ENER/FP7/296009/InSun InSun Industrial Process Heat by Solar Collectors DELIVERABLE 3.1 Documentation of the system installation and integration process Fleischwaren Berger, Austria 1 SOLERA Work Package 3 System Implementation and Documentation 1 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 ([FP7/2007-2011]) 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 20
Content 1 Introduction... 3 1.1 General description of client... 3 1.2 Solar system - Concept... 3 2 Technical description... 5 2.1 Hydraulics... 5 2.2 Collector field... 6 2.3 Substructure for solar panels... 7 2.4 Allocation of technical components... 9 2.5 Solar pump units... 10 2.6 Hot water storage tank... 11 2.7 Expansion units... 12 2.8 Refill pump... 12 2.9 Transmission station... 13 2.10 Control cabinet... 14 2.11 Measuring equipment... 15 3 Experiences, challenges and difficulties... 16 3.1 Substructure for solar collectors... 16 3.2 Space for bulgy material and heavy duty equipment... 17 3.3 Integration into the process... 18 3.4 Connection of the buffer tanks from Solera and SOLID... 18 3.5 Assembly of hot water storage tank... 18 Page 2 of 20
1 Introduction ENER/FP7/296009/InSun 1.1 General description of client Figure 1: Overview of Berger s Manufactury (Source: SOLID) The client of the present deliverable is the company Berger, which was already described for the documentation of the system installation and integration process of the flat plate collector s plant installed by the partner SOLID, as follows. In 1977 begins the generous construction of the new plant at the edge of Sieghartskirchen in Koglerstrasse 8 in an area of 55,000 square meters, which ended in 1988 in the preliminary final stage. But the cold store has a storage capacity of more than 20,000 pigs. 180 employees produce for chain of stores, canning, commercial kitchens, hospitals, asylums, retailers, catering firms and wholesale distributors in Austria. The company Berger has its own meat delicatessen store chain with branches in Vienna, Klosterneuburg and Tulln. In the house of his brother Michael Berger, Rennweg 56, 1030 Vienna, a modern cutting and packing plant for quality beef has emerged. 1997 the production facilities are expanded by a further annex to meet the market demands. The number of employees has now risen to over 200. 1.2 Solar system - Concept The parabolic though collectors (hereinafter PTC) are mounted on a free part of the field beside the solar-collector s field of SOLID. The field is coupled to a 20.000 l buffer tank, which is located close to the existing buffer tank of 60.000 l from SOLID. Page 3 of 20
The PTC plant act as a temperature booster, to support the solar field from SOLID. The buffer tank in this respect is heated up to a temperature and boost depending on the temperature, provided by the SOLID solar plant. The main key figures of the plant are as follows: Collector area 122.4 m² Peak capacity 51 kw Storage capacity 20 m³ Peak consumption Feed Water Preheating 200 kw Hot Water Preheating 240 kw 700 W/m² 30 51 20 Figure 2: Energy flow chart (Source: Solera) Page 4 of 20
2 Technical description ENER/FP7/296009/InSun For the technical planning Solera counted with the support of the company Solem Consulting, which experience in the field. 2.1 Hydraulics The hydraulic concept of the PTC plant is presented in the coming figure 3, in which all the hydraulic connections of the main components can be seen. Figure 3: Hydraulic diagram (Source: Solem Consulting) Table 1: Legend for hydraulic diagram (Source: Solera) A Solar thermal system 122.4 m² B Heat storage tank 20 m³ C Feed water preheating capacity 30 kw Page 5 of 20
2.2 Collector field ENER/FP7/296009/InSun The field for the PTCs is just beside the solar thermal collectors of SOLID. Due to the small space available it is divided in two parts in order to optimize the installation. Three lines with eight collectors each and three lines with four collectors each has been the final planning for the plant. The collector itself is the PTC from the company Smirro. It is a collector with a length of 3 m and a width of 1,20 m. Because it is a closed body, the collector has a high stiffness despite extremely low weight. The construction of the collector is shown in the Figure 4 below: Figure 4: Parabolic trough collector Smirro (Source: Solera) This collector of 3,4 m 2 mirror surface has its working temperature range between 90 and 250 C, being the heat transfer fluid different depending on the type of temperature that is wanted to be obtained (i.e. water with glycol, thermal oil, etc). Its operational principle is based on a one single axle as tracking system. Page 6 of 20
