experience from the commissioning of andasol 3 - · pdf fileexperience from the commissioning...
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![Page 1: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/1.jpg)
Experience from the commissioning of Andasol 3
Dr. Rainer KistnerUTE Andasol 3 / Ferrostaal
E-Mail: [email protected]
![Page 2: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/2.jpg)
(1) Project Structure / Plant Overview
(2) Different Project Phases
(3) TOP
(4) Partial Commissioning
(5) Commissioning of SF
(6) Commissioning of TES
(7) Further Key Commissioning Milestones
Overview of Presentation
![Page 3: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/3.jpg)
September 2011 | 3Andasol III
Project Structure
Marquesado Solar
EPC-Contractor
Plant O&M
Royal Decree 661/2007:
48,9%
26%
Project Sponsor
Project Sponsors
Owner
Project Sponsors
25,1%
Investment of foreign strategic investors:
• 100% balance sheet financed by investors
• No bank financing
LSTK
UTE Andasol 3Legal Framework
Financing UTE OPEMASOL
AS3 KWBtlg. GmbH
O&M
![Page 4: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/4.jpg)
Solar Field Heat Storage Power BlockSteam
Heat Steam Power
Plant Overview
![Page 5: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/5.jpg)
Project Phases
Basic Engineering
Detailed Engineering
Procurement
Construction
Pre-Commissioning
Commissioning Start-Up
Overall MC/ RFC
RFSU PAC
MC: Mechanical Completion
RFC: Ready for Commissioning
PAC: Provisional Acceptance Certificate
![Page 6: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/6.jpg)
From Pre-Commissioning to Hot Commissioning
Pre-Commissioning
Walkdown
Preparation TOP
TOP Sign. Constr. Mang.
TOP Sign. Comm. Mang.
Cold Commissioning
TOP: Turn Over Package *
TOP Sign. Owner / Direct. Fac.
Notifying Body Certificate
Approval by Eng. Chamber
Approval Authority
Hot Commissioning
* Handover protocoll from construction to commissioning
![Page 7: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/7.jpg)
Turn Over Packages
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Example TOP Status Summary
![Page 9: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/9.jpg)
System Breakdown Structure for Solar Field Commissioning
Graph Courtesy of Flagsol GmbH
![Page 10: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/10.jpg)
Example: Hydro-testing of the 152 SF loops
![Page 11: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/11.jpg)
Overlap between Mechanical Completion and Commissioning
Graph Courtesy of Flagsol GmbH
![Page 12: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/12.jpg)
Example: Progress Curves
![Page 13: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/13.jpg)
TES Commissioning: Salt Melting Process
Salt Handling Station
Salt Melting in Furnace
Buffer Tank with Pump
Pumping toCold Tank
Cold Salt Tank
![Page 14: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/14.jpg)
TES Commissioning: Temporary Salt Storage Tanks
Buffer for 5.000t Salt BigBags1 tent 30m x 60m1 tent 30m x 70m
Tent for Salt Handling Equipment1 tent 25m x 10m
During melting continuous salt supply.
![Page 15: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/15.jpg)
Temporary Salt Storage Tents
![Page 16: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/16.jpg)
TES Commissioning: Unloading of salt bags
![Page 17: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/17.jpg)
Salt Handling Equipment
Two parallel lines with working stations for:• Big Bag Transportation• Big Bag Crushing and Opening• Salt Transportation on Conveyor Belts• Salt Milling to desired grain size• Dosing Station to Salt Furnace• Air Filter on working stations
![Page 18: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/18.jpg)
Salt Handling Equipment
![Page 19: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/19.jpg)
Salt Handling Equipment
![Page 20: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/20.jpg)
Crushing of Salt
![Page 21: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/21.jpg)
Salt of the crushing process
![Page 22: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/22.jpg)
Gas fired Furnace with Stack• 20t/h Melting capacity• 5,4MW thermal capacity• 12 Burners• Ca. 570 Nm³/h Gas Consumption• Ca. 28t weight ; 70 t weight filled with salt
TES Commissioning: Melting Furnace
![Page 23: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/23.jpg)
TES Commissioning: Melting Furnace
![Page 24: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/24.jpg)
Buffer Tank• 8,8m³• Internals for Salt impurity separation• Carbon Steel• Heat traced• Trays for drainage of tank and furnace
SM Pump• 14,3 m³/h; 7,5kW• Vertical suspended Pump to transmit salt to Cold Salt Tank
I&C for control of process (L, P, T) located on Buffer Tank
TES Commissioning: Buffer Tank
![Page 25: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/25.jpg)
Pipeline• Carbon Steel• 8“ Line • Fully heat traced• Inlet to Salt Tank with Vent Hole
TES Commissioning: Connection Line to Cold Salt Tank
![Page 26: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/26.jpg)
• 1 Operation Manager available 24hours
• 3 Operation Teams working in 12h shifts– 2 Operators
– 1 Shift Responsable.
– 2 Drivers for Forklift
– 4 Workers
• 1 Shift for Salt Unloading 8.00h – 20.00h– 3 Driver
– 1 Worker
• UTE Commissionning Personnel
TES Commissioning: Personal for Salt Melting
![Page 27: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/27.jpg)
Commissioning Milestone: Steamblow
![Page 28: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/28.jpg)
Video2013 06 12 SonnenkolloquiumK öln Vers 2 .3GP
Commissioning Milestone: Steamblow
![Page 29: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/29.jpg)
Commissioning Milestone: 1st synchronization
![Page 30: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/30.jpg)
Further milestones
• 10 day “Dispatchability Test”
• PAC Performance Test
• Commercial Operation– Interim Performance Test
– Final Performance Test
![Page 31: Experience from the commissioning of Andasol 3 - · PDF fileExperience from the commissioning of Andasol 3 Dr. Rainer Kistner UTE Andasol 3 / Ferrostaal E-Mail: rainer.kistner@ferrostaal.com](https://reader034.vdocuments.us/reader034/viewer/2022051202/5a7970397f8b9a770a8bd054/html5/thumbnails/31.jpg)
September 2011 | 31Andasol III
Thanks for your attention