HomeMy WebLinkAboutCity Tribe Biomass Energy Conservation R3 Trip Report Tanana Biomass Improvements 2023
MEMORANDUM
DATE: Jan. 24, 2023
FROM: Utility Operations Specialist IV
SUBJECT: Trip Report, Tanana – Biomass Energy Improvements, AKAZA2-0999MTS/
TALZ87-1130EEO – Jan. 26-Feb. 11, 2023
TO: FOR THE RECORD
OBJECTIVES:
P rovide biomass energy improvements outlined in the May 2022 Rural Alaska Village
Grant (RAVG) biomass energy audit recommendations.
Provide on-the-job training to the operator on Garn biomass boiler system operation and
maintenance.
Follow up on operational status of the recent Infrastructure Protection Fund (IPF)
improvements installed in December 2022
CONTACTS:
Mr. James Roberts, Water Plant Operator, Tanana Too’gha Inc.
Ms. Gladys Erhart, Finance/Administration, Tanana Tribal Council (TTC)
Mr. Cliff Wiehl, Too’gha Maintenance Manager, TTC
Mr. John Erhart, Maintenance, TTC
Mr. Victor Joseph, Executive Director, Tanana Chiefs Conference (T CC)
Mr. Kyler Charlie, Local Laborer, T T C
Mr. John Walsh, Local Senior Laborer, T T C
Mr. Hal Hail, Local Laborer, T T C
ACCOMPANIED BY:
Mr. Tory Adams, Utility Operation Specialist Assistant, ANTHC
Mr. Kameron Hartvigson, Utility Operations Specialist III, ANTHC
FINDINGS AND ACCOMPLISHMENTS:
Mr. Tory Adams and I departed Anchorage at 11:05 a.m. through Fairbanks via Alaska Airlines
and arrived in Tanana via Wright Air charter at about 3:15 p.m. Jan. 26. Charter flight was
required as we were traveling with excess of 1,200 lbs. of boiler parts, replacement bricks,
plumbing materials, personal tools and additional gear. Upon arrival, we were met by Mr. James
Roberts and Mr. Cliff Wiehl at the airport. We unloaded the plane and transported all items to
Trip Report, Tanana – Biomass Improvements Page 2
Jan. 26-Feb. 11, 2023
the water treatment plant (WTP ) and Garn boiler facility. The weather was overcast and the
temperature was about 10°F. We set up lodging at the tribe’s Detour Inn.
Mr. Adams and I met with Mr. Roberts at the WTP/washeteria to discuss the tasks and scope of
the trip. Mr. Adams and I then went through and unboxed all the freighted items and worked to
stage, organize and inventory the materials to specific locations in the WTP , washeteria and
biomass facility. I called around to locate a local pressure washer, pressure hoses and vacuum
cleaner.
We started setting up for Garn boiler cleaning. Using surplus 1-inch PEX tubing left over from
the 2020 clinic service line work, we installed a temporary water feed service line from the WTP
utility sink area to the bio mass boiler building. The line was routed from the WTP mechanical
room and through the supply and return heat utilidor arctic carrier pipe. The line was not directly
tied into the potable water system, but set up to be manually connected to the utility sink faucet
by means of a washer hose. The utility sink has an integrated vacuum break to prevent cross-
contamination concerns.
RAVG Biomass Improvement Priorities Improvements
Note: Due to limited funding and potential unknowns while performing work, recommendations
were prioritized. Completion of tasks was based on labor assistance, seasonal weather
limitations, available funding, and time schedule constraints.
Recommendation 1- Boiler Water Improvement
Remove all water and sedimentation from biomass system, and pressure wash and
clean interior. Completed. A layer of calcium deposit scaling approximately 3/16-inches
thick was discovered inside of tanks on the burner chamber wall and hot vent piping near
the fire box. The buildup was not as thick on the vent piping farther away from the fire
chamber and was easier to clean. We resorted to manually chipping off the deposit with a
hammer and chisel in order to improve the heat transfer. This was a very slow, labor-
intensive task. The pressure washer could not break up the buildup, and a grinding wheel
generated airborne dust and particulates. Water spray mist was used to control dust.
Clean and rotate inline strainer and add pressure gauges up- and downstream.
Completed. The strainer was opened and discovered to be almost completely clogged with
black/tan tar-like substance. The strainer screen was cleaned and re-installed. Access for
cleaning was greatly improved with ¼-turn resetting of strainer. The gauge ports were
drilled and tapped into housing up- and downstream of the screen for monitoring.
