5101764

Preliminary Design Manual for a
Geothermal Demonstration Plant

at Heber, California
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
EPRl Project Manager

Vase1 W. Roberts
Fossil Fuel and Advanced Systems Division
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
PERFORMANCE OF VARIOUS GEOTHERMAL

BINARY CYCLES
ALTERNATIVE PUMP CONFIGURATIONS
ESTIMATE SUMMARY SHEET
EFFECT OF BRINE/HYDROCARBON EXCHANGER
PINCH POINT ON POWER COST
EFFECT OF CONDENSER LOG MEAN TEMPERATURE DIFFERENCE ON POWER COST
EFFECT OF COOLING TOWER APPROACH TO WET
BULB TEMPERATURE ON POWER COST
.-
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
INSTRUMENTATION AND CONTROL

BUILDINGS AND STRUCTURES
DRAWING NO. 7523-E-3242, REV. C - BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT PLOT PLAN
DRAWING NO. 7523-E-3215, REV. C - BINARY PROCESS P&ID
GEOTHERMAL DEMONSTRATION PLANT, HEBER,
CALIFORNIA
4-10
4-12
4-15
DRAWING NO. 7523-E-3246, REV. C - BINARY PROCESS

COOLING WATER PGID GEOTHERMAL DEMONSTRATION PLANT, HEBER, CALIFORNIA
DRAWING NO. 7523-E-3221, REV. C - INSTRUMENT & PLANT
AIR P&ID GEOTHERMAL DEMONSTRATION PLANT
4-19
DRAWING NO. 7523-D-3222, REV. B - FLARE SYSTEM PGID

GEOTHERMAL DEMONSTRATION PLANT, HEBER,
CALIFORNIA
DRAWING NO. 7523-D-3601, REV. B - BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT MAIN
SINGLE LINE DIAGRAM, HEBER, CALIFORNIA
DRAWING NO. 7523-D-3602, REV. B BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT, 4160 V.
GEOTHERMAL DEMONSTRATION PLANT "MCC-A"
4-17
4-21
4-23
4-25
vi
4-27
4-29
TABLE OF CONTENTS
Page
-
Section
4 (Cont.)

GEOTHERMAL DEMONSTRATION PLANT "MCC-B"
DRAWING NO. 7523-E-3261, REV. B - BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT PIPING
AREA LOCATION PLOT PLAN
GEOTHERMAL DEMONSTRATION PLANT AREA "A"
PIPING PLAN, PUMP PIT G COOLING TOWER
GEOTHERMAL DEMONSTRATION PLANT AREA "B"
PIFTNG PLAN, GRADE TO ELEVATION 18'-0"
DRAWING NO. 75L3-E-3264, REV. B - BINARY PROCESS
PIPING PLAN, ELEVATION 18'-0" AND ABOVE
GEOTHERMAL DEMONSTRATION PLANT AREA "D"
PIPING PLAN
PIPING SECTIONS, SEC. "A-A"
GEOTHERMAL DEMONSTRATION PLANT AREA "C"
PLAN, PIPING SECTIONS
DRAWING NO. 7523-D-3258, REV. A - PIPING STANDARD
SYMBOLS FOR PROCESS FLOW DIAGRAMS AND
PIPING AND INSTRUMENT DIAGRAMS
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
In October 1975, the Electric Power Research Institute authorized Holt/Procon

to make a feasibility study for a low-salinity hydrothermal demonstration
plant. The objective of the first part of the study (Part A) was to make a
technical, economic and environmental analysis of the proposed project and,
if supported by the findings, to recommend a site for the construction of a
25 MWe to 50 MWe geothermal power plant and a process upon which to base the
design. Part A was completed in April 1976, with the following conclusions
and recommendations :
0
The geothermal reservoir at Heber, California is technically

economically, and environmentally feasible for location of
the geothermal demonstration plant.
The binary conversion process is technically, economically,
and environmentally feasible for producing electric power
using fluid from a hydrothermal reservoir. At the Heber site
this process converts geothermal energy into electrical
energy at a lower cost than either the flashed steam process
or the hybrid process.
A 50 MWe binary conversion plant at Heber produces electric
power at a cost that is comparable with other new sources of
power. A smaller plant would experience higher operating
costs which would reduce the profitability of the plant
operation.
Following completion of Part A, a preliminary design study of a 50 W e binary

conversion plant at Heber was initiated and is presented herein.
i
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
A working fluid containing 20 percent i'sopentane and 80 percent isobutane was
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 ) .
Trade-off studies were performed to determine optimum design conditions for

the plant. The following conclusions were reached:
0
Operational economy is favored by a low pinch temperature

between the reservoir fluid and the working fluid.
Operational economy and the cost of energy produced is only
slightly affected by the approach temperature between the
cooling water and the ambient wet bulb temperature.
The cost of energy is affected by cooling water temperature
rise. An intermediate temperature rise of about 11.7 C (21 F)
gives the lowest cost of energy.
A study was made of the hydrocarbon circulating pumps to
determine whether turbines or electric motors should be used
for motive power. It was concluded that electric motors
should be used to drive six vertical centrifugal pumps.
updated cost estimate of the demonstration plant was prepared. The

estimated cost of the plant is $29,634,000 or $592 per kwh. Thi.s cost is
slightly higher than the cost presented in the base case for Heber, California
reported previously ($28,500,000),
due in part to design changes resulting
from the trade-off studies and in part to increased precision of the estimating procedure.
An
The cost of power delivered to a load center was calculated to be 35.84

mills/kwh which is a slight increase over the 35.33 mills/kwh previously
calculated for the base case.
We have defined the plant baseline configuration by the preparation of
process flow diagrams for the initial plant operating condition and the
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
prepared in a separate volume which includes:

0
0
0
schedule for applications and permits

A schedule for engineering and construction
A critical path schedule showing the time sequence of the
critical function affecting plant completion
A
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
"Comparison of Hydrothermal Reservoirs in the Western United

States"
"Reservoir Engineering and Aspects of Geothermal Site Selection at Heber, California and Valle aldera, New Mexico"
"Energy Conversion and Economics fo eothermal Power Generation at Heber, California; Valles Caldera, New Mexico; and
Raft River, Idaho - Case Studies"
"Preliminary Environmental Assessments of Geothermal Power
Generation at Heber, California"
"Geotechnical Environmental Aspects of Geothermal Power Generation at Heber, California"
i
llSocioeconomicEnvironmental Aspects of Geothermal Power Generation at Heber, California"
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
This manual presents t h e r e s u l t s of Tasks 1, 2 and 3 .

The response t o Task B-4 is contained i n a separate report e n t i t l e d "Implementation Plan f o r a Geothermal Demonstration Plant a t Heber, California."
The response t o Task B-5 i s a separate report i n four volumes:
0
Volume I
Volume I1
- Geotechnical Environmental Aspects of Geothermal
Preliminary Environmental Assessments of Geothermal Power Generation a t Heber, California

Power Generation a t Heber, California
Volume I11
Socioeconomic Environmental Aspects of Geothermal

Power Generation a t Heber, California
Volume I V
Appendices
Draft r e p o r t s f o r Task B-5 were submitted i n April.
These r e p o r t s have been
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
Baseline configuration description
Plant requirements document
Equipment specifications
Capital cost estimate
Long lead items procurement s p e c i f i c a t i o n s
2-2
Section 3
DEVELOPMENT OF DESIGN
I n P a r t A, previously reported, conceptual designs were prepared by t h r e e pro-
cesses a t t h r e e sites. These designs and t h e accompanying c o s t estimates were

prepared i n s u f f i c i e n t d e t a i l t o permit a r e a l i s t i c comparison of s i t e s and
processes.
r
Following t h e s e l e c t i o n of a s i t e (Heber) and a process (binary) we focused

our a t t e n t i o n on optimization s t u d i e s leading t o t h e preliminary design presented herein.
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.
Maps showing t h e f i e l d location are presented i n
a separate report e n t i t l e d "Preliminary Environmental Assessments of Geothermal

Power Generation a t Heber,California."
An exact s i t e location w i l l be selected
during t h e f i n a l design phase of t h e work.

*
The geothermal-electric energy conversion p l a n t w i l l occupy approximately

c
24,000 M
(6 acres).
A p l o t plan f o r t h e plant s i t e i s contained i n Section
4 o f - t h i s report.
The production and i n j e c t i o n wells w i l l be d r i l l e d on approximately 0.6 km

(0.4 mile) and 3.2 km (2 miles) r a d i i from t h e center of t h e r e s e r v o i r .
p l a n t w i l l be located adjacent t o t h e production wells.
The exhausted reser-
v o i r f l u i d w i l l be returned t o t h e i n j e c t i o n wells i n a buried pipeline.
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.
Annual average p r e c i p i t a t i o n i s 7.1 c m (2.8 inches), and average d a i l y
Summer dry bulb temperature exceeds 37 C (100 F).
The average minimum Winter
temperature i s -2 C (28 F).

Prevailing winds are generally below 7 m/sec. (15 miles/hour) and from t h e
west.
Average d a i l y r e l a t i v e humidity ranges between 20 and 30 percent.
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
of t h e proximity of Heber t o numerous a c t i v e f a u l t s , a design acceleratim of

0.375g is recommended f o r p l a n t design.
Water Supply
The Central Main Canal, and various subsidiary i r r i g a t i o n canals belonging
t o t h e Imperial I r r i g a t i o n District, pass within about 2 km (1 mile) of t h e
site.
canals.
Water f o r plant cooling and potable uses w i l l be drawn from t h e s e

Cooling tower blowdown water w i l l be discharged t o t h e a g r i c u l t u r a l
drain system as is c u r r e n t l y being done a t t h e San Diego Gas & Electric

Company geothermal f a c i l i t y near Niland, Imperial County, California.
3-2
LiJ
L,
Sanitary wastewater will be treated in a septic tank and dispersed through

a tile drain field.
Access
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
temperature of 182 C (360 F).

rature of the brine would
re to a temperature
reported to hav
y has predicte
u
3-3
The r e s e r v o i r f l u i d has a t o t a l dissolved s o l i d s content of about 15,000 ppm.
No accurate analysis has been made t o determine t h e quantity of noncondensable

gases i n t h e r e s e r v o i r f l u i d , but a program i s c u r r e n t l y i n progress t o d e t e r mine t h e quantity and analysis of such gases i f they are present.
The f i e l d
tests conducted by Chevron i n d i c a t e t h a t t h e noncondensables ( i f any) w i l l

remain i n s o l u t i o n i n t h e hot water and w i l l be r e i n j e c t e d with t h e hot water
back t o t h e r e s e r v o i r .
Heat exchanger tests performed by t h e San Diego Gas & Electric Company a t
Heber showed t h a t t h e s a l t s present i n t h e f l u i d form s c a l e a t a n e g l i g i b l e
r a t e a t temperatures above 132 C (270 F), but below t h a t temperature fouling

occurs a t an increased rate.
From t h e i r d a t a w e estimated t h e following tube-
s i d e fouling f a c t o r s which were used i n t h e design of brine/working f l u i d heat

exchangers:
Temperature, C
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
These f a c t o r s are t e n t a t i v e i n t h a t t h e r e s u l t s of a 22-day t e s t have been

extrapolated t o p r e d i c t a fouling f a c t o r s u i t a b l e f o r one year's operation.
A 2,000-hour t e s t program i s c u r r e n t l y i n progress t o confirm these f i g u r e s and
t o obtain additional corrosion data.
This work i s being funded by EPRI and
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.
No corrosion was observed on t h e titanium
tubes a f t e r 560 hours' exposure; some corrosion occurred t o t h e cupro nickel

tubes a f t e r 200 hours' t e s t i n g ; and s l i g h t p i t t i n g and surface decarbonization
were observed on t h e carbon steel tubes a f t e r 560 hours of t e s t i n g .
It is
possible t h a t t h e s l i g h t corrosion of t h e steel tubes had occurred p r i o r t o

t h e t e s t program.
was negligible.
Chevron has indicated t h a t corrosion during t h e i r test work

