Fundamentals of Commercial Geothermal Wellfield Design

APPENDIX
Fundamentals of
Commercial Geothermal
Wellfield Design
Intended for general distribution to:
Geothermal Wellfield Designers, Engineers & Architects
Distributed by:
GHP Systems, Inc.
1000 N 32nd Ave
Brookings, SD 57006
Prepared by:
Kris Charles Jeppesen
About the Author:
Kris Jeppesen is the President of GHP Systems, Inc.,
a leading manufacturer and supplier of commercial geothermal wellfield
products. Jeppesen has been involved in the geothermal industry
for many years as a contractor, researcher, geothermal training center instructor
and design engineer. He is an IGSHPA Certified Trainer and an AEE Certified
GeoExchange Designer. He received his B.S. and M.S. in Mechanical Engineering
from South Dakota State University.
2010 GHP Systems, Inc.
NOTICE: THIS DOCUMENT REPORTS ACCURATE AND RELIABLE INFORMATION TO THE BEST OF OUR KNOWLEDGE BUT OUR SUGGESTIONS AND
RECOMMENDATIONS CANNOT BE GUARANTEED BECAUSE THE CONDITIONS OF USE ARE BEYOND OUR CONTROL. THE USER OF SUCH INFORMATION
ASSUMES ALL RISK CONNECTED WITH THE USE THEREFORE. THE AUTHOR AND DISTRIBUTOR ASSUMES NO RESPONSIBILITY FOR THE USE OF THE
INFORMATION PRESENTED HEREIN AND HEREBY DISCLAIMS ALL LIABILITY IN REGARD TO SUCH USE.
INDEX
INTRODUCTION
Definition ............................................................................................. 2
GROUND CONDITIONS
Land Area Availability and Drilling Conditions ................................ 2
Test Bore ............................................................................................. 3
Formation Thermal Conductivity Test .............................................. 4
VERTICAL HEAT EXCHANGER DESIGN LENGTH
Effects of Heating versus Cooling of Wellfield Sizing ..................... 5
Effects of Equipment .......................................................................... 6
Geothermal Borehole Resistance ..................................................... 6
Sensitivity Analysis ............................................................................ 7
SYSTEM PIPING DESIGN
Pipe Sizing .......................................................................................... 9
Header Design Using Multiple Circuits ............................................. 9
Reverse Return ................................................................................. 10
Reduced Header ............................................................................... 10
Single Supply and Return Mains ..................................................... 11
Multiple Supply and Return Mains .................................................. 11
Manifolds ........................................................................................... 12
MATERIALS
Pipe .................................................................................................... 13
Grout .................................................................................................. 13
Antifreeze .......................................................................................... 13
APPENDIX
Mean Water Temperature Graph ..................................................... 14
Flow Characteristics of HDPE Pipe ................................................. 15
Example VHE Report ....................................................................... 18
Example Formation Thermal Conductivity Analysis ..................... 19
Detailed Drawings
VHE Borehole Detail ........................................................................ 20
Geothermal Wellfield Layout ............................................................ 21
Vault Detail ...................................................................................... 22
Example Geothermal Wellfield Specifications ............................... 23
FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

NOTICE: THIS DOCUMENT REPORTS ACCURATE AND RELIABLE INFORMATION TO THE BEST OF OUR KNOWLEDGE BUT OUR SUGGESTIONS AND RECOMMENDATIONS
CANNOT BE GUARANTEED BECAUSE THE CONDITIONS OF USE ARE BEYOND OUR CONTROL. THE USER OF SUCH INFORMATION ASSUMES ALL RISK CONNECTED WITH
THE USE THEREFORE. THE AUTHOR AND DISTRIBUTOR ASSUMES NO RESPONSIBILITY FOR THE USE OF THE INFORMATION PRESENTED HEREIN AND HEREBY DISCLAIMS
ALL LIABILITY IN REGARD TO SUCH USE.
INTRODUCTION
With the rapidly growing interest in commercial geothermal heat pump systems, the
demand for qualified designers, engineers and architects who can successfully tackle these
projects has also increased. In many cases, designing the geothermal wellfield causes the
main difficulty for the designer. A poorly designed geothermal wellfield can lead to poor
system performance, excessive installation costs, and unnecessary liability. The intent of
this design guide is to outline procedures and design techniques necessary to optimize the
geothermal wellfield design.
Definition
A closed-loop geothermal wellfield
exchanges energy with the earth by
circulating a water or
water/antifreeze solution through
plastic pipe buried beneath the
earths surface. A vertical closedloop geothermal wellfield typically
consists of multiple vertical heat
exchangers (VHEs). VHEs are
constructed by drilling holes
generally ranging from 50 to 400
feet deep in the earth and then
inserting two pipes with a fitting
joining the two pipe ends at the
bottom (called a u-bend pipe
assembly). The remaining open
annulus of the drilled borehole is
then backfilled or grouted, thereby
encasing the u-bend pipe assembly
(see diagram at right).
VERTICAL HEAT EXCHANGER (VHE)
EARTH
GROUT OR BACKFILL
SPECIFIED DEPTH
U-BEND PIPE
GROUND CONDITIONS
Land Area Availability and Drilling Conditions
A geothermal system can usually be implemented by any heating/cooling application -- providing
that favorable conditions exist to do the geothermal wellfield installation. Available and suitable
land area may be a constraint as to the feasibility of installing a geothermal heat pump system.
A rough rule of thumb is that there should be a minimum of 225 sq-ft of land area available per ton
(12,000 Btuh) of design load capacity. However, designing longer VHE depths and/or tighter VHE
grid spacing can accommodate land area constraints. Installation areas should be relatively level,
dry, free of trees, underground utilities and other obstacles complicating the installation. Once the
geothermal wellfield is installed, this land area can become a parking lot, park, football field or a
variety of other applications.

Another significant factor determining the feasibility of the wellfield is whether or not the drilling
conditions are favorable. Drilling logs from wells drilled in the area can usually be obtained from the
State and can provide the designer with general expectations of the subsoil formation. Additional
information on drilling difficulty can be obtained by contacting local drillers from the area. Obviously,
the more difficult the drilling conditions the more expensive the wellfield installation.
Test Bore
The primary unknown factor that changes from one geothermal wellfield project to the next is the
VHEs borehole composition. The borehole soil/rock composition plays a significant role
determining drilling costs and total required VHE lengths. For smaller geothermal wellfield projects
(30 ton or less), drilling logs of water wells can provide reasonable assumptions. However, a test
bore should be drilled on site to obtain accurate drilling conditions and to increase the design
reliability for larger commercial wellfield projects. In addition, it is also recommended to install a ubend pipe in accordance with the anticipated design length so that a formation thermal conductivity
test can be performed as described in the following section.
Drilling contractors will assume the worst case drilling conditions in their bids if they are unfamiliar
with the drilling conditions and if a drilling log is not provided with the bidding documents. Inflated
drilling costs will significantly increase the bid price for the entire geothermal wellfield project. A
detailed drilling log similar to the one below should be included with bid documents.
TEST BORE DRILLING LOG
DRILLING LOCATION
GHP SYSTEMS, INC.

1000 N 32ND AVE.
BROOKINGS, SD 57006
PERMIT NO
CONTRACTOR
DRILLING LICENSE
NA
JOHN JAMES
XXXX1234
DEPTH IN FEET
FROM
0
3
22
85
153
159
165
187
200
STATIC WATER LEVEL
DRILLING METHOD
TOTAL DRILLING TIME
U-BEND INSTALLED
GROUT TYPE
TO
3
22
85
153
159
165
187
200
DESCRIPTION
TOP SOIL
BROWN CLAY
GRAY CLAY
BROWN CLAY
SAND & GRAVEL
SOFT SAND STONE
GRAY SHALE
RED SHALE
LIMESTONE HARD
15 FEET
MUD ROTARY
1.5 HOURS
YES HDPE PIPE
Thermally Enhance 1:4 ratio bentonite: silica

The drilling log above indicates that drilling becomes difficult at 200 feet when bedrock is hit.
Drilling deeper into the hard limestone would be more expensive per linear foot than the first 200
feet, so the VHEs specified design depth would typically not go beyond 200 feet. If there is an
available land constraint the designer may have to consider going deeper than 200 feet with the
VHE depth.
Formation Thermal Conductivity Test

