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AQYLON ATM-1000H ORC Power Module – Technical Description
CONFIDENTIAL
Disclosures, distribution and copy of this document is not allowed without written permission of AQYLON.
1
AQYLON SAS au capital de 993,810€ Sales office : 46/48, rue René Clair, 75892 PARIS CEDEX 18 France Tel : +33 1 42 58 63 37 SIRET : 51182331200026 – CODE APE : 7112Z TVA CEE : FR09511823312 Registered office: 12, rue Saint Martin, 77890 GARENTREVILLE , France
AQYLON ATM-1000H ORC Power Module – Description
AQYLON ATM-1000H ORC Power Module – Technical Description
CONFIDENTIAL
Disclosures, distribution and copy of this document is not allowed without written permission of AQYLON.
2
Summary
1 Technical features .................................................................................................................................... 3
1.1 ORC block ............................................................................................................................3
1.2 System diagram ...................................................................................................................3
1.3 Performance ........................................................................................................................5
1.4 Working fluid .......................................................................................................................5
1.5 Typical operating conditions. ...............................................................................................5
1.6 Power output ......................................................................................................................6
1.7 Cooling system ....................................................................................................................6
2 Footprint & Arrangement ........................................................................................................................ 8
3 Safety & Norms ........................................................................................................................................ 9
4 Operation .............................................................................................................................................. 10
4.1 Installation ........................................................................................................................ 10
4.2 Power block operation....................................................................................................... 10
4.2.1 Startup....................................................................................................................... 10
4.2.2 Continuous Operation ................................................................................................ 10
4.2.3 Shutdown .................................................................................................................. 10
4.2.4 Data Acquisition ......................................................................................................... 11
4.2.5 Normal Operating Conditions ..................................................................................... 11
4.2.6 Emergency procedure ................................................................................................ 11
5 Scope of supply: Equipment & Services ................................................................................................. 12
5.1 Power Module Equipment Scope of Supply........................................................................ 12
5.2 ORC Power Module Installation Services Scope of Supply .................................................. 13
5.3 ORC Power Module Maintenance Services Scope of Supply ............................................... 13
5.4 Water Loop Cooling Source Equipment Scope of Supply .................................................... 15
5.5 Water Loop Cooling Source Installation Scope of Supply .................................................... 15
5.6 Water Loop Cooling Source Maintenance Scope of Supply ................................................. 16
AQYLON ATM-1000H ORC Power Module – Technical Description
CONFIDENTIAL
Disclosures, distribution and copy of this document is not allowed without written permission of AQYLON.
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1 TECHNICAL FEATURES
1.1 ORC block
The ORC power block proposed by AQYLON is designed to offer following features:
Rugged architecture: The entire plant and turbine in particular, are designed to be simple and
robust. Continuous lubrication and cooling for bearings to last at least a year without
intervention.
Ease of integration: The power unit is composed of different skids containing all components
of the ORC and auxiliaries, that makes it is easy to transport and easy to install.
Ease of use: The power unit is automated, with very low requirements in terms of maintenance
and startup.
Multi-stage radial turbine: simple yet highly efficient architecture to provide long lasting
performance.
1.2 System diagram
The following diagram is a general flowchart of Aqylon’s ORC power block.
AQYLON ATM-1000H ORC Power Module – Technical Description
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Figure 1. Thermodynamic flowchart
The power generation loop (in green) is the one that uses the working fluid. A water condenser is used
to cool and condense the working fluid.
The various features shown in figure 1 are:
Turbogenerator (turbine + generator): Acts as an expander for the superheated vapor of the
working fluid supplied by the vapor generator (Evaporator).
Regenerator/economizer: Recovers thermal energy from superheated low pressure fluid
exiting the turbine prior to condensation. This heat is used to preheat the liquid phase fluid
coming from the pump.
Pump: Compresses the working fluid in the liquid phase.
Condenser: Dissipates the heat energy discharged from the cycle to a water loop (and acts as
heat sink) in order to condense the fluid.
Evaporator: The heat exchanger transfers the heat from the heat transfer fluid to the working
fluid.
The excellent properties of the working fluid improve longevity of the turbine. In fact, during expansion
the fluid will naturally "dry" and any droplets that could be suspended within will disappear, so there
is virtually no wear of the blades.
Organic fluid pump
Turbine
Power generation loop
Thermal oil loop
Heating source
Pump 1
Cooling source
Evaporator
Regenerator
Condenser
Superheater
Electricity Generator
Fumes from furnace
Water pump
Cold source Dry coolers
ORC module
Hot source
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Also included but not shown in the diagram above:
An industrial PC connected to internet for monitoring and supervision of the power unit.
