,BIA,BLM Intervillage Trails and Local Roads -AVCP,BIA,and Tribes Regional Energy and Transportation Plan and Strategy Policy Panel: Summit Summary Formation of a Regional Public Policy Group I.Regional Plan and Strategy The Calista Corporation,Alaska Village Council Presidents (AVCP),Alaska Village Council Presidents -Rural Housing Authority (AVCP-RHA),and Yukon Kuskokwim Health Corporation (YKHC)are working together to organize an effort to bring together each of the regional organizations and member tribes for a summit during the AVCP Mid-year Convention in March 2002 to initiate the development of a regional strategy and planning process for energy and transportation;and to address jobs in these two areas of infrastructure development.Our goals for the regional summit include: Region-wide Energy Plan Develop a comprehensive region-wide energy plan for the Calista region to determine an overall energy strategy that considers energy resource alternatives and provides efficient energy cost savings in electrical power generation and transmission,home heating,fuel consumption for home and business,and telecommunications. Regional Transportation Plan Develop a regional transportation plan for the Calista region that provides for a tribal planning process,promotes economic development opportunities,addresses community infrastructure needs,and reduces the overall cost of transportation of goods and services in the region. There is no comprehensive regional energy plan or strategy for the Calista region that is adopted by the regional organizations or the tribes as a whole.The only regional transportation plan of any consequence is the plan prepared and compiled by the State of Alaska.The state's plan is oriented heavily toward maintenance and improvement of the existing aviation transportation system and does not address creation of new surface transportation infrastructure in the region. Also,there has never been an organized tribal transportation planning process in the Calista region.This proposed effort seeks to incorporate a process and strategy that addresses these two infrastructure needs in the Calista region. Il.Coordination and Community Support Each regional organization and tribe has a direct or indirect connection to energy and transportation,and their respective needs or project plans are relevant in a discussion to develop a unified regional plan and strategy on these two basic issues.Currently funded planning efforts, documented reports and studies should also be addressed at this summit to identify strategies and opportunities that should be incorporated into a regional plan.It is hoped that this summit initiates an ongoing and coordinated planning process that identifies funding priorities and critical areas for coordination of financial and organizational resources to sustain an effective regional strategy.Such a process requires the participation and approval of the regional organizations and tribes. This process has the potential of affecting each and every one of the villages,businesses and utilities in the region.The Calista Corporation,AVCP,AVCP-RHA,YKHC,the 56 tribes and municipal governments,village corporations,utility companies and goods and service industry providers all have a vested interest in energy and transportation.Roads and electrical power are basic infrastructure components that provide the backbone for industry and economic development.They provide a basic cost element at each level of service delivery and business in the region.Each of the affected organizations and businesses are interdependent and need coordination around a regional strategy in order to make the most efficient use of the available funding and organizational resources to implement a unified regional energy and transportation plan. Calista Corporation Specific to Calista Corporation,in the areas of energy and transportation,are a road from Crooked Creek to the Donlin Creek community to support a gold mining project at Donlin Creek along the Kuskokwim River;and a current energy analysis that looks at possible strategies for regional electrical power distribution to provide power to all the villages in the region,and the Donlin Creek project.The Donlin Creek project,tied in with a regional energy plan,has the potential of providing long-term economic development in the region.Calista Corporation has been able to acquire funding for initial planning efforts in these two areas.These include $450,000 for environmental assessment work for the proposed road to the Donlin Creek mine; and $250,000 for an energy needs study and pre-feasibility analysis.These efforts are currently underway. The Calista energy needs study looks at alternatives for electrical power for the region,both with and without the mine.Calista formed Nuvista Light and Power Company,a non-profit,to implement and coordinate the energy needs study and subsequent analysis.Calista envisions Nuvista Light and Power implementing the energy plan for the region with the participation of the regional strategy and planning participants,and the utility companies of the region.Because of the extent of its potential impact,all organizations,tribes,and utility companies should participate in the process. Once the energy needs study and pre-feasibility analysis projects are completed in early 2002, further work will be necessary to complete a feasibility analysis for a regional energy plan based upon strategies adopted at the proposed summit,and an environmental impact statement for the proposed road.Funding for road construction and a regional electrical distribution system will require coordination and support at the regional level in order to gain acceptance and consideration for project funding. AVCP The Association of Village Council Presidents,Inc.is the non-profit regional organization representing the 56 tribes of the Calista region.AVCP has the responsibility to provide for social services and coordination of tribal governance activities with its membership.Funding for these activities are provided through the BIA and other related state and federal agencies.AVCP does not provide for transportation planning for its member tribes.Currently,the majority of planning and engineering capability is outside the region.Almost every infrastructure project funded by state and federal dollars provides for planning and engineering in advance of construction.Much of the funding for these services is spent by state and federal agencies outside the region and no consideration is made to develop the capacity of AVCP or the tribes.AVCP has not had the authority in years past to accomplish this effort on behalf of the region.It is envisioned that this summit will enable AVCP to acquire needed support and funding for planning and engineering for tribal transportation projects within the region.This is an important consideration for a coordinated regional strategy for transportation projects. AVCP-RHA AVCP -RHA receives its funds for housing through HUD under Native American Housing and Self-Determination Act (NAHASDA).This act eliminated a number of federal programs that provided separate funding for infrastructure to support housing projects.Funding is now block- granted under NAHASDA,but no additional funds were provided for infrastructure.Diverting funds from housing for infrastructure has the effect of reducing the ability to meet the growing housing needs.The high cost of infrastructure along with the high cost of housing,combined with the growing need for housing in the region,makes it extremely important that a coordinated strategy for energy and transportation include support for housing.In addition the proposed strategy needs to also outline the current conflicts and policy differences at the state and federal level in funding infrastructure needs for housing.An example of this includes the current conflict surrounding limited dollars through Village Safe Water and a proposed resolution by the Governor's Council on Rural Sanitation to restrict funds being used for new housing hook-ups.It should also be noted that the vast majority of housing participants are low-income and that extremely large portions of their low-income goes to pay the high cost of electricity and home heating fuel.The proposed strategy needs to consider alternative low cost energy for low-income families living in HUD funded housing projects. YKHC The Yukon Kuskokwim Health Corporation receives its funding for health services under the Indian Health Service.Energy and transportation costs are significant factors in the level of health services provided in the region.Its facilities and operations are dependent upon the cost of energy,telecommunications,and transportation services.Other activities including rural sanitation and environmental health projects are indirectly or directly dependent upon transportation infrastructure.Other issues related to energy and transportation that are attributable to YKHC and health delivery are:the historical access to care issues;runways and runway lighting;cost of electricity,fuel oil and related energy products for health service operations. Other issues relate to future easements for roads,power lines,and other utilities (above ground and buried).Use of ice roads and easements for existing winter snow-machine trails connecting villages and right of ways into and out of villages;hovercraft use and access to landing areas for these and all barges. Federal /State Coordination of Funding Federal and state appropriations,for infrastructure development projects in the region,are often held in state or federal treasuries,managed directly by federal and state agencies,until either the projects are ready to be implemented or enough funds are built-up to pay for the costs of construction.Because of future revenue shortfalls by the state and reduced federal spending it is necessary to determine innovative strategies that allow for capacity building and coordination of financial and organizational resources between the agencies,the regional non-profit organizations and tribes.Establishing cost-efficiency and financial-viability for plans and strategies to address these basic infrastructure issues is paramount in determining interagency coordination and funding.A regional strategy for energy and transportation should consider innovative methods to develop the capacity of the regional non-profit organizations and tribes; seek ways to allow them to acquire these funds directly once they are appropriated;and have authority to control these funds and how they are spent for planning and implementation.The regional plan and strategy should consider necessary tribal governing authorities to be provided by the U.S.Congress,including tri-party agreements to help facilitate this process.Because of the potential high cost for infrastructure development,this is an important consideration for enabling a viable regional strategy and plan for energy and transportation. III.Staff Support /Organizational Resources Policy Panel /Management Team: Calista Corporation:Matthew Nicolai,President/CEO YKHC:Gene Peltola,President/CEO AVCP:Art Lake,President AVCP-RHA:Ron Hoffman,Executive Director Staff Support: Calista Corporation: Bob Charles,VP Government and Corporate Relations June McAtee,VP Land and Natural Resources Department Jeff Foley,Geologist,Land and Natural Resources Department Frank Bettine,P.E.,Esquire,Nuvista Light and Power Study YKHC: Robert Beans,Tribal Programs Services Director AVCP: Allen Joseph,Vice-President of Operations AVCP-RHA: Mark Charlie,Deputy Director Staff Responsibilities: Coordinate the regional strategy and planning efforts with the affected organizations,agencies and tribes.Compile and prepare summit documentation and reports,and address summit follow- up issues.This will also include identifying lead staff for coordinating efforts with agencies and representatives of the state and federal governments in respect to transportation and energy. State,Federal and other Resources Mike Harper,AIDEA/AEA Bruce Tiedeman,AIDEA/AEA Mike McKinnon,State DOT Brian Pederson BIA Roads ...5 BLM Niles Cesar,BIA Area Director Jeff Staser,Chair,Denali Commission Al Ewing,Federal Chair,Denali Commission USDA/RDA EDA RDC Alaska State Chamber of Commerce Anchorage Chamber of Commerce Commonwealth North The Kuskokwim Corporation -TKC NovaGold Resources,Incorporated Chugach Electric Association Alaska Village Electric Cooperative,Inc. Other local utilities (tbi) Legislative: U.S.Senator Ted Stevens U.S.Senator Frank Murkowski U.S.Congressman Don Young Alaska Legislature ...(tbi) IV.Project Impact and Sustainability Once a regional strategy and plan is accepted by each of the organizations and tribes in the region,maintenance of a regional planning and strategy process is expected to become part of the regular annua!business of the organizations.It is hoped that each organization will dedicate staff and organizational resources to sustain an annual process for identifying needs and adopting strategies and plans in a coordinated fashion.Such a strategy and plan has the potential of impacting a significant number of the industries that are dependent on roads and power,both directly through construction and maintenance,and those industries that utilize and are benefited by road access and power consumption.A part of the strategy and development and planning process will be to determine the impact and benefit on jobs and economic development in general.It is anticipated that each of the aforementioned regional organizations and tribes will be enabled by obtaining some direct control over the planning and strategy for development in these two basic areas of infrastructure.A regional plan or strategy that has the participation and acceptance of all the affected organizations and tribes has great potential to impact future sustainability and viability of the regional economy.This proposal is intended to address this goal and make it an ongoing concern and practice of the organizations and tribes of the Calista region. 10 Calista Regional Energy Needs Study -Draft Summary Background: Electrical power in the Calista region is provided by 41 relatively small,stand-alone,aging diesel power plants and all fuel,some 20 million gallons,is imported.The plants range in size from less than 100 kW,in small villages,to more than 10 MW in Bethel. The cost of fuel oil in many villages is double that paid in Anchorage or Bethel and heating costs,per BTU,are several times the cost of natural gas heat in Anchorage. The residential rate for electricity in many villages exceeds 50 cents per kilowatt-hour (kWh). The State partially subsidizes rural electrical power through the Power Cost Equalization (PCE) Program.However,even with PCE subsidies,residential power costs in the villages average between 25 and 35 cents per kWh,which is 2.5-3.5 times the cost paid by residential consumers in Anchorage. Even with PCE,the portion of household income spent on electricity in the region is roughly twice that of the national average,although households in the region use only one-half to two- thirds the electricity consumed by the average U.S.household. Fuel costs,population,power demand and diesel-power costs in the region are all expected to increase. PCE funding cannot keep up with these increases.Continued,stand-alone diesel generation is not an acceptable means of supplying future power needs. Summary: A regional energy needs study was completed to identify a strategy to reduce the high cost of electrical power in the Calista Region,southwestern Alaska.In addition to constructing population and electrical load forecasts,the study identified preferred power generation and distribution alternatives,with and without development of the Donlin Creek Mine: A.Absent Donlin Creek Mine development: e Construct 15-MW coal-fired plant and 10-MW combustion turbine plant at Bethel e Insix increments,construct 859 miles of transmission line to interconnect villages. B.If Donlin Creek Mine is developed: e Stage 1 -Construct 30-MW combined-cycle combustion turbine plant at mine site or Crooked Creek and 20-MW combined cycle turbine plant at Bethel.Construct transmission line from Bethel to surrounding villages. e Stage 2 -Install 40-MW coal-fired generation facilities in Bethel and retain 30 MW at Donlin Creek for standby generation.Construct 175-mile 138 kV transmission line from Bethel to mine site. e Stage 3 -Increase Bethel coal-fired capacity to 80 MW. 11 Results and Benefits of Preferred Alternatives: Alternative A: Assuming continued subsidy reliance upon the PCE program,over a forty-year period, benefits to the PCE program would exceed the projected cost of the 15-MW plant and the SWGR transmission line network.Alternative A could save the PCE program approximately $260 million over continued diesel generation,more than enough to pay the entire construction cost ($171 million)of the 15-MW coal plant and the SWGR system. SWGER transmission lines can be built for 1/3 the cost of conventional transmission lines. Compared to increasing costs of continued diesel power generation,present-worth power costs of coal-fired generation would decrease over time.Year 2025 village power cost,in year 2000 dollars,is estimated at 34 cents per kwh for continued diesel generation as compared to 18 -24 cents per kwh for Alternative A.This is less than the power cost most village residential consumers pay today with PCE offsets. Waste heat could be used to heat municipal and other facilities in Bethel,thereby saving Bethel consumers about $1 million annually,and generating about $5 million in revenue. Alternative B: PCE savings of about $250 million would substantially offset the $453 million capital cost of the transmission lines and power plants at Bethel and Donlin Creek. Because Donlin Creek Mine development and operation will triple the power demand in the region and energy requirements will increase almost five times,communities, residents and industry will benefit from lower cost power. Low cost power availability would encourage and improve economics of Donlin Creek and other resource development projects.Power generation costs for this alternative,in year 2000 dollars,are estimated at 9 cents per kwh in the year 2006,decreasing to 5-6.5 cents per kwh in 2020. Hundreds ofjobs would become available to the otherwise depressed region. Providing power to the mine will bring money into the region,some of which could be used to construct transmission lines. Year 2020 forecasted power demand and energy usage in the region with development of Donlin Creek Mine is estimated at 96 megawatts and 698,000-megawatt hours of energy as compared to 25 megawatts and 149,000-megawatt hours absent development of the mine. Waste heat could be used to heat buildings at Donlin Creek as well as in Bethel, offsetting power and heating costs. Alternatives A and B: e Lower cost power would encourage sustainable economic development. e Regional energy usage would increase and residents would experience improved quality of life and increased business opportunities. e Fiber optic cable could be installed along transmission line route,thereby improving telecommunications throughout the region. e Centralized electrical power plants and transmission interties would eliminate the cost and environmental liability of stand-alone power plants and fuel storage facilities. 12 Donlin Creek Road Project -Summary The U.S.Bureau of Indian Affairs (BIA),Alaska Region,is proposing to undertake a road project west and north of the community of Crooked Creek,Alaska (Figure 1 -Propcsed Routes).The BIA has retained Rodney P.Kinney Associates,Inc.to provide consulting services, in accordance with the National Environmental Policy Act (NEPA),to establish consultation with potential Interested Parties to determine if the proposed road project could significantly impact the human environment. Proposed Project Description Construct Donlin Creek Road,(Figure 1)approximately 40 km (25 miles).This road would provide access to the region for mineral exploration and general development of the area by providing a connection inland from the Kuskokwim River.The region has a history of mining operations and exploration,including the DeCourcy Mountain mine,a placer mine at Snow Gulch near Donlin Creek,and current exploration efforts by NovaGold and Placer Dome,near American Creek.Donlin Creek Road would also allow for future gravel mining to support projects in the lower Kuskokwim region. Material Source(s) Preliminary field reconnaissance suggests two potential material sources near the proposed project.One potential source is a hill near the alignment about 4 kin (2.5 miles)from the south end of the project.A second potential source is a rocky knoll northeast of Juninggulra Mountain, near the center of the project.An access road to this source would be 0.6 to 4 km long (0.3 to 2.5 miles),depending on the location of the proposed road.Both of these potential sources are shown in Figure 1.Material sources will be identified through additional field reconnaissance during the feasibility and geotechnical phases of this project.Additional sources near the road may be targeted during design for use if suitable material is available. Staging Area(s) A staging area would be developed west of the Kuskokwim River near the beginning of the project.This would allow for staging of construction equipment offloaded from barges.This area would likely be developed into a permanent staging area to be used during the life of the road, since the road would be accessed from the river.Material sources will also be used as staging areas for processing and stockpiling of material during construction. Geotechnical Survey A geotechnical investigation is planned,after the feasibility phase is complete,to confirm route selection and to provide parameters for designing a stable road structure.Exploration techniques will likely include a powered auger mounted ona track vehicle traveling along the alignment(s) to be investigated.Potential borrow sources will also be evaluated.Any geotechnical investigation will be reviewed beforehand by BIA Roads Archeology and may require archeological monitoring. 13 Identification of Issues and Concerns for NEPA Purposes for the Donlin Creek Road Endangered Species Act,Consultation Pursuant to Section 7 The BIA is maintaining responsibility for compliance with section 7 of the Endangered Species Act.The BIA will request the U.S.Fish and Wildlife Service and the National Marine Fisheries Service (collectively,the Services)to provide comments concerning listed endangered or threatened species and designated critical habitats near or within the proposed project area.The BIA will determine the level of biological assessment necessary for the proposed project.All comments and recommendations issued by the Services to the BIA will be included,and addressed as appropriate,in the NEPA document that will be prepared by the BIA.The NEPA document will be available for review by all Interested Parties. Department of the Army Permit,Pursuant to Section 404 of the Clean Water Act When project design reaches 80%,the BIA will submit a complete 404-permit application package to the Department of the Army,Corps of Engineers.The Corps of Engineers will also be provided with opportunities to review the draft environmental documentation that is issued. Alaska Coastal Management Program,Consistency Review When project design reaches 80%,the BIA will submit a Coastal Project Questionnaire and Certification Statement to the Alaska Division of Governmental Coordination to determine whether the project will require an Alaska Coastal Management Program consistency review. Storm Water Pollution Prevention Plan,National Pollution Discharge Elimination System Permit Pursuant to Section 402 of the Clean Water Act Prior to construction,the BIA will issue a Notice of Intent for storing water discharges associated with construction activities to the Environmental Protection Agency. National Historic Preservation Act,Consultation Pursuant to Section 106 The BIA is also maintaining responsibility for compliance with Section 106 of the National Historic Preservation Act.The BIA will conduct a comprehensive survey (in accordance with 36 CFR Part 800)to locate any historic properties and issue a notification of agency findings to the Alaska State Historic Preservation Office and the Tribe.Other Alaska Native entities (as may be determined by the BIA),the Advisory Council on Historic Preservation,and the public may also be involved,especially if it is found that the proposed undertaking may adversely affect historic properties.The BIA will display a summary of these consultations in the NEPA documentation of this project. Section 4(f)of the Department of Transportation Act Section 4(f)evaluations are required when transportation projects affect cultural resource sites that are found to be eligible for the National Register of Historic Places,and when there is constructive use of public lands.This includes bodies of water,schools,and playgrounds.Given that the proposed project does not affect such known sites or properties,a 4(f)evaluation would not be required unless archeological resources are discovered during field investigations.In this case,the BIA would consult directly with the Federal Highway Administration,as well as with the Alaska State Historic Preservation Officer and other potentially interested parties. 14 eospinea is oe . ° Ab ae eS hae Fee een (Figure |.Proposed Donlin Creek Road Routes) 15 (insert other graphs from energy study and portions from DOT Draft YK Transportation Plan, including information from Denali Commission on energy) 16 Donlin Creek Project, Southwestern Alaska! February,2002 Jeffrey Y.Foley,Senior Exploration Geologist,Calista Corporation The Donlin Creek Project Donlin Creek is a major gold exploration project in the Calista Region, southwestern Alaska.The project site is near the Kuskokwim River,300 miles west of Anchorage and 12 miles upstream from the village of Tarrog wr Location of the Donlin Creek Project in southwestern Alaska. Crooked Creek.The project is operated by NovaGold Resources Incorporated and is on land owned by Calista Corporation (Calista)and the Kuskokwim Corporation (TKC).In 2001,NovaGold acquired an interest in the property from Placer Dome who explored the property from 1995 until 2001,under an Exploration and Mining Lease with Calista. The geology of the Donlin Creek Project area consists of northeast-and northwest-trending Late Cretaceous- early Tertiary felsic igneous dikes and sills that intrude Cretaceous sandstone and shale of the Kuskokwim Group. Gold is associated with disseminated sulfide minerals,sulfide veinlets and quartz-carbonate veinlets in both altered igneous and sedimentary rocks over an area measuring 4 miles in length. Simplified ggeologic map showing the distribution of felsic igneous rocks and associated gold- mineralized corridors. Op int dit,Dontin Creek Acrial View Lith |if,codes =S Be caiaMtb rienowe afPus¢Sapa:eeseg'a re Actialview to north showing mineralized trendsintheDonlinCreekarea. Metallurgical tests indicate that gold mineralization at Donlin Creek is refractory and would require oxidation of sulfide concentrate to recover the gold.Based on commercially available technology,pressure oxidation in autoclaves would be required to process the concentrate.Substantial electrical power,on the order of 20-65 megawatts, would be required to fulfill the project needs.Power needs will include electricity for crushing and grinding of large volumes of ore to liberate the sulfide minerals for sulfide flotation, oxygen generation for pressure oxidation of sulfide concentrate to liberate fine gold particles,and other mill,facilities and camp requirements. As of January 2001,Placer Dome spent $33 million and delineated a 13 million troy ounce gold resource in 136 million tonnes of potential ore,with an average grade of 2.95 grams of gold/tonne.If the project were in a less remote location,it might be economic to mine at those grades.However,because of the currently low gold price,remote project location,and the absence of established infrastructure,the project did not meet financial criteria required by Placer Dome to develop a mine. Accomplishments by Placer Dome while on the property from 1995-2000 include construction of a 75-person camp,17 miles of roads and a 5,000-ft-long airstrip,more than 287,000 ft of diamond drilling,36,000 ft of trenching and 26 line miles of ground geophysical survey.Additionally,an airborne magnetic survey,mapping and ore deposit modeling,metallurgical testing, 4 years of environmental baseline studies,preliminary mine and facilities design and economic evaluation of the project were completed. Given current economic conditions and the large investment made by Placer Dome,several other mining companies were considered for invitation to participate in the project.Because various mining companies have different criteria for evaluating projects,this is a common practice in the mining industry. NovaGold,who acquired Alaska Gold - Company's assets in 1999,and has experience evaluating gold properties in Alaska and Canada,signed an agreement with Placer Dome in 2001.The agreement provides NovaGold the right to earn up to 70 percent of the project by spending $10 million to advance the project.NovaGold is focusing their efforts on high-grade portions of the deposit and plan to generate a positive feasibility report within the next couple years.The NovaGold approach is based on a 4,000-8,000 tonne/day operation with an average ore grade of about 5 grams of gold/tonne.Although an operation of this size would be smaller than the 20,000-30,000 tonne/day -3 grams/tonne operation evaluated by Placer Dome,ore grades are substantially higher and mine costs coupled with low gold prices could be offset by the higher yield per tonne. During their first few months on the property,NovaGold spent more than $2 million and completed 42 diamond-drill core holes.A revised resource calculation resulted in a substantially higher grade.The new resource assessment will be the basis of a prefeasibility study that will allow NovaGold to proceed with mine design and permitting efforts,while additional drilling of high grade zones is undertaken Spring,2002. Potential Benefits of the Donlin Creek Project and power grid -Sustainable Development Many of the problems that characterize the region would experience substantial relief by the advent of lower cost electricity and the economic and social benefits of a world-class gold mine. During a 2-year mine construction period,there would be on the order of 450 jobs at the site.During the 10 plus year operation period there would be about 300 jobs at the mine.Given that many of the mine employees will be from surrounding villages,this will have enormous economic impact on the local and regional economy. Royalties to landowners,increased tax base,increased business and vocational opportunities will have more global effects on the economy.Improved transportation and communications, better education,improved health, strategic defense benefits,economic growth,reduced transfer payments,and other sustainable development issues will be realized.Social benefits will go hand in hand with the economic benefits. Given the remote location and lack of infrastructure,economic development in the Calista region will depend on natural resource development.Whereas any single mining project will ultimately have a finite life,there are more long- term and sustainable benefits to be achieved.The region has a history of mineral development and many prospects remain to be explored.World- class mineral deposits seldom occur by themselves;usually a single large deposit is indicative of more substantial mineral endowment in the region. Vocational training and occupational experience that accompany exploration, mine construction and operation provide marketable skills that are useful in other industries.Skills that would be developed during a mining project include heavy equipment operation, drilling,explosives handling, construction,engineering practices, mechanics,electronics and electrical tasks,environmental technology, plumbing,catering,computer technology and communications.These skills are marketable in other industries and are useful anywhere in the world. Such vocational development would give residents the opportunity to participate,rather than be isolated from the global business community.Other emerging mining and development projects around the state would provide additional employment for this trained work force. For Donlin Creek and other natural resource-based projects to become realities,it is necessary that energy development be made a priority by all interested in the social and economic welfare of the region.State and Federal Agencies are encouraged to combine efforts and resources to make these projects feasible. DRAFT Calista /AVCP /AVCP-RHA/YKHC /56 Tribes Regional Energy and Transportation Summit Bethei,Alaska March 19,2002 "Strategies and plans for achieving low cost energy and viable infrastructure to promote the social and economic well-being of the people of the Calista /AVCP Region.” A collaborative partnership of the regional organizations and tribes. (insert photos /images for cover) Calista (INSERT OTHER LOGOS) Calista -AVCP -AVCPRHA -YKHC -56 Tribes Regional Energy and Transportation Summit Bethel,Alaska-March 2002 (Draft Publication Regional Summit Promotion) Introductory letter from the Regional CEO's/Board Chairmen: Electricity,home heating,fuel for homes and business,telecommunications,and transportation are basic infrastructure needs for the people of the Calista/AVCP region.The high cost of energy and challenges in transportation have a significant impact on our ability to address the social and economic well-being of the people in the region.Our future depends on establishing plans and strategies directed to achieving low cost energy and viable transportation. Calista Corporation,AVCP,AVCP-RHA,and YKHC are all committed to a regional energy and transportation plan that is prepared and adopted by the regional organizations and the 56 tribes. The goal for this effort is to promote low cost energy and viable transportation projects.To accomplish this,we need a long-term plan outlining how we as a region will work together in acoordinatedandunifiedefforttoaddressthesetwobasicinfrastructureissues. We encourage you to participate with us in determining our future in energy and transportation in a Regional Summit on Energy and Transportation during the AVCP Mid-year convention on March 19,2002 in Bethel.Alaska. Sincerely, CALISTA CORPORATION AVCP,INC. YKHC AVCP-RHA 2002 Regional Summit on Energy and Transportation March 19,2002 Draft Agenda AM-Energy (Moderators:Bob Charles,Calista Corporation,Robert Beans,YKHC) PM -Transportation (Moderators:Allen Joseph,AVCP;Mark Charlie,AVCP-RHA) 8:00am -8:30am Registration 8:30am Call to order Welcome Address and Invocation Opening Remarks: Policy Panel addressing Regional Plan and Strategy: AVCP,Art Lake AVCP-RHA,Ron Hoffman Calista Corporation,Matthew Nicolai YKHC,Gene Peltola 9:00am Energy "Considering Energy Resource Alternatives for attaining energy efficiency and providing for energy cost savings for Electricity,Home Heating,Fuel Consumption for Homes and Businesses, and Telecommunications.” Presentations followed by Questions and Answers: Electrical Power Generation and Transmission Nuvista Light and Power Energy Study and Pre-feasibility Analysis Report. Frank Bettine,Nuvista L&P Co. Donlin Creek Overview Rick Van Nieuwenhuyse,NovaGold AIDEA -Alaska Energy Authority Mike Harper/Bruce Tiedeman.AIDEA/AEA Energy Denali Commission Annual Report/Energy Projects -Al Ewing Jeff Staser Enercy Policy Recommendations and Discussion Policy Panel with Tribes and Utility Representatives Loy] 12:00pm -1:30pm 1:30pm -4:00pm Lunch Break Transportation "Providing for a tribal planning process,promoting economic development opportunities, addressing community infrastructure needs,and reducing the overall cost of transportation of goods and services.” 4:00 -5:00pm Presentations followed by Questions and Answers: YK Regional Transportation Plan and Process: YK Regional Transportation -Mike McKinnon,DOT BIA Roads Planning and Engineering --AVCP,BIA Infrastructure Needs for Housing -AVCP-RHA,AHFC Donlin Creek Road --Calista Corporation,BIA,BLM Intervillage Trails and Local Roads --AVCP,BIA,and Tribes Regional Energy and Transportation Plan and Strategy Policy Panel: Summit Summary Formation of a Regional Public Policy Group I.Regional Plan and Strategy The Calista Corporation.Alaska Village Council Presidents (AVCP),Alaska Village Council Presidents -Rural Housing Authority (AVCP-RHA),and Yukon Kuskokwim Health Corporation (YKHC)are working together to organize an effort to bring together each of the regional organizations and member tribes for a summit during the AVCP Mid-year Convention in March 2002 to initiate the development of a regional strategy and planning process for energy and transportation;and to address jobs in these two areas of infrastructure development.Our goals for the regional summit include: Region-wide Energy Plan Develop a comprehensive region-wide energy plan for the Calista region to determine an overall energy strategy that considers energy resource alternatives and provides efficient energy cost savings in electrical power generation and transmission,home heating,fuel consumption for home and business,and telecommunications. Regional Transportation Plan Develop a regional transportation plan for the Calista region that provides for a tribal planning process,promotes economic development opportunities,addresses community infrastructure needs,and reduces the overall cost of transportation of goods and services in the region. There is no comprehensive regional energy plan or strategy for the Calista region that is adopted by the regional organizations or the tribes as a whole.The only regional transportation plan of any consequence is the plan prepared and compiled by the State of Alaska.The state's plan is oriented heavily toward maintenance and improvement of the existing aviation transportation system and does not address creation of new surface transportation infrastructure in the region. Also,there has never been an organized tribal transportation planning process in the Calista region.This proposed effort seeks to incorporate a process and strategy that addresses these two infrastructure needs in the Calista region. IL.Coordination and Community Support Each regional organization and tribe has a direct or indirect connection to energy and transportation,and their respective needs or project plans are relevant in a discussion to develop a unified regional plan and strategy on these two basic issues.Currently funded planning efforts, documented reports and studies should also be addressed at this summit to identify strategies and opportunities that should be incorporated into a regional plan.It is hoped that this summit initiates an ongoing and coordinated planning process that identifies funding priorities and critical areas for coordination of financial and organizational resources to sustain an effective regional strategy.Such a process requires the participation and approval of the regional organizations and tribes.ws This process has the potential of affecting each and every one of the villages.businesses and utilities in the region.The Calista Corporation,AVCP,AVCP-RHA,YKHC,the 56 tribes and municipal governments.village corporations,utility companies and goods and service industry providers all have a vested interest in energy and transportation.Roads and electrical power are basic infrastructure components that provide the backbone for industry and economic development.They provide a basic cost element at each level of service delivery and business in the region.Each of the affected organizations and businesses are interdependent and need coordination around a regional strategy in order to make the most efficient use of the available funding and organizational resources to implement a unified regional energy and transportation plan. Calista Corporation Specific to Calista Corporation.in the areas of energy and transportation,are a road from Crooked Creek to the Donlin Creek community to support a gold mining project at Donlin Creek along the Kuskokwim River;and a current energy analysis that looks at possible strategies for regional electrical power distribution to provide power to all the villages in the region.and the Donlin Creek project.The Donlin Creek project,tied in with a regional energy plan.has the potential of providing long-term economic development in the region.Calista Corporation has been able to acquire funding for initial planning efforts in these two areas.These include $450,000 for environmental assessment work for the proposed road to the Donlin Creek mine; and $250,000 for an energy needs study and pre-feasibility analysis.These efforts are currently underway. The Calista energy needs study looks at alternatives for electrical power for the region,both with and without the mine.Calista formed Nuvista Light and Power Company,a non-profit,to implement and coordinate the energy needs study and subsequent analysis.Calista envisions Nuvista Light and Power implementing the energy plan for the region with the participation of the regional strategy and planning participants.and the utility companies of the region.Because of the extent of its potential impact.all organizations.tribes.and utility companies should participate in the process. Once the energy needs study and pre-feasibility analysis projects are completed in early 2002, further work will be necessary to complete a feasibility analysis for a regional energy plan based upon strategies adopted at the proposed summit,and an environmental impact statement for theproposedroad.Funding for road construction and a regional electrical distribution system willrequirecoordinationandsupportattheregionallevelinordertogainacceptanceand consideration for project funding. AVCP The Association of Village Council Presidents.Inc.is the non-profit regional organization representing the 56 tribes of the Calista region.AVCP has the responsibility to provide for social services and coordination of tribal governance activities with its membership.Funding for these activities are provided through the BIA and other related state and federal agencies.AVCP does not provide for transportation planning for its member tribes.Currently,the majority of planning and engineering capability is outside the region.Almost every infrastructure project funded by state and federal dollars provides for planning and engineering in advance of construction.Much of the funding for these services is spent by state and federal agencies outside the region and no consideration is made to develop the capacity of AVCP or the tribes.AVCP has not had the authority in years past to accomplish this effort on behalf of the region.It is envisioned that this summit will enable AVCP to acquire needed support and funding for planning and engineering for tribal transportation projects within the region.This is an important consideration for a coordinated regional strategy for transportation projects. AVCP-RHA AVCP -RHA receives its funds for housing through HUD under Native American Housing and Self-Determination Act (NAHASDA).This act eliminated a number of federal programs that provided separate funding for infrastructure to support housing projects.Funding is now block- granted under NAHASDA,but no additional funds were provided for infrastructure.Diverting funds from housing for infrastructure has the effect of reducing the ability to meet the growing housing needs.The high cost of infrastructure along with the high cost of housing,combined with the growing need for housing in the region,makes it extremely important that a coordinated strategy for energy and transportation include support for housing.In addition the proposed strategy needs to also outline the current conflicts and policy differences at the state and federal level in funding infrastructure needs for housing.An example of this includes the current conflict surrounding limited dollars through Village Safe Water and a proposed resolution by the Governor's Council on Rural Sanitation to restrict funds being used for new housing hook-ups.It should also be noted that the vast majority of housing participants are low-income and that extremely large portions of their low-income goes to pay the high cost of electricity and home heating fuel.The proposed strategy needs to consider alternative low cost energy for low-income families living in HUD funded housing projects. YKHC The Yukon Kuskokwim Health Corporation receives its funding for health services under the Indian Health Service.Energy and transportation costs are significant factors in the level of health services provided in the region.Its facilities and operations are dependent upon the cost of energy,telecommunications,and transportation services.Other activities including rural sanitation and environmental health projects are indirectly or directly dependent upon transportation infrastructure.Other issues related to energy and transportation that are attributable to YKHC and health delivery are:the historical access to care issues:runways and runway lighting:cost of electricity.fuel oil and related energy products for health service operations. Other issues relate to future easements for roads.power lines,and other utilities (above ground and buried).Use of ice roads and easements for existing winter snow-machine trails connecting villages and right of ways into and out of villages;hovercraft use and access to landing areas for these and all barges. Federal /State Coordination of Funding Federal and state appropriations,for infrastructure development projects in the region,are often held in state or federal treasuries,managed directly by federal and state agencies,until either the projects are ready to be implemented or enough funds are built-up to pay for the costs of construction.Because of future revenue shortfalls by the state and reduced federal spending it is necessary to determine innovative strategies that allow for capacity building and coordination of financial and organizational resources between the agencies,the regional non-profit organizations and tribes.Establishing cost-efficiency and financial-viability for plans and strategies to address these basic infrastructure issues is paramount in determining interagency coordination and funding.A regional strategy for energy and transportation should consider innovative methods to develop the capacity of the regional non-profit organizations and tribes; seek ways to allow them to acquire these funds directly once they are appropriated;and have authority to control these funds and how they are spent for planning and implementation.The regional plan and strategy should consider necessary tribal governing authorities to be provided by the U.S.Congress,including tri-party agreements to help facilitate this process.Because of the potential high cost for infrastructure development,this is an important consideration for enabling a viable regional strategy and plan for energy and transportation. III.Staff Support /Organizational Resources Policy Panel /Management Team: Calista Corporation:Matthew Nicolai,President/CEO YKHC:Gene Peltola.President/CEO AVCP:Art Lake.President AVCP-RHA:Ron Hoffman,Executive Director StaffSupport: Calista Corporation: Bob Charles.VP Government and Corporate Relations June McAtee,VP Land and Natural Resources Department Jeff Foley.Geologist.Land and Natural Resources Department Frank Bettine,P.E..Esquire.Nuvista Light and Power Study YKHC: Robert Beans,Tribal Programs Services Director AVCP: Allen Joseph,Vice-President of Operations AVCP-RHA: Mark Charlie,Deputy Director Staff Responsibilities: Coordinate the regional strategy and planning efforts with the affected organizations,agencies and tribes.Compile and prepare summit documentation and reports,and address summit follow- up issues.This will also include identifying lead staff for coordinating efforts with agencies and representatives of the state and federal governments in respect to transportation and energy. State,Federal and other Resources Mike Harper,AIDEA/AEA Bruce Tiedeman,AIDEA/AEA Mike McKinnon,State DOT Brian Pederson BIA Roads ...»BLM Niles Cesar,BIA Area Director Jeff Staser,Chair,Denali Commission Al Ewing,Federal Chair.Denali Commission USDA/RDA EDA RDC Alaska State Chamber of Commerce Anchorage Chamber of Commerce Commonwealth North The Kuskokwim Corporation -TKC NovaGold Resources.Incorporated Chugach Electric Association Alaska Village Electric Cooperative.Inc. Other local utilities (tbi) Legislative: U.S.Senator Ted Stevens U.S.Senator Frank Murkowski U.S.Congressman Don Young Alaska Legislature ...(tb!) IV.Project Impact and Sustainability Once a regional strategy and plan is accepted by each of the organizations and tribes in the region.maintenance of a regional planning and strategy process is expected to become part of the regular annual business of the organizations.It is hoped that each organization will dedicate staff and organizational resources to sustain an annual process for identifying needs and adoptingstrategiesandplansinacoordinatedfashion.Such a strategy and plan has the potential ofimpactingasignificantnumberoftheindustriesthataredependentonroadsandpower,both directly through construction and maintenance,and those industries that utilize and are benefited by road access and power consumption.A part of the strategy and development and planning process will be to determine the impact and benefit on jobs and economic development in general.It is anticipated that each of the aforementioned regional organizations and tribes will be enabled by obtaining some direct control over the planning and strategy for development in these two basic areas of infrastructure.A regional plan or strategy that has the participation and acceptance of all the affected organizations and tribes has great potential to impact future sustainability and viability of the regional economy.This proposal is intended to address this goal and make it an ongoing concern and practice of the organizations and tribes of the Calista region. 10 Calista Regional Energy Needs Studv -Draft Summarv Background: Electrical power in the Calista region is provided by 41 relatively small,stand-alone.aging dieselpowerplantsandallfuel,some 20 million gallons.is imported.The plants range in size from less than 100 kW,in small villages,to more than 10 MW in Bethel. The cost of fuel oil in many villages is double that paid in Anchorage or Bethel and heatingcosts,per BTU,are several times the cost of natural gas heat in Anchorage. The residential rate for electricity in many villages exceeds 50 cents per kilowatt-hour (kWh).The State partially subsidizes rural electrical power through the Power Cost Equalization (PCE)Program.However,even with PCE subsidies,residential power costs in the villages averagebetween25and35centsperkWh.which is 2.5-3.5 times the cost paid by residential consumers in Anchorage. Even with PCE,the portion of household income spent on electricity in the region is roughlytwicethatofthenationalaverage,although households in the region use only one-half to two- thirds the electricity consumed by the average U.S.household. Fuel costs,population,power demand and diesel-power costs in the region are all expected to increase. PCE funding cannot keep up with these increases.Continued,stand-alone diesel generation is not an acceptable means of supplying future power needs. Summary: A regional energy needs study was completed to identify a strategy to reduce the high cost of electrical power in the Calista Region.southwestern Alaska.In addition to constructingpopulationandelectricalloadforecasts,the study identified preferred power generation and distribution alternatives.with and without development of the Donlin Creek Mine: A.Absent Donlin Creek Mine development: e Construct 15-MW coal-fired plant and 10-MW combustion turbine plant at Bethel e In six increments,construct 859 miles of transmission line to interconnect villages. B.If Donlin Creek Mine is developed: e Stage 1 -Construct 30-MW combined-cycle combustion turbine plant at mine site or Crooked Creek and 20-MW combined cycle turbine plant at Bethel.Construct transmission line from Bethel to surrounding villages. e Stage 2 -Install 40-MW coal-fired generation facilities in Bethel and retain 30 MW at Donlin Creek for standby generation.Construct 175-mile 138 kV transmission line from Bethel to mine site. e Stage 3 -Increase Bethel coal-fired capacity to 80 MW. 11 Results and Benefits of Preferred Alternatives: Alternative A: Assuniing continued subsidy reliance upon the PCE program.over a forty-year period, benefits to the PCE program would exceed the projected cost of the 15-MW plant and the SWGR transmission line network.Alternative A could save the PCE program approximately $260 million over continued diesel generation,more than enough to pay the entire construction cost ($171 million)of the 15-MW coal plant and the SWGR system. SWGR transmission lines can be built for 1/3 the cost of conventional transmission lines. Compared to increasing costs of continued diesel power generation,present-worth power costs of coal-fired generation would decrease over time.Year 2025 village power cost,in year 2000 dollars,is estimated at 34 cents per kwh for continued diesel generation as compared to 18 -24 cents per kwh for Alternative A.This is less than the power cost most village residential consumers pay today with PCE offsets. Waste heat could be used to heat municipal and other facilities in Bethel,thereby saving Bethel consumers about $1 million annually,and generating about $5 million in revenue. Alternative B: PCE savings of about $250 million would substantially offset the $453 million capital cost of the transmission lines and power plants at Bethel and Donlin Creek. Because Donlin Creek Mine development and operation will triple the power demand in the region and energy requirements will increase almost five times,communities, residents and industry will benefit from lower cost power. Low cost power availability would encourage and improve economics of Donlin Creek and other resource development projects.Power generation costs for this alternative,in year 2000 dollars,are estimated at 9 cents per kwh in the year 2006,decreasing to 5-6.5 cents per kwh in 2020. Hundreds of jobs would become available to the otherwise depressed region. Providing power to the mine will bring money into the region.some of which could be used to construct transmission lines. Year 2020 forecasted power demand and energy usage in the region with development of Donlin Creek Mine is estimated at 96 megawatts and 698.000-megawatt hours of energy as compared to 25 megawatts and 149.000-megawatt hours absent development of the mine. Waste heat could be used to heat buildings at Donlin Creek as well as in Bethel, offsetting power and heating costs. Alternatives A and B: e Lower cost power would encourage sustainable economic development. e Regional energy usage would increase and residents would experience improved quality of life and increased business opportunities. e Fiber optic cable could be installed along transmission line route,thereby improving telecommunications throughout the region. e Centralized electrical power plants and transmission interties would eliminate the cost and environmental liability of stand-alone power plants and fuel storage facilities. 12 Donlin Creek Road Project -Summary The U.S.Bureau of Indian Affairs (BIA),Alaska Region.is proposing to undertake a road project west and north of the community of Crooked Creek,Alaska (Figure 1 -Proposed Routes).The BIA has retained Rodney P.Kinney Associates,Inc.to provice consulting services, in accordance with the National Environmenta!Policy Act (NEPA),to establish consultation with potential Interested Parties to determine if the proposed road project could significantly impact the human environment. Proposed Project Description Construct Donlin Creek Road,(Figure 1)approximately 40 km (25 miles).This road would provide access to the region for mineral exploration and general development of the area byprovidingaconnectioninlandfromtheKuskokwimRiver.The region has a history of miningoperationsandexploration,including the DeCourcy Mountain mine,a placer mine at Snow Gulch near Donlin Creek,and current exploration efforts by NovaGold and Placer Dome,near American Creek.Donlin Creek Road would also allow for future gravel mining to support projects in the lower Kuskokwim region. Material Source(s) Preliminary field reconnaissance suggests two potential material sources near the proposed project.One potential source is a hill near the alignment about 4 kin (2.5 miles)from the south end of the project.A second potential source is a rocky knoll northeast of Juninggulra Mountain, near the center of the project.An access road to this source would be 0.6 to 4 km long (0.3 to 2.5 miles),depending on the location of the proposed road.Both of these potential sources are shown in Figure 1.Material sources will be identified through additional field reconnaissance during the feasibility and geotechnical phases of this project.Additional sources near the road may be targeted during design for use if suitable material is available. Staging Area(s) A staging area would be developed west of the Kuskokwim River near the beginning of the project.This would allow for staging of construction equipment offloaded from barges.This area would likely be developed into a permanent staging area to be used during the life of the road, since the road would be accessed from the river.Material sources will also be used as staging areas for processing and stockpiling of material during construction. Geotechnical Survey A geotechnical investigation is planned,after the feasibility phase is complete,to confirm routeselectionandtoprovideparametersfordesigningastableroadstructure.Exploration techniqueswilllikelyincludeapoweredaugermountedonatrackvehicletravelingalongthealignment(s) to be investigated.Potential borrow sources will also be evaluated.Any geotechnical investigation will be reviewed beforehand by BIA Roads Archeology and may require archeological monitoring. Identification of Issues and Concerns for NEPA Purposes for the Donlin Creek Road Endangered Species Act.Consultation Pursuant to Section 7 The.BIA is maintaining responsibility for compliance with section 7 of the Endangered Species Act.The BIA will request the U.S.Fish and Wildlife Service and the National Marine Fisheries Service (collectively,the Services)to provide comments concerning listed endangered or threatened species and designated critical habitats near or within the proposed project area.The BIA will determine the level of biological assessment necessary for the proposed project.All comments and recommendations issued by the Services to the BIA will be included,and addressed as appropriate,in the NEPA document that will be prepared by the BIA.The NEPA document will be available for review by all Interested Parties. Department of the Army Permit,Pursuant to Section 404 of the Clean Water Act When project design reaches 80%,the BIA will submit a complete 404-permit application package to the Department of the Army,Corps of Engineers.The Corps of Engineers will also be provided with opportunities to review the draft environmental documentation that is issued. Alaska Coastal Management Program.Consistency Review When project design reaches 80%,the BIA will submit a Coastal Project Questionnaire and Certification Statement to the Alaska Division of Governmental Coordination to determine whether the project will require an Alaska Coastal Management Program consistency review. Storm Water Pollution Prevention Plan,National Pollution Discharge Elimination System Permit Pursuant to Section 402 of the Clean Water Act Prior to construction,the BIA will issue a Notice of Intent for storing water discharges associated with construction activities to the Environmental Protection Agency. National Historic Preservation Act,Consultation Pursuant to Section 106 The BIA is also maintaining responsibility for compliance with Section 106 of the National Historic Preservation Act.The BIA will conduct a comprehensive survey (in accordance with 36 CFR Part 800)to locate any historic properties and issue a notification of agency findings to the Alaska State Historic Preservation Office and the Tribe.Other Alaska Native entities (as may be determined by the BIA),the Advisory Council on Historic Preservation,and the public may also be involved,especially if it is found that the proposed undertaking may adversely affect historic properties.The BIA will display a summary of these consultations in the NEPA documentation of this project. Section 4(f)of the Department of Transportation Act Section 4(f)evaluations are required when transportation projects affect cultural resource sites that are found to be eligible for the National Register of Historic Places,and when there is constructive use of public lands.This includes bodies of water.schools,and playgrounds.Given that the proposed project does not affect such known sites or properties,a 4(f)evaluation would not be required unless archeological resources are discovered during field investigations.In this case,the BIA would consult directly with the Federal Highway Administration.as well as with the Alaska State Historic Preservation Officer and other potentially interested parties. 14 ”bis'5éLog5<BWek(Figure 1.Proposed Donlin Creek Road Routes) 15 (insert other graphs from energy study and portions from DOT Draft YK Transportation Plan, including information from Denali Commission on energy) 16 Donlin Creek Project, Southwestern Alaska! February,2002 Jeffrey Y.Foley,Senior Exploration Geologist,Calista Corporation The Donlin Creek Project Donlin Creek is a major gold exploration project in the Calista Region, southwestern Alaska.The project site is near the Kuskokwim River,300 miles west of Anchorage and 12 miles upstream from the village of Location of the Donlin Creek Project in southwestern Alaska. Crooked Creek.The project is operated by NovaGold Resources Incorporated and is on land owned by Calista Corporation (Calista)and the Kuskokwim Corporation (TKC).In 2001,NovaGold acquired an interest in the property from Placer Dome who explored the property from 1995 until 2001,under an Exploration and Mining Lease with Calista. The geology of the Donlin Creek Project area consists of northeast-and northwest-trending Late Cretaceous- early Tertiary felsic igneous dikes and sills that intrude Cretaceous sandstone . and shale of the Kuskokwim Group. Gold is associated with disseminated sulfide minerals,sulfide veinlets and quartz-carbonate veinlets in both altered igneous and sedimentary rocks over an area measuring 4 miles in length. pr TE ek iat ea"':Sentin Creek Praject *Pa Simplified geologic map showing the distribution of felsic igneous rocks and associated gold- mineralized corridors. |Ng Creek Aerial View : 7 re R,MerCHELIEYyo, in the Donlin Creek area. Metallurgical tests indicate that gold mineralization at Donlin Creek is refractory and would require oxidation of sulfide concentrate to recover the gold.Based on commercially available technology,pressure oxidation in autoclaves would be required to process the concentrate.Substantial electrical power,on the order of 20-65 megawatts, would be required to fulfill the project needs.Power needs will include electricity for crushing and grinding of large volumes of ore to liberate the sulfide minerals for sulfide flotation, oxygen generation for pressure oxidation of sulfide concentrate to liberate fine gold particles,and other mill,facilities and camp requirements. As of January 2001,Placer Dome spent $33 million and delineated a 13 million troy ounce gold resource in 136 million tonnes of potential ore,with an average grade of 2.95 grams of gold/tonne.If the project were in a less remote location,it might be economic to mine at those grades.However,because of the currently low gold price,remote project location,and the absence of established infrastructure,the project did not meet financial criteria required by Placer Dome to develop a mine. Accomplishments by Placer Dome while on the property from 1995-2000 include construction of a 75-person camp,17 miles of roads and a 5,000-ft-long airstrip,more than 287,000 ft of diamond drilling,36,000 ft of trenching and 26 line miles of ground geophysical survey.Additionally,an airborne magnetic survey,mapping and ore deposit modeling,metallurgical testing, 4 years of environmental baseline studies,preliminary mine and facilities design and economic evaluation of the project were completed. Given current economic conditions and the large investment made by Placer Dome,several other mining companies were considered for invitation to participate in the project.Because various mining companies have different criteria for evaluating projects,this is a common practice in the mining industry. NovaGold,who acquired Alaska Gold . Company's assets in 1999,and has experience evaluating gold properties in Alaska and Canada,signed an agreement with Placer Dome in 2001.The agreement provides NovaGold the right to earn up to 70 percent of the project by spending $10 million to advance the project.NovaGold is focusing their efforts on high-grade portions of the deposit and plan to generate a positive feasibility report within the next couple years.The NovaGold approach is based on a 4,000-8,000 tonne/day operation with an average ore grade of about 5 grams of gold/tonne.Although an operation of this size would be smaller than the 20,000-30,000 tonne/day -3 grams/tonne operation evaluated by Placer Dome,ore grades are substantially higher and mine costs coupled with low gold prices could be offset by the higher yield per tonne. During their first few months on the property,NovaGold spent more than $2 million and completed 42 diamond-drill core holes.A revised resource calculation resulted in a substantially higher grade.The new resource assessment will be the basis of a prefeasibility study that will allow NovaGold to proceed with mine design and permitting efforts,while additional drilling of high grade zones is undertaken Spring,2002. Potential Benefits of the Donlin Creek Project and power grid -Sustainable Development Many of the problems that characterize the region would experience substantial relief by the advent of lower cost electricity and the economic and social benefits of a world-class gold mine. During a 2-year mine construction period,there would be on the order of 450 jobs at the site.During the 10 plus year operation period there would be about 300 jobs at the mine.Given that many of the mine employees will be from surrounding villages,this will have enormous economic impact on the local and regional economy. Royalties to landowners,increased tax base,increased business and vocational opportunities will have more global effects on the economy.Improved transportation and communications, better education,improved health, strategic defense benefits,economic growth,reduced transfer payments,and other sustainable development issues will be realized.Social benefits will go hand in hand with the economic benefits. Given the remote location and lack of infrastructure,economic development in the Calista region will depend on natural resource development.Whereas any single mining project will ultimately havea finite life,there are more long- term and sustainable benefits to be achieved.The region has a history of mineral development and many prospects remain to be explored.World- class mineral deposits seldom occur by themselves;usually a single large deposit is indicative of more substantial mineral endowment in the region. Vocational training and occupational experience that accompany exploration, mine construction and operation provide marketable skills that are useful in other industries.Skills that would be developed during a mining project include heavy equipment operation, drilling,explosives handling, construction,engineering practices, mechanics,electronics and electrical tasks,environmental technology, plumbing,catering,computer technology and communications.These skills are marketable in other industries and are useful anywhere in the world. Such vocational development would give residents the opportunity to participate,rather than be isolated from the global business community.Other emerging mining and development projects around the state would provide additional employment for this trained work force. For Donlin Creek and other natural resource-based projects to become realities,it is necessary that energy development be made a priority by all interested in the social and economic welfare of the region.State and Federal Agencies are encouraged to combine efforts and resources to make these projects feasible. Calista Regional Energy Proposal Request for Funding ; The sum of $4.5 million dollars is requested in grant funds to Nuvista Light &Power Company for constructing an electrical transmission system demonstration project ($4.0 million),perform a feasibility analysis of constructing a power plant to supply initial power demand of the proposed Donlin Creek gold mine project ($0.2 million),and a feasibility analysis for a 15 MW coal fired electrical plant and a 10 MW turbine combustion plant in Bethel and transmission system to interconnect villages to be served by the central plant ($0.3 million).This project is part of a strategy to develop regional energy projects that will lower the cost of providing electrical power in the Yukon Kuskokwim Delta of Southwest Alaska. Demonstration Project Construction of approximately 30 miles of new Single Wire Ground Return (SWGR) power line is requested at a cost of $4,000,000 to demonstrate economic and technical feasibility;research,development,identification of materials,equipment and construction methods using lightweight materials to lower construction costs.This would include development of lightweight gravity-stabilized aluminum or fiberglass structures,low cost and easily installed foundations and anchors,conductor installation and structure erection techniques,and selection/modification of appropriate construction equipment.The power line conductor would also contain a fiber-optic cable to provide high speed/quality telecommunications capabilities. Mine-Site Power Supply Funding in the amount of $200,000 is requested to undertake a feasibility study to accurately determine the cost of power associated with providing on-site power generation for the Phase One of the mine project.Development of the Donlin Creek gold mine project would have an enormous impact on the electrical power needs and economy of the Calista Region.Phase One of the project is expected to become operational on or about the year 2004.Load requirements,for Phase One,are estimated at 20 megawatts and 166,440 mwh's.Phase Two,of the mine development,is estimated to be completed in 2011 and would double the mine's electric load requirements.Phase Two would have a demand of approximately 40 megawatts of power and 332,880 mwh's of electrical energy.The final phase of the project would be completed in 2016 and would increase power demand to approximately 60 megawatts,and require 499,320 mwhs of energy. Development of the Donlin Creek mine project will triple the power demand in the region and energy requirements will increase almost five fold. Central Electrical Plant A feasibility analysis at a cost of $300,000 is requested to determine the cost for providing low cost electrical power to Bethel,villages in the region.Central plant and village intertie configurations will be determined including a 15 MW coal fired facility,a 10 MW combustion turbine plant,and transmission interties to connect villages in the region to the central plant.The benefits of interties are well known.They allow the transfer of low cost energy to high cost areas and consolidate a customer base large enough to make capital-intensive projects economically feasible to develop.Production of lower cost electricity,through a centralized coal-fired generation plant at Bethel,in turn would reduce the regions dependency on fuel oil.By installing fiber-optic cable in the power line conductor,high speed/quality telecommunications capabilities would also be provided throughout the region. Calista Regional Energy Proposal History Calista Corporation is currently involved in an energy study through Nuvista Light &Power Company.The purpose of the study is to investigate and identify alternatives or a combination of alternatives that could provide lower cost power in the region,both with and without the development of the proposed Donlin Creek gold mine project,located near Crooked Creek, Alaska.The mine will have a maximum load demand of approximately 60 megawatts at full operational capacity,with an initial start-up demand in the order of 20 megawatts. Nuvista Light &Power Company (Nuvista)will develop,construct,own and operate any generation facilities or transmission interties recommended by the study.Nuvista is a non-profit organization formed by Calista Corporation to function as non-profit regional Generation and Transmission (G&T)utility.Nuvista would wholesale power to existing utilities for resale to their customers and sell power directly to the mine project. The region is located in southwestern Alaska,in the Yukon-Kuskokwim area,and encompasses 56,000 square miles.There are 47 year round villages located in the region with a population of over 23,000 residents.Electric power in the region is generated by relatively small diesel power plants located in 40 regional villages and Bethel.Only a few of the villages are interconnected to each other or Bethel by power lines.Power costs using diesel generation have continued to slowly increase over the past several decades and will continue to do so in the future.Residential rates in many of the villages exceed 50 cents per kilowatt-hour as compared to 10 cents per kwh in Anchorage and 16 cents per kwh in Bethel.The high cost of power is somewhat offset by the state-funded Power Cost Equalization (PCE)program.However,even when heavily subsidized through the PCE program,residential rates in the villages are 3 times the cost of electricity in Anchorage and twice the cost in Bethel.Few families and businesses can afford such exorbitant energy rates. The primary purpose of the energy study is to identify a comprehensive energy strategy that will reduce the high cost of electrical power in the region.The study is being conducted in two parts. Part I,using a conceptual level approach,has identified preferred alternatives for supplying electrical power to the region,both with and without development of the Donlin Creek gold mine project.Phase II will perform a pre-feasibility analysis of the two preferred alternatives. Preferred Alternatives A draft of Part 1 of the study has been completed and is presently under review by the Alaska Energy Authority/AIDEA.This study identified two preferred alternatives:without the development of the Donlin Creek Mine project;and a second preferred alternative to satisfy the region's power requirements,assuming the mine is developed. e Without the mine development:construct a 15 MW coal plant at Bethel and 859 miles of Single Wire Ground Return (SWGR)transmission system to interconnect regional villages.This includes integrated use of coal-fired generation,waste heat- capture and wind generation. e Assuming development of the proposed Donlin Creek gold mine:combination of mine site generation and the construction of a new generation plant at Bethel.During the initial years of operation,a 20-megawatt mine-site combustion turbine power plant will be required by as early as 2004.As the mine load increases to approximately 40 megawatts,a coal plant would be constructed at Bethel to supply the energy needs of the mine,Bethel and the regional villages.Waste heat from this plant would be captured and utilized in Bethel.The mine would be interconnected to Page 2 Calista Regional Energy Proposal the coal plant by a 175-mile long 138 kV transmission line.The regional villages would be provided power by constructing 859 miles of Single Wire Ground Return (SWGR)transmission system to interconnect regional villages.Prior the construction of the coal plant,the regional villages and Bethel would be provided power by a small combustion turbine plant constructed at Bethel.The project includes an integrated use of coal-fired generation,waste heat-capture and wind generation. SWGR Transmission System Single Wire Ground Return (SWGR)transmission can best be described as single phase -single wire transmission of electricity that uses the earth as the return conductor.The SWGR transmission concept suggested here is point-to-point system with a carefully established grounding system at each point,operating at a voltage of 40 kV or 80 KV to ground. The SWGR transmission system or,single-wire-earth-return (SWER)as it is referred to in other countries,is not a new concept.A SWGR transmission line demonstration project was constructed in 1981 to intertie the village of Napakiak with Bethel.The 8.5 miles of line interconnecting the two communities extends over tundra-covered terrain,which is underlain with permafrost.This demonstration project has operated reliably for 20 years and has proven that a SWGR transmission system is both economically and technically feasible.Presently,well over 100,000 miles of SWGR power lines are in use in Australia.The SWGR system is also used in New Zealand and many other countries that are confronted with the problem of serving small electric loads located at great geographical distances from power generation supplies.It is estimated that SWGR transmission line can be built for less than $90,000 per mile inclusive of all costs including permitting which is less than 1/3 the cost of a conventional power line capable of delivering the same electrical performance. Page 3 FROM :ACP,Inc.Administration PHONE NO.:907 5433369 Mar.