PDF

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.
i
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 Re-
search 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
2 piping system, instruments and controls, and buildings and structures.
iii
L,
TABLE OF CONTENTS
Section -
Page
1 SUMMARY 1-1
2 INTRODUCTION 2-1
3 DEVELOPMENT OF DESIGN 3-1

._
SITE DESCRIPTION 3-1
DESIGN BASIS 3-3
i
PROCESS DESIGN 3-5
TRADE-OFF STUDIES 3-10
ECONOMIC ANALYSIS 3-17
FIGURE 3-1 PERFORMANCE OF VARIOUS GEOTHERMAL

BINARY CYCLES 3-20
FIGURE 3-2 ALTERNATIVE PUMP CONFIGURATIONS 3-21
FIGURE 3-3 ESTIMATE SUMMARY SHEET 3-22
TABLE 3-1 EFFECT OF BRINE/HYDROCARBON EXCHANGER
PINCH POINT ON POWER COST 3-23
TABLE 3 - 2 EFFECT OF CONDENSER LOG MEAN TEMPERA-
TURE DIFFERENCE ON POWER COST 3-24
TABLE 3-3 EFFECT OF COOLING TOWER APPROACH TO WET
BULB TEMPERATURE ON POWER COST 3-25
.- 3-26
3-27
3-28
- BINARY PROCESS
DIAGRAM GEOTHERMAL DEMONSTRATION
START OF RUN 3-29
- BINARY PROCESS FLOW
3-30
V
TABLE OF CONTENTS
Section Page
4 DESCRIPTION OF FACILITIES 4-1
,
PLANT LAYOUT 4-2
ENERGY CONVERSION SYSTEM 4-3
COOLING WATER SYSTEM 4-5
PLANT AND INSTRUMENT AIR SYSTEM 4-6
FLARE SYSTEM 4-7
FIRE WATER SYSTEM 4-8
ELECTRICAL SYSTEM 4-9
PIPING 4-9
INSTRUMENTATION AND CONTROL 4-10
BUILDINGS AND STRUCTURES 4-12
DRAWING NO. 7523-E-3242, REV. C - BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT PLOT PLAN 4-15
DRAWING NO. 7523-E-3215, REV. C - BINARY PROCESS P&ID
GEOTHERMAL DEMONSTRATION PLANT, HEBER,
CALIFORNIA 4-17
DRAWING NO. 7523-E-3246, REV. C - BINARY PROCESS
COOLING WATER PGID GEOTHERMAL DEMONSTRA-
TION PLANT, HEBER, CALIFORNIA 4-19
DRAWING NO. 7523-E-3221, REV. C - INSTRUMENT & PLANT
AIR P&ID GEOTHERMAL DEMONSTRATION PLANT 4-21
DRAWING NO. 7523-D-3222, REV. B - FLARE SYSTEM PGID

GEOTHERMAL DEMONSTRATION PLANT, HEBER,
CALIFORNIA 4-23
DRAWING NO. 7523-D-3601, REV. B - BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT MAIN
SINGLE LINE DIAGRAM, HEBER, CALIFORNIA 4-25
-
DRAWING NO. 7523-D-3602, REV. B BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT, 4160 V.
DRAWING NO. 7523-D-3603, REV. B - BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT "MCC-A"
vi
TABLE OF CONTENTS
Section -
Page
4 (Cont.) DRAWING NO. 7523-D-3604, REV. B - BINARY PROCESS

GEOTHERMAL DEMONSTRATION PLANT "MCC-B"
DRAWING NO. 7523-E-3261, REV. B - BINARY PROCESS
GEOTHERMAL DEMONSTRATION PLANT PIPING
AREA LOCATION PLOT PLAN 4-33
GEOTHERMAL DEMONSTRATION PLANT AREA "A"
PIPING PLAN, PUMP PIT G COOLING TOWER 4-35
GEOTHERMAL DEMONSTRATION PLANT AREA "B"
PIFTNG PLAN, GRADE TO ELEVATION 18'-0" 4-37
DRAWING NO. 75L3-E-3264, REV. B - BINARY PROCESS
PIPING PLAN, ELEVATION 18'-0" AND ABOVE 4-39
GEOTHERMAL DEMONSTRATION PLANT AREA "D"
PIPING PLAN 4-41
PIPING SECTIONS, SEC. "A-A" 4-43
GEOTHERMAL DEMONSTRATION PLANT AREA "C"
PLAN, PIPING SECTIONS 4-45
DRAWING NO. 7523-D-3258, REV. A - PIPING STANDARD
SYMBOLS FOR PROCESS FLOW DIAGRAMS AND
PIPING AND INSTRUMENT DIAGRAMS 4-47
5 EQUIPMENT SPECIFICATIONS 5-1
EQUIPMENT LIST 5-1

VESSELS 5-11
HEAT EXCHANGERS 5-14
PUMPS 5-17
COOLING TOWER 5-27
COMPRESSOR 5-28
TURBINE/GENERATOR 5-29
vi i
W 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.
0 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.
0 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
and increased working fl lation at the lower reservoir
temperature while still maintaining a net output of 50 W e .
1-1
L,
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.
0 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.
0 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.
0 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.
An 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 esti-
mating procedure.
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
U
mid-range plant operating condition. Piping and instrumentation diagrams
have been revised and expanded to reflect the improved plant design. Prelimi-
nary 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 require-
ments 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 A schedule for applications and permits
0 A schedule for engineering and construction
0 A critical path schedule showing the time sequence of the
critical function affecting plant completion
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 sub-
mitted in a series of draft reports listed as follows:
0 "Comparison of Hydrothermal Reservoirs in the Western United
States"
0 "Reservoir Engineering and Aspects of Geothermal Site Selec-
tion at Heber, California and Valle aldera, New Mexico"
0 "Energy Conversion and Economics fo eothermal Power Genera-
tion at Heber, California; Valles Caldera, New Mexico; and
Raft River, Idaho - Case Studies"
0 "Preliminary Environmental Assessments of Geothermal Power
Generation at Heber, California"
e "Geotechnical Environmental Aspects of Geothermal Power Genera-
tion at Heber, California"
i
0 llSocioeconomicEnvironmental Aspects of Geothermal Power Gen-
eration 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
0 TASK B-5 - Environmental Assessment

W
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 "Imple-

mentation 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 - Preliminary Environmental Assessments of Geother-

mal Power Generation a t Heber, California
0 Volume I1 - Geotechnical Environmental Aspects of Geothermal
Power Generation a t Heber, California
0 Volume I11 - Socioeconomic Environmental Aspects of Geothermal
Power Generation a t Heber, California
0 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
0 Baseline configuration description
0 Plant requirements document
0 Equipment specifications
0 Capital cost estimate
0 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 pre-
sented 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
2
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 . The
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
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. The
2
allowable s o i l bearing pressure i s 7,200 kg/m (1,500 p s f ) .
Imperial County i s located within Seismic Zone 3, f o r which a design accelera-

t 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. Water f o r plant cooling and potable uses w i l l be drawn from t h e s e
canals. 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.
LiJ
3-2
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/south-
southeast 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 techni-
cally 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 elec-
trical capacity in order that the cost of power produced from the plant would
ompetitive with methods of generating electric
2
%
reported to hav temperature of 182 C (360 F).
y has predicte rature of the brine would
re to a temperature
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.
b
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 132 350 t o 270 ,0001

132 t o 80 270 t o 176 .OOll
80 t o 65 176 t o 148 .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. Chevron has indicated t h a t corrosion during t h e i r test work
was negligible. 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 per-
cent 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 evolu-

tionary one. Initially the problem is loosely specified and there are
E
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 uni-
formly 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 con-
figuration. A large number of configurations were studied to this end. A
J wide spectrum of aliphatic hydrocarbon fluids including pure hydrocarbons
and mixtures of two and three hydrocarbons were analyzed at various tempera-
I
and 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 necessi-
tated 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 Studying fluids not included in the initial study
0 Establishing the economic sensitivity of the major design
parameters
0 Analyzing the behavior of the various processes at mid-run
"off-design" conditions
0 Reviewing the most promising cycles and screening out those
that presented serious technical or equipment problems
A 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 two-
component 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 per-
formance of the preferred end-of-run case in the Energy Conversion Study.
u
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 two-
phase region without loss of efficiency is a worthwhile objective.)
The process design of plants for mid-run and "off design" conditions involves
t 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
with cycles on either side. This means that flow rates, operating
llmeshll
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
5
In actual practice, the heat exc surface requirements for the
-run case actually decrea g brine temperature due to a
in the log-mean t difference (LMTD). Since the
c
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-of-
run 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 182 C (360 F)
Flow Rate 3.05 x 106 kg/hr (6.72 x 106 lbs/hr)
Hydrocarbon Working Fluid