Accordingly, we have specified t h e use of steel i n a l l
Lid
3-4
LiiJ '
equipment exposed to brine. A final decision on materials will be made on the

basis of the test program currently in progress.
Summer time dry bulb ambient temperatures vary up to 49 C (120 F).
One percent of the time during the summer months, the wet bulb temperature reaches
or exceeds 27 C (80 F). This wet bulb temperature was used for design.
PROCESS DESIGN
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
Thermodynamic Cycle Studies

The initial phases of the.processdesign are reported in detail in the
"Thermodynamic Cycle Analysis" section of "Energy Conversion and Economics
for Geothermal Power Generation at Heber, California; Valles Caldera, New
Mexico; and Raft River, Idaho - Case Studies" (Energy Conversion Study). The
selection of the final working fluids for Heber was done in the same general
manner as the initial screening study, described in the Energy Conversion
Study.
The next phase of the process engineering consisted of:
0
0
Studying fluids not included in the initial study

Establishing the economic sensitivity of the major design
parameters
Analyzing the behavior of the various processes at mid-run
"off-design" conditions
Reviewing the most promising cycles and screening out those
that presented serious technical or equipment problems
class of working fluids not studied in the initial phase is composed of

three hydrocarbon species. Several combinations of propane, isobutane and
isopentane were analyzed, but did not prove to be superior to the twocomponent fluids.
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
Process Flow Diagrams

Drawing 7523-D-3260 is a process flow diagram for this plant at the start-ofrun conditions. The process flow diagram shows principal items of equipment
and presents heat and material balances for the hydrocarbon working fluid and
reservoir fluid.
A summary of the pertinent design data is as follows:
Reservoir Fluid
Temperature
Flow Rate
Hydrocarbon Working Fluid
Composition
(mole basis)
Flow Rate
Gross Generator Output
In-plant Load
Net Power Output
182 C (360 F)
3.05 x 106 kg/hr (6.72 x 106 lbs/hr)
80% isobutane, 20% isopentane
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.
Drawing 7523-D-3275 i s a process flow dia-
gram showing t h e operation of t h e p l a n t using t h e middle-of-run f l u i d .
Perti-
nent design d a t a are as follows:

Reservoir Fluid
Temperature
174 C (345 F)
6
3.48 x 10 kg/hr
Flow Rate
(7.66 x
lo6
lbs/hr)
Hydrocarbon Working Fluid

Composition
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
A t t h e time t h e middle-of-run cycle i s i n s t i t u t e d , it w i l l be necessary t o
add equipment.
be required.
Because of t h e decreasing b r i n e temperature, more b r i n e w i l l

The hydrocarbon/brine heat exchangers w i l l r e q u i r e more surface.
Another heat exchange u n i t w i l l be added, increasing t h e surface by 50%. The

added exchanger w i l l o f f s e t t h e higher pressure drop due t o t h e increased
T
brine circulation.
Since t h e hydrocarbon c i r c u l a t i o n w i l l a l s o increase, an
additional hydrocarbon pump w i l l be added.

f i e l d t o handle t h e increased flow.
The t u r b i n e may have t o be modi-
In addition, one condenser w i l l be added
and t h e cooling tower enlarged by 43%. These modifications w i l l be s u f f i c i e n t

f o r t h e remaining l i f e of t h e
ect and no f u r t h e r equipment additions w i l l
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
temperature declines t h e flow of b r i n e through t h e plant heat exchangers w i l l
3- 9
increase to 4 . 4 7 x 10 kg/hr (9.86 x 10 lbs/hr).

lation of the working fluid remains constant.
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
Minimum temperature difference (pinch) in the brine/hydrocarbon exchangers

Log mean temperature difference in the hydrocarbon condenser
Cooling tower approach to the atmospheric wet bulb temperature
Cooling water temperature rise
Selection of motor or turbine drives for process pumps
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
Total p l a n t c o s t s were estimated by employing f a c t o r s developed i n t h e base

c o s t estimate.
Field c o s t s depend on b r i n e requirements.
Costs of production, i n j e c t i o n
and expected dry wells were estimated f o r each case.
The c o s t s of production
and i n j e c t i o n f a c i l i t i e s (surface i n s t a l l a t i o n ) were developed from t h e e s t i -
mate summary sheet (Figure 8) shown i n t h e Energy Conversion Study.
Only
pressure v e s s e l s , filters, and s i t e preparation s e c t i o n s remained unchanged

f o r a l l cases.
Operating and maintenance c o s t s were derived from p l a n t and f i e l d estimates
as described i n t h e Energy Conversion Study.
The r e s u l t s of t h e s e s t u d i e s a r e presented i n Tables 3-1 through 3 - 6 .
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 .
The c o s t s i n t h e t a b l e s were developed employing
thermodynamic cycles, i n which t h e expansion of t h e working f l u i d passes

through t h e two-phase region.
While such cycles appear a t t r a c t i v e it has not
established whether a t u r b i n e can be designed t o operate e f f i c i e n t l y

i n t h e two-phase region.
Accordingly, we pursued a conservative approach f o r
inch which occu
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),
hydrocarbon c i r c u l a t i o n r a t e and t u r b i n e i n l e t and o u t l e t conditions.
3-11
As
t h e pinch temperature difference i s increased by r a i s i n g t h e r e t u r n temper-
Ld
a t u r e of t h e brine t o t h e f i e l d , t h e c o s t of t h e brine-hydrocarbon exchangers

decreases a t t h e expense of higher b r i n e rates.
As shown i n Table 3-1, with
an increase from 5.5 C pinch t o 11.1 C pinch, t h e cost of t h e exchangers

drops from $1,570,000 t o $815,000 reducing by 4.4 percent t h e c a p i t a l c o s t of
t h e plant.
The brine requirements increase 10.5 percent, r a i s i n g t h e t o t a l
f i e l d cost from 6.5 percent, from $11,460,000 t o $12,210,000.
Power conver-
sion c o s t s reflect t h e lower p l a n t c o s t s , while energy ( f i e l d r e l a t e d ) c o s t s

go up. The additional energy c o s t s o f f s e t t h e savings i n p l a n t r e l a t e d
expenses, r e s u l t i n g i n increased t o t a l power c o s t s as t h e temperature pinch
increases.
I t appears t h a t t h e smaller t h e pinch point t h e b e t t e r .
However, designing
f o r too small a pinch point may unduly r e s t r i c t b r i n e flow and f o r t h i s

reason we selected a pinch point of 15 F.
Effect of Condenser Loe Mean TemDerature Difference on Power Cost
I n order t o determine how t h e mean temperature d i f f e r e n c e i n t h e condenser

would affect the cost of power from t h e p l a n t , t h e cooling water temperature
p r o f i l e was l e f t constant, water coming i n a t 32.2 C (90 F) and leaving a t
about 43.3 C (110 F ) , and t h e turbine exhaust temperature changed t o achieve
t h e desired mean temperature difference.
Table 3-2 shows t h a t an increase
i n mean temperature difference from 6.1 C (11 F) t o 17.2 C (31 F ) , r e q u i r e s

an increase i n turbine exhaust temperature from 76 C (152 F) t o 73 C (164 F),
r e s u l t i n g i n a corresponding reduction i n t h e power generated by each pound
of working f l u i d circulated.
Consequently, a 25 percent increase i n cooling
water c i r c u l a t i o n and about a 22 percent increase i n hydrocarbon c i r c u l a t i o n

and b r i n e rate were required.
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
of some equipment but t h e n e t effect on p l a n t cost was very small.
The
$1,087,000 reduction i n t h e cost of condensers compensated f o r t h e increase

i n t h e cost of t h e hydrocarbon and t h e cooling water c i r c u l a t i o n pumps, t h e
cooling tower and t h e turbine-generator.
The c o s t of energy conversion
therefore changes s l i g h t l y while t h e cost of energy increases.
3-12
The n e t
Lid
result is an 8.4 percent increase in power cost as the temperature difference

increases from 6.1 C to 17.2 C. Consequently, the condensers should be
designed for a small log mean temperature difference to take advantage of
favorable economics. For the power cycle recommended in this study, a log
mean temperature difference of 7.1 C (12.7 F) was selected.
Effect of Cooling Tower Approach to Wet Bulb Temperature Cost
The cost of power was estimated for three cooling tower approaches, 5.5 C
(10 F), 4.4 C (8 F), and 2.8 C (5 F). A reduction in cooling tower approach
causes an equal reduction in cooling water temperature. There are two possible
ways of utilizing this advantage, One alternative is to increase the temperature difference in the hydrocarbon condensers; the other one, is to lower
the hydrocarbon turbine outlet temperature. Both alternatives have been
evaluated over the above range of approaches. The results are presented in
Tables 3-3 and 3-4.
The increase of the temperature difference in the hydrocarbon condensers
from 5.5 C (10 F) to 6.6 C (l.2 F) causes a reduction in the cost of the
condensers, cooling water circulation pumps and cooling water piping. However, the closer approach to wet bulb causes a compensating increase in the
cost of the cooling tower and its basin. The result, shown in Table 3-3 is
a slight increase in plant cost, which coupled with an unchanged field cost,
makes the reduction in approach economically unattractive.
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
i n power c o s t as t h e approach t o wet bulb i s reduced involves a measure of

r i s k i n t h a t we are requiring superior performance of t h e cooling tower
r a t h e r than normal performance.
For t h i s reason w e s e l e c t e d a 5.5 C (10 F)
approach f o r preliminary design.

Effect of Cooling Water Temperature Rise on Power Cost
The effect on power c o s t of t h r e e cooling water temperature rises, 6.1 C (11 F ) ,

11.7 C (21 F) and 18.3 C (33 F), was studied.
To obtain power cycles under
t h i s c o n s t r a i n t , t h e cooling water i n l e t temperature was kept constant a t

32.2 C (90 F) and t h e turbine exhaust temperature increased from 66.7 C (152 F)
t o 70 C (158 F).
Table 5 shows t h a t as t h e temperature r i s e increases t h e
c a p i t a l c o s t of t h e p l a n t declines from $28,310,000 t o $25,250,000.
This
10.8 percent drop is b a s i c a l l y due t o a 66 percent reduction i n cooling water

c i r c u l a t i o n , requiring smaller pumps and cooling tower.
However, t h e b r i n e
rate, b a s i c a l l y i d e n t i c a l i n t h e 6.1 C and 11.7 C temperature r i s e cases,
increases 3 percent i n t h e 18.3 C temperature r i s e case.
This increment i s
due t o t h e higher t u r b i n e o u t l e t conditions which make t h e power cycle less

efficient.
Consequently, even though t h e c o s t of energy conversion i s t h e
lowest, 16.77 millslkwh, t h e energy o r f i e l d r e l a t e d c o s t s are t h e highest.