@1 2002 10:15AM P1 an 101 A Main Street Joe Lomack Office Bullding PO Bor 219Bethel,AK 99559-0219Hop://weew.svop.org Association of Village Council Presidents,Inc. Administration Office Fax Dellver To From >a Bob Charles Allen Joseph - 272-5060 Association of Village Council Presidents,Inc. 907-543-3369 (Fax) Date sent:03/01/2002 Subject:Energy Summit Meeting Number of pages Including cover page:Talliman Please call my office If you have any questions. FROM >ACP,Inc.Administratior PHONE NO.=90?5433369 Mar.@1 2802 16:16AM P2 Printed by.Allen Joseph Wednesday,February 27,2002 12:49:24 PMTitle:Re:Energy Summit Mtg.Page 1 of 2 FAX essage From:¢Allen Joseph Subject:Re:Energy Summit Mtg. To:&bcharles@calistacorp.com Cc:@ Arthur Lake &SBarclay@calistacorp.com Bob, The AVCP Special Convention this March has some explaining ta do.It is not your usual AVCP Convention agenda and a bit more special than "Special”. There will be 2 main agendas.The Kinguliamta Ciunerkaat agenda (attached)is the overall agenda governing the entire conference.There will be 5 breakout groups:The Full Board (their agenda is also attached),to do their normal business,as well as,for the Men's,Women's,Elders and Youth. This conference is geared toward launching the objectives of last fall's regular convention in Aniak concerning "Kinguliamta Ciunerkaat -Securing a Future For Our Children”project,for which AVCP received funds from AFN's Wellness and Alcohol Control Program. The agenda was decided by ivan Ivan,Art Lake,Harold Napoleon,myself and a couple of Kinguliamta Ciunerkaat program advisors.|tried my best to have AVCP's Full Board spend more time on issues such as Calista's rural and transportation plans,but due to the nature of the "special"in this convention,there will be no such luxury.However,the topic is an agenda item in the Full Board's agenda,and to be discussed in a panel set-up in which Matt,Art,Ron and Gene will be present. There will also be an Executive Board meeting on Monday,Mar,18.The E-Board will tackle issues that were to have been scheduled for the Full Board during the convention but were determined to be appropriate for discussion by the E-Board. |know Calista needs to spend mare time on the energy and transportation issues,rather than a "moment”(1 hour or so)during the Special Convention.Perhaps scheduling additional meeting time in the evenings or dedicating an entire day on Friday,Mar.22,or another day,would meet Calista's goal.Still,the evenings will be packed with activitites that are being prepared for all of these people.Also,there is the Regional Economic Development Conference (right after the YKHC Tribal Gathering)to be held during the last days of the first week af April 2002;it might be FROM :,AUCP,Inc.Administratior Printed by:Allen JosephTitle:Re:Energy Summit Mtg. PHONE NO.947 5433363 Mar.Qi 2402 10:17AM P3 Wednesday,February 27,2002 12:49:24 PMPage2of2 an excellent time to spend time of development issues. -Allen J.ar sc} re BANGtre tel Needed seal writes:oress Mar.@1200210:17AMP4>9875433369PHONENO.:,AYCP,Inc.AdministrationFROMAgenda Kinguliamta Ciunerkaat Il Special Convention 9:00 9:15 9:30 10:00 10:45 11:00 12:00 PM 1:30 3:00 4:45 5:00 7:00 Call'to Assambly-tvan MM.Ivan,AVCP Chairman Opening Prayer-Blshop Jacob Nelson,Moravian Church Posting of Colors-Bethe!Nigh School JROTC National Anthem In Yup'ik--Ayoprun Elltnaurvik Students Dance Group -Upallret Dancers Welcome Address-Choirman tvan Antone Anvil,Iraditional Chief,Oru?sorarmuit NativeCouncil State of The Region Address-A Call To Action Arthur J,Lake,AVCP Inc,President How Woe Got Here "You Can”-Harold Napoleon Break Breakout into Groups © Foll Boord:Chairman lyon,President Lake; Elders:Facilitators T8A;Men:Facilitators TBA; Women:Facilitators TBA;Youth:Facilitators TBA; Lonch Brack Continue Groups Breck Raconvene Genaral Assembly: Closing Remarks-Chairman Ivan Closing Prayer-Alec Bird Racess Fiddling Fundraiser -Location TBA Youth Dance-tocation TBA 12:00 PA 1:30 3:00 "3:15 5:30 7:00 Call to Ordar-Cholrmon Ivan Opening Prayer--Tre ditional Chlaf Joa Lomack Donce Group-Chavak Tongik Concers Report to General Assembly-tucy Sparck,Moderator Recap of Previous Day Taking The Second Step-Harold Napoleon Braok Breckavt Groups:Te come up with specific courses ofoclion{o be takon by the Full Sourd,families,elders,then,women,ond youth fo and the suffering of women,children,yoong adulis,and men.(RecommendedActionsfobaaddressedtospacificgroupsorpersons.) Lach Break Continuation of 8reakout Groups Break Goneral Assembly Raconvanas-Report on SpocificCoursesofActionNeededtoEndSufferingandSell-Destructive Behovior and to Bring Healing fo VillagesondFamilies,Open Discussion of Issues andRacommandations-Chalrman Ivan,Moderator Deodline for Resolutions/Supper Break Closing Prayer /Recoss Draft Resolutions for Intreduction to AVCP (Locations ToBeAnnounced) ie Akiak 9:00 9:15 10:30 10:45 12:00 PM 1:00 1:30 3:00 3:15 3:45 4:45 6:00 Call to Order--Chairman Ivan Opening Proyer-Jean Cook,XwigIilingek Yup'ik Singing (frank Napoleon &Dennis O'Brie: Recap of }st ond 2nd Day--Lucy Sparck,Moder Resolutions-Chairman {von &President Lake Break Resolutions (continued) Lunch Break Chavok Tongik Dancers Resolutions (continued) Break Where Do We Go From Hore?-President Lake Closing Comments from Assembly (5-minuta limiperson- Chairman Ivan,Moderator Closing Caramonies Closing Prayer-Paut John,Francis Charlie,Pet:Aluska Adjcurnment-Chaitman lvon Kaluvkag Award Coremonigs-Prosident Laka Fiddling Fundroiser-Locotion TBA a eee AONweg @ a5,Se8,3 $0aAMBS,at gee,"SQ? FROM >AVCP,Inc.Administratior PHONE NO.:90?5433369 Mar.61 2602 1@:18AM PS AVCP,INC. The Association of Village Council Presidents Office of Administration Pouch 219,Bethel,AK 99559 1-800-478-3521 1-907-543-3369 FAX AVCP Full Board of Directors 2002 Special Convention-Bethel,AK Yupiit Piciryarait Cultural Center March 19-21,2002 Bethel,Alaska AGENDA March 19 @ 11:00 AM -4:45 PM I.Call to Order-Ivan M.Ivan,Chairman ll.Roll Call Allen Joseph,Vice President of Operations: lll.Approval of Agenda -Ivan M.Ivan,Chairman IV.Approval of October 2001 Annual Convention minutes -Ivan M.Ivan, Chairman V.The Chairman's Report -ivan M.Ivan,Chairman Vi.The President's Report -Arthur Lake,Presidentvil.Discussion and Action on AVCP.,Ine,Issues: .Kinguliamta Ciunerkaat Update/Future Plans -Arthur Lake,PresidentA B.AVCP By-law Changes -Ivan M.Ivan,Chairman C.Termination of Federal Recognition of AK Tribes Issue -Arthur Lake,President/Eric Johnson,AVCP Attomey D.Calista/AVCP/AVCPRHA/YKHC Energy &Transportation Issues - Matt Nicolai,Calista/Art Lake,AVCP/Ron Hoffman,AVCPRHA/Gene Peltola,YKHC E.Waterfowl Conservation Committee Nominations &Elections - Arthur Lake,President March 20@ 11:00 AM -3:15 PM F.Regional Tribal Justice Center,Scott Sidell,AVCP Attorney G.Subsistence Issues -Moderator.Arthur Lake,President 1.Govemor's Proposal -Eric Johnson,AVCP Attorney 2.Federal Subsistence Board Definition of "Customary Trade”-Mitch Demientieff,Federal Subsistence Board/Carl Jack,BIA-OSM/Allen - Joseph &Eric Johnson,AVCP 3.Subsistence Fishing for Summer of 2002 -Jennifer Hooper,AVCP Natural Resources H.High Seas Fisheries Issues and Tribal Testimony -Steve Davis, NMFS/Eric Johnson,AVCP Attorney/George Owletuck,Alaska Oceans Network March21@ 9:15 AM-3:15 PM @ General Assembly |.Resolutions -Ivan M.Ivan,Chairman/Art Lake,President BETHEL COAL-FIRED POWER GENERATION PLANT FEASIBILITY STUDY FOR NUVISTA LIGHT AND POWER September 12,2003 Prepared By: Precision Energy Services,Inc. Project Development Division PRECISION ENERGY SERVICES INC. P.O.Box 1004 e Hayden,Idaho 83835 (208)772-4457 www.pes-world.com Il IV. VII.*UAW>TABLE OF CONTENTS INTRODUCTION(ou....cccccccccccsssscoscsescnseasescsesecasssssesssesassessestscssessosesessesesseatsesncocsasstescaccetsassasateaenaraveostusosoocaseataeseueuee 1 GLOSSARY oo.cecceccccccccoccesssssscsssscsesececcsesccccensssessesseseescessscescecoucsonseasccacessnseasensssesccescecsessenscecsecsoaseseauansansaseaseocreteanaes®3 PROJECT SPECIFICATIONS ou...ccccccccseessscsscssetcssescsssssateneaascesscsstsaccacecsaccncssencesencecsasscceasanoescesceneagencesseseseasorseeas 4 A.REQUIREMENT SPECIFICATIONS .......cccsscsssesssssscseseesesesesscessessvasesconscccocsccousesceasenscsccccauectsestseessseessessoeaceseonecees 4 B.LOCAL CONDITIONS......cccccceccsccoccstcssocoecccsscecessonscsscssstesssscovsesessescurccscceasssscscocscesesccesonssiseneessenesassssiseaeusesssessaseas 4 C.OTHER DESIGN REQUIREMENTS...........cccescssesescsssssssssessecesccsssastsscesensercacencasonsasencaucncncesssuatanecaseacacenssosssevesssese®5 D.EMISSION STANDARDS........cscceccsscessccecccssessenseseeccecceasessesssstssestescouscessecsscscsoeeeseccosssoascanseasesccecsesscessnaveseeasnsenseas®5 DESIGN PHILOSOPHY .....0.....c.ccsccssssscssssesssscsssscssseessssessoncnesscrsceccusscasecsacssascarsoenonosscasoassatearsoeusussevsseceacuseesesscseuetanes 7 FUEL SELECTION,PROCUREMENT AND LOGISTICS OF SUPPLY ...0......:ccscsscsssoreesessenseccosesconevsonsessessvevevens 8 A.SELECTION OF COAL..,...cccccccsssssocssscevcocsscccsssceccssesecsassnsesenssonctassessorseocecsecscatccccesseasenccaseoscassesossescassonsascaseasenneus 10 B.COAL DEMAND AND STORAGE REQUIREMENT .......0ccc::csssccsccsessecencecssceessesececsececssecerseseeesscessesassossoonsersaneazecs 15 D.COAL TRANSPORTATION PROCEDURE........scsssccssessessoeccesscnssuensoucesssocsncnstaseseesssasentecccceseqecocoueeasseseseeannaseeauas 24 E.SCHEDULE .....cssccssscesscsececssssescsnsssecucsceacecessusesauscaseacssessasesensesensscocsconsecessssnsnsaeseeseeceransenecnocesederenseesaseseqseereecerss 28 DESCRIPTION OF THE POWER PLANT ..........ccccsescssessesesessescescanceceteccascesseeeseseesceasscaecenenseaseasnsnessseasaaseseusaveerenes 30 A COAL STORAGE........cccescssssseccconssesssesronsuctsseessessentestansessscusssssuccouseasessesacensuseseeccensecatsasesscseeseeseeassareccssonscosaeaet 30 B PULVERIZED COAL COMBUSTORS WITH INTEGRATED BOILER ..........sccsccosseesesseeessccotetscrssonseessccocoesenssesersass 34 Cc STEAM TURBINE AND GENERATOR SYSTEM..........scssccsscsssessessesecerevsescenterseascetsaeeccesssesesnecsenssaticescieeaeessesased 37 D ENVIRONMENTAL CONTROL SYSTEM .........cccccssessesessescesessescecaceecsecessnenceecseeasaseesensecesesaeseessscassesesoteecansessesaes 38 E AUXILIARY EQUIPMENT AND INSTALLATIONS ..........csscessescccoccstsonsensessancosterocassonetenscossocuscusensersevetesassnseseceees 43 F INSTRUMENTATION AND CONTROLS,CENTRAL CONTROL ROOM AND MOTOR CONTROL CENTER.........:0+44 G MAINTENANCE SHOP ..0.....ccsccsccecccoccsssssessccossectsesecccenccstssceasceuscccuacuvoseeseessensessesconscsssestasseaecuseastcosccasesoessozaseeee 48 H.SITING OF THE POWER PLANT ..........csccscsseccesceceseesecacscsccaesseseseessscessassasesscsuesesacaceeeeseaeseraseasansecsessesesecenseneats 50 DISTRICT HEATING SYSTEM...u.....ccccceccscsscssssessesestessessesessseesessesenseasaceseessccessnsecseseesssacscesconsueeatsanseesesseenereaaeaes 54 A.PIPES &PUMPS........:ccccecccscescssscccnseesssessesscesssenessseesuccusesuccnsessccesssusauesenecuseascenesectaccescesensesaeenserasersseseeeseaseesnes 55 B.HEAT EXCHANGERS .........cceccsssscessseesesesesesesseesnsescecssnececacecsusaesseessceesscuecateaseeseacessesenseesesecessarsuceeeeseentaeeenaeses 56 C.BACKUP SYSTEM........c:scsccsccecsssseseesessecesccacesesesceccanesseccsccacanccessasenseneneecacecesessseacasessoarsanseencusesseusesteseeaesesseases 56 CAPITAL COST ESTIMATE ..u0....c.ccccccceccsscccssessncesuesessesseseseesesseseeeessssensscessseesscossceesseesesecsansasaseaseaecesssocoeseaseseeseacaue 58 A.LAND -MOUNTED POWER PLANT........:ccsccesssesecesesecccscccseeenoteceosscsssnseesoccuceuesentsuaseesseeceescooeesensntsassensesnresnasoces 58 B.BARGE -MOUNTED POWER PLANT .......0..cscsccsccesssscotstsessonseoccoceasenessesasescccersessseesenscessacestsseseseasecseoressevoeosoreses 59 C.CAPITAL COST IMPLICATIONS OF THE APPLICATION OF USIBELLI COAL 59 D.POSSIBLE SAVINGS FROM UTILIZATION OF HEALY CLEAN COAL POWER PLANT 60 O&M ESTIMATE ...0..ccccccccccccccccccsssccsessssessssessessesessesssssnesssesesocsseesssesnecstsacsossusesecessesecssesecseeassaccnssnessseneensonseesees 63 POWER PLANT PERFORMANCE EFFICIENCY A.FACTORS IMPACTING PERFORMANCE OF THE STEAM POWER PLANT B.SUMMARY OF BETHEL POWER PLANT PERFORMANCE RELIABILITY AND AVAILABILITY STUDY00.00.0000...ccccceccssscesssecoeccesseneescsuscussnecesenasoratentenesesnonecs 70 INTRODUCTION..,..0---0-cs0cccescncesecnsneseracesussccossoesonseasensconsasenssevsesesescanecessecessasassesasiontercascessecasessansessesenovosersesoseasenaeesets 70 BASIS OF HIGH AVAILABILITY AND RELIABILITY ........---:seesescssssusctsecesceeconssarseesseceseessaaecsasessnsseeascscssneceseeuteneneraes 70 OBJECTIVES OF THE STUDY ......-cccscscccecccsccestseseeesnececeecessnenseseussesscarssecseneececeterssaenessceeeestesceeseeqseesdestensecessesseseeteantes 73 E. F. G. MAIN CONCERNS ESTIMATION OF AVAILABILITY OF EQUIPMENT AND SYSTEMS;ADDRESSING THE CONCERNS ESTIMATION OF PLANT AVAILABILITY AND POWER SUPPLY RELIABILITY A rencesevacceeonsesnsccces IDES PRECISIONf"9 SERVICES INC. L INTRODUCTION This report has been prepared as part of a feasibility study of a power plant proposed for the development near the City of Bethel for the supply of electric power to Placer Dome's Donlin Mine and to the City of Bethel,Alaska and neighboring native villages.The power plant under study will be coal fired.In addition to evaluating power generation,the feasibility of providing district heating to the residents of Bethel,local institutions (schools,community college, hospital,local prison)and local businesses is being evaluated.The goal of this report is to provide the project developers with sufficient information,including specific recommendations to identify the most feasible,long-term power production options that would result in generating electric and thermal energy at competitive pricing and facilitate reduction of State payments in the framework of the Power Cost Equalization Program. Permitting standards and expected performance related to the operation of the power plant have been noted to make the developer aware of the possible requirements. The primary step of the Feasibility Study was determining the best fuel for the plant.Section V of this Report evaluates seven coals from USA (3 coal sources)and Canada (4 coal sources).In this section the cost of coal delivered to Bethel in dollars per million Btu fired is determined,on which basis a recommendation is made for the selection of coal.The criteria used for the evaluation,the effective cost per million Btu,is considered to be the broadest because it takes into account the procurement cost,cost of shipping from the mine-side to Bethel,sulfur content,and possible requirement for an FGD (flue gas desulfurization)system including SO2 scrubbing material demand,ash and moisture content,and net heat recovered from the coal.One of the analyzed coals is mined in Alaska. Based on the fuel evaluation step and selection of the best coal,the Pulverized Coal (PC) combustion technology has been selected.Costing information provided herein is based on the application of this firing technology for generating steam in an integrated boiler. The PC combustion is a modern technology that has been proven in the USA in the last 40 years and is characterized by high combustion efficiency (low loss on ignition)and low-cost emission controls.The technology has become an industry standard for coal-based power generation.Bids have been obtained from the most advanced and experienced vendors: Babcock &Wilcox and Alstom,formerly Combustion Engineering Division. The evaluations also include the supply of heat energy and hot utility water to a district heating system in the City of Bethel.The study does not evaluate the feasibility of the application of district heating for specific thermal energy recipients;there is included, however,sufficient information to conduct such evaluations for most of the potential customers of the district heating system. The Study addresses two options of siting of the power plant.First option is based on siting the entire plant on land,south ofthe City of Bethel.The second option is based on siting the coal storage facility and some other bulky systems like cooling towers on land and the steam and generation plant on barges.Advantages and drawbacks of both options are evaluated in DES Sz.f ")SERVICES INC. Section VI.H.Siting of the Power Plant.Barge-mounted power plants (Power Barges)based on combustion turbine or diesel motive power have been popular,primarily in less developed areas and where and at the time when fuel prices are very low.The Feasibility Study shows that coal-fired power barges may be an economically viable option for remote locations where the cost of skilled labor is twice to thrice as high as in Mainland USA. The power plant specifications are provided in Section III. The study also includes in Subsection D.Environmental Control System of Section VI Description of the Power Plant,a viable business option for ash utilization instead of landfilling or ocean dumping.Due to its high content of silicon dioxide (SiO2),aluminum oxide (AI203)and iron oxide (in excess of 87%combined content)the ash will be a good pozzolanic material to be used as a Portland cement substitute and admixture. The thermal system (boiler)of the Power Plant will include a capability to feed and burn local municipal solid waste and partially dried sewage sludge excavated from drying lagoon.This will eliminate the garbage and sewage sludge disposal problem typical for Northern locations with permafrost under layer. IDES PRECISIONa"”SERVICES INC. II.GLOSSARY CHP Cogeneration Heat Plant CT Combustion Turbine CTG Combustion Turbine and Generator set ASL Elevation Above Sea Level DH District HeatingGpmorgpm_US Gallon Per MinuteHRSGHeatRecoverySteam GeneratorMPPModularPowerPlant MWe Mega Watt electric PM Prime Mover STG Steam turbine and Generator set MM Btu Million Btu SCR Selective Catalytic Reduction (of NOx) WG Water Gauge (column)(unit of pressure)MM Million (MM Btu =1 million Btu) MT Metric tonne =2205 Ib ACI American Concrete Institute AISC American Institute of Steel Construction ANSI American National Standards Institute ASME American Society of Mechanical Engineers ASME B31.1 Power Plant Piping ASTM American Society for Testing Materials AWS American Welding Society CTI Cooling Tower InstituteHEIHeatExchangeInstituteHISHydraulicInstituteStandardsIEEEInstituteofElectrical&Electronic Engineers ISA Instrument Society of AmericaNECNationalElectricCode NFPA National Fire Protection AgencyNFPCNationalFireProtectionCode OSHA Occupation Safety &Health ActTEMATubularExchangersManufacturer's AssociationUBCUniformBuildingCodeUMCUniformMechanicalCode UPC Uniform Plumbing Code UL Underwriters Laboratory -industrial insurance company FM Factory Mutual -industrial insurance company "SERVICES INC. Il.PROJECT SPECIFICATIONS A.Requirement Specifications Required electric power supply at the Donlin Mine MWe 70.0 Transmission line losses MWe 5.0 Local usage (Bethel,villages)MWe 9.3 Parasitic power (power plant use)MWe 8.5 Required electric power output,net at transformer MWe 92.8 Thermal energy supply to the District Heating (DH)system Yearly average heat supply million Btu/hr 128.9 Average summer supply million Btu/hr 91.1 Average winter supply million Btu/hr 142.2 Maximum winter supply million Btu/hr 169.0 Extremely low winter temperatures million Btu/hr 180.0 Utility water for consumption lb/hr 151,400 Gpm 303 .Assumed that all utility water is consumed,0 return .Heating water 20%losses,80%return The DH system will use hot water as the energy carrier (see System Description): .Water temperature,outgoing °F 170 -175 .Return °F 125 -130 .Water pressure,out psig 100 .Return,design psig 20 Heating of the hot water will be achieved primarily by utilization of condensing heat exchanger utilizing latent heat of condensation of the steam cycle. B.Local Conditions Elevation above sea level ft ASL 100 Temperatures -see graph on the following page Average humidity:range:60%(summer)to 85%(winter) IDES PRECISIONUGEYS dj "7 SERVICES INC. ii)&8wwTemperature(F/C}oa8'45 - Average Temperatures and Records for Bethel,AK Feb Mar Apr May Jun Jul Aug Sep Oct Now Dec Average High Average Lov Record High/Low Morith Figure 1 Other Design Requirements Job Conditions: .Electrical 460 V,4160 V,3 ®,60 Hz .Equipment Location Indoors .Insurance Codes/Requirements UL,FM,NFPA Emission Standards The most likely standards that the Power Plant will have to comply with are: SO,500 ppm molar fraction Remark:To comply with this standard,the sulfur content in the coal should not exceed 0.5%weight.The sulfur content in the recommended coal is below 0.3% CO There is no State standard for CO emissions from liquid fuel fired power generation equipment;however,exceeding 100 tons per year may trigger the requirement for a New Source Review and setting of a performance standard for the plant. NOx The State of Alaska does not have a standard for NOx;however,the standard to be used here will most likely be 0.065 Ib/million Btu or 35 ppm vol.at 3% Op. RES PRECISION EUEEINOW SERVICES INC. PM The standard for particulate matter (PM)is 0.10 grain per cubic foot at standard conditions averaged over 3 hours. The values for expected standards were obtained from the Alaska Department of Environmental Conservation as guidelines for plant design.The actual performance requirements will be determined based on application for the Permit to Construct and Permit to Operate. oa Scveeot pet =MapPoint Station Crooked_Marshell a crookWADEHAMPTON Stony River,feussian”Red Devs”bession Stootnte” Po ¥=oerawooteeeoot ;. Whiteliah Leke .Yukon Delta National Wildhts Retuge -.:Anker :o .BETHEL 2 MountThomHamilton ao Meunt peesectneoesmoe .Plummer A H_Masighs ausechek,Akiak -awe A wayn geese eres . .r 4 Taylor Pask_Kwethiuk ALA WS:KA ecoee ”=ee 5 ”Kogeuttok Lo ”Kisereiix éoaNishifenlakeLake= __Turtubutes .ceased Kisoratik Upnuk Lake Chichinok _Kwethhsk H whe .Chikominok Tikehia"Eek preeed Lewe .i DILLt*nGHAWMMiddleot Fork Bok P"sean Lake Lake Chavekuktost i 3 Noyakuk LoreKegetLekepew MuyekukPegatileke3genuicAtonAMeuntsin F -Kane:goood . .KobgenekBeringSea :Togias Lake .Jacksmith Bay Goodnews Leke . :Konwok "New Stuyanok 7°Kuakokwim Bay Goodnews i Exwok,ee:@7003 miancen Cop @2003 meteen,,86 feraDT.me.ee oot -Toghak B Location of the City of Bethel saniaPRECISIONEEG}WwSERVICES INC. DESIGN PHILOSOPHY The Bethel Coal-Fired Power Plant design philosophy is based on the following premises: 1.Utilization of the best value coal -fuel cost amounts to around 65%of the total plant operating cost and cost of money combined,therefore fuel efficiency becomes the primary objective of the project. 2.Because of the plant location in Western Alaska and its duty,the required reliability of power supply both to the Donlin Mine and the City must be almost 100%. 3.Modularize as much as possible to be capable of erecting the plant in a short time and in Western Alaska conditions taking into account the short season for shipping supplies to the site.Also,consider location of the plant or a significant portion thereof on one or two power barges that can be assembled in a West Coast port and tugged to Bethel. As aresult,in the fuel selection process we evaluated various coals from the point of view of. .High and Net heating value (HHV and LHV) .Sulfur content -requirement for a flue gas desulfurization system and SO, scrubbing material .Moisture and ash content,both of which are a ballast and are shipped at high cost .Procurement cost and .Shipping cost As the result of the evaluation,the selected coal must be characterized by the lowest cost per million Btu. Another result of the above assumptions in selection of the pulverized coal combustion technology. To achieve the required reliability and availability,it was decided to recommend two parallel process lines,each generating 50%of the demand with each being capable of increasing its capacity by a minimum of 5 MW and supplying 100%of the thermal demand for the district heating system. The study also includes a business-viable option for ash utilization instead of landfilling. Cost,operability,and protection of the permafrost considerations were applied to engineering of the coal delivery,storage,and reclamation system.Foundations and enclosure for this system alone amount to approximately 10%of the entire plant cost.For instance,the study evaluates air supported structure versus prefabricated steel structure;also use of a layer of coal as the permafrost insulating layer versus other insulation methods is being evaluated. sane PRECISION EERO SERVICES INC. FUEL SELECTION,PROCUREMENT AND LOGISTICS OF SUPPLY Fuel selection is the most important activity in the development of a new power plant.It impacts the following: 1.The cost of fuel is the largest portion of the plant's operating and maintenance cost including cost of money. The characteristics of the fuel are very important in the selection of the combustion technology;not every fuel is suitable for the most efficient technology.For instance, high moisture coal should not be used in pulverized coal furnaces. The fuel composition,specifically its Sulfur,Nitrogen and Chlorine content,is very important to the selection of emission control systems. Also the fuel properties have a large impact on the method and cost of storage.For example,coal with a high volatile matter and moisture content will naturally produce combustible gas in an exothermic process,which means that not only will the coal pile heat up locally,but there is also a hazard of spontaneous ignition and explosion ofthe gas at hot spots. In conditions of the Bethel Power Plant,selection of the best value coal becomes an utmost requirement.Due to large fluctuations of the cost of diesel fuel,procurement and delivery of coal to Bethel became one of the most challenging parts of the feasibility study. Fuel selection is impacted by:. General fuel properties (heating value,proximate and ultimate analysis,ash characteristics,moisture content and other) Project specific issues such as: .Delivery is difficult due to distance,climatological,and navigational limitations. .Volume problems -The amount of fuel that has to be delivered to Bethel is the largest volume ever shipping companies active in Western Alaska have ever had to deal with.This creates problems resulting from the lack of experience. Initial evaluation of fuels has shown that the cost of producing electric power in a coal-fired plant is significantly lower than the cost of power generated from liquid fuel,even though the capital cost of such a plant is appreciably higher than that of the liquid fired plant. The following comparison is provided for the purpose of better understanding of the advantages coal-based power generation renders. IDES PRECISIONMy")SERVICES INC. Input energy needed to produce equivalent 1 MW of electric power: Remark:1 MWe is equivalent to 3.412 MM Btu. 1.in coal-fired cycle (with heat supply to District Heating):9.55 MM Btu at a cost of $2.13 /MM Btu (Fording coal)$20.34 /MWe 2.in combustion turbine with combined cycle:5.00 MM Btu at a cost of $7.96/MM Btu (Diesel Fuel DF2)$39.80 /MWe The CT combined cycle option,which is significantly more thermally efficient than the coal-fired option but is still more than twice more costly than the coal fired due to the large difference in the cost of fuel:$2.13 per MM Btu for coal vis-a-vis $7.96 per MM Btu for diesel fuel,delivered to Bethel. In the coal-fired option two cost options are provided;they are based on the way coal barging is organized: -The lower cost is with coal barging being operated by Nuvista or its subsidiary or sister company. -The higher cost is for coal being barged by an outside marine contractor. For further details see Section C.Shipping Coal to Bethel These values include all thermal energy expenses (fuel)including energy for the district heating system and heat recovery.The DH heat is converted to MWe by dividing net heat supply by 3.412 E6.The net electric power includes only the 70 MW sent to the Donlin mine and the supply of 9.3 MW for the City of Bethel and the villages. The difference on a kWh basis is $19.44 per MW.The cost of generation in a significantly more efficient cogeneration system is 96%higher in comparison to coal-fired generation solely due to the difference in delivered fuel cost on a "per million Btu”basis.The difference becomes smaller after the operating cost and the financing cost are taken into account.See feasibility evaluation. The two most important cost factors in the procurement of coal are: .The cost of coal in $per million Btu ($/MM Btu) .The cost of shipping of coal to the plant site This section describes,to the best of our knowledge,coal supply to Bethel and is based on numerous discussions and correspondence with representatives of mining and shipping companies,specifically those that are in the business of shipping bulk material on the Kuskokwim River and other navigational waters in Western Alaska. MES PRECISION Pp SOHRNYGiEniESioroy SERVICES INC. Selection of Coal The basis for coal selection is essentially one factor:the cost of one million Btu obtained from coal.The factor is calculated from a variety of components that are discussed briefly herein. The tables on the following pages show step-by-step the calculation of the final cost of energy obtained from coal.Eight coals from various mines and seams have been evaluated.The table shows coal demand for power generation and district heating of Bethel.The coal cost data has been obtained in the form of budgetary quotes. For the purpose of this study the following coals were analyzed: Kennecott Energy,Spring Creek Mine Kennecott Energy,Colowyo Mine 1.Fording Coal Type A,thermal,Black Bear Mine 2.Fording Coal Type B,thermal,Coal Mountain Mine 3.Luscar Obed Mountain Mine 4.Luscar Coal Valley Mine 5.Usibelli Coal Mines 6.Quinsam Coal 7. 8. Quinsam,Fording and Luscar are Western Canadian coal mines located in British Columbia.The cost of shipping of these coals to a sea port would therefore be lower than that for Kennecott Energy Coal Mines,which are located on the Wyoming/Colorado border. The price of all coals except for Quinsam and Usibelli have been adjusted by the suppliers to reflect the recent increase of the motor fuel prices.Whenever possible,the shipping cost was determined based on motor fuel prices as of January 30",2003. The boiler efficiency given in the table on the following pages was as per Babcock & Wilcox handbook "Steam”. It should be noted that the most feasible coal is the one that has the highest heating value and the lowest sulfur content,the type A thermal coal from Fording's Black Bear seam.The sulfur content is sufficiently low so that no SO?scrubbing is required to perform according to applicable Alaska standards for emissions;as a matter of fact, the sulfur content provides for a sufficient margin in case the Alaska Department of Environmental Control decided to apply a more stringent sulfur dioxide emission standard. It should be noted that the Black Bear coal has the lowest content of volatile matter and moisture.This by itself,as described above,significantly reduces storage and fire prevention costs.According to Westshore Terminals,this coal can be stored without 10 IDES PRECISIONu"'SERVICES INC. compacting or other major fire prevention means for periods exceeding one year. Young,lignite-type coals (Usibelli coal)exhibit inherent tendency to localized overheating and auto-ignition after periods as short as 72 hours. For further considerations,the Black Bear coal supplied by Fording (Elk Valley Coal Corporation)will be used.The currently mined seam has an estimated life of 13 years. There are in the vicinity of the Black Bear mine coal seams that will be opened for exploitation as the demand grows. 11 BETHEL ALASKA POWEA Table 1.COST OF COAL ANALYSIS ERATION PROJECT 1 Fording Coal Luscar Quinsam Coal Kennecott Energy Usibelli Coal Usibelli Coal 2 ckfea)(Coal iouta)Coal Valey |Obed Mountain Mine Colowyo Spring Creek Sub pianinows.as Sub bituminous. 3 |Heating value,net as received Btulb 10,620 4 |HHV as received Btu/lb 12,284 11,130 10,800 11,160 10,450 9,360 7,800 10,500 5 |HV MF (moisture free)Biuib 13,352 12,184 41,520 40,000 11,680 12,551 12,447 6 |MAF (moisture and ash free)Btw 12,240 13,466 13,128 10,800 10,800 7 |Caiculated (Dulong)HHV Btu/b 12,264 11,458 10,843 9,881 11,224 10,559 9,207 7,168 11,142 7 |Calculated (Steinmueller)LHV =equiv.Net HV Btuib 11,952 14,120 10,500 9,481 10,806 10,092 8,708 6,819 10,160 8 |Fuel usage per MM Btu MM Btu 72.3 76.1 63.0 87.4 82.4 90.1 102.5 118.4 86.5 9 |Proximate Analysis Estimatedcomposition 10 Total moisture 8.0%65%10.0%13.0%9.0%16.7%24.8%26.0%12.0% 14 Ash (MF)11.9%16.5%10.2%12.4%13.5%5.7%3.9%9.0%9.0% 12 Fixed carbon (air dry)65.0%55.0%46.4%41.6%47.0%45.0%38.5%29.0%29.0% 13 Volatile matter (air dry)23.0%medium 33.2%33.0%36.5%32.6%32.4%36.0%36.0% 14 |Product Size 15 {50 mm xO mm (Luscar 50 x 25)100%100%6.4%5%100%100% 18 |25 mmx 5mm 51.0%35%100.0% 17 |S mmx 3 mm (Luscar§x 2)15.5%30% 18 |2.0mmxOmm (Luscar 2.0 x 0.5)16.5%20%30% 19 |0.5 mmx 0.2 mm 5.8%8% 20 [0.2 mmnx0 48%4% 21 22 |Ultimate Analysis Carbon 71.0%66.0%63.5%57.3%63.8%60.8%53.9%45.2%55.3% 23 Sulphur 0.29%0.27%0.25%0.50%0.71%04%0.3%0.20%0.24% 24 Ha 3.7%3.7%3.9%3.9%4.19%4.1%3.7%2.9%6.9% 25 Nz 1.0%0.6%0.95%1.2%0.82%1.4%0.7%0.6%0.7% 26 O 5.0%5.9%11.2%11.7%9.2%11.0%12.6%16.1%15.8% 27 cl 0.0%0.0% 28 MC 8.0%8.5%10.0%13.0%9.0%16.7%24.8%26.0%12.0% 29 Ash 11.0%16.1%10.2%12.4%12.3%5.7%3.9%9.0%9.0% 30 100.0%100.0%100.0%100.0%100.0%100.0%100.0%100.0%100.0% 31 {SO lyMM Btu $0,0.48 0.49 0.46 1.00 1.34 0.73 0.74 0.50 0.45 |32 |CA at %XA XAir %20%20%22%25%22%25.0%30.0%35%25% 33 MM Btu 910.90 937.79 933.96 939,97 976.56 959.06 975.18 965 971 34 {Products of Combustion ib/MM Btu 955 971 980 1,483 988 4,029 2,504 998 988 35 |PoC Volume SCFH per MM Btu 12,178 12,434 12,675 18,362 12,714 13,241 30,857 13,024 13,000 36 |PoC %volume CO,13.4%12.8%13.2%8.6%13.1%13.1%5.7%12.8%11.7% 37 H20 8.3%6.5%T4&%5.6%7.6%8.8%46%11.0%118% 38 Nz 78.9%77.5%758%52.7%79.0%74.5%32.5%76.2%76.8% 39 OQ 3.4%3.1%36%33.1%0.3%3.6%57.3%0.0%0.0% 40 SO,0.021%0.020%0.019%0.028%0.055%0.031%0,013%0.021%0.019% 41 100.0%100.0%100.0%100.0%100.0%100.0%100.0%100.0%400.0% 42 |SO2 ppm vol.dry basis at 12%CO,221 213 209 299 890 336 136 232 211 Bold requires scrubber;ime demand 1.6 x st DMM Btu 0.33 43 |Coal demand for Bethel 92.8 MW plant including district heating 44 |Net heat demand MM Btuwhr 1,041 1,041 1,041 1,041 1,044 1,041 41,044 1,041 1,044 45 |Steam generation efficiency (boiler system)88.3%88.3%86.7%85.9%87.5%85.1%84.3%83.44%88.20% 46 |Bethel power plant heat energy demand,gross MM Btu/he 4,178 1,178.69 1,200.73 1,212.05 1,188.61 4,223.45 1,235.22 1,247.20 1,207.27 47 |Required fuel fo/he 95,896 105,802 111,178 424,205 112,016 117,077 131,967 159,698 114,978 49 |US tons @ 99%,reduced summer DH demand wh 442,300 455,322 478,005 521,116 481,606 §03,366 567,387 687,474 494,344 48 |MT -metric tons @ 99%,reduced summer DH demand|MT/Y 374,000 413,100 433,600 472,700 436,900 456,600 514,700 623,700 448,500 Coal data29 09 031,Coal cost anal Page 1 of2 9/30/2003 BETHEL ALASKA POWER Table 1.COST OF COAL ANALYSIS RATION PROJECT Fording Coal Luscar Quinsam Coal Kennecott Energy Usibelli Coal Usibelti Coat 2 Weick Beer (Coat Moureaiy Coal Valey |Obed Mountain Mine Colowyo Spring Creek |SH Btuninous,as-|Sub bihuninous, 50 |Lime supply MTN 1,527 51 |Coal cost 52 |Cost FOB Sea-going port (MT =metric ton)$/MT 35.00 35.00 32.00 28,50 37.00 45.30 27.00 19.00 30.69 53 |Costoflime $/MT 120.00 54 FOB Westshore Terminals or Roberts Bank,Vancouver BC,Canada Texada Is,BC Roberts Bank,Vancouver,BC Seward,AK Seward,AK 55 |SripeingFon at Sect Cot cod cnboeainer Bethel $/MT 38.50 38.50 38.50 38.50 38.50 38.50 38.50 37.00 37.00 56 |Loading at Roberts Bank,Vancouver BC $/MT 3.00 3.00 3.00 3.00 3.00 3.00 3.00 57 {Total coal cost $/MT 76.50 76.50 73.50 70.00 78.50 88.80 68.50 56.00 67.69 58 {Total cost susST 69.40 869.40 66.68 63.50 71.21 78.74 62.14 50.80 61.44 59 |Total fuel and ime cost S/year 28,611,000 31,602,150 31,869,600 33,089,000 34,543,306 39,632,880 35,256,950 34,927,200 30,360,000 60 |Unit cost at Port sits (FO8 deep water ship)$/MM Btu 1.41 1.55 1.47 1.43 1.58 2.10 1.46 41.11 1.33 61 |Total unit cost delivered to Bethel $/MM Btu 2.83 3.42 3.09 3.18 3.38 3.77 3.32 3.26 2.93 62 |Percentage shipping cost in total coal cost 54.2%54.2%56.5%59.3%52.9%47.8%60.8%68.1%54.7% 63 |Shipping to Bethel by NUVISTA barges $/MT 7.60 7.60 7.60 7.60 7.60 760 7.60 7.60 7.60 64 |Total shipping &barging $/MT 58.10 68.10 §5.10 51.60 60.10 68.40 50.10 37.60 49.29 65 |Fuel cost with NUVISTA shipping 21,729,400 24,001,110 23,891,360 24,381,320 26,349,480 31,231,440 25,786,470 23,451,120 22,107,600 66 |Shipping cost savings $/Year 6,881,600 7,601,040 7,978,240 8,697,680 8,193,826 8,401,440 9,470,480 11,476,080 8,252,400 67 |Cost per MM Btuat99%availability 2.13 2.35 2.29 2.32 2.56 2.94 241 2.17 2.11 88 |Percentage shipping cost in total coal cost 39.8%39.8%419%44.8%38.4%33.8%4.1%49.5%37.7% 69 |Power generation kw 92,801 70 |Equivalent DH energy Btu/hr/2412 kw 37,778 71 |Total equivaient power output kW 130,579 72 |Thermal efficiency with district heating Without 37.82%37.80%37.11%36.76%37.45%36.42%36.07%35.72%36.90% 73 \Thermal efficiency without district heating reheat 29.55%29.53%28.99%28.72%29.26%28.45%28.18%28.09%28.83% 74 |Thermal efficiency with district heating With reheat 39.37%39.34%38.62%38.26%38.98%37.80%37.54%37.18%38.41% 75 {Thermal efficiency without district heating 31.02%31.01%30.44%30.15%30.72%29.87%29.59%29.30%30.27% Coat data29 09 031,Coal cost anal Page 2 of2 8/30/2003 IDES PRECISIONEtHEIROY /M "SERVICES INC. Type A thermal coal is supplied by the Black Bear Mine of Fording Type B thermal coal is supplied by the Coal Mountain Mine of Fording Fording and Luscar mining companies have merged into Elk Valley Coal Corporation The above table shows cost in the first year at 99%availability for 20 year cost structure;see attached spreadsheet for 20 year supplies The following items should be added to the calculation of the cost of Quinsam coal: -Capital cost of flue gas desulfurization system estimated $4,600,000 capital including installation;assumed 20 year life of the scrubbing system, cost of money at 5.5%: $0.018 /MM Btu -Operating cost -manpower,repairs (cost of consumables included above)$0.012/MMBtu Total additions $0.030 /MM Btu Effective cost of Quinsam coal $3.39 /MM Btu Attachments 1 to 8 to Section VII.Fuel,coal specifications,as follows: Attachment 1 Fording,Black Bear coal Attachment 2 Fording Coal Mountain coal Attachment 3 Luscar,Obed Mountain Mine Attachment 4 Luscar,Coal Valley Attachment 5 Usibelli Coal Mine Attachment 6 Quinsam Coal Attachment 7&B 'Kennecott Energy,Spring Creek and Colowyo coal 14 PES PRECISION UE ANYREOY SERVICES INC. Coal Demand and Storage Requirement The coal demand of the Bethel Power Plant is: At 100%boiler output:95,900 lb/hr (Fording coal)(at 85%steam generation efficiency) At 99%availability 412,300 short ton (ST) 374,000 metric ton (MT) At 80%demand 333,170 ST 301,700 MT Required storage capacity has been determined based on the following assumptions: .The navigational season lasts from the last ten days of May to the first ten days of October -about 4%months .To account for unforeseen circumstances,such as late start of the navigating season,an early winter,or for security of supply reasons,it was assumed that the fuel delivery season would last 3 months. Consequently,the storage capacity must provide space for storing nine months worth of coal usage or 310,500 ST.The balance,approximately 101,800 ST,will be delivered directly to the coal bunkers or used to replenish the coal in storage during periods of waiting for incoming barges.In calculating the amount of coal in storage, differences in usage of district heating heat and hot water over the year were also taken into account. Coal will have to be stored in an enclosed,air-supported or modular steel structure. This is a requirement resulting from continuous high winds,which will cause major pollution and economical problems.With uncovered outdoor storage,the winds will pick up coal dust.The estimated amount of dust that could be blown away from an uncovered coal pile is up to 5%,especially during stacking and reclaiming operations. This represents a loss of 22,000 ST or an estimated $1,530,000.The cost ofa cover structure of $7.5 million will repay itself just in coal savings within less than five years.Prevention of coal dust air pollution is difficult to express in monetary units, but it is at least as important. 15 PRECISION -")SERVICES INC. Table 2 Coal Demand in Months and Required Storage Capacity Coal demand ST Required storagecapacity Month PP DH PP +DH ST January 32,451 3,222 35,673 35,673 February 29,311 2,725 32,063 32,063 March 32,451 2,682 35,133 35,133 April 31,405 2,595 34,000 34,000 May 32,451 2,346 34,798 34,798 June 31,405 2,271 33,675 33,675 July(3 weeks DH maintenance)32,451 587 33,038 Direct supply toAugust32,451 2,346 34,797 boilersSeptember31,405 2,595 34,000 October 32,451 2,682 35,133 35,133 November 31,405 2,919 34,324 34,324 December 32,451 3,222 35,673 35,673Totals382,089 |30,191 |412,280 310,445 Volume CY 460,000 |CFt 12,420,000 PP =Power Plant demand (power generation);DH =District Heating system demand; PP +DH =total plant demand; ST =short ton 16 COST OF BARGING COAL FROM SECURITY COVE TO BETHEL Capital cost and cost of money [ Pre-owned barge,including overhaul 3 2,800,000 8,400,000 All tons are metric =2205 Ibs unless indicated otherwise Pre-owned tug boat,including overhaul 1 2,200,000 2,200,000 Shipping to Security Cove includes $3.00 per ton loading charge at respective co Other cost 1,000,000 Total Capco 11,600,000 Grant 67%7,730,000 Total requiring financing 3,870,000 Equity 25%of remaining 25%]967,500 Loan 2,902,500 Interest on loan 5.0% At the beginning of Year Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Remaining principal to be repaid 2,902,500 2,671,738 2,429,438 2,175,023 1,907,887 1,627,394 1,332,877 1,023,634 Interest payment 145,125 133,587 121,472 108,751 95,394 81,370 66,644 51,182 Principal repayment 230,762 242,300 254,415 267,136 280,493 294,517 309,243 324,705 Total yearly payment on loan ,375,887 375,887 375,887 375,887 375,887 375,887 375,887 375,887 ist year,delivery of 100%coal Second to Eighth Year;Plant operating at 80%Second to Eighth Year;Plant operating at 80%capacitydemandcapacity OPCO seasonal only 110 days}May 25 -Sept 88 days!May 25 -Aug.24 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Hours 2,640 2,112 2,112 2,112 2,112 2,112 2,112 2,112 Personnel tug 3 barges 6 9 Man-hours 23,760 19,008 19,008 19,008 19,008 19,008 19,008 19,008 Rate incl.O/T and other $40.00|$ 950,400;$ 760,320!1$ 760,320/$ 760,320/$ 760,320/$ 760,320|$ 760,320|)$760,320 Fuel usage gal/year $ 159,700;$ 124500|$ 124,500/$ 124500/$124,500/$124,500|$124,500:$124,500 Fuel at $1.25 /gallon $ 199625/$ 155625/$ 155625|/$155625|$155,625|$155,625;$155,625|$155,625 Lubeoil 1,042 1$2,605.00 2,031 2,031 2,031 2,031 2,031 2,031 2,031 Other consumables 20,000 20,000 20,000 20,000 20,000 20,000 20,000 20,000 Maintenance 530,000 530,000 530,000 530,000 530,000 530,000 530,000 530,000 Insurance 2.5%of value 2.50%327,250 Cost of money +principal 375,887 375,887 375,887 375,887 375,887 375,887 375,887 375,887 Total expenses $2,405,767 |$1,843,863 |$1,843,863 1$1,843,863 |$1,843,863 /$1,843,863]$1,843,863 |$1,843,863 Coal barged tons 374,000 299,200 299,200 299,200 299,200 299,200 299,200 299,200 Cost per ton $/ton $6.43 |$6.16 |$6.16 |$6.16 |$6.16 |$6.16 |$6.16 1$6.16 Charge to Bethel Power $/ton $7.60 |$7.60 |$7.60 |$7.60 |$7.60 |$7.60 |$7.60 |$7.60 Fuel cost (Fording)$/ton $35.00 |$35.00 |$35.00 |$35.00 |$35.00 |$35.00 |$35.00 |$35.00 Shipping to Security Cove*$/ton $15.50 |$15.50 1$15.50 |$15.50 |$15.50 |$15.50 |$45.50 |$15.50 Total fuel cost at Bethel $/ton $58.10 |$58.10 |$58.10 |$58.10 |$58.10 |$58.10 |$58.10 |$58.10 Barge OPCO =9/30/2003 COST OF BARGING COAL FROM SECURITY COVE TO BETHEL Capital cost and cost of money Pre-owned barge,including overhaul Pre-owned tug boat,including overhaulal termina! Other cost Total Capco Grant Total requiring financing Equity 25%of remaining Loan Interest on loan At the beginning of Year Y9 Y 10 Total paid Remaining principal to be repaid 698,928 357,988 Interest payment 34,946 17,899 856,370 Principal repayment 340,941 357,988 2,902,500 Total yearly payment on loan 375,887 375,887 Year 9th to 20th the plant will use only 40%coal OPCO seasonal only 44 days|OPCO seasonal only May 25 -July 7 Y9 Y 10 Y 11 Y 12 Y 13 Y 14 Y 18 Y 19 Y 20 Hours 1,056 1,056 1,056 1,056 1,056 1,056 1,056 1,056 1,056 Personnel Man-hours 9,504 9,504 9,504 9,504 9,504 9,504 9,504 9,504 9,504 Rate incl.O/T and other $_380,160/$ 380,160|$ 380,160|$ 380,160/$ 380,160/$ 380,160/$ 380,160|$ 380,160/$380,160 Fuel usage $62,200 |$62,200 |$62,200 |$62,200 |$62,200 |$62,200 |$62,200 |$62,200 |$62,200 Fuel at $1.25/gallon $77,750 |$77,750 |$77,750 |$77,750 |$77,750 |$77,750 |$77,750 |$77,750 |$77,750 Lubeoil 1,015 1,015 1,015 1,015 1,015 1,015 1,015 1,015 1,015 Other consumables 20,000 20,000 20,000 20,000 20,000 20,000 20,000 20,000 20,000 Maintenance 213,332 213,332 213,332 213,332 213,332 213,332 213,332 213,332 213,332 Insurance 2.5%of value Cost of money +principal 375,887 375,887 0 0 0 0 0 0 0 Total expenses $1,068,144 |$1,068,144/$ 692,257|$ 692,257|$ 692,257|$ 692,257|$ 692,2571)$ 692,257|$692,257 Coal barged 150,000 150,000 150,000 150,000 150,000 150,000 150,000 150,000 150,000 Cost per ton $7.12 |$7.12 |$4.62 |$462 |$4.62 |$4621 $4.62 |$462!$4.62 Chargeto Bethel Power $8.80 1 $8.80 |$5.70 |$5.70 |$5.70 |$5.70 |$5.70 |$§.70 1 $5.70 Fuel cost (Fording)$35.00 |$35.00 |$35.00 |$35.00 |$35.00 |$35.00 |$35.00 |$35.00 |$35.00 Shipping to Security Cove*$15.50 |$15.50 |$15.50 |$15.50 |$15.50 |$15.50 |$15.50 |$15.50 |$15.50 Total fuel cost at Bethel $59.30 |$59.30 |$56.20 |$56.20 |$56.20 |$56.20 |$56.20 |$56.20 |$56.20 Barge OPCO =9/30/2003 RES 2MYmy'SERVICES INC. 337.5 4 * ae oh /. f,202.5 hoe 153.5 % Figure 3 Bethel Windrose The next issue relating to estimating the required storage capacity is the coal pile configuration.As shown below,the issue is important because of the required space and related cost,as well as safety reasons. Coal should be stored in compacted piles to eliminate air pockets and reduce water access to coal or in un-compacted piles to facilitate good air flow through the piles. High rank coal with low moisture content may be stored in un-compacted piles. 18 IDES PRECISION|"SERVICES INC. ZO 25°0.233 | 1.0 Figure 4 Coal Pile Configuration Figure 4 shows a comparison of coal piles'cross-sectional areas and related proportions.The one with the 25°angle of incline is for a compacted (packed)pile. The angle is dictated by the capability of compacting equipment to work safely.The other,with the 38°incline,is an un-compacted coal pile,in which the angle is created by coal's natural angle of repose.The cross-sectional area ofun-compacted coal pile is 67%larger than the cross-sectional area of the packed coal pile._ After taking into account the cross-sectional area proportions and the bulk densities of compacted and loosely deposited coal (70 and 50 Ib/cubic foot,respectively),it was determined that an un-compacted pile will store 20%more coal on the same horizontal area than the packed coal pile.This is concluded with the following brief economic analysis: Capital Expenditure Savings: .Due to smaller building (shorter by 20%)$1.2 million .Due to less working equipment,no D8-R Cat required $500,000 .Due to foundation cost reduction $1.8 million Total capital cost savings $3.5 million Operating Cost Savings: .Reduction of building maintenance cost $25,000/year .Elimination of operation of D8-R Bulldozer (120 days/yr)$100,000/year Total operating cost savings $125,000/tear The above analysis is valid for coal that can be stored un-compacted,such as Fording Black Bear coal.Lower rank coals,especially those with high intrinsic moisture, require compacting for safety purposes -prevention of low-temperature release of combustible gases due to reactions between water and CQ,creating methane,and spontaneous ignition and explosion hazards. 19 MES PRECISION SERVICES INC, Permafrost-related Issues No geotechnical or survey information is available for the proposed plant sites.For this report,we have assumed the plant area to consist of ice-rich,warm permafrost sandy-silts.Foundations will typically consist of a thick layer of compacted sand with a layer of rigid board insulation installed in the pad to limit seasonal thaw to within the sand fill.To preserve the integrity of the underlying permafrost,foundation designs utilize passive refrigeration,thermo siphon flat loop systems and/or thermo helix-piles as deemed necessary.The refrigeration systems will use the phase change properties of CO,to remove heat from the ground whenever the air temperature is below freezing.The cost of constructing foundations in permafrost soils is substantially greater than on non-permafrost soils.It is estimated that the cost of constructing foundations and associated passive refrigeration systems at Bethel will be roughly 2.64 times ($19.2 million vs.$7.3 million)that of constructing conventional foundations in non-permafrost soils of average load bearing capacity,such as firm clays,sands and gravels. 'Shipping Coal to Bethel -see Spreadsheet following page 16 Two options of shipping coal to Bethel were considered: .Load barges at the port of shipping -Vancouver Port,Roberts Bank,or Westshore Terminal,Seward Coal Terminal or Texada Island,B.C.(for Quinsam coal)and tug them directly to Bethel.Following a brief evaluation (presented below),it was decided not to proceed with further research of this option as it became apparent at a very early stage that it is inherently high cost.This results from: -Extended shipping time and -On long distances barge +tug shipping is less fuel efficient than large vessel shipping. According to Foss Maritime Company the cost of shipping coal by barge from Vancouver will be as follows: 5 barge-tug teams are needed to deliver the coal to Bethel during the shipping season of 150 days.One round trip from Vancouver to Bethel will take approximately 21 days;the following cost items are included: -Mobilization at $190,000 per barge/tug $950,000 -Cost to modify existing equipment $3,000,000 -150 days at 80%utilization,$15,750 per barge per day $9,450,000 -Waiting time at $12,750 per barge per day (20%)$1,912,500 -Demobilization at $200,000 per barge -tug $1,000,000 20 PRECISION N «SERVICES INC. Total cost $16,312,500 This cost does not include wharfage,moorage,pilotage assist tugs,local or state taxes or misc.port fees.These items would add as much as $2,175,000 ($5.00 per ton) The resulting shipping cost per ton:$18,487,500 /435,000 =$42.50 The highest cost of shipping using other arrangements,outlined below,is between $20.56 to $37.65 per US ton. .Transport all coal on Handysize type (10,000 to 35,000 DWT)deep-sea bulk carrying vessels to Security Cove or Goodnews Bay,where coal would be transloaded (lightered)onto barges and tugged to Bethel.The waters of the Kuskokwim Bay and the mouth of the Kuskokwim River are rough making transloading from bulk freighter to barges very difficult if not entirely impossible.Additional impact is exerted by the heavy winds in the Kuskokwim Bay area.Both the Goodnews Bay and the Security Cove provide good conditions for lightering. .Refi Screech*Nelson Yukon Dette National Wildlife Refuge MapPoint.land .Tuntutullak,. 2 Eek ALASKA Doodnevs B..iid Topi,Twin Hills Dillingham, <(ManokotaSecurityCove Bee ring Se avy. Brispt.of Bay Figure 5 Location of Security Cove and Goodnews Bay The cost of shipping from Vancouver,BC to Security Cove was determined to be approximately $12.00 to $14.50.The lower cost was provided by Seabulk Systems, 21 RES PRECISION (SIRO SERVICES INC. Inc.of Richmond,BC and World Wide Shipping &Chartering Ltd.also of Vancouver,BC;Navio Corporation of Connecticut quoted the higher price.After lengthy discussions with the bulk shipping companies,we concluded that the price would be in the range of $12.50 when all additional costs are taken into account, including higher fuel cost. Two variants of this option have been evaluated: 1,Barging coal by specialized marine contractors 2.Barging coal by Nuvista or a subsidiary/sister company thereof The following companies were approached to provide the shipping cost from Security Cove to Bethel. Seabulk Systems,Inc. Crowley Maritime Corporation Bering Marine Corporation,a Division of Lynden Incorporated Northland Services,Inc. Foss Maritime Company Seabulk Systems is an engineering company,which also provides shipping services by subcontracting.All other companies have their own fleet or will expand their fleet to fulfill obligations if employed for the job. All of the shipping companies have experience in barging materials up the Kuskokwim River or in other areas of Western Alaska,however,at present the only company with significant Kuskokwim related experience is Northland Services.Northland Services sister company,Yukon Fuel,has been shipping large amounts of fuel to Bethel and other villages on the Kuskokwim river for years.Yukon fuel has been shipping fuel barges from 7,700 dead weight tonnage (DWT)up to 9,000 DWT.Yukon Fuels has submitted the most competitive and comprehensive quote for supplying fuel for the MPP. Foss Maritime's experience includes continuous shipping of lead/zinc concentrate from the Red Dog Mine.The conditions for shipping from the Kivalina port,North of the Kotzebue Sound,are different from those on the Kuskokwim River.Shipping there involves mainly open sea navigation as opposed to traveling on a river with a significant number of shallow places.Also the shipping is done in the other direction, the material is shipped from the mainland to receiving locations outside Alaska.Red Dog Mine owns the self-unloading barges operated by Foss Maritime. Bering Marine (Lynden)provides specialized contract marine services,delivering building materials,equipment,sand,rock and gravel to Alaska's isolated places.The fleet of shallow-draft equipment supports construction of docks,roads,and airstrips. Because they own floating construction equipment,Lynden would possibly be a good 22 EXEMPLARY COAL BARGING SCHEDULE FIRST YEAR USING FOUR 35,000 DWT BULK FREIGHTERS (PAYLOAD 30,000 MT) Required Fording coal ST/Y 434,900 |MT/Y 395,000 Freighter trip time 24 -25 days Barge loading/unloading time:10,000 Tons 6.0 hours 7500 Tons 5.0 hours 0.25 0.21 0.17 0.04 0.88 0.75 0.79 TRIPS by TUG BOAT ; Activity Balance on MT Barges at Security Cove Barges at Bethel Load to Bethel at 21 hrs Empty at trip hours ship on barge |Ship Arrive /10,000 7,500 18 19 Barge Load Depart Arrive Depart 1tug +1 1 tug +2 Time barge barges Ship AA at Security Cove 30,000 05-25 04:00]05-25 22:00 Barge #1 20,000 10,000 05-25 10:00]05-25 22:00;05-2703:00}05-29 02:00 3 1 4 Barge #2 10,000 10,000 05-25 16:00]05-27 21:00}05-2902:00{05-31 07:00 Barge #3 0 10,000 05-25 22:00|05-29 20:00;05-3101:00;05-31 07:00 Ship BB at Security Cove 30,000 06-01 02:00]06-01 20:00 Barge #1 20,000 10,000 06-01 08:00}06-01 20:00}06-0301:00;06-04 16:00 3 1 1 Barge #2 10,000 10,000 06-01 14:00}06-03 19:00}06-0500:00|06-07 05:00 Barge #3 0 410,000 06-01 20:00;06-05 18:00}06-06 23:00]06-07 05:00 Ship CC at Security Cove 30,000 06-08 00:00}06-08 18:00 Barge #1 20,000 10,000 06-08 06:00}06-08 18:00!06-09 23:00;06-11 22:00 3 1 1 Barge #2 10,000 10,000 06-08 12:00]06-1017:00|06-11 22:00}06-14 03:00 Barge #3 0 10,000 06-08 18:00]06-12 16:00;06-13 21:00}06-14 03:00 Ship DD at Security Cove 30,000 06-16 10:00]06-17 04:00 Barge #1 20,000 10,000 06-16 16:00]06-1704:00;06-1809:00|06-20 08:00 3 1 1 Barge #2 10,000 10,000 06-16 22:00!06-1903:00}06-2008:00|06-22 13:00 Barge #3 0 10,000 06-17 04:00}06-2102:00}06-2207:00!06-22 13:00 ShipAA at Security Cove 30,000 06-23 08:00|06-24 02:00 Barge #1 20,000 10,000 06-23 14:00]06-24 02:00}06-2507:00;06-27 06:00 3 1 1 Barge #2 10,000 10,000 06-23 20:00}06-2601:00}06-2706:00|06-29 11:00 Barge #3 0 10,000 06-24 02:00]06-28 00:00}06-2905:00}06-29 11:00 Ship BB at Security Cove 30,000 06-30 06:00}07-01 00:00 Barge #1 20,000 10,000 06-30 12:00]07-0100:00}07-0205:00|07-04 04:00 3 1 1 Barge #2 10,000 10,000 06-30 18:00|07-02 23:00}07-04 04:00}07-06 09:00 Barge #3 0 10,000 07-01 00:00}07-04 22:00;07-06 03:00|07-06 09:00 Coal supply schedule 09-02-2003.xls 1st Y 9/12/2003 Page 1 of 3 EXEMPLARY COAL BARGING SCHEDULE FIRST YEAR USING FOUR 35,000 DWT BULK FREIGHTERS (PAYLOAD 30,000 MT) ||TRIPS by TUG BOAT Activity Balance on MT Barges at Security Cove Barges at Bethel Load to Bethel at 21 hrs Empty at trip hours ship on barge|Ship Arrive /10,000 7,500 18 19 Barge Load Depart Arrive Depart {1 tug +1 1 tug +2 Time barges Ship CC at Security Cove 30,000 07-07 04:00]07-07 06:00 Barge #1 20,000 |10,000|07-0501:00}07-0706:00)07-0811:00|07-1 10:00 3 1 Barge #2 10,000 {|10,000 {07-0706:00}07-0905:00|07-1010:00|07-12 15:00 Barge #3 O{10,000!07-0706:00}07-1104:00|07-1209:00|07-12 15:00 Ship DD at Security Cove 30,000 07-13 10:00}07-14 04:00 Barge #1 20,000 10,000 |07-13 16:00}07-1404:00}07-1509:00|07-17 08:00 3 1 Barge #2 10,000 10,000 07-13 22:00}07-16 03:00]07-17 08:00/07-19 13:00 Barge #3 0;10,000 |07-1404:00}07-1802:00|07-1907:00]07-19 13:00 Ship AA at Security Cove 30,000 07-20 08:00|07-22 23:00 Barge #1 22,500 7,500 |07-20 13:00}07-20 13:00]07-21 18:00]07-22 00:00 4 2 Barge #2 15,000 7,500 |07-2018:00}07-22 23:00|07-24 04:00]07-26 03:00 Barge #3 7,500 7,500 |07-20 23:00}07-24 22:00,07-26 03:00|07-28 08:00 Barge #1 0 7,500 |07-22 23:00!07-26 21:00|07-2802:00|07-28 08:00 Ship BB at Security Cove 30,000 07-29 03:00;07-31 18:00 Barge #1 22,500 7,500 |07-29 08:00}07-2908:00)07-3013:00|07-30 19:00 4 2 Barge #2 15,000 7,500 |07-29 13:00}07-31 18:00|08-01 23:00]08-03 22:00 Barge #3 7,500 7,500 |07-29 18:00}08-0217:00|08-03 22:00|08-06 03:00 Barge #1 0 7,500 |07-31 18:00}08-04 16:00;08-05 21:00]08-06 03:00 Ship CC at Security Cove 30,000 08-06 22:00}08-09 13:00 Barge #1 22,500 7,500 |08-07 03:00}08-07 03:00}08-0808:00|08-08 14:00 4 2 Barge #2 15,000 7,500 |08-0708:00}08-0913:00)08-1018:00}08-12 17:00 Barge #3 7,500 7,500 |08-07 13:00]08-1112:00]08-1217:00|08-14 22:00 Barge #1 0 7,500 |08-09 13:00;08-1311:00|08-14 16:00}08-14 22:00 Coal supply schedule 09-02-2003.xls 1st Y 9/12/2003 Page 2 of 3 EXEMPLARY COAL BARGING SCHEDULE FIRST YEAR USING FOUR 35,000 DWT BULK FREIGHTERS (PAYLOAD 30,000 MT) |TRIPS by TUG BOAT Activity Balance on MT Barges at Security Cove Barges at Bethel Load to Bethel at 21 hrs Empty at trip hours ship on barge |Ship Arrive /10,000 7,500 18 19 Barge Load Depart Arrive Depart 1 tug +1 1 tug +2 Time barge barges Ship DD at Security Cove 30,000 08-15 17:00}08-18 08:00 Barge #1 22,500 7,500 |08-15 22:00}08-15 22:00;08-1703:00;08-17 09:00 4 2 1 Barge #2 15,000 7,500 |08-16 03:00]08-1808:00;08-19 13:00}08-21 12:00 Barge #3 7,500 7,500 |08-16 08:00}08-2007:00}08-21 12:00}08-23 17:00 Barge #1 0 7,500 |08-18 08:00}08-2206:00}08-2311:00}08-23 17:00 Ship AA at Security Cove 30,000 08-24 12:00}08-27 03:00 Barge #1 22,500 7,500 08-24 17:00}08-24 17:00]08-25 22:00|08-26 04:00 4 2 1 Barge #2 15,000 7,500 08-24 22:00}08-27 03:00}08-28 08:00}08-30 07:00 Barge #3 7,500 7,500 08-25 03:00]08-29 02:00]08-3007:00}09-01 12:00 Barge #1 0 7,500 08-27 03:00}08-3101:00}09-0106:00;09-01 12:00 Last day of navigation 09-01 Total number of tug trips 24 20 18 13 Hours of tug trips 504 420 324 247 Percentage of full load 100.0%80.0%35.0%50.0% Gallons of fuel used at 120.5 gallons per full-load hour 60,732 40,488 13,665 14,882 Total fuel usage 129,766 Total fuel usage +15%contingency 149,231 Trips Vancouver BC to Security Cove Trips tons Ship AA 4 120,000 Ship BB 3 90,000 Ship CC 3 90,000 Ship DD 3 90,000 390,000 Shortage at 99%availability,first year ST 5,000 |Will be delivered at the beginning of the next year shipping season Coal supply schedule 09-02-2003.xls 1st Y 9/12/2003 Page 3 of 3 EXEMPLARY COAL BARGING SCHEDULE SECOND TO TENTH YEAR USING FOUR 35,000 DWT BULK FREIGHTERS (PAYLOAD 30,000 MT) Required Fording coal ST/Y 351,000 MT/Y 318,000 Freighter trip time 24 -25 days Barge loading/unloading time:10,000 Tons 6.0 hours 7500 Tons 5.0 hours 0.25 0.21 0.17 0.04 0.88 0.75 0.79 TRIPS by TUG BOAT Activity Balance on MT Barges at Security Cove Barges at Bethel Load to Bethel at 21 hrs Empty at trip hours ship on barge |Ship Arrive /10,000 7,500 18 19 Barge Load Depart Arrive Depart itug+1 1 tug +2 Time barge barges Ship AA at Security Cove 30,000 05-25 04:00}05-25 22:00 Barge #1 20,000 10,000 |05-25 10:00}05-25 22:00]05-27 03:00}05-29 02:00 3 1 1 Barge #2 10,000 10,000 05-25 16:00;05-27 21:00]05-2902:00|05-31 07:00 Barge #3 0 10,000 |05-25 22:00}05-29 20:00}05-3101:00}05-31 07:00 Ship BB at Security Cove 30,000 06-01 02:00]06-01 20:00 Barge #1 20,000 10,000 |06-0108:00]06-01 20:00}06-0301:00]06-04 16:00 3 1 1 Barge #2 10,000 10,000 |06-0114:00}06-03 19:00;06-0500:00;06-07 05:00 Barge #3 «0 10,000 |06-01 20:00!06-05 18:00}06-06 23:00]06-07 05:00 Ship CC at Security Cove 30,000 06-08 00:00!06-08 18:00 Barge #1 20,000 10,000 |06-0806:00}06-08 18:00;06-09 23:00]06-11 22:00 3 1 1 Barge #2 10,000 10,000 |06-08 12:00}06-1017:00}06-11 22:00}06-14 03:00 Barge #3 0 10,000 |06-08 18:00}06-1216:00}06-13 21:00}06-14 03:00 Ship DD at Security Cove 30,000 06-16 10:00}06-17 04:00 Barge #1 20,000 10,000 |06-16 16:00]_06-1704:00}06-18 09:00]06-20 08:00 3 1 1 Barge #2 10,000 |10,000 |06-16 22:00;06-1903:00!06-2008:00|06-22 13:00 Barge #3 0;10,000 |06-1704:00}06-2102:00}06-2207:00!06-22 13:00 Ship AA at Security Cove 30,000 06-23 08:00]06-24 02:00 Barge #1 20,000 10,000 |06-2314:00|06-24 02:00)06-2507:00|06-27 06:00 3 1 1 Barge #2 10,000 10,000 |06-23 20:00}06-2601:00|06-27 06:00}06-29 11:00 Barge #3 0 10,000 |06-2402:00}06-28 00:00]06-29 05:00}06-29 11:00 Ship BB at Security Cove 30,000 06-30 06:00]07-01 00:00 Barge #1 20,000 10,000 |06-30 12:00;07-0100:00|07-0205:00|07-04 04:00 3 1 1 Barge #2 10,000 10,000 |06-30 18:00;07-02 23:00]07-04 04:00}07-06 09:00 Barge #3 0 10,000 |07-0100:00|07-04 22:00|07-06.03:00|07-06 09:00 Coal supply schedule 09-02-2003.xls 2-8 Y 9/12/2003 Page 1 of 3 EXEMPLARY COAL BARGING SCHEDULE SECOND TO TENTH YEAR USING FOUR 35,000 DWT BULK FREIGHTERS (PAYLOAD 30,000 MT) ||TRIPS by TUG BOAT Activity Balance on MT Barges at Security Cove Barges at Bethel Load to Bethel at 21 hrs Empty at trip hours ship on barge |Ship Arrive /10,000 7,500 18 19 Barge Load Depart Arrive Depart 1 tug +1 1 tug +2 Time barge barges Ship CC at Security Cove 30,000 07-07 04:00;07-07 06:00 |Barge #1 20,000 10,000 07-05 01:00;07-0706:00;07-0811:00}07-10 10:00 3 1 Barge #2 10,000 10,000 07-07 06:00}07-09 05:00},07-10 10:00}07-12 15:00 Barge #3 0 10,000 07-07 06:00}07-1104:00}07-12 09:00)07-12 15:00 Ship DD at Security Cove 30,000 07-13 10:00}07-14 04:00 Barge #1 20,000 10,000 07-13 16:00}07-1404:00}07-1509:00|07-17 08:00 3 1 Barge #2 10,000 10,000 07-13 22:00}07-16 03:00;07-1708:00|}07-19 13:00 Barge #3 0 10,000 07-14 04:00}07-1802:00|07-1907:00|07-19 13:00 Ship AA at Security Cove 30,000 07-20 08:00}07-22 23:00 Barge #1 22,500 7,500 07-20 13:00}07-20 13:00]07-21 18:00]07-22 00:00 4 2 Barge #2 15,000 7,500 07-20 18:00}07-22 23:00}07-24 04:00]07-26 03:00 Barge #3 7,500 7,500 07-20 23:00}07-24 22:00!07-26 03:00]07-28 08:00 Barge #1 0 7,500 07-22 23:00}07-26 21:00!07-2802:00|07-28 08:00 Ship BB at Security Cove 30,000 07-29 03:00}07-31 18:00 Barge #1 22,500 7,500 07-29 08:00}07-2908:00;07-3013:00;07-30 19:00 4 2 Barge #2 15,000 7,500 07-29 13:00}07-31 18:00!08-01 23:00]08-03 22:00 Barge #3 7,500 7,500 07-29 18:00}08-02 17:00;08-03 22:00!08-06 03:00 Barge #1 0 7,500 07-31 18:00)08-04 16:00}08-05 21:00]08-06 03:00 Ship CC at Security Cove 22,500 08-06 22:00;08-07 13:00 Barge #1 15,000 7,500 08-07 03:00]08-07 03:00}08-08 08:00}08-08 14:00 4 2 1 Barge #2 7,500 7,500 08-07 08:00|08-07 13:00]08-08 18:00}08-10 17:00 Barge #3 0 7,500 |08-07 13:00}08-09 12:00}08-1017:00}08-12 22:00 Last day of navigation 08-12 Total number of tug trips 24 12 14 11 Hours of tug trips 504 252 252 209 Percentage of full load 100.0%80.0%35.0%50.0% Gallons of fuel used at 120.5 gallons per full-load hour 60,732 24,293 10,628 12,592 Total fuel usage 108,245 Total fuel usage +15%contingency 124 482 Coal supply schedule 09-02-2003.xls 2-8 Y 9/12/2003 Page 2 of 3 EXEMPLARY COAL BARGING SCHEDULE SECOND TO TENTH YEAR USING FOUR 35,000 DWT BULK FREIGHTERS (PAYLOAD 30,000 MT) |TRIPS by TUG BOAT Activity Balance on MT Barges at Security Cove Barges at Bethel Load to Bethel at 21 hrs Empty at trip hours ship on barge |Ship Arrive /10,000 7,500 18 19 Barge Load Depart Arrive Depart 1 tug +1 1 tug +2 Time barge barges Trips Vancouver BC to Security Cove Trips tons Ship AA 3 90,000 Ship BB 3 90,000 Ship CC 3 82,500 Ship DD 2 60,000 322,500 Coal supply schedule 09-02-2003.xls 2-8 Y 9/12/2003 Page 3 of 3 EXEMPLARY COAL BARGING SCHEDULE USING TWO 45,000 NINTH YEAR AND BEYOND USING FOUR 35,000 DWT BULK FREIGHTERS (PAYLOAD 30,000 MT) Required Fording coal ST/Y 176,000 MT/Y 160,000 Freighter trip time 24 -25 days Barge loading/unloading time:10,000 Tons 6.0 hours 7500 Tons 5.0 hours TRIPS by TUG BOAT Activity Balance on MT Barges at Security Cove Barges at Bethel Load to Bethel at 21 hrs Empty at trip hours ship on barge |Ship Arrive /10,000 7,500 18 19 Barge Load Depart Arrive Depart 1 tug +1 1 tug +2Timebargebarges Ship AA at Security Cove 30,000 05-25 04:00}05-25 22:00 Barge #1 20,000;10,000 {05-25 10:00}05-25 22:00|05-2703:00|05-29 02:00 3 1 1 Barge #2 10,000 |10,000 |05-2516:00]05-27 21:00}05-2902:00}05-31 07:00 Barge #3 0}10,000|05-25 22:00}05-29 20:00]05-3101:00)05-31 07:00 Ship BB at Security Cove 30,000 06-01 02:00}06-01 20:00 Barge #1 20,000 |10,000 |06-0108:00|06-01 20:00}06-0301:00}06-04 16:00 3 1 1 Barge #2 10,000 |10,000 |06-01 14:00]06-0319:00;06-0500:00|06-07 05:00 Barge #3 0|10,000 |06-01 20:00]06-05 18:00}06-06 23:00}06-07 05:00 Ship CC at Security Cove _30,000 06-08 00:00}06-08 18:00 Barge #1 20,000 {|10,000 |06-0806:00;06-08 18:00;06-09 23:00}06-11 22:00 3 1 1 Barge #2 10,000;10,000 |06-0812:00}06-1017:00|06-1122:00|06-14 03:00 Barge #3 0 10,000 |06-08 18:00]06-12 16:00}06-1321:00}06-14 03:00 Ship DD at Security Cove 30,000 06-16 10:00}06-17 04:00 Barge #1 20,000 |}10,000;06-1616:00|06-1704:00|06-1809:00}06-20 08:00 3 1 4 Barge #2 10,000 |10,000 |06-16 22:00}06-1903:00!06-2008:00|06-22 13:00 Barge #3 0}10,000 |06-1704:00;06-21 02:00)06-2207:00|06-22 13:00 Ship AA at Security Cove 30,000 06-23 08:00}06-24 02:00 Barge #1 20,000 10,000 |06-2314:00}06-2402:00}06-2507:00|06-27 06:00 3 1 1 Barge #2 10,000 |10,000;06-23 20:00|06-2601:00;06-2706:00|06-29 11:00 Barge #3 O|10,000 |06-2402:00|06-28 00:00};06-2905:00;06-29 11:00 Coal supply schedule 09-02-2003.xls 9-20Y 9/12/2003 Page 1 of 2 EXEMPLARY COAL BARGING SCHEDULE USING TWO 45,000 NINTH YEAR AND BEYOND USING FOUR 35,000 DWT BULK FREIGHTERS (PAYLOAD 30,000 MT) ||TRIPS by TUG BOAT Activity Balance on MT Barges at Security Cove Barges at Bethel Load to Bethel at 21 hrs Empty at trip hours ship on barge |Ship Arrive/10,000 7,500 18 19 Barge Load Depart Arrive Depart 1 tug +1 1tug+2 Time barge barges Ship BB at Security Cove 30,000 06-30 06:00}07-01 00:00 Barge #1 20,000 10,000 |06-30 12:00;07-0100:00|07-0205:00|07-04 04:00 3 1 1 Barge #2 10,000 10,000 |06-30 18:00]07-02 23:00]07-04 04:00]07-06 09:00 Barge #3 0 10,000 |07-01 00:00;07-04 22:00]07-06 03:00]07-06 09:00 Last day of navigation 07-07 Total number of tug trips 18 0 6 6 Hours of tug trips 378 0 108 114 Percentage of full load 100.0%80.0%35.0%50.0% Gallons of fuel used at 120.5 gallons per full-load hour 45,549 0 4,555 6,869 Total fuel usage 56,972 Total fuel usage +15%contingency 65,518 Trips Vancouver BC to Security Cove Trips tons Ship AA 2 60,000 Ship BB 2 60,000 Ship CC 1 30,000 Ship DD 1 30,000 180,000 Coal supply schedule 09-02-2003.xls 9-20Y 9/12/2003 Page 2 of 2 PES PRECISION MMINENY SERVICES INC. choice for bringing in and unloading plant equipment during construction. Crowley Maritime Corporation is the largest barging contractor in the West Coast waters,specifically in the Alaskan waters .Other companies (for instance Northland Services)often lease equipment from Crowley.The company does not have the local experience in shipping on barges large quantities on a continuous basis,as does Northland (Yukon Fuel);however,due to this company's size and involvement in all kind of shipping,it is our belief that Crowley can provide this service with the same success rate as Northland. The second variant of this option is to ship the coal from Security Cove or Goodnews Bay by a subsidiary or sister company of Nuvista Corporation.This undertaking would be carried out as follows: Nuvista would purchase 3 (three)pre-owned barges with 10,000 to 12,000 DWT capacity,maximum draft 12.5 feet,and one pre-owned tug boat with a 3000 to 4000 hp engine.In the first year operation four Handysize freighters (Handysize is a bulk carrier vessel of 10,000 to 35,000 DWT)will deliver the freight to the Security Cove or Goodnews Bay according to a predetermined schedule (see attached schedules). The coal will be unloaded onto the barges so that the bulk carrier will not have to wait for unloading.The tug boat will tow the barges one at a time to Bethel where they will be unloaded.After delivering the first barge the tug boat will travel empty to pick up the next barge and will travel bag with the first barge.After delivering the third barge,the tug boat will tow two barges.The arrival at Security Cove of the next freighter will be scheduled to coincide with the arrival of the barges at this point. In the first year (supply of 412,300 US tons)4 freighters will be employed;two freighters will make four trips each and two freighters will make three trips each.One trip will bring 7,500 tons more than required;this amount will be stored at Bethel.In the second through eighth years three freighters making three trips each and one freighter making only 2 trips will be employed.In the ninth and following years,when the power plant will reduce output to about 40%,4 freighters will be employed;two freighters will make two trips each and two freighters will make one trip each.One of the 2-trip freighters will carry only 20,000 tons;normally the freighters bring in 30,000 ton pay load. The attached schedule of the cost of barging shows that this option will result in significant savings.The trip time includes 8 hour contingency for waiting for tide. Other possibilities were also discussed,for instance: -Partial unloading of the deep-sea freighters onto barges at Security Cove and then move the ship to a location near Eek Island for unloading the remaining coal.This could save some shipping and barging costs,but would require shipping on larger vessels,such as Panamax size (60 to 75 thousand DWT) 23 IPES PRECISION {si victoynewyEUGYY SERVICES INC. and is dependant on the allowable ship draft.After several discussions,this option has been abandoned because of the expected higher cost of freighter shipping and lightering operations. Barging from Vancouver or Seward to Bethel -this option was abandoned early due to cost -see considerations on page 20 and 21. Coal Transportation Procedure After many discussion with all companies we have decided on the following procedures: 1.Navigational Conditions From its mouth to Bethel,the Kuskokwim River includes several shallow places (sand bars)that reduce the allowable vessel draft to below 6 ft.The most severe conditions exist at Johnson's Crossing and Oscar's Crossing. The beginning and end of the shipping season may vary.The best estimate of the navigational season is from approximately May 25"to October 5". Navigation of the Kuskokwim River is strongly related to tides;a sample tide schedule for July 18,2003 at the Apokak Creek entrance is shown in Figure 6. The tide increases the allowable draft to 12.5 feet in low-water season. The navigational season includes two low water periods when the depth is in the range of 12 to 12.5 feet with tide.The periods are: .Mid July to third week of August,due to the dry season .Mid September to the end of the season due to water freezing in mountain streams 11.9 tt tt 85 tt 3 ft 11.4tt07a12:07 714 11:53 Sia Sf |bf eft |10.8 ft Att Bt |1255 16 12:47 3 2338 1:40 7:46 Iae et SA MO,a Pty o eyf2.ara ers Boe TR RoR Z : . *Pal i Boye. 0 Noon 6 am Noon 20 S$am786pm duby 13 2083 -Apokak Creek entrance,ALASKA Kuskokvim Bag and RiverHigh:07718 5-07 am,11.36 «Low:67718 11:53 pm.6.3 ft Figure 6 Kuskokwim River Tide Schedule for July 18,2003 at the Apokak Creek Entrance 2.Equipment 24 IPES PRECISION side nyishiEROY SERVICES INC. Barges and Freighters Due to the short navigating season,draft limitations and the amount of coal that has to be delivered to the power plant site it is recommended that large deck or hopper barges are used.The coal supply schedule presented herein was prepared based on the Crowley 400 ft x 100 ft deck barge.The carrying capacity of this barge in DWT (see next page schematic and specifications)is: .At high water up to 12,000 short tons (ST)(10,870 MT). .At low water -assumed for 11.5 feet 8,800 ST (8,000 MT) Crowley's 400 x 100 barge is representative of the large barges;although other barge dimensions are also used,for instance 418.5'x 75'x 29',14,500 DWT (Portsmouth and Bridgeport type),420'x 80'17,193 DWT,550'x 80'at 33,700 DWT and other.The 550 ft barge is designed as an articulated barge and tug tandem.It is typical for petroleum products shipping with double wall hull and has a draft of over 24 feet,which practically eliminates it from navigating on the Kuskokwim River. Consideration was also given to self-unloading barges of the type being used for shipping Red Dog Mine's concentrate.These barges are significantly more expensive and due to the specifics of their design,have reduced payload tonnage. For ocean shipping from the coal ports near Vancouver,BC,Canada it is recommended to employ 35,000 DWT bulk freighters with continuous unloading capabilities.This type of ship will be able to deliver to Security Cove 30,000 tones of coal and load the barges.Five thousand DWT is dedicated to the weight of the ship's own personnel and supplies -fuel,food and other items. Barge Availability Virtually every one of the above shipping companies will have to obtain barges for this job.At present,possibly only Crowley Maritime has sufficient equipment,which still have to be outfitted for shipping coal. There is a broad range of available pre-owned barges and tug boats.Attached are 2 pages printout of examples of available equipment.In the attached spreadsheet "Coast of Barging Coal ...”it was assumed that the barges can be purchased at $2.8 million each including overhauling and adapting to coal transporting. Unloading Equipment 25 DES:”)SERVICES INC. Ocean-going bulk freighters are equipped normally with unloading/barge loading equipment and only such will be hired for delivering coal to Security Cove.Unloading equipment is required for barges. a.Self-unloading barges -barges that are equipped with unloading equipment.Coal is stowed in large hoppers that discharge onto a conveyor at the bottom of the barge.The conveyor delivers the coal to an elevator (bucket or two-belt conveyor),which discharges the coal to a transporter delivering the coal to a place on the shore most often being a hopper for a subsequent conveyor.This would be the most expensive ofthe three options as the unloading equipment would be built into each barge.This would increase the weight of each barge and reduce the tonnage that it could carry. b.Crane un-loaders are usually simple and the initial cost is most likely the lowest;however they are relatively slow.Crane unloading rate is in the range of up to 500 ton/hr.Evaluation of the system has lead us to conclude that the minimum unloading rate should not be lower than 1500 tons/hr.The equipment cost of cranes for an application of this size is very Close to that of a continuous unloader. Cc Continuous barge unloader,supplied by Heyl-Patterson and proposed for application at Bethel is shown in Figure 7. 