DELIVERABLE 6.2 Installation Handbook 1

Transcription

1 ENER/FP7/296009/InSun InSun Industrial Process Heat by Solar Collectors DELIVERABLE 6.2 Installation Handbook 1 Work Package 6 Dissemination and Training 1 Completion Date: May 2014 (update Sept 2015) This document has been produced in the context of the InSun Project. The research leading to these results has received funding from the European Community's Seventh Framework Programme ([FP7/ ]) under grant agreement n ENER/FP7/296009/InSun. All information in this document is provided "as is" and no guarantee or warranty is given that the information is fit for any particular purpose. The user thereof uses the information at its sole risk and liability. For the avoidance of all doubts, the European Commission has no liability in respect of this document, which is merely representing the authors view. Page 1 of 64

2 Content Laterizi Gambettola, Italy Introduction Authorisations Installation methods and safety Safety regulations Safety instructions Collector safety instructions Installation Delivery of material Setting up the site, preparatory work Collectors foundations Anchoring points Collector installation Site storage and handling Collector pylons and legs Receiver tubes and secondary mirror Primary mirror and support tubes Installation of the solar circuit Piping Insulation Fittings, valves and accessories Installation of Balance of Plant (BOP) Installation of control and power unit Commissioning Pressure and leak testing Filling with solar heat transfer fluid Flushing out the solar circuit Control fine tuning System in operation Fleischwaren Berger GmbH & Co KG Introduction Installation methods and safety Safety regulations Page 2 of 64

3 2.2 Working at heights Collector safety instructions Installation Delivery of material Setting up the site, preparatory work Substructure for collectors Collector installation Structural requirements Transportation and storage Setup options Layout and fixing points Assembly of stands Lifting & positioning collectors Fastening collectors to stands Connecting of collectors Installation of the solar circuit Piping Fittings, valves and accessories Installation of the storage tank Installation of control unit Commissioning Pressure and leak testing Filling with solar liquid Flushing out the solar circuit Setting the pump and controller System in operation Fleischwaren Berger GmbH & Co KG / Solera Introduction Installation methods and safety Safety regulations Working at heights Collector safety instructions Organizational Measures Personnel Selection and Qualifications (general responsibilities) Safety Indications at certain Operation Phases Page 3 of 64

4 2.7 Indications on special Hazards Installation Delivery of material Setting up the site, preparatory work Substructure for collectors Collector installation Structural requirements Transportation and storage Setup options Layout and fixing points Assembly of stands Lifting & positioning collectors Fastening collectors to stands Connection of collectors Installation of the solar circuit Piping Fittings, valves and accessories Installation of the storage tank Installation of control unit Commissioning Pressure and leak testing Filling with solar liquid Flushing out the solar circuit Setting the pump and controller System in operation Page 4 of 64

5 Laterizi Gambettola, Italy 1 Introduction The installation of the solar thermal energy system has three trade skills: Collector installation (incl. substructure) Heat engineering (incl. pipework) Electrical installation (incl. control system) In other words, specialist knowledge in all three areas is required for the installation to be successful. The technical documentation of the manufacturer or the specialist literature for an individual component (particularly the installation instructions) is often insufficient. This installation handbook documents the implementation of the solar process heat demonstration plant at company Laterizi Gambettola SRL in Gambettola (FC), Italy. 2 Authorisations During the detailed design phase a permit from the town council was requested for the installation of the solar system. Such authorisation can be quite different depending on: system size, whether the field is roof or ground mounted, classification of the area (agricultural, industrial, residential...). Given the industrial nature of the area and the size of the system, a town coulcil authorisation was sufficient and no authorisation was required at higher level (county, region). Another authorisation is required for steam system from the local ASL (azienda sanitaria locale) which inspects all installations respects to their safety. Compliance to PED directive (fabrication of components and design of system) and to national DM 329/04 (design of system, commissioning and maintenance) was required. 3 Installation methods and safety The solar collectors are ground mounted on a field next to the factory buildings. Therefore, roof work, roof installation and its safety regulation are not part of this installation handbook. Still safety regulations must be followed during the installation process to provide a safe situation for the workers, especially when working at heights. Also the local laws, rules and safety regulations have to be followed. 3.1 Safety regulations During the installation all workers had to respect the national regulations and the specific regulations in place at the customer s site. The following directives were considered: Directive 97/23/CE (pressure equipment directive) for pressure pipes, tanks, components Directive 06/42/CE (machine directive) for the collectors and all related electrical directives Page 5 of 64

6 Italian decrete DM 329/04: relative to design, commissioning and maintenance of pressure equipment 3.2 Safety instructions When working at heights some precautions have to be taken to prevent any accident. In particular, structure with parapets are required. Personal individual protection equipment is required, such as gloves, helmet, sun glasses. Figure 1: Men at work on stages with safety helmets 3.3 Collector safety instructions It is very important to follow the collector installation instructions and to avoid by any mean to turn the mirrors so that they can focus the sunlight on the receiver tube until the whole collector with its safety sensors is commissioned. Otherwise, the tube would heat up to extremely high temperatures (400+ C) and would break, causing risks for nearby workers. Mirrors are made of tempered glass and therefore are very resistant to accidental bump, however none is allow to lay objects over them or to step onto them. Also, during handling of mirrors, special anti-cut gloves must be worn. Responsibilities of the installer of the solar system: Assembling and installing the system correctly in accordance with the installation manual Compliance with safety regulations and use of mandatory protection equipment Compliance with employment law. Compliance with accident prevention guidelines. Documented training of the user in function, maintenance and use of the system. Page 6 of 64

7 Responsibilities of the user of the solar system: Use of the system in accordance with instruction manual and its designed function Maintenance as per instruction manual Inform insurance company of solar installation Figure 2 View of the solar field Page 7 of 64

8 4 Installation When it comes to the Installation of the solar system, it is important to coordinate all different activities such as: - Site management - Civil works for solar field foundations - Piping and their insulation - Collectors installation - Balance of Plant installation (pump, heat exchanger,...) - Electrical wiring 4.1 Delivery of material The material is delivered by different companies, which are manufacturers on the one hand and executing companies on the other. To simplify the procurement it makes sense, to get consumables and smaller parts delivered straight from the executing subcontractor. Still the bigger and more expensive parts should be order directly at the manufacturer. When the materials are delivered the following must be done: 1. Check for transport damages (especially the solar collectors) 2. Check the completeness and correctness of the delivery 4.2 Setting up the site, preparatory work The final establishment of the collector position, the pipe routes between the main components, through the building and the location of the storage tank and pump units must be planned from one source and then agreed with the customer. The transport route of the collectors has to be fixed, sensitive components and existing installations should be secured from damage while the assembly of the solar system. The materials and tools required for installation are transported directly to the point of installation as needed or stored nearby. 4.3 Collectors foundations The collector s foundations are made of prefabricated cement blocks which were produced by a local subcontractor and delivered to site. The anchoring points are hanger bolts fixed in the cement blocks with a chemical resin in holes drilled at site. The size of the block and of the hanger bolts must be calculated for each installation site, as it must withstand the loads generated by external loads (namely wind, snow) on the collectors. Linear Fresnel collectors, in general, do not generate high loads on the foundations and this task is not particularly challenging. For concentrating collectors it is very important to respect installation tolerances and alignment, otherwise the collectors might not operate properly. An important activity is therefore the initial ground preparation, which consists of mainly of levelling, and also the precise positioning of the foundations blocks. Page 8 of 64

