Basis of Design Edit

PROJECT TITLE
GEOTHERMAL POWERPLANT
SEPARATOR, SCRUBBER AND BRINE
DISPOSAL SYSTEM
BASIS OF DESIGN
TABLE OF CONTENTS
PREPARED BY
2-2-2014
CHECKED BY
APPROVED BY
SFF
DATE
RAT
2-3-14
DOCUMENT NUMBER
PIC-E-NTV-627-003
REVISION
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BASIS OF DESIGN
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SEPARATOR, SCRUBBER AND
BRINE DISPOSAL SYSTEM
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Abbreviations, Definitions, Standards, References
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INSTRUMENTATION
Introduction
1. Site Description
1
1. Environmental Condition
2
1. Measurement Units
3
Instrumentation System Requirements
2. Process Equipment
1
2.1. Separator
1
2.1. Scrubber
2
2.1. Flash Tank
3
2.1. Level Drum
4
2.1. Pump Motor
5
2. Field Instruments
2
2.2. Level
1
2.2. Pressure
2
2.2. Flow
3
2.2. Others
4
2. Control Room
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2.3. Facility
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2.3. Environment and Location
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Junction Boxes
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Instrument Material Selection
Supply System
4. Electrical
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4. Pneumatic
2
Equipment Protection
Earthing System
Cable Requirements
7. Cable Types
1
7.1. Instrument Cable
1
7.1. System Cable
2
7.1. Signal Cable
3
7.1. Power Cable
4
7.1. Special Cable
5
7.1. Junction boxes Cable
6
7. Cable Identification
2
7. Cable Shielding
3
7. Cable Marking
4
7. Cable Runs
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7. Cable Installation
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SAFETY
Introduction
Safety System (Fail Action)
2. System Architecture (DeltaV SIS)
1
Emergency Shutdown System
Fire Detection System
Gas Detection System
Audible and Visual Alarms
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CONTROL
Introduction
Operation System
Safeguarding System
Equipment Locations
4. Methods
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4. Elevation
2
4. Operating Convenience
3
4. Plant Equipment Layout
4
Basic Control and Monitoring
DCS and PLC Requirements
System Architecture
7. Narrative
1
7. Drawing
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NAMING CONVENTION
Introduction
Naming Convention
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DEFINITION
Engineering Procurement Construction Company or EPC
It is the contractor that will make the detailed engineering design and work of the
project. In this case the Process Instrumentation Company will provide for it.
ABBREVIATIONS
UPS
Uninterruptible Power Supply
VIM
Virtual I/O Module
PVC
Polyvinyl Chloride
ESD
Emergency Shut Down
IP
Ingress Protection
HMI
Human Machine Interface
NPT
National Pipe Thread
AWG
American Wire Gauge
AC
Alternating Current
DC
Direct Current
SS
Stainless Steel
CS
Carbon Steel
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DCS
Distributed Control System
PLC
Programmable Logic Controller
VDU
Visual Display Unit
MCC
Motor Control Cabinet
SIS
Safety Instrumented System
HART
Highway Addressable Remote Transducer
AI
Analog Input
AO
Analog Output
DI
Digital Input
DO
Digital Output
FF
Foundation Fieldbus
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REFERENCES
The different standards reflected as references should be used upon the completion
of the project. The dated references shall be necessarily applied. If there are any
changes regarding on the dated references, the client and the contractor shall have an
agreement on whether they will apply it or not. The newest standards and codes shall
be used for the undated references.
International Electro technical Commission (IEC)

IEC 60331
Tests for Electric Cables under Fire Conditions
IEC 61131
Programmable Logic Controllers
IEC 61158
Industrial communication networks Fieldbus specifications
IEC 61508
Functional
safety
of
electrical/electronic/programmable
electronic safety-related systems

IEC 61511
Functional safety safety instrumented systems for the

process industry sector
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IP RATINGS (Ingress Protection)

IP 65
Totally protected against dust ingress, protected against low

pressure water jets from any direction.
IP 55
Limited protection against dust ingress, protected against

low pressure water jets from any direction.
IP 42
Protected against solid objects over 1.0mm e.g. wires,

protected against falling drops of water, if the case is
disposed up to 15 from vertical.
International Society of Automation (ISA)

ISA 5.1
ISA 5.4
ISA 5.7
ISA 7.0.01
ISA 71
Instrumentation Symbols and Identification

Instrument Loop Diagrams
Process and Instrumentation Diagrams
Quality Standards for Instrument Air
Environmental Conditions for Process Measurement and
Control
ISA 75.01
ISA75.04,
ISA75.07,
ISA75.08,
ISA77.22,
ISA/ANSI S 84.01
Control Valve Sizing Equations
Control Valve Stability

Control Valve Noise Measurement and Prediction
Control Valve Face-to-Face Dimensions
Power Plant Automation
Application of Safety Instrumented Systems for the Process
Industry
National Electrical Manufacturers Association (NEMA)

NEMA 250
Enclosures for Electrical Equipment (1000 Volts maximum)
National Fire Protection Association (NFPA)
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NFPA 70
NFPA 1
NFPA 67
National Electrical Codes

Fire Protection Code
Guides on Explosion Protection for Gaseous Mixtures in
NFPA 59A
Pipe Systems
Standard for the Production, Storage, and Handling of
Liquefied Natural Gas (LNG)
NFPA 72
National Fire Alarms and Signaling Code
American Petroleum Institute (API)

API RP 505
Recommended Practice for Classification of Locations for

Electrical Installation at Petroleum Facilities Classified as
Class I, Zone 0, Zone 1 and Zone 2 (2002).
API RP 500
Recommended Practice for Classification of Locations for

electrical Installation at Petroleum Facilities Classified as
Class I, Division 1 and Division 2.
Indian Standard (IS)

IS 5831
PVC insulation
A.
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INSTRUMENTATION
1. INTRODUCTION
The basis of design for instrumentation shall discuss the considerations under
the scope of plant process instrument general requirement e.g. type of materials,
operating ranges, standards for equipment protection and even overview of the
geographic location of the process field. The pre-determined process conditions
such as exposure to corrosive and toxic gases, process ambient temperature and
other factors that may degrade the functionality of the instrument installed shall be
the foundation in selecting the right material to be used. The purchase of the right
equipment shall determine the efficiency of the instrument and the length of its
service.
The basis of design for instrumentation shall state the plant process instrument
general requirement e.g. type of materials, operating ranges, type of connections,
standards for equipment protection and even overview of the geographic location of
the process field. Pre-determined process conditions such as exposure to corrosive
and toxic gases, process ambient temperature and other factors that may degrade
the functionality of the instrument installed shall be the foundation and basis for the
purchase of materials to be used. The basis for instrumentation shall determine
which equipment is suitable for the given application and the length of its service.
1.1
SITE DESCRIPTION
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The Tiwi field is located about 300-km southeast of Manila in the Albay
Province. The Tiwi geothermal field will be located on the northeast flank of Mt.
Malinao, an extinct Quaternary stratovolcano in the East Philippine Volcanic Arc.
This arc is a belt of upper Miocene to Recent calc-alkaline volcanoes
associated with subduction along the Philippine Trench. Mt. Malinao is composed
dominantly of <0.5 million year-old andesitic lavas and lesser pyroclastic rocks.
Tiwi Geothermal Power Plant coordinates are 1327'54" N and 12338'55"
E in DMS (Degrees Minutes and Seconds) or 13.4649487555258 latitude and
123.648541284874 longitudes (in decimal degrees). It has an elevation of ~45
meters.
googlemaps.com
1.2
ENVIRONMENTAL CONDITION
The geothermal plant geographical location has a humid subtropical
climate with 1, 850 2, 300 mm annual rain fall. The ambient temperature is
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ranging from 75.38 F to 82.58 F with relative humidity at 83-96% and 3.6 km/h
North wind speed.
1.3
MEASUREMENT UNITS
Liquid Flow Rate
GPMgpm
Gases Flow Rate
Nm3/h
Steam Flow Rate
kg/hr
Temperature
C0F
Pressure
lb/in2
Vibration
dB
Level Relative
0-100 %
Level Absolute
Gage Pressure
iIn. or
mm
psig
2. INSTRUMENTATION REQUIREMENTS
This part contains the basic requirements of different instruments, and equipment
needed in the process of separator, scrubber and brine disposal system.
2.1
PROCESS EQUIPMENT
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The selection of the process equipment shall be based on conditions and

