DELIVERABLE 3.3 Commissioning protocol Laterizi Gambettola, Italy 1

Transcription

1 Commissioning protocol - SOLTIGUA Final Version ENER/FP7/296009/InSun InSun Industrial Process Heat by Solar Collectors DELIVERABLE 3.3 Commissioning protocol Laterizi Gambettola, Italy 1 Work Package 3 System Implementation and Documentation 1 Update: March 2014 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 18

2 Content 1 Plant information Solar circuit Outdoor SF Collectors Wiring Piping Collector sensors General Indoor SF Expansion unit Circulation Pump Piping and hydraulics Control and regulating devices Heat transfer fluid Safety devices Steam heat exchanger Pressure transmitters Temperature sensors Wiring Valves and accessories Strainer / dirt seperator Outdoor SF Collectors Wiring Piping Collector sensors General Indoor SF Expansion unit Circulation Pump Piping and hydraulics Control and regulating devices Heat transfer fluid Page 2 of 18

3 2.4.6 Safety devices Steam separator Pressure transmitters Temperature sensors Wiring Valves and accessories Strainer / dirt seperator Condensate circuit common condensate circuit Main condensate tank Main supply pump Water treatment unit Piping Safety devices Pressure transmitter Temperature sensors Wiring Valves and accessories Heat meter Motor driven valves condensate circuit SF condensate tank feed water pump Piping Safety devices Pressure transmitter Temperature sensors Wiring Valves and accessories Heat meter Motor driven valves condensate circuit SF condensate tank Feed water pump Page 3 of 18

4 3.3.3 Piping Safety devices Pressure transmitter Temperature sensors Wiring Valves and accessories Heat meter Motor driven valves steam circuit Pump Piping Safety devices Pressure transmitter Temperature sensors Wiring Valves and accessories Heat exchanger Heat meter Motor driven valves Control unit General Caption Hydraulic schematic Documentation General safety equipment Cleanness Comments Page 4 of 18

5 1 Plant information Project: Laterizi Gambettola SRL Operator: Laterizi Gambettola SRL Address: Via Roma Gambettola (FC) Job: Commissioning Maintenance Repair Other: Technician 1: Technician 2: Date Page 5 of 18

6 2 Solar circuit YES NO NA Report Comments / Explanation 2.1 Outdoor SF Collectors Structure checked, no deficiencies identified Visual inspection of collectors (receiver, mirrors, drive) considered OK Test of collector tracking Wiring Weatherproofing existent Protection against animal biting existent Calibration of sensor wiring done Not required by sensors Piping Weatherproofing existent Protection against animal biting existent Insulation checked for completeness and deficiencies Wiring: Capillary sockets and heat shrink tubes used Balancing valves: dp metered, hydraulic balancing, mounting direction OK Thermal expansion considered In the detailed engineering Collector sensors Heat-sink paste (stable up to 250 C) used Temperature sensors installed in heat sinks Temperature sensors protected from disengage Rotation sensors installed Limit switches installed Flow-switch installed General Wire and pipe penetrations protected from water Solar circuit deaerated Shut-off devices opened for normal operation Page 6 of 18

7 2.2 Indoor SF1 YES NO NA Report Comments / Explanation Expansion unit Expansion vessel sealed and with protected shut-off Preset pressure adjusted (bar) 1.5 Maximum pressure (hot) allowed (bar) 5 Intermediate vessel installed Catch tank installed Filling pump installed and connected Nitrogen tank installed and connected Maximum pressure switch installed Minimum level switch installed Circulation Pump Place of installation and quality checked Mounting direction of check valves checked Mounting direction of pumps checked Pumps deaerated Operation test done Piping and hydraulics Solar circuit filled and deaerated Antirust coating clean existent Piping grounded Thermometer and pressure gauges existent and readable Pressure test done (bar) Control and regulating devices Place of installation and quality checked Mounting direction checked DP sensors deaerated Balancing valves: dp metered, hydraulic balancing, mounting direction OK Heat transfer fluid Ready-to-use mixture used Data sheet attached See technical documentation Make / Type: Filling capacity (l): 1200 lt Filling capacity heat transfer fluid (l): Frost protection ( C): -12 C Therminol SP-I Page 7 of 18