A display console for maintenance.
1.3 Performance
Efficiency is highly dependent on inlet and outlet temperatures. Performance is computed on a case
by case basis by finely tuning the power module parameters (evaporation temperature, condensing
temperature, etc.).
Net module power (and efficiency) takes into account:
Consumption by auxiliary components (such as pumps, lubrication system, power electronics,
sensors and control system)
Losses in electrical power conversion and transmission
Pressure drop in the heat exchangers
Friction losses in the bearings
1.4 Working fluid
The working fluid is a well-suited high temperature and high thermal stability ORC fluid:
Hexamethyldisiloxane. We have chosen this fluid mainly because of its excellent thermodynamic
properties:
Providing excellent conversion efficiency for heat introduced between 150 and 300 °C,
allowing efficient heat recovery
High regeneration
Very high thermal stability
Expansion without forming droplets, hence reduced maintenance
Low enthalpy drop in the turbine
Low flow velocity
A relatively small amount of ORC fluid will be stored on-site under low pressure conditions.
1.5 Typical operating conditions.
Operating conditions are the following:
Standard design evaporation temperature 245°C
Standard design condensation temperature 50°C
AQYLON ATM-1000H ORC Power Module – Technical Description
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Note that for a non-standard design, the number of stages of the turbine is adjusted to the new
expansion ratio.
1.6 Power output
Standard electrical power output from ORC Power block is at 400V. Other outputs can be supplied on
request.
The electrical generator is a standard 1500rpm(1600rpm for 60Hz grids) synchronous generator with
automated grid synchronization.
1.7 Cooling system
The cooling system is a water chilled closed loop using air chillers.
The features of the water loop are:
1. Water circulation pump
2. Dry coolers ventilating air through water pipes
3. High galvanized structure with ladders and footbridge
The hot water comes after condensing the working fluid to the air chillers where it exchanges its heat
with ventilated air. It is then pumped back through the circulation pump to the condenser.
1
2
3
Water
In
Out
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The dry coolers are 4 meters high. This size limits their footprint, facilitates maintenance and ensures
high efficiency at a low electricity consumption.
The number of dry coolers is calculated depending on the outside air temperature. Epoxy resin paint
can be added to protect the structure from rusting and improve its longevity.
Dry coolers are controlled through an electronically commutated motor with low slip and friction
losses and absence of electromagnetic noise. This results in higher efficiency at any rotational speed,
lower thermal generation, lower noise and absence of shielded cables.
Air chillers are designed to meet the needed power at 50% of the fan optimal load with an exterior
temperature 15°C below the water mean temperature.
AQYLON ATM-1000H ORC Power Module – Technical Description
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2 FOOTPRINT & ARRANGEMENT
The ATM-1000H ORC Power Module comes in two standard sized containers of 40 feet each that are
piled:
Upper container (“Skid A”) contains the following equipment:
Turbine
Gearbox
Electrical generator (synchronous, 1500 rpm)
Lubrication and cooling systems
Regenerator heat exchanger
Condenser
Bypass valves
Automation and probes
Lower container (“Skid B”) contains the following equipment:
Evaporator with thermal oil connection flanges
Water connection flanges for condenser
Working fluid pump
Note that skid B acts as a support structure for Skid A. Thus, the pump obtains proper NPSH without
additional structures.
AQYLON ATM-1000H ORC Power Module – Technical Description
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3 SAFETY & NORMS
We supply a 0 leakage sealed turbine, best suited to reduce the risk of explosion or fire. Different
norms for the turbine that will be applied by default are the following:
NORM DETAILS
ASME VIII div.1 Pressure vessels
AFNOR FD X 60-000 Corrective maintenance
ASME B16.5 Flanges and welding neck and joints
ASME B31.3 Industrial Piping
ASME IX Welding qualifications
CE - PED - 97/23/EC Manufacturing norm for pressure equipment
EN 62061 Functional safety of safety related electrical, electronic and PLC/ programmable electronics systems
EN 10204 Metallic products (including inspection)
EN 953 Safety of machinery for Guards of Fix and movable parts
EN 982 Safety of Machinery – Fluid and lubricants systems
IEC 61000-2.12 EMC / Electromagnetic Compatibility - Environment - Compatibility level for low frequency conducted disturbances and signaling in public low-voltage supply systems
ISO 10816 Vibration level monitoring, and other preventive maintenance via continuous monitoring of sensors
ISO 12100 Safety of Machinery -Concept and design principle
ISO 138491 Safety related control systems – Design & Validation
ISO 14121 Risk Assessments
ISO 4126 Safety devices for protection against excessive pressure
IP68 Turbo generator
IP45 or plus Electronic cabinet
If not mentioned, all equipment and instruments are provided according to CE standards.
