Professional Documents
Culture Documents
ER-670
Research Project 580
Topical Report, February 1978
Prepared by
q
HOLT/PROCON
(A Joint Venture of The Ben Holt Co. and Procon Incorporated)
201 South Lake Avenue
Pasadena, California 91101
Principal Investigators
Ben Holt
Edward L. Ghormley
DISCLAIMER
This report was prepared as an account of work sponsored by an
agency of the United States Government. Neither the United States
Government nor any agency Thereof, nor any of their employees,
makes any warranty, express or implied, or assumes any legal
liability or responsibility for the accuracy, completeness, or
usefulness of any information, apparatus, product, or process
disclosed, or represents that its use would not infringe privately
owned rights. Reference herein to any specific commercial product,
process, or service by trade name, trademark, manufacturer, or
otherwise does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any
agency thereof. The views and opinions of authors expressed herein
do not necessarily state or reflect those of the United States
Government or any agency thereof.
DISCLAIMER
Portions of this document may be illegible in
electronic image products. Images are produced
from the best available original document.
d
F
LEGAL NOTICE
This report was prepared by Holt/Procon (a Joint Venture of The Ben Holt Co. and
Procon Incorporated), as an account of work sponsored by the Electric Power Research Institute, Inc. (EPRI). Neither EPRI, members of EPRI, Holt/Procon, nor
any person acting on behalf of either: (a) makes any warranty or representation,
express or implied, with respect to the accuracy, completeness, o r usefulness
of the information contained in this report, or that the use of any information,
apparatus, method, or process disclosed in this report may not infringe privately
owned rights; or (b) assumes any liabilities with respect to the use of, or
for damages resulting from the use of, any information, apparatus, method, or
process disclosed in this report.
ABSTRACT
This report presents a preliminary design of a 50 %IWe Geothermal Demonstration
Plant for Heber, California. The report includes a site description, design
basis, process design, trade-off studies to optimize plant operations, and an
economic analysis of the plant.
The plant design provides flow diagrams and equipment specifications for the
"a\
energy conversion system, the cooling water system, the plant and instrument
air system, the flare system, the firewater system, the electrical system, the
piping system, instruments and controls, and buildings and structures.
iii
L,
TABLE OF CONTENTS
Page
-
Section
._
SUMMARY
1-1
INTRODUCTION
2-1
DEVELOPMENT OF DESIGN
3-1
SITE DESCRIPTION
DESIGN BASIS
PROCESS DESIGN
TRADE-OFF STUDIES
ECONOMIC ANALYSIS
3-1
FIGURE 3-1
FIGURE 3-2
FIGURE 3-3
TABLE 3-1
TABLE 3 - 2
TABLE 3-3
3-3
3-5
3-10
3-17
.-
3-20
3-21
3-22
3-23
3-24
3-25
3-26
3-27
3-28
BINARY PROCESS
DIAGRAM GEOTHERMAL DEMONSTRATION
START OF RUN
BINARY PROCESS FLOW
3-29
3-30
TABLE OF CONTENTS
Page
Section
,
4-1
DESCRIPTION OF FACILITIES
PLANT LAYOUT
ENERGY CONVERSION SYSTEM
COOLING WATER SYSTEM
PLANT AND INSTRUMENT AIR SYSTEM
FLARE SYSTEM
FIRE WATER SYSTEM
ELECTRICAL SYSTEM
4-2
4-3
4-5
4-6
4-7
4-8
4-9
PIPING
4-9
4-10
4-12
4-15
4-19
4-17
4-21
4-23
4-25
vi
4-27
4-29
TABLE OF CONTENTS
Page
-
Section
4 (Cont.)
4-31
4-33
4-35
4-37
4-39
4-41
4-43
4-45
4-47
5-1
EQUIPMENT SPECIFICATIONS
EQUIPMENT LIST
5-1
VESSELS
HEAT EXCHANGERS
PUMPS
COOLING TOWER
COMPRESSOR
TURBINE/GENERATOR
5-11
5-14
5-17
5-27
5-28
5-29
vi i
Section 1
SUMMARY
Chevron Oil Company (the field operator) predicts that the reservoir
ill decline from an initial mperature of 182 C (360 F) to a
ture of 162 C (325 F
eriod of 25 years at a production
rate of 200 MWe. Accordingly, th
t has been designed so that it may
economically be modified to accommodate the increased brine
lation at the lower reservoir
and increased working fl
temperature while still maintaining a net output of 50 W e .
1-1
selected for the initial operating conditions. When the fluid temperature
declines to 174 C (345 F), the working fluid is changed to a hydrocarbon
mixture containing 10 percent propane and 90 percent isobutane. This fluid
will operate efficiently in the temperature range from 174 C (345 F) to 162 C
(325 F ) .
An
1-2
L,
U
mid-range plant operating condition. Piping and instrumentation diagrams
have been revised and expanded to reflect the improved plant design. Preliminary piping layout drawings have been prepared and, as a result of these
studies, the plot plan has been enlarged to provide space for future equipment
additions and the large interconnecting pipelines.
Electrical single-line drawings have been revised to reflect the latest plant
configuration. Equipment specifications have been modifed to meet the requirements of the new hydrocarbon mixture working fluid. Preliminary layouts and
specifications have been prepared for the buildings and structures at the
site.
Material and installation specifications have been prepared for piping,
electrical equipment, buildings, and standard construction procedures.
An implementation plan for the design and construction of the plant has been
0
0
The preliminary environmental assessment was revised and updated to show the
effect of construction of a single 50 MWe geothermal plant, and the effect
of 4000 MWe of geothermal capacity would affect the Imperial Valley, and the
Heber area in particular. The environmental assessment is presented in
separate volumes.
1-3
Section 2
INTRODUCT101
The subject feasibility study for a low salinity hydrothermal demonstration
plant consists of a series of tasks divided in two parts. Part A, entitled
Feasibility Analysis Tasks, was completed at the end of April, 1976 and submitted in a series of draft reports listed as follows:
0
0
0
e
0
The conclusions reached as a result of the Part A studies were that the Heber
reservoir in the Imperial Valley is the preferred location for a demonstration
plant,
that the binary cycle is the preferred process, that a 50 MWe plant is
the preferred size, and finally that the proposed project is feasible from a
geotechnical, technical
c
TASK B-5
Environmental Assessment
2-1
Volume I
Volume I1
Volume I11
Volume I V
Appendices
f i n a l i z e d a s a p a r t of our P a r t B tasks.
In preparing t h e Preliminary Design Manual we have focused our a t t e n t i o n on
t h e power generation plant and have l e f t a similar design e f f o r t covering t h e
f i e l d i n s t a l l a t i o n t o a l a t e r date.
This manual contains the following technical r e p o r t s required by EPRI under
Task B-1:
0
Trade-off s t u d i e s
Equipment specifications
2-2
Section 3
DEVELOPMENT OF DESIGN
SITE DESCRIPTION
Location
The Heber geothermal f i e l d i s located a t t h e southern end of Imperial County,
California, approximately 6 km (4 miles) north of t h e United States/Mexico
border, 8 km (5 miles) southeast of t h e City of E l Centro, and 2 km (1 mile)
south of t h e City of Heber.
24,000 M
(6 acres).
4 o f - t h i s report.
3-1
The
Climate
The climate of t h e Heber area, l i k e t h e e n t i r e Imperial Valley, i s hot and
dry.
west.
Topography
The plant s i t e i s on generally l e v e l a g r i c u l t u r a l land approximately 5 f e e t
below sea l e v e l . The t e r r a i n slopes gently downward t o t h e north toward t h e
Salton Sea. Drainage i s provided by t h e New and Alamo Rivers and an extensive
network of manmade a g r i c u l t u r a l drains.
Geology and S o i l s
The upper 15 cm (6 inches) of s o i l i n c u l t i v a t e d areas i s highly organic, with
underlying s o i l of f i n e textured clays which are expansive when wetted.
allowable s o i l bearing pressure i s 7,200 kg/m
The
(1,500 p s f ) .
Imperial County i s located within Seismic Zone 3, f o r which a design accelerat i o n of 0.25g i s recommended by t h e Uniform Building Code.
However, because
site.
canals.
3-2
LiJ
L,
A light-duty paved road runs north/south along the east boundary of the plant
site. Also, a Southern Pacific railroad track running north-northwest/southsoutheast lies within 1 km east of the plant site. Rail sidings presently
exist at Heber, 2 km to the north.
Transmission Lines
The Imperial Irrigation District plans to build a 33 kv substation near Heber,
about 2 km north of the plant site. A 33 kv transmission line would be built
by Imperial Irrigation District from the plant substation to the substation at
Heber to carry electrical energy in and out of the geothermal demonstration plant.
DESIGN BASIS
The previously reported feasibility studies showed that it would be technically and economically feasible to build a demonstration plant at Heber,
sing the binary conversion process to generate electric power.
d that the plant should be built in the range of SO W e electrical capacity in order that the cost of power produced from the plant would
methods of generating electric
ompetitive with
2
reported to hav
y has predicte
u
3-3
The f i e l d
Temperature, F
Fouling Factor
176 t o 132
132 t o 80
80 t o 65
350 t o 270
270 t o 176
176 t o 148
,0001
.OOll
.0033
t h e S t a t e Energy Commission.
The previous exchanger t e s t s were conducted using titanium, 90% cupro nickel
and mild steel exchangertubes.
