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demonstration and exploration of field operating issues, and reliability improvement. The DOE dish/Stirling program is working closely with SES to improve the system performance and reliability and to support SES' deployment in the near term, (both explicit goals of the DOE Solar Program Multi-Year Technical Plan section 4.2.5.3). This year, our primary goal was to install, test, and begin to baseline the performance (reliability, availability, and efficiency) of the SES 25-kW dish/Stirling system. The system, which came from the successful MDC system, has been redesigned to reduce cost and improve manufacturability. SES’s objective is to put this system into production as early as 2007 with a target market of bulk power production in the southwestern United States. This corporate goal is enabled by the DOE goal of determining the baseline performance of the system, so that follow-on work can address performance improvement. 2. Technical Approach SES plans to accelerate the system cost reduction by rapidly moving to high production rates in support of bulk power production. This has the advantage of lower cost through automation early in the product design cycle, and lower O&M cost through consolidation of O&M resources at a single site in comparison to smaller-scale installations distributed at many locations. It also allows for consolidation of O&M activities and knowledge bases for more rapid identification and implementation R&D needs. The CSP Program proposed and implemented close cooperation between the SNL and SES teams; SES determined it best to co-locate its engineering team at the NSTTF in Albuquerque. This provides direct access and the direct transfer of technology and expertise and allows the engineers daily hands-on access to the dish systems. This is critical to accelerating the development and deployment path defined by SES and provides for rapidly training new solar engineers. Early in the fall of 2003, the newly formed Dish Team installed an SES-owned MDC system as a development platform at SNL. The control system was upgraded to the ones developed by WG Associates (which is now a division of SES), SNL’s 10-kW Advanced Dish Development Systems [1]. These controls allowed us to rapidly move to unattended automated operation of the system, greatly increasing the hours of system operation. We used this prototype to catalog issues, verify performance, and test new hardware approaches. This dish system was designated “serial number 00.” During the summer of 2004, SES installed a SES- built dish at SNL, implementing reduced-cost approaches for design and fabrication. This system serves as a prototype for the SES commercial system and, after significant cooperative re-work of the design to address structural issues identified during assembly, the low-cost system performance was improved to exceed that of the original MDC system. This system incorporated drive motor, mirror facet, and mechanical joint design improvements over the MDC system and is the very first system fabricated by SES. This system, which is designated as SN 0, is being used to explore potential reliability and further cost reduction issues. Finally, SES is pursuing an aggressive schedule to install five more dishes at SNL by Christmas 2004, creating a six-dish “mini-power plant” to be used to address field control, operations, and maintenance of a dish power plant. All of the dish system hardware is funded through SES investor financing while, through the DOE CSP program, SNL provides access to technical expertise in the form of in-kind engineering support, technology transfer, training, and facilities. 3. Results and Accomplishments The serial 00 system was operated at SNL for 1,045 hours during FY 2004, primarily in the unattended mode of operation. We developed effective closed-loop tracking algorithms to optimize system performance continually by balancing the cylinder temperatures of the operating Stirling engine. We cataloged the problem areas on this system and used this information to guide development changes on thePDF Image | FY 2004 ANNUAL REPORT DOE Solar
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