The r e s u l t is a minimum power c o s t occurring around t h e 11.7 C temperature
After considering t h i s and o t h e r process v a r i a b l e s we s e l e c t e d a
rise.
10.1 C (18.2 F) cooling water temperature r i s e f o r t h e preliminary design

case.
Hydrocarbon Circulation Pumps
A d e t a i l e d study was made t o optimize t h e design b a s i s f o r t h e hydrocarbon
c i r c u l a t i o n pumps.
The primary purpose of t h e study was t o determine t h e
optimum combination of t h e following v a r i a b l e s :

0
Horizontal and/or v e r t i c a l design
S e r i e s and/or p a r a l l e l flow
Motor and/or turbine d r i v e
Number of pumps
3-14
The f a c t o r s involved i n t h e determination of t h e optimum included c o s t ,

a v a i l a b i l i t y and operational f l e x i b i l i t y .
Five a l t e r n a t e pump systems com-
bining t h e above v a r i a b l e s were s e l e c t e d f o r t h e study.

of t h e a l t e r n a t e s a r e shown on Figure 3-2.
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,
- Three v e r t i c a l pumps i n p a r a l l e l ; motor d r i v e

- Three v e r t i c a l pumps i n p a r a l l e l ; two turbine,
Alternate 111,
Six v e r t i c a l pumps i n p a r a l l e l ; motor d r i v e
one motor d r i v e
Alternate I V ,
Alternate V,
- The following two systems i n p a r a l l e l :
(a)
one v e r t i c a l motor driven pump i n

s e r i e s with one horizontal t u r b i n e
driven pump
(b)
one v e r t i c a l motor driven pump i n

s e r i e s with two horizontal pumps i n
p a r a l l e l , one turbine driven and t h e
o t h e r motor driven
Two systems i n p a r a l l e l , each system cons i s t i n g of a motor driven v e r t i c a l pump i n

s e r i e s with a motor driven horizontal pump.
The following f a c t o r s had a bearing on t h e combination of v a r i a b l e s i n t h e

above a l t e r n a t e s :
Horizontal pumps r e q u i r e v e r t i c a l pumps i n s e r i e s t o provide

adequate NPSH
If t u r b i n e d r i v e s a r e used, a t l e a s t one motor driven u n i t o r

system i s required f o r p l a n t start up.
The minimum number of systems i n p a r a l l e l required t o handle

t h e t o t a l hydrocarbon flow rate i s e s t a b l i s h e d by equipment
s i z e s presently available.
A l l pump systems were s i z e d t o handle a t o t a l hydrocarbon flow r a t e similar
udies conducted t o optimize t h e process.
t o t h a t used i n one of t h e trade-off
mately 3 percent higher than t h a t f o r t h e case u

t h e p l a n t des
Total head requirements a r e i d e n t i c a l .
3-15
Turbine d r i v e r s were considered as operating i n p a r a l l e l with t h e plant

turbine-generator set handling t h e hydrocarbon vapor a t t h e same i n l e t and
o u t l e t conditions, thus reducing t h e required size of t h e turbine-generator
set.
Cost comparisons considered not only t h e pumps and d r i v e r s but t h e changes
i n associated piping and insulation, instrumentation, c i v i l and electrical
requirements.
For t u r b i n e d r i v e u n i t s , t h e r e s u l t a n t decrease i n required
size of t h e p l a n t turbine-generator set was taken i n t o account.

Efficiencies assumed f o r t h e study were as follows:
per cent, generator
percent.
turbine-expander
98 percent, pump t u r b i n e d r i v e r s
85
approximately 83
A geared speed reducer would be required f o r t h e pump turbine
driven u n i t s with a mechanical e f f i c i e n c y of 97 percent.
Pump electric motor
d r i v e r e f f i c i e n c i e s f o r t h e required horsepowers ranged from 93 percent t o

97 percent.
The turbine requires a gear reduction u n i t which reduces e f f i -
ciency of t h e turbine d r i v e system.
With high electric motor e f f i c i e n c i e s
t h e difference between turbine d r i v e and motor d r i v e would be minimal and

was t h e r e f o r e not considered.
The cost summary of t h e f i v e a l t e r n a t e s i s shown i n Table I.
Following is
a tabulation of t h e r e s u l t s i n t h e order of ascending c o s t .

Alternate Case
cost
4,665,000
IV
4,749,000
4,777,000
I11
4,885,000
I1
5,024,000
Cases 11, 111, IV and V u t i l i z e pumps a t t h e upper end of capacity/head l i m i t s
with a limited number of manufacturers available.
3-16
F l e x i b i l i t y is a l s o limited
due t o fewer number of systems i n p a r a l l e l .
I n cases where two pumps are
connected i n series, a f a i l u r e of e i t h e r pump would remove t h e other from

operation.
Alternate I provides t h e b e s t combination of c o s t , f l e x i b i l i t y and manufacturer availability.
Consequently, s i x motor driven v e r t i c a l pumps i n p a r a l l e l
were s e l e c t e d f o r start-of-run process conditions.
The use of t u r b i n e drives f o r t h e cooling water pumps was not considered

because t h e s e pumps r e q u i r e only a f r a c t i o n of t h e horsepower required f o r
t h e hydrocarbon pumps.
If t u r b i n e d r i v e s proved impractical f o r t h e hydro-
carbon pumps they should not be considered f o r cooling water service.

ECONOMIC ANALYSIS
I n t h e previously submitted Energy Conversion Study w e prepared a c a p i t a l

c o s t estimate of t h e Heber binary plant, together with estimates of f u e l
c o s t and t h e c o s t of electrical power delivered t o a load center.
This sec-
t i o n contains an updated c a p i t a l c o s t of t h e power p l a n t , together with an
estimate of t h e cost of f u t u r e additions t o t h e p l a n t t o provide f o r t h e
We have a l s o developed new estimates of

t h e c o s t of power from t h e p l a n t a t t h e start.
a n t i c i p a t e d temperature decline.
Capital Cost
?
The updated i n i t i a l c a p i t a l c o s t is presented i n Figure 3-3.
The estimated
c o s t is $29,634,000 as compared with t h e earlier estimate of $28,500,000.

This estimate is prepared on t h e same b a s i s as t h e earlier one. I t reflects
changes i n design and i n some cases improved accuracy.
The major differences
between t h e two estimates are as follows:

0 '
Major equipment increased by about $300,000. Heat exchangers

went up, t h e cooling tower went down and f r e i g h t was l i s t e d
as a major equipment account r a t h e r than an i n d i r e c t f i e l d cost.
3-17
c,
0
Construction items increased by about $750,000. This reflects

a reduction in the cost of pipe, valves and fittings and an
increase in the cost of concrete, both changes resulting from
a more accurate material take-off than before.
Fee, contingency and escalation were increased in proportion
to total plant cost.
This estimate, like the earlier one, is for a battery limits plant. Excluded
from the cost are the following:
0
0
Cost of field collection and reinjection facilities

Cost of electrical transmission facilities to a loadcenter
Cost of land
Costs incurred by the Owner for managing the project and for
obtaining the necessary permits to construct.
Cost of royalties, if any
Interest and taxes during construction
before, the estimate assumes that the project will be completed by late
1979 and escalation is estimated on this basis.
As
additive expenditure of about $3,800,000 will be required to modify the

plant for low temperature operation. This expenditure assumes that the addition would be made at the same time the original plant is constructed. In
reality, the expenditure would be made at a later date, i.e., about eight
years after initial operation.
An
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
rigorous analysis of the effect of temperature decline of the reservoir

on the cost of power is beyond the scope of this study. Suffice it to say
that the cost clearly will increase because of the continued effects of
inflation, the additional capital investment in the plant and the additional
costs associated with producing and reinjection of more brine.
3-19
B
C
D
E
F
Li
50/50 ISOBUTANE-ISOPENTANE
35/55 PROPANE-ISOBUTANE
20/60/20 PROPANE-ISOBUTANE-ISOPENTANE
10/90 PROPANE-ISOBUTANE
165
170
175
I
180
330
Figure 3-1.
340
350
360
Performance of Various Geothermal Binary Cycles

3-20
CAPACITY:
9700 GPM
CAPACITY
ALTERNATE
ALTERhlAE
9700 GPM A
ALTERNATE Ill
II
4r
1252 GPM
CAPACIT*
CAPACITY: MOO0 GPM
ALTERNATE
fi
CAPACITY:
145006PI.l
CAPACITY: Id500 0PI.l
boooclp
ALTEKNATE
Figure 3-2.
Alternative Pump Configurations
3-21
CUSTOMERElectric
Power Research Institute
LOCATION-
REV. NO.
ACCOUNT
Materials
Subcontract
Labor
DATE 10/1/76
TOTAL
I100 Columns (incl. trays)

1200
Pressure Vessels
1300 Heat Exchangers

1400 Furnace/Heaters
1500 Pumps
1600 Boilers
1'100 Cooling Towers
I800 Turbine-generator
1900 Water Treatment
Pipe, Valves, Fittings
350,000
34,000
8,904,000
568,000
1,500,000
512,000
1,184,000
169,000
400,000
I900 Bui Idings
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
I500 Sales Tax on Material

Fee
535,000
229,000
72,000
114,000
14,000
:.
1200 Home Office Services
I200
10,231,000
84,000
46,000
Painting
Paving, Roads, Fences,Mi
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
3300 Structural Steel

1400 Instruments
1500
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.
Estimate Summary Sheet
3-22
U
Table 3- 1
EFFECT OF BRINE/HYDROCARBON EXCHANGER PINCH POINT ON POWER COST

-~
5.5 C (10 F)
PINCH POINT
PLANT OPERATING CONDITIONS

2,936 (6,473)
BRINE RATE, lo3 kg/hr (lo3 l b s / h r )
HYDROCARBON* CIRCULATION RATE, lo3 kg/hr (lo3 l b s / h r ) 3,639 (8,023)
3,447
(500)
TURBINE INLET - PRESSURE, kPa (psia)
- TEMPERATURE, C (F)
149
(300)
458 (66.4)
TURBINE OUTLET - PRESSURE, kPa (psia)
TEMPERATURE, C (F)
68
(154)
32
(90)
COOLING WATER - TEMPERATURE, C (F)
CIRCULATION RATE, lo3 m3/hr (lo3 gpm) 26.96 (118.7)
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 AVD MATERIAL)
PIPING (LABOR, MATERIAL AND SUBCONTRACT)
ELECTRICAL (MATERIAL AND SUBCONTRACT)
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
FIELD CAPITAL COST, K $