9 4.3.1 Anchoring points The foundations are then checked both in terms of vertical and planar tolerance before tracing the exact position of the anchoring points. By tracing the points at site it is possible to recover all imperfections due to civil works, which cannot be done with the required precision. The hanger bolts exact positions are determined by the general layout and by the collector detailed drawings and must be measured carefully with appropriate devices such as laser, theodolite, total station, etc. Figure 3: Foundations cement blocks Page 9 of 64

10 Figure 4: Defining the anchoring points Figure 5: Hanger bolts in the blocks 4.4 Collector installation The solar collector is the heart and the most special part of the solar system. Therefore, this is the most comprehensive and detailed chapter of the installation handbook. Collectors functionality is guaranteed only if the installation is done following the right procedure. For this, all erection steps must be coordinated by qualified and trained personnel Site storage and handling Concentrating collectors are much larger than flat plate collectors and for transport reasons they are usually shipped disassembled in parts. Several pallets and racks are shipped and must be handled following the instruction manual indications. Typical racks would include: Page 10 of 64

11 - Receiver tube and secondary mirror - Primary mirrors - Support tubes for primary mirrors - Drive pylon - Other pylons A forklift is required full time during the installation phases to move around heavy components (e. g. drive) and components racks. A crane is also required for the installation of the receiver tubes. Figure 6: 7: Forklift with pylons Figure 8: Crane with receiver tube Collector pylons and legs All pylons are fixed on the hanger bolts and then all of them are levelled at the same horizontal plane, so that rotating parts can move freely. All pylons are also checked for horizontal and vertical alignment. This step is important in order to avoid extra stresses in the collector structure. Figure 9: Pylon positioning Page 11 of 64

12 After the pylons are levelled and fixed, then all vertical legs, which will support the receiver tubes and secondary mirrors, are erected. Figure 10: View of assembled vertical legs Receiver tubes and secondary mirror Each collector module has a corresponding receiver tube, which is preassembled to the secondary mirror and to their structure. A crane must lift these components to the top of the legs and two workers, each one standing on a side of the module, will tight it to the structure. As more receivers are installed, the workers also connect them one to the other with their flanged connection and a spirometal gasket. At the end of each collector, before moving to the next steps, it is advisable to execute the pressure test to check for any leakage, so that it can be fixed before assembling the other components under the receiver tubes, which would afterwards limit the accessibility to the receiver with platforms. Figure 11: Two workers mounting the reciever tube Page 12 of 64

13 4.4.4 Primary mirror and support tubes Once the receiver tubes are in place, all primary mirrors support tubes are installed with M14 screws. The tubes are lifted by two people and put in place starting from the inner rows to the outer ones so that access is not compromised. Once the tubes are fixed, then all mirrors can be installed. It is advisable to install them in a vertical position to facilitate accessibility to the area. Figure 12: Support tubes before installation Figure 13: Mirror assembling Page 13 of 64

14 4.5 Installation of the solar circuit In case of high temperature installations, the solar circuit has particular requirements which must be carefully addressed during the detailed design phase. Both hot oil and steam circuits must take into account significant thermal expansion and frequent temperature cycles, and must be designed according to existing regulations Piping The piping is made of carbon steel, heavy series and only qualified operators can weld it. Schedule 40 tubes are fine for the purpose. For high temperature circuits only flanged connections are recommended, with graphite gaskets, to minimize the risk of leakages. Risk analysis according to PED is paramount for detailed engineering. Particular care must be put at designing supports and fixing points, so that: - There is no additional stress on collectors receiver tubes - The supports can carry the pipe weight - Thermal expansion is allowed and considered with frequent temperature cycles (min 0 C, max 250 C). - Earthquake risk is also considered Steam traps and safety valves must be considered and placed in the right position, as well as safety valves if the circuit is long and overpressure can be generated. Freezing protection system must be design for winter, e. g. the possibility of easily emptying the pipes during the coldest periods. It is important to ask and obtain a certificate of conformity relative to piping system. Page 14 of 64

15 Figure 15: View of solar field piping Figure 14: Steam, condensate, feed water lines after insulation Figure 16: Steam line with flexible joints Insulation Thermal insulation made of high density rockwool and aluminium cladding is very important for the energetic performance of the system, and particular attention must be put in the following details: - Insulation of the connections, manifolds, valves Page 15 of 64

16 - Insulation of flanges, especially in case of thermal oil in order to minimize the possibility that rockwool absorbs the oil in case of leakages, which could lead to fire hazard. Figure 17: Insulated pipes Figure 18: Steam,water, oil insulated pipes Fittings, valves and accessories In case of oil circuit, it is necessary to consider de-areators in each loop for initial circuit filling. For high temperatures circuits stainless steel needle valves are a good solution for the purpose. Gate valve must be made of cast iron with stainless steel bellow and must withstand 300 C, with PN class according to the design pressure (eg. For an oil system PN 16 is normally sufficient, whereas for a direct steam generation system PN25 or PN40 classes must be chosen). Gate valves must be installed at inlet and outlet of each loop, so that it can be intercepted for maintenance, and a discharge point should also be considered. If flow in the loops are not naturally balanced (such in case of 3-pipe systems),balancing valves must be installed and they must be of the same material as gate valves. Figure 20: Steam valves Figure 19: Balancing valve Page 16 of 64

17 4.6 Installation of Balance of Plant (BOP) In solar steam generation system it is advisable to preassemble all other equipment and deliver a skid to site, to minimize site works. The skid can be a maritime container, so that it can act as a boiler room if in the existing boiler room there is not sufficient space. Its foundations is a dedicated reinforced cement platform, where beforehand electric ducts were prepared for BOP wiring. Figure 21: Container offloading and positioning Figure 22: Container internal view It is important to agree all technical specifications for BOP components in the contract with the BOP skid supplier, and to ask for detailed technical drawings to be submitted for approval. For the requirements to connection works is referred to chapter 4.5 Page 17 of 64

18 4.7 Installation of control and power unit For large scale solar thermal plants it is important to install a custom-made control system, which is designed and manufactured according the requirements of the specific solar thermal system. It is advisable to ask for it at the BOP supplier, if they have such experience, so that they can certify the all assembly from both a hydraulic and an electric point of view, simplifying the required paperwork to comply with the mentioned standards. The control strategy has to be worked out together with the supplier and with the planner of the system. In the specific case the electric cabinet was integrated in the BOP with a Programmable Logic Controller (PLC), whose software was developed by the BOP supplier in accordance to the planner s control rules. A very important phase is cold commissioning of the BOP, where wiring is checked together with the functionality of all sensors and items (pumps, actuators). It is also very important to track all changes done in the field and to update the electric diagram accordingly. Figure 23: Outdoor wiring of temperatue probe Figure 24: Outdoor wiring of mass flow meter Page 18 of 64

