Scheffler Dish
Scheffler Dish
Scheffler Dish
Prepared By:
lR;eso t;rs
MNRE
MSA RENEWTECH
F O U N D AT I O N
Contents
Acknowledgement 3
About This Manual
3.0 Specifications
3.1 Interpreting System Specifications
3.2 Interpreting Subsystem Specifications
3.3 Interpreting Component Specifications
3.4 P&I Diagram
8
8
8
10
14
16
19
20
20
21
21
22
22
23
23
24
24
25
25
25
26
8.0 Maintenance
8.1 Predictive and Preventive Maintenance
8.2 Consumable Replacement
8.3 Maintenance Dos and Donts
26
26
28
28
9.0 Troubleshooting
29
Acknowledgement
This document is the result of active mentorship, support and inputs from the following individuals:
Dr. S. K. Singh, MNRE
Dr. A. K. Singhal, MNRE-UNDP Project Management Unit
Dr. R. P. Goswami, MNRE
Shri Pankaj Kumar, MNRE-UNDP Project Management Unit
Dr. Kiran Deshpande, Innovation Head at Thermax Ltd.
Dr. Deepak Gadhia, Founder of Gadhia Solar Ltd. and Director of MSA Renew Tech Foundation
Shri Sandeep Mahore, Senior Project Executive at Thermax Ltd.
Shri Sunil Sangwan, Engineer at Thermax Ltd.
Shri Kaliash, Technician at Solar Energy Center, Gurgaon
The manual received significant input from Thermax Ltd. on a pro-bono basis.
3.0 Specifications
3.1
A system to generate heat from Scheffler dishes, consists of a number of sub-systems and components.
However, it is easy to see what the entire system does by specifying just a few basic parameters.
Table 1 below shows the specification of a particular Scheffler system as an example. Please note that
the format for technical specifications will vary by manufacturer.
Table 1. System Specification
Sr.
System
no
Description
1
Nominal Rating
(per dish)
2
Basic Module
Description
Example Values
Description
Working Fluid
System
150C-260C
Temperature Range
End use Application Industrial process steam used for
Cooking/laundry/vapor absorption
for cooling/ milk pasteurization
3.2
The receiving subsystem collects solar radiation in the solar field from parabola shaped reflecting
collectors and transfers it to working fluid such as water or oil.
The tracking subsystem acts as a support to the receiving subsystem. It maximizes the solar energy
captured by moving solar collectors towards the sun for complete day. Some tracking systems also
track the sun as it changes its position during the seasons.
The circulation subsystem carries fluid and transfers the heat received by it to the end use application.
Fluid has to circulate in the system at a certain rate to quickly and efficiently transfer the received
heat from solar field to end use application. Circulation subsystem has a number of components such
as pipes, pumps and valves to control fluid flow and temperature.
The thermal storage subsystem is a part of the circulation system. It extracts heat from the circulating
fluid when the temperature becomes too high. When the temperature is too low, it supplies stored
heat to the fluid.
Finally, the control mechanism is the brain behind tracking and circulation system. It sends signals to
these systems to control the tracking of the receiver and the pressure and flow rate of the circulating
fluid.
The table below shows a sample specification that describes each subsystem in more detail. The
values provided are examples only. Please note that the format for technical specifications will vary
by manufacturer.
Table 2. Subsystem Specification (Case Study of a Scheffler Steam Cooking System)
Sr.
Subsystem
no
Description
Collector System
1
1.1
1.2
Scheffler Dish
Reflecting Surface
Number of Dishes
Total collector area
System energy capacity
(8 hours)
Steam Generation
capacity
Mounting Location
Focus
Example Values
Receiving System
Description
Collects and reflects Suns heat at a
fixed focus point
73 Scheffler Dishes of 16 m2 each
concentrate suns rays on 73 receivers
(heat exchangers) placed in the focus of
each dish
Water from header pipe placed above
the receiver, which enters the receiver
and gets converted to steam due to high
temperature achieved due to high solar
concentration.The steam collected in the
header pipe is piped to the kitchen for
cooking
Collects the heat and converts
it to steam/hot oil
Sr.