It is
was negligible.
Lid
3-4
LiiJ '
The development of a process design for a geothermal project is an evolutionary one. Initially the problem is loosely specified and there are
numerous alternatives. As the project proceeds, more data are made available
and alternatives are eliminated so that the design can be refined. The final
design is a product that is achieved by successive improvements in the
original design premise.
Preliminary geological data and modeling indicate that if the reservoir is
produced at a rate of 200 W e , the temperature is expected to decline uniformly over a period of about 25 years to a value of about 163 C (325 F). A
single plant design would not operate efficiently at both 182 C (360 F) and
163 C (325 F). The task, therefore, was to find a sequence of processes
which would allow generation of the required electrical power over the desired
brine temperature range from minimum modification to the original plant configuration. A large number of configurations were studied to this end. A
wide spectrum of aliphatic hydrocarbon fluids including pure hydrocarbons
and mixtures of two and three hydrocarbons were analyzed at various temperaand pressures. A number of otherwise promising cycles were dropped from
consideration when it was discovered that expansion of the fluid passed into
the two-phase region, making the successful operation of present-day turbines
doubtful. Other good cycles were bypassed because they would have necessitated major changes in the plant equipment or would not have efficiently
ized equipment available from an earlier stage in the plant lifetime.
3-5
Figure 3-1 provides a summary of the procedures which led to the selection of
the final process design. This figure shows graphically the relationship
between reservoir temperature and net power output for a number of working
fluid compositions. Each of these curves has been optimized with respect to
turbine inlet pressure and temperature.
Curve A represents the thermodynamic performance of the best fluid for the
start-of-run conditions as a result of the initial study for the Energy
Conversion Study. This cycle is favored at 182 C (360 F) but the performance
drops off sharply at lower temperatures. Likewise, Curve B shows the performance of the preferred end-of-run case in the Energy Conversion Study.
3-6
Li
This cycle, which is optimum for 163 C (325 F), performs poorly at higher
temperatures. Curve C shows the performance of the 6est three-component cycle
that we studied. It shows significantly lower performance than most of the
two-component cycles. Curve D illustrates the performance of the best case
we found in our study. However, it was rejected because the expansion would
have precipitated excessive liquid in the turbine. (Parenthetically, it
appears that the development of a turbine capable of operating in the twophase region without loss of efficiency is a worthwhile objective.)
The process design of plants for mid-run and "off design" conditions involves
a great deal of complexity. First, the design must be optimum at the given
brine temperature of interest. Second, the process must perform well at
brine temperatures on either side of the optimum. Third, the cycle must
llmeshll
with cycles on either side. This means that flow rates, operating
pressures, heat exchanger surface areas, etc. must be consistent so that in
operating a geothermal plant, a smooth transition can be made from one
process to the next. It was found that the entire desired operating range from
182 C (360 F) to 163 C (325 F) could be accommodated by two cycles with a
switchover occurring when the brine was at 174 C (345 F).
Curves E and F show the performance of the two cycles for the start-of-run
and end-of-run designs which were finally adopted. The discontinuity of
these curves at 174 C (345 F) is an artifact of the assumptions used in the
surface requirements for the
In actual practice, the heat exc
g brine temperature due to a
-run case actually decrea
in the log-mean t
difference (LMTD).
Since the
will not be reduced in size from the initial installation,
the lower temperatures, an excess of hea
sfer surface.
a more effective utilization of the brine
will allow a
rs as heat ex
temperature approach was also investigated. These studies are described in
detail in the section of this report dealing with the trade-off studies.
3-7
182 C (360 F)
3.05 x 106 kg/hr (6.72 x 106 lbs/hr)
6
6
3.49 x 10 kg/hr (7.69 x 10 lbs/hr)
61 W e
11 MWe
50 MWe
The hydrocarbon liquid is preheated and vaporized by heat exchange with the
brine reservoir fluid at a pressure of 3447 kPa (500 psia) and to a temperature of 146 C (295 F). The super-critical vapor drives an expansion turbine
connected to an electrical generator. Exhaust vapor from the turbine is condensed in a group of water-cooled exchangers and collected in accumulators.
The liquid hydrocarbon is pumped at elevated pressure back through the heat
exchangers, completing the cycle.
As the geothermal reservoir is produced continuously for a number of years,
the brine temperature will decrease. Above 174 C (345 F) brine flow to the
plant will be increased as brine temperature drops, but the working fluid
cycle will remain unchanged. At about 174 C (345 F) economic considerations
require a change in working fluid composition and other design parameters.
3-8
LJ
LJ
W
e s e l e c t e d a hydrocarbon mixture consisting of 10%propane and 90% isobutane
f o r t h e middle-of-run condition.
Perti-
174 C (345 F)
6
3.48 x 10 kg/hr
Flow Rate
(7.66 x
lo6
lbs/hr)
90% isobutane
(Mole basis)
10%propane
6
4.09 x 10 kg/hr
6
9.03 x 10 lbs/hr)
Flow Rate
Gross Generator Output
65 MWe
In-plant Load
15 MWe
-
N e t Power Output
50 M
W
e
add equipment.
be required.
brine circulation.
be necessary.
The middle-of-run f l u i d can be used f o r t h e remainder of t h e p r o j
u n t i l t h e r e s e r v o i r temperature declines t o 163 C (325 F).
As t h e r e s e r v o i r
3- 9
ti
However, the rate of circu-
TRADE-OFF STUDIES
Sufficient design work was performed in Part A of this project to show that
the binary process was the optimum process for generation of power at the
Heber reservoir. In Part B of this project detailed trade-off studies have
been performed to define the effect of the following variables on the cost
of power produced:
0
0
0
0
0
Method of Approach
Each of the above variables was studied over the expected range of operating
feasibility. The method of approach was to estimate capital and operating
costs for the plant and for the field installation at each assumed condition.
These costs were then used as input data to the economic analysis program
developed as part of the Energy Conversion Study. The selected variable
which gave the lowest power cost was deemed to be the optimum.
To obtain estimates of plant costs, the following sections of the cost estimate presented in the Energy Conversion Study were selected for estimation:
major equipment, concrete, piping and electrical. The other sections, site
preparation, structural, instrumentation, insulation and painting are relatively insensitive to changes in process conditions and are assumed to be
constant.
3-10
Costs of production, i n j e c t i o n
The c o s t s of production
Only
I t is
t o be noted t h a t t h e t o t a l estimated power c o s t s i n t h e s e t a b l e s are somewhat lower than t h e power c o s t s calculated f o r t h e preliminary design presented i n t h i s r e p o r t .
en t h e b r i n e and t h e working f l u i d
p e r a t u r e differences of 5.5 C (10 F),
3-11
As
Ld
Power conver-
However, designing
These changes a f f e c t e d s i g n i f i c a n t l y t h e c o s t
The
3-12
The n e t
Lid
The reduction in the turbine outlet temperature from 56.1 C (133 F) to 54.4 C
(130 F) increases the power output from every pound of working fluid used,
causing a 4 percent reduction in both hydrocarbon circulation and brine rate.
The cooling water circulation drops by 5.4 percent. As shown in Table 4,
these changes have relatively little effect on related equipment costs. At
the same time, the closer approach to wet bulb causes the cooling tower cost
to increase 65 percent, from $1,000,000 to $1,650,000. The net effect is a
significant increase in plant cost and a slightly more than compensating
decrease in field cost. We conclude that the small saving (0.14 mills/kwh)
3-13
This
However, t h e b r i n e
This increment i s
rise.
c i r c u l a t i o n pumps.
S e r i e s and/or p a r a l l e l flow
Number of pumps
3-14
Piping schematics
A b r i e f description of t h e a l t e r -
n a t e s follows:
Alternate I,
Alternate 11,
Alternate 111,
one motor d r i v e
Alternate I V ,
Alternate V,
(a)
(b)
3-15
turbine-expander
98 percent, pump t u r b i n e d r i v e r s
85
approximately 83
Following is
cost
4,665,000
IV
4,749,000
4,777,000
I11
4,885,000
I1
5,024,000
3-16
F l e x i b i l i t y is a l s o limited
This sec-
Capital Cost
?
The estimated
3-17
c,
0
This estimate, like the earlier one, is for a battery limits plant. Excluded
from the cost are the following:
0
0
before, the estimate assumes that the project will be completed by late
1979 and escalation is estimated on this basis.
As
Cost of Power
The performance of the plant has been improved slightly over the base case
that was reported in.the Energy Conversion Study. As a result, the geothermal
fluid requirement of the plant is reduced, and consequently, the fuel cost
at the plant is reduced. Because of the increase in capital, the
3-18
conversion cost increases over the base case. A comparison of the base case
and the preliminary design case is as follows:
Cost of Energy
Cost of Power Conversion
Cost of Transmission
Total Cost
This Case
Mi11s/kwh
16.53
19.03
0.28
35.84
Base Case
Mi11s/kwh
16.60
18.25
0.28
35.22
3-19
B
C
D
E
F
Li
50/50 ISOBUTANE-ISOPENTANE
35/55 PROPANE-ISOBUTANE
20/60/20 PROPANE-ISOBUTANE-ISOPENTANE
80/20 ISOBUTANE-ISOPENTANE
80/20 ISOBUTANE-ISOPENTANE
10/90 PROPANE-ISOBUTANE
165
170
175
I
180
330
Figure 3-1.
