Loading...
HomeMy WebLinkAboutWaste Heat Information Jan 28, 1999Sent By:AEE;907 349 8001;Jan-28-99 10:47AM;Page 1/16To:DOE ENGINEERING At:2694685 é 'Alaska Energy and Pngineering,InInc..Mailing address-P.O.Box 111401217EastKlattRoad,Suite AAnchorage,AK 99511-1405(907)349-0100349-8001 fax Mr.Jerry SamatoMaintenance Ié PASE 5ChathamSchoolDistrict P.O.Box 109 DEY -S32 Fr Angoon,AK 39820 SUBJECT:Waste Heat Information Dear Mr.Samato: Please find attached some "DRAFT"information regarding the operations andmaintenanceofthewasteheatsysteminAngoon. PLEASE BE ADVISED,THE INFORMATION CONTAINED HEREIN IS BASED ON OPERATIONS AND MAINTENANCE OF OTHER WASTE HEAT SYSTEMS |HAVE BEEN INVOLVED WITH AND WHAT I CAN REMEMBER ABOUT THE SYSTEM INANGOON.DAVID LOCKARD AT THE DIVISIONOFENERGY IS OUT OF THEOFFICEUNTILNEXTWEEK.|HAD HOPED TO GET THIS INFORMATION TO HIM To REVIEW SINCE HE HAS ACCESS TO THE WASTE HEAT DRAWINGS (I DONOT). THE WEATHER SERVICE FORECASTS EXTREME COLD TEMPERATURES FOR THE STATE THIS WEEK.THE WASTE HEAT LOOP FLUID IS PLAIN WATER. THERE IS A VERY SERIOUS RISK THAT THE WASTE HEAT PIPE TO THE HIGH SCHOOL MAY FREEZE IF THE TEMPERATURE AT ANGOON DROPS BELOW FREEZING AND THE HIGH SCHOOL WASTE HEAT PUMP DOES NOT CIRCULATE THE WATER TO KEEP IT WARM. |RECOMMEND THAT YOU GET A NEW PUMP INSTALLED AS SOON AS Possio IF YOU CANNOT GET ONE,CALL ME AND WE CAN DISCUSS SOMEOPTION SEE PAGES 9 THROUGH 12 REGARDING PUMP REPLACEMENT AND HEAT EXCHANGER REPAIRS. If you have any questions or need additional information,please call me at(807)349-0100,or fax your comments to (907)349-8001, Sincerely, .|,PE President attachments -as noted cc:David Lockard,Division of Energy 269-4685 fax Sent By:AEE;907 349 8001;Jan-28-99 10:48AM;Page 2/16 ANGOON WASTE HEAT SYSTEM ANGOON,ALASKA INDEX LIST OF SUPPLIERS «0.0...eee eee ec reeneereeneeitnnsitensnnsiengiensnennaise cies PAGE 2 CRITICAL SPARE PARTS............::::cccecccesccceeseecececeseeeeneesnsaeesaaseneeeessnueesesseeeeenes PAGE 3 MAINTENANCE CHECK LIST...ccc tctececseeertecseteeeennesensesetseeeceneeeetnaes PAGE 3 TROUBLE SHOOTING DIAGRAM 0...eee cee ceecceceeeececeeecisetnaseruaeesesaseneanenennees PAGE 4 OPERATING SEQUENCE AND PROCEDUREG..........ccc ceee ececeeeeeeeceeeeetenteeees PAGE 5 SYStEM PULPOSE....2...cesses tener eee tenteeeeee connate cree se cae ceeeeteneeeeatedeeeeey Page 5 System Description and Operation 2.0.0.0...cece cessssssseeecesensreasreneeeeees Page 5 Power Plant Cooling System Start-up..........0.....ccceccccececeeeateteeeeeeeueneeereens Page 6 Waste Heat Loop Start-up oo...cceesessceececeeeeceeecccceccseeesaeetsssesusupensepesercess Page 6 Elem.School,Teachers Qrirs,High Schoo!Gym System Start-up .............Page 7 High School System Start-up...ccecssssesssseeeeseeeesececesceeeseeeeeeeceeeninnanenenss Page 7 Routine Maintenance and Operation ..........ccecececssessseceeeseeeceeeeesseessseesreeess Page 8 Spring SHUKOWN 20.cece see eeeseeeeeeetteneeneceseetecseetseseecseeestvasenentepeaes Page 8 Fall Start-up ooo...cece crseeceeeeestauaueeeeeseesesevsnseeesecseeeceeeeeecenaaeneeees Page 8 System Trouble-Shooting -2.2.0...cece eesneteseeensneaeereepcceeeseceeseeeeneeeeevenaea Page 8 EQUIPMENT DIRECTORY .........ccccceccessseesteeeneeceeceecseeeeeceeaecnseennausesnuupeeseseceiaeas Page 13 DESIGN DRAWINGS.00...ecececeee een e rene ceecceee cree renecsaepeagaserausensaeceeceseeeees NONE TEMPERATURE LOGS............0.ccccecccceteeseeeneeseneeetencceeesceeecoeseeneesssaesensapeseneseeseeses NONE Angoon Waste Heat System 1 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001; 'ANGOON WASTE HEAT SYSTEM ANGOON,ALASKA LIST OF SUPPLIERS ALASKA PIPE AND SUPPLY 2300 East 63™Ave. Anchorage,Alaska 99507 (907)561-4411 (907)562-4863 ARCTIC CONTROLS 1120 East 5"Avenue Anchorage,Alaska 99501 800-277-7555 (907)277-9295 fax PROCTOR SALES,INC. 5401 Cordova St.