Subsystem
no
Description
2
Tracking Mechanism
Mounting Structure
Tracking
Example Values
Drive mechanism
3.3
North-South (Seasonal)
Manual
DC wiper motor
Description
Elliptical Parabolic Dish mounted on a
stand rotating parallel to Earths Polar
Axis
The direction in which the solar
collectors move to track suns rays on
receiver
Circulation Subsystem
Fluid composition
RO/DM water converted to
steam
Operating pressure
Pressure Reducing Valve
reduces system pressure to
<1Kg/cm2 at cooking vessel
level
Operating
180C< 105 C
temperature
Pressure protection
Safety Relief Valve at Header Pipe and
Jacketed Cooking Vessel to vent excess
steam to ensure that the system pressure
doesnt go above system design pressure
10
Module Description
Surface Area of Collector
Aperture Area of Collector
Dimension & Shape
Reflectivity
Thermal output Capacity
Thermal Efficiency
Footprint Ground Area Required for
Single Dish Stand and Receiver
Rating
16 m2
11.65 m2(Average)
Parabolic
92 %
5.5 KW
42 % (approx.)
35 m2
11
Component
Tracking
System
Gearbox
&cycle
Wiper Motor
Control
System
Timer
Description
Specification and
Units
Gives torque to
Make:
move rotary support Gear Ratio:
with accurate
movement
Gives motion to
drive wiper motor
Make:
Model:
RPM:
Thermopile
Range: 0 to ___ W/ sq.
meter
Output: 0 to ___mV
Wind speed
sensor
To detect storms,
when the wind
velocity exceeds
a certain speed,
parabolic trough
should go to the
stowing position
(0 degree)
3 cup anemometer
Wind Range: 0 to ___
meters/sec
Hot water
circulating pump
Make:
Voltage: ___ Volts
Current: ___ Amps
Speed: ___ RPM
Head: _ bar
Capacity: ___ litres of
water per second
Max Water Temp:
___C
Circulation
System
Hot water
pump
12
Sr.
Component
Description
No.
7 Header Pipe
Store hot water and
maintain pressure in
circulation system
8 Pressure
Reduces pressure
Reducing Valve at the header pipe
(PRV)
outlet to a safe
limit. It protects the
application from
surge pressure
Specification and
Units
Max. Pressure: ___ Kg/
cm2
Volume: ___Ltr.
Valve pressure rating:
__ bar
Maximum temperature:
__ C
Material: CS or
Stainless steel
Manual or Automatic
(controlled by PLC)
End connection used:
Flange or thread end
Open bonnet (for
water and steam) or
closed bonnet (for
thermic oil)
Safety Relief
Valve
Releases pressure
to the atmosphere
when it crosses a
preset limit
10 Flow meter
Digital or Analog
Range: 0 to __m3/h
Inlet water
temperature range:
___C to ___C
Inlet pressure range:
__ bar to __ bar
Range: 0 to __ kg/cm2
13
Sr.
Component
Description
No.
12 Temperature Measurement of
gauge
temperature at a
point in the system
Specification and
Units
Range: 0 to ___C
Capacity in Litres
15 Steam Trap
--
To remove
condensate from
steam distribution
line, while trapping
the steam and not
letting it escape
In Scheffler steam cooking system, the water softener system softens fresh inlet
water by removing dissolved minerals such as calcium and magnesium to prevent
scaling. This soft water is then stored in the feed water tank, from where it is
pumped to the header pipe, whenever level in it goes below its minimum Water
Level (as specified by manufacturer). The Scheffler dish heats up the water to
form steam, which gets collected in its upper portion. This steam passes through
insulated steam line to process heat application, like for indoor cooking. Here we
have two types of vessels- direct cooking vessels and jacketed cooking vessels.
Steam Trap at the bottom of a jacketed cooking vessel collects condensed
steam (water) and moves it out of the vessels while trapping the steam inside
the vessel. Condensed Steam is collected in condensate recovery tank, from
where it is pumped back to header pipe. If at any stage steam pressure in vessel
exceeds its designed pressure due to some failure, or due to a hammering
effect, safety relief valves opens-up to protect vessels from excess pressure.
A P&I (Piping and Instrumentation) diagram shown below in Figure 5 is used by engineers to represent
a full system view of the components in a typical system and the flow of fluid through the system.
Interpretation of this diagram is useful to diagnose and rectify problems.
