DELIVERABLE 3.3 BERGER Commissioning protocol Fleischwaren Berger, Austria 1 SOLID

Transcription

1 ENER/FP7/296009/InSun InSun Industrial Process Heat by Solar Collectors DELIVERABLE 3.3 BERGER Commissioning protocol Fleischwaren Berger, Austria 1 SOLID 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 13

2 Content 1 Plant information Solar circuit Outdoor Collectors Wiring Piping Collector sensors General Indoor Expansion unit Pumps Piping and hydraulics Control and regulating devices Heat transfer fluid Safety devices Heat exchanger Pressure transmitter Temperature sensors Wiring Valves and accessories Strainer / dirt seperator Secondary circuit Storage tanks Pumps Piping Safety devices Pressure transmitter Temperature sensors Wiring Valves and accessories Heat meter Motor driven valves Solar circuit... 9 Page 2 of 13

3 4.1 Feed water preheating Pumps Piping Safety devices Pressure transmitter Temperature sensors Wiring Valves and accessories Heat meter Heat exchanger Motor driven valves Hot water preheating Pumps Piping Safety devices Pressure transmitter Temperature sensors Wiring Valves and accessories Heat meter Heat exchanger Motor driven valves Control unit General Labelling Hydraulic schematic Documentation General safety equipment Cleanness Comments Page 3 of 13

4 1 Plant information Project: Fleischwaren Berger Operator: FLEISCHWAREN BERGER GESMBH & CO KG Address: Koglerstrasse 8, 3443 Sieghartskirchen Job: Commissioning Maintenance Repair Other: Technician 1: Danislav Jovanovic Technician 2: Markus Gründler Date Page 4 of 13

5 2 Solar circuit YES NO Report Comments / Explanation 2.1 Outdoor Collectors Substructure checked, no deficiencies identified Visual inspection of collectors, considered OK Wiring Weatherproofing existent Protection against animal biting existent Calibration of sensor wiring done Not necessary, due to short cable lengths Piping Weatherproofing existent Protection against animal biting existent Insulation checked for completeness and deficiencies Solar field not finished yet Wiring: Capillary sockets and heat shrink tubes used Balancing valves: dp metered, hydraulic balancing, mounting direction OK Thermal expansion considered Collector sensors Heat-sink paste (stable up to 250 C) used Not done yet Temperature sensors with silicon wires (stable up to 250 C) used Temperature sensors protected from disengage General Wire and pipe penetrations protected from water Solar circuit deaerated Shut-off devices opened for normal operation Preadjustment only (see comments next page) Page 5 of 13

6 2.2 Indoor YES NO Report Comments / Explanation Expansion unit Expansion vessel sealed and with protected shut-off Preset pressure adjusted (bar) 1,7 Operating pressure (cold) adjusted (bar) 1,9 Intermediate vessel installed Collecting vessel installed Backfeed pump installed Pumps 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) 9, Control and regulating devices Place of installation and quality checked Direction of rotation checked Balancing valves: dp metered, hydraulic balancing, mounting direction OK No balancing valves installed Heat transfer fluid Ready-to-use mixture used Data sheet attached See technical documentation Make / Type: PEKASOLar 100 (35%) Filling capacity (l): 4000 kg Filling capacity heat transfer fluid (l): = Frost protection ( C): -17 C ph-value: 7,5-9,5 Page 6 of 13

7 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 Heat exchanger Flow direction of both circuits checked Threaded connections retightened Done by piping company Data sheet attached See technical documentation Pressure transmitter Installed and signals checked Temperature sensors Installed and protected from disengage Wiring Calibration of sensor wiring done short cable lengths Capillary sockets and heat shrink tubes used Valves and accessories Not necessary 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 Preadjustment of balancing valves TA STAD-C (position of handwheel): SO-BL SO-BL SO-BL SO-BL SO-BL SO-BL SO-BL Page 7 of 13

8 3 Secondary circuit YES NO Report Comments / Explanation Storage tanks Storage tank(s) filled and deaerated Insulation existent Pumps Mounting direction of check valves checked Mounting direction of pumps checked Operation test done Piping Insulation checked Strainer / dirt seperator clarified Strainer Pressure test done (bar) 6, Safety devices see Safety devices Pressure transmitter see Pressure transmitter Temperature sensors see Temperature sensors Wiring see Wiring short cable lengths Valves and accessories see Valves and accessories Heat meter Installed and data transfer with control unit checked Motor driven valves Installed and checked Comments / sketches Problems with moter-driven butterfly valves the switch cams had to be adjusted Page 8 of 13