#303 Anchorage,AK 99518 (907)562-2608 (907)562-0503 fax WCR,INC. (located in California) (209)266-8374 (209)266-3354 fax QSE P.O.Box 380875 East Hartford,CT 06138 (860)569-2558 (860)568-2843 fax E.D.1. 1884 E.3rd Avenue Anchorage,AK 99501 (907)277-5678 (907)276-6476 fax E.J.BARTELLS CO. 601 Whitney Road Anchorage,Alaska 99501 (907)272-2467 Angoon Waste Heat System Operations and Maintenance Manual -DRAFT PUMPS,THERMOMETERS,PRESS. GAUGES,PRESSURE RELIEF VALVES,EXPANSION TANK,AIR SEPARATOR,PIPE,VALVES,AND FITTINGS AMOT VALVE APV HEAT EXCHANGERS CONTACT:GREG PINASCO This firm reconditions and regaskets heat exchanger plates.Sometimes they have plate packs for exchange 1.C.MOLLER ARCTIC PIPE MOTOR STARTERS,MISC ELECTRICAL INSULATION 2 Jan-28-99 10:48AM;Page 3/16 Sent By:AEE;907 349 8001;Jan-28-99 10:48AM;Page 4/16 CRITICAL SPARE PARTS CART Air Vents Maid-O-Mist #75,or equal Arctic Piping Loop Glycol ARCTIC PIPE LOOP IS PLAIN WATER Pressure Gauges Trerice 600C or Equal Waste Heat Pumps Grundfos UP 43-75F Thermometers SEE EXISTING THERM''S FOR PART #S MAINTENANCE CHECK LIST Daily: e Monitor and record waste heat system temperatures and pressures e Verify operation of waste heat pumps (IN HIGH SCHOOL MECHANICAL ROOM AND GYM BOILER ROOM,TEACHERS QUARTERS,AND ELEMENTARY SCHOOL BOILER ROOM) e Visually inspect piping,valves,and heat exchangers for leaks Semi-Annually: e Trip automatic air vents e Trip pressure relief valves e Actuate butterfly valves 10 Years: e Clean and regasket plate and frame heat exchangers Angoon Waste Heat System 3 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:48AM;Page 5/16 TROUBLE SHOOTING DIAGRAM Angoon Waste Heat System 4 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:49AM;Page 6/16 AWGCCTROUBLESHOOTING IS WASTE HEaf AVAILABLE? IS THE WASTE HEAT LOOP PRESSURE OK? oe s weed |eatHEATEXCHANGER(ors \Wa(Pace BAG VES}EXCHANGER LEAK yoyore# REPAIR||HEAT ExcHaycER (ts)--_|8SEE -OT HEAT(PAGE,CHANGER ©ARE THERE ANY LEAKS IN Oral PERFORM ROUTINE MAINTENANCE,RECURDTEMPERATURESANDPRESSURE(PAGE A) 3 w rele Wntvac/oncuarne PUNPS SEY VALVES CORRECTLY @)"P>dadS)OPERATING (PAGE he, IS POWER AVALABLE TOPUMPS?(PACE dt)s (Ws) B&CIRCUIT BREAKER AND WIRING OK? ARE VALVES SET PROPERLY” as : () RESET CIRCUIT GREAKER/ THE WASTE HEAT L00P REPAIR WIRING PIPING? (No) Me OER OPERATING A00 @eTCO TO WASTE PROPERALY AND ARE THE (es \HEAT LOOP (SEE WASTE SEIPOINTS CORRECT?SS HEAT LOOP START-UP, (pace I]PEM 6 REPAIR BOILERS/ Sent By:AEE;907 349 8001;Jan-28-99 10:49AM;Page 7/16 VO. LOGIC DIAGRAM pe 4 Part IS THE aMOTARETHEDes.AG THE RAOIATOR ASS sot v-_(s)}-RADIATORS RUNNING?-()-laid oa --=-((8}-aN Les}|af mts connecrty 5)PeweeCCONTACTTHEsala REPUCE aorialOPERATORVALVETHERMOSTATSAGEwl10(PE RO | frsao paovecr:<<oFSEA WASTE HEAT RECOVERY SYSTEM TROUBLE SHOOTING LOGIC DIAGRAM ALASKA ENERGY AND ENGINEERING,INC #0.OOK 111e08 ANCHORAGE,ALASKA 59511-1405 PHOME (907)349-0100 pole oF |S AL WO SOME PAL Nene,O&MLOGIC |3¥etr DSENED fy:OS Ore:7 una Pend Wed FST or1 Sent By:AEE;907 349 8001;Jan-28-99 10:49AM;Page 8/16 ANGOON WASTE HEAT SYSTEM OPERATING SEQUENCE AND PROCEDURES ieLic ah SYSTEM PURPOSE: The heat recovery system is designed to capture heat generated by the power plant,that would otherwise be rejected to the atmosphere via the radiators,and transfer this heat to the schoo!buildings.The objectiveis to reduce the amount of fuel oil used to heat the buildings. SYSTEM DESCRIPTION AND OPERATION Hot coolant frorn the on-line diesel engine(s)is piped to a 6-port plate and frame heat exchanger located in the power plant.After passing through the heat exchanger,the coolant is routed to an amot valve which is piped in "mixing mode". The amot valve has 180°factory set thermostatic elements and regulates the flow of coolant to the radiators to maximize the amount of heat available to the waste heat system. When the engine coolant return temperature (temperature leaving .the heat exchanger)is greater than 180 