14
15
Figure 5: P&I Diagram of Scheffler Dish generating Steam for Cooking Purpose
16
17
Figure 9
18
Corrosion
Maintenance
Environmental
Safety
Steam Systems
Steam based systems are high
pressure fired systems, hence
require engineers supervision
19
6.1
Human Safety
Risks from High Temperature
The fluid is at a temperature above 110C, which is scalding temperature. So any
contact with fluid should be avoided
Pipes and other metal parts carrying fluid are at same temperature and are mostly
insulated. However, at any exposed area near insulated hose pipes, the temperature can be high enough to cause skin burns
The area between the reflector and receiver can be extremely hot
Risks from High Pressure
The system is pressurized, with fluid/steam at a pressure much higher than atmospheric pressure. Thus, on any opening/breakage/crack the fluid/steam can come out
as a jet and may come in contact with and injure the human body
Regularly monitor pressure at header pipe. It should be under safe operating limit
(Normal Limit: 10-11 Kg/cm2). If pressure in header pipe exceeds this limit call system maintenance
The pressure and safety relief valves should be set and tuned only by a trained person. Follow
STP 04 to adjust the safety relief valve
Risks from Concentrated Sunlight
Concentrated sunlight seen at the reflector or receiver can severely damage the
human eye
Make sure that focus cannot accidently fall on any ignitable material
Never move or stand between the dish and the receiver, and if at all you
are moving in this region keep closer to dish and away from receiver
Risks from Heights
Catwalk, railings, ladders provided should all be in place and inspected periodically
20
Equipment Safety
Risks to the equipment can occur from the following factors.
Use of excessive force while handling levers or tightening
Placement of sensitive equipment such as temperature and pressure gauges near sources of
heat. For example:
o Temperature and pressure gauges placed close to the receiver and not insulated
o PVC conduit piping or any other non-metallic equipment placed behind the receiver
Control panel, water pump motor, any other electrical equipment in the field should be properly grounded
For all rotating equipment, safety guard and protective mesh are to be installed and well maintained
Control panel is to be installed at a suitable place to prevent direct exposure from rain / dust /
sun light /heat
6.2
6.3
Note: Please refer to the manufacturers manual for the specific make and grade of each piece of equipment
to be used
Hand gloves of appropriate thickness and insulation to protect against hot surfaces
Industrial safety shoes while walking on site
Protective Sunglasses
Fire Extinguisher
While working on height / sloping roof, use
o Foot support (scaffolding / firm roof mounted platforms)
o Safety harness/ Hand-grip rope
General
Do not stand or walk between dish and receiver. If possible, the dishes should be completely
defocused before any maintenance task near receiver area
Wear heavy duty sun goggles always while in side the solar field. Avoid looking at receiver or
dish or focus with naked eyes.
Use always safety helmet while moving inside the installation area
Use hand gloves while handling the mirror
Only authorized persons should enter inside the solar field
Do not touch bare receiver surface. It is kept un-insulated to absorb solar
radiation
While setting focus never over force adjustment lever excessively
Header Pipe stores steam at high pressure, hence avoid going near that region
Keep distance from Safety Relief Valve when releasing Steam
21
Do not disturb tracking lever intentionally and once system is set do not disturb any settings at
tracking mechanism, seasonal adjustment, gearbox, etc.
While Handling Pipeline and Equipment
Flexible hose pipes are generally susceptible to leakages due to high pressure in the system,
hence maintain safe distance
Ensure isolating valves are closed to stop the flow of fluid before attending to a module or
component
Drain hot fluid first through vents before opening any equipment to avoid any chance of contact
Loosen screws and connections only when the system is not under pressure
Wear gloves while removing insulation to avoid skin contact with hot surfaces
If fluid is to be drained by opening the pipe flanges or coupling, ensure:
o Most of body part is above the pipeline
o Stand away from pipe-line while opening drainage valves to avoid fluid spill over the body
While Handling Receiver & Header Pipe
Release steam completely by pressing handle on safety relief valve before opening any equipment, to reduce pressure in Header Pipe to atmospheric pressure
While Working on the Scheffler Dish
When working on the dish at a height, ensure that grip for hands and support for feet is available
to avoid from falling
Dish is made up of glass and is not strong enough to support any load on its surface ensure
that other supports are available before undertaking any work with the dish
Close top/bottom needle valves of water level gauge before removing glass tube to clean it from
the inside
6.4
6.5
Steam Boilers exceeding 22.75 Liters capacity, Steam Pipelines where steam pressure exceeds 3.5 Kg/
cm2 come under the scanner of IBR regulations.
All valves & fittings should be as per IBR specifications with test certification for each valve. During
repair work technician should follow IBR Regulations & specifications for tasks such as procuring
material, welding & plumbing works near Steam Boilers & Steam Pipelines. Operator should refer to
manufacturers specifications for valve/fitting to be replaced.
