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system redesign where feasible. A major change involved eliminating the troublesome “fast slew system” of the old design by replacing the drive motors with faster DC drives and providing secondary fail-safe with azimuth slewing. We also explored possible field alignment tools and schemes for use with the production systems. SN 00 is no longer being operated, but it is available for testing engine modifications if needed. Once SN 00 was installed, daily operations have focused on this unit. The serial 0 system was designed and fabricated using lower-cost fastening systems and employs Panaltec structural facets [1]. These facets have a typical RMS slope error of 0.6 to 0.8 mR, as measured with NREL’s VSHOT system [2]. Combined with the low-iron-glass reflective surface, the optical performance of the new dish has exceeded expectations. Driven by cost reduction, some of the changes implemented in the redesign of SN 0 led to a dish structure that was too flexible for safe operation, as the peak flux in the vicinity of the receiver varied exceeding the design limits by nearly a factor of 3. The design flux in the region of the receiver aperture is 90 W/cm2. Through an aggressive measurement and remediation program, the design team identified and resolved all of the structural issues and reduced the flux levels to acceptable levels. We used flux mapping systems to verify that the flux patterns are now consistent with the system design specifications. All of the system improvements were designed to reduce manufacturing costs and were applied to the design of the five-unit build. System operation of SN 0 started on August 3, and we accrued nearly 300 hours of operation through the end of FY 2004 on September 30. Operation of the system continues as we catalog faults and develop remediation plans to address each fault category. We have started to map the baseline performance of the system by installing traceable, calibrated instrumentation. Finally, based on the upgrades to serial 0, the team completed a revised drawing package, and SES started fabricating the next five units. These units will be installed at SNL, with the goal of having an operational six-dish mini-power plant by December 23, 2004. The design team also started an extensive analytical modeling activity of the new dish structure, in order to provide feedback to the design process aimed at further reducing costs in the next-generation design. The output of the analytical model was compared and calibrated to measure structural deflections as dish mock-up was loaded at the steel fabricator in Phoenix, AZ. Most deflections were found to be in agreement with the predictions of the model within 10%. The model is also being used to validate the design changes that were empirically introduced on SN 0. The team also started designing a major software upgrade to the dish controller to support the mini- power plant operation. The key change involves upgrading the communications so the controls can be integrated into a field-wide SCADA system with a multi-drop serial network. SES is developing the in-house capability to fabricate the Kockums-designed engine. Five new engines are in fabrication at SNL and at subcontract component suppliers. These components and engines will be used in the mini power plant. The engine support structure and radiator assembly has been substantially redesigned to reduce cost, provide superior access to the engine, and use off-the-shelf components where possible. The foundations and conduits have been installed for the additional five systems. System installation will begin with pedestal and electronics in October and dish assembly and alignment will follow in November and December. This rapid deployment of five dishes is aggressive and involves manpower being provided by Schuff Steel, the dish manufacturer. SES is also actively pursuing opportunities for additional multi-unit prototype dish installations in the next year or two. In parallel, SES has a design team addressing issues and developing suppliers and customers for a large-scale deployment. SES is continuing to grow its workforce at SNL with about 12 engineers and technicians on-site permanently and others coming to the NSTTF for periodic testing andPDF Image | FY 2004 ANNUAL REPORT DOE Solar
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