HILL TOP ENERGY CENTER
CARMICHAELS, PENNSYLVANIA
EFI-Solutions played a key role in the development of a complex cooling-water system for Hilltop Energy Center, where the project team faced two major hydraulic challenges: moving massive volumes of river water uphill to support continuous power generation, then safely controlling that same water as it returned downhill.
The project required both a high-capacity Booster Pump Station and a custom below-grade Pressure Reducing Valve (PRV) Station, each designed to manage the demanding flow, pressure, and elevation conditions of the site.
Project Overview
Hilltop Energy Center required a dependable cooling-water system capable of continuously moving millions of gallons of water between the river and the generating facility.
The first challenge was overcoming the significant elevation change between the river intake and the plant. EFI engineered a high-capacity booster pump station capable of delivering the required cooling-water flow uphill while accounting for changing river conditions and fluctuating plant demand.
The second challenge occurred on the return side of the system. As the cooling water traveled back downhill toward the river, gravity created substantial pressure and velocity. Without proper control, the returning flow could create damaging discharge conditions and contribute to erosion at the riverbank.
EFI-Solutions' Role
At the river intake, EFI provided the Booster Pump Station responsible for moving the required volume of cooling water uphill to the plant. On the return side, EFI supplied a custom below-grade Pressure Reducing Valve (PRV) Station designed to reduce pressure and safely manage the flow before the water reached the discharge point.
Rather than relying on multiple field-built installations along the steep site, the equipment was fabricated, piped, integrated, and tested at EFI’s Centralia, Illinois manufacturing facility before delivery.
This factory-built approach reduced the amount of complex work required on the hillside and allowed much of the system integration to be completed in a controlled environment prior to installation.
Collaboration & Impact
Working alongside the broader project team, EFI-Solutions delivered an integrated solution designed around the long-term operating requirements of the generating facility.
The system was engineered for a 30-year operational life cycle under continuous cyclic service and designed to accommodate up to 260 thermal cycles annually, including 10 cold starts, 50 warm starts, and 200 hot starts.
By addressing both the supply and return sides of the cooling-water system, the project provides Hilltop Energy Center with the infrastructure required to support continuous power generation while also controlling the hydraulic forces created by the site’s extreme elevation changes.
This project showcases EFI-Solutions’ ability to deliver complex, factory-built industrial water systems for demanding applications where flow, pressure, elevation, site access, and long-term reliability all have to work together.
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EFI-Solutions specializes in custom-engineered treatment facilities for municipalities and industrial clients. Contact us today to explore how our modular approach can meet your project needs.