22
Startup Sequence
Description
5.
23
7.2
Start-up Precautions
Planned routine maintenance should be done before starting up the system in morning as the
system is cooled down at this stage
Ensure that overload trip lamp is not glowing. If glowing, correct the fault
If thermic fluid is used in circulation system, it should be initially heated up by 20C per hour till
it reaches 100C, so that all moisture is removed from the thermic fluid
Never use hard water to fill the Header Pipe, as it can cause scaling in the system
Check that counter weights are properly hung through the pulley
Check for GI wire ropes, to make sure that they are free to move around pulleys
Electrical wires, rubber pipes should be either hidden, or kept at ground near dish, to protect
them from burning due to excessive heat
Ensure that valves on steam line are closed when not using steam
7.3 Operation
Setting of the focus correctly on the receiver may be required at any time during the operation. Refer
to STP 03 at the end of this document for more details. For a different version of the same procedure,
please also refer to Appendix 3.
Operation for PLC Based Control Panel
1. If by evening or earlier the dishes reach their extreme end, motors move dishes back to
homing position automatically by sensing reverse limit switch.
2. Once the dish reaches to home position, it touches to forward limit switch, which automatically stops the entire system
3. It is necessarily expected that positions of all dishes are properly and mechanically synchronized
Operation for Timer-Based Control Panel ( Non-PLC Based)
1. Operator has to adjust the position of dish so that sun focus is at the center. Forward and
reverse inching push buttons to be used to adjust the position as desired. Operator shall never
use inching buttons while auto mode is ON.
2. After adjustment of dish positions, again heating switch shall be put ON.
3. Now depending on the timer ON/OFF duration setting, the dish moves in forward direction
in steps. 01 sec ON and 18 sec OFF time is set. If required the setting can be changed on the
timer.
4. This tracking shall continue for the whole day automatically. (Battery power is used for this
purpose. Battery keeps on charging whole day if panel is provided)
5. At the end of the day when dish motor reaches and touches the full forward limit switch,
forward movement of the motor stops. Now the motor draws power from grid and starts
reversing automatically. At this moment the operator being evening time shall stop the heating by switching OFF the heating switch. The dishes shall reverse back to original position and
touch full reverse limit switch and stop.
6. Second day same operation shall be repeated by the operator.
7. It is necessarily expected that positions of all dishes are properly and mechanically synchronized.
24
In Manual Mode, the individual motors can be adjusted by using the Push Button on the Push Button
Station on the respective dish row
7.4
Value
10 Kg/cm2
Depends on application
75 % water level
5 Kg/hour
2 Kg/cm2
Monitor pressure at the point where steam is being utilized. It should be within safe limit of the
device which is utilizing that heat.Take readings of the operating parameters in a logbook. Some
examples of the logbooks that could be used are shown in Appendix 2
If dish is moving too fast or too slow and the focus is out of place, follow STP 3, to adjust the timer.
Monitor pressure in expansion tank. Safety relief valve should always go off to vent out excess
steam,
If the safety relief valve does not open after pressure crosses safe pressure limit shut down the
system and call maintenance.
7.5
Power Failure
Power backup is supplied along with system to run electronic timer during power cuts. In case
backup power is also not working, manually defocus dishes to sleep mode so as to protect
insulation near receiver from any damage due to concentrated heat.
Not Using System for Long Time/Rainy Season
o Turn the dish to morning or evening position facing downwards
o Give proper shading, cover items like Timer(daily Tracking Device)/PLC, wiper motor,Valves,
Gearbox, Safety Relief Valve, Pressure Reducing Valves, etc.
o Flush out water from the circulation system
o Turn off all MCBs in Solar Control Panel
7.6
Shutdown Sequence
There are different sets of action followed for different type of systems:
1) Electronic Timers
Go-to Timer and press shut down button. The dish starts turning in anti-clockwise direction.
When the dish reaches sleep position release shut down button.
25
Some timers have option to automatically bring dishes to morning position at a set time in the
afternoon.
2) Electronic Timers with automated Tracking/PLCs
Electronic timers with pre-set time after which it automatically brings back dish to morning
position
3) Manually
Dish can also be brought manually to sleep position by rotating Sprocket Handle.
7.7
Shutdown Precautions
8.0 Maintenance
An exhaustive list of maintenance items is provided below. A sample maintenance chart to be used on
site is provided in Appendix 4.
