csp solar field quality assurance methods

Solar Field Quality Assurance Methods

Klaus Pottler

CSP Services GmbH [email protected]

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

mailto:[email protected]

https://es.linkedin.com/in/klauspottler



http://www.researchgate.net/profile/Klaus_Pottler

http://www.researchgate.net/profile/Klaus_Pottler

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)

CSP Services Main Goals


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

CSP Services Main Goals


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

CSP Services Products & Clients


http://www.cspservices.de

http://www.cspservices.de/

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


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


Efficiency Chain for Parabolic Trough


Exemplary numbers for parabolic trough for normal incidence Note: current collectors usually perform better

Total optical efficiency



Resource assessment



Resource Assessment


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



Resource assessment





Resource assessment



Collector design

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


from: Geyer et al.: “EuroTrough - Parabolic Trough Collector “ SolarPACES-Conference, Sept. 4-6, 2002, Zurich, Switzerland

LS3 Design Torque Tube Design Torque Box Design

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Resource assessment



Collector design



Resource assessment

Mirror panels



Collector design

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)


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]

Rh

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,λ

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0,001

0,002

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0,005

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glass-mirror ρSWH=0.94

polymerfoil ρSWH=0.92

aluminum ρSWH=0.87

Solar Norm G173

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







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


QDec System QDec Test Report



Resource assessment

Mirror panels



Collector design



Resource assessment

Receivers

Mirror panels



Collector design

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)


DLR OptiRec System

Receivers (2) Suggestions




• Confirm technical data through expert laboratories

• Claim frequent sample measurements in fabrication with traceable documentation


http://www.dlr.de/sf/quarz/test-reports

ThermoRec System ThermoRec Test Report






Resource assessment

Receivers

Mirror panels



Collector design



Resource assessment

Receivers

Mirror panels

Assembly&Installation



Collector design

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)


Side note: Intercept Factor Check (1)


Intercept factor measurement of a parabolic trough collector with Camera-Target-Method



Camera-Target-Methode (CTM): Measurement pictures for evaluation of intercept factor



Intercept factor of a trough collector before and after optimization measures

Assembly & Installation (2) Suggestions




• 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)


http://www.sciencedirect.com/science/article/pii/S187661021400684531



Resource assessment

Receivers

Mirror panels




Collector design



Resource assessment

Cleaning, M&O

Receivers

Mirror panels




Collector design

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


Testing (1): DLR QUARZ Center Mirror Panel Performance Tests

• Shape accuracy: QDec


• 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


Testing (1): DLR QUARZ Center Mirror Panel Performance Tests

• Shape accuracy: QDec


• 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


Temperature

control unit

23 m

Eurotrough 12m

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)


OPAC outdoor test sites in Spain and Morocco

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


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)




http://www.estif.org/projects/completed_projects/qaist/project_summary/wp2_solar_thermal_collectors

http://www.solarpaces.org/tasks/task-iii-solar-technology-and-advanced-applications/reflectance-measurement-guideline

















http://www.nrel.gov/docs/fy15osti/63112.pdf

http://www.nrel.gov/docs/fy11osti/52467.pdf




http://www.sciencedirect.com/science/article/pii/S187661021400684531

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


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


Don’t produce just paperwork -> Implement QA efficiently

Correctly implemented Quality Assurance saves money in the long run

csp solar field quality assurance methods

Engineering

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quality assurance cpc2015

parabolic trough cpc2015

csp technologies

resource assessment

collector field quality

annual meeting cpc2015

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