Hot Liquid To Electricity Power System: Product Data and Application Guide

Product Data Hot Liquid
and to Electricity
Application
Guide
Power System
Nominal 280 kW Power
PURECYCLE®
POWER SYSTEM
MODEL 280
Copyright 2009 Pratt & Whitney Power Systems, Inc. Revision B – 09/23/2009 HTE66510
All Rights Reserved.
DISCLAIMER
This document is the property of Pratt & Whitney Power Systems, Inc. (Pratt & Whitney Power Systems or PWPS) and
contains proprietary and confidential information of PWPS. You may not copy or disclose this document or any information
in it, for any purpose, including without limitation, to design, manufacture or repair parts, or obtain any government approval
to do so, without PWPS’s express written permission. Neither receipt nor possession of this document alone, from any
source, constitutes such permission. Copying or disclosure by anyone without PWPS’s express written permission is not
authorized 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 equipment
specifications of the PureCycle power system without obligation with respect to equipment either previously sold or to be
sold. This Product Data and Application Guide is provided by Pratt & Whitney Power Systems for informational purposes
only, and no liability will accrue to Pratt & Whitney Power Systems based on the information or specifications included
herein. No warranties or representations shall apply to the equipment except as stated in the PureCycle power system
Limited 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 the
United States and other countries.
DISCLAIMER
Revision B – 09/23/2009 – Page 2 HTE66510
TABLE OF CONTENTS
Disclaimer ..............................................................2 Evaporator .................................................. 18

PureCycle Power System Reference Condenser................................................... 18
Documents .............................................................4 Cooling Tower................................................. 19
Revision History ....................................................4 Multi-unit Installation ..................................... 20
Overview.................................................................5 Site Design Requirements ................................. 21
System Description...............................................5 Layout and Civil Requirements..................... 21
Organic Rankine Cycle.....................................5 Accessibility and Clearance
System Operation..................................................6 Requirements ............................................. 21
Electrical System ..............................................6 Foundation Design..................................... 21
Working Fluid ....................................................6 Mechanical Requirements ............................. 22
Codes and Safety..............................................6 Resource Water Control System .............. 22
System Components.............................................7 Resource Water Piping Design................. 23
1. Evaporator ....................................................8 Cooling Water Piping Design.................... 23
2. Turbine-Generator Assembly .....................8 Compressed Air Requirements ................ 23
3. Condenser ....................................................8 Vent and Drain Connections ..................... 24
4. Working Fluid Pump ....................................8 Electrical Requirements ................................ 24
5. Electrical Control System........................8 Grid Interconnection.................................. 24
6. Local-Operator Interface .............................9 Utility Grid Line Voltage and Site
Remote Monitoring System................................10 Transformers .............................................. 25
RMS Capabilities/Features.............................10 Disconnect Switch ..................................... 25
Equipment List ....................................................12 Protective Functions.................................. 25
Physical Data .......................................................13 Grid Protection Relay ................................ 26
Dimensions ..........................................................13 Grounding Plan .......................................... 26
Performance Data................................................14 Power Factor Correction ........................... 26
Pressure and Temperature Rating ....................14 Emergency Stop Button ............................ 26
System Sound Level ...........................................15 Control Wiring Requirements ....................... 26
Working Fluid ......................................................15 Data Connection......................................... 26
Application Guidelines .......................................16 Electrical Interfaces and Field-Installed
Power Output ..................................................16 Wiring .............................................................. 27
Hot- Liquid-Resource Temperature and Summary of Customer-Provided Utilities and
Flow ..................................................................16 Materials .......................................................... 27
Cooling Water Inlet Temperature and Flow Safety Considerations........................................ 28
Rate ..................................................................17 Appendix A – Typical Interconnection
Hot-Liquid-Resource Control System...........17 Agreement Data .................................................. 29
Power Derate Control .....................................18 Appendix B – Project Requirements
Resource Liquid Composition.......................18 Document ............................................................ 30
Heat-Exchanger Pressure Drop.....................18

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
Update to production configuration,

B 09/23/2009 provide additional application guidelines,
performance detail and site design
considerations

OVERVIEW
Pratt & Whitney, a division of United Technologies Corporation (UTC), is committed to providing clean, efficient and reliable
power within the growing distributed generation market. Its PureCycle power system, developed by Pratt & Whitney Power
Systems, Inc. (Pratt & Whitney Power Systems or PWPS), is a pre-engineered system that harnesses waste heat to
generate electricity. This results in a 280 kW on-site power-generation system that requires no fuel input except heat in the
form of hot water.
Based on a thermodynamic cycle known as the organic rankine cycle (ORC), the PureCycle power system converts low- and
moderate-temperature resource fluids like water into electricity through vaporizing and expanding a working fluid in a closed
system. The PureCycle power system can utilize heat that is available from many geothermal or oil and gas wells, and from
industrial 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 process
cost and supports an intelligent energy strategy.
The PureCycle power system is only available at Pratt & Whitney Power Systems and delivers a variety of performance
characteristics that make it unique:
 Ease of installation and maintenance
 Fully integrated and assembled, modular-mounted packages that can be sized to match the resource and
rapidly 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 (see
Figure 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 electrical
power.
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.
OVERVIEW
Hot Liquid
Resource
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 to
the system to enable proper operation. The bypass valve is open during start up while a valve upstream of the turbine, the
turbine stop valve, is closed. Once sufficient vapor pressure is available upstream of the turbine, the controller opens the
turbine 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, minimizing
leaks 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 at
380/400/415V/50 Hz) to the utility grid. The induction generator is started as a motor using a solid-state, phase-controlled
starter and must always be synchronized to the grid. This reduces the amount of inrush current required by the motor during
start up.
Working Fluid
The working fluid, R245fa, a hydrofluorocarbon with the chemical composition of pentafluoropropane, is commonly used as a
foam-blowing agent for the insulation industry, and is a new refrigerant for centrifugal chillers. R245fa has zero ozone
depletion potential because it contains no chlorine. With no flash point, the fluid is completely nonflammable. It is not
federally regulated with respect to the Resource Conservation and Recovery Act (RCRA) or by the Department of
Transportation for shipment.
Codes and Safety