8.1
To isolate any module, close down respective gate valves for it before doing the maintenance.
Reflectors and Receivers
Clean reflector dishes or whenever the mirrors are dusty and reflectivity is reduced
Twice a year, check for broken mirrors
o Schedule to replace them soon if there are five or less broken mirrors in a dish
o Schedule immediate replacement (recommended) if there are five or more broken mirrors
in a row
Every five years or whenever necessary check for mirror degradation as shown in Figure 11
below. Check
o Reflectivity of the mirrors should be more than 90%
o Deterioration of mirrors affects the performance of the system
o Replace blind mirrors (with reflectivity less than 80%)
Figure 11: Mirror Condition
26
Good Mirror
with reflectivity
more than 90%
Annually, undertake structural painting and repair of the system to improve its life span
Twice a year, apply black coating on receiver with paint as per manufacturers specification to
improve systems performance
Circulation System
Annually, check for scaling at inner linings of Receiver
and Header Pipe as shown in Figure 12.
o Scaling & its effect on systems performance has to
be visually determined.
o This maintenance task is generally outsourced
because it is rarely performed and requires descaling
systems & industrial grade descaling chemicals
Weekly, check for leakages in the system. Due to
high pressure in the systems, system is susceptible to
leakages especially at points like the Rubber Washer in
Figure 12: Scaling of Inner Lining
the Water Level Indicator, flexible hose pipe. Perform
of Pipe
this operation when you spot leakages in circulation pipe
o Identify the point of leakage and remove insulation for that component
o Repair/Replace component with leakage
o Leave insulation material (mineral wool) open to dry off, and then put it back
On the onset of monsoon remove all the water from the header pipes. Open Blind Plugs connected at the bottom of steam pipelines. This will flush out rust & impurities from pipelines
along with water from header pipe
After the monsoon, add fresh RO/DM water in circulation system & then start the system
Annually, calibrate Temperature Transmitter, Pressure Transmitter, Flow meter and other gauges
Annually, replace soft water resin (if applicable)in RO water purifier
Quarterly, clean Screen in Y-Strainers with brush or by soaking it in a clean solution
Twice a year, clean RO system Cartridge Filler
Tracking System
Quarterly check that GI wire rope is tightly hung at end
points in the tracking system. GI rope can be tightened by
U-clamps
GI Wire should be able to move freely about cycle hubs
Quarterly check for the movement of cycle hubs
Replace hubs which are deformed due to excessive weight
Quarterly, grease & lubricate moving parts in the system
as shown in Figure 13. Lubrication should be done specially
after rainy season
o Lubricate brackets and screw of rotating pipe
o Screws & Levers in seasonal adjustment rods
o Cycle Chain on Gearbox
27
8.2
Consumable Replacement
8.3
Following are the consumable parts in Scheffler System, and hence need standby stock:
1. Coating for receiver as per manufacturers specifications
2. Resin for RO water purifier
3. Feed water if there is no water source near Scheffler Solar System
4. Oil & Grease
5. Mirrors (Though not consumable, but some spare mirrors (around 25 mirrors per dish) should
be stocked as replacement for broken mirrors)
Dos
Carry out maintenance as per the drawn maintenance schedule
Maintain the operation and maintenance log book every time as defined in the log format
For any maintenance work, ensure that power supply to control panel is switched off and dishes
are defocused from the receiver
Follow all the requirements about safety as specified in the Chapter on Safety
Ensure all the settings(temp and pressure) are as per the design criteria
Donts
Do not clean the mirrors with dry cloth or with paper
Do not clean mirror after 8.00 am & before 5.00 pm
Do not modify the system without written approval from the manufacturer
Do not touch the Receiver when focus is on the receiver
Do not walk in between receiver and dish during operation
Do not stop water circulation till temperature drops to 60C
Do not use hard water for mirror cleaning as it may form scaling on mirrors and thus reducing
performance
28
9.0 Troubleshooting
Courtesy: Thermax Ltd.