Install bypass filters and fill point and provide spare filters. Completed. Three
cartridge filters were installed to remove particulates from the biomass water. The filters
were installed immediately upstream of the biomass plate and frame heat exchanger in the
WTP . A Grundfos Alpha pump circulates the water through a secondary loop off the main
line. The three filters are installed in parallel with each other in the secondary loop. Spare
filters were provided and stored on the top shelf above the workbench. An operational
wall chart for monitoring the filter differential pressure and replacing the cartridges will be
sent to the operator.
Trip Report, Tanana – Biomass Improvements Page 3
Jan. 26-Feb. 11, 2023
Install new manway covers, gaskets and low-water cutoff sensors. Completed. Three
newer two-piece hatch covers were installed with new level sensors.
Repair leaky fitting in WTP boiler room. Completed by others/contractors.
Remove three-way valve, install three isolation valves, flush ports, pressure gauges
and temperature indicator on hot side of biomass heat exchanger. Completed. Upon
installing gauges, we immediately identified a 5 PSI pressure drop across the water side of
the heat exchanger. The heat exchanger was disassembled and the plates were removed .
The fouled plates were replaced. After reassembly, only about 0.5 PSI pressure drop was
observed across the heat exchanger.
Recommendation 2 - Airflow and Heat Loss Improvements
Insulate around dampers and reconnect combustion air ducts. Completed. The intake
air return line manifold was lowered about 1¼ inches to allow more clearance. T he
sheetrock covering near the intake area was removed to expose small area of the bare steel
wall of boiler. We discovered 7x6x7-inch reducers had been installed on the damper vent
ducts and were causing airflow restriction so we removed them. The 7-inch motorized
dampers were refitted next to the boiler per the manufacturer’s specifications. The
motorized damper on Boiler 3 was replaced. A small sealed foam insulation box was
installed over the dampers on Boilers 2 and 3. The damper insulation box for Boiler 1 will
be fitted and installed by a local worker. Two new motorized dampers were provided as
spares.
Replace entry door with industrial door. Completed. The existing door was reused. The
door and jamb were removed, adjusted and reset with a new jamb, hinges, strike plate and
lock/latch with door reinforcement. The door was changed to a right-hand swing for inside
light switch access. The door still requires a metal base threshold, a bottom brush seal and
outside trim. These remaining items are to be installed by the operator.
Isolate unused boilers. Partially completed. All boilers can be isolated, however the
heated mass of Boiler 3 is beneficial for longer heat cycles between firings. Any of the
boilers may be isolated by closing the supply-and-return ball valves behind each boiler.
Provide brushes and clean fire tubes/flue pipes. Completed. Two rod sets and three sets
of brushes were provided. We demonstrated how to clean the tubes using brushes and a
vacuum cleaner. The replacement gasket sets did not arrive until the last two days we were
onsite. Gasket saver kits were also provided but not installed yet. The operators were
trained on the replacement of the gaskets and will complete the gasket replacement task.
The three Garn boiler blowers and adjoining sensor ports were cleaned and the gaskets
and gasket savers were replaced. The gaskets and gasket savers will need to be changed on
all the remaining ports when the units get brushed and cleaned.
Trip Report, Tanana – Biomass Improvements Page 4
Jan. 26-Feb. 11, 2023
Recommendation 3 - Freeze Protection/Re-Establish Backup Generator Operation
Level generator module. Not completed. This task was not completed due to snow and
frozen ground conditions.
Reconnect fuel lines. Not completed. This task was not completed due to snow and
frozen ground conditions. Flex lines were provided to the operator for fuel line
reconnection work.
Replace battery for the generator. Partially completed. A replacement battery was
provided but not installed. Oil and spare filters were also provided.
Establish schedule for exercising gen-set. Not completed. This task was not completed
because the gen-set was not re-commissioned and is not operational.
Recommendation 4 - Electrically Isolate Boilers
Confirm foam base under the biomass boiler. Completed. Foam exists under the boiler,
however the boiler weight rests upon 2X dimensional lumber directly under the fork lift
pick points. All three boilers are supported by a steel I-beam frame with three jacks under
each end for leveling. Some leveling effort was performed to pitch boilers forward slightly
to provide better draining. More leveling efforts should be conducted by the operators
during the summer. Leveling the boilers is expected to be a seasonal task.
