# D5.4 Piping, Auxiliary Equipment and Cable Connections

Alain Ferriere

► To cite this version:

Alain Ferriere. D5.4 Piping, Auxiliary Equipment and Cable Connections. [Research Report] European Union. 2022. hal-04750962

HAL Id: hal-04750962

https://cnrs.hal.science/hal-04750962v1

Submitted on 28 Oct 2024

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POLYPHEM

THE FUTURE OF SMALL-SCALE CSP PLANTS

POLYPHEM

Small-Scale Solar Thermal Combined Cycle

# D5.4 Piping, Auxiliary Equipment and Cables Connections

Date of delivery 01/09/2022

Author(s) Alain Ferriere

Institution/Company CNRS

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 764048.
## Document tracks

<table><tr><td>Identification</td><td>POLYPHEM_D5.4_Piping Auxiliaries & Cables</td></tr><tr><td>TITLE OF DELIVERABLE</td><td>Piping, Auxiliary Equipment and Cables Connections</td></tr><tr><td>Author(s)</td><td>Alain Ferriere</td></tr><tr><td>Reviewers(s)</td><td>Lauriane Gonzalez</td></tr><tr><td>Related Work Package (s)</td><td>WP5: Manufacturing and installation of the prototype plant</td></tr><tr><td>Beneficiary responsible of delivery</td><td>CNRS</td></tr><tr><td>Due date of delivery</td><td>28/02/2022</td></tr><tr><td>Actual date of submission/revision</td><td>01/09/2022</td></tr><tr><td>Number of pages</td><td>16</td></tr><tr><td>SUMMARY</td><td>This document is the deliverable D5.4 of the project POLYPHEM. It is planned in the framework of the Work Package 5 (Manufacturing and installation of the prototype plant).<br/>The deliverable D5.4 is a demonstrator. It reports the installation of the piping for the circulation of air and of the heat transfer fluid from the heat source (burner) to the ORC and the thermal energy storage. CNRS was responsible for the design and the construction of the piping. The auxiliary equipment is composed of the electrical cabinets and the power supply of the actuators.</td></tr><tr><td>Dissemination level</td><td>PU</td></tr><tr><td>Repository</td><td>https://dms.polyphem-project.eu</td></tr></table>

## Document History and Validation

<table><thead><tr><td>Date</td><td>Name</td><td>Comments</td></tr></thead><tbody><tr><td>28/08/2022</td><td>Alain Ferriere</td><td>Creation</td></tr><tr><td>29/08/2022</td><td>Lauriane Gonzalez</td><td>Review 1</td></tr><tr><td>30/08/2022</td><td>Alain Ferriere</td><td>Final</td></tr></tbody></table>

All information in this document only reflects the author's view. The European Commission is not responsible for any use that may be made of the information it contains.
## Background: about the POLYPHEM project

<table><tr><td>FULL TITLE</td><td>SMALL-SCALE SOLAR THERMAL COMBINED-CYCLE</td></tr><tr><td>Acronym</td><td>POLYPHEM</td></tr><tr><td>Call identifier</td><td>H2020 LCE-07-2017-RES-RIA-TwoStage</td></tr><tr><td>Instrument</td><td>Research and Innovation Action (RIA)</td></tr><tr><td>Grant Agreement N°</td><td>764048</td></tr><tr><td>Starting Date</td><td>01/04/2018</td></tr><tr><td>Duration</td><td>48 months</td></tr><tr><td>Website</td><td>https://www.polyphem-project.eu</td></tr><tr><td>Keywords</td><td>Renewable electricity; Energy collection, conversion and storage; Renewable energy</td></tr><tr><td>Additional keywords</td><td>Concentrated solar power; Solar tower system; Combined cycle; Gas-turbine; Thermal energy storage; Organic Rankine cycle; Process control</td></tr><tr><td>Beneficiaries</td><td>CNRS, CEA, CIEMAT, Arraela S.L., Fraunhofer ISE, Kaefer Isoliertechnik, Orcan Energy, Euronovia, Aalborg CSP</td></tr></table>

The POLYPHEM project is a research and innovation action funded by the European Union's H2020 program. It is implemented by a European consortium of 4 research centres and 5 industrial partners. The aim is to increase the flexibility and improve the performance of small solar tower power plants. The concept of POLYPHEM consists in implementing a combined cycle formed by a solarized micro gas-turbine and a Rankine organic cycle machine, with an integrated thermal storage device between the two cycles. The need for cooling is minimal.

