CSP Solar Field Quality Assurance Methods
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The construction of concentrating solar power plants (CSP, STE) require a high level of quality assurance to secure high energy output. These slides from the CSP PLAZA conference in Beijing in June 2015 describe appropriate quality measures especially for the buildup of parabolic trough solar fields.
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CSP Solar Field Quality Assurance Methods
- 1. Solar Field Quality Assurance Methods Klaus Pottler CSP Services GmbH cspplaza2015@cspservices.de https://es.linkedin.com/in/klauspottler http://www.researchgate.net/profile/Klaus_Pottler China International CSP Station Conference & CSPPLAZA 2015 Annual Meeting CPC2015, 25-26 June 2015, Beijing, China
- 2. Introduction to CSP Services CPC2015, 25-26 June 2015, Beijing, China 2 Almería, Spain Cologne, Germany Private company founded 2007, >20 Engineers Based in Germany, Office in Spain German Aerospace Center (DLR) Spin-Off Proximity to Plataforma Solar de Almería (PSA)
- 3. CSP Services Main Goals CPC2015, 25-26 June 2015, Beijing, China 3 Implement R&D results in industry to improve CSP technologies For power plant producers • Lower investment risks • Improve project performance • Improved competitiveness For Operators • Increase solar power production • Rise profitability For Society and Environment • Reduce solar electricity costs • Reduce CO2 emissions Heat the tube, not the surroundings
- 4. CSP Services Main Goals CPC2015, 25-26 June 2015, Beijing, China 4 Implement R&D results in industry to improve CSP technologies For power plant producers • Lower investment risks • Improve project performance • Improved competitiveness For Operators • Increase solar power production • Rise profitability For Society and Environment • Reduce solar electricity costs • Reduce CO2 emissions Stay warm but do not burn your feet
- 5. CSP Services Products & Clients CPC2015, 25-26 June 2015, Beijing, China 5 http://www.cspservices.de
- 6. Solar field has a high share of total investment costs • Long-term investment • Large extension (→ adjustments are expensive) • Plant output strongly depends on collector field quality (3-10% field performance can be easily lost) Quality assurance is necessary for • Control of subcontractors • Warranty claims Quality assurance is indispensable and makes economic sense Motivation for Quality Assurance CPC2015, 25-26 June 2015, Beijing, China 6
- 7. Importance of High Quality Components Example: Possible degradation of mirror panels Based on • 200 MWel power plant, annual capacity factor 40%, revenue 0.14 US$/kWh Exemplary degradation of mirrors • 0.3% less reflectance/year → 0.45% less thermal efficiency/year → ≈ 4% less energy production over 20 years Energy generation and losses • 200 MW · 8760 h/year · 40% · 20 years ≈ 14’000’000 MWh total generation • 14’000’000 MWh · 140 US$/GWh * 4% ≈ 78 Million US$ revenue loss Loss of revenues of 78 Million US$ can be avoided with high quality and durable components CPC2015, 25-26 June 2015, Beijing, China 7
- 8. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 8 Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency
- 9. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 9 Resource assessment Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency
- 10. Resource Assessment CPC2015, 25-26 June 2015, Beijing, China 10 Do we REALLY have 100% of DNI available? • High quality ground data & long-time satellite data necessary to get correct weather data time series • Rotating Shadowband Irradiometer (RSI) often better than Pyrheliometer (due to lower soiling) • Excellent maintenance on site is essential Suggestion: Use economic RSI-Stations, ask for frequent maintenance and high-quality data service Satellite map of beam irradiance Pyrheliometer station Rotating Shadowband Irradiometer (RSI) CSPS SolarGIS CSPS
- 11. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 11 Resource assessment Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency
- 12. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 12 Resource assessment Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 13. Collector Design Efficiency influenced by • Cosine effects • Incidence angle modifier (IAM) • Shading / blocking • End losses • Intercept factor Suggestion • Use mature designs • Adapt to local production possibilities • Cross-check drawings • Build full-scale prototypes • Perform extensive geometric, structural and thermal tests CPC2015, 25-26 June 2015, Beijing, China 13 from: Geyer et al.: “EuroTrough - Parabolic Trough Collector “ SolarPACES-Conference, Sept. 4-6, 2002, Zurich, Switzerland LS3 Design Torque Tube Design Torque Box Design TorsionResistanceBendingResistance
