Geothermal Power

WORLD-CLASS RESULTS.

GEOTHERMAL POWER

World-class skills. World-class team.

GEOTHERMAL STEAMFIELD & POWER PLANT ENGINEERS

42 George Street, Mt Eden, Auckland 1024, New Zealand P: +64 9 638 3447 E: [email protected] www.mtlnz.co.nz Mechanical, Civil & Structural Engineers HYDRO GEOTHERMAL THERMAL WATER INDUSTRIAL HYDRO GEOTHERMAL THERMAL WATER INDUSTRIAL GEOTHERMAL POWER GEOTHERMAL POWER GEOTHERMAL POWER

Front End Engineering Don Purdie Input and review of design Chris Mann Process / Mechanical Design concepts for operation and Project and Contract Project & Contract Management Detailed Design cost effectiveness Civil Structural Management, Commissioning Commissioning Management Steamfield, Design to accommodate Management and HAZOP Asset Management Power Station and challenges faced with Facilitator balance of plant geothermal structures

Project Management Commissioning Management of risk, Power Station design teams, project and Steamfield programme, Commissioning procurement and Matt Chubb Phillip Orr construction contracts. Civil and Structural Geothermal Implementation of Design Steamfield project controls Project & Contract Design HAZOP Management Design risk Asset Management assessments of Geothermal Controls* Power Stations Specialist *We partner with Electrical geothermal and Controls Consultants controls WORLD-CLASS SKILLS. experience WORLD-CLASS TEAM. Key Software Capabilities: Process Modelling – Fluid Flow Head Loss – Pipeflow Process Design Transient Modelling – Hytran Pipe Stress Analysis – AutoPipe Steamfield and power plant Electrical* Pipe FEA – Nozzle Pro selection including power Application of electrical Pressure Vessel Design – PV Elite James Powell plant optimisation systems adapted for Stephen Kennedy MTL’s core Microstran – Structural Frame Analysis Project Management, Value Engineering the geothermal industry Design Management, Process Design – AutoCAD P&ID Contract Management, geothermal design Application of geothermal Detailed Engineering Piping Design – AutoCAD Plant 3D Procurement, knowledge to optimise Design skills available. Parametric Modelling – Inventor Scheduling construction cost Structural Design – Revit

ABOUT MTL GEOTHERMAL PROJECTS MTL EXPERIENCE DESIGN PROCESS SKILLS & KNOWLEDGE MTL ROLE MTL, established in 1994 is a Key projects include Steamfield We have experience in preparing MTL follows a formal design process Collectively MTL’s geothermal We believe we have a unique offering medium sized owner operated detailed design for Karaha and Lumat geothermal feasibility studies, detailed for geothermal steamfield design, engineering personnel have a due to our range of skills and our engineering design consultancy Balai Geothermal Power Projects geothermal power station and steamfield utilising industry standard P&ID’s significant amount of specialist organisation’s size. located in Auckland, New Zealand in Indonesia, Owners Engineer for design, geothermal plant procurement, and Engineering Lists to define knowledge and experience to draw We are able to work closely with employing Mechanical Engineers, Olkaria 1 Unit 6 Steamfield in Kenya power station and steamfield the equipment and interfaces. This on. An overview of some of our key clients and partner consultants* to Designers, Civil and Structural and Steamfield detailed design for construction management and practice is also used on existing geothermal engineering personnel repeatedly provide quality results. Engineers and Project Managers. Ngatamariki Geothermal Power commissioning and HAZOP Facilitation. plants, where accurate P&ID’s are and partner consultants* can be Project in New Zealand. We offer the complete package from used to manage plant upgrades, and provided upon request. project feasibility to handover. automation projects.

www.mtlnz.co.nz World-class skills. World-class team. Mechanical, Civil & Structural Engineers GEOTHERMAL POWER GEOTHERMAL POWER GEOTHERMAL POWER

www.mtlnz.co.nz World-class skills. World-class team. Mechanical, Civil & Structural Engineers SELECTED MTL GEOTHERMAL PROJECTS