26 RES PRECISION foi Visine?(snesYSERVICES INC. Figure 7 Heyl-Patterson Stationary Barge Unloader The system is anchored one side on shore and the other on a concrete pile in the water.The system's capacity is up to 2,000 ton/hr.It is powered by electric power with stand-by diesel generator. This unloader is a permanent installation and cannot be moved for winter, therefore,it requires protection against damage caused by ice,specifically at the beginning of the cold season during ice build up and in the spring during ice break up (ice floes). Another unloading system for the application at Bethel is a Catamaran Transfer Vessel (CTV);see picture in Figure 8. The CTV is a mid-stream floating structure supported by columns erected on a pair of self-propelled hulls capable oftrans-shipping bulk cargo from barges into Cape/Panamax size vessels or to the shore.The first CTV with an unloading capacity of 3,000 tons/hour (30,000 ton per day)is working in Indonesia transloading coal onto ocean-going coal freighters. The reclaimer is capable ofunloading at a design rate of2,000 tph of coal and can achieve effective cleaning without front-end loader assistance.The daily average load rate of the CTV is estimated at 20,000 tpd of coal. 27 PES PRECISION fmt att May(EINGNY SERVICES INC. The upper deck supports a unique chain bucket reclaimer with a dual-head moving on a separate trolley across the width of barges. The vessel is capable of unassisted maneuvers along the length of ships and barges using an onboard Dynamic Positioning System of thruster drives.The thrusters enable the vessel to mobilize between transshipment sites at a nominal speed of 6 knots and effectively station-keep during operations as well as mooring.It will be possible to move the CTV for the winter and early spring months into a slough,where ice damage would be prevented. A fully integrated navigation bridge includes a separate cargo control center directly above the bulk/container operations.A satellite communication system on the CTV is used for data management and shore interface.Due to the fact that the CTV,if selected for the Bethel site as barge unloading equipment,will be stationary and the only required movement would be translocation to a slough for winter storage,these features will not be required. Although slightly more expensive than cranes,continuous unloaders have many advantages.They are much faster than other unloading methods; continuous un-loaders will be able to sustain an unloading rate of 2,000 TPH. Continuous un-loaders require only 1-2 operators to run,thereby reducing manpower costs compared to other unloading methods.Currently the pricing for continuous un-loaders is in the range of 5-7 million dollars. Schedule Please see attached schedules. For scheduling purposes it was assumed that 400 x 100 barges with respective tugs are used and that the payload of the barges will be 10,000 MT during normal water level period and 7,500 MT during low water level period. Other assumptions made for scheduling are: Average loading and unloading times of barges,including maneuvering to and away from freighter and dock site in Bethel are as follows: 10,000 MT barge 6.0 hours 7,500 MT barge 5.0 hours 5,000 MT barge 4.0 hours At maximum velocity of 7.5 knots upriver and 8.7 knots downriver (empty) the average loaded trip time is 21 hours one-way.Empty trip down river is assumed at 19 hours.This time includes some contingency for unexpected events that would delay operations. 28 IDES PRECISIONSISSY "SERVICES INC. -In trip planning 8 hours was added as a contingency for waiting for the tide. Figure 8 Catamaran Barge Unloading System Shown in Ship Loading Service,with a Helipad All scheduling presented in the Report or attached documents is based on the lightering operations being done at Security Cove.There is a possibility that lightering will be possible to be done at Goodnews Bay which is some 30 to 35 miles closer to Bethel.Conducting lightering operations in the Goodnews Bay would reduce the barge trip time by four hours and proportionally the cost of barging.The Goodnews Bay navigational conditions must be further investigated. 29 co nnh eocnptber meh arn!rk} wen --7 4 -o amt:{eo paren:ag <.eimewitAcmBasseSr .'sue oy a.<sey Pee eatahateSit »aefaeasAdgtariet&toa ee"yet ogGillette-TTl 'win 0MW:2oomeae PES PRECISION ELGIIOY SERVICES INC, DESCRIPTION OF THE POWER PLANT A complete coal fired power plant has been evaluated for the production of 97 MW of electrical power and required heat for the district heating system.The plant will include two separate process lines,each including one boiler and steam turbine to allow independent operation of the plant on one system at 55 MW and 177 million Btu of heat for the district heating system. The Power Plant will include the following systems: 1. 2. 8. 9. Coal receiving and unloading dock.-Included in Section V Coal storage area including stacking and retrieving equipment,and conveyors for delivering fuel to the boilers.-Included in Section A Two pulverized coal combustors with integrated boiler,superheater,economizer and air heater,and feedwater system.-Included in Section B Two turbine and generator process lines including switchgear and substation,as well as steam condensers with cooling towers and cooling water circulating pumps.- Included in Section C Air pollution control system including baghouse,SCR system,ducting and stack - Included in Section D Auxiliary equipment and installations such as loaders,diesel fuel storage tank,stand by diesel fired combustion turbine,diesel fired boiler for start up and auxiliary steam demand and other.-Included in Section E Instrumentation and controls,central control room and motor control center.- Included in Section F Maintenance shop with tools.-Included in Section G Siting of the Power Plant -Included in Section H The plant will be housed in appropriate buildings.The buildings will also include facilities for the office personnel -locker rooms,lunchroom,etc.The plant may also be partially housed on power barges in which case the on-shore power plant buildings will be reduced to modular structures to house the related needs.-Included in Section J A.Coal Storage The delivery conveyor from the continuous unloader discharges into a receiving hopper and onto the main coal conveyor to the coal storage yard.For this task a covered belt conveyor 60”wide and approximately 1200”long is being recommended. The belt will deliver the coal to the storage yard via a stacking system. 30 IES PRECISION (ahsEsiey SERVICES INC. Several stacking systems were investigated: 1.Linear stacking systems that travel on a track and stack the coal in linear piles, 2.Radial-stacking systems that stack in radially arranged piles, 3.Linear bucket-wheel stacking/reclaiming systems,which incorporate both stacking and reclaiming functions in one system. The first two systems require additionally reclaiming equipment such as: .Front end loaders, .Portal reclaimer,whose reclaiming equipment is similar to that of a barge unloader, °Boom-mounted bucket wheel reclaimer. Both reclaiming systems are applicable only to loosely packed coal.They cannot be used for reclaiming compacted or frozen coal piles,which in Bethel may create a problem,especially because the storage building will not be heated.However,the stacking and reclaiming systems are independent of each other and can perform both operations at the same time. The bucket-wheel stacker/reclaimer can reclaim coal from both packed and un- compacted piles;however,being two-in-one systems,it can do only one kind of operation at the time.This may be problematic during the shipping season when it will also have to reclaim coal for power plant operation.An option is included,in which coal flow from the barge unloader will bypass the stacker and be conveyed directly to the coal bunkers for feeding the boilers. Attached is documentation from METSO Minerals,a USA materials handling equipment fabricating company and MAN TAKRAF,a German materials handling equipment builder and supplier.We have also discussed the application with Thyssen Krupp,another German materials handling equipment builder and supplier.We have not,however,received a quote from this company. Challenges relating to the long-term storage of coal have been mentioned in the section titled Coal Demand and Storage Requirement.Information provided both by the mining company (Fording Coal Mines)and Westshore Terminals indicates that the coal needs not to be compacted for extended storage,in excess of one year. Also,as indicated earlier,coal will have to be stored in a covered facility,primarily to prevent coal fines from being blown and lost due to high winds blowing continuously in the area.Covering of the coal pile will also protect coal from deterioration under the influence ofthe elements and prevent weathering and absorption of moisture from precipitation. The last will result in the elimination of the need for a sophisticated and expensive 31 Geometrica Metal Domes iyfievy ae nae*bacco Concrete Domes ee eeeeee eee ee 2 :i]we Samael me....ier Be Dd il --'we Pp owe ee tt ped ne iS ' . s ip a Be :: ”:8 % wt IPES PRECISION Si estoy nyLAESIONY SERVICES INC. water drainage,collection and disposal system. The coal pile configuration is shown on drawing No.01-000-001.The following four options for coal pile covering were investigated: 1.Pre-Fabricated Steel Building This is one of the more attractive methods for covering the coal in Bethel.Although this method is more expensive than an air supported structure,it offers more flexibility once it is constructed.Steel buildings have good resistance to the elements,if needed,can be heated and can enable good ventilation of the coal pile.The foundations for a building of this type are also simple,making the building easy to erect.A building for the required size would cost roughly 5.5 to 6.5 million dollars,erection cost not included.Garco Buildings of Spokane,WA is a typical supplier of such buildings. Air Supported Structures These are structures in which air under slight pressure hold inflated a fabric roof and side walls.These buildings are easy to transport and offer a short erection time.The structure requires a continuous air supply to stay inflated,which adds a significant amount to the operating cost.The required air pressure is in the range of 2 to 2.5 inch WG.The air exiting the structure must be utilized as combustion air or cleaned before disposal.An air-supported structure of required size would cost about 4 million dollars before erection costs.This price was quoted by Radian Air Supported Structures. Concrete Domes offer a simple option for coal storage that provides a large volume for the space used.This structure is not recommended when compacting of coal is required.The cost of a concrete dome built in the USA Mainland would range between 7 and 9 million dollars depending on the size. Taking into account Bethel conditions and availability of construction materials,the cost may easily double.The supplier of such structures is Dome Technology. Aluminum Frame Domes are similar to pre-fabricated steel buildings.These buildings have a dome shaped roof,but can have standard walls like a regular building.The major benefit of an aluminum frame dome design is that it can be used for large clear-span structures;clear spans of 350 feet or more are not uncommon.A budget materials price of about 6.5 million with an installedpriceofabout$16 million was quoted by Geometrica.These structures are advantageous when structure weight is a major consideration.Otherwise steel prefabricated structures are faster and cheaper to assemble. The buildings which include inlets for the conveyor that brings coal from the dock,for the conveyor(s)transporting coal out of the building and for letting in and out self propelled working machines (loader,bulldozer,etc.)and personnel. 32 rail \.aN 4 ee A PES PRECISION (EIRERLOHGNY SERVICES INC. From the storage building,the coal will be reclaimed and delivered to two bunkers per each boiler via a system with dual conveyors,one conveyor will be stand-by.The conveyors will deliver coal to the bunkers via grizzlies,which will be serve as a backup system for filling the bunkers in case of a reclaimer breakdown.There will also be auxiliary feed hoppers that can be used in the event the stacking and reclaiming system is down for maintenance.For this purpose,the plant will be equipped with CAT 980G front-end loaders. The coal storage building will also include a fire prevention and suppression system. The most important issue in fire/explosion prevention is controlling coal dust.For this purpose,a detailed procedure will be developed. Dust Control In the Coal Storage and Handling System Prevention of coal dust explosions and fire will be the most important safety precaution undertaken in the Bethel Coal-Fired Power Plant,therefore,the coal storage and handling system will have to include several dust control methods and equipment. a.Dust Control Transfer Points -sized and quoted by Martin Engineering.The technology associated with the Martin Engineering low dust transfer points is called PECS -Passive Enclosure Dust Control System.This technology allows transferring coal from one conveyor to another without stirring up excessive dust. The PECS Transfer System uses a "Hood”to control the material stream as it comes off a head pulley.It keeps the material tightly together through the drop chute and directs it onto a "Spoon”receiving chute.The spoon lays the material on the receiving belt at roughly the same speed and direction that the belt is traveling.This minimizes air entrainment and reduces impact that can wear the belt and drive dust into the air. The PECS Transfer System also incorporates seals at the entry to reduce air movement and a stilling zone at the exit to allow dust to settle from the air. b.Belt Cleaning -Keeping belts clean can drastically reduce lost coal especially during transport.The most common method for cleaning belts are stationary scrapers before the section of belt picks up another load of coal. c.Covered Conveyors -Because of Bethel's high wind conditions,all conveyors running outdoors will be covered.Special covers will be included at points where conveyors enter structures,especially if an air-supported structure is used.All covers should extend all the way to transfer points to control dust that is stirred up at the transfer points. d.Coal Buildings -discussed earlier;the advantages from both safety and 33 we adale; RENEw28by - = -- . . he we, cand ah Boo wo + es: , ' . fef\aa reblX4 ' ak:( ' oata\. .NA, 4.-iA.,the : =aNvwoS_" a' oo ™ iAWenah:ion i', a Aes a weitit ewe ; | ; nom aa] i - ' oe idren ) . 253 :t f 28rad - S52 ; awwm==i$E= ' *spemes is 2= i yc®, enn, : == " - ié4 . . ; FAR? 5 a deb WALPessina ME InMM : ae ab Bappaancs eee wreacaget® XO.con cia bh, on ees = wee 5 at!ae Mae cad q at ry wf"e- ne -sesBF h'} eee ieee | . are = |Serene ere aeen eH wd sO hi:msa Tn_d TRODTSZTAVA IPES PRECISION Siuistoyenw .[enero SERVICES INC. environment protection point of view,as well as economical reasons cannot be underestimated. e.Extraction of Air -A system of air extraction from the coal-storage building air will be implemented.The air will be drawn out ofthe building and used as combustion air. f.Some dust control measures inside the plant will be implemented by design. The measures will include sealing off areas with intrinsically high dust generation (e.g.coal pulverizers)from the rest of the plant. Pulverized Coal Combustors with Integrated Boiler The power plant will include two pulverized coal combustors with boilers and auxiliary equipment (superheater,economizer,air heater;fans and blowers for combustion air,flue gas induced draft,and feedwater system).The system will produce superheated steam at the following parameters: Per boiler Total Steam output,continuous design capacity Ib/hr 354,000 708,000 (Includes steam for district heating) Maximum capacity lb/hr 390,000 780,000 Minimum capacity lb/hr 240,000 480,000 Superheated steam pressure,design psig 1,100 maximum (MAWP)psig 1,375 maximum (testing)psig 1,650 minimum psig 1,000 Superheated steam temperature,design °F 1,000 maximum °F 1,100 Furnace thermal input MM Btu/hr 589 1,178 Feedwater temperature entering economizer °F 260 Feedwater temperature entering boiler °F 500 Feedwater Pressure,deaerator exit psig 20 Economizer Exit Gas Temperature to Stack,not to exceed °F 280 Continuous Blowdown 1.75% The superheated steam generation and steam turbine system works in simple Rankine cycle without reheat.Boilers working at the above listed parameters do not normally include reheaters.Application of reheating is being considered together with Babcock &Wilcox and ALSTOM (Combustion Engineering) 34 RES PRECISION (BEINGNY SERVICES INC. Pulverized Coal (PC)combustion is a modern technology that has been proven in the USA in the last 40 years and is characterized by high combustion efficiency (very low loss on ignition)and low-cost emission controls.Coal pulverized in specially designed crusher/grinders is blown into the boilers combustion chamber.The coal behaves like a gaseous fuel -both the speed and efficiency of combustion are high.Because of this,means for process control are simplified.Means for the control of NOx generation can be used such as those for gaseous fuel combustion -flue gas recirculation,staged combustion with overfire air and other similar methods. Bids have been obtained from the most advanced and experienced vendors:Babcock &Wilcox,and Alstom Power,former ABB Combustion Engineering Division. The boiler system will include the following components: .Furnace/combustion chamber,which will provide a minimum of 0.5 seconds residence time for the combustion gases before entering the water-walled section. .Evaporator with steam drum,mud drums,tubing .Superheater with attemperator. °Steam heated and flue gas heated air heater .Economizer .Combustion Air Supply System for each boiler and one stand-by system "Feed Water Chemical Treatment .A complete feedwater system with one pump for each boiler and one stand- by,dual-drive (steam and electric)feedwater pump .One deaerator for each boiler including appropriate control valves The steam drum will be equipped with all ASME Pressure Vessel Code required trim. During the system engineering phase,consideration will be given to installing acoustic fire-side tube cleaning devices,which improve boiler performance. Combustion air will be supplied to the system both underfire and overfire to improve combustion performance and enhance NOx control. 35 IPES PRECISION isi jesiayeonyEMEINO'NY SERVICES INC. Make-up Water Source,Treatment,Filtering and Blow-down Disposal Make-up water requirements are as follows: Boiler make up,1.75%of 2 boilers steaming capacity 11,314 lb/hr =22.6 gpm Cooling tower make-up Circulating water evaporation rate: 1.Condensing steam flow 531,062 lb/hr at 1,042 Btu/Ib 2.Heat to be removed 553.30 MM Btu/hr 3.AT cooling circulating water 20 °F 4.Required flow of cooling water 27,666,000 Ib/hr =55,320 gpm 5.|Evaporation rate 55,320 x 0.1%x AT =1,106 gpm Blow down bleed rate =Evaporation /(#of cycles -1) Bleed rate at 4 concentration cycles 369 gpm Total make-up 1,475 gpm The possible sources of make-up water for the Bethel power plant include: ®Drilling of water wells.This option may provide water that is low in impurities and would likely require the least treatment. .The second is drawing water from the Kuskokwim River.This option could prove to be more difficult than drilling wells for several reasons: )The Kuskokwim River is over 1000 feet away from the power plant, meaning an 8”pipeline would have to be built from the river to the plant complete with pumps for pumping the distance and the head difference estimated 50 ft.This problem is minimized if the plant is barge mounted. °During winter the Kuskokwim becomes frozen,consequently,the water intake must be near the bottom of the river to prevent freezing. As a result of this,the water will contain a large percentage of suspended and dissolved solids.The cost of preparation ofthe make up water will increase significantly. °Spring breakup ice could damage the water intake and the piping. .Drawing water from an artificial (built)cooling pond.This option will experience problems similar to drawing water from the Kuskokwim River. Unless the pond is sufficiently deep,water in the pond may freeze over during winter and require thawing.Also,excavation ofa sufficiently large pond may 36 GE 90 MW Steam Turbine Reeth es arin ce cs eee een bie te te eine te ea tee mine»enetallnatanteaattanatadll PES PRECISION SERVICES INC. be significantly more expensive that drilling a water well or upgrading the quality of the Kuskokwim River water. .Water supply may be also a combination of two methods;for instance:boiler make up water from well and cooling tower make up water,whose quality is significantly lower than the required quality of boiler water,drawn from the cooling pond. Geotechnical and hydrological investigations will have to be conducted to determine related items,such as water availability,required treatment and so on. The plant will include a boiler make-up water treatment system,which will include as a minimum dual ion bed system. Steam Turbine and Generator System As with the boilers,two trains of Steam Turbine and Generator system will be included in the Power Plant;each train will consist of: .Turbine 1,|HP16 -high speed,high efficiency turbine .Turbine 2,LP190--synchronous speed turbine receiving lower pressure steam from the HP turbine. .Each turbine system includes a condensing steam exhaust and one steam extraction outlet with non-return valves for district heating and de-aerator. .Speed Reduction Gear Parallel arrangement .Gland Steam Unit .Gland Steam Condenser .Lube Oil System on separate baseplate for lubrication and control oil with interconnecting piping and oil coolers sized for water temperature 85°F.Two main oil pumps and one emergency,DC-motor driven pump.Including Lube Oil Coolers and De-hydration system. .Hydraulic Oil Supply Unit .Required piping,insulation blankets,sheet metal lagging. .Generator,13.8 kV,60 Hz,3600 rpm,0.85 PF with brush-less excitation and coolers sized for water temperature 85°F.Generator shaft is monitored for vibrations. .Complete stand-alone digital control system handling all required turbine and generator controls (closed and open loop)and monitoring instrumentation (power output,pressures,temperatures,vibrations,etc.)of the steam turbine and generator unit.The control system includes a coordinating controller plus separate control units for the turbine governor function,steam turbine safety trip functions and generator voltage regulator functions. .Operator station with color monitor,keyboard,track ball and event and alarm printer. .Unit is built for indoor installation with noise attenuation to 85 dBA. °Steam Surface Condenser with two liquid ring vacuum pumps,each with 37 IPES PRECISION isi iscinvire nwEEMEIMOYCt:Wate SERVICES INC. 100%capacity.The condenser is built of 304L stainless steel tubing and tubesheets and coal tar epoxy coated water boxes. Cooling Tower System -one per train;fiberglass structure,stainless steel connecting hardware,heavy duty PVC film pack fill,fans,fire-retardant FRP fan cylinders for velocity recovery and other. As an alternative to the cooling tower system use of once-through condenser cooling should be considered,in which the water will be taken from the pond located near the plant site in Bethel.This option will be evaluated in the environmental impact study. Environmental Control System The Bethel Coal-fired Power Plant will be built to satisfy the best Alaskan environment protection standards.With today's technology coal-fired power plants can perform at highest industry levels at reasonable cost not exceeding average industry cost. 1.Emissions The performance of the plant will be as follows: Sulfur dioxide SO. Alaska State standard 500 ppm dry volume (ppmdv) Expected performanceless than 250 ppmdv To achieve this performance the plant will be using Fording's Black Bear coal with a sulfur content of 0.29%.Even if more stringent standards are applied, which reduce the SO?allowable emissions by '4,the plant will still perform better than required by standards. To prevent precipitation of sulfuric acid,which causes corrosion and is harmful to the personnel,the minimum flue gas exhaust temperature will be limited to 272°F. a.Particulate matter PM Alaska State standard 0.05 gr/dscf (grains per dry standard cubic foot) Expected Performance The plant will perform at this very stringent standard. To achieve this performance the plant will include a cyclonic type collector (single cyclone or multi-cyclone)and a baghouse (filter)type collector. b.Opacity 38 PES PRECISION Si ttn NWERGY SERVICES INC. Alaska State standard 20%for less than 3 minutes in 1 hour Expected Performance The plant will perform better than this standard. To reduce opacity excursions the boilers will include acoustic cleaning systems working continuously instead of sootblowers,which cause excursions during sootblowing operations. CO and NOx The State of Alaska does not have standards for NOx and CO.We propose to implement the following standards: CO 0.10 Ib/million Btu fired =118 ppmdv NOx 0.30 Ib/million Btu fired =215 ppmdv The standards that the State may want to impose could be lower,as follows: CO -_0.085 1b/million Btu fired =100 ppmdv NOx =0.150 Ib/million Btu fired =108 ppmdv To achieve emission levels complying with these standards the plant will utilize the following technical means: For CO reduction/control .Pulverized coal combustion (PC)technology,which improves the combustion efficiency thereby reducing the CO content in the flue gas (CO is a product of incomplete combustion; improvement of combustion efficiency =CO reduction). .Combustion chamber design that will provide a minimum of 0.5 seconds residence time for the combustion gases before entering the water-walled section.The longer the residence time the better probability of CO reacting with oxygen. .Catalytic converter for afterburning CO to CO).See remark at the end of NOx reduction/control section (below) The PC technology will also allow minimization of the Loss on Ignition (Lol)to less than 0.5%of the fuel input.Reduction of Lol by 1%is equivalent to saving estimated $300,000 annually.In grate- fired power plants Lol of 2 up to 4%are not unusual. For NOx reduction/control 39 RES = .Flue gas recirculation,which reduces the amount of free ionized oxygen in the flame zone,thereby reducing the amount of oxygen available for reaction with nitrogen. .Staged supply of combustion air to the PC burners and to the combustion chamber;the PC burners will receive below 75% of stoichiometric air.The balance of air will be supplied through upper registers in the combustion chamber. .Selective catalytic or non-catalytic reduction (SCR or SNCR) -to be decided in the engineering phase. Catalytic reduction in an SCR or SNCR requires the supply of ammonia or urea (a compound containing ammonia)to the boiler. Even trace amounts of SO3,created at a rate of 2-5%of the amount of SO,during combustion of sulfur from the coal,react with ammonia and create ABS (ammonium bisulfate),which settles on external surfaces of economizer and air heater tubing causing accelerated corrosion.A catalytic converter,at the same time as it improves afterburming of CO to CO,also promotes conversion of SO2 to SO3,a negative effect of this application. Both the application of the catalytic afterburner and of the catalytic reduction of NOx will be evaluated in the engineering phase. There is a possibility that the Alaska Department of Environmental Conservation will impose on US EPA demand even more stringent standard;for instance NOx 25 ppmdv and CO 0.016 Ib/MM Btu (100 tons per year).To achieve this performance special technical means would be needed,such as Selective Catalytic Reduction System for NOx control and catalytic converter for CO. 2.Effluent Discharge The continuous liquid discharges (effluents)from the plant are: .Boiler blow-down water .Cooling tower blow-down water .Ion exchange regeneration waste water °Sanitary (sewage)water The intermittent discharge wastewater includes: .Boiler and condenser chemical cleaning solvents °Boiler fire-side wash water Boiler blow-down,cooling tower blow-down water and ion exchange 40 PES:PRECISION(ei?ESI OME NYSERVICES INC. regeneration waste water are neutralized with chemicals and deposited in a settling pond.Neutralization results in large quantities of precipitating solids, which settle in the settling pond.Water from the pond can be reused in the cooling tower system or can be disposed of to a local waterway -Kuskokwim River or a nearby pond. The settling pond solids will be periodically removed and deposited locally in a landfill or quarry.The solids are neutral and do not require disposal in a sanitary landfill. Sanitary water includes only effluent from facilities for the personnel at the power plant.It is recommended that sanitary water disposal is contracted to the sanitary services of the City of Bethel. The Power Plant's solid waste includes ash from coal combustion and general human-generated garbage (municipal solid waste:trash,locker and lunch room waste).General waste shall be collected and disposed of by the City of Bethel Sanitary Services. The power plant may also offer to the City of Bethel and neighboring villages a municipal waste disposal service,in which the plant will incinerate all of the City's combustible waste including sludge from sewage sludge drying lagoons. Ash Handling and Utilization System The Black Bear coal to be utilized in the Power Plant contains on average 11%ash.The content of silica (SiOz)and alumina (AI,O3)in this ash is high; as a result of this,the ash is suitable for the production of concrete aggregate. Table 3 Ash Mineral Analysis (Dry Basis) SS)|©)56.86 %AIoO3.......2...cece ee ccs occ eee cevcccuseeseees 27.35 AN ©|©1.81 %Fe,03 ccc o cee cee eee eee tet eet ee een eet ee eee eeers 3.42 0 OF:©3.62 %MEO.oe cccccccecccssssevscsevevecesvsseevevveve 1.02 an SO 0.65 %NaO...oooeceecnaeceeeeceececere 0.60 OL ody)©0.41 %SO3.ccc ccc cee eee eee cee e ee see een eee eaes 2.30 %Undetermined...............0.0 cceeeeeeeeee eens 1.96 The above ash composition shows its very good quality for utilization both as 41 IDES PRECISIONELOY M 1)SERVICES INC. cement substitute and as filler material.The ASTM Standard C618-89a requires that fly ash to be used in Portland Cement Concrete must contain minimum 70%(Class N and F of mineral admixture)of combined silicon dioxide (SiO2),aluminum oxide (AI,Q3)and iron oxide Fe203)(Please see attached Standard). The picture below shows approximate proportions in concrete production. Based on this,we estimated the input materials and possible concrete aggregate production as follows: 6%Air 11%Portland Cement 412%Gravel or Crushed Stone (Coarse Aggregate) 26%Sand (Fine Aggregate) 16%Water Figure 9 Ash production at 100%plant output:45,600 US tons per year Portland cement 6.0% Ash (substituting cement and sand)77.0% Char (from incomplete combustion of coal)0.5% Water (balance) 16.5% At these proportions,approximately 59,220 tons of concrete aggregate can be produced.In order to increase to volume of the aggregate,some local sand and gravel should be used to reduce the percentage of this highly cementaceous ash.The specific formula for aggregate production will be determined at a cement laboratory based of physical tests. The ash production in the second to eighth years will be:36,500 tons The system will include: °Pneumatic ash collection system extracting fly ash from various points on the boiler,economizer,baghouse and other.The system will include appropriate low pressure rotary blowers equipped with intake filter/silencer and exhaust mufflers. .Ash silo capable of holding eight-month supply of ash. .Portland cement silo with holding capacity for 3,700 tons. .Agglomerating machine that will produce the aggregate. 42 quilt Designation:C 618 -89a Standard Specification for Fly Ash and Raw or Calcined Natural Pozzolan for use as aMineralAdmixtureinPortlandCementConcrete' This standard is issued under the fixed designation C 618;the number immediately following the designation indicates the year of original adoption or,in the case of revision,the year oflast revision.A number in parentheses indicates the year of last reapproval.Asuperscriptepsilon(<}indicates an editorial change since the last revision or reapproval. This specification has been approved for use by agencies of the Department of Defense.Consult the DuD index of Specifications and Standards for the specific year of issue which has been adopted by the Department of Defense. 1.Scope 1.1 This specification covers fly ash and raw or calcined natural pozzolan for use as a mineral admixture in concrete where cementitious or pozzolanic action,or both,is desired, or where other properties normally attributed to finely divided mineral admixtures may be desired or where both objectives are to be achieved. Note-Finely divided materials may tend to reduce the entrained air content of concrete.Hence,if a mineral admixture is added to any concrete for which entrainment of air is specified,provision should be made to assure that the specified air content is maintained by air content tests and by use of additional air-entraining admixture or use of an air-entraining admixture in combination with air-entraining hydraulic cement. 1.2 The values stated in inch-pound units are to be regarded as the standard. b 2.Referenced Documents 2.1 ASTM Standards: C260 Specification for Air-Entraining Admixtures for Concrete” C 311 Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for Use as a Mineral Admixture in Portland-Cement Concrete” 3.Terminology 3.1 Definitions: 3.1.1 flv ash-finely divided residue that results from the combustion of ground or powdered coal. Note-This definition of fly ash does not include,among other things,the residue resulting from:(1)the burning of municipal garbage or any other refuse with coal;or (2)the injection of lime directly into the boiler for sulfur removal;or (3)the burning of industrial or municipal garbage in incinerators commonly known as "incinerator ash.” 3.1.2 pozzolans-siliceous or siliceous and aluminousmaterialswhichinthemselvespossesslittleornocemen- titious value but will,in finely divided form and in the presence of moisture,chemically react with calcium hy- 'This specification is under the jurisdiction of ASTM Committee C-9 on Concrete and Concrete Aggregates,and is the direct responsibility of Subcommittee 09.03.10 on Fiy Ash,Slag,Mineral Admixtures,and Supplementary Cementitious Materials. Current edition approved Oct.27,1989.Published December 1989.OriginallypublishedasC618-68T to replace C 350 and 402,Last previous editionC618-87,2 Annual Book ofASTM Standards,Vol 04.02._apaipByitsi4er yy@+F . T! 7 .droxide at ordinary temperatures to form compounds Pos-:sessing cementitious properties..tee 4.Classification a 4.1 Class N-Raw or calcined natural pozzolans thaf-comply with the applicable requirements for the class as given herein,.such as some diatomaceous earths;opaline' cherts and shales;tuffs and volcanic ashes or pumicites,any, of which may or may not be processed by calcination;andvariousmaterialsrequiringcalcinationtoinducesatistactodyproperties,such as some clays and shales.4.2 Class F-Fly ash normally produced from:burninganthraciteorbituminouscoalthat-meets the applicable' requirements for this class as given herein.This class fly has pozzolanic properties.4.3 Class C-Fly ash normally produced from lignite|éfsubbituminouscoalthatmeetstheapplicablerequirementsforthisclassasgivenherein.This class of fly ash,in addition:to having pozzolanic properties,also has some cementitious'properties.Some Class C fly ashes may contain lime contents higher than 10 %.ua 5.Chemical Composition 25.1 Fly ash and natural pozzolans 'shall conform to the requirements as to chemical composition prescribedin Table 1.Supplementary optional chemical requirements are shown' in Table 2. 6.Physical Properties 6.1 Fly ash and natural pozzolans shall conform to the physical requirements prescribed in Table 3.Supplementary optional physical requirements are shown in Table 4. 7.Methods of Sampling and Testing7.1 Sample and test the mineral admixturein accordancewiththerequirementsofMethodsC311. 7.2 Use cement of the type proposed for use in the work and,if available,from the mill proposed as the source of the cement,in all tests requiring the use of hydraulic cement. de,8.Storage and Inspection an ye8.1 The mineral admixture shall be stored in "such a :manner as to permit easy access for proper inspection and .:identification of each shipment.Every facility'shall be;provided the purchaser for careful sampling and inspection,--beither at the source or at the site of the:work-ascmay be::specified by the purchaser. 298 y6 ah C618 TABLE 1 Chemical Requirements _Mineral Admixture Class N F c Siicon dioxide (SiO)plus aluminum oxide (Al,O,)plus iron oxide (Fe,0,),min,%-70.0 280.6 fp 70.0 50.0 guitur trioxide (SOs),max,%ae *g 2.3%5.0 5.0 Moisture content,max,%3.0 3.0 .3.0Lossonignition,max,%|40.0 i's,6.04 6.0 "A The use of Class F pozzolan containing up to 12.0 %loss on ignition may be approved by the user i either acceptable performance records or laboratory test resultsaremadeavailable. TABLE 1A Supplementary Optional Chemical Requirement NoTé-This optional requirement applies only when specifically requested. -_-_- Minera!Admixture Class _ON F Cc Available alkalies,as Na,O,max,%4 i L105 15 4 Applicable only when specifically required by!the purchaser for mineral admixture to be used in concrete containing reactive aggregate and cement to meet a limitationoncontentofalkalies. ; we le-TABLE 2 Physical Requirements * Mineral Admixture Class Fineness:Amount retained when wet-sieved on 45 pm (No.325)sieve,max,x4 ,4 34 34 Strength activity index:®;wee With portiand cement,at 7 days,min,percent of 7§°.,75° ; 75° control . With portiand cement,at 28 days,min,percent of 75°75°759 control . .; With fime,at 7 days min,psi (kPa)8 .800 (5500)800 (5500): wee Water requirement,max,percent of control sts WS 105 OO 105 Soundness:¢ Autoclave expansion or contraction,max,%.oj .--0.8 08.:ot 0.8 Unitormity requirements:.a oe teThespecificgravityandfinenessofindividualsamplessoteteon oeshallnotvaryfromtheaverageestablishedbythe;ee ten preceding tests,or by all preceding tests if the .a ' oe number is less than ten,by more than:' Specific gravity,max variation from average,%5 5 5 Percent retained on 45-um (No.325),max variation,§5 percentage points from average 4"Care.should be taken to avoid the retaining of agglomerations of extremely fine material.®Neitherthestrength activity index with portland cement nor the pozzotanic activity index with lime is to be considered a measure of the compressive strength ofconcretecontainingthemineraladmixture.The strength activity index with portiand cement is determined by an accelerated test,and is intended to evaluate thecontributiontobeexpectedfromthemineraladmixturetothelongerstrengthdevelopmentofconcrete.The weight of mineral admixture specified for the test to determinethestrengthactivityindexwithportlandcementisnotconsideredtobetheproportionrecommendedfortheconcretetobeusedInthework.The optimum arnount of mineral admixture for any specific project is determined by the required properties of the concrete and other constituents of the concrete and should be established bytesting.Strength activity index with portland cementisameasure of reactivity with a given cement and may vary as to the source of both the fly ash and the cement.©If the mineral admixturewill constitute more than 20 %by weight of the cementitious material in the project mix design,the test specimens for autoclave expansionshailcontainthatanticipatedpercentage.Excessive autoclave expansion is highly significant in cases where water to mineral admixture and cement ratios are low,for example,in block or shotcrete mixes. °Meeting the 7 day or 28 day strength activity index will indicate specification compliance. 9,Rejection random,is less than that specified,the entire shipment may . 9.1 The mineral admixture may be rejected if it fails to be rejected...._ meet any of the requirements of this specification.9.3 Mineral admixture in storage prior to shipment for a 9.2 Packages varying more than 5%from the stated Period longer than 6 months after testing may be retestedweightmayberejected.If the average weight of the packages 2nd may be rejected if it fails to meet the fineness require-in any shipment,as shown by weighing 50 packages taken at 'ments. 299 h c618 TABLE 2A Supplementary Optional Physical Requirements Note-These optional requirements apply only when specifically requested. Mineral Admixture Class :N F c Muitiple factor,calculated as the product of loss on ignition and fineness,.amount retained when wet-sieved on No.325 (45-m)sieve,:=max,%4 :. Increase of drying shrinkage of mortar bars at 28 days,max,%°:0.03 0.03 0.03 ;royUniformityRequirements:: ntInaddition,when ak-entreining ¢concrete is specified,the quantity of 20 20 20 ,£air-entraining agent required to produce an air content of 18.0 vol %:4ofmortarshailnotvaryfromtheaverageestablishedbythetenSOprecedingtestsorbyallprecedingtestsiflessthanten,by more athan,%MRReactivitywithCementAlkalies:©. . SReductionofmortarexpansionat14days,min,%75 aes sees = Mortar expansion at 14 days,max,%0.020 0.020 0.020 4 Applicable onty for Class F mineral admixtures since the toss on ignition limitations predominate for Class C. ®Determination of compliance or noncompliance with the requirement relating to increase in drying shrinkage will be made only at the request of the©The indicated tests for reactivity with cement alkalies are optional and alternative requirements to be applied only at the purchaser's request.They need not beyrequestedunlesstheflyashorpozzolanistobeusedwithaggregatethatisregardedasdeleteriouslyreactivewithalkaliesincement.The test for reduction of mortar:expansionmaybemadeusing any high-alkalicementinaccordancewith Methods C 311,Section 35.1 if the portland cement to be used in the work is not known,ors?not available at the time the mineral admixtureis tested.The test for mortar expansion is preferred over the test for reduction of mortar expansion if the portland cement”to be used in the work is known and available.The test for mortar expansion should be performed with each of the cements to be used in the work.ase et 10.Packaging and Package Marking marked on each package.Similar information shall 'be10.1 When the mineral admixture is delivered in pack-Provided in the shippinginvoices accompanying the ship.ages,the class,name,and brand of the producer,and the |ment of packaged or bulk mineral admixture. weight of the material contained therein shall be plainly 2a ANTheAmericanSocietyforTestingandMaterialstakesnopositionrespectingthevalidityofanypatentrightsassertedinconnectionse with any item mentioned in this standard.Users of this standard are expressly advised that determination of the validity of any such patent rights,and the risk of infringement of such rights,are entirely their own responsibility. This standard /s subject to revision at any time by the responsible technical committee and must be reviewed every five years and "aye#f not revised,either reapproved or withdrawn.Your comments are invited either for revision of this standard or for additional standards cw and should be addressed to ASTM Headquarters.Your comments will receive careful consideration at a meeting of the responsibie caibel technical committee,which you may attend.If you feel that your comments have not received a fair hearing you should make your mo] views known to the ASTM Committee on Standards,1916 Race St.,Philadelphia,PA 19103.12meate$|ie{AvshaAE'hshie300 ; f ress PRECISIONh1)SERVICES INC. .Aggregate storage. The aggregate can be produced from ash coming straight from the collection system or from the silo.It is proposed to produce the aggregate seasonally for direct usage locally. Solid waste and Sewage Sludge disposal One of the boilers of the Power Plant will include a capability to feed and burn local municipal solid waste (MSW)and partially dried sewage sludge excavated from drying lagoon.The plants Emission Control System will be capable of handling the extremely small additional load,which is in the range of 0.11%of the weight fuel input or 0.03%of the thermal input. To facilitate this feature the plant will be equipped with: -MSW and sludge receiving station, -Sorting station to remove tramp metals,rocks and non-combustible demolition waste (concrete pieces) -Shredder -Pneumatic system for conveying and injecting the refuse derived fuel into the furnace. E.Auxiliary Equipment and Installations Plant auxiliary systems include: Stand by diesel fired combustion turbine,GTX100 supplied by Alstom or LM6000 supplied by GE.The system will be activated in case of outage of one of the steam power generation process line,boiler or steam turbine generator.As a stand-by system,the combustion turbine will not include a heat recovery steam generator.The combustion turbine start-up time could be as short as 2 minutes. Diesel fired boiler for start up and auxiliary steam demand including district heating steam during outage of one boiler.Steam produced by the stand-by boiler will be used at plant start-up for steam blows (cleaning of steam lines), turbine trials and district heating system start-up. Diesel fuel storage tank.To enable very short combustion turbine start time,a portion of the diesel fuel will be stored in a separate compartment at 70°F. Rolling stock other than that used in the coal storage facility, Maintenance and repair shops,which is described separately in Section G. Buildings and foundations.Specifics on foundations specifically those built in 43 PES PRECISION leisisiontoy SERVICES INC. permafrost conditions are provided in the LCMF LLC report.Covers for the coal storage facility have been described in Section A. Buildings for the power plant will be modular steel construction with appropriate thermal insulation.The buildings will house all equipment and systems except for cooling towers. Instrumentation and Controls,Central Control Room and Motor Control Center The Power Plant will be equipped with all instrumentation and controls necessary for trouble-free operation of the Plant.The central control room (CCR)will include operator stations with color monitors,keyboards,track balls and event and alarm printers.The CCR will house also the output and monitoring devices of the steam turbine power generating system. A separate motor control center (one for the entire plant)will be provided in a separate room of the main building. 1.The Plant DCS System The combustion systems with coal feeding,PC burners,boiler as well as the steam turbine will be controlled through an advanced distributed control system (DCS)consisting of an ABB Advant DCS equipment package.The DCS provides supervisory oversight,monitoring,and set point regulation for local controls devices.The supervisory function allows operation of major plant processes and equipment from the local control room.Processing units function independently,however,the exchange of signals across the communications network for controls purposes is avoided wherever possible. Basic control functions of the boilers to be maintained by the DCS system are: -Steam flow is maintained as a result of power and thermal energy demand; -Steam pressure and temperature;these parameters are maintained constant. The fuel feed rate is automatically controlled as a result of the set parameters; operator's manual input is required only at unusual conditions that require setting the parameters outside the operating range;for instance,decreasing the boiler output below 70%nominal. Controls for the DH system and the BOP systems will also be integrated into the DCS system.The main functions of the DH system to be integrated into the DCS system are: 44 IPES PRECISION SERVICES INC. -Steam supply to the Central Heat Exchange Station based on ambient conditions and demand signals from local heat exchange stations. -System circulating water parameters,and so on. The system will allow a large degree of independence of the DH system within the framework of the Power Plant operation requirements.The Control Philosophy is designed to the needs of the Bethel Power Plant. Process Controls Major plant systems to be controlled and monitored include: a.Combustion System including fuel supply,operation of coal pulverizers and primary,secondary and tertiary combustion air supply at specified pressures Boiler System with economizer,evaporator,and superheater Steam Turbine Generator System Condensate,feedwater and demineralizer Systems District Heating Systempags The plant control system will interface with the Boiler Control System and the Turbine Generator Control System through data links. The Plant operation is designed for a "pushbutton”start locally or from the control room.Its operation is fully automatic.Remote control from the control room is accomplished from the plant control system CRTs via a digital link from the process control systems.The plant control system logs analog and digital data.Under abnormal conditions the output may be lowered for short durations during which time the process lines will operate at a lower efficiency. First time Start-up of the system /Start up after extended outage. PC burners will be used for start-up to gradually heat the furnace and boiler refractory lining to a temperature where fuel may be introduced and combusted properly. The two main considerations during start-up and heating up of the boiler are: a.The rate of warming of the refractory should be not more than 50- 100°F per hour (the applicable rate will depend on the specific properties of the selected refractory) b.The rate of warming of the boiler pressure parts should be 4°F per minute. Steam Turbine Generators (STG): 45 IPES PRECISIONEEAONSERVICESINC. The STG will be supplied with standard stand-alone control system handling all closed and open loop turbine controls.The control system will include: Electronic Governor based turbine loop controls Allen Bradley PLC module for turbine safety trip functions Allen Bradley PLC for turbine auxiliary control Generator AVR Generator protection relays and synchronizing equipment.geRoopBoiler System Control of the boiler will consist of the following loops integrated into the plant DCS system to safely and efficiently maintain steam header and feedwater pressure to match turbine-generator requirements during start-up, normal operation,upsets,and shutdowns. Steam Drum Level Control System Steam Temperature Control Plant Service Steam Temperature Control Deaerator Level Controlaeop Steam Drum Level Control System The drum level control system will be a conventional three-element control system using main steam flow as the feed-forward signal;drum level and feedwater flow as the feedback signals.Based on demand,the system controls a feedwater control valve to adjust the flow to the boiler.The system is designed to operate on single element control using drum level only during Start-up. Main Steam Temperature Control System The purpose of this system is to maintain the final superheater outlet temperature at a manually set value with minimum fluctuation.This is a single station,Cascade-type control system in which the final superheater outlet control unit serves as the primary control unit and the desuperheater outlet control unit serves as the secondary control unit. District Heat Steam Temperature and Flow Control The DH steam will be extracted from the turbine at 120 to 150 psig through a pressure regulator and flow control valve (FCV).The FCV will be modulated by feedback from the Central Heat Exchange Station depending on ambient heating water return temperatures. 46 IPES PRECISION SEM ONICNYLeEISIKOW SERVICES INC. Deaerator Level Control System The deaerator level will be controlled from the control room.If the level is low,make-up will be admitted from the demineralized water storage tank. Overflow will be discharged to the condensate tank.Level switches will be provided to alarm high and low levels and to trip the feedwater pumps on low-low level. Feedwater System Boiler Feedwater systems will be provided with pump minimum flow control, which is furnished by the pump manufacturer.This consists of an automatic recirculation control valve,which will circulate water back to the deaerator during periods of low feedwater demand -start-up,output reduction. Demineralizers The Demineralizer system will be equipped with a programmable controller (PLC).The water conductivity will be monitored in the control room. Plant Monitoring System All required plant parameters would be monitored and indicated,alarmed and/or recorded in the control room to facilitate the plant operator with control of the plant.The gas turbine will be interfaced to the plant control system for monitoring and trending. Local indicating devices,pressure gauges,thermometers,etc.,will be furnished for local monitoring of selected plant parameters.Grab sample ports will be provided on the condensate,feedwater and main steam lines for periodic analysis for other contaminants.Sample coolers,as required,will be provided. 47 RES 2ELYESIQGNY "0 SERVICES INC. G.Maintenance Shop Due to the limited capabilities for local fabrication and repair,the plant will have to include a reasonably sized and well equipped maintenance facility.This facility will be able to service both basic plant equipment and the rolling stock on the premises. It is planned that the maintenance facility will be housed in a land-based building with an area of 100'x 240'.Housing a portion of the shop on the power barges should also be considered.The facility will include the following equipment and tools: 1.Welding shop 70'x 100'with roll-up doors 2.70°x 100'machine shop with roll-up doors This includes heat,sodium vapor lights,rest rooms,locker room,tool room,foreman's office,460 VAC welding equipment plugs in both shops and fire suppression system 3 10 ton bridge crane in welding shop 4 16”engine lathe,10'bed 5.10”bench lathe,5'bed 6.10”post radial drill press 7 Small 5/8 drill press 8.Vertical milling machine 9.Horizontal milling machine 10.=Horizontal cut-off bandsaw 11.Vertical band saw (steel) 12._-_-Iron worker 13.300 Amp wire feed welder (2) 14.300 Amp portable welder gas driven 15.Oxyacetylene welding equipment (3) 16.Steam "Jenney”cleaner 17.50 ton vertical press In addition to the above shop,a rolling stock garage is planned equipped as follows: 1.Garage shop 160'x 80'x 20'high,12,800 sq.ft. Includes heat,sodium vapor high lights,rest rooms,spare parts room, tire storage area,lubrication storage and 460 VAC welding plugs around shop Outside weather shed for various mobile equipment with lights and extension cord connections for engine block heaters 100'x 40'x 15” 300 Amp stick welder Oxyacetylene welding equipment (1) Steam "Jenney”cleaner Spare parts,V belts,oil filters,tire chains,spark plugs,light bulbs and batteries 8.Tires &tubes,chains,tire breaker,compressor,lift &impact wrench 9.Work benches,tool cabinets,floor jacks,dollies,shop vacuum,tireXNAwhw 48 PES PRECISION (IMEENOY SERVICES INC. 10. 11. 12. 13. racks,shelf racks.Jack stands,creepers,trouble lights,flash lights, bench vises,arbor press,light bulbs,show shovels,miscellaneous hand tools,drain pans,parts washer,miscellaneous nuts and bolts bin Hard hats,gloves,cold weather clothing,safety glasses,soap and paper towels,safety shoes Two fuel pump covered island,pumps,readout and totalizers,lighting and infrared heating Underground diesel storage tank including excavation,piping,etc. Underground gasoline storage tank including excavation,piping Maintenance and repair shops Tools and Consumables OCPNNAMAYWNHbotped-©|eleelceceeececncelWOAPNAWMWAYWN:Nw-©One year supply of welding wire 2 to 3 sizes One year supply of welding rod,various sizes and grades Bar steel storage rack Steel rounds,square,alloy,etc. Plate steel 3/16,Y%,4,% Nuts &bolts,grade 5 &8 Set of 6”to 12”calipers Set of inside micrometers Safety glasses Hard hats Coveralls,welding leathers &gloves Steel work benches (4) Vises of several sizes Storage cabinets Milling machine attachments and milling cutters Various lathes attachments and carbide cutters Miscellaneous hand power tools Miscellaneous hand tools Miscellaneous instruments Spare parts and storage Miscellaneous shop furniture 49 PES PRECISION(RESINSYSERVICES INC. Siting of the Power Plant The basic design has the Power Plant sited South of the City of Bethel -see drawing BT20089-00-000-002 and BT20089-00-000-003.The site is in close proximity of the planned dock for equipment and materials receiving during construction and coal receiving during operations.The dock will be connected with the coal storage building with a conveyor. The site is also close to a pond,which could be utilized for disposal of plant's waste water,mainly inert blow down from the cooling towers. A second option that has been investigated and evaluated herein is barge mounting of the power plant as a method of reducing the high costs of skilled installation and construction labor and construction equipment in Alaska and supplying of the plant's systems to Alaska. Two barges,on which most of the power plant would be mounted,would be equipped with the intended systems at a shipyard on the West Coast USA or Canada and shipped on dry dock vessels to the vicinity of Security Cove,Alaska,from where the barges will be tugged to Bethel.A canal-type harbor will be excavated in which the barges will be anchored and connected to the land-based coal storage building,make- up water supply and substation for power export.The inlet to the canal will be closed. Housing cooling towers on the barges is also considered as possible and feasible, however,due to space requirement it may be decided in the engineering phase to site the cooling towers on land,near the barges. Currently barge mounted power plants include combustion turbines or diesel engines as motive power,working in simple or combined cycle.They are predominant in areas with developing power grids and areas without access to sources of low-cost and clean fuels such as natural gas and coal.Barge-mounting of a coal-fired power plant has not been done yet,however,there are many examples of this being possible,for example:steam ships,barge-mounted Kraft pulp plant with a recovery boiler. Realization of this option will encounter several challenges,the most important of which are listed below: a.Method of shipping to Bethel:barges towed from construction/assembling yard would have to be built to satisfy the Standards and requirements for ocean navigating vessels,including US Coast Guard regulations and other. This requirement makes the barge significantly heavier due to strength requirements,even though the barges will practically make only one trip. On the other hand,shipping barges on a "Dry Tow"vessel eliminates all of the above requirements because the power barges are considered to be cargo. The navigability requirements of the barges are reduced to those for river shipping -significantly less demanding due to better navigation conditions. 50 PES PRECISION ERODE SERVICES INC. Barge origin and shipyard where the power barges are assembled -at present, practically all dry-dock type vessels are foreign flagged and because of the Jones Act cannot be used for shipping between US port.Practically,the barges would have to be built and assembled overseas.One company,Jumbo Shipping,has been looking into getting a US flagged heavy lift vessel built in the next few years.Depending on the project timeline,this company may be able to accommodate our needs. Engineering design issues relating to the strength of the barges,distribution of weights,method of mooring the barges to eliminate the swell of the barges caused by winds. A very important issue relating to the stability of the barge mounted plant is prevention of barge movements during fall freezing and spring ice break-up. These issues will be further analyzed during the engineering phase.Three options for mooring the barges are being considered: 1.After the barges are towed into the harbor canal,the inlet would be closed and the water pumped out.The barges would settle on the bottom of the harbor.A support structure will have to be designed so the barge is settled as deemed vital by the requirements of a steam power plant. ii.After the barges are towed into the harbor canal,the inlet would be closed and the water left in.A system for freezing the surrounding water will freeze the barges into place in a controlled way. iii.The third option is a reverse of the second option:instead of freezing, maintain the water temperature above freezing year round. Each option has both advantages and disadvantages.In the first case the stability of the permafrost below the bottom will be of utmost importance.For creating the canal,a minimum of 12 feet would have to be excavated,which means a layer of ground protecting the permafrost would be removed and the permafrost disturbed.We are not qualified to predict the consequences ofthis. One more option that may take place is that there may be no permafrost in area were canal would be excavated or it may be at a significant depth as water from river may have thawed this low ground creating a thaw bulb which is typical of areas adjacent to rivers.Only field investigation will provide info on this. Both the second and the third options are viable means of mooring the barges. With appropriate maintenance of the ice build up around the barges the second option results in their good stabilization. The third option is attractive in this that in a steam generation plant there is a 51 IPES PRECISION ies yELMGEIO'Y SERVICES INC. substantial amount of low-temperature waste heat (for instance,from steam condensing)that can be easily utilized for maintaining the water surface free of ice and at a constant level.Proper anchoring and stabilization of the barges would be an important task for barge engineers. For the purpose of mounting the power plant pre-owned (used)barges can be procured.The structure of the barges will be enhanced appropriately to facilitate mounting of the heavy equipment.Preferably,the construction could take place in one of the West Coast shipyards,such as: -Todd Pacific Shipyard Corp.in Seattle,WA -Nichols Bros.,Inc,Freeland WA -Gunderson,Inc.Portland OR Shipyards on the Coast of the Gulf of Mexico (Texas,Louisiana)have been also considered,however,barges built there will have to be towed through the Panama Canal,where the allowable width of <105 ft precludes the use of dry-dock vessels with 100 foot wide barges set on top.This adds to the significant cost of transportation. Far East shipyards in China (specifically Shanghai,with the world known Shanghai Boiler Works,that manufactures boilers for North American boiler makers,and which is located at the Yangtze River waterfront)or Indonesia may also be a consideration, however,at the time of wniting of this Report,no response from Far East companies was received. The barge sizes evaluated for this purpose are 300'x 100'up to 450'x 100'.400 x 100 barges are presently very popular with the barge shipping companies;as a result, their availability on the pre-owned barge market is almost non-existing.Barge cost is in the range of $2,250 to $2,500 per short ton of barge weight,which translates into $7.5 to $9.5 million per barge.On the pre-owned barge market appropriate equipment can be purchased at $750,000 to $1,250,000 per barge;repairs,enhancing the structure and preparation for mounting the power plant equipment will cost up to $1,500,000.Effectively,the suitable equipment will cost between $2 million and $3 million.In the Capital Cost estimate,the cost for two barges was assumed at $5 million each plus $2,500,000 for dry shipping.Actually both costs can be reduced to a total of $7.5 million for two barges. 