The PureCycle power system is designed to minimize external leaks to the environment. The evaporator and condenser are
stamped with the ASME Boiler and Pressure Vessel Code, and all piping complies with the standards of ASME B31.1, Power
Piping, commonly used for steam systems.
SYSTEM OPERATION
The PureCycle power system is designed to ensure personnel and equipment safety. National Electric Code installation
compliance 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 it
detects a controller malfunction.
 A microprocessor-based control system that continuously monitors key system pressures and temperatures and
automatically 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 the
system if required.
SYSTEM COMPONENTS
The PureCycle power system is supplied as a complete skid-mounted modular and tested assembly, including: turbine
generator assembly, condenser, evaporator, electrical control system (ECS) and working fluid pump (See Figure 2 & 3).
3. Condenser
6. Local Operator
Interface (LOI)
5. Electronic Control
System (ECS)
1. Evaporator
4. Working Fluid Pump
Figure 2 – PureCycle Power System (Front View)
SYSTEM COMPONENTS
3. Condenser
2. Turbine-Generator
1. Evaporator
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 that
capture the resource heat. Optional materials, described in the Equipment List section, are available to meet site-specific
needs. 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’s
standard chiller motor-compressor; however, it is operated in reverse as a turbine-generator. High-pressure vapor drives the
turbine that in turn drives the induction generator through a gear transmission. The oil-and generator-cooling systems are
integral 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 power
at 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 varying
speeds, 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 system
controller, input/output (I/O) modules, working fluid pump motor drive, generator solid-state soft starter, remote monitoring
SYSTEM COMPONENTS
system (RMS), system contactors and relays. The ECS automatically controls the proper start, continuous operation and
disconnect 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 in
both motoring and generating modes.
 Transient voltage and surge-suppressor device protection at utility interface per IEEE standard
C62.411980 (R1995)
 Minimal harmonic distortion for compliance with IEEE 519 Recommended Practices and Requirements for
Harmonic 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.
4 5 6
1. Ethernet connection
2. Generator soft starter interface
3. RJ14 connection
4. Power indicator
5. Alarm (service) indicator
6. Lock out relay (LOR) enable indicator
7. Off/Auto mode switch
1 2 3 7 8 9
8. Reset button
10 9. Lamp test button
10. Emergency stop button
Ground fault circuit interrupter (GFCI)
located on adjacent door.
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 any
safety switch trips or if the emergency stop is closed. Once opened, the relay must be reset locally using the reset
button (#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 is
labeled “Auto” to indicate that the controller is allowed to start if all other criteria are met. The LOR must be in the
SYSTEM COMPONENTS
normal position (LOR Enable light is active) for the unit to start up. The switch may be turned to “Off” for
maintenance 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 may
need to be replaced.
10. Emergency stop button – shuts down the machine in the event of an emergency. Shutting down the system using
the E-stop method is not recommended unless there is an emergency. Doing so repeatedly will result in premature
wear 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.
REMOTE MONITORING SYSTEM

The remote monitoring system (RMS) provides local and remote monitoring and control of PureCycle power systems at a
customer site from the Internet. Connection to remote sites is established through an Internet web portal, through which
users can access current and historical power plant operating data. Product alarms are stored along with product data in a
central database. The RMS design leverages Pratt & Whitney Power Systems’ experience in remote monitoring and
provides low-cost installation and operation.
Firewall Firewall
Remote
UTC Internet Monitoring
Intranet Static IP System
Router
Internet
RMS Server PWPS Customer PWPS

Technician Technician
1-5 PureCycle® Units
1 or more banks of PureCycle® Units
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 that
supports 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. Bandwidth
capability 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 provide
secure communication.
RMS offers the following features:
1. Communications – The remote monitoring system provides tools for the customer or UTC personnel to interface with
the 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 alarms
depends on Warranty and level of service purchased. Please consult your Warranty Agreement and Service Agreement
for further details.
3. Remote monitoring, database queries and reporting – Through WebCTRL® software, customers and UTC
associates with proper authorization can remotely monitor sites through an Internet connection. Individuals logging on
to the portal site are provided with a list of sites they are authorized to monitor. All users will be provided a logon ID and
will 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 user
interface facilitates database queries and the generation of reports. Standard reports are available and can be
configured by the user.
4. Data storage – A database stores all relevant product data and alarm/maintenance history. Data from the RMS will be
uploaded to the database.
5. Remote start/stop – Service personnel have the ability to remotely start and stop the machines. PureCycle power
systems can be wired on-site for Supervisory Control and Data Acquisition (SCADA) site-control remote start/stop if
desired.