Symptom
Problem
reasons
(WHY-1)
1 System not 1.Control Panel
starting in the not switched on
morning
2.Problem in
incoming power
for control Panel
3.Main MCCB
not working in
Control Panel
2 Scattered
focus
1.Improperly fixed
mirrors
2.Mirrors not
cleaned
Problem reasons
(WHY-2)
Problem reasons
(WHY-3)
3.Low radiation
4.Fine tuning not Nut jam for fine
done
adjustment
5.Mirrors tainted Bad quality of
protective coating
Domestic mirrors used
Corrosive weather/
Coastal Area
3 Auto forward 1.Problem in the Carbon deposited on Loose contact
not happening contactor for
internal contacts
forward motion
2.Problem with
Program not
Improper earthing to
the PLC
functioning properly
PLC panels
3.Problem in one
the limit switches
4.Problem in gear
motor
5.Problem in gear
box
4 Water Pump 1.Problem in
not operating signals from
Mobrey
Winding burnt
Due to overload on
motor
No Lubricant for
Gear Box
2.Problem in
contactor for
water pump
3.Problem in
Internal contact burnt
rotary switch for Wiring not proper
water pump
4.Problem in V-belt V belt worn out
for pulleys
Slippage of V belt on
Pulley
Problem
reasons
(WHY-4)
Corrective action
Main switch to be switched ON and ensure
indicating lamps glows
Main distribution panel to be checked and
correct the fault
Check/correct incoming supply to control
panel and / or replace the cable if required
Check/correct/replace the main distribution
Check and replace MCCB
Check/correct the fault
Repair/replace the MCCB
Check and correct the fault
Check/adjusted alignment of mirrors.
Identify manpower from client end for dish
Follow process as per the O & M Manual
Mirror to be cleaned only with soft water
Hose pipe with nozzle, mopping brush and
wiper to be arranged for cleaning mirrors.
No option
Make the adjustment nut free and fine tune
the connection
Replace mirrors with Thermax supplied
solar grade mirrors
Check/clean/correct/replace contactor
with same specs and tighten the electrical
terminations
Check/correct in coordination with PLC
engineers and provide separate instrument
earthings for PLC panels
Check/replace/repair Limit switch
Check/replace/repair Gear motor
Check/repair Gear box
Repair/replace magnetic switch
Clear Float
Check and correct the electric connections
Loose contact
Loose contact
29
5 Focus not
exactly at
center of
receiver
Inclinometer not
available during
installation
Negligence during
installation
2. Dish movement Under sizing of hole at Back bearing nut
is jammed
channel
of rotating pipe is
overtight
Oversizing of bolt at
Top bearing part
rotating pipe
overtight and thus
restricting the dish
movement
Improper lubrication at
top part assembly
3.improper dish Balancing weight not
balancing
installed
4.Improper
Side rope not properly Approach ladder not
seasonal
tight
available
Locking of adjustment
adjustment
levers not tight
Fine adjustment not
Nut jam for fine
done
adjustment
30
for
for
for
for
6 Water
pump not
developing
pressure
Check/rectify/replace NRV
Softener not
available
No breaks
for regular
maintenance
Foreign particles inside Strainer not cleaned Maintenance
the valve seat assembly
not done
properly
4.Problem in gland Wear and tear of Gland Wear and tear of
washer
washer
pump shaft
Gland washer rubber High temperature of
hardened
inlet water
5.Faulty pressure
gauge
6.No Water in
feed water tank
7 Pressure not 1.Low radiation
developing in
stream drum 2.Focus not on
receiver center
3.No water steam
drum
4.Scatterd focus
5. Less focus
intensity
6.Faulty pressure
gauge
Strainer not
cleaned
overpressure
Negligence
31
8 Steam
1.Problem in safety Valve seat wear and
continuously valve
tear
Scale formation on
blowing from
valve seat
drum safety
valve
Spring tension lost
2. Restriction to
steam flow
9 Drum
pressure
rising
continuously
Softener not
functioning
properly
Negligence during
installation
Scale formed dust
inside the NRV casing
Softener not
functioning properly
due to operational
negligence
Improper
welding and poor
workmanship
32
Improper earthings
to PLC panel
Carbon deposited on
internal contacts
Loose contact
Winding burnt
Due to overload on
motor
No Lubricantion for
Gear Box
Sprocket wheel teeth
broken
Pressure at Pump
fluctuating
Due to
improper
alignment
Bearing Jam
Non
lubrication
,rusting
Gear box shaft bend Due to
overload
Probable Cause
Action
Pressure of suction
pump lower or equal to
saturation pressure of
water at that temperature
Y-strainer is choked
Refer to Annexure 3
Refer to Annexure 3
33
: 16 mtr2
: 2 mm thick mirror
: more than 90%
2) Steam Header.
