Product Data and Application Guide

Hot Liquid to Electricity Power System
Nominal 280 kW Power

PURECYCLE® POWER SYSTEM MODEL 280
Copyright 2009 Pratt & Whitney Power Systems, Inc. All Rights Reserved. Revision B – 09/23/2009 HTE66510

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

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APP70613) Electrical Installation Drawing Set (HTE73478 – Single-Unit Installation. provide additional application guidelines. performance detail and site design considerations Reason for Change B 09/23/2009 Revision B – 09/23/2009 – Page 4 HTE66510 . HTE73520 – Multi-Unit Installation) REVISION HISTORY Revision Letter A Date 07/19/2007 Original Issue Update to production configuration.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.

This results in a 280 kW on-site power-generation system that requires no fuel input except heat in the form of hot water. (Pratt & Whitney Power Systems or PWPS). Inc. hot vaporized working fluid then enters the power module and drives a turbine to produce electrical power. efficient and reliable power within the growing distributed generation market. Heat rejected during condensation is sent to a cooling tower. OVERVIEW Revision B – 09/23/2009 – Page 5 HTE66510 . boosted in pressure and sent back to the evaporator to repeat the cycle. Its PureCycle power system. The cooling tower is provided by the customer. ensuring product quality and reliability. until working fluid is vaporized. Low-pressure. developed by Pratt & Whitney Power Systems. It can also use heat produced when a reciprocating engine or gas turbine is in operation. 1. 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. cost-effective option that creates revenue. The PureCycle power system can utilize heat that is available from many geothermal or oil and gas wells. 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. reduces process cost and supports an intelligent energy strategy. is a pre-engineered system that harnesses waste heat to generate electricity. a division of United Technologies Corporation (UTC). The cooled liquid is then sent to the pump. High-pressure. the PureCycle power system converts low. 3.OVERVIEW Pratt & Whitney. a refrigerant R245fa. Hot water enters the evaporator to heat the working fluid.and moderate-temperature resource fluids like water into electricity through vaporizing and expanding a working fluid in a closed system. Based on a thermodynamic cycle known as the organic rankine cycle (ORC). 5. This innovative power solution is built with the proven technology and components of commercial centrifugal chillers. 2. is committed to providing clean. and from industrial facilities. 4. expanded vapor cycles through a condenser where it is cooled and condensed into liquid form. It is a low-maintenance.

Working Fluid The working fluid. Power Piping. SYSTEM OPERATION Revision B – 09/23/2009 – Page 6 HTE66510 . 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. minimizing leaks and eliminating the need for an additional cooling system interface with the customer. The oil system and generator are cooled by the working fluid in a fully enclosed. the working fluid flows through the bypass valve around the turbine until sufficient heat is supplied to the system to enable proper operation.Hot Liquid Resource 195ºF – 300ºF (90ºC – 149ºC) Figure 1 – PureCycle Power System Schematic SYSTEM OPERATION During system start up. The turbine/generator assembly has an integral oil cooling and lubrication system for the bearings and rotating equipment. Once sufficient vapor pressure is available upstream of the turbine. the turbine stop valve. and is a new refrigerant for centrifugal chillers. The evaporator and condenser are stamped with the ASME Boiler and Pressure Vessel Code. hermetically sealed system. It is not federally regulated with respect to the Resource Conservation and Recovery Act (RCRA) or by the Department of Transportation for shipment. R245fa. The bypass valve is open during start up while a valve upstream of the turbine. is closed. commonly used for steam systems. The induction generator is started as a motor using a solid-state. the fluid is completely nonflammable. a hydrofluorocarbon with the chemical composition of pentafluoropropane. With no flash point.1. Codes and Safety The PureCycle power system is designed to minimize external leaks to the environment. is commonly used as a foam-blowing agent for the insulation industry. and all piping complies with the standards of ASME B31. the controller opens the turbine stop valve and closes the bypass valve. 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. R245fa has zero ozone depletion potential because it contains no chlorine.

Electronic Control System (ECS) 1. National Electric Code installation compliance ensures basic electrical and mechanical integrity and safety. An independent lock-out relay circuit that monitors the same pressures and temperatures and shuts down the system if required. A microprocessor-based control system that continuously monitors key system pressures and temperatures and automatically shuts down the system if it detects abnormal operation. Condenser 6. electrical control system (ECS) and working fluid pump (See Figure 2 & 3). including: turbine generator assembly. Working Fluid Pump Figure 2 – PureCycle Power System (Front View) SYSTEM COMPONENTS Revision B – 09/23/2009 – Page 7 HTE66510 . condenser.The PureCycle power system is designed to ensure personnel and equipment safety. 3. Evaporator 4. evaporator. Local Operator Interface (LOI) 5. SYSTEM COMPONENTS The PureCycle power system is supplied as a complete skid-mounted modular and tested assembly. Additional protective measures include:    A watchdog timer that continuously monitors controller performance and automatically shuts down the system if it detects a controller malfunction.

Condenser 2. generator solid-state soft starter. temperature. remote monitoring SYSTEM COMPONENTS Revision B – 09/23/2009 – Page 8 HTE66510 . Electrical Control System The Electrical control system (ECS) is the control system for the power plant. Evaporator The evaporator. Turbine-Generator Assembly The heart of the PureCycle power system is the turbine-generator assembly. are available to meet site-specific needs. The ECS enclosure contains the system controller. an ASME BP&V-coded vessel. is a shell and tube heat exchanger that utilizes copper tubes in which lowpressure vapor is cooled and condensed into a saturated liquid. it is operated in reverse as a turbine-generator. reducing installation cost and site-specific engineering. described in the Equipment List section. Optional materials. working fluid pump motor drive. and speed monitoring. thus reducing installation cost and sitespecific engineering. Optional materials. 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). as are the controls and diagnostic instrumentation for pressure. High-pressure vapor drives the turbine that in turn drives the induction generator through a gear transmission. The condenser is delivered as an integral part of the skid-mounted module. Evaporator Figure 3 – PureCycle Power System (Rear View) 1. input/output (I/O) modules. Turbine-Generator 1. Pump speed is controlled to maximize power-plant-generated power. is a shell-and-tube heat exchanger that utilizes carbon steel tubes that capture the resource heat. are available to meet site-specific needs. 4. 2. controlled by a variable frequency drive.3. 3. however. an ASME BP&-coded vessel. described in the Equipment List section. This assembly is the same platform as Carrier’s standard chiller motor-compressor. 5. Condenser The condenser. The evaporator is delivered as an integral part of the skid-mounted module. The oil-and generator-cooling systems are integral to the fully enclosed hermetic assembly. The pump operates continuously but at varying speeds. Working Fluid Pump The pump delivers the working fluid until the working fluid is vaporized.