340
350
360
CAPACITY:
9700 GPM
CAPACITY
ALTERNATE
ALTERhlAE
9700 GPM A
ALTERNATE Ill
II
4r
1252 GPM
CAPACIT*
ALTERNATE
fi
CAPACITY:
145006PI.l
CAPACITY: Id500 0PI.l
boooclp
ALTEKNATE
Figure 3-2.
3-21
CUSTOMERElectric
LOCATION-
REV. NO.
ACCOUNT
Materials
Subcontract
Labor
DATE 10/1/76
TOTAL
Pressure Vessels
1600 Boilers
1'100 Cooling Towers
I800 Turbine-generator
1900 Water Treatment
350,000
34,000
8,904,000
568,000
1,500,000
512,000
1,184,000
169,000
400,000
r O T A L CONSTRUCTION ITEMS
I I R E C T F I E L D COSTS
ndirect Field Costs (DE. 2)
r O T A L F I E L D COSTS
2,710,000
3,814,000
964,000
7,488,000
11,614,000
4,998,000
1,107,000
329,000
11,943,000
4 998,000
17.719.000
2,356,000
2,68 5,000
3,463,000
20,404,000
3,119,000.
23,523,000
iU6-TOTAL
535,000
229,000
72,000
114,000
14,000
:.
I200
10,231,000
84,000
46,000
Painting
143,000
600,000
'75,000
1,900,000
490,000
78,000
102,000
I600 Electrical
I700 Insulation
I800
1,150,000
3,593,000
201,000
134,000
143,000
384,000
1,272,000
2,129,000
584,000
600,000
75,000
1,900,000
490,000
276,000
162,000
1,144,000
143,000
r O T A L MAJOR EQUIPMENT
Concrete
1,144,000
1,150,000
Labor
Freight
3200
230,000
3,252,000
3,593,000
201,000
134,000
2800 Other
3100
230,000
3,252,000
711,000
+ contingency
2,700,000
Escalation
2,700,000
r O T A L SELLING PRICE
29.634.000
Figure 3-3.
3-22
U
Table 3- 1
PINCH POINT
8 . 3 C (15 F)
11.1 C (20 F)
3,076 (6,781)
3,245 (7,155)
3,639 (8,023)
3,639 (8,023)
3,447
(500)
3,447
(500)
149
(300)
149
(300)
458
(66.4)
458
(66.4)
68
(154)
68
(154)
32
(90)
26.96 (118.72
173
164
1,570
1,080
815
1,310
1,310
1,310
613
613
613
190
TOTAL
32
(90)
26.96 (118.71
253
253
253
1,050
1,050
1,050
3,590
3 ,590
3,590
362
362
362
2,419
2,419
2,419
1,775
1,775
1,775
26,720
25,950
25,540
11,460
11,800
12,210
17.60
17.16
16.92
15.22
15.90
16.57
32.82
33.06
33.49
3-23
Table 3-2
EFFECT OF CONDENSER LOG MEAN TEMPERATURE DIFFERENCE ON POWER COST
(lo3
lbs/hr)
(lo3
gpm)
6.1 C (11 F)
11.7 C (21 F)
2,924 (6,447)
3,233 (7,127)
3,580 (7,8921
3,491 (7,696)
3,842 (8,470)
4,253 (9,376)
3,447
(500)
3,447
(500)
3,447
(5001
149
(300)
149
(300)
149
(300)
430
(62)
495
(72)
568
(82)
67
(152)
70
(158)
73
(164)
32
(90)
25.68 (113.1)
32
(90)
28.76 (126.7)
32
(90)
32.24 (142.0)
175
177
188
1,160
1,200
1,290
1,810
994
723
550
643
660
253
280
280
1,050
1,150
1,300
3,580
3,610
3,640
374
392
2,399
2,450
2,472
1,725
1,775
1,795
26,590
26,040
26,210
11,460
12,210
12,950
17.49
17.24
17.41
15.20
16.55
18.03
32.69
33.79
35.44
36 1
TOTAL
17.2 C (31 F]
3-24
Table 3-3
EFFECT OF COOLING TOWER APPROACH TO WET BULB TEMPERATURE ON POWER COST
APPROACH TO WET BULB TEMPERATURE'l)
MEAN TEMPERATURE DIFFERENCE IN CONDENSER(^)
PLANT OPERATING CONDITIONS
BRINE RATE, lo3 kg/hr (lo3 l b s / h r )
HYDROCARBON(3) CIRCULATION RATE, lo3 kg/hr(103 l b s / h r )
TURBINE INLET - PRESSURE, kPa (psia)
- TEMPERATURE, C (F)
TURBINE OUTLET - PRESSURE, kPa (psia)
- TEMPERATURE, C (F)
COOLING WATER - TEMPERATURE, C (F)
- CIRCULATION RATE, lo3 m3/hr (103 gpm)
PLANT CAPITAL COST, K $
MAJOR EQUIPMENT (MATERIAL)
HYDROCARBON ACCUMULATORS
BRINE/HYDROCARBON EXCHANGERS
HYDROCARBON CONDENSERS
HYDROCARBON CIRCULATION PUMPS
COOLING WATER CIRCULATION PUMPS
COOLING TOWER
TURBINE-GENERATOR
CONCRETE (LABOR AND MATERIAL)
PIPING (LABOR, MATERIAL AND SUBCONTRACT)
ELECTRICAL (MATERIAL AND SUBCONTRACT)
TOTAL
5.5 C (10 F)
4.4 C (8 F)
2.8 C (5 F)
5.5 C (10 F)
6.1 C (11 F)
6.6 C (12 F)
2,748' (6 ,059)
2,741 (6,043)
2,732 (6,024)
3,754 (8,276)
3,447
(500)
3,744 (8,255)
3,447
(500)
3,732 (8,228)
3,447
(500)
(310)
154
384
(56)
384
(56)
56
(133)
56
(133)
(310)
154
384
(56)
56
(133)
154
32
(90)
21.26 (93.61)
31
(88)
19.73 (86.86)
(310)
29
(85)
17.73 (78.08)
205
201
201
1,900
1,890
1,890
1,950
1,770
1,570
643
643
643
201
200
151
1 ,000
1,370
1,600
3,580
3,580
3,570
362
382
426
2,379
2,353
2,304
1,725
1,725
1,715
27,910
28,160
28,090
14.54
14.54
14.54
32.86
32.99
32.94
ENERGY
TOTAL
3-25
Table 3-4
TEMPERATURE, C (F)
TURBINE OUTLET - PRESSURE, kPa (psia)
- TEMPERATURE, C (F)
COOLING WATER - TEMPERATURE, C (F)
- CIRCULATION RATE, 103 m 3/hr (103 gpm)
PLANT CAPITAL COST, K $
MAJOR EQUIPMENT (MATERIAL)
HYDROCARBON ACCUMULATORS
BRINE/HYDROCARBON EXCHANGERS
HYDROCARBON CONDENSERS
HYDROCARBON CIRCULATION PUMPS
COOLING WATER CIRCULATION PUMPS
COOLING TOWER
TURBINE-GENERATOR
CONCRETE (LABOR AND MATERIAL)
PIPING (LABOR, MATERIAL AND SUBCONTRACT)
ELECTRICAL (MATERIAL AND SUBCONTRACT)
TOTAL
FIELD CAPITAL COST, K $
TOTAL
POWER COST, mills/kwh
CONVERSION AND TRANSMISSION
ENERGY
TOTAL
5.5 C (10 F)
4.4 C (8 F)
2.8 C (5 F)
56.1 C (133 F
55.5 C (132 F
54.4 C (130 F
2,748 (6,059)
2,719 (5,994)
2,639 (5,817)
3,754 (8,276)
3,689 (8,133)
3,594 (7,924)
3,447
(500)
3,447
(500)
3,447
(500)
154
(310)
154
(310)
154
(310)
384
(56)
374
(54)
358
(52)
56.1
(133)
55.5
(132)
54.4
(130)
32
(90)
21.26 (93.61)
31
(88)
20.80 (91.60)
205
201
197
1,900
1,850
1,750
1,950
1,920
1,880
643
643
608
201
201
200
1,000
1,200
1,650
3,580
3,580
3,570
362
386
443
2,379
2,373
2,373
1,725
1,725
1,715
27,910
28,130
28,660
11,050
11,050
10,640
18.32
18.43
18.71
14.54
14.52
14.01
32.86
32.95
32.72
3-26
29
(85)
20.12 (88.60)
Table 3-5
lbs/h
COOLING WATER
(lo3
TEMPERATURE, C (F)
- TEMPERATURE, C (F)
CIRCULATION RATE,
lo3
m3/hr
(lo3
gp
6.1 C (11 F)
11.7 C (21 F)
18.3 C (33 F)
3,082 (6,795
3,076 (6,781)
3,175 (7,000)
3,665 (8,080
3,639 (8,023)
3,784 (8,343)
3,447
(500
3,447
(500)
3,447
(500)
149
(300
149
(300)
149
(300)
432
(63
458
(66)
501
(73)
67
(152
68
(154)
70
(158)
32
(90
32
(90)
32
(90)
52.01 (229.0
26.96 (118.7)
17.54 (77.22)
175
173
179
1,120
1,080
1,140
1,300
1,310
1,470
643
613
643
506
253
151
1,450
1,050
800
3,610
3,590
3,570
409
362
335
2,777
2,419
2,271
1,855
1,775
1,715
TOTAL
28,310
25,950
25,250
OTAL
11,800
11,800
12,210
18.49
17.16
16.77
15.90
15.90
16.46
34.39
33.06
33.23
D TRANSMISSION
k,
3-27
Table 3-6
ALTERNATE I
ALTERNATE I1
ALTERNATE II I
683,000
$1,001,000
$1,247,000
3,590,000
3,590,000
3,418,000
3,374,000
3,590,000
122,000
97,000
62,000
189,000
106,000
INSTRUMENTATION
4,000
2,000
19,000
21,000
2,000
PI
53,000
39,000
39,000
55,000
48,000
372,000
331,000
135,000
176,000
380,000
$4,824,000
$5,060,000
$4,920,000
$4,799,000
$4,708,000
PIPING
w
I
ALTERNATE IV
984,000
ALTERNATE V
582,000
N
or,
CIVIL
ELECTRICAL
TOTAL
111
NOTES :
ALTERNATE
ALTERNATE
ALTERNATE
ALTERNATE
ALTERNATE V
(b) motor driven vertical pump in series with turbine driven horizontal pump
motor driven vertical pump in series with motor driven horizontal pump, two systems in parallel
Revision [I] (25 Oct. 76)
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MIDDLE OF RUU
Section 4
DESCRIPTION OF FACILITIES
The following features of the geothermal conversion plant are described in
this section:
Plant layout
Energy conversion system
Cooling water system
Plant and instrument air system
Flare system
Fire water system
Electrical system
Piping
Instrumentation and control
Building and structures
The following preliminary design drawings are included as a part of the report.
