Solar field

Objective

The KURAYMAT 1 Integrated Solar Combined Cycle Power Plant is

located at the northern latitude of 29°16’ and the eastern longitude of
31°15’. It is some 95 km south of Cairo and about 2.5 km from the
eastern shore of the Nile. Egypt. It is planned to generate electricity from
thermal solar energy. For this two main systems are coupled:

The heat transfer fluid (HTF) cycle, which transfers accumulated solar
heat from a parabolic trough solar field to a power block water/steam
cycle and the water/steam cycle which transfers the thermal energy to a
turbine.

The solar power plant is sized to produce nearly 61 MWth.

The total installed mirror area is 130800 square meters.

The HTF cycle is usually driven by two of three HTF main pumps
operating in parallel with a design flow of approximately 125 kg/s each.
At nominal solar field operation the HTF temperature varies from 393°C
(“hot”) leaving the solar field to 293°C (“cold”) leaving the power block
heat exchanger unit.

Due to the characteristics of HTF, several auxiliary systems are required

to keep the HTF cycle able to work. During warming up and cooling
down periods of the HTF its volume increases or decreases. An expansion
system buffers this change of volume. A system of reclamation and ullage
vessels removes sludge, low boiler and high boiler distillates that develop
over time in the HTF system. To prevent HTF from freezing at night or
during cool and cloudy weather periods, a one of two freeze protection

1
pumps circulate the HTF at that time. If necessary, one gas fired heater
keep the HTF cycle warm enough to prevent freezing.

To prevent oxidation or combustion, nitrogen is used to provide nitrogen

blanketing to several HTF vessels. Furthermore the nitrogen is used to
control the system pressure which must be kept higher than the HTF
vapor pressure to avoid flashing with pressure surges.

The most important are

 DNI  Cleanliness of the mirrors
 Mass flow  Quality of tracking

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 Technical Data

HTF System

Design Mass Flow (kg/s): 250 (100%)

Piping according ASME B31.1 Power Piping

Piping material: Carbon Steel

Maximum allowable pressure (bar g): 34

Maximum allowable temperature (°C): 400

Components of HTF System

1. Expansion Vessel – 12VPA10 BB001

Manufacturer: NSF Type: Cylindrical vessel

Capacity: 200 m3 Design pressure: 13 bar g
Design temperature: 400 °C Insulation thickness: 200 mm
Heat tracing: Yes Arrangement: vertical

2. Ullage Vessel – 12VPE30AT001

Manufacturer: NSF Type: Cylindrical vessel

Capacity: 10 m3 Design pressure: 6 bar g

Design temperature: 400 °C Insulation thickness: 200 mm

Heat tracing: YES Arrangement: vertical

3. Ullage Drain Vessel – 12VPE80 BB001

Manufacturer: NSF Type: Cylindrical vessel

Capacity: 5 m3 Design pressure: 0.5 bar g

Design temperature: 300 °C Insulation thickness: 100 mm

Heat tracing: No Arrangement: horizontal

4. Reclamation Flash Vessel – 12VPE10 AT001

Manufacturer: NSF Type: Cylindrical vessel

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Capacity: 3 m3 Design pressure: 6 bar g

Design temperature: 400 °C Insulation thickness: 200 mm

Heat tracing: YES Arrangement: vertical

5. Reclamation Drain Vessel – 12VPE20 BB001

Manufacturer: NSF Type: Cylindrical vessel

Capacity: 5 m3 Design pressure: 0.5 bar g

Design temperature: 400 °C Insulation thickness: 200 mm

Heat tracing: YES Arrangement: vertical

6. HTF Storage Tank – 12VPE95 BB001

Manufacturer: NSF Type: Cylindrical vessel

Capacity: 25 m3 Design pressure: 0.5 bar g

Design temperature: 300 °C Insulation thickness: 100 mm

Heat tracing: YES Arrangement: vertical

7. Collecting Tank – 12VPE90 BB001

Manufacturer: NSF Type: Cylindrical vessel

Capacity: 25 m3 Design pressure: 0.5 bar g

Design temperature: 300 °C Isolation: 100 mm

Heat tracing: YES Arrangement: vertical

8. HTF Heater – 12VPH11 AH001

Manufacturer: Classen Apparatebau Wiesloch

Fuel: LNG (Liquefied natural gas)