A test bore provides the necessary information required by the installing contractor for drilling
purposes. Although the design engineer is now aware of the formation makeup, he must refer to
tables to determine the anticipated thermal conductivity range for each soil/rock type and interpolate
an overall average formation thermal conductivity. At this point, there still remains a large degree of
uncertainty so designs tend to be overly conservative. To obtain a reasonably accurate value for the
formation thermal conductivity, a test measuring this value needs to be performed on a VHE at the
project site. The drilling log test bore can now be used to test the formation thermal conductivity by
installing a u-bend pipe assembly to the anticipated design depth and then grouting the remaining
borehole annulus.
This in-situ thermal conductivity testing or more commonly called heat dump testing, has water that
is heated with a constant energy input circulating through the VHE piping. The temperature of the
water with respect to time is recorded. Based on the increase in water temperature with respect to
time, the formations thermal conductivity can be calculated. The longer the duration of this heat
dump test, the more accurate the results are, but the cost of conducting the longer test increases.
This design guide suggests a minimum of a 24-hour test duration. Industry standards tend to lean
toward a 48-hour test duration producing more accurate results. The implementation of u-bend pipe
separators and/or thermally enhanced bentonite grout will make shorter test durations more
accurate.
The graph below shows the recorded data from a 24-hour formation thermal conductivity test. The
average water temperature data is plotted with respect to the natural log of time. Line source theory
can be used to determine the formation thermal conductivity once the slope of the regression line
for this data is determined. There are several factors that influence the results of these tests, so it is
strongly recommended that experienced personnel analyze the data and calculate the resulting
thermal conductivity (see appendix page 20 for an example report).
TEMP (F)
FORMATION T.C. TEST
-5.00
100
80
60
40
20
0
0.00
5.00
LN TIME (HOURS)
AVG

VERTICAL HEAT EXCHANGER DESIGN LENGTH

Determining the required total VHE length can prove to be the most challenging task in the
geothermal wellfield design process. There are several wellfield design software programs
that assist designers in calculating the total required VHE lengths such as Ground Loop
Design that can be downloaded. Regardless of the software program used, designers need
to have a fundamental understanding of various factors affecting VHE design lengths.
Obviously, the buildings design loads, the grounds soil/rock thermal conductivity and
mean ground temperature play significant roles in determining design lengths (see
Appendix page 15 for Mean Ground Water Temperature Graph). However, other influential
factors that determine design lengths include seasonal diversification between loads,
ground water movement, heat pump efficiencies, borehole resistance, and VHE spacing.
Effects of Heating Versus Cooling of Wellfield Sizing
The most basic concept in understanding the geothermal wellfield loads involves not only the
building loads themselves, but also the effect of which load heating or cooling -- is dominant; also
to be considered is the efficiencies of the geothermal heat pumps used. The following example is
provided to explain this concept of comparing two identical geothermal heat pumps, where one unit
is heating and the other unit is cooling. These units are both operating at 300% efficiency; typically
the efficiency in cooling is higher than in heating.
Heating: For the theological geothermal heat pump in heating, every three units of energy delivered into the conditioned
environment comes from two units of energy extracted from the wellfield and one unit of energy provided by the electricity
required to run the compressor. Therefore, only 2/3 of the
buildings heating load is absorbed from the wellfield.
HEATING
Cooling: For the theological geothermal heat pump in
cooling, every three units of energy that are removed from
the conditioned environment are added to one unit of energy
from the electricity required to run the compressor to be
rejected into the wellfield. Therefore, not only is the entire
building load rejected into the wellfield, but an additional
33% of that load in electrical input is also rejected into the
wellfield.
The purpose of the above example is to demonstrate the
influence of the buildings dominant load on the sizing of the
wellfield. In theory, a building that requires only cooling
could require twice the wellfield capacity as a building with
the same size load that requires only heating. Likewise, a
building with even larger loads -- seasonally diversified in
heating and cooling -- may require a smaller wellfield
capacity, then a building with smaller loads but highly cooling
or heating dominant.
(3 UNITS ENEGY OUT)
ELECTRIC
(1 UNIT ENERGY IN)
LOOPFIELD
(2 UNITS ENERGY IN)
GEOTHERMAL
HEAT
PUMP
(300% EFFICIENT)
LOOPFIELD LOAD = HEATING - ELECTRIC
COOLING
(3 UNITS ENEGY IN)
ELECTRIC
(1 UNIT ENERGY IN)
LOOPFIELD
(4 UNITS ENERGY OUT)
GEOTHERMAL
HEAT
PUMP
(300% EFFICIENT)
LOOPFIELD LOAD = COOLING + ELECTRIC

Effects of Equipment
Geothermal heat pump equipment selection also significantly affects the wellfield design lengths.
This should be clear if the basic theory presented in the preceding section is understood.
Geothermal heat pump models vary in efficiencies. A more efficient heat pump will require a lower
capacity wellfield in cooling, but a larger capacity wellfield in heating, compared to a lower efficiency
heat pump. This is supported by the fact that the more efficient a heat pump is, the less electricity it
will require to provide the same capacity. This means that in the cooling mode, less electrical
energy needs to be rejected into the wellfield along with the energy removed from the building.
However, in the heating mode, a more efficient geothermal heat pump will provide less electrical
energy into the heated environment, so more energy is absorbed from the wellfield to obtain the
same capacity. A geothermal heat pump that has a high heating and low cooling efficiency will
require a much larger wellfield capacity than a geothermal heat pump that will produce the same
capacities, but has a low heating, high cooling efficiency.
Geothermal Borehole Resistance

The performance of a VHE is largely influenced by the soil/rock surrounding the borehole; however,
the backfill or grout used in the borehole and the positioning of the u-bend pipes within the borehole
also significantly contributes to the VHEs performance.
A standard VHE installation has two pipes (that make up the u-bend pipe assembly) that are either
touching or are in close proximity of each other, thus interfering with each others ability to
exchange energy with the earth. These u-bend pipes are usually encased with a 20% solids
bentonite grout (often required by State regulations) in order to seal the borehole to prevent
contamination of water aquifers below ground. Although the bentonite grout mixture is excellent for
sealing the borehole, it has poor heat transfer characteristics and acts as an insulator that restricts
energy exchange between the u-bend pipes and the surrounding soil/rock. Recent technology
(within the last 10 years or so) has developed products that can be utilized to decrease borehole
resistance, thereby significantly increasing the performance of a VHE and lowering the installation
costs by shortening required VHE lengths.
The two most significant breakthroughs in VHE design include thermally enhanced (T.E.) bentonite
grouts and u-bend pipe separators. Currently, there are T.E. grouts that can increase the thermal
conductivity of bentonite grout ranging from 0.4 Btu/hr-ft-F up to as high as 1.4 Btu/hr-ft-F. This
guide suggests that a grout thermal conductivity of 0.90 Btu/hr-ft-F to typically be the most cost
effective for most design conditions. Most T.E. grouts add silica sand to the bentonite to increase its
thermal conductivity while maintaining a low permeability rate of less than 1X10-7 cm/s. Also
available are u-bend pipe separators (GeoClips) that attach to the u-bend pipes positioning them
against the borehole wall directly across from each other. Positioning the u-bend pipes against the
borehole wall and separating them as far apart as possible, significantly lowers the insulating effect
of the bentonite grout, increases the area of energy absorption/rejection and decreases energy
exchange between the two pipes.