TOTAL
POWER COST, millqkwh
CONVERSION AND TRANSMISSION
ENERGY
TOTAL
*HYDROCARBON MIXTURE CONSISTS OF 65 MOLE % ISOBUTANE AND 35 MOLE % ISOPENTANE
3-23
Table 3-2
EFFECT OF CONDENSER LOG MEAN TEMPERATURE DIFFERENCE ON POWER COST
LOG MEAN TEMPERATURE DIFFERENCE

HYDROCARBON* CIRCULATION RATE, lo3 kg/hr
TURBINE OUTLET
COOLING WATER
(lo3
lbs/hr)
PRESSURE, kPa (psia)

TEMPERATURE, C (F)
TEMPERATURE, C (F)
CIRCULATION RATE, lo3 m3/hr
(lo3
gpm)

COOLING TOWER
TURBINE-GENERATOR
CONCRETE (LABOR AND MATERIAL)
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]

TOTAL
POWER COST, mills/kwh
ENERGY
TOTAL
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(^)
HYDROCARBON(3) CIRCULATION RATE, lo3 kg/hr(103 l b s / h r )
- CIRCULATION RATE, lo3 m3/hr (103 gpm)
COOLING TOWER
TURBINE-GENERATOR
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
EFFECT OF COOLING TOWER APPROACH TO WET BULB TEMPERATURE ON POWER COST
APPROACH TO WET BULB TEMPERATURE(^)

TURBINE OUTLET TEMPERATURE(^)
BRINE RATE, lo3 kg/hr ( l o 3 l b s / h r )
HYDROCARBON(3) CIRCULATION RATE, lo3 kg/hr (lo3 l b s / h r
TURBINE INLET
- PRESSURE, kPa (psia)
TEMPERATURE, C (F)
- CIRCULATION RATE, 103 m 3/hr (103 gpm)
COOLING TOWER
TURBINE-GENERATOR
TOTAL
TOTAL
POWER COST, mills/kwh
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
1) WET BULB TEMPERATURE: 26.7 C (80 F)

2) SECONDARY VARIABLE: TURBINE OUTLET TEMPERATURE
3) HYDROCARBON MIXTURE CONSISTS OF 50 MOLE % ISOBUTANE AND 50 MOLE % ISOPENTANE
3-26
29
(85)
20.12 (88.60)
Table 3-5
EFFECT OF COOLING WATER TEMPERATURE RISE ON POWER COST
COOLING WATER TEMPERATURE RISE

3
BRINE RATE, lo3 kg/hr (10 l b s / h r )
HYDROCARBON* CIRCULATION RATE, lo3 kg/hr
TURBINE OUTLET
lbs/h
- PRESSURE, kPa (psia)
COOLING WATER
(lo3
TEMPERATURE, C (F)
CIRCULATION RATE,
lo3
m3/hr
(lo3
gp

COOLING TOWER
TURBINE-GENERATOR
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
CONCRETB (LABOR AND MATERIAL)

D TRANSMISSION
k,
3-27
Table 3-6
HYDROCARBON CIRCULATION PUMP STUDY
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
TURBINE-EXPANDER & GENERATOR
PIPING
w
I
ALTERNATE IV
984,000
ALTERNATE V
582,000
N
or,
CIVIL
ELECTRICAL
TOTAL
111
NOTES :
ALTERNATE
ALTERNATE
ALTERNATE
ALTERNATE
I - six vertical pumps in parallel, motor drive

I1 - three vertical pumps in parallel, motor drive
I11 - three vertical pumps in parallel, one motor drive and two turbine drive
IV - (a) motor driven vertical pump in series with motor driven horizontal pump and turbine driven horizontal pump in
para1le1
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:
Plant and instrument air
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
t h e p l a n t w i l l not be determined u n t i l a s p e c i f i c p l a n t s i t e is selected.

The p l a n t contains four major, c l e a r l y defined functional areas as follows:
0
Brine/hydrocarbon heat exchanger a r e a located i n t h e southeast

corner of t h e site,
Turbine-generator and e l e c t r i c a l gear located a t t h e southern

edge of t h e s i t e near t h e o f f i c e and control building,
Hydrocarbon condenser, accumulator, and c i r c u l a t i n g pump a r e a

located i n t h e c e n t r a l portion of t h e p l a n t site,
Cooling water system a r e a located a t t h e northern edge o f t h e

site.
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 .
Area has been s e t a s i d e f o r i n s t a l l a t i o n of addition-
a l brine/hydrocarbon heat exchangers, hydrocarbon condensers and accumulators,
hydrocarbon feed pumps, cooling tower c e l l s and c i r c u l a t i n g water pumps.
Pipe
sizes have been s e l e c t e d t o permit required increases i n flow during t h e p l a n t

lifetime
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.
Area has been s e t a s i d e t o permit removal
of heat exchanger tubes, inspection and cleaning, and a c c e s s i b i l i t y f o r maintenance equipment.

There a r e t h r e e buildings within t h e p l a n t l i m i t s .
The o f f i c e and control room
building located a t t h e south edge of t h e s i t e , t h e compressed a i r u n i t and

maintenance shop building located i n t h e southeastern s e c t i o n o f t h e p l a n t , and
t h e water treatment system building on t h e northeastern s e c t i o n o f t h e p l a n t .
The s i t e perimeter w i l l be fenced with a 1.8 meter ( 6 foot) Cyclone-type fence
with a 0 . 3 meter (1 foot) ltinvinciblel' barbed wire t o p section.
4-2
When additional geothermal p l a n t s are constructed, each p l a n t w i l l be located

adjacent t o i t s own producing wells.
The p l a n t s w i l l be adequately separated
so t h a t t h e r e w i l l be no interference between adjacent p l a n t s .

ENERGY CONVERSION SYSTEM
Drawing 7523-E-3215B is a piping and instrumentation diagram f o r t h
system
which converts t h e thermal energy i n t h e r e s e r v o i r f l u i d i n t o electrical energy.

Geothermal f l u i d i s pumped i n t o the p l a n t by t h e resource company.
The reser-
v o i r f l u i d i s exchanged with t h e working f l u i d i n t h e brine/hydrocarbon exchangers.
The cooled b r i n e i s then returned t o t h e resource company f o r reinjec-
tion.
Specifications f o r t h e major exchangers are included i n Section 5.
The brine/
hydrocarbon exchangers are fixed-tube sheet design with s i n g l e pass flow on

both sides.
Construction i s TEMA-C without cross b a f f l e s .
This design pro-
vides high s h e l l - s i d e hydrocarbon v e l o c i t i e s , high heat t r a n s f e r c o e f f i c i e n t s

and low pressure drops.
Materials are carbon steel.
have been provided f o r each p a r a l l e l stream.

1,420 w a t t s / ( m 2 )
("C),
[250 BTU/(hr)
(ft2)
Four exchangers i n series
Overall t r a n s f e r rate is about
(OF)].
I t i s anticipated t h a t t h e
exchangers w i l l be cleaned e i t h e r mechanically o r chemically once per year by

an outside contractor.
No f a c i l i t i e s f o r cleaning t h e exchangers have been
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.
A general s p e c i f i c a t i o n f o r the turbine and generator i s pro-
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.
EPRI has issued contracts t o prepare
preliminary design s t u d i e s of a x i a l and r a d i a l turbines f o r service i n a binary process geothermal p l a n t .
LJ
The d a t a developed i n these s t u d i e s should pro-
vide a d e f i n i t i v e answer t o t h e matter of designing a t u r b i n e f o r both

conditions.
4-3
The generator i s designed t o produce 65 W e with an estimated e f f i c i e n c y o f

98%. This capacity i s adequate t o meet t h e end-of-run power requirements o f
t h e p l a n t and s t i l l produce 50 W e o f n e t power.

\
The hydrocarbon condensers are fixed-tube sheet design desuperheating condenConstruction i s TEMA-C and material
s e r s with s i n g l e pass, low finned tubes.

carbon s t e e l .
The condensers w i l l be i n s t a l l e d i n p a r a l l e l overhead of t h e f o u r
horizontal accumulator vessels, two condensers f o r each vessel except f o r t h e

f o u r t h vessel.
The seventh condenser w i l l be i n s t a l l e d over t h i s vessel with
provision f o r adding one more condenser a t a f u t u r e date.

S i x v e r t i c a l motor-driven pumps i n p a r a l l e l a r e provided f o r hydrocarbon circulation.
The u n i t s a r e designed with 1 2 s t a g e s and allow f o r t h e a d d i t i o n

of 2 s t a g e s i n t h e f u t u r e f o r increased head requirements as hydrocarbon comp o s i t i o n i s changed t o operate with lower b r i n e temperatures.
Vertical design
satisfies t h e NPSH and head requirements f o r t h e hydrocarbon f l u i d operating
a t i t s vapor pressure i n t h e accumulators.
t h e v e r t i c a l pumps.
No booster pumps a r e required f o r
Materials of construction a r e carbon s t e e l .
The hydrocarbon inventory i s contained i n four accumulators and a s t o r a g e tank.

A v e r t i c a l 3-stage pump functions as a hydrocarbon makeup and t r a n s f e r u n i t
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
vapor removal from t h e accumulators t o f a c i l i t a t e vessel maintenance, and

minimize hydrocarbon emissions t o t h e surroundings.
Piping i s provided t o permit
t r a n s f e r of t h e vapor t o another accumulator, a condenser, o r t h e s t o r a g e tank.

A t t h e middle-of-run condition, when t h e composition of t h e working f l u i d i s
changed, t h e following equipment a d d i t i o n s t o t h e p l a n t w i l l be required:

Hydrocarbon/brine heat exchangers
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
Also, t o provide t h e required increase i n head, t h e s i x start-of-rmn, 12-stage

v e r t i c a l hydrocarbon c i r c u l a t i o n pumps w i l l r e q u i r e two a d d i t i o n a l stages.
The t u r b i n e w i l l r e q u i r e only a change o f blading.
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
middle and end-of-run requirements.
Piping as shown on t h e piping and i n s t r u -
ment diagram f o r s t a r t - o f - r u n conditions w i l l meet expected requirements

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.
The major equipment c o n s i s t s o f t h e c i r c u l a t i o n pumps, cooling tower,
basin, and t h e make-up water puplps.
The water treatment s e c t i o n c o n s i s t s of
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.
The individual equipment s p e c i f i c a t i o n s can be found under
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
11 increase, and it w i l l be necessary
cells t o t h e
Space has been allowed on t h e p l o t
Centrifugal horizontal c i r c u l a t i n g water pumps were s e l e c t e d f o r t h i s s e r cause of t h e i r low i n i t i a l c o s t and h i

3
equired 8.58 m /sec.
a d d i t i o n a l pump w i l l be furnished t o function as a spare.
4-5
As t h e b r i n e temp-
e r a t u r e decreases and t h e process conditions change, a fourth pump w i l l be

added.
The pump p i t has been designed f o r t h e addition of t h e f o u r t h pump.
A v e r t i c a l type make-up water pump has been selected.
The water w i l l be taken
out of an i r r i g a t i o n canal and, a f t e r a preliminary screen f i l t r a t i o n , w i l l be

pumped through sand f i l t e r s on i t s way t o t h e cooling tower basin.
The make-
up water rate was determined based on evaporative and d r i f t l o s s estimates and

a blowdown rate consistant with a four f o l d concentration of s o l i d s i n t h e
cooling water.
Sand f i l t e r vessels, f i l l e d with sand and a n t h r a c i t e , w i l l remove s i l t and
other p a r t i c l e s i n suspension.
An automatic system w i l l d i v e r t flow from one
vessel a t a time and reverse t h e flow of water i n order t o clean t h e f i l t e r i n g

medium.
The sediment w i l l be discharged i n t o a p i t f o r disposal.
The q u a l i t y of water w i l l be monitored continuously by an analyzer i n t h e water

treatment automatic control system.
S u l f u r i c acid w i l l be added t o t h e make-
up water i n a baffled mixing trough.
The chlorine w i l l be sparged i n t o t h e
water a t t h e discharge of t h e c i r c u l a t i o n pumps.
Corrosion i n h i b i t o r and a
dissolved s o l i d s dispersant w i l l be d i l u t e d i n mixing tanks and t h e solutions

fed t o t h e basin.
In addition, t h e water treatment system w i l l control t h e
cooling water blowdown rate.

