pwps_purecycle_application_guide

Copyright 2009 Pratt & Whitney Power Systems, Inc. Revision B – 09/23/2009 HTE66510All Rights Reserved.

PURECYCLE®

POWER SYSTEM

MODEL 280

Hot Liquidto ElectricityPower SystemNominal 280 kW Power

Product Dataand

ApplicationGuide

DISCLAIMER

Revision B – 09/23/2009 – Page 2 HTE66510

DISCLAIMER

This document is the property of Pratt & Whitney Power Systems, Inc. (Pratt & Whitney Power Systems or PWPS) andcontains proprietary and confidential information of PWPS. You may not copy or disclose this document or any informationin it, for any purpose, including without limitation, to design, manufacture or repair parts, or obtain any government approvalto do so, without PWPS’s express written permission. Neither receipt nor possession of this document alone, from anysource, constitutes such permission. Copying or disclosure by anyone without PWPS’s express written permission is notauthorized and may result in criminal and/or civil liability.

Pratt & Whitney Power Systems reserves the right to change or modify, without notice, the design or equipmentspecifications of the PureCycle power system without obligation with respect to equipment either previously sold or to besold. This Product Data and Application Guide is provided by Pratt & Whitney Power Systems for informational purposesonly, and no liability will accrue to Pratt & Whitney Power Systems based on the information or specifications includedherein. No warranties or representations shall apply to the equipment except as stated in the PureCycle power systemLimited Warranty Terms of Coverage applicable at the time of purchase, a copy of which will be provided upon request.

PureCycle® is a registered trademark of United Technologies Corporation or its affiliates and may be registered in theUnited States and other countries.


TABLE OF CONTENTS

Disclaimer ..............................................................2PureCycle Power System ReferenceDocuments.............................................................4Revision History ....................................................4Overview.................................................................5System Description...............................................5

Organic Rankine Cycle.....................................5System Operation..................................................6

Electrical System ..............................................6Working Fluid ....................................................6Codes and Safety..............................................6

System Components.............................................71. Evaporator ....................................................82. Turbine-Generator Assembly .....................83. Condenser ....................................................84. Working Fluid Pump....................................85. Electrical Control System........................86. Local-Operator Interface .............................9

Remote Monitoring System................................10RMS Capabilities/Features.............................10

Equipment List ....................................................12Physical Data .......................................................13Dimensions ..........................................................13Performance Data................................................14Pressure and Temperature Rating ....................14System Sound Level ...........................................15Working Fluid ......................................................15Application Guidelines .......................................16

Power Output ..................................................16Hot- Liquid-Resource Temperature andFlow..................................................................16Cooling Water Inlet Temperature and FlowRate ..................................................................17Hot-Liquid-Resource Control System...........17Power Derate Control .....................................18Resource Liquid Composition.......................18Heat-Exchanger Pressure Drop.....................18

Evaporator .................................................. 18Condenser................................................... 18

Cooling Tower................................................. 19Multi-unit Installation ..................................... 20

Site Design Requirements ................................. 21Layout and Civil Requirements..................... 21

Accessibility and ClearanceRequirements ............................................. 21Foundation Design..................................... 21

Mechanical Requirements ............................. 22Resource Water Control System .............. 22Resource Water Piping Design................. 23Cooling Water Piping Design.................... 23Compressed Air Requirements ................ 23Vent and Drain Connections..................... 24

Electrical Requirements ................................ 24Grid Interconnection.................................. 24Utility Grid Line Voltage and SiteTransformers .............................................. 25Disconnect Switch ..................................... 25Protective Functions.................................. 25Grid Protection Relay ................................ 26Grounding Plan .......................................... 26Power Factor Correction ........................... 26Emergency Stop Button ............................ 26

Control Wiring Requirements ....................... 26Data Connection......................................... 26

Electrical Interfaces and Field-InstalledWiring .............................................................. 27Summary of Customer-Provided Utilities andMaterials .......................................................... 27

Safety Considerations........................................ 28Appendix A – Typical InterconnectionAgreement Data .................................................. 29Appendix B – Project RequirementsDocument ............................................................ 30


PURECYCLE POWER SYSTEM REFERENCE DOCUMENTS

Product Data and Application Guide (HTE66510)

Product Guide Specification (PRMAN66787)

Installation Instructions (PRMAN66798)

Installation Completion Checklist (PRIM71223)

Commissioning Instructions (PRMAN66799)

Operation and Maintenance Instructions (PRMAN66800)

Mechanical Installation Drawing Set (APP66344, APP70613)

Electrical Installation Drawing Set (HTE73478 – Single-Unit Installation; HTE73520 – Multi-Unit Installation)

REVISION HISTORY

Revision Letter Date Reason for Change

A 07/19/2007 Original Issue

B 09/23/2009

Update to production configuration,provide additional application guidelines,performance detail and site designconsiderations

OVERVIEW


OVERVIEW

Pratt & Whitney, a division of United Technologies Corporation (UTC), is committed to providing clean, efficient and reliablepower within the growing distributed generation market. Its PureCycle power system, developed by Pratt & Whitney PowerSystems, Inc. (Pratt & Whitney Power Systems or PWPS), is a pre-engineered system that harnesses waste heat togenerate electricity. This results in a 280 kW on-site power-generation system that requires no fuel input except heat in theform of hot water.

Based on a thermodynamic cycle known as the organic rankine cycle (ORC), the PureCycle power system converts low- andmoderate-temperature resource fluids like water into electricity through vaporizing and expanding a working fluid in a closedsystem. The PureCycle power system can utilize heat that is available from many geothermal or oil and gas wells, and fromindustrial facilities. It can also use heat produced when a reciprocating engine or gas turbine is in operation.

This innovative power solution is built with the proven technology and components of commercial centrifugal chillers,ensuring product quality and reliability. It is a low-maintenance, cost-effective option that creates revenue, reduces processcost and supports an intelligent energy strategy.

The PureCycle power system is only available at Pratt & Whitney Power Systems and delivers a variety of performancecharacteristics that make it unique:

Ease of installation and maintenance

Fully integrated and assembled, modular-mounted packages that can be sized to match the resource andrapidly deployed according to need

100% remote monitoring and operation

Non-flammable and non-ozone depleting working fluid

ORC turbine derived from a standard centrifugal vapor compressor used in today’s water-cooled chillers

SYSTEM DESCRIPTION

Organic Rankine Cycle

The PureCycle power system operates using a thermodynamic principle known as the organic rankine cycle or ORC (seeFigure 1.

1. Hot water enters the evaporator to heat the working fluid, a refrigerant R245fa, until working fluid is vaporized.

2. High-pressure, hot vaporized working fluid then enters the power module and drives a turbine to produce electricalpower.

3. Low-pressure, expanded vapor cycles through a condenser where it is cooled and condensed into liquid form.

4. The cooled liquid is then sent to the pump, boosted in pressure and sent back to the evaporator to repeat the cycle.

5. Heat rejected during condensation is sent to a cooling tower. The cooling tower is provided by the customer.

SYSTEM OPERATION


Hot LiquidResource

195ºF – 300ºF(90ºC – 149ºC)

Hot LiquidResource

195ºF – 300ºF(90ºC – 149ºC)

Figure 1 – PureCycle Power System Schematic

SYSTEM OPERATION

During system start up, the working fluid flows through the bypass valve around the turbine until sufficient heat is supplied tothe system to enable proper operation. The bypass valve is open during start up while a valve upstream of the turbine, theturbine stop valve, is closed. Once sufficient vapor pressure is available upstream of the turbine, the controller opens theturbine stop valve and closes the bypass valve.

The turbine/generator assembly has an integral oil cooling and lubrication system for the bearings and rotating equipment.The oil system and generator are cooled by the working fluid in a fully enclosed, hermetically sealed system, minimizingleaks and eliminating the need for an additional cooling system interface with the customer.

Electrical System

The turbine drives a two-pole induction generator that transmits three-phase AC power at 480V/60 Hz (or optionally at380/400/415V/50 Hz) to the utility grid. The induction generator is started as a motor using a solid-state, phase-controlledstarter and must always be synchronized to the grid. This reduces the amount of inrush current required by the motor duringstart up.

