Geothermal Power Plant Excellence

Mitsubishi Geothermal Power Plant
December, 2012
2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.
CONTENTS 1. Supply Record 2. What we can do for you 3. Technologies for higher performance and reliabilities 5. Collaboration with PEI
2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2
1. Supply Record
Supply Record of Mitsubishi Geothermal Power Plant
Total Output 3,103 MW Total Unit 102 Units Coped with Different Steam & Brine in 13 Countries
As of 2012 December
Iceland 15-Units 565 MW Greece 1-Unit 2 MW Turkey 2-Unit 94.8 MW Japan 14-Units 272.3 MW Mexico 12-Units 210 MW
USA 18-Units 511.5 MW
Portugal 1-Unit 3 MW
Phillipine 19-Units 702.7 MW Indonesia 6-Units 386.3 MW
Kenya 6-Units 149.8 MW
El Salvador 3-Units 61.1 MW
Costa Rica 2-Units 32 MW
New Zealand 3-Units 113 MW

4
Projects in Indonesia ( KAMOJANG #1, 2 & 3)

Specification #1 Unit OD: 1983 5 stage2, Condensing, Down Exhaust 17 inch 30,000 kW 3,000 rpm 0.65 MPa 162 C 240 t/h 0.013 MPa
Type Last Stage Blade Output Speed Pressure Temp. Flow Rate Exhaust Pressure
#2 & 3 Unit OD: 1987 5 stage2, Condensing, Down Exhaust 23 inch 55,000 kW 3,000 rpm 0.65 MPa 162 C 380 t/h 0.01 MPa
Projects in Indonesia ( DARAJAT #1)
Specification Type Last Stage Blade Output Speed Pressure Temperature Flow Rate Exhaust Pressure
OD: 1994
6 Stages x 2, Condensing, Down Exhaust 23 inch 55,000 kW 3,000 rpm 0.95 MPa 180 340 t/h 0.01 MPa
Projects in Indonesia ( DARAJAT #2, 3)

OD: 2000 (#2), 2007 (#3) 8 Stages x 2, Condensing, Down Exhaust 30 inch ISB 81,300 kW (#2) 110,000 kW (#3) 3,000 rpm 1.35 MPa (#2) 1.45 MPa (#3) 193 (#2) 199 (#3) 450 t/h (#2) 630 t/h (#3) 0.006 MPa (#2) 0.008 MPa (#3)
7
Share in the World
G 5.6% 5.1% O 10.3% A 10.7%
Others
MHI 24.6% T 23.6%
F 20.1%
Share in total (MW basis)

Ref. Proceedings World Geothermal Congress 2010 Geothermal Power Generation in the World 2005-2010 Update Report
Wide Output Range from 100kW to 151MW
TC4F
160
APPRICATION RANGE (MW)
90 70 50 30 10 1 0
1 1 1 1 4 12 12 18 14 14 8 9 5 5 10
UNITS
SC2F
Approx. 120MW
Approx. 60MW
SC1F
15
20
Number of Casing (Exhaust Flow)

ST TYPE SC1 F SC2 F TC4 F 0 2 20 40 60 UNITS 80 31 67
10
Turbine Exhaust Direction

ST EXHAUST DIRECTION
Turbine Condenser
AXIAL LOWER UPPER 0

Turbine
13 37 50 20 40 UNITS 60
Turbine Condenser
Condenser
11
Plant Cycle
PLANT CYCLE
Separator Aux. Steam Gas Extractor Ejector Non-condensable Gas
Dry Steam Single Flash Double Flash
7 75 16 2 20
Evaporator Binary Turbine
Condenser Steam Production Well Cooling Water Turbine Reinjection Well Hot Well Pump Cooling Tower
Binary 0
Separator
Single Flash Cycle
40 UNITS
Generator
60
80
Separator
Gas Extractor Ejector Non-condensable Gas
HP Steam Production Well
Turbine
Production Well
Preheater
Recuperator Cooling Water LP Steam Reinjection Well Condenser Hot Well Pump Cooling Tower Reinjection Well Condenser CWP Work Fluid Pump Cooling Tower
Double Flash Cycle
Binary Cycle
12
RECENT PROJECTS
13
ICELAND HELLISHEIDI #1#6
14

GENERATOR
FL 3300 FL 1925
TURBINE
CONDENSER
FL 0
Specification Type Last Stage Blade Output Speed Pressure Temperature Exhaust Pressure
#1 ~ 4(COD2006,2008) 6 stage x 1, Condensing, Axial Exhaust 30 inch ISB 40,000 kW 4 units 3,000 rpm 0.75 MPa 168 C 0.01 MPa
#5, 6(COD 2010) 45,000 kW 2 units