Composition 80% isobutane, 20% isopentane
(mole basis)
6 6
Flow Rate 3.49 x 10 kg/hr (7.69 x 10 lbs/hr)
Gross Generator Output 61 W e

In-plant Load 11 MWe
-
Net Power Output 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 tempera-
ture of 146 C (295 F). The super-critical vapor drives an expansion turbine
connected to an electrical generator. Exhaust vapor from the turbine is con-
densed 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. LJ
3-8
LJ We 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)
Flow Rate 6
3.48 x 10 kg/hr
(7.66 x lo6 lbs/hr)
Hydrocarbon Working Fluid
Composition 90% isobutane
(Mole basis) 10%propane
Flow Rate 6
4.09 x 10 kg/hr
6
9.03 x 10 lbs/hr)
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. Because of t h e decreasing b r i n e temperature, more b r i n e w i l l
be required. 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. The t u r b i n e may have t o be modi-
I
f i e l d t o handle t h e increased flow. 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
6 6
increase to 4 . 4 7 x 10 kg/hr (9.86 x 10 lbs/hr). However, the rate of circu-
ti
lation of the working fluid remains constant.
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 Minimum temperature difference (pinch) in the brine/hydro-
carbon exchangers
0 Log mean temperature difference in the hydrocarbon condenser
0 Cooling tower approach to the atmospheric wet bulb temper-
ature
0 Cooling water temperature rise
0 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 esti-
mate 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 rela-
tively 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 some-
what lower than t h e power c o s t s calculated f o r t h e preliminary design pre-
sented 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. As
3-11
Ld
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-
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. The n e t
Lid
3-12
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 temper-
ature 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. How-
ever, 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)
W
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
rise. 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
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

0 S e r i e s and/or p a r a l l e l flow
0 Motor and/or turbine d r i v e
0 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. Piping schematics
of t h e a l t e r n a t e s a r e shown on Figure 3-2. A b r i e f description of t h e a l t e r -
n a t e s follows:
Alternate I, - 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

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
Alternate 111, - Three v e r t i c a l pumps i n p a r a l l e l ; two turbine,
one motor d r i v e
Alternate I 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
Alternate V, - Two systems i n p a r a l l e l , each system con-
s 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 :
0 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
0 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.
0 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
c 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

t o t h a t used i n one of t h e trade-off udies conducted t o optimize t h e process.
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: turbine-expander - 85

per cent, generator - 98 percent, pump t u r b i n e d r i v e r s - approximately 83
percent. 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
V 4,665,000
IV 4,749,000
I 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. F l e x i b i l i t y is a l s o limited
3-16
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 manufac-

turer 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
a n t i c i p a t e d temperature decline. 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.
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.
b
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.
0 Fee, contingency and escalation were increased in proportion
to total plant cost.
I
This estimate, like the earlier one, is for a battery limits plant. Excluded
from the cost are the following:
0 Cost of field collection and reinjection facilities
0 Cost of electrical transmission facilities to a load-
center
0 Cost of land
0 Costs incurred by the Owner for managing the project and for
obtaining the necessary permits to construct.
0 Cost of royalties, if any
0 Interest and taxes during construction
As before, the estimate assumes that the project will be completed by late
1979 and escalation is estimated on this basis.
An additive expenditure of about $3,800,000 will be required to modify the

plant for low temperature operation. This expenditure assumes that the addi-
tion 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.
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:
This Case Base Case
Mi11s/kwh Mi11s/kwh
Cost of Energy 16.53 16.60
Cost of Power Conversion 19.03 18.25
Cost of Transmission 0.28 0.28
Total Cost 35.84 35.22
A 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
A - 50/50 ISOBUTANE-ISOPENTANE
Li
B - 35/55 PROPANE-ISOBUTANE
C - 20/60/20 PROPANE-ISOBUTANE-ISOPENTANE
D - 80/20 ISOBUTANE-ISOPENTANE
E - 80/20 ISOBUTANE-ISOPENTANE
F - 10/90 PROPANE-ISOBUTANE
1 I I I
165 170 175 180
330 340 350 360
Figure 3-1. Performance of Various Geothermal Binary Cycles
3-20
CAPACITY:
9700 GPM
CAPACITY 9700 GPM €A
ALTERNATE I ALTERhlAE II ALTERNATE Ill
4r c
1252 GPM
CAPACIT*
CAPACITY: MOO0 GPM
ALTERNATE
fi CAPACITY:
145006PI.l
CAPACITY: Id500 0PI.l
boooclp
I I
I
ALTEKNATE P
Figure 3-2. Alternative Pump Configurations
3-21
CUSTOMERElectric Power Research Institute
LOCATION- REV. NO. DATE 10/1/76
ACCOUNT Materials Subcontract Labor TOTAL
I100 Columns (incl. trays)
1200 Pressure Vessels 230,000 230,000
1300 Heat Exchangers 3,252,000 3,252,000
1400 Furnace/Heaters
1500 Pumps 1,144,000 1,144,000
1600 Boilers
1'100 Cooling Towers 1,150,000 1,150,000
I800 Turbine-generator 3,593,000 3,593,000
1900 Water Treatment 201,000 201,000
2800 Other 134,000 134,000
Labor 143,000 143,000
Freight 350,000 34,000 384,000
r O T A L MAJOR EQUIPMENT 8,904,000 1,184,000 143,000 10,231,000

3100 Concrete 568,000 169,000 535,000 1,272,000
3200 Pipe, Valves, Fittings 1,500,000 400,000 229,000 2,129,000
3300 Structural Steel 512,000 72,000 584,000
1400 Instruments 600,000 600,000
1500 Painting '75,000 75,000
I600 Electrical 1,900,000 1,900,000
I700 Insulation 490,000 490,000
I800 Paving, Roads, Fences,Mi :. 84,000 78,000 114,000 276,000
I900 Bui Idings 46,000 102,000 14,000 162,000
r O T A L CONSTRUCTION ITEMS 2,710,000 3,814,000 964,000 7,488,000
I I R E C T F I E L D COSTS 11,614,000 4,998,000 1,107,000 17.719.000
ndirect Field Costs (DE. 2) 329,000 2,356,000 2,68 5,000
r O T A L F I E L D COSTS 11,943,000 4 998,000 3,463,000 20,404,000
1200 Home Office Services 3,119,000.
iU6-TOTAL 23,523,000
I500 Sales Tax on Material 711,000
I200 Fee + 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
-~
PINCH POINT 5.5 C (10 F) 8 . 3 C (15 F) 11.1 C (20 F)
PLANT OPERATING CONDITIONS

BRINE RATE, lo3 kg/hr (lo3 l b s / h r ) 2,936 (6,473) 3,076 (6,781) 3,245 (7,155)
HYDROCARBON* CIRCULATION RATE, lo3 kg/hr (lo3 l b s / h r ) 3,639 (8,023) 3,639 (8,023) 3,639 (8,023)
TURBINE INLET - PRESSURE, kPa (psia) 3,447 (500) 3,447 (500) 3,447 (500)
- TEMPERATURE, C (F) 149 (300) 149 (300) 149 (300)
TURBINE OUTLET - PRESSURE, kPa (psia) 458 (66.4) 458 (66.4) 458 (66.4)
-
TEMPERATURE, C (F) 68 (154) 68 (154) 68 (154)
COOLING WATER - TEMPERATURE, C (F) 32 (90) 32 (90) 32 (90)
CIRCULATION RATE, lo3 m3/hr (lo3 gpm) 26.96 (118.7) 26.96 (118.72 26.96 (118.71
PLANT CAPITAL COST, K $