Design duty: 2000 KW Nominal HTF flow (tube side): 100 m³/h

Nominal HTF temperature (in / out): 295 °C / 393 °C

Combustion air pressure: 75 mbar g

Tube diameter (inner/outer coil): Ø 88,9 x 3,2 mm / Ø 88,9 x 3,2 mm

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Pipe material: P235HG TC1 acc. To EN 10216

HTF pressure drop: 2.0 bar Design pressure: 22 bar g

Design temperature: 400°C

9. HTF Main Pumps – 12VPC21 AP001, 12VPC22 AP001, 12VPC23 AP001

Manufacturer: HERMETIC-Pumpen GmbH

Model: API 685 design, CNPKf 200x150x350 A1

Type: Canned motor pump Design flow: 550 m³/h

Design head: 195 m NPSHR: 12.5 m

Motor manufacturer: HERMETIC-Pumpen GmbH

Motor data: 545 kW, 3534 min-1 (variable frequency drive)

10. Freeze Protection Pumps – 12VPC61 AP001, 12VPC62 AP001

Manufacturer: HERMETIC-Pumpen GmbH

Model: API 685 design, CNPKf 150x100x230-1

Type: Canned motor pump Design flow: 150 m³/h

Design head: 65 m NPSHR: 5.3 m

Motor manufacturer: HERMETIC-Pumpen GmbH

Motor data: 77.3 kW, 3504 min-1 (variable frequency drive)

11. Ullage Circulation Pumps –12VPE40 AP001

Manufacturer: HERMETIC Pumpen GmbH

Model: API 685 design, CNF 65-40-160B

Type: Canned motor pump Design flow: 15 m³/h

Design head: 15 m NPSHR: 1.3 m

Motor manufacturer: HERMETIC Pumpen GmbH

Motor data: 5.2 kW, 400V, 2845 min-1 Variable frequency drive: No
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12. Ullage Discharge Pump –12VPE50 AP001

Manufacturer: HERMETIC Pumpen GmbH

Model: API 685 design, CAMT 30/7 Type: Canned motor pump

Design flow: 9,4 m³/h Design head: 140 m

NPSHR: 0.8 m Motor manufacturer: HERMETIC Pumpen GmbH

Motor data: 19 kW, 400 V, 2920 min-1 Variable frequency drive: No

13. HTF Drain Pump – 12VPA80 AP001

Manufacturer: HERMETIC Pumpen GmbH Model: CS 50-160

Type: Canned motor pump Design flow: 28 m³/h

Design head: 12 m NPSHR: 2.9 m

Motor manufacturer: HERMETIC Pumpen GmbH

Motor data: 6.8 kW, 400 V, 2830 min-1 Variable frequency drive: No

14. Parabolic Trough Solar Collector Field

Model name of parabolic trough collectors: SKALET-150

Aperture area of each collector (m2): 130.800

Total number of collectors: 160 Number of collectors per loop: 4

Hot leg operating temperature (°C): 393

Cold leg operating temperature (°C): 293

Main concept

The solar field has a total effective mirror area of approximately 130 800
m2, divided into two subfields, west and east, each with 20 HTF loops
including 4 solar collector assemblies (SCA) each. Each subfield has a
motor operated adjusting valve at its HTF inlet, which may be used to
correct HTF flow balances between these two subfields (in the event of
imbalance due to one or more loops being taken out of service). Both the

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inlets to the solar field subfields and the outlets from the solar field
subfields have temperature, pressure and flow instruments each.

To compensate for pressure drops induced in the solar field HTF headers
between one loop and the next, adjusting valves are installed on each
connection from the cold header to the SCA loop inlet. These valves are
adjusted to maintain approximately equal HTF outlet temperatures for all
SCA loops at nominal load.

Each SCA loop may be put out of operation by closing appropriate valves
at its HTF inlet and outlet, and therefore a pressure relief valve is
installed to avoid overpressure in case of warming which can lead to
thermal expansion of the HTF. Due to its flammability and toxicity the
HTF must be relieved into a closed environment. The pressure relief
valve therefore relieves HTF in a closed pipe path from the collector loop
around the hot isolation valve into the hot HTF header.

The solar power plant basically consists of two coupled systems – the
heat transfer fluid (HTF) system and the heat exchanger unit (power
block). The HTF-system transfers accumulated solar heat from a
parabolic trough solar field to the heat exchanger unit.