PLANT AND INSTRUMENT A I R SYSTEM
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
Separate a i r systems are provided f o r p l a n t and i n s t r u -
A manual cross over i s provided between t h e systems so t h a t an
operator could use plant a i r i n t h e instrument a i r system i f t h e instrument
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
The compressed instrument a i r w i l l be cooled and condensables removed before

it flows t o a surge drum.
Further separation of condensables occurs i n t h i s
drum. The a i r then flows through an all-purpose f i l t e r t o remove other foreign
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
This system, shown on accompanying Drawing No. 7523-D3222, may be purchased
as a packaged u n i t .
A f l a r e system has been provided t o burn any hydrocarbon vapors escaping
through p l a n t relief valves.
If process pressures increase above t h e pressure
r a t i n g s of operating equipment, t h e p e r t i n e n t relief valves w i l l open and re-
lease vapors i n t o t h e flare system.
This system has been designed t o handle
t h e l i m i t i n g load of 104,325 kg/hr (230,000 lbs/hr) of hydrocarbon vapor t h a t

would be generated i n case a f i r e occurs i n t h e condenser-accumulator s e c t i o n
of t h e p l a n t .
The vapors w
be routed from t h e r e l i e f header i n t o a knock-
out drum where condensables, i f any, w i l l separate by gravity.
The vapors
start t h e p i l o t i g n i t i o n
i n a water seal drum u n t i l

The vapors w i l l then proe i g n i t e d by t h e p i l o t flame.
d i t i o n a l a i r w i l l be
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.
FIRE WATER SYSTEM
The f i r e water protection system i n t h e p l a n t r e l i e s on a physical separation
of p o t e n t i a l f i r e areas.
These areas coincide with t h e four major functional
areas l i s t e d above under Plant Layout.
Their physical separation permits t h e
i s o l a t i o n of each area from t h e others i n case of f i r e .
Consequently, t h e
f i r e water system has been sized t o s a t i s f y t h e l a r g e s t requirement of any

3
area. This requirement was found t o be 0.189 m /sec. (3,000 gpm) at t h e
condenser-accumulator section.
This flow o f water w i l l be provided by two
pumps s t a r t e d i n automatic sequence i n order t o maintain a 689 kPa (100 psia)

pressure i n t h e l i n e .
one by a d i e s e l engine.
One pump w i l l be driven by an electric motor, t h e o t h e r

A spare d i e s e l engine driven pump has been provided.
A jockey pump w i l l maintain t h e pressure i n t h e l i n e during normal operation
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
includes a loop header along t h e periphery of t h e p l a n t , s i x hydrants, s i x

3
0.0315 m /sec. (500 gpm) monitors, and deluge systems f o r t h e condenseraccumulator area,
t h e brine/hydrocarbon exchanger area, and t h e hydrocarbon
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
The main p l a n t e l e c t r i c a l system i s depicted i n Drawing No. 7523-D-3601.
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.
Two in-plant electrical systems a r e included i n the p l a n t design. A 4160V

system f o r motors above 200 horsepower, and a 480V system f o r lower horsepower motors, l i g h t i n g and controls. The 4160V, 20 MVA system i s shown i n
Drawing No. 7623-D-3602.
Power from the main switchgear flows t o a 3 phase,
13.8KV/4160V transformer, Substation B.
High voltage power from Substation B
i s used t o drive t h e hydrocarbon c i r c u l a t i n g pump and c i r c u l a t i n g water pump

motors.
The 3 phase 480V, 2500 KVA in-plant system i s outlined i n Drawing No. 7523-D3603 and D-3604.
A 13.8 KV/480V transformer, Substation C y feeds power t o t h e
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.
treatment system motors, a i r compressors and make-up pumps, provide indoor

and outdoor l i g h t i n g and instrumentation and control power.
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
Piping s e c t i o n s f o r Areas B and C are
The above piping drawings were prepared i n order t o e s t a b l i s h major equipment
LJ
and piping locations which provide a b a s i s f o r estimating p l a n t construction

costs.
The drawings are preliminary i n nature, therefore, piping and equip-
ment locations established during f i n a l design may vary somewhat from those
shown.
i
Piping design s p e c i f i c a t i o n s are included i n Section 6 of t h i s report.

INSTRUMENTATION AND CONTROL
Chevron has s t a t e d t h a t t h e maximum v a r i a t i o n i n well flow rate should be no
more than + 15 percent.
While well flow may be reduced quickly (on t h e
order of seconds) t h e rate must be increased slowly (on t h e order of minutes).

Because of t h i s l i m i t a t i o n it appears t h a t t h e p l a n t should be operated as
a base-load f a c i l i t y , although means f o r emergency load-shedding must be

provided.
Preliminary control i s based on t h e premise t h a t p l a n t output w i l l vary with
power demand.
i
Consequently, a load control with manual set point i s included
f o r t h e generator, c o n t r o l l i n g t h e hydrocarbon flow rate t o t h e turbine.

Brine flow r a t e i s controlled by t h e temperature of hydrocarbon vapor entering
t h e turbine.
Adjustment of hydrocarbon and b r i n e flow rates t o each p a r a l l e l
t r a i n of hydrocarbon/brine heat exchangers t o achieve balance i s manual.

Adjustment of hydrocarbon and cooling water flow rates t o each p a r a l l e l hydrocarbon condenser i s a l s o manual.
The p l a n t w i l l include a system f o r quick and o r d e r l y emergency shutdown o f
t h e t u r b i n e under conditions such as overspeed, load shed, excess vibration,
low o i l pressure o r any o t h e r condition which could damage t h e t u r b i n e o r
generator.
Major changes i n demand w i l l r e q u i r e manually s t a r t i n g up o r s h u t t i n g down
of one o r more of t h e hydrocarbon c i r c u l a t i n g pumps and perhaps cooling tower
fans.
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.
arbon analyzers will be instal d in the heat exchan

arbon condenser cooling water
et t o check fo
1eakage
brine outlet and
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
Automatic control valves will be pneumatically operated, each valve having a

current-to-air converter which accepts a 4-20 ma input signal and develops a
proportional pneumatic output to position the valve. All control valves will
have provisions for positive failure in specified positions (open or closed)
in event of an electric or pneumatic power failure.
Field-mounted instruments will be weatherproof and suitable for the electrical
classifications of the areas in which they are located.
Low voltage DC signal wires (4-20 ma, thermocouples, etc.,) will be twisted
pairs and will be run in separate conduit and raceways from AC wiring. Thermocouple extension wires will be continuous from the primary element to the cold
junction.
Equipment protection will be provided by relief valves and a flare relief
header system.
BUILDINGS AND STRUCTURES
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 o f f i c e and control building w i l l have walls of concrete block.
The roof
w i l l be bondable build-up type over insulation.
Landscaping around t h e building as well as t h e adjacent parking area w i l l be

c a r e f u l l y planned with t h e a s s i s t a n c e of a professional landscape a r c h i t e c t .
The shop and compressor building w i l l house t h e p l a n t and instrument a i r sys-
tems, t h e heavy equipment shop, and locker f a c i l i t i e s f o r t h e p l a n t employees.

The building i s approximately 25' x 50'.
be provided i n t h e shop area.
An 1800 kg h o i s t and monorail w i l l
The building w i l l be a steel Butler-type
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.
approximately 20' x 6 0 ' .

t h e chlorine cylinders.
The building i s
A n 1800 kg h o i s t and monorail i s provided t o move
This building w i l l a l s o be a steel Butler-type build-
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
t o withstand earthquake accelerations of
no less than 0.375 g coupled t o a resonance s p e c t r a observed i n t h e 1940 E l

Centro earthquake.
A l l s t r u c t u r a l s t e e l w i l l be fireproofed t o a height of 11 meters (35 f e e t )
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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REFERENCE D R A W I N G
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THE BEN HOLT CO.

MARK
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AP :I24 H I
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4-23
REFERENCE D R A W I N G
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REFERENCE DRAWING
DRAWINGNO
TITLE
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THE BEN H O U CO.
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SOTHERMAL DEMONSTRATION PLANT
TITLE
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MCC-A' SINGLE LINE DIAGRAM
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4-29
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PtPlNG ANDEQU1PMENTSYMBOI.S
INSTRUMENT SYMBOLS
rnmuuam.
REFERENCE DRAWING
nw
AIR COOLCDUUIT
'eurTWP
Y
iDu)wDowu
RUPWPa DISC
ilU
4mm
IU
DHD
XIION
XCMOOWU VALVE
5wuTbovvU
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FLOW
h
b
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iumcAm*l(i COUTWUC~R
&
&-
FLOW MCtOP WITH IUDICA;K)R
~ ~ s ~ onJRncanwt
n v e
8
6
PWWPeCORDCR
eoKco DWWDOWU OR
Y- R 4 W R U VALVE
FLOW PtCOPOlUG COWROLLER
R t C I P O a T I U Q WMP
B U R PUMP
SUMP PUMP
FLOW JwlrcH
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UNE NUMBI
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B O A R D HOUUTED INSTRUMCUT
INSTRUMEUT WITH TWO PUUCtK)US
CONTINUOUS
DPAl
PQ
(e 1,2,3, ETC. FOP S l Z a
STEAM T R A P
(eIl2,3,PTC. FOR SIZE)
RLVIYI
;SUED FOR
PUMP
ROTARY PUMP
Section 5
EQUIPMENT SPECIFICATIONS
bd
SHEET
EQUIPMENT LIST
& - 204 A.B
E
E
'61
OF
DATE
14
205 A:G
Hydrocarbon Condenser
12
2001 A,B
Air Compressor After Cooler
FS-2001
4th Stage Hvdrocarbon/Brine
A/C
REvsion
1400
Furnaces and Heaters

~
Flare Stack
203
Compressor Knockout mWn Calrod
204
Flame Front Generator

(Supplied with FS
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.
Instrument Air Compressor
2002
Plant Air Compressor
,--
- .
5-2
SHEET
EQUIPMENT LIST
CONTRACT No.
7523
REVISION
CUSTOMER Electric Power Research Institute
5-3
OF
DATE
3
-~
OF
SHEET
EQUIPMENT LIST
CONTRACT No.
7571
CUSTOMER
REVISION
DATE
Electric Power Research Institute
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