degrees,some of the coolant is diverted to the radiator(s)for cooling.The "cooled”coolant returning from the radiator(s)is mixedintheAmotvalvewiththe"hot"coolant from the heat exchanger to produce a return coolant temperature to the engine of about 180°.If the coolant temperature is below 180”as it exits the heat exchanger,the amot valve bypasses the radiator and returns the coolant directly to the engine. Heat is transferred from the diesel engine coolant to the waste heat loop via the plate heat exchanger without mixing the fluids.The heat exchanger is a 6-port, three chambered plate heat exchanger with two separate waste heat loops (one to the Elementary School and Teachers Quarters and one to the High School and High School Gym).The heated waste heat water is then piped through arctic pipe to the school buildings.The waste heat loops are tied directly into all building heating systems (except the High School)via direct connections to the boiler return piping upstream of the boilers (i.e.,the building heating fluid is pumped through the waste heat loop to the power plant). The High School is equipped with a plate heat exchanger located in the second floor mechanical room.The High School plate heat exchanger isolates the building heating system from the waste heat loop and transfers heat from the waste heat loop to the building heating system without mixing the fluids.The High School waste heat loop expansion tank is located in the second floor mechanical room and provides expansion capacity for the High School waste heat piping loop.The Angoon Waste Heat System 5 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:49AM;Page 9/16 Elementary School waste heat loop does not have an expansion tank since it is tied directly into the school heating systems ({i.e.,the building heating syStem expansion tanks provide for the waste heat loop expansion). There is one circulating pump (Grundfos UP 43-75F)located in each boiler/mechanical room which circulates the waste heat fluid through the arctic pipe from the power plant to the schoo!buildings.These pumps should be inspected periodically to ensure they are operating properly. POWER PLANT COQLING SYSTEM STARTUP (Refer to THREA) THREA power plant operator to perform all power plant start-up operations. Coordinate with the power plant operator the filling and start-up of the waste heat system. Fill the cooling system piping between the power plant cooling manifold and the plate heat exchanger with pre-mixed ethylene glycol and water (Refer to THREA for recommended glycol concentration). Vent air from all high points.Do not add heat to the waste heat loop (keep waste heat circulating pumps in the schools off).Ensure all air is out of power plant cooling system and the diesel engine is up to operating temperature prior to transferring load to the generator. WASTE HEAT LOOP START-UP: The waste heat system is filled with plain water,only,since it is tied directlyintotheElementarySchool,Teachers Quarters,and High School Gym heating systems When filling the waste heat system,it is important to make sure that all air is vented fram the piping.Air is vented at system high points by automatic air vents.The water should be pumped into the arctic piping without heating the water.Sincebothofthewasteheatloopsaretieddirectlyintotheschoolbuildingheating systems (except the High School),the only practical way to accomplish this is to start-up the waste heat loops when the school boilers are off-line.