EQUIPMENT LIST
Table 1 – Equipment List
STANDARD OPTION
(Factory Installed)
PureCycle Model 280 Power System
Power plant assembly, model 280, 480 V, 60 Hz

2
Evaporator assembly :
Carbon steel tubes – SA214 GR70
Carbon steel tube sheets & heads – SA516-70N
Hinged head on service end
Carbon steel nozzle – SA53 GR B
Carbon steel ring flange – SA-350 LF2

2
Water-cooled condenser assembly
X
Copper tubes – B75 UNS C12200
Carbon steel tube sheet & heads – SA516-70N
Hinged head on service end
Carbon steel nozzle – SA53 GR B
 Turbine assembly
 Working fluid pump
 Electronic control system (ECS)
 Power plant AC disconnect switch
1
Consumables
 Turbine oil X
 R245fa refrigerant
3
Remote monitoring system (RMS) X
2
Alternate evaporator tube side wetted materials
 Stainless steel
o Tubes – SA249 316/316L
o Tube Sheet – SA240 316/316L
o Internal cover sSurface – Heresite® Coating
 Titanium
o Tubes – SB338 GR2 Welded X
o Tube sheet – SB265 GR1 Cladding
o Internal cover surface – Ceramalloy Coating
 Duplex
o Tubes – 2205 welded
o Tube sheet – 2205
o Internal cover surface – Heresite® Coating
2
Alternate condenser tube side wetted materials
 Stainless steel
o Tubes – SA249 316/316L Welded
o Tube sheet –SA240 316/316L
o Internal cover surface – Heresite® Coating X
 Titanium
o Tubes – SB338 GR2 Welded
o Tube sheet – SB265 GR1 Cladding
o Internal cover surface – ceramalloy coating
Alternate evaporator exit location
Located on same side as evaporator inlet; allows for all heat X
exchanger plumbing connections to come from one side
Alternate voltage and frequency configuration
X
 380/400/415V/50 Hz
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.
EQUIPMENT LIST
PHYSICAL DATA
Table 2 – Physical Data
English SI
PureCycle Power System
Operating weight 33,300 lbs 15,104 kg
Shipping weight 27,600 lbs 12,519 kg
Dimensions (L x W x H) 19’ x 7’-6” x 11’-3” 5790 x 2290 x 3430 mm
Maximum whipping height 10’-3” 3200 mm
DIMENSIONS
The following schematics are presented to give general dimensions required for a PureCycle installation. Standard drawings
containing mechanical, electrical and civil requirements for constructing a typical PureCycle installation (Mechanical
Installation Drawing Set APP66344 and APP70613) are available upon request. Please refer to these drawings for more
detailed site engineering requirements.
Figure 6 – PureCycle Power System Dimensions

PERFORMANCE DATA
Table 3 – Performance Data
Performance Characteristics
Gross electrical power output 280 kW 272 kW 263 kW
1 1,2 1,2 1,2
Net electrical power output 265 kW 257kW 248 kW
Voltage and frequency standard 480 V, 3 phase, 3 wire 400/415V, 3 phase, 3 wire, 380V, 3 phase, 3 wire,
60 Hz 50 Hz 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 1.10 to 0.88
(vs. rated line voltage)
Line voltage unbalance ±3%
Voltage Total Harmonic Distortion (THD) < 5%
Harmonics
Current THD < 5% (IEEE 519 compliant)
The system interrupts if it detects an abnormal grid condition. It can be configured
Interruption/disconnection
to 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 are
U1 stamped per the ASME Boiler and Pressure Vessel Code Section VIII.
Table 4 – Pressure and Temperature Rating
Assembly Pressure Rating Temperature Rating

Condenser
Shell side 150 psig (1034 kPa) 225ºF (107ºC)
1
Tube (water) side 150 psig (1034 kPa) 120ºF (49ºC)
Evaporator
Shell side 345 psig (2380 kPa) 330ºF (177ºC)
Tube (water) side 150 psig (1034 kPa) 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 plant
pressure relief valves for the working fluid is also required to prevent overpressure of the system. Refer to ASHRAE 15
Safety Standards for Refrigeration Systems for proper installation of equipment.
PERFORMANCE DATA
SYSTEM SOUND LEVEL
System sound level for the PureCycle power system is typically stated as 78 dBa at 10 m. Local codes or ordinances may
require 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
PureCycle® Model 280

Sound Pressure Level (SPL) vs Distance
100.00
95.00
90.00
SPL (dBA)
85.00
80.00
75.00
70.00
1 10
Distance (m)
• Assumed omnidirectional sound radiation

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 transfer
the heat available in the resource fluid. R245fa is commonly used as a foam-blowing agent for the insulation industry, and is
a new refrigerant for centrifugal chillers. By virtue of its lack of chlorine, R245fa has zero ozone depletion potential. With no
flash point, the fluid is completely nonflammable. It is not federally regulated with respect to RCRA or the Department of
Transportation, and OSHA does not list the fluid for toxicity. It has a global warming potential (GWP) of 950. R245fa is
categorized 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 same
DOT 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 x
1.2 m x 1.5 m h).
Pratt & Whitney Power Systems recommends a hard shaded surface for working fluid storage. PWPS recommends a 10’ x
10’ (3 m x 3 m) fenced area, segregated from the power plants and utilizing pole-barn-type shade. One to two containers
with some fluid and three to four empty containers for holding fluid during machine repair/maintenance activities are
recommended. 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 is
shipped with a nitrogen charge of 15 psi. Storing the PureCycle power system above 60ºF (15.5ºC) protects against the
introduction of non-condensable gas into the system. Please refer to the PureCycle Model 280 Installation Manual
PRMAN66798 for more information.
Genetron® is a registered trademark of Honeywell International, Inc.