Field Mounted
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

Field Mounted
V m , 1-1/2"
Flow
-
FS
AT
Flow Switch, In-line
Hydrocarbon Analyzer Transmitter
~~
__ __
5 -8
SHEET
EQUIPMENT LIST
CONTRACT No.
7523
CUSTOMER
Instrument List
REVISION
OF
DATE

Panel Mounted
5-9
EQUIPMENT LIST
CONTRACT No.
7523
CUSTOMER
Instrument List
REVOION
DATE

Panel Mounted
5-10
hd
HORIZONTAL VESSEL DESIGN DATA

~~~
~~
CODE STAMP
AW
qpCt
VIII
OTHER SPECS.:
DESIGN PRESS.AT TEMP.
OPER. PRESS.
AT
TEMP.
STRESS RELIEVINO
WELD EXAMINATION
165 PSI AT450 OF
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
3000# Cplg ' TI

3000# Cplg
lev vel Indic

PT
Equalizing
-#
REMARKS
RF
Manwav

Heber, California
Hydrocarbon Accumulator
V-201A,B,C,D
VESSELS
REMARKS

Heber, California
Hydrocarbon Storage Tank
v-202
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"
3000# Cplg Calrod
REMARKS

Heber , California
Compressor Suction Knockout Drum
5-13
3000# Cplg Level Gage
1 1/4"
FACING

L O C A T l ON
Heber, California
SERVICE
Hydrocarbon/Brine Heat Exchanzer
SIZE 60" dia. x 59' (est. over%1# E
CEN
CONNECTED IN
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
80% Isobutane - 20% 1sOpentaI.e

7.687 (10") lb/hr
FLU1D C I R C U L A T E D
TOTAL FLUID ENTERING
TUBE SIDE
Brine (14,600 PPM Tots

Dissolved Solid
VAPOR
I 7.687 110") lb/hr
I ioiiin
NON- CONDE N SABL E S

FLUID VAPORJZED OR CONDENSED
S T E A M CONDENSED
GRAVITY-LIOUlG @TEMP
VISCOSITY-LIOUID @TEMP.
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.)
6.722 (loo] lb/hr
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
jnlet temp. to 271F-.0001

I o
to 217'F-.0011; 216'F to 177'F-.0011; 176'F to 153'F-.0033
B.T.U./HR.
1,420.8 (lob)
M.T. D. ( C o r r e c t e d 1
F O U L I N G F A C T O R (MIN.)
F.F. (tube side) 270'F
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)
see attached enthalpy diagram
5-14
PSI0
PSI6
OF
gor
0
Ip
r-
0
0
-I?
E
m
ST-s
PI
JOB NO.
7
5
2
3
ITEM No. E-205A-G

REV. NO.
DATE7/17/76
Heber, California
QUOTE NO.
Hydrocarbon Condenser
REFERENCE
overa
S I Z E 81" dia. x 52' (est.
E CJN
CONNECTED IN SERIES/PARALLEL
1/7
TOTAL SURFACE 1 101 000 ftL
7
SURFACE PER SHELL 157,286ftL NO. OF SHELLS
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
ASME Sect. VI11

BUNDLE
W/o cross baffles
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
CENTRIFUGAL PUMP SPECIFICATION

JOB N O . 3 3
CUSTOMER
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
-
BEARINGS WATER JACKETED:
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
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
PUMP, BASE, CPLG.
LE.
MOTOR
LE.
Special Instructions or Features
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
I M P E L L E R RlNGS-Ze
VERTICAL
FOOT
C/L
PUMP, BASE, CPLG.
t APT h i n 4
5-19
..
LB.
RECIPROCATING PUMP S PEClFlCATlON

GENERAL
ElePower R e s e
CUSTOMER
PLANT
G
-o
eLOCATION
Heber. California
SERVICE
Cooline Water Dispersant
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)
CORR. MATERIAL- 316 ss EROSIVE MATERIAL

%OR --P.RM.
-Oh
OR
BBM.
USERS EXPERIENCE WITH MATERIALS SPECIFIED
GOOD
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.
MATERIALS AND CONSTRUCTION FEATURES

STEAM
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
LIQUID VALVE STEMS

VALVE SPRINGS
NO PISTON RINGS
PISTON PACKING
STUFFING BOXES
GLANDS
CYLINDER L I N E R S - MATERIAL
TYPE
LUBRICATOR M A K E
COMP.
CAP'Y
HYDROSTATIC TEST-FLUID END -PSlG
HYDROSTATIC T E S T -STEAM END-PSlG
WATER RATE DESIGN LOAD

STEAM I N L E T
PSlG
STEAM E X H A U S T
PSlG
--
- 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
..
--
OPER AT ING CONDIT 10NS
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.
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.
M A T E R I A L S AND CONSTRUCTION FEATURES

STEAM CYLINDERS
PI STONS
PISTON RODS
VALVES
MTL.
NO. PISTON RINGS
P I STON PACKING
TYPE
LIQUID VALVE STEMS

VALVE SPRINGS
NO PISTON RINGS
PISTON PACKING
STUFFING BOXES
GLANDS
CYLINDER LINERS- M 4 T f R l A L
TYPE
LUBRICATOR- M A K E
COMP.
C A P'Y
HYDROSTATIC TEST- FLUID END
PISTONS
P I S T O N RODS
VALVES- MTL.
VALVE SEATS
TYPE
-_
DRIVER DATA MOT0

MAKE
TYPE
LE V
DIAMETER RODS
SIZE OF PACKING
PING WEIGHT
PUMP, BASE
MOTOR
LB
Special Instructions or Featuras
-.-
.-
FEEDS
P S IG
GENERAL
CUSTOMER E l e c t r i c Power Research I n s t i t u t e

PLANT Geothermal Demonstration Plant
NO REWIRED
LOCATION
Heber, California
DIRECT ACTINGSERVICE Cooling Water Acid
POWER FRAME ----
N AVAILABLE
P REQUIRED
S REQUIRED
FT.(liguid)
FT.(liguid)
FT.(watrr)
JOB NO. 7523

ITEM NO. p-208
REV. NO.
QUOTE NO.
REFERENCE
DATE 7- 17 - 7(
CORR. MATERIALEROSIVE MATERIAL

70OR
RBM. -O/o
OR
RPM.
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.
MATERIALS AND CONSTRUCTION FEATURES

STEAM CYLINDERS
PISTONS
PISTON RODS
VALVES MTL.
LlOUlD VALVE STEMS

VALVE SPRINGS
NO PISTON RINGS
PISTON PACKING
STUFFING BOXES
GLANDS
CYLINDER L I N E R S - MATERIAL
TYPE
LUBRICATOR- M A K E
COMP.
CAP'Y
TYPE
NO. PISTON RINGS

P I STON PACKING
PISTONS
P I S T O N RODS
VALVES- MTL.
--
--
TYPE
VALVE SEATS
HYDROSTATIC TEST-FLUID
FEEDS
END--PSlG
HYDROSTATIC T E S T -STEAM END-PSlG
DRIVER DATA -MOTOR (Pwr.Frame) STEAM DATA- (Direct Acting)

MAKE
TYPE
PHASE -CYCLE
HP
R.P.M.
V O L T S
WATER RATE DESIGN LOAD

STEAM I N L E T
PSlG
STEAM E X H A U S T
PSlG
LBS/HR.
BHP
OF
L I Q U I D END
S T E A M END
OF
VALVE
RODS
STUFFING BOX LENGTH

DIAMETER RODS
SIZE OF PACKING
NET WEIGHT
SHIPPING WEIGHT
LB
PUMP, BASE
MOTOR
PUMP,BASE
LB
S p e c l o l lnstructlons
or Feoturas
5-22
LB
Electrical Power Research Institute

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
CASING e NOZZLE
7-17-76
NO.-DATE-
NO. R E Q U I R E D ~ ( SPS+@V.
~~~
LOCATION
SERVICE
JOBNO.
SECTION DWG.
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
STUFF. BOX WATER JACKET:
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
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
PUMP, BASE, CPLG.
H.P.
~
LBSIHR. EHP.
P.S.I.G.
OF
P.S.I.G.
OF
SHIPPING WEIGHT
LE.
PUMP, BASE, CPLG.
LE.
to meet API 610 sDecification
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
K.O. Drum Pump
TURBINE DRIVE-
REFERENCE
IMPELLER
c . s.
CASE S P L I T
c. I.
SUPPORT
VERTICAL
HORIZONTAL
C/L
FOOT
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
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
CENTRIFUGAL PUMP SPECIFICATION
7523
P-2002 IA-C)
IJoBNO.

Binary Process-Geothermal Demonstration Plant
I T E M NO.
CUSTOMER
- -
- -
PLANT-
Heber. California
LOCATION
QUOTE NO.
REFERENCE
C
T
Bronze
CASE SPL1.T
I1
VERTICAL
HORIZONTAL
SUPPORT C I L
11
CASING RING
A1 lov
Graphite Impreg ASB
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:
SHAFT
DRIVER DATA
One
ltvfiP!NEhFfw=
PACKING
MOTOR DRIVE
Diesel Enpine
S E R ~ ~ C E Firewater
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

Binary Process-Geothermal Demonstration P,18p&EQu, RED
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-
BEARINGS WATER JACKETED.
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
11
SHAFT
p-2003
REFERENCE
SUPPORT C / L
11
I T E M NO.
Bronze
CASING RING
7523
DRIVEX
QUOTE NO.
TURBINE DRIVE-
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
PUMP, BASE, CPLG.
LB.
MOTOR
LE.
PUMP, BASE. CPLG.
Special Instructions or Features
5-26
LB.
THE BEN HOLT CO.

COOLING TOWER SPECIFICATIONS
LOCATION
Electric Power Reserach Institute

Geothermal Demonstratinn Plant
Heber , Ca 1ifornia
SERVICE
Hydrocarbon Cond enser C o w a k r
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
gpm. Temp. In:
Woter
OF
Temp. Out: ,
Bb/Hr.; PetfonrcTost Code.
S ELECTK)N
Manufacturer:
Model:
Type:
No. of Calls:
DESIGN
Wet Bulb Temp:
80
Fill Wetted Surf.

No. of Fans Req*d.
OF;
Static
35 (max>
Pumpin9 Hd.
Ft. Eff. Cool. Vat.
Sq. Ft; Total Wetted Surf.
Sq. Ft; Eff. Splosh S
ChdFan
Sproy Loss. Max. 9.
Fromework
Cosins
Stairway
Hdrr.
Fon Blade
Code for Lumbor Grades

**Exception: Wind Lo=ding,
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
Bolts Nuts, Mise. Hardware

Woter inlot
Fan Cylinder
In. HzO; Normal DHP/Fon
;Static Pros.
Evaporation Loss. Mor. X
Fr; Speed .
~RPM;
TYPO
T i p Speed
b mSize
TIP.-
8HP; Mechanicd Eff.
Rotod Cop.
TYPO
S o n i c . Foetor
Speed
x
RPM
Frame
REMARKS
P.O. TO:
5-27
STANDARD DATA SHEET FOR RECIPROCATING COMPRESSORS
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
.,
THE BEN HOLT CO.