55 MW POIHIPI 50 MW LIHIR WAIRAKEI REINJECTION 30MW KARAHA GEOTHERMAL GEOTHERMAL SYSTEM DESIGN 90 MW NGATAMARIKI STEAMFIELD DESIGN PROJECT PROJECT PROJECT STEAMFIELD DESIGN

70 MW OLKARIA 1 16.5 MW EXORKA MOKAI II EXPANSION UNIT 6 STEAMFIELD, SAN JACINTO STEAMFIELD DESIGN KENYA PROJECT

1997 2001 2003 2005 2007 2009 2011 2013 2015 2017

250 MW TAUHARA TE MIHI STEAMFIELD 55MW LUMUT BALAI CONCEPT DESIGN PROCESS DESIGN STEAMFIELD DESIGN

5 MW ROTOKAWA WAYANG WINDU II KA-51 BRINE 80 MW MUARA LABOH OEC21 DESIGN ASSISTANCE REINJECTION LINE STEAMFIELD DESIGN

www.mtlnz.co.nz HYDRO GEOTHERMAL THERMAL WATER INDUSTRIAL GEOTHERMAL POWER Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz www.mtlnz.co.nz OLKARIA 1 UNIT 6 OWNERS ENGINEER OWNERS 6 UNIT 1 OLKARIA PROJECT PARTNERS: PROJECT PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: Fichtner, McMahon Electrical. MTL has worked closely with KenGen to produce a comprehensive a comprehensive produce to closely with KenGen MTL has worked project is preliminary requirements. The design that suits KenGen’s stage. currently in tender MTL is performing the role as the steamfield Owners Engineer. Fichtner the role as the steamfield MTL is performing the Geothermal Power Owners Engineer Services for are providing three into wells gathered utilises 12 production steamfield Plant. The country cross of piping. 14km of with a total plants separation KenGen are custodians of a significant geothermal resource in the Rift resource geothermal a significant of are custodians KenGen KenGen’s will add 70MW to I Unit 6 project Olkaria The Kenya. Valley, to optimise The project aim is capability. geothermal significant minimising project wells, unutilised production existing, the use of risks. development 70 MW Geothermal Steamfield. Fichtner / KenGen, Rift Valley, Kenya RiftFichtner / KenGen, Valley, GEOTHERMAL POWER Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz www.mtlnz.co.nz KARAHA STEAMFIELD DESIGN STEAMFIELD KARAHA PROJECT PARTNERS: PROJECT PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: Hawkins / BCK, McMahon Electrical, Beta. / BCK, McMahon Electrical, Hawkins MTL worked closely with the constructors to produce an optimised produce to closely with the constructors MTL worked was successfully The design topography. the difficult design for phase is currently underway. and construction delivered The steamfield consists of 22km of cross-country piping on steep of cross-countryof 22km piping on steep consists steamfield The (clusters), production wellpads along with four mountainous terrain, steep The plants and pump stations. separation which included of three and mechanical both the process, challenges for posed many terrain civil design. MTL was the steamfield (FCRS) detailed designer for the EPC contract contract for the EPC designer (FCRS) detailed the steamfield MTL was in is located development The Plant. Power build the 30MW Karaha to operator for Indonesia, and is being constructed Province, Java the West wells. and new Pertamina Geothermal Energy (PGE) using existing 30MW Geothermal Power Plant. 30MW Geothermal Power (Fluid Collection and Reinjection System) (Fluid Collection / BCK Singapore Ltd Hawkins GEOTHERMAL Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz www.mtlnz.co.nz WELLHEAD PIPING WELLHEAD Central North Island, New Zealand North Island, New Central PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: The project was completed in June 2013. completed project was The The design connected the well via a DN300 line to the existing cross over cross over the existing to via a DN300 line the well design connected The the included design of Our scope production systems. piping between and pressure relief. bypasses such as drains, secondary systems MTL carried out the detailed design of the wellhead piping including the piping the wellhead out the detailed design of MTL carried and foundations. the pipe supports design of civil and structural Connection of a wellhead into the existing wellhead manifold. wellhead the existing into a wellhead of Connection GEOTHERMAL POWER Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz www.mtlnz.co.nz PRODUCTION PIPING PRODUCTION PROJECT PARTNERS PROJECT PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: Transfield Worley. Transfield The project was constructed in 2013, and started producing in 2014. in 2013, and started constructed project was The their a pipeline that suited deliver closely with the client to MTL worked sound and efficientrequirements while offering engineering solutions. The wellhead piping had the challenges of an unusually high design an unusually of piping had the challenges wellhead The phase pipeline is two 112barg and 320°C. The of pressure and temperature two the existing pad to DN500 and runs 1.1km from the production well phase production line. MTL were engaged as the designer to connect the new production well into into production well the new connect the designer to engaged as MTL were detailed design included the design The production piping system. existing cross country piping, tie-in two-phase piping, the high pressure wellhead of all pipe supports and foundations. design of piping and civil/structural Connection of production well to Power Station production facilities. Power to production well of Connection Central North Island, New Zealand North Island, New Central GEOTHERMAL Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz Market Award “BEST 2013 PROJECT” World GeoPower World www.mtlnz.co.nz NGATAMARIKI STEAMFIELD NGATAMARIKI Hawkins Infrastructure Ltd, Central North Island Central Ltd, Infrastructure Hawkins PROJECT PARTNERS: PROJECT PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: Mercury NZ, Hawkins Infrastructure, McMahon Electrical. The project is fully operational. The design was completed under completed design was The project is fully operational. The met. were ensure that project objectives to tight time constraints the Steamfield, of closely with the constructor