SYSTEM SOUND LEVEL
The accumulation of working fluid in an enclosed space can displace oxygen and cause asphyxiation. Indoor installations
require leak detection, as well as adequate ventilation in accordance with ANSI/ASHRAE 15, especially for enclosed and low
overhead spaces.
APPLICATION GUIDELINES
Power Output
Power output is a function of installation-specific variables, including resource liquid temperature and flow rate and cooling
water temperatures. The following sections of this document will describe the influence of these installation-specific
variables and provide guidelines for system performance. Interested customers should complete the Project Requirements
Document (PRD) in Appendix B and contact Pratt & Whitney Power Systems for specific application performance 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, preferably 85ºF (30°C) or less. The hot resource flow required to produce full power output varies
between 180 and 1100 gpm and is a function of installation-specific variables, including resource liquid temperature and
cooling water temperature. For information on applications outside of these temperature and flow ranges, please complete
the 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. Two
machines operating in parallel would require twice the flow of one machine.
Table 5 – PureCycle Model 280 Performance
280°F/138°C Resource 240°F/116°C Resource 200°F/93°C Resource

Hot Resource (Evaporator)
Inlet Temperature 280ºF 138ºC 280ºF 138ºC 240ºF 116ºC 240ºF 116ºC 200ºF 93ºC 200ºF 93ºC
Exit Temperature 170ºF 77ºC 185ºF 85ºC 172ºF 78ºC 194ºF 90ºC 173ºF 78ºC 173ºF 78ºC
Flow 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/s
Material Carbon Steel Carbon Steel Carbon Steel
Cooling Water (Condenser)
Inlet Temperature 60ºF 16ºC 80ºF 27ºC 60ºF 16ºC 80ºF 27ºC 60ºF 16ºC 80ºF 27ºC
Exit Temperature 78ºF 26ºC 98ºF 37ºC 78ºF 26ºC 98ºF 37ºC 78ºF 26ºC 98ºF 37ºC
Flow 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/s
Material Copper Copper Copper
Power Output
Gross Power Output 280 kW 280 kW 280 kW 205 kW
Net Power Output 260 kW 265 kW 265 kW 190 kW
Voltage/Frequency 480 V / 60 Hz 480 V / 60 Hz 480 V / 60 Hz
1
Power output at low resource temperatures and high condensing temperatures is derated due to evaporator flow limitations.
If the resource temperature decreases from its design value (typically the value selected from the figures above), power
output 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 shut
down.
Gross Power Output
480 V/ 60 Hz Configuration
300
250
Gross Power Output (kW)
200
150
100
Minimum Power Output ~ 80 kW
50
0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Percent of Design Flow
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 model
seasonal variation in performance due to ambient conditions and is helpful for cooling tower selection. Interested customers
should 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. During
operation, 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 the
evaporator so that heat is not transferred into the system. Automated bypass control and manual isolation valves should be
provided 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). This
output power reduction is expected to correspond with an ambient temperature exceeding 104ºF (40ºC) but may vary based
on site conditions including, but not limited to, cooling water inlet temperature, solar loading and orientation, wind conditions
and 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 offers
alternate 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 exchangers
and reducing performance and life. Applications with high particulate levels may be viable if the proper chemical treatments
and cleaning processes are used. The evaporator is designed to be easily inspected and cleaned in the field. In all cases, it
is 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 greater
resource 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 variation
and reduce the pressure drop required for the controlling band.
Evaporator
Pressure Drop vs. Resource Flow Rate
30
25
Power Plant Flow

Evaporator Pressure Drop (psi)
Control Valve
~ 60% Open
20
Consult Controlling Band

PWPS for
15 Applications Power Plant
in this
Range
Flow Control
Valve
~ 80% Open
10
0
100 200 300 400 500 600 700 800 900 1000 1100
Resource Flow Rate (gpm)
Figure 10 – Evaporator Pressure Drop
Condenser
Condenser pressure drops will vary with flow rate and condenser inlet temperature. Typical pressure drops for the
condenser are shown in Figure 11. For the condenser, the minimum design flow is 600 gpm (37.9 l/s), and the maximum
design flow is 2000 gpm (126.2 l/s).
Condenser
Pressure Drop vs. Cooling Water Flow Rate
30
25
20
Pressure Drop (psid)
High Temperature Resource