VERTICAL HEAT EXCHANGER

BOREHOLE CONFIGURATION
RESULTING ENERGY EFFECTS

BASED ON BOREHOLE CONFIGURATION
STANDARD U-BEND INSTALLATION

STANDARD BENTONITE GROUT
TYPICAL STANDARD CAPACITY

VERTICAL HEAT EXCHANGER
U-BEND PIPE SEPARATOR

STANDARD BENTONITE GROUT
ENERGY APPLIED

T.E. GROUT
ENERGY APPLIED
LARGE CAPACITY INCREASE

OVER STANDARD INSTALLATION
CAPACITY INCREASES EVEN MORE WITH
U-BEND PIPE SEPARATOR AND T.E. GROUT
ENERGY APPLIED
The diagram above illustrates how the energy flux of a VHE is affected by its configuration. The first
configuration uses no performance enhancing technology; therefore, the borehole resistance
greatly inhibits the exchange of energy of the circulating fluid and the earth. The energy flux
increases significantly with the use of u-bend pipe separators in the second configuration. An even
greater increase in capacity is gained by incorporating a T.E. grout with the u-bend pipe separator
as shown in the third borehole configuration. A key point to consider is that there is a balance
between the added cost of increasing VHE performance and the savings incurred by shortening the
total VHE length.
Sensitivity Analysis
The objective in sizing and designing a VHE is to obtain the required wellfield capacity for the
lowest installation cost. The areas of control when designing a VHE include pipe placement, grout
thermal conductivity, u-bend pipe size and VHE grid spacing. The following graphs show how each
parameter influences the VHE design lengths.
VHE U-BEND SIZING & VHE GRID

SPACING COMPARISON
(12,000 Btuh cooling)
VHE DESIGN LENGTH (feet)
The graph to the right demonstrates the effects

that grid spacing and u-bend pipe sizes have on
VHE design lengths. This example is typical in
that the design depth decreases dramatically as
the VHE grid spacing approaches 10 feet and
continues to decrease as grid spacing gets
larger. In this example the VHE decrease isnt
significant enough to justify the extra cost of
going beyond twenty-foot grid spacing. Typical
designs find 15 to 20 foot grid spacing optimum.
However, warmer climates with cooling dominate
loads and higher mean earth temperatures can
justify grid spacing greater than 20 feet. This
example also shows an increase in performance
by using larger diameter u-bend pipes; but, this is
usually outweighed by the additional cost of the
larger pipe and increased volume of antifreeze
required. U-bend pipe size should be determined
by required flow as pertaining to head loss and/or
turbulent flow (see VHE pipe sizing section for
more detail).
450
400
350
300
250
200
5
10
15
20
25
VHE GRID SPACING (feet)

3/4" U-BEND
1" U-BEND
1 1/4" U-BEND

VHE DESIGN LENGTH VERSUS PIPE

PLACEMENT & GROUT T.C.
(12,000 Btuh Cooling / VHE)
VHE DESIGN LENGTH (feet)
The graph to the right demonstrates the effects

of u-bend pipe placement within the borehole
and grout thermal conductivity on VHE design
lengths. As previously mentioned, lowering the
borehole resistance significantly shortens the
required VHE design length. By simply
implementing a u-bend pipe separator, the
design length in this example is decreased by
50 feet. This example also demonstrates how
increasing the grout thermal conductivity
correlates directly with the decrease in design
lengths. However, as with VHE grid spacing in
the example above, there is a point of
diminishing returns. Higher thermal
conductivity grouts are more expensive and
labor intensive to mix and pump. In most
instances, either a 0.90 Btu/hr-ft-F thermally
enhanced grout by itself or a combination ubend pipe separator with a lower 0.57 Btu/hr-ftF thermal conductivity grout optimizes cost
versus performance.
260
240
220
200
180
160
140
GROUT THERMAL COND. (Btu/hr-ft-F)
Random Pipe Placement
U-bend Pipe Separator

SYSTEM PIPING DESIGN

Pipe Sizing
Excessive head loss of circulating fluid through the wellfield can account for a large portion of the
entire geothermal heat pump systems operating costs. This guide suggests keeping the entire
wellfield head loss below 50 feet of head. This can typically be achieved by designing the entire
wellfield piping to have around 3 (maximum of 4) feet of head loss per 100 feet of pipe or less.
For the VHE pipe size the industry practice tries to achieve turbulent flow or a Reynolds Number
greater than 2,500 (transition) in all of the VHEs to attain the maximum heat transfer between the
circulating fluid and the pipe during peak operation. For large wellfields that are designed around
ground thermal buildup or depletion (usually a 10 year modeling period is used), turbulent flow
plays less importance because the wellfield size is significantly increased to compensate for the
long term thermal effects. If the circulating solution is pure water, turbulent flow is easily achieved
because a flow rate of 2 GPM will be turbulent even in a 1 u-bend pipe. The flow must be much
higher if the circulating fluid consists of a 25% propylene glycol/water solution and the solution
temperature gets down in the 30F range. Now to be in turbulent flow the u-bends minimum flow
rate for requires 3 GPM, 1 requires 4 GPM and 1 requires 5 GPM. The corresponding
feet of head loss per 100 of pipe are 4.1 for , 2.0 for 1 and 1.0 for 1. Typical designs use
u-bends for flow rates up to 3 GPM, 1 u-bends for flow rates between 3 to 6 GPM and
1ubends for flow rates between 6 to 12 GPM. This information pertains to DR11 (160 psi) pipe.
Header Design Using Multiple Circuits

The wellfield header is used to connect all of the VHEs together. The planning of the header design
plays an important factor on the performance, installation cost and reliability of the geothermal
wellfield. A recommended design practice is to header the VHEs using multiple 2 or 3 circuit
piping. This guide recommends having at least 4 circuits when possible so that if a leak would ever
develop you could isolate that circuit and only lose 25% of your wellfield. This would allow the
geothermal system to still operate in a limited capacity while waiting for the leak to be repaired.
A common practice is to use 2 circuits on smaller commercial wellfield projects so there is greater
control especially for isolation purposes. On larger wellfield projects 3 circuits usually provide the
most economic installations because you can significantly reduce the number of circuits.
To keep the head loss in the range previously mentioned in the Pipe Sizing section our design
would limit 2 (DR11) pipe to flow rates between 30 to 35 GPM and between 80 to 100 GPM for
3 (DR15.5) pipe. With these flow rates you would typically see designs with (8 to 14) - , (6 to 8)
- 1 or (3 to 6) - 1 VHEs being serviced on a single 2 circuit. A single 3 circuit would commonly
have designs servicing (24 to 40) - , (18 to 24) - 1 and (9 to 18) - 1 VHEs. Of course the
number VHEs on a circuit can fall outside those listed above depending on the type of circulating
solution and the required VHE flow rates (see Appendix page 16 for Flow Characteristics of High
Density Polyethylene (HDPE) Pipe).

Reverse Return Circuit
3 GPM
3 GPM
3 GPM
3 GPM
3 GPM
3 GPM
3 GPM
3 GPM
3 GPM
30 GPM
3 GPM
To obtain balanced flow through all of the

VHEs, each circuit header design should
have a reverse return. As illustrated to the
right, with a reverse return header, the first
VHE hooked up on the supply line is the last
VHE on the return line. This header
technique will balance flow between the
VHEs on this circuit, provided that all of the
u-bend pipe lengths are approximately the
same.
Reduced Header
Once the headering process is complete, the entire wellfield piping system needs to be flushed of
all debris and purged of air. This process is performed by circulating water through all of the
wellfield piping system at high flow rates. The industrys accepted standard is to obtain a minimum
velocity of 2 feet per second through all piping. If a reduced header is not used, it may be
impossible to obtain this flow rate through portions of the header.
3/4"
1"
1 1/4"
2"
2"
1 1/4"
1"
3/4"
The reduced piping in the above header diagram can be explained by reviewing the required
velocities needed to purge the VHEs (see Appendix page 16 for Flow Characteristics of High
Density Polyethylene (HDPE) Pipe). This example uses HDPE DR11 pipe for the VHEs which
requires a flow rate of approximately 3.75 GPM to obtain a velocity of 2 feet per second through
each VHE. The main line, which is 2 HDPE DR 11, requires a flow rate of 19 GPM to obtain the
necessary 2 feet per second velocity. If the main line does not reduce in size as it approaches the
last VHEs hooked up in parallel to the main line, the flow rates will fall well below the required 2 feet
per second velocity, thus allowing air and debris to remain in that portion of the header pipe. In this
example, 13 VHEs need to be flushed and purged, at the same time requiring a total flow rate of
about 48 GPM at 3.75 GPM through each VHE. The reduced header system shown will flush and
purge all header piping as well as all the VHEs and not add excessive head pressure to the system
under normal operation.