Plot plan
Piping and instrumentation diagrams for the following systems:
4- 1
PLANT LAYOUT
The p l o t plan f o r Heber i s shown i n Drawing No. 7523-E-3242.
d i r e c t i o n shown on t h i s drawing i s a plant-north.
The tlNorthll
The a c t u a l o r i e n t a t i o n of
The p l a n t has been arranged t o allow f o r maximum f l e x i b i l i t y as p l a n t modifications a r e required t o accommodate a reduction i n geothermal f l u i d temperature
over t h e p l a n t l i f e t i m e .
Pipe
Where p o s s i b l e a symmetrical layout has been observed c o n s i s t e n t with t h e funct i o n a l requirements of t h e equipment.
4-2
system
The reser-
tion.
Specifications f o r t h e major exchangers are included i n Section 5.
The brine/
("C),
[250 BTU/(hr)
(ft2)
(OF)].
I t i s anticipated t h a t t h e
provided.
The working f l u i d i s va orized i n t h e exchangers and flows t o the turbine.
The t u r b i n e w i l l be an a x i a l o r r a d i a l flow u n i t with an expected e f f i c i e n c y
of 85 percent.
vided i n Section 5 .
From our contacts with t u r b i n e manufacturers, w e expect t h a t it w i l l be possi b l e t o provide a turbine which w i l l meet beginning and end-of-run conditions
with minor o r perhaps no modifications.
LJ
The hydrocarbon condensers are fixed-tube sheet design desuperheating condenConstruction i s TEMA-C and material
Vertical design
satisfies t h e NPSH and head requirements f o r t h e hydrocarbon f l u i d operating
t h e v e r t i c a l pumps.
between a l l of t h e v e s s e l s .
A pump out compressor with suction knockout drum i s provided f o r hydrocarbon
4 -4
1 p a r a l l e l l i n e of 4 u n i t s i n
series
ti
Hydrocarbon Condensers
-1 exchanger s h e l l i n p a r a l l e l
Hydrocarbon c i r c u l a t i o n pumps
-1 pump i n p a r a l l e l
No f u r t h e r changes w i l l
be required a t t h e end-of-run as t h e b r i n e temperature decreases t o 163 C a t
t h e end-of-run.
Design pressures of a l l s t a r t - o f - r u n equipment w i l l meet f o r
I
throughout t h e p l a n t l i f e t i m e . Additional piping, instrumentation and e l e c t r i cal m a t e r i a l required f o r t h e equipment w i l l be added when t h e middle-of-run
change over occurs.
COOLING WATER SYSTEM
The cooling water system i s shown on piping and instrument flow sheet No. 7523E-3246.
sand f i l t e r , f a c i l i t i e s t o add a c i d , chlorine, corrosion i n h i b i t o r , and dispers a n t , and an automatic control t h a t monitors and maintains t h e q u a l i t y of t h e
c i r c u l a t i n g water.
S p e c i f i c a t i o n s , Section 5 of t h i s r e p o r t .
An induced d r a f t cooling tower has been selected.
ell.
I t w i l l c o n s i s t o f seven
As t h e b r i n e temperature
cells t o t h e
4-5
As t h e b r i n e temp-
The make-
Corrosion i n h i b i t o r and a
The plant and instrument a i r system is shown on piping and instrumentation flow
sheet No. 7523-D-3221.
ment a i r .
I
a i r system should f a i l .
The instrument a i r compressor w i l l have non lubricated pistons t o prevent o i l
contamination of t h e instrument a i r system.
4 -6
materials. The a i r i s then d r i e d t o a -4OC dewpoint i n regenerative s o l i d desiccant beds, and f i l t e r e d before being used.
The plant a i r system i s similar t o t h e instrument a i r system except t h a t t h e
conpressor i s of t h e lubricated type, and no a i r dryer i s provided.
FLARE SYSTEM
D
as a packaged u n i t .
A f l a r e system has been provided t o burn any hydrocarbon vapors escaping
The vapors w
The vapors
start t h e p i l o t i g n i t i o n
he 43 meter (140 f o o t )
c
y during emergencies
a i r blowers a t t h e stack
base was not considered j u s t i f i a b l e .
ispersion of t h e gaseous
e f f l u e n t s , such t h a t ground level concentrations of any p o l l u t a n t generated
w i l l be below regulatory l i m i t a t i o n s .
4-7
To prevent accumulation o f hydrocarbons heavier than air, a hydrocarbon analyzer with alarm mounted on t h e control panel, w i l l be i n s t a l l e d a t t h e foot of
t h e flare stack.
of p o t e n t i a l f i r e areas.
Consequently, t h e
condenser-accumulator section.
o f t h e plant.
To insure an appropriate f i r e water coverage throughout t h e p l a n t , t h e system
storage area.
The f i r e water supply i s taken from t h e cooling tower basin.
l a s t about t h r e e hours a t t h e maximum f i r e water flow rate
This supply w i l l
without make-up.
The rate of t h e water make-up t o t h e cooling tower i s about equal t o t h e consumption of t h e f i r e water system.
4-8
Li
'6)
ELECTRICAL SYSTEM
3600 RPM, 76.5 MVA synchronus generator produces power a t 13.8 KV.
The power
i s fed t o the 4000 A main switchgear where in-plant power is removed. The n e t
remaining power, approximately 50 MWe, flows through t h e 13.8/33KV main transformer and main breaker t o t h e 33 KV e l e c t r i c u t i l i t y system substation.
480V switchgear.
Two motor control centers, MCC-A and MCC-B are fed from t h e
Power from MCC-A and -B w i l l d r i v e cooling tower fans, water
480V switchgear.
PIPING
The p l a n t s i t e has been divided as shown on Drawing 7523-E-3261 t o designate
piping area locations f o r preparation of piping drawings.
Preliminary piping
plan drawings f o r Areas A, By C, D and F have been prepared, and are shown on
Drawings 7523-E-3262 and 3265 and 3269.
shown on Drawings 7523-E-3268 and 3269.
4-9
LJ
ment locations established during f i n a l design may vary somewhat from those
shown.
i
Ld
4-10
\d
The plant ,instruments and controls are shown by symbol on the Piping and
Instrumentation Flow Diagrams. Drawing No. 7523-D-3258 is provided in this
section to define these symbols.
Instruments for supervision of the plant will be centralized at the main control panel. The panel will have a semi-graphic section with color-coded symbols illustrating the complete process. Indicators, recorders, controllers,
motor control stations, etc., will be arranged logically to facilitate overall
control of the plant operations from this location.
The panel will include an annunciator alarm system connected to a network of
sensors which continuously monitor significant process variables throughout
the plant. If one or more off-normal conditions occur, the system will immediately alert the plant operator (by audible E visible signals) and will identify the type and location of each condition in effect.
comprehensive data logging system has been included to provide a maximum of
information on process variables during plant operation. In addition to aiding
plant operation, the data should prove beneficial in the design or refinements
thereof for future units. The computor data logging terminal is designed so
that it be used for additional geothermal units constructed at the Heber
reservoir.
e electronic with 4 to 20 m
mission signals. Panel mounted instruments for these systems will be miniature
types.
ss instrument systems wil
The control panel will be a vertical free-standing unit of welded steel construction. It will be shop-fabricated and tested completely before shipment
4-11
to the jobsite. No process fluids will enter the panel. Electrical power at
the panel will be limited to nominal 120 volts.
Li
There will be three buildings in the plant. The largest will be the office
and control building measuring 85' x 50' and approximately 15' high. The
interior will be paritioned into a control room measuring 40' x 35', and additional rooms housing the switchgear, office, instrument and electronic maintenance, and laboratory areas. The building will be located next to the
turbine/generator area, will have a door opening to the operating area, and
have windows located so that the operators can maintain visual contact with
the major equipment areas. A heat pump will supply heating and cooling for
all the areas in the building.
the office and control building will have many visitors, special attention
will be given to its appearance through the use of architectural treatment.