Working Fluid

The working fluid, R245fa, a hydrofluorocarbon with the chemical composition of pentafluoropropane, is commonly used as afoam-blowing agent for the insulation industry, and is a new refrigerant for centrifugal chillers. R245fa has zero ozonedepletion potential because it contains no chlorine. With no flash point, the fluid is completely nonflammable. It is notfederally regulated with respect to the Resource Conservation and Recovery Act (RCRA) or by the Department ofTransportation for shipment.

Codes and Safety

The PureCycle power system is designed to minimize external leaks to the environment. The evaporator and condenser arestamped with the ASME Boiler and Pressure Vessel Code, and all piping complies with the standards of ASME B31.1, PowerPiping, commonly used for steam systems.

SYSTEM COMPONENTS


The PureCycle power system is designed to ensure personnel and equipment safety. National Electric Code installationcompliance ensures basic electrical and mechanical integrity and safety. Additional protective measures include:

A watchdog timer that continuously monitors controller performance and automatically shuts down the system if itdetects a controller malfunction.

A microprocessor-based control system that continuously monitors key system pressures and temperatures andautomatically shuts down the system if it detects abnormal operation.

An independent lock-out relay circuit that monitors the same pressures and temperatures and shuts down thesystem if required.

SYSTEM COMPONENTS

The PureCycle power system is supplied as a complete skid-mounted modular and tested assembly, including: turbinegenerator assembly, condenser, evaporator, electrical control system (ECS) and working fluid pump (See Figure 2 & 3).

Figure 2 – PureCycle Power System (Front View)

3. Condenser

1. Evaporator4. Working Fluid Pump

5. Electronic ControlSystem (ECS)

6. Local OperatorInterface (LOI)

3. Condenser

1. Evaporator4. Working Fluid Pump

5. Electronic ControlSystem (ECS)

6. Local OperatorInterface (LOI)

SYSTEM COMPONENTS


Figure 3 – PureCycle Power System (Rear View)

1. Evaporator

The evaporator, an ASME BP&V-coded vessel, is a shell-and-tube heat exchanger that utilizes carbon steel tubes thatcapture the resource heat. Optional materials, described in the Equipment List section, are available to meet site-specificneeds. The evaporator is delivered as an integral part of the skid-mounted module, thus reducing installation cost and site-specific engineering.

2. Turbine-Generator Assembly

The heart of the PureCycle power system is the turbine-generator assembly. This assembly is the same platform as Carrier’sstandard chiller motor-compressor; however, it is operated in reverse as a turbine-generator. High-pressure vapor drives theturbine that in turn drives the induction generator through a gear transmission. The oil-and generator-cooling systems areintegral to the fully enclosed hermetic assembly, as are the controls and diagnostic instrumentation for pressure,temperature, and speed monitoring. The turbine drives a two-pole induction generator that transmits three-phase AC powerat 480V/60 Hz (or at 380/400/415V/50 Hz with the alternate voltage option).

3. Condenser

The condenser, an ASME BP&-coded vessel, is a shell and tube heat exchanger that utilizes copper tubes in which low-pressure vapor is cooled and condensed into a saturated liquid. Optional materials, described in the Equipment List section,are available to meet site-specific needs. The condenser is delivered as an integral part of the skid-mounted module,reducing installation cost and site-specific engineering.

4. Working Fluid Pump

The pump delivers the working fluid until the working fluid is vaporized. The pump operates continuously but at varyingspeeds, controlled by a variable frequency drive. Pump speed is controlled to maximize power-plant-generated power.

5. Electrical Control System

The Electrical control system (ECS) is the control system for the power plant. The ECS enclosure contains the systemcontroller, input/output (I/O) modules, working fluid pump motor drive, generator solid-state soft starter, remote monitoring

1. Evaporator

2. Turbine-Generator

3. Condenser

1. Evaporator

2. Turbine-Generator

3. Condenser

SYSTEM COMPONENTS


system (RMS), system contactors and relays. The ECS automatically controls the proper start, continuous operation anddisconnect of electrical energy for the turbine/generator, oil pump, oil heater, process controls, and other components.

Additional features of the electrical control system include

Motor control and protection, including reduced-voltage start up thermal capacity protection for operation inboth motoring and generating modes.

Transient voltage and surge-suppressor device protection at utility interface per IEEE standardC62.411980 (R1995)

Minimal harmonic distortion for compliance with IEEE 519 Recommended Practices and Requirements forHarmonic Control in Electrical Power Systems

Power factor correction to 0.95 lagging minimum at full load.

User interface for remote and manual operation

Provision, via an internal signal, for non-utility grade metering of motor/generator power

A disconnect switch (not shown, but installed) used for Lock Out Tag Out (LOTO) service provision,reducing site costs and installation time associated with installing a separate switch

6. Local-Operator Interface

The local-operator interface (LOI), the local user interface to the system, provides several key functions, including power,alarm indicaiton and emergency stop.

1. Ethernet connection2. Generator soft starter interface3. RJ14 connection4. Power indicator5. Alarm (service) indicator6. Lock out relay (LOR) enable indicator7. Off/Auto mode switch8. Reset button9. Lamp test button10. Emergency stop buttonGround fault circuit interrupter (GFCI)

located on adjacent door.

1 2 3

4 5 6

7 8 9

10

1 2 3

4 5 6

7 8 9

10

Figure 4 – Local-Operator Interface (LOI)

1. Ethernet connection – an Ethernet port for service access to the local network

2. Generator soft-starter interface – shows the generator soft starter data

3. RJ14 connection – a connection for local service access to power plant controller

4. Power button – indicates whether 480 VAC (or optionally 380/400/415V) power is available to the unit

5. Alarm indicator – indicates whether one or more controller alarms are active

6. LOR is a safety circuit with pressure switches and a microprocessor watchdog timer. The circuit opens when anysafety switch trips or if the emergency stop is closed. Once opened, the relay must be reset locally using the resetbutton (#8 on this figure) or remotely by a PWPS service technician.

7. Mode switch – local interface on machine for turning the unit on or off (typically for service). The switch position islabeled “Auto” to indicate that the controller is allowed to start if all other criteria are met. The LOR must be in the

REMOTE MONITORING SYSTEM


normal position (LOR Enable light is active) for the unit to start up. The switch may be turned to “Off” formaintenance and provides local override in the “Off” position.

8. Reset button – resets the LOR described above

9. Lamp test button – tests the indicator lamps for proper function. Lamps that do not light up during this test mayneed to be replaced.

10. Emergency stop button – shuts down the machine in the event of an emergency. Shutting down the system usingthe E-stop method is not recommended unless there is an emergency. Doing so repeatedly will result in prematurewear of the turbine, working fluid pump, and evaporator and degradation of the oil.

A GFCI outlet located on the adjacent panel door provides 120 V service for maintenance ease.


The remote monitoring system (RMS) provides local and remote monitoring and control of PureCycle power systems at acustomer site from the Internet. Connection to remote sites is established through an Internet web portal, through whichusers can access current and historical power plant operating data. Product alarms are stored along with product data in acentral database. The RMS design leverages Pratt & Whitney Power Systems’ experience in remote monitoring andprovides low-cost installation and operation.

Static IPInternetInternetUTC

IntranetUTC

Intranet

InternetInternet

RMS Server

Firewall

PWPSTechnician

Customer

RemoteMonitoring

System

1-5 PureCycle® Units

1 or more banks of PureCycle® Units

Firewall

PWPSTechnician

Router

Figure 5 – Remote Monitoring System Architecture

RMS Capabilities/Features

The RMS collects data and forwards it to a database accessible through WebCTRL software, a Web server interface thatsupports remote monitoring/control through a Web browser. Communication to the RMS is established through a customer-supplied dedicated high speed internet with a unique static IP address and/or appropriate routing equipment. Bandwidthcapability should be T1 or equivalent (1.54 Mb minimum bandwidth) for the best functionality. Data connection requirements

WebCTRL® is a registered trademark of Automated Logic Corporation.



are detailed in the Control Wiring Requirements section of this document. Data encryption techniques are used to providesecure communication.

RMS offers the following features:

1. Communications – The remote monitoring system provides tools for the customer or UTC personnel to interface withthe equipment. Remote communication is used to facilitate troubleshooting and remotely update software.

2. Alarm logging – Alarms are retained in the database and are accessible through the portal. Response to alarmsdepends on Warranty and level of service purchased. Please consult your Warranty Agreement and Service Agreementfor further details.