the desired standards for which it is expected to comply. The main goal for
detailing these conditions is to be efficient in terms of equipment reliability.
2.1.1 SEPARATOR
The type of separator to be used is the Upgraded CE Natco. It
shall be constructed with 316L stainless steel to comply with the tank
design temperature and pressure which is 400 F and 200 psi. The
diameter of the tank shall be 2743 mm and 7620 mm height. to
accommodate 600-800 kph flow rate capacity. Its operating parameters
shall range from130 180 psig at water level. Its two-phase entry will be
tangential. The height of steam outlet to inlet is recommended to be
positive with acceptable pressure drop of 7-10 psi.
Principle of Operation
The two phase fluid enters the separator through the two phase inlet
nozzle.
The separation process commences by utilizing the difference in

density of the liquid and the vapor phases of the two phase fluid.
It operates by using the centrifugal force of the spinning steam and

brine mixture inside the separator to force the brine to the wall of the
vessel.
The brine then drops to the bottom of the vessel exiting to the brine
outlet while the lighter steam and gas exits through a pipe extending
up the inside of the vessel.
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The 2-phase phase fluid usually contains carryovers and impurities

present in the steam such as silica and chloride and non-condensable gas
(NCG). The carryovers can be removed by the centrifugal action possible
with the separators design while silica and chloride and non-condensable
gases are found to be difficult to remove, proper selection of materials that
can withstand their effects must be put into consideration.
2.1.2 SCRUBBER
The scrubber purifies the steam by separating the pure steam from
other impurities that the separator failed to remove. This is done to meet
the minimum requirements of the power plant. TheThe plant steam quality
requirements are as follows:
Silica
Maximum of 1.0 ppm
Chloride
Maximum of 1.0 ppm
Steam Quality
Minimum of 99.75%
Non-Condensable gases
Should be between 1.0 to 3.0 ppm
The steam quality can be achieved by using Porta-test scrubber. This high
pressure scrubber shall have an inner diameter of 3657 mm with 1066.8 mm
height. It s shall be built to operate atdesign temperature and pressure will be
405F deg. Fahrenheit temperature and pressureand of 200 pPsig.
Principle of Operation
Primary separation takes place as gas enters through a tangential nozzle,
creating centrifugal force and forcing the heavier liquid particles to the vessel
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wall. From there, the liquids drain to the stilled chamber in the bottom of the
vessel.
Secondary separation occurs as the spinning gas converges at the center
of the separator and enters the vortex finder tube. Inside the vortex finder tube,
the gas spins at a higher velocity and forces any remaining entrained liquid to the
tube wall. This liquid is swept upward toward the gas outlet. Prior to exiting the
vessel, the liquid and a 10% side stream of gas are drawn through a small gap in
the vortex finder tube and returned to the primary separation section. A low
pressure area in the primary separation section created by the spinning gas
provides the necessary differential pressure driving force.
2.1.3 FLASH TANK
Flash tank is where a pressurized high-temperature water enters,
as water enters the flash tank a sudden decrease in the pressure causes
the liquid to vaporize into steam. This vapor is released into the
atmospheresteam and the cois thendensate is disposed to the sumpuse
for power generation. Its material construction shall be the made with
carbon steel same with the scrubber since the pressure andwith design
temperature and pressure of experienced by the vessels is measured to
be around 200 psi at 400 F and 200 psi. The flash tank parts are brine
inlet and outlet and vapor outlet for vapor venting, and manhole for
maintenance and inspection.The vessel must be made of corrosion
resistant materials.
2.1.4 LEVEL DRUM
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Level drum is ashall hold condensate holding vessel acquired from

scrubber which is expected to hold liquid with high pressure and
temperature condensate and.
low pressure vapors. The level drum
dimension shall be: 406.4mm inner diameter and height of 1524 mm

constructed with materials carbon steel designed with that are capable to
operate at 200 psi and 400F.
2.1.5 Seal Water Tank

Seal water tank stores fresh water supply that is to be fed into the
brine pumps. The tank shall be constructed with carbon steel material and
shall be designed with low temperature and pressure.
2.1.65 PUMP MOTOR

The pump that will be used for saturate disposal must be able to
operate at 405F temperature with low pressure head required. The
centrifugal pump used to drive brines and other fluids in geothermal
process shall adopt ISO 5199:2002 Technical specifications for centrifugal
pumps Class II. Its casing is preferred to be made up of carbon steel
with hard iron impeller for erosion-corrosion and abrasion resistance. Its
working parts including float, valves and mechanical linkage shall be 316L
stainless steel. Zinc anodes and epoxy paintings for protection shall be
considered. The pPump motor will be driven by 3-phase with YB-type
explosion proof motor squirrel-cage induction motor.
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2.1.6 PIPELINES
Pipelines shall be routed as short as possible to minimize turns and
incline. The most important aspect in its design is usually to keep the route
monotonic and the incline slight in order to minimize pressure drop and
slug flow conditions in the pipeline. Pipe insulation shall be designed to
lessen pressure drop during steam transmission.
For the separator and scrubber steam pipelines, stainless steel
shall be used where the properties of steel e.g. corrosion resistant, high
tolerance to pressure and temperature can increase productivity. The
pipeline for brine disposal shall be made up of carbon steel for a thicker
material selection.
The pipelines shall be according to its application. For steam
pipelines, the material construction shall be made up of 316L stainless
steel with design pressure and temperature of 200 psi and 400F. As well
as the pipelines for brines with minimum material requirement of carbon
steel construction.
2.2
FIELD INSTRUMENTS
All field instruments must withstand the extreme process for which they
are installed for. The highest range of pressure involved is at 200 psi while
temperature is expected to be at around 405 F. The type of material construction
must protect the mechanical and electrical components of an instrument to give
accurate results and prolong its service.
2.2.1 LEVEL
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The saturated fluid and condensate level shall be controlled using

equipment that determines the said process variable. This equipment
follows the standards that satisfy the requirement for which it is intended
to be use.
LEVEL TRANSMITTERS
Level transmitters are used to measure and indicate level in the
process. It shall have an electrical output signal of 4-20mA in order to

transmit signal to the controllers and other instruments. Transmitters with
flush flange connected both sides are used for direct mounting, capillary or
process connections.
The pipe size and fittings for the level installation shall be in inch
and threads in NPT. The transmitter shall use 1199 Remote Seal to form a
Tuned-System Assembly that improves performance and reduced cost.
Other installed components shall be 316 SST conduit plug. For process
connections, NPT is used. The enclosure rating shall be IP66 for
ingress protection of the transmitter.
LEVEL GAUGES
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Level Gauges are installed so that the liquid level in the transparent
sight tube is same as the liquid inside the tank. Level gauge shall
compose of the following parts: armored shield with two flanges, sight
tubing and two self-sealing Super-Seal inserts. Only the PTFE Teflon
Super-seal inserts and the borosilicate sight tubing are exposed to the
process fluids. The standard shields shall be epoxy-coated carbon steel.
For installation, the support brackets should be longer than 10 ft. or
heavier than 75 lbs. and the alignment should be in vertical position.
LEVEL SWITCHES
Level Switches sense high or low liquid levels. These shall operate
in safety shutdown systems and use a displacer-style sensor located in an

external cage. The displacer cage with 4 diameter shall have two NPT
pipe plugs for easy relocation. For electrical connections, the external size
shall be NPT. The standard construction material of level switch shall
comply the metallurgical requirements of NACE MR0175-200.
2.2.2 PRESSURE
Pressure is measured to determine its effect to the process and for
the equipment safety monitoring. Turbines requires specific amount of
pressure to be applied, by measurements acquired from process
instruments, the operators can determine whether the amount of pressure
can drive the turbines or not.
DIFFERENTIAL PRESSURE TRANSMITTER
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The differential pressure transmitter shall consist of a mechanical

measuring system with elastic pressure element of magnetic-fielddependent sensor with amplifier and case. The resulting differential
voltage from the coupled sensor is amplified to current signals. It shall
have a standard output signal of 4-20mA. The maximum working pressure
may be 100 up to 250 psig.
The pressure connections shall be 2xG female. Wetted parts and
case shall be made of stainless steel and NiCrCo alloy. It shall meet the
standard for the ingress protection of the transmitter which is IP65.
PRESSURE TRANSMITTER
Pressure transmitters shall be in-line to the process pipeline and
shall provide gage pressure measurement and indication. It shall have an

output signal of 4-20mA based on HART protocol. A change in signal is
directly proportional to the pressure measured by the diaphragm sensor.
The pressure range shall be -14.7 to 300psi. The maximum measured
error shall have a tolerance of +/-0.15% of span. Isolating diaphragm and
wetted material parts shall be 316L SST and Alloy C-276. -14 NPT
female may use for the process connection.
PRESSURE INDICATORS
Pressure indicators shall be used for local indication. The
measuring element shall be diaphragm seal to protect from slurry fluids.
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Using this type of indicator, the size of flanged shall be 1 . The range
shall read approximately 1/3 to 2/3 of full scale and its maximum error
shall not exceed 1% of the span. The window material shall be of Shatterproof glass.
Its process connection shall be bottom entry type of SS 316 and
NPT. The indicators shall capable of withstanding 130% of maximum
range without affecting its accuracy. The enclosure shall be weather proof
to NEMA 4X/IP66.
2.2.3 FLOW
An instrument for flow determination is designed to compensate the
information that the level controllers cannot acquire from level instruments.
The accuracy of these instruments can be preserved by using appropriate
instrument material construction.
ORIFICE PLATE FLOW METER