Material used for steam header
Design pressure
Insulation material used
3) Receiver
Type
Material
Design pressure
Working pressure
Insulation material
4) System steam and feed water piping
Steam header pipe
Common header pipe
Steam out let line from header pipe
to common Steam collecting line
Common steam collecting line from
header pipe
Steam out let line from common
header to Kitchen header
Common feed water line
Insulation material
Feed water line from common line
to header pipe
34
35
Daily Observation Report on Steam Pressure (Kg/cm2) in different Header Pipes in Scheffler Solar
Cooking System:
Steam
Header
no.
1
2
3
4
8:00
AM
9:00
AM
10:00
AM
11:00
AM
12
noon
1:00
PM
2:00
PM
3:00
PM
4:00
PM
5:00
PM
Sr.
No.
Date
System
Starting
Time
Feed
Water
Meter
Reading
Steam
Meter
Reading
LPG
Cylinders
used
Climate
(Sunny/
Cloudy/
Rainy)
1
2
3
4
5
6
7
If System used for cooking Generated Steam (Steam Supply to kitchen)
Sr.
No.
Date
System
Stopping
Time
Feed
Water
Meter
Reading
Steam
Meter
Reading
1
2
3
4
5
6
7
36
Rice
(kg)
Dal
(kg)
Others
(Specify)
Supervisor
Remarks
Appendix 2 (Contd.)
Courtesy: Thermax Ltd.
Solar Steam Generation System-Log Sheet
Page 1 of 2
Client
Solar Steam Generation
Date
Site
Site Engineer
Project
Commissing engineer
Capacity
Solar fild:
Type of Mirrors
Location Data
Parameters
Time
Unit 8.00 8.30 9.00 10.00 10.30 11.00 11.30 12.00 12.30 1.00 1.30 2.00 2.30 3.00 3.30 4.00 4.30 5.00
Global Radiation Gb w/m2
Diffuse radiation Gd w/m3
Ambient
Ta C
temperature
Wind speed
W m/sec
Solar field
Temperature
Unit
Time
8.00 8.30 9.00 10.00 10.30 11.00 11.30 12.00 12.30 1.00 1.30 2.00 2.30 3.00 3.30 4.00 4.30 5.00
Steam Drum
Utility 1:
Utility 2:
Unit
P1 kg/cm2 g
P2 kg/cm2 g
P3 kg/cm2 g
Time
8.00 8.30 9.00 10.00 10.30 11.00 11.30 12.00 12.30 1.00 1.30 2.00 2.30 3.00 3.30 4.00 4.30 5.00
Unit
Gb w/hr
Page 2 of 2
Date
Time
8.00 8.30 9.00 10.00 10.30 11.00 11.30 12.00 12.30 1.00 1.30 2.00 2.30 3.00 3.30 4.00 4.30 5.00
Water Level
Time
37
For vertical movement of the focus:Use Seasonal adjustment setting by the lever provided and geared motor initially.
Refer fig no 2,3 and 4
Seasonal adjustment is essentially required when the focus is vertically up ward or down ward on
the respective receiver.
Circle 01 in Fig 1 Correct Focus (At the CENTRE of Receiver)
Circle 02 in Fig 1 Needs Seasonal Adjustment (Focus vertically UP of Receiver)
Circle 03 in Fig 1 Needs Seasonal Adjustment (Focus vertically DOWN of Receiver)
Frequency: - Once in two days and carry out the adjustment at 10.00 12.00 noon.
We need to adjust the Dish so that focus is always at the centre of respective receiver.
There are two levers with locking arrangements which are provided on the structure for seasonal
adjustment.
One lever is at the upper and another is at the lower end of dish. Refer Fig for Seasonal adjustment
lower side & Seasonal adjustment upper side.
38
respective
adjustment
39
40
41
Appendix 4: Maintenance
Courtesy:Thermax Ltd.
Maintenance activity
Daily
Weekly
Monthly
Quarterly
Half
yearly
Yearly
Calibrate temperature
indicators & controllers
42
Revision: 001
This Standard Task Procedures is used:
1. As a learning aid
2. To assess competence
Preparation
/
Material: Cloth, Bucket
Other prerequisites:
Safety Equipment:
Documentation to be
completed
a. Maintenance Log sheet
Submitted to
By when
Supervisor
On Task Completion
Pre-operational checks
Check state of system
Step
Criteria
2. Opening strainer
Loosen nuts and bolts from cover with a spanner of suitable size.
3. Collecting sludge in a
bucket
CAUTION!