3. Remote monitoring, database queries and reporting – Through WebCTRL® software, customers and UTCassociates with proper authorization can remotely monitor sites through an Internet connection. Individuals logging onto the portal site are provided with a list of sites they are authorized to monitor. All users will be provided a logon ID andwill be required to select a password to gain access to the system.

The portal site also serves as an interface to a database that stores historical performance data. A graphical userinterface facilitates database queries and the generation of reports. Standard reports are available and can beconfigured by the user.

4. Data storage – A database stores all relevant product data and alarm/maintenance history. Data from the RMS will beuploaded to the database.

5. Remote start/stop – Service personnel have the ability to remotely start and stop the machines. PureCycle powersystems can be wired on-site for Supervisory Control and Data Acquisition (SCADA) site-control remote start/stop ifdesired.

EQUIPMENT LIST


EQUIPMENT LIST

Table 1 – Equipment List

STANDARD OPTION(Factory Installed)

PureCycle Model 280 Power System

Power plant assembly, model 280, 480 V, 60 Hz Evaporator assembly2:

Carbon steel tubes – SA214 GR70Carbon steel tube sheets & heads – SA516-70NHinged head on service endCarbon steel nozzle – SA53 GR BCarbon steel ring flange – SA-350 LF2

Water-cooled condenser assembly2

Copper tubes – B75 UNS C12200Carbon steel tube sheet & heads – SA516-70NHinged head on service endCarbon steel nozzle – SA53 GR B

Turbine assembly Working fluid pump Electronic control system (ECS) Power plant AC disconnect switch

X

Consumables1

Turbine oil R245fa refrigerant

X

Remote monitoring system (RMS)3 XAlternate evaporator tube side wetted materials2

Stainless steelo Tubes – SA249 316/316Lo Tube Sheet – SA240 316/316Lo Internal cover sSurface – Heresite® Coating

Titaniumo Tubes – SB338 GR2 Weldedo Tube sheet – SB265 GR1 Claddingo Internal cover surface – Ceramalloy Coating

Duplexo Tubes – 2205 weldedo Tube sheet – 2205o Internal cover surface – Heresite® Coating

X

Alternate condenser tube side wetted materials2

Stainless steelo Tubes – SA249 316/316L Weldedo Tube sheet –SA240 316/316Lo Internal cover surface – Heresite® Coating

Titaniumo Tubes – SB338 GR2 Weldedo Tube sheet – SB265 GR1 Claddingo Internal cover surface – ceramalloy coating

X

Alternate evaporator exit locationLocated on same side as evaporator inlet; allows for all heatexchanger plumbing connections to come from one side

X

Alternate voltage and frequency configuration 380/400/415V/50 Hz

X

1 Pratt & Whitney Power Systems provides initial fill. Only Genetron® R245fa is acceptable for use in the PureCycle power system.Turbine oil is a formula unique to PWPS’s application and should be obtained from PWPS.

2 Corrosive effects on tube side wetted surfaces will vary. Consult industry expert for material compatibility with resource fluid.3 One RMS system can operate with up to 5 PureCycle power system units. Monitoring service is offered as a separate option.

Heresite® is a registered trademark of Heresite Protective Coatings, Inc.


PHYSICAL DATA

Table 2 – Physical Data

English SI

PureCycle Power System

Operating weight 33,300 lbs 15,104 kgShipping weight 27,600 lbs 12,519 kgDimensions (L x W x H) 19’ x 7’-6” x 11’-3” 5790 x 2290 x 3430 mmMaximum whipping height 10’-3” 3200 mm

DIMENSIONS

The following schematics are presented to give general dimensions required for a PureCycle installation. Standard drawingscontaining mechanical, electrical and civil requirements for constructing a typical PureCycle installation (MechanicalInstallation Drawing Set APP66344 and APP70613) are available upon request. Please refer to these drawings for moredetailed site engineering requirements.

Figure 6 – PureCycle Power System Dimensions

PERFORMANCE DATA


PERFORMANCE DATA

Table 3 – Performance Data

Performance Characteristics

Gross electrical power output 280 kW 272 kW 263 kW

Net electrical power output1 265 kW1,2 257kW1,2 248 kW1,2

Voltage and frequency standard 480 V, 3 phase, 3 wire60 Hz

400/415V, 3 phase, 3 wire,50 Hz

380V, 3 phase, 3 wire,50 Hz

System sound level 78 dBa at 10 m (33 ft)

Electrical Characteristics

Frequency range 59.3 – 60.5 Hz 49.0 – 51.0 Hz 49.0 – 51.0 Hz

Power factor Greater than 0.95 lagging

Maximum line voltage deviation(vs. rated line voltage)

1.10 to 0.88

Line voltage unbalance ±3%

HarmonicsVoltage Total Harmonic Distortion (THD) < 5%

Current THD < 5% (IEEE 519 compliant)

Interruption/disconnection The system interrupts if it detects an abnormal grid condition. It can be configuredto automatically re-start in < 20 minutes.

Protection parameters Grid protection includes over/under voltage/frequency.1 Net power is the gross generator power minus internal parasitic power within the PureCycle system. It does not account for additional

parasitic power required by the site to provide resource and cooling water flow.2 Net power output is resource-liquid and cooling-water dependent. Contact your Pratt & Whitney Power Systems representative for

more information and an analysis of your specific resource.

PRESSURE AND TEMPERATURE RATING

Heat exchangers in the PureCycle power system have the following pressure and temperature ratings. Heat exchangers areU1 stamped per the ASME Boiler and Pressure Vessel Code Section VIII.

Table 4 – Pressure and Temperature Rating

Assembly Pressure Rating Temperature Rating

CondenserShell sideTube (water) side

150 psig (1034 kPa)150 psig (1034 kPa)

225ºF (107ºC)120ºF (49ºC)1

EvaporatorShell sideTube (water) side

345 psig (2380 kPa)150 psig (1034 kPa)

330ºF (177ºC)325ºF (163ºC)

1 Condenser temperature limit is set by system operating limit of exit cooling water temperature below 120ºF (49ºC).

Site design must provide safety relief for the evaporator on the customer water side. Proper venting of the power plantpressure relief valves for the working fluid is also required to prevent overpressure of the system. Refer to ASHRAE 15Safety Standards for Refrigeration Systems for proper installation of equipment.

SYSTEM SOUND LEVEL


SYSTEM SOUND LEVEL

System sound level for the PureCycle power system is typically stated as 78 dBa at 10 m. Local codes or ordinances mayrequire sound attenuation if the noise level at a particular distance exceeds a specified threshold. For those purposes,sound levels at various distances are shown in

Figure 7 – PureCycle Model 280 System Sound Level

Figure 7 – PureCycle Model 280 System Sound Level

WORKING FLUID

The PureCycle power system utilizes a hydrofluorocarbon called R245fa (pentafluoropropane) as its working fluid to transferthe heat available in the resource fluid. R245fa is commonly used as a foam-blowing agent for the insulation industry, and isa new refrigerant for centrifugal chillers. By virtue of its lack of chlorine, R245fa has zero ozone depletion potential. With noflash point, the fluid is completely nonflammable. It is not federally regulated with respect to RCRA or the Department ofTransportation, and OSHA does not list the fluid for toxicity. It has a global warming potential (GWP) of 950. R245fa iscategorized as Category B1 for ASHRAE Safety Standard 15.

Typical charge for the PureCycle power system is ~ 3200 lbs (1450 kg). Please refer to the Material Safety Data Sheet(MSDS) for R245fa provided by Honeywell. Only Genetron®® 245fa is acceptable for use in the PureCycle power system.

The refrigerant should be stored in a cool, well-ventilated area. Refrigerant is delivered and should be stored in the sameDOT containers. Each container holds approximately 1,000 lbs (454 kg) of fluid and has a tare of approximately 400 lbs(181 kg). The containers are designed with fork-lift pockets for easy handling and are approximately 4’ x 4’ x 5’ h (1.2 m x1.2 m x 1.5 m h).

Pratt & Whitney Power Systems recommends a hard shaded surface for working fluid storage. PWPS recommends a 10’ x10’ (3 m x 3 m) fenced area, segregated from the power plants and utilizing pole-barn-type shade. One to two containerswith some fluid and three to four empty containers for holding fluid during machine repair/maintenance activities arerecommended. When designing the site, accommodations for the refrigerant storage should be considered.