Orifice flowmeter shall be comprise of a concentric square edged
orifice plate designed for flange tap and capable of withstanding

differential pressure equal to full line pressure without zero or calibration
change. Flange taps shall be of size NPT.
It shall meet the requirements of BS 1042 and ISO 5167 in all
aspects in measuring flowrate. For two wires, the output signal shall be 4-
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20mA. The wetted materials such as orifice assembly, stem, and manifold
shall be made of 316L stainless steel.
PITOT TUBE FLOW METER

The Pitot tube flow meter shall have cross-sectional T shape that
allows flow separation at a fixed point. It shall be comprised of high and

low pressure plenums and shall have the ability to accommodate RTD
integral to the sensor. Also, the sensor shape shall promote less turbulent
zones on the backside of the sensor.
These flowmeters shall be made in 316L stainless steel and
hastelloy 276, and can withstand in the maximum pressure and
temperature of 200 psig at 405 F. The mounting material shall be
constructed from same material as process pipe. Threaded and welded
opposite side support assemblies shall be applicable.
2.2.4 OTHERS
This includes the other general instruments involved in the
separator, scrubber and brine disposal system such as valves, actuators,
etc. which are not classify in the four process variable measurement.
CONVERTERS
Converters are used to change an analog signal (4-20mA) to a
proportional linear pneumatic output (3-15psig) or vice versa. For split

ranging, it shall be recalibrated to provide higher output signals.
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The minimum supply pressure shall be 3 to 15 psig. For safety

purposes, it should be enclosed when installed in outdoor environment
with an enclosure rating of IEC standards IP65.
HAND SWITCHES
Hand Switches are electrical switches actuated by hand motion.
The switches shall have three position changeover sequence for open, off
and auto control. The position indexing options may be 900 or 450. The
current rating should be 6A with a rated voltage of 690V. Silver/Nickel shall
be the contact material. For finger terminal protection, IP2X standard shall
be used.
HAND CONTROLLERS
Hand Controllers shall be protected against transient voltages and
reverse polarity. The supply voltage and current may be 24V AC/DC at
250mA.The temperature operating condition may be 32F to 122 F.
These controllers must be installed inside a NEMA 3 (IEC IP54), or
better enclosure and mount to standard 35mm DIN rail track.
ACTUATORS
The cylinder type actuators shall be used in the whole process.
These actuators shall be direct acting that provides fail-to-open for

normally close valves. The standard pressure range shall be 3-15psig. Its
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maximum operating pressure may be up to 150psig. The connection shall

be in NPT.
Cylinder actuators shall be supplied with a compound link and lever
arrangement
designed
to
minimize
water
hammer
by
providing
characterized opening and closing. Each unit shall comply AWWA C54093 Standard for Power Actuating Devices. All wetted parts of the cylinder
shall be nonmetallic, except the cylinder rod which shall be chromium
plated stainless steel. The rod seals shall be of the nonadjustable, wear
compensating type.
CONTROL VALVES
The control valves body shall be made of high temperature cast
steel. The temperature range should be -320 to 800F and its pressure
rating shall comply the ANSI Class 125-300. These control valves shall
consist of a body with trim, bonnet and pneumatic actuator with metal
bellows or insulating extension. Also, these valves shall have fail-safe
action upon loss of air supply. All control valves scale shall be calibrated
from 0-100% and may installed vertically and horizontally.
SOLENOID VALVE
The solenoid pilot-operated diaphragm valve is suitable for
controlling air pressure. For general atmospheres, the material shall be

brass body. It can be used to pilot large actuators for quick closing of
control valves. It shall be resilient seating for tight shutoff and can be
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mounted in any position. For pipe sizes from 3/8-1 NPT, with pressure
ranges from 10psi to 250 psi.
PRESSURE SAFETY VALVE

Pressure safety valve with rupture disk housing shall be made of
316 SS base on IP 65, IP 66 IEC 61508. The size of the rupture disk
device is generally the same as the PRV inlet connection. It shall be loop
powered with the 4-20mA transmitter signal to the controller. Proper
cabling type and diameter shall be used for input power as well as for the
output signal. Shielded stranded copper shall be. It shall have a size
between 10 to 14 AWG.
2.3
CONTROL ROOM
The control room shall provide shelter for operators and workstations and
must be constructed with materials that do not easily corrode. It must be

enclosed to avoid exposure from hydrogen sulfide and other air contaminants
that may deteriorate control room facilities. Air filters can be installed to provide
total protection against air impurities.
2.3.1 FACILITY
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The centralized control room shall consist of workstations, alarm

consoles, HMI- interface, ESD switches/pushbuttons and visual and
audible alarms. Auxiliary power source such as gGenerators and
uninterruptible power supply will be considered in case of power failure
occurs. Air-conditioning units shall be installed to protect control facilities
from overheating and for operator comfort. Fire extinguisher must also be
available.
Marshalling cabinets will be located at an area opposite to the
operator consoles or workstations, as well as the system cabinets. The
preferred entry of wirings from the field to its designated cabinets is top
entry since the central control room will be designed to be at ground level
with certain elevation..
2.3.2 ENVIRONMENT AND LOCATION

The central cControl rooms will be located 1400700 m at most from
the process field to avoid being exposed from the heat released by the
steam and hydrogen sulfide which can cause severe corrosion. The
ambient temperature inside the control room must be maintained at 18
deg. Celsius with 50% relative humidity and 0.1ms-1 maximum air speed.
2.4
JUNCTION BOXES
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Junction boxes provide termination of process instruments cables

because instrument wire cannot send signals at a further receiver. These boxes
are within process areas where nearby instruments are found and therefore
exposed to hazardous and corrosive environment. The minimum standards for
junction boxes will be based on NEMA enclosure type which covers corrosion
resistance and ability to protect from rain and submersion or the NEMA 4x types.
The enclosure will be made up of 316L stainless steel with 1.5 mm thickness.
The cables that will be inserted into the junction box will be protected by epoxy
stainless steel cable glands to prevent entry of corrosive gases inside the
junction box.
All the wires of field instruments are terminated to the junction boxes. An
area in the fieldn area may consist of different junction boxes depending on its
capacitysignal type. Each instrument has input and output signals which can be
classified either Analog or Digital.Instruments with analog signals will be
terminated in analog junction boxes, while cables with digital signals are
terminated in digital junction boxes.
These boxes shall be elevated with minimum elevation of 1.5 feet,
depending on its size and capacity.
There are cases considering the assigned I/O signal type to the field instruments. If the
accessories are separated from its main field device, then the I/O signal type is
assigned to the accessories instead to the main field device. For example, if the
transducer (I/P Converter) is separated to the control valve, then the Analog Output
signal from the control valve is assigned to the transducer (I/P Converter).
3.0
INSTRUMENT MATERIAL SELECTION
BASIS OF DESIGN
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Instrument material selection must be according to its application. In geothermal

process where critical and extreme conditions are involved, material selection must
always consider the process temperature and pressure to prevent degradation of the
instruments accuracy. Instruments that havewhich involve direct contact with
superheated fluid or steam must have an operating range prior to actual measurements
with additional tolerance. for fluids at 400 F and can handle pressure at 200 Psi. Also,
materials should be corrosion resistiveresistant to corrosion since the underground
steam releases hydrogen sulfide which reacts fast with metals with no corrosion proof.
The manufacturers below are expected to meet or supply the instruments required in
the production of steam.
List of Manufacturers/suppliers: to follow
For the selection of instruments,
Rosemount instruments are taken into consideration as well as Fisher in
selecting the appropriate valves for the process.
4.0
SUPPLY SYSTEM
Power supply of the control system shall be of highest available quality for
reliability and long service life. Power supplies for all transmitters, controllers, signal
converters, electric system and components in shutdown system shall be supplied from
UPS. Power distribution to each instrument shall be through proper, independent switch
and fuse. Protective fuses shall be of indicating cartridge type mounted in fuse holders.
4.1
ELECTRICAL
BASIS OF DESIGN
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In general, the following Power Supplies shall be used for instrumentation