oil heater. via an internal signal. alarm indicaiton and emergency stop.95 lagging minimum at full load. Mode switch – local interface on machine for turning the unit on or off (typically for service).system (RMS). Lock out relay (LOR) enable indicator 7. but installed) used for Lock Out Tag Out (LOTO) service provision. The circuit opens when any safety switch trips or if the emergency stop is closed. 1 2 3 7 8 10 9 Figure 4 – Local-Operator Interface (LOI) 1. Ethernet connection 2. Ethernet connection – an Ethernet port for service access to the local network Generator soft-starter interface – shows the generator soft starter data RJ14 connection – a connection for local service access to power plant controller Power button – indicates whether 480 VAC (or optionally 380/400/415V) power is available to the unit Alarm indicator – indicates whether one or more controller alarms are active LOR is a safety circuit with pressure switches and a microprocessor watchdog timer. for non-utility grade metering of motor/generator power A disconnect switch (not shown. the local user interface to the system. Transient voltage and surge-suppressor device protection at utility interface per IEEE standard C62. provides several key functions. Once opened. Power indicator 5. system contactors and relays. reducing site costs and installation time associated with installing a separate switch 6. Lamp test button 10. The ECS automatically controls the proper start. process controls. Additional features of the electrical control system include        Motor control and protection. Alarm (service) indicator 6. 4 5 6 1. 4.411980 (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. Emergency stop button Ground fault circuit interrupter (GFCI) located on adjacent door. User interface for remote and manual operation Provision. SYSTEM COMPONENTS Revision B – 09/23/2009 – Page 9 HTE66510 . 3. RJ14 connection 4. Reset button 9. continuous operation and disconnect of electrical energy for the turbine/generator. The LOR must be in the 7. 5. 2. oil pump. The switch position is labeled “Auto” to indicate that the controller is allowed to start if all other criteria are met. including reduced-voltage start up thermal capacity protection for operation in both motoring and generating modes. including power. 6. and other components. Local-Operator Interface The local-operator interface (LOI). the relay must be reset locally using the reset button (#8 on this figure) or remotely by a PWPS service technician. Off/Auto mode switch 8. Generator soft starter interface 3.

Data connection requirements WebCTRL® is a registered trademark of Automated Logic Corporation. The RMS design leverages Pratt & Whitney Power Systems’ experience in remote monitoring and provides low-cost installation and operation. 8. Bandwidth capability should be T1 or equivalent (1. Doing so repeatedly will result in premature wear of the turbine.normal position (LOR Enable light is active) for the unit to start up. and evaporator and degradation of the oil. Firewall Firewall Remote Monitoring System UTC Intranet Internet Static IP Router Internet RMS Server PWPS Technician Customer PWPS 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. 10.54 Mb minimum bandwidth) for the best functionality. Product alarms are stored along with product data in a central database. Connection to remote sites is established through an Internet web portal. Shutting down the system using the E-stop method is not recommended unless there is an emergency. working fluid pump. REMOTE MONITORING SYSTEM Revision B – 09/23/2009 – Page 10 HTE66510 . Communication to the RMS is established through a customersupplied dedicated high speed internet with a unique static IP address and/or appropriate routing equipment. 9. The switch may be turned to “Off” for maintenance and provides local override in the “Off” position. Lamps that do not light up during this test may need to be replaced. Reset button – resets the LOR described above Lamp test button – tests the indicator lamps for proper function. through which users can access current and historical power plant operating data. 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. a Web server interface that supports remote monitoring/control through a Web browser. A GFCI outlet located on the adjacent panel door provides 120 V service for maintenance ease. Emergency stop button – shuts down the machine in the event of an emergency.

are detailed in the Control Wiring Requirements section of this document. Remote communication is used to facilitate troubleshooting and remotely update software. 5. Remote start/stop – Service personnel have the ability to remotely start and stop the machines. 4. Alarm logging – Alarms are retained in the database and are accessible through the portal. Communications – The remote monitoring system provides tools for the customer or UTC personnel to interface with the equipment. Data encryption techniques are used to provide secure communication. Data storage – A database stores all relevant product data and alarm/maintenance history. 2. The portal site also serves as an interface to a database that stores historical performance data. database queries and reporting – Through WebCTRL® software. 3. All users will be provided a logon ID and will be required to select a password to gain access to the system. Data from the RMS will be uploaded to the database. Please consult your Warranty Agreement and Service Agreement for further details. REMOTE MONITORING SYSTEM Revision B – 09/23/2009 – Page 11 HTE66510 . customers and UTC associates with proper authorization can remotely monitor sites through an Internet connection. Response to alarms depends on Warranty and level of service purchased. A graphical user interface facilitates database queries and the generation of reports. Standard reports are available and can be configured by the user. Remote monitoring. PureCycle power systems can be wired on-site for Supervisory Control and Data Acquisition (SCADA) site-control remote start/stop if desired. RMS offers the following features: 1. Individuals logging on to the portal site are provided with a list of sites they are authorized to monitor.

Only Genetron® R245fa is acceptable for use in the PureCycle power system. Monitoring service is offered as a separate option.EQUIPMENT LIST Table 1 – Equipment List STANDARD PureCycle Model 280 Power System Power plant assembly. Inc. 480 V. Corrosive effects on tube side wetted surfaces will vary. model 280. Consult industry expert for material compatibility with resource fluid. One RMS system can operate with up to 5 PureCycle power system units. 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 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 Consumables  Turbine oil  R245fa refrigerant Remote monitoring system (RMS) 3 2 1 OPTION (Factory Installed) X X X 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 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  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. Heresite® is a registered trademark of Heresite Protective Coatings. EQUIPMENT LIST Revision B – 09/23/2009 – Page 12 HTE66510 . Turbine oil is a formula unique to PWPS’s application and should be obtained from PWPS. allows for all heat exchanger plumbing connections to come from one side X X X 1 2 3 Alternate voltage and frequency configuration X  380/400/415V/50 Hz Pratt & Whitney Power Systems provides initial fill.