10
Single Supply & Return Mains

The wellfield layout illustrated to the
right shows all smaller header circuits
connected to a single large main header
that is brought into the building.
Although there is nothing wrong with this
type of header system from a balanced
system flow standpoint, it is not the best
option when considering liability. The
primary concern is that if a leak would
occur, the entire wellfield is in jeopardy
of going down until the leak is repaired.
Locating that leak could become a major
ordeal because there is no individual
circuit isolation to perform pressure
checks. The entire wellfield also needs
to be flushed and purged at the same
time, which requires a very large
pumping and filtering system.
SINGLE SUPPLY & RETURN MAINS

TO BUILDING
D
E
D
N
E
M
M
O
C
E
R
T
NO
Multiple Supply & Return Mains

This guide suggests using a wellfield
header system that has multiple valved
circuits that are either brought into the
building or to a vault where they are
connected to a manifold as illustrated to
the right. The primary advantage of
implementing this type of header system
is that if a leak occurs, only a small
percentage of the VHEs are taken out of
service. A leaking circuit can be isolated
by shutting off valves connecting that
circuit to an accessible manifold. The
task of locating a leak is also much
easier by pressure testing and
identifying which circuit needs to be
repaired. Another advantage is that
each circuit can be flushed and purged
individually. Balancing valve can be
used on this system to balance flow
between circuits.
MULTIPLE SUPPLY & RETURN MAINS
TO BUILDING

11
Manifolds
A typical manifold (interior manifold shown below) includes butterfly isolation valves, combination
balancing/isolation valves and pressure/temperature ports for each circuit. With this design setup,
circuit isolation, pressure testing and flow balancing can be easily performed. Each circuit can be
individually flushed and purged and accessed by connecting to the fill port. The mains should also
have isolation valves so the wellfield contractor can complete his portion of the installation
independent of the interior mechanical. Having temperature and pressure indicators installed on the
mains can aid in quick system checks during startup as well as during normal operation (see
appendix page 23 for vault layout).

12
MATERIALS
Pipe
High density polyethylene (HDPE) pipe is the geothermal industrys standard piping material.
The specific pipe used is a PE3408 HDPE with a minimum cell classification of 345464C per
ASTM D-3035. Typically, a DR 11 (160 psi) rating is used for u-bends and header pipe diameters
two inches and smaller; and a minimum of DR 15.5 (110 psi) is used for header pipe diameters
greater than two inches. Pipe produced specifically for the geothermal industry generally carries
a 50-year or longer warranty and has a life expectancy of over 100 years.
Advantages to using HDPE pipe include the following characteristics: toughness, durability,
and chemical and corrosion resistance. Another advantage of HDPE pipe is that it requires no
mechanical or glued fittings that could corrode or fail. All joints are permanently joined (welded)
with heat fusion, providing a leak proof joint when properly joined. The smooth wall of this pipe
accommodates low-pressure losses.
Grout
Many State and local regulatory agencies dictate grouting material and procedures for VHE
installations. In most cases, a 20% solids bentonite grout that is pumped from the bottom of the
borehole up in a continuous fashion will meet those requirements. The purpose of grouting with
bentonite is to form a hydraulic seal which will prevent contamination of aquifers. The permeability
rate of bentonite is approximately 1 x 10-9 centimeters per second; therefore, it is an excellent
medium for sealing a borehole. Bentonite grout products are usually bagged in a dry powder or
granular form; and, when mixed with water, will hydrate swelling to many times its dry size.
The primary drawback of using straight bentonite grout in VHEs is that it has a poor thermal
conductivity (K = 0.4 Btu/hr ft-F). Since the u-bend pipes are encased in the bentonite grout,
they are restricted from exchanging energy with the surrounding soil/rock. Thermally Enhanced
bentonite grouts add silica sand in with the bentonite/water slurry to increase its thermal
conductivity ranging up to 1.4 Btu/hr -ft-F. However, these thermally enhanced bentonite grout
products are expensive and labor intensive; therefore, it is rarely cost effective to increase the
thermal conductivity higher than 0.9 Btu/hr-ft-F.
Antifreeze
An ideal antifreeze solution for use in a geothermal wellfield system would be non-corrosive,
non-toxic, economical, possess low flammability and low viscosity, and meet all state & local
regulations. Currently, there is no particular antifreeze product that meets all of the desired
characteristics. For commercial geothermal heat pump systems, the most common antifreeze
used is propylene glycol (usually with inhibitors) and in many States, it is the only antifreeze
solution allowed in vertical wellfields. Propylene glycol is non-corrosive, non-toxic, possesses
low flammability and moderate heat transfer characteristics and meets State regulations. On the
negative side, propylene glycol is very viscous at low temperatures and is relatively expensive.
It is not recommended to use less than 20% propylene glycol by volume, in order to avoid dilution
of the products inhibitors and to avoid the promotion of organic growth. It is also not recommended
to exceed 30% propylene glycol by volume, because it may lower the performance of the
geothermal heat pumps. At 25% propylene glycol by volume, a water/antifreeze circulating solution
is freeze protected down to around 15 F. At this same concentration, propylene glycol at low
temperatures will increase the head loss of the circulating solution by approximately 36% over
straight water.
13
APPENDIX
MEAN WATER TEMPERATURE GRAPH
EXAMPLE GEOTHERMAL WELLFIELD SPECIFICATIONSClosed Circuit Heat Exchanger (VHE)

CANNOT BE GUARANTEED BECAUSE THE CONDITIONS OF USE ARE BEYOND OUR CONTROL. THE USER OF SUCH INFORMATION ASSUMES ALL RISK CONNECTED WITH THE USE
THEREFORE. THE AUTHOR AND DISTRIBUTOR ASSUMES NO RESPONSIBILITY FOR THE USE OF THE INFORMATION PRESENTED HEREIN AND HEREBY DISCLAIMS ALL LIABILITY IN
REGARD TO SUCH USE.
14
APPENDIX
Pipe Size:
Pipe Volume:
FLOW CHARACTERISTICS OF WATER IN HDPE PIPE (PE345464C)

DR 11, 0.86 I.D.
3.02 Gallons/100 ft
Pipe Size:
Pipe Volume:
1 DR 11, 1.075 I.D.

4.71 Gallons/100 ft
GPM
Velocity
(ft/sec)
Head Loss
(ft/100ft)
GPM
Velocity
(ft/sec)
Head Loss
(ft/100ft)
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
3.25
3.50
3.75
4.00
4.25
4.50
4.75
5.00
5.25
5.50
6.00
6.50
7.00
7.50
8.00
0.41
0.55
0.69
0.83
0.97
1.10
1.24
1.38
1.52
1.66
1.80
1.93
2.07
2.21
2.35
2.49
2.62
2.76
2.90
3.04
3.31
3.59
3.87
4.14
4.42
0.13
0.18
0.22
0.27
0.80
1.01
1.24
1.49
1.76
2.05
2.36
2.68
3.03
3.39
3.35
3.71
4.09
4.48
4.89
5.32
6.21
7.17
8.19
9.27
10.41
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
10.00
11.00
12.00
13.00
14.00
15.00
0.18
0.35
0.53
0.71
0.88
1.06
1.24
1.41
1.59
1.77
1.94
2.12
2.30
2.47
2.65
2.83
3.00
3.18
3.36
3.53
3.89
4.24
4.60
4.95
5.30
0.04
0.07
0.11
0.15
0.52
0.71
0.93
1.17
1.44
1.74
1.82
2.13
2.46
2.81
3.18
3.57
3.98
4.41
4.86
5.33
6.32
7.39
8.53
9.75
11.03
Pipe Size:
1-1/4 DR 11, 1.358 I.D.
Pipe Volume: 7.52 Gallons/100 ft
Velocity
Head Loss
GPM
(ft/sec)
(ft/100ft)
4.00
4.50
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
10.00
10.50
11.00
12.00
13.00
14.00
15.00
16.00
17.00
18.00
19.00
20.00
21.00
0.89
1.00
1.11
1.22
1.33
1.44
1.55
1.66
1.77
1.88
1.99
2.10
2.22
2.33
2.44
2.66
2.88
3.10
3.32
3.54
3.77
3.99
4.21
4.43
4.65
0.39
0.48
0.57
0.68
0.79
0.91
0.92
1.04
1.17
1.30
1.44
1.59
1.74
1.90
2.06
2.41
2.78
3.18
3.60
4.04
4.50
4.99
5.50
6.03
6.58
Pipe Size:
1-1/2 DR 11, 1.554 I.D.
Velocity
Head Loss
GPM
(ft/sec)
(ft/100ft)
7.00
8.00
9.00
10.00
11.00
12.00
13.00
14.00
15.00
16.00
17.00
18.00
19.00
20.00
21.00
23.00
25.00
27.00
29.00
31.00
33.00
35.00
37.00
39.00
41.00
1.18
1.35
1.52
1.69
1.86
2.03
2.20
2.37
2.54
2.71
2.88
3.04
3.21
3.38
3.55
3.89
4.23
4.57
4.91
5.24
5.58
5.92
6.26
6.60
6.94
0.54
0.61
0.75
0.91
1.08
1.26
1.46
1.67
1.88
2.12
2.36
2.61
2.88
3.16
3.45
4.06
4.72
5.42
6.16
6.94
7.77
8.64
9.55
10.50
11.48