MAJOR EQUIPMENT (MATERIAL)
HYDROCARBON ACCUMULATORS 190 173 164
BRINE/HYDROCARBON EXCHANGERS 1,570 1,080 815
HYDROCARBON CONDENSERS 1,310 1,310 1,310
HYDROCARBON CIRCULATION PUMPS 613 613 613
COOLING WATER CIRCULATION PUMPS 253 253 253
COOLING TOWER 1,050 1,050 1,050
TURBINE-GENERATOR 3,590 3 ,590 3,590
CONCRETE (LABOR AVD MATERIAL) 362 362 362
PIPING (LABOR, MATERIAL AND SUBCONTRACT) 2,419 2,419 2,419
ELECTRICAL (MATERIAL AND SUBCONTRACT) 1,775 1,775 1,775
TOTAL 26,720 25,950 25,540
FIELD CAPITAL COST, K $
TOTAL 11,460 11,800 12,210
POWER COST, millqkwh

CONVERSION AND TRANSMISSION 17.60 17.16 16.92
ENERGY 15.22 15.90 16.57
TOTAL 32.82 33.06 33.49
*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 6.1 C (11 F) 11.7 C (21 F) 17.2 C (31 F]

BRINE RATE, lo3 kg/hr (lo3 l b s / h r ) 2,924 (6,447) 3,233 (7,127) 3,580 (7,8921
HYDROCARBON* CIRCULATION RATE, lo3 kg/hr (lo3 lbs/hr) 3,491 (7,696) 3,842 (8,470) 4,253 (9,376)
TURBINE INLET - PRESSURE, kPa (psia) 3,447 (500) 3,447 (500) 3,447 (5001
- TEMPERATURE, C (F) 149 (300) 149 (300) 149 (300)
TURBINE OUTLET -PRESSURE, kPa (psia) 430 (62) 495 (72) 568 (82)
-TEMPERATURE, C (F) 67 (152) 70 (158) 73 (164)
- CIRCULATION RATE, lo3 m3/hr (lo3 gpm) 25.68 (113.1) 28.76 (126.7) 32.24 (142.0)
BRINE/HYDROCARBON EXCHANGERS 1,160 1,200 1,290
i HYDROCARBON CONDENSERS 1,810 994 723
COOLING TOWER 1,050 1,150 1,300
TURBINE-GENERATOR 3,580 3,610 3,640
CONCRETE (LABOR AND MATERIAL) 36 1 374 392
TOTAL 26,590 26,040 26,210
TOTAL 11,460 12,210 12,950
POWER COST, mills/kwh

ENERGY 15.20 16.55 18.03
TOTAL 32.69 33.79 35.44
3-24
Table 3-3
EFFECT OF COOLING TOWER APPROACH TO WET BULB TEMPERATURE ON POWER COST
APPROACH TO WET BULB TEMPERATURE'l) 5.5 C (10 F) 4.4 C (8 F) 2.8 C (5 F)

MEAN TEMPERATURE DIFFERENCE IN CONDENSER(^) 5.5 C (10 F) 6.1 C (11 F) 6.6 C (12 F)

BRINE RATE, lo3 kg/hr (lo3 l b s / h r ) 2,748' (6 ,059) 2,741 (6,043) 2,732 (6,024)
HYDROCARBON(3) CIRCULATION RATE, lo3 kg/hr(103 l b s / h r ) 3,754 (8,276) 3,744 (8,255) 3,732 (8,228)
- TEMPERATURE, C (F) 154 (310) 154 (310) 154 (310)
TURBINE OUTLET - PRESSURE, kPa (psia) 384 (56) 384 (56) 384 (56)
- TEMPERATURE, C (F) 56 (133) 56 (133) 56 (133)
- CIRCULATION RATE, lo3 m3/hr (103 gpm) 21.26 (93.61) 19.73 (86.86) 17.73 (78.08)

COOLING TOWER 1 ,000 1,370 1,600
CONCRETE (LABOR AND MATERIAL) 362 382 426
TOTAL 27,910 28,160 28,090
ENERGY 14.54 14.54 14.54
TOTAL 32.86 32.99 32.94
3-25
i
Table 3-4
EFFECT OF COOLING TOWER APPROACH TO WET BULB TEMPERATURE ON POWER COST
APPROACH TO WET BULB TEMPERATURE(^) 5.5 C (10 F) 4.4 C (8 F) 2.8 C (5 F)

TURBINE OUTLET TEMPERATURE(^) 56.1 C (133 F 55.5 C (132 F 54.4 C (130 F

BRINE RATE, lo3 kg/hr ( l o 3 l b s / h r ) 2,748 (6,059) 2,719 (5,994) 2,639 (5,817)
HYDROCARBON(3) CIRCULATION RATE, lo3 kg/hr (lo3 l b s / h r 3,754 (8,276) 3,689 (8,133) 3,594 (7,924)
-
TEMPERATURE, C (F) 154 (310) 154 (310) 154 (310)
TURBINE OUTLET - PRESSURE, kPa (psia) 384 (56) 374 (54) 358 (52)
- TEMPERATURE, C (F) 56.1 (133) 55.5 (132) 54.4 (130)
- CIRCULATION RATE, 103 m 3/hr (103 gpm) 21.26 (93.61) 20.80 (91.60) 20.12 (88.60)
COOLING TOWER 1,000 1,200 1,650
CONCRETE (LABOR AND MATERIAL) 362 386 443
TOTAL 27,910 28,130 28,660

TOTAL 11,050 11,050 10,640
POWER COST, mills/kwh

ENERGY 14.54 14.52 14.01
TOTAL 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
Table 3-5
EFFECT OF COOLING WATER TEMPERATURE RISE ON POWER COST
COOLING WATER TEMPERATURE RISE 6.1 C (11 F) 11.7 C (21 F) 18.3 C (33 F)

3
BRINE RATE, lo3 kg/hr (10 l b s / h r ) 3,082 (6,795 3,076 (6,781) 3,175 (7,000)
HYDROCARBON* CIRCULATION RATE, lo3 kg/hr (lo3 lbs/h 3,665 (8,080 3,639 (8,023) 3,784 (8,343)
TURBINE INLET - PRESSURE, kPa (psia) 3,447 (500 3,447 (500) 3,447 (500)
- TEMPERATURE, C (F) 149 (300 149 (300) 149 (300)
TURBINE OUTLET - PRESSURE, kPa (psia) 432 (63 458 (66) 501 (73)
- TEMPERATURE, C (F) 67 (152 68 (154) 70 (158)
COOLING WATER - TEMPERATURE, C (F) 32 (90 32 (90) 32 (90)
- CIRCULATION RATE, lo3 m3/hr (lo3 gp 52.01 (229.0 26.96 (118.7) 17.54 (77.22)

COOLING TOWER 1,450 1,050 800
CONCRETB (LABOR AND MATERIAL) 409 362 335

TOTAL 28,310 25,950 25,250
OTAL 11,800 11,800 12,210
D TRANSMISSION 18.49 17.16 16.77

15.90 15.90 16.46
34.39 33.06 33.23
k,
3-27
I - -
I
Table 3-6
HYDROCARBON CIRCULATION PUMP STUDY
ALTERNATE I ALTERNATE I1 ALTERNATE II I ALTERNATE IV ALTERNATE V
HYDROCARBON CIRCULATION PUMPS $ 683,000 $1,001,000 $1,247,000 $ 984,000 $ 582,000
TURBINE-EXPANDER & GENERATOR 3,590,000 3,590,000 3,418,000 3,374,000 3,590,000
PIPING 122,000 97,000 62,000 189,000 106,000
w INSTRUMENTATION 4,000 2,000 19,000 21,000 2,000