52 IDES PRECISION|©)SERVICES INC. BTA. Figure 10 ; Example of "Dry-dock”vessel shipping of power barges from Batangas/Phillipines and Singapore to Salvador (Baia de Todos os Santos),Brazil (via Cape of Good Hope)for Nordeste Generation Ltd.,Singapore. Cargo Specifics: Length (m)Breadth (m)Height (m)Weight (MT) Power barge I 67.0 18.30 4.27 2274 Power barge II 82.3 21.33 5.60 2907 Power barge III 77.7 24.40 4.90 2132 Power barge IV 81.6 22.66 4.88 3300 Power barge V 81.6 22.66 4.88 3300 Fuel Barge 85.0 ;27.00 5.41 1500 Pump House Barge 26.8 9.15 4.70 500 Load-Out Operation: Loading float-on Discharging float-off Transit time Approx.30 days 53 IDES PRECISION(SiN !"SERVICES INC. Vil.DISTRICT HEATING SYSTEM The plant will include provision for supplying thermal energy to a district heating system for the City of Bethel.The system will meet the diverse thermal energy needs of Bethel's residential,institutional,commercial and industrial customers.It will include a heat exchanger for heating water circulating between the plant and the heat receivers in the neighboring communities.The circulating water will be heated with extracted steam in condensing heat exchangers.At the maximum demand for heat,the plant will supply to the district heating system 230 MM Btu/hr. Based on the heating oil usage records and projected city and surroundings growth,we estimate that Bethel will require the following heat supply: .Summer supply,average:91.1 million Btu/hr averaged over 4 months for May-August .Winter supply,average:142.2 million Btu/hr averaged over January & December .Maximum winter supply 169.0 million Btu/hr .Extremely low winter temperatures,about 40°F 180 million Btu/hr .Yearly average supply:128.9 million Btu/hr The thermal energy supply rates include both heat and hot water for consumption.Since the numbers represent monthly averages,the actual minimums and maximums may differ significantly from the given amounts.It is planned that during a 2 to 3 week period in July or August,the system will be shut down for maintenance.The maximum winter demand of 180 million Btu/hr is estimated based on recorded lowest temperatures. The system has been engineered so that every building in Bethel can be supplied with heat and hot water.This includes all residential housing,schools,the community college buildings, government and city buildings,the hospital,the prison,the airport,and local businesses.The system can also provide heat to an existing or new swimming pool for the general population of Bethel. The development of the Bethel Power Plant will include the construction of trunk pipelines (see drawing 89-00-00-01)for supplying heat to one Central Heat Exchange Station.From there one main trunk line will serve the airport and one will serve the City.The pipeline to the City will branch out to the North and East.Tie-ins for buildings or groups of buildings will be constructed by the City or by private enterprise.Buildings that include more than 3 recipients of heating service will be equipped with local heat exchange stations that supply heat and hot utility water to individual recipients. Heating of buildings is accomplished by circulating hot water that is heated in a condensing heat exchanger by steam,which is extracted from the power plant's steam turbines,and then piped to receivers around whole districts.Providing both heat and hot water is an extremely efficient use of fuel and demands co-ordination of energy supply with local physical planning. There are over 30,000 district heating systems in the USA.Hot water district heating meets 54 DES|©)SERVICES INC. the thermal energy needs of residential,commercial and industrial users from the same distribution line. The coal fired power plant if operating as power generator only has an efficiency of29.6%;in a plant with thermal energy supply to the district heating system the efficiency goes up to 37.8%.In both cases the efficiency is calculated by dividing useful power (Donlin demand + Bethel demand +transmission loss +thermal energy supplied to DH)converted into thermal units (x 3.412 MM Btu/MWe)by the heat input. The Bethel district heating system will be based on using hot water instead of steam as the thermal energy carrier.Older district heating systems use steam for this purpose,however, there has been a general movement towards using hot water,which is recommended by the International Energy Agency -an international body with headquarters located in Europe that promotes energy efficiency by using district heating and heat pumps.The advantages ofwater heating over steam heating are several,the most important of which are: A.Safety:Water is used in district heating systems with temperatures in the range of 170 -194°F (77 -90°C),which is sufficiently below the water boiling temperature.A leak in the piping,whether outside or inside the heated space,will not result in rapid conversion of water to steam,which prevents the possibility of scalding or a steam explosion. B.At working pressures the volume of steam is 180 times larger than the volume of the same mass of water.This means that water requires smaller diameter piping and valves,as well as smaller size pumping and heat exchange equipment.Smaller diameter piping results in lower overall heat losses;hot water systems lose only a maximum of 10%of their energy before it is delivered to the desired location, whereas same duty steam -based systems lose as much as 30%of their energy to ambient air. C.Due to safety considerations,pressurized steam systems must be built according to the ASME Code;asa result,they are significantly more expensive in both capital and operating cost terms.Steam systems are also more expensive due to larger pipe sizing and the requirement for higher horsepower of drives for pumping equipment.The maintenance cost of steam-based systems is also significantly higher than that of water-based systems. System Specifics A.Pipes &Pumps Sizing pipe for the district heating system was determined by the estimated heat usage of the Bethel community.The heat capacity of the Bethel district heating system was based on the average heating oil usage,accounting for 20%growth over 10 years.We estimated a heat delivery rate of 169 MM Btu/hr average load in winter,with a 55 IPES PRECISION Si yes >EMESINOY SERVICES INC. maximum momentary winter load of 180 MM Btu/hr.The heat load also accounts for utility hot water usage.Heating water delivery rate is based on the heat demand and the temperature difference between the delivery and return lines.At a AT of 65°F the required pipe size to avoid incurring excessive pumping costs while balancing capital costs is 16”pipe. For supplying pipe we have contacted several manufacturers that are familiar with district heating pipe.Prices for the pipe ranged from $25 per linear foot for 10-inch pipe to $83.00 per linear foot for 24-inch pipe. The pump size needed was also determined.The 16-inch pipe seems to be the most economic.The required horsepower at 169 MM Btu/hr is 500 HP and 600 HP for 230 MM Btu/hr.This gave us the general pump size and required operating energy. Heat Exchangers The District Heating system will include main heat exchangers where the district heating water is heated with heat supplied from the Power Plant.The size of the heat exchanger was determined by the average winter heat rate of 169 MM Btu/hr. However,the system will have sufficient capacity to allow for heating demands during extreme low temperatures.The heat exchanger is a condensing type to make use of the latent heat of vaporization. After the main exchange station at the Power Plant,there will be several local exchange stations to deliver heat to individual or groups of houses.These stations will have heat exchangers that transfer the heat to a lower pressure loop that delivers hot water below 15 psig.The reason for the low-pressure loop is to meet the 15 psig limit for ASME building codes.The size of the intermediate heat exchangers will be determined by the heat requirements of the surrounding structures. Using water directly from the District heating system should be avoided to prevent contamination of the water in the main trunk lines,and to extend the life of the system.Contaminated water increases maintenance costs and causes premature failure in the main distribution lines.Also,the pressure for delivery water needs to be kept low for safety reasons.Since the delivery pressure in the main lines will be above 70 psi,an intermediate loop will allow the pressure to be dropped to a reasonable level for safety. At the final delivery point,radiant heaters will be installed in individual buildings for heating.These heaters will run off the intermediate exchangers that are linked to the main trunk lines.In some cases,forced air heating units can be retrofitted for district heating. Backup System 56 -"SERVICES INC. For the modular Power Plants,we will include a stand-by package oil-fired boiler used to supply heat for district heating.This boiler will only be operated when the plant is down for maintenance. System Installation The scope of the feasibility study only covers the basics of main trunk piping,primary heat exchangers,and the average costs of hooking up a single household.A more thorough investigation will be needed to obtain a better knowledge of the customer base and the engineering specifics of a complete district heating system. The overall capital equipment cost includes the main trunk lines,the delivery pumps,the primary heat exchangers and the hookups for households.At the time of construction there may be additional equipment costs. The install costs for a district heating system will be significant,as several miles of main trunk lines will have to be laid.With our current information,we estimate that laying the main trunk line,installing the central exchange station,and insulating pipe joints will take about 40,000 man-hours.Additional residence and hookup costs will depend on the size and demand on the district heating system. The only needed regular maintenance for the district heating system will be on the primary feed pumps and heat exchangers at the Power Plant.Main trunk lines for district heating will have to be inspected yearly,as will intermediate heat exchangers. 57 RESMd"”SERVICES INC. Vill.CAPITAL COST ESTIMATE The following cost estimates for the project have been based on equipment quotations obtained from major equipment vendors and estimates.The estimates below include all cost components as:engineering,procurement,installation,allocated foundation and common system cost,construction management and all other related cost items.Cost of equipment and system installation was based primarily upon vendor estimates;some costs were estimated as a percentage of equipment cost,based on average industry data.The position Start-Up and Commissioning includes labor and consumable cost during the six months start up/run-in period. A.Land -Mounted Power Plant Fuel Receiving and Storage $33,267,400 Steam Plant $55,466,300 Generating System $23,509,200 Ash Handling &Disposal System $626,200 Environmental Systems &Controls $4,085,300 Rolling Stock $2,142,500 Plant Utilities &Services $13,590,600 Civil &Structural $5,253,000 LCMF Foundations and Civil Work $39,651,100 Project Services and Facilities $16,793,600 Start-Up and Commissioning $4,876,100 Total Systems $199,261,300 Contingency 10%$15,961,000 Total Plant $215,222,300 Cost per Megawatt @ 96.6 MW Gross Output $2,227,974 /MWe Total Plant cost excluding specific provisions $172,554,000 for coal storage and permafrost protection Cost per Megawatt @ 96.6 MW Gross Output $1,786,300 /MWe Not Included In Total Plant: 1.District Heating System $11,6000.000 2.Environmental Impact Assessment Study $3,000,000 3.Stand-by CTG (GTX100 /LM6000)$16,862,000 Sub-Total Not Included in Plant $31,462,000 58 DES igisxoy f m)SERVICES INC. The following cost schedule is for the Power Barge Option.As above,the cost of the district heating system,stand-by CTG,and Environmental Impact Study are listed separately. B.Barge -Mounted Power Plant Fuel Receiving and Storage Steam Plant Generating System Ash Handling &Disposal System 626,200 Environmental Systems &Controls 3,003,000 $33,267,400 $ $ $ $ Rolling Stock $2,142,500 $ $ $ $ $ 47,156,800 20,896,700 Plant Utilities &Services 9,684,100 Civil &Structural 2,123,800 Barges (2)including cargo-shipping to Bethel 9,600,000 LCMF Foundations and Civil Work (coal storage &dock only)31,355,300 Project Services and Facilities 13,812,700 Start-Up and Commissioning $3,876,100 Total Systems $177,544,600 Contingency 10%$14,618,900 Total Plant $192,163,500 Cost per Megawatt @ 96.6 MW Gross Output $1,989,270 /MWe The cost difference between the land mounted and barge mounted power plants,$23,058,800, is the result of savings obtained from eliminating high-cost foundations of the steam and power generating plants and reducing the cost of manpower.During estimating the cost,the difference in productivity resulting from work in northern conditions,especially during the arctic fall and winter,was not taken into account.Some savings resulting from higher productivity of personnel assembling the power barges in milder climate (for instance Seattle) will most certainly result. C.Capital Cost Implications of the Application of Usibelli Coal The heating value of Usibelli coal is 7,800 Btu/Ib vs.12,284 Btu/lb of Fording coal.As a result (12,284 /7,800 =)1.57 times more Usibelli coal is needed.If we take also into the account the fact that there is a 5.5%difference in the boiler efficiency (89.1%versus 83.4%)due to higher moisture and oxygen content in the fuel,the proportion of Usibelli coal demand to that of Fording becomes in excess of 1.8 times.In fact,the power plant operation requires 412,300 tons of Fording coal or 687,500 tons of Usibelli coal.This fact dictates 80%physically larger (and more costly)coal storage facilities,boilers,ducts, emission control equipment and higher expenses on moving coal,air and combustion gases. The cost of the storage building only would be about $25,000,000 higher.The storage building cost increase includes material handling equipment inside the building. 59 IDES PRECISION|m)SERVICES INC. Other additionally required capital items would include: i.Larger boiler due to larger flows and required larger heat transfer surface (lower quality coal burns at lower temperature with lower heat transfer coefficient); estimated cost increase:$5,800,000 ii.Larger flue gas ducts outside boiler,passages and stacks $1,500,000 lil.Higher cost of conveying system $1,000,000 iv.NOx Control System $920,000 v.Coal bunkers with dust control $1,000,000 Total estimated Capital Cost increase,including coal storage cost $35,220,000 D.Possible Savings from Utilization of Healy Clean Coal Power Plant Only preliminary investigations were carried out;they consisted of contacting the persons responsible for the project on the part of AIDEA (Alaska Industrial Development and Export Authority)and the Federal Department ofEnergy,as well as reading progress reports of this project.The conclusions/recommendations presented herein are preliminary;an in-depth evaluation of the plant is required. The Healy Clean Coal Power Plant (HCCP)was designed to use 50%Usibelli run-of-the- mine coal and 50%waste coal.The applied technology is TRW's "entrained /slagging” combustion and B&W's spray drier absorber desulfurization system.The technology was designed for burning high ash and moisture content coal with a significant content of Sulfur. For the Bethel Coal-fired Power Project the TRW combustion technology is not suitable due to selecting a higher quality coal,which resulted in the following basic advantages: -Lowest cost fuel when the cost is expressed in $/million Btu -Flue gas desulfurization not required -Capability of applying the high efficiency pulverized coal combustion technology The B&W spray drier absorption system is not applicable either due to low sulfur content in the coal. Before actually inspecting the boiler it is impossible to state its suitability for the Bethel project;however,some assumptions can be made based on the coal characteristics.We are familiar with the characteristics of the Usibelli coal (see attachments);it is high ash and very high moisture ( 26%).In addition to this coal,50%of coal waste,which is usually very high in mineral matter content (rocks,silt and similar)and moisture,further deteriorates the value of the fuel.The boiler combusting such fuel should be designed for large flue gas volumes (moisture converts into water vapors at a rate of 130 cubic feet per pound of water;for comparison,combustion of one pound of Black Bear coal generates less than %of this amount).The boiler would have to be re-rated for the Bethel application. 60 DES =LMI 7 m)SERVICES INC. Of the steam plant,some of the boiler ancillary equipment may be utilized: -Combustion air blowers -Feedwater pumps -Boiler controls and instrumentation -Induced draft fan -Filter baghouse -De-aerator -A significant portion of the coal delivery and feeding system -Portions of the ash handling system -depending on the design ofthe existing one. The turbine generator side of the HCCP can most likely be utilized in its entirety.During the design and procurement of the second steam-generator line,care must be applied to equipment selection so that the Bethel Plant will not need to warehouse double amounts of Spare parts. The equipment would have to be delivered to a Southern Alaska port (Seward)where it would be put on a barge and shipped to a West Coast shipyard (Vancouver,BC,Anacortes, WA,or other)where the boiler and the rest of the equipment would be assembled on the power barge. 61 The savings are estimated as follows: Expenses 1.Acquisition at no cost 2.Disassembly,shipping to Seward -$1,450,000 3.Preliminary mounting on barge and shipping to West Coast port -$730,000 Other installation and shipping cost items will be the same as for a new plant. Avoided equipment cost,estimate $11,700,000 Estimated savings $9,520,000 Remark:This amount is an estimate of possible savings.It will be confirmed only after a thorough investigation of the Healy Plant. 62 IDES PRECISIONuf")SERVICES INC. IX.O&M ESTIMATE The following estimate was based in part on information obtained from a power plant in Gillette,WY where B&W PC boilers are working,PES'experience with a 100 MW CFB coal fired plant,and other industry sources.Adjustments were made to labor costs for the plant location.For the cost of coal see Section V.Fuel Selection,Procurement,and Logistics of Supply.The cost of ash disposal is assumed to be neutral due to proposed ash utilization option. Gross Power Produced:96.6 MW including 5 MW for transmission losses and 8.5 MW parasitic load (for plant internal usage).Net Power Produced fir sale:82.8 MW including 70 MW for the Donlin Mine and 12.8 MW for the City of Bethel and the Villages. Table 4 Operating Cost Items and Estimates Positions No.of Employees Yearly Cost Management Plant Manager 1 -120,000 Production Manager 1 72,800 Shift Hourly Personnel Shift Supervisor (4)4 210,413 Auxiliary Operator (4)4 190,861 Fuel Handler (4)4 151,174 Equipment Operator (4)4 148,595 Scheduled OT 4 shifts 8.8%use 10%115,672 Hourly personnel Administrative Assistant 1 42,390 Purchasing and Coal &Ash Administration 1 54,080 Fuel Barge Unloaders (6)Part-time 6 85,442 Journeyman Mechanic 1 51,189 Millwright Machinist 1 52,104 Apprentice Mechanic 1 36,150 Garage Mechanic 1 45,531 Journeyman Welder 1 47,840 Journeyman Electrician 1 48,776 I&C Technician (2)2 133,120 Total Direct payroll employees and cost 28 1,405,023 Burden Rate %32%449,607 Scheduled OT &Part Time 201,114 Non-Scheduled OT $5,579 Total Personnel Cost 2,111,324 63 DES =:M ©)SERVICES INC. Other Operating and Yearly Cost Fuel for rolling stock and standby utility boiler 118,000 Technical Services and Outside Support 300,000 Testing,outside Lab Analysis,Inside water Lab and testing supplies 25,000 Travel,Training and Safety $0,000 Contact services-Janitorial 24,000 Consumables office 5,000 Consumables plant including water treatment chemicals 200,000 Urea cost 1500 tons per year 150,000 Ash disposal (ash to be made into aggregate,concrete cost)-neutral 0 Replacement tools and equipment 15,000 Phone,mail and express service 12,000 Parts and materiel shipment to port,annual barge and misc.air 350,000 Water -no cost included in maintenance &station power 0 Spare parts &maintenance cost (Eqt 5%,Bldg 1%,El.10%,Rolling Stock 10%)+Reserve of $500,000 Annually 3,200,000 Waste removal &disposal (except ash)15,000 Property lease 0 Insurance fee (Fire,Accident)300,000 Taxes 0 Miscellaneous contingency 5%238,200 Subtotal other operating cost 5,002,200 Total O&M $7,113,524 Power production per year at net 100%sales MWh 99%availability 718,075 O&M cost per net MWh $/MWh 9.91 $/kWh 0.009 Estimated major additional operating cost resulting from the application of Usibelli coal: 1.Due to dusting and the tendency to spontaneous heating and auto-ignition,storage of the Usibelli coal would require constant monitoring of hot spots and pile compacting, yearly $250,000 ii.Additional maintenance of materials handling equipment and rolling stock,including spare parts,yearly $280,000 Total additional operating cost $530,000 64 RES A. PRECISION SERVICES INC. POWER PLANT PERFORMANCE EFFICIENCY Factors Impacting Performance of the Steam Power Plant The power plant performance efficiency depends on several factors the most important of which are: 1,Boiler efficiency 2.Steam cycle 3.Steam turbine efficiency 4.Utilization of available thermal energy Boiler efficiency relates primarily to the process of conversion of the chemical energy contained in the fuel to thermal energy carried out of the boiler system in the superheated steam (heat absorbed).The process includes combustion and heat transfer from combustion gases to water/steam in the tubes. The losses inherent to this process are: -Losses with the flue gases -Losses due to evaporating and heating water in fuel and in combustion air -Losses due to moisture produced from combustion of hydrogen -Sensible heat loss with ash -Loss due to incomplete combustion -Loss due to radiation and convection to the outside of the boiler system Losses with the flue gases originate in the fact that the exhaust temperature of the flue gas must be usually above 280°F.This is primarily due to moisture and sulfuric acid precipitation,as well as extremely low efficiency of heat recovery at the temperature range below 300°F.The sulfur content normally determines the minimum exhaust temperature.For the Fording Black Bear coal,the H2SO,the precipitation temperature is 269°F;for the Usibelli coal the respective temperature is 276°F,which means that the exhaust temperature must be minimum 286°F.For the Bethel plant,the 6-degree difference in flue gas exhaust temperature is equivalent to 13 million Btu per hour larger loss -an equivalent of 10,000 Ib of steam or 1500 kW generated.In general,these losses account for approximately 5 to 8%of heat input. Losses due to evaporating and heating water in fuel and in combustion air include heat dispensed to evaporate the water content and heat it up to the flue gas exhaust temperature.Heat of evaporation,which amounts to around 1000 Btu/Ib of water is not being recovered in boiler systems primarily due to reasons mentioned above.The higher the moisture content in the fuel the higher the loss. For example in case of the Bethel plant,the difference in thermal energy loss between the usage of the Black Bear coal and the Usibelli coal is 39.5 million Btu/hr. 65 PES PRECISION SERVICES INC. Losses due to moisture produced from combustion of hydrogen is of the same character as the loss due to evaporation;water produced in the reaction between hydrogen and oxygen is being evaporated and the heat used for this purpose is lost. The higher the proportion of hydrogen to carbon,the higher is this loss.Lower grade coals have high H2/C ratios. Sensible heat loss with ash is in the order of 0.3%of total heat input with coals containing around 10%ash.0.3%in the Bethel plant equals approximately 3 million Btu/hr equals 3 tons of coal daily. Loss due to incomplete combustion is marginal when high-efficiency combustion process is utilized.The Bethel plant will utilize the pulverized coal technology that's one important characteristic is its low loss due to incomplete combustion in the order of 0.7%.This includes uncombusted solid fuel (char in the ash)and loss in the gaseous phase -incomplete conversion to CO instead of to CO). Loss due to radiation and convection to the outside of the boiler system and with the boiler blow down could account for 1.5%to 3.0%.Good insulation of the boiler system reduces heat transfer to the surroundings.Good management and preparation of feedwater reduces blow down losses. Steam cycle The coal-fired power plant will operate in the simple Rankine cycle,the efficiency of which depends on the steam pressure and temperature.The Bethel plant will operate at 1100 psig and 1000°F.In this cycle,steam expands to 1.5 inch mercury (Hg)and is condensed for supply to the feedwater pumps.Partial expansion of steam in the steam turbine to 100 psig and its utilization for district heating (DH) improves the efficiency because the entire heat contained in the DH steam is utilized in a condensing heat exchanger as opposed to utilization of the steam energy only in the condensing turbine. Increasing the temperature and pressure beyond the above values would improve slightly the cycle efficiency;however,the associated materials cost and requirement for significantly high qualifications of operators make this method not feasible. Another method of increasing the efficiency of the steam cycle is to introduce a reheat step -see following section. Steam turbine generator efficiency accounts for the mechanical efficiency of the system,steam leaks through various seals and glands,as well as steam usage for air ejection.Modern steam turbine generator assemblies have efficiencies approaching 85 to 87%.The efficiency used in the system calculations is 85%. Utilization of available thermal energy was partially mentioned in section 2,Steam 66 PES PRECISION SERVICES INC. Cycle -use of condensing heat exchangers for the district heating system.The latent heat of vaporization of water that has to be removed from steam in the condenser is the largest energy inefficiency -more than 60%of plant thermal input is dissipated (wasted)in the condenser and cooling tower. Other means of better utilization of the thermal energy are: -Partial preheat of combustion air and make up water by recovering heat from condenser circulating (cooling)water.This water removes heat given off by condensing steam.The return water temperature is in the range of 80°F.It is possible to pre-heat the combustion air by 10°F,which will save about 3 million Btu/hr and improve furnace performance particularly in cold winter. -Application of the Heat Pump technology to recovering low quality heat was evaluated,however,the conclusion reached was that this technology is still too expensive to provide a return on investment.A system with appropriate heat pumps would require the supply of 6 MW plus,which would allow recovering about 20 million Btu/hr -basically a "zero balance”at an additional capital and operating cost. -Steam reheat -steam,after initial expansion in the turbine,is taken out and supplied to a separate section of the boiler,where it is reheated near the superheat temperature and directed back to the next lower-pressure section of the turbine.This is used in all large steam power plants. Introduction of steam reheating renders the capability to improve the heat rate by approximately 5%;that is increase the expansion efficiency by 4.5% to 89.5%.This improvement will reduce the amount of needed coal by near 16,000 tons or estimated $930,000 per year.We have requested both Babcock &Wilcox and Alstom (Combustion Engineering)to determine the implications of this improvement. 67 IES PRECISIONi.|”SERVICES INC. B.Summary of Bethel Power Plant Performance Power demand net,Donlin Mine MW 70.00 Bethel &villages MW 9.30 transmission losses MW 5.00 parasitic power MW 8.50 Total power output MW 92.80 Heat rate without DH heat supply,simple cycle,Fording coal Btu/kWh 11,547 Efficiency 29.6% Heat rate without DH heat supply,simple cycle,Usibelli coal Btu/kWh 12,145 Efficiency 28.1% Heat rate without DH heat supply,with reheat,Fording coal Btu/kWh 10,998 Efficiency 31.0% Heat rate without DH heat supply,with reheat,Usibelli coal Btu/kWh 11,647 Efficiency 29.3% Heat rate with DH heat supply,simple cycle,Fording coal Btu/kWh 9,021 Efficiency 37.8% Heat rate with DH heat supply,simple cycle,Usibelli coal Btu/kWh 9,551 Efficiency 35.7% Heat rate with DH heat supply,with reheat,Fording coal Btu/kWh 8,568 Efficiency 39.8% Heat rate with DH heat supply,with reheat,Usibelli coal Btu/kWh 9,176 Efficiency 37.2% .;0 ;:fet ycor (nth DEL simple eycle)85%steam turbine efficiency,ton/year 412,300 Coal consumption Fording coal at 89.5%steam turbine ton/year 396,400efficiency,first year with reheat Coal savings ton/year 15,900 Coal consumption Fording coal at 85%steam turbine efficiency,ton/year 330,0002”year and beyond i tion Fordin my,iCouconsumptioneringcoaa9Yeseamutine --Nsege |317,300 Coal savings ton/year 12,700 The coal consumption numbers account for reduced district heating demand in summer 68 BES PRECISION")SERVICES INC. The heat rates and resulting efficiencies have been established for the Feasibility Study purposes conservatively for modern equipment.We would like to direct the attention to the significant increase of efficiency with the application of district heating,where the entire heat contained in the steam,both due to temperature and latent heat,is transferred to the system (in a steam turbine the latent heat is removed in the condenser and wasted in the cooling tower). During engineering of the Power Plant and selection of equipment,attaining the highest possible overall efficiency will be given highest priority.Some of the means that can be applied are: a.Use of reheat The isentropic efficiency (steam path efficiency)of modern steam turbines is typically within a range of 88-92%,depending on actual steam conditions and cycle configuration. For instance,the exhaust section of a reheat unit has a better isentropic efficiency than the exhaust section of a non-reheat unit,due to the lower moisture content in the exhaust of the reheat unit. Consideration will be given to increasing the steam pressure and temperature,which may improve the thermal efficiency by 1.5 -3.5%. Consideration will be given to the use of steam drive for major equipment such as combustion air blower,induced draft fan,feedwater pumps and similar.Use of the steam drive eliminates the inefficiencies relating to steam to electric and mechanical power conversion.This may improve the plant overall efficiency by 1 to 1.5%. It is expected that with all measures implemented the overall plant efficiency may be increased to the vicinity of 40%with the district heat supply. 69 Me PRECISION Sivisl0X3}Ww SERVICES INC. RELIABILITY AND AVAILABILITY STUDY A.Introduction The Feasibility Study of the Bethel Coal-fired Power Plant includes as an important section,Determination of the Plant's Predicted Availability and Reliability. Reliability is defined as the probability that an item (component,equipment,system or even an entire plant)will operate without failure for a stated period under specified conditions. Availability is defined as the fraction of the total time that a device or system is able to perform its required function.The availability can be expressed as a fraction (or percentage)as follows: MTTFAvailabilityA=;MTTF +MTTR Where: MTTF =mean time to failure (mean time the items is working or available to do the work) MTTR =mean time to repair. MTTR +MTTF=total time Reliability is represented by:R =TT-UPOT |TT Where: TT =total time in the period UPOT =unplanned outage time The reliability quotient includes planned outage (for instance,for planned maintenance or plant vacation shut down)in the time the system is ready to work.Only unplanned outages reduce the reliability factor. Basis of High Availability and Reliability Plant operating availability and reliability depends on the following major areas: Engineering &Construction System/Equipment Redundancy Equipment and Manufacturers Maintainability and Operability Operating &Maintenance Practicesweweno 70 IPES PRECISION SERVICES INC. 6. 1. Safety Engineering &Construction Desired plant availability and reliability starts at the drafting table and engagement of the design company of the project from the very beginning. This is done through contracting with a reputable engineering and construction company that has the characteristics outlined below.The desirable situation would be a construction company with a strong engineering division specializing in power generation projects. The characteristics of desirable engineering and construction contractors: .Extensive and recent experience on similar or comparable projects .Excellent track record and client references .High caliber staff of professional engineers and managers .Good Quality Assurance Program based on company's own experience .Use of good engineering and design practices including; constructability,operability,maintainability,and adherence to safety System /Equipment Design and Redundancy System/Equipment Design and Redundancy should provide for most efficient and reliable technology and layout,as well as for sufficient redundancy.One important ingredient of an efficient system is that it is based on equipment design that has been used extensively and successfully in similar applications with as much redundancy as practical. .Systems or equipment,which by their nature of service,require frequent maintenance or whose loss would cause unit or plant outage should be designed with inherent redundancy. .Use of system and equipment designs that have been applied and proven in similar applications exhibiting high availability and reliability. Equipment and Manufacturers The objective here is to procure reliable equipment and to shorten downtime with the availability of Service Representatives and proximity of service shops. .Procure equipment from leading and quality manufacturers that have excellent track record in the industry or similar applications .Proximity and responsiveness of manufacturer's Service Representatives when called to assist .Proximity of manufacturer's repair or overhaul shop 71 DES 27SERVICESINC. 4.Maintainability and Operability The objective of plant maintainability and operability is to minimize the complexity and time required for maintenance and to operate the plant with minimum number of operator surveillance.This is generally accomplished by the following: .Using equipment having features of low maintenance design .Equipment designed to be maintained in-place with minimum disassembly and minimum usage of temporary scaffolding/rigging and handling tools. .Installation of permanent maintenance platforms where required .Accessibility and adequate space around equipment .Permanent cranes and hoists where practical .Environmental protection where necessary .Equipment and system design selections based on minimizing operator attention .Automatic startup and shutdown operation .Manual intervention features of automatic processes .Equipment capacity selection to provide maximum turndown,as may be required »Monitoring of systems and equipment to provide operators information for safety and indications for required maintenance .Remotely located control panels properly positioned for operator's visual and physical access in the control room .Local control panels properly positioned for operator's visual and physical access .Adequate lighting,ventilation and acoustic softening on operational areas .Accessible valves,switches and other instruments 5.Operating &Maintenance Practices Perhaps this is the most significant factor affecting the reliability and availability of a plant.The objective here is to minimize unscheduled shutdowns ofthe plant by well planned operating and maintenance procedures or practices.Some of the elements of good O&M practices are: .Having operating staff with the nght training and educational credentials .Concise,easy to follow maintenance and operating procedures .Diligent monitoring and trending the systems and equipment performance .Preventive maintenance as recommended by equipment manufacturers .Adequate spare parts inventory .Membership in a spare engine pool .Good housekeeping practices 72 IDES PRECISIONstig Uf "SERVICES INC. 6.Safety Prevention of accidents and resultant injuries contribute significantly to plant availability and reliability.Here are some key OSHA items to consider: Any hazardous materials should be stored and handled as required by applicable codes and standards Rotating equipment shall be provided with appropriate guards against accidental direct contact by operators and dropped tools that could ricochet to cause injuries or damage to sensitive equipment, instruments and devices. Surfaces that are warmer than 120°F that are accessible to operators during routine maintenance and inspection procedures should be insulated. Comfortable working environment Operators free of prohibited drugs and alcohol Adequate lighting and ventilation Good housekeeping practices C.Objectives of the Study Phase 1.NO-_Phase 2. Concept and Definition/Design and Development Identify major contributors to risk and significant factors involved; Provide input to the design process and to assess the adequacy of overall design; Provide input to the assessment of the acceptability of proposed potentially hazardous facilities or activities; Provide information to assist in developing procedures for normal and emergency conditions; Evaluate risk with respect to regulatory and other requirements. Construction,Production,Operation and Maintenance Monitor and evaluate experience for the purpose of comparing actual performance with relevant requirements; Provide input to the optimization of normal and emergency procedures; Update information on major contributors to risk and influencing factors; Provide information on plant risk status for operational decision- making; Evaluate the effects of changes in organizational structure,operational practices and procedures,and plant and equipment. 73 IPES PRECISION LEROY SERVICES INC. The project is at the first phase,Concept,Project Definition,and Development Decision;therefore,the study will concentrate on the predicted reliability and availability of the Power Plant from the standpoint of Project Concept,Input Design Specifications and Preliminary Selection of Equipment and Systems. Scope Definition Objectives: .To define the system being analyzed; .Describe the main concerns that originated the risk analysis; .State assumptions and constrains governing the analysis; °Identify the decisions that have to be made,criteria for these decisions,and the decision-makers; Definition Of The System Summary Nuvista Light and Power is planning to construct and operate a new power plant in Western Alaska.The Plant will supply electric power to the Placer Dome's Donlin Mine,to the City of Bethel,and the neighboring villages and will supply steam and hot water to a district heating system for the City of Bethel.The subject of this Reliability Study is the Bethel Coal-Fired Power Plant option,in which PC-fired boilers with steam turbine generators would be applied for power and heat generation. Plant Description For specifics of the Plant,please refer to Sections V and VI.The plant will be sited to the south west of the City of Bethel at an area sized at approximately 80 acres.The site is in the proximity of the Kuskokwim River.The site sub- surface conditions are silty ground on top of not fully stable Permafrost.The average temperature of the frozen ground is slightly below water freezing, around 30°F -31.5°F.Soil geotechnical conditions are generally known for preliminary design of foundations and support structures;however,more testing and evaluation is required to avoid errors in foundation design. Power Plant The Plant will include two independent,parallel generation lines,each consisting of a boiler system,steam turbine generator with condenser and cooling tower.The gross capacity ofthe Plant is 96.6 MWe +230 million Btu thermal. 74 PES E. PRECISION SERVICES INC. Fuel System Coal will be stored in a covered storage yard in two piles.Coal will be brought in during the Kuskokwim navigable period,between June 1 and September 30, by means of bulk barges with a capacity of approximately 10,000 ton each. During low water periods,the capacity of the barges will be reduced to 7,500 ton.The barges will be unloaded at the coal pier,from where it will be conveyed to the storage building and stacked by a stacker/reclaimer in two piles approximately 1200 feet long. In addition to coal,the plant will include one diesel fuel tank with a capacity of 1.5 million gallons.The tank will be replenished during the navigational season. There are two 10 million gallon tank farms located between the City of Bethel and the Power Plant operated by fuel shipping companies (Yukon Fuel Co.and Crowley Maritime Corp.)storing mostly diesel fuel. Other plant systems are described in Section VI.Description Of The Power Plant. The content of sulfur in fuel and resulting from this content of SO,in flue gas is such that the plant will perform below Environmental Standard requirements that will be imposed on the Plant,therefore,removal of SO2 from flue gas (FGD system)will not be required. Nitrogen oxides will be controlled by different means as described in Section D. Environmental Control System Plant Operation The Power Plant will be operated on a 24-hour,7 days/week basis with no planned shutdowns.The two generation lines can produce up to 55 MWe each, 10%above design output.Planned maintenance with shutdown will be conducted during months of reduced demand,July and August.The plant also includes one stand-by CTG unit,therefore,the plant can satisfy full demand even with forced outage of one process line. In a highly unlikely situation,when two steam generating lines are out of commission,the stand-by CTG will supply 42-46 MWe,a diesel fuel-fired stand-by boiler will provide all steam needs for heating.All of the generated electric power will be sent to the Donlin Mine and the City of Bethel will start up their stand-by diesel generator. Main Concems 1.Power Supply Interruptions 75 IPES PRECISION[SEINYSERVICES INC. The Power Plant will produce electric power to be supplied to the City of Bethel,the Donlin Mine (82.8 MWe +5 MWe transmission loss)and villages, as well as thermal energy to be supplied to Bethel and the villages. Interruption of power and heat supply may be harmful to both the residents and to the mine operations.The related main concern is downstream of the process (supplying the customers). Ground Stability The plant will be built in the Kuskokwim delta where the ground is unstable permafrost with the top layer being siltous material.Localized damage to the permafrost caused by heating and unnecessary penetrations may result in extensive losses of foundation stability and permanent damage to the plant. With plant siting on barges,the exposure related to ground stability is increased in case of selecting the first option for power barge mooring (see Section H.Siting of the Power Plant).The other two mooring options reduce somewhat the impact of ground movements.The third option (barges moored in water-filled canal)introduces some low risk to plant stability due to sway caused by winds. Fuel Supply As in any combustion power plant,fuel supply is critical for uninterrupted operation.This issue is described in full in Section V.Possible vulnerabilities are: .Late start of fuel supply season due to navigating conditions on the Kuskokwim River .Shortage of fuel on the market due to international conditions. .Inadequate fuel quality Late start of the navigational season due to weather conditions may result in disruptions of power generation near the end of May and into June.Shortage of fuel on the market is a real possibility in the liquid fuel market.The coal market is more stable and the availability of coal may be predicted many years in advance.The coal pile will include a compacted layer of coal,serving as a ground-insulating layer and as a coal reserve.The amount of coal in this layer is sufficient for over two months of operation. Inadequate fuel quality may result in increased fuel consumption (due to lower heating value),which in turn will result in faster depletion of the fuel stored in the tank farm.This,as with availability on the market,can be determined well ahead of time. 76 PRECISION igLEMGIO'YhPodSERVICES INC.Instrumentation and controls are extremelyimportant to reliable operation ofthesystem.Theissue is flagged here to raise the awareness of the engineer during the design and system supplier selection process. 5.Plant Operations Management and Control System (DCS) Even the smallest errors in process design including the distributed control system and in operating and maintenance procedures may result in extensive reduction of the system reliability and availability. 6.Other Concerns Other concerns include factors whose impact on the plant reliability is presently perceived to be minimal yet in certain conditions could be detrimental to the availability.Included here are: .Make-up water supply and treatment;interruption of make-up water supply for a period longer than 48 hours will require shutting down the steam plant and,as a consequence,will eliminate stop power generation. .Excessive snowfall may limit access to the equipment modules.The largest snow precipitation values are in the range of 3 to 5 feet over the winter period.Larger snowfalls,especially such that happen in a short time span may cause significant operating and maintenance problems. .Winds.The Bethel area has a very high proportion of strong winds. The Pressure Vessel design Code requires that structures be designed for winds up to 110 miles per hour. .Plant lighting and grounding .Fire prevention F,Estimation of Availability of Equipment and Systems;Addressing the Concerns In this study the main concern is the Reliability(R)and the Availability (A)of the entire power plant,not just single equipment items or even systems. 1.Power Supply Interruptions are the results ofpossible operating problems.As described above,the plant layout provides for various arrangement of equipment that result in high reliability.At normal operations and properly conducted planned maintenance and available stand-by CTG,the system will achieve a reliability factor approximating 100%.The main processing equipment -PC combustors with boilers and steam turbine generators, installed and commissioned properly,exhibit reliabilities in the range of 99.5% to 99.8% 77 PRECISION LRGEIUOY -”)SERVICES INC. The plant has stand-by,redundant prime movers to eliminate any uncertainty of their operation. In light of this,the Availability of the prime movers,including generators, can be assumed as 100%.The Reliability of the prime moving system with redundant equipment,whose time from start to full capacity does not exceed two minutes due to "hot stand-by”,can also be assumed as 99.5%.The percentages are not for single equipments but for the entire prime power generation system. 2.Ground Stability In predicting the ground stability the most important step is selection of engineering and construction contractors with extensive and recent experience,excellent track record with high caliber staff of professional engineers and managers.Based on the predictions,the same team will design and build the foundations for the plant.It is proposed that the R and A factors for ground stability be assumed in the range of 99.5%. 3.Fuel Supply To prevent any process interruptions caused by fuel supply problems,some important measures will be undertaken,such as: .Enter into fuel supply agreements with a reputable company. .Acquire own fuel barges and a tug(s),which would be dedicated to bringing fuel to the plant. With all measures undertaken to assure fuel supply,the Reliability and Availability values are proposed to be 100%. 4.Instrumentation and Controls and Plant Operations Management and Control. The Reliability and Availability of the Plant due to these factors will be controlled by high quality engineering of the process and the control system, including where required sufficient redundancy,as well as procuring the equipment from the most reliable suppliers (ABB,Honeywell,Allan-Bradley, Emerson). It is proposed to assume the R and A factors as 100%. 5.Other factors Taking into account all auxiliary systems having impact on the Reliability and Availability of the plant and built in redundancy,it is proposed to assume the 78 IDES =PRECISIONNESLUGNYSERVICESINC. R and A factors as 100%.Some of the redundancies include: .Doubled water treatment and preparation system (100%redundancy) .All process equipment is housed in appropriate buildings. .Fire alarming and fighting systems as well as stringent implementation of fire prevention means .Coal feeding system with built in redundancies (dual conveyors, bunkers capable of feeding to both process lines,bunker capacity sufficient for one day operation and other). G.Estimation of Plant Availability and Power Supply Reliability The plant consists of several in-line (series)and parallel systems. In-line:fuel supply >storage >delivery to pulverizers >combustion in boilers >steam to steam turbines >power generation > substation (transformer and breakers)>supply to clients. Parallel:2 steam production and generation lines; 1 stand-by CTG line Auxiliary systems. In line system reliability Fuel supply to coal storage 100% Fuel supply from storage to pulverizers 100% Process (boilers +generators +substation)99.5% Ground stability 99.5% All other factors combined 100% Total line reliability =100%x 100%x 99.5%x 99.5%x 100%=99.0% Forced Outage Rate (F.O.R.)=1-0.99 =0.01 Hours per year unavailable to serve load =0.01*8760=87.6 hrs/year The plant availability will be reduced by planned maintenance of systems impacting the output of the entire plant.Since these systems include sufficient redundancy for maintenance work,it could be assumed that the Power Plant Availability =Power Plant Reliability =99.0% 79 RANSMISSION LINES \ STRICT HEATING MAIN SERVICE LINE \ INTENANCE SHOP E-mail:energy@pes-world.com PRECISION ENERGY SERVICES INC. P.O.BOX 1004 HAYDEN LAKE,1D 83835Phone(208)772-4457 =Fax (208)762-1113 WAS 376.2'x96.4'BARGE,GRAPHIC SCALE WAS 30'09/12/03) FOR REVIEW AND COMMENT ONLY oa /12/03) BETHEL ALASKA COGENERATION PLANT 400°x 100'BARGE CONCEPT REVISION DATE SITE PLAN DRAWN.BY:TNO APPROVED BY:RB DATE:AUG.11,2003 SCALE;1»600 PLOT SCALE:1=1 FILE:8T20089990010038 ORAWING NO.SHEET:'BT20089 99-000-003 1 oF Web Site:htto/www.pes-wortd.com 50°"125'-0"28-0"56-0"54'.0"40"aT RS a lt 'Ws<aR>a aude CONTROL ROOM myAOT110°"440°" MAJOR EQUIPMENT LIST ITEM QTy DESCRIPTION WEIGHT ITEM QTY DESCRIPTION WEIGHT wi +407 |DOCK FACILITIES -BULKHEADS CONCRETE &STEEL n 2 PULVERIZER HOT AIR COAL TRANSPORT FAN 25 TONS we 2 1 DOCK FACHITIES-BARGE UNLOADING SYSTEM 420 TONS 2 2 BOILER No 1&2 STACK 150 TONS #3 2 CONVEYOR -No.1 TRANSFER TO STORAGE SUPPORTS BOC 2 400 PLE 23 1 TURBINE 100 TONS wa 5 CONVEYOR -No.2 TRANSFER TO STORAGE SUPPORTS BOCs 400 PLE Py)1 GE MODEL Ne.LM6000 TURBINE 100 TONS AY ws 2 COAL STORAGE -PILE,130°WIDE x 1.400 LONG (92.575 TONS EACH)SO PCF 2s i G E.LM6000 TURBINE STACK sotons |/A\ La)i RECLAMER -SUCKET WHEEL STACKER RECLAMER 750 TONS Fa 1 ASH STORAGE SLO 65 TONS "7?8a CONVEYOR -PILE STACKING/RECLAIM SUPPORTS 27 0.0.x 350 PLE Ed 2 COOLING TOWER 430 TONS 8s 2 CONVEYOR -STORAGE TO BUNKER TRANSFERS 810 PLE Eo i STAND-BY BOLER ANO STACK *9 2 CONVEYOR -No.1 BUNKER NFEED TRANSFER 995 PLE 2 1 No.2 DIESEL FUEL STORAGE TANK TOOK U S GAL.300 TONS *10 2 CONVEYOR -No 2 BUNKER NFEED TRANSFER 995 PLE »1 COOLING POND PUMP HOUSE "2 COAL BUNKER -1807 x 80°TALL 950 TONS u 4 TANK -RAW WATER STORAGE 30'DIA x 45°TALL 350 TONS 12 6 CONVEYOR -BUNKER OUTFEED 55's LONG 995 PLE 32 'DEMINURALZED WATER STORAGE 20 OW x38 TALL 150 TONS 13 2 CONVEYOR -PULVERIZER 'NFEED 1107+LONG 995 PLE Ex}3 PROCESS PUMPING STATION -FEED WATER.CIRCULATION .20 TONS 4 6 PULVERIZER -AND DISTRIBUTION 20 TONS ™'BORER BULOING 250°SPAN x 200'L x 1304 2.130 TONS 15 2 BOWER 420 TONS 35 1 TURBINE BUILDING 120 SPAN x 250°L x 70°74 1.190 TONS 18 2 AR HEATER 598 TONS 36 1 WATER TREATMENT/CHEMICALS BUILOING 50'SPAN x 250'L x 70'H 100 TONS 7 2 BAGHOUSE 80 TONS Bu o STAND-BY S0LER SUILONG 18 2 FORCE DRAFT FAN 31 TONS Et at)2 INDUCE OR AFT FAN 82 TONS 9 EI 2 OVERFIRE AIR FAN 30 TONS 40 TOTAL WT.= w OENOTES ITEMS NOT SHOWN ON THIS SHEET REFER TO PES OWG.No.8T20069-01-000-001 SHT 2 PRECISION ENERGY SERVICES INC. P.O.BOX 1004 HAYDEN LAKE,iD 83835 Phone (208)772-4467 Fax (208)762-1113 E-mail:energy@pes-wortd.com Web Site:hitp/Awew.pes-world.com©|WAS L#2500 ows |TNO |RBC|GENERAL CONCEPT REVISION o7mons |two |RB BETHEL ALASKA COGENERATION PLANT®|GENERAL CONCEPT REVISION o7r2saa |TNO |RB GENERAL ARRAN GENET PLANA}FOR REVIEW AND COMMENT ONLY o7rzsma {TNO |RB [oaawnay ino APPROVED BY:RO DATE Ly Z3.2003 NO.REVISION OATE ey CHK TSCALE ihe 21-0"PLOT SCALE 154 FILE 9720089990010020 THES ORAWHNG 18 THE PROPERTY OF PES,THECESON WEREON ARE 0 SHALL NOT Of 208 NO,ORAWANG NO.'weer.[a)COPIED OF DSCLOSED TO OTHERS,iN WHOLE OR IN PART,WITHOUT WRITTEN PERM @6ION FROM PES.BT20089 99-001-002 10F4 oH .f -}¥Lake oN|a;7|fo 4£|7 -Aosmi @380 1 (127%f SBS |c "PP _' Ae.en t jr i "3 we *CaninAS ff a '13B kV TLINESR,Ve a can '4 4 Ye G \,------_---orrw on ey ee [250@90LL"The ."*-er 5.wot_Pit *rs ;aePtPANLsex-aacanrsnrnn:CN STATION | *'ref SAL if fe te ISTRICT HEATING Lom ts »ait .3 :6 0 Local HEAy fi "do,;sy foie a Hine:MAIN TRUNK LINES"EXCHANGE STATIONS Sat yy yo a a 1775 @ 3%.is,savin p JONs t pe fe ISTRICT HEATINGe8,}/\\fRiser 2 SasapeeMAINTRUNKLINES”a)ay .Rosenpee1PatAflleer===e '.ooee!IR Mees}Lo B %-'se eae DAZQL 3 'iorovefe\at |t we 857 @ eat ISIRICT HEATING i neeoas3sTRUNKINES':. oo ':+% +,i Carl .5 ,3 aie @0 Proposed Access FROad we cee ane reer ene ro pe eea.''71.t i.tum L i|!a Proposed Deck Locationy”i ee Vise @270,)J |"Runway E-tansion I q /\q -|oars Oe ee tae an GE UNLOADING|:ae ek Se .f TATION AND DOCK "| }4 "a *.!Pa , y 4 "ABroposed Road!ref24aRANSFER[see Zi ,' epee [Point A @ 0.0 mil7 SS.v7 BARGE TO[Stone PILE * or cee - i OAL STORAGE PILE f '99ot.f G sRECAIMER SYSTEM . j i \,Ln i Peppy Com PetCoalPlantLocation,80 Actes”, 4 eG 4 ca a)'sy f ig .'4 s ?sy ee .Yosw er,|S nyeer=ral * ry rn 4.woe :TRANSFER CONVEYOR ial ;j a i |yo BLOWDOWN P pase an eee ee PILE TO BOILER BUNKERS.,.apaorlsonCOOLINGTOWER"ne ry ("BOILER &igen one oo wis ma !=:8 vin ra Ie FACILITIES|:"- PRECISION P.0.BOX 1004 HAYOEN LAKE,1 83835 DRAWN BY:IND APPROVED BY:PES DATE:APR 29,2003GESbeyBere(0Afm GoneNs BETHEL ALASKA COGENERATION PLANT Fore"=9--MiLES [Aut SCE,T=680 _[File:BT20089-C0--000-002-B8SERVICESINC.URL_ww pee eercom DISTRICT HEATING 708 NO.DRAWING NO.ISSUED FOR REVEW WIG.05708755 |SS Une?CSRSAAD SealHer8 SERED BP RAS SO GENERAL ARRANGEMENT BT20089 Q0-000-002 |)SUED FOR REWEW MTC.08/25/03} gotbedProposed Barge Power Pl 'Proposed "+|LocationCoalPlant -: ant Location Locate Boilers andBarges this mi- .below bluff _'Barges.ae. 'CROWLEYMARINESERVICES 2 Northpoint Drive,Suite 900 Houston,Texas 77060 A Subsidiary of Crowley Maritime Corporation ww w.crowley.com Sat ty TY hs a aT bad Li ae 6 3 o}a 3 o oa io 2 | ®oa ie oy ie a a i Real al!-me sl on Ww roy xx 99°62 4 oe Specifications re,my x 20%;aa ev Summer Load Line Keel Draft 142.75” Summer Load Line Displacement 15,416 ST Summer Load Line Deadweight Lightship Draft Lightship Displacement Lightship LCG Lightship VCG 12,035 ST 4'0.5" 3,380 ST 203.4 ft FWD of Transom 10.5 ft above BL Draft Mark Locations Fwd Marks Aft Marks 320 ft Fwd of Transom 50 ft Fwd of Transom Longitudinal Strength Data Maximum Allowable Still Water Bending Moments In Port At Sea 122,850 LT-f 57,950 LT-f Maximum Allowable Still Water Shear Force In Port At Sea 4,083 LT 1,897 LT DWT |DRAFT]DISPL]TPI(S/T)|(FEET)|(S/T,S.W.) 12000 =14 215000 |104 11000 =13 -=-14000 10000 -3=1 =13000==1029000===120008000==11 4000 7000 -=-10 49999 |100 6000 =9 -=9000 000 =3 ==8000|98 4000 -3==70003000==!goo0 |9%=6 =2000 ===5000 94 1000 25 = 02.44==3000 90 3 1404"PRECISIONBESENERGYSERVICESINC. P.O.BOX 1004 HAYDEN LAKE,iD 834835 Phone (206)772-4467 |_E-mad:energy@pes-workd.com Fax (208)762-1113 Wea Site:http:/www.pes-world.com 05/01 /ox TNO ae BETHEL ALASKA COGENERATION PLANT COAL FIRED POWER PLANT GENERAL ARRANGEMENT A [ISSUED FORREVIEW AND COMMENT DRAWN BY:TNO APPROVED BY:OATE:APRE_16,2003 NO.REVISION Oare av |CHK [scHE:1°=100.0 PLOT SCALE:Iwt FRE:@T200890000000A SHEET:|.ATMSDRUMDEPROPERTYOFPES.THE ESIC WM OCG SHOWN HEREON ARE COMFORT,0 SHAUL ROT SE 08 NO.ORAMING NO. Hes>C)¢SHEET 2 FOR AREA LOAQ CALLOUTS 250'-0"PL.&)4't---.i)i}1ictWhooTteeipt---4ana-+0"Ts{ { [ t New,p REFER TO SHEET 2,FOR WEIGHTS r GIVEN ON THIS SHEET-EowefreeeoeeeeeeOeeoPeoeeeeeeeUehet44|!tt'i|aRetand-MWRbkbeeeflenbefeekkk8keoenpeS = 16'-0".el RS ae116'-0 Sy u 7 o PROJECT KEY PLAN 5 oy §/al?RES PRECISION7ENERGY@)te 4 SERVICES INC.|J L ;P.O.BOX 1004 HAYDEN LAKE,iD 83835\SS Phone (206)772-4457 Fax (208)762-1113_/E-mail:energy pes-wortd.com Web Site:http/Awew.pes-workd.com i THE: o 2 2 eo 2°eo me o----O-2 v rN 2 2 m +o >-o--__@---or .BETHEL ALASKA COGENERATION PLANTOVERALLSITEPLAN EQUIPMENT ARRANGEMENT &LOAD LOCATIONS A ISSUED FOR REVIEW AND COMMENT ONLY 05-07-03 TNO |RE [onsen ar TNO APPROVED BY:RG OATE:MAY 07,2003aa!3 NOL REVISION Gate ay |CHK [ScCME1°=100.0°PLOT SCALE:mt FE:BTZ0089O100000TA :DHS ORANG 1 THE PROPERTY OF PES.THE DESIGN AQ DEAS SHOWN HEREON ARE CONPDEMA,wn Gell NOT BE [408 NO.ORMANG NO,'SHEET:ASAE1©100 COPED ON OFSCLOSED 10 OTHERS.IN WHOLE OR 1 PART,MITHOUT WRITTEN PtrEasnon FROM PES.BT20089 01-000-001 1 OF 4 REY moomooaT|rs]tyee!aidiedednedeniedies|irtF@!250'-0"290°-0" ELECTRICAL SWITCH YARD 190°-0"100'-9"25°-0"yu MAINTENANCE &It MACHINE SHOP 9 i !2/: J! a rs rr es ae -i I |d|} |4 iil !t i\to _ LY -|= !eS | ! TO |ailOo . iC5 i vaa ia-a 3If]4gfi: RB.LY 30'-0" 116'-9°58'-0"309'-0"6C0'-0" LOADING SCHEDULE (EWR TH RE fe:Sram TM |aty DESCRIPTION WEIGHT '1-LoT |OOCK FAGILINES =BULKHEADS CONCRETE &STEEL 2 1 DOCK FAGUTIES -HEYL &PATTERSON INC,BARGE UNLOADING SYSTEM |420 TONS 3 72 |CONVEYOR =No.f TRANSFER TO STORAGE SUPPORTS 80'0.C.+oo PUF hd S|COnVEYOR -No.2 TRANSFER TO STORAGE SUPPORTS 80°0.C.+woo PUP S|2]GOAL STORAGE =PILE,130°WIDE x 1,400"LONG (92.575 TONS EACH)|sa PCF §||REGLAMER -MAN-TAKRAF INC.BUCKET WHEEL STACKER/RECLAMER 730 TONS 7 86 CONVEYOR =PILE STACKING/RECLAN SUPPORTS 20°0.C.+350 PUP 8 2 |CONVETER -STORAGE TO QUNKER TRANSFERS 610 PLF $2.|CONVEYOR -No.1 BUNKER INFEED TRANSFER 995 PLE 10 2 |CONVEYOR -No.2 BUNKER INFEED TRANSFER 995 PYF nN 2 |COAL QUNKER -JO”SOUARE x 60°TAL 950 TONS '2 6 CONVEYOR -QUNKER OUTFEED SS't LONG 995 PU 13 2 CONVEYOR =PULVERIZER INFEED 110'LONG 995 PUF 14 6 PULYERIZER =ALSTOM MODEL No.AND DISTRIBUTION 20 TONS 'S 2 BOER =ALSTOM MODEL No.420 TONS is 2 NR HEATER ALSTON MODEL No.$94 TONS 7 2 BAGHOUSE 60 TONS 18 2 FORCE DRAFT FAN 31 TONS 'a 2 INOUCE ORAFT FAN 62 TONS za 2 OVERFIRE AR FAN 30 TONS a 2 PULYERIZER HOT AR COAL TRANSPORT FAN 25 TONS 22 2 BOILER Ma.|&2 STACK 150 TONS 23 4 TURBINE ALSTOM NOOEL No.GTX100 100 TONS 24 1 G.E MODEL Ne.L2S00 TUREINE 100.TONS 25 'G.E,LN2500 TURBINE STACK 8)TONS 1 ASH STORAGE SLO 65 TONS 2 COOUNG TOWER 430 TONS 1 STANO-8Y BOILER AND STACK 1 No.2 DIESEL FUEL STORAGE TANK 700K U.S.GAL 300 TONS 1 COOUNG PONG PUNP HOUSE 1 TANK -RAW WATER STORAGE 30°OWAx45°TALL 350 TONS 1 DEMINURALIZED WATER STORAGE 20°OIA x 35°TALL 150 TONS 3 PROCESS PUMPING STATION =FEED WATER,CIRCULATION...20 TONS {BOWER GULDING 250°SPAN ©200°Le 150°H 2.130 TONS 1 TURBINE BUKDING 120°SPAN x 750°L x 70°H 1,190 TONS 1 WATER TREATMENT/CHEMICALS BUILDING $0'SPAN x 250°|x 70°H 100 TONS 1 STANO-8Y BOILER QUILDING q(SSai ' THIS SHEET: PROJECT KEY PLAN PRECISION ENERGY SERVICES INC. P.O.BOX 1004 HAYDEN LAKE,ID 83835Phone(206)772-4457 =Fax (208)782-1113aE-mad:energy@pes-world.com Wed Site:http:/Awww.pea-world.cont THLE: BETHEL ALASKA COGENERATION PLANT STEAM PLANT EQUIPMENT ARRANGEMENT &LOAD SCHEDULE A JISSUED FOR REVIEW AND COMMENT ONLY ORAM BY:TNO APPROVED BY:RB OATE:MAY 7,2005nO.REVISION OaTe ay |CHK ESCNE:1°=30.0 PLOT SCALE:Imt FALE:917200890 1000001ATSORANGISTHEPROPERTYGFPES.THE DESIGN ANC)IDEAS SHOWN HEREON ARE COMFDENTIN.amy StL MOT BE [408 NO.ORANG NO.SHEET:[A_|COPIED OR DISCLOSED TO OTHERS,IN WHOLE OR IN PART,WTHOUT WRITTEN PERMISSION FROM PES.BT20089 01-000-001 zara = COAL SUPPLIERS &SPECIFICATIONS The following is a list of coal suppliers,coal specifications,and cost per short ton FOB port of departure. 1.Quinsam Coal Corporation PO Box 5000 Campbell River (Vancouver Island) B.C.Canada Type -Thermal coal Heating Valve Gross (dry)"12,240 Btu/Ib Gross (air dry)11,880 Btw/Ib Gross as rec'd 11,160 Btw/Ib Net as rec'd 10,620 Btu/Ib Proximate Analysis Total moisture 9.0% Ash content (air dried)13.5% Fixed carbon (air dried)47.0% Volatile matter (airdried)36.5% Ultimate Analysis Carbon 70.1% Sulphur 0.8% Ash content 13.5% Product Size 100%-50 mm x Omm 30%-2.0mmx0mm Cost FOB Texada Island F:\projects\ak\bc20089\coal suppliers &specifications 12/31/02 2.Fording Coal Limited2059"Ave.S.E. Calgary,Alberta Canada A Type -Thermal Coal (black bear) Heating Valve Gross (dry basis)13,352 Btw/lb Proximate Analysis Total moisture (as received)8.0% Ash content (air dry)11.9-12.4% Fixed carbon 64-66% Volatile matter (air dry)22-24% Ultimate Analysis (dry base) Carbon 77.22% Sulphur 0.32% Ash content 11.92% Product Size 100%-50 mm x 0 mm B Type -Thermal Coal (Coal Mountain) Heating Value Gross (Net as received)11,130 Btu/Ib Proximate Analysis Total Moisture (as received)8.5% Ash content (as received)15% Fixed carbon (as received)54-56% Volatile matter -medium Ultimate Analysis (dry basis) Carbon 721% Sulphur 0.8% Ash content 16.5% F:\projects\ak\bc20089\coal suppliers &specifications 12/31/02 Product Size 100%-50 mm x Omm Cost FOB Westshore Terminals at Roberts Bank (Vancouver BC) 3.Luscar Ltd. 1600 Oxford Tower 10235 101 St. Edmonton,Alberta Canada Type -Thermal Coal (Obed Mountain Mine) Heating Value Gross as received 10,000 Btu/Ib Proximate Analysis (as received basis) Total moisture 13% Ash content 12.4% Fixed carbon 41.6% Volatile matter 33% Ultimate Matter Carbon 76.8% Sulphur 0.67% Ash content 12.4% Product Size 5%-50 mm x 25 mm 35%-25mmx5mm 30%-5mmx3mm 20%-2 mmx .5mm 6%-.5mmx .2mm 4%-.2mmx0mm Cost FOB Westshore Terminal at Roberts Bank (Vancouver B.C.) FAprojects\ak\bc20089\coal suppliers &specifications 12/31/02 4.Usibelli Coal Mine Inc. PO Box 1000 Healy,AK USA Type -Sub-bituminous Heating Value Gross (as received)7,800 Btu/Ib Gross (dry basis)10,500 to 10,800 Btu/Ib Proximate Analysis (as received) Total moisture 26% Ash content 9% Fixed carbon 29% Volatile matter 36% Ultimate Analysis Carbon 69.5% Sulphur 0.3% Ash content 9% Product Size Coal crushed to 2”x 0” Screening circuit can reduce minus /%”to less than 10%with top size to 6” Cost FOB Port Seward Coal Terminal Alaska 5.Kennecott Energy Company P.O.Box 3009 Gillette,WY USA Type -Sub-Bituminous Thermal Coal -Spring Creek Heating Value Gross (as received)9350 Btw/lb Gross (dry basis)12447 Btwlb F.\projects\ak\bc20089\coal suppliers &specifications 12/31/02 Proximate Analysis (as received) Total Moisture 24.80% Ash Content 3.90% Fixed Carbon 38.54% Volatile Matter 32.43% Ultimate Analysis Carbon 53.88% Sulfur 0.33% Ash Content 3.90% Product Size Coal Crushed to 3-inch minus Cost FOB Roberts Bank Terminal $27/Short Ton 6.Kennecott Energy Company P.O.Box 3009 Gillette,WY USA Type -Sub-Bituminous Thermal Coal --Colowyo Heating Value Gross (as received)10450 Btu/Ib Gross (dry basis)12551 Btu/Ib Proximate Analysis (as received) Total Moisture 16.74% Ash Content 5.66% Fixed Carbon 45.02% Volatile Matter 32.57% Ultimate Analysis Carbon 60.78% Sulfur 0.38% Ash Content 5.66% Product Size Coal Crushed to 3-inch minus Cost FOB Roberts Bank Terminal F:\projects\ak\bc20089\coal suppliers &specifications 12/31/02 BUDGET COST ESTIMATE Power Plant Feasibility Study Bethel,Alaska MATERIAL UNIT MATL FREIGHT No.ITEM QTY UNITS COST TOTAL $0.20/tb TOTAL Mobilization/Demobilization ..........0c00c0ccseseesearoae 100,000 t Mob/DeMob 1 SUM 100,000 100,000 100,000 Earthworks 6,065,000 2 Sand Fill 195,000 CY 15 2,925,000 2,925,000 3 Gravel Surface Course 8”20,000 CY 80 1,600,000 1,600,000 4 Access Roads 7,000 LF 220 1,540,000 1,540,000 Gootentile......cccccsccoccceacovcosccocccoscseccscecscovccsecocssssacarsensscncseosecescerecseccocssedceusucsoscoccesccecsccecsocsccoceccouescesccousass [292,350]5 Non-Woven Geotextile 148,000 SF 0.10 14,800 29,600 44,400 6 Woven Geotextile 826,500 SF 0.10 82,650 165,300 247,950 Thermal P; 7 Maint Bldg Rigid Insulation 165,000 BF 1.00 165,000 16,500 181,500 8 Maint Bidg Flat Loop Thermo Syphon w/Hybrid Condensor 24 «EA 7,000 168,000 8,640 176,640 9 Power Plant Rigid Insulstion 1,800,000 BF 1.00 1,800,000 180,000 1,980,000 10 Power Plant Flat Loop Thermo Syphon w/Hybrid Condensor 60 EA 12,500 750,000 48,000 798,000 Foundations ..cssessscssstsevessoscsnsosenscnsuseenssvisssnecnsinstanntoaneensussnsvnsesusnasnerss 11 Maint.Bldg Slab on Grade w/Footings &Grade Beams 280 CY 1,000 280,000 30,240 310,240 12.Pwr Plant Slab on Grade w/Footings &Grade Beams 2,600 CY 1,000 2,600,000 280,800 2,880,800 13 Stoker Slabs in Power Plant 120 CY 1,000 120,000 12,960 132,960 14 Raw Water &Demineralized Water Tank Ringwalls 20 CY 1,000 20,000 2,160 22,160 1S Admin,Bldg.Thermo Helix-Piles (Incl.Installation)24 EA 7,100 170,400 13,440 183,840 16 Cooling Tower Thermo Helix-Piles (Incl.installation)32.EA 7,100 227,200 17,920 245,120 17 Ash Silo Thermo Helix-Piles (Incl.Installation)4 EA 7,100 28,400 2,240 30,640 18 Housing Thermo Helix-Piles (Incl.Installation)36 EA 7,100 255,600 20,160 275,760 Tanks ...cccreccsoscreneenococserceeccceaosaconsosccccecenvasssccoovueessacvsoseoseseceseae 900000"{532,209]19 Intermediate Fuel Tank (12,000 Gallon,Double Walled)2 EA 26,000 52,000 9,600 61,600 20 Intermediate Tank Appur 2 XLS 10,000 20,000 400 20,400 21 Raw Water Tank (700,000 Gallon,Steel,Erected)1 EA 252,000 252,000 34,539 286,539 22 Raw Water Tank Appurtenances 1 Ls 10,000 10,000 200 10,200 23 Demineralized Water Tank (80,000 Gallon,Steel,Erected)1 EA 126,000 126,000 17,270 143,270 24 Demineralized Water Tank Appurtenances rt Ls 10,000 10,000 200 10,200 Fuel &Raw Water Pipelines ........cccscssscescsoccvosecevsccescosaasancsesnccccooseneccssnonesnsceasarersescscasscaneenascsensnseeceosnesesesdacebananescacoscascoansneoouenes 238,063 25 Coated 4"Sch 40 Pipe 3,700 LF 60 222,000 7,985 229,985 26 4"Plug Valve 2 EA 1,750 3,500 38 3,538 27 4”Check Valve 2 EA 360 720 24 744 28 4"Gate Valve (Water Tanks)2 EA 495 990 44 1,034 29 3"Ball Valve (Fuel Bypass)2 EA 400 800 20 820 30 Fill Limiting Valve 2 EA 965 1,930 12 1,942 Dock.....cscseeccoccccccassacsasscvgreopscgseanaracceasesycaassssscess0000000oe0socccs ose paaannadoscasonacccenvoceosagoarsnecsonacscesooesosaeuavabuasouscoocbeconeeens -2,211,350 31 Fuel Dock 400 LF 5,500 2,200,000 2,200,000 32 Marine Header Containment 1 Ls 7,500 7,500 1,000 8,500 33 Marine Header Assmbly 1 EA 2,500 2,500 350 2,850 Security Fencing [181,530] 34 Chain Link Fence 9,635 LF 15 144,525 28,905 173,430 _ 35 Vehicle Gate 2 EA 4,000 8,000 100 8,100 Electrical ......:..ccoossescooccecnsuscasesossscsacsaavaccengasszencenenacsaecgeeceossc00o0 coo vessceeosansoecoaeesvacssce woes 36 Electrical Controls 1 SUM 100,000 100,000 1,000 101,000 37 Lighting 1 SUM 100,000 100000 2500 102,500 Sub-Total 17,041,662 Contingency @ 15%2,556,249 Overhead &Profit @ 35%979,896 Bonding and Insurance @ 1.5%293,969 Coal Fired Plant &Buildings Total:20,871,775) BUDGET COST ESTIMATE Power Plant Feasibility Study a MATERIAL UNIT MATL FREIGHT No.ITEM QTY UNITS}_COST TOTAL $0.20/1b TOTAL Mobilization/Demobilization .{C -100,000]1 Mob/DeMob 1 SUM 100,000 100,000 100,000 Earthworks .....0cccccsscocsccascecssacssoscesovccsacsoessesvesseeon [5,877,000]2 Sand Fill 100,000 CY 15 1,500,000 1,500,000 3 Gravel Surface Course 8”8,000 CY 80 640,000 640,000 4 Access Roads 7,100 LF 220 1,562,000 1,562,000 5 Harbor Excavation 65,000 CY 5 325,000 325,000 6 Breakwater Dike Fill 30,000 CY 10 300,000 300,000 7 Breakwater Dike Gravel 3,000 CY 80 240,000 240,000 8 Armor Rock (3-foot size)3,100 TON 100 310,000 310,000 9 Pier,Dolphins &Moorage 1 Ls 1,000,000 1,000,000 1,000,000 G UN€...ccccccssesonsesescceconsesscasevevese 10 Non-Woven Geotextile 148,000 SF 0.10 14,800 29,600 44,400 11 Woven Geotextile 400,000 SF 0.10 40,000 =80,000 120,000 Thermal P 12 Maint Bldg Rigid Insulation 165,000 BF 1.00 165,000 16,500 181,500 13 Maint Bldg Flat Loop Thermo Syphon w/Hybrid Condensor 24 «EA 7,000 168,000 8,640 176,640 14 Water Tank Building Rigid Insulation 50,500 BF 1.00 50,500 5,050 55,550 15 Water Tank Bldg Thermo Syphon w/Hybrid Condensor 1S EA 7,000 105,000 5,400 110,400 Foundations [1,1 78,560]16 Maint.Bldg Slab on Grade w/Footings &Grade Beams 280 CY 1,000 280,000 30,240 310,240 17 Water Tank Building Slab on Grade w/Footings &Grade Beams 100 CY 1,000 100,000 10,800 110,800 18 Raw Water &Demineralized Water Tank Ringwalls 20 CY 1,000 20,000 2,160 22,160 19 Admin.Bidg.Thermo Helix-Piles (Incl.Installation)24 EA 7,100 170,400 13,440 183,840 20 Cooling Tower Thermo Helix-Piles (Incl,Installation)32.EA 7,100 227,200 17,920 245,120 21 Ash Silo Thermo Helix-Piles (Incl.Installation)4 EA 7,100 28,400 2,240 30,640 22 Housing Thermo Helix-Piles (Incl.Installation)36 EA 7,100 255,600 20,160 275,760 Tanks 23 Intermediate Fuel Tank (12,000 Gallon,Double Walled)2 EA 26,000 52,000 9,600 61,600 24 «|diate Tank Appur 2 LS 10,000 20,000 400 20,400 25 Raw Water Tank (700,000 Gallon,Steel,Erected)1 EA 252,000 252,000 34,539 286,539 26 Raw Water Tank Appurtenances 1 LS 10,000 10,000 200 10,200 27 Demineralized Water Tank (80,000 Gallon,Steel,Erected)1 EA 126,000 126,000 17,270 143,270 28 Demineralized Water Tank Appurtenances 1 Ls 10,000 10,000 200 10,200 Fuel &Raw Water Pipeli cocccssecevavsvcessenccecs {306,436] 29 Coated 4”Sch 40 Pipe 4,800 LF 60 288,000 10,358 298,358 30 4"Plug Valve 2 =&EA 1,750 3,500 38 3,538 31 4"Check Valve 2 EA 360 720 24 144 32 4"Gate Valve (Water Tanks)2 =+&EA 495 990 44 1,034 33 3°Bail Valve (Fuel Bypass)2 EA 400 800 20 820 34 Fill Limiting Valve 2 EA 965 1,930 12 1,942 Dock sesesentnsceicensneenentntstnvnsnieeepnpnennsnvessscensnsnsevnsnsctnsavnsugssnenesetniavncsinsseresseasnsegssensuse 35 Fuel Dock 400 LF 5,500 2,200,000 2,200,000 36 Marine Header Containment 1 Ls 7,500 7,500 1,000 8,500 37 Marine Header Assmbly EA 2,500 2,500 350 2,850 Security Fencing ......eesescooe {148,500] 38 Chain Link Fence 7,800 LF 15 117,000 23,400 140,400 39 Vehicle Gate 2 EA 4,000 8,000 100 8,100 Electrical ...secsesssessseesecssseans .[203,500] 40 Electrical Controls 1 SUM 100,000 100,000 1,000 101,000 41 Lighting &SUM 100,000 100000 2500 102,500 Sub-Total:11,246,046 Contingency @ 15%1,686,907 Overhead &Profit @ 5%$46,648 Bonding and Insurance @ 1.5%193,994 Barge Mounted Plant Option Total:13,773,594) BUDGET COST ESTIMATE Power Plant Feasibility Study MATERIAL UNIT MATL FREIGHT No.{TEM QTY UNITS COST TOTAL $0.20/1b TOTAL Mobilization/Demobilization .........0:000¢0000 aoe {100,000]t Mob/DeMob 1 SUM 100,000 100,000 100,000 Earthworks 2)Tank Farm Sand Fill 13,000 CY 15 195,000 195,000 3 Tank Farm Gravel Surface Course 8"1,500 CY 80 120,000 120,000 G il cvercecasccccoesssecoesesreccoscsscnacserecaceeceosvovesesocoasconseasseessseseccaasessoevenenseseeveccesecessoceronccsssconenoes 26,250 4 Tank Farm Non-Woven Geotextile 15,500 SF 0.10 1,550 3,100 4,650 5 Tank Farm Woven Geotextile 72,000 SF 0.10 7,200 14,400 21,600 Thermal Protection .......s.sccccccocscesencseesooesnsessonsceesceos sccvensosccsoreascccecaesasssscesosovsccccvcoeereverseecs {626,240] 6 Tank Farm Rigid Insulation 310,000 BF 1.00 310,000 31,000 341,000 7 Tank Farm Flat Loop Thermo Syphon w/Hybrid Condensor 30 EA 9,000 270,000 15,240 285,240 Secondary Containment ......c..csssocssesseressessessoassecsosscsecevassevessasaseceasseoacnscsseooecesseous veveseasvecesersesoucessasoeoesee . 8 Tank Farm Primary Liner 50,000 SF 4.00 200,000 10,000 210,000 Tank Foundations .....cccosszsccouscorsssesssonsvoncesonsnsocascesessocesessusessnvosnecoanssacunsasoncesssscasereneasonsossoasnecesanenes .-{____83,100] 9 Tank Farm (60'Dia)Foundations 75 cy 1,000 75,000 8,100 83,100 Tanks 1,384,836 10 Tank Farm (800,000 gal Insulated Tank,Erected)4 EA 260,000 1,040,000 72,000 1,112,000 11 Tank Coating 41,469 SF 3.84 159,372 664 160,036 12 Tank Catwalks 4 EA 15,000 60,000 12,000 72,000 13 Tank Farm Appurtenances 4 LS 10,000 40,000 800 40,800 Tank Farm Walkways ......2c2ccccs000 200000000000 {129,633] 14 Walkway Supports 20 EA 2,200 44,000 4,800 48,800 15 Steel Catwalk 250 LF 175 43,750 15,000 $8,750 16 Coating 5500 SF 4.00 22,000 88 22,088 Pipelines and Valves.[209,345] 17 Coated 4"Sch 40 Pipe 350 LF 60 21,000 755 21,755 18 Coated 2"Sch 40 Pipe 365 LF 15 5,475 266 5,741 19 4”Plug Valve 4 EA 1,750 7,000 296 7,296 20 4"Gate Valve 1 EA 1,255 1,255 62 1317 21 4"Check Valve 5 EA 360 1,800 275 2,075 22 3°Ball Valve 4 EA 400 1,600 40 1,640 23 2”Ball Valve 6 EA 200 1,200 20 1,220 24 Pipe Supports 320 EA 300 96,000 12,800 108,800 25 Pig Catcher 1 EA 7,000 7,000 2,500 9,500 26 Cathodic Protection 1 EA 50,000 50,000 50,000 Pumph Mect U Systems ...,..cccccacseeeesoeccouscesouoseocaecsoovoncesecese coe caccesseessoccocsess0csvcccseeoneeeesoccoccevesess 86,996 27 +4”Sch 40 Pipe 50 LF 60 3,000 286 3,286 28 4”Plug Valve 2 EA 1,750 3,500 38 3,538 29 4"Ball Valve 2 EA 550 1,100 30 1,130 30 6”Butterfly Valve 2 EA 700 1,400 60 1,460 3t 3"Sch 40 Pipe 50 LF 50 2,500 150 2,650 32 3”Ball Valve 2 EA 400 800 20 820 33 3°Check Valve 2 EA 350 700 12 112 34 30 hp Pumps (Fuel Transfer)2 EA 20,000 40,000 120 40,120 35.Filter/Separator 2 EA 10,000 20,000 40 20,040 36 Accumulators 2 EA 1,500 3,000 40 3,040 37 Misc Accessories it LS 10,000 10,000 200 10,200 Purmphouse Building ..........-.sssssessssssseesssesssossssssvesveveusvesssesssssssersssssesssseesscessueceseseseeseseeusceeseceesesssssssanssssssanssnsuunseveseess 38 20'x30'Building 600 SF 150 90,000 90,000 Dispensing Station.............cscvssssssccossrcssssesssvcccessstecsonscsenssnseansesscessecoaressaessnsensaatssoesacecucessecaessansessenessooroeecneseoercesnaesee 105,000 39 Containment Area 1 LS 65,000 65,000 65,000 40 Dispensing Pumps,Piping &Appurtenances 1 Ls 40,000 40,000 40,000 Sub-Total:3,366,404 Contingency @ 15%504,961 Overhead &Profit @ 5%193,568 Bonding and Insurance @ 1.5%58,070 4,123,004) 3 Mil Gal Fuel Tank Farm BUDGET COST ESTIMATE Power Plant Feasibility Study Bethel,Alaska MATERIAL UNIT MATL FREIGHT No.ITEM QTY UNITS COST TOTAL $0.20/lb TOTAL Earthworks .........cccsccccncncecesceneseccoeee eset nee eeneesee ene ne eens ee een eee ee nee nese eee ee eae nene sees sete eeee eee Ee GEO E PESO ES EE EA SEERE ESSE SE;RG SIDES GE EEDE EEE OceDsSESEeEES 1,420,000 1 Sand Fill 58,000 CY 15 870,000 870,000 2 Access Roads 2,500 LF 220 550,000 550,000 C00)(>.