Thermal solar energy Pressure Temperature Level Calibration
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Pressure
Temperature
Level
Calibration
Thermal solar energy
Alexander Wiegand
Chairman and CEO WIKA
Over the past 60 years WIKA Alexander Wiegand SE & Within the WIKA Group 7.300 employees are dedicated
Co. KG has built a reputation as a renowned partner and to maintaining and improving technology in pressure
competent specialist for any task in the field of pressure and temperature measurement. Over 500 experienced
and temperature measurement. On the basis of steadily employees of the sales department consult the
growing efficiency, innovative technologies are applied customers and users competently on a partnership
when developing new products and system solutions. basis.
The reliability of the products and the readiness to face More than 300 engineers and technicians are searching
all challenges of the market have been the key factors for continually on behalf of WIKA to provide solutions for
WIKA to achieve a leading position in the global market. innovative products, improved materials and more
economical production methods. In close co-operation
with renowned universities, institutes and industrial
companies, solutions for specific applications are
developed and designed.
Contents
Unlimited opportunities 4
Collector field 8
Power block 12
Thermal storage 14
Water treatment 16
Service 18
References 19
Pictures:
Page 6: Solar Millennium AG
Page 8: Solar Millennium AG, Paul Langrock
Page 9: Abengoa
Page 11: ©2009 NOVATEC BIOSOL AG
Page 14: Solar Millennium, AG
Page 19: Solar Millennium, AG, fotosearch.de, Abengoa
3
Unlimited opportunities
The sun generates 400,000,000,000,000,000,000,000,000 The advantages of solar energy are impressive:
Watts and will continue to do so for the next 5 billion
years. More energy reaches the earth in 30 minutes n Unlimited availability
than mankind can use in an entire year. The sun is n No pollutant emissions
the source of life; without it our ecological system n No climate damage due to greenhouse effects
could not exist.
The reduction in CO2 emissions is the main benefit of
Our energy consumption has nearly tripled over the last this technology. Over the past 50 years, CO2 content
30 years and approximately 80 % of this energy is gained in the atmosphere has increased by roughly 20 % and
from fossil fuels - largely oil. intensified the negative effects of greenhouse gases on
The debate on energy focuses mainly on three essential our climate and the planet's ecological system.
criteria: The safety factor, CO2 emissions and production
costs.
4
Unlimited opportunities
Security against uncontrollable failures is as good or These technologies store energy during sunny periods
even better than for other technologies. However, the and pass it into the mains network when there is no
disadvantages of this alternative soon become clear sunshine.
when we look at reliable and continuous supply, as this
is only guaranteed so long as the sun shines, and is At present the costs for gaining energy from solar sources
interrupted at night or on cloudy days with little sunshine. are still higher than for conventional power generation;
nonetheless, we are looking at a technology with tremen-
In order to ensure uninterrupted supply, we need modern dous potential. It should also be noted that a direct cost
technologies for thermal storage. comparison with conventional energy does not take into
account the environmental damage the latter creates.
5
Suitability of locations for solar thermal power plants
very good
good
suitable
unsuitable
Solar energy is best exploited in the “sunbelt”. At present there are two technologies for generating
This zone has up to 2,600 kWh/m2/year available, solar energy: Photovoltaic and solar thermal systems.
compared to approx. 1,000 kWh/m2/year in Central
Europe. In photovoltaic energy generation, a solar module
consisting of a group of semiconductor layers releases
This sunbelt is located in the regions between latitude electrons. These solar modules are generally employed
40 degrees north and latitude 40 degrees south, in (semi) independent units, such as pocket calculators,
e.g. between southern Spain and South Africa. One sensors, transmitters, satellites, batteries, as well as on
thousandth of the desert area would itself be sufficient to roofs or in the modules installed in solar complexes.
cover energy requirements with solar plants alone.
6
Unlimited opportunities
Solar modules convert sunlight directly into electricity,
whereas solar thermal systems concentrate sunlight to
heat thermal carriers up to 400 to 800 °C. At the moment,
solar thermal systems are the only solar energy form that
can compete with nuclear power plants or fossil fuels.
The experiences gained with plants in Spain and the
USA are future-oriented. According to a study by Green-
peace and the European Solar Thermal Industry Asso-
ciation (ESTIA)*, by 2040 these plants will be supplying
more energy than nuclear and hydro power plants put
together.