Because the refrigerant should not be mixed with air or oxygen at pressures above atmospheric, the PureCycle system isshipped with a nitrogen charge of 15 psi. Storing the PureCycle power system above 60ºF (15.5ºC) protects against theintroduction of non-condensable gas into the system. Please refer to the PureCycle Model 280 Installation ManualPRMAN66798 for more information.

Genetron® is a registered trademark of Honeywell International, Inc.

PureCycle® Model 280Sound Pressure Level (SPL) vs Distance

• Assumed omnidirectional sound radiation

70.00

75.00

80.00

85.00

90.00

95.00

100.00

1 10Distance (m)

SP

L(d

BA

)

APPLICATION GUIDELINES


The accumulation of working fluid in an enclosed space can displace oxygen and cause asphyxiation. Indoor installationsrequire leak detection, as well as adequate ventilation in accordance with ANSI/ASHRAE 15, especially for enclosed and lowoverhead spaces.


Power Output

Power output is a function of installation-specific variables, including resource liquid temperature and flow rate and coolingwater temperatures. The following sections of this document will describe the influence of these installation-specificvariables and provide guidelines for system performance. Interested customers should complete the Project RequirementsDocument (PRD) in Appendix B and contact Pratt & Whitney Power Systems for specific application performance andoptimization.

Hot- Liquid-Resource Temperature and Flow

The PureCycle power system generally requires a hot-liquid-resource temperature between 195°F (90ºC) and 300°F (149ºC)and a cold water source, preferably 85ºF (30°C) or less. The hot resource flow required to produce full power output variesbetween 180 and 1100 gpm and is a function of installation-specific variables, including resource liquid temperature andcooling water temperature. For information on applications outside of these temperature and flow ranges, please completethe PRD in Appendix B and consult your PWPS sales consultant or applications engineer.

Table 5 describes PureCycle Model 280 Performance. Multiple systems can be installed if sufficient flow is available. Twomachines operating in parallel would require twice the flow of one machine.

Table 5 – PureCycle Model 280 Performance

If the resource temperature decreases from its design value (typically the value selected from the figures above), poweroutput will decrease accordingly. This power output as a function of design flow rate for a single unit is described in Figure 8.When resource flow has decreased such that gross power output is less than 80 kW, the PureCycle power system will shutdown.

Hot Resource (Evaporator)Inlet Temperature 280ºF 138ºC 280ºF 138ºC 240ºF 116ºC 240ºF 116ºC 200ºF 93ºC 200ºF 93ºCExit Temperature 170ºF 77ºC 185ºF 85ºC 172ºF 78ºC 194ºF 90ºC 173ºF 78ºC 173ºF 78ºCFlow Rate 180 gpm 11 l/s 227 gpm 14 l/s 345 gpm 21 l/s 510 gpm 31 l/s 1100 gpm 66 l/s 1100 gpm 66 l/sMaterialCooling Water (Condenser)Inlet Temperature 60ºF 16ºC 80ºF 27ºC 60ºF 16ºC 80ºF 27ºC 60ºF 16ºC 80ºF 27ºCExit Temperature 78ºF 26ºC 98ºF 37ºC 78ºF 26ºC 98ºF 37ºC 78ºF 26ºC 98ºF 37ºCFlow Rate 960 gpm 58 l/s 1030 gpm 62 l/s 960 gpm 58 l/s 1030 gpm 62 l/s 1160 gpm 70 l/s 1285 gpm 77 l/sMaterialPower OutputGross Power OutputNet Power OutputVoltage/Frequency

1 Power output at low resource temperatures and high condensing temperatures is derated due to evaporator flow limitations.

280°F/138°C Resource 240°F/116°C Resource 200°F/93°C Resource

480 V / 60 Hz

280 kW265 kW

480 V / 60 Hz

Carbon Steel

Copper

280 kW260 kW

480 V / 60 Hz

CopperCopper

Carbon Steel Carbon Steel

280 kW265 kW

205 kW190 kW



PureCycle® Model 280

Gross Power Output

480 V/ 60 Hz Configuration

0

50

100

150

200

250

300

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Percent of Design Flow

Gro

ss

Po

we

rO

utp

ut

(kW

)

Minimum Power Output ~ 80 kW

Figure 8 – PureCycle Model 280 Gross Power Output as a Function of Design Flow Rate

Cooling Water Inlet Temperature and Flow Rate

Lower cooling water temperatures allow for higher power output per unit up to the unit rating. It may be necessary to modelseasonal variation in performance due to ambient conditions and is helpful for cooling tower selection. Interested customersshould consult Pratt & Whitney Power Systems to determine the actual performance for their site conditions.

Hot-Liquid-Resource Control System

Operation of the PureCycle power system requires control of the resource liquid flow through the evaporator. Duringoperation, the system controller automatically modulates the liquid flow rate to maximize power output and prevent over-heating the working fluid. When the system is shut down, a control valve stops all resource water flow through theevaporator so that heat is not transferred into the system. Automated bypass control and manual isolation valves should beprovided by the customer in the site design. A concept is shown in Figure 9.

Figure 9 – Resource Control System Concept



Power Derate Control

The PureCycle power system is designed for operating ambient temperature between -20ºF and 122ºF (-28ºC and 50ºC).Output power may decrease with electronic control system (ECS) enclosure internal temperatures over 113ºF (45ºC). Thisoutput power reduction is expected to correspond with an ambient temperature exceeding 104ºF (40ºC) but may vary basedon site conditions including, but not limited to, cooling water inlet temperature, solar loading and orientation, wind conditionsand elevation.

Resource Liquid Composition

Resource liquid quality is highly site specific and is the customer’s responsibility to determine suitability for this application.Typically, water consultants are hired to assist in the proper selection of materials. Pratt & Whitney Power Systems offersalternate heat-exchanger materials for use with various contaminants.

Particulates in the resource water must also be carefully examined to determine the potential for fouling the heat exchangersand reducing performance and life. Applications with high particulate levels may be viable if the proper chemical treatmentsand cleaning processes are used. The evaporator is designed to be easily inspected and cleaned in the field. In all cases, itis the responsibility of the customer to develop cleaning processes to maintain maximum performance and evaporator life.At a minimum, annual inspection of the heat exchanger tubes is recommended.

Heat-Exchanger Pressure Drop

Tube-side pressure drop across the evaporator and condenser will vary depending on the flow for the proposed application.

Evaporator

Typical pressure drops for the evaporator are shown in Figure 10. For the evaporator, the minimum design flow is 180 gpm(11.4 l/s), and the maximum design flow is 1100 gpm (69.4 l/s). Generally, lower resource temperatures will require greaterresource flows. The two lines shown represent the expected power plant pressure drop range through several flow ranges.At the site level, pressure drop through the site piping and balance of plant should be managed to minimize the flow variationand reduce the pressure drop required for the controlling band.

Evaporator

Pressure Drop vs. Resource Flow Rate

0

5

10

15

20

25

30

100 200 300 400 500 600 700 800 900 1000 1100

Resource Flow Rate (gpm)

Ev

ap

ora

tor

Pre

ss

ure

Dro

p(p

si)

Controlling BandPower PlantFlow ControlValve~ 80% Open

Power Plant FlowControl Valve~ 60% Open

ConsultPWPS for

Applicationsin thisRange

Figure 10 – Evaporator Pressure Drop



Condenser

Condenser pressure drops will vary with flow rate and condenser inlet temperature. Typical pressure drops for thecondenser are shown in Figure 11. For the condenser, the minimum design flow is 600 gpm (37.9 l/s), and the maximumdesign flow is 2000 gpm (126.2 l/s).

Figure 11 – Condenser Pressure Drop

Cooling Tower

The PureCycle system requires the heat rejection of the system to be dissipated to the atmosphere or some other heat sinkto allow the system to operate as intended. Typically, a cooling tower is utilized to perform this function but other equipmentor processes can be used depending on the design of the specific system involved. This discussion will focus exclusively onthe use of cooling towers since they are the most common type of equipment used for this purpose in commercialinstallations.