The HTF-system is a closed-circuit system, in which the heat transfer

medium is circulated. The HTF system mainly comprises the HTF main
pumps (or freeze protection pumps in case of low flow), all the HTF
piping within the solar field

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 Components Functions

1. HTF Expansion Vessel

The HTF cycle is connected to an expansion vessel to balance the HTF

expansion or contraction within the cycle with changing HTF-
temperatures. The expansion vessel consists of an elevated expansion
vessel (12VPA10 BB001, sized about 200 m3). The expansion vessel is
pressurized with a nitrogen blanketing.

The expansion vessel pressure varies with the current HTF content but is
always high enough to surely prevent HTF flashing.

Some internal fittings within the expansion vessel allow HTF distribution
for stripping of gaseous contamination or low boiling HTF degradation
products. The expansion vessel pressure varies as a function on the
current HTF temperature in the HTF cycle and is high enough to surely
prevent HTF flashing. The pressure provides a sufficient net positive
suction head to the HTF cycle pumps (HTF main pumps and freeze
protection pumps).

A concrete containment pit sized to accommodate the full HTF content of

the expansion vessel is located below the expansion vessel. The pit can be
drained by a HTF Drain Pump (canned motor pump).

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1.2 Nitrogen System

The HTF cycle is pressurized to avoid flashing of hot HTF. Nitrogen

blanketing is used to prevent HTF oxidation or combustion. Pressure
control is realized by vent control valve and nitrogen control valves

[Link] System

Low boiling HTF degradation products accumulate in the fluid as well as

in the nitrogen blanketing and increase the system pressure over time. To
limit the concentration of these products and to limit the system pressure,
a mixture of nitrogen, degradation gases and HTF vapour will be
sometimes vented from the expansion vessel into a so called ullage
system. The ullage system mainly comprises two vessels one equipped
with a circulation pump and each with a cooler unit. The first ullage
vessel 12VPE30AT001 is kept just cold enough to condensate HTF vapor
but warm enough to keep the low boiler vapor gaseous. The HTF
condensates are given back to the HTF cycle, the low boiler vapors are
transferred into the colder second ullage drain vessel 12VPE80BB001 to
condense as much as possible for external disposal. Remaining vapors
and nitrogen are vented via flame arrester into the concrete containment
pit (atmosphere)

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2.1Ullage Pumps

The Ullage Circulation - and Discharge Pump are centrifugal, canned

motor pumps without external cooling system. The ullage discharge
pump is a 7-stage pump.

HTF degrades into high and low boilers. The low boilers are removed
from the HTF system through the ullage system.

When the expansion vessel is vented, a mixture of nitrogen, gaseous low

boiling degradation products and gaseous HTF enters the ullage vessel
and the ullage drain vessel. HTF vapor condensates and remains in the
ullage vessel, while the mixture of nitrogen and low-boiling products is
directed to ullage drain vessel for further treatment.

In order to avoid condensed HTF resting in the vessels, reaching its

boiling temperature, the ullage circulation pump supplies the HTF
towards an air-cooled heat exchangers, where the temperature of the fluid
is reduced, and returned to the ullage vessels.

The HTF condensed in the ullage vessel is discontinuously pumped back

to the HTF system through the ullage discharge pump. It is controlled by
a switch signal, which is generated by a level sensor installed in the
ullage vessel.

[Link] System

High boiling degradation products accumulate in the fluid over time, too.
To limit the concentration of high boiling degradation products in the
HTF after some years of operation, a small flow of hot and pressurized
HTF is temporarily given into the reclamation system. The hot HTF
immediately flashes in the un-pressurized reclamation flash vessel

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12VPE10 AT001. The generated HTF vapour is transferred to the ullage
vessel, condensed and returned back to the HTF cycle, and the non-
flashing high boilers are collected in a reclamation drain vessel
(12VPE20 BB001) for external disposal.

[Link] System

Big solids within the heat transfer fluid are separated by the pump
strainers; smaller ones like fine sand or rust particles are separated by the
HTF filter 12VPC71 AT001 which is integrated in the freeze protection
cycle. It will be operated in mode 4 (freeze protection mode without
heating).

[Link] Main Pumps

The HTF main pumps 12VPC21-23 AP001 are variable speed pumps
with external cooling system for dissipation of heat from the motor. HTF
main pump operation is needed for the solar field operation modes (mode

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1 and 2). Normally 2 of 3 installed pumps operate in parallel at the same
time, but operation of just one pump is possible, too.