REGARD TO SUCH USE.
15
APPENDIX
Pipe Size:
2 DR 11, 1.943 I.D.
Pipe Size:
3 DR 15.5, 3.048 I.D.
GPM
Velocity
(ft/sec)
Head Loss
(ft/100ft)
GPM
Velocity
(ft/sec)
Head Loss
(ft/100ft)
10.00
11.50
13.00
14.50
16.00
17.50
19.00
20.50
22.00
23.50
25.00
26.50
28.00
29.50
31.00
34.00
37.00
40.00
43.00
46.00
49.00
52.00
55.00
58.00
61.00
1.08
1.24
1.41
1.57
1.73
1.89
2.06
2.22
2.38
2.54
2.71
2.87
3.03
3.19
3.35
3.68
4.00
4.33
4.65
4.98
5.30
5.63
5.95
6.28
6.60
0.31
0.40
0.50
0.61
0.73
0.85
0.99
1.13
1.28
1.45
1.62
1.79
1.98
2.17
2.38
2.81
3.27
3.76
4.28
4.83
5.42
6.03
6.67
7.34
8.04
40.00
45.00
50.00
55.00
60.00
65.00
70.00
75.00
80.00
85.00
90.00
95.00
100.00
105.00
110.00
120.00
130.00
140.00
150.00
160.00
170.00
180.00
190.00
200.00
210.00
1.76
1.98
2.20
2.42
2.64
2.86
3.08
3.30
3.52
3.74
3.96
4.18
4.40
4.62
4.84
5.28
5.72
6.16
6.60
7.04
7.47
7.91
8.35
8.79
9.23
0.43
0.54
0.65
0.77
0.90
1.04
1.19
1.34
1.51
1.68
1.86
2.06
2.25
2.46
2.68
3.13
3.62
4.14
4.69
5.26
5.87
6.51
7.18
7.88
8.61
Pipe Size:
4 DR 15.5, 3.92 I.D.
Pipe Size:
6 DR 15.5, 5.771 I.D.
GPM
Velocity
(ft/sec)
Head Loss
(ft/100ft)
GPM
Velocity
(ft/sec)
Head Loss
(ft/100ft)
53.00
58.50
64.00
69.50
75.00
80.50
86.00
91.50
97.00
102.50
108.00
113.50
119.00
124.50
130.00
141.00
152.00
163.00
174.00
185.00
196.00
207.00
218.00
229.00
240.00
1.41
1.56
1.70
1.85
1.99
2.14
2.29
2.43
2.58
2.72
2.87
3.02
3.16
3.31
3.46
3.75
4.04
4.33
4.63
4.92
5.21
5.50
5.80
6.09
6.38
0.21
0.26
0.30
0.35
0.40
0.46
0.51
0.57
0.64
0.70
0.77
0.85
0.92
1.00
1.08
1.25
1.43
1.62
1.83
2.04
2.27
2.50
2.75
3.00
3.27
200.00
220.00
240.00
260.00
280.00
300.00
320.00
340.00
360.00
380.00
400.00
420.00
440.00
460.00
480.00
520.00
560.00
600.00
640.00
680.00
720.00
760.00
800.00
840.00
880.00
2.45
2.70
2.94
3.19
3.43
3.68
3.93
4.17
4.42
4.66
4.91
5.15
5.40
5.64
5.89
6.38
6.87
7.36
7.85
8.34
8.83
9.32
9.81
10.30
10.79
0.37
0.44
0.51
0.59
0.67
0.76
0.86
0.96
1.06
1.17
1.28
1.40
1.52
1.65
1.78
2.06
2.36
2.67
3.00
3.35
3.72
4.10
4.50
4.92
5.35

REGARD TO SUCH USE.
16
APPENDIX
Pipe Size:
8 DR 15.5, 7.513 I.D.
Pipe Size:
10 DR 15.5, 9.362 I.D.
GPM
Velocity
(ft/sec)
Head Loss
(ft/100ft)
GPM
Velocity
(ft/sec)
Head Loss
(ft/100ft)
300.00
320.00
340.00
360.00
380.00
400.00
420.00
440.00
460.00
480.00
500.00
520.00
540.00
560.00
580.00
620.00
660.00
700.00
740.00
780.00
820.00
860.00
900.00
940.00
980.00
2.17
2.32
2.46
2.61
2.75
2.89
3.04
3.18
3.33
3.47
3.62
3.76
3.91
4.05
4.20
4.49
4.78
5.07
5.36
5.64
5.93
6.22
6.51
6.80
7.09
0.21
0.24
0.27
0.30
0.33
0.36
0.39
0.43
0.46
0.50
0.54
0.58
0.62
0.66
0.71
0.80
0.89
0.99
1.10
1.21
1.32
1.44
1.57
1.69
1.83
550.00
600.00
650.00
700.00
750.00
800.00
850.00
900.00
950.00
1000.00
1050.00
1100.00
1150.00
1200.00
1250.00
1350.00
1450.00
1550.00
1650.00
1750.00
1850.00
1950.00
2050.00
2150.00
2250.00
2.56
2.80
3.03
3.26
3.50
3.73
3.96
4.19
4.43
4.66
4.89
5.13
5.36
5.59
5.83
6.29
6.76
7.22
7.69
8.16
8.62
9.09
9.55
10.02
10.49
0.22
0.26
0.30
0.34
0.39
0.44
0.49
0.54
0.60
0.66
0.72
0.78
0.85
0.91
0.98
1.13
1.29
1.46
1.63
1.82
2.01
2.21
2.42
2.64
2.87

REGARD TO SUCH USE.
17
APPENDIX
EXAMPLE VERTICAL HEAT EXCHANGER REPORT

REGARD TO SUCH USE.
18
APPENDIX
EXAMPLE FORMATION THERMAL CONDUCTIVITY ANALYSIS
Project:
Washington School
1000 32nd Ave
Brookings, SD 57006
Test Date:
01/01/03 01/02/03
Test Conducted By:
ACME Drilling, Inc.
Test Analyzed By:
GHP Systems, Inc.
Drilling Log:
FORMATION T.C. TEST
TOP SOIL
SAND/GRAVEL
CLAY
GRAY SHALE
Vertical Heat Exchanger:

VHE Type
U-bend depth
U-bend pipe size
Borehole diameter
Grout ( Bentonite)
U-bend pipe separator
80
TEMP (F)
0 - 3
3 - 10
10 - 191
191 - 200
60
AVG WATER TEMP
40
20
0
2 pipe
200
3/4
5
20% solids
10 spacing
10
20
30
TIME (HOURS)
FORMATION T.C. TEST

Circulating Fluid
Water
Average input volts

Average input amps
Average power (watts)
Test duration
Time period analyzed
215.71
12.86
2,774
24 hours
12 - 24 hours
TEMP (F)
In-situ Testing/Analysis:
100
90
80 y = 3.1385x + 66.348
.
70
60
0.00
2.00
4.00
50
AVG WATER
TEMP
Linear (AVG
WATER TEMP)
LN TIME (HOURS)
T .C. =
Q
47.34
=
= 1.20
4m 4 (3.1385)
where:
Q = Power input (Btuh) per liner foot of VHE
m = slope of the regression line
Calculated Thermal Conductivity: 1.20 Btu/hr-ft-F

REGARD TO SUCH USE.
19
APPENDIX
EXAMPLE DETAIL DRAWINGS
VHE Detail Example 1
FOILED BACK WARNING TAPE
(ALONG ENTIRE LENGTH OF HEADER PIPING)
TRACER WIRE
EARTH BACKFILL
(COMPACT AS SPECIFIED)
18"
FINAL GRADE
SAND BACKFILL
18"
6'
MAINTAIN MINIMUM PIPE BENDING RADIUS

OF 25 TIMES THE PIPE DIAMETER
300''
T.E. BENTONITE GROUT

50:200 BENTONITE/SILICA SAND
(K = 0.9 0 BTU/HR FT F)
1" HDPE PIPE DR11
PE3408 CC 345464C
PREMANUFACTURED U-BEND
FOILED BACK WARNING TAPE

TRACER WIRE
EARTH BACKFILL
(COMPACT AS SPECIFIED)
18"
FINAL GRADE
SAND BACKFILL
18"
200'
10' TYP
6'
MAINTAIN MINIMUM PIPE BENDING RADIUS