Risk for hand! Wear hand gloves. Check that temperature of circulating liquid is safe to
handle before touching it.
43
Step
Criteria: Operating/Safety/Quality
Cleaning of Filter
When no more circulating fluid is
coming out, remove filter (Screen)
from inside the strainer.
Wear Gloves
44
Revision: 001
This Standard Task Procedures is used:
1. As a learning aid
2. To assess competence
Preparation
Material: Cloth
Other prerequisites:
Documentation to be
completed
a. Maintenance Log sheet
Pre-operational checks
Check state of system
Step
Submitted to
By when
Supervisor
On Task Completion
Criteria
Criteria: Operating/Safety/Quality
45
Step
2. Remove wire mesh and
insulating material
Criteria: Operating/Safety/Quality
Untie wire mesh to loosen glass wool from the pipe.
Use wire cutter to remove wire mesh if required.
3. Maintenance operation on
pipeline/equipment
After pipe has been satisfactorily repaired, fold wire mesh around
the pipe to be insulated, fill back insulation material in wire mesh
and twist metallic ends of wire mesh so as to hold insulation
material at its position.
If wire mesh is not in condition to be reused, get a new mesh.
Put back Aluminum/ SS sheets and tighten them with
screws.
CAUTION!
Risk for hand! Wear hand gloves.
46
Revision: 001
This Standard Task Procedures is used:
2. To assess competence
/
Material: Cloth, Bucket
Other prerequisites:
Pre-operational checks
Criteria
a. Check state of system
When focus is not at the center of receiver
Step
Criteria: Operating/Safety/Quality
Daily Adjustment
Tuning of PLC/electronic
timer for automatic daily
tracking of Scheffler Dish
47
/
/
48
49
Revision: 001
This Standard Task Procedures is used:
1. As a learning aid
2. To assess competence
Preparation
/
Material:
Other prerequisites:
Documentation to be
completed
a. Maintenance Log sheet
Pre-operational checks
a. Check state of system
Step
Submitted to
By when
Supervisor
On Task Completion
Criteria
/
/
Preparation for
Calibration
5. To increase outlet pressure, turn the screw nut clockwise and screw
in anti-clockwise direction while monitoring the outlet pressure,
till outlet pressure becomes equal to required set pressure.
6. To decrease outlet pressure, turn the screw nut anti-clockwise and
screw in clockwise direction while monitoring the outlet pressure,
till outlet pressure becomes equal to required set pressure.
7. Close back Top Cover on Adjusting Screw.
CAUTION!
High pressure in steam pipeline can harm application device, or the operator hence operate carefully
50
Revision: 001
This Standard Task Procedures is used:
1. As a learning aid
2. To assess competence
Preparation
Documentation to be
completed
a. Operations Log sheet
Pre-operational checks
Submitted to
By when
Supervisor
On Task Completion
Criteria
Preparation for
Calibration
Other prerequisites:
Safety Equipment:
Step
Criteria: Operating/Safety/Quality
1.
2.
3.
4.
Take a vessel.
Put oil, which can sustain temperature of about 300 C
Heat the oil using heater.
Use a calibrated thermometer to observe temperature of Silicon
oil bath (in range 200-230 C)
Calibrating Temperature
Transmitters
51
Step
Criteria: Operating/Safety/Quality
1. Continuously stir the oil bath.
2. Keep the temperature bath at steady state for 15 min by using
ON/OFF switch.
3. Note the readings of thermometer and TT simultaneously (adjust
your watch time with the data logging system time)
4. Adjust Shunt (pot) resistance/Amplifier of all thermocouples to
give temperature of oil bath on SCADA screen.
CAUTION!
Risk for hand! Wear hand gloves.
For thermocouples used at high temperatures, replacement rather than recalibration is recommended.
52
Revision: 001
This Standard Task Procedures is used:
1. As a learning aid
2. To assess competence
Preparation
Safety Equipment:
Documentation to be
completed
a. Operations Log sheet
Submitted to
By when
Supervisor
On Task Completion
Pre-operational checks
Criteria
Preparation
Step
Criteria: Operating/Safety/Quality
1. When several modules are to be descaled, the units are to be
disconnected and descaled individually
2. Close isolating gate valve to isolate system module to be descaled.
3. Get the following items:
Descaler Pump
Bucket
Hoses
Vinegar and Water*
53
Setup
Criteria: Operating/Safety/Quality
Starting Descaling
Process
CAUTION!
Acid Spill, wear Hand Gloves
54
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