110kW ORC for Steam Condensate Heat Recovery

PetroVietNam CaMau Fertilizer Joint Stock Company (PVCFC)

HanPower Energy Technology Co. Ltd.

Lab：桃園市幼獅工業區高獅路 897 號
(NO.897, Gaoshi Road, Youth Industrial Park, Yangmei Dist., Taoyuan City, Taiwan, R.O.C.)
Office：台北市中山區南京東路二段 124 號 4 樓
(4F. No. 124, Section 2, Nanjing East Rd., Zhongshan Dist., Taipei City, 10491, Taiwan, R.O.C.)

Tel: (Int’l +886) 3-485 5177 FAX: (Int’l +886) 3-485 2226
Mobil: (Int’l +886) 918-116-769 Contact: Chi-Ron, Kuo (GM)

November 8, 2018

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 Contents

1 REQUIREMENT ANALYSIS........................................................................................ 3

1.1 HEAT SOURCE .......................................................................................................... 3

1.2 HEAT SINK ................................................................................................................. 3

1.3 PRODUCT CHARACTERISTICS ........................................................................... 4

2 SYSTEM DESCRIPTIONS ........................................................................................... 5

3 ORC SPECIFICATIONS ............................................................................................... 7

4 SCOPE OF SUPPLY ..................................................................................................... 10

5 LIST OF EXCLUSIONS .............................................................................................. 11

6 TERMS & CONDITIONS ........................................................................................... 12

6.1 PRICE ........................................................................................................................ 12

6.2 PAYMENT TERM .................................................................................................... 12

6.3 DELIVERY ................................................................................................................ 12

6.4 VALIDITY ................................................................................................................. 12

6.5 WARRANTY ............................................................................................................. 12

6.6 SUPERVISION OF INSTALLATION AND COMMISSIONING ....................... 13

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Seller: HanPower Energy Technology Co., Ltd., a company organized and existing under the
laws of Taiwan, having its principal place of business at No.897, Gaoshi Road, Youth
Industrial Park, Yangmei Dist., Taoyuan City, Taiwan (hereinafter called the “Seller”).
Buyer: PetroVietNam CaMau Fertilizer Joint Stock Company (PVCFC), a company organized
and existing under the laws of Vietnam, having its principal place of business at Lot D,
Industry Ward 1, Ngo Quyen street, Ward 1, Ca Mau city, Ca Mau Province (hereinafter
called the “Buyer”)

1 Requirement Analysis

The Buyer is to set up an ORC (organic Rankine cycle) for conversion steam condensate

heat into power. Where the condensate directly flows into the ORC evaporator to vaporize the

ORC working fluid, and cooling water circulated from a cooling tower is to reject heat via the

ORC condenser. The ORC generating electricity will connect to the site grid via a breaker.

According to the requirements and given design parameters from the Buyer, the Seller

submits this ORC proposal for the Buyer’s heat recovery application. The design parameters of

the ORC system are as followings.

1.1 Heat Source

 Steam condensate

 Flow rate: 53T/hr

 Inlet temperature to ORC evaporator: 111C

1.2 Heat Sink

 Cooling water

 Inlet temperature to ORC condenser: 35C

 Outlet temperature from ORC condenser: 41C

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 1.3 Product Characteristics
 Electric features: 380V, 50Hz, 3-

 Generator Type: Induction generator (IG)

 Genset type

 Hermetic type

 Screw-expander and IG integrated in a common casing

 Installation site

 non-hazardous area (non-explosive area)

 Indoor or outdoor with shelter

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2 System Descriptions
Fig. 1 illustrates the schematic diagram of the ORC system and the Seller’s scope of

supply. The system consists of an ORC unit, a steam condensate supplying loop, a cooling

water circulating loop with a cooling tower, etc. Steam condensate and cooling water

directly flow into the ORC evaporator and the ORC condenser, respectively.

Fig. 1 ORC System Layout & Scope of Supply

R245fa is selected as the ORC working fluid for obtaining superior thermodynamic

characteristics under such temperature level. A hermetic type screw-expander generator set

is designed as the core engine of the ORC to avoid from the working fluid leak-off

problem and to give high performance. Inside the screw-expander generator set, the dual

screw expander converts thermal heat to mechanical power and an induction generator

converts mechanical power into electrical power.

