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Chapter 6 Commissioning The commission started on December 12, 2012 and lasted for about a week. Before commissioning, the ORC system (the Green Machine or GM) user needs to install heat source, heat sink, electrical circuit, and a dedicated internet line (as mentioned in the previous chapters) to the GM based on the requirement list provided by the manufacturer of GM, ElectraTherm (ET). The completed GM Installation Requirement list and a Pre- Commissioning Check list need to be received by ET before any engineer can be dispatched for commissioning. During the commissioning, the ET commissioning engineer performed the following: Checked the installation of the supporting systems: This included investigation of all the installed heating, cooling, and electrical systems and the internet connection. There were many discussions between the ET engineer and the UAF engineers. Checked the Green Machine: A double check of the information and locations of the labels, installations and functionalities of the components, match of the specification received by the customer and the specification of the manufacturer’s record, etc. Working fluid transferring: Conducted pressure test and transferred working fluid from storage bottles into GM. Details could be found in Chapter 5 (Fluid Transferring) of the GM manual. Parameter setup: Set up start parameters, operation parameters, default parameters, and other parameters using HMI. Details could be found in Chapter 7 (Set Up) of the GM manual. Starting up of the GM: Tested of emergency stop, operation mode, alarm mode, and PLC-IO, etc. Details could be found in Section 3.4 of the (Operation) and Chapter 7 (Distributor Manual) of the GM manual. Training: A comprehensive training was held for the ACEP engineers involved in this project. The training includes the most important materials covered in the GM manual, which include: information of installation, routine maintenance and special tools, operation, background, fluid transferring, tasks and applications of HMI. This part training is for general audience (many of the ACEP engineers, students, faculty and staff members). Hands on system set up and operation training: This training is for an engineer and a graduate student who would perform the GM test. In addition, some design issues have been discussed. Two important examples are listed below: 1. All the components of GM have been designed for the capacity of 65kW, but the system was rated as a 50kW system. This down grade was due to the lack of an emergency by pass valve to prevent the screw expander from over speeding while the engine is shutting-off. This unit can be modified with a retrofit to make it operate at 65kW safely. 2. To start the GM, the temperature of the heating fluid entering into the GM cannot be too high. Otherwise, the screw expander will be over speed and the 28PDF Image | Optimizing Heat Recovery Systems for Power Generation in Rural AK
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