As
4-12
The roof
bui 1ding.
A t h i r d building w i l l enclose t h e water t r e a t i n g equipment.
The building i s
ing.
Structures supporting t h e condensers and heat exchangers have been designed
t o d i s t r i b u t e t h e loads a t t h e base t o a maximum of 7320 kg/m
A l l s t r u c t u r e s have been designed
abovegrade. Specifications pertaining t o buildings and structures are contained i n Section 6 of t h i s manual.
4-13
(1,500 l b s / f t ) .
1'
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4-29
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INSTRUMENT SYMBOLS
rnmuuam.
REFERENCE DRAWING
nw
AIR COOLCDUUIT
'eurTWP
Y
iDu)wDowu
RUPWPa DISC
ilU
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IU
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B O A R D HOUUTED INSTRUMCUT
INSTRUMEUT WITH TWO PUUCtK)US
CONTINUOUS
DPAl
PQ
STEAM T R A P
(eIl2,3,PTC. FOR SIZE)
RLVIYI
;SUED FOR
PUMP
ROTARY PUMP
Section 5
EQUIPMENT SPECIFICATIONS
bd
SHEET
EQUIPMENT LIST
E
E
'61
OF
DATE
14
205 A:G
Hydrocarbon Condenser
12
2001 A,B
FS-2001
A/C
REvsion
1400
Flare Stack
203
204
2001)
S-1
.7
OF
SHEET
EQUIPMENT LIST
REVISION
DATE
CT-201
Cooling Tower
A/C
K
K
K
1800
Compressors E Blowers
201
Unloading Compressor
2001.
2002
,--
- .
5-2
SHEET
EQUIPMENT LIST
CONTRACT No.
7523
REVISION
5-3
OF
DATE
3
-~
OF
SHEET
EQUIPMENT LIST
CONTRACT No.
7571
CUSTOMER
REVISION
DATE
Pressure Gage w/
~-~
Pressure Transmi
Pressure Transmit
P r e s s u r e - R A MVal=Pressure Relief Valve,
5-4
SHEET
EQUIPMENT LIST
CONTRACT No.
7523
CUSTOMER
Instrument L i s t
REVISION
OF
DATE
5 -5
SHEET
EQUIPMENT LIST
EOV
Solenoid Valve
REVISION
OF
DATE
i'
c
5-6
SHEET
EQUIPMENT LIST
5-7
REVISION
OF 7
-
DATE
SHEET
EQUIPMENT LIST
7523
CONTRACT No.
CUSTOMER
Instrument List
I .V
I,evel -01
OF
REVISION
DATE
V m , 1-1/2"
Flow
-
FS
AT
~~
__ __
5 -8
SHEET
EQUIPMENT LIST
CONTRACT No.
7523
CUSTOMER
Instrument List
REVISION
OF
DATE
5-9
EQUIPMENT LIST
CONTRACT No.
7523
CUSTOMER
Instrument List
REVOION
DATE
5-10
hd
~~
CODE STAMP
AW
qpCt
VIII
OTHER SPECS.:
DESIGN PRESS.AT TEMP.
OPER. PRESS.
AT
TEMP.
STRESS RELIEVINO
WELD EXAMINATION
1
MARK
NOZZLE SCHEDULE
RATING
SIZE
SERVICE
Nl
N2
18"
18"
150# RF
150# RF
HC In
HC In
4"
150# RF
HC Makeup
1508 RF
PSV
56 PSI AT104 OF
per Code
3000# Cplg I PI
,";y;,";&!
3000# Cplg
3000# Cplrr Level Alan
150# RF
HC Out
-#
REMARKS
RF
Manwav
VESSELS
REMARKS
5-12
VESSELS
VERTICAL VESSEL DESIGN DATA
CODE STAMP ASME Section VI11
OTHER SPECS.:
DESIGN PRESS.AT TEMP. 165PSI AT 450 O F
OPER. PRESS. AT TEMP. 134
PSI AT 120 OF
Per Code
STRESS RELIEVING
WELD EXAMINATION
None
INSULATION
C0RR 0 S ION
ALL0WA NCE
1116"
MATERIALS
SHELL
HEADS
INTERNALS
SUPPORTS
C.S.
LINING
TRAYS
NOZZLE SCHEDULE
610"
SIZE
RATING
N1
3"
150# RF
HC Vapor Inlzt
N2
3"
150# RF
HC Vapor Inlet
N3
1"
E O # RF
Drain
MARK
14 (A,B)
1"
REMARKS
5-13
1 1/4"
FACING
JOB NO.
ITEM NO.
CUSTOM E R
PLANT
7523
E-201A,B
REV. NO.
>
E-204A,B
DATE 7/17/76
QUOTE NO.
REFERENCE
SERIES/PARALLEL
S H E L L SIDE
FLU1D C I R C U L A T E D
TOTAL FLUID ENTERING
TUBE SIDE
VAPOR
I ioiiin
7.687 (10')
Whr
0.550
0.151
C.S.
M O L E C U L A R WEIGHT- VAPORS
61
, SPECIFIC H E A T - LIQUIDS See ent$alpy CUmeS
TEMPERATURE I N
TEMPERATURE O U T
OPERATING PRESSURE
N U M B E R OF PASSES PER S H E L L
VELOCITY
PRESSURE DROP(ALLOW/CALC.)
109
109
-885
0.18
OF
OF
B.T.U. / L B
C.S.8
1 016
OF
B.T.U./LB
109
295
535 ( in1et)
(2) 360
(2) 153
PSlG
138
1
FT./SEC.
(allow 15 max.)
50
PSI
360
360
OF
*F
OF
OF
OF
OF
OF
40
P S 10
FT./SEC.
PSI
F O U L I N G F A C T O R (MIN.)
H E A T EXCHANGED
TRANSFER R A T E S E R V I C E
CLEAN
670
DESIGN P R E S S U R E
T E S T PRESSUR E
360
DESIGN T E M P E R A T U R E
WEIGHTS- EACH S H E L L
REMARKS:
(1) w/o cross
PSlG
PSlG
1 .nns
OF
F U L L OF WATER
BUNDL E
baffles
180
270
360
(2)
5-14
PSI0
PSI6
OF
gor
0
Ip
r-
0
0
-I?
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m
ST-s
PI
JOB NO.
7
5
2
3
CUSTOMER
PLANT
LOCATION
SERVICE
I
(est
-J
i
TUBE SIDE
S H E L L SIDE
FLU1D C I RCUL A T E 0
TOTAL FLUID ENTERING
VAPOR
NON-CONDENS ABL ES
FLUID VAPORJZED OR CONDENSED
7.687(10)
lb/hr
BAFFLE LONG
TYPE
TUBE SUPPORTS
C.S.
GASKETS
001
CONNECTIONS- SHELL- I N
CHANNEL
IN
OUT
CORROSION ALLOWANCE S H E L L S I D E
CODE REQUIREMENTS
WEIGHTS- EACH S H E L L
(11
Cooling Water
20% 1sopentar.e
7.687 (100) lb/hr
67.783 (lob) lb/hr
7.687(10) lb/hr
80% Isobutane
THICKNESS
THICKN E S S
SERIES
150 lb RF
SERIES
150 1b RF
TUBE SIDE
1/16"
TEMA C L A S S
C (1)
F U L L O F WATER
5-16
hd
JOB NO.
CUSTOMER
PLANT&
NO. R E Q U I R E D 6
MOTOR
LOCATION
SERVICE
Hydrocarbon Circulation
P-201A- F
REV. N O . L D A T E 7 -
DRIVEL
QUOTE NO.
TURBINE DRIVE-
5-17
7
5
2
3
ITEM NO.
REFERENCE
E l e w P
PLANT
G e o t h e r m a l o n Plant
Heber , California
Hydrocarbon Makeup
LOCATION
CASING & N O Z Z L E
IMPELLER
I T E M NO.
REV.
MOTORDRIVE
QUOTE NO.
TURBINE DRIVE-
REFERENCE
C.S.
CASE S P L I T
C.I.
SUPPORT
VERTICAL
HORIZONTAL
I M P E L L E R RINGS
STUFF. B O X W A T E R J A C K E T :
MECH. SEAL
Allnv
C.S.
DRIVER DATA
- MOTOR
PHASF
FRAME
DRIVER DATA
nl?
MAKE
TEFC
3
COUPLINGGUARD:
R.P.M.
'
CYCLE
60
lo
3500
VOLTS
MAKE
0 NO
- TURBINE
H.P.
TYPE
WATER RATE
TYPE
0 YES
MAKE
460
R.P.M.
DESIGN LOAD-
LBS/HR.
STEAM I N L E T
P.S.I.G.
STEAM EXHAUST
P.S.I.G.
5-18
N A LANCED-
0 NO
GREASE
F L E X I B L E COUPLING:
BASE P L A T E
0 NO
0 YES
LUBRICATION O I L
PACK ING
SEMI-ENC.
0 YES
BA L A N C E D U
D OU B L E
-
SEAL CAGE
TYPE
CLOSED
XINTERNA
EXTERNAL
SINGLE-
PACKING GLAND
BRACKET
FOOT
C/L
IMPELLER OPEN
SHAFT S L E E V E
~ 0 . 1 ~ ~ ~ ~ 7 / 1 7 / 7 6
NO. REQUIRED-
CASING RING
SHAFT
P-203
BHP.