In contract to an open-type ORC, the advantages of a hermetic-type one are:

(1) No working fluid leak-off problem: a mechanical seal is not necessary.

(2) No misalignment and vibration problem: a coupling is not necessary.

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 (3) No cooling fan for generator: the generator efficiency is further improved.

(4) Low maintenance required and long product service time (greater than 20 years).

Outlet
Expander Generator Expander Generator
Coupling
Rotor Rotor Rotor Rotor

Outlet
Inlet
Inlet

Generator Generator
Bearings Bearings Seal
Stator Stator

Hermetic Type Open Drive Type

O No Coupling: Common Shaft X Coupling: misalignment, Vib.
O No Mechanical Seal X Seal: Leak-off, Maintenance
O No Fan: Working fluid Cooling X Fan: Reducing Generator Eff.

Fig. 2 Advantages of hermetic type ORC over open drive type ORC

Due to the induction electrical features, the ORC generated electricity can be direct

connected to the grid via an NFB (or an ACB).

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3 ORC Specifications
Table 1 lists the specifications of the ORC, where the gross power is the power

generated by the induction generator of the ORC. The cycle power is the difference of the

gross power and the power consumed by working fluid pump, oil pump and control

equipments. The net power is the difference of the cycle power and the power consumed

by the cooling water pump and the cooling tower fan.

Table 1 Specifications of the ORC on design point

R245fa Screw Expander ORC:50Hz, 380V,3φ Induction Alternator

Gross Power, kW 110.6
Cycle Power, kW 101.9
Net Power, kW 74.4
Heat Source: Steam Condensate Heat Sink: Cooling Water
Flow Rate ,T/hr 53.0 Flow Rate, T/hr 243.0
T_in, ℃ 113.0 T_in, ℃ 35.0
T_ex, ℃ 81.4 T_ex, ℃ 41.0
Heat Supply, kW 1,835.2 Heat Rejection, kW 1,685.0

To verify the ORC performances, an acceptance test will be performed in Seller’s

ORC laboratory before delivery. The acceptance criteria are that both the gross power

and the cycle power are greater than 90% of those listed in Table 1.

(1) Steam condensate

 Flow rate = 53.0T/hr
 Supply/Return temperature (evaporator) = 111°C/81.4°C

(2) Cooling water

 Flow rate = 243T/hr
 Inlet/Outlet temperature (condenser) = 35°C/41°C

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 (3) ORC Unit Specifications

 Working Fluid Pump

R245fa is selected as the working fluid of the ORC. A multi-stage centrifugal

pump is used to lift the pressure of liquid R245fa.

 Evaporator: brazed plate type heat exchanger with plate material of 316L.

 Condenser: shell-and-tube type with fixed tube sheet and carbon steel shell and

water box. The condenser also used as the liquid R245fa storage tank.

 Expander-Generator Set

A dual screw expander converts heat to rotating shaft power; then, an induction

generator (IG) converts shaft power into electricity. The rated speed of the screw

is 3,000rpm which directly drives an induction generator (IG). The

screw-expander-generator set is designed as a hermetic type where the

screw-expander and the IG are integrated and installed inside a common casing

to avoid from vapor leak-off.

 Oil Lubrication System and Oil Separator

The lube oil is used to lubricate and cooling all the bearings of the

screw-expander-generator set. An oil separator, also used as the oil tank, is

designed to separate working fluid and oil.

 Skid

MS (mild steel) fabricated common skid for the generator set with oil lubrication

system, evaporator, condenser, working fluid pump, and control/power panel.

 Control and Power Panel

 Breaker power panel
 Metering/ protection relay panel

 Dimensions and Weight (as shown in Fig. 3, for reference, the details will be

determined after detailed design).

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  Dimension: 4,000 mm(L) x 2,200 mm (W) x 3,000mm(H)
 Weight: 7,000kg

Fig. 3 The ORC arrangement and its dimensions (for reference)

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4 Scope of Supply
The total scope of supply delivered to the Buyer shall be:

1 The ORC layout diagram.

2 The piping and instrumentation diagram (P&ID) of the ORC.

3 The ORC unit: the items/constituents of the unit will be:

(1) The major components of the unit consist of a screw-expander generator set, an

evaporator, a condenser, a working fluid pump, and valves and control device. All

the components are piped and instrumented, and packaged on a single skid.