PHYSICAL DATA Table 2 – Physical Data English PureCycle Power System Operating weight Shipping weight Dimensions (L x W x H) Maximum whipping height 33.600 lbs 19’ x 7’-6” x 11’-3” 10’-3” SI 15. Figure 6 – PureCycle Power System Dimensions Revision B – 09/23/2009 – Page 13 HTE66510 . Please refer to these drawings for more detailed site engineering requirements.104 kg 12.300 lbs 27.519 kg 5790 x 2290 x 3430 mm 3200 mm DIMENSIONS The following schematics are presented to give general dimensions required for a PureCycle installation. electrical and civil requirements for constructing a typical PureCycle installation (Mechanical Installation Drawing Set APP66344 and APP70613) are available upon request. Standard drawings containing mechanical.

It does not account for additional parasitic power required by the site to provide resource and cooling water flow.2 272 kW 257kW 1. rated line voltage) Line voltage unbalance Harmonics Interruption/disconnection 59. 49. Site design must provide safety relief for the evaporator on the customer water side. PRESSURE AND TEMPERATURE RATING Heat exchangers in the PureCycle power system have the following pressure and temperature ratings. Refer to ASHRAE 15 Safety Standards for Refrigeration Systems for proper installation of equipment. 3 wire. 50 Hz 78 dBa at 10 m (33 ft) 380V.88 ±3% Voltage Total Harmonic Distortion (THD) < 5% Current THD < 5% (IEEE 519 compliant) The system interrupts if it detects an abnormal grid condition.3 – 60. Contact your Pratt & Whitney Power Systems representative for more information and an analysis of your specific resource. 3 wire 60 Hz 400/415V. Net power output is resource-liquid and cooling-water dependent.95 lagging 1. Table 4 – Pressure and Temperature Rating Assembly Condenser Shell side Tube (water) side Evaporator Shell side 1 Pressure Rating 150 psig (1034 kPa) 150 psig (1034 kPa) 345 psig (2380 kPa) Temperature Rating 225ºF (107ºC) 120ºF (49ºC) 1 330ºF (177ºC) Tube (water) side 150 psig (1034 kPa) 325ºF (163ºC) Condenser temperature limit is set by system operating limit of exit cooling water temperature below 120ºF (49ºC).0 – 51. PERFORMANCE DATA Revision B – 09/23/2009 – Page 14 HTE66510 .2 263 kW 248 kW 1. Proper venting of the power plant pressure relief valves for the working fluid is also required to prevent overpressure of the system.10 to 0.2 Voltage and frequency standard System sound level 480 V.5 Hz 49.0 Hz Greater than 0. 50 Hz Electrical Characteristics Frequency range Power factor Maximum line voltage deviation (vs. It can be configured to automatically re-start in < 20 minutes. Net power is the gross generator power minus internal parasitic power within the PureCycle system. 3 wire. 3 phase. 3 phase.PERFORMANCE DATA Table 3 – Performance Data Performance Characteristics Gross electrical power output Net electrical power output 1 280 kW 265 kW 1.0 – 51. 3 phase.0 Hz 1 2 Protection parameters Grid protection includes over/under voltage/frequency. Heat exchangers are U1 stamped per the ASME Boiler and Pressure Vessel Code Section VIII.

the fluid is completely nonflammable.SYSTEM SOUND LEVEL System sound level for the PureCycle power system is typically stated as 78 dBa at 10 m.00 80. SYSTEM SOUND LEVEL Revision B – 09/23/2009 – Page 15 HTE66510 . Each container holds approximately 1.2 m x 1.00 70.00 90. R245fa is categorized as Category B1 for ASHRAE Safety Standard 15. Local codes or ordinances may require sound attenuation if the noise level at a particular distance exceeds a specified threshold. R245fa has zero ozone depletion potential.00 SPL (dBA) 85. One to two containers with some fluid and three to four empty containers for holding fluid during machine repair/maintenance activities are recommended. It is not federally regulated with respect to RCRA or the Department of Transportation. The refrigerant should be stored in a cool. For those purposes. It has a global warming potential (GWP) of 950. With no flash point. Genetron® is a registered trademark of Honeywell International. Typical charge for the PureCycle power system is ~ 3200 lbs (1450 kg). segregated from the power plants and utilizing pole-barn-type shade. Storing the PureCycle power system above 60ºF (15. Because the refrigerant should not be mixed with air or oxygen at pressures above atmospheric. Please refer to the Material Safety Data Sheet (MSDS) for R245fa provided by Honeywell.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. Refrigerant is delivered and should be stored in the same DOT containers.5ºC) protects against the introduction of non-condensable gas into the system. Pratt & Whitney Power Systems recommends a hard shaded surface for working fluid storage. well-ventilated area. By virtue of its lack of chlorine. Please refer to the PureCycle Model 280 Installation Manual PRMAN66798 for more information. When designing the site. The containers are designed with fork-lift pockets for easy handling and are approximately 4’ x 4’ x 5’ h (1.000 lbs (454 kg) of fluid and has a tare of approximately 400 lbs (181 kg). Only Genetron®® 245fa is acceptable for use in the PureCycle power system.5 m h). the PureCycle system is shipped with a nitrogen charge of 15 psi. accommodations for the refrigerant storage should be considered.00 75. R245fa is commonly used as a foam-blowing agent for the insulation industry.00 95. and is a new refrigerant for centrifugal chillers. sound levels at various distances are shown in PureCycle® Model 280 Sound Pressure Level (SPL) vs Distance 100. PWPS recommends a 10’ x 10’ (3 m x 3 m) fenced area. Inc.2 m x 1. and OSHA does not list the fluid for toxicity.