The load of pumps will significantly vary over the day depending on solar
irradiation and operation mode. Most frequent operating condition is at
40 to 50 % of the 250 kg/s.

The external cooling system is equipped with a separate circulation pump

(canned motor pump) and an air cooler (3 fans).

The external cooling system must be in operation, even in case the

respective main pump is in standby. In case of expected ambient
temperature below 12°C the external pump cooling system must be
running, too. The heat dissipated by the circulation pump into the piping
system is high enough to avoid freezing in the external cooling system (in
particular air cooler).

[Link] Protection Pumps

The HTF freeze protection pumps 12VPC61/62 AP001 are variable speed
pumps with external cooling system as the main pumps. Only difference

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to the main pumps air coolers the air cooler is equipped with only one
fan. The freeze protection pumps are needed for the Modes 4, 5 and 6.

The HTF Freeze Protection Pumps have the following tasks:

 An important reason for regular starting of freeze protection mode

after shutdown even in case of still high HTF temperatures is the
avoidance of great temperature differences in HTF system and
resulting material stress, which will occur without HTF circulation
because of different cool down of insulated and not insulated plant
parts.
 To avoid HTF freezing after shutdown, HTF shall be circulated if
low ambient temperatures are expected or if somewhere in the HTF
cycle any temperatures drop below 40°C. In this case, the operator
has to start freeze protection mode with heating (mode 5).
 The freeze protection pumps are used for protection in case of
power blackout. Therefore both freeze protection pumps, the DCS-
system and the pneumatic and electrical valves are fed by the UPS
system. In case of solar field operation (Mode 1, 2 or 3) and a
power blackout (indicated by signal from the electrical system)
both freeze protection pumps will automatically start and assure the
maximum possible mass flow to avoid excessive heat in the solar
field absorber tubes.

7. HTF Drain Pump

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The Drain Pump is a single-stage centrifugal-, canned motor-, self-
priming pump without external cooling system, which is installed near
to the pit, with a suction pipe into the 5 meter depth pit.

Drain Pump shall pump either the fluids contained in the collecting pit
(leaked HTF, collected rain water, small solid particles, etc.) into the
collecting tank or directly into a tank-truck.

Note: The drain pump may be operated only in the

temperature range between 20 and 80°C. This must be strictly
observed.

Instructions before startup

The Pressure control of the HTF system must be available and operate
in automatic mode. Thus the following control valves and
instrumentation must work in automatic mode:

21NEX20 AA501 nitrogen control valve in front of expansion vessel

21NEX20 AA502 nitrogen control valve in front of expansion vessel

21NEX20 CP201 nitrogen pressure in front of control valve

21VPA23 AA501 control valve to ullage system

21VPA10 CP201/202 pressure of expansion vessel

 The cooling of the HTF (heat exchanger unit) must be available

and in automatic mode. Thus the following components and
instrumentation must work in automatic mode:
21VPE40AP001 ullage circulation pump
21VPE50AP001 ullage discharge pump
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 21VPE40AN001 ullage cooler 1
21VPE60AN001/002/003 ullage cooler 2
21VPE50AA301 shut-off device behind ullage discharge pump
21VPE30CL201/202 level indicator of ullage vessel
21VPE80CL201/202 level indicator of ullage drain vessel
21VPE40CT201 temperature of ullage vessel
21VPE60CT201 temperature of ullage drain vessel
 The level indicator of expansion vessel must be in the range of
20% to 80%
 The level indicator of ullage vessel must be in the range of 10%
to 40%
 The level indicator of ullage drain vessel must be in the range of
0% and 90%
 Inlet Heat exchanger unit valve 12VPD10AA351 and the HTF
bypass valve21 VPC31AA351 must be available in automatic
mode.
 The HTF vent valves must be available and operated in
automatic mode.
 At least 2 main pumps, 12VPC21 to 23 AP001, must be
available and operated in automatic mode.
 The UPS system must be supplying, and the freeze protection
pumps 12VPC61 and or 62 AP001 must be available.
 One of two freeze protection pumps 12VPC61/62 AP001 must
be available for emergency flow (in case of power blackout).
 The shutdown mode (mode 3) must be available.
 The emergency flow mode (mode 6) must be available

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Operation Modes Overview

If ever possible, the HTF system shall operate in an automatic mode.