Engineers-Constructors
201 So. Lake Avenue
Pasadena, California 91101
--NO.
Date
Revisions
5-28
By
TURBINE-GENERATOR

Palo Alto, California
Specification No. 2801
'
Holt Job No. 7523

March 1977
Page 1 of 23 Pages
GENERAL REQUIREMENTS
1.
SCOPE
The manufacturer shall furnish one (1) hydrocarbon turbine-generator rated

and equipped in accordance with these specifications. The manufacturer's
proposal shall include in the quoted price freight to the rail siding
nearest Heber, California. The manufacturer's proposal shall include in
the quoted price the services of an engineer to provide technical direction of installation.
2.
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

Holt Job No. 7523

March 1977
Page 2 of 23 Pages
5. PREPARATIONS FOR SHIPMENT

Preparation for shipment shall be in accordance with Section 8 of API
Standard 617. Paragraphs 8.1.3, 8.1.4, and 8.1.5 of this standard shall
not apply. The preparations for shipment of the lube and seal oil system
shall conform to Section 5 of API Standard 614.
6. LEGAL LIABILITIES
All warranties, patent rights, tax liabilities, terms of payment, and

other legal liabilities shall be clearly defined in the manufacturer's
proposal.
7.
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
8. TYPE AND DESIGN REQUIREMENTS
The turbine, which shall be rated in accordance with the requirements of

these specifications, shall be directly connected to and shall drive the
generator described herein.
When in normal operation the unit and its associated equipment shall be
sufficiently strong to withstand without injury, any strain that might
result from sudden application or withdrawal of normal load, or from any
transient speed to 120 percent of rated speed. The unit shall be designed
to conform to all API mechanical specifications for equipment handling
highly flammable fluids, i.e., API Standard 617.
A system torsional and lateral critical speed analysis shall be made.
The design flow requirements for the turbine at rated throttle conditions
are as specified below:
5-30
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Page 3 of 23 Pages
Fluid
Flow Rate
Inlet Pressure
Design Pressure
Inlet Temperature
Design Temperature
Outlet Pressure
Efficiency
Rated Horsepower
80% Isobutane, 20% Isopentane

3,490,000 kg/hr (7,687,000 lb/hr)
3,450 kPa (500 psia)
4,480 kPa (650 psia) and full vacuum
146 C (295 F)
182 C (360 F)
498 kPa (72.3 psia)
85%
83,560
It will also be designed to be easily and inexpensively modified to meet

the following requirements:
Fluid
Flow Rate
Inlet Pressure
Inlet Temperature
Outlet Pressure
Efficiency
Rated Horsepower
10% Propane, 90% Isobutane

4,098,000 kg/hr (9,027,000 lb/hr)
4,067 kPa (590 psia)
140 C (285 F)
660 kPa (96.1 psia)
85%
88,900
9. CONSTRUCTION AND FEATURES
9.1 General
All parts which are subject to temperature c,.anges shall be des-,pel

and supported so as to permit free expansion and contraction in an
effort to minimize harmful distortion or misalignment.
9.2
Turbine Casings and Diaphragms

Turbine casings shall conform to API Standard 617, Section 2.3 and
Section 3. Provisions shall be made in the design of the turbine
to control thermal stresses in the turbine casing. The main horizontal joint and/or the main vertical joint in the turbine shell
shall be metal to metal. The turbine shells and diaphragms shall
be supported so that their movement relative to the shaft be minimized. Their design shall be made to minimize the time required
for an inspection or a repair. A design which permits bearing
inspection or removal without removal of the turbine shells is
required. The casing shall be equipped with suitable drains.
5-31
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Holt Job No. 7523

March 1977
Page 4 of 23 Pages
9.3 Turbine Rotor

The rotor shall be stiff-shaft type and conform to the requirements
of the appropriate section of API Standard 617. The completed turbine rotor shall be balanced in the manufacturer's plant so as to
run smoothly and without excessive vibration. After machining operation of the rotor, it shall be given a heat stabilization test to
minimize thermal stresses. A grounding device shall be provided
between the stationary and rotating parts of the turbine to prevent
the flow of turbine shaft currents between the rotor and the bearings.
Provision shall be made in the design of the rotor to minimize stress
concentrations.
9.4 Buckets
(Axial Flow Turbines)
The turbine buckets shall be securely and adequately anchored and

shall be readily renewable. Welding of buckets to wheel disc will
not be acceptable in any stage. The natural frequency of the buckets
shall be such as to avoid resonant vibration at or near normal operating speed.
9.5 Shaft Sealing
A shaft sealing system shall be provided which will prevent the escape of hydrocarbon from the shaft ends and also prevent sealing
oil from entering the turbine casing. The seals shall conform to
Section 2.15 of API Standard 617. The seals may be either Labyrinth
Type or Mechanical (Contact) Type as described in Paragraphs 2.15.3a
and 2.15.3b.
9.6 Turbine Stop and Control Valves
The unit shall be equipped with an emergency stop or throttle valve

which will include provisions to actuate the main circuit breaker
when the valve is closed and also provisions for testing while unit
is in operation. It shall include a solenoid trip and signal
switches to indicate the valve position. The valve shall be located
in the proximity of the front of the unit or on the casing. Supports for the valve shall be supplied as well as piping to connect
stop valve to turbine.
A removable corrosion-resistant integral strainer shall be furnished

with the emergency valve with a temporary fine mesh strainer for
startup.
5-32
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TURBINE-GENERATOR

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Page 5 of 23 Pages
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
An automatic speed governor shall be supplied which will regulate

the flow to the turbine through a suitable governing mechanism. It
shall prevent the unit from reaching the overspeed tripping point
in the event of an instantaneous change in load from full to no
load. The governor shall be furnished with a means of manually
limiting the turbine-generator output. The governor shall be furnished with an adjustment for regulating the speed and/or load of
the turbine-generator manually from a remote location.
In addition to the automatic speed governor, a separate quick acting
emergency governor will be furnished that will cause flow to be shut
off to the unit when it reaches approximately 10 percent overspeed,
but can be reset when the speed is reduced to approximately normal,
thus permitting the unit to be synchronized with other units. This
governor shall be of a type which can be tested at no load.
9.8 Hydraulic, Lubrication and Seal Oil System
A complete hydraulic fluid system shall be furnished to provide hydraulic fluid to the turbine control valve gear and emergency trip
system. This system may be combined with the lubricating oil and
Oil reservoir
Oil coolers
Oil filters
5-33
TURBINE-GENERATOR
Electric Power Research I n s t i t u t e

Holt Job No. 7523

March 1977
Page 6 of 23 Pages
A l l system components s h a l l be i n accordance with t h e applicable

sections of API Standard 614. I n t e r p r e t a t i o n of t h i s standard s h a l l
be as follows:
General - Paragraphs 2.1.2,

614 s h a l l not apply.
2.1.4,
2.1.7,
and 2.1.9 of API Standard
O i l Reservoirs - Paragraphs 2.2.6,

614 s h a l l not apply.
2.2.7,
and 2.2.13 of API Standard
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.
Coolers - Coolers s h a l l be i n accordance with Section 2.4 of API

Standard 614.
F i l t e r s - F i l t e r s s h a l l be i n accordance with Section 2.5 of API
Standard 614.
Overhead Tanks
Paragraph 2.7.4 of API Standard 614 s h a l l not apply.
Seal O i l Drain Traps - Paragraph 2.9.la of API Standard 614 s h a l l

not apply. The vent gas s h a l l be piped t o t h e turbine exhaust and
t h e drain l i n e s s h a l l be piped t o t h e o i l reservoir.
Piping - Piping s h a l l be i n accordance with Section 2.11 of API
Standard 614.
Controls and Instrumentation
of API Standard 614.
Shall be i n accordance with Section 3
Drawings s h a l l be provided i n accordance with Paragraphs 6.1.2 and

6.1.5 of API Standard 614.
9.9
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
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TURBINE-GENERATOR

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March 1977
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All radial bearings must be split to permit removal of the upper

half for inspection and must be removable without removing the rotor.
Radial bearings shall conform to Paragraph 2.13.1 of API Standard
617.
A thrust bearing shall be provided to maintain the correct axial relationship between the rotating and the stationary parts. The axial
position of the turbine rotor must be adjustable when the unit is at
rest. Thrust bearings shall conform to Paragraph 2.13.2 of API
Standard 617.
9. 0 Vibration and Balance
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
a tachometer generator and an indicating instrument.

Industrail dial-type thermometers and wells shall be provided for all main
bearings and thrust bearing oil drains and for the oil cooler outlet temperatures.
A thrust failure trip device shall be provided
for both active and inactive
sides of thrust bearing.
5- 35
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Holt Job No. 7523

March 1977
Page 8 of 23 Pages
complete turning gear system shall be furnished with necessary interlocks

to prevent the turning gear from operating until proper oil pressure has
been established. Engagement of the turning gear at standstill shall be
accomplished by hand.
All special maintenance tools shall be furnished including sledging

wrenches for bolts and nuts 1-1/2" and larger, eyebolts, casing guide pins,
jacking bolts, turbine casing lifting slings, turbine rotor lifting slings,
and other tools depending on special turbine construction.
Low hydraulic pressure alarm switch, piped and wired to a terminal board.
Turbine bearing low oil pressure alarm switch.
'Soleplates are to be furnished.
Metal lagging for high temperature parts of the turbine and heat retention
insulation for installation by the purchaser as follows:
Plastic insulation for upper and lower turbine shells and valve
bodies.
A coupling for connecting the turbine and generator shafts shall be
provided. The coupling shall be balanced.
Block insulation for stop valve flanges and flanges at the turbine
she11.
Reusable blankets and/or block type insulation for the horizontal
and vertical shell flange joints.
I11 GENERATOR
12. TYPE AND DESIGN REOUIREMENTS
The generator shall be an alternating current synchronous generator,
rated in accordance with the requirements of these specifications, and
shall be directly connected to and driven by the turbine described herein.
The generator shall be of the nonsalient pole revolving field type.
The telephone influence factors of the generator shall be in accordance
with the latest ANSI and NEMA standards.
Lid
5-36
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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
Snecification No. 2801

Holt Job No. 7523

March 1977
Page 10 of 23 Pages
13. CONSTRUCTION AND FEATURES

13.1
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

Holt Job No. 7523

March 1977
Page 11 of 23 Pages
housing in such a manner as will permit removal from service for

cleaning of any one section when required without shutting down the
generator. Cooler tubing material shall be 90-10 copper nickel.
Maximum cooling water temperature is 32 C (90 F).
14. ACCESSORIES
In addition to those accessories already mentioned in the specifications
above, the following shall be included:
Steel oil piping shall be provided to the main bearings to the requirements set forth in a previous paragraph.
Industrial dial-type thermometers and wells shall be provided for main
bearing oil drains.
The generator shall be equipped with six temperature detectors embedded
in the stator windings, four temperature detectors in the gas cooler outlets, and four in the gas cooler inlet.
Special wrenches for all special bolts and nuts and lifting equipment
for the generator rotor shall be furnished, including a rotor lifting
sling and rotor skid with shims.
Sole plates are to be furnished.
IV EXCITER
15. TYPE
The exciter shall be of the nonrotating type and rated in accordance with
the requirements of these specifications. The exciter shall supply generator field excitation by utilizing power from the armature terminals of
the generator. The excitation system shall regulate and maintain the desired terminal voltage as specified herein. The excitation system shall
consist of power transformers, rectifiers,
- --and excitation controls.
16. CONSTRUCTION AND DESIGN CONSIDERATIONS
The exciter shall be wide range stablized to permit stable operation down
to 25 percent of rated exciter voltage on manual control. The exciter
5-33
TURBINE-GENERATOR
Electric Power Research I n s t i t u t e

Holt Job No. 7523

March 1977
Page 1 2 of 23 Pages
c e i l i n g voltage as defined by.ANSI manual standards w i l l be a t least

120 percent of r a t e d voltage when operating with a load r e s i s t a n c e equal
t o t h e generator f i e l d . The e x c i t e r s h a l l be capable of supplying ceiling e x c i t a t i o n under load f o r a t least one minute. The rate of response
of t h e e x c i t e r as defined by ANSI standards w i l l be a t least 0.5. The
response r a t i o w i l l be 0.5 foz an e r r o r s i g n a l of 10 percent. Terminal
voltage s h a l l be held within -0.5 percent no load t o f u l l load a t r a t e d
voltage
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.
T e s t a u x i l i a r y o i l pump regulator, i f applicable.