I
N
or,
CIVIL PI 53,000 39,000 39,000 55,000 48,000
ELECTRICAL 372,000 331,000 135,000 176,000 380,000
TOTAL 111 $4,824,000 $5,060,000 $4,920,000 $4,799,000 $4,708,000
NOTES :
ALTERNATE I - six vertical pumps in parallel, motor drive
ALTERNATE I1 - three vertical pumps in parallel, motor drive
ALTERNATE I11 - three vertical pumps in parallel, one motor drive and two turbine drive
ALTERNATE IV - (a) motor driven vertical pump in series with motor driven horizontal pump and turbine driven horizontal pump in
para1le1
(b) motor driven vertical pump in series with turbine driven horizontal pump
ALTERNATE V - motor driven vertical pump in series with motor driven horizontal pump, two systems in parallel
Revision [I] (25 Oct. 76)
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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 re-
port.
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. The tlNorthll
d i r e c t i o n shown on t h i s drawing i s a plant-north. 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,
0 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,
0 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,
m 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 modifi-

cations 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 func-
t 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 main-
tenance 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
u 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 exchan-
gers. 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. Four exchangers i n series
have been provided f o r each p a r a l l e l stream. Overall t r a n s f e r rate is about
1,420 w a t t s / ( m 2 ) ("C), [250 BTU/(hr) (ft2) (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 poss-

i 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 bin-
ary process geothermal p l a n t . 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
LJ 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 conden-

s e r s with s i n g l e pass, low finned tubes. Construction i s TEMA-C and material
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 cir-

culation. 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 com-
p 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. No booster pumps a r e required f o r
t h e v e r t i c a l pumps. 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 - 1 p a r a l l e l l i n e of 4 u n i t s i n

series
4 -4
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. 7523-
E-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 disper-
s 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. I t w i l l c o n s i s t o f seven

ell. As t h e b r i n e temperature
11 increase, and it w i l l be necessary
.
c
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. As t h e b r i n e temp-
4-5
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. Separate a i r systems are provided f o r p l a n t and i n s t r u -
ment a i r . A manual cross over i s provided between t h e systems so t h a t an
I 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
U
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 des-
iccant 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 pro-
he 43 meter (140 f o o t ) e i g n i t e d by t h e p i l o t flame.
c d i t i o n a l a i r w i l l be
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 .
W
4-7
To prevent accumulation o f hydrocarbons heavier than air, a hydrocarbon analy-
Li
zer 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 pump w i l l be driven by an electric motor, t h e o t h e r
one by a d i e s e l engine. 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 condenser-
accumulator 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. This supply w i l l
l a s t about t h r e e hours a t t h e maximum f i r e water flow rate 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 con-
sumption of t h e f i r e water system.
4-8
'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. A

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 trans-
former 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 horse-
power 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-D-
3603 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
480V switchgear. Power from MCC-A and -B w i l l d r i v e cooling tower fans, water
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. Piping s e c t i o n s f o r Areas B and C are
shown on Drawings 7523-E-3268 and 3269.
4-9
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. Consequently, a load control with manual set point i s included
i
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 hydro-
carbon 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 con-
trol panel. The panel will have a semi-graphic section with color-coded sym-
bols 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 immed-
iately alert the plant operator (by audible E visible signals) and will iden-
tify the type and location of each condition in effect.
A 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 brine outlet and
arbon condenser cooling water et t o check fo
1eakage.
ss instrument systems wile electronic with 4 to 20 m
mission signals. Panel mounted instruments for these systems will be miniature
types.
The control panel will be a vertical free-standing unit of welded steel con-
struction. It will be shop-fabricated and tested completely before shipment
4-11
Li
to the jobsite. No process fluids will enter the panel. Electrical power at
the panel will be limited to nominal 120 volts.
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. Thermo-
couple 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 add-
itional rooms housing the switchgear, office, instrument and electronic main-
tenance, 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.
As the office and control building will have many visitors, special attention
will be given to its appearance through the use of architectural treatment.
i
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'. An 1800 kg h o i s t and monorail w i l l
be provided i n t h e shop area. 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. The building i s

approximately 20' x 6 0 ' . A n 1800 kg h o i s t and monorail i s provided t o move
t h e chlorine cylinders. 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

2 2
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 (1,500 l b s / f t ) .
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 con-
tained i n Section 6 of t h i s manual.
4-13
/
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REFERENCE D R A W I N G
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THE BEN HOLT CO.

MARK RLWSIOII
W W AP :I24 H I
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4-23
REFERENCE D R A W I N G
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DRAWINGNO I TITLE
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TITLE
SOTHERMAL DEMONSTRATION PLANT

5b #.*f MCC-A' SINGLE LINE DIAGRAM
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4-29
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I 1 P
c INSTRUMENT SYMBOLS PtPlNG ANDEQU1PMENTSYMBOI.S
5 AIR COOLCDUUIT
'eurTWP
rnmuuam.
REFERENCE DRAWING
nw
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RUPWPa DISC ilU
4mm
IU
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CONTINUOUS DPAl PQ
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STEAM T R A P
@ (eIl2,3,PTC. FOR SIZE)
RLVIYI
;SUED FOR
c
Section 5
EQUIPMENT SPECIFICATIONS
bd EQUIPMENT LIST
SHEET
REvsion
1
DATE
OF .7
& - 204 A.B 4th Stage Hvdrocarbon/Brine 14
E - 205 A:G Hydrocarbon Condenser 12

E - 2001 A,B Air Compressor After Cooler 3
A/C 1400 - Furnaces and Heaters ~
FS-2001 Flare Stack 5

X - 203 Compressor Knockout mWn Calrod
X - 204 Flame Front Generator 5
'61 (Supplied with FS - 2001)
S-1
SHEET OF 3
EQUIPMENT LIST REVISION DATE
CT-201 Cooling Tower 6

I
\
A/C 1800 - Compressors E Blowers
K - 201 Unloading Compressor ,-- 3
K - 2001. Instrument Air Compressor - . 3

K - 2002 Plant Air Compressor
5-2
3 -~
3
W
SHEET OF
CONTRACT No. 7523 CUSTOMER Electric Power Research Institute
5-3
EQUIPMENT LIST
SHEET
REVISION DATE
OF 7
c
Pressure Gage w/
~-~
Pressure Transmi
Pressure Transmit
P r e s s u r e - R A MVal=-
Pressure Relief Valve,
5-4
W SHEET * OF

Instrument L i s t - Field Mounted
5 -5
SHEET 3 OF
EOV Solenoid Valve 1
i'
c
5-6
OF 7
-
W EQUIPMENT LIST
SHEET
REVISION DATE
5-7
SHEET
5 OF

Instrument List - Field Mounted
I .V I,evel -01 V m , 1-1/2" 1
Flow
-
FS ~- ~
Flow Switch, In-line 1 - __ __
AT Hydrocarbon Analyzer Transmitter 1
5 -8
SHEET OF 7