<0 |(ncoooceo 234,000 3 Module &Tank Pad Woven Geotextile 780,000 SF 0.10 78,000 156,000 234,000 Foundations..............c.0seeeeeeee SEPREEREEEEOOSECSOSOOOSESECOOOOOOOOSOOROOOOOOOOOOOOOOOOCOOOOOOOOOOOOSSOOOOOOOCOOOOOSOEOOOSOOSESSOOOOOOOSOOSOSSSOOOOOOOOCOOSESSSOOOOOOSIOOSS 4,187,500 4 Building -Driven 12"Steel Piling (Installed)110 EA 7,100.00 781,000 61,600 842,600 5 Conveyors -Driven 8"Steel Piling (Installed)70 EA 3,750.00 262,500 39,200 301,700 6 Stacker/Reclaimer -Thermo-Helix Piles 320 EA 7,100.00 2,272,000 179,200 2,451,200 7 40 HP Active Refrigeration System 4 EA 146,000.00 584,000 8,000 592,000 Electrical ..........ccccesececeeee eens ee ee ec eens eee ee ee eeeeee ee eee nese ee en enna en ee en eee e eee Ae eG EEE EEE EE DS EGEEEOEOEDEOSEEEED RS EE SE DESE ED EG EOFS OEE EE SSEEESESEE ESSE SEED EC CREASE EOE EEES |105,000] 8 Lighting 1 SUM 100,000 100000 5000 105,000 Sub-Total:5,946,500 Unlined Coal Storage Contingency @ Overhead &Profit @ Bonding and Insurance @ 15%891,975 5%341,924 1.5%102,577 Total:7,282,976} BUDGET COST ESTIMATE Power Plant Feasibility Study Bethel,Alaska MATERIAL UNIT MATL FREIGHT No.ITEM QTY UNITS COST TOTAL $0.20/Ib TOTAL Earthworks .........csc0ccocccconcseesesscncssesetecsnsacsaeeeeeneeeeseneeneeeensesesseeesseensteneetensesencenceceetseeeseesentensnetectssteesccuaensscessecsetsesessouseccecouseecs 1,420,000 1 Sand Fill 58,000 CY 15 870,000 870,000 2 Access Roads 2,500 LF 220 $50,000 550,000 Geotextile..........cccccceeesee soc t eet eenonne ee ee ee eee ee ee eee ee et ee neat en De MGA O OES eH EE SE DEO EEO OA ES EGER DEES EE ESE OEE EEEO EE REEOR EEG SEES EEO;DEEEEEEES EEG ESEEEGEG ES EGEGES DESEO EES 234,000 3 Woven Geotextile 780,000 SF 0.10 78,000 156,000 234,000 Pre Thaw Permaffrost.............cc02ccecceeseeeseeeeeseeseeeeeseessceeneeeeseeseeseeseeseaseussnsssseseseneeeeseeseDeeeeneeseuebeenbeeeeoeeeeesaeeeeeeeeeoseesesccesarouorneenes 4 Thaw Pipes 7,000 EA 500.00 3,500,000 70,000 3,570,000 5 Pumps,Piping and Appurtenances 1,000,000 LS 1 1,000,000 1,000,000 Foundations.............0c2cececenececcencececeeeeeeececeeeneeeeeeasesentsseeseeeGeeeesesesaseeeereseteeeasesesesentsenseneneaeseeseceeseeacesnsecacenseeeeseeeneesvaccoeenseess 3,249,500 6 Building -Driven 12"Steel Piling (Installed)EA 7,100.00 781,000 61,600 842,600 7 Conveyor -Driven 8"Steel Piling (Installed)EA 3,750.00 262,500 39,200 301,700 8 Stacker/Reclaimer Concrete Footings 1,900 CY 1,000 1,900,000 205,200 2,105,200 Secondary Containment ..............0.cseeceeecececeoenenseceeeseneeeeeeseensessatneeeeeeeneaeeseenseeeaeaeeeesnsetectasesenensaenseroneceeseeteresensnrtecessoverteccocouses 3,276,000 9 Primary Liner 780,000 SF 4.00 3,120,000 156,000 3,276,000 Electrical ...............cccescccscceee cc eeocse et eeeeecee renee ecteetneeeeene ee eeneeeeneeeeeeeeneeec ease eeecneeeeneeeasesereneesesssestsscosaecegeseeteteserrerstecesoctsoroseossens 105,000 10 Lighting 1 SUM 100,000 100000 5000 105,000 Sub-Total:12,854,500 Contingency @ 15%1,928,175 Overhead &Profit @ 5%739,134 Bonding and Insurance @ 1.5%221,740 |Total:15,743,549] Lined Coal Storage w Prethaw BUDGET COST ESTIMATE Power Plant Feasibility Study Bethel,Alaska MATERIAL °UNIT MATL FREIGHT No.ITEM QTY UNITS COST TOTAL $0.20/Ib TOTAL Earthworks .......cc.sccccccssecccseoscesesocessc5¢000sG0acoccasecevcgcedessesaeeGonaeeOoeROESaOSESEenoRODOeSORSSENSEDESEOOSDDCSESEDCEoaOGSEEEabeeeeuaessGeroesesousocsocecesoeeesees 396,000 1 Access Roads 1,800 LF 220 396,000 396,000 Cooling,Lake System................ccsccsccsscsccscosscsscnsccsssocssccoseecesscsecseunsccocessccesesccscssseesesocscccssceacsenasasencescgosesesecassepeasaaeacsoeessoscecseveoses 3,900,720 2 48°OLD.Pipe (Installed)7,150 LF 200 1,430,000 360,360 1,790,360 3 Pipe Supports (60'Centers)130 EA 7,800 1,014,000 83,200 1,097,200 4 48"Gate Valve 3.EA 120,000 360,000 4,500 364,500 5 Building (16 x 20)320 SF 150 48,000 4,800 52,800 6 Driven 8"Steel Piling for Building (Installed)6 EA 3,750.00 22,500 3,360 25,860 7 1000 HP,55,000 GPM Pump 2 EA 225,000 450,000 20,000 470,000 8 Misc Accessories 1 LS 50,000 50,000 50,000 9 Discharge Structure 1 LS 25,000 25,000 25,000 10 Intake Structure 1 LS 25,000 25,000 25,000 Security Fencing ..........ccsccscssesseeeccsoccccvsescsscsscsocecrsscceccscasccccssssoeseeassuevesssessanoesecsusssdssacecssoasesescaeocsacusonseeecescrsccesaesssceseseseccescocses 157,100 11 Chain Link Fence 8,500 LF 15 127,500 25,500 153,000 12 Vehicle Gate 1 EA 4,000 4,000 100 4,100 Electrical .......c.ccecsscescosscsnssvcnesuseuscesaccosssoncoscucsssucouccasscoususesseasaccossstucsassucascucovesceaccsasssasnecsessssasnasassussusassnsassuseusnsessiesesseesesceces 13 Electrical Controls 1 LS 100,000 100,000 1,000 101,000 14 Lighting 1 LS 50,000 50000 2500 52,500 Delete Cooling Tower .........0.ccsssesscsccosoeecoesocsusvcsesecscsecccccescsccssseeccvcesssoceeusosecesceuscseabonseeousousanccoacarecseanecaaeaccasccoseccesonecesecsecsceeees 15 Cooling Tower Thermo Helix-Piles -32 +EA 7,100 -227,200 -_-17,920 -245,120 Sub-Total:4,362,200 Contingency @ 15%654,330 Overhead &Profit @ 5%250,827 Bonding and Insurance @ 1.5%75,248 |Total:5,342,604] Cooling Lake Option BUDGET COST ESTIMATE Power Plant Feasibility Study Bethel,Alaska MATERIAL UNIT MATL FREIGHT No.ITEM QTY UNITS COST TOTAL $0.20/Ib TOTAL Earthworks .........0.ccececeeceneccecenencecseneneeeeneeaenenseeeeeeeeeeeeaseseeeneeeeeenseseneeeceasecenseeeaseneneseeasenesssnsensusersnseseueseenetereeeessectseectscogseseers 2,500,000 1 Sand Fill 130,000 CY 15 1,950,000 1,950,000 2 Access Road 2,500 LF 220 550,000 550,000 Geotextile.occ ce cece ccc c eee eceneeecee seen ee ecee eee eens seen teen seen eeeeeen ee eG Sees Sees see eG en ee eas ea eee eseaee seen eeeeenseseseseeeneneaeesenueasseusesensaensoesesoseeeses 234,000 3 Woven Geotextile 780,000 SF 0.10 78,000 156,000 234,000 Thermal Protection ............ccececenereseeee ec eeee ence scene eeeneeeeeneesee sees been es eases een nesses es ee eases snes eG eeeteeesensesassceneescessseseasasevacaeeseaeesesusncrsenears 6,302,400 4 Rigid Insulation (4 inches thick)3,120,000 BF 1.00 3,120,000 312,000 3,432,000 5 Flat Loop Thermo Syphon w/Hybrid Condensor 390 EA 7,000 2,730,000 140,400 2,870,400 Foundations.............cccccccceneceeneeerencceneneeeeereeeeeeeeeeeeeaseeneeeeeeesseesasscooeeeeneeteeesenseeeeseseneusueneeestenessuesseucesensueseneusontaeusaersenecensscuees 6 Building -Thertno Helix-Pile w/Hybrid Condensor (Installed)110 EA 7,100.00 781,000 61,600 842,600 7 Conveyor -Driven 8'Piles (Installed)70 EA 3,750.00 262,500 30,800 293,300 8 Stacker/Reclaimer Concrete Footings 1,900 CY 1,000 1,900,000 205,200 2,105,200 Secondary Containment ...........ccscecasccnccveececscenereteeeeenseteecesesseenesesseccneeeeeeeseaeaeneneeteenensesuesessusenessnsasnssessesececenesectaesneeseasaveensuseses 3,276,000 9 Primary Liner 780,000 SF 4.00 3,120,000 156,000 3,276,000 Electrical ......0..c0.ccccscssecoccessesseaseecscsscassusecsssesecssccsssaceaevsaeusceeesvassereseensessecceseseecesscacssvscessasssesevavasesvisessacerscervateesstesteccacaeeed 105,000 10 Lighting 1 SUM 100,000 100000 5000 105,000 Sub-Total:15,658,500 Contingency @ 15%2,348,775 Overhead &Profit @ 5%900,364 Bonding and Insurance @ 1.5%270,109 {Total:19,177,748] Lined Coal Storage w P-Frost IVIGIUULL LCL UaUOUAL,LIC,-SNIP DIOKeIs of iviarine Consultants Page 1 of 2 Marcon International,Inc.For Sale News &Articles ;Newsletters |Market Reports |Sales Reports |Library :About Marcon ;Home For Sale >Vessels for Sale e@ Barges for Sale @ Vessel/Barge Inquiry Charters New Construction All Listings List Your Vessel Get Tow Quote Search for a Vessel or Barge by file number. Enter file No. Go| http://www.marcon.com/main/marcon_st2.cfm?StoryID=203&Detail=1 &File=TG30113 Last Update:03-Mar-03VesselSpecifications ©Print Friendly Page Available for:[Xicontact Us Sale File No.TG30113 Tug -Twin Screw Flag:US. Built:1966 -Rebuilt:1990Builder:McDermott S/YPrice/Rate:$1,770,000.00 Inspection:U.S.Southeast Delivery: Dimensions LOA:105.0 ft. Beam:28.0 ft. Depth:12.0 ft. Draft:9.0 ft.light Dwt:Lt.Disp:G/NRT:144.0 /98.0 Classification none Length (Reg):97.1 ft. 11.0 ft.loaded Capacities Deck Cargo: ClearDeck:98 Hold Cap No.Holds: Hatch Sizes: No.Hatches: FO:48000g FW:1400g DW: Liq Mud: Deck Machinery Windlass: Anchors:1-300# Chain/Wire:/ Crane: Derrick: Winch: LO:1400g BW:4000g Dry Bulk: Brine/CaCl: Markey TDSD28 Double Drum/GM6-71 powered 125,000#Wire:2000 ft of 2" cable &1800'x 2" Stern roller:Y Linepull: No Image Available Navigation /Communications Gyro:Y A/P:Y Radar:Y DF: SSB:2 VHF:2 Satcom:GMDSS: GPS:Y Loran:Y Fathometer: Steering:Elec.hydraulic Accommodations Quarters:8 berths in 5 cabins Passengers: AirCond:Y Galley:Y Walk-in Cooler/Freezer:Y Propulsion Engines:2 x EMD12-645E2 complete overhaul of M/E's in 2000 567 blocks w/654 power packs BHP:3000 Gears:Falk 3:1/RMS-1443 Shafts:9" Props:4 blade SS 86"x64" Korts: Speed:11/12kn Consumption:2350/3450gpd Bowthruster:Thrust: Bollard Pull:33it Aux.Machinery Pumps: Generators:2-75KW/GM6-71 Firefighting: Aux: Remarks:Keel coolers.Converted from single screw tug in '90.567 blocks with 645 power packs.Suitable for docking or offshore towing.Main engines &gens rebuilt 2000.Try offers. Keen seller. &Printer Friendly Page aaa Contact Us Details believed to be correct,but without guarantee.Offered subject to availability. 9/4/2003 IVLALUUL UMCIUAUUMAL,WIC.-SNIP DIOKCIS &IvlaTINe CONSUITants Page |of| Marcon International,Inc.For Sale News &Articles ;Newsletters ;Market Reports ;Sales Reports |Library |About Marcon ;Home For Sale Vessels for Sale >Barges for Sale ¢Vessel/Barge Inquiry Charters New Construction All Listings List Your Vessel Get Tow Quote Search for a Vessel or Barge by file number. Enter file No. [G9] All Listings |For Sale Listings |Charters Last Update:14-May-03BargeSpecifications EE)Prin Friendly Page Available for:PJContact Us - Sale More Information File No.DB40020 Deck Barge -Ocean Flag:US. Built:1975 Rebuilt: Builder:Bethlehem Steel Corp. Price/Rate:On Request Inspection:U.S.Southeast Delivery: Dimensions LOA:400.1 ft.Length (Reg): Beam:99.6 ft. Depth: Draft:3.8 ft.light Dut:12500.0 Lt.Disp:3150.0 mt. G/NRT:6642.0 /6642.0 Classification ABS +A1.Loadline valid til 2/2000 with annual/drydocking due. Deck Machinery Windlass: Anchors: Chain/Wire:/ Winch: Crane: Capacities Deck Cargo:12500T ClearDeck: Deck Strength: Hold Cap No.Holds: Hatch Sizes: No.Hatches: FO: BW: BBL: WT Comp: Plate: FW: Coiled: No.Tanks: Bulkheads:8 trans'v Rakes:Ship bow/rakes stern Aux.Machinery Pumps: Generators: Remarks:Marcon exclusive broker.Drydocking over due 1/99.Last in-water "docking"9/96. Last out-water last docking 1/94.Requires steel renewals to bow rake plate and internals in tanks 1 &2.Worked 10/98.Internal wastage. &Printer Friendly Page 4 Contact Us More Information Details believed to be correct,but without guarantee.Offered subject to availability. (Atop of Page New Construction :List Your Vessel :News &Articles |Newsletters : http://www.marcon.com/main/marcon_st2.cfm?StoryID=204&Detail=1&File=DB40020 Market Reports |Sales Reports |Library |About Marcon |Home Marcon International,Inc.P.O.Box 1170,9 NW Front Street,Coupeville,WA 98239 USA Phone:360-678-8880 |Fax:360-678-8890 9/11/2003 Babcock &Wilcox -xsCael'M: tana £2 enh,Bw eT Fiatereatewee 5 « }otldwide iss ;jerates Complete Power:Dperates Complete Powel itfaqOd>. iy keSince 1867;Babcock &Wilcox (Be)coat en ange'has been engineering,manufacturing JAG"a "seme ke Sta ageFaridstipplying.innovative technologytohelppowergenerationplantsaga=s be reoperatemoreefficiently and reliably.-BaW PowerSystemis has built on this>iat”mt oC Ce,arefexperienceandknowledgetobecome iynochMieoem=5faprojectdeveloper,owner,full-service'a Te We °vme ata Bon se Bk a URESWEAi:contractor,an;and operator of |poweraeide:aecoeMESTENeRSEBaW!Power.Systems goes beyondaonecysMraetytPeeee'the ttraditional itivelcag concept by::eh?es tne TE AT:Mig FAT atetja.providing fullscopeproducts andServicesatcompetitiveglobal3 Seopamarket ba eea odanaenk re2etppricesasalen£10 ertdevelo Sh ETL Ressesua etekEngineering:procurement and'FatconstructionLEPC)contracting. The B&W Advantage © ®Major international player - 290,000 megawatts of experience in 85 countries =Worldwide manufacturing facilities and joint venture licensees #Global sales and agents coverage =One-stop shopping for co-development,equity,EPC, O&M and asset management «Long-term owner and partner «Ability to structure projects to attract export credit agency support «Total-scope service capabilities - from parts supply to turnkey construction =Engineering excellence - innovative,cost-effective solutions "State-of-the-art research and development facilities B&W is a Developer BaW Power Systems has a proven track record of developing successful projects,including the setup and management of efficient fuel sourcing and mining operations.Backed by our extensive experience and flexibility,we fulfill diverse project requirements - from development and partnering to EPC contracting and plant operations. B&W is a Partner,Owner and Asset Manager Our partnering philosophy is simple: to maximize project returns by selecting partners with congruent goals and structuring the project to meet those goals.We believe in maintaining a long-term ownership presence in our projects,as opposed to selling our ownership position when construction is complete. This philosophy enhances the long-term economic performance of a project and encourages a commitment to: #Continuous and innovative improvements =Project excellence and quality through long-term ownership and management B&Wis a Builder BaW's full-scope engineering, procurement and construction services,combined with our many inter- national joint venture and manufacturing facilities,make us a very cost-effective global partner. As a builder with proven international business and labor relations experience,B&W offers: ®Tailored project solutions «Engineering and technology expertise . ®High-quality,on-schedule construction «Dedicated project management Baw is an Operator BaW Power Systems has extensive operating experience burning difficult fuels,while simultaneously achieving profitability,high plant availability and reliability,and meeting strict compliance with safety and environmental goals.This is accomplished through: «Sound management practices =A trained and experienced staff ®Setting high safety and environmental standards and practices a Integrated systems =Ongoing research and development In addition to this 1,600-megawatt pulverized coal-and oil-fired facility in Indonesia,BaW is involved with projects in:Australia;the Czech Republic;Egypt; India;Mexico;the Middle East;North, South and Central America;Pakistan; the People's Republic of China;Poland;Russia;the United Kingdom;and Taiwan. 3 Shaeehra Construction «.Lo anv: pte ge tab a ,Bal understandsthe many elements';that must be pulled tagether before iataprojectbegins.As a result,we forn;the right team to complement project <+&,oat )Project Development Expertise -The Key to Successful Projects In bringing our capabilities to power projects worldwide,Babcock &Wilcox fulfills a vital role:that of an experi- enced developer.Our goal is to create financeable,technically feasible and economically viable projects. BaW Power Systems has the resources and expertise to assure a project's success,from conception through its entire operating life.We can tailor solutions to specific project needs and objectives by offering these flexible project approaches: ®Build,own,operate «Partnering s Engineer,procure,construct ®Refurbishment =Repowering ASRiy seFe Multi-Skilled Development Team The BaW Power Systems team consists of highly skilled business development managers,qualified engineers, knowledgeable project analysts and experienced plant managers.Our team is experienced in complying with international environmental requirements,working with labor and O&M practices unique to a country, and is backed by our extensive legal and financing resources. Experienced ProjectDevelopmentOrganization BaW's experienced project development organization has the necessary insight and knowledge to recognize the many developmental and operational factors that can impact operating revenues. Identifying potential problems and risks early in the development process minimizes costly changes later in the project,and allows for a timely and efficient development schedule. To further ensure success,B&W addresses the following development issues at the onset of a project: «Technical feasibility,screening and due diligence «Structure and negotiation of all operative agreements -power, fuel,EPC,O&M ®Ownership structure ®In-depth pro forma financial projections =Cost estimates for construction and O&M ®Project financing =Fuel procurement,mining and management =Regulatory and international issues «Environmental permitting and compliance BaW developed and operates the cogeneration facility (left)in Ebensburg,Pennsylvania,and main- tains a 50 percent ownership position. BaW also developed and operates the Revioc reclamation operation (above), which provides a reliable supply of low-cost,quality fuel to the Ebensburg cogeneration facility while improving the environment. Ownership Through PartneringSpells Success Babcock &Wilcox knows that in today's world of power generation,it's difficult to go it alone. BaW Power Systems strives to structure relationships based on commonality of interests.We constantly work toward improving the project'sperformanceinthemostcost-effective manner.Additionally,Power Systems can design a financial package and ownership structure tailored to each individual project. B&W's Partnering Benefits As a partner,B&W brings many benefits to a project: «Financial and project accounting expertise =Asset management =Plant operating and maintenance Management experience s Global procurement organization ®International manufacturing facilities -allowing more financing alternatives Revitalizing problem projects is possible with BaW's engineering expertise and extensive plant oper- ating experience with difficult fuels. Bankable Partnerships With single-point responsibility, BaW can provide lenders with the added comfort of conducting seamless transactions with a financially strong company.B&W also is able to draw upon the extensive technical and financial resources of its parent company,McDermott International,Inc. _B&W's Approach B&W's partnership approach offers: "An overall reduced project schedule and cost «Compatibility with off-balance sheet financing ot.ge. =Active customer/partner involvement =Benefits from BaW's OEM expertise =A good citizen commitment As a partner and operator of this facility in West Enfield,Maine,BaW employed its circulating fluidized-bed technology to efficiently burn biomass for power production. te Soyer eeryldsamas:ANODELetetix"LeharesaT hte bikaeapeseeeasectEp ke:pee *")aa be : ;*by.; 5 ae SeTAT nate.::Engineering,A Consirucign,Coonstruction ; oe echacme 22!ape:SL eeueRenaTaeProjec:--phenteshe2"Proposeanger 8 a .ER ae TRS |"B.i=e Mase Re'ECProcurement Manager ., Pete ae Rene Beseler'sieeecagpoe e has the background"and experience to,#!Y achieve the goals of =eee aWier«the partnership and Beestheproject."gs3e% Building Complete Power Plants Worldwide EPC Capabilities As a leading designer,manufacturer and erector of steam generating equip- ment and systems,Babcock &Wilcox is familiar with all the equipment and components required to build, upgrade or repower a facility.Asalong-term owner and operator,B&W has a vested interest in ensuring the successful execution of the EPC contract. As a worldwide EPC contractor,BaW is experienced in preparing financeable project packages based on price, performance and delivery.Our projects are enhanced further by our various support services: =Project management "Project scope definition,planning and scheduling =Conceptual design §Detailed engineering «Global procurement and manufacturing UX}Ra"Pretewhii=Permitting and environmental compliance «Construction management =Start-up,performance testing and commissioning International Operations Today's power generation products and projects require advanced engineering and manufacturing capabilities,as well as proven international experience and continuous research programs. To meet these demands,B&W has: =11 manufacturing facilities located in seven countries - all ASME code approved =Two dedicated research and development facilities =International licensees ®Joint venture products exported worldwide ®Stringent quality assurance control procedures and requirements .r+e © LA Sb Ree * et Beal's engineering expertise,global procurement resources,construction capabilities and financial know-how provide the foundation needed to successfully design and build power plants worldwide. BaW is a leading single-source supplier of field construction,main- tenance services and construction management. BsW's manufacturing and distribution facilities,located in seven countries, support our global procurement resources.Pictured here is BsW's manufacturing plant in Beijing,People's Republic of China. i hges ©egy 5.obot nite5aDfoBENvasTe GaatanTee eT ip tqe =i £38BOher5&YUE +bs 'Padhin J is -: wee,Wwe &SR 236 bh EO.DP bh Oe Se eS eee t 7 £4 : La ey pugeda4[otiehOOMR|OMS.LFhoenytAtag r tidy.Ag coma oe og ete oT OT ee esl bts -ee Operations:Safety,Environmental Compliance,High Availability and Profitability Babcock &Wilcox's full-scope operation and maintenance services maximize plant availability and profitability while maintaining outstanding safety and environmental compliance records.We have extensive operating experience with power plants utilizing difficult fuels,and the capability to revitalize problem projects.This,coupled with B&aW's reputation for quality performance and engineering excellence,uniquely qualifies us for operating any plant, including distressed or at-risk ventures. Our operating procedures include: «Extensive technical,financial and environmental auditing «A self-directed management approach with key support from the home office PptBaW's O&M staff works together with the owner to produce positive and profitable results through reliable performance,high availability,and continuous plant and process improvements. Staffing and Trainin$Expertise BaW knows that people are the founda- tion of any exceptional O&M program. Therefore,we offer an experienced core group of operating personnel who are cross trained at all staffing levels. Comprehensive training and start-up services also are provided so the staff is fully capable of operating a plant when it achieves commercial operation. Maintenance Management_Maximizes Plant Efficiency BaW designs custom maintenance programs to maximize availability while optimizing equipment life. To further enhance a maintenance Management system,B&aWusesa - computer-controlled parts inventory and procurement program to reduce man-hours and maintain properinventorylevels. Prior to start-up,B&W conducts site-specific classroom training,hands-on equipment training and walkdowns of the plant's systems.Vendor-assisted training also is used when needed. From concept through long-term operation,B&W economically and efficiently coordinates the optimal resources -equipment,services and personnel - to meet your needs.B&W Power Systems operates this 60-megawatt refuse-to-energy project in West Palm Beach,Florida,under a 21-year contract. 10 eae REL TSE eeaearedevelopers,we are patareoneBeWPowerS}4 aE ei To etesiccessfulenergy0"Whenyouneedaoewrtgn”to Babcock &Wilcox PowerSystems:fates Lele», Peer ra 's ; osiad(Through'barmaork'and innovation:aiand through building zie,SE omnes intoall our projects and processes,BaWis¥'tSmae7committedtamaintainingourglobal'technology leadership A¥i375andachievingthefighest|level of customer Satisfaction.phan Xesg ,a!Ne ee! _For more information,or a complete listing ofoursalesandserviceofficesworldwide,call 1-800-BABCOCK (222-2625)in North America. Outside North America,call (330)753-4511 or fax (330)860-1886 (Barberton,Ohio,USA). Canada: Cambridge,Ontario Edmonton,Alberta Halifax (Dartmouth),Nova Scotia Montreal,Quebec Saint John,New Brunswick Vancouver (Richmond),British Columbia Czech Republic:Praque Egypt:Cairo” England:London India:Pune Indonesia:Jakarta Mexico:Mexico City People's Republic of China:Beijing Poland:Warsaw Russia:Moscow Taiwan:Taipei Turkey:Ankara United States of America: Atlanta,Georgia Charlotte,North Carolina Cherry Hill,New Jersey Chicago (Downers Grove),Illinois Cincinnati,Ohio Denver (Sheridan),Colorado Houston,Texas Kansas City,Missouri San Francisco (Vacaville),California Powering the World Through Teamwork and Innovation” The information contained herein is provided for general information purposes only and is not intended or to be construed as a warranty,an offer,or any representation of contractual or other legal responsibility. ©The Babcock &Wilcox Company.All rights reserved. Powering the World Through Teamwork and InnovationisaservicemarkofTheBabcock&Wilcox Company. E101-3151 4MD6G In all tié-world,thereis;mr only-one Babcock &:Wi Cet tne '2Theatatoedwadsal ayy 8 eet mw y Tis ;we ; 7:Ereriwekes A Complete Range ofServicesfromOneSource Babcock &Wilcox Construction Co.,Inc.(BWCC)Construction Expertise Known for our extensiveboilerconstructionexperi- ence,BWCC provides total construction services including the entire balance of plant.From environmen- tal projects,such as flue gas scrubbers or selective cat- alytic reduction systems,to complex coal gasification projects;from foundations and structural through _ piping and instrumentation, BWCC delivers quality pro- jects on time and on budget with the safe performance you require from a construc- tion contractor.This includes: is a single-source supplier of a full range of field construction,construction management and main- fenance services.With more than 130 years of experience,we operate regional offices to serve customers anywhere in the United States.BWCC provides a qualified management team,skilled craftsmen and complete support fo assure the safe «Planning and scheduling «Proven safety programs *Dedicated project management *+©Prompt estimating and proposal preparation «Responsive site manage- ment and field engineering #Automated project control systems =Established quality control programs success of your construction or maintenance project. A Babcock &Wilcox Construction Co.,Inc.is a single-source supplieroffieldconstruction, maintenance services and construction man- agement for diverseindustries,projectscopesandsizes. =Experienced procure- ment,transportation and materfal control systems =Proactive labor relations and management *Constructability reviews =Rigging and heavy lift engineering and design "Quality assurance Servicing Today's Industries As an integral part of Babcock &Wilcox (B&W) and McDermott,Inc.(parent company of B&W),BWCC understands and services the energy construction and maintenance needs of major industries,including: §Utilities =Pulp &Paper =Cogeneration =Independent Power Producers =Refineries =Chemical/Petrochemical "Waste-to-Energy =Primary Metals =General Industry asym Environmental UpgradesCapabilities Environmental equipment upgrades (and new con- struction)will help you comply with today's stringent environmental requirements while increasing plant effi- ciency.BWCC's capabilities in this area include: ®Selective Catalytic Reduction (SCR)systems and upgrades =Low NO,burner installa- tion and pressure part replacement #Flue Gas Desulfurization (FGD)systems and upgrades ®Low odor conversions ia ae Sect]|«This limestone FGDconversionforawestern utility is being designed_and constructed throughateamingarrangement. A Modularized FGD 'scrubber being set in place at a1300-megawatt facility. 4 BWCC helps itscustomersmeet today'sstringentenvironmental requirements,Here,an SCR system for NOxcontrolisbeingliftedintoplace. + ni'LLeeanx.Opportunities Through.Teaming and Alliances BWCC is an industry leader in taking a teaming approach to major construction projectsandmaintenancecontracts. * "Teaming offers many oppor-tunities for improved quality and cost-effectiveness while developing an atmosphere much more conducive to innovation,teamwork,trust and commitment,With more than $350 million in completed teaming projects and more than a century in the industry,BWCC is a company you can trust to manage and execute all facets of your project. Based on past and current experiences with teaming arrangements,proven«benefits have included: «Improved cost,quality and scheduling «Reduced overhead =Continuous improvements a Shared risks and reward Through a teamingarrangementwiththismidwesterncustomer,, BWCC is providing SCRandairheaterreplace-ment utilizing largederricksonthefacility'sroofforcomponentplacement. > Plant Maintenance BWCC has maintenance ex- perience with major utilities and refineries worldwide. Through maintenance contracts,BWCC provides the supervision,equipment and labor to supplement customers'in-house mainte- nance programs.Our goal is to increase productivity and reduce overall maintenance costs for our customers while offering comprehen- sive services covering emergency,outage and non-emergency maintenance activities.We provide these services with the planning, quality and safety our cus- tomers expect. MillCare™Pulverizer Services Reliable coal pulverizer per- formance is essential for sustained full-load opera- tion of your plant.We offer the MillCare™program to handle your requirements, including inspection,inven- tory management,wear part replacement and component rebuilding. yN Pulverizer maintenance services can minimize your costs associatedwithdowntime,invento- ries,workforce utilization, equipment investmentandrecordkeeping. sistanibPHeBalbigbsBinal,Edyeopis35.phan,EYCogeneration andCombined-Cycle Experience BWCC's broad capabilities =Gas turbines are exemplified by our «Heat-recovery steamexperienceintheconstruc-generatorstionofcogenerationand«Associated steamcombined-cycle facilities.turbinesFromgreenfieldinstalla- tions to existing systems upgrades,BWCC has exten- sive experience installing:ekPretoVea, BER SEaeeereekaPeSort Complete installation oftwelve(12)85-megawattgasturbinesataformernuclearsiteconvertedto a large cogenerationplant. v Cata>eaten 'gewePypeeiSibnlHeelLeerrs-aarBWCC's experience inthecogenerationmarketincludesheat-recoverysteamgeneratorsandcombined-cycle facilities. 4 i oe:ens Fweoat at wWeuePs akNormans cneerip rine:rs ND sk High-Quality Standards,Innovative Solutions Scheduling Project planners and sched- ulers use the work breakdown and activity durations devel- oped in detailed planning sessions to design project schedules,This can be in bar chart form or a CPM network depending on the project complexity and the needs of our customers. BWCC utilizes Primavera Project Planner®,P3®and CueaTral Deniact Manager™WME AAO Se ard © These systems provide flexibility and speed for planning and scheduling and has the capability to produce the necessary status reports and graphs. Quality Assurance BWCC's Quality Assurance (QA)staff is an integral part of the construction management team.Our QA professionals are involved in every aspect of a project, from specification review through construction and start-up.This not only provides a superior product, but minimizes costly delays and expenses on a project. We are certified to [SO 9001,and hold ASME A (A-001),S,U and PP,aswellasNBICR(R-1) certificates of authorization. Labor Management BWCC is a union contractor operating under several agreements with a long and successful history of effec- tive labor relations with the building trade unions.BWCC is signatory to the National Maintenance Agreement. Support Network BWCC has regional sales and construction offices strategically located throughout the United States,Residing at these offices are regional con- struction managers and... sales personnel responsible. for developing projects and serving your needs, Dedicated Project Management BWCC's resourceful and flexible management capa- bilities allow for tailored and creative project solu- tions,as well as innovative construction techniques and designs.Directed by a dedi-- cated team of experienced site managers,engineers and project administrators, we provide consistent leadership and the varie disciplines necessary for any construction project. Let BWCC demonstrate how we can provide you with innovative,high-quality and cost-competitive construction and both long-term and short-term maintenance solutions. Rigging/Heavy Lift Engineering and Design BWCC provides project- specific rigging,heavy lift engineering and design services for field operations through our Construction Technology Group.The group's mission is to provide technical direction in the preparation of proposals and execution of contracts, with the goals of reducing cost of field operations, minimizing project time span,constructing a quality product and providing a safe working environment.The services provided also include construction plan- ning,product configuration and constructability reviews, Safety Program The management of BWCC is committed to safety as a guiding business principle. We have adopted Target Zero as a vision for continu- ous safety improvement. Target Zero means that over time,BWCC will strive to perform all work activities on all construction projects free of accidents.Manage- ment believes this vision is attainable.The guiding principles to achieve this vision are: s All accidents are preventable. a Preventing injuries is morally right and is good business. METAS SCURRY Cas =Safety is a management responsibility. «Management has a responsibility to train employees to work safely, =Personnel can be reason- ably safeguarded against construction hazards, =Working safely is a condition of employment.PatNaepeniw4oe:4frTe?SA As an example ofBWCC's goal of reducingprojectspan,this boilerforanorthwesternpulpandpapercompanywasground-assembled in two major sub-assem- blies:the furnace box as one assembly andthesteamdrumswith generator tubes anddowncomersasanother. The two systems wereliftedinteplaceonsuccessivedays,significantly reducingconstructiontime. BWCC Is headquartered in Barberton, Ohio.Let us demonstrate how we can provide innovative,high-quality,safe and cost-competitive solutions for your construction needs. Babcock &Wilcox Construction Co.,Inc. 90 East Tuscarawas Avenue .Barberton,Ohio 44203 Phone:(330)753-4511 Fax:(330)860-6248 For more information,or a complete listing of our sales and service offices worldwide, call 1-800-BABCOCK (222-2625)in North America.Outside North America,call (330) 753-4511 or fax (330)860-1886 (Barberton, Ohio,USA),Or access our Web site at http://Awww.babcock.com. Regional Sales Offices: Atlanta,Georgia Barberton,Ohio Charlotte,North Carolina Chicago (Downers Grove),Illinois Cincinnati,Ohio Dallas,Texas Denver (Sheridan),Colorado Fairfield,New Jersey Houston,Texas Kansas City,Missouri Mt.Holly,New Jersey Pittsburgh,Pennsylvania San Francisco (Napa),California St.Petersburg,Florida The je ined hereinis ded for general information purposes only and is notortobeaaty,an offer,or any representationofcontractualorotherlegalresponsubiity. MiCare is a service mark of The Babcock &Wilcox Company.Primavera Project Planner andP3areregisteredtrademarksandSureTrakProject4isaofPriSystems,inc. ©1998 8:&Wiicox Cor ion Ca.,Inc.All rights reserved. E101-3174 SMD8I a NS heya3 2S ae _* ine towerpak Doler Teatures &lal lUTN ace woth proviugs a uiiy yaspathandpositivecirculationinallgeneratingtubes.This configurationenablescompletecombustionandtotalburnoutofsolidfuelparticles. Emissions and furnace exit temperatures are lowered.Reduction toa minimum of sotid fuel carryover protects the generating bank fram pluggage and erosion.End result:higher thermal efficiency. By increasing the length of the tubes,not the length of the drum ornumberoftubes,we improved performance and reduced additional! machining and assembly complexities.Well-defined downcomers in thesecondgaspassrunthebank's full width.Circulating water doesn't have to run the length of the drum to reach the downcomers,eliminatingpossibledrumlevelgradients.The positive circulating head increases velocities which avoids the risk of stagnation in the generating tubes. All six sides of the furnace are water cooled.offering a heat absorbingsurfacethatminimizestheneedforrefractory.Maintenance costs are kept law.: B&W's membrane wall design withstands high furnace pressures, making casing repairs a thing of the past.Uniform wall temperatures end thermal expansion/contraction problems.On smalier units tangent. tubewall construction with seal-welded,ten-gauge skin casing is available as an option. Versatility -the Towerpak can turn virtually any fuel into productive steam The Towerpak's capacity to efficiently burn unconventional fuels i¢ particularly attractive as gas and oil prices continue to escalate.Hogged tuel,sander dust,wood shavings,bagasse,coffee grounds -all can be burned alone or in combination with equal facility. Towerpak boilers can be equipped to introduce solid fuels to the furnace by a wide variety of methods -Dutch Oven,air-swept wood spouts,screwfeeder,travelling or vibrating grate stoker.The most preferable method of feeding hogged fuel to the furnace is via an under- floor screw conveyor.Its quiescent fuel entry eliminates suspension burning,reduces carryover and combines with maximum flame travel to burn fuel cleanly -critical in a small furnace. To further increase efficiency and fuel savings,additional heat recovery equipment can readily be supplied such as tubular air neaters, regenerative air heaters and economizers.For superheated steam anaddedpendantsuperheatercanprovidesuperheattemperaturesto00°F (482°C). mo tantsANLat:BANE Be4,is .rar bhe ip iy O° Waste wood of various descripuons (overteal)18 fed to ihe Towerpak bolers via asophistiwatedconveyingsystem,fom storage bin to screwleede!.supped by B&W Canada fabove} Economical,efficient,versatile -a unique boller >designedto burn an unusual variety of fuels No othér shop-assembied boiler can offer the advantages and benefits "Q&W Canada's Towerpak.Features usually found only in larger field- cted units are combined: Fully membraned furnace enciosure ensures gas tightness Vertical furnace flow for minimum particulate carryover Long flow bank to minimize erosion,pluggage and gas-side draft loss Bottom-suppored to eliminate grid steel Qccupies minimal floor space =_, Features such as these add up to lower erection and maintenance costs while delivering outstanding performance from an unusually broad range of fuels.In addition to burning conventional fuels like oil and gas, the Towerpak can likely turn whatever is available in inexpensive local abundance -waste wood,coal,bagasse,sander dust,even waste like coffee grounds -into productive steam.Such versatility can dramatically reduce dependency on traditional,but expensive,fossil fuels. B&W Canada can provide total project turnkey scope,on schedule.For F.F.Soucy Inc.,a major Quebec paper producer,we supplied a complete boiler facility from the foundations to the sprinkler system.This includes controls,fans,flues and ducts,dust collectors,stack,and an all- encompassing fuel handling system -reclaim hopper,conveyors,bark hogger,pneumatic blowing system,stcrage bins and metering screw conveyors.All erection,installation and commissioning was includedinB&W Canada's scope of supply. At Soucy's paper mill 3.5 million pounds of steam per day were required to help produce 500 tons of newsprint daily -7000 pounds per ton of paper.Two package boilers were providing the necessary steam but in the process annually guzzied more than 8 million gallonspreciousBunkerCoil.in an effort to cut prohibitive fuel costs Soucy ose twin B&W Canada Towerpaks,each designed to generate 60,000 pounds per hour of steam burning waste wood readily available in quantity from Soucy's own chipping operation and from local sawmills. Time elapsed from order to first steam -just 15 months. ihe turnkey prorect scope tor F F Soucy mvolved a complete boiler faciity trom toundations tothesorinklersvstam ee PRE eA nS PO aE Oe Eee)a Sten oS Tne shop-assembdied Towerpak features a ngid Steel Dase frame shipped with the pover to accommodate hiting by crane tom rai car to foundations by means of reinforced hiting lugs Shop-assembly ensures rigid adherence to criticalspecificationsandavoidshighon-site erection costs B&W Canada has _been-the nation's leading boiler manufacturer fordecades.As a subsidiaryof Babcock &Wilcox,we are a vital part of a-"pany that is one of the world's premier designers and builders ofimgenerationsystems. ihese considerable resources and years of experience enable us to supply our customers with single source responsibility for thetr project. B&W Canada's half million square foot works in Cambridge,Ontario, 10Use some of the country's most advanced fabricatién and quality sontrot facilities.Precision assembly is completed to rigid shop standards fifficult to match in the fietd.-_ 1&W Canada's twin 60,000 PPH Towerpaks ourn wasle wood and annually save FF Soucy & aitron gallons of ot Corrugated weatherpioof aluminum ouler casings protect the boiler hom re elemenis Ail sides feature high-temperature blanket insulation [0 cul heat loss «nd cool ulet Casings. ;f SS "ips Sega yn gtayRathaU,ae Fala weeeeeS;ogsf,raedAFvin Towerpak boilers and asaociated iuipment auppiled by B&W Canada Hydrauhc-ram operaied live-bottom wood wasie storage bin Slorage bin variable-speed teed .Puiiy memoraned,water-cooled turnace enclosure Auxiliary burners Soviblowers High pressure overfire air poris Low presgure overtire air ports 12.Forced draft fan ''=4erlloor screw conveyor 14a Primary Dust Collector lom-supponed dosiqn 14 Serondary Oust Coffector 'p-assembied tubular arfheater 1§Induced draft fan High pressure blower 18.Common stack with separate inner ftucs ACRE "82 08°S5AM BND HERR BaGerrdnnawatvertdesandet effectivefy*® "alhgonstruction and field 'operations are performed by ourinternationalService&Construction department.Nationally our services-.are available through regional offices.in major Canadian cities.Overseas-.customers are servedthrougha strategic network of agents and regionalalesofficeslocatedaroundtheworld. A wide range of services is offered: Turnkey project management Boiler erection and repair Field inspection,diagnostic testing Upgrades,rebuilds and supply of parts for any make or type of boilerBalaqceofplanterectionandrepairOperation,maintenance or plant upgrading -B&W Canada has the proven expertise to ensure peak performance, B&W Canada's versatile Towerpak boiler Fuei Range Capacity Range Tempersture Range Pressure Range Scope of Supply F.F.Soucy Inc.,Riviére-du-Loup,Quebec Major Equipment Supply Two shop-assembled Towerpak watertube boilers each complete with: Mountings,refractory,insulation and lagging Sootblowing system Auxiliary gas and oil burners Duplex ail pumping and heating set Rotary undergrate wood screwfeeder compiete with receiving hopper and motor drive Forced drat fan and motor drive Induced draft fan with motor drive High pressure blower and motor drive Flues and ducts complete with insulation and outer lagging Shop-assembted tubular air heater Steam coil heater Mechanical dust collectors Motorized rotary seal valves Pneumatic combustion controls complete with 3-element feedwater control,indicators,recorders,transmitters.panel,02 analyser,steam coil air neater control and flame failure equipment Ash handling conveying system Common stack,125 ft.(38.1m)high,11 ft.(3.35m)in diameter with separate 4ft.6in.(1.37m)inner flues Balance of Plant Building,including ail foundations,building steel,walkways,stairs, reof,siding All electrical equipment including motor control centre,wiring, cabling and lighting All interconnecting piping (steam,fuel,feed-water,cooling water, sprinkler) Complete waste wood handling system inciuding building,steelwork, reclaim hopper,conveyors,hog and pneumatic conveying system from wood preparation area to boiler house storage bins 5 4 .TET Bartel Satie TeLeeaadswt | ae,a a1,Sanita:oa mone , rhs 'nea"Naaged ce UES The Towerpak Shop Assembled Water Tube Boiler Babcock &Wilcox Canada Ltd. An exciting concept becomes an extraordinary boiler... The Babcock &Wilcox Towerpak. Even a cursory inspection tells you that this isnoordinaryboiler.{n tact,that unique,verticaldesignistheveryreasontorTowerpak's economy,versatility and outstanding performance.With the Towerpak boiler,Babcock &Wilcoxcreatedforthefirsttimeahigh-capacity design thatcouldbetransportedbyrailinonepackage,and stil!adhere to allowable shipping clearances.To achievethis,we built "up”instead of increasing length,placing the unit flat on its back while in transit.So ailtheadvantagesofashap-assembied boiler wereretained,butin a design capable of producing steamfromavarietyofsolid,liquid and gaseous fuels atarategreaterthanyouwouldnormallyexpectframashopassembledboiler.Once installed,the Towerpak's vertical design also achieves a Standard of efficiency and maintenance-free performance unusual in conven-tional boilers in this capacity range.The same is truewhetheryouteburningconventionalfuelssuchasoilandgas,or solid fuels such as wood,coal,bagasse,sander dust,even the office waste,coffee groundsandpaper-tor Towerpak is as versatile as it isefficient. More than i100 years of experience have goneintotheTowerpakdesign-that's how long Babcock &Wilcox have been producing economical,dependablesteamgeneratingequipment.With such a history,unmatched in the industry,it's no wonder they caliBabcock&Wilcox 'the boiler peonte”. Shop assembly... where the advantages of the Towerpak begin. in the following pages,you'll discover now a simple,but uniquely designed boiler can offer you unmatched economy and pertormance.But first,let's see why this Babcock &Wilcox Towerpak boilerStartsmakingsuchgoodsenserigntintheBabcock&Wilcox plant,where the Towerpak is shop assembled to exact specificatians. l.Faster delivery Only with a factory-assembled boiler is specialized labor and precision machinery $o readily available.When this is the case,a boiler can clearly be ready foroperationinlesstimethanon-site erection allows. Further,transportation of a complete unit means there's less fuss with fewer arrangements to be made. 2.Lower capital expenditure Because it goes on the line sooner,the shop assembled boiler puts investment dollars to work faster,And since the work is done in the Babcock & Wilcox plant,not yours,interference with your plantOperationsisreduced.Package boilers requireminimalspaceandarebottom-supported...a 2ie.NEaeiEewigdrastic savingon building costs,Engineering costsarealsosignificantlylower,as all units are "pre:engineered”. 3.Manufacturing Excellence Fram initial design right through to final assembly,the constant attention of hignty speciatized per-sonnel ensures standards of quality contro!difficulttoattainwithfield-erected units.Shop assembly alsofacilitatestheswifthandtingofcustomdesignsandspecifications.You get the right boiler for the job attherighttime. 4.Future flexibility With its simple foundation and compact nature,apackageboilerisobviouslymoreportable.Thisbecomesanattractiveadvantageshouldyourplantbealtered,or even moved toa different site.Again,shop assembly can save you time,trouble and expense. These are just some af the reasons for goingwithshopassembly.Your Babcock &Wilcsx rep-resentative will give you many more.And with today's increasing capacity limits tor packagedwatertubeboilers,it makes more sense than ever, You'll see,as you read about the Babcock &Wilcox Towerpak.just what a shop-assembled boifer can do for you.ip Unique design...so Towerpak offers you unmatched performance,economy,efficiency. Symmetrical furnace design means uniform heatabsorptian. The arrangement of furnace and burner is ideal,Since all furnace walls are equidistant from the flame centre line,an even heat load across the furnace is assured,as is uniform heat absorption inallttswatercircuits.The hot flue gases exiting fromthefurnaceenterthefullwidthofthegenerating bank perpendicular to the drums.Safe circulation results from uniform loading of the steam separating equipment located in the steam drum. Maximum flame travel allows complete fuel bumout. The tall furnace design offers a lang gas pathformaximumburnoutofsolidfuelparticles.In view of today's pollution concerns,this ig a mostimportantfeatureinburningsclidwastefuels.Lower emissions,lower furnace exit temperatures,andhigherthermalefficiencyareachievedinthisway,.while reduced carryover of solid fuel particlesprotectsthegeneratingbankfrompluggageand erosion. Longitudinal gas tlow ensures maximum efficiency. __Another important advantage of the TowerpakCesigntsatotallyunobstructed,vertical gas flowthroughoutthegeneratingbank.By allowing the gastoflowatongthetubesratherthanoverthem,significantly lower draft loss and reduced furnacepressureareexperienced,with less chance for gassidepluggageanderosion.Aconventional boiler oftheTowerpak's Capacity would require a powerful andcastlyforceddraftfantaprovidecombustionairand drive the hot gases through the generating bank.Quetaitsfreeflowingdesign.the Towerpak requires a TOWERPAK'S HEIGHT ALLOWS POSITIVE CIRCULATION IN ALL STEAM GENERATING TUBES INCREASED ORUM CENTERS CREATE A DESIRABLE CIRCULATION Conk WHILE MINIMIZING MAINTFNANCE COST ANO INITIAL DOWNONERSSteam oullet Secondary Siram scrubber Cyetesre seDarator simpler,lower horsepower fan for maximum perfor- mance.Depending on the type of fuel being fired,apressurizedorbalanceddraftsystemmaybe employed. Vertically orientated for positive circulation. Babcock &Wilcox designers found thatincreasingthelengthofthetubes,rather thanincreasingthelengthofthedrumsandthenumber oftubes,was a much more efficient and economical aperoach.The well defined dawncomers are locatedinthesecondgaspass(the coldest sectian of thegeneratingbank),and run the full width of the bank. To reach them,circulating water does not have to run the length of the drum,thus eliminating the possibility of drum level gradients.Towerpak's height gives a positive circulating head for greatestvefocitiesandMinimumstagnationinalithe steam generating tubes. A TOWERPAK SCH ER CESIGNED TO BE OIL AND WCOD FIRED aig - jt Babcock &Wilcox keeps maintenance costs waydown. All six sides cf the furnace are water cooled, offering maximum heat absorbing surtace withouttheneedforrefractory.Complete water coolingkeepsfurnaceexittemperaturesbelowashfusion point,far cleaner generating banks and superheat-ers (if fitted}.An erosion free gas path,uniform heatandsteam/water distribution and minimum refrac- tary cambine to reduce maintenance costs. Shorter drums,fewer tubes cut initial outlay. Fabrication af the steam and mud drums, drilling the tube holes,and the cutting,bending,assembling and expanding af the tubes are the most costly operations in making any boiler.In view of this,the Towerpak's shorter drums and fewer tubes represent 4 considerable reduction in capital ex- penditure. "O3 @G:azam noe Construction...indoor or outdoor installation, Babcock &Wilcox workmanship means you stay on line. 2 Types of construction available. Depending on your requirements,B&W can supply you with a Towerpak boiler in either af twobasredesigns:membrane wall Construction or the tangent tube inner-cased design.The membrane wall design,a B&W exctusive,is generally recom- mended for all Towerpak boilers,because it has been outstandingly successful in eliminating leak-age of noxious and corrosive combustion gases. Soap-air test ensures gas-tight enclosure. B&W's patented membrane construction iscapableofwithstandinghigherfurnacepressures THE RASIC CONSTRUCTION OF THE TOWERPAK BOILER gEIhe MS BSE TE eT ee :Lid mA eery Dpry PUSS pl pegMttreaneSEa Fa. than other designs,thus eliminating the need forfuturecasingrepairs.Therma}expansion/contrac-tion problems are also etiminated,as membranewalltemperaturesareuniform.Where tangent tubeconstructionisempioyed,a completely weldedInner-casing 's supplied to form a gas-tight encio-sure.In beth instances,a stringent soap-air test iscarriedoutbeforetheunitieavesthefactory,toensureagas-tight enclosure. Baw'S EXCLUSIVE MEMBRANE WALL OLSIGN FEATURES A GASTIGHTWELDEDCONSTRUCTION TO ENSUREA COMPLETELY GAS-TICHT FURNACE ENCLOSUAE,PreTOWERPAKUNDERGOES&THOROUGH SOAP-AIR TEST BEFORELEAVINGTHEFACTORY. fat,;= = Raat 4 x :av:)Fente DatesNaat ff ee_R=°i, if:Re x ;we TE ape aPaden Bl +L AE -a reir, , ° F ™%< Sturdy,weatherproct exterior.sprayed with a special preservative coating toOnlyB&W package boilers feature outer prevent corrosion. casings of neat,corrugated panels with no need forunattractivestiffeners.This aluminum weather-Water-cooled on six sides. proof design allows the Towerpak to be located All furnace walls of the Towerpak are com-culdoors without special protection.In addition,pletely and efficiently water-cooled.Radiation lossthewalls,floor and roof are insulated with high-and refractory maintenance are thus minimized.temperature blanket insulation to minimize radia-The furnace is equipped with many aspirated,widetionlossandkeeptheoutercasingscool.For job angie observation ports for complete,effective view.sites located near salt water,orwhen Towerpaksare ing of combustion.Access doors are also providedshippedoverseas,the aluminum casings are where internal inspection is deemed necessary. INNER CASING INNER CASING BLANKET INSULATION BLANKET f B ¢ -STUO PLATES INSULATION f NN\A 8B \™, CORRUGATED 'REINORCING SS .ALUMINUM OUTER;la CASING t.REFRACTORYCORRUGATEDALUMINUM(APPLIEO FLUSHOUTERCASINGWITHCUTSIDE A 8 OF TUBES) 4 aoc PLAN A;TANGENT TUBE-SKIN CASED COMSTRUCTION REINFORCINBOILERREARWALL,wine ew SFURNACESIOEWALL,WELDED TO STUDFRONTWALLANDOPLATESON3”ROOF CENTERS reeseOf,Rw)Ste'4le",MEMBRANE WALL cA BLANKET INSULATION /ee CORRUGATED |;Ae en oNON ALALUMINUMCUTERCASING$4 no;SPACED TUSE-FLAT STUDCED-SKIN CASED CONSTAUCTION BOILER SICEWALL LL FRONT WALL ANDO ROOF UL ZR ems an. Versatility ...Towerpak delivers dependable performance on a wide variety of fuels. Versatile.A word that is synonymous withtheBabcock&Wilcox Towerpak wherever steam isgeneratedinquantity.With rapidly rising oil and gaS prices,particularly attractive is the Towerpak's ability to burn sctid waste fuels.Canventionat oil, gas and coal,hogged wood,sander dust,wood shav-ings,bagasse...a/)these,alone orin combination. can be burned with equal facility.Consider thevarietyofapplicationstowhichtheTowerpakcan be So ideally adapted. Towerpak boilers can be equipped to feed solid fuels to the furnace in a wide variety of ways. These include Dutch Oven,screw feeder and travelling grate stoker,to name the more canven- tional methods.The actual design used on any specific bailer would depend on the type of solidfueltobeburnedandtherequiredlimitatiansonemissions.The perfect boiler for the job is further assured by the availability of a wide range of ancillary components,everything from burners togasClean-up equipment. No other wood-fired boiler burns so claanly An under-flaar screw conveyor has proved itself ta be a most efficient way of introducing hogged wood fuel into the furnace.By this method, -quiet entry of fuel,elimination of suspension buming,and reduced carryover or solid particles combine with maximum flame travel ta make Towerpak the cleanest burning wood-fired boiler on the market. Having deen introduced to the furnace,the wood is then deposited on a pile on a stationary grate that covers the furnace floor.Since the woodisfedupfromthebottomofthepile,it can be WINDSWEPT SPOUTS 1S ONE AMONGST A WIDE VARIETY OF METHODS FOR FEEDING SOLID FUEL TO THE FURNACE pre-dried with the help of not underffoor air fromtheairheater,introduced through pinholes in the grate. In the event of a momentary stoppage of thescrewfeeder,the pile will continue to burn, Maintaining staam production for a short duration. Stationary grate allows maximum combustion withminimummaintenance. For better pile burning,the under-floor grateairisdividedintotwosections.High pressure air istedtothecentreofthegrate,lower pressure air toitsperiphery.Capable of withstanding the ex-tremely high temperatures necessary for bettercombustion,the stationary grate is water cooled forlonglife,and employs no moving parts forminimummaintenance. Ease of cleaning is a further plus. With its self cleaning ''Venturi''air holes,the furnace floor grate remains in optimum operat-ing condition.The grate is sloped towards easilyaccessibleashcleanoutdoors,while sequential steam jets assist ash removal.The amount of gratecleaningisdependantonthefiringrateandashcontentinthefuel. Coal-a fuel of the future. With the prospects of ever diminishing oil and gas reserves,many industrial customers are considering returning to coal firing.As might be expected,the versatile Towerpak can be readily adapted to caal by adding the necessaryeaguipment. ELIMINATION OF SUSPENSION BURNING AND REOUCEDCARRYOVEROFPARTICLESISACHIEVEDWITHTHEUSEOFUNDER-FLOOR SCREW CONVEYOR. THE FURMACE FLOOR GRATE 1S SLOPED TOWARDS EASILY ACCES-SIGLE ASH CLEANOUT OCORS Equipment...full range of ancillary components tailors the Towerpak to your needs. Soothiowers:Towerpak boilers normally come equipped with rotary,stationary scotbiowersforcleaningoftheboilertubesurfaces.Retractable soatblawers may be fitted to units where tempera-ture or contaminants in the fue!make stationary sootbiowers impractical. On gas-fired jobs,witn light oil standby,sootblowers are not required.However,all Towerpaks are fitted with sootblower bearingsinthegeneratingbank,and wall boxes forfutureinstallationifrequired. Heat recovery equipment:For highest pos-sible efficiency and fuel savings,additianal heat recovery equipment can readily be added to the Towerpak.This includes B&W tubular air heaters or regenerative air heaters,and economizers..Superheaters;When superheated steam is Hay -Hi required,a pendant superheater can be added to 3 |7 oetheTowerpakforsuperheattemperaturesuptooseer900"F.All-weided construction is used.All tubes .riage Fearestrength-welded into the superheater headers to i eypreventtubeleaks.On multipass superheaters,BS IES es a Sfhandholesareprovidedfarinspection.An access ;*PSE door in the Boiler setting allows easy access for B&W WILL SUPPLY PANELS TO CONTROL ANO MONITOR IMPORTANTsuperheaterinspection.FACETS OF BOILER OPERATIONJfhe Installation... Towerpak can be installed simply and quickly.SAREas"tedeeeASbeesFeeeeB&W engineers have designed the Tawerpak boiler for the simplest,mast economical instaila- tion possible.Since the Towerpak is bottom supported, expensive structural steel normally associated withsolid-fuet-fired boilers of equivalent capacities is eliminated. Itusesa minimum numberof transfer pointsatthepressureparts,allawing free expansion . without imposing unnecessary stresses.Therma! expansion is allowed for by specially designed low-friction pads under Sliding surfaces... Lifting lugs are provided.so the entire unit can be lifted from the top to make untoading andplacingextremelysimole, The Towerpak is shop assembied in a rigidstee!base frame which can be shipped with the boiler to be used for transportation between the rail car and the foundations. When the boiler reaches the foundations,it can be turned and set in piace using two medium oronelargecrane,depending on the size of the unit. JUL 28 '83 @9:47AM R onm it NADA ra oO;The Venturi Burner...a Babcock &Wilcox exclusive, especially designed to complement the Towerpak boiler. Wide choice of fuels;The Venturi burner 's engineered to be fired with a wide variety of fuels,including Bunkay "'C''oil,natural gas,crude oll,refinery gas,petraleum,naphtha,pyrolysis and many others. Venturi Throat Burner-a B&W exclusive:Thisextremelyefficientburnerwasdesignedfor,and istheB&W standard,on all Towerpak boilers.It offersincreasedturndawn,better fuel atomization,reducedsteamconsumption,simpler cantral,and is capableoftowexcessairoperation.it is specifically designedtooperatewithintheconfinesofapackageboilerfurnacewithoutflameimpingement.Simple control &low maintenance are features:The B&W Venturi Throat Burner can besuppliedtoburnoi!only,gas only,or gas and oll incombination.For tiring fuel ails,a'Racer'style,steam-assisted atomizer is used,utilizing constant steam pressure throughout the range of the burner. This eliminates the need for a constant steam-to-oil pressure differential valve,simplifying contrat and reducing maintenance. Dual atomizers eliminate cleaning down.- time:The Venturi Throat Surner can be fitted with one or two atomizers;in the latter case,each ane is capable of supplying full load ait flaw.The dual-atomizer system permits one gun to be cleanedwhiletheotheristiringtheboiler,so you experience no loss in steam pressure. B&W promises total bailer-burner respansi- bility:B&W produces both boiler and burner.Thus, when you equip your Tawerpak boiler with a B&W nurner,total responsibility for design,installationandfuturemaintenancerequirementsareinoneset of hands rather than severa)-by far the most effi- cient and prablem-free way ot doing business. A WOCD-FIRED TOWLHPAK BUILEN IN OPERATION AT A LUMBER:-CHIP COMPLEX 7 DNR 1 Ase wetSHOTEOE Sebeesayt The Babcock &Wilcox Professionals: They come as part of the package. When it comes to selection and installation of a Babcock &Wilcox boiter,yau can rely an the adviceandsupervisionofthemostwidelyexperienced professionals in the business...THE BABCOCK & WILCOX PACKAGE SOILER TEAM.The men you see below are part of it,and right down the line,they'llStaywithyoufor: 1.Equipment selection-Your boiler will be inserviceforalongtime,$0 you want to be sure you get the one that suits your exact needs.Babcock & Wilcox makes sure, 2.Installation supervision-Whether you require afullytrainedandexperiencederectioncrewtohandlacompleteinstallation,or speciallzed on-site .2d Sexe.aEpon5it:weaweCSC.aesupervision,Babcock &Wilcox will willingly supplythebestthereis. 3.Start-up and training service--Members of theBabcack&Wilcox skilled service force are avaliable ta you for start-up operations,operator training -and.of course,service over your Towerpak bailer'sife. Babcock &Wilcox is Canada's largest boilermanufacturer.Our plant in Cambridge,Ontario isthemostmodernintheindustry,The most up-to-date production metheds,together with the higheststandardsofqualitycontrol,assure in the Towerpakaboilerofthefinestqualityavailabletoday. Oe nt "igs ae 11 eran neete oe The Full-Service Provider in Power Generation ALSTOM |" The Full-Service Provider ALSTOM's Power Sector offers the broadest scope of power generation systems,equipment and services in the industry. This uniquely comprehensive capability enables us to provide our customers with the maximum of options and the mest economical and environmentally friendly technologies. We are able to deliver total solutions, from components to turnkey power plants.But we are not only a products and systems supplier,we want our customers to look upon us as a 'full service provider',helping to maximise the potential of their power generation capabilities and enhance their competitive position. A Powerful Partnership For example,our services also include plant operation and maintenance,total plant management,and alliance programmes,where we continually strive to increase output,reduce outages and meet environmental compliance.All at reduced cost. We want to build long-term partnerships where we can help to ensure that our customers are provided with a good return on their capital investments. Our rapidly developing ecommerce strategy will also bring benefits, enabling us to work more efficiently with both our customers and suppliers. www.power.alstom.com Delivering the Products and Services You Need . Whether you are a utility,an independent power producer,or in industry,we can provide you with the products and services you need. @ Tum ey Power Pla ntseteCustomerS¢rvices” vironmental Controls Progress Through Technology The future development of new and existing products is guaranteed through our increased capacity in Research and Development. The extensive resources of 12 laboratories and over 2,000 research technologists support this capability. With these facilities,we will continue to develop our products,and therefore ensure that we provide our customers with technology that is designed to improve their competitive edge... In the technologies and products wedevelop,we arecommitted to saving energy;reducing harmful emissions, _dimiting noise and all other environmental impacts. Our existing product range:embodiestheverybestoftheséworldJeadingtechnologies. coal technologiesiaoeeAEEicteneturbine.upgrades:= 12 R&D Labs Local Organisations in 63 Countries In 2002,ALSTOM and Rolls-Royce signed a long term technologyagreementwhichwillenableALSTOM _technology iin the development of its heavy duty gas turbine product range. Rolls-Royce aeroengines operate using very high temperature technologies,_advanced aerodynamics.and veryhigh_strength/high'tfemperature materials. The expertise and knowledgein these areas gained by Rolls-Royce in developing its world leading aeroengines will be applied to ALSTOM's heavy duty gas turbines to improve efficiency,power output and durability. Our worldwide sales are supported by our global presence. 54 Manutacturing Centres 70 Service Centres Where You Need Us, When You Need Us In terms of orders,presence and multicultural diversity we are the most international of the world's leading suppliers. With over 45,000.people'in morethan70countries,we are able to combine our global expertise with extensive knowledge of local markets. This expertise is delivered to our customers through our greatest resource,our people.Asia Pacific Americas Benefit From Our Experience We also have our vast operationalexperiencetodrawupon.We havesuppliedalmost20%of the world's total installed capacity in power generation equipment.This experienceisusedtoensurethatweprovideour customers with the optimum solutions. These capabilities,and ourcomprehensiverangeoftechnologies,products and services,make us confident that whatever your requirements,we are equipped tobecomeyourbestlongtermpariner in the power generation industry. Orders by Product Boilers &Environment 21% Gas Turbine 18% Customer Plant 12%Steam Power Plant 12%Services 28% Industrial Turbine 13%Hydro 8% as ae 8Recece onyiAete 12%rote I ay exaee Europe 72% Africa /Middle East 1% 5,"ALSTOM is$the globond, :activities inin power generation crand:: |specialist nhayraatinsetaeag299infrastructures;:5,serving e ene rgy mai power+fransmission:aneeaethioucandtheevparineeroe @ Transport @ Marine We design,supply ond serviceacompleterangeoftechnologicallyadvancedproducts'and systems for:our customers,and possess &uniguexpertiseinsystemsintegration.andthroughdifemaintenanceandservice. In fiscal year 2002 we'had cennvalsalesof23billioneurosand.=employed more than 118,000:peoplein over 70 countries. ALSTOM is listed on the Paris, London and New York stock exchanges. -.Market Overview Increasing Demand During the next 25 years the world's installed power generation capacity is expected to double,and most of the current equipment will have to be replaced. Demand for power generation equipment will be driven firstly by the - continuing need for developed countries to modernise aging plants,increase efficiency,cut costs and reduce emissions;and secondly,by the rapidly growing economies and populations of the developing countries.In addition, the availability of different types of fuels and renewable energy,combined with the volatility of some fuel prices, will strongly influence the demand. Accordingly,suppliers to the power industry have to reflect these dynamics in the market through being flexible, adaptable and innovative,helping customers to find the optimum technological and costeffective solutions to meet their particular needs. From fossil fuels to renewables such as hydro and biomass,we have world leading technologies in all the key areas of power generation and the determination to sustain this position through investment in new products the Challenge We believe that for each specific situation or need there is an appropriate solution that we can offer you. Supported by our global sales and service network covering more than 70 countries,we believe we provide the most complete offering to the power generation industry,making us the world's foremost 'Full Service Provider'. TYPICAL VU40 BOILER DESCRIPTION Supplied by Alstom Power FURNACE The furnace features welded wall construction of 3"O.D.SA-192 seamless tubing on 4" centers.Welding of waterwalls provides structural rigidity to the construction,provides a positive seal from leaking furnace gases for greater personnel protection,eliminates casing hot spots and the need for an inner casing.The furnace wall tubing has a built-in thickness tolerance for long tube life and unit availability. The furnace setting height is measured from the centerline lower rear waterwall header to the centerline of the lower drum.The furnace waterwall at the bottom of the unit are designed to accommodate various furnace bottoms including vibrating grates,stationary grates,traveling grate and furnace hopper floors with a scraper conveyor and the bottom (this is for PF Fired boilers). The furnace is designed for balanced draft operation and a pressure tap is provided at the furnace outlet.This pressure tap is linked to the ID.fan to maintain a constant -0.1” w.g.under all firing conditions.This design prevents the escape of hot flue gases fromthecombustionchamberandalsodampenstheeffectofafurnace"puff”or excursion to positive pressure.The furnace buckstay system is designed for +/-26.5”w.g.at 100% yield. SUPERHEATER The superheater arrangement consists of two-stage platen and spaced sections.The first stage employs a parallel flow pattern superheater,which exposes the low temperature steam to the hottest flue gases and also takes advantage of the luminous radiation in the furnace.The final stage superheater is a counterflow arrangement,the optimum pattern for heat transfer. The tubes are arranged in-line for ease of inspection,access,maintenance,and cleanability.The superheaters and boiler bank are separated by 24"access/sootblower cavities to provide ample access.Cable openings are provided in the furnace roof for ease of upper furnace maintenance.Observation ports are provided to inspect superheater tubes. To provide a gas tight seal in the penthouse,the superheater assemblies will be supplied with shop installed high crown seals where the tubes penetrate the furnace roof.A steam cooled spacer is being supplied to maintain the lateral or transverse alignment of the superheater tubes.Flex ties re being supplied to maintain the front to rear or longitudinal spacing of the tubes. Saturated steam from the drum is delivered to the first stage superheater inlet header via carbon steel connecting tubes.These connecting tubes are evenly spaced along the width of the unit to promote uniform steam flow distribution both through the drum internals and into the inlet header. The first stage platen superheater is designed to maximize heat transfer,prevent bridging and facilitate ash deposit removal from the tubes.The platen design consists of pendant tubes arranged in-line parallel to the direction of gas flow.The in-line tubes are arranged on 12"transverse spacing and spaced longitudinal son centers equal to the tube diameter plus 0.375”. The final stage spaced superheater tubes are placed on 6”transverse spacing and longitudinal spacing of two times the tube diameter. The Bidder utilizes internally established minimum tube wall thicknesses for bending to avoid excessive thinning of the tube during the bending process.This assures that the tube bends have sufficient thickness remaining to withstand unit design pressure as well as provide a margin of tolerance for high unit availability.All superheater elements shall be stress relieved. BOILER BANK A single pass,cross flow boiler bank design is used.The boiler bank,located after the superheater,features in-line carbon steel,SA-192 seamless,tubing arranged in two sections.The sections are separated by an 18”cavity,which allows installation of a sootblower and facilitates maintenance and inspection.The tubes are rolled during erection into the upper and lower drums without any butt welds. The flue gas makes a single pass across the boiler bank,which contains saturated water or a steam/water mixture.The most active steam generating circuits are located in the front bank,where the hottest gas temperatures exist.The final few rear tube rows primarily act as downcomers.The boiler bank also acts as a heat sink to absorb any system transients. ECONOMIZER The final pressure part heat transfer surface is the economizer,which is located within ductwork following the boiler bank.The economizer contacts hot flue gas with the incoming feedwater to increase overall unit efficiency.The surface is arranged for countercurrent flow,with the flue gas flowing down over the tubes and feedwater flowing wn incide the thheeupmsicetheoes. CIRCULATION SYSTEM The Bidder's design employs a natural circulation system.The feedwater is preheated in the economizer.Feedwater then enters the steam drum where it is distributed along the entire length via a distribution pipe.The feedwater then mixes with the saturated liquidinthedrumandthesteam/water mixture rising from the generating circuits. The steam drum is sized to separate the maximum quantity of steam to be generated.. The steam drum is supplied with a three fold set of drum internals,which include a hydraulic baffle,unitized perforated centrifugal separators,and secondary screens.The druni internals are capable of handling load swings of +20%per minute.The upper drum is supplied with the continuous blowdown (CBD)connection. The boiler bank acts as a heat sink and buffer between the superheater and economizer. The first half of the boiler bank tubes are essentially riser circuits between the upper and lower drums.The rear half of the boiler bank acts as heated downcomers feeding water to the lower drum The lower drum contains the chemical feed connection.By placing the chemical feed on the lower drum the chemicals combine with the circulating water and are better mixed before entering the steam drum.Also,the drum internals are protected from any possible attack by the chemicals and there is no chance of chemicals short-circuiting and being discharged through the continuous blowdown system.This can be an expensive and unneeded waste of chemicals. The preheated water is then fed through unheated downcomers,which supply the lower furnace headers.The lower furnace headers are connected form a ring to supply water to all four waterwalls.The 3"O.D.tubes on 4"centers provide a low tube velocity so as not to inhibit the natural circulation,but maintain a high enough velocity to prohibit departure from nucleate boiling which can lead to overheated waterwall tubes. The waterwall tubes generate a steam/water mixture,which is carried into the steam drum as follows: 1.The front wall tubes also form the partial roof and relieve directly into the steam drum. 2.The rear wall tubes relieve into the lower drum where the steam/water mixture is baffled into the first three boiler bank tube rows and passed to the steam drum. 3.The sidewall tubes relieve into upper headers (one on each side)which are in turn relieved by a series of riser tubes that feed into the steam drum. Ta epee: HEYL&PATTERSONMatecRocy|BY THE DESIGN Pic JiEFFICIENT,RUGGED, naeeseergehig 6Senheateas ” re ae esshaea since 1887, Heyl &Patierson has designedandconstructed a full line of the most efficient,rugged, durable bargeunloadersinthe bulk material handling business - The Heyl &Patterson line of high capacity machines has solved a variety of unloading problems for many cusiomers. Diverse cargoes such as coc, iron ore,bauxite,alumina, com,wheat,soybean, agricultural by-products, woodchips and limestone are successfully unicaded. aridge Style Continuous Unicocar Cne of mony simicr mocnnesthebelowpicturect,S000 TPHcscfictingtcteynngecboombucketelevarerunioacerhostecometheoccepiedincusiry moved service Crone 50necessity,The barge brecstngstemochustchieveriiccily&Cesignedtooccemmodcteborewicthsfrom26to$0 it. instciiedatShinpirgport.PA insunioccerNesofreediggingtataof$000 TPH,bul cvercoesJOCOTPH Normal time fot monudi nauiegeinechangeofcocut10rrinutes"hes teen recuced to 3 1/2 rrinutesDyusingthesemicuromatictowsporsystempictured.HoviageropesfromofwoenginevarichiespeedbergeNeu!sysfern cnagemmanentlycliochedtoina feat.EngagementoftheDergetitbyIheheavysleellocpcitechedfaanatxuictingcrmisramctatycontrolledbymeuricoderoperoterandocccrmiknedinefrottercfsaconcs.Scfety hazoxisofmenuallinenenctingareofcourseedminctedcamanpowerrequiremcoarsareminmizec.Ernongencymonualiccpedwis[Cpe connectionsandsta¥tyreaccesstoGorges5orovided. Avatichte Cntlons °Vorlotie Soeed Bucher Crives*LutrcotedBucketDriveChain *Sorting Loeded exile SuchetUneNese «Tuss cr Box Gece Structure *Weter Spry or Ory Dust Collectors*Brice or ContieverShe «Boon EnciosedCustQrrouc*Double Strond LoddersferCrcofive24)Wicle Barges *BorgeHouSysiems with siding moteriat to Slernd withpowerpion!ochifechra. Csminucus Uniceder for ExtremeWeterLevelChange The bucket sevotor coct unicoderctGhent.KY §roted at 3600 TPHondcobemocifedto4000IPH.Ths design csclictestocccom-modata vonous barge wictns.cs cothehingedboommachines.Wetec_edavorion cdjustmenis ore modebyhootingthecounterweightedconeversection.which supportsthefokecwcyconveyerandfedbucketboom.Ths type of designmustbeusedwhencperciingwoterlevelchengeexceeds35". Boge hou engines cre borge mountedctthsinsteticticnardcorgesavekeyedtocelh,thusetrninotinghawogeropecatencryproblems.Breosting device 4 thefornfiarstemtype. Design Pioneers - solving bulk materials handling problems since 1887 taRABRAS,ietSndah Continuous Grom Unicoder ContinuouscoctunioacingtechnologywesreadilyocieptchiefoGroinunoacingwithhwomajorinnovations,Grcin barges ce.hctch coverec,nerefere removal&hondingtimehodtobarecucedofedmincied.in ocicition.Gust control equicmentwesmondctoary.The ahoctograrhctograinuniooderofOestrehan,LA.with o roted capacityof100.000 busneis per hour Cactyitusirctesthesemnovetions.A dryustccilectionsystem§mountedcntheoscdkiingircileycndthestructuresocns0doublesipclawingNotcnremovecnareciocementcnonesxiawhileuniocctngiscocompisnedcnothersce. 