1/54 Circulation pump, safety valve, expansion vessel

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1 1/54 Circulation pump, safety valve, expansion vessel pressure loss efficiency of pump secured heat output safety valve sizing expansion vessel sizing

2 Circulation pump 2/54 similar principle as for heating system flowrate according to collector area (specific flowrate l/h.m 2 ) regime (high-flow, low-flow, according to collector producer) calculation of pressure loss of collector loop influence of heat transfer fluid properties (viscosity, density) low consumption of electricity for pump in operation working point in the area of high efficiency of pump circulators with permanent magnets

3 Pressure loss calculation 3/54 friction loss local loss (valves, fittings, etc.) loss of components (collector field, heat exchanger) determination of reference working point P flowrate of fluid (according to collector area) pressure loss for considered temperature (20 C, 80 C) selection of pump

4 Friction loss 4/54 p l l l d 2 w 2 friction coefficient l calculation, diagram laminar flow l = 64/Re turbulent flow for hydraulic smooth pipes (Blasius) l 0,316 4 Re

5 Friction loss 5/54

6 Viscosity of propylenglycol 6/54 [mm 2 /s] propylenglykol+voda voda t [ C]

7 Local loss 7/54 p l w 2 2 problematic determination of coefficient for local loss in laminar flow zone available only tables for developed turbulent flow simplified calculation 0.3 x friction loss

8 Pressure loss of solar collectors 8/ S p [Pa] M Z T V [l/h]

9 Working point 9/54 8 discharge pressure (total head] [m] field of maximum efficiency 6 20 C dispoziční tlak [m] C flowrate [m3/h] průtok [m 3 /h]

10 Efficiency of pump 10/54 consumption of electricity by solar system consumption of primary energy x savings of primary energy efficiency of electricity production 35 % effort to reduce electricity consumption efficiency of circulator (conversion of electricity to mechanical energy) P P č e Y V P e p V P e

11 Efficiency of pump 11/54 5 H [m] 4 efficiency účinnost 0,5 efficiency účinnost 0,4 3 0, water propylenglycol/water H - V V [m 3 /h] 0,2 0,1 0

12 Efficiency of pump 12/54 0,5 efficiency účinnost 0,4 0,5 efficiency účinnost 0,4 0,3 0,3 0,2 0,2 0,1 0,1 0,0 0,0 1,0 2,0 3,0 V [m 3 /h] 0, V [m 3 /h] in maximum efficiency point eta = 5 to 15 % real operation: < 5 % small systems: effectivity is low

13 Hydraulic stations 13/54 simplification of installation circulation pump valves check valve connection for expansion vessel safety valve themometers attention: circulation pump could be significantly oversized!

14 Hydraulic stations 14/54

15 Electricity consumption 15/54 annual electricity need volume flowrate pressure loss of collector loop hydraulic power efficiency of circulation pump power input of pump typical annual operation period 2000 h calculation for typical operation point t m = 40 C

16 Pressure loss calculation 16/54 low flow velocity w = 0.4 m/s Reynolds number Re = 3183 friction coefficient l = 0.02 (laminar flow) (turbulent) friction loss pl = Pa local loss pm = 0.3 * pl = Pa pressure loss of heat exchanger 3000 Pa (450 l/h) pressure loss of collectors 2000 Pa (balance valves) total: Pa

17 Pressure loss calculation 17/54 high flow velocity w = 0.6 m/s Reynolds number Re = 9593 friction coefficient l = (turbulent) friction loss pl = Pa local loss pm = 0.3 * pl = Pa pressure loss of heat exchanger 6000 Pa (2600 l/h) pressure loss of collectors 2000 Pa (balance valves) total: Pa

18 Power input of circulation pump 18/54 P e p V pressure loss [Pa] flowrate [m3/s] efficiency 15 % power input: 24 (LF) 140 W (HF) annual consumption: Pe * 2000 h 46 kwh 280 kwh

19 19/54 Safety and protection devices pressures in system safety valve expansion vessel

20 Safety and protection devices 20/54 safety valve protects the collector loop against non-permissible pressure expansion vessel allows changes of fluid volume (due to thermal expansion) without extreme increase of pressure above non-perimissible limit (safety valve will not react during standard operation)

21 Pressures in solar system 21/54 opening pressure of safety valve p SV maximum operation pressure p e p p e e p SV 0,9 p 20 kpa SV for for p p SV SV 300 kpa 300 kpa operation pressure range influences the sizing of expansion vessel p 0 h g s p d filling pressure p 0 hydrostatic pressure p h minimum operation pressure in highest point p d = 20 kpa to... kpa

22 Safety (relief) valve 22/54 relief pressure respects pressure endurance of system components influences size of expansion vessel cap spring ring membrane screw joint sealing

23 Safety (relief) valve 23/54

24 Boiling point 24/54 p 0 p e

25 Location of safety valve 25/54 between safety valve and collector must not be any valve pressure loss at vapour mass flowrate < 3 % of relief pressure m p Q r p p Q p [kw] 0.58 kwh/kg [kg/h] no closure free outflow has to be assured from relief regular checks provided

26 Location of safety valve 26/54

27 Safety line 27/54 internal diameter of safety line d s 15 1,4 Q S not less than 19 mm maximum heat output of collector field for G = 1000 W/m 2 Q S 0 A c G

28 Safety valve dimension 28/54 saddle cross section area S Q S o [kw, mm 2 ] for steam K W p s [kpa] K [kw.mm -2 ] 1,12 1,26 1,41 1,55 1,69 1,83 1,97 2,1 2,37 2,64 2,91 3,18 saddle cross section area So W 2 Q S p SV [kw, kpa, mm 2 ] for liquid