including resource liquid temperature and flow rate and cooling water temperatures. If the resource temperature decreases from its design value (typically the value selected from the figures above). APPLICATION GUIDELINES Power Output Power output is a function of installation-specific variables. Hot. The following sections of this document will describe the influence of these installation-specific variables and provide guidelines for system performance. When resource flow has decreased such that gross power output is less than 80 kW. especially for enclosed and low overhead spaces. preferably 85ºF (30°C) or less. Interested customers should complete the Project Requirements Document (PRD) in Appendix B and contact Pratt & Whitney Power Systems for specific application performance and optimization. including resource liquid temperature and cooling water temperature. Table 5 – PureCycle Model 280 Performance 280°F/138°C Resource Hot Resource (Evaporator) Inlet Temperature Exit Temperature Flow Rate Material Cooling Water (Condenser) Inlet Temperature Exit Temperature Flow Rate Material Power Output Gross Power Output Net Power Output Voltage/Frequency 1 240°F/116°C Resource 138ºC 85ºC 14 l/s 240ºF 172ºF 345 gpm 116ºC 240ºF 78ºC 194ºF 21 l/s 510 gpm Carbon Steel 16ºC 80ºF 26ºC 98ºF 58 l/s 1030 gpm Copper 280 kW 265 kW 480 V / 60 Hz 116ºC 90ºC 31 l/s 200ºF 173ºF 1100 gpm 200°F/93°C Resource 93ºC 200ºF 78ºC 173ºF 66 l/s 1100 gpm Carbon Steel 16ºC 80ºF 26ºC 98ºF 70 l/s 1285 gpm Copper 93ºC 78ºC 66 l/s 280ºF 170ºF 180 gpm 138ºC 280ºF 77ºC 185ºF 11 l/s 227 gpm Carbon Steel 16ºC 80ºF 26ºC 98ºF 58 l/s 1030 gpm Copper 280 kW 260 kW 480 V / 60 Hz 60ºF 78ºF 960 gpm 27ºC 37ºC 62 l/s 60ºF 78ºF 960 gpm 27ºC 37ºC 62 l/s 60ºF 78ºF 1160 gpm 27ºC 37ºC 77 l/s 280 kW 265 kW 480 V / 60 Hz 205 kW 190 kW Power output at low resource temperatures and high condensing temperatures is derated due to evaporator flow limitations. the PureCycle power system will shut down. APPLICATION GUIDELINES Revision B – 09/23/2009 – Page 16 HTE66510 . power output will decrease accordingly.The accumulation of working fluid in an enclosed space can displace oxygen and cause asphyxiation. Two machines operating in parallel would require twice the flow of one machine. as well as adequate ventilation in accordance with ANSI/ASHRAE 15. Multiple systems can be installed if sufficient flow is available. The hot resource flow required to produce full power output varies between 180 and 1100 gpm and is a function of installation-specific variables. For information on applications outside of these temperature and flow ranges. This power output as a function of design flow rate for a single unit is described in Figure 8.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. please complete the PRD in Appendix B and consult your PWPS sales consultant or applications engineer. Indoor installations require leak detection. Table 5 describes PureCycle Model 280 Performance.

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. When the system is shut down. Interested customers should consult Pratt & Whitney Power Systems to determine the actual performance for their site conditions. It may be necessary to model seasonal variation in performance due to ambient conditions and is helpful for cooling tower selection. During operation. A concept is shown in Figure 9. the system controller automatically modulates the liquid flow rate to maximize power output and prevent overheating the working fluid.PureCycle® Model 280 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. Figure 9 – Resource Control System Concept APPLICATION GUIDELINES Revision B – 09/23/2009 – Page 17 HTE66510 . Hot-Liquid-Resource Control System Operation of the PureCycle power system requires control of the resource liquid flow through the evaporator.

For the evaporator. 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 Typical pressure drops for the evaporator are shown in Figure 10. Resource Liquid Composition Resource liquid quality is highly site specific and is the customer’s responsibility to determine suitability for this application. but not limited to. water consultants are hired to assist in the proper selection of materials. and the maximum design flow is 1100 gpm (69.Power Derate Control The PureCycle power system is designed for operating ambient temperature between -20ºF and 122ºF (-28ºC and 50ºC). annual inspection of the heat exchanger tubes is recommended. Resource Flow Rate 30 25 Evaporator Pressure Drop (psi) 20 Power Plant Flow Control Valve ~ 60% Open 15 Consult PWPS for Applications in this Range Controlling Band Power Plant Flow Control Valve ~ 80% Open 10 5 0 100 200 300 400 500 600 700 800 900 1000 1100 Resource Flow Rate (gpm) Figure 10 – Evaporator Pressure Drop APPLICATION GUIDELINES Revision B – 09/23/2009 – Page 18 HTE66510 . it is the responsibility of the customer to develop cleaning processes to maintain maximum performance and evaporator life. wind conditions and elevation. Evaporator Pressure Drop vs. Typically. Output power may decrease with electronic control system (ECS) enclosure internal temperatures over 113ºF (45ºC). Heat-Exchanger Pressure Drop Tube-side pressure drop across the evaporator and condenser will vary depending on the flow for the proposed application. Particulates in the resource water must also be carefully examined to determine the potential for fouling the heat exchangers and reducing performance and life. lower resource temperatures will require greater resource flows. Applications with high particulate levels may be viable if the proper chemical treatments and cleaning processes are used. solar loading and orientation. cooling water inlet temperature. At a minimum. The two lines shown represent the expected power plant pressure drop range through several flow ranges. The evaporator is designed to be easily inspected and cleaned in the field. Generally.4 l/s). At the site level. This output power reduction is expected to correspond with an ambient temperature exceeding 104ºF (40ºC) but may vary based on site conditions including. the minimum design flow is 180 gpm (11. Pratt & Whitney Power Systems offers alternate heat-exchanger materials for use with various contaminants. In all cases.4 l/s).

Sizing and selection of a cooling tower is dependent on knowing the heat rejection from the condenser. APPLICATION GUIDELINES Revision B – 09/23/2009 – Page 19 HTE66510 . Condenser Pressure Drop vs.149ºC) Low Temperature Resource 195ºF . which has a relatively large surface area to improve heat transfer. Cooling Water Flow Rate 30 25 Pressure Drop (psid) 20 High Temperature Resource 280ºF . 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.Condenser Condenser pressure drops will vary with flow rate and condenser inlet temperature. 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. 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).5ºC to 10ºC). the minimum design flow is 600 gpm (37. Typically. Typical pressure drops for the condenser are shown in Figure 11.9 l/s). the design ambient wet-bulb temperature.138ºC) 15 10 5 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.2 l/s). Contact cooling tower manufacturers to assist with sizing the tower to the specific application. thereby cooling the remaining water to within a few degrees of the ambient wet-bulb temperature. For the condenser.300ºF (138ºC . 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. 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”. As an example. Air is drawn over or through the fill section (typically by one or more fans) causing evaporation of a portion of the water.280ºF (90ºC . 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. and the maximum design flow is 2000 gpm (126.