Cooling towers transfer heat from the water circulated in the PureCycle system’s condenser to the atmosphere by pumpingor spraying the water over the cooling tower “fill”, which has a relatively large surface area to improve heat transfer. Air isdrawn over or through the fill section (typically by one or more fans) causing evaporation of a portion of the water, therebycooling the remaining water to within a few degrees of the ambient wet-bulb temperature. The actual water temperature isdependent on the sizing of the tower but most towers are selected at approach temperatures (the difference between thewet-bulb temperature and the leaving water temperature) of between 10° F to 18° F (5.5ºC to 10ºC). As an example, a towerselected for a 10° F approach could achieve a return water temperature to the condenser of 85° F given a design wet-bulbtemperature of 75° F.

Sizing and selection of a cooling tower is dependent on knowing the heat rejection from the condenser, the design ambientwet-bulb temperature, the cooling water flow and the supply and return water temperatures (the approach temperature canbe determined if both the design cooling water return temperature and the design wet-bulb temperature are known). Contactcooling tower manufacturers to assist with sizing the tower to the specific application.

CondenserPressure Drop vs. Cooling Water Flow Rate

0

5

10

15

20

25

30

600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

Cooling Water Flow Rate (gpm)

Pre

ss

ure

Dro

p(p

sid

)

High Temperature Resource280ºF - 300ºF

(138ºC - 149ºC)Low Temperature Resource

195ºF - 280ºF(90ºC - 138ºC)



As a result of evaporation of some of the water, it is necessary to replenish whatever amount of water is lost. Generally,evaporation loss accounts for approximately 1% of the amount of water in circulation. In addition, about .2% is also lost dueto droplets being entrained into the air (drift), as well as to regular draining. Blow-down, the process of removing or bleedinga portion of water from the main water circulating line to maintain an acceptable level of dissolved solids or minerals, typicallyequates to about a .3% loss. The total loss attributed to all of these conditions, approximately 1.5-2% of flow, determines theamount of make-up water that has to be added, which is usually done by automatically maintaining a predetermined level inthe cooling tower sump or basin via a float valve.

To aid in properly maintaining water quality and cleanliness, as well as to prevent corrosion or fouling of the condenser, awater treatment system should be provided on each installation. This can be either a manual or automatic system thatcontrols the chemical and biological properties of the water to prevent corrosion, algae and fouling. The tower manufacturercan recommend additional equipment or maintenance procedures accordingly. Fouling can result if a chemical treatmentsystem is not installed or if blow-down is not performed regularly in the cooling water system. Without proper treatment tothe cooling system, fouling of the condenser can occur quickly.

Temperature control of the water is a critical element in the design and selection of a cooling tower for a PureCycle system,since it influences power output. Providing colder water is beneficial, as it allows the condenser to operate more efficiently.However, the return cooling water temperature to the condenser should be maintained above a minimum limit of 50ºF. Watertemperature is typically controlled by either cycling the fan(s), utilizing variable-speed or two-speed fan motors or byincorporating a tower bypass valve into the system design.

Location of the cooling tower will vary according to local site design and other considerations. In general, the location of thecooling tower should allow for unrestricted airflow and to prevent recirculation, consideration for fogging or drift and whatother equipment or objects might be wetted in the event of strong winds, consideration of the increase in sound level to thesurrounding area, and the weight of the tower if installed on a roof. Close proximity to the condenser should also beconsidered to avoid long pipe runs and increased pumping costs. If installed in areas where the ambient temperature can gobelow 32°F, attention should be paid to providing an auxiliary sump located inside a heated space to preclude freezing of thewater. Alternatively, a heated sump could also be used. Insulation of the cooling water piping should also be considered incold climates.

The manufacturer of the cooling tower can provide more details on the design and installation of the tower relative to thespecific job-site requirements.

Multi-unit Installation

A multi-unit installation will consist of multiple blocks of one to five PureCycle systems in a parallel configuration. Eachsystem will be able to operate independently. However, starting more than one system at a time is not recommended. Tolimit start up current draw and electrical demand charges, the site control should be set up to stagger-start multiple units andprovide feedback so that peak currents do not overlap. Motoring time and requirements for stagger start are described in theElectrical Requirements section of this document.

A grid connection is required to start and/or operate. Each system is able to start automatically without direct control. Thepower plant allows for direct control from a site control computer. Safety features in the control permit one or more to shutdown by remote command or automatically. Loss of grid connection for load will produce an automatic shut down of all thesystems. Loss of cooling water will produce an automatic shutdown of all the systems simultaneously.

SITE DESIGN REQUIREMENTS



The following is a list of general site characteristics required to install a PureCycle power system. Pratt & Whitney PowerSystems has standard mechanical and electrical installation drawings (Mechanical Installation Drawing Set APP66344 orAPP70613 and Electrical Installation Drawing Set HTE73478 or HTE73520) to provide further details for a PureCycle

installation.

Review all site permits that may be affected by the installation of the PureCycle system prior to initiating construction.

Layout and Civil Requirements

Accessibility and Clearance Requirements

In addition to the equipment footprints, the layout requires an additional four-foot-wide paved area around the equipment tofacilitate service. Area in front of the condenser and evaporator is required for tube maintenance and replacement, asdetailed in Figure 12 below. Be sure to include sufficient clearance around the site to allow a crane to maneuver and placeequipment.

Figure 12 – Maintenance Clearance Requirements

Foundation Design

The PureCycle power system is delivered complete as a skid-mounted assembly and requires a concrete foundation forinstallation. The skid-mounted modular system assembly (turbine-generator with controls, condenser, evaporator, andworking fluid pump) are mounted as a system on the foundation. The foundation pad must be level to within ±¼” over 10 ft. Itis important that the concrete foundation extend below the frost line. The foundation construction must be designed andfabricated in accordance with the Requirements for Reinforced Concrete ACI 318, as well as any local and state codes. Theskid-mounted modular system assembly should be secured in place with anchor bolts as shown in the MechanicalInstallation Drawing APP66344 or APP70613.

4’ minimum perimeter, flat hard surface

Area required for tubemaintenance /replacement

16.5’ min

25’

15.2’

Hot waterInlet

Cooling water inlet andoutlet

Hot waterOutlet

7.2’

Area requiredfor electricalmaintenance

Area requiredfor turbine

maintenance

4’ minimum perimeter, flat hard surface

Area required for tubemaintenance /replacement

16.5’ min

25’

15.2’

Hot waterInlet

Cooling water inlet andoutlet

Hot waterOutlet

7.2’

Area requiredfor electricalmaintenance

Area requiredfor turbine

maintenance



Mechanical Requirements

The mechanical design of a PureCycle installation includes the specification and design of the following systems:

Resource water supply and return piping

Cooling water supply and return piping

Compressed air supply design for actuating PureCycle internal control valves

Table 6 lists the mechanical connections directly to the PureCycle power system as they are called out on the MechanicalInstallation Drawings APP66344 and APP70613.

Table 6 – Mechanical Connections

TECHANICALINTERCONNECTIONS

INTERCONNECTIONTYPE AT UNIT

Compressed gas supply inlet 1/2” FNPT

Evaporator

Low TemperatureApplications195ºF – 225ºF(90ºC – 107ºC)

HighTemperatureApplications225ºF – 300ºF

(107ºC – 149ºC)Resource water inlet 6 in. – 150 lb flange 4 in. – 150 lb flange

Resource water outlet 6 in. – 150 lb flange 4 in. – 150 lb flangePressure relief valves 2 x 1 ½” FNPT

Condenser

Cooling water inlet 10 in. – 150 lb flangeCooling water outlet 10 in. – 150 lb flange

Pressure relief valves 2 x 1 ½” FNPT

Resource Water Control System

This section describes the standard means of controlling the resource liquid flow to the PureCycle unit(s). Genericrequirements and considerations include the following points:

The flow rate of resource liquid through the evaporator must be able to be continuously controlled.

To control power output and protect the equipment, consider how the addition of the PureCycle system can beincorporated into the existing site controls without adversely affecting the existing facility operation. It is essential toensure that a shut down of the PureCycle system for routine maintenance or system malfunction does not cause ashut down or other disturbance to the facility.

The customer is expected to provide sufficient system pressure to the PureCycle power system to prevent the hotliquid from flashing. In geothermal applications, for example, this would typically require a reinjection pump.

Protect the system from water hammer in the event of a rapid shut down of the power plants. Rapid shut down willclose the PureCycle power system flow control valve in approximately 2-5 seconds.

During start up and shut down, the site must accommodate the excess flow that the system does not use. Arecommended approach is for the site to include a bypass leg with a pressure-regulating valve. The regulatingvalve maintains the proper pressure conditions upstream of the system while the power plant ramps up to fullpower. During shut down, the regulating valve would adjust to match flow as the system reduces power.