OF
OF
b,
C-STO~ER
G e o t h e r m a l t r a t ion P1ant
Heber. Cal ifornia
SERVICE
Coolincr Water Circulation
PLANT
NO. REQUIRED-
LOCATION
MOTOR D R I V E
7523
ITEM NO.
P-204AsBsC
re
sp-RJV.
NO.-DATE7117/76
QUOTE
TURBINE DRIVE-
NO.
REFERENCE
DIMENSIt 1 P R I N T
CIRCULAR NO.
JOBNO.
SECTION DWG.
MATERIALS OF CONSTRUCTION
CONSTRUCTION FEATURES
CASE S P L I T H O R I Z O N T A L
CASING 8: N O Z Z L E c
.
I
,
Bronze
Bronze
IMPELLER
CASING RING
SUPPORT
I M P E L L E R OPEN
SHAFT
SHAFT S L E E V E
PACKING G L A N D
Alloy Steel
Bronze
Bronze
MECH. SEAL
SINGLE-
LUBRICATION O I L
F L E X I B L E COUPLING:
BASE P L A T E
COUPLINGGUARD:
- MOTOR
TYPE
DRIVER DATA
H
MAKE
I1
PHASE.~,CYCLE
R.P.M.
60
NET WEIGHT
TYPE
0 NO
H.P.
R.P.M.
LOAD
L B S I H R . BHP.
STEAM I N L E T
P.S.I.G.
OF
STEAM EXHAUST
P.S.I.G.
OF
SHIPPING WEIGHT
LE.
MOTOR
LE.
N B A LANCED
0 NO
- TURBINE
0 YES
MAKE
MAKE
TYPE
585
~ 0 ~ ~ ~ 4WATER
1 6 R0A T E @ DESIGN
FRAME
EXTERNAL
-B A L A NC ED U
0 YES
0 NO
x
GREASE
SEAL CAGE
DRIVER DATA
SEMI-ENG
0 YES
INTERNAL
D OU B L E
PACKING
BRACKET
CLOSED
STUFF. B O X W A T E R J A C K E T :
I M P E L L E R RlNGS-Ze
VERTICAL
FOOT
C/L
t APT h i n 4
5-19
..
LB.
h Insaute
NO REQUIRED
DIRECT ACT1 NG
POWER FRAME
--
7523
P-206
JOB NO.
ITEM NO
REV. NO.
QUOTE NO.
REFERENCE
DATE-
N AVAILABLE
P REOUIRED
S REQUIRED
FT.(liguid)
FT.(liguid)
FT. (woter)
FA1R
NONE
__-
PUMP SPECIFICATIONS
MANUFACTURER
SIZE
DRIVE -LIO.
SPEED
0HP@ DESIGN
CIRCULAR NO.
-STROKE
-EFF.
--
Metering
PUMP TYPE
FT./MIN.
MAX. BHP. REQD
RECOMMENDED DRIVER HI?
DIMENSION P R I N T
SECTION DWG.
CYLINDERS
PISTONS -PISTON RODS
VALVES
MTL.
NO. PISTON RINGS
P I STON PACKING
L I Q U I D CYLINDERS
PISTONS
P I S T O N RODS
VALVES- MTL.
VALVE SEATS
--
MAKE
TYPE
PHASE ,-,CYCLE
HP
R.P.M.
-,VOLTS
TYPE
1/3
,-.
MOTOR
- --
--
TYPE
N E T WEIGHT
PUMP, BASE
--
- FEEDS
LBS/HR.
BHP
-OF
OF
SHIPPING WEIGHT
LB
LB
PUMP,BASE
S p e c i a l Instructions or Features
5-20
LB
JOB NO.
7523
ITEM NO. p-207
REV. NO.
QUOTE NO.
REFERENCE
GENERAL
CUSTOMER Electric Power Research I n s t i t u t e
PLANT G e o t h e r m a l i n n P l a n
NO REQUIRED
DIRECT ACTINGLOCATION H e b e r r C a l l f o r n i a
SERVICE c O O 1 1 - b
POWER FRAME
..
--
LlQUlD PUMPED
CAPACITY, GpH
F ! t , SPGR.
6OoF SF! GR.
N AVAILABLE
P REQUIRED
S REQUIRED
fin
ka
h S
CPS VAF! PR.-RS.I.A.
CPS VAF! PR. -RS.I.A.
VISC.
VISC.
T . PRESSURE -P.S.I.G.
DIFF: PRESSURE -RS.I.
EROSIVE MATERIAL
FT. (water)
BCM.
USERS EXPERIENCE WITH MATERIALS SPECIFIED
GOOD
FAIR
PUMP SPECIFICATIONS
MANUFACTURER
SIZE
SPEED
BHF! G? DESIGN
CIRCULAR NO.
DISCH. P R E S S U R E ~ ~ P . S . I . G
F.P.T.
OF NORMAL --,DESIGN
DATE- 7-17-'
DRIVE
-LIQ. -STROKE
PUMP TYPE
NONE
__-
Metering
FT./MIN. _. EFF.
MAX. BHP. REOD
RECOMMENDED DRIVER HR
DIMENSION P R I N T
SECTION DWG.
TYPE
L I Q U I D CYLINDERS
PISTONS
P I S T O N RODS
VALVES- MTL.
VALVE SEATS
TYPE
-_
DIAMETER RODS
SIZE OF PACKING
PING WEIGHT
PUMP, BASE
MOTOR
LB
-.-
.-
FEEDS
P S IG
GENERAL
N AVAILABLE
P REQUIRED
S REQUIRED
FT.(liguid)
FT.(liguid)
FT.(watrr)
DATE 7- 17 - 7(
GOOD
FAIR
-~
NONE-.
PUMP SPECIFICATIONS
MANUFACTURER
SIZE
PUMP TYPE
--
DRIVE -LIO.
STROKE
SPEED
FT./MIN.
EFF.
MAX. BHP. REQD
RECOMMENDED DRIVER HF!
DIMENSION P R I N T
SECTION DWG.
BHI? DESIGN
CIRCULAR NO.
TYPE
--
--
TYPE
VALVE SEATS
HYDROSTATIC TEST-FLUID
FEEDS
END--PSlG
HP
R.P.M.
V O L T S
LBS/HR.
BHP
OF
L I Q U I D END
S T E A M END
OF
VALVE
RODS
NET WEIGHT
SHIPPING WEIGHT
LB
PUMP, BASE
MOTOR
PUMP,BASE
LB
S p e c l o l lnstructlons
or Feoturas
5-22
LB
CUSTOMER
PLANT
7523
I T E M NO.'
210 A E
Heber, California
Make-up Water
CIRCULAR NO.
MOTORDRIVE
QUOTE NO.
TURBINE DRIVE-
REFERENCE
DIMENSI( 4 P R I N T
MATERIALS OF CONSTRUCTION
CASING e NOZZLE
7-17-76
NO.-DATE-
NO. R E Q U I R E D ~ ( SPS+@V.
~~~
LOCATION
SERVICE
JOBNO.
SECTION DWG.
CONSTRUCTION FEATURES
CASE S P L I T H O R I Z O N T A L
SUPPORT C / L
IMP ELL ER
VERTICAL
F O O T A R A C K E T
CASING RING
I M P E L L E R OPEN
I M P E L L E R RINGS
SHAFT
MECH. SEAL
SHAFT S L E E V E
CLOSED
D OU B L E-B
SINGLE-
0 YES
INTERNAL
0 NO
N B A LANCED ___
0 YES
LUBRICATION O I L
PACKING
EXTERNAL
A LA NC E O U
PACKING G L A N D
SEMI-ENG
0 NO
GREASE
S E A L CAGE
F L E X I B L E COUPLING:
BASE P L A T E
COUPLINGGUARD:
MAKE
0 YES
TYPE
0 NO
_ _ _ _ _ _ ~
DRIVER DATA
MAKE
TYPEPHASE
- MOTOR
TEFC
DRIVER DATA
HJ?
R.P.M.
3C Y C L E -60
75
- TURBINE
MAKE
1200
TYPE
STEAM I N L E T
STEAM EXHAUST
NET WEIGHT
MOTOR
Special Instructions w F e a t u r e s -
R.P.M.
WATER R A T E @ DESIGN L O A D .
VOLTS-
FRAME
H.P.
~
LBSIHR. EHP.
P.S.I.G.
OF
P.S.I.G.
OF
SHIPPING WEIGHT
LE.
LE.
5-23
LE.
JOBNO.
7523
CUSTOMERU~~
ic Power Research Institute
I T E M NO.
p-2001
Binary Process-Geothermal Demonstration Plant
PLANT
NO. REQUIRED
One
REV. NO.-DATELOCATION
Heber. California
MOTORDRIVE
QUOTE NO.
SERVICE
TURBINE DRIVE-
REFERENCE
CONSTRUCTION FEATURES
MATERIALS OF CONSTRUCTION
CASING & N O Z Z L E
IMPELLER
c . s.
CASE S P L I T
c. I.