*Concentrated Solar Thermal Power - Now, Greenpeace, ESTIA, Solarpaces; Brussels, September 2005
7
Collector field
Parabolic trough power plant
Solar thermal energy is based on the principle of Parabolic trough power plant
radiation concentration to heat a thermal carrier
fluid, which is then used to generate steam. This This technology employs curved mirrors which are set,
steam is then used to generate electrical energy. using hydraulic devices, at ideal angles to the sun. In
the focal line of these mirrors are located high-efficiency
Using special mirrors, the collector fields capture sunlight tubes, in which the thermal carrier fluid (synthetic oil) is
and reflect it onto fluid-filled tubes (parabolic trough heated to temperatures of approx. 400 °C.
power plant, Fresnel reflectors), a tower (solar tower
power plant) or a motor (Stirling Dish plant). This oil is pumped into a series of heat exchangers to
generate steam. The steam drives a turbine which in turn
generates electrical energy.
8
Collector field
Solar tower power plant
Solar tower power plant
A solar tower power plant consists of a heliostat field,
which is computer-controlled to face the sun in order to Temperature measurement of the HTF
capture maximum solar radiation. The mirrors reflect the
radiation and guide the rays to a receiver at the top of the The state-of-the-art HTF oils (heat transfer fluid) are
tower. thermal oils which can be heated up to 400 °C. If this
temperature is exceeded, the oil is split into carbons
The thermal carriers are air, steam, oil, liquid sodium and hydrocarbons by cracking. These products reduce
or liquid salt. As with conventional plants, the heat the thermal carrier capacity.
dissipated by these media is used to generate electrical
energy via steam turbines. WIKA sensors, temperature transmitters and
thermowells are specifically designed to ensure
accurate, quick and reliable temperature
measurement for the HTF. This increases the
efficiency and safety of the system.
9
Stirling Dish plant Fresnel reflectors
Stirling Dish plant Fresnel reflectors
Stirling Dish plants are particularly suited to decentral- Fresnel reflectors guide sunlight to a permanently
ised energy generation. This plant uses mirrors with a installed receiver. These flat reflectors allow for wide
diameter of 3 to 25 m and produces outputs up to 50 kW.
opening angles and short focal points at far lower weight
The parabolic mirror tracks the position of the sun and and volume compared to the parabolic versions.
focuses the radiation onto a receiver in the focal point of
the dish. A thermal carrier, usually helium or hydrogen, is The design of this system is simpler and less expensive
heated at this point. than any other system as the receiver is not mounted
on the mirror and does not require a hydraulic system to
A Stirling motor converts the heat into mechanical
track the sun. To improve efficiency several receivers can
energy and then, employing a generator, into electrical
energy. be installed which bundle the radiation at preset intervals.
10Collector field
Solar thermal power plant with Fresnel technology in Puerto Errado (direct steam generation)
Pressure measurement of the HTF
To avoid the oil solidifying, which would lead to a block-
age in the HTF system, the oil must be kept permanently
in circulation.
WIKA diaphragm seal assemblies (with process trans-
mitter in picture) ensure the precise measurement of
pump pressures at process temperatures up to 400 °C.
11Power block
Turbine
Steam
Generator
Heat exchanger
Water-steam circuit Steam turbine
The water-steam circuit transports steam from the point Over 70 % of electrical energy generated worldwide is
of generation (heat exchanger unit) to the steam turbine produced with steam turbines. In these, the water-steam
and returns the condensate to the boiler. circuit and the auxiliary turbine systems need to be
monitored and controlled precisely.
Steam is used as thermal carrier for the following
reasons: It is an inexpensive medium and available Pressure, temperature and level measurement
virtually everywhere. Due to the relationship between its technology is employed in the steam and condensate
pressure and temperature, the temperature can be set circuits for lubrication of the turbine, speed control, and
with high precision and modulated via control valves. the systems for steam extraction.
Furthermore, it enables the transport of large amounts of
energy from the point of generation over great distances
to the point of use.
12Power block
Level measurement
For safety reasons, the tanks of the steam and conden-
sate circuits require robust, reliable level control, in many
cases supplemented by redundant systems.
Bypass systems provide local displays with analogue
output signals and/or alarm contacts. These are low-
maintenance mechanical systems which can withstand
process temperatures up to 400 °C.
Temperature measurement
The monitoring of temperature in the power
block is essential for constant energy generation
at maximum output.
Temperature sensors with local displays
and HART® protocol are integrated into the
monitoring system of the plant.
The thermowells for the
temperature sensors are
designed in accordance with the
ASME 'Performance Test Codes
19.3. Rev. 2010' standard.
13Thermal storage
During the daytime the collector field provides sufficient energy During nighttime the hot salt is pumped into the tank contain-
to cover the daily requirements and for storage in salt tanks. ing cold salt via a heat exchanger and transfers heat to the
medium. This medium generates steam which is converted into
electrical energy using a turbine.