- 14. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 14 Resource assessment Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 15. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 15 Resource assessment Mirror panels Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 16. Mirror Panels (1) Efficiency influenced by • Specular reflectance • Shape accuracy (“focus deviation”) • Degradation State of the art (for RP3 mirror panel) • Specular reflectance: > 94 % (solar weighted, 15°, 12.5 mrad) • Focus Deviation (FDx): < 7 mm (RMS) CPC2015, 25-26 June 2015, Beijing, China 16 Hemispherical Reflectance 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 250 500 750 1000 1250 1500 1750 2000 2250 2500 wavelength [nm] Rhem,λ 0 0,001 0,002 0,003 0,004 0,005 0,006 0,007 0,008 0,009 0,01 relativesolarirradiance glass-mirror ρSWH=0.94 polymerfoil ρSWH=0.92 aluminum ρSWH=0.87 Solar Norm G173
- 17. Mirror Panels (2) Price reduction and quality improvement of solar mirrors from: R. Pitz-Paal, Kosten und Wert von CSP Solarstrom, 18. Sonnenkolloquium, Cologne, May 2015 http://www.dlr.de/sf/desktopdefault.aspx/tabid-10498 CPC2015, 25-26 June 2015, Beijing, China 17
- 18. Mirror Panels (3) Suggestions • Specify “state of the art” in tender documents • Claim long term warranty in procurement • Evaluate offers in respect to costs and quality • Confirm technical data through expert laboratories • Claim frequent sample measurements in fabrication with traceable documentation CPC2015, 25-26 June 2015, Beijing, China 18 QDec System QDec Test Report
- 19. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 19 Resource assessment Mirror panels Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 20. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 20 Resource assessment Receivers Mirror panels Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 21. Receivers (1) Efficiency influenced by • Transmittance of glass cover tube • Absorptance of steel tube • Heat loss • Bellow design • Degradation State of the art (for Ø70 mm tube) • Optical Efficiency: ≈ 106% (relative to DLR OptiRec artificial reference) • Transmittance: > 96 % • Heat Loss: ≈ 150 W/m (@350 °C) ≈ 230 W/m (@400 °C) CPC2015, 25-26 June 2015, Beijing, China 21 DLR OptiRec System
- 22. Receivers (2) Suggestions • Specify “state of the art” in tender documents • Claim long term warranty in procurement • Evaluate offers in respect to costs and quality • Confirm technical data through expert laboratories • Claim frequent sample measurements in fabrication with traceable documentation CPC2015, 25-26 June 2015, Beijing, China 22 http://www.dlr.de/sf/quarz/test-reports ThermoRec System ThermoRec Test Report
- 23. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 23 Resource assessment Receivers Mirror panels Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 24. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 24 Resource assessment Receivers Mirror panels Assembly&Installation Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 25. Assembly & Installation (1) Efficiency influenced by intercept factor • 3D-Accuracy of Concentrator Structures • Concentrator Shape Accuracy • 3D-Deformation (tracking angle, wind) • Receiver and Module Alignment • Tracking Accuracy State of the art (for EuroThrough geometry) • Mirror support bracket position -> mirror tilt deviation: < 0.8 mrad (RMS) • Mirror support bracket angle -> effect on mirror geometry: < 1.0 mrad (RMS) • Receiver alignment -> lateral deviation of receiver position: < 3.0 mm (RMS) • Module alignment -> deviation to drive: < 1.0 mrad (RMS) • Collector torsion -> torsion between drive and all modules: < 1.0 mrad (RMS) • Tracking accuracy -> deviation of optical axis: < 1.0 mrad (RMS) CPC2015, 25-26 June 2015, Beijing, China 25
- 26. Side note: Intercept Factor Check (1) CPC2015, 25-26 June 2015, Beijing, China 26 Intercept factor measurement of a parabolic trough collector with Camera-Target-Method
- 27. Side note: Intercept Factor Check (2) CPC2015, 25-26 June 2015, Beijing, China 27 Camera-Target-Methode (CTM): Measurement pictures for evaluation of intercept factor
- 28. Side note: Intercept Factor Check (3) CPC2015, 25-26 June 2015, Beijing, China 28 Intercept factor of a trough collector before and after optimization measures
- 29. Assembly & Installation (2) Suggestions • Specify “state of the art” in tender documents • Claim long term warranty in procurement • Evaluate offers in respect to costs and quality • Check prototypes by independent experts • Elaborate suitable process descriptions for assembly and solar field installation • Check all components during solar field fabrication • Frequently check metal structures by adequate 3D-measurement methods in assembly hall • Check solar field installation quality Details are given in this paper K. Pottler et al: Ensuring Performance by Geometric Quality Control and Specifications for Parabolic Trough Solar Fields http://www.sciencedirect.com/science/article/pii/S187661021400684531) CPC2015, 25-26 June 2015, Beijing, China 29
- 30. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 30 Resource assessment Receivers Mirror panels Assembly&Installation Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 31. Efficiency Chain for Parabolic Trough CPC2015, 25-26 June 2015, Beijing, China 31 Resource assessment Cleaning, M&O Receivers Mirror panels Assembly&Installation Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better Total optical efficiency Collector design