There are 6 operation modes foreseen for operation of the HTF system:

 Mode 1: Regular warm-up

 Mode 2: Heat transfer from solar field to heat exchanger unit
 Mode 3: Shutdown (of HTF System)
 Mode 4: Freeze Protection Mode without heating (with HTF-Filter-
operation)
 Mode 5: Freeze Protection Mode with heating (without HTF-Filter
operation)
 Mode 6: Emergency flow (power blackout)

Change of operation mode shall be done by operator except for

emergency flow mode (which starts automatically in case of loss of
electrical power with solar field operation at the same time) and

shutdown, which can be initiated by operator and by the control

system in case of trouble.

Mode 1Regular warm up

In this mode the HTF flow and temperatures will be increased up to

their steady-state operating conditions by setting all required valves
appropriate, starting two HTF main pumps to establish a minimum
flow within the solar field and tracking the solar field collectors into
the sun. Warm-up develops until HTF temperature reaches the

16
required values for automatic start of heat transfer to heat exchanger
unit. These temperature limits are variable and depend on actual
conditions at the heat exchangers.

Normal HTF operation temperatures 293°C at solar field inlet and

393°C at solar field outlet – are usually reached within 20 to 60
minutes after starting the solar energy accumulation. Duration
primarily depends on initial HTF cycle temperatures and actual solar
irradiation.

Mode 2 Heat transfer from solar field to heat exchanger unit

In this mode the thermal energy from the solar field is solely used to
generate electrical power.

After regular warm-up the heat transfer to the heat exchanger unit
starts as soon as HTF flow is supplied to the heat exchanger unit.
Subject to sufficient solar irradiation, the HTF outlet temperature in
the solar field continues to rise until reaching the design set point
(approximately 393 ºC.(

Mode 3 Shutdown

If solar radiation ends, or under certain alarms and weather conditions,

operator will shutdown the heat exchanger unit and stop the HTF
circulation by stopping the HTF main pumps. Before stopping the
HTF circulation through the solar field all SCA must have left the
tracking position.

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Mode 4, 5 Freeze Protection Modes

This mode is foreseen to avoid HTF freezing in the HTF cycle after
shutdown. As long as the solar field temperatures are high enough, a
freeze protection mode without heating is sufficient (mode 4).
Otherwise low temperature alarms will be indicated on the control
screen, and the Operator shall start the freeze protection mode with
heating (mode 5)

The huge HTF volume and heat capacity in the cycle allow many
hours of operation without heating. But at the latest if the temperatures
in the cycle reach certain minimum limits (and such alarms are
indicated on the operation screen), the HTF heater is put into
operation to raise the HTF temperatures.

Mode 6 Emergency flow

In case of solar field operation (indicated by tracking of the solar

collector assemblies) and a blackout longer than one second, one or
both (if available) freeze protection pumps will automatically start to
avoid excessive heat in the solar field absorber tubes due to lack of
HTF flow. Freeze protection pump motors will be fed from the
Uninterruptable Power Supply system (UPS) in this situation. The
freeze protection pumps will feed the field with HTF at least until full
absorber tube defocusing is achieved by natural change of sun
position.

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 Startup sequences

Before starting the solar field the temperatures between the solar field
and the HTF system need to be equalized. This is normally carried out
with operation mode 4 (HTF freeze protection mode without heating).
In case of no operation in mode 4 the main pumps shall be operated at
least one hour before starting the operation of the solar field.

Usually the operation of the solar field starts at sunrise if it is expected

that there will be sufficient sunshine on that day. The limitation for
operation of the solar field (receiver tubes) is a minimum required
mass flow of 30%. That means a minimum DNI (approx 033 .W/m²)
must be expected. To start tracking the solar field a DEPLOY (Virtual
track) command has to be sent to the SCAs. A DEPLOY (Virtual
track) command can be sent to the complete solar field or only to pre-
selected SCAs or solar field sections.

To send the DEPLOY (Virtual track) command please follow the

following steps:

-Switch to view Modes

-Select all collectors/LOCs, which should be sent to track mode.

-Select the Deploy-command(Virtual track) in the command bar

- Click the Send-button

Note: If the power block is ready to absorb energy and gives the
signal to receive energy, and if the operation starts at sunrise, usually
the complete solar field is send into TRACKING at once.

19
Note: If solar field operation starts when there is already a high solar
irradiation (DNI >033 W/m², value to be confirmed during
commissioning of solar field), not all collectors should start tracking at
the same time. Start with the last collectors in every loop. Then wait 5
minutes until you send a DEPLOY command to the third collector in
every loop. Then wait another 5 minutes until you continue with the
second collector. After another 5 minutes you can send a DEPLOY
command to the remaining collectors. The delay time of 5 minutes has
to be optimized during the commissioning in dependence of the
accepted start-up ramp of the heat exchanger unit.