Developed from a patented technology by CNRS and CEA, the pressurized air solar receiver is integrated in the micro-turbine cycle. The thermal efficiency targeted for the receiver is 80% with a cost of 400 €/kW. The innovative thermal storage uses a thermal oil and a single thermocline tank with a technical concrete filler material.

The main expected impact of this project is to enhance the competitiveness of low-carbon energy production systems through the technology developed. The expected progress is a better fitting of electricity generation to variable local needs, an overall conversion efficiency of solar energy into electricity of 18% for an investment cost of less than 5 €/W and a low environmental impact. By 2030, the cost of electricity production targeted by the POLYPHEM technology is 165 €/MWh for an annual direct normal irradiation of 2600 kWh/m²/year (North Africa and Middle East) and 209 €/MWh under 2050 kWh/m²/year (Southern Europe). In addition to decentralized power generation, other applications are considered for the deployment of this technology used in poly-generation: industrial heat production, solar heating and cooling, desalination of seawater or brackish water.

A prototype plant of 60 kWel with a thermal storage of 1300 kWh is designed, built and installed on the site of the experimental solar tower of Themis in Targasonne (France). The objective of the project is to validate the technical choices under test conditions representative of actual operating conditions.

*This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 764048*
## Table of content

<table><tr><td>1. CONSTRUCTION OF PIPING AND AUXILIARY EQUIPMENT</td><td>6</td></tr><tr><td>1.1 Organization of the work</td><td>6</td></tr><tr><td>1.2 Hot air circuit</td><td>6</td></tr><tr><td>1.3 Plans of construction</td><td>6</td></tr><tr><td>1.4 Time-table of the construction</td><td>8</td></tr><tr><td>1.5 Pictures of the construction</td><td>9</td></tr><tr><td>2. SITUATION ON 31 AUGUST 2022</td><td>16</td></tr></table>

## List of Figures

<table><tr><td>Figure 1: Integration of the combustor in the air circuit</td><td>6</td></tr><tr><td>Figure 2: Plans of construction - views of components (top) and piping (bottom)</td><td>7</td></tr><tr><td>Figure 3: Beginning of the construction of piping [24-28 Jan 2022]</td><td>9</td></tr><tr><td>Figure 4: Implementation of pumps in the circuit [31 Jan - 04 Feb 2022]</td><td>10</td></tr><tr><td>Figure 5: Supporting structure at Themis site [31 Jan - 04 Feb 2022]</td><td>10</td></tr><tr><td>Figure 6: Combustor under construction, by Aalborg CSP [31 Jan - 04 Feb 2022]</td><td>10</td></tr><tr><td>Figure 7: Implementation of all piping in the container (left), and small expansion vessel on the roof of the container (right) [07-18 Feb 2022]</td><td>11</td></tr><tr><td>Figure 8: Integration of the burner in the combustor [07-18 Feb 2022]</td><td>11</td></tr><tr><td>Figure 9: The container with the piping [21 Feb-04 Mar 2022]</td><td>11</td></tr><tr><td>Figure 10: The combustor is manufactured [21 Feb - 04 Mar 2022]</td><td>12</td></tr><tr><td>Figure 11: Installation of the combustor on the roof of the container [07-11 Mar 2022]</td><td>12</td></tr><tr><td>Figure 12: Installation of the shelter [07-11 Mar 2022]</td><td>12</td></tr><tr><td>Figure 13: Delivery and installation of the components at Themis site [21 Mar 2022]</td><td>13</td></tr><tr><td>Figure 14: Components installed at Themis site - Views from S (top) and from N (bottom) [21 Mar 2022]</td><td>14</td></tr><tr><td>Figure 15: Construction of the outdoor piping and implementation of the auxiliary equipment</td><td>14</td></tr><tr><td>Figure 16: The control cabinet is installed in the container [22 Apr 2022]</td><td>15</td></tr><tr><td>Figure 17: Thermal insulation of the piping [18 Jul - 03 Aug 2022]</td><td>15</td></tr></table>

## List of Tables

<table><tr><td>Table 1: Main steps of the construction of the piping and auxiliary equipment</td><td>8</td></tr></table>
List of Acronyms and Abbreviations