(This is important to allow the air to be vented from the piping prior to the waste heat loopwaterexpanding).While filling the arctic piping loops,the power plant cooling system should bypass the plant plate heat exchanger and reject all engine heat through the power plant radiators. Fill the arctic piping to at least 10 psig prior to turning on the waste heat pumps intheschoolbuildings.Cycle the pumps on and off to help force the air to piping high points for venting.The automatic air vents may be hand-tripped by removing the Angoon Waste Heat System 6 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:50AM;Page 10/16 .DRAFT screwed-on cap and depressing the valve stem.Auto air vents are located in the piping at high points.At least once per year,the air vents should be manually tripped.Care should be taken not to discharge hot water from the air vents. Continue to cycle the waste heat pumps add water until the air has been vented and the system pressure is at least 10 psig (with the pumps tumed off).(Since the waste heat loops are tied into the school building heating systems,the arctic pipe (waste heat foop)pressure will be the same as the building heating system pressure where the waste heat piping connects to the building heating piping).Do net pressurize the waste heat loop above the normal building system operating pressure. After the waste heat system has been filled and vented,tum on the school boilers and allow the beller systems to bring the waste heat loops up to temperature (at least 160F)prior to routing the engine coolant through the power plant heat exchanger. (NOTE:THE ARCTIC PIPING SYSTEM SHOULD ALWAYS BE ALLOWED TO COME UP TO OPERATING TEMPERATURE BY USING THE BOILERS TO PREHEAT THE SYSTEM PRIOR TO ALLOWING HOT ENGINE COOLANT TO ENTER THE POWER PLANT PLATE HEAT EXCHANGER). Additional air should be vented from the system as the fluid circulates.Cycle pumps on and off and vent high points until all air has been purged from piping. ELEMENTARY SCHOOL,TEACHERS QUARTERS,HIGH SCHOOL GYM SYSTEM START-UP Vent air through piping high-paint vents.Adjust all boiler temperatures to fire between 165F and 175F.Confirm proper setpoint with piping thermometers,do not rely on the boiler control setpoint. HIGH SCHOOL SYSTEM START-UP Fill the piping between the school boilars and the plate heat exchanger with the same mixture of fluid used in the High School heating system.Vent air through high-point vents.Verify boilers are set to fire between 16SF and 175F.Confirm proper setpoint with piping thermometers,do not rely on the boiler control setpoints. Verify adequate loop pressures at heat exchanger (boiler side and waste heat !oop side)and open the valves on the boiler side of the heat exchanger. ROUTINE MAINTENANCE &OPERATION: Angoon Waste Heat System 7 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:50AM;Page 11/16 :fe.Oiai The waste heat piping system should be maintenance free.The waste heat supply and return temperatures should be recorded daily to provide a historical record and to alert maintenance personnel of impending problems.A master form for recording temperatures and pressures is included in this manual and may be copied for use. The circulating pumps should also be checked periodically for proper operation. Pump operation can also be checked by removing the silver end-cap from the pump housing and visually inspecting the pump shaft rotation (refer to manufacturers instructions). SPRING SHUTDOWN: Unless problems occur with overheating the school buildings during the summer,the waste heat loops should continue to circulate. If the waste heat loops are to be shut down for the summer,turn off all waste heat loop pumps. Notify the Plant Operator prior to shutting down the waste heat system. FALL STARTUP: Refer to System Startup above.Notify the Plant Operator prior to starting up the waste heat system. Prior to system startup,verify that the waste heat system pressure is at least 5 psig prior to tuming on the pumps.The building heating water make-up systems should keep the waste heat loop system pressurized. Use boiler systems to bring the waste heat loops up to temperature (at least 160F) prior to circulating the power plant engine coolant through the plate heat exchanger. (NOTE:THE ARCTIC PIPING LOOPS SHOULD ALWAYS BE ALLOWED TO COME