Main task of the operator during automatic operation is to observe the

collectors at the FSC screen and to react properly to alarm conditions.

Note: After an alarm was cleared manually or automatically the

collector will not be sent automatically back into track modus by the
FSC or the LOC. This has to be done for each non tracking SCA by
the operator via the FSC. The only exception is the overtemp alarm. If
the temperature falls again below a certain level (Temp_ok), the
collector starts tracking again, as long as no other command like
FOLLOW was issued by the FSC in the mean time.

Note: If possible the operator should immediately sent a deploy

command to a LOC, as soon as an alarm could be cleared or has
disappeared.

The operator shall also:

 Adjust daily the control valves at the inlet of the East or West
subfield in order to optimize the outlet temperature according to
the procedure described later

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  Check and optimize at least weekly the adjusting valves at the
inlet of the loops according to the procedure described later

Adjustment of Mass Flow in each Subfield

The HTF main pumps are designed for a theoretical calculated mass flow
of 250 kg/s (100%). Due to the different solar irradiation is the mass flow
of the HTF-cycle variable between 30 and 100% or higher. Due this fact
the pressure drop in the HTF-cycle varies as a function of mass flow in an
enormous range between 1 bar and 15 bar g. For a safe operation of the
HTF main pumps the Cold Header Lines West and East are equipped
with a bypass system. For operation the main pumps in this optimized
operating point each header bypass is equipped with a control valve for
adjusting the required pressure drop.

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Note: Operation of modes 1, 3, 4, 5 and 6 of the HTF system will be
executed through the East and West header bypass in the range of 30
to 100 % or higher mass flow. The inlet valves at each subfield
11SXX71/72AA551 must be closed. During mode 2 above 40% mass
flow the header bypass valves11SXX71/72AA552 shall be 100% open
and the header valves 11SXX71/72AA551 shall be 40% open to
increase the maximum performance(this action shall be taken
automatically by the DCS).

The operator should continuously observe the outlet temperature at each

subfield. If some loops become not available (maybe for washing or
maintenance works) or the average loop outlet temperatures of the two
subfields permanently deviates some degrees Celsius from each other,
Operator must manually adjust the flow distribution between the two
subfields.

The mass flow in the two subfields needs to be adjusted by the control
valves located at the inlet of each subfield (11SXX71/72 AA551). For
adjustment of the valves please apply the following rules.

 Adjustment should be done at least once a day or if the number of

tracking collectors (loop(s)) in a subfield changes significantly due to
failures or alarms or other conditions.
 At the subfield with the lowest number of tracking collectors, this
control valve in header bypass 11SXX71/72AA552 must be throttled for
adjustment in the DCS by operator.

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 First step is a rough adjustment of subfield flows to the collector/loop
availability: If (as an example) only 90% of the collectors/loops in certain
subfield are available but 100% of the collectors/loops in the other
subfield, the according mass flow of the certain subfield shall be adjusted
to be approximately 90% of the other subfield mass flow.
 The mass flow in the other subfield should be directly proportional to
the number of tracking collectors. 10% less tracking collectors means
10% less mass flow in the affected subfield. Adjust the Header bypass
control valve 11SXX71/72 AA552 accordingly by DCS.
 Second Step: After five (5) minutes the adjustment must be checked.

The 15 minutes interval considers the time lag to achieve stable

conditions after an adjustment. If the average HTF outlet temperature of
the loops in a certain subfield is more than 1°C lower than the average
HTF outlet temperature of all the other loops in the other subfield, the
flow through this subfield shall be reduced 1% per °C difference
temperature. Control valve 11SXX71/72AA552 must be closed slightly.
If the difference temperature is less than 1°C, adjustment is finished
except for significant more “dumping” in this subfield than in the other
ones which makes a little bit more flow necessary. In case of more
dumping in a subfield the flow there shall be increased 1 to 2% (Control
valve 11SXX71/72AA552) must be opened slightly) and 5 minutes later
the temperatures and the dumping shall be checked again.

Check of Adjusting Valves at each Loop Inlet

In order to optimize the HTF outlet temperature of the solar field each
solar field loop is equipped with an adjusting valve. Ideally all the single
loop outlet temperatures are the same.