Liquid salts for thermal storage
The most modern method for thermal storage is based In this type of plant design, the liquid salts are stored in
on the use of liquid salts as a storage medium in special two tanks: a hot and a cold tank. A heat exchanger heats
tank vessels. the salts during daytime on their transfer to the hot stor-
age tank.
A solar power plant with thermal storage has the ad-
vantage of also being able to generate electricity using When thermal energy is required, the salts are again
the heat stored during daytime in those parts of the day passed through the heat exchanger to heat a thermal
without sunshine (up to 8 hours). carrier oil up to 400 °C.
14Thermal storage
Surface measurement Multi-point measurement
The liquid salt tanks are made In order to measure the temperature in the cold and hot
of temperature-resistant carbon salt tanks at various points, “multi-point” thermocouples
steel or stainless steel. are used.
“Skin-point” temperature sen- These are employed to measure temperatures at various
sors are suitable for monitoring points of the cold and hot salt tanks. These measure-
the temperatures at the tank walls by measuring at differ- ments, together with heating resistors connected via a
ent points. This enables recording the mechanical stress control circuit, prevent a drop in the temperature of the
of the tank walls which is induced by thermal expansion. salt to the solidification point of approx. 250 °C.
15Water treatment
Geographical areas offering the most sunshine are Power plants require filtered water, osmosis water, and
also those suffering from the largest shortages of demineralised water for operation.
water. A thermal solar plant with parabolic troughs
requires approx. 3,000 litres of water per generated The filtered water is used as industrial water for the
MWh, and a solar tower plant requires approx. 1,900 cooling tower and for the fire-extinguishing systems. The
litres. osmosis water is used for cleaning the mirrors of the
parabolic troughs or heliostats. The demineralised water
The largest part of the water is consumed by the wet is employed to operate the circuit and the closed cooling
cooling system of the power block. In comparison, water system.
thermal solar power plants based on Stirling Dish
technology are the most economical, requiring only
80 litres per MWh.
16Water treatment
Pressure transmitters
WIKA pressure transmitters are used in various process
stages of the water treatment plant. The untreated water
contains numerous solids and sludge, which might block
the pressure-channel holes in the instrument. For this
reason, process connections with flush diaphragms or
diaphragm seals are used.
17Service
Consulting and training
We not only manufacture instruments, but also offer
training, locally or in our facilities, based on the extensive
knowledge and experience of our team.
In our training we confer our know-how to the operating
personnel and explain the correct handling of pressure,
Calibration temperature and level measuring instruments.
The reliability and reproducibility of the instruments is
essential for the correct and efficient operation of solar
thermal power plants. Regular calibration of the instru-
ments is needed to ensure correct operation of the plant.
WIKA has calibration laboratories for pressure and
temperature, as well as offering an on-site calibration
service. Furthermore, we supply a comprehensive range
of portable and stationary calibration instruments for use
in laboratories.
Commissioning
Correct installation and commissioning of the instruments
are essential for their reliable operation. We offer quali-
fied and experienced personnel who would be pleased
to support you with the start-up in your plant.
18References
Realised projects
Spain:
ANDASOL I, Guadix PUENTE ERRADO II, Calasparra
ANDASOL II, Guadix SAMCASOL I, La Dehesa
ANDASOL III, Aldeire SAMCASOL II, La Dehesa
ASTEXOL II, Badajoz SOLABEN III, Logrosán
EXTRESOL I, Torres St. Miguel SOLACOR I, Córdoba
EXTRESOL II, Torres St. Miguel SOLACOR II, Córdoba
GEMASOLAR, Fuentes SOLNOVA I, Sanlúcar
HELIOENERGY I, Écija SOLNOVA III, Sanlúcar
HELIOENERGY II, Écija SOLNOVA IV, Sanlúcar
IBERSOL, Puertollano VALLE I, San José, Cádiz
LEBRIJA, Sevilla VALLE II, San José, Cádiz
MAJADAS, Majadas del Tietar
MANCHASOL I, Ciudad Real Other countries:
MANCHASOL II, Ciudad Real BENI MATHAR, Morocco
MORON, Sevilla COALINGA, USA
ORELLANA, Orellana la Vieja HASSI R‘MEL, Algeria
PALMA DEL RIO I, Córdoba KURAYMAT, Egypt
PALMA DEL RIO II, Córdoba SHAMS, VAE
PS 10, Sanlúcar la Mayor SOLANA, USA
PS 20, Sanlúcar la Mayor
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