<table><thead><tr><td>Acronym/abbreviation</td><td>Meaning/full text</td></tr></thead><tbody><tr><td>CNRS</td><td>Centre National de la Recherche Scientifique</td></tr><tr><td>HTF</td><td>Heat Transfer Fluid</td></tr><tr><td>ORC</td><td>'Orcan Energy AG' or 'Organic Rankine Cycle'</td></tr><tr><td>PU</td><td>Public</td></tr><tr><td>RHX</td><td>Recovery Heat Exchanger</td></tr><tr><td>TC</td><td>Thermocouple</td></tr><tr><td>TES</td><td>Thermal Energy Storage</td></tr></tbody></table>
# 1. CONSTRUCTION OF PIPING AND AUXILIARY EQUIPMENT

## 1.1 ORGANIZATION OF THE WORK

The engineering and construction of the piping was done by CNRS. An engineering company was subcontracted by CNRS to make the detailed design of the thermal process, and a company specialized in construction was subcontracted to supply the subcomponents and to construct the plant on site. A small expansion vessel (360 l) was supplied by ARRAELA S.A. This component is implemented in the prototype plant to allow for the commissioning of the circuits without the availability of the thermocline storage tank.

The electrical cabinets and the power supply of the actuators were implemented by CNRS. An engineering and construction company specialized in electrical devices and cabling was subcontracted by CNRS to realize the work.

The engineering is reported in the deliverable POLYPHEM D4.2 *Report on the general engineering*, dated on 08/07/2022.

## 1.2 HOT AIR CIRCUIT

The hot air circuit was redesigned by CNRS in October and November 2021, in order to adapt the process after the decision was taken by the consortium of the project to modify the initial plan and not install the solar receiver and the gas turbine. AALBORG CSP designed and supplied the combustor and a shelter, and CNRS integrated the combustor in the air circuit. The scheme of this integration is presented in Figure 1.

<figure><img src="image_7.png" /><figcaption>Figure 1: Integration of the combustor in the air circuit</figcaption></figure>

## 1.3 PLANS OF CONSTRUCTION

In January 2022, CNRS delivered the plans of construction. These plans integrate the components of the thermal process and the piping and auxiliary equipment. The plans are presented in 3D views in Figure 2.
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<figure><img src="image_9.png" /><figcaption>Figure 2: Plans of construction - views of components (top) and piping (bottom)</figcaption></figure>
## 1.4 TIME-TABLE OF THE CONSTRUCTION

The construction of the piping and auxiliary equipment was executed from January 2022 to August 2022. The main steps of the construction are summarized in Table 1.

<table><caption>Table 1: Main steps of the construction of the piping and auxiliary equipment</caption><thead><tr><td>Date</td><td>Action</td><td>Participants</td></tr></thead><tbody><tr><td>24-28/01/2022</td><td>Beginning of manufacturing of piping</td><td>CNRS</td></tr><tr><td>31/01-04/02/2022</td><td>-Implementation of pumps in the circuits.<br/>-Starting of construction of the combustor by AALBORG in Spain.</td><td>CNRS<br/>AALBORG</td></tr><tr><td>07-18/02/2022</td><td>-Implementation of all piping in the container, and small expansion vessel on the roof of the container.<br/>-Construction of the supporting structure for the container at Themis site<br/>-Integration of the burner in the combustor</td><td>CNRS<br/>AALBORG</td></tr><tr><td>21/02-04/03/2022</td><td>-The container with the piping is finished<br/>-The combustor is finished</td><td>CNRS<br/>AALBORG</td></tr><tr><td>07-11/03/2022</td><td>Installation of the combustor on the roof of the container.<br/>Installation of the shelter.</td><td>CNRS</td></tr><tr><td>21/03/2022</td><td>Delivery and installation of the components at Themis site</td><td>CNRS</td></tr><tr><td>22/03-01/04/2022</td><td>Construction of the outdoor piping<br/>Implementation of the auxiliary equipment</td><td>CNRS</td></tr><tr><td>11/04/2022</td><td>Delivery of thermal oil at Themis site</td><td>CNRS</td></tr><tr><td>22/04/2022</td><td>The control cabinet is installed in the container</td><td>CNRS</td></tr><tr><td>18/07-03/08/2022</td><td>Thermal insulation of the piping</td><td>CNRS</td></tr></tbody></table>
**1.5 PICTURES OF THE CONSTRUCTION**