and Control: -For Process Platforms: 220V AC + 5%, 60HZ + 1% (UPS) for all
instruments control. However, all components e.g. instruments, system shall be
suitable for 220 V + 10% AC, 60 Hz + 3%; For Process & Well Platforms: 24V
DC + 5% Battery Negative earthed for Platform interlock system, solenoid valves,
fFire and gGas system and status lamp.
.
4.2
PNEUMATIC
For pneumaticPneumatic
instruments, dry instrument gas / air supply
compressor output shall range from shall 100 psi minimum to 200 psi. For
pneumatic valve actuation, the operating air supply pressure shall range from
120 psi to 150 psi.be as follows:
100 psi (minimum)
200 psi (normal)
300 psi (maximum)
5.0
EQUIPMENT PROTECTION
Since a process involving geothermal is hazardous, all aspects involve in here
must be clearly stated and finalized. One of the most important parts of a system is the
equipment. Without these equipments, a system cant be operational and so, for the
safety of this equipment, certain protection is defined.
5.1
ENVIRONMENTAL PROTECTION
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All instruments/equipments must be suitable with the working environment

as well as its position whenn the installed. The basis for installation should also
consider equipment exposure to several factors like wind, temperature, vibration,
shock and many others. It must also withstand these conditions during shipment
or storage.
5.2
INGRESS PROTECTION
All field instruments shall have ingress protection to IP 65 or better.
Pneumatic field instruments used for control applications shall have ingress
protection to IP 55 or better. All instruments installed inside pressurized
equipment / control rooms shall have ingress protection to IP 42 as a minimum.
5.3
TROPICALIZATION
All electrical components shall be tropicalized to protect against humidity,
moisture and fungal growth by means of hermetically sealed units, protective

coating on circuit boards, gold plated edge connectors, etc.
5.4
HERMETIC SEALING
All relays and switches shall be hermetically sealed, and those utilized in
24 V DC control logic circuits shall have gold plated contacts rated 0.5 Amp at 24
V DC. Those interfacing with field equipment shall be rated 2 Amp 24 V DC.
5.5
HAZARDOUS AREA INSTRUMENTATION
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The Contractor shall classify hazardous areas in accordance with API 500
and specify various equipments accordingly. All instruments which are mounted
outside of normally pressurized control / equipment rooms shall be certified by
bodies such as FM / UL / BASEEFA / CSA / DGMS / CMRS for use in Class I,
Division I, Group D, T3 hazardous area, even if the instruments location is
classified as a normally non-hazardous area. Intrinsic safety approval shall be
based on entity concept and necessary compatibility checks shall be carried out
by Contractor before selecting any equipment. Intrinsically safe protection using
external barriers shall be provided for all process transmitter loops (closed as
well as open). Isolating barriers shall be of the plug-in type, mounted on modular
back plane termination units. Each input and output in a loop shall have a
separate barrier. No barrier shall be shared between two loops in input / output.
All other instrument loops shall be provided with explosion proof / flame proof
protection. Solenoid valves, electric hand switches, signaling lamps and Intercom
/ Paging system shall be Explosion proof / flame proof to Ex d or NEMA 7. If
specialist instrumentation cannot be provided with the above methods of
protection, then alternative methods suitable for the classified area and certified
by an acceptable Authority may be proposed. The Contractor shall submit a
technical
report justifying
the
instrument selection for the
Companys
consideration.
5.6
R F INTERFERENCE
All equipment shall remain unaffected by radio transmissions (Levels of
permissible RFI shall be as per IEC 801). Band-pass and / or band stop filers
shall be fitted, as necessary.
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5.7 SEALING
Seal systems shall be used to isolate instrument from the process fluid
encountered in the following services:
a. Wet gas, which may condense in the instrument lines.
b. Process fluids that vaporize condense or solidify under operating pressure and
ambient temperature.
c. Process fluids that will subject the element to high temperature.
d. Process fluids that will subject the element to high temperature.
e. Viscous liquids.
Sealing may be accomplished with diaphragm seals. All venting
instrument and pilot valves shall have bug screens fitted to atmospheric vents.
6.0
EARTHING SYSTEM
Safety of the system as well as its people is the two most important aspects to be
considered. Earthing system is provided to protect a system from sudden mishap or

short circuit that can harm lives of inhabitants.
6.1
ELECTRICAL SAFETY EARTH

Bonded to the site structure and utilized for electrical safety of metal
enclosures and chassis on all instrument and electrical components.
6.2
BASIS OF DESIGN
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INSTRUMENT CLEAN EARTH
Instrument clean earth will serve as basis for the earthing of DC instruments that
are usually located near or inside the control rooms. Data and communication busses
are earthed due to vulnerability of low level CMOS and microprocessor circuits and to
prevent noise interference or risk of data/communication loss.
6.3
INTRINSICALLY SAFE EARTH

Process equipment such as motors, lightings, and power distribution
system which runs at 120VAC, 220VAC and 480 VAC are power earthed due to
high current level switching and to prevent radio frequency or electromagnetic
interference.
.
7.0
CABLE REQUIREMENTS
A well-designed and applicable system cable is necessary to achieve the
required performance of the system.

7.1
CABLE TYPES
There are several cable types for each area to be used for. Certain
standards must be followed in choosing the right cable for each function. The
inner and outer jacket of the cables shall be made of extruded flame retardant
194 F PVC to IS 5831 type ST2. The O 2 index of PVC shall be over 30. The
BASIS OF DESIGN
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temperature index shall be over 482 F.The following products shall be within the
jurisdiction of this Group: NEC, NEMA and, IEC.
7.1.1 INSTRUMENT CABLE
Cables with soft annealed bare or tinned copper conductors and
PVC flame retardant insulations and jackets are the standard offering for
300V Power-limited tray instrumentation installation. The specified cable
to be use is #18 AWG, 8 pair tinned copper conductor with PO (Polyofelin)
insulation.
7.1.2 SYSTEM CABLE
The core of a single-mode fiber is smaller (<10 micrometers) and
requires more expensive components and interconnection methods, but
allows much longer, higher-performance links. Installed cable shall be
8.3/125micron core/cladding, single mode, and graded index glass fiber.
All materials in the cable are to be dielectric. A multipair shielded #20 AWG
type of cable is used in the system. It is made up of copper with PVC
jacket material.
7.1.3 SIGNAL CABLE
Typical cable shall be #18 AWG twisted pair, PVC insulation, braid
or foil shield, with drain wire, PVC jacket with rated voltage of 220600VAC. The drain wire shall be connected at one end of the cable
choosing the end with the lowest impedance ground source.
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Multi-pair cables shall have the following additional features:
Color coding or tagging of the wires.

Individual pair shielding apart from overall shielding.
Maximum of 12 pairs per cable
7.1.4 POWER CABLE

Power Cables shall be PVC sheathed 3 core, minimum of 2.5mm 2
conductor area (Max. conductor resistance of 7.41/km), 0.9 mm nominal
thickness of insulation, and minimum thickness of inner sheath of 0.3mm.
7.1.5 JUNCTION BOX CABLE
Instrument cable and signal cable are terminated inside the junction
box. Typical cable shall be #18 AWG shielded twisted pair. The specified
home run cable used is a traditional MC Cable with interlocking metal-tape
armor. This MC Cable carries no limit of current-carrying conductors as
per NEC Table 310.15(B)(3)(a). Several cable types are used for
different junction boxes.
JB No.
Cable Type
BASIS OF DESIGN
Sheet
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DJB-A-001
DJB-C-003
DJB-A-001
DJB-A-003
DJB-B-001
DJB-C-003
AJB-A-002, AJB-C-004,
AJB-A-002
AJB-A-004
AJB-B-002
AJB-C-004
7.2
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1 pair
2 pair
8 pair
5 pair
6 pair
2 pair
2 core
18 core
25 core
12 core
28 core
CABLE IDENTIFICATION
All wiring, cables, tubes, multi-tube bundles, junction boxes and auxiliary
equipment shall be suitably identified clearly as per tag or addresses. Plastic

adhesive tapes shall not be used for instrument identification. All wiring shall be
tagged with slip on or clip-on wire marker at both ends with the wire number
specified on the drawings.
Terminals for power cables, polarity, ground connection, shall be identified
according to the specified tag.
Cable cores shall be colored as follows:
24VDC Digital Circuits: Positive: Red, Negative: Black, Ground: Yellow green
Analog Circuits:
Positive: White, Negative: Black
Cable outer sheaths shall be colored as follows:
Intrinsically Safe:
Blue
7.3
BASIS OF DESIGN
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Black
CABLE SHIELDING
All instrument signal cables shall be braid/foil shielded/shield grounded at
the same point as the signal circuit.