The customer should note that hot resource liquid exit temperature is not directly controlled by the PureCycle powersystem. To maintain a consistent resource exit temperature, other site parameters must be controlled to reach thedesired temperature.

Cascaded units will use the exit of the higher resource as the inlet to the second unit. This should provide sufficientpressure upstream so that one plant can modulate flow without significant perturbation to a second plant’s flow.



Resource Water Piping Design

When designing the piping to provide resource water to the evaporator, consider the following points:

Analyze the chemical composition of the resource water to screen for potential corrosion of the evaporator tubes.

Particulate matter in the resource water may deposit on the evaporator tubes, thereby degrading performance orcausing hazardous waste. Water-quality management, including temperature or chemistry control, may berequired.

Install pressure relief on the customer resource plumbing to the evaporator.

Insulate hot piping to prevent heat loss and/or to protect facility or service personnel from hot surfaces.

Provide maintenance access to piping internals for routine cleaning and inspection.

Cooling Water Piping Design

When designing the piping to provide cooling water to the condenser, consider the following points:

The system control scheme should have an internal sensor to confirm the presence of cooling flow before it acceptsresource flow or requests the power plant to start. PWPS recommends that site controls interface with thePureCycle power system cooling water flow switch before supplying hot resource flow.

Loss of cooling water will result in an immediate system shutdown, including hot resource shutoff. The shut downimmediately shuts off the resource flow through the system.

Once all systems are shut down, approximately 5 minutes after the shutdown request or initiation, the site coolingwater can be shut off.

Compressed Air Requirements

A source of compressed air is required to actuate the pneumatic resource and turbine flow control valves (bypass, dump,and stop valves). The gas supply shall be from filtered, dry compressor air. The requirements for the compressed air are

85 psi minimum

4 SCFM (piping must be sized to supply 10 SCFM instantaneous demand)

Compressor air must be filtered using a 30 micron filter and dried to a dew point of 35ºF (1.7ºC)

A pressure relief valve must be installed in the piping to prevent the air line from exceeding 125 psig for protectionof equipment within the power plant

PWPS provides a pressure switch with a dry contact input to the PureCycle controller to ensure the availability ofcompressed gas prior to starting power plant.



Figure 13 – Pneumatic Valve and Pressure Relief Valve Locations

Vent and Drain Connections

Pressure relief valves are installed on the evaporator and condenser, as shown in Figure 13. Dual pressure relief valves areincluded for maintenance ease and calibration. The upper set of pressure relief valves is installed in on site to preventshipping damage. Discharge lines should be installed for safety and should be piped according to ASHRAE 15 and localcodes. If the PureCycle power system is installed indoors, the pressure relieve valves must be piped outside.

Electrical Requirements

The PureCycle power system has electrical connections that must be made in the field, including several power and controlconnections. Standard electrical drawings (Electrical Installation Drawing Set HTE73478 or HTE73520) are available as areference. The customer is responsible for consulting the appropriate handbooks or codes to confirm that the site designcomplies with local and national electric codes.

Grid Interconnection

Grid interconnection of the PureCycle system typically requires permitting, interconnection agreements and metering.Because the permitting and interconnection agreement process can be lengthy, Pratt & Whitney Power Systems encouragesthe customer to conduct a grid interconnect study early in the project development. For the utility’s planning purposes, aninterconnection study allows the utility to determine whether the add-on of the proposed power operator will adversely affectthe electrical system’s normal operating parameters. Please refer to Appendix A for a list of typical interconnectionagreement questions and data.

An induction generator is the counterpart to an induction motor. While an induction motor consumes power by operating atslightly below grid frequency, the induction generator supplies power by operating at slightly greater than grid frequency (so-called negative slip). The amount of power supplied to the grid is controlled by torque applied from the turbine to thegenerator shaft. Unlike synchronous generator and inverter-based technologies, an induction generator is self-synchronizingand can be started as an induction motor. A soft starter and/or fluid assist are used to control and minimize the starting in-rush current.

CustomerPneumaticConnectionInterface

PressureReliefValves(InstalledOn Site)

Pneumatically operated valves

CustomerPneumaticConnectionInterface

PressureReliefValves(InstalledOn Site)

Pneumatically operated valves



The PureCycle power system utilizes a two-pole induction generator that transmits 3-phase AC power at 480V/60 Hz (or at380/400/415V 50 Hz with the alternate voltage option). The induction generator is started as a motor using a solid-statephase-controlled starter and is always synchronized to the grid. The facility or installation must be capable of providing theRMS current requirements for a single unit start up shown in Figure 14.

Figure 14 – RMS Current Requirements for Single Generator Start up for 480V/60 Hz Configuration

The customer is responsible for obtaining interconnection approval from the local distribution utility and procuring therequired interconnection equipment. The customer is also responsible for conducting any special tests required by the utilityto verify functionality of the interconnection protection protocols.

Utility Grid Line Voltage and Site Transformers

The PureCycle power system utilizes an induction generator rated for 480-volt service. Alternate voltage options areavailable for 380/400/415-volt service. A transformer or other equipment may be required to rectify the site voltage to supply480-volt (or 380/400/415-volt) service to the PureCycle power system.

Disconnect Switch

The PureCycle power system is equipped with a safety disconnect switch rated for 600 Amp service for connecting to thecustomer local utility interface. This circuit delivers the power generated by the power plant and also provides the source forstart up power.

Please refer to Appendix A for detail on the disconnect switch rating.

Protective Functions

The PureCycle power system has several self-protection features and grid-protection equipment. These features include

Thermal or pressure overload protection

Solid-state starter with integral overload protection

Two transient voltage surge suppressors

A watchdog timer that continuously monitors controller performance and automatically shuts down the system if itdetects a controller malfunction

A microprocessor-based system that continuously monitors key system pressures and temperatures andautomatically shuts down the system if it detects abnormal operation

Typical RMS Current Requirement

for a Single PureCycle® Power System

Generator Start as Motor

Approximately800 Amps

Approximately600 Amps

0

100

200

300

400

500

600

700

800

-1 0 1 2 3 4 5 6 7 8 9 10 11 12

Time (sec)

RM

SC

urr

en

t(A

mp

s) Induction Machine is started

by a phase controlled solidstate starter as a motor andimports KVA from theconnected utility source

Induction Machineapproaches synchronousspeed and is connecteddirectly to the utility sourcevia contactors by the starter

Transition topower export



Grid Protection Relay

The PureCycle power system requires grid protection functions, typically served by a multifunction protective relay providedby the customer. This relay can be programmed to meet the utility’s requirements. Typical trip programming is shown in thetable below. Please refer to the Electrical Installation Drawings (HTE73478 or HTE73520) for the programming details.

Table 7 – Typical Grid Protection Relay Programming

Symbol Function

27 Phase Under Voltage 1,2

59 Phase Over Voltage 1,2

81O Over Frequency

81U Under Frequency

The PureCycle system internally monitors power production and consumption. The unit will shut down on low gross power inall power generating states when power is < 80 kW. During states where the unit is expected to motor, shutdown occurs iftime exceeds 30 seconds.

If reverse power protection is required to provide protection against extended operation as a motor, the customer mustprocure and install a separate protective relay at the site. The grid protection relay CT’s (current transformers) and PT’s(potential transformers) should be placed at the power wiring going into the PureCycle system AC disconnect switch in aseparate enclosure. The ANSI 32 (directional overpower) function should be set to trip for a reverse power greater than thenormal power expected during a system start up but less than the no-load amperage of the induction generator for a timegreater than the start up period of the induction generator.

For example, for a single PureCycle unit with a 300 kVA generator rating, the reverse power setting should be between theKVA of the unloaded motor (√3*460 VAC*57A = 45.4 kVA) and the maximum expected power draw from the support systems

during a start up (22*1.25 margin = 28 kVA). This corresponds to - 0.1 PU. The time delay must exceed the maximum motorrun times discussed above to assure normal operation (20 + 30) sec*1.25 margin = 62.5 sec). This corresponds to 3750cycles for 60 Hz.

Grounding Plan

The PureCycle power system utilizes a single-point ground at the utility interface. The utility provides the electrical ground forthe system. This ground is attached to the equipment and chassis grounds for the power module and condenser. Theevaporator and other ancillary equipment may require a separate ground. Please refer to the applicable codes for groundingall equipment.