Other norms & conditions can be followed upon client request.
AQYLON ATM-1000H ORC Power Module – Technical Description
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4 OPERATION
4.1 Installation
The power block is designed to minimize on-site operations and civil engineering works for the installation.
Civil engineering: installation of the studs/ concrete slab
Craning the four containers according to the preview
Connecting pipes to the thermal oil loop
Connecting pipes to the cooling water loop
Electrical connection of the alternator output
Electrical connection of the control cabinet of the ORC auxiliaries
Ethernet connection of the PLC (Modbus TCP/IP)
4.2 Power block operation
The power block is designed for unmanned operation with automatic start up and shutdown. In the
following section, we describe the main aspects of power block operation:
4.2.1 Startup
The power block unit starts automatically when the necessary conditions for its operation are met.
More specifically, it will automatically detect the available waste heat power at the various hot sources
by detecting:
flow rate of coolant,
the temperature profile according to the flow circuit of heat transfer from HTF (Heat Transfer
Fluid).
The controller then starts the procedure by starting the generator and the power electronics. The
pumps start working. In doing so, this drives the turbine to its rated speed and starts electricity
production.
4.2.2 Continuous Operation
The control server automatically adjusts the settings of the equipment (mainly the pump flow and fan
speed of the dry coolers).
It automatically detects power fluctuations and reacts accordingly. No action or human intervention is
required.
4.2.3 Shutdown
If the heat source decreases below the minimal load level, the control unit of the ORC power block will
trigger an automatic shutdown. If for some reason the client wants to cut off the ORC unit, the
emergency stop can be used to trigger the shutdown.
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4.2.4 Data Acquisition
The ORC Power block is fitted with an instrumentation system for adequate control and monitoring of
the unit.
The instrumentation, like the software for data acquisition, does not affect the control system. The
data acquisition system includes an industrial PC communicating via Modbus interface with different
sensors and PLCs of the ORC Power block.
The industrial PC is installed in a dedicated place within the power block box. Data is stored in a PC
hard drive and can be sent to AQYLON’s server located offsite via an Ethernet connection for remote
monitoring.
4.2.5 Normal Operating Conditions
If the evaporator pressure decreases due to a decrease of the incoming thermal power from waste
heat (i.e. fall in thermal oil flow rate or temperature), electricity production will decline accordingly.
Similarly, if the air flow within the air condenser changes (due to changes in ambient temperature
above or below nominal values); the power unit will generate more or less electricity.
The control system for the power block is via server (installed on an industrial PC in the system) that
can handle both analog and digital signals received by the control unit: in this context, the presence of
the operator is only required to start installation and periodically to check some gauges as required for
maintenance (see above).
4.2.6 Emergency procedure
Emergency procedures are automatically handled by the control system of the power unit, just like the
usual operating procedures, ensuring the safety of the site without the need for human intervention.
Since the ORC power block is highly robust and reliable because of its simplicity, a shutdown of the
unit due to internal problems is highly unlikely. However, there are periodic maintenance procedures
in place and they are to be followed.
This means stopping the unit can occur mainly due to external reasons such as a change in the incoming
waste heat that is beyond the limits required for proper use of the machine.
AQYLON ATM-1000H ORC Power Module – Technical Description
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5 SCOPE OF SUPPLY: EQUIPMENT & SERVICES
5.1 Power Module Equipment Scope of Supply
ORC Power Module includes all the equipment for the operation of the ORC cycle, as listed below:
Turbo-generator unit with lubrication system, gearbox, seal control and cooling, probes, lubrication barrier and filters
Working fluid pump with lubrication system, frequency driver, seal control and cooling
Power electronics for automated grid synchronization (Electrical output 50 Hz, 400 V 3PH+N, according to customer requirements)
Heat exchangers Evaporator, Regenerator and Condenser heat exchangers with appropriate insulated piping and control valves
Monitoring and control system with all accessories, including a server installed on an industrial computer connected to the Internet, deployed on-site for:
Data acquisition
Operating conditions recording
The PLC setting security installation
PLC takes over in case of failure of the server
Skids and casing The ORC skid and casing (Skid A, Skid B)
Working Fluid
Supplied in separate barrels
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5.2 ORC Power Module Installation Services Scope of Supply
Installation With 2 technicians (at least 1 English/French speaking).