7.4 CABLE MARKING
All cables shall be identified with stainless steel cable markers securely
fixed to the cable with cable tie wraps at the following locations:
All cable glands
Entering and leaving cable ladders, ducts, and supports
Both sides of walls or bulkheads
Cable markers shall be fitted during or immediately after cable termination.
7.5
CABLE RUNS
All cables going to and from control panels shall be supported with the
cable manager or tray. Power cables shall not be combined along with the control
cables in one cable manager. Cables in intrinsically safe circuits shall preferably
be not run in the cable manager for cables in non-intrinsically safe circuits. If run
in the same cable manager, a metallic earthed separator shall be provided.
Conduits carrying intrinsically safe cables shall be painted with the blue color
bands at each end.
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The entry and exit of the conduit shall be smooth and free from burrs.
Cables shall be put inside the conduit to prevent damage. Splices shall be made
only at the end of each terminal of the instrument cables going to the junction
boxes.
7.6
CABLE INSTALLATION
All cables including serial link and data highway cables going to or from
the equipment rooms shall be armored and continuously screened with screen
grounded at the equipment room end only.
For ease of instrument disconnection, an adjustable elbow or union shall
be provided between the terminating gland and the instrument.
A neat loop of 250mm diameter shall be left immediately adjacent to all
instrument devices in the field.
Cabling for locally mounted instruments carrying sensitive signals and
normal/emergency walkways or other installation that can interfere with the
equipment shall be separated.
Cable transits shall be used to provide gas-tight cable penetrations
through decks or firewalls.
7.7
CABLE TERMINATION
BASIS OF DESIGN
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All cable glands shall be double compression type and explosion proof.
Cable glands subjected to salt water spray shall be weather proof. All
terminations shall be screw type terminals for 2.5mm 2 conductors (minimum)
Insulated crimp lugs shall be used for all cable core connections, with only one
conductor per terminal side.
Cables shall be terminated in 316 SS glands. The inner sheath shall be left
on the cable after the gland, and removed at the point of entry into wiring duct.
Cable cores shall not be pig-tail finish. Electrical tapes or other safety
accessories shall be provided for safety.
Cable screens and drain wires shall be securely insulated at the final field
termination.
The communications conductor of a cable shall be terminated in the bottom
terminal of a row of terminals.
Printed sleeve-type ferrules shall be used in both terminals of control wires
or any other cables depending on the size of the wire being used.
Only one conductor shall be used per terminal side.
Cable entry to control room/ other rooms shall be through listed multicable
transits.
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Terminal blocks shall be vibration proof, din rail mounted, stack on type and
shall use screws for terminals. Fused terminal blocks shall also be used for
safety purposes. Termination of shall be through the use of wire lugs / ferrules.
Cable termination of skid items: Manufacturer supplying skid mounted
equipment or vessels with instrumentation (alarms, shutdowns, control functions)
shall be accessible and terminated on a central junction box near skid boundary,
available for hook up by contractor.
B.
CONTROL
1.
INTRODUCTION
Geothermal powerplant separator, scrubber and brine disposal system
process control shall be according to DCS and PLC control system. User
interface and remote control capability of the said types of control are the basis
for control for the processes involved. Less human intervention shall be adopted
using the advanced control system.
2.
OPERATION SYSTEM
Central DCS located at control room shall monitor and control all process
units for the entire project. Control room shall provide adequate space and
guarantee a safe, effective and efficient control and monitoring of the plant. Every
major and minor unit of the plant shall operate independently from its dedicated
console, providing machine edition HMI and VDU-based DCS Monitor Interfaces.
Each of these consoles shall have 32 LED monitor.
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The DCS operator interface (VDU based) shall be the primary integrated
window for operation of the control and safeguarding systems and shall provide
access to:
2.
Process Control
Sequence Control
Equipment Status
Alarm Overview
Trip Status Overview
Real-time Trending
Fire and Gas Detection Status
SAFEGUARDING SYSTEM
The main objective of the plant and its control system is to, safely, reliably, and
continuously produce on-specification product. Without compromising these objectives,

the control systems shall also be designed to maximize plant availability, minimize plant
energy consumption, adverse environmental impact and requirements for operator
interventions. The principle objective of the safeguarding systems is the protection of
personnel, environment, plant and equipment and the maintenance of safe operating
conditions compatible with production requirements.
This shall result in control and safeguarding design that is:
1
Safe
Simple to maintain and operate
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Reliable and flexible to accommodate changes in technology and

operating requirements.
3.
Low cost
EQUIPMENT LOCATIONS
The location plan for equipment installation shall be based on methods where
instruments are accessible for maintenance. Instrument installation shall be based on

the manufacturers specifications.
3.1
METHODS
Two general methods are used to position equipment:
Group Pattern where vessels, exchangers, columns, pumps and

etc., are group in separate areas. This method shall be applied in
the project.
Flowline Pattern where equipments are laid out as arranged in the

process flowsheet.
For the process, a compromise between the two shall be used for ease of
operation and maintenance.
3.2
ELEVATION
BASIS OF DESIGN
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Heavy and bulky units such as columns, tanks, and etc. shall be
placed on the ground with proper support to avoid high expense of
elevating equipments.
Therefore, pumps or other equipments shall be used to force the

fluids to flow unnaturally.
3.3
OPERATING CONVENIENCE
Equipments requiring frequent attention shall be grouped together

to facilitate operation and maintenance. However, the safety
clearance between the units has to be observed to ensure safest
possible arrangement and the most hazard prone equipment shall
be placed at the location most convenient for it to be removed.
Equipments that provide local indication shall be mounted within

eye level for ease access of operator.
A rectangular setup with a central overhead pipe rack permits

equipment to be installed along both sides of the pipe way with
ease of access.
3.4
PLANT EQUIPMENT LAYOUT
BASIS OF DESIGN
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Pumps shall be located in line along each side of an access way

with
the
motors
aligned
outwards
for
easy
access
and
maintenance.
Equipments requiring large cranes for services shall be located at

the perimeter of the rectangular set up, adjacent to the main road.
Compressors shall be installed to allow for rapid dismantling and

reassembly thus avoiding from the needs to have a standby unit.
Compressors with bottom suctions and discharge connections shall
be used, supporting it on a platform above ground level
(approximately 2.5 m or so).
4.
BASIC CONTROL AND MONITORIING

This level comprises basic control and monitoring of process, utility,
equipment and auxiliary systems and is implemented in DCS. These
functions can be categorized as follows:
4.1
UNIT MONITORING
Unit monitoring comprises all Human Machine Interface (HMI)
function provided to those responsible for monitoring and control of the

process and its environment. These includes alarm and monitoring
display, group and detail displays, custom graphic displays, data historian
and retrieval, reporting, etc.
4.2
BASIS OF DESIGN
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REGULATORY CONTROL
Basic regulatory control provides closed loop control functions for
stable and safe operation around steady points of operation. The basic
control functions comprise mainly of flow, level and pressure control loops
required as a minimum to operate and control the process. These loops
may include extended regulatory control functions such as: split range
control, override control, ratio control, and cascade control. They may also
include control based on calculated variables, such as heat duty control,
pressure compensated temperature control, etc. all of these shall be
realized on the central DCS system only.
5.
BASIC SEQUENCE, CONTROL, LOGIC, INTERLOCKS

All Sequence control, interlocks and logic shall be realized in the central DCS to
provide automatic performing of task in a defined sequence.