Instrument List - Panel Mounted
5-9
EQUIPMENT LIST REVOION DATE

Instrument List - Panel Mounted
5-10
hd
~~~
HORIZONTAL VESSEL DESIGN DATA
~~ ~
1 NOZZLE SCHEDULE
CODE STAMP AW qpCt VIII MARK SIZE RATING SERVICE
OTHER SPECS.: Nl 18" 150# RF HC In
DESIGN PRESS.AT TEMP. 165 PSI AT450 OF N2 18" 150# RF HC In
OPER. PRESS. AT TEMP. 56 PSI AT104 OF
STRESS RELIEVINO per Code
WELD EXAMINATION 4" 150# RF HC Makeup
1508 RF PSV
3000# Cplg I PI
3000# Cplg ,";y;,";&!
3000# Cplrr Level Alan
150# RF HC Out
3000# Cplg ' TI
3000# Cplg lev vel Indic
PT
Equalizing
-# RF Manwav
REMARKS Geothermal Demonstration Plant
Heber, California
Hydrocarbon Accumulator
V-201A,B,C,D
VESSELS
REMARKS Geothermal Demonstration Plant

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
STRESS RELIEVING Per Code
WELD EXAMINATION
INSULATION None
C0RR 0 S ION ALL0WA NCE 1116"
MATERIALS
SHELL
HEADS
INTERNALS
SUPPORTS C.S.
LINING
TRAYS
NOZZLE SCHEDULE
610"
MARK SIZE RATING FACING
N1 3" 150# RF HC Vapor Inlzt
N2 3" 150# RF HC Vapor Inlet
!
N3 1" E O # RF Drain
14 (A,B) 1" 3000# Cplg Level Gage
1 1/4" 3000# Cplg Calrod
I I I 1
i
REMARKS
Geothermal Demonstration Plant

Heber , California
Compressor Suction Knockout Drum
5-13
r >
JOB NO. 7523
CUSTOM E R Electric Power Research Institute ITEM NO. E-201A,B - E-204A,B
PLANT Geothermal Demonstration Plant REV. NO. DATE 7/17/76
L O C A T l ON Heber, California QUOTE NO.
SERVICE Hydrocarbon/Brine Heat Exchanzer REFERENCE
SIZE 60" dia. x 59' (est. over%1# E CEN CONNECTED IN SERIES/PARALLEL
L
S H E L L SIDE TUBE SIDE
FLU1D C I R C U L A T E D 80% Isobutane - 20% 1sOpentaI.e Brine (14,600 PPM Tots
TOTAL FLUID ENTERING 7.687 (10") lb/hr Dissolved Solid
VAPOR
I I ioiiin I 7.687 110") lb/hr 6.722 (loo] lb/hr
NON- CONDE N SABL E S

FLUID VAPORJZED OR CONDENSED 7.687 (10') Whr
. S T E A M CONDENSED
GRAVITY-LIOUlG @TEMP 0.550 @ 109 OF -885 @ 360 OF
VISCOSITY-LIOUID @TEMP. 0.151 C.S. e 109 OF 0.18 C.S.8 360 *F

M O L E C U L A R WEIGHT- VAPORS 61
, SPECIFIC H E A T - LIQUIDS See ent$alpy CUmeS B.T.U. / L B OF 1 016 B.T.U./LB OF
TEMPERATURE I N 109 OF(2) 360 OF
TEMPERATURE O U T 295 OF(2) 153 OF

OPERATING PRESSURE
535 ( in1et) PSlG 138 P S 10
N U M B E R OF PASSES PER S H E L L 1
VELOCITY FT./SEC. (allow 15 max.) FT./SEC.
I PRESSURE DROP(ALLOW/CALC.) I 50 / PSI I 40 / PSI
F O U L I N G F A C T O R (MIN.) I o jnlet temp. to 271°F-.0001
F.F. (tube side) 270'F to 217'F-.0011; 216'F to 177'F-.0011; 176'F to 153'F-.0033
H E A T EXCHANGED - B.T.U./HR. 1,420.8 (lob) M.T. D. ( C o r r e c t e d 1
-
TRANSFER R A T E S E R V I C E CLEAN
DESIGN P R E S S U R E 670 PSlG 180 PSI0

T E S T PRESSUR E 1 .nns PSlG 270 PSI6
DESIGN T E M P E R A T U R E 360 OF 360 OF
WEIGHTS- EACH S H E L L BUNDL E F U L L OF WATER

REMARKS: (1) w/o cross baffles (2) see attached enthalpy diagram
5-14
ST-s
e # PI
w
0 0 0
0 0 0
0
6
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JOB NO.
ITEM No. E-205A-G
7523 i
CUSTOMER Electric Power Research Institute
PLANT Geothermal Demonstration Plant REV. NO. DATE7/17/76
LOCATION Heber, California QUOTE NO.
SERVICE Hydrocarbon Condenser REFERENCE
S I Z E 81" dia. x 52' (est.
overa
I IE CJN CONNECTED IN SERIES/PARALLEL 1/7
SURFACE PER SHELL 157,286ftL NO. OF SHELLS 7 TOTAL SURFACE 1 101 000 ftL
(est -J i
S H E L L SIDE TUBE SIDE

FLU1D C I RCUL A T E 0 80% Isobutane -
20% 1sopentar.e Cooling Water
TOTAL FLUID ENTERING 7.687 (100) lb/hr 67.783 (lob) lb/hr
VAPOR 7.687(10°) lb/hr
NON-CONDENS ABL ES I
FLUID VAPORJZED OR CONDENSED I 7.687(10°) lb/hr
-
BAFFLE LONG
TUBE SUPPORTS
GASKETS
C.S.
TYPE THICKNESS
THICKN E S S
I
CONNECTIONS- SHELL- I N 001 SERIES 150 lb RF
CHANNEL -
IN OUT SERIES 150 1b RF
-
CORROSION ALLOWANCE S H E L L S I D E TUBE SIDE 1/16"
CODE REQUIREMENTS ASME Sect. VI11 TEMA C L A S S C (1)
WEIGHTS- EACH S H E L L BUNDLE F U L L O F WATER
(11 W/o cross baffles
5-16
hd
JOB NO. 7523
CUSTOMER Electric Power Research Institute ITEM NO. P-201A- F
PLANT& NO. R E Q U I R E D 6 REV. N O . L D A T E 7 -
LOCATION MOTOR DRIVEL

QUOTE NO.
SERVICE Hydrocarbon Circulation TURBINE DRIVE- REFERENCE
5-17
CENTRIFUGAL PUMP SPECIFICATION
JOB N O . 3 3
CUSTOMER E l e w P o w 2 I T E M NO. P-203

PLANT G e o t h e r m a l o n Plant NO. REQUIRED- REV. ~ 0 . 1 ~ ~ ~ ~ 7 / 1 7 / 7 6
LOCATION Heber , California MOTORDRIVE QUOTE NO.
Hydrocarbon Makeup TURBINE DRIVE- REFERENCE
CASING & N O Z Z L E C.S. CASE S P L I T HORIZONTAL VERTICAL

IMPELLER C.I. SUPPORT C/L FOOT BRACKET
CASING RING IMPELLER OPEN CLOSED SEMI-ENC. -

I M P E L L E R RINGS STUFF. B O X W A T E R J A C K E T : 0 YES 0 NO
SHAFT Allnv MECH. SEAL XINTERNA
EXTERNAL
SHAFT S L E E V E SINGLE- D OU B L E
- BA L A N C E D U N A LANCED-
PACKING GLAND BEARINGS WATER JACKETED: 0 YES 0 NO
PACK ING LUBRICATION O I L GREASE
SEAL CAGE F L E X I B L E COUPLING: MAKE TYPE
BASE P L A T E C.S. COUPLINGGUARD: 0 YES 0 NO
DRIVER DATA - MOTOR DRIVER DATA - TURBINE

MAKE nl? lo MAKE H.P.
TYPE TEFC ' R.P.M. 3500 TYPE R.P.M.
PHASF 3 CYCLE 60 VOLTS 460 WATER RATE e DESIGN LOAD- LBS/HR. BHP.
FRAME STEAM I N L E T P.S.I.G. ~ OF
STEAM EXHAUST P.S.I.G. OF
5-18
b, JOBNO. 7523
C-STO~ER Electric Power Research Institute ITEM NO. P-204AsBsC
re
sp‘-RJV.
PLANT G e o t h e r m a l t r a t ion P1ant NO. REQUIRED- NO.-DATE7117/76
LOCATION Heber. Cal ifornia MOTOR D R I V E x QUOTE NO.

SERVICE Coolincr Water Circulation TURBINE DRIVE- REFERENCE
CIRCULAR NO. DIMENSIt 1 P R I N T SECTION DWG.
MATERIALS OF CONSTRUCTION CONSTRUCTION FEATURES