Install dielectric flange kits. Completed. Dielectric isolation already exists at steel-to-
copper transition flanges behind boilers.
Install electric isolation kits on motor/control panel. Completed. Isolators were added
on all three boiler motors. Two of the existing older blower motors were cleaned and set
up for backup spares. Two more gasket savers are required for those motors.
Recommendation 5 - Other Required Biomass Improvements
Establish testing and maintenance plan. Completed. All maintenance requirements for
Garn units is outlined in detail within the boiler manual. Both electronic and hard copies
were provided during December 2022 biomass training
Establish maintenance/cleaning schedule and provide wall charts. Completed.
Provided both electronic and hard copies of the boiler manual during December 2022
biomass training. Additionally, Garn maintenance videos were provided.
Develop spare parts list. Completed. Provided both electronic and hard copies of the
boiler manual during December 2022 biomass training. Reviewed a short list of items for
the operator to maintain on the shelf. Ordering spare parts can be easily done via the Garn
website.
Trip Report, Tanana – Biomass Improvements Page 5
Jan. 26-Feb. 11, 2023
Replace broken fire bricks. Completed. The fire chambers in all three boilers were
cleaned and new fire bricks were installed.
Replace lighting with LEDs. Completed. All three lighting fixtures were replaced with
medium-base, screw-in LED shop lamp bulbs with directional light adjustment and
switchable on-board occupancy sensing.
Replace attic vents. Not completed. A new vent needs to be purchased and shipped to the
site for the operator to install. A hood should be added to cover the vents at both gable
ends of building.
Recommendation 6 - Other Recommended Biomass Improvements
Install pressure gauges downstream and upstream of bio mass heat circulation pumps
manifold. Partially completed. Only one gauge was installed downstream of the pumps.
The upstream gauge was not installed because the required fittings were damaged during
shipment to the site. Spare gauges were left on the WTP workbench. The required fittings
to complete the installation of the upstream gauge will be mailed to the site for the
operator to install. The upstream gauges were installed as part of re-installed strainer
recommendations above.
Replace Garn boiler door handles and hinge pins. Completed. All Garn doors were
rebuilt with new gaskets (for positive seal), hinge pins, handles, and grade 8 latch bolts
with safety pins. Three new gaskets should be ordered by the operator as critical spare
parts and put on the shelf.
Provide moisture meter. Not provided. A meter will be purchased and shipped to the
site.
Provide replacement gaskets for the biomass plate and frame heat exchanger.
Completed. Both gaskets and a complete set of new plates were provided and installed.
The old fouled plates were stored in a shipping crate. The fouled plates can be cleaned and
reset with new gaskets when plugging next occurs and a change-out is required.
Add insulation to and weather seal garage door. Not attempted due to freezing winter
conditions. Still need to order door brush seal. Additionally, the door rails and springs
needs to be reset and adjusted. We observed the bio-building foundation has moved and
settled over the years. The door brush seal will be sent out to the site for the operator to
replace.
Add lighting at back side of boilers. Completed. The ceiling fixtures were replaced with
LED fixtures and lamps. The new fixtures and lamps provide adequate light to illuminate
the back of the boilers.
Provide shelving and workbench. Not attempted. The large Knack box or one of the
existing shelving units on east wall will need to be removed to provide space for a
workbench. Unistrut steel for a workbench build was provided.
Trip Report, Tanana – Biomass Improvements Page 6
Jan. 26-Feb. 11, 2023
Re-integrate remote monitoring (RM) with Wi -Fi rather than cell data. Not
attempted. The existing RM system is functional with current cell data. The existing plant
Wi-Fi is slow and limited. T his could be upgraded if Tanana receives an upgrade to its
RM system.
Replace pro -press copper pipe joints with solder fittings. Not attempted. A retrofit is
beyond the existing RAVG budget. If the pro-press copper pipe fittings are removed in the
future, the pipe and fittings should be changed out for PEX pipe to allow for the Garn
boiler to move and flex due to observed boiler foundation concerns.
Replace wood walkway with metal alternative. Not attempted. A retrofit is beyond the
existing RAVG budget. Used 3/4-inch plywood to build a working deck to support boiler
cleaning.
Add insulation in attic. Not attempted. A retrofit is beyond the existing RAVG budget.