UP TO OPERATING TEMPERATURE BY USING THE BOILERS TO PREHEAT THE SYSTEM PRIOR TO ALLOWING HOT ENGINE COOLANT TO ENTER THE POWER PLANT PLATE HEAT EXCHANGER). SYSTEM TROUBLE-SHOOTING: Because the components of this system are relatively few,the process of locating any problems should be relatively simple.Some potential problems and solutions are as follows: Angoon Waste Heat System 8 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:50AM;Page 12/16 :DRAFTLowFlowOrLackOfHeat: lf the diesel generator(s)is running and producing heat and the waste heat supply temperature is below 160F,first verify that the boilers in the buildings are operating and set to fire between 165F and 175F.Also,verify that the valves in the power plant are set for the engine coolant to flow through the power plant plate heat exchanger and the AMOT Bypass Valve is closed (ONLY THREA PERSONNEL SHOULD ACTUATE POWER PLANT VALVES).Verify that all valves in the school buildings are set properly. Next,verify that the waste heat pumps in each schooi building are running.Pump operation can be verified by removing the silver end-cap and visually inspecting to see if the shaft is spinning.If a pump is not working be sure the proper circuit breaker is on,and the pump motor starter switch is in the ON position.if the pump still does not work,verify that power is available at the pump.If so,replace the pump. Check the fluid pressure in the waste heat system.Make sure the waste heat loop pressure is at least 10 psig.If the system still does not operate properly,there may be air in the arctic piping.To correct this condition shut off the circulating pumps for a few moments and manually trip the air vents.Restart the pumps and repeat if necessary.This helps to vent the air through the auto air vents at the system high points. Pump Replacement Close the valves at both the suction and discharge ports of the pump.Ensure that the circuit breaker providing power to the pump is off and disconnect the electrical wiring from the pump motor.(Refer to Manufacturers instructions)Remove the bolts from the pump flanges and remove the pump.Install the new pump in the reverse order.Before starting the pump,fully open the valve on the suction side of the pump.Open the valve at the discharge side of the pump only about 25%. Check to see that the system pressure is at least 10 psi.Start the pump and allow the fluid to circulate and allow the waste heat loop to come up to operating temperature (REFER TO WASTE HEAT LOOP START-UP PROCEDURES, ASOVE).Slowly open the pump discharge valve 100%. NOTE:THE HIGH SCHOOL WASTE HEAT LOOP BUTTERFLY VALVES ARE NOT "LUG-STYLE”.WHEN THE BOLTS ARE REMOVED,THE VALVES WILL FALL OUT.IN ORDER TO PREVENT THIS FROM OCCURRING,IT IS POSSIBLE TO SECURE THE VALVES IN PLACE BY USING A COUPLE OF NUTS THAT ARE CUT IN HALF TO MAKE THEM THINNER.REMOVE TWO OF THE BUTTERFLY VALVE BOLTS THAT ARE OPPOSITE EACH OTHER.SLIDE THE THIN NUTS BETWEEN THE BUTTER FLY VALVE AND THE FLANGE THAT IS TO BE REMOVED AND SECURE THE BUTTER FLY VALVE TO THE FLANGE Angoon Waste Heat System 9OperationsandMaintenanceManual-DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:51AM;Page 13/16 ON THE PRESSURIZED SIDE OF THE PIPING.BOLTS SHOULD PREVENT THE WASTE HEAT LOOP WATER FROM DRAINING OUT AS LONG AS THE WASTE HEAT LOOP PRESSURE IS NOT TOO HIGH. Radiator Aquastat Setpoint and Amot Valve (ONLY THREA PERSONNEL SHOULD ACTUATE POWER PLANT VALVES) If the radiator fan(s)are running constantly and the waste heat loop temperature is low it may indicate a problem with the Amot valve or radiator aquastat setpoint(s).If the setpoint is below 180F,contact the power plant operator to determine why the setting is low (DO NOT ADJUST ANY POWER PLANT CONTROLS).VERIFY THAT THE ENGINE COOLANT IS FLOWING THROUGH THE PLATE HEAT EXCHANGER AND THE AMOT BYPASS VALVE IS CLOSED.If the radiator setpoint(s)are correct,the engine