19 Figure 25: Inside details of the control cabinet Figure 26: View inside of the control cabinet Page 19 of 64

20 5 Commissioning After installation is over, the commissioning phase begins. Commissioning activities must follow a detailed protocol with a checklist in order to avoid any potential damage to the solar thermal plant and to bring it to its full functionality. It is recommended that the following professionals assist to these activities: Planner or its representative Control engineer Solar installer Electrician At the end a commissioning report should be signed by both the supplier and the client. 5.1 Pressure and leak testing During commissioning, an important phase is pressure test. Normally partial segment of the system can be tested, especially when the circuit is very long and articulated. In case of steam pipes, they are tested with water at a pressure equal to 1.5 times the working pressure. In case of an oil circuit, the test can also be done with air because working pressures are lower. If the water/air pressure in the system is not declining for several hours (e.g. overnight), the solar plant is leak-proof and can be filled with solar heat transfer fluid. 5.2 Filling with solar heat transfer fluid Oil system should always be equipped with a catch tank and a filling station, which are very useful also for maintenance reasons if the circuit must be emptied. Catch tank volume should be 1.5 times the oil volume in the circuit. At initial filling oil is pumped from the catch tank to the expansion tank, which is kept at a certain pressure ( barg). Oil flows from the expansion tank to the circuit and, thanks to the static pressure, fills all pipes pushing air towards the highest points, where de-areators are. It is advisable to fill and deaerate single loops one by one. Page 20 of 64

21 Figure 26: Filling the oil catch tank Figure 27: Oil expansion tank Figure 28: Refill pump unit Page 21 of 64

22 5.3 Flushing out the solar circuit After filling the circuit the circulation pump is started so that any remaining air bubble can flow through the air separator which sends it to the expansion tank. The collectors must be kept off tracking to avoid fluid heating and this must continue for some hours. The filling pump is kept in auto mode so that it replenish the volume of air which is left until the level in the expansion tank remains fixed for some hours, which means that the circuit is deareated. The first time that the circuit is heated there could be some circulation troubles at around 100 C; if there are some remaining water droplets that vaporize and become and obstacle to proper fluid circulation. They have to be separated in the same way as air bubbles trough the air separator. All the above operations are executed with the 3 way valve closed, preventing hot oil to enter the heat exchanger. After the flushing and before starting the solar heat production, the strainer has to be cleaned. Figure 29: Solar primary pump The following point is to fill the condensate tank and from there the heat exchanger steam side, with the feed water pump. The 3 way valve can now be open and the heat coming from the solar collectors, which heat up the solar liquid circulated by the solar primary pump, is transferred by the solar heat exchanger to the heating water which starts boiling. 5.4 Control fine tuning Once the hot commissioning is completed, operational parameters must be optimized by the control engineer in order to maximize heat production. Page 22 of 64

23 5.5 System in operation When finally everything is working properly and the sun is shining, solar steam can be produced and it flows to the steam network to be supplied to the heat users. Figure 32: Steam flow meter Page 23 of 64

24 Fleischwaren Berger GmbH & Co KG 1 Introduction The installation of the solar thermal energy system has three trade skills: Collector installation (incl. substructure) Heat engineering (incl. pipework) Electrical installation (incl. control system) In other words, specialist knowledge in all three areas is required for the installation to be successful. The technical documentation of the manufacturer or the specialist literature for an individual component (particularly the installation instructions) is often insufficient. This installation handbook documents the implementation of the solar process heat demonstration plant at company Fleischwaren Berger in Sieghartskirchen, Austria. 2 Installation methods and safety The solar collectors are ground mounted on a field next to the factory buildings. Therefore, roof work, roof installation and its safety regulation are not part of this installation handbook. Still safety regulations must be followed during the installation process to provide a safe situation for the workers, especially when working at heights. Also the local laws, rules and safety regulations have to be followed. 2.1 Safety regulations Before the start of the installation works the projects was submitted to the local authority. Especially safety is an important for the competent administration. There are large differences between individual countries regarding the safety regulations to be followed during the installation of a solar heating system. In the case of Berger compliance with the following regulations were dictated: Avoiding of hazards according to 74 Abs. 2 Z. 1 GewO 1994 Restriction of negative effects according to 74 Abs. 2 Z. 2-5 GewO 1994 (Austrian trade, commerce and industry regulation act) ÖVE/ÖNORM E8001 (Austrian standard for electrical installations) MSV 2010 (Austrian safety of machinery act) Kesselgesetz (Austrian act for pressure tanks and vessels) 2.2 Working at heights This applies mainly to the storage tank with an overall height of about 10 m. For the pipe and insulation works at the storage tank a temporary platform was built around the storage tank. This is an essential safety item when working at heights. Working platforms features typically are as follows: Page 24 of 64

25 Minimum width to cover the working area Sufficient strength to support loads (including personnel, tools and materials) Sufficient integrity to prevent tools and debris from falling bellow Main guardrail, intermediate rail and a toe-board Figure 1: Storage tank with working platform and finished with fixed platform 2.3 Collector safety instructions Collectors exposed to sunlight can become very hot, reaching temperatures of up to 200 C before start-up, during installation or when the circulation is switched off. There is a high risk of burned if the collectors are touched. As a protective measure, the collectors can be covered with heatresistant material or suitable protective clothing can be worn. The liquid inside the collector can boil and evaporate even in normal daylight. Steam escaping from the collector inlets and outlets is a scald hazard. Do not put pressure on the glass cover. It is not allowed to step on the collectors, especially during installation or maintenance. The collectors, especially the sealing parts are designed for distributed area loads, not for concentrated point loads. Responsibilities of the constructor of the solar system: Assembling and installing the system correctly in accordance with good practice Compliance with safety regulations and use of mandatory protection equipment Page 25 of 64

26 Compliance with employment law. Compliance with accident prevention guidelines. Use of biodegradable antifreeze mixtures. Documented training of the user in function, maintenance and use of the system. Responsibilities of the user of the solar system: Use of the system in accordance with instructions and its designed function Annual visual inspection of all system components Annual check of all safety devices Annual check of antifreeze Check the junctions for leaks Check the collectors for any damage of class and covering Inform insurance company of solar installation Figure 2: View on finished solar field from top of storage tank Page 26 of 64