SUPPORT
VERTICAL
HORIZONTAL
C/L
FOOT
I M P E L L E R OPEN
I M P E L L E R RINGS
STUFF. B O X W A T E R J A C K E T :
A1 lov
SHAFT
MECH. SEAL
SHAFT S L E E V E
SINGLE-
INTERNAL
0N O
EXTERNAL
D OU B L E EA L A N C E D -U
COUPLINGGUARD:
N BA L A N C ED -
0 YES
0 NO
GREASE
F L E X I B L E COUPLING:
r s.
SEMI-ENG ___
0 YES
LUBRICATION O I L
PACKING
S E A L CAGE
BASE P L A T E
PACKING GLAND
BRACKET
CLOSED
CASING RING
MAKE
TYPE
0 YES
0 NO
I
DRIVER DATA
- MOTOR
MAKE
lu?
TYPE-
R.P.M.-
PHASE
FRAME
CYCLE
6o
DRIVER DATA
15.0
VOLTS
460
- TURBINE
MAKE
H.P.
TYPE
R.P.M.
WATER R A T E @ DESIGN L O A D
LBS/HR.
EHP.
STEAM I N L E T
P.S.I.G.
OF
STEAM EXHAUST
P.S.I.G.
OF
5-24
7523
P-2002 IA-C)
IJoBNO.
I T E M NO.
CUSTOMER
- -
- -
PLANT-
Heber. California
LOCATION
QUOTE NO.
REFERENCE
CONSTRUCTION FEATURES
C
T
Bronze
CASE SPL1.T
I M P E L L E R OPEN
I1
VERTICAL
HORIZONTAL
SUPPORT C I L
11
CASING RING
A1 lov
D OU B LE-
BASE P L A T E
COUPLINGGUARD:
SEMI-ENG
0 NO
EXTERNAL
BA L A N C E D U N B A L A N C E D
0 YES
LUBRICATION O I L
0 NO
GREASE
F L E X I B L E COUPLIpJG:
S E A L CAGE
0 YES
PACKING G L A N D
INTERNAL
SINGLE-
SHAFT S L E E V E
CLOSED
WATERJACKET:
I M P E L L E R RINGS
SHAFT
DRIVER DATA
One
ltvfiP!NEhFfw=
MATERIALS OF CONSTRUCTION
PACKING
MOTOR DRIVE
Diesel Enpine
S E R ~ ~ C E Firewater
CASING & N O Z Z L E
IMP ELL ER
~ 0 . ~ ~ ~ ~ ~ 7 - 2 1 - 7 6
NO. R E Q U I R E D - ~ ~ ~ S G P
MAKE
0 YES
TYPE
0 NO
- MOTOR
MAKE
TYPE
PHASE
TEFC
2C Y C L E L
R.P.M.
1770
V O L T S d h n
R.P.M.
A T E @ DESIGN L O A D
1770
_______ L B S / H R .
P.S.I.G.
STEAM EXHAUST
SHIPPING WEIGHT
structions or Features
5-25
P.S.I.G.
BHP.
OF
OF
CUSTOMER
PLANT
LOCATION
SERVICE
Heber. California
Firewater Jockey
MOTOR
CASE S P L I T
Alloy
MECH. SEAL
BRACKET
0 YES
0 YES
0 NO
GREASE
LUBRICATION O I L
SEAL CAGE
F L E X I B L E COUPLING
BASE P L A T E
COUPLINGGUARD.
0 NO
DOUBLE-BALANCEDUNBALANCED-
PACKING
SEMI-ENC ___
CLOSED
XINTERNA
EXTERNAL
SINGLE-
PACKING GLAND
MAKE
TYPE
0 YES
0 NO
DRIVER DATA
MAKE
TYPE
- MOTOR
TEFC
P H A S E ~ C Y C L E6
w
R.P.M.
DRIVER DATA
- TURBINE
MAKE
3500
H.P.
TYPE
DESIGN
T E @0
0 ~ 0 ~ ~ WATER
~ 4R A6
FRAME
NET WEIGHT
VERTICAL
FOOT
STUFF. B O X W A T E R J A C K E T
SHAFT S L E E V E
REV. NO.-DATE-
HORIZONTAL
I M P E L L E R OPEN
11
SHAFT
p-2003
REFERENCE
SUPPORT C / L
11
I M P E L L E R RINGS
I T E M NO.
CONSTRUCTION FEATURES
Bronze
CASING RING
7523
DRIVEX
QUOTE NO.
TURBINE DRIVE-
MATERIALS OF CONSTRUCTION
CASING e NOZZLE
IMPELLER
T)np
JOBNO.
R.P.M.
LOAD
L B S I H R . BHP.
STEAM I N L E T
P.S.I.G.
OF
STEAM EXHAUST-
P.S.1
OF
.G.
SHIPPING WEIGHT
LB.
MOTOR
LE.
5-26
LB.
LOCATION
SERVICE
cusfohim
PLANT
i
CT-291
ITEM NO.
REV. NO.
QUOTE NO.
REFERENCE
PERFORMANCE
Circuloting Rote:
137.0 85
Cooling Duty
1 2 4 3 . 3 [ i n6 )
* A t Option of Owner
108.7
Woter
OF
Temp. Out: ,
S ELECTK)N
Manufacturer:
Model:
Type:
No. of Calls:
DESIGN
Wet Bulb Temp:
80
OF;
Static
35 (max>
Pumpin9 Hd.
ChdFan
Fromework
Cosins
Stairway
Hdrr.
Fon Blade
Oiamohr
Manufacturer
Reduction Rotio
cu.
Ft.
Ft.
Noila
Nozxles
Basin
Fon Hub
Fan Shaft.
Code lor Lumber Struct. Design
See lnquiy or
P.O.
____---
----
-I
AUXILIARY EQUIPMENT
Manufacturer
Fill
MATERIALS OF CONSTRUCTION
Fan Cylinder
;Static Pros.
Fr; Speed .
~RPM;
TYPO
T i p Speed
b mSize
TIP.-
Rotod Cop.
TYPO
S o n i c . Foetor
Speed
x
RPM
Frame
REMARKS
P.O. TO:
5-27
P l a n t Binary Process
~pothprmalDemot i h b No.
7523
Location
Heber, California
No. Reqd.
ONE
Item No.
K-LUl
Manufacturer
G-CONTROLS: TYPE &i DESCRlPTION
A -SERVICE
a E t a r t i n g unloader furnished
Type Gas Handled H
vMix
b )Capacity Control:( VarSpeed)(on-off )
Normal Capacity S. C. F. M.
(multi-speed unloade r)f dua1)etc.
Number of Stages
c ) Unloade r ope ration(E l e c t P n e u. Comb)
Operating Speed, RPM
.
H-CONSTRUCTION MATERIALS
Direction of Rotation, F r o m Driver End
Cyls P Heads
Total B. H. P.
Type of D r i v e r
Electric Motor
Pistons
B-OPERATING CONDITIONS
Piston Rines
Stages
a
P i s t o n Rods
Actual CFM @ Suction Conditions 25
Conn. Rods
Suction P r e s s u r e Variable 14.7 PSLA Min
Crankshaft
Disch. P r e s s u r e 149
PSIA
Valves
Ratio of Compression 10.1 Max.
Valve Springs
Suction T e m p e r a t u r e 120
* FMax
Crank Case
Disch. T e m p e r a t u r e
"F
B o r e and Stroke
IIX I t
B a s e Plate
Flvwheel
Piston Disdacement
C. F.M.
Clearance Volume
VI
I
Coupling Guard
I -CONSTRUCTION DE TAILS
Volumetric Efficiency
Type Crosshead
B r a k e HorseDower Per Staee
Type Valves
No. Inlet Valves /Cyl.
No. Disch. Valves/Cyl.
Type Rod Packing
Mate rial
I
No. of Rings & Size
A r e Stuffing Boxes W a t e r Cooled
, Molecular Wt.
60.8
Main Bearings, No. & Type
Size
Ratio of Cp /Cy
Connecting Rod Bearings, Type
C OmDr e s s ibilitv Factor
Size
D-COMPRESSOR DETAILS
Crosshead Guide Brgs. Type
Mfrs. Type & Designation
Crosshead P i n Brgs. Type
No. of C o m p r e s s o r Cylinders
Size
Cylinder Arrangement
Lubrication of Bearings
4
Single o r Double Acting
I n e r t i a F o r c e s & Couples
Lubrication of C r o s s h e a d
4 NONE
Lubrication of Cvlinders
1
Max. Safe Operating Speed
E -DRIVER( Motor)(Turbine)(Engine)
Cooling W a t e r , GPM. F o r Intercoolers
D r i v e r R. P. M.
D r i v e r H. P.
10
Hd. Loss thru Cyl. J a c k e t s
Ft.
Hd. Loss t h r u I n t e r c o o l e r
Ft.
NO. of Motor,
Data Sheet
Type of Drive(direct)(GearrV-belt)
J -GENERAL
Size & Type of Gear o r Belt
Normal & T h e r m a l Rating of Drive
P r i c e , Each (FOB) ( F R T Allowed)
I
Type of Coupling
Extra for Driver
Size of Coupling
E x t r a f o r Gear, Belts, Cplgs, etc.
Extra for
F-PRESSURE RATING O F CYL. (Max. )PSIG
Weight. Unit onlv
I
M a x Differential P r e s s u r e
Weight, D r i v e r
Suction Nozzle Size & Rating
Weight
Disch. Nozzle Size & Rating
Shipment f r o m Receipt of O r d e r , Wks.
,
- -
I
I
.,
--NO.