In addition. Each system is able to start automatically without direct control. Loss of grid connection for load will produce an automatic shut down of all the systems. Providing colder water is beneficial. 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. as well as to regular draining. Alternatively.2% is also lost due to droplets being entrained into the air (drift). fouling of the condenser can occur quickly. A grid connection is required to start and/or operate. Temperature control of the water is a critical element in the design and selection of a cooling tower for a PureCycle system. To limit start up current draw and electrical demand charges.As a result of evaporation of some of the water. Location of the cooling tower will vary according to local site design and other considerations. the site control should be set up to stagger-start multiple units and provide feedback so that peak currents do not overlap. However. since it influences power output. consideration for fogging or drift and what other equipment or objects might be wetted in the event of strong winds. as it allows the condenser to operate more efficiently. starting more than one system at a time is not recommended.3% loss. The total loss attributed to all of these conditions. the location of the cooling tower should allow for unrestricted airflow and to prevent recirculation.5-2% of flow. Each system will be able to operate independently. However. Loss of cooling water will produce an automatic shutdown of all the systems simultaneously. Water temperature is typically controlled by either cycling the fan(s). 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. Generally. utilizing variable-speed or two-speed fan motors or by incorporating a tower bypass valve into the system design. In general. Motoring time and requirements for stagger start are described in the Electrical Requirements section of this document. Safety features in the control permit one or more to shut down by remote command or automatically. the return cooling water temperature to the condenser should be maintained above a minimum limit of 50ºF. Fouling can result if a chemical treatment system is not installed or if blow-down is not performed regularly in the cooling water system. Insulation of the cooling water piping should also be considered in cold climates. it is necessary to replenish whatever amount of water is lost. determines the amount of make-up water that has to be added. To aid in properly maintaining water quality and cleanliness. approximately 1. a water treatment system should be provided on each installation. 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. Blow-down. attention should be paid to providing an auxiliary sump located inside a heated space to preclude freezing of the water. about . and the weight of the tower if installed on a roof. consideration of the increase in sound level to the surrounding area. Close proximity to the condenser should also be considered to avoid long pipe runs and increased pumping costs. typically equates to about a . APPLICATION GUIDELINES Revision B – 09/23/2009 – Page 20 HTE66510 . If installed in areas where the ambient temperature can go below 32°F. a heated sump could also be used. Multi-unit Installation A multi-unit installation will consist of multiple blocks of one to five PureCycle systems in a parallel configuration. The tower manufacturer can recommend additional equipment or maintenance procedures accordingly. Without proper treatment to the cooling system. which is usually done by automatically maintaining a predetermined level in the cooling tower sump or basin via a float valve. The power plant allows for direct control from a site control computer. evaporation loss accounts for approximately 1% of the amount of water in circulation. as well as to prevent corrosion or fouling of the condenser.

evaporator. Be sure to include sufficient clearance around the site to allow a crane to maneuver and place equipment. condenser. flat hard surface Area required for tube maintenance / replacement Cooling water inlet and outlet Area required for electrical maintenance 7. Area in front of the condenser and evaporator is required for tube maintenance and replacement. Review all site permits that may be affected by the installation of the PureCycle system prior to initiating construction. as well as any local and state codes.5’ min Area required for turbine maintenance 25’ Hot water Outlet Hot water Inlet 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. It is important that the concrete foundation extend below the frost line. Layout and Civil Requirements Accessibility and Clearance Requirements In addition to the equipment footprints. 4’ minimum perimeter. The skid-mounted modular system assembly should be secured in place with anchor bolts as shown in the Mechanical Installation Drawing APP66344 or APP70613. The foundation construction must be designed and fabricated in accordance with the Requirements for Reinforced Concrete ACI 318.SITE DESIGN REQUIREMENTS The following is a list of general site characteristics required to install a PureCycle power system. The skid-mounted modular system assembly (turbine-generator with controls. the layout requires an additional four-foot-wide paved area around the equipment to facilitate service.2’ 16. as detailed in Figure 12 below.2’ 15. 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. The foundation pad must be level to within ±¼” over 10 ft. and working fluid pump) are mounted as a system on the foundation. SITE DESIGN REQUIREMENTS Revision B – 09/23/2009 – Page 21 HTE66510 .

In geothermal applications. Generic requirements and considerations include the following points:   The flow rate of resource liquid through the evaporator must be able to be continuously controlled. This should provide sufficient pressure upstream so that one plant can modulate flow without significant perturbation to a second plant’s flow. – 150 lb flange 10 in. this would typically require a reinjection pump. for example. Protect the system from water hammer in the event of a rapid shut down of the power plants. the site must accommodate the excess flow that the system does not use. The regulating valve maintains the proper pressure conditions upstream of the system while the power plant ramps up to full power. Rapid shut down will close the PureCycle power system flow control valve in approximately 2-5 seconds. A recommended approach is for the site to include a bypass leg with a pressure-regulating valve. Cascaded units will use the exit of the higher resource as the inlet to the second unit. – 150 lb flange 4 in. During shut down. – 150 lb flange 4 in. The customer should note that hot resource liquid exit temperature is not directly controlled by the PureCycle power system. The customer is expected to provide sufficient system pressure to the PureCycle power system to prevent the hot liquid from flashing. – 150 lb flange 6 in. During start up and shut down. – 150 lb flange 2 x 1 ½” FNPT 10 in. – 150 lb flange 2 x 1 ½” FNPT Condenser Cooling water inlet Cooling water outlet Pressure relief valves Resource Water Control System This section describes the standard means of controlling the resource liquid flow to the PureCycle unit(s). other site parameters must be controlled to reach the desired temperature. the regulating valve would adjust to match flow as the system reduces power. consider how the addition of the PureCycle system can be incorporated into the existing site controls without adversely affecting the existing facility operation.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 INTERCONNECTIONS Compressed gas supply inlet INTERCONNECTION TYPE AT UNIT 1/2” FNPT Evaporator Low Temperature Applications 195ºF – 225ºF (90ºC – 107ºC) High Temperature Applications 225ºF – 300ºF (107ºC – 149ºC) Resource water inlet Resource water outlet Pressure relief valves 6 in. To maintain a consistent resource exit temperature.      SITE DESIGN REQUIREMENTS Revision B – 09/23/2009 – Page 22 HTE66510 . 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. To control power output and protect the equipment.