CASING 8: N O Z Z L E c.I ,CASE S P L I T H O R I Z O N T A L VERTICAL
IMPELLER
Bronze SUPPORT C/L FOOT BRACKET
CASING RING Bronze I M P E L L E R OPEN CLOSED SEMI-ENG -
I M P E L L E R RlNGS-Ze STUFF. B O X W A T E R J A C K E T : 0 YES 0 NO
SHAFT Alloy Steel MECH. SEAL x INTERNAL EXTERNAL
SHAFT S L E E V E Bronze SINGLE- D OU B L E -B A L A NC ED U N B A LANCED -
PACKING G L A N D Bronze BEARINGS WATER JACKETED: 0 YES 0 NO
PACKING LUBRICATION O I L xGREASE
SEAL CAGE F L E X I B L E COUPLING: MAKE TYPE
BASE P L A T E COUPLINGGUARD: 0 YES 0 NO
DRIVER DATA - MOTOR DRIVER DATA - TURBINE

MAKE H F z 2 o o o MAKE H.P.
TYPE “I1 R.P.M. 585 TYPE ~ R.P.M.
PHASE.~,CYCLE 60 ~ 0 ~ ~ ~ 4WATER
1 6 R0A T E @ DESIGN LOAD L B S I H R . BHP.
FRAME STEAM I N L E T P.S.I.G. OF
~
NET WEIGHT SHIPPING WEIGHT

PUMP, BASE, CPLG. LE. PUMP, BASE, CPLG. LB.
MOTOR LE.
Special Instructions or Features t APT h i n 4

.. . s
5-19
RECIPROCATING PUMP S PEClFlCATlON
GENERAL JOB NO. 7523
CUSTOMER Ele- Power R e s e h Insaute ITEM NO P-206
PLANT G
-o
e- NO REQUIRED REV. NO. DATE-
LOCATION Heber. California DIRECT ACT1 NG - QUOTE NO.
SERVICE Cooline Water Dispersant POWER FRAME -- REFERENCE
N AVAILABLE FT.(liguid) CORR. MATERIAL- 316 ss EROSIVE MATERIAL -

P REOUIRED FT.(liguid) %OR --P.RM. -Oh OR BBM.
S REQUIRED FT. (woter) USERS EXPERIENCE WITH MATERIALS SPECIFIED
H GOOD FA1R NONE __-
PUMP SPECIFICATIONS
MANUFACTURER PUMP TYPE Metering --
SIZE DRIVE -LIO. -STROKE
SPEED FT./MIN. -EFF.
0HP@ DESIGN MAX. BHP. REQD RECOMMENDED DRIVER HI?
CIRCULAR NO. DIMENSION P R I N T SECTION DWG. -
MATERIALS AND CONSTRUCTION FEATURES
STEAM CYLINDERS LIQUID VALVE STEMS
PISTONS -- VALVE SPRINGS - --
PISTON RODS NO PISTON RINGS --
VALVES - MTL. TYPE PISTON PACKING
NO. PISTON RINGS STUFFING BOXES --
P I STON PACKING GLANDS
L I Q U I D CYLINDERS CYLINDER L I N E R S - MATERIAL
- --
I
PISTONS TYPE
P I S T O N RODS -
LUBRICATOR M A K E -
VALVES- MTL. TYPE COMP. CAP'Y - FEEDS
VALVE SEATS HYDROSTATIC TEST-FLUID END -PSlG
HYDROSTATIC T E S T -STEAM END-PSlG
MAKE HP 1/3 WATER RATE DESIGN LOAD LBS/HR. BHP

TYPE R.P.M. STEAM I N L E T PSlG -OF
PHASE ,-,CYCLE -,VOLTS ,-. STEAM E X H A U S T PSlG OF
N E T WEIGHT SHIPPING WEIGHT

PUMP, BASE LB PUMP,BASE LB
MOTOR LB
S p e c i a l Instructions or Features
5-20
CUSTOMER Electric Power Research I n s t i t u t e ITEM NO. p-207
PLANT G e o t h e r m a l i n n P l a n NO REQUIRED REV. NO. DATE- 7-17-'
LOCATION H e b e r r C a l l f o r n i a DIRECT ACTING- QUOTE NO.
SERVICE c O O 1 1 - b
..POWER FRAME -- REFERENCE
OPER AT ING CONDIT 10NS

LlQUlD PUMPED e F.P.T. DISCH. P R E S S U R E ~ ~ P . S . I . G
CAPACITY, GpH ka fin OF NORMAL --,DESIGN h S U C T . PRESSURE -P.S.I.G.
F ! t , SPGR. VISC. CPS VAF! PR.-RS.I.A. DIFF: PRESSURE -RS.I.
6OoF SF! GR. VISC. CPS VAF! PR. -RS.I.A.
N AVAILABLE EROSIVE MATERIAL -
P REQUIRED BCM.
S REQUIRED FT. (water) USERS EXPERIENCE WITH MATERIALS SPECIFIED
H GOOD FAIR NONE __-
PUMP SPECIFICATIONS
MANUFACTURER PUMP TYPE
Metering
-
SIZE DRIVE -LIQ. -STROKE
SPEED FT./MIN. _. EFF.
BHF! G? DESIGN MAX. BHP. REOD RECOMMENDED DRIVER HR
CIRCULAR NO. DIMENSION P R I N T SECTION DWG. -
M A T E R I A L S AND CONSTRUCTION FEATURES
STEAM CYLINDERS LIQUID VALVE STEMS
PI STONS - VALVE SPRINGS -.-
PISTON RODS NO PISTON RINGS -
VALVES -
MTL. TYPE PISTON PACKING
NO. PISTON RINGS STUFFING BOXES .-
CYLINDER LINERS- M 4 T f R l A L -
L I Q U I D CYLINDERS
PISTONS
LUBRICATOR- M A K E
TYPE -
P I S T O N RODS
VALVES- MTL.
VALVE SEATS
TYPE COMP. C A P'Y
HYDROSTATIC TEST- FLUID END -_ FEEDS
P S IG
DRIVER DATA MOT0 -

MAKE
TYPE
LE V O
DIAMETER RODS
SIZE OF PACKING
PING WEIGHT
PUMP, BASE
MOTOR -LB
Special Instructions or Featuras
CUSTOMER E l e c t r i c Power Research I n s t i t u t e ITEM NO. p-208
PLANT Geothermal Demonstration Plant NO REWIRED REV. NO. DATE 7- 17 - 7(
LOCATION Heber, California DIRECT ACTING- QUOTE NO.
SERVICE Cooling Water Acid POWER FRAME ---- REFERENCE
N AVAILABLE FT.(liguid) CORR. MATERIAL- EROSIVE MATERIAL -

P REQUIRED FT.(liguid) 70OR -
RBM. -O/o OR RPM.
S REQUIRED FT.(watrr) USERS EXPERIENCE WITH MATERIALS SPECIFIED
H GOOD FAIR NONE-. -~
PUMP SPECIFICATIONS
MANUFACTURER PUMP TYPE
SIZE DRIVE -LIO. -- STROKE
SPEED FT./MIN. - EFF.
BHI? DESIGN MAX. BHP. REQD RECOMMENDED DRIVER HF!
CIRCULAR NO. DIMENSION P R I N T SECTION DWG.
MATERIALS AND CONSTRUCTION FEATURES

STEAM CYLINDERS LlOUlD VALVE STEMS
PISTONS VALVE SPRINGS --
PISTON RODS NO PISTON RINGS
VALVES MTL. - TYPE PISTON PACKING
NO. PISTON RINGS STUFFING BOXES -
L I Q U I D CYLINDERS CYLINDER L I N E R S - MATERIAL -
PISTONS -
TYPE --
P I S T O N RODS LUBRICATOR- M A K E -
VALVES- MTL. TYPE COMP. CAP'Y FEEDS
VALVE SEATS HYDROSTATIC TEST-FLUID END--PSlG
HYDROSTATIC T E S T -STEAM END-PSlG
DRIVER DATA -MOTOR (Pwr.Frame) STEAM DATA- (Direct Acting)

MAKE HP WATER RATE DESIGN LOAD LBS/HR. BHP
TYPE R.P.M. STEAM I N L E T PSlG OF
PHASE -CYCLE V O L T S - STEAM E X H A U S T PSlG OF
L I Q U I D END S T E A M END VALVE RODS

STUFFING BOX LENGTH
DIAMETER RODS
SIZE OF PACKING

PUMP, BASE LB PUMP,BASE LB
MOTOR -LB
S p e c l o l lnstructlons or Feoturas -
5-22
JOBNO. 7523
CUSTOMER Electrical Power Research Institute I T E M NO.' 210 A E
PLANT Geothermal Demonstration Plant 7-17-76
NO. R E Q U I R E D ~ ( SPS+@V.
~~~ NO.-DATE-
LOCATION Heber, California MOTORDRIVE QUOTE NO.
SERVICE Make-up Water TURBINE DRIVE- REFERENCE
CIRCULAR NO. DIMENSI( 4 P R I N T SECTION DWG.