Here it can be seen the final 122,4 m² mirror-area of the 36 collectors, divided in two parts. Figure 5 : Parabolic collector field at Berger (Source: Solera) 2.3 Substructure for solar panels 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 PTCs. Page 7 of 20
In the coming figures, different pictures of the described process for the foundation and location of the substructure of the PTCs is presented. Figure 6 : The foundation of the collectors (Source: Solera) 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 do not pollute by splashing rain. Figure 7: Steel structure (Source: Solera) Page 8 of 20
2.4 Allocation of technical components For the technical components allocation Solera uses the same housing as SOLID, which has been already presented in the documentation of the system installation and integration process realized by the company SOLID for the plant of flat collectors that was also installed in Berger. As it was said, the mechanical room is directly built to the existing boiler house to use its waste heat against freezing. In this room nearly all components of the solar plant are located. Housing is made of foam filled trapezoidal sheet. The substructure of the mechanical room is a concrete foundation which is designed for heavy load of solar parts and does stand beside the storage tank. Design and Surface of housing: Outside: Inside: visible side 25 micron polyester coating, hot zinc dipped thin sheet metal polyurethane hard foam, approximately 95% closed shear resistant steel sheet, space weight is about 40kg/m³ Figure 8: Connection assembly of housing (Source: SOLID) Figure 9: Housing Front side (Source: SOLID) Page 9 of 20
2.5 Solar pump units ENER/FP7/296009/InSun The solar pump for the primary circle is inside the housing. Figure 4 : Solar pump with the sensor for preasure and the flow meter (Source: Solera) Figure 11: The primary pump unit with piping inside the heatinghouse (Source: Solera) Page 10 of 20
2.6 Hot water storage tank ENER/FP7/296009/InSun To store the entire energy Solera uses a storage tank with a volume of 20 m³. Figure 5: Storage tank (Source: Solera) Figure 13: Storage tank with piping (Source: Solera) Page 11 of 20
2.7 Expansion units ENER/FP7/296009/InSun For the expansion units Solera had to build a special, small room besides because there was not enough space inside the solar heating room, originally built only for the solar plant of SOLID. Figure 6 : Expansion unit (Source: Solera) The expansion unit is inside of the new, small building so that is protected during wintertime. 2.8 Refill pump For refilling the system there is a mobile refill pump. Figure 7: Mobil Refill pump (Source: Solera) Page 12 of 20
2.9 Transmission station ENER/FP7/296009/InSun Through a heat exchanger the generated heat is fed into the system. Figure 18: The installed heat exchanger (Source: Solera) Figure 97: The piping parallel to SOLID s system (Source: Solera) Page 13 of 20
2.10 Control cabinet ENER/FP7/296009/InSun The control unit enables to analyse temperatures and heat and electricity flows. IT is possible to have an external access to this information in order to monitor thanks to internet. Figure 10: Control unit (Source: Solera) Figure 11: Control unit inside (Source: Solera) Page 14 of 20
2.11 Measuring equipment ENER/FP7/296009/InSun To monitor the function and the efficiency of the system there are special heat meters, temperature sensors, pressure transmitter and flowmeters. Figure 12: Heat meters (Source: Solera) Figure 13: Integration on the SOLID system (Source: Solera) Page 15 of 20
3 Experiences, challenges and difficulties The main bottleneck during the planning phase was the available time. As communicated by Solera before starting the planning; a period of minimum 6 month is needed for this size of installation and all the finishing work, in order to get a finished PTC plant. These minimum period of 6 months is under certain conditions (i.e.: no delays with providers, the mounting system is properly manufactured and installed and no rework is needed, good weather and no delays due to weather conditions, etc.). This period of time starts just after the hydraulic plan is prepared and in-house, therefore at the final stage of the design phase. Solera had a little bit less than 4 months instead of the 6 months period needed due to delays in the amendment acceptance. Nevertheless the commitment of the company was so high that the challenge was overcome, beside the several challenges that appeared on the way as having two months less. To get the finishing date right on time, it was needed to have a constant and well documented