5.1
SEQUENCES
Sequences shall be used where appropriate for frequently repeated
series of control actions. All sequences shall include feedback for the
operator of the current step and status of the sequence. All transitions
must be configured with an alternative path in the event of the failure of an
action that drives the process to a safe state. If possible, large sequences
should be broken into smaller components that can be activated from a
supervisory sequence. For example, if a pump with inlet and outlet valves
is part of a sequence, the pump start/stop can be made into a smaller
sequence called from the main process sequence.
5.2
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INTERLOCK
Interlocks refer to logic that would be used to control the operation
of devices. In general all interlocks must default to a state that would drive
the process to a safe state. Any interlocks that are uncertain or have bad
signals transmission would be assumed to be in the fault state. The
system will be configured to include bypass interlocking operation
whenever presence of inconvenient process occurs.
Hardwired Interlock
A signal wired directly to the motor control relay. Hardwired
interlocks may be required by construction codes or for fundamental

safety. These interlocks could only be bypassed by inserting jumpers in
the field which should never be required.
Safety Interlock
A logic required for the safe operation of a device and
equipment protection. These interlocks cannot be bypassed except by

changing the control logic.
Process Interlock
A logic required for the normal operation of a device in the
process. In local mode process interlocks could be bypassed. In the

transition to remote mode, all process interlocks would be activated.
Permissive
BASIS OF DESIGN
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A condition that must be true for a device to change state but

when the state has changed it would be ignored.
All interlocks, except permissive, would be latched in the control
system and require acknowledgement by the operator. Motor controls
would only start on a direct start command and would not be set to trigger
when an interlock clears or is acknowledged.
6.
DCS DESIGN REQUIREMENTS
The process shall have workstations, for control, for monitoring, for
maintenance, and for data archiving. Control shall be centralized in
one control room. Each workstation must compose of one engineer
to monitor the plant operation. EXIDA will be used to provide
functional safety and security software feature in the system.
Redundancy of smart switch must be provided for 100% reliable
communication.
The DCS shall be using Delta-V S series controller for economical

and reliable control of the plant. Also SIS (Safety instrumented
System) as supported by S-series, will be used for safe and
maintainable control of ESD devices and MCC (Motor Control
Cabinet) devices. Stand-by controller or a redundant controller
must be used as a backup control for emergency situation.
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Redundancy of controllers, power supply, network switch, I/O

modules and other significant devices must be provided as a
backup during emergency situation, e.g. emergency shutdown.
The controllers must have enough number of AI, AO, DI, and DO
modules to support digital and analog devices. Also it shall support
HART devices, thus it must contain HART module.
Complete software, hardware, and communication load shall not

exceed 50% system load even after the complete implementation
of project and running pick load. This also includes redundant
processor.
The system shall have 50% margin in software memory load for
future spare addition without replacing or upgrading existing system
hardware or software at all levels. Also it shall be capable of loading
up to 100% without overrun or degradation of performance. It also
must report all type of load limit alarm, diagnostic alarms up to
channel level, communication alarm system, hardware failure alarm
and other global information with alarm facility on engineering or
operator station in real time with 1 second resolution.
System shall support various types of control, interlock, sequence

algorithm and shall also support various types of high level
programming language like function block and sequential function
chart in real time control application in addition to standard control
algorithms available in DCS.
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The system shall also support several of hourly shifts, daily and
monthly, report logs, totalizes reports, snap shots reports, etc in
Microsoft excel format only. The layout and type of reports or data,
number of tags per report, etc shall be as per owners requirement.
All operator stations and engineering stations shall be equipped
with MS Office license copy. And system shall support minimum of
1000 tag historian software at 1 second interval.
Purchaser shall provide 230Vac +/- 10% at 50Hz -3/+1 Hz, UPS
grade, floating/grounded power supply for complete DCS system at
cabinet room. All digital inputs shall have 24Vdc interrogation
voltage level. All digital outputs shall drive 24Vdc, 2 NONC, socket
mounted, interposing relays with 230D AC/5Amp contact ratings.
All field loads from digital output, including solenoid valves, MCC
switch gear signals, etc. shall be interfaced via these interposing
relays only to avoid interference problems in low voltage instrument
signal cables.
There shall not be any interposing relays for field Digital inputs but
all MCC digital inputs shall be wired to DCS via interposing relays.
While preparing the DCS database, all configurations like graphic
symbols, color codes, control or logic schematics, etc. shall be
based on ISA standards.
7. SYSTEM ARCHITECTURE
7.1
BASIS OF DESIGN
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NARRATIVE
The proposed DCS System Architecture for Geothermal Power Plant
Separator, Scrubber and Brine Disposal System is composed of five workstations. It

includes Delta-V Pro-plus for Engineering Workstation, Operator workstation, AMS Suite
for Maintenance workstation, OPC server and Historian workstation for alarm logging.
These workstations gather the data from field devices to execute commands and to
monitor the status of field devices for maintenance purposes.
Delta-V Pro-plus is used in engineering workstation, where the operator or
an engineer has an access in making changes in the control system program. Since
Operator workstation is for monitoring and manually operating the system, it does not
need any Delta-V Pro-plus. AMS Suite for maintenance workstation is used to monitor
field devices status, whether they should be calibrated or replaced with other devices,
this intelligent device manager avoid further damage of the field devices and secure that
plant operation is efficient. Historian workstation archived all the alarms and log errors
to trace them and monitor that the process is in its normal state and is efficiently
running.
These workstations communicate with two smart switches via Industrial
Ethernet to avoid error in delivering the signals from the controllers to the workstation.
Redundant S-series controllers and SIS (Safety Instrumented System) are useused as
a back-up if the active controllers fail to work. SIS or Safety Instrumented System
controller is used for those ESD field instrument. HART module is used for HART
(Highly Addressable Remote Transducer) devices. All digital devices will only be in a
conventional type of wiring. A motor control cabinet (MCC) is provided for centralized
control of motor. All MCC devices are controlled by active S-series controller and SIS
BASIS OF DESIGN
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controller for safety control via interposing relay cabinet to avoid interference problem in
low voltage instrument signal cables and communicate via HART protocol.
7.2
DRAWING
(See Document No. PIC-E-SYS-396-001)
C.
SAFETY
1.
INTRODUCTION
The production of steam can acquire can cause several types of hazards which
are being pre-determined to evaluate the appropriate safety standards to be followed.
These standards are guidelines for the purchase of materials that are applicable for
the area that is classified according to the hazards that are most likely to occur and for
personnel safety considerations. Potential hazards include process hazards, presence
of flammable fluids and combustible gas or vapors, and toxic gases.
Area classifications are based on the presence of possible cause of hazards that
are pre-determined and assumed in a specific location. The most commonly used
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codes are from IEC/NEC standards which defines the level of hazard present that may
affect process equipment and personnels health.
Geothermal process hazards are due to the critical temperature and pressure by
which the control system is operating. Another hazard that must be put into
consideration is the emission of hydrogen sulfide and CO2. Hydrogen sulfide is a
highly flammable, explosive gas, and can cause possible life-threatening situations if
not properly addressed. In addition, hydrogen sulfide gas burns and produces other
toxic vapors and gases, such as sulfur dioxide. Excessive amount of carbon dioxide
released to the surface is health threatening and creates environmental issues. At this
stage government involvement is felt.
Basis of Safety and Layers of Protection

Plant safety integrity can be measured by the level of protection it applies. Safety
starts with the basic control system. The BPCS or the basic process control system
provides significant safety through proper design. This automatic sequence has
already considered safety procedures but is not reliable enough to sustain external
sources of hazards. Sometimes the equipment itself can be the source of unsafe
process control. Process equipment exposed to high temperature and pressure and
corrosive environment application are prone to deterioration.
The next layer is still based on the control system wherein automated shutdown
routine is enforced as long as it is within the scope of the configured cause and effect
matrix.
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The next layer for protection is the intervention of the operators. In this situation
the accurate decision making determines whether alarming condition can be put into
stabilized state. Operators shall follow enacted protocols as a guide to proper response
to emergencies whenever it occurs.
Another high degree of protection uses automatic SIS. The safety instrumented
system is based on ANSI/ISA 84 functionality safety standards which state the
requirement under IEC/NEC 61511. Automatic SIS does not only include the process
level safety but also for the safety of the personnel. By integration of fire and gas and
basic process control system emergency detection the automatic, SIS is able to
determine the action to take. These actions are configured in the engineering
workstation. Safety instrumented system is also capable of diagnosing the process
equipment reliability.
The next active layer is by means of rupture disks, valves, etc.to mechanically
release process variable at an uncontrolled stage and prevent explosion or fire.
The final layer is the emergency response which includes evacuation plans,
firefighting, etc. and means to minimize ongoing damage, injury or loss of life. Plant
safety regulating body shall impose protocol whenever an emergency occurs. They
shall also assigned areas for evacuation which shall be designed to be accessible all
the time. These areas must be safe all the time even during presence of hazards in
other plant areas. Medical teams and means of transport for evacuation shall also be
considered due to critical process environment.
2.
Safety System (Fail Safe Action)