The gas supply shall be from filtered. 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. approximately 5 minutes after the shutdown request or initiation. Particulate matter in the resource water may deposit on the evaporator tubes. PWPS recommends that site controls interface with the PureCycle power system cooling water flow switch before supplying hot resource flow.   Compressed Air Requirements A source of compressed air is required to actuate the pneumatic resource and turbine flow control valves (bypass. consider the following points:   Analyze the chemical composition of the resource water to screen for potential corrosion of the evaporator tubes. SITE DESIGN REQUIREMENTS Revision B – 09/23/2009 – Page 23 HTE66510 . including hot resource shutoff. may be required. Provide maintenance access to piping internals for routine cleaning and inspection. Once all systems are shut down. and stop valves). Insulate hot piping to prevent heat loss and/or to protect facility or service personnel from hot surfaces.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. the site cooling water can be shut off. including temperature or chemistry control. thereby degrading performance or causing hazardous waste.    Cooling Water Piping Design When designing the piping to provide cooling water to the condenser. Loss of cooling water will result in an immediate system shutdown.Resource Water Piping Design When designing the piping to provide resource water to the evaporator. 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. dry compressor air. Install pressure relief on the customer resource plumbing to the evaporator. The shut down immediately shuts off the resource flow through the system. dump. Water-quality management.

The upper set of pressure relief valves is installed in on site to prevent shipping damage. the induction generator supplies power by operating at slightly greater than grid frequency (socalled negative slip). The customer is responsible for consulting the appropriate handbooks or codes to confirm that the site design complies with local and national electric codes. an induction generator is self-synchronizing and can be started as an induction motor. For the utility’s planning purposes. Grid Interconnection Grid interconnection of the PureCycle system typically requires permitting. 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. An induction generator is the counterpart to an induction motor. as shown in Figure 13.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. Electrical Requirements The PureCycle power system has electrical connections that must be made in the field. Because the permitting and interconnection agreement process can be lengthy. SITE DESIGN REQUIREMENTS Revision B – 09/23/2009 – Page 24 HTE66510 . the pressure relieve valves must be piped outside. Discharge lines should be installed for safety and should be piped according to ASHRAE 15 and local codes. A soft starter and/or fluid assist are used to control and minimize the starting inrush current. including several power and control connections. Please refer to Appendix A for a list of typical interconnection agreement questions and data. interconnection agreements and metering. Dual pressure relief valves are included for maintenance ease and calibration. While an induction motor consumes power by operating at slightly below grid frequency. Unlike synchronous generator and inverter-based technologies. Pratt & Whitney Power Systems encourages the customer to conduct a grid interconnect study early in the project development. If the PureCycle power system is installed indoors. The amount of power supplied to the grid is controlled by torque applied from the turbine to the generator shaft. Standard electrical drawings (Electrical Installation Drawing Set HTE73478 or HTE73520) are available as a reference.

Alternate voltage options are available for 380/400/415-volt service. Protective Functions The PureCycle power system has several self-protection features and grid-protection equipment. 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. The facility or installation must be capable of providing the RMS current requirements for a single unit start up shown in Figure 14. This circuit delivers the power generated by the power plant and also provides the source for start up power. Utility Grid Line Voltage and Site Transformers The PureCycle power system utilizes an induction generator rated for 480-volt service. 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 SITE DESIGN REQUIREMENTS Revision B – 09/23/2009 – Page 25 HTE66510 . 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. Please refer to Appendix A for detail on the disconnect switch rating. The customer is also responsible for conducting any special tests required by the utility to verify functionality of the interconnection protection protocols. Typical RMS Current Requirement for a Single PureCycle® Power System Generator Start as Motor 800 Approximately 800 Amps 700 Approximately 600 Amps Induction Machine approaches synchronous speed and is connected directly to the utility source via contactors by the starter 600 RMS Current (Amps) 500 400 Induction Machine is started by a phase controlled solid state starter as a motor and imports KVA from the 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 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.

For example. The time delay must exceed the maximum motor run times discussed above to assure normal operation (20 + 30) sec*1.2 Over Frequency Under Frequency The PureCycle system internally monitors power production and consumption. 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.95 lagging.Grid Protection Relay The PureCycle power system requires grid protection functions. This button will cause the safety chain in the system to trip and initiate an emergency shut down. Please refer to the Electrical Installation Drawings (HTE73478 or HTE73520) for the programming details.25 margin = 62. shutdown occurs if time exceeds 30 seconds. is also provided in the ECS cabinet.25 margin = 28 kVA). the reverse power setting should be between the KVA of the unloaded motor (√3*460 VAC*57A = 45. The button will not disconnect the electrical feed to the unit.0. If reverse power protection is required to provide protection against extended operation as a motor. This corresponds to 3750 cycles for 60 Hz. this is not recommended as a standard method for shutting down the unit. Therefore. During states where the unit is expected to motor. The utility provides the electrical ground for the system. Please refer to the applicable codes for grounding all equipment. operates in series with the emergency stop. Pratt & Whitney Power System's management server must be able to access the power plant on demand SITE DESIGN REQUIREMENTS Revision B – 09/23/2009 – Page 26 HTE66510 . This relay can be programmed to meet the utility’s requirements. An interface for an optional remote E-stop. Emergency Stop Button An emergency stop (E-Stop) button is installed on the LOI located on the front panel of the ECS cabinet. Since the E-stop button causes the unit to shut down in an abnormal manner. Typical trip programming is shown in the table below.2 Phase Over Voltage 1. typically served by a multifunction protective relay provided by the customer. The unit will shut down on low gross power in all power generating states when power is < 80 kW. the customer must procure and install a separate protective relay at the site.1 PU. The PWPS warranty requires this high-speed connection. Power Factor Correction The PureCycle power system contains power factor correction equipment capable of maintaining a power factor greater than 0. This ground is attached to the equipment and chassis grounds for the power module and condenser. the unit will not go Black when the E-stop button is pushed. 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.4 kVA) and the maximum expected power draw from the support systems during a start up (22*1. 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.5 sec). for a single PureCycle unit with a 300 kVA generator rating. Grounding Plan The PureCycle power system utilizes a single-point ground at the utility interface. This corresponds to . Table 7 – Typical Grid Protection Relay Programming Symbol 27 59 81O 81U Function Phase Under Voltage 1. The evaporator and other ancillary equipment may require a separate ground.

