CSP plant optimization

1. a d v a n c e d s o l u t i o n s f o r C S P p l a n t s
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CADE focuses on delivering integrated solutions for all problems related to the design,
construction and operation of concentrated solar power (CSP) plants by combining
advanced capabilities in mechanical and process engineering with extensive experience
in the CSP industry.
- HTF circuit optimization
- Design, validation and optimization of steam generator exchangers
- Analysis of optimization-potential for existing plants
- Mechanical analysis of equipment and piping
CADE´s goal is to provide answers in response to the growing necessity for advanced
technological solutions and give specialized support to conventional engineering. To
achieve this objective, CADE collaborates with multiple players involved in the solar
energy sector ranging from consultants and engineering firms to constructors and
operators.
The scope which our services cover:

2. F i n i t e E l e m e n t A n a l y s i s
F E A a p p l i c a t i o n s
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One basic requirement in the conceptual design phase of a solar power
plant is to estimate the cost of the solar steam system. The fundamental
elements that must be taking into consideration to calculate said cost
are numerous and include among others, the solar collectors, control
system, heat transfer fluid (HTF) piping system, HTF pump system and
steam generator´s solar heat exchangers.
The HTF piping system is made up of header piping, valves, fittings,
supports and insulation. Due to the fact that the piping system can
constitute up to 10% of the solar field total cost, it is extremely important
to make sure that the design is tailored to the specific needs of each
plant.
The HTF piping system has a significant impact on the performance
of the plant and thus on the plant’s overall yields. The pumping power
needed in order to properly circulate the heat transfer fluid through the
system is a significant contributor to the plant parasitic power requirement.
Further, the piping heat loss reduces the useful heat delivered by the
solar field to the power plant.
For all of the aforementioned motives, personalized optimization of a
solar energy plant, which takes into account each individual location
and all pertinent financial factors on a case-to-case basis is a fundamental
factor to achieve an optimal CSP plant design.
CADE has developed its own methodology, implementing a series of
highly complex tools, to study CSP plants in order to achieve the optimal
design.
H T F c i r c u i t o p t i m i z a t i o n
Current problematic issues
Fig. Hourly Time Series
Fig. comparative distribution of DNI (direct normal irradiation) between two different plant locations

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Parameters to be considered:
- Plant location
- Cost of piping and fittings
- Specific economic parameters (capital invested, amortization schedule, expected returns, etc.)
- Plant´s service life
Results:
- Plant layout optimization
- Diameter and insulation optimization of header piping
- Calculation of appropriate pumping requirements
- 3D model, isometrics and bill of materials
Research options:
- During design phase
- During revision of basic engineering phase
BENEFITS:
Save between 10-20% off cost of solar field (header piping, supports, pumping consumption, etc.)
throughout the plant's service life. partnering
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H T F c i r c u i t o p t i m i z a t i o n
Approach of study:
- Preliminary study to evaluate optimization potential / Collector sampling
- Detailed study: solar field + pumping system + steam generator
There is a notable difference in the expenses associated with piping throughout the service life of a CSP plant
depending on the design criteria applied for its design.
These expenses are the sum of not only the costs related to the piping itself but also the equivalent costs deriven
from thermal losses and pumping requirements.
The implementation of optimization criteria compared to the common practice of using generic design standards
makes it possible to reduce costs related to piping by up to 15%.
CADE provides an improved, in-depth technical and economic analysis during the design phase of a CPS plant
which takes into account particular parameters for each plant on an individual basis.
solutions

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steam generator equipment: design, validation and optimization
The steam generator´s heat exchangers are some of the most sensitive equipment in the HTF system. This
equipment is not only subject to extremely severe nominal operating conditions but also susceptible to
thermal-mechanical fatigue phenomena due to their operatting cycles (temperature and pressure). In addition
to these factors, the variable operational requirements, specifically in the turbine startups, should be considered
during the design phase.
These different dynamics make the thermal and mechanical design validation extremely important for all possible
operation points, including startup ramps and operation cycles.
CADE takes an integrated approach to the described problems by combining advanced capabilities in
both process and mechanical engineering to tackle the tasks of designing and optimizing solar equipment
considering the complex operational conditions (heating/cooling cycles and startup/shutdown cycles).
Stationary thermal design
Analysis of dynamic performance based on plant´s location, HTF system
and steam turbine requirements
Process validation and attainment of startup ramps and operational cycles
Mechanical design, stress calculations and fatigue analysis
Thermal shock analysis
Computational Fluid Dynamics (CFD) analysis

5. Critical elements
- Shell to bottom joint
- Welded joints
- Nozzles
- Shell to plate joint
- Shell to saddle joint
m e c h a n i c a l e q u i p m e n t a n d p i p i n g a n a l y s i s
Along with the steam generator´s exchangers, the piping and the rest of the HTF system equipment
(expansion vessel, overflow tanks, flash purification vessel and condensation vessel) are also subject
to numerous mechanical stresses deriven from the operating cycles and conditions.
In order to correctly evaluate the equipment´s performance under said conditions, CADE tediously
analyzes every critical element through the use of finite element analysis software which helps carry out
the thermal-mechanical analysis necessary. (static/dynamic, stationary/transient, linear/nonlinear)
- Piping flexibility analysis
- FEM and fatigue analysis
- Serviceable lifespan analysis / Fitness for service assessment
- Thermal shock analysis
- Enhancement and maintenance proposals
Paseo de la Innovación, 3 - 02006 ALBACETE - SPAIN - ESPAÑA - TEL. +34 967 190 172 - FAX. +34 967 190 172 - www.cadesoluciones.com
partnering
adaptability
specialization
solutions

6. Paseo de la Innovación, 3 - 02006 ALBACETE - SPAIN - ESPAÑA - TEL. +34 967 190 172 - FAX. +34 967 190 172 - www.cadesoluciones.com
partnering
adaptability
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a n a l y s i s f o r e x i s t i n g p l a n t s
Due to the influence and variability of solar resources, a CSP plant’s operation must be able to adapt
to variable operating conditions far from the ideal conditions considered during design. In many cases
such design conditions are not optimized for a plant´s specific location.
This fact affects many different aspects of the HTF system: pumping costs, heat losses in the piping
system, heat transmission efficiency in steam generator’s heat exchangers, startup ramps, etc.
Given the importance of the aforementioned factors with respect to a plant’s yield, CADE has developed
specific applications used to detect these weaknesses and thus improve the overall performance of an
existing plant´s HTF system.
Solar energy plant:
Critical plant parameter monitoring
Steam generator:
Transient operational mode and startup ramp research
Analysis and enhancement proposals
solutions