27 3 Installation When it comes to the Installation of the solar system, the coordination of workflow and the different subsections and executing companies is very important. Furthermore there should be continuous communication with the customer or its representative. 3.1 Delivery of material The material is delivered by different companies, which are manufacturers on the one hand and executing companies on the other. To simplify the procurement it makes sense, to get consumables and smaller parts delivered straight from the executing subcontractor. Still the bigger and more expensive parts should be order directly at the manufacturer. When the materials are delivered the following must be done: 3. Check for transport damages (especially the solar collectors) 4. Check the completeness and correctness of the delivery 3.2 Setting up the site, preparatory work The final establishment of the collector position, the pipe routes between the main components, through the building and the location of the storage tank and pump units must be planned from one source and then agreed with the customer. The transport route of the collectors has to be fixed, sensitive components and existing installations should be secured from damage while the assembly of the solar system. The materials and tools required for installation are transported directly to the point of installation as needed or stored nearby. 3.3 Substructure for collectors The solar collectors are ground mounted on a field next to the factory buildings. Before the mounting of the collector racks there have to be installed foundations. A very common and popular application for the substructure of ground mounted solar thermal collectors is the use of concrete base bars (also used for the installation on flat roofs). Another possibility is to make concrete piles. At Berger both solution would have been connected to high constructions costs. Therefore, a solution was devolved, which in fact is widely-used for large ground mounted photovoltaic plants, but still is very little known in the field of solar thermal installations. These special ground anchoring bolts are ground screws made of steel with welded-on threads. Page 27 of 64

28 Figure 3: Special designed ground screw used at Berger Ground screws are basically installed into firm ground using driving equipment designed to the appropriate performance level. It is driven into the ground without vibration, by a rotary drive with simultaneous downward pressure. Insertion of the screw leads to sideways displacement and compaction of soil. No more concrete pouring or excavating or back-filling is needed. The screw takes only minutes to install and has an immediate load bearing capacity allowing the installation of the collector racks to begin immediately. Before installing screw foundations, an assessment and calculation must be made for existing loads and respective ground conditions in order for the correct ground screw to be selected. If small rocks are encountered the screw pushes them aside, if the screw stops because of a larger rock, the screw is removed and a pilot hole drilled, the screw is then reinserted and follows the pilot hole cracking right through the rock making it extremely compact. Figure 4: Field with assembled ground screws Page 28 of 64

29 3.4 Collector installation The solar collector is the heart and the most special part of the solar system. Therefore, this is the most comprehensive and detailed chapter of the installation handbook. The function and leak-tightness of the system is only guaranteed if the installation is done correctly. All installation work must be done by properly authorized, trained and qualified persons in compliance with all applicable national and local standards and safety regulations Structural requirements Before installation, the structure that will carry the collectors must be surveyed and approved by a structural engineer. As well as the dimensional stability and load-bearing ability of the substructure, the survey must take account of factors that could increase the loading on the collectors at the specific site (position, wind, etc.) Transportation and storage The collectors are transported lying flat and covered with water- and weatherproof wrapping. The inlet and outlet connections are protected with plastic caps. On site, the solar collectors must be stored in a dry place. If they are stored outdoors, they must be protected from the weather. Figure 5: On-site outdoor storage of the solar collectors For transportation the collectors are fixed on special wooden (or steel) transport frames. Page 29 of 64

30 Figure 6: Drawing of a wooden transport frame Setup options The stand kit is used to set up collectors in a free standing configuration on the ground, or on flat and shallow sloping roofs. The collectors are normally set up at angles of 45 or 30 to horizontal. It is important to install the free-standing collectors at an angle of at least 20 above horizontal, with the drip edge at the bottom. At angles of less than 20, the weatherproofing of the collector units is not guaranteed, and their operational life will be shortened. At Berger a setup angle of 40 was chosen due to the optimal yearly solar yield. The collectors must be installed with at least 30cm free space above gravel, paving, earth, sand or grass. The distance off the ground is important for ventilation (separation from ground damp) and to avoid splashing Layout and fixing points Based on the information from the collector manufacturer a collector layout has to be drawn. In this layout the fixing points of the collector stand kits on the substructure are sketched. This is very important, as this is most often an interface between different subsections. This was the case at Berger as well. Figure 7: Fixing points for a single solar collector By means of the collector layout the subcontractor for the substructure was able to position and mount the ground screws, on which the stand kit was fixed. For each collector at least 4 ground screws are necessary to mount 2 collector racks. Page 30 of 64

31 Figure 8: Collector layout overview Assembly of stands For the installation of the stand kits the following tools are required: Torque wrench ½ at least 85 Nm ½ hexagon socket, width across flat 19 Spirit level/angle meter 2 box wrenches width across flat 19 Measuring tape: length min. 5 m A collector rack basically consists of the following installation materials: 2 pcs. 4 point collector rack, hot-dip galvanized 4 pcs. M16 DIN 934 galvanized nut 4 pcs. M16 DIN 125 galvanized plain washer 2 pcs. M12 x 30 DIN galvanized screw 2 pcs. M12 DIN 125 galvanized plain washer 2 pcs. M12 DIN 934 galvanized nut Page 31 of 64

32 Figure 9: Drawing and picture of a collector rack Lifting & positioning collectors When the stands have been set up, the collector should be lifted into place by crane. Between each collector and the next there should be a gap of 20cm so that enough space remains for the pipe connections. As lifting gear 2 lifting ropes are needed. Clip the lifting ropes into the eyebolts on the collector. Lift the collector above the stands in a horizontal position. Before lowering the collector onto the stands, tilt it up to about 5 steeper than the stand. This makes it easier to fit the collector into the stand. Carefully lower the collector into the stand and adjust to the right position Figure 10: Installation of the solar collectors Page 32 of 64

33 Figure 11: Lifting of the collector Figure 12: Tilted collector Figure 13: Positioning of the collector Page 33 of 64

34 3.4.7 Fastening collectors to stands For the mounting of a collector the following tools and fixing materials are required: Power screwdriver Hexagon socket - 8mm 16 pcs. ökotech self-drilling screw with elastomer seal ; A2-6,5 x 80 / DS16 The solar collectors should be mounted with self-drilling screws on the top and the bottom of the stands. The dimensions of the stands and the number of screws need to be approved by a structural engineer. Do not over tighten the screws and therefore use a power screwdriver with a torque limiter Connecting of collectors If a number of collectors are being set up in a row, they must be connected with flexible tubing to absorb the thermal extension between the single collectors of a collector field. This is done by corrugated hose connectors made of stainless steel. The pipes may only be sealed by using special solar grade soft solder (melting temperature min. 250 C). Figure 14: Flexible connection between solar collectors 3.5 Installation of the solar circuit The solar circuit has special requirements for its piping and installed fittings, valves and accessories. The heating circuit basically can be carried out according the know-how of an installer for heating systems. Still it is important to discuss all steps together with the system engineer, the project leader and the customer or its representative. Page 34 of 64