3-phase with ground RECOMMENDED WIRING SIZE Two 350 MCM wire per phase One 1AWG ground wire Wiring rated to 90°C (194°F) CONDUIT Two 3” – 3 ½” ECS Connections TB1-10. 3 phase. per PWPS standard electrical installation drawings (Single Unit Installation. A site telephone line is recommended to facilitate communications for on-site service personnel. It is expected that the customer provide for the Internet connection per the listed requirements. A typical setup consists of an external IP address provided through a local ISP such as a cable or phone company. In order to use the web site. Electrical Interfaces and Field-Installed Wiring The following table identifies the electrical connections that must be installed at the site. 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. Use of the router is intended to limit the number of ports open through a customer's firewalls. The remote monitoring system uses WebCTRL® software with appropriate remote hardware. HTE73520 . Table 8 – Electrical Connections SYSTEM ELECTRICAL INTERCONNECTIONS Disconnect switch INTERCONNECTION POINT Grid connection SERVICE 480 VAC. TB1-11 ESW1 RMS02 TB4-9. The server polls the remote device and continually stores the data.Multi-Unit Installation). access to the internet and Microsoft® Internet Explorer® with Java® are required. SITE DESIGN REQUIREMENTS Revision B – 09/23/2009 – Page 27 HTE66510 . TB4-10 External grid protection Relay Ethernet port Analog phone line (optional) Remote e-stop (optional) (Jumpered by default) Signal – dry contact Communication Communication Signal – dry contact 16AWG Cat 5e RJ45 Max wire length 100 m (328 ft) RJ11 16AWG 3/4” 3/4” 3/4” 3/4” Summary of Customer-Provided Utilities and Materials The customer is responsible for engineering and procuring the following utilities and materials:   480-volt. and the remote monitoring device must be able to query the server on demand through the same ports.through the standard BACnet ports 47806 to 47808. 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. 600 amp service Dedicated high-speed Internet physical broadband connection with a unique static IP address. It also generates displays on demand for service and customer use to monitor and control some aspects of the power plant. as it is the best positioned to determine the best method of communication. Inc. Access to the remote monitoring service by the customer is provided through a web site. 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 good judgment and safety precautions to avoid damage to equipment and property or injury to personnel. When operating this equipment. 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 Revision B – 09/23/2009 – Page 28 HTE66510 .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.

Pickup settings 2. System operates only in grid parallel mode. Is the application for new generating capability or an addition to existing generating capability? Is there net metering? Will the power be used to supply power to the interconnection customer (will the power be consumed on-site)? Will the power be used to supply power to others (exported to the interconnecting utility grid)? If so. Transient direct axis reactance (PU) Pratt & Whitney Power Systems PureCycle Model 280 Power System Induction Baldor Electric Company. how much power is expected to be exported? 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. SC Model V02XR24001725GN 0.296 gross output of generator 0. N/A This is an induction generator system that will operate only in grid synchronization. Nominal voltage and acceptable voltage range (volts ±%) F. Maximum gross output (MW) D. SC time constant = 0. Load rating. 5.050 sec C. 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. OV 110% UF 57 Hz OF 60. Greenville. Estimated load factor. Prime Mover Manufacturer Model Name A. Substransient Reactance = 0. Minimum/maximum excitation limits J. Stability Data: 1.280 gross out put of generator Internal PFC capacitors provided to yield pf ~ 0. Additional questions typically asked by the interconnecting utility include those listed below. Excitation system data 4. Upon loss of the grid. Interconnecting circuit breaker (disconnect switch) 1. Please contact your Pratt & Whitney Power Systems representative for further assistance. Inertia of turbine/generator (sec) 2. interrupting rating K.347 sec See generator data sheet A. utility or customer to provide balance of reactive power. 65 KAIC Fault Rating Beckwith Electric Company Model 3410A or equivalent.95 at rated power 480 volt + 10%.95 at rated power. VOLTAGE/FREQUENCY LIMITS 1. Rated lagging power factor E. 3. Revision B – 09/23/2009 – Page 29 HTE66510 . Answers will vary by site.APPENDIX A – TYPICAL INTERCONNECTION AGREEMENT DATA The table below provides typical data requested during an interconnection study or interconnection agreement application. the system will shut down. 4. Roll off rates I. OC time constant = 2. Interconnection protective relay 0. number of hours/year of operation or MWh/year G. UV 88%. -12% 100% rated operation 3. 1.1345 B.193 sec Internal PFC capacitors provided to yield pf ~ 0.5 Hz UV 2 seconds. Manufacturer 2. Governor data and Laplace transform block diagrams of the control equipment H. Type of generating unit Manufacturer B. OV 1 seconds UF 10 cycles. 2. OF 10 cycles N/A Induction Generator Siemens Model SHMD69600A 600 A Load Rating. Rated MVA C.

please provide the following minimum required information by completing the attached Project Requirements Document (PRD) and returning to Patti Orlowski (patricia. ave/min/max (ºF/ºC) Hot months Hot months Hot months Cold months Cold months Cold months APPENDIX B – PROJECT REQUIREMENTS DOCUMENT Revision B – 09/23/2009 – Page 30 HTE66510 . pH.APPENDIX B – PROJECT REQUIREMENTS DOCUMENT To estimate net output and other PureCycle power system performance parameters for a specific application.utc.5 l/s) Thot = 300°F (150°C). Tcold range 50°-80°F (10°C-27°C). Cold Flow = 1100 . 4°C-27°C) Outlet temp restriction (if any) Water quality report Cooling tower Holding pond River water Ground water Sea water Other Attached Available cold flow rate (gpm or kg/s) Type of cold water source Answer the following questions if a cooling tower will be utilized Existing New Make/Model Source of make up water Local air temp. Hot Flow* = 150GPM (11. salinity.4 l/s). Cold Flow = 950 .com) at PWPS. Hot Flow* = 1100GPM (69.4 l/s).1300GPM (72. etc. Tcold range 50°-80°F (10°C-27°C). ave/min/max (ºF/ºC) Relative humidity or Wet bulb temp.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): (195°F-300°F.orlowski@pw. 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 Project Developer Power Producer Engineering/EPC Energy Efficiency Operating Window (Typical flow requirements for 260kW max net power with water as hot liquid source) Thot = 195°F (90°C). 90°C-150°C) Outlet temp restriction (if any) Water quality report Existing Geothermal Industrial process New Oil & gas wells Biomass boiler Engine jacket Water Solar thermal Engine exhaust Other Attached Available hot flow rate (gpm or kg/s) Existing or new hot water source Type of hot water source Known hot water quality issues (TDS.) Cold Water Source Tcold – Temperature of source input (ºF/ºC) (50°F-80°F.