required working This ensure timely delivery the project. to of Infrastructure Hawkins The production well pads included for well minimum flow systems to allow to allow systems minimum flow well pads included for production well The The minimum flow shutdowns. during Steamfield operation well continued that included to be developed, systems fluid handling required separated and reinjection pumping systems. brine reticulation, storage brine cooling, MTL were part of a design build team for the Steamfield led by Hawkins by Hawkins led the Steamfield for team a design build part of MTL were 2 including Steamfield of 7.5km over of detailed design The Infrastructure. production and hot reinjection well brine pipework, phase pipework, system. injection pumping condensate vessels and pad piping, flash design included DN750 and DN900 2 phase piping and support The channels. water and cooling systems Steamfield to serve the 82 MW Ngatamariki Geothermal Power Station. to serve MW Ngatamariki Geothermal Power the 82 Steamfield GEOTHERMAL POWER World-class skills. World-class team. skills. World-class World-class Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, www.mtlnz.co.nz www.mtlnz.co.nz TE MIHI REINJECTION PUMP STATION TE MIHI REINJECTION PROJECT PARTNERS: PROJECT PROJECT OUTCOME: PROJECT MTL ROLE: PROJECT: MB Century, McMahon Engineering Consultants, and Sigma Consulting. MB Century, McMahon Engineering Consultants, The Karapiti Pump Station has been in operation since 2011, providing 2011, providing since Pump Station has been in operation Karapiti The of brine. 3000 tonnes/day reliable service over re-injecting The design accommodates a range of different operating scenarios that scenarios operating of different a range design accommodates The Stations their Power in operating Energy with flexibility Contact provides cleaning pump assembly for of a complete removal safe for and allows of the pump station. An OPEX analysis offsite while maintaining operation identify to the as part of the final pump selection process completed was optimum configuration. MTL undertook the detailed design of Contact Energy’s Karapiti Pump Energy’s Karapiti the detailed design of Contact MTL undertook to for the brine reinjection for which provides facility Station, a critical 132 MW and Poihipi 164 MW, Wairakei Stations; TeMihi Power three Contact (brine) water pump station re-injects geothermal separated The 55 MW. discharged from the production wells. Te Mihi Steamfield Geothermal Reinjection Pump Station. Mihi Steamfield Te Contact Energy, New Zealand Energy, New Contact GEOTHERMAL Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz www.mtlnz.co.nz TE MIHI STEAMFIELD MIHI TE Contact Energy. New Zealand. New Energy. Contact PROJECT PARTNERS: PROJECT PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: MB Century, Consulting. McMahon and Sigma The Te Mihi steamfield has been operating successfully since 2014, supplying since successfully has been operating Mihi steamfield Te The Station, and re-injecting over Mihi Power Te to water and separated steam brine. of 3000 tonnes/day A flexible process design was required to accommodate the various stages the to accommodate was required design process A flexible covered design station. Process power the new with integrating involved pressure intermediate plants, dump systems, separation phase systems, two for condensate water, pressure separated low systems, water separated reinjection systems. water reinjection, and separated Process design for the expanded Te Mihi steamfield serving Mihi steamfield the new Te the expanded design for Process Station. Power old Wairakei Station and the 60 year Power Mihi Te 162 MW Te Mihi Steamfield process design, Pump Station detailed design. process Mihi Steamfield 162 MW Te GEOTHERMAL POWER Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz www.mtlnz.co.nz LIHIR GEOTHERMAL POWER STATION POWER GEOTHERMAL LIHIR PROJECT PARTNERS: PROJECT PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: Smec, Lihir Gold Ltd. The selection of turbine was interesting as 5 by 10 MW surplus second 10 MW surplus second as 5 by interesting turbine was selection of The blades. used, including reversing LP turbines were frigate war world a geothermal to suited turbines are very robust and well These a for successfully station has been operating power The application. supplying the gold mine. years number of MTL was engaged to provide detailed design for the Balance of Plant of the Balance detailed design for provide engaged to MTL was plant MW power stage 20 the first stage 30 MW, and second (BOP) for supervision construction and commissioning site projects. MTL provided the 10 MW steam the BOP on both stages, and commissioned for location. the remote of because challenging project was turbines. The 50 MW Geothermal Power Station. 50 MW Geothermal Power Lihir Gold Ltd, Papua New Guinea Papua New Lihir Gold Ltd, GEOTHERMAL Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz www.mtlnz.co.nz ROTOKAWA OEC21 ROTOKAWA Mercury NZ, Central North Island Mercury NZ, Central PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: The power plant has continued to operate successfully for over 10 years. over for successfully operate to plant has continued power The This project involved the construction of an Ormat 5 MW OEC plant to utilise an Ormat 5 MW OEC plant to of the construction project involved This from the available was The brine brine from the plant’s steamfield. excess from the hot fluid extracted at the plant inlet, and the energy separator the reinjection system. being passed to before MTL provided engineering services for this plant from initial procurement this plant services engineering for MTL provided during on site Our Engineers were plant commissioning. through to advice contractor, period, managing the mechanical construction the complete the workmanship. the quality of and overseeing 5 MW Geothermal Binary Power Station. 5 MW Geothermal Binary Power GEOTHERMAL POWER