Geothermal power plant process control system safety and efficiency shall not
only be based on the configured final control element response to configured sequence.
Programmed sequences are dependent on system supplies such as pneumatic and
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electrical supplies. When these supplies fail, process sequence are interrupted which
will make process control unstable. Fail safe actions must not be dependent on the
program which the final control elements follows but must beare mechanically capable
of giving the safest possible position in case power interruptions occur. The required
predetermined control elements fail-safe actions of final control elements areis shown
in Table 1. Also, provided at Table 2 is the action taken at a specific process alarm
condition..
Table 1. Control Element Fail Actions
Tag No.
Loop
Description
Service
Fail action
LCV-103B
No.
L-103B
Level control valve
Discharge saturate to D-1200
Fail-to-open
LCV-103B
L-103A
Level control valve
Discharge saturate to D-1100
Fail-to-open
-Brine disposal to wells 33,77,

LCV-104
L-104
Level control valve
LCV-504
L-504
Level Control Valve
PCV-505A
P-505A
Pressure Control Valve
31A, 50 & binary
Fail-to-Close
-To hot brine injection

-Condensate discharged to
sump S-1100
-Reduce outgoing steam
pressure to secondary rock
Fail-to-Open
Fail-to-Open
muffler (M-700)
-Reduce outgoing steam
PCV-505B
P-505B
Pressure Control Valve
pressure to secondary rock
Fail-to-Open
muffler (M-700)
Table 2. Alarm Summary and Actions

Loop
ALARMS
LAH-102
No.
L-102
Description
Level alarm high
Actions
Start P-300B, opens LCV-103A
LAHH-102
L-102
Level alarm very high
Start P-300C, opens LCV-103B
LAL-104
L-104
Level Alarm very low
Disables AVS-102
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LALL-104
L-104
Level alarm very low
Trips P-300A and Closes LCV-104
PAH-306A
P-306
Pressure Alarm High
Trips P-300A
PAH-306B
P-306
Pressure Alarm High
Trips P-300B
PAH-306C
P-306
Pressure Alarm High
Trips P-300C
PAH-105
P-105
Pressure Alarm High
Trips all active brine pumps
LAH-203
L-203
Level Alarm High
Start P-200
LAL-203
L-203
Level Alarm Low

Differential Pressure Alarm
Stop P-200
dPAHH-301A
P-300
Very High
Trip P-300A
dPAHH-301B
P-300
Very High
Trip P-300B
dPAHH-301C
P-300
V-
Very High
Trip P-300C
VAH-302A/B/C
300A/B/C
Vibration Alarm High
Operator action/SIS
PAH-306A
P-306
Pressure Alarm High
Trip P-300A
PAH-306B
P-306
Pressure Alarm High
Trip P-300B
PAH-306C
PAH/PAHH-
P-306
Pressure Alarm High

High and Very High
Trip P-300C
Close LCV-104 on condition that all Brine
305A/B/C
P-305
Pressure Alarm
Pumps are tripped
LAH-401
L-401
Level Alarm High
Start P-400A/B
LAL-401
L-401
Level Alarm Low
Operator Action
LALL-401
L-401
Level Alarm Very Low
Trip P-400A/B
FAL-308A
F-308
Flow Alarm Low
Trip P-300A
FAL-308B
F-308
Flow Alarm Low
Trip P-300B
FAL-308C
F-308
Flow Alarm Low
LAHH-
L-502/L-
Trip P-300C
Disable AVS-502B, Open LCV-504 and
502/LAHH-503
503
Level Alarm Very High
closed solenoid valve for PCV-505A and
LAH-
L-502/L-
502B/LAH-503
503
PCV-505B air supply.

Level Alarm High
Disable AVS-502B, Open LCV-504
2.1
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System Architecture (Delta V SIS)

The integrated Delta V SIS in the system architecture shall have a
separate controller from the basic process controllers to achieve a higher degree of
plant and personnel protection and in compliance with IEC 61508 and IEC 61511
standards. The geothermal process control system shall have a redundant safety
instrumented system to maximize safety and efficiency within process control.
Safety instrumented system is composed of any combination of sensors, logic
solvers, and final elements which is separated from the process control system.
This can include safety instrumented control functions, safety instrumented
protection functions, or both.
The role of the workstations for safety purposes in the system architecture is as
follows: 1.) Proplus Station for cause and effect matrix configuration; 2.) Operator
workstation for process monitoring and remote intervention to process controls
specially during occurrence of process emergencies; 3.) Application workstations
(Historian) for alarm data archiving coming from process control transmitters and
fire and gas detectors; 4.) Application workstations configured as OPC is
responsible for open communication between devices with different protocols and
5) Application workstations for maintenance which diagnose process equipment
problems before they occur. The communication between controller and supervisory
level will be made possible using Ethernet.
The Delta V SIS controller will act as back-up system for which the main purpose
is to monitor continuously the ability of sensors, logic solvers, and final elements to
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perform on demand, with faults diagnosed before they cause spurious trips and
implement response to alarms in case the basic process control system fails.
Unstable process control results to alarming conditions that affects plant integrity in
operating at stable and safe conditions.
3.
Emergency Shutdown System
The imposed safety system will include an emergency shutdown that is not
dependent on loop action as it independently shutdown control elements. The ESD
system is integrated in to the fire and gas system where both prevent and provide safety
from incidents and unnecessary shutdowns. All plant areas will be provided with safety
fire and gas detecting instruments in compliance with the standards imposed by the
regulating bodies for safety.
ESD system shall be hierarchal. Minor alarm action will trip an instrument so that
technicians can troubleshoot the area affected. Hierarchal ESD minimize dead time
costs or losses due to production loss.
An overall shutdown will be located at the central control room. The officers-incharge or authorized personnel are responsible in tripping this centralized ESD push
button except for extreme and critical situations.
Safety board will assign level of
alarming condition where crews nearby can use this emergency button.
Strategic location for ESD stations with panels for system conditions, alarm
monitoring and location of affected area will be provided. Response is predetermined for
officer in charge to choose the corresponding action to a specific alarm condition. Push
buttons installed for a specific emergency response are hard-wire and normally deenergized to prevent short circuit, line breaks, or ground fault. ESD can also be initiated
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using the safety console integrated into the control system. Only authorized personnel
can activate the ESD.
ESD initiation will be based on the following:

ESD TYPE
ESD #1
ESD #2
ESD #3
RESPONSE
Unit shutdown
Process Shutdown
Over All shutdown
ESD Summary
Process Emergency Status -
Initiate fail safe actions
Fire Emergency Status -
ESD initiation is based on fire alarm status
Gas Emergency Status -
ESD initiation is based on gas alarm status
3. Leak Detection System

Process equipments which areis responsible for process variable such as steam,
brine and fresh water supply transmission shall be monitored to keep thesethese
equipments reliable in transmitting the expected process output.
A level transmitter is integrated in all non-submersible pumps to detect fluids that
comesfluids that come out from these pumps. The transmitter will link its
measurement to the SIS controller to give the corresponding action to take. The
action usually taken at this condition is tripping the working pump and gives its work
to a back-up pump.
4. Fire Detection System
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The fire detection system is integrated into the design to minimize risk of
equipment destruction and personnel safety. Smoke detectors and other fire
detecting instruments are looped separately from process design but are integrated
into the delta V SIS for to provide interlocks to process equipment and provide safety
action in case fire occurs. Multiple installation of fire detecting instruments in an area
will increase the accuracy in terms of locating the defective area. Fire detecting
instruments are hard wired to delta V SIS controllers therefore special modules will
not be required.
Operator interfaces and indicators shall be installed to determine level of risk and
location of fire. Stations for manual fire alarm trigger will also be installed in different
plant areas. When these alarms are triggered by officers in charge, it usually intends
to imply a heightened level alert and response would be overall emergency
shutdown and evacuation. Personnel are obliged to report emergency status and
provide appropriate response to these alarms.
Fire detector output such as audible and visual consoles will be based on how
critical the present situation is. This is to provide accurate response in case fire
occurs.
Below are areas within geothermal power plant that are prone to fire and explosion.
Location
# of Detectors
ESD Initiation
Separator
Scrubber
Flash tanks
Pipelines
Level Drums
Multiple detection
Multiple detection
Single detection
Multiple detection
Single detection
ESD #1-2
ESD #1-2
ESD #1
ESD #1-3
ESD #1-2
HMI
Active Alarm Consoles