15
TURBINE SECTIONAL DRAWING
16
Low Turbine House (Crane Level)

CRANE
17

Complete Turbine Module fully assembled before Shipping
18

Complete Turbine Module fully assembled before Shipping
19
KENYA OLKARIA #1~#3
Specification OD: #1,2 2003, #3 2010 Type Last Stage Blade Output Speed Pressure Temperature Flow Rate Exhaust Pressure 6Stages x 1, Condensing, Down Exhaust 30 inch 34,830 kW 3,000 rpm 0.5 MPa 150 389 t/h 0.007 MPa
20
TURKEY GERMENCIK
Specification Type Last Stage Blade Output Speed Pressure Temperature Exhaust Pressure
Feature
OD: 2009
6 Stages x 2, Condensing, Top Exhaust 24 inch ISB 47,400 kW 3,000 rpm 0.588 MPa 158 0.02 MPa
High Gas Content: 12.4% in HP steam High Availability: 99.9% in first year
ICELAND NESJAVELLIR #1~ #4

Specification OD: 1998 (Unit#1,2), 2001 (Unit#3), 2005 (Unit#4) Type Last Stage Blade Output Speed Pressure Temperature Flow Rate Exhaust Pressure
8 Stages x 1, Condensing, Top Exhaust 24 inch 30,000 kW (Rated), 3,000 rpm 1.2 MPa 188 206.1 t/h 0.02MPa
22
JAPAN SUMIKAWA
Feature Applied Top Exhaust Design to Double Flow Turbine Water Cooled Nozzle
OD: 1995 5Stages x 2, Condensing, Top Exhaust 23 inch 50,000 kW 3,000 rpm 0.49 MPa 151 389 t/h 0.011 MPa
2. What we can do for you
24
Unit Output
If you provide
- Production Well Characteristic
- Atmospheric Conditions (Pressure and Wet Bulb Temperature)
MHI propose ECONOMICAL Plant with

- Optimum Cycle - Optimum Design Conditions Main Steam Pressure Condenser Pressure Wet Bulb Temperature - Plant Output based on above conditions
- Optimum Turbine Type with minimum exhaust loss
25
Single Flash Cycle
Separator Aux. Steam
Gas Ejector
Vacuum Pump Non-condensable Gas
Steam Production Well
Condenser
Cooling Water Turbine Reinjection Wel Hot Well Pump Cooling Tower
26
Double Flash Cycle
Separator
Gas Ejector
Vacuum Pump Non-condensable Gas
Condenser HP Steam Turbine Production Well LP Steam Reinjection Wel Cooling Water Cooling Tower Hot Well Pump
27
Advantage Double Flash
30.0 25.0
kW (%)
20.0 15.0 10.0 150
Bottom Hole Temp. ()
200
250
300
Calculated Conditions Brine flow rate of production well : Constant Turbine exhaust pressure : 0.1 bara HP main steam pressure : Optimized Pressure LP main steam pressure : Constant (1.2 bara)
Main Steam Pressure
600 500
Steam Flow (ton/h)
80
Generator Output (MW)
400 300 200 100 0 0 5 10 15 Main Steam Pressure (bara.)

Steam Flow
70
60
MW
X
Heat Drop in Turbine
50
Conditions : Turbine Exhaust Press. = 0.1 bara Inlet Steam : Saturated
40 0 5 10 15 Main Steam Pressure (bara.)
29
Main Steam Pressure
Wetness of Turbine Exhaust (%)
20
Exhaust Press. = 0.05 bara 0.10 bara 0.15 bara
15
10
5 0 5 10 15 Main Steam Pressure (bara.)

30
Condenser Pressure
Gross Output (A)
Output (MW) ($)
Parasitic Load (B)

Condenser Pressure (bara.) Condenser Pressure (bara.) Condenser Pressure (bara.)
(C) - (D) ($)
Optimum Pressure
Net Output (C) = (A) - (B)
Construction Cost ($)
Construction Cost (D)
31
Design Wet Bulb Temperature

Generator Output (%)
110
Case-2 Case-1
100
Case-1 Design Wet Bulb Temp. Generator Output Cost for Cooling Water System Low Low Low
Case-2 High High High
90 30 20 10 0 0 2 4 6 8
Case-2 Case-1
Design Wet Bulb Temp.
Wet Bulb Temp. ()
(month)
32
10 12
3. Technologies for higher performance and reliabilities
33
Standard Feature for Geothermal Steam Turbine