After a building fire around 2019, the repairs to the ceiling sheetrock were poorly
implemented. The ceiling sheetrock requires re-fastening to the rafters.
Recommendation 7 - Other Recommended Biomass Improvements
Re-integrate existing solar-voltaic array system to biomass supplemental electrical
heating elements system. Not attempted. Improvement is beyond the existing RAVG
budget. Although this has great potential to reduce wood consumption during late spring,
summer and fall, this will require engineering and additional funds for equipment
adaptation.
During the biomass improvement work and training efforts, participation by the operator and
local workers was very limited. As much training information as possible was passed on from
hands-on work demonstrations, however additional training could have been provided had the
operator and workers been present for longer. Mr. Kyler Charlie worked with Mr. Adams for 2-
1/2 days during the first week. Mr. John Walsh (Feb. 4-10) and Mr. Hal Hail (Feb. 6-10) became
available and assisted with efforts to finish the boiler tank cleaning to bring the last boiler back
on line just before I departed.
Community Support Assistance
On Jan. 31, Mr. Roberts approached me and requested electrical assistance at the river intake
building. He reported that the control panel was not operating the river pump and the water level
in the water storage tank (WST) was at about 4 feet. Power was checked through control panel
and nominal 230-volt single phase power was available through the starter contactors. I
discovered the overload on the 1-1/2 HP motor control box fed from the panel was tripped and
continued to trip upon reset. The three-wire control box power fed into a double-throw switch
that directs the power to either a well pump inside a casing located in the intake building or to
the 230-volt twist outlet outside the building for feeding power to the river pump cord. Resetting
and testing amperage draw, I discovered the river pump drawing 43 amps and the well pump
Trip Report, Tanana – Biomass Improvements Page 7
Jan. 26-Feb. 11, 2023
drawing 34 amps, far above the max rating of the 11.5-amp max safety rating. Either a short
circuit or locked rotor condition was assumed.
The river submersible pump (WILO #TWI 4.25-7.10 - P/N# 2711984, Model # FM4301031A, 3
wire, 1 HP , 230 Volt, 8.4 Amp, 3450 RPM, 1 PH) was taken to the WTP to warm up, dry out and
be inspected. The motor windings resistance was checked and the motor shaft was not locked
and showed no physical resistance when turned by hand. The pump impellers were not clogged.
Multiple attempts were made to bump test the pump, but the overload continued to trip.
No critical spare pump or splice kits were available for either the river submersible or well
submersible pump. It was later discovered that both pumps had quit operating during the la test
pumping events. In an attempt to find a solution, we located spare pump wire and replaced the
submerged wire section area where nicks and cuts were observed on the insulation hoping it
might remedy high amp draw if a short existed. The wire change-out allowed the pump to
operate when tested out of water however it still tripped when submerged under load. The
Fairbanks remote maintenance worker (RMW) group located and sent a 1-HP two-wire
submersible pump, but it didn’t arrive until Feb. 2. The WST water level continued to drop to
very low critical level. The operator located a gas-powered fire pump, adapted it, and was able to
pump water during the evening of Feb. 1 till the early morning hours, adding to the WST level
and keeping the system pressurized. T he two-wire pump from the RMW group was adapted to
the existing wiring and was put into operation by the evening of Feb. 2.
The urgent event re-enforced the importance of having critical spare pumps on hand at all times.
I requested the ANTHC engineering group to locate a vendor to provide a quote for a backup
pump, control box and splice kits. I provided that quote to the operator and TTC representatives
via text message.
I was fortunate to be able to walk through the WTP with Mr. Victor Joseph to review the system,
from raw water to treatment to storage and distribution, and pointed out the different
improvements ANTHC was involved with since 2020. Two points of concern I shared with Mr.
Joseph:
1. The importance of having backup utility operators for the Tanana water and sewer system
since Mr. Roberts is expected to start rotational employment with UIC North Slope
utilities in the near future.
2. Maintaining critical spare parts on hand for the Tanana water and sewer utility to reduce
emergencies like the river pump failure and low WST levels. When asked what items are
needed for critical spares, I informed Mr. Joseph most operation and maintenance (O&M)
manuals list critical equipment needed. Each system is slightly different and an inventory
of parts on hand versus parts needed would require assessment. ANTHC only has a draft
copy of the Tanana WTP O&M manual, which doesn’t include a critical spare parts list.