35 3.5.1 Piping The piping is made out of steel and copper. Only qualified personnel with a certificate for the used materials is allowed to work on the piping. Copper pipes can be soldered with a high-temperature resistant solar-soldering flux (Alloy S- Sn97Cu3, e.g. Felder Löttechnik soldering flux Cu-Rotin 3 ), hard soldered or pressed with a solar certificated pressed fitting system. Because of the common load alternations it s important to have an eye on the long-term behaviour of the Piping, for example the embrittlement of the hard soldered fittings or the fatigue of the mechanical force closure of pressed fittings. Figure 15: Copper piping at solar collector Steel pipes can be welded by tungsten-inert gas technique, with oxyacetylene flame or electrically. A quality attestation with radiographic test must be made on a random basis. (Approx. 10% of all welding seams) It s important to coat the Steel Piping two times with rust protection paint. Figure 16: Steel piping at collector field Page 35 of 64

36 Pre-insulated steel pipe systems are only valid when the casing (outer core barrel) has a temperature resistance of min. 160 C. The absolute temperature resistance of the Pipe subsections based on the isobaric boiling cruces of the heat transfer medium has to be verified. Further the static s of the pipe subsections must be defined, based from a 0 C earth temperature to the absolute operating temperature and/or the absolute stagnation temperature as well as the below indicated cycles to failure. Figure 17: Pre-insulated steel piping to collector field The pipe mounting must be made after state of the art and appropriate standards. The fixture points and extension bends for the Piping must be calculated in a way, that there is no stress on the individual collector due to the thermal extension from uptake and connection tubing. This is also relevant for sealed Building or Container Lead-in. The static calculation of the piping (position of the fixture points, extension bends, compensators), in the Solar circuit must be designed for an absolute temperature difference, between -20 C (minimal ambient temperature) and a maximum temperature to +180 C (stagnation). Due to the day cycle it often comes to load alternations. Minimum load alternations per lifetime of the solar system: part load alternations with min. 90K part load alternations with min. 200K If possible take distance from attaching expansion joints because of the common load alternations and the high temperature. When it s absolute needed to attach an expansion joint, it has to be approved by the solar construction supervision. Page 36 of 64

37 3.5.2 Fittings, valves and accessories The de-aeration of the collector circles or single collectors must be guaranteed, therefore needed system components (air valve, drag-down De-aeration pipes with ball valve) have to be installed at the highest and hottest points of the collector loops. It s necessary to configure the single collector fields (Low Flow operation) to the nearly same temperature range. Instruments for the hydraulic adjustment (balancing valves) have to be installed in the return pipe of all necessary collector loops. At a minimum of 8 collector fields, depending on the hydraulic facts, two or more collector fields can be merged together to a shut-off and adjustment unit. If it s possible to shut of single collectors or collector fields, it s indispensable to have a safety valve in every single unit. The blowing off-pressure must be defined after the nominal pressure of the used collectors and in consultation of the solar construction supervision. All fittings, valves and accessories have to be designed for steam, which is common in the solar circuit, and for antifreeze (Glycol) ratio up to 40%. For flange connections high quality gaskets have be used. Figure 18: Balancing valve, ball valve, de-aeration, safety valve (left to right) 3.6 Installation of the storage tank The biggest single component of the solar thermal plant is the storage tank with overall dimensions of about 10 meters in height and 3 meters in diameter. Finished and filled it has a weight of about 70 tons. Therefore there are special requirements on the following issues: Manufacturing Transportation Foundation Unloading & positioning Connection works Page 37 of 64

38 For the manufacturing a company is needed, which is specialized in tank construction. If possible it should be produced in one piece at the factory. It is very common that the manufacturer takes care of the transport to the installation site as well, but not for the unloading. Figure 19: Delivery of the storage tank Because of the heavy load of the storage tank a special foundation plate of reinforced concrete has to be poured. The static calculation should be done by a structural engineer. The design of the storage tank itself, the drawings of it at the place of installation and the expected load information have to be provided by the engineer or planner of the solar thermal system. Page 38 of 64

39 Figure 20: Concrete foundation for the storage tank For the unloading and positioning of the storage tank a suitable telescopic crane is necessary. The appropriate crane is usually selected by a specialized company, which supplies the crane and the trained personnel. Beside the crane operator the construction supervisor has to take care and is responsible for the tilting up and the proper positioning of the storage tank. Page 39 of 64

40 Figure 21: Tilting up and positioning the storage tank For the requirements to connection works is referred to chapter 2.2 Working at heights. 3.7 Installation of control unit For large scale solar thermal plants it is important to install a custom-made control system, which is designed and manufactured according the requirements of the specific solar thermal system. This is usually done by a company, which is specialized on control system and advantageously has experience with solar thermal systems. The control strategy has to be worked out and provided by the planner of the system. Also a hydraulic schematic and a parts list, where all field devices and electrical components are shown, which basically are: Pumps Heat and flow meters Control and switch valves, motor-driven ball and/or butterfly valves Temperature, pressure and radiation sensors Level switches Hardware (control cabinet including the PLC) and software (programming and visualisation) are delivered by the control company, as well as the wiring diagram, which is very important for electric installation company. Page 40 of 64

41 Figure 22: Example page of the wiring diagram In the wiring diagram you can find all important information about the electrical parts of the solar thermal installation, which are: Internal and external wiring drawings Symbol and number of all electrical components Drawing of the control cabinet Cable list (for the wiring between the control cabinet and the field devices) Material list (components used in the control cabinet) Figure 23: Outdoor wiring of field devices Page 41 of 64

42 Figure 24: View inside of the control cabinet Figure 25: Inside details of the control cabinet Page 42 of 64

43 4 Commissioning When all installation works are finished according to the design, the technical specifications and drawings, the solar thermal plant can be set into operation. For this several preliminary steps have to be made. The presence and assistance of the following professionals is recommended: Commissioning engineer Control engineer Solar installer Electrician Furthermore a checklist is very helpful to check the solar thermal system for its completeness. After the start-up an installation and commissioning report - which was prepared by the project manager - should be completed and signed by the commissioning staff. 4.1 Pressure and leak testing Before commissioning the solar system, it must be checked for leaks by means of a pressure test. It is recommended to use air for the pressure test in combination with foam-building liquids according to DIN EN for the leak testing. Pressure testing with water is not allowed for the solar collectors, if there is any danger of frost in the region. If the air pressure in the system is not declining for several hours (e.g. overnight), the solar plant is leak-proof and can be filled with liquid. 4.2 Filling with solar liquid For large scale solar thermal installations it is recommended to plan a permanently installed refill pump, which can be used for the first filling of the solar system with solar liquid too. Therefore the solar liquid (Water-Glycol) has to be filled into the collecting tank by a mobile filling pump. From the collecting tank the solar liquid is pumped into the solar system by the refill pump. First of all the solar pump unit and the main pipes to the solar field are filled and de-aired. The solar collector fields are shut off. This can be done during the day also when the sun is shining. Then one solar collector field after the other has to be filled and de-aired. This has to be done when the sun is not shining, ideally in the evening or in the early morning. As soon as the solar collectors are filled and the sun is shining, the solar pump unit has to be ready to circulate the solar liquid and to transfer the heat to the storage tank to avoid stagnation and evaporating of the solar liquid. Page 43 of 64