coolant is flowing through the heat exchanger, and the AMOT Bypass Valve is closed,and the fans are still running and the waste heat loop temperature is low,replace the thermostatic elements in the Amot valve. First open the amot bypass valve and then close the isolation valves at all three amot ports.Drain the coolant from the Amot valve and remove the housing bolts, cover,and thermostatic elements.Install the new elements in reverse order using new o-rings and housing seal (refer to manufacturers instructions).Open the isolation valves and wait a few minutes to allow the Amot to come up to the engine cooling loop temperature before closing the bypass valve (NOTE:ALWAYS ACTUATE THE BUTTERFLY VALVES SLOWLY TO AVOID A SUDDEN PRESSURE CHANGE IN THE PIPING SYSTEM.SUDDEN PRESSURE CHANGES MAY DISLODGE THE ENGINE THERMOSTATS.) Heat Exchanger Repair: If a heat exchanger starts to leak severely,the heat exchanger isolation valves (supply and return)can be closed to prevent the engine cooling loop,waste heat loops,or high schoo!heating system from being drained down. Power Plant Heat Exchanger if the power plant heat exchanger starts leaking,inspect the fluid to see if it is ethylene glycol (usually pink or green)or water (clear).If the leaking fluid is ethylene glycol this indicates that the engine cooling side of the heat exchanger is leaking.If the leak is severe,first open the valve(s)to bypass the engine coolant around the heat exchanger and slowly closethe engine cooling loop supply and return valves at the heat exchanger.Notify maintenance personnel that the waste heat loop is net working,and that some of the power plant coolant has leaked. Angoon Waste Heat System 410 Operations and Maintenance Manual -DRAFT Sent By: ¢ AEE;907 349 8001;Jan-28-99 10:51AM; OeAPT if the fluid is water,this indicates that the waste heat loop is leaking.!f the leak is severe,shut down the waste heat circulating pumps at the affected school buildings and close the waste heat supply and return valves at the heat exchanger.(Note: The waste heat pumps will burn out if they continue to run with the power plant heat exchanger valves closed.)If it is determined which loop of the heat exchanger is leaking (Elementary or High School loop),the loop that is not leaking may continue to operate. Small leaks can sometimes be repaired by simply tightening the heat exchanger bolts (Refer to Manufacturers instructions).First,mark the leak on the plate with a permanent marker to identify which plate gasket is leaking.Prior to tightening the bolts,the pressure inside the heat exchanger must be relieved.To do this,first shut down the waste heat circulating pumps and then OPEN THE PLANT HEAT EXCHANGER BYPASS VALVE,and close the engine cooling loop valves and the waste heat loop valves at the heat exchanger.(Note:Notify the plant operator and school maintenance personnel that the waste heat system is not working.) Drain the cooling loop (ethylene glycol)and waste heat loop (water)fluids from the heat exchanger to ensure that the pressure in the heat exchanger is atmospheric (O psi gauge pressure).Tighten the heat exchanger plate pack bolts according to Page 14/16 the manufacturers instructions.Be careful not to strip the bolts.Pump the drained. fluids back into the heat exchanger and vent the air out the piping.Open the waste heat loop valves at the heat exchanger and turn on the waste heat circulating pumps in the school buildings.Inspect the heat exchanger to see if it leaks.Allow the arctic piping loop to come up to operating temperature (REFER TO WASTE HEAT LOOP START-UP PROCEDURES,ABOVE).Open the heat exchanger valves for the engine cooling loop and close the heat exchanger bypass valve.Add proper fluid to the piping loops as necessary to maintain system pressures. If the leak persists it will be necessary to tear-down the heat exchanger to repair the leak.Usually the cause of a