8 2.2.6 Safety devices Safety valves installed non lockable and checked Lead sealing existent Blow-off pipe installed sloping with observable manner Blow-off pressure checked Steam heat exchanger Flow direction of both circuits checked Data sheet attached See technical documentation Level switch installed Pressure switch installed Steam valve installed Pressure transmitters Installed and signals checked Temperature sensors Installed and protected from disengage Wiring Calibration of sensor wiring done Not required by sensors Capillary sockets and heat shrink tubes used Not necessary Valves and accessories Data sheets attached See technical documentation Shut-off devices opened for normal operation Checked for leak tightness and free movement Devices for filling, draining and deaeration existent Strainer / dirt seperator Strainer / dirt separator existent and clarified Comments / sketches Preadjusment of balancing valves (position of handwheel): V-01 fully open V-02 fully open Page 8 of 18

9 2.3 Outdoor SF Collectors Structure checked, no deficiencies identified Visual inspection of collectors (receiver, mirrors, drive) considered OK Test of collector tracking Wiring Weatherproofing existent Protection against animal biting existent Calibration of sensor wiring done Not required by sensors Piping Weatherproofing existent Protection against animal biting existent Insulation checked for completeness and deficiencies Wiring: Capillary sockets and heat shrink tubes used Balancing valves: dp metered, hydraulic balancing, mounting direction OK Loops balancing done with electric valves Thermal expansion considered In the detailed engineering Collector sensors Heat-sink paste (stable up to 250 C) used Temperature sensors installed in heat sinks Temperature sensors protected from disengage Rotation sensors installed Limit switches installed Flow-switch installed General Wire and pipe penetrations protected from water Solar circuit deaerated Shut-off devices opened for normal operation In SF 2 (DSG) air enters every night and deareation happens during operations Page 9 of 18

10 2.4 Indoor SF1 YES NO NA Report Comments / Explanation Expansion unit Expansion vessel sealed and In SF2 (Direct Steam Generation) with protected shut-off there is no expansion tank Preset pressure adjusted (bar) -- Maximum pressure (hot) allowed (bar) -- Intermediate vessel installed Catch tank installed Filling pump installed and connected Nitrogen tank installed and connected Maximum pressure switch installed Minimum level switch installed Circulation Pump Place of installation and quality checked Mounting direction of check valves checked Mounting direction of pumps checked Pumps deaerated Operation test done Piping and hydraulics Solar circuit filled and deaerated Antirust coating clean existent Piping grounded Thermometer and pressure gauges existent and readable Pressure test done (bar) Control and regulating devices Place of installation and quality checked Mounting direction checked DP sensors deaerated Balancing valves: dp metered, hydraulic balancing, mounting direction OK Heat transfer fluid Ready-to-use mixture used Data sheet attached Make / Type: Filling capacity (l): Filling capacity heat transfer fluid (l): Soft water Approx 2000 lt Page 10 of 18

11 Frost protection ( C): 0 C An electric heater is installed for cold nights Safety devices Safety valves installed non lockable and checked Lead sealing existent Blow-off pipe installed sloping with observable manner Blow-off pressure checked Steam separator Piping connections checked Data sheet attached See technical documentation Level switch installed Pressure switch installed Steam valve installed Pressure reducing station installed Pressure transmitters Installed and signals checked Temperature sensors Installed and protected from disengage Wiring Calibration of sensor wiring done Not required by sensors Capillary sockets and heat shrink tubes used Not necessary Valves and accessories Data sheets attached See technical documentation Shut-off devices opened for normal operation Checked for leak tightness and free movement Devices for filling, draining and deaeration existent Strainer / dirt seperator Strainer / dirt separator existent and clarified Comments / sketches Page 11 of 18

12 3 Condensate circuit YE S NO N A Report Comments / Explanation 3.1 common condensate circuit Main condensate tank Storage tank(s) filled Storage tank deaerated It s an atmospheric tank Insulation existent Level switch installed Feed-water automatic valve installed Main supply pump Mounting direction of check valves checked Mounting direction of pumps checked Operation test done Water treatment unit Water treatment unit installed Chemical dosing pump tested and regulated Piping Insulation checked Strainer / dirt seperator clarified Pressure test done (bar) Safety devices see Safety devices Pressure transmitter see Pressure transmitter Temperature sensors see Temperature sensors Wiring see Wiring Valves and accessories see Valves and accessories Heat meter Installed and data transfer with control unit checked Not directly present on condensate line Page 12 of 18

13 Motor driven valves Installed and checked 3.2 condensate circuit SF condensate tank Storage tank(s) filled Storage tank deaerated It s an atmospheric tank Insulation existent Level switch installed Feed-water automatic valve installed feed water pump Mounting direction of check valves checked Mounting direction of pumps checked Operation test done Piping Insulation checked Strainer / dirt seperator clarified Pressure test done (bar) Safety devices see Safety devices Pressure transmitter see Pressure transmitter Temperature sensors see Temperature sensors Wiring see Wiring Valves and accessories see Valves and accessories Heat meter Installed and data transfer with control unit checked Not directly present on condensate line Motor driven valves Installed and checked Page 13 of 18