<figure><img src="image_10.png" /><figcaption>Container – Oil circuits</figcaption></figure>

<figure><img src="image_11.png" /><figcaption>RHX in container</figcaption></figure>

<figure><img src="image_12.png" /><figcaption>Container - Air circuit</figcaption></figure>

<figure><img src="image_13.png" /><figcaption>Container – Top – supporting structure</figcaption></figure>

<figure><img src="image_14.png" /><figcaption>Oil tank</figcaption></figure>

<figure><img src="image_15.png" /><figcaption>Oil tank – Outer envelope</figcaption></figure>

<figure><img src="image_16.png" /><figcaption>Oil tank – top cover</figcaption></figure>

<figure><img src="image_17.png" /><figcaption>Instruments & parts</figcaption></figure>

**Figure 3: Beginning of the construction of piping [24-28 Jan 2022]**
<figure><img src="image_18.png" /><figcaption>Figure 4: Implementation of pumps in the circuit [31 Jan – 04 Feb 2022]</figcaption></figure>

<figure><img src="image_19.png" /><figcaption>Figure 5: Supporting structure at Themis site [31 Jan – 04 Feb 2022]</figcaption></figure>

<figure><img src="image_20.png" /><figcaption>Figure 6: Combustor under construction, by Aalborg CSP [31 Jan – 04 Feb 2022]</figcaption></figure>
<figure><img src="image_21.png" /><figcaption>Figure 7: Implementation of all piping in the container (left), and small expansion vessel on the roof of the container (right) [07-18 Feb 2022]</figcaption></figure>

<figure><img src="image_22.png" /><figcaption>Figure 8: Integration of the burner in the combustor [07-18 Feb 2022]</figcaption></figure>

<figure><img src="image_23.png" /><figcaption>Figure 9: The container with the piping [21 Feb-04 Mar 2022]</figcaption></figure>
<figure><img src="image_24.png" /><figcaption>Figure 10: The combustor is manufactured [21 Feb - 04 Mar 2022]</figcaption></figure>

<figure><img src="image_25.png" /><figcaption>Figure 11: Installation of the combustor on the roof of the container [07-11 Mar 2022]</figcaption></figure>

<figure><img src="image_26.png" /><figcaption>Figure 12: Installation of the shelter [07-11 Mar 2022]</figcaption></figure>
<figure><img src="image_27.png" /></figure>

<figure><img src="image_28.png" /></figure>

<figure><img src="image_29.png" /><figcaption>Installation of the container at Themis site</figcaption></figure>

<figure><img src="image_30.png" /></figure>

<figure><img src="image_31.png" /></figure>

<figure><img src="image_32.png" /><figcaption>Installation of the oil tank at Themis site</figcaption></figure>

<figure><img src="image_33.png" /></figure>

<figure><img src="image_34.png" /></figure>

<figure><img src="image_35.png" /><figcaption>Installation of the combustor and shelter at Themis site</figcaption></figure>

<figure><img src="image_36.png" /></figure>

<figure><img src="image_37.png" /><figcaption>Installation of the ORC group at Themis site</figcaption></figure>

Figure 13: Delivery and installation of the components at Themis site [21 Mar 2022]
<figure><img src="image_38.png" /><figcaption>Figure 14: Components installed at Themis site – Views from S (top) and from N (bottom)[21 Mar 2022]</figcaption></figure>

<figure><img src="image_39.png" /><figcaption>Figure 15: Construction of the outdoor piping and implementation of the auxiliary equipment
[22 Mar -01 Apr 2022]</figcaption></figure>
<figure><img src="image_40.png" /><figcaption>Figure 16: The control cabinet is installed in the container [22 Apr 2022]</figcaption></figure>

<figure><img src="image_41.png" /><figcaption>Figure 17: Thermal insulation of the piping [18 Jul – 03 Aug 2022]</figcaption></figure>
## 2. SITUATION ON 31 AUGUST 2022

The Grant Agreement of POLYPHEM ends on 31 August 2022. At this date, the piping and the auxiliary equipment are installed at Themis site. The cables are connected. The actuators are powered.