'wo voriotiespeedbargehaulsystemscraraquiredfomointancantinuousoperdiionondthepreviousymoniicnedbargenreastingstam&center mountedfooccommodciebargescnethersi9.Coercter'scabiscenterfrountedfermoxirrumnvisitillfy. This instcticticnisorecoftenthetaresimilerandcoudreadilybemecifiedfosoncie&0.000 -140,006 Bushes Per Hour Sg a be xh Sede:OE:Ss tine egies°hee et Micsirecam Contnuous Unicoder As shown,o box girctercantileveredbucketelevctorbargeunloadernesbeenhullmountedondintegratedintogqmicestrecrngainsonsfertennnctThe.uricaderwesdesignedwithahetchcoverstorageplofoenchcvefhemainstructurewhich |Clsa supports a ship loactng bce..Karding cranes,bins,conveycrs._sampling cad weighing sysiens craintegrotedIntothis- mid-stecrn terminal. a a a a aan aes i ; Bi ai *,erate)eee SH ee re SackVeetaeeeagSPsettigPASpntaa Pt *, bl siVOLIOWUSUOD JOBS KOY 20 Sy]«(QMO)SUID fOw »SIGLYNG OPIOIDAH « SwOOg MANS PAjnHors «Rurug eSouorss edoeSIGNBOUDUDFINS «E.xseeyAapoyAcOH«SWGISAS OILIAGpeadsAGILYWeIODd-SWISS CQUUID JEN PAOAGILESAODPaUNOW,Aapoy «SOD JODIGD OQDEAD|K »Hel}OOS1 Oi SELIOOTAOD BEMLOGI JOPOOPUN QO?D BIQojlOay' uedcoy aBarcys a;FeAad J8p70Ng truved utda |BY"VOUSTUSUCSJanuGxOg§JeMO]BU!uewaSuorpvaioarnapetyAQpeyuGowampjouswiagauddonedaotuusunu0]USsep su ompaoSaiuysAaqayAgogxnpLy UbuurnyUise7nyBy)"senuD paadsBQOUDADyJODdwypadainda80UDseuLaowSU"apOo.NnPDASJayINGSIONUBUODPusCSByLOTUOSQOIDOAS6.5SUDKOOAQUOSFIDuDaesSAUD, SIQQUCD IooUFeG "uasAS ADOMODyeco:eurSue omy D AG JepOOWNeu;uSnony panow a saaiog "SING IFUYE IGN}Syl JO BDF yIOQ GYi UO PoyNowSUSUIONDSUdZDSFDISTPADPLOpazennd©Bus;Ly 'SiGeOyeCOY1DJasUSDWOJBADY 3DElJoymoOwoudeclAyseu)ey! ASIQEV WMLLGDSMOEDPUDBCA]Sy JO SGULNOWOWLOpax&a>§QuadBy!"HO UEP10;Egy PUD Gamo UPA pEezurEesarcPPaDSesIOYAUILIOWY"SUNOSOF&GLA E94."aug AIBDMOSWiHdlO0S119army5uS5paay©up Janooun6G0qAaimayactosAuoyosUOwALDY1pASHO5]PBFY Td JBPOOUN NANG Gag AmDVoES weet: weoegScpaWEa tarog Tom Monter From:Jerry Spehar [Jes@heylpatterson.com]"Sent:Wednesday,March 26,2003 11:45 AM To:Tom.monter@pes-world.com Subject:Tom POF shows Barge_Unloaders.p df Tom In response to our telephone conversation,I've attached a pdf of our barge unloaderbrochure.As discussed a ballpark price on an unloader delivered the jobsite in Alaska is $3.5 million.If you have any questions,please feel free to contact me. Regards Jerry Spehar Ph.724-743-1000 Fax 724-743-2850 Jerry Spehar Ph.724-743-1000 x Fax 724-743-2850 Tom Monter From:Jerry Spehar [Jes@heyipatterson.com]Sent:Thursday,March 27,2003 4:06 AM To:Tom.Monter@pes-world.com Subject:RE:Tom BP103.dwg Tom This equipment is in not portable in any way.It is to be mounted on substantial cells, which I have never hear of being damaged by weather conditions.See attached drawing for a general idea of equipment size.It usually costs 30%of the cost of the equipment to erect,however I suspect costs will be higher in Alaska. Jerry Spehar Ph.724-743-100Q Fax 724-743-2850 >>>"Tom Monter"<Tom.Monter@pes-world.com>03/26/03 03:37PM >>> Jerry, I did have a few additional questions for you.I wanted to know what the erection costs would be for a system like this (ballpark figure).What happens if we have to move it from the river each year? The belt from the unloader:is it a boom or would it be supported at both ends? Next question is,what kind of foundation does the unloader require?is it on pontoons or do you have to sink some type of pilings into the river.This last question concerns me the most as we have to deal with the river ice and sprink breakup which could damage permanent pilings.We may have to make pilings that can be removed at the end of the shipping season if they are required. One final question would be what is the total power required to operate an unloader like this?This is important as we have to adjust power plant size and output based on equipment loads.Thanks. Tom Monter (208)772-4457 Precision Energy Services 10780 N,Highway 95 - Hayden Lake,ID 83835 Tom.monter@pes-world.com -----Original Message----- 'From:Jerry Spehar [mailto:Jes¢heylpatterson.com] Sent:Wednesday,March 26,2003 11:45 AM To:Tom.monter@pes-world.com Subject:Tom Tom In response to our telephone conversation,I've attached a pdf of our barge unloader brochure.As discussed a ballpark price on an unloader delivered ithe jobsite in Alaska is $3.5 million.If you have any questions,please .feel free to contact me. Regards Tom Monter _From:Jerry Spehar [Jes@heylpatterson.com] "\Sent:Thursday,March 27,2003 10:05 AM To:Tom.Monter@pes-world.com Subject:RE:Tom Tom Yes,all of our projects are custom designed for the client's application.Costs I gave you assumed wider barges than shown on the print. regards Jerry >>>"Tom Monter”™<Tom.Monter@pes-world.com>03/27/03 11:56AM >>> Jerry, I did have one more question for you concerning this unloader:Can it be adapted for wider barges?the barges we will likely be using are likely going to be 60-80ft wide not 30ft.Also what effect if any would this have on the capital costs?Thanks. Tom Monter -----Original Message----- From:Jerry Spehar {mailto:Jes¢heylpatterson.com] Sent:Thursday,March 27,2003 4:06 AM To:Tom.Monter@pes-world.com Subject:RE:Tom Tom This equipment is in not portable in any way.It is to be mounted on substantial cells,which I have never hear of being damaged by weather conditions.See attached drawing for a general idea of equipment size.It usually costs 30%of the cost of the equipment to erect,however I suspect costs will be higher in Alaska. Jerry Spehar Ph.724-743-1000 Fax 724-743-2850 Tom Monter __From:James J.Wallaert [James@heylpatterson.com] "Sent:Tuesday,April 01,2003 9:04 AM To:Tom.Monter@pes-world.com Ce:jcowles@heylpatterson.com;Jerry Spehar Subject:CBU Unloader for Alaska Tom, Jerry is on vacation this week so I am pinch-hitting to answer his email.The approximate weight of the machine is: Boom,including buckets,chain and bucket drive..............265,000# Trolley,including boom hoist and discharge chute.............145,000# Main structure,including conveyor and positioner.............425,000# The approx.erection man-hours are; Structural/mechanical.....cece ccc cece eee eee ee eee eens 8500 mhr ELSCtrical...cece eee ee eee ee ee ee eee eee ee ee ee eee eee ees 3000 mhr Should you need additional information,please call. Regards, Jim Wallaert Tom Monter _From:James J.Wallaert [James@heylpatterson.com]""\Sent:Wednesday,April 09,2003 6:21 AM To:Tom.Monter@pes-world.com Ce:Jerry Spehar Subject:RE:CBU Unloader for Alaska Tom, Our estimate would be that 5-40ft containers would be required.They would contain the following parts:Handrail,walkway sections with grating,buckets with chain,drives,wire rope,overhead crane,electrical equipment .The remainder of the equipment would be break-bulk and would include the following parts;Trolley,Boom structure,boom hangers, Bucket drive,main structural box members,conveyor structure with idlers attached, maintenance crane. Our budget price would include delivery to Bethel,Alasaka. Jim Wallaert >>>"Tom Monter"™<Tom.Monter@pes-world.com>04/08/03 03:21PM >>> Jerry, Do you have any idea of how many containers would be required for shipping the unloader?(40 foot containers I assume).Also how much of the assembly would not be shipped in containers.Also I was told the FOB price was delivered in Alaska,which port or was that delivered to Bethel?Thanks. Tom Monter -----Original Message-----; From:James J.Wallaert [mailto:James@heylpatterson.com] Sent:Tuesday,April 01,2003 9:04 AM To:Tom.Monter@pes-world.com Cc:jcowles@heylpatterson.com;Jerry Spehar Subject:CBU Unloader for Alaska Tom, Jerry is on vacation this week so I am pinch-hitting to answer his email. The approximate weight of the machine is: Boom,including buckets,chain and bucket drive..............265,000# Trolley,including boom hoist and discharge chute.............145,000# Main structure,including conveyor and positioner.............425,000# The approx.erection man-hours are; Structural/mechanical......ccc cee eee ee eee eee eee eee eee eens 8500 mhr ElLSOctrical...cc ee ee ee ete eee eee ee ee ee teen eee 3000 mhr 8 + Should you need additional information,please call. Regards,. Jim Wallaert Tom Monter _From:James J.Wallaert [James@heylpatterson.com] "Sent:Friday,May 30,2003 1:20 PM 'To:Tom.Monter@pes-world.com Ce:jcowles@heyipaiterson.com;Jerry Spehar Subject:Re:A few CBU questions concerning foundations. Hello,Tom, Concerning your attached email of 5/28,the supply of our continuous bucket unloader is generally limited to the machine only--we specify the size,number and location of anchor bolts but the design of the foundations is by others.Thus,the pile caps and number of piles are based upon our loads but the pile number,length and arrangement is by others. The additional loads to be considered would be the impact loads imparted to the foundation by the machine and we recommend that this be at least 25%. The general drawings which we had earlier sent was a "bridge-type"machine with two support columns located inshore and two support columns located offshore.Indeed,we have built machines were all four columns are located inshore which is called a "cantilever- type"machine.The loads previous given for the bridge-type would NOT apply to the cantilever-type.: We are not familiar with piling design and the time necessary to install them. Regards, Jim Wallaert >>>"Tom Monter"<Tom.Monter@pes-world.com>05/28/03 05:26PM >>> We have some more specific questions concerning the continuous barge un-loader and the required dock &Piling mounting. Are there additional loads that must be considered before building a mounting for this?What type of loads do the pilings need to support?Are there any special considerations for the pilings? Can the un-loader have one side mounted on the shore or should it be totally offshore? Is one method of mounting the un-loader preferable?(Offshore or partly mounted onshore?) For the pilings,how are they installed?Are the pre-fabricated and sunk as a whole or in sections? How many man-hours do the pilings for the Un-loader take?Also,how much concrete is required for the pilings? Should the pilings be shielded in case a barge bumps into them? Tom Monter (208)772-4457 Precision Energy Services 10780 N Highway 95 Hayden Lake,ID 83835 Tom.monter@pes-world.com Tom Monter From:James J.Wallaert [James@heylpatterson.com] ™Sent:Monday,June 02,2003 11:36 AM To:Tom.Monter@pes-world.com Ce:jcowles@heyipatterson.com;Jerry Spehar Subject:RE:A few CBU questions concerning foundations. Tom, We are indeed familiar with this photo/picture,as it is a rendering of a barge unloader proposed by a company in Richmond,B.C..Seabulk Systems.We worked with them on a proposal and the boom and trolley that is shown is a "Heyl Patterson".The support structure and catamaran were developed by Seabulk. Jim Wallaert >>>"Tom Monter”<Tom.Monter@pes-world.com>06/02/03 11:10AM >>> James, I have a couple more questions concerning the unloader.Since we have the ice breakup problem in Bethel,would it be possible to modify the design to fit the attached picture.This is a picture of a catamaran barge unloader.A unloader of this type doesn't need to be seaworthy,just be able to be moved to a slough during the winter to prevent damage by river ice.Since we have so many issues with river ice,an idea such as this would be preferrable. Please let me know what you think.If you can,quote me on the additional cost compared to the shore and piling mounted version.Thanks. Tom Monter @ ® a1'-0"=§TO fF GROERS &COLLONS ors"or-6" T/GIRBER STL. CLs 65e-" sy-r-fro Ecos "cl FA ° OPERATORS CAB \ag an r]4 ccyoe ,J (a¥}Try T Try iFeymahafarelenaleglearekecakL=|4 }- == ak y TN TA,4 Se ene Te .|a or\LAND SIDE 'J a - ESE aces pee ac voy a Ep Bi es Fe y HIGH VATER3)EL»60e-¥ - ZELB-2 "wena,WATERiser \ELEVATION of INBOARD COL UMNS-COL Leet LINE arefse-9 c LOWEST DIGGING a7)EL.Se4-6°\ |per rr We DARE ee 2 '- SIDI_ELEVATIONofUNLOADER@4i'-0° §TOP GIRDERS &COLLINS © oy-6".2y-6" rs ve Wel 72f TOf TROLLEY Rams vs ae ove iva ve 6Y'-¢°-0VERALL_LOTH of MAIN GIRDER 5 Fa fconner |A oe w-r-fro peaues er 3 ve TROLLEY TROLLEY §wars €L=652"-¢"POSITIONER -.|T/GIRDER STEEL .Neosfle6so-7 2 |LADDER iS 3 ye sine Lom qd t T $TAS i --*v s ae a .aan a ;;;T.*:1 HH |©|at $+--+a . °ny woomeeEH TD | , BOOM PrvoT STOW HOOK s B |a > baer a8 2B =|g ) >>T/CONV.BELT va as y Ls os it pe ry 5 >- b a u+%.N: an TROLLEY ae °rr ,|bas SI WATER sine >Tconc.eo"-: fa sire -a §|R Z. pEierg tes an =i !>ie 'es 3 a |me =saree3B)sagt warer O°6"BUCXET-TYP, ie]eso"Ls >!Low warer Fe ®4 a Le sor &- ELAN_TEY AANY ae WIE LSS..owe \.£ieee BPO103 "6 ig =an Ta i wre ware EYL &Parrmrson,Inc. BS -in IABte07 --MELes-RIVER FLOW BARE_TRAVEL,=cities} DURING OPERATION a ed oor oad WICEPTEN Saal -OeL.PvE een |PR Coron 8 ha peor oF HE =,OH ELEVATION Me uneuehoconOONE FoROUINeeG |Oy ee onee ENTIfi Tr I [BG rT ps I Ir ee (SSS SSS 5525S Sania====---=====.|q t hed hl hid hed Lf |J.TeTTTt HEYL PATTERSUN C 7MAN TAKRAF,Inc.MAN .TAKRAF APRIL 25.2003 7995 East Prentice Avenue Suite 211 Greenwood Village,Colorado 80111 Telephone:303 770 8161 Facsimile:303 770 6307 E-mail:ghertel@takraf.comPRECISIONENERGYSERVICES 10780 N.HIGHWAY 95 HAYDEN LAKE,ID 83835 Attn.Mr.Tom Monter Tel.:208 -772 -4457 SUBJECT:STACKING /RECLAIMING SYSTEMS POWER PLANT,FUEL STORAGE SYSTEM MAN TAKRAF REF.:P306 -01 Dear Mr.Monter. We refer to your E-mail inquiry dated April 10.2003,and comment /quote as follows: We could propose 2 systems suited for your application.One system consists of 2 individual machines,1 x Stacker and 1 x Portal Reclaimer.The second system would be one combined Bucket Wheel Stacker/Reclaimer. SYSTEM #1: -1X Traveling Luffing Stacker -1x Full Portal Scraper Reclaimer The Stacker and the Reclaimer operate independent of each other.While one pile is being stacked,the other pile can be reclaimed.Both machines are even able to work on one pile,since the Reclaimer has a special control logic to reclaim sections out of a pile. Each machine has its own conveyor and its own set of rails. We attach data sheets for the Stacker and the Portal Reclaimer . SYSTEM #2: -1X Bucket Wheel Stacker/Reciaimer. Here we assumed that stacking and reclaiming would not happen at the same time. The Bucket Wheel Stacker/Reclaimer is a combined machine with a reversible boom conveyor.This machine requires only one set of rails and one yard conveyor,which is used for stacking and reclaiming.The yard conveyor is not reversible. Page 1 of 3 J)MAN TAKRAE,Inc. [MAN TAKRAF The machine is also equipped with a bypass /splitter gate,which allows the material flow to be split if required. This gate can be set to: -100%Bypass -100%Stacking -Split in certain percentages for stacking and bypass The reclaim rate of S0OMTPH is small as to what a Bucket Wheel can achieve,however this combined Stacker/Reclaimer is attractive in the overall cost.Besides the lower machine price,only one conveyor and 1 set of rails are required. Attached is a data sheet with major technical data. SYSTEM #3: .Besides the above 2 systems,some special designs are also available,such as using a Portal Reclaimer and attach a tripper and a stacker boom to it.These are however very special designs,and need to be specifically engineered for this application. STORAGE VOLUME: We attach a preliminary storage volume calculation,showing that with the given pile dimensions,a storage capacity of only 86,600MT can be achieved.These pile dimensions also result in a pile height of approx.24m,which is very high for a coal pile.The internal pressure with the presence of air pockets in the pile could lead to instantaneous combustion.One way to avoid this is to compact the pile with dozers,however this would deform the pile,make it difficult to be reclaimed by a Portal Reclaimer. We would recommend not exceeding a 18m pile height without compacting. DRAWINGS /SKETCHES: We attach 2 sketches made in VISIO,showing plan views of system #1 and #2.We also attach 2 drawings,one showing a Stacker and a Portal Reclaimer operating on one pile, and the second one showing a typical Bucket Wheel Stacker/Reclaimer. PRICING: SYSTEM #1: STACKER: -approx.weight:154 MT -machine ex-works:$1.85 million -set of rails:$500,000.- -appr.Freight to Port of Export incl.Export packing:$120,000.- -approx.erection man-hours:7,500 hrs. Page 2 of 3 J)MAN TAKRAF,Inc._%[_MANTAKRAF PORTAL RECLAIMER: -approx.weight:285 MT -machine ex-works:$3.2 million -set of rails:$480,000.- -appr.Freight to Port of Export incl.Export packing:$160,000.- -approx.erection man-hours:12,000 hrs. SYSTEM #2: BUCKET WHEEL STACKER /RECLAIMER: -approx.weight:450 MT -machine ex-works:$4.4 million -set of rails:$500,000.- -appr.Freight to Port of Export incl.Export packing:$190,000.- -approx.erection man-hours:17,000 hrs. Please note that the above pricing is budgetary only with an accuracy of plus /minus 15% Delivery time for each system is approx.12 -14 months. We hope that the information submitted is still helpful for your studies.Please do not hesitate to contact us in case of any questions. SINCERELY MAN TAKRAF Inc. \orreanst Sy.Henied?- GERHARD T.HERTEL Page 3 of 3 PRELIMINARY STORAGE CALCULATION CONSULTANT: CUSTOMER: REFERENCE: LOCATION: EQUIPMENT: KRI -REF.#: DATE: MATERIAL: DENSITY: ANGLE OF REPOSE: NUMBER OF PILES PILE WIDTH: PILE LENGTH: DISTANCE BETW.2 PILES PILE WIDTH =a PILE HEIGHT =h ANGLE OF REPOSE =b TAN.ANGLE ANGLE OF REPOSE PILE LENGTH =L FL CR.SECT.LENG=L1 CONE LENGTH =L2 CROSS SECT.PILE=A CONE VOL.=CV FULL CROSS SECT.PILE VOL. TOTAL PILE VOL.=PV PILE CAPACITY ACTUAL PILE CAPACITY REQUIRED TOTAL STORAGE LENGTH PRECISION ENERGY SERVICES POWER PLANT USA COAL HANDLING USA STACKING /RECLAIM SYSTEMS P 306 -01 APRIL 24.2003 US -SYSTEM COAL 50.00 PCF 38 DEGREE 4 200 FT 584 FT 6 FT 200 FT 78 FT 38 DEGREE 0.78 FACTOR 584 FT 384 FT 200 FT 7,813 SQFT 817,746 CUBFT 3,000,137 CUBFT 3,817,882 CUBFT 95,447 ST 3,817,882 CUBFT 137,787 ST 5,511,464 CUBFT 2,354 FT METRIC COAL 0.80 T/M3 38 DEGREE 4 61 M 178 M 2 M 61 M 24 M 38 DEGREE 0.78 FACTOR 178 M 117 M 61 M 726 SQM 23,168 CUBM 84,954 CUBM 108,122 CUBM 86,600 MT 108,122 CUBM 125,000 MT 156,065 CUBM 717 M SjMAN TAKRAF,Inc./MAN :TAKRAF MAY 21.2003 7995 East Prentice Avenue Suite 211 Greenwood Village,Colorado 80111 Telephone:303 770 8161 Facsimile:303 770 6307 E-mail:ghertel@takraf.comPRECISIONENERGYSERVICES 10780 N.HIGHWAY 95 HAYDEN LAKE,ID 83835 Attn.Mr.Tom Monter Tel.:208 -772 -4457 SUBJECT:BUCKET WHEEL STACKER/RECLAIMER POWER PLANT BETHEL,ALSKA,FUEL STORAGE MAN TAKRAF REF.:P306 -01 Dear Mr.Monter. We refer to your E-mail dated May 15.2003,and comment as follows: 1.AVAILIBILITY: We unfortunately do not have a data collection on operating Bucket Wheel Machines regarding the availability of these machines.Customers are not too keen to share these internal operating data. We developed the availability factor of 95%based on the lifetimes of the mechanical and electrical components,the replacements during warranty and the spare parts ordered. This factor of 95%includes the operating time of the machine.The regular maintenance is not included in this figure.This factor is also based on proper maintenance being performed on a regular base.To give you an idea on the kind of maintenance,|attach a very general maintenance schedule.The time listed in each single category is for checking,lubrication,cleaning,etc.The time required for possible repairs is not included. 2.BELT SCHEME: The standard Bucket Wheel Stacker/Reclaimer operates with a non-reversible yard conveyor.The yard conveyor is looped around a tripper connected to the Bucket Wheel Machine.A diverter gate is installed underneath the tripper discharge pulley,to direct the coal either onto the boom conveyor for stacking,or into a bypass chute system discharging the coal back onto the yard conveyor.When replacing this diverter gate with a splitter gate,the material flow could also be split in certain percentages between stacking to the pile and discharging back to the yard conveyor. Page 1 of 3 "J MAN TAKRAF,Inc.-MAN TAKRAF A reversible yard conveyor is used when the reclaimed coal has to be conveyed back to the transfer tower.In this case the Bucket Wheel tripper is provided with it's own conveyor,and a collapsible tripper is located in the yard conveyor. When stacking,the tripper in the yard conveyor will discharge the coal onto the tripper conveyor and then to the boom conveyor. When reclaiming,the tripper in the yard conveyor will be collapsed.Coal will be discharged from the boom conveyor (reverse direction)directly onto the yard conveyor. The yard conveyor will be reversed. For better understanding |attach a sketch showing a Bucket Wheel Machine with a standard tripper,and a sketch showing a Bucket Wheel with a tripper conveyor and a collapsible yard conveyor tripper.Another sketch shows more details on the tripper/conveyor and the collapsible tripper. In all above cases only one yard conveyor is used. To have a redundant system,at least in the reclaim mode,a second parallel yard conveyor could be installed.On the Bucket Wheel Machine we would provide a chute system,allowing the reclaimed coal to be discharged to either conveyor.With this scheme you would have a redundant reclaim system,the stacking would still be based on one conveyor. 3.TOWER HEIGHT: As mentioned in my e-mail dated May 14,this machine would have a mast with a top elevation of approx.30m above top of rail.It is definately possible to reduce this height by using a different design,however this would require a detailed layout and some engineering. 4.DIFFERENT BUCKET WHEEL SYSTEM: This is just for your information.When |discussed your project in Germany with our engineers,they came up with another scheme.This is a circular storage system using a Bucket Wheel Stacker/Reclaimer.The machine has a pivot point where the yard conveyor ends,and is traveling on a curved rail to built a kidney shaped pile.Through the slewing bucket wheel boom,any position in the pile can be reached. Let me know if this is of interest to you. Page 2 of 3 syMAN TAKRAF,Inc. f MAN TAKRAF We hope that the information submitted iis helpful for your studies.Please do not hesitatetocontactusincaseofanyquestions. SINCERELY MAN TAKRAF Inc. \oreanst Sp.Herte?- GERHARD T.HERTEL Page 3 of 3 PRELIMINARY MAINTENANCE CHECKLIST BUCKET WHEEL STACKER/RECLAIMER -DAILY VISUAL WEEKLY VISUAL |MONTHLY CHECK |ANNUAL CHECKCOMPONENTCHECKFORsySTEM-_|SYSTEM RUNNING|SYSTEM STOPPED |SYSTEM STOPPEDRUNNNING MECHANICAL COMPONENTS NOISE X r XIDLERSPROPERLYROTATINGxx CENTERED LOAD X x DAMAGED SURFACE x X BELT DAMAGED EDGES X X CONDITION OF SPLICE X X STRAIGHT RUN x X PROPERLY GREASED x X BELT TAKE-UP SYSTEMS PROPER TENSION X x EQUAL LOADING X x BEARING NOISE X XPULLEYSRUBBERLAGGINGXx ROTATION X x DUST X x LOADING POINTS RUBBER SEALS x x RUBBER BOOT X x LEAKS X X HYDRAULIC SYSTEMS HOSES x x PROPER FUNCTION x NOISE X x OIL LEVEL X x\VEYOR DRIVE ASSEMBLY ot ENE * PROPER FUNCTION x NOISE X x OIL LEVEL X XSLEWDRIVEASSEMBLYore PROPER FUNCTION X NOISE X x SLEW BEARING EQUAL SPACING X X PROPERLY GREASED X X LEVEL GREASE CONTAINER x X GREASE SYSTEM SLEW BEARING BLOCKED LINES x x PROPER FUNCTION X NOISE X x OIL LEVEL X XTRAVELDRIVEASSEMBLYeerramx PROPER FUNCTION x NOISE ON BEARINGS X X TRAVEL WHEELS WHEEL WEAR X X PROPERLY GREASED x x PROPERLY GREASED X x PIVOT POINTS EQUALIZER,BOGIES noes z - NOISE X X OIL LEVEL x x RUC KET WHEEL DRIVE ASSEMBLY ee x PROPER FUNCTION Xx NOISE x xBUCKETWHEELBEARINGSNSEGHEXSEDx x Page 1 of2 DAILY VISUAL |WEEKLY VISUALCOMPONENTCHECKFORSYSTEM MONTHLY CHECK |ANNUAL CHECK 7 SYSTEM RUNNING |SYSTEM STOPPED |SYSTEM STOPPED - RUNNNING SLAIM BUCKETS WEAR X X LINERS IN PLACE X X TRANSFER CHUTES WEAR ON LINERS X X MATERIAL BLOCKAGE X X CORRECT POSITION X x SPLITTER GATE PROPER FUNCTION XWEARXxx CORRECT POSITION X X RAIL CLAMPS PROPER FUNCTION x x ALIGNMENT x BEARING NOISE X X FAN NOISE x XELECTRICALMLECTRICALMOTORSALIGNMENT x PROPER OPERATION x ELECTRICAL FIELD DEVICES PROPER MOUNTING X XEMERGENCYSTOPSWITCHESPROPERFUNCTIONxx PROPER MOUNTING X XZEROSPEEDSWITCHESPROPERFUNCTIONx PROPER MOUNTING x XBELTMISALIGNMENTSWITCHESPROPERFUNCTIONx PROPER MOUNTING X xcLPROBESPROPERFUNCTIONx PROPER MOUNTING X XANGLEENCODERSPROPERFUNCTIONX PROPER MOUNTING X xLIMITSWITCHESPROPERFUNCTIONX PROPER MOUNTING X xBACK-UP LIMIT SWITCHES PROPER FUNCTION x PROPER MOUNTING X XLOCALP.B.STATIONS PROPER FUNCTION Xx CABLE /WIRE TERMINATIONS PROPERLY CONNECTED x x PERSONNEL/TIME REQUIRED HRS HRS HRS HRS OPERATOR 1 --: ELECTRICIAN °2 6 9 MECHANIC °4 8 18 PIPE FITTER °°2 ° NOTE: Above hours cover checking,cleaning and lubricating only.Maintenance,repairs,repaicements,etc.,are not included. Page2of2 MAN TAKRAF,INC. SERVICE REPRESENTATIVE COMMISSIONING ENGINEER AT THE CUSTOMER'S REQUEST,MTI WILL FURNISH THE SERVICES OF A COMPETENT SERVICE ENGINEER,BASED ON THE FOLLOWING FEE SCHEDULE. THE CHARGE PER CALENDAR DAY,WHICH INCLUDES TRAVELING IS: COST FORA SERVICE ENGINEER:$1,200.00 PER 8 HOUR DAY/CALENDAR DAY, BASED ON A 40 HOUR WORK WEEK (EXCLUDING ALL LOCAL TAXES ) $150.00 PER HOUR THE MINIMUM CHARGE WILL BE AN 8 HOUR DAY (EXCLUDING ALL LOCAL TAXES ) OVERTIME WILL BE CHARGED AS FOLLOWS: 150%:FOR EACH ADDITIONAL HOUR OVERTIME PER DAY (EXCEEDING 8 HRS.PER DAY,MONDAY THROUGH FRIDAY,AND ALL SATURDAY) 175%:FOR ALL SATURDAYS,SUNDAYS AND HOLIDAYS SUITABLE HOTEL ACCOMMODATION,EXPENSES AND TRAVELING WILL BE AT THE ACTUAL INCURRED COST.(30 CENTS PER MILE FOR COMPANY OR PRIVATE AUTOMOBILE,RENTAL CAR INCLUDING GASOLINE AT ACTUAL COST).DOMESTIC AIR TRAVEL WILL BE IN COACH,OVERSEAS AIR TRAVEL WILL BE IN BUSINESS CLASS. LIVING ALLOWANCE WILL BE CHARGED AT A FIXED RATE OF $50.00/PER CALENDAR DAY,INCLUDING | TRAVEL DAYS. COST OF TELEPHONE CALLS,INTERNET SERVICE,TELEFAXES,ETC.WILL BE INVOICED AS PER ACTUALS. AFTER EVERY THREE MONTHS STAY ON SITE,SERVICE REPRESENTATIVE IS ENTITLED TO ONE TRIP HOME.AIRFARE TO BE PAID BY CUSTOMER. THE CUSTOMER IS TO MAKE ALL PREPARATIONS IN SUCH A WAY THAT MTI SERVICE PERSONNEL MAY COMMENCE WORK AND PROCEED WITHOUT DELAY. SINCE THE PER DIEM CHARGE DOES NOT COVER THE COST OF INSURING AGAINST THE RISK AND HAZARDS INVOLVED IN PROVIDING THIS SERVICE,THE CUSTOMER AGREES TO HOLD MT!FREE AND HARMLESS AGAINST ALL CLAIMS AND ACTIONS CONNECTED WITH OR ARISING OUT OF ANY ACT OR OMISSION OF SUCH PERSON IN PERFORMING SERVICES HEREUNDER. MT1]WILL PROVIDE PURCHASER WITH EVIDENCE OF WORKER'S COMPENSATION INSURANCE COVERAGE,IN ACCORDANCE WITH THE LAWS OF THE STATE WITHIN THE USA UNDER WHICH SUCH 'COMPENSATION !S PAYABLE,OR EMPLOYER'S LIABILITY INSURANCE TO PROTECT MTI REPRESENTATIVE.MTI WILL ALSO PROVIDE EVIDENCE OF GENERAL LIABILITY INSURANCE AND AUTOMOBILE INSURANCE COVERAGE AS NEEDED. ACCEPTANCE OF THE ABOVE TERMS FOR FIELD SERVICES SHALL CONSTITUTE AN AGREEMENT INDEPENDENT OF,AND SEPARATE FROM ANY CONTRACT TO FURNISH AND SELL EQUIPMENT. PAYMENT FOR SUCH SERVICES SHALL BE MADE WITHIN TWENTY (20)DAYS OF DATE OF INVOICE. THE ABOVE STATED RATES ARE SUBJECT TO CHANGE Rev.05/03 AdMAN TAKRAF,INC. -SERVICE REPRESENTATIVE ELECTRICAL /CONTROLS /INSTRUMENTATION SITE ADVISOR AT THE CUSTOMER'S REQUEST,MTI WILL FURNISH THE SERVICES OF A COMPETENT SERVICE ENGINEER,BASED ON THE FOLLOWING FEE SCHEDULE. THE CHARGE PER CALENDAR DAY,WHICH INCLUDES TRAVELING IS: COST FORA SERVICE ENGINEER:$1,080.00 PER 8 HOUR DAY/CALENDAR DAY, BASED ON A 40 HOUR WORK WEEK (EXCLUDING ALL LOCAL TAXES ) $135.00 PER HOUR THE MINIMUM CHARGE WILL BE AN 8 HOUR DAY (EXCLUDING ALL LOCAL TAXES ) OVERTIME WILL BE CHARGED AS FOLLOWS: 150%:FOR EACH ADDITIONAL HOUR OVERTIME PER DAY (EXCEEDING 8 HRS.PER DAY,MONDAY THROUGH FRIDAY,AND ALL SATURDAY) 175%:FORALL SATURDAYS,SUNDAYS AND HOLIDAYS SUITABLE HOTEL ACCOMMODATION,EXPENSES AND TRAVELING WILL BE AT THE ACTUAL INCURRED COST.(30 CENTS PER MILE FOR COMPANY OR PRIVATE AUTOMOBILE,RENTAL CAR INCLUDING GASOLINE AT ACTUAL COST).DOMESTIC AIR TRAVEL WILL BE IN COACH,OVERSEAS AIR TRAVEL WILLBEINBUSINESSCLASS. LIVING ALLOWANCE WILL BE CHARGED AT A FIXED RATE OF $50.00/PER CALENDAR DAY,INCLUDING TRAVEL DAYS. COST OF TELEPHONE CALLS,INTERNET SERVICE,TELEFAXES,ETC.WILL BE INVOICED AS PER ACTUALS. AFTER EVERY THREE MONTHS STAY ON SITE,SERVICE REPRESENTATIVE IS ENTITLED TO ONE TRIP HOME.AIRFARE TO BE PAID BY CUSTOMER. THE CUSTOMER IS TO MAKE ALL PREPARATIONS IN SUCH A WAY THAT MTI SERVICE PERSONNEL MAY COMMENCE WORK AND PROCEED WITHOUT DELAY. SINCE THE PER DIEM CHARGE DOES NOT COVER THE COST OF INSURING AGAINST THE RISK AND HAZARDS INVOLVED IN PROVIDING THIS SERVICE,THE CUSTOMER AGREES TO HOLD MTI FREE AND HARMLESS AGAINST ALL CLAIMS AND ACTIONS CONNECTED WITH OR ARISING OUT OF ANY ACT OR OMISSION OF SUCH PERSON IN PERFORMING SERVICES HEREUNDER. MTI WILL PROVIDE PURCHASER WITH EVIDENCE OF WORKER'S COMPENSATION INSURANCE COVERAGE,IN ACCORDANCE WITH THE LAWS OF THE STATE WITHIN THE USA UNDER WHICH SUCH COMPENSATION IS PAYABLE,OR EMPLOYER'S LIABILITY INSURANCE TO PROTECT MTI REPRESENTATIVE.MT!WILL ALSO PROVIDE EVIDENCE OF GENERAL LIABILITY INSURANCE AND AUTOMOBILE INSURANCE COVERAGE AS NEEDED. ACCEPTANCE OF THE ABOVE TERMS FOR FIELD SERVICES SHALL CONSTITUTE AN AGREEMENT INDEPENDENT OF,AND SEPARATE FROM ANY CONTRACT TO FURNISH AND SELL EQUIPMENT. PAYMENT FOR SUCH SERVICES SHALL BE MADE WITHIN TWENTY (20)DAYS OF DATE OF INVOICE. THE ABOVE STATED RATES ARE SUBJECT TO CHANGE Rev.05/03 ByMAN TAKRAF,INC. :SERVICE REPRESENTATIVE MECHANICAL/STRUCTURAL SITE ADVISOR AT THE CUSTOMER'S REQUEST,MT]WILL FURNISH THE SERVICES OF A COMPETENT SERVICE ENGINEER,BASED ON THE FOLLOWING FEE SCHEDULE. THE CHARGE PER CALENDAR DAY,WHICH INCLUDES TRAVELING IS: COST FORASERVICE ENGINEER:$960.00 PER 8 HOUR DAY/CALENDAR DAY, BASED ON A 40 HOUR WORK WEEK (EXCLUDING ALL LOCAL TAXES ) $120.00 PER HOUR THE MINIMUM CHARGE WILL BE AN 8 HOUR DAY (EXCLUDING ALL LOCAL TAXES ) OVERTIME WILL BE CHARGED AS FOLLOWS: 150%:FOR EACH ADDITIONAL HOUR OVERTIME PER DAY (EXCEEDING 8 HRS.PER DAY,MONDAY THROUGH FRIDAY,AND ALL SATURDAY) 175%:FOR ALL SATURDAYS,SUNDAYS AND HOLIDAYS SUITABLE HOTEL ACCOMMODATION,EXPENSES AND TRAVELING WILL BE AT THE ACTUAL INCURRED COST.(30 CENTS PER MILE FOR COMPANY OR PRIVATE AUTOMOBILE,RENTAL CAR INCLUDING GASOLINE AT ACTUAL COST).DOMESTIC AIR TRAVEL WILL BE IN COACH,OVERSEAS AIR TRAVEL WILL BE IN BUSINESS CLASS. LIVING ALLOWANCE WILL BE CHARGED AT A FIXED RATE OF $50.00/PER CALENDAR DAY,INCLUDING TRAVEL DAYS. COST OF TELEPHONE CALLS,INTERNET SERVICE,TELEFAXES,ETC.WILL BE INVOICED AS PER ACTUALS. AFTER EVERY THREE MONTHS STAY ON SITE,SERVICE REPRESENTATIVE IS ENTITLED TO ONE TRIP HOME.AIRFARE TO BE PAID BY CUSTOMER. THE CUSTOMER IS TO MAKE ALL PREPARATIONS IN SUCH A WAY THAT MTI SERVICE PERSONNEL MAY COMMENCE WORK AND PROCEED WITHOUT DELAY. SINCE THE PER DIEM CHARGE DOES NOT COVER THE COST OF INSURING AGAINST THE RISK AND HAZARDS INVOLVED IN PROVIDING THIS SERVICE,THE CUSTOMER AGREES TO HOLD MTI FREE AND HARMLESS AGAINST ALL CLAIMS AND ACTIONS CONNECTED WITH OR ARISING OUT OF ANY ACT OR OMISSION OF SUCH PERSON IN PERFORMING SERVICES HEREUNDER. MTI WILL PROVIDE PURCHASER WITH EVIDENCE OF WORKER'S COMPENSATION INSURANCE COVERAGE,IN ACCORDANCE WITH THE LAWS OF THE STATE WITHIN THE USA UNDER WHICH SUCH COMPENSATION IS PAYABLE,OR EMPLOYER'S LIABILITY INSURANCE TO PROTECT MTI , REPRESENTATIVE,MTIWILE ALSO PROVIDE EVIDENCEOF GENERAL LIABILITY INSURANCEShedFNLedetiedEO AUTOMOBILE INSURANCE COVERAGE AS NEEDED. ACCEPTANCE OF THE ABOVE TERMS FOR FIELD SERVICES SHALL CONSTITUTE AN AGREEMENT INDEPENDENT OF,AND SEPARATE FROM ANY CONTRACT TO FURNISH AND SELL EQUIPMENT. PAYMENT FOR SUCH SERVICES SHALL BE MADE WITHIN TWENTY (20)DAYS OF DATE OF INVOICE. THE ABOVE STATED RATES ARE SUBJECT TO CHANGE Rev.05/03 --py4swee PLANVIEW BUCKET WHEEL STACKER /RECLAIMER SYSTEM #2 SLEVANG BOOMBUCKETWHESL, |*S.200m SLEW RANGE ',x'\ -4f--222--2--ee ew AL ee eee (eee ee eee eee eee eee REVERSIBLE BOOM \ PILE #1 p-CONVEYOR '. ' 1 i eepe=--_- gO -Eeeee (Ee;a STa-_nn aaah iN fn ee ee oeiy RECLAIM /STACKING YARD CONVE YOR \\BUCKET WHEELTRIPPERSTACKER/RECLAIMER MAN TAKRAF,ine. 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PROPOSED LAYOUT CROSS SECTION TOTAL WIDTH =424 ft AZ 108n aon {8a R 1217 RECLAIM CONVEYOR #1 STACKING CONVEYOR /PILE #1 /PILE #2 / RECLAIM CONVE YOR £2 file://C:\Documents%20and%20Settings\tmonter\Local%20Settings\Temp\REV.LAYOUT.... RALS HOPPER CAR 42 MAN TAKRAS,ino,04 2903GTH 7/7/2003 CONVEYOR ARRANGEMENT UNDERNEATH BUCKET WHEELSTACKER/RECLAINER CONVEYOR #1:60"WIDE STACKING &RECLAIM CONVEYOR #2:60"WIDE RECLAIM ONLY SLEW PLATFORM | i | i | i 1 oF| r t (gq _-__-__SLEW BEARING ' | | T tt Lu4+---4.1 ||CONVEYOR #2'NW i[||' il vo rej}ee |oe on MAN TAKRAF,Inc. 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YARD CONVEYOR MAN TAKRAF,Inc.R YARD CONVEYOR "1 MAY 21.2003 ':GTH file://C:\Documents%20and%20Settings\tmonter\Local%20Settings\Temp\DUAL.CONV.R...7/7/2003 i t 1 ta>_Dual Yard Conveyor ' i LT ' i] Reclaiming Yard Conveyor #2 1 100% 1) i) 'A100 % 1 ' i I 1 t 1 t 1 1 1 1 'i i ' J t 1 ' J 1Yr RupPERi]a 1 1 !' t i] t t t $ t 4 't ° i AN TAKRAF,IncARDCOMone.YARD CONVEYOR#2 YARD CONVEYOR #1 MAY 21.2003 1 'GTH5 file://C:\Documents%20and%20Settings\tmonter\Local%20Settings\Temp\DUAL.CONV.R...7/7/2003 /)Stacking 100% t >Dual Yard Conveyor ' ' ' MAY 21.2003 'GTH A 100 %a i \ 4 1 4 4 1 1 '100% 1 4 1 1 1 1 'oa '|- _T RIPPER i t 1 ' Fl i V 1 1 1 t ' ; YARD CONVEYOR #2 YARD CONVEYOR #1 MAN TAKRAF,Inc. 1 4 1 file://C:\Documents%20and%20Settings\tmonter\Local%20Settings\Temp\DUAL.CONV.S...7/7/2003 i]' i]'|»_Dual Yard Conveyor "Ao Stacking 50%'Bypass 50% '; t ' t 4 i 50%- 1 1 ]1 '1 100'% y|TRIPPER H 1 !| |! a 'MAN TAKRAF,Inc.YARD CONVEYOR f2 YARD CONVEYOR #1 MAY 2.70034' 1 file://C:\Documents%20and%20Settings\tmonter\Local%20Settings\Temp\DUAL.CONV:S...7/7/2003 7,---g-7 = 'RAILS 1 '1 i}ian™Single Yard Conveyor Bypass 100% |100%' ;i ', 't I t !1 't !' 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YARD CONVEYOR file://C:\Documents%20and%20Settings\tmonter\Local%20Settings\Temp\SING.CONV.ST...7/7/2003 GENERAL INFORMATION /DATA B.W.STACKER/RECLAIMER CONSULTANT:PRECISION ENERGY SERVICES CUSTOMER:POWER PLANT USA REFERENCE:COAL HANDLING LOCATION:USA EQUIPMENT:STACKER MTI-REF.#:P 306-01 DATE:APRIL 24.2003 SCOPE:DESIGN +SUPPLY MATERIAL DATA US -SYSTEM METRIC MATERIAL:COAL COAL DENSITY:50.00 PCF 0.80 T/M3 MOISTURE:6.00 %6.00 % LUMP SIZE:2.00 INCH 50.80 MM ANGLE OF REPOSE:|37.00 DEGREE 37.00 DEGREE STOCKPILE DATA STORAGE CAPACITY PER PILE (REQUIRED )137,787 ST 125,000 MT 5,511,464 CUBFT 156,065 CUBM STORAGE CAPACITY PER PILE (ACTUAL )95,447 ST 86,600 MT 3,817,880 CUBFT 108,122 CUBM NUMBER OF PILES:4 4 PILE WIDTH:200 FT 61 M PILE LENGTH:584 FT 178 M PILE HEIGHT:78 FT 24 M TOTAL STORAGE LENGTH:2,354 FT 717 M RECLAIM CAPACITY (NOMINAL)551 STPH 500 MTPH STACKING CAPACITY (NOMINAL )2,205 STPH 2,000 MTPH traveling into STACKING CAPACITY (INTO FLOW )2,418 STPH 2,194 MTPH yard conveyor RAIL GAUGE:26 FT 8 M BOOM CONVEYOR DISCHARGE PULLEY TO CENTER SLEW 132 FT 40 M CENTER PULLEY DISTANCE 165 FT 50 M BELT WIDTH 60 INCH 1,524 MM BELT SPEED 620 FPM 3 M/SEC DRIVE PULLEY DIAMETER 24 INCH 610 MM RETURN PULLEY DIAMETER 24 INCH 610 MM BELT TAKE UP AT TAIL PULLEY TAIL PULLEY CONVEYOR LIFT WITH BOOM AT HIGHEST POSITION 36 FT 11 M BOOM CONVEYOR DRIVE NUMBER OF MOTORS 1 1 MOTOR RATING 200 HP 150 KW BOOM HOIST BOOM HOIST TYPE HYDRAULIC HYDRAULIC BOOM TIP SPEED 12 FPM 0 M/SEC BOOM LOWEST POSITION "13 DEGREE -13 DEGREE BOOM HIGHEST OPERATING POSITION 12 DEGREE 12 DEGREE BOOM HIGHEST POSITION OUT OF OPERATION 15 DEGREE 15 DEGREE NO.OF LUFFING CYLINDERS 2 2 HYDRAULIC PUMP DRIVE NUMBER OF MOTORS 1 1 MOTOR RATING 30 HP 22 KW BOOM SLEWING TYPE OF DRIVE ELECTRO -MECHANIC,VARIABLE SPEED BOOM TIP SPEED 80 FPM 24 M/MIN SLEWING RANGE PILE 1 90 DEGREE 90 DEGREE TOTAL SLEWING RANGE 110 DEGREE 110 DEGREE SLEWING DRIVES NUMBER OF MOTORS 2 2 MOTOR RATING 15 HP 11 KW BUCKET WHEEL BUCKET WHEEL DIAMETER 11.48 FT 3.50 M BUCKET WHEEL SPEED 4.00 RPM 4.00 UPM BUCKET VOLUME 17.66 CUBFT 500.00 L NUMBER OF BUCKETS 5 5 BUCKET DISCHARGES 20 7 MIN 20 /MIN BUCKET WHEEL DRIVE NUMBER OF MOTORS 1 1 MOTOR RATING 100 HP 75 KW TRAVEL DRIVE TYPE OF DRIVE ELECTRO -MECHANICAL OPERATING TRAVEL SPEED 78.00 FPM 23.77 M/MIN NUMBER OF WHEELS MACHINE 32 32 HEREOF DRIVEN:16 16 NUMBER OF WHEELS TRIPPER 8 8 HEREOF DRIVEN 0 0 WHEEL DIAMETER 24 INCH 610 TOTAL TRAVEL DISTANCE:2,354 FT 717 M TRAVEL DRIVE NUMBER OF MOTORS 16 16 MOTOR RATING 75 HP 6 KW RAIL CLAMPS NUMBER OF RAIL CLAMPS 2 2 TYPE OF ACTUATION HYDRAULIC HYDRAULIC NUMBER OF MOTORS 1 1 MOTOR RATING 5 4 OPERATOR'S CABIN LEVELLING TYPE OF DRIVE HYDRAULIC HYDRAULIC LEVELLING RANGE -15 TO +15 DEGREE -15TO+15 |DEGREE HYDRAULIC PUMP DRIVE NUMBER OF MOTORS 1 1 MOTOR RATING 5 HP KW TIP OF BOOM SKIRTBOARD RAISE /LOWER TYPE OF DRIVE HYDRAULIC HYDRAULIC FED FROM SAME HYDRAULIC UNIT AS CABIN LEVELLING CENTER CHUTE SKIRTBOARD RAISE /LOWER TYPE OF DRIVE HYDRAULIC HYDRAULIC HYDRAULIC PUMP DRIVE NUMBER OF MOTORS 1 1 MOTOR RATING HP 2.2 KW 7 MISCELLANEOUS ITEMS 7 -BELT SCALE IN BOOM CONVEYOR TOTAL INSTALLED POWER 560 HP 420 KW MAXIMUM OPERATING POWER 480 HP 360 KW GENERAL INFORMATION /DATA TRAVELING,LUFFING,STACKER|CONSULTANT:PRECISION ENERGY SERVICESCUSTOMER:POWER PLANT USAREFERENCE:GOAL HANDLINGLOCATION:USAEQUIPMENT:STACKER MTl-REF.#P 306 -01 DATE:APRIL 24.2003SCOPE:DESIGN +SUPPLY US -SYSTEM METRIC MATERIAL DATAMATERIAL:GOAL GOALDENSITY:50.00 PCF 0.80 TIM3MOISTURE:6.00 %6.00 % LUMP SIZE:2.00 INCH 50.80 MM ANGLE OF REPOSE:37.00 DEGREE |37.00 |DEGREE STOCKPILE DATA STORAGE CAPACITY PER PILE (REQUIRED )137,787 ST 125,000 MT5,511,464 |CUBFT |156,065.|CUBM STORAGE CAPACITY PER PILE (ACTUAL )95,447 ST 86,600 MT3,817,860 |CUBFT |108,122 |CUBM NUMBER OF PILES:4 4 PILE WIDTH:300 FT 61 M PILE LENGTH:584 FT 178 M PILE HEIGHT:78 FT 24 M TOTAL STORAGE LENGTH:2,354 ET 717 M MACHINE DATA GENERAL STACKING CAPACITY (NOMINAL )3305 STPH 2.000 MTPH STACKING CAPACITY (DESIGN )2,418 STPH 2,194 MTPH _|lfaveling into yardconveyor RAIL GAUGE:20 FT 6 M BOOM CONVEYOR BELT WIDTH:60 INCH 1,524 MM BELT SPEED:620 FPM 3 M/SEC LOCATION DRIVE PULLEY:TAIL TAIL LOCATION TAKE UP PULLEY:TAIL TAIL CENTER DISTANCE PULLEYS:140 FT 43 M DISCH.PULLEY TO BOOM PIVOT:130 FT 40 M DISCH.PULLEY DIAM.:24 INCH 610 MM DISCH.PULLEY FACE WIDTH:66 INCH 1,676 MM DRIVE PULLEY DIAM.:24 INCH 610 MM DRIVE PULLEY FACE WIDTH:66 INCH 1,676 MM CONVEYOR LIFT AT HIGHEST POSITION:40 FT 12 M BOOM CONVEYOR DRIVE NO.OF MOTORS 1 1 MOTOR RATING 150 HP 110 KW BOOM HOIST BOOM HOIST SYSTEM: HYDRAULIC HYDRAULIC BOOM HIGHEST POSITION:17.00 |DEGREE 17.00 DEGREE BOOM LOWEST POSITION:-15.00 DEGREE -15.00 DEGREE BOOM LUFFING SPEED/BOOM TIP:7.50 FPM 2.29 M/MIN HYDRAULIC PUMP DRIVE _a NO.OF MOTORS 1 1 MOTOR RATING 10 HP 75 KW TRAVEL DRIVE OPERATING TRAVEL SPEED:60 FPM 18 M/MIN REPOSITIONING TRAVEL SPEED:60 FPM 18 M/MIN NO.OF WHEELS STACKER:10 10 HEREOF DRIVEN:8 8 NO.OF WHEELS TRIPPER:6 6 HEREOF DRIVEN:0 0 WHEEL DIAMETER:24 INCH 610 MM REQUIRED SIZE OF RAILS 171 CR 171 CR GANTRY SUPPORTING CONCEPT:3 -POINT 3 -POINT TOTAL TRAVEL DISTANCE:2,354 FT 717 M MAINTENANCE BAY:0 0 TRAVEL DRIVE NO.OF MOTORS 4 4 MOTOR RATING 15 HP 11 KW INSTALLED POWER 300 HP 220 KW MAXIMUM OPERATING POWER 260 HP 190 KW GENERAL INFORMATION /DATA PORTAL RECLAIMER,SINGLE ARM,WITH BENT CHAIN OUTDOOR APPLICATION,TYPE VP -1BNT. CONSULTANT:PRECISION ENERGY SERVICES CUSTOMER:|POWER PLANT USA |REFERENCE:-_|{COAL HANDLINGLOCATION:USA |EQUIPMENT:A-FRAME PORTAL RECLAIMER TYPE:VP-1/BENT MTI -REF.#:P 305 -04 |DATE:APRIL 25.2003 SCOPE:DESIGN+SUPPLY 7 US -SYSTEM METRIC MATERIAL DATA MATERIAL:COAL COAL DENSITY:VOLUME 50.00 PCF 0.80 T/M3 LOAD 50.00 PCF 0.80 T/M3 MOISTURE:oo -6.00 %6.00 % LUMP SIZE:2.00 INCH 50.80 MM ANGLE OF REPOSE MAXIMUM 40.00 DEGREE|40.00 |DEGREE ANGLE OF REPOSE MINIMUM 36.00 DEGREE 36.00 DEGREE ANGLE OF REPOSE:USED 37.00 DEGREE 37.00 DEGREE STOCKPILE DATA STORAGE CAPACITY PER PILE REQUIRED 137,787 ST 125,000 MT 5,511,464 CUBFT 156,065 CUBM STORAGE CAPACITY PER PILE ACTUAL 95,447 ST 86,600 MT 3,817,880 CUBFT 108,122 CUBM NO OF PILES:4 4 PILE WIDTH (ACTUAL ):200 FT 61 M PILE LENGTH:584 FT 178 M PILE HEIGHT:78 FT 24 M TOTAL STORAGE LENGTH:2,304 FT 117 M MACHINE DATA GENERAL RECLAIM CAPACITY:551 STPH 500 MTPH LOWEST CAPACITY REQUIRED:200 STPH 181 MTPH RAIL GAUGE:210 FT 64 M REGLAIM CHAIN CHAIN SPEED:a 138 FPM 1 M/SEC RECLAIM BOOM LENGTH FROM PIVOT (CTR.SPR.)197 FT 60 MLENGTHINCLINEDSECTION(CTR.SPROCKET)16 FT 5 M RECL.FLIGHT DIMENSIONS: LENGTH 71 INCH 1,803 MM HEIGHT 14 INCH 356 MM TOTAL SYSTEM OPERATING LOAD 46,000 LBS 20,909 KP TOTAL OPERATING LOAD PER STRAND 23,000 LBS 10,455 KP CHAIN BREAK.STRENGTH/STRAND 165 KIPS 75 MT CHAIN BREAK.STRENGTH SAFETY FACTOR 7 7 TYPE OF CHAIN ROLLER CHAIN ROLLER CHAIN CHAIN PITCH 12.00 INCH |304.80 MM SCRAPER FLIGHT CENTER DISTANCE 36.00 INCH |914.40 MM CHAIN DRIVE NUMBER OF MOTORS 1 1 MOTOR RATING 250 HP 185 KW HOIST RECLAIM BOOM BOOM HOIST TYPE ROPE ROPE BOOM TIP SPEED REPOSITIONING 35.00 FPM 0.18 M/SEC BOOM TIP SPEED OPERATING 3.50 FPM 0.02 M/SEC BOOM LOWEST POSITION 0 DEGREE 0 DEGREE BOOM HIGHEST POSITION 42.00 _|DEGREE|42.00 |DEGREE REPOSITIONING SPEED DRIVE NO.OF MOTORS 1 1 MOTOR RATING 30 HP 22 KW OPERATING SPEED DRIVE NO.OF MOTORS 1 1 MOTOR RATING 3 HP 2.2 KW TRAVEL DRIVE REPOSITIONING SPEED 25 FPM 8 M/MIN OPERATING SPEED FROM ANGLE OF REPOSE DOWN TO 8 DEGREE 8 DEGREE TRAVEL SPEED 6 FPM 2 M/MIN TRAVEL SPEED LOWER PILE PORTION 3 FPM 1 M/MIN NO.OF WHEELS TOTAL:16 -16 HEREOF DRIVEN:8 8 WHEELS PER CORNER 1 A-SIDE:2 2 WHEELS PER CORNER 2 A-SIDE:2 2 WHEELS PER CORNER1 B-SIDE:7 1 1 WHEELS PER CORNER 2 B-SIDE:1 1 NO.OF SINGLE WHEEL TRUCKS:2 2 NO.OF TWO WHEEL BOGIES:2 2 TOTAL TRAVEL DISTANCE:2,354 FT 717 M MAINTENANCE BAY:0 FT 0 M TRAVEL DRIVE REPOSITIONING NUMBER OF MOTORS 8 / 8 MOTOR RATING 5 HP 3.7 KW TRAVEL DRIVE OPERATING NUMBER OF MOTORS 8 8 MOTOR RATING 1 HP 0.70 KW INSTALLED POWER 390.00 HP 290.00 KW MAXIMUM OPERATING POWER 330.00 HP 250.00 KW ZTom Monter From:Gerhard Hertel [ghertel@takraf.com] Sent:-Friday,June 27,2003 2:57 PM To:Tom Monter Subject:RE:STACKING /RECLAIMING SYSTEMS COMMISSIONING.E EL.CONTR.INSTR.AMECHAN.ADVISOR. NGINEER.doc DVISOR.doc doc Dear Mr.Monter. Let's assume the installation of this machine takes 4 months.We would recommend to have one mechanical /structural advisor on site during the entire erection period.One electrical site advisor would be required for 3 months.In addition to these 2 advisors one commissioning engineer is required for the testing,dry run,wet run and acceptance test of the machine,which should take another 5 weeks.Supplier representatives for the hydraulic system,VFD drives,etc.should also be on site when required.The daily costs of these specialist is around USS 1,500.-per day. I attach MAN TAKRAF's site personnel rates which will be charged for each day on site.In addition there will be cost for lodging,rental car,meals, air fare and miscellaneous expenses,which we would charge at actual costs. Since I do not know the pricing structure in Alaska I cannot give you a lump sum price.I can follow up with a lump sum price if you can give me average costs for:Hotel -Rental car -meals. BEST REGARDS GERHARD T.HERTEL -----Original Message----- From:Tom Monter [mailto:Tom.Monter@pes-world.com] Sent:Thursday,June 26,2003 12:24 PM To:Gerhard Hertel Subject:RE:STACKING /RECLAIMING SYSTEMS Mr.Hertel, What would the supervisory Services cost for a bucket wheel stacker-reclaimer while it was being installed?I'm just looking to get a estimate for the final writeup on this alaska project.Thanks. Tom Monter Precision Energy Services Tom Monter From:Gerhard Hertel [ghertel@takraf.com] Sent::Friday,June 27,2003 2:33 PM To:Tom Monter Subject:RE:STACKING /RECLAIMING SYSTEMS Dear Mr.Monter. It is very difficult to provide a yearly parts cost for the Bucket Wheel machine.In the first 2 years for instance,you should not have any need for parts except the normal lubrication material such as grease,reducer oil, hydraulic fluid,etc.However for emergency you should have certain parts available.We usually split them in Commissioning parts,Parts for 2 years of operation and Insurance parts.Commissioning parts usually consist of PLC parts,some electrical field devices and some idlers.Parts for 2 years of operation usually include electrical /controls and instrumentation parts, some idlers,some seals and gaskets for reducers and hydraulic systems.The insurance parts contain a complete set of reducers,belting,travel wheels, hydraulic unit,hydraulic cylinder,motors,pulleys,etc.For the Bethel machine the commissioning parts would be roughly US$180,000.-the 2 years parts roughly US$280,000.-insurance parts roughly US$800,000.- With the above parts on site and an excellent maintenance on the machine should cover the operation of the Bucket Wheel machine. I hope this is of help for your study. BEST REGARDS GERHARD T.HERTEL -----Original Message----- From:Tom Monter [mailto:Tom.Monter@pes-world.com] Sent:Thursday,June 26,2003 12:26 PM To:Gerhard Hertel Subject:RE:STACKING /RECLAIMING SYSTEMS I did have an addendium to my last question.Considering we can't ship equipment for 7 months out of the year,what would you estimate the yearly parts cost for a bucket wheel stacker/reclaimer of the size for the Bethel project?Thanks again Tom Monter Precision Energy Services Tom Monter -From:Gerhard Hertel [ghertel@takraf.com] "s Sent:Friday,May 23,2003 1:19 PM To:TOM MONTER Subject:BUCKET WHEEL STORAGE,BETHEL ALASKA PRELIM.MAINT.CHE CK.LIST.BUCKET... Dear Mr.Monter. Attached is one excel file with a preliminary general maintenance schedulemfor a Bucket Wheel Stacker/Reclaimer.As listed in the spreadsheet, the hours mentioned only include the time for checking,cleaning and lubricating.Any time for replacements,repairs,overhaul are not included. BEST REGARDS GERHARD T.HERTEL P.S.I am still working on a sketch to show the conveyor arrangements underneath the Bucket Wheel machine,as well as a general sketch showing the various stacking and reclaim possibilities. Tom Monter From:Gerhard Hertel [ghertel@takraf.com] "Sent:Wednesday,May 21,2003 1:21 PM To:Tom Monter Ce:Mike Oswald;Sam Fulton;Rafal Berezowski Subject:RE:Stacker Availability &Bypass B.W.CIRCULAR.SY =Bekohi2.jog BW.S.R.COLLTR.p BW.S.R.STAND.TRI COVER.LETTER.O5.H-SCHL 1.TIFSTEM.jpg df PPER.pdf 21.03.doc Dear Mr.Monter.. PLease find attached explanations and some sketches to your below questions. I am still working on the maintenance schedule and the sketch for the belt scheme using 2 parallel conveyors.I will follow up with this information by tomorrow May 22. BEST REGARDS GERHARD T.HERTEL -----Original Message----- From:Tom Monter [(mailto:Tom.Monter@pes-world.com] Sent:Thursday,May 15,2003 10:37 AM To:Gerhard Hertel Cc:Mike Oswald;Sam Fulton;Rafal Berezowski Subject:Stacker Availability &Bypass Mr.Hertel, I had a few more questions concerning the stacker-reclaimer you have proposed.The first question is concerning the availability of the stacker/reclaimer for our feasibility study.Do you happen to have some hard data on availability numbers for a system like this one?We would like to have this data for several reasons:First,we need to know how many hours a year we can plan on running loaders or another alternate means of reclaiming when the reclaim system is down for repairs or scheduled maintenance. Second,we need an idea of how much extra money we can plan to spend to keep the stacker-reclaimer running on a yearly basis.Third,we need the data to present to our client to show that we have investigated and planned for contingencies so that we can provide 99%power availability (not including scheduled maintenance or outages). The second question I had was concerning the belt feeding the stacker-reclaimer.Can this belt be doubled up to provide added reliability? The second belt could be just used for the reclaiming portion of the operation if need be,we would just like to have the added reliability built in.Also this stacker does include a bypass so that we can feed the bunkers directly from the coal incoming from the river correct?Could you provide a more detailed drawing or picture of how the conveyor system for the stacker-reclaimer works?We are curious so that we can design out storage area with this information in mind. My last question is what would the tower height be on this bucket wheel system?We just need to know so that if need be we can fit it under a building.Again any information you can provide about reliability in a document form would be appreciated since we need to provide this in our report.Thank you. Tom Monter From:Gerhard Hertel ([ghertel@takraf.com] ™Sent:Wednesday,May 14,2003 7:02 AM To:Tom Monter Subject:RE: Dear Mr.Monter. Thanks for your e-mail.I am at our headquarters in Germany right now.In talking to our engineers,I can give you the following information: 1.The rough weight of this machine is about 700MT (including counterweight).The average wheel load for this kind of machine is in the range of 30 to 35MT. 2.Based on above weight,the shipping volume for this machine (excluding counterweight)is in the range of 3,500 cubm.There is not much to be shipped in containers.Most of the shipments will be bulk,we may have about 4 x 20'containers for smaller mechanical items.: 3..A very rough budgetary price for this Bucket Wheel Stacker /Reclaimer suited for cold weather is in the range of US-Dollar 5.8 Million,FOB Seattle. 4.The highest point on this machine is the mast,holding the boom as wellasthecounterweight.The top of this mast is at an elevation of approx.30 m. If you have further questions,please send them to my e-mail address.I am checking my e-mails daily.I am back in my Denver office next week Tuesday. BEST REGARDS GERHARD T.HERTEL -----Original Message----- From:Tom Monter [mailto:Tom.Monter@pes-world.com] Sent:Monday,May 12,2003 9:42 AM To:Gerhard Hertel Subject: Mr.Hertel, I was curious if you had the rough weight of the bucket wheel stacking/reclaiming machine.If you don't have the weight offhand could you possibly estimate (within 15%)what it will weigh?We are trying to get theapproximateweightssothatwecandesignfoundationsforBethelwhichhave special concerns due to permafrost conditions.Additionally,could youpossiblyestimatehowmanycontainersitwilltaketoshiptheequipment toAlaska,and the estimated price FOB seattle?The last question I had was how high for the machine you quoted would the tower for the reclaiming boom stick in the air?Thank You.. Tom Monter (208)772-4457 Precision Energy Services 10780 N Highway 95 Yayden Lake,ID 93835 Tom.monter@pes-world.com Tom Monter -.From:Gerhard Hertel [ghertel@takraf.com] Sent:Tuesday,April 29,2003 7:11 AM To:Tom.Monter@pes-world.com Subject:STORAGE SYSTEM BETHEL ALASKA REV.LAYOUT.CROS REV.LAYOUT.PLAN.$.04.29.03.vsd 04.29.03.vsd Dear Mr.Monter. Thanks for your E-mail yesterday.Reviewing your requirements of total storage volume,covered storage,reliable operation without major downtimes, and assuming that some redundancy in reclaiming is necessary,I do not believe that an automated reclaim system be it a Portal Reclaimer or Bucket Wheel Stacker Reclaimer would be suited.The Portal Reclaimer is the more reliable machine than the Bucket Wheel,due to its simplicity in design.It would certainly fulfill the requirement of high availibility,but when compacting the coal,the pile will change its shape,which requires a longdressingtimeuntilmaterialisbeingreclaimed.The height of the Portal Reclaimer would also require a much higher building.The Bucket Wheel could reclaim a compacted pile without any problem,however it requires more maintenance than the Portal Reclaimer.It also requires a higher building, and you cannot stack and reclaim at the same time. Both automated Reclaimers also have the disadvantage that,if a malfunction occurs,you are without any fuel feed to the power plant.Putting 2 machines in to have redundancy,bears a considerable price tag. In my opinion the ideal system for your application is stacking 2 parallel piles with a slewing stacker in between both piles.Reclaiming should be done using Front End Loaders,which you already have in your plant.You may need to purchase one or two more to also cover the pile compacting.On the outside of each pile you would have one reclaim conveyor.Each reclaim conveyor has its own motorized Reclaim Hopper Car.Since your reclaim rate is low,one Front End Loader could easily achieve 500 MTPH.The Hopper Car would always be positioned to have the travel distance for the Loader as short as possible.The Loader Operator can reposition the Hopper car with radio control.Maintenance would not be a problem since you would only need one Loader for reclaiming. I attach 2 sketches showing the layout of the system.I will call you today to discuss the Layout. BEST REGARDS GERHARD T.HERTEL AOE"ddd WLiMATYidll OO" | || :=|Aw Sf[at =|=- -..-_-ee ee ee ee es ee ee ee --4 cme ee eeee neee ee. pprox 6600 prox S0000 HOCHESBoizROPE SCHEME NOTY1 u =I lfe {|=|sii AP =Ve -f Lis 1biaAS>H N NL NIN ENE NE NE NINE NEI AI NE NEN INE RE ERIN LE IRIN INI NINE INE II NIN IEE RINE NE IN INI REN Re 14000 .44000- AHA £000--7800-51300 "35: 4 A i= im: LOADS /WHEEL(tons) 6-8 Vi=V2 "4 . VS =V4 38 . HY =H2 of 22 HS =He _8 {Al cy 2 28 Al Loade are te be multiply by Impoct Factor 1.3 Pon TT” T Tort { t HDan! {! a I )meme¢aHauIL ait om, as a yn So =pS meeY-LSA BO S222 7 4$000 -26300--- I Boor Side !WHEEL LOAD PLAN é LOADS/WHEEL (TONS)é 1S)Ve=ve a5Vine7 PRELIMINARY ONLY A =Comayor ve 18 _.vid 16 tatrervit10LINEARCOALSTORAGENTS Al Loads to be muitiply StockerondPortalRecloimer9pfbyimpactfooter-1 ==WA =£-2294 BeeKASDa ay eonmae, [ne " ayy MeN Kya AA:tatedSieSoewasek ie(=Air Supported Conveyor Air-supported conveyor systems were a revolutionary concept when they were introduced in Europe in 1971.But early systems were plagued by two problems:inconsistency in airflow,which reduced performance and increased problems like belt wander,and high costs for construction and operation. But through proper engineering and construction techniques, Martin Engineering has solved these problems with the SClass”Air-Supported Conveyor. MARTIN?S-Class” Air-Supported Conveyor Conveyor idle Conveyor running Hi This film of air,only four-hundredths of an inch (one-millimeter)thick,How it Works supports the moving belt,eliminating the need for carrying idlers.The thin film of air will support loads up to 200 pounds per square foot (976 kg/m?) :;at high speeds with no mechanical friction.The air support system limitsthroughacarefullycalibratedseriesofmechanicalfrictiontotheconveyordrive(typically at the head pulley),theholesundemeaththetroughedsurface.tail pulley,and the take-up assembly.This results in a dramatic reduction This air lifts the conveyor belt off the in operating maintenance costs.trough,so its only carrying side friction The system features interlocked controls,so the beit will not run withoutpointsaretheheadandtailpulley.air pressure,and the air system does not operate without the belt running. Air from a low horsepower fan is forced 3 {sCompresion Required Prove it to Yourself :es Carrying SidéIdlers”The first step may be to install one (or several)eTalenLubrication:modular section of S-Class”Air Conveyor on anFesdSealsexisting(conventional)belt conveyor structure. CRT ERE That way you'll see the effectiveness and efficiency of the S-Class”Air-Supported Conveyor without requiring a full conveyor system.Beetchae Soe pean sae pete ines Bd 6 Boletos ae y (nica eae eee incere Sing Si Sk rene <r S Ddvadunmace ge Agra ened aie Cet ,NBelt(Convey tS alata.Hy Newie bnyeyo S.Class™AirSupported Conveyor Offers In new construction,the S-Class'Conveyor is an engineered conveyor Benefits for Upgrading Existing Conveyors system designed to provide simplicity in design and economy in operation. @ Economical Improvement "Are Save money by reusing existing stringers,belt,and drive system.Modular SClass”Air Supported Conveyorsectionsdropontoexistingconveyorstringersforapriceconsciousretrofit.,Offers Benefits in Engineering New Conveyors @ Fits Existing Structure @ Allows Greater Inclines Patented S-Class”Retrofit System is designed to CEMA standards By eliminating load agitation,SClass Air Supportedandwillfitexstingstandardorwidebaselayouts.Conveyor can safely and effectively move loads at angles up to 25 degrees.@ Use as Much as You Need {8 Modular assemblies Jet you install a 10 foot (3048 mm) section at a time.Install as much as you like now; extend the airsupported section anytime. @ Skilled Installation Available Martin Services crews provide fast installation for op spec operation with miniinal downtime. @ Save Money on Walkways Because it eliminates troughing {dlers and so reduces the need for routine lubrication and conveyor maintenance, the MARTIN®SClass”Conveyor may allow you to dispense with conveyor catwalks. @ Allows Reversible Conveyors By the reduced number of rolling components and,hence, 7 the amount of friction,the S Class”AirSupportedaConveyorsimplifiestheprocessofchangingdirections. @ Allows Long,Unsupported Spans The strength of the V-Plenum design allows spans of up to 40 feet (12.2 meters)without requiring additlonal sup- port structure, @ Skilled Installation Available 1 Martin Services crews provide fast installation for "onspec”performance. [PREP PEEEY be'conveyor inlet. Although it Is a fairly simple process to install an upgraded system,Martin Engincering rec- ommends that SClass™Air Supported MARTIN®S-Class”Air-Supported Conveyors Conveyor Systems @ Standard trough angle is 35 @ Vulcanized belt is recommended. be installed by crews from degrees.(Mechanical splices-particulany if - M y @ Available for belts from 12 to 60 not properly recessed-can dam-artin Services.inches (300 to 1500 mm)wide.age the air dispersion trough.) @ Conveyor is suitable for light impact ' loading.m4>Sater *eee 1d of benefits 0over a conventional beltconveyor. Benefits of S-Class"Conveyors: Reduced Energy Expense The low-friction S-Class”System can,reduce conveyor power requirements by 30%on a horizontal installation.That means you pay less for energy {and you may save more because you can buy a smaller lower-cost drive). Reduced Maintenance Expense There are no carrying side idlers.That means there are no expensive rollers to replace and no idler lubrication required. Reduced Conveyor Noise No idler bearing noise;no noisy compressor.The S-Class”Conveyor Operates at the sound output of an electric fan (70 dBA)rather than the typical conveyor noise level (85 dBA). Longer Belt Life With fewer friction points,there is less wear on belt's bottom surface. And because there's no need for conveyor skirting,there is no abrasion on the carrying side from material entrapment in pinch points. Stabilizes Belt Path Because the belt is carried on a smooth film of air over a smooth troughed surface,the belt's path is stable for improved dust control. Reduced Spillage Because it is fully enclosed,the S-Class”Conveyor eliminates the need for skirting. Improved Dust ControlWiththeS-Class”Conveyor,the film of air is released below the belt at such low volumes the airflow will not carry fines off the top of the belt.The belt's smooth profile keeps fines out of the air and on the belt. Improved Product Condition The S-Class”Conveyor's air-supported belt is gentle to the cargo. There is no bumpy "roller coaster”ride over the idlers,so there is no material segregation,no product degradation and no breakage. And because it is fully enclosed,there's no contamination of conveyed material. For nearly 60 years,Martin Engineering -has focused on improving plant bulk solids handling operations. Around the corner or around the world, MARTIN?Systems and Services improve the movement,storage,recovery,and movement of bulk materials.Martin Engineering strives to reduce maintenance and downtime and improve efficiency and profitability. MARTIN?Products include: @ Belt Conveyor Cleaning Systems Air Cannons ®Transfer Point Sealing Systems Pneumatic and Electric Vibrators Load Zone Impact and Belt Support Cradles ®Belt Training Devices #Molded Urethane Wear Parts Dust Suppression Systems Dust Collection Systemsoe¢©Air-Supported Conveyor Systems MARTIN?Services include: ®System Installation ®Specialized Maintenance ®Silo Cleaning Laser Conveyor Surveying @ Turnkey Projects ©System Design Engineering Form No.L3576-3/02 WP ©Martin Engineering 2001 1SO-9001 DNV Patent #5,829,577 CERTFIED Air-supported conveyor technology patented by Grisley Components,Inc. --i -Fh Ee |ENGINEERING One Martin Place Neponset,Illinois 61345-9766 USA 800-544-2947 or 309-594-2384 FAX:309-594-2432 http://www.martin-eng.com .Solutions for Bulk Solids Handlingwaa.MARTINENGINEERING For more than 55 years Martin Engineering has made bulk materials handling cleaner,safer,and more productive.All MARTIN®Products and Services are backed by the company's Absolutely,Positively,No Excuses Guarantee. Vessel Activation ¢XHV BIG BLASTER®Ambient-Temp.Air Cannons ¢XHV BIG BLASTER®High-Temp.Air Cannons ¢XHD Bin Whip ¢XHD Bin Drill and Chunk Buster Vibratory Systems *MOTOMAGNETIC®Electric Vibrators ¢BRUTE™Motor-Driven Vibrators (Hydraulic,Pneumatic,and Electric) «VIBROLATOR?®Pneumatic Bail Vibrators «VIBROLLER®Pneumatic Roller Vibrators «VIBROTOR®Pneumatic Roller Vibrators *Pneumatic Piston Vibrators ¢Vibrator Mounts,Controls,and Accessories «Screen Vibrators and Retrofit Kits Bulk Transport Unloading Systems ¢BOOT-LIFT®Railcar Connector *BOOT-LIFT®Vertical Connector «MARTIN®Railcar Openers *DC Truck Vibrator ¢Railcar Vibrators SYSTEMSTO IMPROVE I,BELTCONVEYOR OPERATION= Belt Cleaning Systems ¢S-CLASS™Air Supported Conveyor System ¢DURT HAWG?Belt Cleaning System ¢DURT TRACKER?Belt Cleaning System +IN-LINE Belt Cleaning System ¢SAF Belt Cleaning System ¢XHD "Extra Heavy-Duty”Belt Cleaning System ¢SHD "Super Heavy-Duty”Belt Cleaning System *QC®"Quick Change”Belt Cleaning Systems ¢ZHD Belt Cleaning System «PIGLET™Food-Grade Belt Cleaning Systems *Chevron Belt Cleaning System ¢Rotary Brush Cleaning System *Spray Wash Belt Cleaning System *CYA®Inspection Doors -Steel and Rubber *Tail Pulley Protection Plows ¢Vibrating Dribble Chute Transfer Point Systems *GUARDABELT®Impact Systems «GUARDASEAL™Belt Support Cradle *Catenary Idler Stabilizer Systems *TRAC-MOUNT Idler *DURT TAMER™Wear Liner ¢APRON SEAL™Skirting System ¢Tailgate Sealing Box Dust Management ¢FOG Dust Suppression System *FOAM Dust Suppression System *Dust Bag and Curtains *Insertable Dust Collectors Belt Alignment Systems *TRACKER Belt Tracking System *SPIROLL GUIDE™Alignment Roller *7MARTIN®ON-SITE SERVICES Sae™:; *Installation Service «Equipment Maintenance Service *Silo Cleaning Service *Laser Survey and Alignment Service *Engineered Systems Analysis {/REPAIR/WEAR PARTS Sixnuehi cen: *Urethane Classifier Shoes ¢EZ-PATCH™Repair Kit *Sheet Urethane*Urethane Spray Deflectors,Plow Tips,and Spinner Disks ;MARTIN?CUSTOM SYSTEMS#225 Martin Engineering can design and build custom solids handling systems to fit specialized application requirements. For more information on our products,call 800-544-2947 (USA only)or 309-594-2384 martin-eng.com *e-mail:martinone@martin-eng.com Form No.L3281 4/02 7 baa.MARTIN _.ENGINEERING ISO 9001 QUALITY SYSTEM CERTIFIED One Martin Place Neponset,IL 61345-9766 USA Phone:800-544-2947 or 309-594-2384 FAX:309-594-2432 Website:http:/Avww.martin-eng.com April 17,2003 DUST CONTROL THROUGH AIR SUPPORTED CONVEYORS Tom Monter os ay nenPrecisionEnergyServicesSSS10780N.Highway 95 i Sie Hayden Lake,UT 83835 2h Pac.tyProposalnumber:03125-AS me RAG Dear Tom,my We appreciate your interest in our Martin Engineering patented S-CLASS™Air-Supported Conveyor.This is a component-based method for upgrading troughing conveyors to a more reliable and cost-effective air-supported conveyor.Designed according to CEMA (Conveyor Equipment Manufacturers Association)standards,the S-CLASS™ ASC utilizes the troughing conveyor's existing support structure,drive mechanism,and belt. Using this technology is quickly making the S-CLASS™ASC the industry standard for high performance conveying.The S-CLASS™ASC is more efficient,reliable,and cost-effective than conventional conveying technologies.Our retrofit system not only simplifies the process of upgrading troughing conveyors,but by eliminating the source of wear (friction from moving parts),the S-CLASS™ASC will substantially reduce the conveyor's operating and maintenance costs. Martin Engineering has made the S-CLASS™ASC available at a per-section cost comparable to that of a conventional and regularly scheduled retrofit.The "V”Plenum retrofit provides all of the inherent benefits of air-supported conveying,and it does so by using the troughing conveyor's existing structure,which results in a substantial reduction in installation costs and downtime. Based on the information provided Martin Engineering guarantees that this system will deliver the required capacity with no spillage due to this system and with no additional horsepower required by the systems drive motor. If you have any questions,please contact me 800-544-2947 Ext.324. THINK CLEAN® Me 2 Gary Swearingen Project Manager st Maa wagrin g8 ENGINEERING a ONY, PROPOSAL SYSTEM PARAMETERS .60 Inch Belt Width 2000 TPH Design Capacity 2 Inch Minus Coal at 55 pounds per cubic foot 8%Moisture Content 450 FPM Belt Speed Single Load Zone I understand that power requirements are a big issue for this application.With the information given I estimate that the horsepower savings for a belt of this size would be approximately 22% or 30 horsepower.Due to the length of this belt and the quantity of material conveyed,(4)30 horsepower fans will be required to lift and carry the belt plus material.I realize that this is not the savings you were looking for but the numbers given are realistic. By reviewing the product information on our website you will be able to see that the S-CLASS™Air Supported Conveyor is a totally enclosed system eliminating the need for additional covers to protect the material conveyed from outside elements and keeps the conveyed material on the belt.Ido understand that this application is close to a residential area and fugitive material could be an issue.The S-CLASS™Air Supported Conveyor System also will eliminate the need for maintenance on the trough side of the belt with the elimination of troughing rolls and in most cases a need for an access walkway.The elimination of troughing idlers will also reduce noise. Scope of Equipment 1400 feet of 60 inch wide S-CLASS™Air Supported Plenums,each 5 foot section consisting of the following: e One -V-Plenum weldment assembly with 12 GA galvanized "V”sheet and 3/8” thick carbon steel end laser cut end flanges."V”sheet continuously welded to inside of the flange. e One -Pan weldment 12 GA galvanized attached to 3/8”thick end flanges with continuous seal weld on the inside,full length sheets with a relief ground on the 3/8”flange for continuous seal weld. ¢Two -Cover Splice plate weldment 10 GA carbon steel with 1-1/2”bar channel reinforcing. e Two -Galvanized Cover assemblies 14 GA. e Three -Support bracket assemblies carbon steel 2 1/2”x 2 1/2”x 1/4” angle with as base angles and 3/8”bar pads. Precision Energy Services Page 2 of 6 April 17,2003 Proposal No.03125-AS The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company.Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. mea warrin 18 ENGINEERING | DNV e All fabricated steel will be prepared to SSPC-SP2 wire brush clean and given one standard primer coat-1.5 -2.0 mils DFT. e Plenum parts will ship loose for assembly in the field. e Four -Pressure blowers evenly spaced to provide proper lift based on operating parameters. e One -Smooth line loading spoon installed in the drop zone to alleviate any material impact. Budget price for required equipment each belt:$1,009,976.00 STANDARD PAYMENT TERMS AVAILABILTY:8-10 Weeks SHIPPING:FOB:Point of origin/Freight not included Above quote is for equipment only with standard Martin Engineering terms applying. All Prices are FOB Neponset,IL. Prices valid for 60 days from date of proposal.Equipment manufacturing to commence immediately upon receipt of purchase order.Quotation does not include shipping charges or federal and/or state sales or use taxes.All applicable taxes and freight to be paid by Precision Energy.One complete set of equipment installation manuals and system requirements will be provided upon receipt of order.Additional sets available upon request. Note:Above quote is based on information collected,if actual conditions vary Martin Engineering reserves the right to adjust this quote to ensure success of this project. Note:Dust Collection addressed by current system. Note:All electrical work to be the responsibility of the customer.The S-CLASS™™ Air-Supported Conveyor requires 230/460 three phase to operate the pressure blower and 110 single phase for the pressure switch that is used as an interlock into the customers existing logic system. GUARANTEE Martin Engineering offers an "Absolutely Positively No Excuses”Guarantee.Simply stated, "if the engineered system,installed by Martin Services or a Martin Service Technician,does not perform to the customer's satisfaction,the customer may return the equipment for cash or credit equal to the cost of the installed system.Martin Engineering has extensive experience in Precision Energy Services Page 3 of 6 April 17,2003 Proposal No.03125-AS The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company.Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. Ml.MARTIN ,L8ENGINEERINGcennnen solving material build-up problems such as are experiencing.We warranty our products to befreeofdefectsinmaterialsandworkmanshipfortwelvemonthsafterdateofpurchase. Precision Energy Services Page 4 of 6 April 17,2003 Proposal No.03125-AS The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company.Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. ada.48 @.marrin $4 ENGINEERING :cenrinen Reference List for MARTIN®S-CLASS™Air-Supported Conveyor System Bridgewater Power PO Box 678,Route 3 Ashland,NH 03217 Contact:Michael O'Leary Phone#:(603)968-9602 Three (3)conveyors installed in 1987,36”(hog fuel)wood chips CMC 33-3683 Hasting Street Vancouver,B.C.Canada Contact:Rene Wedding Phone#:(604)294-6483 Various installations;grain handling,petroleum,coke HCH A/S Ringsheduet 7-11 Soko,Denmark DK-4180 Contact:Hans Houmand -Consulting Engineer knowledgeable in the advantages of ASC Phone#:011-45-57-83-300 Various applications;cement,sugar,coal National Gypsum 2001 Rexford Rd Charlotte,NC 28211 Contact:Bob Piaseki Phone#:(704)365-7300 -Headquarters Phone#:(813)952-1100 -Apollo Beach,FL Three (3)conveyors 3M Company 900 Bush Ave,Bldg 21-1E-06 St Paul,MN 55133 Contact:Denny Helender Phone#:(651)778-5193 Eight (8)conveyors (roofing granules) Southern Company State Line Power 103™Street and Lake Michigan Hammond,IN 46320 Contact:Dave Matitevich Phone#:(219)473-6400,x6490 CONDITIONS OF SALES Precision Energy Services Page 5 of 6 April 17,2003 Proposal No.03125-AS The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company. Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. amia.MARTIN ENGINEERING TAXES AND OTHER CHARGES:Amy macrefactarer'surz.uae tz sales tke.custouns det,or tax of any asture whatsoever,which may beassessedagainstthisorderofmachinery,shall be added to the prices quote or invoiced and shail be paid bythepurchaser,and,im the event Marin Engncenng heremafter referred to 2s The Company,is required topaysuchdutyortaxthePurchasershailretmourseTheCompanytherefore,or in liew of sech payment thePurchasershailprovideTheCompanyatthetimetheanderissubmitted,an cremption cern ficate of otherdocumentacceptabletocustomsorWingsathoritics. RESERVATIONOFTITLE:Title to ail goods shail remain in The Campasy and The Company shail have a security interest in the goods'with ail of the rights and remextics of a secured party wader the provisions of the Uniform Commercial Code,'anol psyment im fail is made by Purchaser.Any notes or checks offered and accepted will be evidence ofthedebtonlyandnotaspaymentomaccamntentitheyhavebeenconvertedintocashbyTheCompany.In defanit of payment of amy sales contract,or upon failure of the Parchaser to comply with any one or ailconditionsofamysalecontract,The Company may at any tne,cither persomailly or by its agem using 25machforceasmaybenecessary,cuter im or upon ihe premises where said machinery or goods may be,withorwithoutissuanceofamywritorreplevia,or wadertaking of any legal process whatsoever,and take legalofsudytheymaybefound.And for sp doing,The Company shail not beliablemanyactiona¢iw or in equity om the part of the Purchaser for such reclamation of its property,sorfortherepaymentofamymancy,or monies which have deem paid by the Purchaser im any part for saidmachineryormatcriais,It is further agreed that the machinery or materials shall not become a fixture by reasom of being attached torealestate,but may be separated from the reai estate and reclaimed or solid by The Company in accordance'with te items of amy sades contract,and without liability om the part of The Coarpeny or ite agents for suchsaleorremoval. WARRANTIES:New Equipment Only:Defects:The Company warrants the equipment to be free fom defects im material and workmanship,whichwarrantyislimitedtodefectsreportedwithimaperiodofome(1)operanng scasom or six (6)months fom thedateofshipment,whichever comes firs.The Company objigavou under this warranty will be expresstylimitedtobatsotiing,F.O.B.pount of -defective parts and the actual cost ofremedyingdefectiveworkmanship.Tide:The Company warrants thas it has title wo the equipmem free of any security interest,or other tien or encumbrance. Fimess for Purpose:Toe Coaspeny warrancs al sew eqripment 10 be St snd situ or the pactoee iwhichxisorifitisecifiedtothedesignofthePurchaser.Ur Purchnew ia sucble &mane ee perform,i 'written notice shailbegivenTheCompanyasweilasfriendly2ssistancettheendthatTheCompanywayassistPurchaserimmakingtheequipmentperformssuitablytofaifillthiswarranty,Purchaser shall rejoed the same and The CompanywillpaytheretarefreightandrepaythePurchaserfortheitemsoretarned,less any amouncs owing TheCompany.Possession of the equipment for more thas thirty days after installation and/or operation of 180 days aftershipmem,whichever cames first.without writica soucs above requared,shail be canciusive evidence thatthiswarrantybasbeensatisfied. WARRANTEIS:Used Equipment Only:The Company makes n0 warranty for used equipment except the warranty of title and such additionalwarrantiesasmaybewrittenintotheorder. LIMITATIONS APPLICABLE TO ALL WARRANTIES: 1 Any attempt on the pert of Purchaser,or amy other perso to repair defects in woriamanship orteplacedefectivepertsshallmakethiswarrantyvordas00suchdefectsandparts30repairedor.Teplaced and any ition,defectorpart arising or 4:as aresait thereot 2 If Perchaser is enable w make the equipment perform,immediate written notice must be given totheCompany.The Purchaser must provide friendly assistance so that the Company may assistPurchaserinsuakiogtheceipmnentperform0Gollthiswarrmy.Purchaser wiil be responsibletorwithallfreighttarifilsandgoodshippingpracticeanycatipeocottobereturned29theCompany.The Companywiilpaythererurn freigitandrepaythePurchaserforthetem30retarsed,lems axy amounts owing the Company. 3.Possession of the equipracnt for more tham thirty days after instailatios or operation of 180 daysaftershipment,whichever comes first,without wrtien aotice of a warranty claim,shail beconciusiveevidencethatthiswarrantybasbeensansfied. 4 This warranty is tioned that the equi be wsed that it be kept propertylubricated.that it be operated im with 7 practiceandthattheCompanybegivenimmediatenoticeimwritingofthedefect. 5s.This warranty does not extend w items not by the C ided however thatPurchasershailhavethebenesitofallwarrantiesmadebythemanufacturerofsuchitemsandtheCompanywillassistPurchaserimsecuringthebenetitofsechwarrandcs. This warranty extends only to the original purchaseroftheprodsct.The Company expreasty disctaians ail cher warranties of any kind whatsoever 2:te theproductsseidbytheCompanywhetherexpressorimpiied,inciuding,without imitation,impiied warranties of merchantability or fitmess for a particniar parpase. 8.Any sample submicict by the Company w Purchseer sadany descriptions or ljesrations i tradeorobershailuotbeaoperformance.color,quality or dimension,and any flere w couforan ©exch samples,deseriptionsorillustrationsshallnotconstineteabreachoftheseLermsandconditionsbytheCompany."em9 The commpany wil net bs Hable (9 Parchaser or any third party for (1)any dumate,oruiaaryoFspecial,direct or indirect,Seance far foes af mien er Som af anaictpated preties or vaviown,(0)ony atuar dala anumrtedagaiastparchaserty2thirdparty,or (lil)for any parysical injuries or death,arising,directlyorindirectty,owt of or tn'commection with the manafactare,sale,ave or defect of the prodectsseidhereeader. lo.Limitation ef liability.The Company'ssoleliabilityferary product sold perseant to thisagreementislimitedte(he replacement of the product or 2 refund of the parchase price paid. CLAIMSANDSHORTAGES.ETC:The Purchaser agrees to inspect ail merchandise usoa receint and to notify The Company of any claics orabortage,damage,or otherwise,oot Later tham Wurty (50)days of such receipt. AGREEMENTS:This order,25 tendered (ifia excens of 55.000.)is sebject to scecptance by mm exative of The Companyaad,if accepted,will be by =a will all previous aad aii prior or and 'nderstandings whether oral or implied,except that amy particaiar documents of specified part or partsthereofmaybemadepartofscantractbyinthewrittenAllfigures10weightanddimengoasareapproximate,unless certified by 3 qualified official of The Company.Any to the jon of a plant,as 3 whole or im parts,or as to pieces of equipment ofpeststhereofarevoid,sniess written imeo the order or the Acknowledgement.The Company assumes no respansibility for anything that is not written into the order,ar theAcknowledgement. Precision Energy Services April 17,2003 1SO-9001 ba CERTIFIED uaa ty avsTeM INCONSISTENTTERMSSUPERSEDED:The parchase of all or amy part of the equipment described shall be only upan the terms set rth berein.All accepuc in wring by a2 aubsneod otice of The Coomeny, DELIVERY: Detivery ou The Coorpany's part wall aust of either of the two following options:C of for shi to a licensect carrier whose receipt thereof willConstitutefallandvalidevidenceofsuchdelivery.2 Shipping materiais via The Company's muck.A packing list signed by the receiver willConsutatefallandvalidevidenceofsechdelivery. All detivery dates will be calculated trom the date of the receipt of the order,Ow orders requiringCestomer's approval of plans or specScapons,or where specific informauon or components are requiredfromthecasiomerbeforetheordercambeprocessed.delivery dates will be calculated fram the imtest date onwhichthemformanoaorapprovalwasprovided.In no event will The Company be responsible for any jossordamagesdmeto(ailure tp make delivery mm accordance with the delivery dates,Detivery is cosungent epom deiays beyond The Company's reasonable control,Ali freight,duty and similar carriage or revense taenfis will be defrayed by the Purchaser.Any excess material which my be shipped remains the property of The Company and shail be returned toTheCompany.All figures inmg 10 weightsand di sons arc PRICES: L Uniess ouberwise stated,ail prices quoted are firm for a period not to exceed thirty (30)days. 2 Orders received withost prior and/or prevailing quotation will be billed af currentprevailingprices,3.The mmimem net billing charge is $50.00.4 The price of items purchased by The Compauty for resale will a4 all times be thatprevailingattheumeofshipment.5 The Company reserves the right to refuse or cance!any order based on 3 quotationcontaining4grosscrrorwithoutfinancialliability.4 If shipment is postponed at the request of the Purchaser after manufacture bas begun,payment will be due om notice fom The Company that the equipment is ready forshipment.2.Peale of an over is delayed by more than seven calendar days dee w a lack oforpartialpaymentwillbedueomnoucefoeTheGannesyitthemeeneenador onhand. 8 Orders accepted with deizyed or restricted deliveries are billed at prices in effeer 30 dayspriortothedatecachreleaseismade.Pro rate payments shail be expected for partialshipments, CANCELLATION: Canceliasons or stop work requests on any order or part thereof must b made ia writing and the PurchaseragreestopayTheCompanyatitsusealratesforalllaborandcostsincurredandmaterialspurchasedforthatorder,less the saivagevalineand/or chargesof the or partaily goods, Page 6 of 6 Proposal No.03125-AS The information contained hereinis privilege and confidential information andis intended only for the use of the addressee's company.Anydissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. By CONTINENTAL SCREW CONVEYOR A Subsidiary af IPS Group,Inc. 4343 Eastou Road St.Joseph,MO 64503 USA May 1,2003 Precision Energy Services 10780 North Hwy.95 Haydon,Idaho 83835 Phone:208-772-4457 Fax:208-762-1113 Attention:Tom Montor Reference:60”Conveyor Tnuss and Supports Budgetary Quotation No.B-231-03 We are pleased to provide you this budgetary quotation for this equipment based on the information we discussed.We are a sub-supplier to Martin Engineering for their "S”class air supported conveyor plenums and have supplied several projects over the last two years.We will work closely with Marnn Engineering to adhere to the design requirements for air supported belt conveyors. The conveyor we are proposing is complete excluding the carrying side plenum section,the truss" section will have hole to accept the plenum support legs.The support trusses are capable of spanning 75”,we have supplied a 12'x 12”square support tower at each end in additions to "H”frame supports every 75'with braces.Also included in the quote is 30”wide walkway systems and two Martin Engineering V-plows and Martin Engmeering dual belt cleaning systems. DESCRIPTION:ONE -SLIGHTLY INCLINED NO MORE THAN TWO DEGREES CONVEYOR FRAME AND SUPPORTS FOR 60”x 1400'-0”center-to-center length,with 60”deep truss frame. OPERATION:Conveyor to operate at approximately 600 FPM belt speed to convey 2,000 MTPHdesigncapacityofCoalat50-55 PCF with 50 PCF for capacity and 5S PCF for HP.Ambient temperaturemax.material sized 3”minus with an angle of repose varying from 30 to 32 degrees. CONVEYOR DRIVE:200 HP 1800 RPM TEFC motor 230/460 volt,3 phase,60 cycle,with Allen Bradley SMC Flex soft start rated at 251 Amps.Dodge TA9415H15 shaft mounted reducer with 109 RPM output with internal backstop and V-belt drive with 1.5 service factor,including totally enclosed guard.Fixed overhead motor mount with adjustable base. HEAD PULLEY:20”Dia.x 63”wide Crown face pulley with 1/2”thick Herringbone groovedyuleanicedlnesinewith$.15/167 C-1045 she with 4 15/16”turndown for reducer.Dodge Type"E”§-15/16”4-bolt pillow block bearings with adjusting blocks. SNUB PULLEY:16”Dia.x 63”wide Flat face plain pulley with 1/4”plain lagging 3-7/16”C-1045 shaft and Dodge Type "E”3-7/16”4-bolt pillow block bearings with adjusting blocks.Web Address E-mail Address Ph.316-233-1800 www.tconvevors.com excegisconyevors.com Fax 316-233-3315 MANUFACTURER of BULK MATERIAL HANDLING and PROCESSING EQUIPMENT Precision Energy Services Budgetary Quotation No.B-231-03 TAIL PULLEY:18”Dia.x 63”wide Crown face Wing pulley with fabricated rolled rings and4-7/16"C-1045 shaft with 4-7/16"Dodge Type "E”4+-bolt pillow block bearings with adjusting blacks. GTU TAKE-UP PULLEY:18”Dia.x 63”wide Crown face Wing pulley with fabricated rolled rings and 4-7/16"C-1045 shaft with 4-7/16”Dodge Type "E”4-bolt pillow block bearings with adjusting blocks. GTU BEND PULLEY:18”Dia.x 63”wide Flat face plain pulley with 4-7/16"C-1045 shaft with 4-7/16"Dadge "E”4-balt pillow block bearings with adjusting blocks. GRAVITY TAKE-UP SYSTEM:Two GTU conveyor mounted frames with adjusting blocks,two slide assemblies and personne]safety barrier at grade.NOTE:The amount of GTU weight will be calculated but the actual material supplied in the field, TRANSITION TDLERS.CEMA C-6”20 degree 3/4”seajed for life ball bearing idlers mounted at the head and tail. ROLLER RETURN:CEMA C-6”returns mounted on 10'-0”centers with Trainer returns mounted every 150'. CONVEYOR BELTING:3 Ply 330 PIW MOR oil resistant belting 3/16”top x 1/16”bottom covers. Additional belting will be supplied for field vulcanized splice,material and labor "By Others”. BELT CLEANERS:Two Martin Engineering V-plows and dual belt cleaner system with QC #1 primary and QC #2 secondary with tensioner. HEAD and TAIL PLENUM ASSEMBLIES: One -Head section 1/4”carbon steel x 10'-0”long with adaptor flange for air support conveyor frame with combination bolted take-up frames,18”x 24”Martin Eng CYA door for inspection of belt cleaners and removable pulley panels. One -Tail section 1/4”carbon steel x 10'-0”long with adaptor flange for air support conveyor frame with combination bolted take-up frames and pulley panels and discharge assembly.Including 18"x 24”Martin Eng.CYA door and removable pulley panels. INTERMEDIATE PLENUM ASSEMBLIES:"By Others” CONVEYOR SUPPORT FRAME: 60”Deep Heavy-duty truss fabricated with A325 3/4”bolted joints made up as follows: Top chords C8x11.5 with bottom chord 5”x 3”x 3/8”angle. Vertical walkway supports 3°x 3”x 3/8”angles back to back Upper panel cross braces 3”x 3”x 3/3”angies. Two side panel cross braces 3x 3”x 3/8”angles. 3/8”Thick gusset plates typical. 3/4”Thick splice plates at bolted joints. Support beam assemblies at bent locations. 3 Precision Energy Services Budgetary Quotation No.B-23 1-03 SUPPORTS:12'-0”x 12'-0”x 20'-0”Tall support towers with platforms and handrail at head and tail, Heavy-duty "H”frame supports x 20'-0”tall with knee braces spaced every 75'-0”. WALKWAY:Approximately 1390'-0”of 30”wide Gripstrut 11 Ga galvanized walkway grating with42”double handrail and support system mounted to truss on 5'-0”centers. SAFETY EQUIPMENT:Eight Conveyor Components model RS-2 emergency pull switches with vinyl coated safety pull chord attached to conveyor frame.One Conveyor Components madel CMS zero speed switch with accessories. COATINGS:All fabricated steel will be prepared to SSPC-SP2 wire brush clean and given one standard primer coat and one finish coat of light gray 1.5-2.0 mils DFT each.Guards and safety covers wil]be given one coat of safety yellow.Vendor parts will remain their standard color and finish and not be painted. ASSEMBLY:Head and tail plemum section will be assembled with pulley assemblies.Intermediate 40'truss sections with return rolls mounted.Belting shipped in two section for two field vulcanized splices.Plenum installation kits "By Others”and instailed in the field. MISCELLANEOUS:Required hardware and assembly bolts,operation,maintenance and parts manual with layout &erection drawings. Estimated Weight 361,750 pounds BUDGETARY PRICE $697,100.00 AVAILABILTY:4-6 Weeks for approval drawings. 12-14 Weeks for equipment after receipt of approval drawings. NOTES:Field engineering available for installation and/or startup service is $650.00 per diem plus travel and living expenses. FOB:Point of Ongin freight not included. NET:Payment terms will be finalized at time of order. As I am sure you are aware for a project of this magnitude additional information would be required toproperlydesignandlayouttheconveyorsandthatanysignificantchangestothelayoutof'the conveyors could impact the price.As this additional information becomes available please forward ittomyattention. Thanks for the opportunity of providing this budgetary quotation;if you have questions or needadditionalinformationpleasefeelfreetocall. =-_,uy, Chuck Leonard Manager of Belt Conveyor Systems sad.MARTIN ENGINEERING ISO.9001 QUALITYSYSTEM CERTIFIED One Martin Place Neponset,IL 61345-9766 USA Phone:800-544-2947 or 309-594-2384 FAX:309-594-2432 Website:http:/Avwww.martin-eng.com May 5,2003 Mr.Tom Montor Precision Energy Services 10780 N.Highway 95 Hayden Lake,UT 83835 Phone:(208)772-4457 Fax:(208)762-1113 RE:PECS Systems for transfer between conveyors MS Proposal#:03156-PEC Dear Mr.Montor: We are pleased to provide to you our proposal for your consideration. We appreciate your interest in our PECS (Passive Enclosure Dust Control System)Transfer System. The PECS Transfer System is a patented system and is the most exciting new technology we have had to offer in many years.This technology will revolutionize bulk material transfer chutes across a broad spectrum of industries. Should you have any questions or require additional information,you may reach me at 800-544-2947 Ext.467.Remember,Martin's strategic principle is "Applying MARTIN® Expertise and Products to the unique needs of individual customers”. Thank you for considering our technology,products,and service. THINK CLEAN® MR Fred McRae Project Estimator st c Brad Neptune yf fg |mae.MARTIN ENGINEERING MARTIN ENGINEERING Introducing the PECS Transfer System: The Passive Enclosure Dust Control System--PECS--is the most exciting new technology Martin Engineering has offered in several years.We feel this concept will revolutionize bulk material transfer chutes across a broad spectrum of industries... The PECS Transfer System will control the dust generated at the transfer between two conveyors so well that the need for bag house type dust collectors may be eliminated. The PECS Transfer System uses a "Hood”to control the material stream as it is comes off a head pulley.It keeps the material tightly together through the drop chute and directs it onto a "Spoon” receiving chute.The spoon lays the material on the receiving belt at roughly the same speed and direction as the belt is traveling.This minimizes air entrainment and reduces impact that can wear the belt and drive dust into the air. The PECS Transfer System also incorporates seals at the entry to reduce air movement and a stilling zone at the exit to allow dust to settle from the air. The PECS Transfer System is custom-designed for each specific application;there are no "stock”parts.These systems are typically capital projects requiring preliminary engineering studies.The preliminary study will give us the information required to generate each design and create a firm cost proposal. The features and benefits of the PECS Transfer System are numerous.The following summary touches on some of the areas worthy of mention: Economic Advantages: Reduced Energy Cost:No motors for dust collector fans so energy consumption is reduced. Reduced Dust Collector Costs:Eliminates the costs for service and replacement of bag house cartridges. Reduced Maintenance Expense:No more bag house service;no more labor for spillage cleanup. Extended Belt Life:Centralized loading prevents mis-tracking and edge-damage.Belt life can be extended by 40%due to minimal impact and cover wear. Eliminate Outages from Plugged Chutes:Inertia flow maintains controlled loading stream;no 90°corners or zero speed areas to clog or choke. No Need for Suppression:Dust is controlled without spray;reduced material degradation; no chemicals to buy. Reduced Wear and Material Degradation:"Soft loading”technology eliminates loading zone impact. Extended Liner Life:Sliding vs.impact abrasion increases liner durability up to eight times normal.Exclusive PECS design allows 85%of material to ride on itself.VvVvVvVVVWVVVWEnvironmental Advantages Precision Energy Services Page2of7 . May 6,2003 Proposal No.03156-PEC The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company.Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. 1$O-9001prepayMARTINba ENGINEZAING , PNV >Reduces Employee Exposure to Respirable Dust. >Reduces Fugitive Dust Emissions by four times when compared to a fully operationalbaghousesystem. >Best Available Control Technology:Rated BACT for belt-to-belt,belt to bin,and crusher to belt installations. >Reduces Air Quality Hassles:Controls dust to achieve regulatory limits and avoids "Potential to Emit”(PTE)triggering thresholds. >Reduces Overall Point Source Emissions:Mitigates problems with Potential for Significant Deterioration (PSD)Permit Requirements. >Reduces Spillage:Central loading and reduced material turbulence keep material on the belt. >Reduces Air Speed:Primary and secondary stilling zones slow air velocity,reducing release of dust and eliminating need for energy-consuming dust collectors. PASSIVE ENCLOSURE CONTROL SYSTEM (PECS) THE PRODUCT: Material handling technology that affectively mitigates respirable and fugitive dust at conveyor transfers. HOW THE PRODUCT WORKS: The system keeps the material (that's being transferred from one belt to another)in a coherent stream,not allowing it to impact any conveyor structure.It then lays (no material- to-belt impact)the material stream onto the belt in the same direction and at the same speed as the receiving belt.Stilling zones within the enclosure further reduce air velocities and allow dust to agglomerate and fall to the belt prior to exiting the transfer zone. PRODUCT POSITION: PECS is positioned as the best available technology,on the market today,for controlling dust and spillage at conveyor transfers.This versatile technology can be used as a stand-alonesystemorinpart,with other MARTIN®Transfer Point Technolo gies. FEATURES OF THE PECS TRANSFER SYSTEM: -Hood and Spoon technology,used to maintain the material in a coherent stream, eliminate material impacts,and minimize the creation of positive air pressures. -Spoon also assures the material will be loaded properly in the center of the receiving belt. Precision Energy Services Page 3 of 7 May 6,2003 Proposal No.03156-PEC The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company.Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. 1)martida,MARTIN ENGINEERING -Entry seals are added at the entrance of the enclosure to reduce induced air. -Still zones,primary and secondary,reduce air velocity with in the transfer enclosure. -Available for new or retrofit applications. -Has received BACT approval in Wyoming,a state that has a more stringent dustcontrolstandardthanthatofthefederalgovernment. BENEFITS TO THE CUSTOMER FROM USING THE PECS TRANSFER SYSTEM: -Eliminates dust -400%more affective in mitigating fugitive dust than a conventional transfer -Meets regulatory standards. -Eliminates safety issues related to dust -33%more affective in controlling respirable dust than a conventional transfer -Air quality compliance. -Improves operating environment -30%quieter than a conventional transfer. -Reduces maintenance expenses -Extend conveyor belt life by 40%. -Reduces operating expenses -Either eliminates the need of a dust collection system, or lessens the burden of an existing system making it more efficient. -Reduces maintenance concerns /labor -Improves belt alignment. -Reduces maintenance expenses -Eliminates cleanup,requires minimal system maintenance. -Eliminates material degradation -Prevents material from free falling or impacting,in the chute and on the belt. -Eliminates plugged chutes -Inertia flow maintains controlled loading. Summary and Proposal: With the PECS (Passive Enclosure Dust Control System)Transfer System,we can control dusting and greatly reduce top cover wear.With the PECS Transfer System you get improved center loading of the material for improved belt tracking.In order to ensure that acceptable dust levels are maintained the best approach to this project is to proceed in (2)two phases as follows: Phase I -Preliminary Engineering A complete set of 2-D Conceptual Drawings and a 3-D Conceptual Model will be created for the PECS Transfer System between conveyors.These drawings will be submitted for review upon completion.We will send a representative to your site to review drawings and verify field dimensions of the entire scope of work for this project.A schedule will be developed and submitted for approval.A final scope of work will be submitted for approval along with the final cost Precision Energy Services Page 4 of 7 May 6,2003 Proposal No.03156-PEC The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company.Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. =aMail,waRgria ENGIMNEZARING proposal.Preliminary engineering will be billed upon notice to proceed and award of purchase order for this item.Preliminary engineering includes travel to your site,as well as verification of field dimensions for the scope of work or this project.Conceptual drawings are included. Phase II -Fabrication Upon completion of Phase I,we will fabricate the PECS Transfer System per the agreed upon schedule.Fabrication will be billed as per included payment schedule (see payment terms). Fabrication of the PECS Transfer System will include a new redesigned head chute,relocated magnet,Hood,new drop chute,Spoon,stilling zone,and a high speed belt cleaner system.All wear areas to be lined with AR 500 or a material best suited for the promotion of material flow and long wear liner life based on the material being conveyed. Cost Summary for convevor to conveyor PECS Transfer: Phase I -Firm Price $9,600.00 Phase II -Budget Price $126,509.00 TOTAL for PECS Transfer $136,109.00 NOTE:Final price will be within plus or minus 10%of budget price excluding required structural changes discovered during Phase I. SYSTEM DESIGN PARAMETERS 60”Belt 2000TPH 2”Minus Coal @55 Ibs per cubic foot 8%of Moisture 450 FPM Single Load Zone STANDARD PAYMENT TERMS AVAILABILTY:PHASE I 3-4 Weeks for conceptual drawings after order Precision Energy Services Page 5 of 7 May 6,2003 Proposal No.03156-PEC The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company.Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. rdpape MARTIN ENGINEZSING PAYMENT: PHASE II Net 30 days of original invoice. 3-4 Weeks for approval drawings after order 10-12 Weeks for equipment after approval drawings PAYMENT:30%Due at order placement 60%Due when PECS material arrives on site 10%Retained not to exceed 90 days of finished date SHIPPING:FOB Point of origin/Freight not included Prices are validfor 60 days from date ofproposal.Equipment manufacturing will commence immediately upon receipt offinal approval drawings.Quotation does not include shipping charges or federal and/or state sales or use taxes.All applicable taxes andfreight must be paid by Precision Energy Services. CONDITIONS OF SALES TAXES AND OTHER CHARGES: All manefacturer's,ese,sales,and other taxes of any mafere whatsoever and castow which may beassessedagainstthisorderofyaretheothePThePurchasermastpaythetaxordaty,fernish Martin E:(the C )with an certificate or otherdocumentacceptabletecustomsortaxingauthorities,or reimburse the Company the 2mount of tax ordutythattheCompanypays, RESERVATION OF TITLE: Unul Purchaser makes payment in fil,title to all goods remains in the Company and Purchaser grantstheCoarpanyasecurityinterestinthegoodswithailoftherightsandremediesofasecuredpartyundertheprovisionsoftheUniformCommercialCode.Any note of check accepted will be evidenceofdetxonlywillnotbepaymemtomaccountunuiconvertedintocashbytheCompany. In default of payment of any sales contract,or upon failure of the Purchaser to comply with any one orailconditionsofanysalecontract,the Company will have all remedies available at law or by "self-help.”in enforcing any remedy,the Company shail not be liabie in any action at isw or in equity on thepartofthePurchaserforreciamatioaofitsproperty,nor for the repaymentofanymoney,or monieswhichhavebeenpaidbythePurchaserinanypartforanymachineryormaterials. WARRANTIES:New EquipmentOniy: Defects:The Cowpamy warrants the equipment to be free from defects in material snd workmanship,which warranty is limited to defects reparted within a period of one (1)operating season or 12 monthsfromthedateofshipment,whichever comes firs.The Company obligauoa under this warranty wilbeexpressiylimitedtoing,bul cot ing,F.0.B.pout of manufacture,defective parts andtheactualcostofremedyingdefectiveworkmanship. Tide:The Company warrants that it has tide to the equipment free of any security interest.or other lienorcocumbrance. FitiessforPurpose:The Company warrants all new equipment to be fit and suitable for the purpose forwhichitismanufactured,but acccpts a0 responsibility for equipment if it is specified to the design of the Purchaser. WARRANTIES:Used Equipment Only: The Company makes no warranty for used equipment except the warranty of tile and those additionalwarrantiesthatar¢written into the order. LIMITATIONS APPLICABLETO ALL WARRANTIES: in Any attempt on the part of Purchaser,or any other persca to repair defects in workmanship orreplacedefectivepartsshallmakethiswarrantyvoidastosachdefectsandpartssorepairedoreplacedandamycondition.defect or part arising or di d as a result Precision Energy Services May 6,2003 2 If Purchaser is unable to make the equipment perform,immediate written notice must be giventotheCompany.The Purchaser must provide friendly assistance so that the Company mayasmPorchsscrinmakingtheequspmentperformtofuiillthiswarrantyPurchaserwillbeinwithailifreighttariffsandgoodshippingPontosanyexuhraentnfeemecedinchsCromerTheCompanywillpaythererumfreightandrepaythePurchaserfortheitemsoreturned,less any amounts owing the Company. Possession of the equipment for more than thirty days after installation or operation of 180 daysaftershipment,whichever comes first,without written notice of a warranty claim,shall beconclasiveevidencethatthiswarrancyhasbeensatisfied. This warranty is that the equi be usedlubricated,that it be operated in with i Companybegiven immediate aoticein writing of the defect. that it be kept property1gpracticeandthatthe This warranty docs not extend to items not manufactured by the Company provided howeverthatPurchasershailhavethebenefitofalliesmadebytheofsuchitemsandtheCompanywillassistPurchaserinsecuringthebenefitofsuchwarrantics. This warranty extends onty to the original purchaser of the prodact. ail otherTheCoawanyexp:as totheproductssoidbytheCompanywhetherexpressorineplied,incteding,withoat fimitation,implied warranties of merchantability or fitness for 1 particular perpose. Any simple sabmraad by the Company ta Purchaser and any deacripuons or illustrations iatradeLishallnotbeastombeuaceperixmanes,color quaaualty or dimension,and any failure o conform wo suchshailnos of any kind samples,C4 2 breach of these terms and conditionsbytheCompany. The company will sot be Hable te Parchaser or any third party for (I)any damage,ordiaary or special,direct or indirect,ow without [imettation,damsges for loes of sales or leas of anticipated profits or savings,(ii)amy otheraimeassertedagzinstpurchaserby2thirdparty,or (iii)for any physical injuries or death,arising,directly or indirectly,out of or in with the sale,use or defect of the productssold hereunder, Limitation of ability.The Company's sole lizbility for any product sold pursuant to thisauscementisiimitedioibereplacementuf(he product ur a refuad of the purchase price Page 6 of 7 Proposal No.03156-PEC The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company.Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. 7.waa.MARTIN ENGINEERING CLAIMS AND SHORTAGES,ETC: The Purchaser agrees to inspect all merchandise upon receipt and to noufy the Company of any claimorshortage,damage,or otherwise,not later tham 30 days of receipt. FORCE MAJEURE: Performance of the terms and conditions hereof is necessanty subject to any deiay caused by fire,Good,acadent,civil disturbance,stnice,lockout,or other labor dispute,loss,damage,or detay ofcamert,shortageoffuel,inability to obtain material,war embargo,or go resraim and jon of whatsoever ind and any other cause beyond the reasonable control of the Company. AGREEMENTS, This order,as tendered (if in excess of $25,000)is subject to acceptance by an executive of theCompany3NeponsctIinoes,and.sxcemyad.wil be fi by an *”form,The ail previous and and ail pnororand'whether oral or implied,except that amy paruculardocumentsofspecifiedpartorpartsthereofstaybemadepartofacontractbyreferenceinthewrittenAllfigures%o werght and are uniess cerufiedbyaquaitiedoffictaloftheCompany. The terms and conditions of saie shall be go by and in with the isws anddecanonsoftheStateofIino, Any to the of a plant,as a whole or in parts,or as to pieces ofequipmentofpartsthereofarevoad,uniess wnities unio ube order of the Aciknowiedgement, The Company axsumes responsibility only for une terms thas are written into the order or the Acknowledgement, INCONSISTENT TERMS SUPERSEDED: The purchase of al or any par ofthe equipment described shal be nly upon ths terms st forth bereiaandintheortermsofsale,whether oral or inSngetnathawsmadaostafPerchamcysorsforaoyenerdoconnast,sal be sepervecedbythebereofuniessacceptedimwrungbyanauthorizedofficeroftheCompany.: DELIVERY: Delivery on the Company's part will const of cither of the two following options at the Company'sedecton: 4 ing of for and vai evidenceofdelivery. 2,Shipping materials vie the Company's trucks.A packing list signed by the receiver will constitutefullandvalidevidenceofdelivery. Precision Energy Services July 21,2003 a licensed carer whose recerpt thereof will consutute full 10-9001 ba DNV -CERTIFIED approval In no event will the CompanybeTesponsbleforanylosordamagesduefofairetomakedeliveryinaccordancewiththedelivery Detivery is contingent upon delays beyond the Company's reasonable control The Purchaser will payallfraght,duty and samisr camage or revenue tanfis. Any cecess material thas may be shipped remains the of the C and shail be returnedamproperty'company to All figures pertaining to weights and dimensions are approximate. PRICES: 1 Unless otherwise stated.ail proces quoted are firm for a period nat to exceed 60 days. a Orders recerved without prevailing oc prior quotation will be billed at current prevailing prices. 3,The muummus net billing charge is $50.00. 4.The pince of items purchased by the Company for resale wil!at ail times be that prevailing at theumeofshipment. 3 The Company reserves ube night to refuse or cancel any order based om a quotation containing agrosserrorwithoutfinanczaliiabulity. 6,If shipment is postponed at the request of the Purchaser after manufacture has begun,paymentiilbeduconnoucefromtheCompanythattheequipmentisreadyforshipment. 'A Uf completion of an order is delayed by more than seven calendar dzys dus to 8 iack ofPurchaserorparualpaymentwillbedueonnouce from the'Company in the amoum to cover work and/or on band. 8.Orders accepted with delayed or restricted deliveries are billed at prices in effect 30 days priortothedatecachrejeasetsmade,Pro rate payments shail be expected for partial shipments. CANCELLATION: Cancellatiogs or stop work requests om any order or part thereof must be made inwritingandthePorchaseragreestepaytheCompanyatitsusualratesforailJaberandcostsincurredandmateriaispurchasedforthatecder,less the saivage valueand/or restocking charges of the compicte er partially compieted geods, Page 7 of 7ProposalNo.:03156-PEC The information contained herein is privilege and confidential information and is intended only for the use of the addressee's company. Any dissemination,distribution,or copying of this material to others,in whole or in part,is strictly prohibited without the written permission of Martin Engineering,Inc. a,cr i}'zsa@ Sele "esny yay a Pa cdLan x+|2) & r eh ae uh She SS&*SUF Bal .”oes by "o &*CP Ve Mls ma."eee Whe,"Bu,ia Ait Be Cen eS ae *he ee :me et Pn weet amor bib 12 eee =e *wo exh ABSOLUTELY @ POSITIVELY @ NO EXCUSES "Our Engineered Systems will perform to your satisfaction,or you may return our equipment for credit or a cash refund.” 8CERTIFIED QuALITY SrSTEM AreLOREa0 /SEGSE.MARTIN flew (lo CalioadENGINEERING Ed Peterson Chairman oesner.nae<sa'Pan,Form L3187-4/98 ey..." . beara?: nd Se 7 tts :7 Rad te ba tenNOTES:1)ALL DIMENSIONS ARE GIVEN IN INCHES (M2 2>ALL DIMENSIONS ARE FOR REFERENCE ONLY. 3>FIELD LOCATE AND INSTALL PRESSURE SWITCHBULKHEADFITTINGINACONVIENIENTLOCATION. **PRESSURE SWITCH IS TO BE WIRED INTO THE CONVEYOR HE PRE PRESSURE SWITCH AND PRESSURE BLOWER ARE EXPLOSION PROOF,AND CAN BE INSTALLED IN EXPLOSIVE ATMOPHERES.PLENUM SUPPORT BRACKETS TO BE FIELD LOCATED AND WELDED TO PLENUM. FINAL INSTALLATION REQUIRES DRILLING OUT THE (12>HOLESINEACHPANTOACALCULATEDDIAMETER,HOLES MUST BE DRILLEDASSPECIFIEDORCONVEYORWILLNOTOPERATEPROPERLY. >QUANITY OF PLENUMS DETERMINED BY LENGTH OF CONVEYOR,9)AIR SUPPORTED CONVEYOR IS AVAILABLE IN BELT WIDTHS18.00 THRU 72.00 10>CONTACT MARTIN ENGINEERING FOR SPECIAL PLENUM LENGTHS. > 6 7 vueESSURE SWITCH 1/2-NPT CONDUIT CONNECTION STD.TROUGHING IDLER SHIMED 50 (13]OFF STRINGER PRESSURE BLOWER INLET FILTER LEXIBLE INLET DUCT 12.5'SUPPLIED e-6 SEE NOTE 3 ITEM |QTY.DESCRIPTION PaRT NUMBER i PRESSURE BLOWER ASSEMBLY 3EE6BS-XXXXX 2 t INLET PLENUM ASSEMBLY 36630 XXXXXXKA 3 2 _|PLENUM ASSEMBLY [36630-XXXXXXX SEE NOTE 7 JrTRYlanAS44.63 £6.00 C1134 #152) TYP 14.88 26.00 -= (3782152 ] 119.00 €3023) SCALE 1/8 SEE NOTE 7 TD.TROUGHING IDLER SHIMED '50 (13)OFF STRINGER Coapyright aM8 arta Cogn A rights reservedCoveredby 8 wel fareigntentsordwand,fi TH betcate tredwerksofMartinC CPE.waanrin Niners.ENGINEERING USA TITLE Xo MARTIN ?STEALTH AIR SUPPORTED CONVEYOR fixe Ke DRAWNAPDATE_6709/0,CHECKED DESCRIPTION ECN DATE BY REVISION PRETESD {|SALES DRAWING f $36654 pat do inane a ih Ronen oie ,dencemtitecs un Mast a Pre eeThis complete transfer chute and enclosure system-precision-engineered for each application-provides the best system to control fugitive material and achieve air quality sta Benefits of PECS 7TransferChutes Control Dust without Baghouses Reduces the load on existing dust collectors.May eliminate the requirement for baghouses or cancel the need to upgrade these systems to improve dust control. @ Achieves Regulatory Standards Complies with air quality standards by providing effective control of respirable and fugitive dust. ®Reduces Operating Expense No moving parts.No fan motors to run.No baghouse cartridges to clean or replace.System operates without outside energy supply. @ Reduces Maintenance Expense Reduces costs for cleanup labor and baghouse maintenance.PECS Systems needs minimal system maintenance. @ Extends Belt Life Reduces impact in load zone to reduce abrasion and extend belt service life by 40 percent or more. Controlled flow improves load centering,which improves tracking and prevents edge damage. 2 Jo f Best Available In testing at the Rochelle Mine on PRB Coal, the PECS System (without dust collection) reduced the fugitive dust load by 75 percent in comparison to the same conveyor operating with conventional dust collection. As a result,the PECS System has been ndards. @ Reduces Noise Reduces impact and channels material flow to minimize noise levels. ©New or Retrofit Applications Precision-engineered to match materials, equipment,and conditions. ®Prevents Plugged Chutes Controlled inertia flow through system eliminates chute blockages. fo .fa .*s af.jControlechnology designated "Best Available Control Technology”by the Wyoming Department of Environmental Quality.The PECS System is the only enclosure system that has been permitted as a replacement for baghouse collectors in facilities handling PRB coal. Adjustment Control Mechanism allows fine-tuning of material trajectory for optimum Hmaterialplacementandreduceddust.ood Stilling Zone Staggered dust curtains slow airflow,allowing dust to settle back into cargo. Improved Belt Support Proper belt support maintains stable belt profile to eliminate belt sag and reduce spillage and fugitive material.Support system uses closely spaced roller or bar cradles as required. Engineered clamshell channels material trajectory to maintainacoherentstream.This reduces load expansion,air entrainment,and dust escape. Spoon Smoothline transfer chute places material on receiving belt with proper speed and direction.There's no impact,no turbulence, and minimal expelled air. Entry Seals Curtains at transfer point entry control flow of air into transfer point to minimize air induction. Replaceable liners Enclosure unbolts for simplified replacement of worn components without confined space entry. a on @ INTERNATIONAL INC. 3913 Algoma Road *Green Bay,Wisconsin 54311-9707 *920-468-1000 *Fax:920-469-5110 +°www.feeco.com «USA-) March 3,2003 Ref:#E001840 PRECISION ENERGY SERVICES 10780 N.Highway 95 Hayden Lake,ID 83835 Attention:Mr.Tom Monter Dear Tom: Enclosed please find our Budget Quotation E001840 covering 60”wide belt conveyors to handle 1200 TPH of coal @ 55 PCF.I selected three different lengths in an attempt to develop a priceperfootthatyoucoulduseforyourprojectcostestimate.Please note that the total price listed is based on 2,050 feet of conveyor.Your e-mail stated 2500'to 2800'would be required for theproject. For your review,I have included detailed data sheets that describe each conveyor and it's components.The truss selection is based on nominal 75'support spacing.I have not included any transfer towers in the pricing. Tom,we certainly appreciate the opportunity to bid on your requirements and hope you find our proposal useful in the development of this project.We would welcome the opportunity to discuss any items in more detail at your convenience. Sincerely, FEECO INTERNATIONAL,INC.Lk itTimMatzke Regional Sales Encl:Quotation #E001840 Cc:Walter Hawkins -FEECO International,Inc. a,FEECOINTERNATIONAL GREEN BAY WI USA 3913 ALGOMA ROAD GREEN BAY,WI 54311-9707 PHONE:920-468-1000 FAX:920-469-5110 USA PRESENTS THIS QUOTATION TO: PRECISION ENERGY SERVICES 10780 N.HIGHWAY 95 HAYDEN LAKE,ID 83835 FOR YOUR PLANT AT: COVERING: 60”WIDE BELT CONVEYORS MARCH 3,2003 -£001840 DATE FEECO Quote No. Your # EQUIPMENT DESIGNERS AND MANUFACTURERS www.feeco.com Form #Q508 N FEECO INTERNATIONAL "BUDGET”QUOTATION #E001840 PRECISION ENERGY SERVICES 10780 N.Highway 95 Hayden Lake,ID 83835 Attention:Tom Monter Monday,March 03,2003 The following items quoted are based on FEECO International designs and shop practices. 1.Belt Conveyors: 1A)Three (3)60 "wide belt conveyors per the enclosed FEECO International Belt Conveyor Specification Sheets.(Please note,the lengths selected were chosen arbitrarily to come up with an average price per foot to use for budget purposes.The total price of $1,142,000.00 for 2,050'of conveyor equals $557.00 per foot)Transfer towers are NOT INCLUDED. TOTAL BUDGET SELLING PRICE EX-WORKS GREEN BAY,WISCONSIN:.........:ssscessscessscsecnscssserscseetenssenanee $1,142,000.00 >ASSEMBLY:Conveyor Assembly Listing for Shipping -see attached data sheet VvTERMS:Progress Payments 15%of order at time of award. 65%of order in equal monthly installments. 20%at time of shipment. Payment due net upon invoice.VWTAXES:By Buyer WDELIVERY:Approval drawings 3 to 4 weeks after receipt of order. Equipment 12 to 14 weeks after approval of drawings. >STANDARD SURFACE PREPARATION:FEECO International prepares surfaces in accordance with SSPC-SP-6 with steel grit.This commercial blast is a method of preparing steel surfaces which,when viewed without magnification,shall be free of all visible oil,grease,dirt,dust,mill scale,rust, paint,oxides,corrosion products,and other foreign matter,except for staining. Page 1 of 4 JSTANDARD PRIMER COAT:Sherwin Williams'Red Steel Spec Universal Primer (BSONV6227).FEECO International,Inc.applies 1-2 mils D.F.T.to ensure an effective coverage. STANDARD PAINT FINISH:Quick Dry 350 Enamel Precaution Blue,an industrial finishing enamel,is a fast drying enamel intended for coating various metal,iron,and steel products.FEECO International,Inc.applies 3 mils total D.F.T.over multiple passes to ensure an effective coverage.This paint offers versatility and efficiency of application because of its quick air drying properties and it is environmentally friendly because it is lead/chromate free and VOC compliant.(Sherwin Williams Paint CC-B22). PAINT NOTE:Vendor supplied components come with their standard paint system. RETENTION OF SECURITY INTEREST:Seller shall retain a purchase money security interest in the collateral,identified as the equipment listed in the purchase order and any and all proceeds of such collateral including,but not limited to,whatever is received upon the sale,exchange,collection or other disposition of collateral or proceeds. WELDING:FEECO International,Inc.adheres to the nationally recognized standard,ANSI/AWS D14.4-97 "Specification for Welded Joints in Machinery and Equipment",for weld design and quality control.Qualification of welders and the procedures employed in welding are done in accordance with ASME Section IX "Welding and Brazing Qualifications”. WELDING QUALITY CONTROL:All non-destructive testing is performed by a qualified third-party source. VALIDITY:Our quotation shail be valid for a period of 30 days.Acceptance of an order during that time period shall be subject to satisfactory credit approval by FEECO International,Inc. SERVICE RATES:FEECO Service Rates -see attached data sheet PRECISION ENERGY SERVICES -FEECO INTERNATIONAL,INC. BY:>LAE im Matzke TITLE:Regional Sales DATE: NOTE:"Terms and Conditions”are attached Page 2 of 4 FEECO INTERNATIONAL 3913 Algoma Road *Green Bay,WI 54311 *USA STANDARD CONVEYOR ASSEMBLY LIST FOR SHIPPING The conveyors of this quotation will be assembled as outlined below. 1. 2. 9. The head section will have the pulley,shaft,and bearing mounted. The tail section will have the pulley,shaft and bearing mounted. In case of screw take-ups on the tail section,the screw take-ups will be mounted. The gravity take-ups will have the pulley,shaft,and bearings mounted to the slide brackets. Conveyor frames will be assembled in 20-foct sections. "A”frames and other small conveyor supports small enough to fit on truck will be shipped assembled,but not attached. "A”frames too large to fit on truck will be shipped in sections for field assembly with bolted connections. Transfer and any other towers will be shipped in pieces for field assembly with bolted connections. Skirtboards will be shipped loose for bolted assembly in field. 10.ltems to be field mounted include,but are not limited to,the following: e Idlers Covers Walkways and Grating Speed Switches,Cable Switches and Other Safety Devices Chutes and Hoppers Drives and Drive Guards Beltingeoeeee@ Page 3 of 4 FEECO INTERNATIONAL 3913 Algoma Road «Green Bay,WI 54311 °USA Schedule of Charges For Technical Services Rendered in 2001 FEECO International is committed to providing the highest level of service and training in the Material Handling/Processing Industries.Our qualified service representatives are a part of an overall effort to deliver quality continuing services.We are here to support our Customers in areas relating to installation,start-up,emergency trouble-shooting, diagnostics,routine maintenance,and training. DAILY FEES Actual billings for travel and site work are based on the rates below and are annually adjusted on the first of January.All time accrued to the work is recorded into our computerized cost accounting system. Mechanical/Electrical Troubleshooting and Startup:$880/day Process Start-Up/Project Management:$1020/day Multipliers on the above rates are 1.2 and 1.4 for Saturdays and Sundays/Holidays, respectively.Excessive daily hours (more than 10)shall be charged out as an hourly adder equal to 1/8 of the relevant daily rate. REIMBURSEABLE EXPENSES Expenses which may be incurred in addition to the hourly fees above include: Travel:Air travel (coach class),car rental,gas,taxi,lodging Miscellaneous:Actual office expenses such as internal office support,long distance telephone charges,reproduction expenses,fax,postage, etc. Layover:A $350 per day fee applies should service personnel be required to stay a weekend day or holiday without productive duties. Schedule Changes:Daily service rates for weekday work shall be applied when service personnel are unable to perform work due to schedule changes beyond FEECO's control. Two week notice shall be given by purchaser to ensure personnel availability and flight economies.Purchase order must be received prior to service being rendered. INVOICES Billing will be generally on a monthly basis.Payment is due and payabie upon receipt. Carrying charges for overdue accounts beyond 30 days of billing date are charged at (1) percent per month of amount due.Time sheets and copies of expense receipts will be provided only if specified on the purchase order. Page 4 of 4 FEECO Incesuacional,Ina.Confidential 3/3/03 Estimate No E00 Precision Energy Services Precision Energy Services Precision Energy Services March 3,2003 March 3,2003 March 3,2003 Idaho Idaho Idaho No.Ttem "Description Bescription Bescription Conveyor #Conv.aT Conv.#2 Conv.#3 T [Length cic TOO 1 300 ft.TSO 2 [Rise 25 tt.Zot vied J [Capacity coal coal coal 1210 STPH@55 pct 1210 STPH@55 pef 1210 STPH@55 pet.qT [Bolt Speed 350 fpm 350 Tpm 350 fpm 5 [Belt Width 60 inch BO inch 60 inch 6 [Head Section Includes pulley,shaft,Includes pulley,shaft,Includes pulley,shaft, bearings all assembied bearings all assembled bearings all assembled on head section on head section on head section T [Asad Pulley 3 Inch diameter with 172 inch 30 inch diameter with 172 Inch 30 Inch diameter with 172 Inch diameter.Herringbone lagging (FFWS)Herringbone lagging (FFWS)Herringbone lagging (FFWS)8 [Head Shak 6 15/16 inch dia.6 76 inch dia.6 15/76 inch dia. diameter SKF-SAF or equal SKF-SAF or equal SKF-SAF or equalbearings.pillow blocks pillow blocks pillow blocks _¥[Snub Pulley Té Inch diameter CFWS TS inch diameter CFWS TS inch diameter CFWS Diameter TO [Snub Shatt 47TH inch dia.47H6 inch dia.TTAGInch dia. diameter SKF-SAF or equal SKF-SAF or equat SKF-SAF of equalbearings.pillow blocks pillow blocks pillow blocksTT[Motor AP T50 Hp,T750 RPM,3ph,60 Az,2460 VSS«STOO Hp,TSO RPM,Sph,60 Hz,30400SCO«dESS*S*S*«2 Ap,1750 RPM,3ph,60 Hz,2sudo0 SYTypeTEFC,Severe Duty,EPACT Efficiency TEFG,Severe Duty,EPACT Efficiency TEFC,Severe Duty,EPACT Efficiency TZ TReducer -Type Dodge,Shaft Mount Dodge,Shafi Mount Dodge,Sha Mount Size TXT 1325 TXT 1225 TXT1225 Class Class WW,of equal Class II,or equal Class ll,or equal T3 [Backstop Taternal Toternal Internal 'TP V-Belt or V-Belf Included V-Belt Included V-Beli Included Chain Drive. TS [Drive Guard Fabricated of 12ga.CS Fabricated of T2 ga.CS Fabricated of 12 ga CS T&[Discharge Hopper (1)fabricated of PT6 inch MS.(1)fabricated of STE inch MS.(7)fabricated of 3/76 Inch MS. T7 [Belt Cleaner Marin OC#TE Burk Hawgwi Spring Tensioner Uual Cleaning System of Cqual Martin OC#TE Dur Hawg wi Spring Tensioner ual Cieaning System or Equal Martin OC#T &Dut Hawg wi Spring Tensioner ual Lieaning System or Equat 18 [Gravity Take-up 24 inch diameter CFWS 24inch diameter CFWS 24 inch diameter CFWS Pulley diameter. TS [Shak diameter 4 TANG inch dia 47H6 inch dia.TT inch dia bearings.SKF-SAF or equal SKF-SAF or equal SKF-SAF or equal pillow blocks pillow blocks pillow blocks20[Bend pulley {Finch diameter CFWS {B inch diameter CFWS TB inch diameter CFWS diameter. 21 [Bond shat 415/16 inch dia.4 TS/16 Inch dia.415/16 inch dia. diameter SKF-SAF or equal SKF-SAF or equal SKF-SAF of equalbearings.pillow blocks pillow blocks pillow blocks22GravityTake-up guard Expanded Metal Shroud Expanded Metal Shroud ExpandedMetalShroud 23 {take-up TS High Service Platform TS"High Service Platform TS High Service Platformplatform.wiAccess Ladder and Grating wiAccess Ladder and Grating wiAccess Ladder and Grating24[Counterweight Fabricated of Carbon Steel Fabricated of Carbon Steel Fabricated of Carbon Steel box. 2 [Counterwelght Included Included Included punchings. Master.xls Page 1 WEECO I..-senacional,Ino.Confidential 3/3/03 on tail section on tail section EstimateNo"E0U Precision Energy services Precision Energy Services Precision Energy Services March 3,2003 March 3,2003 March 3,2003 idaho Idaho idaho No.Kem Description Description Besciiption Conveyor #Conv.#7 Conv.#2 Conv.#3 Conveyor Frame.TOOO TE GU Inch truss section 300K 60 Inch truss section '750 1 60 inch truss section Drip pan.NA NA NA Includes pulley,shalt,Tncludes pulley,shaft,Tncludes pulley,shaf, bearings all assembled bearings ail assembied bearings all assembled on tail section Tail Pulley diameter. |20 27 28 |Tail Section i: Ki) 24 inch diameter CFWS Winch diameter CFWS 24 Inch diameter CFWS Tail Shatt TTS inch dia.TTSI6 inch dia.TTSTB inch dia diameter SKF-SAF of equal SKF-SAF or equal SKF-SAF or equal bearings.pillow blocks pillow blocks.pillow blocks 3T [Self Cleaning Ni NA Na tail pulley. 32 [Tail Pulley Expanded MetalShroud Expanded Metal Shroud Expanded Metal Shroud Guard "SI [Screw take-up NA NA NA travel. 34 THorizontal NI NA NA take-up. 3B [Skitboard 20 Ig.of Martin of Equal Apron Seal wi One Pes.5 inch high adj.rubber seals and wi 1/4 inch AVR liner @ impacts 2 Ig.of Martin of Equal Apron Seal wi One Pes.5 inch high adj.rubber seals and wi 1/4 inch AVR liner @ impacts 20 1g.of Martin of Equal Apron Seal wi One Pcs.5 inch high adj.rubber seals and wi 1/4 inch AJR liner @ impacts Vulcanized Splice By Others Vulcanized Splice By Others Deck Plate 80 of 12 Ga.Deck Plate BY of 17 Ga.Deck Plate BO of [7 Ga Deck Plate 37 [V-Plow.Martin V-Plow or Equat Martin V-Plow orEqual Martin V-Plow or Equal 38 [Belting BU Inch,3 ply,330 PIW,RMA Grade TT 60 Inch,2 ply,220 PIW,RMA Grade BO Inch,2 ply,2:fi fade Specification.4/16 inch x 1/16 inch covers 3/16 inch x 1/16 inch covers 3/16 inch x 1/16 inch covers Vulcanized Splice By Others 39 {Troughing Idlers 20/35 deg CEMA C,3 inch dia. rolls with roller bearings. (Steel Rolls),Sealed CEMA TC,5 Inch dia. falls with roller bearings. (Steel Rolls),Sealed CEMA C,3 inch dia. rolls with rolier bearings. (Steel Rolls),Sealed 40 [Return Idlers.CEMA CG,5 inch dia. folis with roller bearings. (Steel Rolls),Sealed CEMA CT,5 inch dia. rolls with roller bearings. (Steel Rolls),Sealed CEMA C,5 inch dia folts with roller bearings. (Steel Rolls},Sealed Mastec.xls At [Training (10)CEMA C8 inch dia:(3)CEMA C,5 inch dia.(8)CEMA ©,3 inch dia roughing rolls with roller bearings folls with roller bearings rolis with roller bearings idlers.(Steel Rolis),Sealed (Steel Rolts),Sealed (Steel Rolls),Seated 42 [Training (10)CEMA C,3 inch dia.(3)CEMA C,Sinch dia.(8)CEMA ©,3 inch dia. return rolls with raller bearings folis with roller bearings rolls with raller bearings idlers (Steel Rolls),Sealed (Steel Rolls),Sealed (Steel Rolls),Sealed 43 [Entra Idlers (7)CEMA C,5 Inch dia.(7)TEMA C,5 inch dia:(7)CEMA,3 inch dia. under feed folls with roller bearings rolls with roller bearings rolls with roller bearings points.(Rubber Dise Rolls),Sealed {Rubber Disc Rolls),Sealed (Rubber Disc Rolts),Sealed 44 [Idler Spacing.4"Carrying 4°Carrying 4°Carrying 10'Returns 10°Returns 10'Returns 1'Loading 1'Loading 1'Loading 4 [Conveyor TOON of 22 gauge galvanized SOY of 22 gauge galvanized TSO of 22 gauge galvanized covers.hinged covers hinged covers hinged covers|46 [Side weather NA NA NA covers. 47 |Special transfer Nit NA NA platform with tailing and FEECO 1..-srnational,Inc.Confidential 3/3/03 Estimate No:E00 Precision Energy Services Precision Energy Services Precision Energy Services March 3,2003 March 3,2003 March 3,2003 idaho idaho Idaho "No.Kem Description Description Description Conveyor #Conv.#7 Conv.#2 Conv.#3 grating. 48 [Double walkway Included Included Tncluded and failing athead end [49{Walkway with NA NA NA supports and angle railing. 30 [Walkway with TOO Tong x 30 inch wide SOF Tong x 30 inch wide T50 Tong x 30 inch wide supports and One Side One Side One Side pipe railing OT [Walkway Steel Galv.Bar Grating for Steel Galv.Bar Grating for Steel Galv.Bar Grating forgrating30inchwidewalkway30inchwidewalkway30inchwidewalkway 82 [Stalrway with NA NI Mi treads and © railing 53 |Cadder and NA NA NI safoty cage. 54 A"trame one @ IU high,and twelve @ 20 high one @ TU high,and four @ 20 high.one @ {0 high,and nine @ 20 high. supports. 55 [Angle leg NA NA NA supports "968 [Spoclal supporis.Head &Tail Supported Head &Tail Supported Head &Tail Supported "BT [Zero spead (1)Process Control Systems (1)Process Contro]Systems (i)Process Control Systemsswitches.Maxigard A1500 wi bracket "Maxigard A1500 w/bracket Maxigard A1500 wi/bracket 58 ]Emergency (6}Conv.Comp.RS-T complete (2)Conv.Comp.RS-T complete ()Conv.Comp RS-T complete stop switches.wi cable and brkts or Equal wi cable and brkts of Equal wi cable and brkts of Equal One Side One Side One Side 59 [Belt Misalign.(3)pair Conv.Comp.TA-T (2)pair Conv.Comp.TA-T (3)palr Conv.Comp.TA-Tswitches.complete with brkts or Equal compiete with brkts of Equal complete with brkts or Equal Plug Chute NI NA Ni Switch 6T |Bekt Scale NI Na Ni 62 [Blasting SSPC-SP-6 SSPC-SP-6 SSPO-SP-6 63 [Primer Sherwin Willams Universal Primer Sherwin Wiliams Universal Primer Sherwin Willams Universal Primer "BF [Intermediate AA NT Na 65 [Finish Sherwin Willams Quick Dry 350 Enamel Sherwin Wihams Quick Dry 350 Enamel Sherwin Wiliams Quick Dry 350 Enamel|-66 [Sataty Colors Ni NI NN &7 [Galvanizing Ni NA NI Packing &Loading Eq Included Included Included 69 [Assembly.FEECO Standard Assembly FEECO Standard Assembly FEECO Standard Assembly Master.xls Page 3 EESGsGalGew:a minerals Maren 26,2003 Precision Energy Services,Inc. 10780 N.Highway $5 P.O.Box 1004 Hayden,IO 82835 Attention:Mr.Sam Fulton Subject CoatFired Power Plant Barge Univading Equipment Bethel Alaska Metso Minerals Reference No,W-89383 Gentlemen: in accordance with our recant discussions,we are pleased to provide the following budget infermation for the subject project. "To design and supply,F.O.8.point cf manufacture,one (1)2,000 tph Coal,Barge.Mounted Continucus BargeUnioader,to unicad 5,000 ton barges,with a 120 ft.boom to shore and a 2,500 ft,ground conveyer,your budget prices are:: Barge for mounting the Unicader ae $1,900,000 Continuous Barge Unfoader,including a Barge Haul System ANG BOOM tO SNCS oo.uescsescerreeaewecrsesconssereseasererescseurcascserenesteeaseasaesesenens sesesenee §3.600.000 2,800 ft,2,000 teh Ceal,Ground Cenveyor..vessenee $1,900,000 Total F.O.B.Budget Prica 3 7,400,000" General Notes: 1.We expect that the barge unloader would be preassembled at a West Coast shipyard and then tewed to Alaska.We estimate that this assembly would cost about $1,800,000. 2.The conveyer scuipment will require aporeximately 26 truck shipments.Twenty-one of the shipments weuld mest likely be from a structural fabricator in British Columbia. 3.Cest for fieid acvisory and start-up and commissicning pecpie are not included in cur budget drives. if there are any questicns,or if additional information Is needed,please comtact me at (412)269-5140. o Sincarely,= METSO MINERALS INDUSTRIES,INC.Lime feeManagerProductSupport Metso Minerats industries,Inc.4800 Grand Avenue,Pirsburgh,PA 1522$-1599 Tal.+1 412 269 5000(Fax +1 412 289 $151{www.mecsominerais.com TOTAL P.@tL Tom Monter From:ben.dudek@metso.com Sent:Wednesday,May 14,2003 10:59 AM To:Tom.Monter@pes-world.com Ce:berezowski@pes-worid.com;tim.sexton@metso.com Subject:89383-Coal Stacking-Reclaiming system Tom, After some consideration,we have come up with what think is a cost effective storage building solution.The attached drawings provide the storage building clearance dimensions and the machine arrangement. The budget cost for this machine is e $US 4,400,000 (4 millions-4 hundred thousand US dollars) Price is FOB,Portland Oregon area.The price does not include rails and rail supports,yard conveyor,field wiring materials or equipment erection.Building cost is not included. if you have any further technical questions,you may contact me.If you have commercial questions,you may contact Tim Sexton as listed below. Best Regards Ben Dudek Principal Engineer Metso Minerals 4800 Grand Avenue Pittsburgh,PA 15225 e-mail:ben.dudek@metso.com phone:412-269-5214 fax:412-269-5161 Tim Sexton,Proposal Manager e-mail:Tim.Sexton@metso.com phone:412-269-5140 IMPORTANT.This email,including its attachments,is from Metso Corporation or its affiliate and is intended only for the named addressee(s).This email may contain confidential information and it may be subject to privilege,copyright and privacy.Unauthorized transmittal and other use are prohibited.If you have received this email in error,please return it to Metso and delete it from your system without retaining copies thereof.Thank you. 7/10/2003 (05/14/2003-18:00am=USPFORM3624-1481-0138-6"38 |110"-0 MACHINE OATA ONS it /FP-LOOSEIf50LS/FP-46 |75 LBS/FT'=COMPACTED DESIGN STACKING RATE 2000.TPH -'©DESIGN RECLAIM RATE ©500 TPH >emma al aI B 'we ' L 4 2 . INN|a Pas }Tt tt TT 4Eamatea4 .I TS.OE nt\=w = AWWA RINE AN YN RUIN N ; 38 200'-0 SE Metso Minerols|wt metso |Stats torn1mineralsPittsburgh,PA 15225 fl =14 FA PRECISION ENERGY SERVICES INC.[|===SS at SOMW POWER PLANT +/<<'ye BUCKET WHEEL STACKER/RECLAIMER vit a =|:=STRAY Ria 7 a GENERAL ARRANGEMENT ==" aa -=Coeae Z ]|pee:OnE:OD Shemenen_eee =DISCLOSED NEREN Sealwe mepRoDuCED oR [--r-7 OR:JAH DATE:5/12/05]PASSED:DISTRIBUTION7 3E viens 08 USED OR DISCLOSED TO OTHERS =L-4 CHK;5 OATE:OATE: =-SCALE:_1/8"=1'-0 DRAWING NO REV]SECTION JE METSD MNERALS WHEN SUPPUED OR USE =5 SSE TOR PROPOSAL TAA CONT.Wp9 383YEW46 RRERALS OE Leseeree cacrnc._|REF OWG DESCRIPTION REY [DATE DESCRIPTION BY_[APRO|NO:89383-0-002 |0NETSOMINERALSBULKMATERIALSHANOLING. '|5 2 1 05/14/2003-1:30pm-USPIBOudpo3621k1854'-0"262'--0"140'--0"CENTERLINE OF /_STACKER/RECLAIMER $00,000 TONS STORAGE -------=aeefCENTERUNE OF TRIPPER RAILS 262' 0" 43'-6"39'-a"113'-8"39'-8"25'-6°30°-0"\INSIDE CLEARANCE r=).! mn \-__---UNCOMPACTED COAL HEIGHT i=) A .©# J g COMPACTED COAL HEIGHT N BUNGE ° |°o Nn WRUNG ARUING-LRIAWRNIRINWREINTANININ RINGER ARRAN RR WANG Metso Mineralsmetso|Hii ttemineralsPitteburgh,PA 15225 200'-0"22'=0"PRECISION ENERGY SERVICES INC. SOMW POWER PLANT BUCKET WHEEL STACKER/RECLAIMER a STORAGE BUILDING CONTROL DIMENSIONSWWATORALSHAMOLNGAREOIScLONEDPERE=-_7 APPD:DATE:oO FoRfrcrrenttomSHALLgeNePROouceDon[--be 7 OR 80 DATE ST PASSED:DISTRIBUTION(weirs VD OR paca To MOS -r-7 CHK:DATE:DATE:FOR ey PURPOSE NOT AsTHORZED BY =a SCALE:AS NOTED DRAWING NO REV ANTARING EQUEMENT To wien If RIFE =0 [+1443]ISSUED FOR BUDGET 80 CONT.W89383 89383-0-001 0WeTSOMINERALSBULKMATERILSANDLING.|REF _OWG DESCRIPTION REV [DATEL DESCRIPTION BY [APPD|NO: 438 Industnal Drive Post Office Box 400 Winfield,Alabama 35594-0400 Telephone:205/487-6492 Fax:205/487-4233 CONTINENTAL CONVEYOR &EQUIPMENT COMPANY ANESCO COMPANY The World Laader in Conveyors and Conveyor Technology SALES OFFICES:BIRMINGHAM,AL-BOSTON,MA-CORBIN,KY-DELTA,BRITISH COLUMBIA-GASSAWAY,WV--HOUSTON,TX--LAKEWOOD,CO-LOS ANGELES,CA-MT.VERNON,IL-NEW YORK,NY-OAK HILL,WVOMAHA,NE-PHILADELPHIA,PA-PITTSBURGH,PA-PORTLAND,OR--SALT LAKE CITY,UT-SALYERSVILLE.KY-TAMPA,FL-WINFIELD,AL March 10,2003 Precision Energy Services 10780 N Hwy 95 Hayden Lake,ID 83835 Attention:Mr.Tom Monter Gentlemen: Thank you for your interest in our company.We are pleased to enclose the literature you requested about our products.After you have had an opportunity to review this material, we will be glad to answer any questions you may have and to assist you in any way possible with lowering the cost of your materials handling requirements.You may contact our field representative,whose name and address are shown below,or contact us here at the factory at 205-487-6492. If we can be of additional assistance,please let us know. Sincerely, CONTINENTAL CONVEYOR &EQUIPMENT COMPANY tGrayCen)Larry N.Atkinson Manager of Engineering/Engineered Systems a ym = Enclosure cc:Jerry Theusch,District Manager Jim Smothers J.T.Industrial Sales Mike Roberts 5319 S.W.Westgate Drive,Suite 105 Portland,OR 97221 Telephone:503-297-5628 Fax:503-297-5629 lied -hed dedi Tom Monter From:Russell Beach [rbcce@starband.net] Sent:Friday,March 28,2003 1:59 PM To:Tom.monter@pes-world.com Ce:Jim Smothers;Ron Stough;Mike Roberts;Nelda Madison;theusch@attglobal.net Subject:Budget for Coal Handling Conveyor,Bethel Ak Tom, We offer the following budget for the above referenced project. One (1)54 inch BW conveyor to handle 2,000 STPH of coal at 55 PCF to include the following: Terminals: One (1)Remote Dual 150 HP drive (motors,reducers,couplings),discharge pulley,discharge hood/chute,belt scrapers,tail loading section with impact idlers,pulley outfits,bearings,and gravity take-up.v4 Intermediate Structure: 54 inch BW truss (elevated 20 'above grade)with 180 degree belt covers,safety switches with pull cord,walkway both sides,troughing and retur idlers,belt,and bents spaced at approximately 80'centers. Your Budget Price,FOB Factory,Winfield,Alabama is............:csesssscssereeeeeeetees $907,000.00 The above is based on 1,400'centers and elevated 20'above grade.Please call with any questions you may have or if you need additional information. Regards, Russell Beach 3/28/2003 Tom Monter From:Russell Beach [rbcce@starband.net] Sent:Friday,April 04,2003 1:46 PM To:Tom.Monter@pes-world.com Ce:Mike Roberts Subject:Bethel,Ak Coal Handling Budget Tom, |apologize for not responding to your request earlier this week. Estimated freight from Winfield,Alabama to Seattle port is $45,000.00 for the Bethel project. Erection should fall in the range of $300,000.00 to $400,000.00. Please let me know if you need more information. Regards, Russell Beach 7/21/2003 Gareo: ProjectManagement DesignSpecificatigns About Garco Partfalia Qur Builders Fabrication Contact Us What's New! Site Mep Heme Page Search Garco Building Systems Address: S.2714 Garfield Rd. Airway Heights,WA 99001 Telephone: 509.244.5611 800.941.2291 Fax: 509.244.2850 Maximum GarcoBuildingValue-smangsjaene Value means more than simply what you pay for a building right now.Garco builds in the flexibility and solid construction that keeps delivering over the long run... That's "Maximum Building Value”. Measurable Quality Maximum Building Value can be measured in many ways,beginning with quality.At Garco Building Systems,quality means each project receives the kind of attention that only the industry's best engineers,detailers and craftsmen can provide.Garco''s design policies exceed even the strictest of general engineering guidelines.Our custom-tailored drawings and documentation are generally viewed as the best in the industry.And our aggressive in-house quality management program,as confirmed by certifications from the most exacting independent qualifiers,ensures the structural integrity of each client's final product. pete taiandeane °[HOHIHOHSROLCOHG DAL UES Garco is a member of the Metal Building Manufacturers Association and has American Institute of Steel Construction,Inc.(AISC)Category MB Certification.Also,we maintain ICBO Fabricatorstatus,Canadian Welding Bureau Certification and numerous other credentials of quality.This makes us part of a small,elite group who care enough about quality to put their products and people to the test. Diversity of Expertise Garco Building Systems continually demonstrates the ability to engineer and manufacture a full range of products,from our standardized "Express" structures to multi-faceted heavy industrial complexes;from attractive commercial centers and institutional facilities to sophisticated office buildings.We have the proven ability to meet each client's unique set of needs --and thewillingness to do it. Garco's staff acts in a supporting role to the overall project design team.Our readiness to participate with other disciplines,offering the experience gained on a wide variety of projects,is a valuable resource our clients depend on.Our experienced project coordinators act as the sole point of communication throughout the construction cycle.Garco's team approach, coupled with our respected ability to analyze,problem solve,visualize and design cost effectively,facilitates the successful completion of the most challenging projects. Ability to Adapt The key to Garco's success in providing quality products and customer service is summed up in one important word...flexibility.We believe clients BEELEReeOS. http://www.midcoinc.com/about/mbv.html 7/31/2003 should not be asked to compromise the functionality of their building to meet the manufacturer's standardized product formats. Garco provides buildings designed to meet each customer's needs,with every project viewed for its own set of peculiarities.We regularly customize our project drawings and designs to meet client requests.We account for field construction requirements and special site conditions throughout the project,on everything from connection designs to the shipment of steel for juséin-time arrival on site.Garco's manufacturing schedules are planned to respond to the most stringent of construction timetables. Clients know that when Garco Building Systems joins the project team,theywillbeworkingwithanorganizationcommittedtosatisfyingtheirunique requirements. Capacity to Perform Our manufacturing facility is able to offer a wide variety of superior factory applied primary and secondary coatings designed to withstand the most severe environments.We have the ability to handle almost any size and shape structure required in our manufacturing area.And we have the tooling and machinery that gives our engineering staff the flexibility to design structures using the best possible solution rather than designs dictated by the limitations of equipment. From well maintained manufacturing equipment to continual computer upgrades that ensure the flexibility and power to efficiently handle complex projects,Garco practices a philosophy of giving our people the tools to get the job done right.Reinvestment in the company is one example of Garco's commitment to meeting client needs today and in the future,ensuring our continued ability to provide leading edge product applications. Solutions Oriented Garco has been in the metal building industry since 1958;many of our customers have been with us nearly as long.Clients tell us that they view Garco as an extension of their company when doing a ee building project.We believe this reflects our commitment to total customer satisfaction...a record of outstanding service resulting from a strong sense of urgency throughout the company to provide the best value available in the time frame required. Over the course of the project,changes may occur for a variety of reasons;we accommodate these changes quickly and smoothly.Garco is a solutions company. Clients know when they come to us that we'll do more than design to meet specifications and codes.We will look for ways to respond to each of their needs in the most efficient and beneficial manner. Partnership Approach Ultimately,our goal is this:upon project completion,we want every client to walk away with absolute confidence they made the right decision to include Garco on their"Project team.This means there are no unansweredered,questions about the design or material 'provided © :structure will continue to perform as it was intended long after building completion.They ecg know rat future questions,modification requests http://www.midcoinc.com/about/mbv.html 7/31/2003 =-«a MoyvyVE This feeling of trust comes from Garco's strong adherence to the qualities of integrity,honesty and craftsmanship.We cultivate a relationship with our clients based on professional respect and mutual effort.Clients enjoy working with us and know we will always respond with excellence. Perfect Fit Just as each building project is unique,so are the priorities each professional brings to the project.But when the focusis on quality,Frexibilty.accuracy of fit,ease of erection,customer service pou and dependability,Garco has the proven ability to Ibe perform.We believe that the combination of all , these factors is an accurate measure of Maximum Building Value. ey wap eth be sie : For an opportunity to experience working with an organization that puts your needs first,from beginning to end,call your local Garco builders or Garco Building Systems.We look forward to providing you with Maximum Building Value on your next building,roof system or steel structure. Metal Building Systems |Maximum Building Value About Garco |Garco History |FAQ Map to Garco |Garco Certifications Contact Us |Employment Opportunities Project Management |Design Specifications About Garco |Portfolio |Our Builders Fabrication |Contact Us |What's New Site Map |Home Page |Search Last Updated February,2002 All original graphics and text are copyrighted ©2002 by Garco Building Systems and may not be used without permission. This site created for Garco Building Systems by:WebMaker -Web Site Productions http://www.midcoinc.com/about/mbv.html 7/31/2003 Tom Monter From: Sent: To: Mike Berry [MikeB@garcobuildings.com] Wednesday,May 21,2003 12:02 PM tom.monter@pes-wortd.com Subject:Coai Cover Building for power plant,Alaska Tom: Please note the following budget information regarding the coal cover building for Alaska power plant.OBNDARWN=Feel free to Regards, Mike Berry Building Dimensions:250'wide x 1300'long x 45'eave height Building size:325,000 sq ft Frame type:Gable clearspan rigid frame Roof &wail panel (full coverage):24 GA color Roof snow load:50 psf Wind load:110 mph;Exposure "D” Seismic Zone:UBC Zone 3 Collateral load:10 psf on roof Building supply budget price:$12 per sq ft Building shipping costs:$1.5 per sq ft Building erection hours:20,000 manhours Building erection costs:not included Building weight:18-19 Ibs per sq ft contact me with any questions or comments. Manager Heavy Industrial Tel:509-444-7106Cell:509-979-0628 7/31/2003 a oesPr¢__/Vif Roky e8u,, en agrorn® Radian LLC is the Industrial Agent For Air Supported Structures Manufactured By Air Structures American Technology,Inc (A.S.A.T.]) LLC SUBJECTIVE PROPOSAL AIR SUPPORTED STRUCTURE FOR CUSTOMER:Precision Energy Services APPLICATION:400,000 mt coal storage Date:15 April,2003 Size:300'W X1000'L X 125'High with rectangular 90 degree comers All of the structure's welded seams will be constructed to be stronger than the fabric. The total envelope will be pre-engineered to fit your site and anchorage grade beam. The vinyl coated polyester can have an optional clear hard barrier coating,"Stay Clean”,formulated especially for air supported structures which keeps the structure clean and increases resistance to abrasion.The strength and specifications for the outer fabric are as follows: a.Total Weight:31 oz.Per yard b.Color:White Translucent Cc.Base Type:Polyester d.Trapezoid Tear 106/146 Ibs. e.Grab Tensile 934/923 Ibs. f.Strip Tensile 595/564 Ibs./in. g.Fire Retardant:Meets NFPA 701I,meets Calif.Fire Marshals Req. and Pass 2 sec.Flame-out Method 5903. h.Operating Temp.Minus 40 degrees F.to +150 degrees F. Construction:The structure is to be fabricated by means of dielectric welded seams. A.S.A.T.].has the equipment and 40 years of experience to produce welded seams, which are as strong as the fabric itself.Heat sealed seams are used throughout the major portion of the structure envelope to provide maximum strength in high stress areas and to serve as rip stops to help prevent tear propagation.Larger buildings are made in sections and joined on site with our 35 year proven clamp system. Patented Bias Safety Net System:(100%Stress Relief) For 40 Ibs snow load and 110 mph windload.The bias harness net system is prefabricated totally encapsulating the air structure envelope.This harness system uniformly releases fabric tension in all directions,transforming fabric loads directly to the harness.When fabric stress is transferred to the harness net system,fabric load will be a maximum of 6lbs per inch in all directions.Roof convolutions are less than 4 inches when the structure is inflated to 1.5 -3.0”water static pressure.Low Radian,LLC 1195 E.1100N.,Shelley,Idaho 83274 USA,Phone 1 208 243 3450 -Fax 1 208 485 7808 email:Ifielding@radianlic.us convolutions prevent trapping of snow and water.The bias harness net system shall be constructed of pre-stressed galvanized vinyl coated steel cable (3/8”diameter minimum)which is bias interlocked to form a complete encapsulating net so the net will lay evenly distributed over the total air structure fabric envelope.Proper distribution of the harness net system is designed to allow the fabric to carry a minimum stress load during 110 mile per hour winds and an internal pressure of 1.5 -3.0”wsp.The bias construction of the harness system causes the wind load side and leeward side of the air structure to balance between opposite forces such that there is hardly any noticeable change in the structure's shape of stability during heavy wind load. Continuous Airtight Anchorage System: This method of continuous anchorage at the base of the structure has proven in actual usage to be extremely successful and the best that can be offered.The angle bar or aluminum extrusion is so designed to incorporate hold down required for the harness net system and the air structure envelope.This system eliminates the need for separate large hold down points. *Seepage of water into the structure at the base from snow and rain will be minimized. *Air loss around the base perimeter is greatly reduced providing savings on inflation. *A.S.A.T.1.Anchorage system is designed to leave no protrusions above grade when the structure removed. *The Air Structure Institute Design and Standard Manual rates the continuous clamp anchorage system as the most airtight anchorage system available. *Buyer to provide concrete foundation with anchors and steel,or aluminum extrusion, for installation into grade beam.