Last Stage Stationary Drain Groove/Hallow Blade Last Stage Rotating BladeStelight Shield Rotating Blade Integral Shroud Blade Rotating Blade Material12Cr, 17-4PH Nozzle Material 12Cr,18Cr-8Ni High Stress Part in Rotor Shot Peening Rotor Disc Low stress by Tapered Shape
Drain Chatcher
Rotor MaterialLow Sulfiur CrMoV Alloy
40
Optional Feature for Dirty Steam

CasingCarbon Steel Diaphragm Fitting Part : Stainless Welding
Rotor GlandInconel Coating for Low Sulfur CrMoV Alloy Rotor Material 12Cr Alloy
Rotating Blade Titanium Alloy
DiaphragmCarbon Steel Horizontal Surface and Fitting Part : Stainless Welding

41
3-D Design Blade

Conventional
Internal Efficiency Ratio
1.15 1.10 1.05 1.00 0.95 0.90 0.85

Conventional F3-D Nozzle
3-D Design
0.2 0.3 0.4 0.5 0.6 0.7 0.8
Velocity Ratio
Efficiency Improvement due to 3-D Nozzle
42
Erosion Protection
Drain Ditch on Stationary Blade
Hollow Nozzle
Stellite Strip on Moving Blade

Stellite Strip
To Turbine Exhaust Drain Hole Ditch Drain Hole Ditch Drain
43
Measures Against Scaling (at 1st Stage Nozzle)

How to Supervise Scrubber
Geothermal Steam Clean Steam Separator Injection Pump Clean Water ( 10 % of Steam) Drain with Impurity Steam Temp. Nozzle Metal Temp. To Turbine Clean Water ( 2 % of Steam) No Re-Evaporation Water Cooled Nozzle To Turbine Steam (Inlet) Concave Flow Area Steam Nozzle
Measures Scrubber & Blade Washing Water Cooled Nozzle

Width Convex Cooling Water To Water Cooler
Scaling
Blade Washing
Narrower Flow Area
Geothermal Steam
Steam (Outlet) ReEvaporation Conventional Nozzle
Cooling Water Hole
Less Output
Temperature Distribution
2% 2 Water Inject
GPxA
G: Flow Rate
1 A
Test Results in Actual Turbine

1 1 % Water Inject
(P/G) - (P/G)0
Conventional Nozzle
Water Cooled Nozzle
P: Pressure at Nozzle Inlet A: Nozzle Flow Area : Clean Condition (P/G)0 : Clogged Condition (P/G)0
0 10
Verification in Actual Turbine

5
After 9 Months Operation

0

24
48
72 (Hour)
44
PEEK LINING BEARING

PEEK : PolyEtherEtherKetone Higher allowable contact pressure
120
- Downsizing - Lower mechanical loss

Journal Bearing
Bearing Loss [%] %
100 100 80 80 60 60 40 40 20 20 0 0
62%
62% Reduction
Conventional (White metal)
PEEK
PEEK
Thrust Bearing
45
Rotor Gland Protection

Welding overlay and thermal spraying for rotor gland area were developed to protect a rotor from erosion-corrosion. Problem at Rotor Gland Area Air + Geothermal Steam Erosion/Corrosion Damaged part Countermeasure Inconel 625 (Welding overlay or Thermal spray)
Inconel 625 (thermal spray) Base metal
Damage on rotor gland
Thermal spray by Inconel 625

46
Material Selection for Geothermal Turbine

Rotor
1. Materials Low Sulfur CrMoV (10325MGB) Standard Material Low Susceptibility against SCC 12Cr (10325GSR) Very Corrosive Geothermal Steam Low Susceptibility against SCC Low Corrosive Rate High Toughness
For
Moving Blade
1. Materials 12Cr (10705BA) For Intermediate Stages 17-4PH (10705BX, 10725BX, 10725DW) For 1st Stage and Last 2 3 Stages Tensile Strength, Corrosion Fatigue Strength: Higher Corrosion Rate: Lower Titanium Alloy (Ti-6A-4V) 1st Stage in Very Corrosive Geothermal Steam Tensile Strength, Corrosion Fatigue Strength: Highest Corrosion Rate: Lowest
For
Failure Stress (kg/mm2)
2. Mechanical Properties
Property 0.2 % Yield Stress Tensile Strength Elongation Deduction in Area Absorbed Impact Energy at 25 50 % FATT Corrosion Rate* Unit MPa MPa % % J mm/Year 10325MGB 635 740 15 40 20 80 0.023 10325GSR1 635 740 16 45 30 40 0.0015
50 40 30 20
17-4PH Ti-6A-4V 12Cr Corrosion Fatigue Strength (in Geothermal Steam)

105 106 107 108
8 Corrosion Rate (mg/cm2/3 Months) 6 4 2
SS400 SB410
Corrosion Rate in Geothermal Steam