communication culture between suppliers and planners. With the help of that structure and with weekly on-site meetings, Berger and Solera managed to finish the project in the given time. The experiences that SOLID already made with their flat plate collector field, were taken into account. One important aspect is to check right from the start that there is enough space for the big bulgy components in the borders of the company owned ground. In connection with the challenges regarding the integration of the parabolic though collector field into the existing solar field from SOLID, it has been clear after the project that all the hydraulic changes in the systems for a more efficient use of the solar thermal heat, have to be integrated right from the start into the hydraulic planning. To ease out the building process in the second phase of the project it is necessary that all the material are ordered on time, so that they can be also documented. Therefore all the different trades should be planned for a smooth building of the project. Due to a really flexible and supporting manner of the company Berger, these challenges could be handled very well and the project could be finished on the given time. 3.1 Substructure for solar collectors When Solera visited the field, the team realized that there were significant differences in altitude. That brought some challenges because the collector rows must be positioned always exactly at the same altitude. The solution consisted of two steps. Solera was able to compensate one part of the difference in height thanks to civil works, with levelling the ground. The remaining difference in height was equalized with different heights of the foundation. The substructure was made out of an I-beam with a mounting plate welded on top. The I-Beam was 40 cm sunk into soft concrete and let harden out. The beams needed to be mounted with a small tolerance being plumb and being in the same height like the other beams. Page 16 of 20
Figure 21:I-Beam for the bearings of the collectors (Source: Solera) 3.2 Space for bulgy material and heavy duty equipment With the experiences which SOLID made, Solera planned ahead to have enough space for the storage of collectors and for the heavy duty equipment to put the needed components in place. Figure 142: lifting equipment to unhook the buffer tank (Source: Solera) Page 17 of 20
Figure 23: heavy lifting equipment (Source: Solera) 3.3 Integration into the process Thanks to the work from SOLID, Solera could integrate their solar thermal power into the existing system. With light further improvements of the integration schema, Solera integrated at first into the piping of SOLID. The company Berger plans to build a new gas boiler that will have a new integration point in the steam network of the company. They will also change the solar technical room. Therefore, although initially Solera planned a different integration point into the system of SOL- ID, it was decided together with the in-house engineers, to take into account the future plans of Berger and do the connection of Solera s system in the 40 m piping of SOLID, to facilitate the coming modifications. 3.4 Connection of the buffer tanks from Solera and SOLID For an efficient use of the solar heat and due of changes in the production line of the company Berger, the weekends in summer result in over temperatures in the buffer tank of SOLID. This does stress the safety devices and all the other components in the buffer tank circuit. That is why Berger built a bigger buffer tank for the Solera plant, to store the overcapacity in the Solera tank from the flat plate collectors of SOLID. Therefore the buffer tanks got hydraulically connected. As a result the heat can be efficiently transferred from one buffer tank to the other, without the loss caused by heat exchangers. 3.5 Assembly of hot water storage tank Considering to the measurements of the 20m³ tank, it was quite a huge challenge to install the so a large tank. The height of over 10 meters and with a diameter of 1.6 meters required heavy duty lifting equipment. Page 18 of 20
Figure 15: Storage tank on the truck (Source: Solera) Figure 16: Lift of the Storage tank (Source: Solera) Page 19 of 20
process Final Version The access road to the place where the tank was going to be installed was quite small. Therefore Solera was forced to lift the tank over the mechanical room. After the lift Solera was not able to remove the hook, from the top of the tank. But the electrical company nearby could provide a lift with a hydraulic arm to unhook the buffer tank from the crane. Figure 25: Unhook the tank (Source: Solera) Page 20 of 20