(Turn-Key Installation Estimate Available) Field Junction Seam Joints;4 A.S.A.T.I.engineered a mechanical field seam joint to allow the total envelope to be separated into smaller sections for easy erection and removal.The joints are mechanically sealed with aluminum non-rusting clamps.The Air Structure Institute Design and Standards Manual shows clamped field seam joints to be the most airtight seams available in the industry.The seams are extra protected from water leakage by an exterior seal flap,which locks over the mechanical joint. Entrance Openings And Fabric Boots:0 All door openings will be fitted with fabric roll-up flaps,which will be laced closed when the structure is inflated.This allows the structure to be inflated without first connecting doors to the structure's fabric (which is a difficult job).The fabric flaps can also be rolled down and laced closed during the structure's use so that doors can be removed and repaired without causing an air pressure drop in the air structure (a great safety feature). Personnel Exit Door:3 The primary purpose of this door is to give an emergency means of egress.Due to the air structure's static pressure on the interior side of the door,we have engineered an emergency door that opens outward without force.The door automatically returns Radian,LLC 1195 E.1100N.,Shelley,Idaho 83274 USA,Phone 1 208 243 3450 -Fax 1 208 485 7808 email:Ifielding@radianllic.us Closed against the air structure internal air pressure.This design has receivedcompleteacceptancebytheBuildingCodeOfficialsandtheAirStructureInstitute's design standards. *All aluminum welded construction that never rusts and never needs paint. *Lightweight and easy to remove when the structure is removed. *Lexan vision panels are unbreakable and offer lifelong service.. *Free standing with panic hardware and outward opening and self closing. *Emergency exit door with top panel for mounting ASATI's supplied emergency exit lighting. *Exit signs lights (pre-wired). Revolving Door:3 Our revolving doors are the most efficient method of moving people in and out of an air structure.As you enter or exit,each door vane acts as an airlock.Therefore,large numbers of people can move safely in and out of the structure without causing a pressure drop. *All aluminum welded construction that never rusts and never needs paint. *Lightweight and easy to remove when the structure is removed. *Lexan vision panel is unbreakable and offers lifelong service. Vehicular Airlock:2 (15'X 15'X 80') Two doors will be provided for each airlock for allowing vehicles and equipment to pass in or out of the air structure without changing the safe operating internal pressure.The pre-wired electric motors with push button stations are designed so that only one door can electronically open at atime.Therefore,one door is always closed maintaining the air structure's internal pressure. «Complete with one U.L.approved electric motor,push button stations and steel roll up doors. *Steel frame,fabric cover and hardware are pre-packed and complete for assembly. *Manual pull chains are supplied for each door so doors can be opened manually should electric power fail. Primary Inflation System:1 This inflation system supplies internal air pressure to inflate and shape the structure envelope.When the structure is pressurized ta 1.5”wsp (internal pressure),the envelope of the structure is pre tensioned and stabilized to withstand aerodynamic forces imposed by 80 mph winds and live loads caused by snow load. *Complete package self contained in an exterior weatherproof housing. «Electric motors and components are UL listed. *Blowers are rated in accordance with A.M.C.A.standards. *Electric motors vcltage available to meet your specific requirements. Control Panel:(1) Provides a visual gauge and indicator lights to monitor operation of each blower and to show the level of operating pressure for the air structure building system. Radian,LLC 1195 E.1100N.,Shelley,Idaho 83274 USA,Phone 1 208 243 3450 -Fax 1 208 485 7808 email:Ifielding@radianlic.us Secondary Pressurization &Auxiliary Backup System:1 This backup electric and gas motor inflation system is pressure controlled to supply internal air pressure to inflate and shape the structure envelop during pressure loss or primary failure.When the internal pressure drops below 1.0 w.s.p.or on electrical power failure,the unit will activate automatically and continue to supply additional c.f.m.until the high limit setting is tripped and resets the system or power is restored. >Complete package,self contained in an exterior weatherproof housing. >Motors and components are UL listed. >Blowers are rated in accordance with A.M.C.A.standards. >Electric motors voltage available to meet your specific requirements. >The system is complete with a 12 voit battery,automatic choke,automatic controls with pressure sensing probe and automatic regulating battery charger,all enclosed in a weatherproof enclosure. >Gaseous fueled engine designed to operate on propane or gasoline.(Choice of one upon placement of order)Diesel upon special request 1,Pre-packaged and pre-wired complete with electric motors,inflation fans,automatic dampers,all assembled into an insulated weatherproof exterior housing,painted with a corrosion and heat resistant finish complete with all required ducting. 2.All components U.L.listed.Factory Mutual Insurance and F.1.A.available on request.Inflation fans A.M.C.A.rated manufactured to meet N.Y.C.code. 3.Electric motors to meet site electric service.Natural gas,propane,oil (choice of one must be specified upon placement of order) *Engineering Drawings and Calculations stamped by A.S.A.T.I.N.Y Professional Engineer PRICE:$2,562,192.00 fob Upstate New York *Prices quoted do not reflect duties,federal,state or local taxes and are firm for 30 days. Lead Time:16 to 20 weeks after receipt of signed contract Warranty:10 years Pro Rata on air structure fabric envelope material & workmanship.1 year on all other mechanicals Terms:35%Upon signing of contract 30%Upon start of manufacturing 30%Upon completion of manufacturing 5%Upon delivery or 30 days after completion of production,whichever comes first. .Radian,LLC 1195 E.1100N.,Shelley,Idaho 83274 USA,Phone 1 208 243 3450 -Fax 1 208 485 7808 email:Ifielding@radianllc.us *Final payment to be paid by certified check. Technician For Installation:Includedfor 10 days Any future services of a Field Technician will be provided at $600.00 per 8-hour weekday (overtime hours where applicable)plus direct travel,food and lodging expenses to supervise your labor for spreading and erecting of the air structure. Options: Daft Hang Lite 2000 Lighting System: The Hang Lite 2000 System is an integrated package of precision engineered components that require no ground support poles and consist of a complete light assembly,fixture,bulb,wiring and flexible hanging support system.Hang Lite,is so lightweight it can be hung from air structure fabric walls,roof,and or positioned wherever it will produce the maximum reflective return of indirect lighting to the interior floor surface.Result:more interior foot candles of light with the expenditure of 20%to 30%less wattage. *No perimeter poles inside the structure. *Operational cost reduced by 20 to 30 percent while increasing foot candles of illumination by 100%. *Can be removed by one person and stored in a closet size room if structure is to be removed seasonally.- "No support poles,eliminates possible damage to fabric structure. Complete Turnkey Installations: e Price upon request &review of site. e Concrete foundation,anchorage,electrical work,fuel supply,mechanical equipment start up and labor &equipment for unloading and installation of structure. Radian,LLC 1195 E.1100N.,Shelley,Idaho 83274 USA,Phone 1 208 243 3450 -Fax 1 208 485 7808 email:Ifielding@radianilc.us Supported StructureLxideAiOuts 10 By eoaedNEN <Pebaf, LO eS TM eT ANY:. "we Noa ve" & aeoan 4iet'tSonht Inside Air Supported Structure pany aieaee fer aASOIorp!Siecle alaomate.vt-}.¥¥.PadfecdSSWWeee_s . }an +> ro na a RUS ise s 2. Tom Monter From:_Linden Fielding [Ifielding@radianilc.us] Sent:Monday,May 12,2003 3:16 PM To:Rafal Berezowski Ce:Tom Monter Subject:Re:Air supported structure Dear Rafal /Tom, I can answer some of your question now and hopefully can answer the rest tomorrow. |-The normal air pressure to maintain the structure is between 1.75 -2.50 water column inches.The lower end of the range is sufficient in calm weather.The higher end of the range is needed to support the structure in high winds or when there is a snowload.Some operations choose to keep the pressure at the high end rather than change the pressure depending on the weather. 2 -The air leakage or make-up air for a structure this size would normally be 7,000 -10,000 cfm. However,in this case where you are concerned about a build up of combustible gasses it is necessary to vent much more air.About 2 years ago,Elk Run Coal Co.in Whitesville,West Virginia put up several ASATI air supported structures to cover their coal piles.I have a call in for the Chief Engineer,Mr. Kenny Williams,to discuss how many air changes per hour they use and also about their emergency fire plan.He was unavailable today and I will try again tomorrow.Feel free to call him yourself,if youprefer.His numberis 304 854-1890 Ext 206. 3 -The cost ofthe building resized to 300'W X 1600'L X 125'H would be $3,836,278.All of the items includes and excluded would remain as in the previous quote.In addition,the cost of the extra blowers and vents to provide the needed air changes are not included.We first need to determine what the target will be for the extra air volumn. I will put in the mail to you a couple of press releases about the Elk Run project. Sincerely, Linden PS.On another subject,have you been involved in any power generation project that uses agricultural waste;i.e.straw,for a fuel source?= [x]Close Signature.JPG 7/21/2003 Tom Monter From:Linden Fielding [Ifielding@radianilc.us] Sent:Friday,May 23,2003 11:38 AM To:Rafal Berezowski;Tom Monter Subject:Coal Storage Questions Hi Rafal /Tom, |contacted Mr.Kenny Williams and Elk Creek Coal to discuss your concer about the amount of dust which may escape from around the conveyor penetration.Their solution to the problem was to construct a small air lock around the conveyor at that point,then attach a smail dust extraction filter to the air lock.He said it has worked very well and has no concerns about it. As to man power to erect the building,the 1600'long building,it will take about 1000 man-days.The crew will need to be a minimum of 30.However,up to 60 men could be utilized.The more men,the shorter the erection time.Depending on the crew size,erection will take from 3 to 6 weeks.The work will be mostly manual labor. This also assumes the men are physically strong and quite productive.|know in some cultures,you have to make adjustments to the required labor force due to the physical size,strength,and efficiency of the local labor force.Also needed will be 2 -all terrain,10 ton,forklifts. Please let me know if there are any other questions.Also,keep me in mind on any of your other projects that may need a concrete dome or air supported building. Linden Fielding Executive Director Radian LLC lfielding@radianiic.us Ph 208 243-3450 Fax 208 485-7808 ][x] Pet Coke Storage, Concrete Domes,St,Croix, Virgin Is. ey Fertilizer Storage,Air Supported Building,Gulf Coast,USA 7/21/2003 Tom Monter From:Linden Fielding [Ifielding@radianilc.us] Sent:Thursday,May 15,2003 8:04 AM To:Rafal Berezowski Cc:Tom Monter Subject:Re:Air supported structure Dear Rafal /Tom, I have a few more details about the operation of the Elk Run Coal facility.They store up to 60,000 tonsofcoal.This is at a mine so they are constantly filling and emptying the storage.Inside they have 2 - D10 Caterpillar dozers that push the coal into slide gates that lead to an undergound tunnel.With the 2 dozers,they can load out 5000 tons per hour. They exhaust 35,000 cfm of air.This volume is this high due to the constant operation of the dozers. Their coal is also giving off a significant amounts of methane gas since it is fresh out of a mine.I can see that the amount of exhaust air needed will vary greatly depending on the specific environment of operation.If Bethal were to use an electric powered reclaimer,and,if the coal is being shipped in and has had a chance to air-off,the amount of exhaust air could be reduced significantly.But,I believe you're the experts in this area. On another subject...I'm involved with a company that has been running a County landfill operation in S.E.Idaho for the last 14 years.The landfill site is full and is closing down.This company is looking for another venture to get involved in.One idea we've discussed is a power generator that uses straw or other ag products for all or part of it's fuel.Hense,my previous question about your knowledge of such an operation.I suppose,since it may be considered alternative energy,there may be some Government grants available.But the bottom line is still the same,can a generator using this type of fuel source be profitable???? I'd appreciate your insite on this matter.And,let me know if I can research any other questions conceming the Bethal Coal Storage Project. Linden |[=]Close Signature.JPG = 7/21/2003 Tom Monter From:Linden Fielding [lfielding@radianic.us] Sent:Friday,May 09,2003 7:21 PM To:Tom Monter Subject:Re:New Specifications for an air supported structure Hi Tom, I've attached a picture showing how conveyors are run in and out of an air supported building.To remove the combustable gasses,we could add some additional volumn capacity to the inflation fans. Then attached special vents onto the building that will exhaust the proper amount of air while maintaining the needed pressure inside the building.You tell us how many air changes per hour you need and we will supply the proper sized fans and venting to achieve it. The flamibility of the fabric we use is discribed as "difficult to ignite or resists flame."We can treat the fabric with an additive that improves the flamibility to "non-combustable".This treatment also improves the UV and dirt resistance,which extends the life of the fabric.However,the fabric will melt or disinigrate if it is exposed to continuous flame or extreme heat. I will go to work on an estimate for the new size and will respond as soon as possible.I will also talk to other companies who are using an air structure to cover coal and ask them about their fire fighting plan. Be sure to view the attached pictures of the conveyor treatments. Sincerely, Linden |[x]Close Signature.JPG 7/21/2003 CALIFORNIA DEPARTMENT OF FORESTRY and FIRE PROTECTIONOFFICEOFTHESTATEFIREMARSHAL REGISTERED FLAME RESISTANT PRODUCT Product:Registration No. DURASKIN FA-536001 Product Marketed By: VERSEIDAG INDUTEX GMBH INDUSTRIESTR 56 47803 KREFELD GERMANY - This product meets the otininmon requirements of fame resistance established by the California State Fire Marshal for products ideatified in Section 13115,California Beaith and Safety Code. The scope of the approved use of this product is provided im the current edition of the CALIFORNIA APPROVED LIST OF FLAME RETARDANT CHEMICALS AND FABRICS, GENERAL AND LIMITED APPLICATIONS CONCERNS published by the CalifamiaState Fire Marshal. Mu ye2-Expires:06/30/2003DepryBidaceFry,Marchal veo *d uwisssz7y e0/STt/Sa BV@Srcesrts tLyvsy A.S.A.Td.NY EGo*Tectraato®eye31oz.ASAT]Stay Clean Structural Fabric Soueciications STYLE STANDARD Base -Type Polyester Fabric -Weight 10 oz/sq.yd. *Transiucency 14% Finished Coated +2 Weight 31-1 Method 5041 oz./sq.yd Tongue Tear 290/285 Ids. Method 5134 8 x 10°sample size Trapezoid Tear 106/146 Ibs. Method 5136 ASTM D5733-95 Grab Tensile 934/923 Ibs. Method 5100 Strip Tensile 595/564 Ibs./in. Method $102 Adhesion (mm.)}12 Ibs.An. Method 5970 HydrostaticResistance 500 psi Method 5512 Dead Load 2°seam Room Temperature 268 Ibs. 160°F./7 1°cs 133 Ibs. Cold Crack MIL-C-20696C LTC Pass -40°F Para.446 Flame Sample not consumedResistancewithin2minutesFRPass2sec.Hame-outMeetsCalif.Fire Marshal Req.,UL 214,NFPA-701 tasts. Rail Specifics Wigth _98"142.24 an Size 100 yds.91.4m. 211 South Ridye Street,3rd Floor,Rye Brook,New York 10573 (914)937-4500 1-800-AIR-BLDG FAX:(914)937-6331 waw.airbidg.com WP eae Sgt ET ied &a :4 ye mashaaltaoe£46rkEneegnee>redSaksia2ee"sotpeesSte_:aN233aigS28ateek-¥;-soreraindeiamdied=oraakreec=<ats+y2-tweetBeePASSCenae15RioeareseaeaeS:-te,te AS.asySek 02s, Carywsmea | a COAL MINE OPERATOR WILL STRIVE TO KEEP DUST UNDER BIG BUBBLE A WEST VIRGINLA COAL MINE OPERATOR is erecting three wirsupported structures to contain dust emissions from stock- piles.The measure will cost about $6 mil- lion,but ETk Run Coal Co,hopes it will placate residents of nearby Svivester,as well as state and federal renulators. Acting on several years of complaints abour wind-blown coal particulate coat- ing the hamlet's homes and businesses inside and out,state and federal inspec- jars in December threatened to shut down FIK Run's operadon unless the division of Richmond.Va-based Massev Energy Co.found a permanent solution. The regulators'ultimatum.prompted Elk Rut engincers.to cover eight stock- piles and coal convevors.E]k Run hired Air Structures American Technologies lne.,Rve Brook,N.Y.a manufacturer of _alv-and frame-supported structures. ASAT]engineers worked with Elk Run todesigna27-acre,240x80x 105-ft domethatcouldclearstackingtubesandcon- vevors 40-ft high.Elk Run has hired Beck- lew-based Powell Construction Co,to haild three structures,each costing about $2 million,to cover more than half a million tons of maw and crushed coal. These mevadlomes dwarf tradigenal tenniscourt "bubbles.”Betore inflation, ASATI surrounds the vinyl fabric with a patented biasnet sustem of lightweight galvanized airerait cable.Then,the net is anchored to a.concrete foundation.The technique allows ASATI to design itir- supported structures without ground or height resuictions,The domes can wid+ stand snow and ice loads to 50 Ib per sq ft and wind speeds to 150 mph.design- ers clan."This technology allows fabric loads to wanster from the fabric to the bias cablenet svstem.so the envelope is)2% not under the same pressure as it would he without the net.”savs Donato Fraioli Sr ASATT CEO and cable-net inventor. The domes are guaranteed for 10 years and are expected to last 20.Once a dome is pressurized,contractors will install a vendlation svstem to filter par- ticulates from the air.A 30-hp blower will move up to 120.000 cu ft olair per hour Boge and provide three air changes each hour in the structures.Each dome has a spare. The U.S.Mine Safety and Health Administration and the state Dept.of Environmental Protection approved the plans in March."Our current project isa perimeter foundation for the lirst dome,requiring mininial excavation and 1.000cavdofconcrete.”savs Kenny Williams,Elk Run project manager and chief engeneer.Itincludes a U4t-high retaining wall. Williams savy the biggest challenge was engineering around convevors and stacking tubes that will remain in con- tinuous operation."The dome would have been much cheaper had we built the facility prior to building the stackingtubes,”he savs.The job is scheduled towrapbymid-Mav.3 By Tudor Hampton RAISING A DOME Fabric bundles are placed and unrolled by crane positioned to reach canter of conveyor floor (1).Spreader bars [ft fabric to tensioned guy wires reaching from ground to top of stacking tower "3 (2).Cable net bundies are roiled out get from top cf conveyer and icined together with ASAT]hardware (3). News©News *News +News ©News ©News Elk Run Constructing High-Tech Dome Facility Elk Run is currently constructing an air-supported building to cover the direct ship stockpiles adjacent to the Chess Processing Plant.Thebuilding,when complete,will be supported only by air pressure supplied by an electric blower.This blower will also supply fresh air while equipment is in operation in the facility.It will be equipped with two additional back-up blowers and a back-up power generator to ensure that no mechanical failure or power outage will cause the dome to deflate. When completed,the facility will measure 490'°L X 240'W X 111' H;this is approximately 2.7 acres and will require 9 million cubic feet of air to inflate.To make room for the building a retaining wall 360 feet in length and up to 24 feet in height has been built.The foundation for the building will contain nearly 1,000 cubic yards of concrete and be more than a quarter of a mile around the outside of the building. Construction began in January and is on schedule to be completed soon.The facility will allow Elk Run to enhance the quality of its direct ship coal by a reduction in moisture content. Kenny Williams ChiefEngineer,Elk Run Foundation of high-tech dome facility at later stages of construction. FAIA INI AIAV AV VAY AV AV AV AVA WVAV AAV AVAV AV AVAVAVAVAVAV AVAVAVAVAVAVAVAVAVAVAVAVAVAVAVATAY,2 ®CAAAAAAAAAAAAALRAAAAL v7 AAA?AA AAAA Geometrica 10 July,2003 Mr.Tom Monter, Project Engineer Precision Energy Services 10780 N.Highway 95 Hayden,ID $3835 Dear Mr.Monter: More and more plants and mines worldwide have realized the benefit in covering their stockpiles with a Geometrica dome. Until recently,covering large volumes of bulk materials was not affordable.Geomertrica offers cost efficient dome covers for the largest capacity stockpiles;from under 10,000 tons in simple conical stockpiles to over 250,000 tons in circular automated piles. Additional value our structures have to offer: *Custom designs -In addition to our standard domes.the versatile Geometrica®system make it possible to manufacture highly customized structures.We can meet special requirements such as covers for uneven slopes and/or irregular shaped stockpiles as well as specialized accessories like load-release panels or load bearing platforms. *Corrosive resistant and maintenance-free covers -manufactured in aluminum or galvanized steel Geometrica structures can resist the harshest environments and require no maintenance. *Easy Installation -in most cases,assembly is performed by local labor,requires no special liftung equipment and may be scheduled without interruption to the plant's day-to-day operations. *Optimized designs -the efficiency of the dome's geometry and of the Geometrica system allow for coverage of large spans with particularly lightweight structures,minimizing material and foundation costs. *Aesthetically appealing -in addition to the practical application of a storage cover,the image and quality of the workplace are substantially enhanced with a Geomewica dome. We estimate,preliminarily,that a dome like you describe might run in the range of US330.00/sq.ft. installed in Alaska. It makes good business sense to think of Geometrica for your bulk material covers.To request more information or a firm proposal,please contact us by phone,fax or e-mail. Sincerely, Geomenrrica.Inc. Francisco Castano, President Geometrica,Inc. 908 Town &Country Bivd.,Suite 330 Houston,Texas 77024 USA ph:(713)722-7555 fax:(713)722-0331 e-mail:geoine @ geometrica.com http://www.geometrica.com WHiecialists an PRE-GLENDING DOMES ay Geometrica specializes in long-span bulk storage enclosures for the power,cement,mining,: ; StoraGe Domesagriculturalandotherindustrialandcommercialindustries.We serve them by supplying cost efficient FREEDOME®TECHNOLOGYsolutionsintheformofsteeloraluminumdomesandenclosures.The inherent economy of the dome shape conserves materials and eliminates wasted space,saving you,the client,time and money.LONGITUDINAL STRUCTURES Dome structures have been used for centuries,but the Geometrica system is different.Absence of welding makes them fast and simple to install.The doubly-curved geometry distributes loads more efficiently than conventional structures at a fraction of the weight.The patented Geometrica connector is one of the strongest and most versatile joints known.Geometrica domes emulate nature with simplicity and beauty. Neorks "a =COCO LALA a NeAV,DAVIE I OFSMaes.i oF ee, Basic geometrical shapes provide the most efficient and elegant templates for man-made forms.For the coverage of coal,limestone,cement,fertilizer,grain,wood Geometrica has applied and refined this principle with a single goal:To bring economical and pulp and other raw materials,there is a Geometrica solution. With the largest available spans,from 50 m to 30)innovative structural solutions to industrial and architectural applications.To do this Geometrica has 5 P om 50 m to 300 m ,in diameter,no stockpile or application is toospentcountlesshoursonresearchanddevelopmentofnewtechnologysuchastheFreedome?,o .;P p e gy su ur big.Versatile designs.Fast assembly. unique connector,and our in house design,modeling and manufacturing software.Cost effective solutions.All you need to know is , :...Ge ica.Because you need the fastest service,best possible solution and safest storage alternative,we are ometzica dedicated to bring you Storage Domes,Pre-blending Domes,Freedome®s and Longitudinal Structures with the most effident shape at the most effective cost.We are Geomeitrica. Egoz :Longitudinal structures are ideal for covering homogenizing beds of raw materials like coal,limestone and ores.Open ended or completely enclosed,these structures may be designed with different sectional profiles to provide the most efficient envelope over materials,machinery and vehicles. Soe ee,ees wes Pe'againspapeste eh yet le*J . :Phe ities um. Foe voeaal :ae Sess eSORCea=&'csi bey pcr AspeaSoAme a r 2 Ss :Me eee?grapaSoreseen :M52 "mr span,rave material storagesChi KeSYE presMenieAEEMSAUaedSexiSeeSatseSoe,eae AASlelraeit H} 36)GE Power Systems GE Aero Energy Products LM6000 Overview Jim Canon -Western Region Account Manager LM6000 Gas Turbine Generator Set a toy:ae oa caehaaeripaoe?et Product Heritage -PC 43MW 5 lath LPC +HPCCan2Sprint™ HPC Sprint 47.3MW B Dry Low Emissions ed is St te, SN ae oebEcs sgt Rati 1985 1990 1992 1995 1997 1998 2000 Continuous Product Improvements to Grow with Customer CTQs LM6000° vn Fleet Experience "we Units FleetHours High Time 8200 Hours 000 559 5,795,000 77,900 0 20.0 40.0 Temparanae on 80.0 100.0 120.0 ; eed SPRINT Fleet Experience one TT,Units Fleet H High Ti | Product Capability/Availability nis Fleet Hours HighTime Output Efficienc Emissions Delive (MWe)(%)y (NOx ppm ref 15%02)(Months.P40)1 1,000,000+25,000+ Gas-DLE 41.9 41 25 Inquire GE Sales Gas-Wtr 43.5 40.2 25 Inquire GE Sales Gas-Stm 43.5 43.4 25 Inquire GE Sales Liq-DLE 39.9 40.1 104 Inquire GE Sales Liq-Wtr 43.6 39.5 42 Inquire GE Sales Full Portfolio of Configuration Options to Enable Customer Specific Needs Sprint™Features 7 Uses less than 5m°3/hr of deionized water pag A AN = Tp HPC SPRINT™ Nozzles LPC SPRINT™Nozzles Performance -LM6000-PC vs.PC+Sprint™Power(kWe)52000"0 5 10 15 20 25 30 35°C 50000° 48000" 46000" 44000-y i42000xa 40000 a 36000 |--|Sea Level 60%Relative Humidity 34000 j---/5 in.H20 inlet;6 in.HO exhaust losses Natural Gas Fuel -LHV 19000 Btu/Ib Base L . 32000 |-|Water Injection to achieve 25ppm NOx po -_-,M6000-PC No VIGVs,60Hz,13.8kV,0.9PF NN30000"= 28000" | 20 30 40 50 60 70 80 90 100 Inlet Temperature °F A LST OM GTX100 -GENERAL &COMMERCIAL ITH10066 3.1 (28) Project:GTX100 Standard 3/24/2003 Sianetue Scope of Supply Project Name:GTX100 Standard Customer:BETHEL STAND RY Reference Number: Type of Installation:MAS 102 Modified Turbine Type:GTX100-PG Table of contents GTX100 GAS TURBINE,GENERATOR DRIVE 2 SCOPE OF SUPPLY AND TERMINAL POINTS 2 Part 1 General 2 Basic definition:2 Part 2 Technical specification 2 Terminal Points to Customer 6 Outlets to Atmosphere.7 Scope of supply 9 Part 3 Gas turbine -Principal components 9 Part 4 -Auxiliary systems 11 Part 5 -Generator 16 Part 6 -Electrical and control equipment 18 Part 7 -Installation and building 23 Part 8 Inspection,erection,testing and commissioning 25 Part 9 Documentation,operation and maintenance 26 Main exclusions 28 Sec-number Edition PageALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 3 2 (28) Project:GTX100 Standard 3124/2003 Signature Scope of Supply Comment GTX100 Gas Turbine,Generator Drive Scope of Supply and Terminal Points Part 1 General Basic definition: This Scope of supply forms a functioning unit within the terminal points (utilities/consumables such as auxiliary power, fuel,water,lubricating oil and grease are excluded).Alternative configurations are available. Part 2 Technical specification Application -Onshore (simple cycle delivery) Operating mode -Continuous base load Units -US-units Nominal Output -43 MW electrical ISO (59°F,sea level,no inlet and exhaust pressure losses,60%relative humidity)and 70.5 MW heat (related to ambient conditions)with 269 lb/s at 1013°F exhaust gas flow. Design conditions -5 to 104°F ambient temperature. -Moderate dust loading Installation -Outdoor Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product Information\GTX100\Budget PhangTepeofSupplyGTX100ITH10066Ed3.doc Industral Turbine Segment Doc-number Edition PageALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 3 3 (28) . Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment Wind speed and seismic zone -<=131 ft/s and UBC code (1997)zone 1,S3 (foundation not considered) Site forces -Site 0.5 x g in any horisontal direction and 0.5 x g in vertical direction. Area classification -Safe area Surface treatment -Indoor or outdoor inland (>5 km/>3 miles from sea). Corrosivity category C3 medium.The internal equipment is treated for corrosivity category C2. -Corrosivity factors according to ISO 12944-2:1998 Design sound level -85 dB(A)near field at 3 ft distance (outside the GT enclosure wall and 5 ft above ground level),far field 65 dB(A)/300 ft.Measured according to ANSI S 12.36 and ISO 3746-1995. Combustion chamber -Dry Low Emission system Fuel -Gas fuel,fulfilling ALSTOM gas fuel specifications (GTI X241010E)or accepted project fuel data sheet (GTI W241009E). Lubricating oil cooling -Water (water /antifreeze fluid TEMPER or equivalent), cooling media,supply temperature <95 °F Generator cooling /protection form -Protection/cooling form:TEPV Generating voltage /frequency -13.8kV/60 Hz Based on scovedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product informason\GTX100\8udget Prong industrial Turbine SegmentToois\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Doc-number Edition PageALSTOMGTX100-GENERAL &COMMERCIAL -ITH10066 3 4 (28) Project:GTX100 Standard 2124/2003 =" Scope of Supply Comment Auxiliary voltages,frequency and standards for motors -440 -480 VAC,60 Hz,(TN-C-S system)start motor 690 VAC,3-phase.240 VAC UPS.Standards:EN/IEC. Emergency battery voltage -440 VDC Shutdown system -"1 out of 2"and "1 out of 1" Control system -ABB Advant providing a fully automatic unit. Vibration probes -Vibration transducers (accelerometer type). Designation system -German based KKS tag number system.The components are identified in a hierarchical system according to the functional placement in the plant. Codes and standards -Drawings:_ISO5457-1980 -Noise emissions:ISO3746-1995 and ANSI S 12.36 -Exhaust emissions:TS09096-1992 and ISO10849- 1996 -Pressure vessels in ASME Section VIII (excl.U- auxiliary systems:stamp). -Pipes (dimensions):DIN or ANSI,on-skid/off-skid -Pipes (design):Swedish pipe code RN-78 and AFS 1999:6,on-skid.Swedish pipe code RN-78,AFS 1999:6 and ASME B31.3 (gas fuel system),off-skid. -Flanges (dimensions):DIN,ANSI (fuel systems), on-skid/off-skid -Flanges (design):Swedish pipe code RN-78, AFS 1999:6 or ANSI B16.5, on-skid/off-skid -Steel beams:EN287/EN288 Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Tt Product TX100\Budget Pnang Industrial Turbine SegmentTools\Scope of Supply Standard GTX100 [TH10066 Ed 3.doc A LSTOM GTX100 -GENERAL &COMMERCIALProject:GTX100 Standard Scope of Supply Dec-number Edition ,Page ITH10066 3 5 (28)Signa!Creation date 2/24/2003 -Terminal point flanges (dimensions): -Terminal point flanges (design): -Pipe coupling threads: -Fire extinguishing (design): -Gas detection: -Gas fuel system: -Pumps: -Bolts/nuts: -Vibration: -Gear: -Generator: -MCC: -Control cubicles: -Control system: -Power cables: -Control cables: -Cables joints of MM- type: -Frequency converters: -Other electrical equipment: -Enclosure and base frame: Based on scopedatabase edition 24 1/23/2003 Comment ANSI Swedish pipe code RN-78, AFS 1999:6 and ANSI B16.5 for fuel systems ISO 228:1-1994 and SMS 2165 SBF 110 or NFPA 12 with exceptions EN 50018 Explosion group IIC (zone 1) Swedish standard (NGSN:1987 andSAIFS:1996/8) DIN and/or ISO DIN 1SO10816-4,1998 AGMA 421.06 &API 613 with E &C NEMA MGI-1993 rev.1 TEC/EN60439 part1, TEC/EN60529,IEC/EN60947 part 2,3 and 4-1 IEC/EN60439 partl, IEC/EN60529,IEC/EN60947 part 2,3 and 4-1 IEC/EN50081,IEC/EN50082, IEC/EN60068 part 2, ITEC/EN60439-1, TEC/EN60950,IEC/EN61010- 1 IEC/EN60227,IEC/EN60228, IEC/EN60331,IEC/EN60332, IEC/EN60502,IEC/EN60811 IEC/EN60227,IEC/EN60228, IEC/EN60331,IEC/EN60332, IEC/EN60502-1 IEC EN50262 EN60204 part 1,EN60529, EN61800 part 3. Applicable IEC/EN-code BSK-1994 (corresponding to 1SO2394-1986) ALSTOM Power Sweden AB S.AMedium GasT oduct Inft TX100\Budget Phang Tools\Scope of Suppty Standard GTX100 ITH10066 Ed 3.doc Industrial Turbine Segment ALST Om GTX100 -GENERAL &COMMERCIAL ITH10066 3 6(28) Project:GTX100 Standard 3/24/2003 "= Scope of Supply Comment -Balancing:ISO 1940-1 and ISO 11342- 1998 -Lubricating oil system:API614withE&C -Gas turbine:API 616 withE&C 431 Vibration monitoring:API 670 with E &C Welding procedures:EN 287/288 The Package is complying with the Machinery Directive,the Low Voltage Directive,the EMC requirements and the ATEX Directive 94/9/EC valid within the European Community. A classification plan of the installation according to the European standard EN 60079-10,as well as a Risk Analysis which is the base for the Certificate of Conformance according to the Machinery Directive,are available. A life cycle assessment study (LCA)according to ISO 14040-43 is available.It contains quantifications of the resource depletion, generation of waste and emissions to the environment caused by the manufacturing,use and disposal of the product. Enclosure -For the Gas Turbine,Auxiliaries,Speed reduction gear and Generator. -Signal treatment module located adjacent to the GT enclosure. Exhaust direction from the Gas Turbine outlet -Horisontal,axial Maintenance opening -Left side (looking from the exhaust towards the air inlet) Delivery -Delivery acc.to INCOTERMS 2000 as per tender letter. Terminal Points to Customer For data at the terminal points,please refer to separate document. Gas Fuel System Gas fuel connection,upstream the gas isolation valve located at gas fuel unit,auxiliary skid side acc.to the layout drawing. Based on scovedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product information\GTX100\Budget Pneing Toois\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Industrial Turbine Segment Doc-number Edition PageALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 3 7 (28)' ; Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment 442 Cooling Water System -Incoming/outgoing water connection flanges for water cooled lube oil cooler located close to the auxiliary skid. 482 Instrument Air --Common connection located at the GT enclosure wall, auxiliary skid side. 491 Drains -Connection for emptying of the drain tank located at the enclosure wall,auxiliary skid side. 590 Medium Voltage -Generator lineside,busbars located inside the AC Generator MV terminal box. 626 Auxiliary Power Terminals on motors and heaters -Terminals in electrical panels. 630 Control &Instrumentation Terminals in the skid mounted signal treatment module. -Terminals in control panels. 684 Grounding -Grounding connections on delivered equipment. 720 Interface to Foundation -Lower end of multi point support for the GT and driven equipment -Lower end of the support structures for: -Air intake system. -1x100%watercooled cooler for the lubricating oil system. -Gas filter skid for gas fuel system Outlets to Atmosphere. For data at the outlet points,please refer to separate document. 410 Lubricating oil Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product Informatoni\GTX 100\Buaget Pricing industrial Turbine SegmentTooisiScopeofSupplyStandardGTX100ITH10066Ed3.doc Doc-number Edition PageALSTOM.GTX100 -GENERAL &COMMERCIAL ITH10066 3 8 (28) .Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment -Outlet from lubricating oil system ventilation fan,located on the GT enclosure roof. 423 Ventilation -Outlet from the GT and EG enclosure to atmosphere, downstream the weather louvers,located on the enclosure roof 431 Gas fuel system -Gas fuel ventilation,located above the GT enclosure roof. 438 Purge air -Purge air ventilation,outlet located above the GT enclosure roof. Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product informaton\GTX100\Budget Phang industrial Turbine SegmentTofSupplyStandardGTX100ITH10066Ed3.doc Doc-numberALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 300 330 Project:GTX100 Standard 2/24/2003 Scope of Supply Edition Page 3 9 (28)Signature Scope of supply Part 3 Gas turbine -Principal components Single shaft,ALSTOM Power GTX100,modular concept industrial design,consisting of: -Compressor inlet casing and inlet bellmouth casing. -Thrust bearing #1 (tilting pad,directed mineral oil lubrication)combined with radial journal bearing #1 (tilting pad,directed mineral oil lubrication),located in the inlet bellmouth casing. -15-stage axial flow compressor with 3 rows of variable guide vanes (AC servo motor driven),electron-beam welded compressor rotor,inner stator casing with vane carriers forming air flow path,vertically split outer casing --2 bleed valves (pneumatically actuated)for air bleed during start-up and shutdown. -Central casing with diffuser for compressor discharge air. -2 ignition burners and 2 high energy spark plugs for engine start-up. -1 annular combustion chamber incl.30 low emission AEV burners and 2 optical flame detectors. -3-stage bladed turbine rotor,connected to the intermediate shaft by tie-bolts. -Turbine casing with gas flow path and 3 stages of turbine guide vanes. -Radial journal bearing #2 (directed mineral oil lubrication), located in the turbine exhaust diffuser casing. -Turbine exhaust casing with exhaust diffuser. -Drain valves (manually operated)from compressor inlet plenum,compressor bleed cavities #1 &#2,central casing and exhaust casing. -BN,accelerometer type,vibration probe:|off in bearing #1 and |off in bearing #2 Speed reduction gear (6600/1800 rpm),double helical design. -High speed side,quillshaft connection to the gas turbine. -Low speed side,quillshaft connection to the generator. -4 journal bearings of sleeve type for mineral oil lubrication. Based on scopedatabase edition 24 1/23/2003 Comment P&ID 993800 P&ID 993804 ALSTOM Power Sweden AB S:\M Gas Turdines\Product|TX100\Buaget Pneing Tools\Scope of Supply Standard GTX100 [TH10066 Ed 3.doc Industrial Turbine Segment Doc-number Edition PageALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 3 10 (28)Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment -|temperature transducer in each of the four bearings -1 BN,accelerometer type,vibration probe located on the casing at the high speed (pinion)turbine side. 380 Mounting details -Pendelum supports,spring loaded supports,fix point support and side support for the gas turbine,down to the main baseframe.Supports for the diffuser,down to the foundation. 385 Turbine base frame -Welded I-beam baseframe for the GT driver unit 390 Insulation -Insulation of the Gas Turbine (including exhaust casing)for personnel safety,heat and noise reduction. Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:Medium Gas Tt roduct TX100\Budgat Pricing Industrial Turbine SegmentToois\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Doc-numberALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 401 402 403 Project:GTX100 Standard 2/24/2003 Scope of Supply Edition Page 3 11 (28)Signature Part 4 -Auxiliary systems Some auxiliary systems and parts of the control system are mounted on a separate skid located side by side with the GT unit.See layout and General Arrangement drawings. Instrumentation Instrumentation pipes,instrument valves and fittings in 316L stainless steel Cooling &Sealing air system,with valves and piping for the gas turbine Extraction from compressor stage #3 for external turbine stator cooling and sealing air around bearing #2 during operation,including temperature measurement,strainer with diff.pressure transmitter,butterfly valve and orifice. Extraction from compressor stage #5 for bleed to exhaust, external turbine stator cooling and sealing air around bearing #2 during start-up and shutdown-and cooling to turbine stator stage #3 during start-up and shutdown,including temperature measurement,strainer with diff.pressure transmitter,butterfly valve,orifice and bleed valve. Extraction from compressor stage #10 for bleed to exhaust during start-up and shutdown -and cooling of turbine stator stage #2 and air supply to the balance piston during start-up, operation and shutdown,including temperature measurement, strainer with diff.pressure transmitter,butterfly valve,orifice and bleed valve. Instruments and components for standard cooling and sealing air system Electric Start &Barring system including: Static Frequency Converter (SFC). Electric start and barring motor with gearbox. Driver shaft with bearings and free wheel (SSS-type)clutch. Instruments and Components for Electric Starting &Barring system Based on scovedatabase edition 24 1/23/2003 Comment P&ID 993801 P&ID 993804 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product InforrnagoniGTX 100\Budget PrangToois\Scope of Suppiy Standard GTX100 ITH10066 Ed 3.doc Industrial Turbine Segment Doc-numberALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 410 422 Project:GTX100 Standard 2/24/2003 Scope of Supply Edition Page 3 12 (28)Signature Lubricating Oil System designed for ISOVG46 mineral oil fulfilling ALSTOM specification 8121-09 -Covering: -The Gas Turbine -The Speed Reduction Gear -The Generator -Carbon steel lube oil tank with 2 heaters. Supply piping for the lube oil system in carbon steel,stainless steel downstream the filter to the GT. Discharge piping in stainless steel. -Pumps and fan with redundant power supply. -3x 80%AC motor driven centrifugal type pumps (2 in operation and |in stand-by mode).The pumps are normally utilised to 2 x 50%but the SFC's and motors are designed to increase the capacity of the pumps during tranfer from the operational to the stand-by pump. -1x 100%AC motor driven oil system ventilation fan. -Oil system ventilation filter with filter housing in stainless steel|Each pump and the fan is driven by a Static Frequency Converter.DC back-up is provided on each pump and the fan by the 440VDC battery feed to the SFCs. -1x 100 %water cooled lube oil cooler (plate type)designed for +95°F cooling media inlet temperature,including lub.oil piping -2x 100 %lube oil filter with delta P transmitter. -Instruments and Components for standard Lubricating Oil system. Fire Extinguishing System,CO2 -Fire detection and extinguishing system for the GT enclosure. -Fire detection system for the generator. -According to NFPA 12 (US code) -1x 100 %discharge for fire protection as above. -Piping,valves and nozzles. -Fire detection and portable Fire extinguishing in control module. -5 IR detectors,6 heat detectors covering the gas turbine and auxiliaries located inside the enclosure. Based on sconedatabase edition 24 1/23/2003 Comment P&ID 993813 ”P&ID 993836 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product information\GTX100\Budget PacingTools\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Industrial Turbine Segment 423 ALSTOM °&'”-GENERAL &COMMERCIAL rTH10066 3 13(28) Project:GTX100 Standard 2/24/2003 =" Scope of Supply Comment 4smoke detectors in the generator enclosure --4smoke detectors in the control module -2 warning lights located outside the GTencosure and 2 acoustic alarms (one CO2-driven and one electrically driven) located inside the GTenclosure. -1 warning light,1 CO2 blocked indication light and 1 manual release button,located outside each normal entrance door of the GT enclosure. -Central fire suppression unit for alarm and automatic extinguishing.The central unit is connected to the Advant control system for alarm announciation. -Instruments and Components for standard Fire Extinguishing system. Ventilation system P&ID 993826 424 Weather louvers at the ventilation inlet and outlet of the GT enclosure. Weather louvers at the ventilation inlet and outlet of the generator enclosure. Silencers as required for the specified sound level,on ventilation inlet and outlet of the GT enclosure. 1 stage air filter (barrier type,disposable)for the GT enclosure. 1 stage air filter (barrier type,disposable)for the aircooled generator air inlet. Shut off dampers on the ventilation inlet and the ventilation outlet of the GT enclosure. 1 x 100 %AC motor driven fan placed in the ventilation outlet of the GT enclosure,i.e.GT enclosure subatmospheric pressure. Air conditioning unit (1x100%)for the signal treatment module 1 x 100%AC driven fan placed in the ventilation inlet of the generator enclosure,i.e.generator enclosure overpressure. Ventilation ducts in Carbon steel. Gas Detection System 2 semi-conductor gas detectors,located in the ventilation outlet from the GT enclosure (one in low position and one in high position). Based on edition 24 1/23/2003 P&ID 992889/- P&ID 993829 ALSTOM Power Sweden AB Product int TX100\Budget PrengS.A Gas Tt Tools\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Industrial Turbine Segment Doc-number *Edition Page.A LSTOM GTX100 -GENERAL &COMMERCIAL "ITH10066 3 14 (28) .Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment -The detectors are connected to the Advant control system via the gas detection central unit.Each gas detector has an alarm and an engine shutdown level. 431 Gas Fuel System P&ID 993809 Gas fuel unit 1 -Gas isolation valve (spring closing,pneumatically operated) -Connection for N2 purging located at filter,for maintenance purpose. -1x 100%(3 micrometer)last chance coalescer filter with deltaP transmitter. -Total gas flow meter -Stainless steel piping downstream filter. Gas Fuel unit 1,located outside the enclosure acc.to ALSTOM standard layout. Gas fuel unit 2 -Two quick shut-off valves in series (spring closing, pneumatically operated). -Ventilation valve between the quick shut-off valve. -Ventilation valve between the isolation valve and the first quick shut-off valve -Gas control valve (AC-servo motor operated)with position transducer,for the 2 pilot gas manifolds. -Pilot gas flow meter. --2 pilot gas manifolds with 18 and 12 connection points respectively from each manifold to the 30 burners. -1 main gas manifold with 30 connection points to the 30 burners. -Gas control valve (AC-servo motor operated)with position transducer,for main gas manifold. -All piping in gas fuel unit 2 and internal GT-skid piping in stainless steel -Ventilation lines to atmosphere,standard location above the air intake filter. 438 Purge Air System P&ID 993802 -All internal piping. -3 shut-off valves (spring closing type),1 on main supply line for pilot and main,1 on pilot line and 1 on main line. Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S.\Medium Gas Turbines \Product Information\GTX100\Budget Pricing industrial Turbine SegmentTools\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Doc-nu itionALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 3 18 (28)i Crea ignaiProject:GTX100 Standard 2/24/2003 "ure Scope of Supply Comment -Ventilation line with ventilation valve (spring opening type) to atmosphere. 439 Ignition System P&ID 993837 Natural gas fuel for gas supply to ignition burners during startup. Shut-off and vent valves (spring closing,pneumatically operated). -Pressure regulators. -Ignition burners and high energy spark plugs (see Item 300) 442 Cooling water system Terminal point at the lube oil cooler. 482 Instrument air system P&ID 993818 -Internal piping in stainless steel. -Instrument air supply by customer. 491 Compressor washing system P&ID 993828 -Washing unit for compressor washing,consisting of: -Water tank with heater,level gauge and temperature gauge. -Detergent tank with heater,level gauge and temp.gauge. -Filter. -AC driven pump (reciprocating type). -Pressure regulating valve and pressure gauge. -Piping,inlet manifold and injection nozzles for offline washing. -7 manually operated drain valves with piping,to common location at skid edge,from the Gas Turbine (see Item 300 and 310) Drain tank with transparent cover for level check and level gauge,including drain pump. -Instrumentation and piping according to P&ID Equipment acc.to "Safe area”area classification. Based on edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Mequm Gas Turbines\Product Informason\GTX 100\Buaget Pnang industrial Turbine SegmentToots\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Ooc-number Edition Page-A LSTOM GTX100 -GENERAL &COMMERCIAL ITH10066 *i(ité« S 16 (28); . Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment Part 5 -Generator 500 Equipment according to MV Single Line Diagram W500046E 501 Generator type AMS 1250 A LG 3BSM003582-A 50,0 MVA at 104°F cooling air temperature and P.F.0.8. -Frequency /speed /voltage:60 Hz/1800 RPM/13.8 kV. Standard,NEMA. -Four pole (salient)three phase synchronous generator. -Protection/cooling form:TEPV -Brushless AC-exciter with rotating rectifier. -PMG for excitation power supply. -Insulation according to class F. -Temperature rise at rated output and P.F.0.8 within class B absolute according to §16.3.4 of IEC 34-1 within the ambient temperature range. -Temperature monitoring by RTD. -Vibration monitoring by accelerometers. -Lube oil supply from the turbine system. -Line and neutral side termination points for MV terminal enclosure. -Anti condensation heaters in the main machine,exciter and MV terminal box. -Separate junction boxes for instruments,excitation and heaters. 580 Excitation and voltage regulator system The system consists of an ABB AC100 Controller and a power and measuring unit.The system includes the following: -One single-phase thyristor rectifier bridge. -Automatic Voltage Regulator (AVR) -Manual Voltage Regulator (MVR,Fieid current control). -Power factor control. -Reactive power control. -Excitation current limiter with cooling air bias. -Stator current limiter with cooling air bias -Under excitation limiter. Based on base edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas T Product ION\G TX100\Budget Pricing Industrial Turbine SegmentTools\Scope of Supply Standard GTX100 ITH10066 Ed 3.dec ALSTOM =ST%100-GENERAL &COMMERCIAL ITHi0066 =17(28) .Creation date SignatureProject:GTX100 Standard 212412003 Scope of Supply Comment 590 Generator Medium Voltage (MV)terminal enclosure Enclosure for line and neutral side MV equipment.Phase conductors of solid copper bars. Design prepared for various earthing options. Equipment data: Rated voltage:13,8 kV Rated current:Max FLC (Full Load Current) Rated frequency:60 Hz Highest system voltage:15 kV Rated insulation level,1 min 38 kV 50/60 Hz: Impulse 1.2/50 microseconds,95 kV peak: Short circuit current,|sec.:40 kA Short circuit current,peak:100kA Degree of protection:IP55 The enclosure accomodates the following: Sased on scovedatabase edition 24 1/23/2003 Undrilled Cu busbars at lower end of enclosure suitable for cable or busduct connection. Lightning/surge arrestors,line side.(3 nos.single phase units, connected YN). Voltage transformers line side (3 nos.single phase units, connected YN). Current transformers line side.(3 nos,3 secondaries,1 A/phase). Generator stator terminals (6 nos.). Generator star point. Current transformers neutral side.(3 nos,3 secondaries,1A /phase). Neutral point resistor,LOA,10 sec. Excitation rectifier module with transducers for electrical quantities. Mobile earthing tool for maintenance work. ALSTOM Power Sweden AB SM T pe of Supply rd GTX100 ITH10066 Ed 3.docediumGesT!Product inf TX100\Budget Priang Industral Turbine Segment :Doc-numi ition ageALSTOM-GTX100 -GENERAL &COMMERCIAL ITH10066 348 (28)}:Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment 620 626 625 Part 6 -Electrical and control equipment. Electrical auxiliary systems Electrical auxiliary systems as specified below: Motor Control Centre ABB MNS Light W MCC board,Isc =35 kA. Supplies all consumers (except starting system)within the scope of supply and is provided with: -Withdrawable load break switch incomer with Volt-and Ammeters. -Withdrawable fuseless motor starters and MCCB feeders. Protection class [P21,IP31 on the front and IP 20 internally. Lube oil and control system Power Supply System The system provides AC and back-up DC power to the AC motor driven lube oil pumps and the oil ventilation fan of the turbine package. A UPS unit and a UPS distribution board for supply of the I&C equipment of the turbine is as well integrated within the free standing panel arrangement. The system is completely self contained and designed with low voltage panels from the ABB MNS Light W switchgear family and have protection class [P21,(IP31 on the front and IP20 internally) The panel arrangement contains the following equipment: +One AC power distribution board with MCCB breakers supplying the frequency converters,and the emergency battery charger. -One DC power distribution board with MCCB breakers supplying the frequency converters. -Static frequency converters for the lube oil pumps. -Static frequency for the oil ventilation fan. -One UPS unit with internal back-up battery.1 hour autonomy time. Based on b edition 24 1/23/2003 SLD X620029E ALSTOM Power Sweden AB S:\Medium Gas Turtines\Product informasonGTX 100\Budget PricingTeofSupplyStandardGTX100ITH10066Ed3.doc industrial Turbine Segment Oce-numbar-ALSTOM GTX100 -GENERAL &COMMERCIAL .ITH10066 623 629 630 634 Edition Page 3 19 (28) Project:GTX100 Standard 2/24/2003 _ Scope of Supply Comment -One UPS power MCB breaker board for I&C equipment. -Emergency battery charger,440 VDC. PLC based emergency back-up operation system. 440VDC sealed lead acid emergency battery. Capacity for a complete 10h emergency cool down cycle. Frequency converter(s). -Starting frequency converter,ABB ACS607,690VAC 50/60 Hz supply,protection class [P21. Control equipment for automatic start-up,operation and shut down. Micro Processor based control,supervision and protection system with a PC based operators station.The system is designed for highest possible operators friendliness with colour process graphics,log and alarm /event displays,printer for lists and hardcopies from the screen.The system has various openings to external computer systems.The system program provided is in the US English language. The following division of functionality described below constitutes the turbine control system: Operators station PC based (Windows 2000)operators interface,ABB process Portal A with necessary software to operate the GT in all operation modes.Midi tower type computer with redundant Hot- Swop,RAID controllers.Software for on-line programming of the control system is included.A conventional hard wired back- up operation panel with instrumentation further described below is also included. The PC based operators interface consists of: -Desk mounted turbine HMI with 19"TFT screen,keyboard, mouse and inkjet colour printer. -MB300 interface to turbine controllers. Basad on sconedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Ti Product inf i TX100\Budget PhangTools\Scope of Supply Standard GTX 100 [TH10066 Ed 3.doc Industnal Turbine Segment ALST OM GTX100 -GENERAL &COMMERCIAL ITH10066 3 50(28) .Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment 635 636 * The OS station performs apart from providing normal operators dialogue: -Trending and storing of process parameters. Self diagnostics and displays of system and individual board status. The back-up panel includes the following: -Synchronisation instruments. -Generator f,U,P and Q meter. -Turbine "Start"/"Stop"push buttons. -Turbine "Trip reset"push button. -Governor "Increase"/"Decrease"push buttons. -AVR/MVR "Increase"/"Decrease"push buttons. -Generator CB "Open"/"Close"push buttons. -Synchronising mode selector,"Auto"/"Manual". -Synchronising "By-pass"push button. -Selector switch,"Local"/"Remote”operation. -Back-up panel "Enable"switch. -Start counter. -Operating,equivalent operating hour and cycle counter. -MWh and MVArh counters. Main process controller ABB Advant AC400 The main Advant controller contains system and application programs to run the turbogenerator set,the programs are stored in Flash EPROM's.The main tasks of the AC400 controller are: -Analogue and Binary I/O handling. -Sequencer for start and stop. -Gas turbine set monitoring. Digital fuel governor The AC160 controller contains system and application program for the correct governing of the GT set.The controller serves as well as the second channel of the dual channel GT protection system.The programs are stored in Flash EPROM's.The main tasks of the cntroller are: -Frequency/load control. -Gas turbine speed and temperature control control. -Gas turbine acceleration and deceleration control. Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Ti Product TX100\Budget PrangTools\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Industrial Turbine Segment Doc-numberaALSTOMGTX100-GENERAL &COMMERCIAL ITH10066 631 631 3 21 (28) SignatureProject:GTX100 Standard 2/24/2003 ™ Scope of Supply Comment Unit protection system Two ABB AC160 controllers (2 independent process controllers)working with the principle "1 out of 1”or "1 out of 2”.All trip signals works with the principle of "fail safe”,i.e. signal loss generates a turbine trip. The "fail safe”principle is also valid for alarms.The system operates with 24VDC Following signals are duplicated and works with the "1 out of 2” principle: -Turbine overspeed. -Flame supervision. -Purge time monitoring. -Ignition failure. -High exhaust gas temperature. -Low lubrication oil pressure. -High lubrication oil temperature. -Control equipment failure. All protection system actions are registered and informed to the operator on the main operators station. Generator protection system Modularised micro processor based generator protection system (ABB Combiflex).Protection functions by dedicated protection modules.Tripping circuits,power supplies and protection modules in two sub systems as indicated below. TEEE-code(Sub) -Differential protection 87G (1) -Stator earthfault protection 59N (1) -Voltage restraint over 51V (2) current protection -Negative sequence 46 (2) protection -Under excitation protection 40 (1) -Over/under voltage 59/27 (2) protection Reverse power protection 32 (1) Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product Information\GTX 100\Budget PangToois\Scope of Supply Standard GTX100 ITH10068 Ed 3.doc Industrial Turbine Segment Doc-number Edition PageALSTO'M -GTX100 -GENERAL &COMMERCIAL 1TH10066 3 22 (28) . Creation date SignatureProject:GTX100 Standard 2/24/2003 Scope of Supply Comment -Rotating diode fault 58 (1) protection -Over/under speed protection 12/14*.(1) *)GT control system function 639 Synchronising equipment Automatic and manual (semiautomatic)synchronising system for the Generator Circuit Breaker (GCB).The system is provided with a "Synchronising by-pass”switch for breaker closing against a "dead bus". 680 Electrical installation -Control and instrumentation cables on the turbine and auxiliary systems skid to the signal treatment module. Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Turdines\Product jon\G TX 100\Budget Pricing industrial Turbine SegmentToois\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc .Doe-numi ition eALSTOM °%'00-SENERAL &COMMERCIAL ITH10066 3 23(28) Project:GTX100 Standard 2/24/2003 "- Scope of Supply Comment Part 7 -Installation and building 710 Enclosures -Weather proof,outdoor: -Acoustic enclosure for the Gas Turbine,auxiliaries,gear and Electric Generator. -Complete with access doors,emergency doors,walkways, stairs,internal lighting and a 8 tonnes maintenance overhead crane in the GT enclosure. -Signal treatment module located on the auxiliary skid,outside the GT enclosure. -Maintenance door for GT removal on left hand side (looking from the exhaust towards the air intake). 711 Electrical and control equipment module(s) -Signal treatment module on the auxiliary systems skid containing: -Connection and turbine controler cabinets with Advant Fieldbus connection to the main controler and Operators station. Weather proof,outdoor enclosure for the following electrical and control equipment: -Operators station -Control panels. -MCC -Starting frequency converter -Lube oil drive system -Emergency back-up battery (If included in the scope of supply) -UPS-unit for turbine controls (If included in the scope of supply) -Fire fighting panel (If included in the scope of supply) The module is provided with internal lighting,heating and air conditioning systems.All systems are tested together with the GT and auxiliary systems (factory tests). 720 Foundation -Outline drawing of the foundation with static and dynamic loads Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium Gas Turbines\Product Informaton\GTX100\Budget Pring Industrial Turbine SegmentTpeofSupplyStandardGTX100ITH10066Ed3.doc Ooc-numi iALSTOmGTX100-GENERAL &COMMERCIAL 7 ITH10066 3.24 (28) ; Creation date SignatureProject:GTX100 Standard .2/24/2003 Scope of Supply Comment 731 Static air intake system -Two stage filter elements -Prefilter of disposable barrier type -High efficiency filter:Inland (>3 miles from sea) /City/Light Industy -Ducting for standard outdoor installation with support structure. -Acoustical lined duct and silencer for the air intake Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medum Gas Turbines\Product information\GTX100\Budget PreingTools\Scope of Suppty Standard GTX100 TH10066 Ed 3.doc industnal Turbine Segment Doc-number Edition PageALSTOMGTX10®-GENERAL &COMMERCIAL ITH10066 3 25 (28)} ; Creation date SignatureProject:GTX100 Standard -2/24/2003 Scope of Supply Comment Part 8 Inspection,erection,testing and commissioning 810 Transport -Packaging for sea transport and maximum 3 months storage -Delivery acc.to INCOTERMS 2000 as per tender letter. -Rental of lifting tools for on/off loading during the erection period.The tools are property of ALSTOM. -Rental of transport/storage cover for main machinery unit and auxiliary unit.The weatherproof cover equipment is property of ALSTOM. 820 Inspection -Quality control acc.to standard Inspection Plan 852 Factory tests -Balancing and overspeeding of the turbine and generator rotors. -Standard Gear test at the subsupplier's workshop -Standard Electric generator routine test at the subsupplier's workshop -Stationary testing: -System tests of the assembled equipment,including sequence test up to GT ignition (without engine rotation), with contract auxilliary systems and contract control equipment. Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S:\M Gas Tu Product TX100\Budget Pricing Industral Turbine SegmentTools\Scope of Supply Standard GTX100 (TH10066 Ed 3.doc Dee ; A LSTO'M GTX100 -GENERAL &COMMERCIAL '1TH10066 3.26 (28): . Creation data SignatureProject:GTX100 Standard -2/24/2003 Scope of Supply Comment 935 940 980 Part 9 Documentation,operation and maintenance Customer training -Customer training is excluded.For the safe and reliable operation it is recommended that training is included Spare parts Documentation The Final Documentation is divided into four classes A,B,D and I: -A=Operating and Maintenance Documentation produced by ALSTOM Power -Bl =Technical Documentation produced by ALSTOM Power,used in Operation and Maintenance documentation -B2=Technical Documentation produced by ALSTOM Power,not used in Operation and Maintenance documentation -D1 =Component Documentation provided by subsupplier, used in Operation and Maintenance documentation -D2=Component Documentation provided by subsupplier, not used in Operation and Maintenance documentation -I =Test and Inspection documentation The Final Documentation includes the following documentation blocks:, 1.Documentation overview. This is an introduction to the final documentation structure and comprises key information on how to recognize and find the appropriate documents and how to understand the typical symbols used.” Based on sc edition 24 1/23/2003 ALSTOM Power Sweden AB S:\Medium GasT:Pr NGTX100\Budget Pneng industrial Turbine Segment4TOGUCGIT Tools\Scope of Supply Standard GTX100 [TH10066 Ed 3.doc .Doc-number Edition PageALSTOMGTX100-GENERAL &COMMERCIAL -ITH10066 3 27 (28) .Creation date SignatureProject:GTX100 Standard -2/24/2003 Scope of Supply Comment -Documentation overview.Document class A. 2.Operator documentation. The Operator Documentation serves as the manual for operation of the gas turbine and for handling the unit in emergencies.The included System Descriptions,P&IDs and technical data lists form an appropriate level of information for understanding the basic systems design and function.This part is mainly intended for the operation personnel. -Operation instruction,including fault procedures.Document class A. -System description.Document class B1. -P&ID drawings.Document class B1. -Setting list and electrical load list.Document class B1 3.Maintenance and Technical Documentation. The Maintenance and Technical Documentation is structured as an introducing Maintenance Documentation and the associated Technical Documentation contains detailed technical information.The technical part is further divided into documentation related to Components,Electrical-,Control-and Building Items.This part is mainly intended for the maintenance personnel. -Maintenance documentation.Document class A. Component documentation -Component documentation,technical information and data sheets (subsuppliers excluded).Document class B2. -Component documentation from subsupplier,Operation and Maintenance instructions.Document class D1 -Component documentation from subsupplier,technical information and data sheets.Document class D2 Electrical documentation.Document class B2. Control documentation.Document class B2. Building documentation.Document class B2. Test and inspection documentation This includes inspections plans,different types of certificates for the electrical and mechanical equipment,and when these options are included,documentation regarding the erection and commissioning. -Test and inspection documentation.Document class I. Based on scopedatabase edition 24 1/23/2003 ALSTOM Power Sweden AB S.\Medium Gas Turbines\Product WGTX 100\Budget Pricing Industnal Turbine SegmentTools\Scope of Supply Standard GTX100 [TH10066 Ed 3.doc ' A L ST Oo M GTX100 -GENERAL &COMMERCIALProject:GTX100 Standard Scope of Supply Ooc-number ITH10066 Creation date 2/24/2003 Edition Page 3 -28(28)Signature Language and number of binders: -Documentation in English for class A,B,D and I. -3 copies of documentation for class A -3copies of documentation for class B -3 copies of documentation for class D Binders Documentation Class A,B &D 1 copy of binders for class I -Documentation in binders. Main exclusions -Supply of auxiliary power -Drain from terminal point -MV connection (cabling or busduct)between the generator and the generator cicuit breaker or step-up transformer. -Generator circuit breaker. -LV power cables,installation materials and installationexternaloftheGTGpackage. -Signal and control cables,installation materials and installation external of the GTG package. -Earthing network external to GTG set All civil works including foundations -Embedded steel plates -Counterflanges,gaskets and bolts at terminal points -if not specifically agreed in final scope of supply. -Trial run -Training -Exhaust system downstream the GT exhaust diffuser flange. The equipment downstream the GT exhaust diffuser flange must be designed and manufactured to meet the overall plant noise requirements. Based on scopedatabase edition 24 1/23/2003 Comment ALSTOM Power Sweden AB S:\Medium Gas T TOdUct GTX 100\Buaget PrangToois\Scope of Supply Standard GTX100 ITH10066 Ed 3.doc Industral Turbine Segment