OF 25 TIMES THE PIPE DIAMETER
T.E. BENTONITE GROUT
50:50 BENTONITE/SILICA SAND
(K = 0.5 7 BTU/HR FT F)
3/4" HDPE PIPE DR11
PE3408 CC 345464C
GEOCLIP AS MANUFACTURED BY GBT, I NC.
VHE Detail Example 2
PREMANUFACTURED U-BEND

REGARD TO SUCH USE.
20
APPENDIX
EXAMPLE GEOTHERMAL WELLFIELD LAYOUT

REGARD TO SUCH USE.
21
APPENDIX
EXAMPLE VAULT DETAIL
120V Sealed Utility Light With Protective Shield

Ventilation Blower And Flexible Duct
1" Electrical Conduit, Switches And
Outlet Boxes Provided But Not Wired
(Electrician Is Responsible)
1 1/4" HDPE
Sump Pump
Discharge
Number of
Circuits
Typ. of 20
To
To Sump
Sump
4" Valved
Bypass
Tracer Wire Conduit
2" Butterfly Valve (Typ)

P/T Port (Typ)
2" Balancing/Isolation Valve (Typ)
EPDM Sump Pit Seal

14"
14" xx 14"
14" xx 15"
15" Stainless
Stainless Steel
Steel Sump
Sump Pit
Pit
Number of
Circuits
Typ. of 20
Little Giant
Giant Sump
Sump Model
Model 6
6 CIA-RFS
CIA-RFS
Little
W/ Mercury
Mercury Switch
Switch (Provided)
(Provided)
W/
8" Valved Main (Typ of 2)
Sump Pit
W/ Pump
Pressure Ind.
(Typ of 2)
Steel Sleeve W/ Link Seals

(Typ Of All Wall Penetrations)
Temperature Ind.
(Typ of 2)
2" Fill Port (Typ of 2)

REGARD TO SUCH USE.
22
APPENDIX
EXAMPLE GEOTHERMAL WELLFIELD SPECIFICATIONS
Closed Circuit Vertical Heat Exchanger (VHE)
DESCRIPTION OF WORK
A.
This design has been prepared in accordance with the materials standards and
accepted installation practices of the International Ground Source Heat Pump
Association (IGSHPA). The wellfield contractor shall comply with these standards
and practices along with all State and local regulations pertaining to the installation.
B.
The wellfield contractor is responsible for all aspects involved with the complete
geothermal wellfield installation. All materials, drilling, water supply, excavation,
hauling of backfill, dewatering, building penetration, manifold/vault installation, leak
testing, soil compaction, final flushing/purging, adding glycol and labor required shall
be included in the bid price.
C.
The wellfield contractor shall take note: There is no guarantee to the wellfield
contractor that the location of any existing utilities are exactly as indicated on the
plans. Some areas may require hand digging to locate that utility. The wellfield
contractor must include in the bid price, the repair of any domestic water, electrical,
communication or any service line that may be damaged during the construction of
this project. Any offsets required to route over or under existing lines shall also be
included in the bid price of the project.
QUALIFICATIONS
A.
The wellfield contractor must have on this project a certified IGSHPA installer.
The wellfield contractor performing this work must have a minimum of two years
experience in performing underground closed circuit VHE work of this projects size
or larger.
B.
VHE fabricators must be heat fusion certified by an authorized high density

polyethylene (HDPE) pipe manufacturers representative of the brand of pipe used.
Certification must include: successful completion of a written heat fusion exam as
well as demonstrating proper heat fusion techniques under the direct supervision
of the authorized HDPE pipe manufacturers representative.

REGARD TO SUCH USE.
23
APPENDIX
PRODUCTS
A.
Pipe
The pipe shall be PE3408 HDPE with a minimum cell classification of 345464C per
ASTM D3035 and a DR11 (160 psi) rating for u-bends and header pipe two inches
and smaller and a minimum of DR15.5 (110 psi) for header pipe greater than 2 inch
in diameter. This pipe will carry a warranty of no less than 50 years.
Each pipe shall be permanently indent marked with the manufacturer's name,
nominal size, pressure rating, relevant ASTM standards, cell classification number
and date of manufacture.
The VHE will have a factory fused u-bend with pipe lengths long enough to reach
grade from the bottom of the bore so no field fusions are required below the header
pit. Approved pipe manufacturer is Performance Pipe.
B.
Fittings
Pipe fittings shall meet the requirements of ASTM D2683 (for socket fusion fittings)
or ASTM D3261 (for butt/saddle fusion fittings). Each fitting shall be identified with
the manufacturer's name, nominal size, pressure rating, relevant ASTM standards
and date of manufacturer. Saddle fusion is not allowed except when performed by a
manufacturer normally engaged in that type of work. No field installed saddle fittings
are allowed. Approved fabrication manufacturer is GHP Systems, Inc. and approved
fitting manufacturers are Performance Pipe, Central Plastics and Viega.
C.
Manufactured Infield Extended Headers

The header sections shall be factory assembled with all branches ready for
connection to the u-bend pipe ends. The infield extended headers used to connect
the VHE u-bends in each circuit shall be constructed as shown on project drawings.
All 2" and smaller header pipe sections will come in one complete coil that is
palletized. All 3" and larger header pipe sections will be shipped in long straight
sections which are typically between 40' to 50' in length. All packaging shall be as
necessary to minimize damage in transit/handling and facilitate ease in unloading
and storage. The infield extended headers shall be GeoHeaders as manufactured
by GHP Systems, Inc. and will be manufactured with the same pipe and fitting
specifications as listed in those sections.
D.
Interior Manifold (Use in place of Vault)

The interior manifold shall be constructed as shown on project drawings. The
manifold shall be the GeoManifold as manufactured by GHP Systems, Inc. and will
be manufactured with the following specifications.
High density polyethylene (HDPE) pipe and fittings, joined together with heat fusion,
shall be used for all circuit and main header piping. All HDPE pipe and heat fused

REGARD TO SUCH USE.
24
APPENDIX
materials shall be manufactured from high-density, high molecular weight PE 3408
polyethylene compound that meets or exceeds ASTM D 3350 cell classification
345464C, and is listed by the Plastic Pipe Institute in PPI TR-4 with HDB ratings of
1600 psi (11.04 MPa) at 73F (23C) and 800 psi (5.52 MPa) at 140F (60C). All 3"
and larger HDPE piping will be DR15.5 and all 2" and smaller HDPE piping will be
DR11. All circuits 2" and greater shall include butterfly valves constructed of lug
type/lever with cast iron body, aluminum-bronze disc, EPDM Seat, 416 stainless
steel stem, rated at 200 psi. All circuit setter flow balancing valves will have a fixed
port venture orifice, have blow-out proof stem, flow measurement function
independent of ball position, install in any position, and serve as a service shutoff
with a tamper resistant memory stop to accurately reset to balancing. Circuits
smaller than 2" and all fill ports shall be ball valves with full port opening with blow
out proof stem, 600 psi non-shock cold WOG. Pressure/temperature ports shall be
brass and have a dual seal core of Nordel, good up to 350F for water and shall be
rated zero leakage from vacuum to 1000 psig. Plug shall be capable of receiving a
1/8" pressure or temperature probe. A stainless steel pressure gauge with "
isolation valve will be included on both supply and return mains. The pressure gauge
will be Sisco brand with 4 " dial size and read 0 100 psig. A stainless steel
bimetal thermometer will be included on both supply and return mains. The
pressure gauge will be Ashcroft brand with 3" dial size with 4" stem and reads 0
250F. The manifold will be leak proof checked at factory with 100 psi pressure for a
period of 24 hours or more.
E.
Composite Steel/Concrete Vault (Use in place of interior manifold)