CASING e NOZZLE CASE S P L I T H O R I Z O N T A L VERTICAL
IMP ELL ER SUPPORT C / L F O O T A R A C K E T
CASING RING I M P E L L E R OPEN CLOSED SEMI-ENG -
I M P E L L E R RINGS STUFF. BOX WATER JACKET: 0 YES 0 NO
SHAFT MECH. SEAL INTERNAL EXTERNAL
SHAFT S L E E V E SINGLE- D OU B L E-B A LA NC E O U N B A LANCED ___
PACKING G L A N D BEARINGS WATER JACKETED: 0 YES 0 NO
PACKING LUBRICATION O I L GREASE
S E A L CAGE F L E X I B L E COUPLING: MAKE TYPE
BASE P L A T E COUPLINGGUARD: 0 YES 0 NO
_ _ _ _ _ _ ~ ~
DRIVER DATA - MOTOR HJ? 75

DRIVER DATA - TURBINE
MAKE MAKE H.P.
TEFC R.P.M.
1200 TYPE R.P.M.
TYPE- ~
PHASE 3C Y C L E -60 VOLTS- WATER R A T E @ DESIGN L O A D . LBSIHR. EHP.

FRAME STEAM I N L E T
STEAM EXHAUST - P.S.I.G.
P.S.I.G.
OF
OF

PUMP, BASE, CPLG. LE. PUMP, BASE, CPLG. LE.
MOTOR LE.
Special Instructions w F e a t u r e s - to meet API 610 sDecification
5-23
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.-DATE-
I LOCATION Heber. California MOTORDRIVE QUOTE NO.
SERVICE K.O. Drum Pump TURBINE DRIVE- REFERENCE

CASING & N O Z Z L E c . s. CASE S P L I T HORIZONTAL VERTICAL
IMPELLER c. I. SUPPORT C/L FOOT BRACKET
CASING RING I M P E L L E R OPEN CLOSED SEMI-ENG ___

I M P E L L E R RINGS STUFF. B O X W A T E R J A C K E T : 0 YES 0N O
SHAFT A1 lov MECH. SEAL x INTERNAL EXTERNAL
SHAFT S L E E V E SINGLE- D OU B L E -EA L A N C E D -U N BA L A N C ED -
PACKING GLAND BEARINGS WATER JACKETED: 0 YES 0 NO
S E A L CAGE F L E X I B L E COUPLING: MAKE TYPE
BASE P L A T E r s. COUPLINGGUARD: 0 YES 0 NO
I
DRIVER DATA - MOTOR 15.0
DRIVER DATA - TURBINE
MAKE lu? MAKE H.P.
TYPE- R.P.M.- TYPE R.P.M.
PHASE CYCLE 6o VOLTS 460 WATER R A T E @ DESIGN L O A D LBS/HR. EHP.
5-24
CENTRIFUGAL PUMP SPECIFICATION
IJoBNO. 7523
CUSTOMER Electric Power Research Institute I T E M NO. P-2002 IA-C)
Binary Process-Geothermal Demonstration Plant
PLANT- - - - - NO. R E Q U I R E D - ~ ~ ~ S G P ~ 0 . ~ ~ ~ ~ ~ 7 - 2 1 - 7 6
LOCATION Heber. California MOTOR DRIVE One QUOTE NO.
S E R ~ ~ C E Firewater
Diesel Enpine
ltvfiP!NEhFfw= REFERENCE

CASING & N O Z Z L E CT CASE SPL1.T HORIZONTAL VERTICAL
IMP ELL ER Bronze SUPPORT C I L F O O T U R A C K E T
11
CASING RING I M P E L L E R OPEN CLOSED SEMI-ENG ~
I1
I M P E L L E R RINGS WATERJACKET: 0 YES 0 NO
SHAFT A1 lov INTERNAL EXTERNAL
SHAFT S L E E V E SINGLE- D OU B LE- BA L A N C E D U N B A L A N C E D -
PACKING G L A N D BEARINGS WATER JACKETED: 0 YES 0 NO
PACKING Graphite Impreg ASB LUBRICATION O I L GREASE
S E A L CAGE F L E X I B L E COUPLIpJG: MAKE TYPE
BASE P L A T E r $ COUPLINGGUARD: 0 YES 0 NO
DRIVER DATA
MAKE
- MOTOR
TYPE TEFC R.P.M. 1770 R.P.M. 1770
PHASE 2C Y C L E L V O L T S d h n A T E @ DESIGN L O A D _______ L B S / H R . BHP.
P.S.I.G. - OF
SHIPPING WEIGHT
structions or Features
5-25
c 1
JOBNO. 7523
CUSTOMER Electric Power Research Institute I T E M NO. p-2003
Binary Process-Geothermal Demonstration P,18p&EQu, RED
PLANT T)np REV. NO.-DATE-
LOCATION Heber. California MOTOR DRIVEX

QUOTE NO.
SERVICE Firewater Jockey TURBINE DRIVE- REFERENCE

CASING e NOZZLE CASE S P L I T HORIZONTAL VERTICAL
IMPELLER Bronze SUPPORT C / L FOOT BRACKET

11
CASING RING I M P E L L E R OPEN CLOSED SEMI-ENC ___
11
I M P E L L E R RINGS STUFF. B O X W A T E R J A C K E T 0 YES 0 NO
SHAFT Alloy MECH. SEAL XINTERNA
EXTERNAL
SHAFT S L E E V E SINGLE- DOUBLE-BALANCEDUNBALANCED-
PACKING GLAND BEARINGS WATER JACKETED. 0 YES 0 NO

SEAL CAGE F L E X I B L E COUPLING MAKE TYPE
BASE P L A T E COUPLINGGUARD. 0 YES 0 NO
I I
DRIVER DATA
MAKE
- MOTOR
w
t DRIVER DATA
MAKE
- TURBINE
H.P.
TYPE
TEFC R.P.M.
3500 TYPE R.P.M.
P H A S E ~ C Y C L E6 0 ~ 0 ~ ~ WATER
~ 4R A6
T E @0DESIGN LOAD L B S I H R . BHP.
STEAM EXHAUST- P.S.1 .G. OF

PUMP, BASE, CPLG. LB. PUMP, BASE. CPLG. LB.
I MOTOR
I
LE.
Special Instructions or Features
5-26
THE BEN HOLT CO.
COOLING TOWER SPECIFICATIONS
s - i
cusfohim Electric Power Reserach Institute ITEM NO. CT-291
PLANT Geothermal Demonstratinn Plant REV. NO.
Heber , Ca 1ifornia
LOCATION
SERVICE Hydrocarbon Cond enser C o w a k r

-
PERFORMANCE
QUOTE NO.
REFERENCE
I
Woter Circuloting Rote: 137.0 85 gpm. Temp. In: 108.7 OF Temp. Out: , A . O F
Cooling Duty 1 2 4 3 . 3 [ i n6 )~ Bb/Hr.; PetfonrcTost Code.
* A t Option of Owner
S ELECTK)N -
Manufacturer: Model:
Type: No. of Calls:
DESIGN
Wet Bulb Temp: 80 OF; Static Pumpin9 Hd. 35 (max> Ft. Eff. Cool. Vat. cu. Ft.
Fill Wetted Surf. Sq. Ft; Total Wetted Surf. Sq. Ft; Eff. Splosh S u r f j t . Ft.
No. of Fans Req*d. ChdFan ;Static Pros. In. HzO; Normal DHP/Fon
Evaporation Loss. Mor. X Sproy Loss. Max. 9.

- -
- MATERIALS OF CONSTRUCTION -
Fromework Cosins Fill
Fan Cylinder Stairway
Bolts Nuts, Mise. Hardware Noila
Woter inlot Hdrr. Nozxles Basin
Fon Blade Fon Hub Fan Shaft.
Code for Lumbor Grades Code lor Lumber Struct. Design
**Exception: Wind Lo=ding, See lnquiy or P.O. --- -
____---
--
AUXILIARY EQUIPMENT
-I
Manufacturer TYPO
Oiamohr Fr; Speed . ~RPM; T i p Speed - b m-
Manufacturer P TIP.- Size
Reduction Rotio Rotod Cop. 8HP; Mechanicd Eff. x
TYPO Speed RPM
S o n i c . Foetor Frame
REMARKS
P.O. TO: I
5-27
STANDARD DATA SHEET FOR RECIPROCATING COMPRESSORS
P l a n t Binary Process - ~pothprmalDemo- t i h b No. 7523
Location Heber, California No. Reqd. ONE -
Item No. K-LUl Manufacturer
A -SERVICE G-CONTROLS: TYPE &i DESCRlPTION
Type Gas Handled H v- Mix a E t a r t i n g unloader furnished
Normal Capacity S. C. F. M. b )Capacity Control:( VarSpeed)(on-off )
Number of Stages (multi-speed unloade r)f dua1)etc.
Operating Speed, RPM c ) Unloade r ope ration(E l e c t P n e u. Comb)
. Direction of Rotation, F r o m Driver End H-CONSTRUCTION MATERIALS
Total B. H. P. Cyls P Heads
Type of D r i v e r Electric Motor
B-OPERATING CONDITIONS - - - Pistons
Stages Piston Rines a
Actual CFM @ Suction Conditions 25 P i s t o n Rods