Power Factor Correction

The PureCycle power system contains power factor correction equipment capable of maintaining a power factor greater than0.95 lagging.

Emergency Stop Button

An emergency stop (E-Stop) button is installed on the LOI located on the front panel of the ECS cabinet. This button willcause the safety chain in the system to trip and initiate an emergency shut down. The button will not disconnect the electricalfeed to the unit. Therefore, the unit will not go Black when the E-stop button is pushed. Since the E-stop button causes theunit to shut down in an abnormal manner, this is not recommended as a standard method for shutting down the unit. Aninterface for an optional remote E-stop, is also provided in the ECS cabinet, operates in series with the emergency stop.Please refer to HTE73478 or HTE73520 for further details

Control Wiring Requirements

Data Connection

Remote communications and monitoring of the PureCycle power system requires a dedicated physical high speedbroadband connection with a static IP address accessible from the internet. The PWPS warranty requires this high-speedconnection. Pratt & Whitney Power System's management server must be able to access the power plant on demand



through the standard BACnet ports 47806 to 47808, and the remote monitoring device must be able to query the server ondemand through the same ports. It is expected that a router will be assigned to forward the communications from the staticIP address to the remote device assigned an internal IP address. Use of the router is intended to limit the number of portsopen through a customer's firewalls. A typical setup consists of an external IP address provided through a local ISP such asa cable or phone company. A router/switch then routes the limited ports on to the remote monitoring system and allows thecontroller to communicate with the remote monitoring system. It is expected that the customer provide for the Internetconnection per the listed requirements, as it is the best positioned to determine the best method of communication.

Access to the remote monitoring service by the customer is provided through a web site. In order to use the web site,access to the internet and Microsoft® Internet Explorer® with Java® are required. The server polls the remote device andcontinually stores the data. It also generates displays on demand for service and customer use to monitor and control someaspects of the power plant. The remote monitoring system uses WebCTRL® software with appropriate remote hardware.

A site telephone line is recommended to facilitate communications for on-site service personnel.

Electrical Interfaces and Field-Installed Wiring

The following table identifies the electrical connections that must be installed at the site, per PWPS standard electricalinstallation drawings (Single Unit Installation; HTE73520 - Multi-Unit Installation).

Table 8 – Electrical Connections

SYSTEM ELECTRICALINTERCONNECTIONS

INTERCONNECTIONPOINT

SERVICERECOMMENDED

WIRING SIZE

CONDUIT

Disconnect switch Grid connection 480 VAC, 3-phasewith ground

Two 350 MCM wire per phaseOne 1AWG ground wire

Wiring rated to 90°C (194°F)Two 3” – 3 ½”

ECS Connections

TB1-10, TB1-11 External grid protectionRelay Signal – dry contact 16AWG 3/4”

ESW1 Ethernet port Communication Cat 5e RJ45Max wire length 100 m (328 ft) 3/4”

RMS02 Analog phone line (optional) Communication RJ11 3/4”

TB4-9, TB4-10 Remote e-stop (optional)(Jumpered by default) Signal – dry contact 16AWG 3/4”

Summary of Customer-Provided Utilities and Materials

The customer is responsible for engineering and procuring the following utilities and materials:

480-volt, 3 phase, 600 amp service

Dedicated high-speed Internet physical broadband connection with a unique static IP address. An account with anInternet Service Provider along with Microsoft® Internet Explorer® web browser is required to view data from theunit through the WebCTRL® software

Piping and access to the resource heat source

Piping and access to the cooling source

Compressed air for valve actuation

Spare 120v outlets (preferable) for service tools and equipment

Ethernet line to monitor the system locally

Piping & supports for relief valve discharge lines

Phone line (preferable) for voice communication with on-site service personnel

Site lighting (preferable) to facilitate service after hours

Java® is a registered trademark of Sun Microsystems, Inc.

SAFETY CONSIDERATIONS


SAFETY CONSIDERATIONS

PureCycle power systems are designed to provide safe and reliable service when operated within design specifications andall applicable instructions and operating materials. When operating this equipment, use good judgment and safetyprecautions to avoid damage to equipment and property or injury to personnel. Be sure to understand and follow theprocedures and safety precautions contained in this guide and in all applicable instructions and operating materials.


APPENDIX A – TYPICAL INTERCONNECTION AGREEMENT DATA

The table below provides typical data requested during an interconnection study or interconnection agreement application.

Prime Mover ManufacturerModel Name

Pratt & Whitney Power SystemsPureCycle Model 280 Power System

A. Type of generating unitManufacturer

InductionBaldor Electric Company, Greenville, SCModel V02XR24001725GN

B. Rated MVA 0.296 gross output of generatorC. Maximum gross output (MW) 0.280 gross out put of generatorD. Rated lagging power factor Internal PFC capacitors provided to yield pf ~ 0.95 at

rated powerE. Nominal voltage and acceptable voltage range

(volts ±%)480 volt + 10%, -12%

F. Estimated load factor, number of hours/year ofoperation or MWh/year

100% rated operation

G. Stability Data:1. Inertia of turbine/generator (sec) 0.347 sec2. Transient direct axis reactance (PU) See generator data sheet

A. Substransient Reactance = 0.1345B. SC time constant = 0.050 secC. OC time constant = 2.193 sec

3. Excitation system data Internal PFC capacitors provided to yield pf ~ 0.95 atrated power, utility or customer to provide balance ofreactive power. System operates only in grid parallelmode.

4. Governor data and Laplace transform blockdiagrams of the control equipment

N/A This is an induction generator system that will operateonly in grid synchronization. Upon loss of the grid, thesystem will shut down.

H. VOLTAGE/FREQUENCY LIMITS1. Pickup settings UV 88%, OV 110%

UF 57 Hz OF 60.5 Hz2. Roll off rates UV 2 seconds, OV 1 seconds

UF 10 cycles, OF 10 cyclesI. Minimum/maximum excitation limits N/A Induction GeneratorJ. Interconnecting circuit breaker (disconnect

switch)1. Manufacturer2. Load rating, interrupting rating

Siemens Model SHMD69600A600 A Load Rating, 65 KAIC Fault Rating

K. Interconnection protective relay Beckwith Electric Company Model 3410A or equivalent;customer provided

The customer will typically be asked to provide one-line block diagrams and site layouts showing the generatorinterconnection to the existing facility as well as the grid interconnection.

Additional questions typically asked by the interconnecting utility include those listed below. Answers will vary by site.Please contact your Pratt & Whitney Power Systems representative for further assistance.

1. Is the application for new generating capability or an addition to existing generating capability?

2. Is there net metering?

3. Will the power be used to supply power to the interconnection customer (will the power be consumed on-site)?

4. Will the power be used to supply power to others (exported to the interconnecting utility grid)? If so, how muchpower is expected to be exported?

5. Will a transformer be used between the generator and the point of common coupling? If so, the customer should beprepared to provide information on the transformer.

APPENDIX B – PROJECT REQUIREMENTS DOCUMENT



To estimate net output and other PureCycle power system performance parameters for a specific application, please providethe following minimum required information by completing the attached Project Requirements Document (PRD) andreturning to Patti Orlowski ([email protected]) at PWPS.

PROJECT REQUIREMENTS DOCUMENT (PRD)Pratt & Whitney Power Systems PureCycle® Power System

Date

Customer/site name

Company

Your company's role

Site location

Site address

Contact name

Contact number

Contact e-mail

Application description

Hot Water Source

Thot – Temperature of source input (ºF/ºC): Outlet temp restriction (if any)(195°F-300°F, 90°C-150°C)

Available hot flow rate (gpm or kg/s) Water quality report

Existing or new hot water source

Type of hot water source

Known hot water quality issues

(TDS, salinity, pH, etc.)