The vault shall be a composite steel and concrete structure constructed as shown
on project drawings. The vault shall be shipped from factory preformed for a
concrete pour with all reinforcement rods, manifolds, valves and piping secured
in place. The vault weight by itself will overcome all buoyancy forces without any
additional anchoring. The vault will come traffic load ready without any additional
manhole rings, covers, bracing, or concrete pours. The approved vault is the
GeoVault as manufactured by GHP Systems, Inc and will be manufactured with
the following specifications.
Structure: The interior shell shall consist of a heavy-duty steel frame and base
where all joints have a continuous weld. The base frame and cross bracing shall be
constructed of 1/4" 3" x 8" square steel tubing. The base cross bracing shall be
spaced a maximum of 2 feet on center with " 3" x 8" square steel tubing. The
sidewall and ceiling frames and all cross bracing shall be constructed of " 3" x 3"
angle iron. Sidewall and ceiling cross bracing shall be spaced a maximum of 2 feet
on center. The steel interior walls/ceiling, stainless steel floor and stainless steel
sump pump pit shall be constructed of 12-gage sheet that are specially treated with
an epoxy coating on interior side. All interior sheet steel shall have a continuous
weld on seams and a 2" weld every 12" at support framing and exterior form walls.
#5 reinforcement rods shall be placed on a 12" spacing for sidewalls and #6
reinforcement rods shall be placed on a 12" x 12" grid spacing for the ceiling. All
25
APPENDIX
steel pipe sleeves will be schedule 40 and have a continuous weld on interior side.
All reinforcement rods shall be located 3" within the concrete from the interior side
and welded to steel framing every 2 feet or less. The outer shell of the walls and
ceiling shall consist of 8" thick 4,000 psi concrete that is poured by the contractor onsite and vibrated into place. The manhole shall be constructed of " sheet steel with
a 3" flange that is anchored into ceiling concrete and welded to ceiling frame; all
manhole welds being continuous. The manhole cover shall be constructed of "
steel tread plate with framing constructed of " 3" x 3" angle iron. The manifold
stands support channel shall run continuous between circuits and be constructed of
" 3" x 3" angle iron with 1/8" 1" tube supports every 3 feet welded to the floor.
Manifolds: High density polyethylene (HDPE) pipe and fittings, joined together with
heat fusion, shall be used for all circuit and main header piping. All HDPE pipe and
heat fused materials shall be manufactured from high-density, high molecular weight
PE 3408 polyethylene compound that meets or exceeds ASTM D 3350 cell
classification 345464C, and is listed by the Plastic Pipe Institute in PPI TR-4 with
HDB ratings of 1600 psi (11.04 MPa) at 73F (23C) and 800 psi (5.52 MPa) at
140F (60C). All 3" and larger HDPE piping will be DR15.5 and all 2" and smaller
HDPE piping will be DR11. All circuits 2" and greater shall include butterfly valves
constructed of lug type/lever with cast iron body, aluminum-bronze disc, EPDM Seat,
416 stainless steel stem, rated at 200 psi. All circuit setter flow balancing valves will
have a fixed port venture orifice, have blow-out proof stem, flow measurement
function independent of ball position, install in any position, and serve as a service
shutoff with a tamper resistant memory stop to accurately reset to balancing.
Circuits smaller than 2" and all fill ports shall be ball valves with full port opening with
blow out proof stem, 600 psi non-shock cold WOG. Pressure/temperature ports shall
be brass and have a dual seal core of Nordel, good up to 350F for water and shall
be rated zero leakage from vacuum to 1000 psig. Plug shall be capable of receiving
a 1/8" pressure or temperature probe. A stainless steel pressure gauge with "
isolation valve will be included on both supply and return mains. The pressure gauge
will be Sisco brand with 4 " dial size and read 0 100 psig. A stainless steel
bimetal thermometer will be included on both supply and return mains. The
pressure gauge will be Ashcroft brand with 3" dial size with 4" stem and reads 0
250F. The manifold will be leak proof checked at factory with 100 psi pressure for a
period of 24 hours or more.
Keyed Entry: The manhole cover of the vault will be fastened with four stainless
steel pentagon head bolts requiring a special socket key for removal. These bolts
will be counter sunk a minimum of 1" in a circular hole just large enough to
accommodate the socket key to inhibit tampering/removal with conventional tools.
Two socket keys will be included with each vault.
Seals: All HDPE pipe penetrations in the vault will utilize a Link-Seal EPDM
modular hydrostatic seal to water proof and anchor the pipe. This seal will be
removable to allow replacement of the HDPE pipe should it ever be damaged at the
26
APPENDIX
point of vault penetration. The manhole cover and stainless steel sump pit will utilize
EPDM gaskets for seals where bolted connections are made.
Sump Pump: A Little Giant series 6 with mercury switch will be supplied with the
vault. The pump will be 1/3 HP, continuous duty rated, 60Hz, 120V - 9.0A. The pump
will discharge at a rate of 46 GPM at the point it exits the vault.
Ventilation: Vault will come with its own ventilation blower and 8" flexible ducting.
The blower will be industrial grade made with heavy duty metal construction and
produce high velocity air movement. The blower will be Aloha model 39008 rated for
60Hz, 120V - 1.4A. The blower will produce 1,580 CFM open and 1,200 CFM
connected to 20 feet of 8" industrial grade flexible ducting. The blower will be ceiling
mounted at the opposite end of the manhole within the vault. The 8" flexible duct will
be run from the blower up to the top of the manhole entry. The blower will be
switched with the lights with this switch being located right below the manhole cover.
Electrical: The electrical service required for the vault is 60 Hz, 120V - 20A with
GFCI breaker. The vault shall have all required electrical conduit and boxes ceiling
mounted with 1" conduit exiting the vault. All outlets, light fixture(s), switch and
weatherproof covers will be included with the vault. The vault is to be field wired by a
licensed electrician in the state of installation.
The electrical components include:
1.
Light Fixture(s): Sealed glass lens with aluminum guard and aluminum
ceiling mounted base. The fixture is suitable for damp locations and uses
a 100 W bulb.
2.
Switch: The switch will be a 120V - 20A heavy duty double pole that will
power the lights as well the ventilation outlet
3.
Outlets: The two outlets used will be 120V - 20A heavy duty duplex.
The utility outlet will be wired continuous power for sump pump and servicing
equipment. The ventilation outlet will be switched with the lights for the
blower.
All alternate vaults must at a minimum meet the following criteria to be considered
for approval by engineer.
1.
Quality Assurance: The vault shall come from the factory with the HDPE
manifold mounted in place and all main and circuit piping stubbed out of vault
housing. The manufacturer shall be specialized in the manufacturing of
commercial geothermal vaults, have manufactured at least 200 geothermal
vaults and shall have manufactured geothermal vaults for a minimum of 5
27
APPENDIX
years. Proof of experience shall be required for approval.
F.
2.
Structural Integrity: Vault shall come from the factory traffic load rated and
capable of handling all traffic and service/utility equipment loads encountered
regardless of the vaults location. If additional structural support (such as a
concrete surface pad with manhole ring and cover) is required to meet this
criterion, it must have a PE stamped design. The vault shall have a flat base
that extends out to the complete width and length of the vault. This wide base
will have a reinforced footing surface area that carries a load of no more than
12 lb per square inch of the installed vaults weight.
3.
Buoyancy: The weight of the vault housing itself must overcome all bouncy
forces at the installed depth. The vault must not be able to float in a flooded
open vault pit during installation. If any additional vault weighting/anchoring is
required to meet this criterion, it must have a PE stamped design. The design
calculations will use complete saturated soil conditions.
4.
Component Replacement: All vault supply/return pipe penetrations must

utilize a positive hydrostatic seal (equivalent to Link-Seal) to allow field
replacement should the pipe be damaged. Pipe cannot be heat fused (or
extrusion welded) to vault structure or be secured in any fashion which
promotes crack propagation in the pipe or hinders pipe replacement. All
valves and gauges within the vault must be able to be replaced without any
heat fusion repair required.
5.
Safety/Servicing: The vault shall have switched lighting, switched fresh air
ventilation (minimum 1200 CFM), service outlet and a sump pit/pump. The
vault shall have a minimum of a 30" square manway or a 34" diameter
manway with an OSHA approved ladder and a tamper resistant non skid
cover with a gasket seal. There must be a minimum 2' wide walkway between
circuits with a minimum 6 high unobstructed ceiling. All ceiling mounted
lights, ventilation blower, outlets and etc. must be mounted to the side of this
walkway.
Grout (Design option 1)

The thermally enhanced bentonite based grout used to seal the VHE shall have a
minimum of 63% solids. This grout will also have a permeability rate of less than
1X10-7cm/sec. The silica sand used will have a 4030 mesh or finer. The minimum
grout thermal conductivity is 0.90 Btu/hr-ft-F (50lb bentonite/200lb silica sand).
Approved grout manufacturers are Black Hills Bentonite (TG Lite), Wyo-Ben Inc.
(ThermEx) and Baroid (Barotherm Gold).
28
APPENDIX
G.
U-bend Pipe Separators (Design option 2 - use with 0.57 TC grout)