Suction P r e s s u r e Variable 14.7 PSLA Min Conn. Rods
Disch. P r e s s u r e 149 PSIA Crankshaft
Ratio of Compression 10.1 Max. Valves
Suction T e m p e r a t u r e 120
Disch. T e m p e r a t u r e
.
* FMax
"F
Valve Springs
Crank Case
B o r e and Stroke IIX I t B a s e Plate
Piston Disdacement C. F.M. Flvwheel
Clearance Volume VI I Coupling Guard
Volumetric Efficiency
B r a k e HorseDower Per Staee I I -CONSTRUCTION DE TAILS
Type Crosshead
Type Valves
No. Inlet Valves /Cyl.
No. Disch. Valves/Cyl.
Type Rod Packing
Mate rial
I
No. of Rings & Size
, Molecular Wt. 60.8 I A r e Stuffing Boxes W a t e r Cooled

Main Bearings, No. & Type
Ratio of Cp /Cy
C OmDr e s s ibilitv Factor
D-COMPRESSOR DETAILS
I Connecting Rod Bearings, Type
Size
Size
Mfrs. Type & Designation Crosshead Guide Brgs. Type
No. of C o m p r e s s o r Cylinders Crosshead P i n Brgs. Type
Cylinder Arrangement Size
Single o r Double Acting Lubrication of Bearings ., 4
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
Max. Safe Operating Speed Lubrication of Cvlinders 1
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.
NO. of Motor, Data Sheet Hd. Loss t h r u I n t e r c o o l e r Ft.
Type of Drive(direct)(GearrV-belt)
Size & Type of Gear o r Belt J -GENERAL
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
v . 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. ,
THE BEN HOLT CO. ---
Engineers-Constructors
201 So. Lake Avenue
Pasadena, California 91101 NO. Date Revisions By
5-28
TURBINE-GENERATOR ~ ' Specification No. 2801
Electric Power Research Institute Holt Job No. 7523
Palo Alto, California March 1977
Geothermal Demonstration Plant 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 direc-
tion of installation.
2. REQUIRED EQUIPMENT
Turbine
One hydrocarbon turbine rated as specified herein.
Generator
One totally enclosed hy ooled synchronous generator rated 76.5 MVA,
.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 non-
rotating, 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 par-
ticle inspections, casting processings, radiographic testing, and sonic
testing performed that currently applicable ASTM
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 Specification No. 2801
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 de-
sire 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
W TURBINE-GENERATOR Specification No. 2801
Fluid 80% Isobutane, 20% Isopentane

Flow Rate 3,490,000 kg/hr (7,687,000 lb/hr)
Inlet Pressure 3,450 kPa (500 psia)
Design Pressure 4,480 kPa (650 psia) and full vacuum
Inlet Temperature 146 C (295 F)
Design Temperature 182 C (360 F)
Outlet Pressure 498 kPa (72.3 psia)
Efficiency 85%
Rated Horsepower 83,560
It will also be designed to be easily and inexpensively modified to meet
the following requirements:
Fluid 10% Propane, 90% Isobutane
Flow Rate 4,098,000 kg/hr (9,027,000 lb/hr)
Inlet Pressure 4,067 kPa (590 psia)
Inlet Temperature 140 C (285 F)
Outlet Pressure 660 kPa (96.1 psia)
Efficiency 85%
Rated Horsepower 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 hori-
zontal 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 mini-
mized. 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
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 tur-
bine rotor shall be balanced in the manufacturer's plant so as to
run smoothly and without excessive vibration. After machining opera-
tion 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 oper-
ating speed.
9.5 Shaft Sealing
A shaft sealing system shall be provided which will prevent the es-
cape 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. Sup-
ports 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.
L!
5-32
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 fur-
nished 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 hy-
draulic 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
hi
Electric Power Research I n s t i t u t e Holt Job No. 7523
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, 2.1.4, 2.1.7, and 2.1.9 of API Standard

614 s h a l l not apply.
O i l Reservoirs - Paragraphs 2.2.6, 2.2.7, and 2.2.13 of API Standard

614 s h a l l not apply.
i 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 - Shall be i n accordance with Section 3

of API Standard 614.
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 pre-
f 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
u TURBINE-GENERATOR Specification No. 2801
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 re-

lationship 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 Speci-
fication 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 tem-
peratures.
A thrust failure trip device shall be provided
- for both active and inactive
sides of thrust bearing.
5- 35
A 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
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 stabi-
lized 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 min-
ute 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, pro-
vided 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 mxi-
mum phase current obtained from the three-phase fault.
rdance with
mance establ ormal ratin
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

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 maxi-
mum 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 op-
erating 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 Specification No. 2801
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 require-
ments 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 out-
lets, 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 gen-
erator field excitation by utilizing power from the armature terminals of
the generator. The excitation system shall regulate and maintain the de-
sired 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 Specification No. 2801 id
Electric Power Research I n s t i t u t e Holt Job No. 7523
Geothermal Demonstration Plant 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 ceil-
ing 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 com-

ponents 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
I) TURBINE-GENERATOR Specification No. 2801
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 volt-
effective 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 Specification No. 2801 b
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 con-
nections.
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
Electric Power Research Institute ' Holt Job No. 7523
18.2 Turbine
Guaranteed hydrocarbon rates at 100 percent load point, and an esti-
mate 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 fab-
rication 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 maximum cooling water
temperature.
Description of method of cooling stator and rotor.
5-43
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
Does purchaser have flexibility

in locating oil tank below floor? 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
Yes No
without external a
Shipped assemble
during erection
Heaviest piece and weight to be handled
LJ after erection
5-45
L,
, TURBINE-GENERATOR Specification No. 2801
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
L
5 -46
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 pro-
vision to move rotor axially under load Yes No
Are sight flows provided Yes No
Oil System
Capacity of oil tank (gals)
5-47
L,
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 Yes No
5-48
W
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
Synchronous at rated current Xd

'bd
5 -49
Lid
, 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 @ 206 kPa (30 psia),
H2 98% purity
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 cu.ft .
purge air 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 pre-
fabricated in the factory (%I
5-50
What portion of the hydrocarbon piping is

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

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Preliminary Design Manual for a

Geothermal Demonstration Plant

Topical Report, February 1978

EPRl Project Manager

This report was prepared as an account of work sponsored by an

Portions of this document may be illegible in

This report presents a preliminary design of a 50 %IWe Geothermal Demonstration

3 DEVELOPMENT OF DESIGN 3-1

FIGURE 3-1 PERFORMANCE OF VARIOUS GEOTHERMAL

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

4 (Cont.) DRAWING NO. 7523-D-3604, REV. B - BINARY PROCESS

5 EQUIPMENT SPECIFICATIONS 5-1

EQUIPMENT LIST 5-1

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

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

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

An 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

We have defined the plant baseline configuration by the preparation of

Material and installation specifications have been prepared for piping,

The subject feasibility study for a low salinity hydrothermal demonstration

0 TASK B-5 - Environmental Assessment

The response t o Task B-4 is contained i n a separate report e n t i t l e d "Imple-

The response t o Task B-5 i s a separate report i n four volumes:

0 Volume I - Preliminary Environmental Assessments of Geother-

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

In preparing t h e Preliminary Design Manual we have focused our a t t e n t i o n on

This manual contains the following technical r e p o r t s required by EPRI under

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

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

The Heber geothermal f i e l d i s located a t t h e southern end of Imperial County,

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

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

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

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

Imperial County i s located within Seismic Zone 3, f o r which a design accelera-

The Central Main Canal, and various subsidiary i r r i g a t i o n canals belonging

Temperature, C Temperature, F Fouling Factor

176 t o 132 350 t o 270 ,0001

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

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

The development of a process design for a geothermal project is an evolu-

Preliminary geological data and modeling indicate that if the reservoir is

The next phase of the process engineering consisted of:

A class of working fluids not studied in the initial phase is composed of

A summary of the pertinent design data is as follows:

Hydrocarbon Working Fluid

Gross Generator Output 61 W e

As the geothermal reservoir is produced continuously for a number of years,

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

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

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

Operating and maintenance c o s t s were derived from p l a n t and f i e l d estimates

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

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. As

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

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

Effect of Cooling Tower Approach to Wet Bulb Temperature Cost

The increase of the temperature difference in the hydrocarbon condensers

Effect of Cooling Water Temperature Rise on Power Cost