Date
Revisions
5-28
By
TURBINE-GENERATOR
'
GENERAL REQUIREMENTS
1.
SCOPE
REQUIRED EQUIPMENT
Turbine
One hydrocarbon turbine rated as specified herein.
Generator
ooled synchronous generator rated 76.5 MVA,
One totally enclosed hy
.85 power factor, 3 phase, 60 cycles, .58 short circuit ratio, and 13,800
volts. The generator shall be equipped with water to hydrogen type heat
exchangers for cooling. Each generator shall be equipped with a nonrotating, brushless type exciter and automatic voltage regulator.
Turbine-generator shall be suitable for outdoor location.
3.
MATERIALS
n the construct
of this unit
They shall have the necessary magnetic particle inspections, casting processings, radiographic testing, and sonic
currently applicable ASTM
testing performed that
4.
tative reserv
spect fully all phases of the manufacture of the turbine and the generator
to insure that the manufacturer is complying with the specifications. Any
item found to be not in accordance with the specification will be rejected
at no additional cost to the Purchaser. The Purchaser's inspection shall
not relieve conformance to the specifications or release from warranty.
5-29
Lid
TURBINE-GENERATOR
VARIATIONS
Any variations from the requirements of this specification, because of
manufacturer's standards, shall be clearly stated in the manufacturer's
proposal. Any alternates in construction which the manufacturer may desire to offer shall be described in complete detail.
I1 TURBINE
The design flow requirements for the turbine at rated throttle conditions
are as specified below:
5-30
TURBINE-GENERATOR
Fluid
Flow Rate
Inlet Pressure
Design Pressure
Inlet Temperature
Design Temperature
Outlet Pressure
Efficiency
Rated Horsepower
9.1 General
5-31
TURBINE-GENERATOR
5-32
L!
TURBINE-GENERATOR
All of the valves, valve stems, and valve seats shall be made of
corrosion and erosion-resistant materials which have been proven
suitable for successful operation and durability in other existing
applications.
9.7 Turbine Governors
system. This system may be combined with the lubricating oil and
Oil reservoir
Oil coolers
Oil filters
5-33
TURBINE-GENERATOR
2.1.4,
2.1.7,
2.2.7,
Pumps and Drivers - Paragraphs 2.3.2 and 2.3.6 of API Standard 614
s h a l l not apply. This system s h a l l not u t i l i z e steam turbine drivers.
Bearings
A l l bearings s h a l l be designed f o r pressure l u b r i c a t i o n and s h a l l
operate without injurious temperature rise o r undue wear. I t i s pref e r r e d t h a t a l l main bearings must be provided with a p o s i t i v e v i s u a l
check point on o i l flow through t h e bearings. Leakage of o i l o r o i l
vapors from t h e bearing housings must be minimized.
5-34
hi
TURBINE-GENERATOR
The turbine design and testing shall conform to Section 2.18 of API
Standard 617.
Vibration and position detectors shall be provided in accordance
with Section 2.14 of API Standard 617. Paragraphs 2.14.3 and 2.14.4
of this standard shall not apply.
10. MOTORS
10.1 All AC motors shall be in accordance with Specification No. 3600-2.
10.2
All wiring shall be in accordance with electrical components Specification No. 3600-3.
11. ACCESSORIES
In addition to those accessories already mentioned in these specifications,
the following shall be included:
An electric type speed indicating device will be furnished consisting of
5- 35
TURBINE-GENERATOR
Lid
5-36
TURBINE-GENERATOR
The deviation factor of the open circuit terminal voltage wave of the
generator shall not exceed 10 percent as defined by ANSI and NEMA
standards.
The generator armature shall be capable of operating at 13 percent of
rated armature current for at least one minute, starting from stabilized temperatures at rated conditions.
The generator field windings shall be capable of operating at a field
voltage of 125 percent of rated load field voltage for at least one minute starting from stablized temperatures at rated conditions.
The generator will be capable of withstanding, without injury, the thermal
effects of unbalanced faults at the generator terminals, including the
decaying effects of field current (where protection is provided by causing
field current reduction, such as with a field breaker or equivalent) and
the d-c component of the stator current, for times up to 120 seconds, provided the integrated product (Iz2t) of generator negative phase sequence
current (Iz) and time (t) does not exceed 30.
The generator shall be capable of withstanding without mechanical injury,
any type of short circuit at its terminals for times not exceeding the
short time thermal capabilities, when operating at rated KVA and power
factor and five percent overvoltage, provided the maximum phase current
is limited by external means to a value which does not exceed the mximum phase current obtained from the three-phase fault.
rdance with
ormal ratin
mance establ
t full load
ent temperature
stator coils and 125OC for the field when operating at full load or below.
The stator and rotor insulation shall be Class F.
5- 37
TURBINE-GENERATOR
Stator
The stator coils shall be insulated with multiple layers of mica
tape and compounded to eliminate any voids so as to form a long
lasting and durable insulation of the stator coils. Insulation
of stator core laminations shall be nonaging and of a type which
will maintain its insulating properties at high temperatures.
Leads from both ends of all phase windings shall be brought out to
an accessible location.
13.2
Rotor
The generator rotor shall be machined from a solid forging.
Rotor retaining rings shall be protected from damage due to single
phase or unbalance loads and be free of contact with the rotor body.
13.3 Bearings
All bearings must be split to permit removal of the upper half for
inspection. Bearings will be provided with a positive visual check
point on oil flow through the bearings.
Under normal operating conditions the maximum amplitude of.vibration
as measured on the bearing cap, shall not exceed 1 mil. The maximum amplitude of vibration on the stator frame except for the end
shields shall not exceed 1-1/2 mils vibration.
Bearings shall be insulated where necessary to prevent the flow of
"shaft current".
13.4 Generator Cooling System
The generator shall be equipped with finned tube surface gas coolers
with suitable surface area to maintain the generator within the operating range. The coolers shall be of sufficient size and number
so that the unit may operate at.a minimum of 80 percent rated KVA
with one cooler section out of service. The gas coolers shall be
arranged in four sections and shall be mounted in the generator
5-38
b)
TURBINE-GENERATOR
5-33
TURBINE-GENERATOR
V TESTS
17.
TESTS
The following l i s t e d tests s h a l l be performed on t h e u n i t and i t s components t o insure t h a t t h e s t a r t u p of t h e u n i t can be accomplished with
a minimum of t e s t i n g a t t h e work s i t e .
17.1
Turbine
The following tests s h a l l be made:
T e s t of o i l pumps.
Heat s t a b i l i z a t i o n of r o t o r .
Ultrasonic t e s t on r o t o r .
Magnafluxing of buckets and rotor1
Hydrostatic t e s t of high pressure turbine casing.
5-40
id
I)
TURBINE-GENERATOR
17.2 Generator
Mechanical Inspection.
Mechanical balance and high speed run to 110 percent of rated speed.
Measurement of cold resistance of armature and field windings.
Di-electric tests:
Armature - The standard test voltage shall be an alternating
voltage whose effective value is 1,000 V plus twice the rated
voltage of the generator. Test shall be applied for 60 seconds
duration.
Field
17.3
Transformers
Polarity test.
5-41
TURBINE-GENERATOR
Rectifiers
Voltage drop at reduced current.
Reverse leakage test.
General
Voltage regulator gain test.
High potential tests on all circuits to ground.
Test to insure operation of all services associated with the
excitation system.
5-42
TURBINE-GENERATOR
'
18.2 Turbine
Guaranteed hydrocarbon rates at 100 percent load point, and an estimate performance curve for 0 percent - 105 percent of full load.
Description of the type of turbine rotor construction.
Description of the type of inlet valve gear and advise approximate
number of valves included in each set of gear.
Description of turbine shaft sealing system.
Description of method of fastening blades to turbine wheels or fabrication of impellers.
Description of lubrication and hydraulic oil system.
Description of the control system.
Description of the turbine stop valve.
Description of emergency trip system.
Description of emergency overspeed governor.
18.3 Generator
The following curves for the generator size and rating specified
herein.
Typical saturation and synchronous impedance curves.
Typical reactive capability curves.
Typical excitation Vee" curves.
Transient and subtransient reactances.
Required cooling water flow rate at 95'F
temperature.
5-43
TURBINE-GENERATOR
Lid
Lit#
5 -44
LJ
TURBINE-GENERATOR
Yes
No
Yes
No
without external a
Shipped assemble
during erection
LJ
5-45
L,
,
TURBINE-GENERATOR
5 -46
TURBINE-GENERATOR
Blading material
Banding of blading (yes or no)
Stationary hydrocarbon path
Blade rings or diaphragms
Nozzle material
Method of support
Type of interstage seals
Shaft Sealing System
Type of system
Sealing Fluid
Bearings
Number of journal bearings
Turbine
Generator
Type of journal bearings
Type of thrust bearing
Dummy piston required
Yes
No
If dummy piston required, is there provision to move rotor axially under load Yes
No
No
Oil System
Capacity of oil tank (gals)
5-47
Yes
L,
TURBINE-GENERATOR
5-48
Yes
No
TURBINE-GENERATOR
'bd
5 -49
Lid
,
,
TURBINE-GENERATOR
Kw
H2 consumption
H2 98% purity
Guaranteed
cu.ft./24 hours
Expected
purge air
cu.ft .
cu.ft.
Yes
No
Yes
No
Yes
No
5-50
(%I
TURBINE-GENERATOR
5-51