280ºF - 300ºF
(138ºC - 149ºC)
15
Low Temperature Resource
195ºF - 280ºF
(90ºC - 138ºC)
10
0
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Cooling Water Flow Rate (gpm)
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 sink
to allow the system to operate as intended. Typically, a cooling tower is utilized to perform this function but other equipment
or processes can be used depending on the design of the specific system involved. This discussion will focus exclusively on
the use of cooling towers since they are the most common type of equipment used for this purpose in commercial
installations.
Cooling towers transfer heat from the water circulated in the PureCycle system’s condenser to the atmosphere by pumping
or spraying the water over the cooling tower “fill”, which has a relatively large surface area to improve heat transfer. Air is
drawn over or through the fill section (typically by one or more fans) causing evaporation of a portion of the water, thereby
cooling the remaining water to within a few degrees of the ambient wet-bulb temperature. The actual water temperature is
dependent on the sizing of the tower but most towers are selected at approach temperatures (the difference between the
wet-bulb temperature and the leaving water temperature) of between 10° F to 18° F (5.5ºC to 10ºC). As an example, a tower
selected for a 10° F approach could achieve a return water temperature to the condenser of 85° F given a design wet-bulb
temperature of 75° F.
Sizing and selection of a cooling tower is dependent on knowing the heat rejection from the condenser, the design ambient
wet-bulb temperature, the cooling water flow and the supply and return water temperatures (the approach temperature can
be determined if both the design cooling water return temperature and the design wet-bulb temperature are known). Contact
cooling tower manufacturers to assist with sizing the tower to the specific application.
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 due
to droplets being entrained into the air (drift), as well as to regular draining. Blow-down, the process of removing or bleeding
a portion of water from the main water circulating line to maintain an acceptable level of dissolved solids or minerals, typically
equates to about a .3% loss. The total loss attributed to all of these conditions, approximately 1.5-2% of flow, determines the
amount of make-up water that has to be added, which is usually done by automatically maintaining a predetermined level in
the 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, a
water treatment system should be provided on each installation. This can be either a manual or automatic system that
controls the chemical and biological properties of the water to prevent corrosion, algae and fouling. The tower manufacturer
can recommend additional equipment or maintenance procedures accordingly. Fouling can result if a chemical treatment
system is not installed or if blow-down is not performed regularly in the cooling water system. Without proper treatment to
the 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. Water
temperature is typically controlled by either cycling the fan(s), utilizing variable-speed or two-speed fan motors or by
incorporating 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 the
cooling tower should allow for unrestricted airflow and to prevent recirculation, consideration for fogging or drift and what
other equipment or objects might be wetted in the event of strong winds, consideration of the increase in sound level to the
surrounding area, and the weight of the tower if installed on a roof. Close proximity to the condenser should also be
considered to avoid long pipe runs and increased pumping costs. If installed in areas where the ambient temperature can go
below 32°F, attention should be paid to providing an auxiliary sump located inside a heated space to preclude freezing of the
water. Alternatively, a heated sump could also be used. Insulation of the cooling water piping should also be considered in
cold climates.
The manufacturer of the cooling tower can provide more details on the design and installation of the tower relative to the
specific 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. Each
system will be able to operate independently. However, starting more than one system at a time is not recommended. To
limit start up current draw and electrical demand charges, the site control should be set up to stagger-start multiple units and
provide feedback so that peak currents do not overlap. Motoring time and requirements for stagger start are described in the
Electrical 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. The
power plant allows for direct control from a site control computer. Safety features in the control permit one or more to shut
down by remote command or automatically. Loss of grid connection for load will produce an automatic shut down of all the
systems. 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 Power
Systems has standard mechanical and electrical installation drawings (Mechanical Installation Drawing Set APP66344 or
APP70613 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 to
facilitate service. Area in front of the condenser and evaporator is required for tube maintenance and replacement, as
detailed in Figure 12 below. Be sure to include sufficient clearance around the site to allow a crane to maneuver and place
equipment.
4’ minimum perimeter, flat hard surface

Cooling water inlet and
Area required for tube outlet
maintenance /
Area required
replacement for electrical
maintenance
15.2’
7.2’
Area required
16.5’ min for turbine
maintenance
25’ Hot water

Inlet
Hot water
Outlet
Figure 12 – Maintenance Clearance Requirements
Foundation Design
The PureCycle power system is delivered complete as a skid-mounted assembly and requires a concrete foundation for
installation. The skid-mounted modular system assembly (turbine-generator with controls, condenser, evaporator, and
working fluid pump) are mounted as a system on the foundation. The foundation pad must be level to within ±¼” over 10 ft. It
is important that the concrete foundation extend below the frost line. The foundation construction must be designed and
fabricated in accordance with the Requirements for Reinforced Concrete ACI 318, as well as any local and state codes. The
skid-mounted modular system assembly should be secured in place with anchor bolts as shown in the Mechanical
Installation Drawing APP66344 or APP70613.

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 Mechanical
Installation Drawings APP66344 and APP70613.
Table 6 – Mechanical Connections
TECHANICAL INTERCONNECTION
INTERCONNECTIONS TYPE AT UNIT
Compressed gas supply inlet 1/2” FNPT
High
Low Temperature
Temperature
Applications
Evaporator Applications
195ºF – 225ºF
225ºF – 300ºF
(90ºC – 107ºC)
(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 flange
Pressure relief valves 2 x 1 ½” FNPT
Condenser
Cooling water inlet 10 in. – 150 lb flange
Cooling 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). Generic
requirements 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 be
incorporated into the existing site controls without adversely affecting the existing facility operation. It is essential to
ensure that a shut down of the PureCycle system for routine maintenance or system malfunction does not cause a
shut down or other disturbance to the facility.
 The customer is expected to provide sufficient system pressure to the PureCycle power system to prevent the hot
liquid 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 will
close 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. A
recommended approach is for the site to include a bypass leg with a pressure-regulating valve. The regulating
valve maintains the proper pressure conditions upstream of the system while the power plant ramps up to full
power. 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 power
system. To maintain a consistent resource exit temperature, other site parameters must be controlled to reach the
desired temperature.
 Cascaded units will use the exit of the higher resource as the inlet to the second unit. This should provide sufficient
pressure 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 or
causing hazardous waste. Water-quality management, including temperature or chemistry control, may be
required.
 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 accepts
resource flow or requests the power plant to start. PWPS recommends that site controls interface with the
PureCycle 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 down
immediately 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 cooling
water 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 protection
of equipment within the power plant
PWPS provides a pressure switch with a dry contact input to the PureCycle controller to ensure the availability of
compressed gas prior to starting power plant.