12CrMo SUS 304 SUS 316 17-4PH Ti-6A-4V
Susceptibility against SCC*
at
*:
0.2 x 3.3
at
0.2 x 3.3
Tested in Actual Geothermal Steam
Material
47
Exhaust Direction
Exhaust Direction TG Pedestal Turbine House (Crane Hook Height) Pressure Loss in Exhaust No. of Exhaust Flow
Turbine
Bottom Tall Tall (FL 16.4m) ~ Zero Any
Top Middle Middle (FL 13.5m) High Any
Axial Low Low (FL 10m) Recover Only 1 Flow
Turbine Condenser Turbine Condenser
Condenser
48
Condenser (Direct Contact, Shell & Tube)
Direct Contact Condenser

Condenser
Shell & Tube Condenser

Condenser
Cooling Tower Hotwell Pump Circ. Water Pump
Cooling Tower
Level difference between Cooling Tower and Condenser is required.
No Level difference between Cooling Tower and Condenser is required. Additional small condensate pump is required. NCG temperature is higher
49
Condenser (Direct Contact vs. Shell & Tube)
Direct Contact
Shell & Tube
Condenser at lower level than turbine.

Condenser at the same level as turbine.

50

Shell & Tube Condenser
51
Advanced Direct Contact Condenser (ADCC)
52
53
Fill Material
54
CONTROL SYSTEMS DEPARTMENT

Installation Records of DIASYS ( for Power Plant )
56
Installation Records of DIASYS ( for Geothermal Plant )
Nation ICELAND ICELAND ICELAND ICELAND MEXICO EL SALVADOR KENYA INDONESIA JAPAN JAPAN JAPAN JAPAN
Plant Name / Location KRAFLA NESJAVELLIR HELLISHEIDI HENGILL CERRO PRIETO AHUACHAPAN OLKARIA II DARAJAT TAKIGAMI OHNUMA YAMAGAWA OGIRI 2U
Unit
Capacity 30MW 30MW 40MW 45MW 25MW 30MW 35.1MW 110MW 25MW 12.5MW 30MW 30MW
3U,4U,COMMON 3U,4U 5U 1U,2U,3U,4U 1U,3U 1U,2U,3U 3U 1U 1U 1U 1U
57
High Speed , Critical and Scalability

Applied to Wide Range of Power Plant For Total DCS Use -Combined Cycle / Conventional Power / Coal Gasification -Plant Coordination Control / Automatic Start & Shutdown Control, Training Simulator For Critical Control Use -Steam/Gas Turbine Speed Control & Interlock System -Gas Engine / Turbine for Shipment -Super Critical Boiler For Utility Control Use -Desulfurizing Plant -Coal Handling -Water Treatment
58

Geothermal Power Plant Excellence

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Mitsubishi Geothermal Power Plant

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Supply Record of Mitsubishi Geothermal Power Plant

USA 18-Units 511.5 MW

Phillipine 19-Units 702.7 MW Indonesia 6-Units 386.3 MW

Kenya 6-Units 149.8 MW

El Salvador 3-Units 61.1 MW

Costa Rica 2-Units 32 MW

New Zealand 3-Units 113 MW

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Projects in Indonesia ( KAMOJANG #1, 2 & 3)

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Projects in Indonesia ( DARAJAT #1)

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Projects in Indonesia ( DARAJAT #2, 3)

Share in the World

G 5.6% 5.1% O 10.3% A 10.7%

MHI 24.6% T 23.6%

Share in total (MW basis)

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Wide Output Range from 100kW to 151MW

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Number of Casing (Exhaust Flow)

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Turbine Exhaust Direction

AXIAL LOWER UPPER 0

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Dry Steam Single Flash Double Flash

Single Flash Cycle

Gas Extractor Ejector Non-condensable Gas

HP Steam Production Well

Double Flash Cycle

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

ICELAND HELLISHEIDI #1#6

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

ICELAND HELLISHEIDI #1#6

#5, 6(COD 2010) 45,000 kW 2 units

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

ICELAND HELLISHEIDI #1#6

TURBINE SECTIONAL DRAWING

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

ICELAND HELLISHEIDI #1#6

Low Turbine House (Crane Level)

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

ICELAND HELLISHEIDI #1#6

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

ICELAND HELLISHEIDI #1#6

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

KENYA OLKARIA #1~#3

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

ICELAND NESJAVELLIR #1~ #4

2. What we can do for you

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

- Production Well Characteristic

- Atmospheric Conditions (Pressure and Wet Bulb Temperature)

MHI propose ECONOMICAL Plant with

- Optimum Turbine Type with minimum exhaust loss

2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Single Flash Cycle

Separator Aux. Steam

Vacuum Pump Non-condensable Gas