9 4 Solar circuit YES NO Report Comments / Explanation 4.1 Feed water preheating Pumps Mounting direction of check valves checked Mounting direction of pumps checked Operation test done Piping Insulation checked Strainer / dirt seperator clarified Strainer Pressure test done (bar) 6, Safety devices see Safety devices Pressure transmitter see Pressure transmitter Temperature sensors see Temperature sensors Wiring see Wiring short cable lengths Valves and accessories see Valves and accessories Heat meter Installed and data transfer with control unit checked Heat exchanger see Heat exchanger Motor driven valves Installed and checked Comments / sketches Leakage on entry of feed water pipe into heat exchanger Page 9 of 13

10 4.2 Hot water preheating YES NO Report Comments / Explanation Pumps Mounting direction of check valves checked Mounting direction of pumps checked Operation test done Piping Insulation checked Strainer / dirt seperator clarified Strainer Pressure test done (bar) 6, Safety devices see Safety devices Pressure transmitter see Pressure transmitter Temperature sensors see Temperature sensors Wiring see Wiring short cable lengths Valves and accessories see Valves and accessories Heat meter Installed and data transfer with control unit checked Heat exchanger see Heat exchanger Motor driven valves Installed and checked Comments / sketches Page 10 of 13

11 5 Control unit YES NO 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 Output signal of pressure transmitter (ma or V) adjusted correctly Pressure values with values of pressure gauges checked Heat meter (power supply, M--Bus) connected correctly Temperature sensors for heat meter installed correctly Addressing of heat meter done correctly Display/units of heat meter checked Display of heat meter-values verified Limit temperatures within the designed limits Internet connection checked Connection for remote maintenance (e.g. TeamViewer) possible Control parameters set as required Power supply/control sigmal to all electromechanical devices Operation of control unit checked Operation of frequency converter checked Page 11 of 13

12 6 General YES NO Rep. Comments / Explanation Labelling Sensor wires Not done yet Piping = Pumps = Heat exchanger = Shut-off and control devices = Motor driven valves = Safety valves = Strainer/dirt seperator = Exmpansion 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 Labelling checked according to the hydraulic schematic and found correct Not done yet Documentation Pictures before start of work taken Pictures during work taken Pictures of important occurrences taken Detailed pictures after Finalization of work taken Partly General safety equipment Fire extinguisher existent and clearly visible Emergency shut-off existent Label with mergency numbers (fault service, firefighters,...) placed Cleanness Waste removed, site left clean swept Page 12 of 13

13 7 Comments In the following the most important comments are described more detailed. The installed collector area consists of 7 collector fields. At each field a balancing valve is installed, which is fully open while installation. During the pressure loss calculation while the designs phase the pre-setting of the balancing valves is fixed. When the solar plant is started up, first the balancing valves are pre-adjusted according to the calculated handwheel positions, which are as follows: SO-BL-01 (DN32) 3.5 SO-BL-02 (DN32) 3.0 SO-BL-03 (DN32) 2.5 SO-BL-04 (DN32) 2.5 SO-BL-05 (DN25) 3.0 SO-BL-06 (DN20) 2.0 SO-BL-07 (DN15) 3.0 As a next step the flow rates of each collector field are measured with a special measuring device, beginning with the field with the highest pressure loss. Then all other fields are measured, compared with the calculation and adjusted if necessary. Simultaneously the collector outlet temperatures are check, as they should be as close to each other as possible. The calibration of the temperature sensor wiring was not necessary, due to short cable lengths between the sensors and the control unit (switch cabinet) of less than 50 meters. In this case the temperature variation due the resistivity of the sensor cable is very low (tenths of a degree) and therefore insignificant. While the commissioning there have occurred two main problems: 1. There were problems with the motor-driven butterfly valves for the loading and unloading of the storage tank. Some of them didn t open any more after they were closed. They overtraveled the closing position and the motor didn t have enough drive to reopen the valve. Therefore the switch cams inside of the electric motor of the butterfly valves had to be adjusted manually with an Allen wrench. 2. When the feed water preheating was taken into operation, a leakage occurred on the feed water side. The screw connection on entry of feed water pipe into heat exchanger was leaky. Therefor the gasket of the screw connection had to be changed by a skilled worker. Page 13 of 13