Pneumatically operated valves
Pressure
Relief
Valves
(Installed
On Site)
Customer
Pneumatic
Connection
Interface
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 are
included for maintenance ease and calibration. The upper set of pressure relief valves is installed in on site to prevent
shipping damage. Discharge lines should be installed for safety and should be piped according to ASHRAE 15 and local
codes. 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 control
connections. Standard electrical drawings (Electrical Installation Drawing Set HTE73478 or HTE73520) are available as a
reference. The customer is responsible for consulting the appropriate handbooks or codes to confirm that the site design
complies 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 encourages
the customer to conduct a grid interconnect study early in the project development. For the utility’s planning purposes, an
interconnection study allows the utility to determine whether the add-on of the proposed power operator will adversely affect
the electrical system’s normal operating parameters. Please refer to Appendix A for a list of typical interconnection
agreement questions and data.
An induction generator is the counterpart to an induction motor. While an induction motor consumes power by operating at
slightly 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 the
generator shaft. Unlike synchronous generator and inverter-based technologies, an induction generator is self-synchronizing
and 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.

The PureCycle power system utilizes a two-pole induction generator that transmits 3-phase AC power at 480V/60 Hz (or at
380/400/415V 50 Hz with the alternate voltage option). The induction generator is started as a motor using a solid-state
phase-controlled starter and is always synchronized to the grid. The facility or installation must be capable of providing the
RMS current requirements for a single unit start up shown in Figure 14.
Typical RMS Current Requirement

for a Single PureCycle® Power System
Generator Start as Motor
800
Approximately
800 Amps
700
Approximately
600 600 Amps
Induction Machine
approaches synchronous
speed and is connected
RMS Current (Amps)
500 Induction Machine is started

directly to the utility source
by a phase controlled solid
via contactors by the starter
state starter as a motor and
imports KVA from the
400
connected utility source
300
200
Transition to
power export
100
0
-1 0 1 2 3 4 5 6 7 8 9 10 11 12
Time (sec)
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 the
required interconnection equipment. The customer is also responsible for conducting any special tests required by the utility
to 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 are
available for 380/400/415-volt service. A transformer or other equipment may be required to rectify the site voltage to supply
480-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 the
customer local utility interface. This circuit delivers the power generated by the power plant and also provides the source for
start 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 it
detects a controller malfunction
 A microprocessor-based system that continuously monitors key system pressures and temperatures and
automatically shuts down the system if it detects abnormal operation

Grid Protection Relay
The PureCycle power system requires grid protection functions, typically served by a multifunction protective relay provided
by the customer. This relay can be programmed to meet the utility’s requirements. Typical trip programming is shown in the
table 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 in
all power generating states when power is < 80 kW. During states where the unit is expected to motor, shutdown occurs if
time exceeds 30 seconds.
If reverse power protection is required to provide protection against extended operation as a motor, the customer must
procure 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 a
separate enclosure. The ANSI 32 (directional overpower) function should be set to trip for a reverse power greater than the
normal power expected during a system start up but less than the no-load amperage of the induction generator for a time
greater 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 the
KVA 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 motor
run times discussed above to assure normal operation (20 + 30) sec*1.25 margin = 62.5 sec). This corresponds to 3750
cycles for 60 Hz.
Grounding Plan
The PureCycle power system utilizes a single-point ground at the utility interface. The utility provides the electrical ground for
the system. This ground is attached to the equipment and chassis grounds for the power module and condenser. The
evaporator and other ancillary equipment may require a separate ground. Please refer to the applicable codes for grounding
all equipment.
Power Factor Correction
The PureCycle power system contains power factor correction equipment capable of maintaining a power factor greater than
0.95 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 will
cause the safety chain in the system to trip and initiate an emergency shut down. The button will not disconnect the electrical
feed to the unit. Therefore, the unit will not go Black when the E-stop button is pushed. Since the E-stop button causes the
unit to shut down in an abnormal manner, this is not recommended as a standard method for shutting down the unit. An
interface 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 speed
broadband connection with a static IP address accessible from the internet. The PWPS warranty requires this high-speed
connection. 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 on
demand through the same ports. It is expected that a router will be assigned to forward the communications from the static
IP address to the remote device assigned an internal IP address. Use of the router is intended to limit the number of ports
open through a customer's firewalls. A typical setup consists of an external IP address provided through a local ISP such as
a cable or phone company. A router/switch then routes the limited ports on to the remote monitoring system and allows the
controller to communicate with the remote monitoring system. It is expected that the customer provide for the Internet
connection 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 and
continually stores the data. It also generates displays on demand for service and customer use to monitor and control some
aspects 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 electrical
installation drawings (Single Unit Installation; HTE73520 - Multi-Unit Installation).
Table 8 – Electrical Connections
SYSTEM ELECTRICAL INTERCONNECTION RECOMMENDED CONDUIT