14 3.3 condensate circuit SF condensate tank Storage tank(s) filled Storage tank deaerated It s an atmospheric tank Insulation existent Level switch installed Feed-water automatic valve installed Feed water pump Mounting direction of check valves checked Mounting direction of pumps checked Operation test done Piping Insulation checked Strainer / dirt seperator clarified Pressure test done (bar) Safety devices see Safety devices Pressure transmitter see Pressure transmitter Temperature sensors see Temperature sensors Wiring see Wiring Valves and accessories see Valves and accessories Heat meter Installed and data transfer with control unit checked Motor driven valves Installed and checked Not directly present on condensate line Comments / sketches Page 14 of 18

15 3.4 steam circuit Pump Mounting direction of check valves checked Mounting direction of pumps checked Operation test done Piping Insulation checked Strainer / dirt seperator clarified Pressure test done (bar) Safety devices see Safety devices Pressure transmitter see Pressure transmitter Temperature sensors see Temperature sensors Wiring see Wiring Valves and accessories see Valves and accessories Heat exchanger see Heat exchanger Heat meter Installed and data transfer with control unit checked On heat exchanger it is implemented on PLC Motor driven valves Installed and checked Only in SF2 Comments / sketches Page 15 of 18

16 4 Control unit YES NO NA Rep. Comments / Explanation Shielding of all sensor wires connected Temperature sensors clamped and connected correctly Calibration of sensor wiring done, offsets fed in Pressure transmitter clamped and connected correctly Differential pressure transmitters connected correctly Flow transmitters connected correctly Pressure values with values of pressure gauges checked Heat meter (power supply, Bus) connected correctly Temperature sensors for heat meter installed correctly Pressure sensors for heat meter installed correctly Commissioning of heat meter Display of heat meter-values verified Limit temperatures within the designed limits Internet connection checked Connection for remote maintenance Commissioned Control parameters set as required Power supply/control signal to all electromechanical devices Operation of control unit checked Operation of frequency converter checked Page 16 of 18

17 5 General YES NO NA Rep. Comments / Explanation Caption Sensor wires Piping Pumps Heat exchanger Shut-off and control devices Motor driven valves Safety valves Strainer/dirt seperator Expansion vessel/pressure-maintaining station (with inspection tag) Hydraulic schematic Mounting positions of all components checked according to the hydraulic schematic and found correct Hydraulic connections checked according to the hydraulic schematic and found correct Caption checked according to the hydraulic schematic and found correctempfunden Documentation Pictures before start of work taken Pictures during work taken Pictures of important occurences taken Detailed pictures after Finalization of work taken Hydraulic project sent to local authorities electric project sent to local authorities General safety equipment Fire extinguisher existent and clearly visible Emergency shut-off existent Label with emergency numbers (fault service, firefighters,...) placed Cleanness Waste removed, site left clean swept Page 17 of 18

18 6 Comments Some problems were detected during commissioning or during first months of operations of the plant. 1. Solar field 1: falling pressure of thermal oil expansion tank (nitrogen blanket). This issue was not originally detected because of the autofilling function available for the equipment, which was pumping nitrogen in the tank to replace the depleted volume. When the automatic function was switched off, the low pressure alarm for the expansion tank became quite frequent, signalling an abnormal situation. After a leakage research, two causes were found: a. Some dirt was preventing a nitrogen on/off valve from properly tight closure b. The thread of a screwed connection had the Teflon tape not properly positioned so gas was leaking Once the two problems were fixed there were no more frequent alarms 2. Solar field 1 and 2: alarm on the mechanical room related to absent electric power During weekly tests of the back-up electric batteries, the mechanical rooms alarms related to electric power were regularly switching on. After several tests and analysis it came out that the type of UPS which is used (on line interactive), while compatible with electronic devices like pcs and plc, is not compatible with electric switches. As a solution for Insun the mechanical rooms are fed directly by the grid, bypassing the UPS, whereas for future system a different type of UPS will be adopted. 3. Solar field 1: Oil Inlet temperature broken The sensor was giving a value significantly lower than the value measured at the collectors outlet. The sensor was preassembled by an external supplier in the equipment. After testing the sensor and the RTD->mA converter, the sensor was replaced and afterward has been measuring more proper values. Page 18 of 18