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Operator must check (and adjust, if necessary) the valve adjustment at
least once a week to reach a yearly plant efficiency according to the
contract. Adjustment shall be done preferably.

 at steady mass flow (mass flow for adjusting shall be 70-

90% of nominal mass flow in summer, 50-70% of nominal
mass flow in spring and autumn and 40-50% of nominal
mass flow in winter)
 at good weather conditions (no clouds, low wind)
 without “dumping” forced by DCS mass flow control

Adjustment procedure:

1. Operator must check all the loop outlet temperatures in a

certain subfield if the subfield has been in tracking mode
since 15 minutes or more. If there is no dumping” and all the
temperatures deviates less than 4 degrees Celsius from each
other, the loops are well adjusted and more adjustment is
unnecessary.
2. Otherwise Operator shall select 3 loops with the most
frequent “dumping” or – if there is no dumping – the highest
outlet temperatures, and open the adjusting valves there a
little bit more. (If they are fully open, all the other loops in
the subfield must be throttled a little bit). Operator shall also
select 3 loops with the coldest outlet temperatures and close
the adjustment valves there a little bit more.
3. After 15 minutes the outlet temperatures of these 6 loops
shall be checked again. If the outlet temperatures of the
former “hot” loops are still higher than the average loop
outlet temperature in the according subfield or “dumping”

24
 goes on, throttling procedure must be repeated. If the outlet
temperatures are now lower than the average loop outlet
temperature, throttling was too much and must be partly
reversed.
4. Procedure for the former “cold” loops is similar: If the outlet
temperatures there are still lower than the average loop outlet
temperature in the according subfield, adjustment valve
opening must be continued. If the outlet temperatures are
higher than the average loop outlet temperature, opening was
too much and must be partly reversed.
5. Adjustment of the 6 loops is finished, if they don’t “dump”
and the outlet temperatures deviate less than 2 degrees
Celsius from the average outlet temperature in the subfield.
6. This adjustment procedure must be repeated for the other
loops until there is no “dumping” and there are for all the
loops less than 2 degrees Celsius temperature difference to
the average outlet temperature.

Note: Only loops with 3 available collectors are allowed to be

adjusted as described before. Adjustment of a loop with only 1 or 2
available collectors can generate too low flow with high film
temperature and HTF decomposition and must be strictly avoided.
Operator must take such a loop out of operation or keep it in
operation at normal flow with comparatively low outlet temperature.
Such low outlet temperature must not be considered when
calculating the average loop outlet temperature for adjustment of
other loops.

25
Determination and Adjustment of required HTF Mass Flow
In automatic mode, mass flow is controlled by the DCS the DCS also
calculates a dumping factor (percentage of solar field, which is not
necessary to reach the required heat demand from the heat exchanger
unit) and communicates it to the FSC. The FSC then controls the
collectors according to a specific dumping strategy. In manual mode this
has to be done by the operator. The operator has to start with roughly
determined values and has to adjust them later on. Some general
guidelines to support him in the decisions are described below.

Mass Flow

An estimation for required mass flow, which has to be provided by the

HTF main pumps, can be taken from the following Figure. This curve
represents only the nominal temperature condition (solar field inlet/outlet:
293°C/393°C). If the actual required temperature difference differs from
the nominal value of 100 K the mass flow has to be adapted linear. That
means, if the actual difference is e.g. 20% lower (80 K), the required
mass flow has to be 20% higher. The mass flow can be adjusted by
changing the speed of the HTF main pumps at the DCS. The total HTF
mass flow is shown at the DCS screen. Nevertheless the operator has to
check during operation, if the mass flow, which was set manual by this
procedure, is correct, and he has to adjust the mass flow accordingly.

Note: In any case the operator should ensure that there is a minimum
flow in the solar field (15% mass flow corresponds to165 m³/h at
293°C) per operated subfield). This minimum mass flow is a safety
device for the receiver tubes

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The overall mass flow control can be summarized as follows:
 As long as the energy available from the solar field can be absorbed
from the heat exchanger unit the set point for the mass flow will be the
calculated flow mass flow m SF,max which will be adjusted by an
integral term that corrects the solar field outlet temperature.