Because Tanana is a Village Safe Water (VSW) community, O&M manuals and other
records are only available upon request from VSW. A copy of the record WTP
constructed design plan set exists in ANTHC’s archives.
Trip Report, Tanana – Biomass Improvements Page 8
Jan. 26-Feb. 11, 2023
Of the 17 days spent on travel and work, 2-1/2 days were spent providing community support to
repair the river submersible intake pump. T his delayed progress on the biomass system upgrades
and training. Thirteen days on-site were dedicated to biomass improvement work and 1-1/2 days
were spent on travel from Anchorage.
Mr. Adams arrived on-site on Jan. 26 and departed Feb. 2. Mr. Hartvigson arrived on Feb. 6 and
departed on Feb. 10. I departed Tanana on Feb. 11 and arrived back in Anchorage later that
evening.
RECOMMENDATIONS AND/OR CONCLUSIONS:
1. ANTHC to follow up with Tanana utility on biomass operation and needed maintenance
items for the utility to procure and stock.
2. Tanana utility should work with the TCC RMW group to assess and develop a utility
critical spare parts list to order and stock.
Martin Wortman
Attachments:
Photos
cc: James Roberts, Water Plant Operator, Tanana Too’gha Inc.
Cliff Wiehl, Too’gha Maintenance Manager, TTC
Gladys Erhart, Finance/Administration, TTC
Victor Joseph, Executive Director, TCC
ec: Lee Meckel, RMW, TCC
Noah Tsigonis, RMW Supervisor, TCC
Oscar Menendez, Village Safe Water Engineer, Alaska Department of Environmental
Conservation
DEHE – Brian Menghini/ Valerie Zeedar/
Bailey Gamble/ James Fowler/
Tory Adams/ Kameron Hartvigson
Trip Report, Tanana – Biomass Improvements Page 9
Jan. 26-Feb. 11, 2023
PEX Water Supply Line
3/16” Calcium Buildup on Biomass Boiler Hot Vent Piping
Trip Report, Tanana – Biomass Improvements Page 10
Jan. 26-Feb. 11, 2023
Cleaning and Vacuuming Biomass Boiler
Boiler Hot Vent Piping Scraped and Cleaned
Trip Report, Tanana – Biomass Improvements Page 11
Jan. 26-Feb. 11, 2023
Biomass Boiler Y-Strainer Before Maintenance
Y-Strainer Removed for Maintenance
Trip Report, Tanana – Biomass Improvements Page 12
Jan. 26-Feb. 11, 2023
Cleaning Y-Strainer Screen
Y-Strainer Screen After Cleaning
Trip Report, Tanana – Biomass Improvements Page 13
Jan. 26-Feb. 11, 2023
Y-Strainer Reinstalled with Gauges
Biomass Water Conditioning Filters
Trip Report, Tanana – Biomass Improvements Page 14
Jan. 26-Feb. 11, 2023
Old Biomass Boiler Manway Cover
New Biomass Manway Cover and Level Sensor
Trip Report, Tanana – Biomass Improvements Page 15
Jan. 26-Feb. 11, 2023
Biomass Boiler Heat Exchanger Before Bypass Valve Replacement
Biomass Boiler Heat Exchanger After Bypass Valve Replacement
Trip Report, Tanana – Biomass Improvements Page 16
Jan. 26-Feb. 11, 2023
Clogged Plates in Biomass Heat Exchanger
Replacing Heat Exchanger Plates
Trip Report, Tanana – Biomass Improvements Page 17
Jan. 26-Feb. 11, 2023
Original Biomass Intake Air Vent
Intake Air Damper Next to Boiler
Trip Report, Tanana – Biomass Improvements Page 18
Jan. 26-Feb. 11, 2023
Insulated Box and Direct Vent
Biomass Fire Chamber Before Cleaning
Trip Report, Tanana – Biomass Improvements Page 19
Jan. 26-Feb. 11, 2023
Biomass Fire Chamber After Cleaning
New Biomass Fire Chamber Bricks Installed
Trip Report, Tanana – Biomass Improvements Page 20
Jan. 26-Feb. 11, 2023
Biomass Firebox Door with Worn Gasket
Worn Biomass Door Latch Handle
Trip Report, Tanana – Biomass Improvements Page 21
Jan. 26-Feb. 11, 2023
Worn Biomass Door Hinge Pin
Biomass Firebox Door with New Gasket