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to smaller prototype installations spread out at many locations, has the advantage of lower cost through production automation early in the product design cycle and lower O&M cost through consolidation of O&M resources. SES has co-located its engineering team at the SNL National Solar Thermal Test Facility, which provides direct access to technology transfer and expertise and allows the engineers daily hands-on access to the dish systems. This is critical to accelerating the development and deployment path and rapidly training new solar engineers. Last year, SES and SNL installed and began operating the first SES-built dish system at SNL. This system is designated “serial 0.” This fiscal year, SES installed the remaining five systems, heavily utilizing its steel fabrication partner Schuff Steel in the erection process. This experience is critical to developing rapid-deployment tools for the large deployments. All of the dish system hardware is funded through SES investor financing, while SNL, through the DOE Concentrating Solar Power Subprogram, provides in-kind engineering support, technology transfer, training, and facilities. 3. Results and Accomplishments Initial installation of the five new units was scheduled for completion in December. However, late in the installation process two structural issues arose. The elevation jackscrew failed on two units. Extensive gravity and wind-load modeling by SNL led to specification of a slightly larger diameter jackscrew. During dish assembly, a bolted joint on the boom failed. Extensive SNL analysis evaluated the design of every bolted joint in the new boom design and led to field rework to replace most of the structural bolts with welds. Subsequent detailed analysis by SES contractors has agreed with SNL’s initial analysis. The field-rework and drive upgrades were completed by May. The power conversion units (PCUs) include engines under various stages of development, fromfullyKockums-builtPCUstoSES-builtPCUs. The Kockums engines are fully refurbished by SES. SNL designed and prototyped a new engine package system that utilizes commercial-off-the- shelf (COTS) radiators, a robust cavity, and better access to the engine for maintenance. This package is the subject of another paper [1]. SNL developed a capability to operate the engines in a test cell at about half power, a critical function to 111 ensure safe operation of the engine prior to solar testing. The facility uses a quartz lamp array salvaged from prior heat pipe receiver work. The engines were operated and controls calibrated in this facility. To support rapid manufacturing with the existing mandrel choices, SNL performed CIRCE2 modeling of the flux on the receiver for a variety of facet focal length combinations. We determined a 2-focal-length arrangement, with two-thirds of the facets at a long focal length, provided the best blend of performance and manufacturing speed. SNL, with cooperation from NREL, performed flux mapping of one new dish to ensure that the key design changes did not add flexibility to the structure. Flux mapping was performed from the horizon to over 60 degrees elevation, and no substantial changes were noted in the flux pattern. This verifies the analytical work performed to redesign the main beam assembly, as well as the CIRCE2 [2] predictions of flux profiles with the new facetdistribution. SNL spent considerable effort on understanding and improving the alignment scheme of the systems. This aspect has the potential for a substantial payoff, as the scheme selection can substantially affect the aperture size, and therefore thermal losses and efficiency, with no change in cost. The alignment scheme must balance the flux distribution to avoid hot spots locally, but must also balance the power between cylinders for maximum engine performance. The original MDC alignment scheme “dithers” some facets out of “perfect” single-point alignment in order to balance the power, filling in the slot caused by the pedestal. However, this scheme requires an aperture that is 2 inches larger in diameter, a substantial thermal loss when compared to a single-pointalignment.Initialeffortswithasingle- point alignment were promising, but the power imbalance proved greater than desirable. SNL developed an approach that considers the flux distribution not only at the receiver, but also at the aperture. Through use of a code similar to molecular dynamics modeling, and applying constraints at both the aperture and the receiver, we proposed, modeled, and implemented a new aimpoint strategy. CIRCE2 modeling indicates a flux and power distribution at the receiver equivalent to the MDC strategy, but an aperture diameter equal to the single-point alignment. Initial on-sun testing indicates a very uniform cylinder-to- cylinder power distribution. Solar Thermal R&D Concentrating Solar PowerPDF Image | DOE Solar Energy Technologies Program
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