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Table 5 - Plate heat exchanger specifications of cavitation but compromise the system performance. The pump in the ORC-B has been placed 1.2 m below the condenser to increase the static head at the inlet of the pump and reduce the likelihood of cavitation. 4.4 Buffer Tank A custom manufactured 1.8 L buffer tank is located before the pump to allow the system to behave dynamically during startup and while testing different operating conditions. The tank also ensures that there is always liquid being provided to the pump as vapour can damage the seals in the pump. A level switch deactivates the pump if vapour is detected within the tank. Figure 12 - Buffer tank 4.5 Piping and Instrumentation Once all the components have been selected the piping and instrumentation diagram in Figure 13 was designed to allow instrumentation and control components to be selected. Number of Plates Heat Transfer Operating Pressure Channel 1 Channel 2 Evaporator K205-60 60 20.0 kW 7.0 bar Evaporating R245fa Inlet 30°C, Outlet 80°C Purity FG Oil Inlet 110°C, Outlet 90°C Condenser K095-40 40 19.1 kW 2.1 bar Condensing R245fa Inlet 30°C, Outlet 80°C Water Inlet 15°C, Outlet 22°C 4.3 Feed Pump The ORC feed pump is used to provide the evaporator with a constant supply of liquid. Pump selection charts were used to determine the type of pump required. Typically a centrifugal pump would be used in a large scale ORC as the flow and pressure requirements could easily be matched. A small scale ORC requires a much lower flow rate with the same pressure. 4.3.1 Plunger Pump A reciprocating positive displacement plunger pump was selected to meet the pressure and flow requirements. A small reciprocating pump can meet the pressure requirements of an ORC system while maintaining low flow rates Table 6 - Feedpump specifications Parameter Pump Model Displacement Duty Flow Rate Max Flow Duty Pressure Max Pressure Specification Cat 2SF22ELS 4.8 cc/rev 5.1 LPM 8 LPM 480 kPa 20.0 MPa As this is a positive displacement machine the pump will meet the systems pressure requirements at the selected flow rate. The flow rate can also be calculated as a function of the motor RPM. Coupling the pump to a Variable Speed Drive (VSD) allows the pump flow rate to be set via PID control. Figure 11 - Cat plunger pump coupled to VSD 4.3.2 Cavitation Cavitation is a large issue for pumps in ORC systems, as the working fluid leaving the condenser is only slightly sub- cooled and evaporates if the pump suction is too high. Auxiliary sub-coolers can be used to reduce the occurrence Figure 13 - ORC-B piping and instrumentation diagram 4.5.1 Bypass Line A bypass line was installed around the expander. This will be used during startup as the installation of a needle valve allows a pressure differential to be reached before the expander is started. The bypass line is also used as a safety feature in case the expander jams or an emergency shutdown is required. 4.5.2 Piping Two types of piping are used within the system: stainless steel tube and PTFE flexible tube. The rigid stainless steel is used between the heat exchangers and expander, as these 35th New Zealand Geothermal Workshop: 2013 Proceedings 17 – 20 November 2013 Rotorua, New ZealandPDF Image | DESIGN AND BUILD OF A 1 KILOWATT ORGANIC RANKINE CYCLE POWER GENERATOR
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