(2) Electrically driven oil pump lubrication system with closed loop pressurized

lubrication to all bearings.

(3) Control system, which is PLC based, with I/O modules for health monitoring and

‘fail-safe’ trip. The ORC control panel is a main control panel, all the other

accessories, pumps and valves, etc. will be connected to the ORC panel.

(4) Inverter, feedback controlled by the R245fa conditions at the evaporator exit,

controls the frequency of the motor of the working fluid pump.

(5) Power panel incorporating NFB (or ACB) for electrical controls with other

safeties.

4 The ORC is charged with R245fa working fluid and refrigerant oil before delivery to

the Buyer.

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5 List of Exclusions
Following are excluded from the Seller’s scope of supply and scope of work. These are to

be carried out by the Buyer at the Buyer’s cost.

1 All statutory clearances.

2 All civil works including foundation for ORC.

3 Steam condensate supply and return piping for evaporator.

4 Cooling water supply and return piping for condenser.

5 Cooling towers, cooling water loop pump and related piping work.

6 Instrumentation air supply and air piping.

7 All field instrument cabling.

8 All power cabling.

9 Power evacuation from generator breaker panel.

10 Earthing for all equipment.

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6 Terms & Conditions

6.1 Price
A. Our price towards design, engineering, manufacture and supply of the ORC shall be
USD174,600 (USD One Hundred Seventy-Four Thousand and Six Hundred).
B. Basis of Offer: The price quoted by the Seller is FOB, Taiwan.

6.2 Payment Term

A. 40% of order value as advance along with the purchase order.
B. 60 % of order value prior to delivery.

6.3 DELIVERY
Six (6) months from the Effective Date of Contract (EDC), the Seller arranges the

transportation to deliver the ORC to the Buyer’s site. Note that EDC is the date of receipt of

clear order/ contract along with advance.

6.4 VALIDITY
This offer shall be valid for 30 days from the date of submission.

6.5 WARRANTY
All our equipment are tested before dispatch and therefore can be depended upon for long

trouble free service. The Seller undertake to make good by replacement or repair, defects

arising out of faulty design, material or workmanship, within eighteen (18) months of the date

of dispatch or twelve (12) months from the date of commissioning, whichever is earlier.

Providing that if the Seller is so required, the parts in respect of which complaint are made,

must be sent at the Buyer's expense to the Seller’s works before liability can be entertained.

Electrical components such as fuses, contactors, etc. and instruments such as pressure

gauges, thermometers, RTDs, etc., are not covered under this warranty. Bought out components

other than those falling in the categories mentioned above are guaranteed by the Seller only to

the extent of guarantees given to the Seller by the Seller’s suppliers.

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 This warranty will be valid subject to:

(1) Installation having been completed within six months of dispatch of the equipment or

alternatively stored with care without damage.

(2) The equipment or part thereof not being subject to accident alteration, abuse or misuse.

(3) The installation having been made in a proper manner as per our Installation Manual.

6.6 Supervision of Installation and Commissioning

The Seller can undertake supervision of installation and commissioning of the equipment

supplied with one 3-working day visit for free of charge. For additional visit of the Seller, as

requested by the Buyer, the charges to be borne by the Buyer are:

(1) To and fro airfare from Taiwan to the airport nearest to site.

(2) Boarding and lodging expenses in a first class hotel or equivalent.

(3) Local conveyance to be provided by you between airport, hotel and site.

(4) US$300 per day per the Seller’s Engineer.

The Seller’s engineers will be departed within ten (10) to fifteen (15) days of receipt of:

(1) Visa/Work Permit where applicable.

(2) The Buyer’s confirmation in writing by letter/cable/telex that all necessary customer

facilities have been arranged.

Please note that the charges are for supervision of mechanical erection/commissioning

only and the following facilities should be provided by the Buyer:

(1) Skilled and unskilled labor

(2) Consumables

(3) Tools and tackles

(4) Water, power and other energy supply

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