Mechanical, Civil & Structural Engineers Civil & Structural Mechanical, World-class skills. World-class team. skills. World-class World-class www.mtlnz.co.nz www.mtlnz.co.nz POIHIPI POWER STATION POWER POIHIPI PROJECT PARTNERS: PROJECT PROJECT OUTCOME: PROJECT MTL ROLE: MTL PROJECT: that designed and built this 55 MW powerChris stationMann – inMTL 18 monthsProject Manager- a very tight “MTL’s experienced Mechanical Engineers were a key part of the team McMahon Electrical. Commissioned successfully in 1997 and has operated reliably since. The The reliably since. in 1997 and has operated successfully Commissioned control station and power steamfield an integrated station incorporates commissioned. of its kind when be the first thought to system, Design for the new 55 MW power station including; Preliminary design, from 55 MW power the new Design for initial layouts, through to drawings, Fuji turbine and generator of the receipt the Detailed design of principal plant procurement; plant arrangements, and instrumentation, and controls electrical, plant, mechanical, complete supervision; and Construction Commissioning construction; suitable for training. Operator 55 MW Geothermal Power Station. 55 MW Geothermal Power Mercury Geotherm Ltd, Central North Island, New Zealand. North Island, New Mercury Central Geotherm Ltd, project program for a project of this size” WORLD-CLASS RESULTS.

GEOTHEMAL POWER

World-class skills. World-class team.

GEOTHERMAL STEAMFIELD & POWER PLANT ENGINEERS