SERVICE
INTERCONNECTIONS POINT WIRING SIZE
Disconnect switch Grid connection 480 VAC, 3-phase Two 350 MCM wire per phase
with ground One 1AWG ground wire Two 3” – 3 ½”
Wiring rated to 90°C (194°F)
ECS Connections
External grid protection
TB1-10, TB1-11 Signal – dry contact 16AWG 3/4”
Relay
Cat 5e RJ45
ESW1 Ethernet port Communication 3/4”
Max wire length 100 m (328 ft)
RMS02 Analog phone line (optional) Communication RJ11 3/4”
Remote e-stop (optional)
TB4-9, TB4-10 Signal – dry contact 16AWG 3/4”
(Jumpered by default)
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 an
Internet Service Provider along with Microsoft® Internet Explorer® web browser is required to view data from the
unit 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
PureCycle power systems are designed to provide safe and reliable service when operated within design specifications and
all applicable instructions and operating materials. When operating this equipment, use good judgment and safety
precautions to avoid damage to equipment and property or injury to personnel. Be sure to understand and follow the
procedures and safety precautions contained in this guide and in all applicable instructions and operating materials.
SAFETY CONSIDERATIONS
APPENDIX A – TYPICAL INTERCONNECTION AGREEMENT DATA
The table below provides typical data requested during an interconnection study or interconnection agreement application.
Prime Mover Manufacturer Pratt & Whitney Power Systems
Model Name PureCycle Model 280 Power System
A. Type of generating unit Induction
Manufacturer Baldor Electric Company, Greenville, SC
Model V02XR24001725GN
B. Rated MVA 0.296 gross output of generator
C. Maximum gross output (MW) 0.280 gross out put of generator
D. Rated lagging power factor Internal PFC capacitors provided to yield pf ~ 0.95 at
rated power
E. Nominal voltage and acceptable voltage range 480 volt + 10%, -12%
(volts ±%)
F. Estimated load factor, number of hours/year of 100% rated operation
operation or MWh/year
G. Stability Data:
1. Inertia of turbine/generator (sec) 0.347 sec
2. Transient direct axis reactance (PU) See generator data sheet
A. Substransient Reactance = 0.1345
B. SC time constant = 0.050 sec
C. OC time constant = 2.193 sec
3. Excitation system data Internal PFC capacitors provided to yield pf ~ 0.95 at
rated power, utility or customer to provide balance of
reactive power. System operates only in grid parallel
mode.
4. Governor data and Laplace transform block N/A This is an induction generator system that will operate
diagrams of the control equipment only in grid synchronization. Upon loss of the grid, the
system will shut down.
H. VOLTAGE/FREQUENCY LIMITS
1. Pickup settings UV 88%, OV 110%
UF 57 Hz OF 60.5 Hz
2. Roll off rates UV 2 seconds, OV 1 seconds
UF 10 cycles, OF 10 cycles
I. Minimum/maximum excitation limits N/A Induction Generator
J. Interconnecting circuit breaker (disconnect
switch)
1. Manufacturer Siemens Model SHMD69600A
2. Load rating, interrupting rating 600 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 generator
interconnection 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 much
power 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 be
prepared 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 provide
the following minimum required information by completing the attached Project Requirements Document (PRD) and
returning to Patti Orlowski (patricia.orlowski@pw.utc.com) at PWPS.
PROJECT REQUIREMENTS DOCUMENT (PRD)

Pratt & Whitney Power Systems PureCycle ® Power System
Date
Customer/site name
Company
Your company's role Project Developer Power Producer Engineering/EPC Energy Efficiency
Site location
Site address
Contact name
Contact number
Contact e-mail
Application description
Operating Window (Typical flow requirements for 260kW max net power with water as hot liquid source)
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)
* Can vary depending on hot fluid and environmental conditions
Max Thot Pressure = 150psig (10bar)
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 Attached
Existing or new hot water source Existing New
Type of hot water source Geothermal Oil & gas wells Engine jacket Water Engine exhaust
Industrial process Biomass boiler Solar thermal Other
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 Attached
Type of cold water source Cooling tower River water Sea water
Holding pond Ground water Other
Answer the following questions if a cooling tower will be utilized

Existing New 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

Project and Installation Information
Do you have project financing in place? Yes No
Power consumed on-site, or for sale to the grid On-Site 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 Grid-connect Diesel gensets Other (describe)
60Hz 50Hz 480V 415V 400V 380V
Installation type Retrofit Replacement Greenfield
Location of unit Outdoor Indoor
Communication means for remote monitoring system Telephone Internet Other high speed
Minimum 4 ft (1.2 m) of service clearance for equipment Yes No (explain)
Site sketch Attached
Distance from power plant to grid (transmission lines)

List non-standard requirements, codes, regulations
For geothermal, are new wells required? Yes No
For geothermal, is there existing infrastructure in place? Yes No
Is an electrical take-off agreement in place with utility? Yes No Attached
Have electrical load flow and interconnect studies been done? Yes No Attached
Has an environmental impact study been done? Yes No Passed
Do you have land and mineral rights concessions? Yes 10-20 Years 20+ Years
Transportation/Shipping
Nearest major shipping port?
Is the facility accessible from a paved road? Yes No
Method for transporting the unit once in destination country? Truck Other (describe)
Will more than one country be transited to get to the site? Yes No
Can PureCycle machine be uploaded at site with a crane? Yes No

Product Data Hot Liquid
and
Application to Electricity
Guide Power System
Supplement Nominal 280 kW Power
PURECYCLE®
POWER SYSTEM
MODEL 280
Copyright 2009 Pratt & Whitney Power Systems, Inc. Revision A – 09/23/2009 HTE75367
All Rights Reserved.
DISCLAIMER
This document is the property of Pratt & Whitney Power Systems, Inc. (Pratt & Whitney Power Systems or PWPS) and
contains proprietary and confidential information of PWPS. You may not copy or disclose this document or any information
in it, for any purpose, including without limitation, to design, manufacture or repair parts, or obtain any government approval
to do so, without PWPS’s express written permission. Neither receipt nor possession of this document alone, from any
source, constitutes such permission. Copying or disclosure by anyone without PWPS’s express written permission is not
authorized 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 equipment
specifications of the PureCycle power system without obligation with respect to equipment either previously sold or to be
sold. This Product Data and Application Guide is provided by Pratt & Whitney Power Systems for informational purposes
only, and no liability will accrue to Pratt & Whitney Power Systems based on the information or specifications included
herein. No warranties or representations shall apply to the equipment except as stated in the PureCycle power system
Limited 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 the
United States and other countries.
Revision A – 09/23/2009 – Page 2 HTE75367