leak is a leaking gasket.This is not difficult to repair but does take time.Before dismantling the heat exchanger,have on-hand several plate gaskets and all (6)port gaskets.Mark the leak on the plate with a permanent marker to identify which plate gasket is leaking. Shut down the circulating pumps and close all supply and return valves at the heat exchanger.Drain down the heat exchanger of ail fluids.Prior to disconnecting the piping connections at the heat exchanger follower (back-plate)flush both the inside and outside of the heat exchanger with clean water.To flush the inside of the heat exchanger,connect a hose to the boiler drain at the bottom of one of the heat exchanger ports and run clean water through the heat exchanger until the water is clear and free of glycol (this needs to be done for each of the 3 heat exchanger chambers).Drain all water from the exchanger.Loasen and remove the bolts from the heat exchanger (refer to manufacturers instructions for the proper loosening sequence.)Inspect all the plate gaskets for wear or bulges.Replace Angoon Waste Heat System 11 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:52AM;Page 15/16 ta BeAPr the leaking gasket(s).Prior to reassembling,rinse off all plates and gaskets and ensure the gaskets are clean and in place.Reassemble the plates and tighten according to the manufacturers instructions.Reconnect the piping to the heat exchanger ports and replace the fluid removed from the heat exchanger.Open the valves and bleed the air from the system (Refer to system start-up procedures above for proper system start-up).Inspect for Jeaks. High School Heat Exchanger If the High School heat exchanger starts leaking,inspect the fluid to see if it is ethylene glycol (usually pink or green)or water (clear).If the leaking fluid is ethylene glycol this indicates that the boiler side of the heat exchanger is leaking.If the fluid is water,this indicates that the waste heat loop is leaking If the boiler side is leaking,slowly open the heat exchanger bypass valve and close the building heating loop supply and return valves at the heat exchanger (refer to drawings). lf the waste heat loop side is leaking,shut off the waste heat circulating pump and close the heat exchanger valves on the waste heat supply and return valves at the heat exchanger.(Refer to Power Plant Heat Exchanger repair section above for information on trouble shooting and repairing the heat exchanger.) NOTE: THE WASTE HEAT SYSTEM IN DESIGNED TO REDUCE THE FUEL CONSUMPTION OF THE EXISTING BUILDING HEATING SYSTEMS BY PRE- HEATING THE BUILDING HEATING RETURN FLUID AS IT ENTERS THE BOILER(S).IF THE BUILDING HEATING SYSTEM(S)DO NOT WORK PROPERLY,THE WASTE HEAT SYSTEM WILL NOT WORK PROPERLY. IT IS IMPERATIVE THAT THE BUILDING HEATING SYSTEMS ARE ALWAYS MAINTAINED IN GOOD OPERATING CONDITION.ALSO,THE BOILER SETPOINTS SHOULD BE SET BETWEEN 168 AND 175F SO THAT THE BOILERS WILL MAINTAIN THE REQUIRED BUILDING HEATING LOOP TEMPERATURE,AND NOT BACK FEED THE WASTE HEAT SYSTEM. Angoon Waste Heat System 12 Operations and Maintenance Manual -DRAFT Sent By:AEE;907 349 8001;Jan-28-99 10:52AM; i é Page 16/16 °EQUIPMENT DIRECTORY HEATING: Air Vents Maid-O-Mist #75,or equal Amot Valve 4BOCF-180-01 Arctic Pipe 1.C.Moller Expansion Tank: High School Waste Heat Loop UNKNOWNGlycol:DRA aiArcticPipingLoopPLAINWATERa Power Plant Cooling Loop REFER TO THREA Heat Exchangers: Power Plant:APV Crepaco SR- High School APV Crepaco SR-25 Pressure Gauge Pressure Relief Valve Pumps: WASTE HEAT PUMPS Thermometers Thermometer Well Valves: Ball Butterfly(should be "lug"style) Gate Circuit Balance Angoon Waste Heat System Trerice 600C or Equal Watts 174 &740 Grundfos UP43-75F Trerice BB560205AA Trerice 76-D42 Brass 2 1/2" Crane Capri No.9302,or equal Crane Monarch No.23,or equal Crane Class 150,No.1334,or equal Armstrong CBV,or equal Operations and Maintenance Manual -DRAFT 13