Cold Water Source

Tcold – Temperature of source input (ºF/ºC) Outlet temp restriction (if any)(50°F-80°F, 4°C-27°C)

Available cold flow rate (gpm or kg/s) Water quality report

Type of cold water source

Answer the following questions if a cooling tower will be utilized

Make/Model

Source of make up water

Local air temp, ave/min/max (ºF/ºC) Hot months Cold months

Relative humidity Hot months Cold months

or Wet bulb temp, ave/min/max (ºF/ºC) Hot months Cold months

Operating Window (Typical flow requirements for 260kW max net power with water as hot liquid source)

NewExisting

Attached

Attached

NewExisting

Geothermal Oil & gas wells Engine jacket Water Engine exhaust

Industrial process Biomass boiler Solar thermal Other

Cooling tower River water Sea water

Holding pond Ground water Other

Project Developer Power Producer Engineering/EPC Energy Efficiency

Thot = 195°F (90°C), Hot Flow* = 1100GPM (69.4 l/s), Tcold range 50°-80°F (10°C-27°C), Cold Flow = 1100 - 1300GPM (72.5 l/s)Thot = 300°F (150°C), Hot Flow* = 150GPM (11.4 l/s), Tcold range 50°-80°F (10°C-27°C), Cold Flow = 950 - 1050GPM (60 l/s)

Max Thot Pressure = 150psig (10bar)

* Can vary depending on hot fluid and environmental conditions



Project and Installation Information

Do you have project financing in place?

Power consumed on-site, or for sale to the grid

If power sale to the grid, expected PPA price (US ¢/kWh)

If power consumed on site, current power cost (US¢/kWh)

Power plant startup and synchronization source

Installation type

Location of unit

Communication means for remote monitoring system

Minimum 4 ft (1.2 m) of service clearance for equipment

Site sketch

Distance from power plant to grid (transmission lines)

List non-standard requirements, codes, regulations

For geothermal, are new wells required?

For geothermal, is there existing infrastructure in place?

Is an electrical take-off agreement in place with utility?

Have electrical load flow and interconnect studies been done?

Has an environmental impact study been done?

Do you have land and mineral rights concessions?

Transportation/Shipping

Nearest major shipping port?

Is the facility accessible from a paved road?

Method for transporting the unit once in destination country?

Will more than one country be transited to get to the site?

Can PureCycle machine be uploaded at site with a crane?

GreenfieldRetrofit

IndoorOutdoor

Replacement

InternetTelephone

On-Site Grid

Other high speed

Yes No (explain)

Yes

Yes

Truck Other (describe)

Yes

NoYes

No

Yes No

Attached

Diesel gensetsGrid-connect Other (describe)

10-20 Years

No

Yes

Yes

No

No

20+ Years

Yes No

Passed

Yes No

Yes No

Attached

Attached

60Hz 50Hz 480V 415V 400V 380V

Copyright 2009 Pratt & Whitney Power Systems, Inc. Revision A – 09/23/2009 HTE75367All Rights Reserved.

PURECYCLE®

POWER SYSTEM

MODEL 280

Hot Liquidto ElectricityPower SystemNominal 280 kW Power

Product Dataand

ApplicationGuide

Supplement

Revision A – 09/23/2009 – Page 2 HTE75367

DISCLAIMER

This document is the property of Pratt & Whitney Power Systems, Inc. (Pratt & Whitney Power Systems or PWPS) andcontains proprietary and confidential information of PWPS. You may not copy or disclose this document or any informationin it, for any purpose, including without limitation, to design, manufacture or repair parts, or obtain any government approvalto do so, without PWPS’s express written permission. Neither receipt nor possession of this document alone, from anysource, constitutes such permission. Copying or disclosure by anyone without PWPS’s express written permission is notauthorized and may result in criminal and/or civil liability.

Pratt & Whitney Power Systems reserves the right to change or modify, without notice, the design or equipmentspecifications of the PureCycle power system without obligation with respect to equipment either previously sold or to besold. This Product Data and Application Guide is provided by Pratt & Whitney Power Systems for informational purposesonly, and no liability will accrue to Pratt & Whitney Power Systems based on the information or specifications includedherein. No warranties or representations shall apply to the equipment except as stated in the PureCycle power systemLimited Warranty Terms of Coverage applicable at the time of purchase, a copy of which will be provided upon request.

PureCycle® is a registered trademark of United Technologies Corporation or its affiliates, and may be registered in theUnited States and other countries.


TABLE OF CONTENTS

Disclaimer ..............................................................2PureCycle Power System Reference Documents

..........................................................................4Revision History ....................................................4Overview.................................................................5

Application Guidelines......................................... 5Power Output .................................................... 5Hot-Liquid-Resource Temperature and Flow 5Cooling Tower................................................... 6


PURECYCLE POWER SYSTEM REFERENCE DOCUMENTS

Product Data and Application Guide (HTE66510)

Product Guide Specification (PRMAN66787)

Installation Instructions (PRMAN66798)

Installation Completion Checklist (PRIM71223)

Commissioning Instructions (PRMAN66799)

Operation and Maintenance Instructions (PRMAN66800)

Mechanical Installation Drawing Set (APP66344, APP70613)

Electrical Installation Drawing Set (HTE73478 – Single-Unit Installation; HTE73520 – Multi-Unit Installation)

REVISION HISTORY

Revision Letter Date Reason for Change

A 09/23/2009 Original Issue

OVERVIEW


OVERVIEW

This document is intended to be a supplement to the PureCycle power system Product Data and Application Guide(HTE66510). Additional performance parameters are provided herein for site design assistance.


Power Output

Power output is a function of installation-specific variables, including resource liquid temperature and flow rate and coolingwater temperatures. This document will describe the influence of these installation-specific variables and provide guidelinesfor system performance. Interested customers should complete the Project Requirements Document (PRD) in Appendix B ofthe Product Data and Applications Guide (HTE66510) and contact Pratt & Whitney Power Systems for specific applicationperformance and optimization.

Hot-Liquid-Resource Temperature and Flow

The PureCycle power system generally requires a hot-liquid-resource temperature between 195°F (90ºC) and 300°F (149ºC)and a cold water source of 85ºF (30°C) or less. The hot resource flow required to produce full power output varies between180 and 1100 gpm and is a function of installation-specific variables, including resource liquid temperature and cooling watertemperature. For information on applications outside of these temperature and flow ranges, please complete the PRD inAppendix B and consult your PWPS sales consultant or applications engineer.

Figure 1 describes PureCycle power system full power output and describes the resource flow and temperaturerequirements to produce full power at various cooling water temperatures. Multiple systems can be installed if sufficient flowis available. Two machines operating in parallel would require twice the flow of one machine.

Figure 1 – PureCycle Model 280 Performance

PureCycle® Model 280 Performance280 kW Gross, 260 kW Net, 60 Hz/480V

Carbon Steel Evaporator, Copper Condenser

180

190

200

210

220

230

240

250

260

270

280

290

300

100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100

Resource Flow (gpm)

Re

so

urc

eT

em

pe

ratu

re(º

F)

82

87

92

97

102

107

112

117

122

127

132

137

142

147

6 11 16 21 26 31 36 41 46 51 56 61 66Resource Flow (l/s)

Re

so

urc

eT

em

pe

ratu

re(º

C)

80ºF (26.6ºC) Cooling Water Inlet Temperature60ºF (15.5ºC) Cooling Water Inlet Temperature70ºF (21ºC) Cooling Water Inlet Temperature50ºF (10ºC) Cooling Water Inlet Temperature

BelowMinimumEvaporator Flow

Rate

Assumptions: 18ºF (10ºC) Cooling Water DTCooling Water Flow Rate: 960 gpm (58 l/s) for resource



Cooling Tower

Sizing and selection of a cooling tower are dependent on knowing the heat rejection from the condenser, the design ambientwet-bulb temperature, the cooling water flow and the supply and return water temperatures (the approach temperature canbe determined if both the design cooling water return temperature and the design wet-bulb temperature are known). Typicalcooling water flow rates are shown in Figure 2 at several common temperature differences. Contact cooling towermanufacturers to assist with sizing the tower to the specific application.

Figure 2 - Cooling Water Flow Rate Requirements

PureCycle® Model 280

Approximate Cooling Flow Requirements

600

800

1000

1200

1400

1600

1800

2000

2200

190 200 210 220 230 240 250 260 270 280 290 300

Resource Temperature (ºF)

Co

olin

gF

low

Ra

te(g

pm

)

38

48

58

68

78

88

98

108

118

128

138

90 95 100 105 110 115 120 125 130 135 140 145

Resource Temperature (ºC)

Co

olin

gF

low

Ra

te(l

/s)

dT = 10º F (5.5ºC)

dT = 18º F (10ºC)

dT = 15º F (8.3ºC)