TABLE OF CONTENTS
Disclaimer ..............................................................2 Application Guidelines......................................... 5

PureCycle Power System Reference Documents Power Output .................................................... 5
..........................................................................4 Hot-Liquid-Resource Temperature and Flow 5
Revision History ....................................................4 Cooling Tower................................................... 6
Overview.................................................................5

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 cooling
water temperatures. This document will describe the influence of these installation-specific variables and provide guidelines
for system performance. Interested customers should complete the Project Requirements Document (PRD) in Appendix B of
the Product Data and Applications Guide (HTE66510) and contact Pratt & Whitney Power Systems for specific application
performance 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 between
180 and 1100 gpm and is a function of installation-specific variables, including resource liquid temperature and cooling water
temperature. For information on applications outside of these temperature and flow ranges, please complete the PRD in
Appendix 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 temperature
requirements to produce full power at various cooling water temperatures. Multiple systems can be installed if sufficient flow
is available. Two machines operating in parallel would require twice the flow of one machine.
PureCycle® Model 280 Performance

280 kW Gross, 260 kW Net, 60 Hz/480V
Carbon Steel Evaporator, Copper Condenser
Resource Flow (l/s)
6 11 16 21 26 31 36 41 46 51 56 61 66
300
147
290
142
280 137
270 132
Resource Temperature (ºC)

Resource Temperature (ºF)
260 127
122
250
Below
Minimum 117
240 Evaporat
or Flow
Rate 112
230
107
220
102
210
97
80ºF (26.6ºC) Cooling Water Inlet Temperature
200 60ºF (15.5ºC) Cooling Water Inlet Temperature 92
70ºF (21ºC) Cooling Water Inlet Temperature
190 87
50ºF (10ºC) Cooling Water Inlet Temperature
180 82
100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100
Resource Flow (gpm)
Assumptions: 18ºF (10ºC) Cooling Water DT
Cooling Water Flow Rate: 960 gpm (58 l/s) for resource
Figure 1 – PureCycle Model 280 Performance

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

Approximate Cooling Flow Requirements
Resource Temperature (ºC)
90 95 100 105 110 115 120 125 130 135 140 145
2200 138
128
2000
118
1800
Cooling Flow Rate (gpm)
Cooling Flow Rate (l/s)

108
1600 dT = 10º F (5.5ºC)

98
1400 88
78
1200
dT = 15º F (8.3ºC) 68
1000
58
800
dT = 18º F (10ºC) 48
600 38
190 200 210 220 230 240 250 260 270 280 290 300
Resource Temperature (ºF)
Figure 2 - Cooling Water Flow Rate Requirements

Hot Liquid To Electricity Power System: Product Data and Application Guide

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Product Data Hot Liquid

Disclaimer ..............................................................2 Evaporator .................................................. 18

Revision B – 09/23/2009 – Page 3 HTE66510

Revision Letter Date Reason for Change

A 07/19/2007 Original Issue

Update to production configuration,

Revision B – 09/23/2009 – Page 4 HTE66510

 Ease of installation and maintenance

 100% remote monitoring and operation

 Non-flammable and non-ozone depleting working fluid

Figure 1 – PureCycle Power System Schematic

Codes and Safety

Figure 2 – PureCycle Power System (Front View)

Figure 3 – PureCycle Power System (Rear View)

4. Working Fluid Pump

5. Electrical Control System

Additional features of the electrical control system include

 Power factor correction to 0.95 lagging minimum at full load.

 User interface for remote and manual operation

Figure 4 – Local-Operator Interface (LOI)

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

8. Reset button – resets the LOR described above

REMOTE MONITORING SYSTEM

RMS Server PWPS Customer PWPS

1-5 PureCycle® Units

1 or more banks of PureCycle® Units

Figure 5 – Remote Monitoring System Architecture

WebCTRL® is a registered trademark of Automated Logic Corporation.

RMS offers the following features:

REMOTE MONITORING SYSTEM

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

Figure 6 – PureCycle Power System Dimensions

Revision B – 09/23/2009 – Page 13 HTE66510

PRESSURE AND TEMPERATURE RATING

Assembly Pressure Rating Temperature Rating

PureCycle® Model 280

• Assumed omnidirectional sound radiation

Figure 7 – PureCycle Model 280 System Sound Level

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

Hot- Liquid-Resource Temperature and Flow

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

Cooling Water Inlet Temperature and Flow Rate

Hot-Liquid-Resource Control System

Figure 9 – Resource Control System Concept

Resource Liquid Composition

Heat-Exchanger Pressure Drop

Power Plant Flow

Consult Controlling Band

Resource Flow Rate (gpm)

Figure 10 – Evaporator Pressure Drop

High Temperature Resource

Figure 11 – Condenser Pressure Drop

Layout and Civil Requirements

4’ minimum perimeter, flat hard surface

25’ Hot water

Figure 12 – Maintenance Clearance Requirements

SITE DESIGN REQUIREMENTS

 Resource water supply and return piping

 Cooling water supply and return piping

Resource Water Control System

SITE DESIGN REQUIREMENTS

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