10 working days on site;
1 trip to site and back;
On site costs.
Start up
With 2 technicians (at least 1 English/French speaking).
10 working days on site.
1 trip to site and back.
On site costs.
5.3 ORC Power Module Maintenance Services Scope of Supply
Preventive and corrective maintenance is done to reduce the probability of system failure and
degradation in power generation performance over time.
In the following, we present the listed maintenance tasks for the ORC unit:
Audit / planned maintenance/check
Frequency Nature of operations Duration
Structure Checks Annual Visual Inspection of support structure for exchangers (internal exchangers and air-cooled condensers)
2h
Control cabinet cooling exchangers checks
Annual Visual inspection of cooling exchangers 4h
Circulation pumps and fluids levels check
Annual Visual inspection of the circulation pumps and fluids levels (working fluid & thermal oil), as per OEM requirements.
5h
Control system checks Annual Reboot and control electronics 5h
Turbine system
checks
Annual
Visual inspection:
lubricating circuit, replacement of parts if necessary
Complete change of lubricant (automatic).
3 days
AQYLON ATM-1000H ORC Power Module – Technical Description
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Quality control of used lubricant (detection of abnormal degradation)
Bearings check, change if necessary
Vibration analysis of rotating parts
the general condition of the machine (chassis, electrical connection)
Power electronics checks
2 years Control key components of power electronics, done by the manufacturer.
2h
Dry coolers checks 2 years Check for fouling on the dry coolers and cleaning if required as per OEM instructions.
1h
Maintenance of controls for security
2 years Unit tests for PLC controls for emergency 6h
General maintenance of the cooling system
5 years Comprehensive examination of the cooling system 5 days
Software maintenance 5 years Replacement of industrial computer and PLCs.
System reconfiguration and updates.
3h
Turbine maintenance 5 years Complete disassembly of the turbogenerator unit for:
Change of the bearings (imperative)
surfaces checks and fouling if necessary scrub/treatment
balance control of the rotating parts and if necessary rebalancing
Check for damages
Change of seals
Sealing test parts containing the refrigerant and replacement if necessary
15 days
Maintenance of Plate Exchangers
5 years Inspection and test for leak tightness for plate exchangers and replacement if necessary, as per OEM instructions.
8 days
Maintenance of power electronics
10 years Replacement of key components of the power electronics, done by the manufacturer.
2 days
During ORC maintenance a check of flue ways, ventilators, filters and hydraulic equipment will be
scheduled.
Corrective maintenance:
The interventions for corrective maintenance are intended for the rehabilitation of the power unit as a result of the degradation of parts. This is done to avoid equipment breakdown. The goal is to perform periodic checks to put the system back to use as soon as possible.
Spare parts needed for the restoration of the facility are directly provided by AQYLON.
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5.4 Water Loop Cooling Source Equipment Scope of Supply
Water Loop Cooling Source includes all the equipment for the operation of water loop
Dry coolers
The number of dry coolers is based on local meteorological conditions and performance targets. Dry coolers use state of the art high efficiency electrical motors for reduced consumption of auxiliaries.
Circulation pump Standard offer includes 2 pumps, the second one acts as back-up pump, and automated wear balancing and failure detection is included.
Water loop piping Standard offer includes the piping for a distance of 10m between the ORC power modules installation location and the air chillers farm.
Support structures
Standard offer includes the support structure for 4 m high installation that reduces footprint and increases thermal power dissipated per unit of electricity consumed by the chillers fans.
Monitoring and control system with all accessories
Data acquisition Detection of systems operating conditions
5.5 Water Loop Cooling Source Installation Scope of Supply
Installation With 2 technicians (at least 1 English/French speaking).
10 working days on site;
1 trip to site and back;
On site costs.
Startup
With 2 technicians (at least 1 English/French speaking).
10 working days on site.
1 trip to site and back.
On site costs.
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5.6 Water Loop Cooling Source Maintenance Scope of Supply
Battery cleaning Standard offer includes Water jet cleaning of heat exchange batteries (once a year). Frequency of cleaning operations can be increased depending on local conditions.
Fans Change of damaged fan motors, test of control system
Early detection of failures Visual Inspection (annual) and test of valves and piping.
Corrective maintenance operations
Replacement of damaged equipment within the scope of supply
Recommended