Audible
Visual
Workstations
Control Room
Other control
system loops
5.
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Multiple detection
ESD #3
Single detection
ESD #1
Gas Detection System

Gas detection system comprise of instruments that measures level of risk once
an unstable amount of toxic gases or combustible gases reaches the surface or

exposed to an area. These gases are usually in the form of carbon dioxide and
hydrogen sulfide. Gas detectors are either installed at multiple points in an area or
single gas detectors.
Alarms will only read normal gas condition, toxic or combustible gas level rising
and alarming level of gas detected.
Gas detection system does not require special module in a controller. Its 4-20 mA
signal to controller can support interfacing with the controller level and into the
supervisory level for complete safety compliance with IEC 61511.
Plant areas that usually exposed to this combustible and toxic gas are usually
found in venting areas. These areas include the well-field and the plant-site vent
mufflers. Pipelines will also be provided with gas detectors for cases where leaks occur.
Graphical and tabulated data will be recorded in the in the historian workstation
for periodically evaluation of plant safety status. Location, alarm status and options for
alarm action will be displayed in HMIs and workstations.
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Below are the details for gas detection locations, console and ESD response
6.
Active Alarm Consoles

HMI Audible Visual Workstations
Location
# of Detectors
ESD Initiation
Separator
Multiple detection
ESD #1-3
Scrubber
Multiple detection
ESD #1-3
Flash tanks
Single detection
ESD #1-3
Rock mufflers
Single detection
ESD #1
Pipelines
Multiple detection
ESD #1
Level Drums
Single detection
ESD #1
Well Field
Multiple Detection
ESD #3
Audible and Visual Alarms

OSHA standards and guidelines which focus on the personnel safety shall be
implemented as well as the general industry standards. Installation of audible and visual
alarms especially for remote plants comply the requirements stated by the said
standards. To alert the personnel in case of emergency is the main objectives of these
alarm hardware. Indication of these consoles shall only mean occurrence of
emergencies involving life threatening events.
The design for geothermal plant alarms shall indicate the following events:
Visual alarms (in the form of emergency lamps)
Indications:
Green plant operating in normal condition
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Yellow presence of unstable process/environmental issue

Red- ESD 3 response or evacuation
Audible alarms (usually Beacons/ Alarm Bells)
Indications:
No sound - Plant operating in normal conditions
Non-continuous sound - presence of unstable process/environmental issue
Continuous sound - ESD 3 response or evacuation
D.
NAMING CONVENTION
1.
SCOPE
This document contains the naming convention of different deliverables, and
used as a reference for easy identification of each part.

1
NAMING CONVENTION
The naming convention of each deliverable can be determined by the following:

X symbolizes alphabet letters (e.g. A, B, C, D)
0 symbolizes numbers (e.g. 0, 1, 2, 3..)
1
DOCUMENT/DRAWING
XXX X XXX 000 - 000

SHEET
NO.
NO. CODE
DELIVERABLE
CLASSIFICATION
COMPANY NAME
BASIS OF DESIGN
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Rev.
No.
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No.
Abbr
Example: PIC-E-PID-396-001
Company Name PIC
(Process Instrumentation
Company) is the company
name used in this document.
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Description
v.
DWG
NAR
IDX
SPC
Drawing
Narrative
Index
Specifications and
LST
SCD
Datasheets
List
Schedule
No.
Code
396
627
439
773
578
723
Classification To determine either Engineering (E) or Design (D) is

involved in the deliverables.
Deliverable - The list of requirements provided by the company.
No. Code - This is used for determining the main deliverables.
Sheet No. - This is used for determining the subtopics of main deliverables.
Abbr
Description
v.
PID
Process and Instrument
NTV
SARC
SPC
SHT
INDX
IOL
JBL
CBL
IAM
WRG
LPD
LOC
INS
Diagram
Narrative
System Architecture
Specification
Data Sheet
Index
I/O List
Junction Box List/Schedule
Cable List/Schedule
Instrument Air Manifold
Wiring Diagram
Loop Diagram
Location (JB/IAM)
Installation
DELIVERABLES
NO.CODE
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2.2 JUNCTION BOX

XXX X - 000
Example: DJB-A-001
JUNCTION BOX
NO.
AREA
TYPE OF SIGNAL
Type of Signal - The instruments signal type can either be Analog (A) or
Digital (D). After determining its signal type, JB initials is followed which
stands for Junction Box.
Area- It represents A which stands for Area.
Junction Box No. - It identifies the number of junction box within the area.
2
DEVICE CABLE
XX XXX - 000
INSTRUMENT TAG
NO.
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DEVICE CABLE
Example: DC-LSH-102
Device Cable- It represents DC which stands for Device Cable.
Instrument Tag No. The instrument tag number is based on its function
and loop in the process.
3
SYSTEM CABLE
XX XXX - 000
INSTRUMENT TAG
NO.
SYSTEM CABLE
Example: DC-LSH-102
System Cable- It represents SC which stands for System Cable.
Instrument Tag No. The instrument tag number is based on its function
and loop in the process.
4
LINE
0 XX X/X000 - X/X000 - 00
NUMBER
TO EQUIPMENT
FROM EQUIPMENT
SIZE
MATERIAL
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Example: 24-CS-D1100-T100-01
Size- It indicates the pipe size in the process line, and usually measured in
inches.
Material- The pipe in the process is made of carbon steel (CS).
From and To Equipment These specify the connection of pipe between
equipment. In this case, - is removed in the tag name of equipment.
5
MARSHALLING CABINET
XX 000
Example: MC-LIT-104
MARSHALLING
CABINET NO.
MARSHALLING
CABINET
Marshalling Cabinet - It represents MC which stands for Marshalling

Cabinet.
Marshalling Cabinet No. - It identifies the number of junction box within the
area.
6
MAIN CABLE
XX XXX X 000: 0 - 0
TERMINAL STRIP
NO.
TERMINAL BLOCK
NO.
JUNCTION BOX
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MAIN CABLE
Example: MC-DJB-A-001:1-1
Main Cable - It represents MC which stands for Main Cable.

Junction Box The place where the main cable is located.
Terminal Block No. The main cable is terminated in a certain terminal
block no.
Terminal Strip No. - The numerator value of the terminal strip is used.
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PROJECT TITLE

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Emergency Shut Down

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National Pipe Thread

American Wire Gauge

Distributed Control System

Programmable Logic Controller

Visual Display Unit

Motor Control Cabinet

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International Electro technical Commission (IEC)

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electronic safety-related systems

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IP RATINGS (Ingress Protection)

Totally protected against dust ingress, protected against low

Limited protection against dust ingress, protected against

Protected against solid objects over 1.0mm e.g. wires,

International Society of Automation (ISA)

Instrumentation Symbols and Identification

Control Valve Sizing Equations

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National Electrical Manufacturers Association (NEMA)

National Electrical Codes

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American Petroleum Institute (API)

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Indian Standard (IS)

Gases Flow Rate

Steam Flow Rate

The selection of the process equipment shall be based on conditions and

The separation process commences by utilizing the difference in

It operates by using the centrifugal force of the spinning steam and

The 2-phase phase fluid usually contains carryovers and impurities

Maximum of 1.0 ppm

Maximum of 1.0 ppm

Should be between 1.0 to 3.0 ppm

Level drum is ashall hold condensate holding vessel acquired from

low pressure vapors. The level drum

dimension shall be: 406.4mm inner diameter and height of 1524 mm

2.1.5 Seal Water Tank

2.1.65 PUMP MOTOR

The saturated fluid and condensate level shall be controlled using

process. It shall have an electrical output signal of 4-20mA in order to

in safety shutdown systems and use a displacer-style sensor located in an

DIFFERENTIAL PRESSURE TRANSMITTER

The differential pressure transmitter shall consist of a mechanical

shall provide gage pressure measurement and indication. It shall have an

measuring element shall be diaphragm seal to protect from slurry fluids.

ORIFICE PLATE FLOW METER

orifice plate designed for flange tap and capable of withstanding

PITOT TUBE FLOW METER

allows flow separation at a fixed point. It shall be comprised of high and

proportional linear pneumatic output (3-15psig) or vice versa. For split

The minimum supply pressure shall be 3 to 15 psig. For safety

These actuators shall be direct acting that provides fail-to-open for

maximum operating pressure may be up to 150psig. The connection shall

controlling air pressure. For general atmospheres, the material shall be