The calculated mass flow in this case is primarily a function of the

current solar radiation, the collector performance and corrective
factors considering the current status of the system.
 If the energy available from the solar field cannot be absorbed from the
heat exchanger unit the set point for the mass flow will be determined by
the thermal energy needed for the desired heat exchanger unit operation.
The amount of energy to be dumped from the solar field will be
calculated and that information will be passed to the FSC. The solar field
outlet temperature will be limited in this case by the local controllers of
the collectors. The temperature span over a loop will be decreased by
increasing the average tracking error of the collectors in that loop.

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Dumping strategy

The plant is designed in a way that not always all energy, which could be
collected by the solar field, can really be handled by the heat exchanger
unit. Therefore it may occur that energy needs to be dumped. This
generally will be realized by defocusing of collectors.

Minimum HTF Temperature Requirements

There are a few temperatures monitoring in the HTF system. Each

temperature monitoring sends a freeze warning to the DCS or FSC in case
of too low HTF temperature. The low temperature limits depend on
location and freeze risk and will be 40°C. In case of low temperature
warning somewhere in the HTF cycle it will be probably sufficient to
start HTF circulation through the Freeze protection pumps. If anywhere
in the HTF cycle temperature drops to 40°C, energy supply is necessary,
and Operator must start freeze protection mode 5 with heating (HTF
heater in operation). Set temperature for the HTF heater shall be 120°C.
If no heater is available the Operator shall start the HTF main pumps
(with approx. 80% frequency) for freeze protection in the HTF system.
Freeze protection mode prevents HTF from freezing exclusively in the
main circulation lines. Some lines besides like lining from / the main
pumps e.g. are excluded. In case of extreme long periods (some days)
without other operation modes, these excluded lines might cool down
(alarm indication), too, and the Operator must manually set the according
valves appropriate to generate HTF circulation and to prevent HTF from
freezing there. If the operator has a freeze warning in the discharge line
from the main pumps, he must stop the freeze protection mode 5 and start
for a short time the HTF main pumps manually with approx. 80%

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frequency for freeze protection in the HTF main pump area. After a
sufficient HTF-circulation (no freeze warning in the main pump area) and
stopping the main pumps the operator start the freeze protection mode 5
again. If such manual HTF circulation cannot be realized, the affected
equipment must be drained.

Boiling out procedure

Water and thermal fluid do not mix. Due to this it is necessary to remove
as much water as possible from heat transfer fluid before the HTF System
will be brought up to the designed operational temperature of 393°C.
Under ambient pressure water turns to steam at roughly 100°C and
increases its volume at least 1000 to 1, depending on the pressure and
temperature. HTF Therminol VP1 vaporized at approximately 257°C. at
ambient pressure. If there is water in HTF system, the risk of major
pressure fluctuations (cavitations) on HTF pumps, of corrosion of the
inside of the HTF piping and of sudden blow-outs of thermal fluid from
expansion vessel is substantial and nitrogen use will be greatly increased.
Even if the expansion vessel can handle the increase in volume, the
resulting cavitation will accelerate pumps wear. The free water must be
removed from the system as far as possible; the process of water
removing is known as boiling out procedure. To explain it more clearly,
boiling-out of thermal fluid in solar field loop piping system means to
remove free water infiltrations by turning water to steam and venting this
steam off the system into the ullage vessel. Expansion vessel is the only
place where the generated water steam can be released out of system. The
key to do it successfully and in shortest time possible is to keep the
temperature of expansion vessel above 100°C to prevent water steam
from re-condensing. Besides, low-pressure nitrogen flushing helps to

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sweep water steam out of expansion vessel and prevents additionally
thermal fluid’s oxidation. Because the suction pressure of the freeze
protection pumps is limited at 2 bar g (interlock), the pressure in the
expansion vessel must be higher. The thermal oil temperature can be
controlled exactly by FSC (set point 140°C) and boiling out can be done
if the solar irradiation is sufficient.

Stop of System
Whenever solar field operation or maintenance work is finished, the
operator must send affected SCAs to stow position:
- Select all affected collectors
- Select the Stow-command in the command bar
- Click the Send-button

Note: Send all collectors to stow position after solar field operation or
any other maintenance work. Do not leave the collectors for a longer
period in any other position, especially not in a position west of the
sun. If there is no flow or circulation in the solar field, focused
sunlight will destroy heat collecting elements (HCE`’s). If there is
only low flow by freeze protection pump, focused sunlight might
cause high film temperature and HTF decomposition.

Note: Some minutes after such a STOW command the operator must
make sure that all the collectors have arrived STOW position and he
must take appropriate actions in case of some collectors fail to do so.

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