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55 Roc. 1 New Workshop 1989 THE CIRCULATING WATER AND GAS EXTRACTION SYSTEMS FOR OHAAKI POWER STATION D. P. Brown, N. R. Hall New Zealand Ltd, P 0 Box 668, Wellington 0PTIMISATION The paper provides discussion on two of the The second major influence on the systems key systems installed at Ohaaki Power Station: the being considered is the optimisation process circulating water and gas extraction systems. The required to ensure that minimum costs and maximum authors briefly consider the constraints placed on revenue are achieved. these systems by the environment, operating re- quirements and the optimisation process before The circulating water and gas extraction continuing to discuss the design decisions that led are not only capital and energy intensive to the final design. The systems, in terms of both in themselves but also have a significant effect on equipment and operation, are also described. the performance of the turbo-generator and hence power station efficiency and output. Optimisation procedures are therefore necessary to determine the JNTRODUCTION best solution based on the large number of often apparently conflicting variables. The development of Ohaaki during the a time of increasing concern as to the effects of The optimisation process for Ohaaki considered power developments on the environment, resulted in the turbine in association with the key components steamfield and power station systems designed with of the two systems. Traditionally such processes the environment in mind. would consider a single design point based on the limited meteorological data available; the key This paper addresses two of the power station parameters for the process being wet and dry' bulb systems that have been influenced by environmental temperatures and atmospheric pressure. In the considerations - the circulating water (CW) system, Ohaaki case, four years of on-site climate data was which provides cooling water for the intermediate available and therefore a computer programme was pressure (IP) turbo-generator condensers, and the developed to make use of this data and carry out gas extraction system, which removes the optimisation over the full range of anticipated able gases from the condenser. The approach used to conditions. meet the environmental constraints differs between the two systems - the system by either avoiding The complex model, previously described by discharge or using reinjection, and the gas ex- Pearce combined the effects of capital and traction system by encouraging the widest possible operating costs of the major plant items (turbines, dispersal of the discharge. condensers, CW pumps, gas exhausters, etc), their predicted performance data and predicted operating The paper also provides a brief insight into regime and the climatic data to determine the net the key design decisions and a description of the station value, this value being the difference systems and plant installed. between the capitalised value of the power gener- ated and the total cost of the plant. OPERATIONAL REO By maximising the net station value, the optimum key parameters of CW flow, cooling tower Before considering the design decisions made, design point, condenser pressure range, etc. can be it is necessary to review the other influences on determined. over a range of conditions them. The first of these is the operational re- results in plant sizing for the optimum. and not quirements imposed by both the geothermal resource necessarily the maximum duty point, the effects of and the electricity demand. The impracticality of .which will be discussed later. using a geothermal resource to supply vastly varying quantities of steam and the requirement for cheap continuous power to supplant more expensive generation dictated that Ohaaki would be a base load station. DESIGN DECISIONS Ohaaki is also relatively close to Wairakei A number of design decisions were made at a Power Station and the economics of operating it as very early stage based on anticipated environmental a stand alone power station were unattractive when considerations (Canvin (1989)). Others flowed from compared with making Ohaaki a satellite operation the optimisation process discussed above. from Wairakei. A simple step from the concept of decisions had ultimately to be made on a sound satellite operation was that of unmanned operation, engineering basis with due weight to operational a philosophy which had a significant effect on the factors and the availability of proven hardware. design of the systems. Some of these aspects are discussed in more detail by Tokeley (1989). 56 D P Brown, N Hall a) Plant Operation CIRCULATING WATER SYSTEM As previously discussed, Ohaaki was required This section provides a description of the to be a satellite of Wairakei. This led to the various components of the CW system. ,Figures 1 2 further decision to make it unmanned. indicate the extent of the system. A number of aspects are however common to all or most of the b) CW System components. Concern for the environment led to a decision a) Materials not to apply for water rights to obtain cooling water from the Waikato River and therefore a closed The nature of the fluids present in various parts of the CW system, due to the H and CO cooling system with cooling was adopted. 2 dissolved in the condensate lead to a Condenser Type selection of materials to ensure long-life. The use of direct contact condensers, almost Materials actually used in the system fall standard practice in the geothermal industry, was into two categories; metallic and non metallic. All an early decision. The choice of condenser type, metallic components in contact with the circulating between barometric leg and pumped extraction types, water are manufactured from 316 stainless steel. was eventually decided in favour of the former This includes the condensers, which for economic primarily due to its inherent safety flooding, reasons are fabricated from clad stainless steel particularly important for an unmanned station. plate, being of 316 backed by of carbon steel for structural strength. d) Cooling Tower Type A variety of non metallic materials are used, The economics did not produce a clear advan- the major ones being fibre reinforced plastic (FRP) tage between natural draft or mechanical draft and high density polyethylene (HDPE). is used cooling towers. The decision in favour of the for the barometric legs, the buried culvert and CW single natural draft tower installed was therefore pump discharge pipeline and HDPE for the cooling based largely on environmental considerations. The tower pack and the smaller auxiliary cooling water Waikato River valley at Broadlands is subject to supply lines. fogs which would be made worse by low level dis- charge from mechanical draft cooling towers. Additionally the natural draft tower could be used to aid non-condensable gas dispersion. The power station will operate unattended and therefore extra safeguards have to be built into e) Gas Extraction the system to ensure that it reverts to a safe condition in the event of trips etc. key factor The choice between rotary gas exhausters and in determining the required extent of these safe- steam ejectors was made in favour of the former on guards was the power station location at the top of the basis of pure economics when relatively high a hill overlooking a number of environmentally percentages of gas have to be removed. sensitive areas along the Waikato River. The possibility of a large scale overflow into the Waikato River had to be minimised. FIG.l Simplified CW System Diagram 57 D P Brown, N R Hall This was achieved by two means. Firstly the Water supply to the first three sections of hotwell, as the lowest point in the system, in- the condenser is controlled by the butterfly cludes a substantial overflow chamber which can condenser control valves, with a separately con- collect all the water discharged from the condenser trolled supply used for the gas cooler .section. barometric legs following an emergency trip caused This reflects the findings of the pilot plant work by a major electrical power loss. In the unlikely and will allow for the possibility of some control event that there is insufficient capacity in the of CW chemistry. A second control valve is in- overflow chamber, the excess water will flow over a stalled in parallel to the main ones to be used weir in the hotwell wall into a large bunded whilst they are out of service for maintenance etc. overflow Both the condenser control valves and their Secondly, vital valves have been duplicated isolation valves are fitted with nitrogen powered with a second valve in series and/or provided with pneumatic motors for emergency use. a stored energy system nitrogen gas or hydraulic accumulator) to provide operation in the The barometric leg discharge from the con- event of power failure. denser leaves from below the counter-current section. CONDENSERS. GAS COOLERS AND INTERCOOLERS An intercooler is fitted between stages of each gas exhauster in the gas extraction system. Condenser design is critical to both the power These direct contact heat exchangers are used to output of the power station and the resultant water reduce the gas temperature part way through the gas chemistry in the CW system itself. Poor control of compression cycle of the gas exhausters thereby the CW chemistry may lead to corrosion or slime reducing power requirements and water vapour problems. A pilot plant was used at Ohaaki to carry-over. flow into the intercoolers is investigate the best method of controlling the controlled by butterfly valves and is discharged to of and into the CW within the the hotwell via separate barometric legs. condenser and gas cooler. The results of these pilot studies were made available to the - condenser designers for use in the con- LEVEL CONTROL SYSTEM denser design. The hotwell level control system bypasses CW The condenser itself is divided into four from the CW culvert directly into the hotwell.