44 Figure 26: Refill pump unit 4.3 Flushing out the solar circuit Right after the solar collectors are filled and de-aired, the solar primary pump can be started to circulate and flush the solar circuit. This has to be done until the solar liquid is clear. The dirt and particles which may be in the system because of the pipe installation (soldering and welding) is concentrated in the strainer which is installed in the main solar supply pipe right before the heat exchanger. After the flushing and before starting the solar heat production, the strainer has to be cleaned. Therefore the solar pump has to be stopped and the strainer has to be shut off by the ball valves which have to be installed before and after the strainer. Figure 27: Solar primary pump unit with strainer As a next step the solar secondary pump unit can be started to circulate the heating water. The heat coming from the solar collectors, which heat up the solar liquid circulated by the solar primary Page 44 of 64

45 pump, is transferred by the solar heat exchanger to the heating water, which is loaded into the storage tank by the solar secondary pump. Figure 28: Solar secondary pump unit with heat exchanger 4.4 Setting the pump and controller The control engineer has to check all functions of the control cabinet with the PLC, the field devices and electrical components, the electric wiring and the communication to the main computer which usually is installed next to the control cabinet in the solar technical plant room. Figure 29: Solar main computer and PLC inside the control cabinet By means of the main computer, on which the visualisation is installed, all functions can be check and the proper working of the solar system can be monitored. The possibility to remote access the visualisation is recommended for large scale solar thermal installations, especially in the industrial sector. Therefore a connection to the internet has to be provided. Page 45 of 64

46 The pre-setting of the controller and the set values for the function of the pumps and all electric valves have to be adjusted during the commissioning and can be changed later on as needed. 4.5 System in operation When finally everything is working properly and the sun is shining, the storage tank can be heated up with solar thermal energy and at least the first kilowatt-hours of heat energy can be delivered to the production process. Figure 30: The first heat delivery to the system (recorded by a heat meter) Page 46 of 64

47 Fleischwaren Berger GmbH & Co KG / Solera 1 Introduction The installation of the solar thermal energy system has three trade skills: Collector installation (incl. substructure) Heat engineering (incl. pipework) Electrical installation (incl. control system) In all three areas is specialist knowledge required for a successful installation. The technical documentation of the manufacturer and the existing specialized literature are usually not sufficient. This installation handbook documents the implementation of the Parabolic-trough-demonstrationplant at company Fleischwaren Berger in Sieghartskirchen, Austria. 2 Installation methods and safety The solar collectors are ground mounted on a field next to the factory buildings. Therefore, roof work, roof installation and its safety regulation are not part of this installation handbook. Still safety regulations must be followed during the installation process to provide a safe situation for the workers, especially when working at heights. Also the local laws, rules and safety regulations have to be followed. 2.1 Safety regulations Before the start of the installation works the projects was submitted to the local authority. Especially safety is an important for the competent administration. There are large differences between individual countries regarding the safety regulations to be followed during the installation of a solar heating system. In the case of Berger compliance with the following regulations were dictated: Avoiding of hazards according to 74 Abs. 2 Z. 1 GewO 1994 Restriction of negative effects according to 74 Abs. 2 Z. 2-5 GewO 1994 (Austrian trade, commerce and industry regulation act) ÖVE/ÖNORM E8001 (Austrian standard for electrical installations) MSV 2010 (Austrian safety of machinery act) Kesselgesetz (Austrian act for pressure tanks and vessels) 2.2 Working at heights This applies mainly to the storage tank with an overall height of about 10 m. For the pipe and insulation works at the storage tank a temporary platform was built around the storage tank. This is an essential safety item when working at heights. Working platforms features typically are as follows: Page 47 of 64

48 Minimum width to cover the working area Sufficient strength to support loads (including personnel, tools and materials) Sufficient integrity to prevent tools and debris from falling bellow Main guardrail, intermediate rail and a toe-board Figure 31: Storage tank delivery and crane for the lift Figure 32: Storage tank and truck-mounted crane 2.3 Collector safety instructions The parabolic trough collector system is designed according to the state of the art and recognized safety regulations. Nevertheless its use can be danger to the life and limb of the users or third parties, or can damage tangibles. The parabolic trough collector system can only be used in perfect operating conditions, in accordance with regulations and awareness of safety and danger, and taking into account the user s guide!. Any faults that can affect the safety of the system should be immediately rectified! Page 48 of 64

49 2.4 Organizational Measures The user s guide should be always available in the location of the parabolic trough system! In addition to the user s guide, generally applicable legal and other binding regulations, in connection with accident prevention and environment protection, should be taken into account and followed. This type of responsibilities can also be regarding to the dealing with hazardous materials or with wearing/carrying protective equipment. User s guide includes instructions of the supervisory and notifications requirement duties for operational characteristics e.g. regarding to work organisation, work procedures, employed personnel. Previous starting to work, the personnel in charge of the machine must have read the user s guide, especially the part concerning safety and risk prevention. It would be too late to read it among the working hours. This is an important instruction especially valid for occasional implemented workers that maintain the parabolic trough collector. The safety and hazards awareness should be at least occasionally checked, in accordance with the user s guide. The Personnel should not have long hair down, wear loose clothes or jewellery, including rings. There is a risk of being injured, e.g. by get caught or pulled into. Where required or due to regulations, personnel should use personal protective equipment. All the safety instructions and warnings of the parabolic trough collector system should be taken into consideration! All the safety instructions and warnings of the parabolic trough collector should be kept in legible conditions. If some important changes in the safety of the parabolic trough collector system, or in its operating behaviour, are being detected, the system or the collector should be immediately switched of and the failures should be reported to the competent authority or person! No changes, additions and modifications in the parabolic collector system, which may affect the safety, can be made without the authorization of Smirro GmbH. The spare parts must meet the technical requirements specified by the manufacturer. The original ones are always guaranteed. Do not make any changes in the software of the control system without discussing them with Smirro GmbH! Hydraulic pipelines - hose lines should be changed in the indicated period or at a reasonable interval, even if there are no visible defects! Page 49 of 64

50 The required periods of time, or the ones that are in the user s guide specified, should be followed! To carry out the maintenance s actions it is absolutely essential an adequate working equipment. The location and usage of the extinguishers must be announced! Pay attention to the fire alarm and the other firefighting equipment! 2.5 Personnel Selection and Qualifications (general responsibilities) The work made in/with the parabolic trough collector system must just be carried out by reliable staff. Pay attention to the minimum statutory age! Employ just trained and qualified personnel. The responsibilities for the operation, equipping, maintenance and preservation must be clearly defined! Be sure that just authorized people work in the facility! Trainees should work by a supervisor while working on the parabolic trough collector system The task related to the electrical equipment of the parabolic trough collector system, should just be carried out by an electrician or a qualified person under the supervision and direction of an electrician, in accordance to the electrical regulations. All in connection with the hydraulics equipment must be done by personnel with specific qualification and experience in hydraulics! 2.6 Safety Indications at certain Operation Phases Normal Operation Mode Omit any task that may be unsafe! Take into consideration the necessary actions to make sure that the parabolic trough collector is operated in a safe and reliable way! Operate the parabolic trough collector system just when all the protective and safety equipment e.g. detachable safety devices, emergency shutdowns and sound attenuation are available and work! At least one per day, the parabolic trough system should be checked to detect if there are any damages or defects! If there were any detected changes (also in connection with the performance) report them straightway to the competent authority or person. Shutdown and secure the plant immediately! In case of function failures, shutdown and secure the parabolic trough collector system immediately! Page 50 of 64