Speed governor t e s t and adjustment.
Emergency overspeed governor t e s t and adjustment.
Stop valve o r t h r o t t l e valve t e s t .
Balance of turbine r o t o r and operation of turbine r o t o r t o
110 percent of r a t e d speed f o r at least t h r e e minutes.
Assembly of turbine.
Physical and chemical analysis of major r o t a t i n g p a r t s .
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

Holt Job No. 7523

March 1977
Page 13 of 23 Pages
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
The standard test voltage shall be an alternating volteffective Val

ill be ten times the field rated
excitation voltage but not less than 1,500 V. The test shall
be applied for 60 seconds duration.
Air leakage test of stator frame.
Resistance temperature detector tests.
Physical and chemical analysis of major rotating parts.
17.3
Transformers
Polarity test.
Induced potential test at twice operating voltage for not less

than 400 cycles.
5-41
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 14 of 23 Pages
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.
VI DATA AND INFORMATION TO BE SUBMITTED IN PROPOSALS

18. GENERAL
Each manufacturer shall furnish, in his proposal, all the complete data
to fully describe the equipment proposed. The data shall include, but
not be limited to, the following information and all items must be fully
covered in a complete manner.
18.1 Combined Turbine-Generator Unit
Dimensioned outline prints of the turbine-generator unit, 'giving
approximate weights on the foundation and showing main piping connections.
A list of all accessories shall be furnished. This shall include
all accessories required by these specifications.
A list of turbine, generator, and exciter tests.
Manufacturer's comments, interpretations, and exceptions to this
specification.
Manufacturer's experience or installation list of units similar to
the type required by this specification.
5-42
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 15 of 23 Pages
'
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.
maximum cooling water
Description of method of cooling stator and rotor.
5-43
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 16 of 23 Pages
Lid
For hydrogen cooled generators, description of hydrogen cooling

system, and shaft-seals.
18.4 Exciter
Description of excitation system and each major component.
Nominal excitation rating, voltage, and amperes.
List of devices which must be mounted by Purchaser.
18.5 Fill in Data
Manufacturers shall answer all questions as briefly as possible.
These shall represent their best judgement as to what is proposed
in the manufacturer's design. This is not meant to restrict the
successful bidder to supplying a final design in all details as
filled in on this sheet. It is meant primarily to compare bids
for evaluation purposes.
Manufacturer
Overall dimensions and weights (approx.)
,
Length (above floor)

Width
Height above floor
Minimum distance required from floorline
to CL crane hood to lift largest piece.
During erection
(Specify which piece)
After erection
(Specify which piece)
How far forward from front end of turbine
below floor does oil tank extend?
Lit#
5 -44
LJ
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 17 of 23 Pages
Does purchaser have flexibility

in locating oil tank below floor?
Yes
No
Yes
No
If (Yes) what are approximate

limitations?
What are the pulling dimensions from CL
of generator for removing generator field?
Straight pull
Canted
Approximate box dimensions of components
Oil Tank (including oil coolers)
Seal Oil control unit (if applicable)
H2 cabinet (if applicable)

Excitation cubicle
Assembled weight of turbine complete without
external accessories
without external a
Shipped assemble
during erection
LJ
Heaviest piece and weight to be handled

after erection
5-45
L,
,
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 18 of 23 Pages
18.6 Turbine-Generator Features (ADDroximate Datal

TVpe of turbine
Impulse
Reaction
Combination impulse-reaction
Number of stages
Stop or Trip Throttle Valves:
Number
Where located
Casing
Method of support
Material
Number of inner shells
Methods employed in construction
and/or operating procedures to
reduce thermal stresses
Size of openings:
Inlet
Exhaust
Turbine rotor
Material
Built-up wheels, solid, or combination
Blading fastening method
5 -46
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 19 of 23 Pages
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
Are sight flows provided
No
Oil System
Capacity of oil tank (gals)
5-47
Yes
L,
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 20 of 23 Pages
Number and type of pumps on oil tank
Type of main pump

What provisions for isolating oil tank
from H2 shaft sealing system
Are pressurized oil feedlines guarded
(yes or no)
Oil Coolers
Number
Total cooling capacty (%)
Tubing diameter and thickness
Tubing material
Required cooling water flow rate
at 35 C (95 F) max. temperatures
Governing
Type of system
Manufacturer
Maximum predicted speed under
rejection of maximum load
Can emergency governor be tested
5-48
Yes
No
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 21 of 23 Pages
How is generator core mounted?
Number of generator coolers

How mounted
% load with one cooler out of service
Type of H2 seal (if applicable)

Can bearings be inspected without
removal of H2 (if applicable)
Armature winding material
Armature slot material
Method of fastening end turns of
armature bars
Method of balancing generator rotor
'bd
Synchronous at rated current Xd
5 -49
Lid
,
,
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 22 of 23 Pages
SCR at rated KVA

Total generator loss excluding bearings
Kw
Generator efficiency at rated KVA and

rated power factor
Generator regulation at rated KVA and

rated power factor
H2 consumption
H2 98% purity
206 kPa (30 psia),
Guaranteed
cu.ft./24 hours
Expected
cu.ft /24 hours
H2 required to fill to 30 psig after

purging
cu.ft.
C02 required to scavenge H2
purge air
cu.ft .
cu.ft.
Generator field current at maximum

excitation
18.7 Installation Data
Will turbine be shipped assembled
Yes
No
Will generator be shipped assembled
Yes
No
Will oil tank and coolers be shipped

assembled
Yes
No
Are electrical connections made up to

junction boxes at the factory or in the
field
What portion of oil piping is prefabricated in the factory
5-50
(%I
TURBINE-GENERATOR

Holt Job No. 7523

March 1977
Page 23 of 23 Pages
What portion of the hydrocarbon piping is

(%I
prefabricated in the factory
What portion of seal oil piping is prefabricated at the factory (if applicable)
(%I
5-51

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Preliminary Design Manual for a

Geothermal Demonstration Plant

EPRl Project Manager

PERFORMANCE OF VARIOUS GEOTHERMAL

INSTRUMENTATION AND CONTROL

DRAWING NO. 7523-E-3246, REV. C - BINARY PROCESS

DRAWING NO. 7523-D-3222, REV. B - FLARE SYSTEM PGID

DRAWING NO. 7523-D-3604, REV. B - BINARY PROCESS

In October 1975, the Electric Power Research Institute authorized Holt/Procon

The geothermal reservoir at Heber, California is technically

Following completion of Part A, a preliminary design study of a 50 W e binary

A working fluid containing 20 percent i'sopentane and 80 percent isobutane was

Trade-off studies were performed to determine optimum design conditions for

Operational economy is favored by a low pinch temperature

updated cost estimate of the demonstration plant was prepared. The

The cost of power delivered to a load center was calculated to be 35.84

prepared in a separate volume which includes:

schedule for applications and permits

"Comparison of Hydrothermal Reservoirs in the Western United

This manual presents t h e r e s u l t s of Tasks 1, 2 and 3 .

- Geotechnical Environmental Aspects of Geothermal

Preliminary Environmental Assessments of Geothermal Power Generation a t Heber, California

Socioeconomic Environmental Aspects of Geothermal

Draft r e p o r t s f o r Task B-5 were submitted i n April.

These r e p o r t s have been

Baseline configuration description

Plant requirements document

Capital cost estimate

Long lead items procurement s p e c i f i c a t i o n s

I n P a r t A, previously reported, conceptual designs were prepared by t h r e e pro-

cesses a t t h r e e sites. These designs and t h e accompanying c o s t estimates were

Following t h e s e l e c t i o n of a s i t e (Heber) and a process (binary) we focused

Maps showing t h e f i e l d location are presented i n

a separate report e n t i t l e d "Preliminary Environmental Assessments of Geothermal

An exact s i t e location w i l l be selected

during t h e f i n a l design phase of t h e work.

The geothermal-electric energy conversion p l a n t w i l l occupy approximately

A p l o t plan f o r t h e plant s i t e i s contained i n Section

The production and i n j e c t i o n wells w i l l be d r i l l e d on approximately 0.6 km

p l a n t w i l l be located adjacent t o t h e production wells.

The exhausted reser-

v o i r f l u i d w i l l be returned t o t h e i n j e c t i o n wells i n a buried pipeline.

Annual average p r e c i p i t a t i o n i s 7.1 c m (2.8 inches), and average d a i l y

Summer dry bulb temperature exceeds 37 C (100 F).

The average minimum Winter

temperature i s -2 C (28 F).

Average d a i l y r e l a t i v e humidity ranges between 20 and 30 percent.

of t h e proximity of Heber t o numerous a c t i v e f a u l t s , a design acceleratim of

Water f o r plant cooling and potable uses w i l l be drawn from t h e s e

drain system as is c u r r e n t l y being done a t t h e San Diego Gas & Electric

Sanitary wastewater will be treated in a septic tank and dispersed through

temperature of 182 C (360 F).

The r e s e r v o i r f l u i d has a t o t a l dissolved s o l i d s content of about 15,000 ppm.

No accurate analysis has been made t o determine t h e quantity of noncondensable

tests conducted by Chevron i n d i c a t e t h a t t h e noncondensables ( i f any) w i l l

r a t e a t temperatures above 132 C (270 F), but below t h a t temperature fouling

From t h e i r d a t a w e estimated t h e following tube-

s i d e fouling f a c t o r s which were used i n t h e design of brine/working f l u i d heat

These f a c t o r s are t e n t a t i v e i n t h a t t h e r e s u l t s of a 22-day t e s t have been

t o obtain additional corrosion data.

This work i s being funded by EPRI and

No corrosion was observed on t h e titanium

tubes a f t e r 560 hours' exposure; some corrosion occurred t o t h e cupro nickel

were observed on t h e carbon steel tubes a f t e r 560 hours of t e s t i n g .