29 Safety valve dimension 29/54 DN S o w

30 Expansion vessel 30/54 closed solar systems pressure expansion vessel with a membrane

31 Size of expansion vessel 31/54 minimum volume of expansion vessel min. volume of fluid in EV in cold state V s 1 10 % collector loop volume, min. 2 liters change of fluid volume V in collector loop by thermal expansion b from t 0 = 10 C to t max = 130 C absorbing collector volume V c expelled at stagnation from collectors (possibly to include piping above lowest part of collector) V EV,min V V b s V c

32 Coefficient of thermal expansion 32/54 b v( t max v( t ) v( t 0 ) 0 ) ( t ( t 0 ) max ) 1

33 Size of expansion vessel 33/54 pressure factor (usability of EV volume) p p e e p p 0 b p e maximum pressure in solar system (relief pressure) p 0 minimum pressure in solar system (filling pressure) p b atmospheric pressure (100 kpa) V EV p 100 V V V e s b c (x 1.3) p p e 0

34 Expansion vessel 34/54 selection of expansion vessel from a manufacturer predefined sizes (closest higher volume)

35 Expansion vessel - location 35/54 right wrong presetting pressure in EV: p v = p 0 30 kpa

36 Expansion vessel sizing 36/54 collectors l/m x 100 m = total collector loop volume 30 l 31 l 61 l minimum volume in EV: b * V = 0.1 * 50 l = collector volume V EV,min = 6 l 6 l 30 l 42 l

37 Expansion vessel sizing 37/54 relief pressure of p SV 600 kpa max. pressure p e = 0.9 * 600 kpa = 540 kpa hydrostatic p h = 15 * 1000 *9.81 = 150 kpa minimum pressure p 0 = p h + 30 kpa = 180 kpa = ( )/640 = 0.56 V EN > 42 l * 1.3 / 0.56 = 98 l... (140 l)

38 38/54 Heat exchangers power temperature difference efficiency

39 Heat exchangers 39/54 heat power transfer from collector loop (collectors) to secondary loops (storage, load) liquid separation collector loop (glycol) secondary loop (heating water, hot water) internal HX inside stores (tube) external HX outside stores, separate (plate, tube)

40 Heat exchanger balance 40/54 solar collectors Q Q 1 2 U A t m / // M c t // Q M c t Q t1 / t2 heat exchanger heat storage

41 Transferred heat power 41/54 heat power transferred = collector field heat power Q k A k G a t t A a t t 0 1 m e k 2 m e 2 first select operation conditions, e.g.: G = 1000 W/m 2 t e = 20 C t m = C better several operation points flowrate, temperature very sensitive

42 Temperatures 42/54 counterflow Q U A t m t max t m t I ln t t I t II II thermal efficiency of HX Q Q max C C 1 min t t 1 max C C 2 min t t 2 max target > 75 %, t m < 8 K

43 Boundary conditions 43/54 defined operation point x dynamic behaviour in real operation flowrates M 1 a M 2 given by hydraulic and pumps sizing result of HX calculation (optimization) heat power given by solar collector field Q k temperatures at the input to HX are given by operation primary (collector) loop secondary loop / t C / t C HX sizing = sizing U.A [W/K] return calculation of temperature conditions for selected size of HX

44 Tube heat exchangers 44/54 tube HX inside storage tank U = 100 to 300 W/m 2 K A = 1 to 5 m 2 (laminar flow, free convection)

45 Shell and tube 45/54 swimming pool HX U = 500 to 1000 W/m 2 K A = 0.2 to... m 2 (laminar / turbulent flow) low pressure loss in pool circuit (large flowrates) resistant to pool water (chlorides) stainless steel resistant to salty water titan alloys

46 Plate heat exchangers 46/54 plate counterflow HX outside the tank U = 1000 to 3500 W/m 2 K A = 0.1 to 2 m 2 (developed turbulent flow on both sides) number and shape of plates defines the power output soldered screwed demountable (cleaning)

47 Sizing with nomograms 47/54 U A t m,1 0 t m,2

48 correction factor [%] correction factor [%] Sizing with nomograms 48/54 difference between input temperatures [K] percentage of nominal flowrate [%]

49 Plate heat exchangers - software 49/54

50 Plate heat exchangers - software 50/54

51 Change of heat power from nominal 51/54 low temperature difference from nominal 80/60 C lower flowrate, higher viscosity, laminar flowrate lower heat transfer coefficient change of HX power Q U A nominal power (80/60 C 20 C, 1,5 m 3 /h) = 150 kw real power in solar system (55/45 C 20 C, 0,4 m 3 /h) = t m 5 kw use of large HXs with higher area lower output temperature to collectors higher system efficiency

52 Change of operation conditions 52/54 Q = 20 kw t m = 3.3 K Q = 13.7 kw t m = 12 K 50 C 47 C 50 C 39 C 780 l/h 93 % 640 l/h 780 l/h 63 % 640 l/h 25 C 20 C 33 C 20 C U = 1500 W/m 2 K U = 1900 W/m 2 K A = 4 m 2 A = 0.6 m 2

53 Optimization 53/54 optimum temperature difference at HX with solar system with heat power 240 kw (collector area 400 m 2 ) Temperature difference [K] Area [m 2 ] 8,9 11,1 14,8 22,2 Increase of area [%] System efficiency [%] 40,0 41,5 43,0 44,5 Paybakc time [years] 1,2 1,6 2,4

54 Operation 54/54 HX fouling change of pressure loss reduction of heat transfer, decrease of power heat insulation temperature sensors at outputs (function indication)

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