51 Pay attention to the switching on-off and control signals that should be in accordance with the user s guide! Before connecting the parabolic trough collector system, it should be ensured that nobody can be endangered by the starting of the system! Special work in connection with the use and maintenance of the parabolic trough collector system, as well as the trouble-shooting in the work routine, disposal All the setting, maintenance and inspection activities, and the deadlines for the replacement of parts/equipment that are described in the user s guide must be fulfilled! These activities must just be carried out by qualified personnel. Since the start of the project implementation, inform the operating staff about the special and normal maintenance tasks. Designate a supervisor! Pay attention to all the work related to the operation, production adjustment, refitting or setting, as well as, inspection, maintenances or reparations, and to the switching on and off, in accordance with the user s guide and the maintenance instructions. Ensure that the maintenance area, if needed, is properly insured! If the parabolic trough collector system is completely off, due to maintenance and repairing works, it must be ensured that there is no reconnection, by o o Installing a warning sign in the main switch. Lock up the fuse box Fasten and secure the individual parts and big assemblies when they are being replaced, in order to avoid any hazard. Use just appropriate and technically perfect lifting gears and devices with enough capacity! Don t stay or work under suspended loads! For instruction of crane operators use only experienced staff. The banksman have to be in visual and/or voice contact with the operator. During the mounting period, use always specially designed ladders and platforms. Don t use the machine s parts as a ladder! Wear fall protection when doing high altitude maintenance works! Keep free from dirt, snow and ice all the handles, steps, handrails, platforms, landings and ladders. Clean the parabolic trough collector system, especially connections and fittings, when starting with the maintenance/repairing of the oil residues. Don t use any abrasive cleaners, especially at the mirror! Use free fibre cleaning rags! Page 51 of 64

52 For safety and/or functional reasons, before cleaning the parabolic trough collector system with water or steam (high pressure washer) or other cleaning product, cover/seal all the openings, to prevent that water/steam/cleaning product enters. The collector s mirror must not be cleaned with a high pressure cleaner, to avoid the risk of deforming the mirror! After cleaning process, remove completely the covers before using the system again. After the cleaning, inspect all the hydraulic and electrical lines to see if there are any leaks, loose connections or damages! Repair any defects immediately. Tighten always the loose screws, during the maintenance and repairing works During the maintenance and repairing works, the disassembling of the safety equipment is required. Afterwards, do a reassembly and verification of them! For a reliable and environmentally friendly waste management, take care of the process materials and the replacement parts! 2.7 Indications on special Hazards Electric Energy Use only original fuses with its specific current! Shut down immediately the parabolic trough collector system, if there are any electrical power supply failures! Works on the electrical system or equipment must just be carried out by a qualified electrician or a trained person under the supervision of a qualified electrician, following the electronic regulations. If inspection, maintenance and repair works in machines and parts of the system are required, during these activities all items have to be switched off. First check all parts of absence of voltage, then ground and isolate all adjacent equipment! The electric equipment of the parabolic trough collector system should be regularly inspected/checked. Defects, as loose connections or burnt cables, must be immediately removed. When working in the parts that are energized, a second person must be there to ensure that if there is an emergency, somebody does the emergency shutdown or release the voltage of the main switch. Cordon off the working area, with a red and white safety chain, and put a warning sign. Use only insulated tools. When working with high voltage assemblies, after shutting down the power supply, connect the cable supply to a masse and the other components, e.g. the capacitors, with a ground rod. Gas, Dust, Steam, Fume Page 52 of 64

53 In the parabolic trough collector system, only expressly authorized works of welding, burning and polishing can be done. Before welding, burning or polishing, clean the parabolic trough collector system and its environment from dust and combustible materials and have adequate ventilation (danger of explosion)! When working in confined spaces, take into account the related existing national regulations! Hydraulic, Pneumatics The works on the hydraulic equipment must only be carried out by qualified people with experience in hydraulic issues. Check regularly if all the pipes, hoses and fittings have any leaks or obvious damages! Repair any damage immediately! Splashed oil may cause injuries and fires. Before starting to perform repairs in openable sections and pressure lines (hydraulic, pneumatic), depressurize the described assemblies. Install and mount the hydraulic and pneumatic lines in a technical correct manner! Do not interchange connections! The fittings, length and quality of the hoses must comply with the requirements. Oil, Greases and other Chemical Substances When handling with oil, greases and other chemical substances, take into account the safety regulations applicable to the product! Be careful when handling hot operating supplies and auxiliary supplies (danger of burning or scalding) Figure 33: View on the installed collector field Page 53 of 64

54 3 Installation When it comes to the Installation of the solar system, the coordination of workflow and the different subsections and executing companies is very important. - Site management - Civil works for solar field foundations - Piping and their insulation - Collectors installation - Balance of Plant installation (pump, heat exchanger,...) - Electrical wiring - Monitoring and electronic Communication Furthermore there should be continuous communication with the customer or its representative. 3.1 Delivery of material The material is delivered by different companies, which are manufacturers on the one hand and executing companies on the other. To simplify the procurement it makes sense, to get consumables and smaller parts delivered straight from the executing subcontractor. Still the bigger and more expensive parts should be order directly at the manufacturer. When the materials are delivered the following must be done: 1. Check for transport damages (especially the superficies of the parabolic troughs) 2. Check the completeness and correctness of the delivery 3.2 Setting up the site, preparatory work The final establishment of the collector position, the pipe routes between the main components, through the building and the location of the storage tank and pump units must be planned from one source and then agreed with the customer. The transport route of the collectors has to be fixed, sensitive components and existing installations should be secured from damage while the assembly of the solar system. The materials and tools required for installation are transported directly to the point of installation as needed or stored nearby. 3.3 Substructure for collectors The solar collectors are ground mounted on a field next to the factory buildings. Before the mounting of the collectors there have to be installed foundations. In the coming figures, different pictures of the described process for the foundation and location of the substructure of the PTCs is presented. Page 54 of 64

55 Figure 34: Foundation of the collectors A special designed substructure was used in order to install the collectors in a safety way, so that they were located with the accuracy needed for this technology in order to work in a perfect way. 49 manufactured studs where set into a concrete strip foundation. For a millimetre accurate alignment in the strip foundation, the Styrofoam blocks were fixed to the ground of the empty strip foundation. Then the concrete got poured and was let hardened over the night. Afterwards the blocks where pulled giving an opening free to set in the studs. The position of the studs was measured out by a geographer to have the exact position of the posts. Then the needed height of the posts got filled in the openings with the objective that the studs could be set straight at the same height. After that, the studs where positioned with the help of wooden wedges and wooden boards to lean the stud. Then the height got again precisely checked with a laser levelling device. Afterwards Solera put the bearings on the top. With all the strings levelled out, the substructure was prepared for the self-supporting of the PTC s. Page 55 of 64