- 32. European Testing Centers (Selection) German Aerospace Center: DLR QUARZ Center, Germany • Component laboratory tests (e.g. Receivers, Mirror Panels) German Aerospace Center: DLR KONTAS Test Bench, Spain • Full scale test for parabolic through modules under real sun conditions CIEMAT and DLR: PSA OPAC Laboratory, Spain • Accelerated Aging Tests CSP Services: Germany and Spain • Quality Inspection Systems • Solar Field Expert Services CPC2015, 25-26 June 2015, Beijing, China 32
- 33. Testing (1): DLR QUARZ Center Mirror Panel Performance Tests • Shape accuracy: QDec • Specular reflectance • Spectral hemispheric reflectance Receiver Performance Tests • Optical efficiency: OptiRec • Thermal power loss: ThermoRec • Overheating & thermal cycling • Bellow fatigue tests • Operability tests under real solar conditions: KONTAS CPC2015, 25-26 June 2015, Beijing, China 33
- 34. Testing (1): DLR QUARZ Center Mirror Panel Performance Tests • Shape accuracy: QDec • Specular reflectance • Spectral hemispheric reflectance Receiver Performance Tests • Optical efficiency: OptiRec • Thermal power loss: ThermoRec • Overheating & thermal cycling • Bellow fatigue tests • Operability tests under real solar conditions: KONTAS CPC2015, 25-26 June 2015, Beijing, China 34 Temperature control unit 23 m Eurotrough 12m
- 35. Testing (2): PSA OPAC Laboratory Accelerated Aging Tests ISO 6270-2CH: Thermal Cycling with Humidity ISO 9227: Neutral Salt Spray Test (NSS) ISO 9227: Copper Accelerated Salt Spray Test (CASS) ISO 11507: UV + Water Test ISO 21207: Corrosion Test (NO2, SO2) IEC 61215: Thermal Cycling Test IEC 62108: Damp Heat Test & Humidity Freeze Test MIL-STD 810G / ISO 11998 / DIN ISO 9211-4: Abrasion Tests DIN 50018 / ISO 6988: Kesternich Test (SO2) CPC2015, 25-26 June 2015, Beijing, China 35 OPAC outdoor test sites in Spain and Morocco
- 36. Testing (3): CSP Services Measurement Systems • MHP / MDI: Automatic Weather Stations • QDec: Mirror Shape Check Station • QFoto: Concentrator Frame 3D Check Station • QRec: Receiver Optical & Thermal Check Stations (On-Site) Expert Services • Handling Measurement Services for DLR QUARZ Center • Weather Data Check, TMY • Solar Field Expert Consulting • 3D-Accuracy of Prototype Collectors, Concentrator Shape • Alignment Measurements: Mirror, Receiver, Module • Local Intercept Factor Measurement • Thermal Efficiency Measurement CPC2015, 25-26 June 2015, Beijing, China 36
- 37. Standards and Guidelines Active Standards • EN 12975:2006 Thermal solar systems and components - Solar collectors (for low and middle temperature range) • ISO 9488:1999 Solar energy - Vocabulary • ISO 9806:2013 Solar energy - Solar thermal collectors - Test methods • UNE 206009:2013 Solar thermal electric plants. Terminology (in Spanish) • UNE 206011:2014 Solar thermal electric plants. Procedure for Generating a Representative Solar Year (in Spanish) • UNE 206010:2015 Tests for the […] performance of […] plants with parabolic trough collector technology (in Spanish) General Information (open web access) • IEC 62862 / Technical Committee TC 117: Solar thermal electric plants (standard under development) http://www.iec.ch/dyn/www/f?p=103:7:0::::FSP_ORG_ID:7851 • QAiST: A Guide to the Standard EN 12975, May 2012 http://www.estif.org/projects/completed_projects/qaist/project_summary/wp2_solar_thermal_collectors • SolarPACES Guideline: Official Reflectance Guideline Version 2.5, 2013 http://www.solarpaces.org/tasks/task-iii-solar-technology-and-advanced-applications/reflectance-measurement-guideline • NREL/TP-5D00-63112: Best Practices Handbook for the Collection and Use of Solar Resource Data for Solar Energy Applications, 2015 http://www.nrel.gov/docs/fy15osti/63112.pdf • NREL/SR-5500-57272: Utility-Scale Power Tower solar Systems: Performance Acceptance Test Guidelines, 2013 http://www.nrel.gov/docs/fy11osti/52467.pdf • DLR-QUARZ: Test and Qualification Center for Concentrating Solar Power Technologies http://www.dlr.de/sf/desktopdefault.aspx/tabid-7236 • K. Pottler et al: Ensuring Performance by Geometric Quality Control and Specifications for Parabolic Trough Solar Fields http://www.sciencedirect.com/science/article/pii/S187661021400684531) CPC2015, 25-26 June 2015, Beijing, China 37
- 38. Summary Quality Assurance is necessary and possible • Prevents financial losses and improves profits • Testing Infrastructure available • First Standards & Guidelines available, International Standards under development Quality Assurance includes • Resource Assessment • Collector & Solar Field Design • Component Qualification • Assembly & Installation • Operation & Maintenance CPC2015, 25-26 June 2015, Beijing, China 38
- 39. Summary Quality Assurance is necessary and possible • Prevents financial losses and improves profits • Testing Infrastructure available • First Standards & Guidelines available, International Standards under development Quality Assurance includes • Resource Assessment • Collector & Solar Field Design • Component Qualification • Assembly & Installation • Operation & Maintenance CPC2015, 25-26 June 2015, Beijing, China 39 Don’t produce just paperwork -> Implement QA efficiently Correctly implemented Quality Assurance saves money in the long run