ATM-1000h - Power Module - Documentation V1.7

AQYLON ATM-1000H ORC Power Module – Technical Description

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Disclosures, distribution and copy of this document is not allowed without written permission of AQYLON.

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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


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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


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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.


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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


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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.


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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.


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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.


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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.


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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


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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

Documents

ATM-1000h - Power Module - Documentation V1.7