codes.2 m) of service clearance for equipment Site sketch Distance from power plant to grid (transmission lines) List non-standard requirements. expected PPA price (US ¢/kWh) If power consumed on site. 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? Retrofit Outdoor Telephone Yes Attached Replacement Indoor Internet No (explain) Other high speed Yes Yes Yes Yes Yes Yes No No No No No 10-20 Years Attached Attached Passed 20+ Years 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? Yes Truck Yes Yes No Other (describe) No No APPENDIX B – PROJECT REQUIREMENTS DOCUMENT Revision B – 09/23/2009 – Page 31 HTE66510 . or for sale to the grid If power sale to the grid. are new wells required? For geothermal. current power cost (US¢/kWh) Power plant startup and synchronization source Grid-connect 60Hz 50Hz Diesel gensets 480V 415V Other (describe) 400V Greenfield 380V Yes On-Site No Grid Installation type Location of unit Communication means for remote monitoring system Minimum 4 ft (1.Project and Installation Information Do you have project financing in place? Power consumed on-site. regulations For geothermal.

Revision A – 09/23/2009 HTE75367 . All Rights Reserved.Product Data and Application Guide Supplement Hot Liquid to Electricity Power System Nominal 280 kW Power PURECYCLE® POWER SYSTEM MODEL 280 Copyright 2009 Pratt & Whitney Power Systems. Inc.

without notice. 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. You may not copy or disclose this document or any information in it. and may be registered in the United States and other countries. from any source. This Product Data and Application Guide is provided by Pratt & Whitney Power Systems for informational purposes only. Pratt & Whitney Power Systems reserves the right to change or modify. including without limitation. or obtain any government approval to do so. for any purpose. constitutes such permission.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. PureCycle® is a registered trademark of United Technologies Corporation or its affiliates. Neither receipt nor possession of this document alone. without PWPS’s express written permission. to design. manufacture or repair parts. Revision A – 09/23/2009 – Page 2 HTE75367 . a copy of which will be provided upon request. Copying or disclosure by anyone without PWPS’s express written permission is not authorized and may result in criminal and/or civil liability. the design or equipment specifications of the PureCycle power system without obligation with respect to equipment either previously sold or to be sold. and no liability will accrue to Pratt & Whitney Power Systems based on the information or specifications included herein.

.......................................................................2 PureCycle Power System Reference Documents .............. 5 Power Output ..............................................................4 Revision History .................................................................5 Application Guidelines.......................TABLE OF CONTENTS Disclaimer .................................................4 Overview.......................... 5 Hot-Liquid-Resource Temperature and Flow 5 Cooling Tower.................... 6 Revision A – 09/23/2009 – Page 3 HTE75367 ....................................................................

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 A Date 09/23/2009 Original Issue Reason for Change Revision A – 09/23/2009 – Page 4 HTE75367 .

Additional performance parameters are provided herein for site design assistance. Multiple systems can be installed if sufficient flow is available. 60 Hz/480V Carbon Steel Evaporator. 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. Two machines operating in parallel would require twice the flow of one machine.6ºC) Cooling Water Inlet Temperature 60ºF (15.5ºC) Cooling Water Inlet Temperature 70ºF (21ºC) Cooling Water Inlet Temperature 50ºF (10ºC) Cooling Water Inlet Temperature 97 92 87 82 950 1000 1050 1100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 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 Revision A – 09/23/2009 – Page 5 HTE75367 Resource Temperature (ºC) Resource Temperature (ºF) 270 132 . For information on applications outside of these temperature and flow ranges. APPLICATION GUIDELINES Power Output Power output is a function of installation-specific variables. The hot resource flow required to produce full power output varies between 180 and 1100 gpm and is a function of installation-specific variables. PureCycle® Model 280 Performance 280 kW Gross. 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. including resource liquid temperature and cooling water temperature.OVERVIEW OVERVIEW This document is intended to be a supplement to the PureCycle power system Product Data and Application Guide (HTE66510). including resource liquid temperature and flow rate and cooling water temperatures. Copper Condenser Resource Flow (l/s) 6 300 290 280 11 16 21 26 31 36 41 46 51 56 61 66 147 142 137 260 250 240 230 220 Below Minimum Evaporat or Flow Rate 127 122 117 112 107 102 210 200 190 180 100 80ºF (26. 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. This document will describe the influence of these installation-specific variables and provide guidelines for system performance. please complete the PRD in Appendix B and consult your PWPS sales consultant or applications engineer. 260 kW Net.

Typical cooling water flow rates are shown in Figure 2 at several common temperature differences. 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). the design ambient wet-bulb temperature.5ºC) 98 88 78 1400 1200 dT = 15º F (8.3ºC) 1000 68 58 800 dT = 18º F (10ºC) 600 190 48 38 300 200 210 220 230 240 250 260 270 280 290 Resource Temperature (ºF) Figure 2 .Cooling Water Flow Rate Requirements Revision A – 09/23/2009 – Page 6 Cooling Flow Rate (l/s) HTE75367 .APPLICATION GUIDELINES Cooling Tower Sizing and selection of a cooling tower are dependent on knowing the heat rejection from the condenser. Contact cooling tower manufacturers to assist with sizing the tower to the specific application. PureCycle® Model 280 Approximate Cooling Flow Requirements Resource Temperature (ºC) 90 2200 95 100 105 110 115 120 125 130 135 140 145 138 128 118 1800 2000 Cooling Flow Rate (gpm) 108 1600 dT = 10º F (5.