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Chapter 4 Test Plan, Design and Selection of Components, and procurement TEST PLAN AND DESIGN/SELECTION OF COMPONENTS Test plan includes two parts: a 600-hour reliability test and a 50-hour performance test. As mentioned in Chapter 2, the reliability test focuses on system reliability and performance consistency of the ORC system for long term operation and performance test focuses on identify system and components performance characteristics under different operation conditions. The required equipment to obtain the desired information for these two parts of testing includes a heating source and a cooling source of which the fluid flow conditions are controllable, a power up loading (generated by ORC system) and consuming (e.g., by pumps) circuit, measurement and data acquisition devices for measuring and collecting operation and performance data of critical components in the system, and an internet connection between the ORC system and ElectraTherm facilities. Other accessories needed include piping pressure regulator, safety devices, filters, etc. The ORC system is a complete self regulated system with system performance measurement and control/safety/monitoring devices for some of its critical components. The interface between the ORC system and the environment are through the heating fluid inlet and exit ports (for heating fluid), cooling fluid inlet and exit ports (for cooling fluid), the UAF electrical motor center (for power up-loading from the ORC system to the UAF power plant and power consumption of pumps and actuators), and internet connection box (for remote monitoring and control from the ElectraTherm company). Manual interface devices between human and machine include HMI, emergency switch, manually operated valves, etc.). The ORC system doesn’t have enough measurement devices for performance evaluations of all the major components (i.e. expander, evaporator, condenser, and pump). If performance evaluation is required for every major component, extra sensors for temperatures and pressures pertinent to the components are needed. Due to the integrated nature in manufacturing the ORC system, temperature sensors cannot be installed in direct contact with the working fluid. Therefore, temperature sensors are installed to pipe outside surfaces immediately next to the fluids at the locations of interest. Since the measurements are for steady state operation conditions, the deviations between the measured temperatures and the respective true temperatures of fluids are expected small enough to have minimal effect on the conclusions of this project. The final selected test site is a vacant space in the UAF Power Plant building. UAF power plant has plenty of steam supply for heating, water supply for cooling, and pressurized de-ionized water for pipe pressure maintenance. All of the available resources made the installation and operation expenses low and affordable. The final design layout of the heating and cooling loops has been obtained through several design iterations and the design was based on the availability of the test space, available project budget, accessible resources, codes and standards, and timing constraints. The final testing system includes a closed steam loop coupled with a closed hot water loop for heating, an open cooling water loop for cooling, an electrical circuit for power up- loading/consumption, instrument and signal processing circuits for data acquisition/performance monitoring and control, and an internet connection for remote monitoring/control. A detail of the available floor space for installation is given in 19PDF Image | Optimizing Heat Recovery Systems for Power Generation in Rural AK
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