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Support for the teams is being provided for materials testing, modeling, and system testing. New ICS system models have been produced to model the new systems. A new procedure for rating the ICS systems is undergoing testing and validation. Pipe freezing, freeze-protection valves, and overheating have been tested and analyzed. A new task in FY 2004 looks at cost-reduction opportunities for cold-climate SDHW. 2. Technical Approach The cost of saved energy is the ratio of total costs to discounted total energy savings. Total cost is the sum of hardware, installation, and marketing costs (these three costs sum to 1st cost) and present value of O&M costs. The approach here focuses on cost reductions rather than performance increases. Hardware, installation, and O&M costs are reduced through two related strategies: 1) use of polymer materials and manufacturing methods, and 2) product redesign aimed at parts’ count reduction and simplified installation. The development process has been structured in three stages: conceptual design, engineering design, and product development. Conceptual design (FYs 2000–2001) began with five teams, down-selected to two teams at the end of conceptual development. In FY 2004, teams were entering the product-development stage, with redesigns based on feedback from “torture tests” and field tests. The key issue in using low-cost polymer materials and manufacturing is durability. Thus, accelerated testing of proposed materials is being done at NREL for both glazings and absorbers. Because the new system types have features not previously modeled, new ICS and thermosiphon models have been developed at NREL to accommodate them. The new models are integrated into a new rating procedure. Pipe freezing, freeze-protection valves, and overheating have been addressed through laboratory testing at NREL. Opportunities for cost reduction of cold-climate systems were identified by modeling costs in detail and projecting performance through simulation. Budget allocations by task are provided below. Task Number and Title 1. Polymer ICS Field Test 2. ICS Development 3. Technical Support 3. Results and Accomplishments FY 2004 Budget ($K) 260 374 473 • Field installations were completed by both teams. • Testing-based redesigns were done by 8/04 for DEG/SE, whereas a new system type is being proposed and developed by FAFCO. • New ICS models and test procedures were developed, forming the basis for SRCC performance ratings for ICS systems. • Specific improvements in cold-climate systems were identified that could lead to >50% reduction in the cost of saved energy. 3.1 Tasks 1,2 for DEG/SE The DEG/SE system is shown in Fig. 1. The system has been performing somewhat above expectation in field trials. Expectation of saved energy is based on a standard draw volume and profile, and the high-draw volume and dispersed profile of the residences chosen yield increased performance relative to the standard case. The system was subjected to a variety of torture tests, including wind uplift, salt corrosion, water spray, hail impact, rough handling, panel creep, and wet/dry stagnation. The wind uplift test led to redesign of the glazing-tank clips. Unsatisfactory rate of leaks on rotomolding has led to a revised mold design that has apparently corrected the leaks. Projected COSE is 5.4 ¢/kWh, a 46% reduction vs. conventional ICS. 3.2 Tasks 1,2 for FAFCO The new FAFCO thermosiphon system is shown by a CAD perspective in Fig. 2. The collector is a glazed pool collector. A direct, open-loop version with collector and storage at line pressure and with storage tubes alongside the collector is shown. This version suffers dramatically for standard draw profiles from reverse thermosiphoning at night. Performance loss compared to a version with storage above the collector (not shown) is estimated at 50%, becausePDF Image | FY 2004 ANNUAL REPORT DOE Solar
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