The u-bend pipe separators used to position the u-bend pipes against the borehole
wall directly across from one another shall be the GeoClip brand manufactured by
GBT, Inc. These separators will be positioned every ten feet on the u-bend pipe.
H.
Warning Tape
Warning tape used must be foil backed, two inches wide or greater with a
continuous message printed every 36 inches or less reading: "CAUTION
GEOTHERMAL PIPELINE BURIED BELOW". The tape shall be highly resistant to
alkalis, acids and other destructive agents found in the ground.
EXECUTION
A.
Drilling
The vertical boreholes will be drilled to a depth allowing complete insertion of the
VHE to its specified depth. The maximum borehole diameter will be six inches. If a
larger diameter is required, it must be approved by the design engineer.
B.
U-bend Pipe Assembly

The u-bend pipe shall be filled with water and pressurized to 100 psi to check for
leaks before insertion. If necessary, an iron (sinker) bar can be attached at the base
of each u-bend to overcome buoyancy. This iron bar will have all sharp edges
adequately taped to avoid scarring and/or cutting of the polyethylene pipe. No
driving rod that is pulled out after u-bend insertion will be allowed. The entire
assembly is inserted to the specified depth in the borehole.
C.
Grouting Procedures
The VHE is to be grouted from the bottom on up in a continuous fashion using a one
inch or larger HDPE tremie pipe. The tremie pipe will be pulled out during the
grouting procedure maintaining the pipes end just below grout level within the
borehole. All State regulations will be met for borehole grouting of the VHE.
D.
Heat Fusion Pipe Joining

All underground pipe joining will be heat fused by socket, butt or saddle (sidewall)
fusion in accordance to ASTM D2610, ASTM D2683 and the manufacturer's heat
fusion specifications. The operator shall be heat fusion certified and experienced in
executing quality fusion joints.
29
APPENDIX
E.
Excavation and Backfilling for Piping

The wellfield contractor shall do all excavating, backfilling, shoring, bailing and
pumping for the installation of their work and perform necessary grading to prevent
surface water from flowing into trenches or other excavations. Sewer lines shall not
be used for draining trenches and the end of all pipe and conduit shall be kept
sealed and lines left clean and unobstructed during construction. Only material
suitable for backfilling shall be piled a sufficient distance from banks of trenches to
avoid overloading. Unsuitable backfill material shall be removed as directed by the
design engineer.
Sheathing and shoring shall be done as necessary for protection of work and
personnel safety. Unless otherwise indicated, excavation shall be open cut except
for short sections. The wellfield contractor shall install geothermal locating (warning)
tape 18 inches above all horizontal/header piping.
Prior to drilling or trenching, the wellfield contractor shall be responsible for
reviewing with the general contractor the location of underground utilities. Existing
utility lines uncovered during excavation shall be protected from damage during
excavation and backfilling.
F.
Pipe Installation
The u-bend pipe ends will be sealed with fusion caps or tape prior to insertion into
the borehole. Reasonable care shall be taken to ensure that the geothermal wellfield
pipe is not crushed, kinked, or cut. Should any pipe be damaged, the damaged
section shall be cut out and the pipe reconnected by heat fusion.
The VHEs must be connected as indicated on the plans. The header design
accounts for balanced flow as well as flushing and purging flow rates. No variations
can be made in the circuit hookup or the pipe sizes that are indicated without
approval from the design engineer. The minimum bend radius for each pipe size
shall be 25 times the nominal pipe diameter or the pipe manufacturer's
recommendations, whichever is greater. The depth of all headers and supply and
return piping is indicated on the plans and must be maintained.
Circuits will be pressure tested before any backfilling of the header trenches is
executed. The individual circuits will be pressure tested with water at 60 psi;
however, not to exceed DR 11 pipe working pressure at bottom of the u-bend pipe.
G.
Flushing/Purging and Glycol

During installation, all debris shall be kept out of the pipe. Ends of the HDPE pipe
shall be sealed until the pipe is joined to the circuits.
Flushing and Purging: Each supply and return circuit shall be flushed and purged
with a water velocity of two feet per second. The lines shall be left filled with clean
30
APPENDIX
water and then pressure tested. If connection to the manifold is not immediate,
piping must be capped. The wellfield contractor must coordinate with the mechanical
contractor on propylene glycol antifreeze installation. The mechanical contractor is
responsible for the interior pipings propylene glycol antifreeze. See Mechanical
Specifications for antifreeze specifics.
Glycol Charging: Follow all manufacturers instructions for product handling.
1.
Circuits: Isolate and charge one circuit at a time. Close all main valves and
all other circuits. Gradually introduce premixed propylene glycol solution,
through the fill port, until a concentration of 25% is obtained. Repeat
procedure for each remaining circuit.
2.
Mains: Close valves to all circuits, isolate and charge one pair of mains at a
time. Open valves on primary supply/return mains in mechanical room. Open
bypass valve in mechanical room or vault.
3.
Allow untreated water to be displaced from the system as solution is

introduced. Handle discharged water according to manufacturers
recommendations, state and local regulations.
4.
While charging, repeatedly check concentration at vault manifolds to minimize

product loss. Immediately discontinue introducing solution when testing
confirms a concentration of 25%.
SHOP DRAWINGS
Before geothermal wellfield construction begins, the wellfield contractor must submit shop
drawings to the design engineer. The shop drawings shall include all applicable
manufacturers specifications, warranties, and material safety data sheets for all materials
used in the geothermal installation. No substitutions will be allowed without authorization
from the design engineer.
31

Fundamentals of Commercial Geothermal Wellfield Design

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APPENDIX

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

VERTICAL HEAT EXCHANGER (VHE)

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

GHP SYSTEMS, INC.

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

Formation Thermal Conductivity Test

FORMATION T.C. TEST

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

VERTICAL HEAT EXCHANGER DESIGN LENGTH

(3 UNITS ENEGY OUT)

(1 UNIT ENERGY IN)

LOOPFIELD LOAD = HEATING - ELECTRIC

(1 UNIT ENERGY IN)

LOOPFIELD LOAD = COOLING + ELECTRIC

Geothermal Borehole Resistance

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

VERTICAL HEAT EXCHANGER

RESULTING ENERGY EFFECTS

STANDARD U-BEND INSTALLATION

TYPICAL STANDARD CAPACITY

U-BEND PIPE SEPARATOR

U-BEND PIPE SEPARATOR

LARGE CAPACITY INCREASE

VHE U-BEND SIZING & VHE GRID

The graph to the right demonstrates the effects

VHE GRID SPACING (feet)

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

VHE DESIGN LENGTH VERSUS PIPE

VHE DESIGN LENGTH (feet)

The graph to the right demonstrates the effects

GROUT THERMAL COND. (Btu/hr-ft-F)

Random Pipe Placement

U-bend Pipe Separator

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

SYSTEM PIPING DESIGN

Header Design Using Multiple Circuits

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

Reverse Return Circuit

To obtain balanced flow through all of the

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

Single Supply & Return Mains

SINGLE SUPPLY & RETURN MAINS

Multiple Supply & Return Mains

MULTIPLE SUPPLY & RETURN MAINS

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

FUNDAMENTALS OF GEOTHERMAL WELLFIELD DESIGN

EXAMPLE GEOTHERMAL WELLFIELD SPECIFICATIONSClosed Circuit Heat Exchanger (VHE)

FLOW CHARACTERISTICS OF WATER IN HDPE PIPE (PE345464C)

1 DR 11, 1.075 I.D.

EXAMPLE GEOTHERMAL WELLFIELD SPECIFICATIONSClosed Circuit Heat Exchanger (VHE)

EXAMPLE GEOTHERMAL WELLFIELD SPECIFICATIONSClosed Circuit Heat Exchanger (VHE)

EXAMPLE GEOTHERMAL WELLFIELD SPECIFICATIONSClosed Circuit Heat Exchanger (VHE)

EXAMPLE GEOTHERMAL WELLFIELD SPECIFICATIONSClosed Circuit Heat Exchanger (VHE)

Test Conducted By:

ACME Drilling, Inc.

Test Analyzed By:

GHP Systems, Inc.

Vertical Heat Exchanger:

FORMATION T.C. TEST

Average input volts

Calculated Thermal Conductivity: 1.20 Btu/hr-ft-F

EXAMPLE GEOTHERMAL WELLFIELD SPECIFICATIONSClosed Circuit Heat Exchanger (VHE)

MAINTAIN MINIMUM PIPE BENDING RADIUS