56 3.4 Collector installation The solar collector is the heart and the most special part of the solar system. The function and leak-tightness of the system is only guaranteed if the installation is done correctly. All installation work must be done by properly authorized, trained and qualified persons in compliance with all applicable national and local standards and safety regulations. Figure 35: installed collectors Structural requirements Before installation, the structure that will carry the collectors must be surveyed and approved by a structural engineer. As well as the dimensional stability and load-bearing ability of the substructure, the survey must take account of factors that could increase the loading on the collectors at the specific site (position, wind, etc.) Transportation and storage The panels have a special stacking element so that eight of them can be placed on one another. Each stack is positioned for transportation on specific pallets and fixed by a wooden frame. Figure 36:storage and transport of the parabolic through collectors Page 56 of 64

57 3.4.3 Setup options Through the proper positioning of the steel post, the exact installation of the parabolic troughs is predetermined. The steel structure is designed specifically to support the PTC and for the resulting wind loads. It is designed to keep 15 cm distances between the collectors and the ground. This ensures that they don t get polluted by splashing rain. Figure 37: Steel structure Layout and fixing points Based on the information of the layout of the collector field are the fixing points installed where the steel structure is positioned. Figure 7 : Layout Figure 8 : Fixing points with steel structure Page 57 of 64

58 3.4.5 Assembly of stands An exact installation of the stands is very important. They must be very precise both in height and in alignment. Figure 38: steel structure with the first collectors fitted Lifting & positioning collectors If the position of the stand fits, then two persons without special tools or lifting crane are able to install the parabolic trough collectors. Figure 39: messuring of the height of the collectors Fastening collectors to stands After installing all the panels it s necessary to align them and fix them with a torque wrench. Page 58 of 64

59 Figure 40: worker fixing the second row of collectors Connection of collectors The interconnection of the collectors is realized with an stainless steel axle, the collectors get connected via an clamp connection. So an accurate alignment of the collectors is possible. Figure 41: The collectors fixed to the stands and to the right pipework and insulation finished 3.5 Installation of the solar circuit Piping The piping is made out of steel and the absorbers are stainless steel. Only qualified personnel Page 59 of 64

60 with a certificate for the used materials is allowed to work on the piping. Figure 42: pipework outside on the field, bare, insulated, inhouse insulated and earth burden fully insulated Fittings, valves and accessories The de-aeration of the collector circles must be guaranteed therefore needed system components (air valve, drag-down De-aeration pipes with ball valve) have to be installed at the highest and hottest points of the collector loops. The blowing off-pressure must be defined after the nominal pressure of the used collectors and in consultation of the solar construction supervision. All fittings, valves and accessories have to be designed for steam, which is common in the solar circuit as an antifreeze/water ratio of up to 40%. For flange connections high quality gaskets have be used. 3.6 Installation of the storage tank The biggest single component of the solar thermal plant is the storage tank with overall dimensions of about 10 meters in height and 1.60 meters in diameter. Finished and filled it has a weight over 20 tons. Therefore there are special requirements on the following issues: Manufacturing Transportation Foundation Unloading & positioning Page 60 of 64

61 Connection works Figure 43: buffer tank on the truck, foundation work for the buffer, buffer placement and buffer connected to the system and fully insulated For the manufacturing a company is needed, which is specialized in tank construction. If possible it should be produced in one piece at the factory. It is very common that the manufacturer takes care of the transport to the installation site as well, but not for the unloading. 3.7 Installation of control unit For a parabolic trough collector plant it is important to install a custom-made control system, which is designed and manufactured according the requirements of the specific solar thermal system. This is usually done by a company, which is specialized on control systems and advantageously has experience with solar thermal systems, in the case of Solera. The control system is designed and build by solera them self s. The control strategy has to be worked out and provided by the planner of the system. Also a hydraulic schematic and a parts list, where all field devices and electrical components are shown, which basically are: Pumps Heat and flow meters Temperature, pressure and radiation sensors Level switches Angle sensors, Sun detecting sensors Page 61 of 64

62 Figure 44: control cabinet on the field, piping work on the field, control cabinet in solar room Hardware (control cabinet including the PLC) are delivered by the electric wholesaler. The software (programming) is delivered by Solera, as well as the wiring diagram, which is very important for the documentation. The visualisation will be realized over the control company of Solid. Since the visualization will be delivered and be programmed over Schneid the control company of Solid. 4 Commissioning When all installation works are finished according to the design, the technical specifications and drawings, the solar thermal plant can be set into operation. For this several preliminary steps have to be made. The presence and assistance of the following professionals is recommended: Commissioning engineer Control engineer Solar installer Electrician Furthermore a checklist is very helpful to check the solar thermal system for its completeness. After the start-up an installation and commissioning report - which was prepared by the project manager - should be completed and signed by the commissioning staff. 4.1 Pressure and leak testing Before commissioning the solar system, it must be checked for leaks by means of a pressure test. It is recommended to use air for the pressure test in combination with foam-building liquids according to DIN EN for the leak testing. Pressure testing with water is not allowed for the solar collectors, if there is any danger of frost in the region. If the air pressure in the system is not declining for several hours (e.g. overnight), the solar plant is leak-proof and can be filled with liquid. Page 62 of 64

63 4.2 Filling with solar liquid For the collector field a mobile filling pump is necessary to fill the solar liquid in the system. First of all the solar pump unit and the main pipes to the solar field are filled and de-aired. The collectors have to be out of the focus. Then one collector line after the other has to be filled and de-aired. As soon as the solar collectors are filled and the sun is shining and the absorber is focused to the sun, the solar pump unit has to be ready to circulate the solar liquid and to transfer the heat to the storage tank to avoid stagnation of the solar liquid. 4.3 Flushing out the solar circuit Right after the solar collectors are filled and de-aired, the solar primary pump can be started to circulate and flush the solar circuit. This has to be done until the solar liquid is clear. The dirt and particles which may be in the system because of the pipe installation (soldering and welding) is concentrated in the strainer which is installed in the main solar supply pipe right before the heat exchanger. After the flushing and before starting the solar heat production, the strainer has to be cleaned. Therefore the solar pump has to be stopped and the strainer has to be shut off by the ball valves which have to be installed before and after the strainer. 4.4 Setting the pump and controller The control engineer has to check all functions of the control cabinet with the PLC, the field devices and electrical components, the electric wiring and the communication to the main computer which usually is installed next to the control cabinet in the solar technical plant room. Page 63 of 64

64 Figure 45: Cabelling check of the primary circuit pump 4.5 System in operation When finally everything is working properly and the sun is shining, the storage tank can be heated up with solar thermal energy and at least the first kilowatt-hours of heat energy can be delivered to the production process. Page 64 of 64